2002 MAZDA 6 service

F2–220
TROUBLESHOOTING
NO.22 VIBRATION CONCERNS (ENGINE)A6E408018881224
Diagnostic Procedure
22 VIBRATION CONCERNS (ENGINE)
DESCRIPTION•Vibration from under hood or driveline.
POSSIBLE
CAUSE•Loose attaching bolts or worn parts
•Cooling fan No.1 or cooling fan No.2 seat are improper
•Engine or transaxle mounts are improperly installed
•Components malfunction such as worn parts
•Erratic signal from CMP sensor
•ECT sensor or related circuit malfunction
•Accelerator position sensor or related circuit malfunction
•MAF/IAT sensor or related circuit malfunction
•Idle switch or related circuit malfunction
•Incorrect adjustment of accelerator position sensor and/or idle switch
•Fuel injector malfunction
•Vacuum leakage
•Improper tension or damaged drive belts
•Improper balance of wheels or tires
•Driveline malfunction
•Suspension malfunction
Warning
The following troubleshooting flow chart contains the fuel system diagnosis and repair
procedures. Read the following warnings before performing the fuel system services:
•Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel.
•Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injury or death
and damage. Fuel can also irritate skin and eyes. To prevent this, always complete “BEFORE
REPAIR PROCEDURE” and “AFTER REPAIR PROCEDURE” described in this manual.
STEP INSPECTION RESULTS ACTION
1 Inspect following components for loose attaching
bolts or worn parts:
•Cooling fan No.1
•Cooling fan No.2
•Cooling fan No.1 and cooling fan No.2 seat
•Drive belt and pulley
•Engine mounts
•Exhaust system
Are all items okay?Yes Go to next step.
No Readjust or retighten engine mount installation
position.
Service as necessary for other parts.
2 Inspect vacuum leakage.
Are vacuum hoses okay?Yes Go to next step.
No Service as necessary.
Repeat Step 2.

TROUBLESHOOTING
F2–221
F2
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3 Connect WDS or equivalent to DLC-2.
Turn engine switch to ON.
Retrieve any DTC.
Is DTC displayed?YesDTC is displayed:
Go to appropriate DTC test.
Communication error message is displayed:
Inspect following:
•Open circuit between PCM control relay and PCM
terminal 53 or 79
•Open circuit PCM control relay and PCM terminal
69
•PCM control relay stuck open
•Open or poor GND circuit (PCM terminal 65, 85,
103 or 104)
•Poor connection vehicle body GND
NoNo DTC is displayed:
Go to next step.
4 Inspect adjustment of accelerator position
sensor and idle switch.
(See F2–72 ACCELERATOR POSITION
SENSOR INSPECTION)
(See F2–70 IDLE SWITCH INSPECTION)
Are accelerator position sensor and idle switch
adjusted correctly?Yes Go to next step.
No Adjust accelerator position sensor and idle switch
correctly.
(See F2–73 ACCELERATOR POSITION SENSOR
ADJUSTMENT)
(See F2–71 IDLE SWITCH ADJUSTMENT)
5 Inspect adjustment of neutral switch.
(See F2–69 NEUTRAL SWITCH INSPECTION)
Is neutral switch adjusted correctly?Yes Go to next step.
No Adjust neutral switch correctly.
6 Visually inspect CMP sensor and teeth of pulse
wheel.
Are CMP sensor and teeth of pulse wheel okay?Yes Inspect following PIDs:
(See F2–65 PCM INSPECTION)
•ECT
•IAT
•MAF
•RPM
If PID value is not as specified, repair or replace
malfunctioning parts.
If PID value is okay, go to next step.
No Replace malfunctioning parts.
7 Inspect fuel injector.
(See F2–56 FUEL INJECTOR INSPECTION)
Is fuel injector okay?Yes Inspect following systems:
•Wheels
•Transaxle and mounts
•Driveline
•Suspension
Service as necessary.
No Repair or replace as necessary.
8 Verify test results.
•If okay, return to diagnostic index to service any additional symptoms.
•If malfunction remains, replace PCM. (See F2–64 PCM REMOVAL/INSTALLATION) STEP INSPECTION RESULTS ACTION

F2–222
TROUBLESHOOTING
NO.23 A/C DOES NOT WORK SUFFICIENTLYA6E408018881225
Diagnostic Procedure
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23 A/C DOES NOT WORK SUFFICIENTLY
DESCRIPTION•A/C compressor magnetic clutch does not engage when A/C switch is turned on.
POSSIBLE
CAUSE•Improper refrigerant charge amount
•Open A/C switch magnetic clutch
•Open circuit between A/C relay and A/C magnetic clutch
•Poor GND of A/C magnetic clutch
•Improper A/C magnetic clutch clearance
•Refrigerant pressure switch is stuck open
•A/C relay is stuck open
•Improper A/C cut-off control
•Open circuit between A/C switch and PCM through both refrigerant pressure switch and A/C amplifier
STEP INSPECTION RESULTS ACTION
1 Perform self-test function using WDS or
equivalent.
Turn engine switch to ON.
Retrieve any DTC.
Is DTC displayed?YesDTC is displayed:
Go to appropriate DTC test.
Communication error message is displayed:
Inspect for following:
•Open circuit between PCM control relay and PCM
terminal 53 or 79
•Open circuit PCM control relay and PCM terminal
69
•PCM control relay stuck open
•Open or poor GND circuit (PCM terminal 65, 85,
103 or 104)
•Poor connection vehicle body GND
YesNo DTC is displayed:
Go to appropriate DTC test.
2 Disconnect A/C compressor connector.
Start engine and turn A/C switch to ON.
Is there correct voltage at terminal of A/C
compressor magnetic clutch connector?
Specification
More than 10.5 VYes Inspect for GND condition of magnetic clutch on A/C
compressor.
If GND condition is okay, inspect magnetic clutch coil
for open circuit.
No Go to next step.
3 Disconnect refrigerant pressure switch
connector.
Connect jumper wire between terminals of
refrigerant pressure switch connector.
Turn engine switch to ON.
Turn A/C switch on and set blower fan at any
speed.
Measure PCM terminal 84 voltage.
Is voltage below 1.0 V?Yes Inspect refrigerant pressure switch operation.
If switch is okay, go to next step.
No Inspect for following:
•A/C switch is stuck open
•Open circuit between refrigerant pressure switch
and PCM terminal 84
•Open circuit of blower motor fan switch and
resistor (if blower motor does not operate)
•Evaporator temperature sensor and A/C amplifier
4 Inspect A/C cut-off operation.
Does A/C cut-off work properly?Yes Go to next step.
No Repair or replace malfunctioning part according to A/C
cut-off system inspection results.
5 Remove jumper wire from switch connector.
Reconnect connector to refrigerant pressure
switch.
Start engine and turn A/C switch on.
Does fan operate?Yes Inspect for stuck open A/C relay.
Replace if necessary.
No Inspect following and repair or replace as necessary:
•Refrigerant charging amount
•Seized A/C compressor
6 Verify test results.
•If okay, return to diagnostic index to service any additional symptoms.
•If malfunction remains, replace PCM. (See F2–64 PCM REMOVAL/INSTALLATION)

TROUBLESHOOTING
F2–223
F2
NO.24 A/C ALWAYS ON OR A/C COMPRESSOR RUNS CONTINUOUSLYA6E408018881226
Diagnostic Procedure
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24 A/C ALWAYS ON OR A/C COMPRESSOR RUNS CONTINUOUSLY
DESCRIPTION•A/C compressor magnetic clutch does not disengage.
POSSIBLE
CAUSE•A/C compressor magnetic clutch stuck engagement
•A/C relay is stuck closed
•Improper A/C compressor magnetic clutch clearance
•Short to GND circuit between A/C switch and PCM
•Short to GND circuit between A/C relay and PCM
•A/C relay to magnetic clutch circuit shorts to battery power
STEP INSPECTION RESULTS ACTION
1 Perform self-test function using WDS or
equivalent.
Turn engine switch to ON.
Retrieve any DTC.
Is DTC displayed?YesDTC is displayed:
Go to appropriate DTC test.
Communication error message is displayed:
Inspect for following:
•Open circuit between PCM control relay and PCM
terminal 53 or 79
•Open circuit PCM control relay and PCM terminal
69
•PCM control relay stuck open
•Open or poor GND circuit (PCM terminal 65, 85,
103 or 104)
•Poor connection vehicle body GND
NoNo DTC is displayed:
Go to appropriate DTC test.
2 Start engine and run it at idle.
Turn A/C switch on.
Remove A/C relay.
Does A/C magnetic clutch disengage?Yes Inspect for following:
•A/C relay is stuck closed
•Short to GND circuit between A/C relay and PCM
terminal 73
If both items are okay, go to next step.
No Inspect if circuit between A/C relay and magnetic
clutch shorts to battery power circuit.
If circuit is okay, inspect magnetic clutch stuck
engagement or clearance.
3 Start engine and turn A/C switch on.
Measure PCM terminal 84 voltage while
disconnecting refrigerant pressure switch
connector.
Note
•PCM terminal 84 voltage should read B+
when disconnecting connector. If PCM
terminal 84 voltage reading remains
below 1.0 V, short to GND circuit may be
present.
Is voltage B+?Yes Inspect for short to GND circuit between refrigerant
pressure switch and PCM terminal 84.
No Go to next step.
4 Reconnect refrigerant pressure switch
connector.Measure PCM terminal 84 voltage
while turning off A/C switch.
Note
•PCM terminal 84 voltage should read B+
when turning A/C switch off. If PCM
terminal 84 voltage reading remains
below 1.0 V, short to GND circuit maybe
present.
Does voltage remain B+?Yes Inspect for following:
•Short to GND circuit between A/C switch and A/C
amplifier.
•Short to GND circuit between A/C amplifier and
refrigerant pressure switch.
No Inspect for stuck closed A/C switch.
5 Verify test results.
•If okay, return to diagnostic index to service any additional symptoms.
•If malfunction remains, replace PCM. (See F2–64 PCM REMOVAL/INSTALLATION)

F2–224
TROUBLESHOOTING
NO.25 A/C DOES NOT CUT OFF UNDER WIDE OPEN THROTTLE CONDITIONSA6E408018881227
Diagnostic Procedure
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25 A/C DOES NOT CUT OFF UNDER WIDE OPEN THROTTLE CONDITIONS
DESCRIPTION•A/C compressor magnetic clutch does not disengage under wide open throttle.
POSSIBLE
CAUSE•Accelerator position sensor malfunction
•Accelerator position sensor misadjustment
•Loosely installed accelerator position sensor
STEP INSPECTION RESULTS ACTION
1 Does A/C compressor disengage when A/C
switch is turned off?Yes Go to next step.
No Go to symptom troubleshooting “NO.24 A/C ALWAYS
ON OR A/C COMPRESSOR RUNS
CONTINUOUSLY”.
2 Perform self-test function using WDS or
equivalent.
Turn engine switch to ON.
Retrieve any DTC.
Is DTC displayed?YesDTC is displayed:
Go to appropriate DTC test.
Communication error message is displayed:
Inspect for following:
•Open circuit between PCM control relay and PCM
terminal 53 or 79
•Open circuit PCM control relay and PCM terminal
69
•PCM control relay stuck open.
•Open or poor GND circuit (PCM terminal 65, 85,
103 or 104)
•Poor connection vehicle body GND
NoNo DTC is displayed:
Inspect adjustment of accelerator position sensor.
If accelerator position sensor adjustment is not
correct, adjust accelerator position sensor.
3 Verify test results.
•If okay, return to diagnostic index to service any additional symptoms.
•If malfunction remains, replace PCM. (See F2–64 PCM REMOVAL/INSTALLATION)

F2–226
TROUBLESHOOTING
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8Note
•Purpose of this step is to determine if
WDS or equivalent is communicating with
PCM.
Reconnect appropriate sensor connector.
Turn engine switch to ON.
Attempt to access ECT PID.
Can ECT PID be accessed?Yes Go to next step.
No Go to Step 11.
9 Are DTCs present for two or more sensors
connected to PCM terminal 91?
Sensor connected to PCM terminal 91:
•Accelerator position sensor. (P0122, P0123,
P0222, P0223).
•ECT sensor (P0117, P0118)
•Fuel pressure sensor (P0192, P0193)
•Fuel temperature sensor (P0182, P0183)
•MAF/IAT sensor (P0102, P0103, P0112,
P0113)
•IAT sensor No.2 (P0097, P0098)Yes Go to next step.
No Repair open GND circuit to sensor where constant
voltage circuit inspection failed.
10 Turn engine switch to OFF.
Disconnect WDS or equivalent from DLC-2.
Disconnect PCM connector.
Measure resistance between GND circuit at
appropriate sensor connector and PCM
connector terminal 91.
Is resistance less than 5.0 ohms?Yes Reconnect sensor connector.
Go to appropriate DTC test.
No Repair open GND circuit.
11 Turn engine switch OFF.
Disconnect PCM connector.
Measure resistance between battery negative
terminal and PCM terminals 65, 85, 103 and
104.
Is each resistance less than 5.0 ohms?Yes Go to next step.
No Repair open GND circuit.
12 Turn engine switch to OFF.
Measure resistance between GND circuit at
following sensor connector and GND:
•Accelerator position sensor
•ECT sensor
•BARO sensor
•Fuel pressure sensor
•Fuel temperature sensor
•MAF/IAT sensor
•IAT sensor No.2
Is resistance below 5.0 ohms?Yes GND circuits are okay.
Inspect sensor connector for constant voltage again.
No Inspect for open GND circuit.
13 Turn engine switch to OFF.
Disconnect accelerator position sensor.
Turn engine switch to ON.
Measure voltage between constant voltage
circuit at accelerator position sensor and battery
negative terminal.
Is voltage less than 0.5V?Yes Inspect sensor connector for constant voltage again.
No Repair constant voltage circuit shorted power in
harness.
14 Verify test results.
•If okay, return to diagnostic index to service any additional symptoms.
•If malfunction remains, replace PCM. (See F2–64 PCM REMOVAL/INSTALLATION) STEP INSPECTION RESULTS ACTION

G–1
G
GENGINE ELECTRICAL SYSTEM
OUTLINE............................................................... G-2
OUTLINE OF CONSTRUCTION......................... G-2
SPECIFICATIONS .............................................. G-2
STRUCTURAl VIEW ........................................... G-3
OUTLINE............................................................... G-4
SUPPLEMENTAL SERVICE INFORMATION .... G-4
LOCATION INDEX .............................................. G-4
CHARGING SYSTEM............................................ G-5
BATTERY REMOVAL/INSTALLATION .............. G-5
BATTERY INSPECTION..................................... G-6
BATTERY RECHARGING .................................. G-6
GENERATOR REMOVAL/INSTALLATION ........ G-7
GENERATOR INSPECTION .............................. G-7
STARTING SYSTEM............................................. G-9
STARTER REMOVAL/INSTALLATION .............. G-9
STARTER INSPECTION .................................. G-11 FEATURES
SERVICE

G–4
OUTLINE
SUPPLEMENTAL SERVICE INFORMATIONA6E470202000204•The following changes and/or additions have been made since publication of the Mazda6 Workshop Manual
(1730-1*-02C).
Battery
•Removal/Installation procedure has been added. (MZR-CD (RF Turbo) engine model)
•Inspection procedure has been added. (MZR-CD (RF Turbo) engine model)
•Recharging procedure has been added. (MZR-CD (RF Turbo) engine model)
Generator
•Removal/Installation procedure has been added. (MZR-CD (RF Turbo) engine model)
•Inspection procedure has been added. (MZR-CD (RF Turbo) engine model)
Starter
•Removal/Installation procedure has been added.
•Inspection procedure has been added. (MZR-CD (RF Turbo) engine model)
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LOCATION INDEXA6E470202000206MZR-CD (RF Turbo)
.
End Of Sie
OUTLINE
3
1
2
A6E4702W100
1 Battery
(See G–5 BATTERY REMOVAL/INSTALLATION)
(See G–6 BATTERY INSPECTION)
(See G–6 BATTERY RECHARGING)2 Generator
(See G–7 GENERATOR REMOVAL/
INSTALLATION)
(See G–7 GENERATOR INSPECTION)
3Starter
(See G–9 STARTER REMOVAL/INSTALLATION)
(See G–11 STARTER INSPECTION)