2002 MAZDA 6 charging

TROUBLESHOOTING
F2–187
F2
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 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 next step.
4Note
•The following test should be performed on
the vehicles with A/C system. If the
following test cannot be performed due to
engine stalling, go to next step.
•Go to next step for the vehicle without A/C
system.
Connect pressure gauge to A/C line.
Turn blower and A/C switches on.
Is pressure within specifications?Yes Go to next step.
NoA/C is always on:
Go to symptom troubleshooting “NO.24 A/C ALWAYS
ON OR A/C COMPRESSOR RUNS
CONTINUOUSLY”.
Other symptoms:
Inspect for following:
•Refrigerant charging amount
•Cooling fan No.1 and/or cooling fan No.2 operation
5 Depress accelerator pedal slightly.
Crank engine.
Does engine start now?Yes Inspect idle speed.
(See F2–34 IDLE SPEED INSPECTION)
No Go to next step.
6 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)
7 Inspect for fuel leakage from fuel pipe.
Is any fuel leakage found on fuel pipe?Yes Repair or replace as necessary.
No Go to next step.
8 Visually inspect CKP sensor and teeth of pulse
wheel.
Are CKP sensor and teeth of pulse wheel okay?Yes Go to next step.
No Replace malfunctioning parts.
9 Measure gap between CKP sensor and teeth of
pulse wheel.
Specification
1.5—2.5 mm {0.059—0.098 in}
Is gap within specification?Yes Go to next step.
No Adjust CKP sensor position.
10 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.
11 Inspect fuel pressure sensor.
(See F2–79 FUEL PRESSURE SENSOR
INSPECTION)
Is fuel pressure okay?Yes Go to next step.
No Replace common rail.
12 Inspect suction control valve.
(See F2–54 SUCTION CONTROL VALVE
INSPECTION)
Is suction control valve okay?Yes Go to next step.
No Repair supply pump.
(See F2–54 SUPPLY PUMP INSPECTION) STEP INSPECTION RESULTS ACTION

TROUBLESHOOTING
F2–191
F2
5 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)
6 Measure voltage PCM terminal 33 and 56.
Is voltage okay?Yes Go to next step.
NoPCM terminal 33 does not specified:
Inspect clutch switch and related harness.
PCM terminal 56 does not specified:
Inspect neutral switch and related harness.
7 Visually inspect CKP sensor and teeth of pulse
wheel.
Are CKP sensor and teeth of pulse wheel okay?Yes Go to next step.
No Replace malfunctioning parts.
8 Measure gap between CKP sensor and teeth of
pulse wheel.
Specification
1.5—2.5 mm {0.059—0.098 in}
Is gap within specification?Yes Go to next step.
No Adjust CKP sensor position.
9 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.
10 Inspect fuel pressure sensor.
(See F2–79 FUEL PRESSURE SENSOR
INSPECTION)
Is fuel pressure okay?Yes Go to next step.
No Replace common rail.
11 Inspect suction control valve.
(See F2–54 SUCTION CONTROL VALVE
INSPECTION)
Is suction control valve okay?Yes Go to next step.
No Repair supply pump.
(See F2–54 SUPPLY PUMP INSPECTION)
12 Is engine compression correct?
(See B2–8 COMPRESSION INSPECTION)Yes Go to next step.
No Inspect for following:
•Damaged valve seat
•Worn valve stem and valve guide
•Worn or stuck piston ring
•Worn piston, piston ring or cylinder
•Improper valve timing
Service as necessary.
13 Inspect fuel injector.
(See F2–56 FUEL INJECTOR INSPECTION)
Is fuel injector okay?Yes Go to next step.
No Repair or replace as necessary.
14Note
•The following test should be performed on
the vehicles with A/C system. If the
following test cannot be performed due to
engine stalling, go to next step.
•Go to next step for the vehicle without A/C
system.
Connect pressure gauge to A/C line.
Turn blower and A/C switches on.
Is pressure within specifications?Yes Go to next step.
NoA/C is always on:
Go to symptom troubleshooting “NO.24 A/C ALWAYS
ON OR A/C COMPRESSOR RUNS
CONTINUOUSLY”.
Other symptoms:
Inspect following:
•Refrigerant charging amount
•Cooling fan No.1 and/or cooling fan No.2 operation
15 Inspect EGR system operation.
Is EGR system operation normal?Yes Go to next step.
No Repair or replace malfunctioning part according to
EGR system operation results.
16 Inspect glow system operation.
(See T–19 RELAY INSPECTION)
Is glow system operation normal?Yes Go to next step.
No Service as necessary. STEP INSPECTION RESULTS ACTION

TROUBLESHOOTING
F2–193
F2
Diagnostic Procedure
STEP INSPECTION RESULTS ACTION
1 Is idle speed stable? Yes Go to next step.
No Go to symptom troubleshooting “NO.8 ENGINE RUNS
ROUGH/ROLLING IDLE”.
2 Is engine overheating? Yes Go to symptom troubleshooting “NO.17 COOLING
SYSTEM CONCERNS—OVERHEATING”.
No Go to next step.
3 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 next step.
4 Inspect for following:
•Fuel quality (e.g.: including water
contamination, winter/summer blend)
•Fuel line/fuel filter clogging and/or restriction
•Intake-air system restriction or clogging
•Exhaust system and/or catalyst converter
restriction
•Cooling fan No.1 or cooling fan No.2 seat
Are all items okay?Yes Go to next step.
No Service as necessary.
Repeat Step 4.
5 Does engine run normal after warm-up? Yes Inspect glow system operation.
(See T–19 RELAY INSPECTION)
Replace any malfunctioning part as necessary.
If glow system is okay, go to next step.
No Go to next step.
6Note
•The following test should be performed on
the vehicles with A/C system. If the
following test cannot be performed due to
engine stalling, go to next step.
•Go to next step for the vehicle without A/C
system.
Connect pressure gauge to A/C line.
Turn blower and A/C switches on.
Is pressure within specifications?Yes Go to next step.
NoA/C is always on:
Go to symptom troubleshooting “NO.24 A/C ALWAYS
ON OR A/C COMPRESSOR RUNS CONTINUITY”.
Other symptoms:
Inspect following:
•Refrigerant charging amount
•Cooling fan No.1 and/or cooling fan No.2 operation
7 Inspect hose bands between following parts:
•Turbocharger compressor housing and air
cleaner
•Turbocharger compressor housing and
charge air cooler
Are hose bands loose?Yes Retighten hose bands.
If concern is resolved, complete inspection.
If concern still exists, go to next step.
No Go to next step.
8 Inspect for improper operation, kinks, clogging or
disconnection on guide blade actuator.
Is guide blade actuator okay?Yes Turbocharger is okay.
Go to next step.
No Repair or replace as necessary.
If concern is resolved, complete inspection.
If concern still exists, turbocharger is okay.
Go to next step.
9 Perform EGR system inspection.
Is EGR system okay?Yes Go to next step.
No Repair or replace malfunctioning part according to
EGR system operation results.
10 Inspect idle speed.
(See F2–34 IDLE SPEED INSPECTION)
Is idle speed correct?Yes Go to next step.
No Repair or replace malfunctioning part according to idle
speed inspection results.

TROUBLESHOOTING
F2–203
F2
3 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 next step.
4Note
•The following test should be performed on
the vehicles with A/C system. If the
following test cannot be performed due to
engine stalling, go to next step.
•Go to next step for the vehicle without A/C
system.
Connect pressure gauge to A/C line.
Turn blower and A/C switches on.
Is pressure within specifications?Yes Go to next step
NoA/C is always on:
Go to symptom troubleshooting “NO.24 A/C ALWAYS
ON OR A/C COMPRESSOR RUNS
CONTINUOUSLY”.
Other symptoms:
Inspect following:
•Refrigerant charging amount
•Cooling fan No.1 and/or cooling fan No.2
operation.
5 Access ECT PID.
Drive vehicle while monitoring PID.
Is PID within specification?Yes Go to next step.
No Inspect for coolant leakage, cooling fan No.1 and
cooling fan No.2 operations or thermostat operation.
6 Inspect idle speed.
(See F2–34 IDLE SPEED INSPECTION)
Is idle speed okay?Yes Go to next step.
No Go to symptom troubleshooting “NO.7 SLOW
RETURN TO IDLE”.
7 Perform EGR system inspection.
Is EGR system okay?Yes Go to next step.
No Repair or replace malfunctioning part according to
EGR system operation results.
8 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)
9 Is engine compression correct?
(See B2–8 COMPRESSION INSPECTION)Yes Go to next step.
No Inspect for following:
•Damaged valve seat
•Worn valve stem and valve guide
•Worn or stuck piston ring
•Worn piston, piston ring or cylinder
•Improper valve timing
Service as necessary.
10 Inspect fuel injector.
(See F2–56 FUEL INJECTOR INSPECTION)
Is fuel injector okay?Yes Go to next step.
No Repair or replace as necessary.
11 Perform turbocharger inspection.
(See F2–38 TURBOCHARGER INSPECTION)
Is turbocharger okay?Yes Go to next step.
No Replace turbocharger.
12 Inspect guide blade valve operation.
(See F2–229 ENGINE CONTROL SYSTEM
OPERATION INSPECTION)
Is there any problem?Yes Repair or replace as necessary.
No Go to next step.
13 Visually inspect CKP sensor and teeth of pulse
wheel.
Are CKP sensor and teeth of pulse wheel okay?Yes Go to next step.
No Replace malfunctioning parts. STEP INSPECTION RESULTS ACTION

F2–222
TROUBLESHOOTING
NO.23 A/C DOES NOT WORK SUFFICIENTLYA6E408018881225
Diagnostic Procedure
End Of Sie
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
F2–225
F2
NO.26 CONSTANT VOLTAGEA6E408018881228
Diagnostic Procedure
26 CONSTANT VOLTAGE
DESCRIPTION•Incorrect constant voltage.
POSSIBLE
CAUSE•Constant voltage circuit malfunction
•Accelerator positions sensor or related circuit malfunction
•Fuel pressure sensor or related circuit malfunction
•Boost sensor or related circuit malfunction
•ECT sensor GND circuit malfunction
•MAF/IAT sensor GND circuit malfunction
•IAT sensor No.2 GND circuit malfunction
•Fuel temperature sensor GND circuit malfunction
Note
•Accelerator position sensor, fuel pressure sensor and boost sensor use constant voltage.
STEP INSPECTION RESULTS ACTION
1 Disconnect appropriate sensor connectors
(accelerator position sensor, boost sensor and
fuel pressure sensor) where constant voltage
circuits inspection failed.
Turn engine switch to ON position.
Measure voltage between following appropriate
sensor connector terminals:
•Constant voltage terminal and GND terminal.
Is constant voltage above 6.0 V?Yes Repair constant voltage circuit short to power in
harness.
No Go to next step.
2 Is voltage across battery terminals above 10.5
V?Yes Go to next step.
No Inspect charging system.
3 Turn engine switch to OFF.
Leave appropriate sensor connectors
disconnected where constant voltage inspection
failed.
Measure voltage between positive terminal and
GND circuit at appropriate sensor vehicle
harness connector.
Is voltage above 10.5 V and within 1.0 V of
battery voltage?Yes Go to next step.
No Go to Step 8.
4Note
•Purpose of this step is to determine if
WDS or equivalent is communicating with
PCM.
Turn engine switch to ON.
Attempt to access ECT PID.
Can ECT PID be accessed?Yes Go to Step 7.
No Go to next step.
5 Turn engine switch to OFF.
Disconnect accelerator position sensor and
PCM connectors.
Turn engine switch to ON.
Measure voltage between PCM connector
terminals 104 and 53/79.
Is voltage greater than 10.5 V?Yes Go to next step.
No Repair open circuit between PCM terminal 53/79 and
PCM control relay.
6 Leave accelerator position sensor and PCM
connectors disconnected.
Measure resistance between PCM connector
terminals 104 and 90.
Is resistance greater than 10,000 ohms?Yes Inspect sensor connector for constant voltage again.
No Repair constant voltage circuit short to GND.
7 Turn engine switch to OFF.
Leave accelerator position sensor
disconnected.Disconnect PCM connector.
Measure resistance between PCM connector 90
and constant voltage circuit at appropriate
sensor connector.
Is resistance less than 5.0 ohms?Yes Inspect sensor connector for constant voltage again.
No Repair open constant voltage circuit.

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)
End Of Sie
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)