2002 MAZDA 6 check engine

F1–28
FUEL SYSTEM
Fuel Pump Cap Installation Note
1. Verify that the fuel tank mark is aligned with the
fuel pump unit mark as shown.
2. Using the SST, tighten the fuel pump cap without
shifting the mark.
Tightening torque
80—90 N·m {8.2—9.1 kgf·m, 60—66 ft·lbf}
Plastic Fuel Hose Installation Note
Note
•A checker tab is integrated with quick
release connector for new plastic fuel hoses.
The checker tab will be released from the
quick release connector after it is completely
engaged with the fuel pipe.
1. Inspect the fuel pump unit sealing surface for
damage and deformation, and replace as
necessary.
•If the quick release connector O-ring is
damaged, replace the plastic fuel hose.
2. Slightly apply clean engine oil to the sealing
surface of the fuel pump unit.
3. Align the fuel pipe on the fuel pump unit and quick
release connector so that the tabs of the retainer
are correctly fitted into the quick release
connector. Push the quick release connector
straight into the retainer until a click is heard.
4. Lightly pull and push the quick release connector
a few times by hand and verify that it can move
2.0—3.0 mm {0.08—0.11 in} and it is connected
securely.
•If quick release connector does not move at
all, verify that O-ring is not damaged and
slipped, and reconnect the quick release
connector.
Fuel Leak Inspection After Fuel Pump Unit Installation
1. Drive the vehicle.
2. Perform a quick start and a hard brake 5—6 times.
3. Stop the vehicle.
4. Verify that there is no fuel leakage near the fuel pump unit in the vehicle interior.
End Of Sie
A6E39122013
CHECKER
TA B
NEW PLASTIC
FUEL HOSE
A6E3912W004
OILOIL
PLASTIC FUEL HOSE QUICK RELEASE
CONNECTOR SEALING
SURFACE
A6E3912W006

F2–1
F2
F2FUEL AND EMISSION CONTROL SYSTEMS
[MZR-CD (RF Turbo)]
OUTLINE.............................................................. F2-3
OUTLINE OF CONSTRUCTION ....................... F2-3
FEATURES ........................................................ F2-3
SPECIFICATIONS ............................................. F2-3
CONTROL SYSTEM DIAGRAM ........................ F2-4
CONTROL SYSTEM WIRING DIAGRAM.......... F2-5
INTAKE-AIR SYSTEM.......................................... F2-8
OUTLINE ........................................................... F2-8
STRUCTURAL VIEW......................................... F2-9
FUEL SYSTEM................................................... F2-10
OUTLINE ......................................................... F2-10
STRUCTURAL VIEW....................................... F2-11
EXHAUST SYSTEM........................................... F2-13
OUTLINE ......................................................... F2-13
STRUCTURAL VIEW....................................... F2-13
EMISSION SYSTEM........................................... F2-14
OUTLINE ......................................................... F2-14
STRUCTURAL VIEW....................................... F2-15
WARM UP OXIDATION CATALYTIC
CONVERTER DESCRIPTION ...................... F2-16
CONTROL SYSTEM........................................... F2-16
OUTLINE ......................................................... F2-16
STRUCTURAL VIEW....................................... F2-18
BLOCK DIAGRAM ........................................... F2-20
CONTROL DEVICE AND CONTROL
RELATIONSHIP CHART .............................. F2-22
CRUISE CONTROL SYSTEM ......................... F2-23
CONTROLLER AREA NETWORK (CAN) ....... F2-24
ON-BOARD DIAGNOSTIC................................. F2-24
OUTLINE ......................................................... F2-24
DTC.................................................................. F2-24
KOEO/KOER SELF-TEST ............................... F2-26
PID/DATA MONITOR AND RECORD ............. F2-27
SIMULATION TEST ......................................... F2-27
LOCATION INDEX............................................. F2-28
INTAKE-AIR SYSTEM ..................................... F2-28
FUEL SYSTEM ................................................ F2-29
EMISSION SYSTEM........................................ F2-31
CONTROL SYSTEM........................................ F2-32
ENGINE TUNE-UP............................................. F2-34
ENGINE TUNE-UP PREPARATION ............... F2-34
IDLE SPEED INSPECTION ............................. F2-34
CORRECTION PROCEDURE ......................... F2-34
INTAKE-AIR SYSTEM........................................ F2-35
VACUUM TUBE ROUTING DIAGRAM............ F2-35
INTAKE-AIR SYSTEM
REMOVAL/INSTALLATION .......................... F2-36
AIR CLEANER ELEMENT INSPECTION ........ F2-37
TURBOCHARGER INSPECTION ................... F2-38
GUIDE BLADE ACTUATOR INSPECTION ..... F2-39
VARIABLE BOOST CONTROL (VBC)
SOLENOID VALVE INSPECTION ................ F2-40VARIABLE BOOST CONTROL (VBC)
CHECK VALVE INSPECTION ...................... F2-41
VARIABLE SWIRL CONTROL (VSC)
VALVE ACTUATOR INSPECTION ............... F2-41
VARIABLE SWIRL CONTROL (VSC)
SOLENOID VALVE INSPECTION ................ F2-42
GLOW PLUG REMOVAL/INSTALLATION ...... F2-42
GLOW PLUG INSPECTION ............................ F2-43
GLOW PLUG LEAD INSPECTION .................. F2-43
ACCELERATOR PEDAL COMPONENT
REMOVAL/INSTALLATION .......................... F2-44
ACCELERATOR PEDAL COMPONENT
DISASSEMBLY/ASSEMBLY ........................ F2-44
FUEL SYSTEM................................................... F2-45
BEFORE REPAIR PROCEDURE .................... F2-45
AFTER REPAIR PROCEDURE ....................... F2-45
FUEL TANK REMOVAL/INSTALLATION ........ F2-45
FUEL TANK INSPECTION .............................. F2-49
NONRETURN VALVE INSPECTION............... F2-50
FUEL FILTER COMPONENT
REMOVAL/INSTALLATION .......................... F2-50
FUEL FILTER COMPONENT
DISASSEMBLY/ASSEMBLY ........................ F2-51
FUEL WARMER INSPECTION........................ F2-51
SEDIMENTOR WATER DRAINING................. F2-52
SEDIMENTOR SWITCH INSPECTION ........... F2-52
SUPPLY PUMP REMOVAL/INSTALLATION .. F2-53
SUPPLY PUMP INSPECTION......................... F2-54
SUCTION CONTROL VALVE INSPECTION ... F2-54
COMMON RAIL INSPECTION ........................ F2-54
FUEL INJECTOR REMOVAL/INSTALLATION F2-55
FUEL INJECTOR INSPECTION ...................... F2-56
EXHAUST SYSTEM........................................... F2-57
EXHAUST SYSTEM INSPECTION ................. F2-57
EXHAUST SYSTEM
REMOVAL/INSTALLATION .......................... F2-57
EMISSION SYSTEM........................................... F2-59
EGR VALVE REMOVAL/INSTALLATION........ F2-59
EGR VALVE INSPECTION .............................. F2-59
EGR SOLENOID VALVE (VACUUM)
INSPECTION ................................................ F2-60
EGR SOLENOID VALVE (VENT)
INSPECTION ................................................ F2-60
EGR CONTROL SOLENOID VALVE
INSPECTION ................................................ F2-61
INTAKE SHUTTER VALVE ACTUATOR
INSPECTION ................................................ F2-62
INTAKE SHUTTER SOLENOID VALVE
INSPECTION ................................................ F2-63
CONTROL SYSTEM........................................... F2-64
PCM REMOVAL/INSTALLATION .................... F2-64
PCM INSPECTION .......................................... F2-65
PCM CONFIGURATION .................................. F2-68
CLUTCH SWITCH INSPECTION .................... F2-68
NEUTRAL SWITCH INSPECTION .................. F2-69
IDLE SWITCH INSPECTION ........................... F2-70
IDLE SWITCH ADJUSTMENT ......................... F2-71
ACCELERATOR POSITION SENSOR
INSPECTION ................................................ F2-72
ACCELERATOR POSITION SENSOR
ADJUSTMENT .............................................. F2-73 FEATURES
SERVICE

F2–4
OUTLINE
CONTROL SYSTEM DIAGRAMA6E400218881204
.
End Of Sie
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

F2–14
EMISSION SYSTEM
OUTLINEA6E401601007201•The emission 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
End Of Sie
EMISSION SYSTEM
ItemMazda6
(GG,GY)Current
MPV (LW)
Remark for new model
MZR-CD (RF Turbo)
Rollover valve×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Shape has been changed
Check valve (two-way)×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Shape has been changed
Intake shutter valve actuator×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Intake shutter solenoid valve
(half) (full)×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
EGR valve×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
EGR solenoid valve (vacuum)
(vent)×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
EGR control solenoid valve×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
EGR water cooler×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Warm up oxidation catalytic
converter×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Oxidation catalytic converter×Same function as MPV (LW) MZR-CD (RF Turbo) engine model

EMISSION SYSTEM
F2–15
F2
STRUCTURAL VIEWA6E401601007202Engine room side
.
Fuel tank side
.
9
8
7
5
4
3
10
6
2
1
A6E40162018
1EGR water cooler
2EGR valve
3 Intake shutter solenoid valve (full)
4 Intake shutter solenoid valve (half)
5 EGR solenoid valve (vacuum)6 Warm up oxidation catalytic converter
7 Intake shutter valve actuator
8 Oxidation catalytic converter
9 EGR solenoid valve (vent)
10 EGR control solenoid valve
1
2
A6E40162019
1 Rollover valve2 Check valve (two-way)

LOCATION INDEX
F2–29
F2
End Of Sie
FUEL SYSTEMA6E400001006201Engine room side
1 Air cleaner
(See F2–36 INTAKE-AIR SYSTEM REMOVAL/
INSTALLATION)
(See F2–37 AIR CLEANER ELEMENT
INSPECTION)
2 Turbocharger
(See F2–38 TURBOCHARGER INSPECTION)
3 Charge air cooler
(See F2–36 INTAKE-AIR SYSTEM REMOVAL/
INSTALLATION)
4 Intake manifold
(See F2–36 INTAKE-AIR SYSTEM REMOVAL/
INSTALLATION)
5 Guide blade actuator
(See F2–39 GUIDE BLADE ACTUATOR
INSPECTION)
6 VBC solenoid valve
(See F2–40 VARIABLE BOOST CONTROL (VBC)
SOLENOID VALVE INSPECTION)7 VBC check valve
(See F2–41 VARIABLE BOOST CONTROL (VBC)
CHECK VALVE INSPECTION)
8 VSC valve actuator
(See F2–41 VARIABLE SWIRL CONTROL (VSC)
VALVE ACTUATOR INSPECTION)
9 VSC solenoid valve
(See F2–42 VARIABLE SWIRL CONTROL (VSC)
SOLENOID VALVE INSPECTION)
10 Accelerator pedal component
(See F2–44 ACCELERATOR PEDAL
COMPONENT REMOVAL/INSTALLATION)
(See F2–44 ACCELERATOR PEDAL
COMPONENT DISASSEMBLY/ASSEMBLY)
11 Glow plug
(See F2–42 GLOW PLUG REMOVAL/
INSTALLATION)
(See F2–43 GLOW PLUG INSPECTION)
12 Glow plug lead
(See F2–43 GLOW PLUG LEAD INSPECTION)
9
8
7
5
4
3
6
10
6
4
3
L.H.D.
R.H.D.
A6E40002003

ENGINE TUNE-UP, INTAKE-AIR SYSTEM
F2–35
F2
Injection Amount Correction
Note
•Perform this procedure at the recommended interval as described under “Fuel injection system” in
“SCHEDULED MAINTENANCE.”
1. Perform “Engine Tune-up Preparation”. (See F2–34 ENGINE TUNE-UP PREPARATION.)
2. Perform “Injection Amount Correction” using the WDS or equivalent.
MAF Correction
Note
•Perform this procedure after replacing the MAF/IAT sensor or at the recommended interval as described
under “E.G.R. system” in “SCHEDULED MAINTENANCE.”
1. Perform “Engine Tune-up Preparation”. (See F2–34 ENGINE TUNE-UP PREPARATION.)
2. Perform “MAF Correction” using the WDS or equivalent.
End Of Sie
VACUUM TUBE ROUTING DIAGRAMA6E401020030201
End Of Sie
INTAKE-AIR SYSTEM
EGR CONTROL SOLENOID
VA LV E
VBC SOLENOID VALVE
VBC CHECK VALVE
EGR SOLENOID VALVE
(VACUUM)EGR SOLENOID VALVE
(VENT) VSC SOLENOID VALVE
VSC SHUTTER VALVE
ACTUATOR
INTAKE SHUTTER VALVE
ACTUATOREGR VALVE
INTAKE SHUTTER
SOLENOID VALVE
(HALF)
INTAKE SHUTTER
SOLENOID VALVE
(FULL)VBC VACUUM DAMPER GUIDE BLADE ACTUATOR
A6E40102007

F2–36
INTAKE-AIR SYSTEM
INTAKE-AIR SYSTEM REMOVAL/INSTALLATIONA6E401001005203
Warning
•When the engine and intake-air system are hot, they can cause severe burns or injury. Turn off the
engine and wait until they are cool before removing or installing the intake-air system.
•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 injuries or death and
damage, Fuel can also irritate skin and eyes. To prevent this, always complete the following “Fuel
Line Safety Procedure”. (See F2–45 Fuel Line Safety Procedures.)
Note
•Perform “ MAF Correction” after replacing the MAF/IAT sensor. (See F2–35 MAF Correction.)
1. Disconnect the negative battery cable.
2. Remove the front bumper.
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.
.
A
A
C
C
B
B
20—30
{2.1—3.1, 15—22}
19—25
{1.9—2.6, 14—18}6.9—9.8 N·m
{70—100 kgf·cm,
61—86 in·lbf}
2.5—3.4 N·m
{25—35 kgf·cm,
22—30 in·lbf}
6.9—9.8 N·m
{70—100 kgf·cm,
61—86 in·lbf} 7.8—11.8 N·m
{80—120 kgf·cm,
70—104 in·lbf}
6.9—9.8 N·m
{70—100 kgf·cm,
61—86 in·lbf} 17.6—26.5
{1.8—2.7,
13.0—19.8}6.9—9.8 N·m
{70—100 kgf·cm,
61—86 in·lbf}
6.9—9.8 N·m
{70—100 kgf·cm,
61—86 in·lbf}
2.5—3.4 N·m
{25—35 kgf·cm,
22—30 in·lbf}
TO EGR CONTROL SOLENOID VALVE
AND EGR SOLENOID VALVE (VENT)
TO VBC
CHECK VALVE
TO INTAKE SUTTER
SOLENOID VALVE (HALF)
9
10
19
17
11
20
21
1
2
3
5
4
7
6
8
12
14
13
15
16
18
0.55—0.85 N·m
{5.6—8.6 kgf·cm,
4.9—7.5 in·lbf}
N·m {kgf·m, ft·lbf}
R
RR
R
17.6—26.5
{1.8—2.7,
13.0—19.8}17.6—26.5
{1.8—2.7,
13.0—19.8}
4.9 N·m
{50 kgf·cm, 43 in·lbf}
4.9 N·m
{50 kgf·cm,
43 in·lbf}
4.9 N·m
{50 kgf·cm, 43 in·lbf}4.9 N·m
{50 kgf·cm,
43 in·lbf}
4.9 N·m
{50 kgf·cm,
43 in·lbf}
4.9 N·m
{50 kgf·cm,
43 in·lbf}
RUBBER MOUNT
(FRAME SIDE) RUBBER MOUNT
(ENGINE SIDE)
TO VBC
SOLENOID
VA LV E
A6E4010L030