2002 MAZDA 6 fuses

F2–168
TROUBLESHOOTING
×: Applicable
Troubleshooting item
1 Melting of main or other fuses
2 MIL illuminates
3 Will not crank
4 Hard start/long crank/erratic start/erratic crank×××
5 Engine stalls After start/at idle×××
6 Cranks normally but will not start××
7 Slow return to idle×
8 Engine runs rough/rolling idle××××
9 Fast idle/runs on×
10 Low idle/stalls during deceleration××
11Engine stalls/quits Acceleration/cruise××××
Engine runs rough Acceleration/cruise×××× ×
Misses Acceleration/cruise××××××
Buck/jerk Acceleration/cruise/ deceleration××××××
Hesitation/stumble Acceleration××××××
Surges Acceleration/cruise××××××
12 Lack/loss of power Acceleration/cruise×××××××
13 Knocking/pinging×××××
14 Poor fuel economy××××
15 Emissions compliance× ××××××
16 High oil consumption/leakage
17 Cooling system concerns Overheating×× × ×
18 Cooling system concerns Runs cold××
19 Excessive black smoke××××
20 Fuel odor (in engine compartment)
21 Engine noise××
22 Vibration concerns (engine)×× ×
23 A/C does not work sufficiently
24 A/C always on or A/C compressor runs continuously
25 A/C does not cut off under wide open throttle conditions
26 Constant voltage
Improper engine coolant levelWater and anti-freeze mixture is improperCooling system malfunction (Radiator, hose,
over-flow system, thermostat, etc.)Cooling fan system malfunctionEngine or transaxle mounts are improperly installedCooling fan No.1 or No.2 seat are improperFuel qualityEngine overheatingIntake-air system clogging or restrictionAir leakage from intake-air systemVSC system malfunctionVacuum leakage

TROUBLESHOOTING
F2–169
F2
×: Applicable
Troubleshooting item
1 Melting of main or other fuses
2 MIL illuminates×× × ×
3 Will not crank
4 Hard start/long crank/erratic start/erratic crank×× ×××××××
5 Engine stalls After start/at idle×× ×××××××
6 Cranks normally but will not start×× ×××××××
7 Slow return to idle××××××××
8 Engine runs rough/rolling idle×××××××××
9 Fast idle/runs on×
10 Low idle/stalls during deceleration××××××××××
11Engine stalls/quits Acceleration/cruise× × ×××××××
Engine runs rough Acceleration/cruise× ××××××××××
Misses Acceleration/cruise× ××××××××××
Buck/jerk Acceleration/cruise/ deceleration× ××××××××××
Hesitation/stumble Acceleration× ××××××××××
Surges Acceleration/cruise× ×× ×××××××
12 Lack/loss of power Acceleration/cruise××× ×××××××××
13 Knocking/pinging××××× ××× × ×
14 Poor fuel economy××× ×××××× ×
15 Emissions compliance×××××××××××××
16 High oil consumption/leakage×
17 Cooling system concerns Overheating×
18 Cooling system concerns Runs cold
19 Excessive black smoke××× × ××× ×××
20 Fuel odor (in engine compartment)××
21 Engine noise× ××× ×
22 Vibration concerns (engine)
23 A/C does not work sufficiently
24 A/C always on or A/C compressor runs continuously
25 A/C does not cut off under wide open throttle conditions
26 Constant voltage
Turbocharger malfunctionCarge air cooler malfunctionVBC system malfunctionGlow system malfunctionIncorrect fuel injection timingIncorrect idle speedCKP sensor is damaged (e.g.: open or short circuits)CKP sensor pulse wheel is damagedImproper gap between CKP sensor and pulse wheelSupply pump malfunctionSuction control valve malfunctionFuel pressure limiter malfunctionFuel line restriction or clogging

F2–170
TROUBLESHOOTING
×: Applicable
Troubleshooting item
1 Melting of main or other fuses
2 MIL illuminates××
3 Will not crank
4 Hard start/long crank/erratic start/erratic crank× × ××××× ×
5 Engine stalls After start/at idle×××××××××
6 Cranks normally but will not start× × ×××× × ×
7 Slow return to idle××××
8 Engine runs rough/rolling idle× × ×××× ××
9 Fast idle/runs on××
10 Low idle/stalls during deceleration× × ×××× ×
11Engine stalls/quits Acceleration/cruise× ××××× ×
Engine runs rough Acceleration/cruise× ××××× ×
Misses Acceleration/cruise× ××××× ×
Buck/jerk Acceleration/cruise/ deceleration× ××××× ×
Hesitation/stumble Acceleration× ××××× ×
Surges Acceleration/cruise× ××××× ×
12 Lack/loss of power Acceleration/cruise× ××××× ×
13 Knocking/pinging××××
14 Poor fuel economy×××××××
15 Emissions compliance× ×××××××
16 High oil consumption/leakage
17 Cooling system concerns Overheating×
18 Cooling system concerns Runs cold
19 Excessive black smoke××××
20 Fuel odor (in engine compartment)×
21 Engine noise××××
22 Vibration concerns (engine)×××
23 A/C does not work sufficiently
24 A/C always on or A/C compressor runs continuously
25 A/C does not cut off under wide open throttle conditions
26 Constant voltage×
Fuel injectors malfunction (Leakage or clogging,
inoperative)Fuel leakage from fuel system (including insulator,
fuel injector)Fuel filter restriction or cloggingCMP sensor is damaged (e.g: open or short circuit)CMP sensor pulse wheel is damagedIDM or related circuit malfunctionExhaust system restriction or cloggingCatalyst converter malfunctionEGR system malfunctionEGR water cooler malfunctionV-reference voltage supply circuit malfunction

TROUBLESHOOTING
F2–171
F2
×: Applicable
Troubleshooting item
1 Melting of main or other fuses
2 MIL illuminates×××××× × ×××
3 Will not crank
4 Hard start/long crank/erratic start/erratic crank×× ×× ×
5 Engine stalls After start/at idle×× × × × ××
6 Cranks normally but will not start×× ×
7 Slow return to idle××× × × ×××
8 Engine runs rough/rolling idle××× × × ××××
9 Fast idle/runs on×××
10 Low idle/stalls during deceleration××× × × ××××
11Engine stalls/quits Acceleration/cruise× × × × ××××
Engine runs rough Acceleration/cruise××× × × ××××
Misses Acceleration/cruise× × × × ××××
Buck/jerk Acceleration/cruise/ deceleration× ×××× × ××××
Hesitation/stumble Acceleration× ×××× × ××××
Surges Acceleration/cruise× ×××× × ××××
12 Lack/loss of power Acceleration/cruise× ×××× × ××××
13 Knocking/pinging××××× ×
14 Poor fuel economy× ×××× ×××
15 Emissions compliance×××××× × ×××
16 High oil consumption/leakage
17 Cooling system concerns Overheating×
18 Cooling system concerns Runs cold
19 Excessive black smoke×× ×
20 Fuel odor (in engine compartment)×
21 Engine noise××××× ×
22 Vibration concerns (engine)×× ××××
23 A/C does not work sufficiently×
24 A/C always on or A/C compressor runs continuously
25 A/C does not cut off under wide open throttle conditions××
26 Constant voltage××××× ×
PCM control relay malfunctionECT sensor or related circuit malfunctionNeutral switch or related circuit malfunctionMAF/IAT sensor or related circuit malfunctionIAT sensor No.2 or related circuit malfunctionBoost sensor or related circuit malfunctionAccelerator position sensor or related circuit malfunctionAccelerator position sensor misadjustment
(including looseness)Idle switch or related circuit malfunctionIdle switch misadjustment (including looseness)Fuel pressure sensor or related circuit malfunctionImproper refrigerant charging amount

F2–172
TROUBLESHOOTING
×: Applicable
End Of Sie
Troubleshooting item
1 Melting of main or other fuses
2 MIL illuminates
3 Will not crank×
4 Hard start/long crank/erratic start/erratic crank
5 Engine stalls After start/at idle×× ×
6 Cranks normally but will not start×
7 Slow return to idle
8 Engine runs rough/rolling idle×××
9 Fast idle/runs on
10 Low idle/stalls during deceleration××
11Engine stalls/quits Acceleration/cruise××××
Engine runs rough Acceleration/cruise××××
Misses Acceleration/cruise××××
Buck/jerk Acceleration/cruise/ deceleration××××
Hesitation/stumble Acceleration××××
Surges Acceleration/cruise××××
12 Lack/loss of power Acceleration/cruise×× × ×
13 Knocking/pinging
14 Poor fuel economy××××× ×
15 Emissions compliance×
16 High oil consumption/leakage
17 Cooling system concerns Overheating××× ×
18 Cooling system concerns Runs cold××
19 Excessive black smoke
20 Fuel odor (in engine compartment)
21 Engine noise××
22 Vibration concerns (engine)××××
23 A/C does not work sufficiently××
24 A/C always on or A/C compressor runs continuously××
25 A/C does not cut off under wide open throttle conditions
26 Constant voltage
A/C relay (A/C control siganl) circuit malfunctionA/C magnetic clutch or related circuit malfunctionCooling fan No.1 system malfunctionClutch slippageAir in power steering fuluid lineVSS or related circuit malfunctionBrake draggingLoose partsImproper balance of wheel or tiresDriveline malfunctionSuspension malfunctionImmobilizer system and/or circuit malfunctionCoolant heater system malfunction

TROUBLESHOOTING
F2–173
F2
NO.1 MELTING OF MAIN OR OTHER FUSESA6E408018881203
End Of Sie
1 Melting of main or other fuses
[TROUBLESHOOTING HINTS]
Inspect condition of fuse.
Damaged fuse Related wiring harness
MAINMAIN fuse
•BTN fuse
•FAN fuse
•AD FAN fuse
•IG KEY 2 fuse
IG KEY 1IG KEY 1 fuse
•Engine switch
—ENGINE fuse
FUEL PUMPFUEL PUMP fuse
•Fuel warmer
•PCM control relay
BTNBTN fuse
•ROOM fuse
IG KEY 2IG KEY 2 fuse
•Engine switch
ROOMROOM fuse
•DLC-2
ENGINEENGINE fuse
•PCM
INJINJ fuse
•PCM
•IDM
•MAF/IAT sensor
•VSC solenoid valve
•VBC solenoid valve
•EGR control solenoid valve
•EGR solenoid valve (vacuum)
•EGR solenoid valve (vent)
•Intake shutter solenoid valve (half)
•Intake shutter solenoid valve (full)
GLOWGLOW fuse
•Glow plug relay
—Glow plug
—GLOW SIG
ENG+BENG+B fuse
•PCM
FANFAN fuse
•Cooling fan relay No.2
AD FANAD FAN fuse
•Cooling fan relay No.1
Shorted harness
Repair shorted harness and replace fuseFuseDeterioration
Replace fuse

TROUBLESHOOTING
F2–175
F2
End Of Sie
5 Is there continuity between PCM GND terminals
65, 85, 103, 104 and GND?Yes Go to next step.
No Repair or replace wiring harness.
6 Measure voltage between PCM GND terminals
65, 85, 103, 104 and coil terminal C.
Is the voltage below 1.0?Yes Go to next step.
No Repair or replace wiring harness.
7 Turn engine switch to ON.
Access VPWR PID.
Is VPWR PID okay?
Specification
Battery voltageYes Go to next step.
No Repair or replace wiring harness.
8 Disconnect coil connector.
Turn engine switch to ON.
Is there battery voltage at coil connector terminal
D (harness-side)?Yes Inspect for following:
•Open or short circuit between coil terminal A and
PCM terminal 80
•Open or short circuit between coil terminal B and
PCM terminal 28
No Repair or replace wiring harness between coil
connector terminal D and fuse panel.
9 Is there continuity between PCM terminal 57 and
starter relay?Yes Go to next step.
No Repair replace wiring harness.
10 Inspect following:
•Battery connection
•Battery condition
•Fuses
Are all items okay?Yes Go to next step.
No Service as necessary.
Repeat Step 10.
11 Is clicking sound heard from starter when engine
switch is turned to START?Yes Go to Step 13.
No Go to next step.
12 Inspect starting system.
Is starting system okay?Yes Inspect for seized/hydrolocked engine, flywheel.
No Repair or replace components as required.
13 Do any other electrical accessories work? Yes Go to next step.
No Inspect charging system.
14 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:
Inspect for following:
•START circuit in engine switch
•Open circuit between engine switch and starter
15 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) STEP INSPECTION RESULTS ACTION

G–6
CHARGING SYSTEM
BATTERY INSPECTIONA6E471018520202MZR-CD (RF Turbo)
Battery
1. Inspect the battery with the following procedure.
Load test chart
Battery positive voltage with load
Back-up Current
1. Verify that the engine switch is off and that the engine key has been removed.
2. Disconnect the negative battery cable.
Caution
•Operating electrical loads while measuring the back-up current can damage the circuit tester.
3. Measure the back-up current between the negative battery terminal and the negative battery cable.
(1) If the current exceeds the maximum, remove the fuses in the main fuse block and the fuse block one by
one while measuring the back-up current.
(2) Inspect and repair harnesses and connectors on the fuse where the current has been reduced.
Back-up current
20 mA max.
End Of Sie
BATTERY RECHARGINGA6E471018520203MZR-CD (RF Turbo)
Caution
•To avoid damage to the battery, do not quick charge for over 30 min.
•When disconnecting the battery, remove the negative cable first and install it last to prevent
damage to electrical components or the battery.
•To avoid deformation or damage to the battery, remove the battery plugs while charging the
battery.
Step Inspection Result Action
1Measure open circuit
voltage of battery.Above
12.4 VGo to Step
3.
Below
12.4 VGo to next
step.
2Quick-charge for 30 min.
and recheck voltage.Above
12.4 VGo to next
step.
Below
12.4 VReplace
battery.
3Apply load test (see load
test chart) to battery using a
battery load tester and
record battery voltage after
15 s. Is voltage more than
specification?YesBattery
okay.
NoReplace
battery.
Battery Load (A)
95D31L (64) 250
115D31L (70) 320
Approximate battery temp. Minimum voltage (V)
21°C {70°F} 9.6
15°C {60°F} 9.5
10°C {50°F} 9.4
4°C {40°F} 9.3
–1°C {30°F} 9.1
–7°C {20°F} 8.9
–12°C {10°F} 8.7
–18°C {0°F} 8.5