2002 MAZDA 6 fuel pump

F1–2
OUTLINE
OUTLINE OF CONSTRUCTIONA6E390218881201•The fuel and emission control systems are essentially carried over from the current Mazda6 (GG), except for
the following features. (See Mazda6 Training Manual 3359-1*-02C.)
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FEATURESA6E390218881202System simplification
•Controller area network has been adopted with TCM communication (4WD).
TCM adoption
•DTC for CAN (TCM communication) has been adopted.
Modifications to match the vehicle characteristics
•The idle speed has been modified.
•Fuel pump (transfer) has been adopted.
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SPECIFICATIONSA6E390218881203
*1: Without the BARO sensor
*2: With the BARO sensor
Bold frames: New specifications
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OUTLINE
Item 2WD 4WD
Air cleaner element Type Paper element (oil permeated)
IAC valve Type Duty control
Fuel injectorType Hi-ohmic
Type of fuel delivery Top-feed
Type of drive Voltage
Pressure regulatorRegulating pressure
(kPa {kgf/cm
2, psi})440 {4.5, 64}
Fuel tankCapacity
(L {US qt, lmp qt})64 {68, 56} 62 {65, 54}
Fuel SpecificationUnleaded
(RON 90*
1/95*2 or above)Unleaded (RON 95 or above)
Catalyst Type TWC (monolythic)
EGR control Type Stepping motor type
Evaporative emission control
systemType Canister type
PCV system Type Closed type

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

OUTLINE
F1–5
F1
11 Knock sensor
12 CKP sensor
13 CMP sensor
14 Fuel injector No.1
15 Fuel injector No.2
16 Fuel injector No.3
17 Fuel injector No.4
18 IAC valve
19 Oxygen sensor heater (front)
20 Oxygen sensor heater (rear)
21 A/C relay22 Cooling fan relay
23 Cooling fan relay
24 Cooling fan relay
25 TR switch
26 Fuel pump relay
27 Coil
28 Security light
29 Ignition switch
30 Main relay
31 TR switch
32 Starter relay

F1–8
OUTLINE
.
15 Fuel injector No.2
16 Fuel injector No.3
17 Fuel injector No.4
18 IAC valve
19 Oxygen sensor heater (front)
20 Oxygen sensor heater (rear)
21 A/C relay22 Cooling fan relay
23 Cooling fan relay
24 Cooling fan relay
25 Cooling fan relay
26 Fuel pump relay
27 Ignition switch
28 Main relay
1AA
1Q
1Z
1AC
1K
1C1D 4M4R 4N4K 4H4E
4T 4C4U 1AD1B 1A 2AB4X
39
38
37
35
36
33
31
32
40
44
43
41
42
34
29
30
A6E39022004
29 Generator
30 Refrigerant pressure switch (middle)
31 PSP switch
32 Blower motor
33 Refrigerant pressure switch (high and low)
34 A/C switch
35 Brake switch
36 Brake light37 Ignition coil
38 Generator
39 Purge solenoid valve
40 VAD control solenoid valve
41 EGR valve
42 Variable tumble control solenoid valve
43 VIS control solenoid valve
44 OCV

FUEL SYSTEM
F1–9
F1
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OUTLINEA6E391201006201•The fuel system is essentially carried over from that of the current Mazda6 (GG), except for the following. (See
Mazda6 Training Manual 3359-1*-02C.)
—A saddle type fuel tank has been adopted.
—A fuel pump (transfer) for fuel transmission has been added.
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STRUCTURAL VIEWA6E391201006202
.
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FUEL SYSTEM
7
5
4
3
6
1
2
A6E39122001
1 Fuel gauge sender sub-unit
2 Quick release connector (fuel tank side, transfer
hose part)
3 Non-return valve4 Quick release connector (fuel tank side, main fuel
pipe part)
5 Fuel tank
6 Fuel pump unit
7 Filler cap

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

FUEL SYSTEM
F1–11
F1
Operation
•The fuel jet pump (venturi) is installed in the return passage from the pressure regulator, and fuel in the fuel
tank is pumped to the left side from the right side using the vacuum generated in the passage.
•When the return fuel pressure exceeds a specified value, the relief valve is opened. The relief valve delivers the
return fuel directly to the fuel tank. In this way, pressure of the return fuel passing through the fuel jet pump is
kept constantly below the specified value.
.
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9
8
7
54
3
10
14
13
11
12
6
1
2
:
:
2
15
A6E39122003
1 Fuel pump unit
2 Fuel pump (transfer)
3 Fuel injector
4 Fuel tank (left side)
5 Fuel tank (right side)
6 Relief valve
7 Discharge outlet
8 From pressure regulator9 From fuel tank (right side)
10 Fuel jet pump
11 To fuel tank (left side)
12 Fuel jet pump
13 From fuel tank (left side)
14 Fuel flow
15 Pumped fuel flow

F1–14
CONTROL SYSTEM
OUTLINEA6E394018880201•The control system is essentially carried over from the current Mazda6 (GG), except for the following. (See
Mazda6 Training Manual 3359-1*-02C.)
Vehicle Adoption
4WD ATX model
•TCM has been adopted. Due to this the PCM terminal of ATX device has been replaced to TCM. The ATX
device information which is needed by the fuel and emission control systems is communicated to the PCM by
the controller area network (CAN).
Unleaded (RON 90 or above) model
•BARO sensor has been eliminated. Due to this the BARO factor for purge control has been eliminated.
Input Device
×:Applicable
—: Not applicable
*
1: For MTX model
*2: With Immobilizer system
CONTROL SYSTEM
Item SignalMazda6 (GG, GY)
Remark for new model
4WD ATX Unleaded
(RON 90 or
above)Current
model
MAF/IAT sensor MAF and IAT×Same as current model
TP sensor TP×Same as current model
MAP sensor MAP×Same as current model
ECT sensor ECT×Same as current model
CMP sensorCylinder
identification×Same as current model
CKP sensor Engine revolution×Same as current model
Knock sensor Knocking×Same as current model
HO2S (Front, Rear)Oxygen
concentration×Same as current model
BARO sensor BARO×—×Same as current model
Neutral switch*
1Load/no load
distinction×Same as current model
Clutch switch*
1Load/no load
distinction×Same as current model
Brake switchBrake pedal
condition×Same as current model
PSP switchP/S oil pump load
condition×Same as current model
VSS Vehicle speed—×—
A/C switch, refrigerant
pressure switch (high,
low pressure)A/C operational×Same as current model
Refrigerant pressure
switch (middle
pressure)A/C compressor load×—×Same as current model
Battery Battery voltage×Same as current model
Generation voltage
(Generator terminal P)Generation voltage×Same as current model
Immobilizer unit*
2Immobilizer system
communication×—×Same as current model