2002 MAZDA 6 engine

F2–2

MASS AIR FLOW (MAF)/INTAKE AIR
TEMPERATURE (IAT) SENSOR
INSPECTION ................................................ F2-74
INTAKE AIR TEMPERATURE (IAT)
SENSOR NO.2 INSPECTION....................... F2-75
ENGINE COOLANT TEMPERATURE (ECT)
SENSOR REMOVAL/INSTALLATION .......... F2-76
ENGINE COOLANT TEMPERATURE (ECT)
SENSOR INSPECTION ................................ F2-76
FUEL TEMPERATURE SENSOR
INSPECTION ................................................ F2-77
BOOST SENSOR INSPECTION ..................... F2-78
FUEL PRESSURE SENSOR INSPECTION .... F2-79
CAMSHAFT POSITION (CMP) SENSOR
REMOVAL/INSTALLATION .......................... F2-80
CAMSHAFT POSITION (CMP) SENSOR
INSPECTION ................................................ F2-80
CRANKSHAFT POSITION (CKP) SENSOR
REMOVAL/INSTALLATION .......................... F2-81
CRANKSHAFT POSITION (CKP) SENSOR
INSPECTION ................................................ F2-82
CALIBRATION RESISTOR INSPECTION ....... F2-83
INJECTOR DRIVER MODULE (IDM)
INSPECTION ................................................ F2-84
ON-BOARD DIAGNOSTIC................................. F2-85
ON-BOARD DIAGNOSTIC TEST .................... F2-85
DTC CONFIRMATION PROCEDURE ............. F2-85
KOEO/KOER SELF-TEST PROCEDURE ....... F2-86
AFTER REPAIR PROCEDURE ....................... F2-86
DTC TABLE ..................................................... F2-87
DTC P0016 ...................................................... F2-88
DTC P0088 ...................................................... F2-89
DTC P0091 ...................................................... F2-90
DTC P0092 ...................................................... F2-92
DTC P0093 ...................................................... F2-94
DTC P0097 ...................................................... F2-95
DTC P0098 ...................................................... F2-97
DTC P0102 ...................................................... F2-99
DTC P0103 .................................................... F2-101
DTC P0107 .................................................... F2-103
DTC P0108 .................................................... F2-105
DTC P0112 .................................................... F2-107
DTC P0113 .................................................... F2-109
DTC P0117 .................................................... F2-111
DTC P0118 .................................................... F2-113
DTC P0121 .................................................... F2-115
DTC P0122 .................................................... F2-116
DTC P0123 .................................................... F2-118
DTC P0182 .................................................... F2-120
DTC P0183 .................................................... F2-122
DTC P0191 .................................................... F2-124
DTC P0192 .................................................... F2-125
DTC P0193 .................................................... F2-127
DTC P0200 .................................................... F2-129
DTC P0221 .................................................... F2-131
DTC P0222 .................................................... F2-132
DTC P0223 .................................................... F2-134
DTC P0300 .................................................... F2-136
DTC P0336 .................................................... F2-137
DTC P0337 .................................................... F2-138
DTC P0341 .................................................... F2-140
DTC P0342 .................................................... F2-141
DTC P0380 .................................................... F2-143
DTC P0504 .................................................... F2-145
DTC P0510 .................................................... F2-148
DTC P0512 .................................................... F2-150
DTC P0564 .................................................... F2-152
DTC P0602 .................................................... F2-154DTC P0606..................................................... F2-155
DTC P0610..................................................... F2-155
DTC P0661..................................................... F2-156
DTC P0662..................................................... F2-158
DTC P0850..................................................... F2-160
DTC P1190..................................................... F2-162
DTC P2228..................................................... F2-164
DTC P2229..................................................... F2-164
TROUBLESHOOTING...................................... F2-165
SYMPTOM DIAGNOSTIC INDEX .................. F2-165
SYMPTOM QUICK DIAGNOSIS CHART ...... F2-167
NO.1 MELTING OF MAIN OR
OTHER FUSES ........................................... F2-173
NO.2 MIL ILLUMINATES ............................... F2-174
NO.3 WILL NOT CRANK ............................... F2-174
NO.4 HARD START/LONG CRANK/ERRATIC
START/ERRATIC CRANK .......................... F2-176
NO.5 ENGINE STALLS-AFTER
START/AT IDLE .......................................... F2-178
NO.6 CRANKS NORMALLY BUT WILL NOT
START ........................................................ F2-181
NO.7 SLOW RETURN TO IDLE .................... F2-184
NO.8 ENGINE RUNS ROUGH/ROLLING
IDLE ............................................................ F2-186
NO.9 FAST IDLE/RUNS ON .......................... F2-189
NO.10 LOW IDLE/STALLS DURING
DECELERATION ........................................ F2-190
NO.11 ENGINE STALLS/QUITS, ENGINE RUNS
ROUGH, MISSES, BUCK/JERK,
HESITATION/STUMBLE, SURGES ........... F2-192
NO.12 LACK/LOSS OF
POWER-ACCELERATION/CRUISE ........... F2-195
NO.13 KNOCKING/PINGING......................... F2-199
NO.14 POOR FUEL ECONOMY.................... F2-202
NO.15 EMISSION COMPLIANCE.................. F2-205
NO.16 HIGH OIL
CONSUMPTION/LEAKAGE ....................... F2-209
NO.17 COOLING SYSTEM
CONCERNS-OVERHEATING .................... F2-210
NO.18 COOLING SYSTEM
CONCERNS-RUNS COLD ......................... F2-212
NO.19 EXCESSIVE BLACK SMOKE ............. F2-213
NO.20 FUEL ODOR
(IN ENGINE COMPARTMENT) .................. F2-216
NO.21 ENGINE NOISE .................................. F2-217
NO.22 VIBRATION CONCERNS (ENGINE) .. F2-220
NO.23 A/C DOES NOT WORK
SUFFICIENTLY ........................................... F2-222
NO.24 A/C ALWAYS ON OR A/C
COMPRESSOR RUNS
CONTINUOUSLY........................................ F2-223
NO.25 A/C DOES NOT CUT OFF UNDER
WIDE OPEN THROTTLE CONDITIONS .... F2-224
NO.26 CONSTANT VOLTAGE ...................... F2-225
INTERMITTENT CONCERN
TROUBLESHOOTING ................................ F2-227
ENGINE CONTROL SYSTEM
OPERATION INSPECTION ........................ F2-229

OUTLINE
F2–3
F2
OUTLINE OF CONSTRUCTIONA6E400218881201•The common rail injection system has been adopted for Mazda6 (GG, GY) MZR-CD (RF Turbo) engine
models.
•The fuel and emission control system is essentially carried over from that of the current MPV (LW) MZR-CD
(RF Turbo) engine models, except for the following features. (See MPV Workshop Manual Supplement 1737-
1*-02C.)
End Of Sie
FEATURESA6E400218881202Improved Emission Performance
•Warm up oxidation catalytic converter capacity has been increased.
System Simplification
•Immobilizer unit has been equipped into PCM
•Cruise control system has been adopted.
•Electrical fan control has been changed.
•CAN has been changed.
Improved Serviceability
•DTCs, PID monitoring items, and simulation test items have been changed.
•KOEO/KOER self-test items have been changed.
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SPECIFICATIONSA6E400218881203
Bold frames: New specifications
End Of Sie
OUTLINE
ItemNew Mazda6 (GG, GY) Current MPV (LW)
MZR-CD (RF Turbo)
Air cleaner element Type Non woven fabric (dry)
Supercharger Type Turbocharger
Glow plug Type Metal
Pump Type Supply pump
Fuel tankCapacity
64 {16.9, 14.1} 75 {19.8, 16.5}
(L {US gal, lmp gal})
Catalyst Type Warm up oxidation catalyst, Oxidation catalyst
EGR control Type Duty control
PCV system Type Closed

F2–4
OUTLINE
CONTROL SYSTEM DIAGRAMA6E400218881204
.
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5
4
3
6
1
2
8
7
910
13
11
12
19
18
17
1516
14
202928
27
25
26
24
2321
22
30
393837
35
3633
31
32
40
34
494847
45
464443
4142
50
54
515253
A
A
BB
A6E40022001
1 Air cleaner
2 Vacuum chamber
3 VBC check valve
4 MAF/IAT sensor
5 VBC solenoid valve
6 Vacuum damper
7 Guide blade actuator
8 Turbocharger
9 Charge air cooler
10 IAT sensor No.2
11 Boost sensor
12 Intake shutter valve actuator
13 Intake shutter solenoid valve (half)
14 Intake shutter solenoid valve (full)
15 EGR solenoid valve (vacuum)
16 EGR solenoid valve (vent)
17 EGR control solenoid valve
18 EGR valve
19 EGR water cooler
20 VSC valve actuator
21 VSC solenoid valve
22 Fuel tank
23 Fuel filter
24 Fuel warmer
25 Supply pump
26 Suction control valve
27 Fuel temperature sensor28 Common rail
29 Fuel pressure sensor
30 Fuel pressure limiter
31 Glow plug
32 Fuel injector
33 ECT sensor
34 Calibration resistor
35 CMP sensor
36 Warm up oxidation catalytic converter
37 Oxidation catalytic converter
38 Silencer
39 Vacuum pump
40 CKP sensor
41 Idle switch
42 Accelerator position sensor
43 Glow plug relay
44 IDM
45 PCM
46 BARO sensor
47 PCM control relay
48 Engine switch
49 Starter (starter signal)
50 Neutral switch
51 Clutch switch
52 A/C switch
53 CAN bus
54 To PCM

F2–6
OUTLINE
.
a
b
c
d
e
f
gCBD
A
CBD
ACBD
ACBD
A
3762
89 11C
BABABABABABABABABA
81 55 29 3 99 72
1017410067 77
h
i
j
k
l
m
n
oA
B
C36
10
A
BCD8831
90
A B CA
BA
B
A B 6135
87 94 93 8
A
B76
E
C
A D
M84
10273 8668
AB
C D
M
M A B
29282725262430
1
393837353633
31
3240
49
48
47454644
4341
42
50
59
58
57
55
5654
60
64
63
61
62
34
51
5253
A6E40022003
1PCM
2DLC-2
3 Water heater unit
4Fuel pump
5 Other unit6IDM
7Battery
8 Engine switch
9 Starter relay
10 Starter

F2–8
INTAKE-AIR SYSTEM
OUTLINEA6E401001005201•The intake-air system is essentially carried over from that of the current MPV (LW) MZR-CD (RF Turbo) engine
model. (See MPV Workshop Manual Supplement 1737-1*-02D.)
×:Applicable
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INTAKE-AIR SYSTEM
Item Mazda6
(GG, GY)Current
MPV (LW)
Remark for new model
MZR-CD (RF Turbo)
Fresh-air duct ×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Shape has been changed
Air cleaner×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Shape has been changed
Turbocharger×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Charge air cooler×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Shape has been changed
Intake manifold×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
VBC system×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
VSC system×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Glow plug×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Glow plug lead×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Glow plug relay×Same function as MPV (LW) MZR-CD (RF Turbo) engine model

F2–10
FUEL SYSTEM
End Of Sie
OUTLINEA6E401201006201•The fuel system is essentially carried over from that of the current MPV (LW) MZR-CD (RF Turbo) engine
model. (See MPV Wordshop Manual Supplement 1737-1*-02D.)
×:Applicable
*1: With fuel warmer
End Of Sie
FUEL SYSTEM
ItemMazda6
(GG, GY)Current
MPV (LW)
Remark for new model
MZR-CD (RF Turbo)
Fuel tank×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Shape has been changed
Fuel gauge sender unit×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Shape has been changed
Fuel filter bodyFuel filter×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Priming pump×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Fuel warmer
*1×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Common rail injection system×Same function as MPV (LW) MZR-CD (RF Turbo) engine model

FUEL SYSTEM
F2–11
F2
STRUCTURAL VIEWA6E401201006202Engine room side
.
1
2
3
4
5
6
7
9
8
10
11
12
10
A6E40122031
1 Fuel warmer
2 Sedimentor switch
3 Supply pump
4 Suction control valve
5 Common rail
6 Priming pump7 L.H.D.
8 Fuel injector
9 Priming pump
10 Fuel filter
11 R.H.D.
12 Sedimentor switch

EXHAUST SYSTEM
F2–13
F2
OUTLINEA6E401440000201•The exhaust system is essentially carried over from that of the current 626 (GF)/626 Station Wagon (GW) RF
Turbo engine models. (See 626 626 Station Wagon Workshop Manual Supplement 1688-1*-00G.)
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STRUCTURAL VIEWA6E401440000202
.
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EXHAUST SYSTEM
5
4
3
6
1
2
A6E40142005
1 Exhaust manifold
2 Warm up oxidation catalytic converter
3 Front pipe4 Oxidation catalytic converter
5 Middle pipe
6 Main silencer