2002 MAZDA 6 wheel

F1–58
TROUBLESHOOTING
QUICK DIAGNOSTIC CHARTA6E398018881202
X: Applicable
Possible factor
Troubleshooting item
Starter motor malfunction (Mechanical or electrical)
Starter circuit including ignition switch is open.
Starter interlock switch malfunction (MTX with starter
interlock system)
Improper engine oil level
Low or dead battery
Charging system malfunction
Improper engine compression
Improper valve timing
Hydrolocked engine
Improper engine oil viscosity
Improper dipstick
Base engine malfunction
Drive plate or flywheel are seized.
Improper tension or damaged drive belts
Improper engine coolant level
Water and anti-freeze mixture is improper.
Cooling system malfunction (Radiator, hoses,
overflow system, thermostat, etc.)
Cooling fan system malfunction
Engine or transaxle mounts are improperly installed.
Cooling fan or condenser fan seat are improper.
Accelerator cable free play misadjustment
Cruise control cable misadjustment
Fuel quality
1 Melting of main or other fuses2 MIL illuminates x x x x x x x3 Will not crank4 Hard to start/long crank/erratic start/erratic
crankx
5 Engine stalls. After start/at idle x x x x6 Cranks normally but will not start x x x x7 Slow return to idlex8 Engine runs rough/rolling idle x x x9 Fast idle/runs onxx10 Low idle/stalls during decelerationEngine stalls/quits. Acceleration/cruise x x xEngine runs rough. Acceleration/cruise x x xMissesAcceleration/cruise x x xBuck/jerk Acceleration/cruise/
decelerationxx x
Hesitation/stumble Acceleration x x x
11
Surges Acceleration/cruis
exx x12 Lack/loss of powerAcceleration/cruisexx x13 Knocking/pingingAcceleration/cruisexx14 Poor fuel economy x x x x x x15 Emission compliance x x x x16 High oil consumption/leakage x x x17 Cooling system concerns Overheatingxx x x x18 Cooling system concernsRuns cold x x19 Exhaust smoke x x x20 Fuel odor (in engine compartment)21 Engine noise x x x22 Vibration concerns (engine) x x 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 smellx27 Constant voltage28 Spark plug condition x x29 ATX concernsUpshift/downshift
engagementSee Section K, TROUBLESHOOTING
A6E39802001

TROUBLESHOOTING
F1–61
F1
End Of Sie
X: Applicable
Possible factor
Troubleshooting itemIAT sensor and related circuit malfunction
Barometric pressure sensor malfunction
Neutral or clutch switch and related circuit
malfunction (MTX)
MAF sensor and related circuit malfunction
Knock sensor and related circuit malfunction
TP sensor and related circuit malfunction
TP sensor misadjustment (including looseness)
P/S pressure switch and related circuit
malfunction
Improper refrigerant charging amount
A/C relay (A/C control signal circuit malfunction
A/C compressor magnetic clutch malfunction
Condenser fan system malfunction
Improper load signal input
Clutch slippage
ATX related parts malfunction
VSS and related circuit malfunction
Improper ATF level
Brake dragging
Loose parts
Improper balance of wheels and tires
Drive line malfunction
Suspension malfunction
PATS operating (if equipped)
1 Melting of main or other fuses2 MIL illuminates x x x x x x x x3 Will not crankx4 Hard to start/long crank/erratic
start/erratic crankx
5 Engine stalls. After start/at idle x x x x6 Cranks normally but will not startx7 Slow return to idle8 Engine runs rough/rolling idle x x x x x x9 Fast idle/runs onx10 Low idle/stalls during deceleration x x x x x xEngine stalls/quits.Acceleration/cruisex x xx xx xxxEngine runs rough. Acceleration/cruisex x xx xx xxxMissesAcceleration/cruisex xx xx xxxBuck/jerk Acceleration/cruise
/decelerationx xx xx xxx
Hesitation/stumble Acceleration x x x x x x x x x
11
Surges Acceleration/cruise x x x x x x x x
12 Lack/loss of power Acceleration/cruise x x x x x x x x13 Knocking/pingingAcceleration/cruise x x x14 Poor fuel economy x x x x x15 Emission compliance x16 High oil consumption/leakage17 Cooling system
concernsOverheating x x x
18 Cooling system
concernsRuns cold x
19 Exhaust smoke20 Fuel odor (in engine compartment)21 Engine noisex22 Vibration concerns (engine)xxxx23 A/C does not work sufficiently. x x x24 A/C is always on or A/C compressorruns continuously.xx25 A/C is not cut off under WOT conditions x x26 Exhaust sulfur smell27 Constant voltage x x x x x x28 Spark plug condition x x29 ATX concernsUpshift/downshift/e
ngagementSee Section K, TROUBLESHOOTING
A6E39802004

TROUBLESHOOTING
F1–63
F1
End Of Sie
4 Is strong blue spark visible at each disconnected
high-tension lead while cranking engine?Yes Inspect for following:
•Spark plugs malfunction
•CMP sensor is improperly installed.
•Trigger wheel damage on camshaft
•Open or short circuit on CMP sensor
•Open or short circuit between CMP sensor and
PCM terminal 2J or 2M
Repair or replace malfunctioning parts.
If okay, go to next step.
No Inspect following:
•High-tension leads
•Ignition coil and connector
5 Install fuel pressure gauge between fuel pipe
and fuel distributor.
Start engine and run it at idle.
Measure fuel line pressure at idle.
Is fuel line pressure correct at idle?Yes Go to next step.
NoZero or low:
Inspect for clogged fuel line.
If okay, replace fuel pump unit
High:
Replace fuel pump unit.
6 Inspect for VTCS operation.
Does VTCS work properly?Yes Go to next step.
No Repair or replace malfunctioning parts.
7Note
•The following test should be performed for
vehicles with variable valve timing control
system. Go to next step for vehicles
without variable valve timing control
system.
Inspect for variable valve timing control system
operation.
Does variable valve timing control system work
properly?Yes Go to next step.
No Repair or replace malfunctioning parts.
8Note
•The following test should be performed for
vehicles with VIS. Go to next step for
vehicles without VIS.
Inspect for VIS operation.
Does VIS work properly?Yes Go to next step.
No Repair or replace malfunctioning parts.
9 Remove and shake PCV valve.
Does PCV valve rattle?Yes Go to next step.
No Replace PCV valve.
10 Inspect for restriction in the exhaust system.
Is there any restriction?Yes Inspect exhaust system.
No Go to next step.
11 Inspect for contaminated MAF sensor.
Is there any contamination?Yes Go to next step.
No Inspect for cause.
12 Inspect MAF sensor for contamination.
Is there any contamination?Yes Replace MAF sensor.
No Go to Step 14. (2WD)
Go to next step. (4WD)
13 Inspect electrically controlled 4WD system
operation.
Is operation of electrically controlled 4WD
system okay?Yes Go to next step.
No Repair or replace malfunctioning parts.
14 Is engine compression correct? Yes Inspect valve timing.
No Inspect for cause.
15 Verify test results.
•If okay, return to diagnostic index to service any additional symptoms.
•If malfunction remains, replace PCM. STEP INSPECTION RESULTS ACTION

F1–64
TROUBLESHOOTING
NO.22 VIBRATION CONCERNS (ENGINE)A6E398018881204
Diagnostic procedure
End Of Sie
22 VIBRATION CONCERNS (ENGINE)
DESCRIPTION•Vibration from under hood or driveline
POSSIBLE CAUSE•Loose attaching bolts or worn parts
•Components malfunction such as worn parts
STEP INSPECTION RESULTS ACTION
1 Inspect following components for loose attaching
bolts or worn parts:
•Cooling fan
•Condenser fan
•Drive belt and pulleys
•Engine mounts
All items okay?Yes Inspect following systems:
•Wheels
•ATX
•Driveline
•Suspension
•Electrically controlled 4WD system
No Readjust or retighten engine mount installation
position.
Service if necessary for other parts.
2 Verify test results.
•If okay, return to diagnostic index to service any additional symptoms.
•If malfunction remains, replace PCM.

F2–24
CONTROL SYSTEM, ON-BOARD DIAGNOSTIC
CONTROLLER AREA NETWORK (CAN)A6E404018881206Outline
•The PCM transmit/received the information other units using CAN to simplify the system.
Transmit Information
•Engine speed
•Vehicle speed
•Accelerator pedal position
•Fuel injection information
•Torque reduction inhibit
•Intake air temperature
•Engine coolant temperature
•Travelled distance
•Glow indicator light conditions
•Engine displacement
•Number of cylinders
•Air induction type
•Fuel type and delivery
•Country
•Transmission/axle type
•Tire circumference (front/rear)
•Cruise main indicator light conditions
•Cruise set indicator light conditions
Received Information
•Torque reduction request from DSC HU/CM
•Wheel speed from ABS HU/CM or DSC HU/CM
—Front left
—Front right
•Travelled distance from ABS HU/CM or DSC HU/CM
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OUTLINEA6E407018881201•The on-board diagnostic system is essentially carried over from that of the current MPV (LW) MZR-CD (RF
Turbo) engine models, except for the following. (See MPV Workshop Manual Supplement 1737-1*-02C.)
—DTCs, PID monitoring items, and simulation items have been changed.
—KOEO/KOER self-test items have been changed.
End Of Sie
DTCA6E407018881202
×: Applicable –: Not applicable
ON-BOARD DIAGNOSTIC
DTC Condition Detection condition MILMemory
function
P0016Crankshaft position-camshaft position
correlation malfunctionInput signals from CKP sensor and CMP sensor
are misaligned.××
P0088 Fuel pressure system too highFuel pressure is higher than preprogrammed
criteria.–×
P0091 Suction control valve circuit low inputInput voltage from suction control valve does not
change from off to on.××
P0092 Suction control valve circuit high inputInput voltage from suction control valve does not
change from on to off.××
P0093 Fuel system leak detectionFuel pressure after fuel injection is lower than
preprogrammed criteria.××
P0097 IAT sensor No.1 circuit low input Input voltage from IAT sensor No.1 is below 0.1 V.××
P0098 IAT sensor No.1 circuit high input Input voltage from IAT sensor No.1 is above 5.0 V.××
P0102 MAF sensor circuit low input Input voltage from MAF sensor is below 0.2 V.××
P0103 MAF sensor circuit high input Input voltage from MAF sensor is above 4.9 V.××
P0107 Boost sensor circuit low inputInput voltage from boost sensor is below 1.9 V
when engine speed is 2,400 rpm or above and
accelerator opening angle is 50% or above.××
P0108 Boost sensor circuit high input Input voltage from boost sensor is above 4.9 V.××

F2–38
INTAKE-AIR SYSTEM
TURBOCHARGER INSPECTIONA6E401013700201
Note
•If the following problems exist, diagnosis the turbocharger using the following symptom troubleshooting
procedures.
1. Lack of power: perform “NO.12 LACK/LOSS OF POWER”. (See F2–195 NO.12 LACK/LOSS OF POWER-
ACCELERATION/CRUISE.)
2. Oil leak: perform “NO.16 HIGH OIL CONSUMPTION/LEAKAGE”. (See F2–209 NO.16 HIGH OIL
CONSUMPTION/LEAKAGE.)
3. Noise: perform “NO. 21 ENGINE NOISE”. (See F2–217 NO.21 ENGINE NOISE.)
Compressor Wheel Inspection
1. Remove the air pipe between the air cleaner and the turbocharger. (See F2–36 INTAKE-AIR SYSTEM
REMOVAL/INSTALLATION.)
2. Visually inspect the compressor wheel from view A and verify that all fins are free from damage, cracks or
bends.
•If there are damaged fins, cracks or bends, replace the turbocharger.
Note
•To make the inspection easier, set a small
mirror as shown in the figure and use a
penlight.
•If the compressor wheel is interfering with
the compressor housing, it is likely that the
fin edges are cracked, damaged, or bent.
•If the compressor wheel is damaged, check
the following before replacing the
turbocharger to avoid reoccurrence of the
problem.
—Foreign material in intake air/exhaust
system.
—Oil pipe clogging.
MIRROR
A
A6E40102009

INTAKE-AIR SYSTEM
F2–39
F2
Turbine Wheel Inspection
1. Remove the warm up oxidation catalytic converter between the flexible pipe and the turbocharger. (See F2–57
EXHAUST SYSTEM REMOVAL/INSTALLATION.)
2. Visually inspect the turbine wheel from view B and verify that all fins are free from damage, cracks or bends.
•If there are damaged fins, cracks or bends, replace the turbocharger.
Note
•To make the inspection easier, set a small
mirror as shown in the figure and use a
penlight.
•If the turbine wheel is interfering with the
turbine housing, it is likely that the fin edges
are cracked, damaged, or bent.
•If the turbine wheel is damaged, check the
following before replacing the turbocharger
to avoid reoccurrence of the problem.
—Foreign material in intake air/exhaust
system.
—Oil pipe clogging.
End Of Sie
GUIDE BLADE ACTUATOR INSPECTIONA6E4010137002021. Disconnect the vacuum hose from the guide blade actuator.
2. Connect the vacuum pump to the guide blade
actuator.
3. Apply vacuum and verify that the rod moves as
specified.
•If not as specified, replace the turbocharger.
Specification
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MIRRORB
GRINDING MARK
A6E40102010
Vacuum (kPa {mmHg, inHg}) Rod movement
Below –14.5 {–108, –4.27} Starts to move
Above –44.9 {–337, –13.3} Fully pulled
VACUUM PUMP
ROD
A6E40102011

TROUBLESHOOTING
F2–167
F2
SYMPTOM QUICK DIAGNOSIS CHARTA6E408018881202
×: 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
Starter motor malfunction (Mechanical or electrical)Starter circuit including engine switch is openImproper engine oil levelLow or dead bateryCharging system malfunctionLow engine compressionImproper valve timingHydrolocked egineImproper engine oil viscosityImproper dipstickBase engine malfunctionSeized flywheelImproper tension or damaged drivebelts