2002 MAZDA 6 fuel filter

SCHEDULED MAINTENANCE
GI–17
GI
Scheduled Maintenance Service (Specific Work Required)
•The specific work required for each maintenance item is listed in the following table. (Please refer to the section
applicable to the model serviced.)
For Europe (L.H.D. U.K.)
Bold frames: New item
Maintenance Item Specific Work Required
ENGINE
Engine valve clearance Measure clearance
Drive beltsInspect for wear, cracks and fraying, and check tension.
Replace drive belt.
Engine timing belt Replace engine timing belt.
Engine oil Replace engine oil and inspect for leakage.
Oil filter Replace oil filter and inspect for leakage.
COOLING SYSTEM
Cooling system
(including coolant level adjustment)Check coolant level and quality, and inspect for leakage.
Engine coolant Replace coolant.
FUEL SYSTEM
Air cleaner elementInspect for dirt, oil and damage.
Clean air cleaner element (by blowing air).
Replace air cleaner element.
Fuel filter Replace fuel filter.
Fuel lines and hoses Inspect for cracks, leakage and loose connection.
Fuel injection system (for MZR-CD (RF Turbo)) Update to injection amount correction with WDS. (see W/M)
IGNITION SYSTEM (FOR GASOLINE)
Spark plugsInspect for wear, damage, carbon, high-tension lead condition and measure
plug gap.
Replace spark plugs.
EMISSION CONTROL SYSTEM
Evaporative system (for gasoline)Check system operation (see W/M), vapor lines, vacuum fitting hoses and
connection.
E.G.R. system (MZR-CR (RF Turbo))Check system operation (see W/M), vacuum fitting hoses and connection.
Update to MAF correction for E.G.R control with WDS. (see W/M)
ELECTRICAL SYSTEM
Battery electrolyte level and specific gravity Check level and specific gravity.
CHASSIS AND BODY
Brake fluidCheck fluid level and inspect for leakage.
Replace brake fluid.
Brake lines, hoses and connectionsInspect for cracks, damage, chafing, corrosion, scars, swelling and fluid
leakage.
Parking brake Check lever stroke.
Power brake unit and hosesCheck vacuum lines, connections and check valve for improper attachment,
air tightness, cracks chafing and deterioration.
Disc brakesTest for judder and noise. Inspect caliper for correct operation and fluid
leakage, brake pads for wear. Check disc plate condition and thickness.
Power steering fluid and linesCheck fluid level and lines for improper attachment, leakage, cracks,
damage, loose connections, chafing and deterioration.
Power steering fluid Check fluid level.
Power steering system and hosesCheck lines for improper attachment, leakage, cracks, damage, loose
connections, chafing and deterioration.
Steering operation and gear housingCheck that the steering wheel has the specified play. Be sure to check for
changes, such as excessive play, hard steering or strange noises.
Check gear housing and boots for looseness, damage and grease/gear oil
leakage.
Steering linkages tie rod ends and armsCheck ball joint, dust cover and other components for looseness, wear,
damage and grease leakage.
Front and rear suspension and ball joints Inspect for grease leakage, cracks, damage and looseness.
Manual transmission/transaxle oilCheck oil level and inspect for leakage.
Replace manual transmission/transaxle oil.
Automatic transmission/transaxle fluid level Check fluid level.

COMPRESSION PRESSURE, TIMING BELT
B2–9
B2
7. Install the SSTs into the glow plug hole.
8. Crank the engine and note the maximum gauge
reading.
9. Inspect each cylinder as above.
•If the compression in one or more cylinders is
low, pour a small amount of clean engine oil
into the cylinder and reinspect the
compression.
—If the compression increases, the piston,
the piston rings, or cylinder wall may be
worn and overhaul is required.
—If the compression stays low, a valve may
be stuck or improperly seated and
overhaul is required.
—If the compression in adjacent cylinders stays low, the cylinder head gasket may be damaged or the
cylinder head may be distorted and overhaul is required.
Compression
kPa {kgf/cm
2, psi} [rpm]
10. Remove the SSTs.
11. Install the glow plug. (See F2–42 GLOW PLUG REMOVAL/INSTALLATION.)
12. Instal the engine cover. (See B2–9 TIMING BELT REMOVAL/INSTALLATION.)
13. Reconnect the fuel injector connector.
14. Erase DTC from PCM memory using the SST. (WDS or equivalent).
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TIMING BELT REMOVAL/INSTALLATIONA6E231612040201
Warning
•Fuel vapor is hazardous. It can very 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 injures or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line
Safety Procedure”. (See F2–45 Fuel Line Safety Procedures.)
1. Disconnect the negative battery cable.
2. Remove the front tire (RH).
3. Remove the splash shield (RH).
4. Remove the washer tank.
5. Remove the drive belt. (See B2–4 DRIVE BELT REPLACEMENT.)
6. Remove the fuel filter with the fuel hose still connected and position the fuel filter so that it is out of the way.
( L.H.D.) (See F2–50 FUEL FILTER COMPONENT REMOVAL/INSTALLATION.)
7. Remove in the order shown in the table.
8. Install in the reverse order of removal.
9. Start the engine and inspect the pulleys and the drive belt for runout and contact.
Item Specification
Standard 3,500 {35.7, 507.7} [250]
Minimum 3,100 {31.6, 449.4} [250]
Maximum difference
between cylinders196.1 {1.999, 28.44}
49 S010 1A0
49 S013 102
A6E2314W101
TIMING BELT

OUTLINE
F1–3
F1
CONTROL SYSTEM DIAGRAM (4WD)A6E390218881204
.
* : Equipped for L3 engine modelEnd Of Sie
9
8
7
54
3
10
19
18
17
15
16
14
13
11
12
20
29
28
27
25
26
24
23
21
22
30
3938
3735
33
36
31
32
40
6
1
2
3441
A6E39022000
1PCM
2 Ignition coil
3 Generator
4* VAD shutter valve
5 Air cleaner
6 MAF sensor
7* VAD shutter valve actuator
8* VAD control solenoid valve
9* Vacuum chamber
10* VAD check valve (one-way)
11 IAC valve
12 Purge solenoid valve
13 TP sensor
14 MAP sensor
15* VIS control solenoid valve
16 Variable tumble control solenoid valve
17* VIS shutter valve actuator
18* VIS shutter valve
19 VTCS shutter valve actuator
20 VTCS shutter valve
21 Fuel injector22* OCV
23 CMP sensor
24 EGR valve
25 Knock sensor
26 ECT sensor
27 PCV valve
28 CKP sensor
29 HO2S (front)
30 HO2S (rear)
31 Charcoal canister
32 Check valve (two-way)
33 Pressure regulator
34 Fuel filter (high-pressure)
35 Fuel pump
36 Fuel filter (low-pressure)
37 Fuel tank
38 Rollover valve
39 Pulsation damper
40 Fuel pump (transfer)
41 To PCM

F1–10
FUEL SYSTEM
SYSTEM DIAGRAMA6E391201006203
.
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FUEL PUMP (TRANSFER)A6E391213350201Function
•The fuel tank for 4WD is saddle type. Fuel in the fuel gauge sender sub-unit side (right side) is pumped to the
left side of the fuel tank using the fuel pump (transfer).
Structure
•The fuel pump (transfer) is integrated into the fuel pump unit and it cannot be separately disassembled.
•The fuel pump (transfer) is composed of a relief valve and fuel jet pump.
87
5
4
3
6
1
2
:
9
10
A6E39122002
1 Filler cap
2 Pressure regulator
3 Fuel pump (transfer)
4 Fuel filter (high-pressure)
5Fuel pump6 Fuel filter (low-pressure)
7 Fuel pump unit
8 Pulsation damper
9 Fuel injector
10 Fuel flow

F1–26
FUEL SYSTEM
FUEL PUMP UNIT REMOVAL/INSTALLATIONA6E391213350202
Warning
•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, do not damage the sealing surface of
the fuel pump unit when removing or installing.
Caution
•Disconnecting/connecting the quick release connector without cleaning it may possibly cause
damage to the fuel pipe and quick release connector. Always clean the quick release connector
joint area before disconnecting/connecting using a cloth or soft brush, and make sure that it is
free of foreign material.
Note
•Since the fuel pump unit is integrated with the fuel filter, it needs to be replaced every 75,000 km.
1. Complete the “BEFORE REPAIR PROCEDURE”.
2. Disconnect the negative battery cable.
3. Complete the following in order to the work area.
(1) Loosen the bolt of the fuel tank strap.
(2) Lower the fuel tank to a position where the SST can be attached from the service hole cover.
4. Remove the rear seat cushion.
5. Remove in the order indicated in the table.
.
6. Install in the reverse order of removal.
7. Complete the “AFTER REPAIR PROCEDURE”.
8. Complete the “Fuel Leak Inspection After Fuel
Pump Unit Installation.“ (See F1–28 Fuel Leak
Inspection After Fuel Pump Unit Installation.)
1 Service hole cover
2 Connector
3 Plastic fuel hose (fuel tank side, main fuel pipe part)
(See F1–27 Plastic Fuel Hose Removal Note)
(See F1–28 Plastic Fuel Hose Installation Note)
4 Plastic fuel hose (fuel tank side, transfer hose part)
(See F1–29 FUEL HOSE (FUEL TANK SIDE,
TRANSFER HOSE PART) REMOVAL/
INSTALLATION)
5Fuel pump cap
(See F1–27 Fuel Pump Cap Removal Note)
(See F1–28 Fuel Pump Cap Installation Note)
6 Packing
7 Fuel pump unit
3
7
1
4
5
2
6
80—90 {8.2—9.1, 60—66}
R
SST
N·m {kgf·m, ft·lbf}
A6E39122009

F1–60
TROUBLESHOOTING
X: Applicable
Possible factor
Troubleshooting item
Injectors malfunction (Leakage or clogging, inope-rative
Fuel leakage from fuel system (including insulator,
injector O-ring)
Fuel filters restriction or clogging
CMP sensor is damaged. (e.g. open or short circuit)
Camshaft is damaged.
Improper air/fuel mixture ratio control
Exhaust system restriction or clogging
Catalytic converter malfunction
EGR system malfunction (Unleaded gasoline models)
EVAP control system malfunction
PCV valve malfunction
Constant voltage supply circuit malfunction
Main relay malfunction (Mechanically or electrically)
ECT sensor malfunction
TR sensor misadjustment (ATX)
TR sensor malfunction (ATX)
Break switch and related circuit malfunction
Manifold absolute pressure sensor and related circuit
malfunction
HO2S and related circuit malfunction (Unleaded
gasoline models)
Variable resistor misadjustment (Leaded gasoline
models)
Improper electrically controlled 4WD system operation
1 Melting of main or other fuses2 MIL illuminates x x x x x x x3 Will not crankxx4 Hard to start/long crank/erratic start/erratic
crankx xx xxx x
5 Engine stalls. After start/at idle x x x x x x x x x6 Cranks normally but will not start x x x xxxxxx x7 Slow return to idlex8 Engine runs rough/rolling idle xxxxxx xxx x9 Fast idle/runs onx10 Low idle/stalls during deceleration x x x x xEngine stalls/quits.Acceleration/cruisex xxxxx xxxxx xEngine runs rough. Acceleration/cruisex xxxxx xxxxx xMissesAcceleration/cruisex xxxxx xxxxx xBuck/jerk Acceleration/cruise/
decelerationx xxxxx xxxxx x
Hesitation/stumble Acceleration xxxxxx xxxxx x
11
Surges Acceleration/cruise xxxxxx xxxxx x
12 Lack/loss of power Acceleration/cruise x x x x x x x x13 Knocking/pingingAcceleration/cruise x14 Poor fuel economy x x x x x x15 Emission compliancexxxxxxxxx x16 High oil consumption/leakage x17 Cooling system concerns Overheating18 Cooling system concernsRuns cold19 Exhaust smoke x x20 Fuel odor (in engine compartment) x x21 Engine noise22 Vibration concerns (engine)x23 A/C does not work sufficiently.24 A/C is always on or A/C compressor runs
continuously.
25 A/C is not cut off under WOT conditions.26 Exhaust sulfur smell x x27 Constant voltage x x x x x28 Spark plug condition x x x x29 ATX concernsUpshift/downshift/en
gagementSee Section K, TROUBLESHOOTING
A6E39802003

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
.
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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