2002 MAZDA 6 wiring

F2–42
INTAKE-AIR SYSTEM
VARIABLE SWIRL CONTROL (VSC) SOLENOID VALVE INSPECTIONA6E401013110202
Note
•Perform the following test only when directed.
1. Inspect airflow between the ports under the
following conditions.
•If not as specified, replace the VSC solenoid
valve.
•If VSC solenoid valve is okay, perform the
“Circuit Open/Short Inspection”.
Circuit Open/Short Inspection
1. Inspect for open/short circuit in the following
wiring harnesses.
•If there is open/short circuit, repair or replace
wiring harnesses.
Open circuit
•If there is no continuity, the circuit is open. Repair
or replace the harness.
—VSC solenoid valve terminal A (harness-side)
and PCM control relay terminal C
—VSC solenoid valve terminal B (harness-side)
and PCM terminal 101
Short circuit
•If there is continuity, the circuit is shorted. Repair of replace the harness.
—VSC solenoid valve terminal A (harness-side) and GND.
—VSC solenoid valve terminal B (harness-side) and power supply
End Of Sie
GLOW PLUG REMOVAL/INSTALLATIONA6E401018601201
Caution
•Do not damage the heated section of the glow plug.
•Do not reuse a glow plug that has been dropped over a height of 10 cm, even when there are no
scratches and resistance is normal (approx. 0.6 ohms [20°C {68°F}]).
•Do not remove the glow plug unless you are replacing it.
1. Disconnect the negative battery cable.
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.
A
A B
B
C
A6E40102018
: Airflow
Por t
C B
A
GND B+
ABTerminal
Step
1
2
A6E40102020
BAA
B
C
D VSC SOLENOID VALVE
HARNESS SIDE CONNECTORFUSE BOX
(PCM CONTROL RELAY)
A6E40102021
1 Glow plug lead
2Glow plug
(See F2–43 Glow Plug Removal Note)
(See F2–43 Glow Plug Installation Note)0.8—1.5 N·m
{8—15 kgf·cm,
7—13 in·lbf}
15—20 N·m
{1.5—2.0 kgf·m,
11—14 ft·lbf}
12
A6E40102022

FUEL SYSTEM
F2–51
F2
FUEL FILTER COMPONENT DISASSEMBLY/ASSEMBLYA6E4012348022021. Disassemble in the order indicated in the table..
2. Assemble in the reverse order of removal.
Sedimentor Switch Installation Note
1. Apply a small amount of fuel to a new O-ring.
2. Tighten the sedimentor switch enough to the fuel
filter by hand.
Fuel Filter Installation Note
1. Apply a small amount of fuel to the fuel filter O-ring.
2. Tighten the fuel filter approx. 3/4 by hand after the O-ring contacts the priming pump.
End Of Sie
FUEL WARMER INSPECTIONA6E401234802203For Cold Areas
1. Remove the fuel warmer. (See F2–51 FUEL FILTER COMPONENT DISASSEMBLY/ASSEMBLY.)
2. Verify that the resistance between terminal A and
the fuel warmer body is within the specification
when vacuum of –31.3— –38.0 kPa {–235— –
285 mmHg, –9.2— –11.2 inHg} is applied to port
A of the fuel warmer.
•If as specified, carry out the “Circuit Open/
Short Inspection”.
•If not as specified, replace the fuel warmer.
Specification
Circuit Open/Short Inspection
1. Inspect for open/short circuit in the following
wiring harnesses.
•If there is open/short circuit, repair or replace
wiring harnesses.
Open circuit
•If there is no continuity, the circuit is open. Repair
or replace the harness.
—Fuel warmer terminal A (harness-side) and
GND
—Fuel warmer terminal B (harness-side) and
power supply
Short circuit
•If there is continuity, the circuit is shorted. Repair or replace the harness.
—Fuel warmer terminal B (harness-side) and GND
End Of Sie
1 Connector
2 Fuel hose
3 Priming pump
4Fuel filter
(See F2–51 Fuel Filter Installation Note)
5Sedimentor switch
(See F2–51 Sedimentor Switch Installation Note)
6 Drain plug
7 Fuel warmer
R
17.6—26.5
{1.8—2.7,
13.0—19.8}
7
5
4
3
6
1
2
N.m {kgf·m, ft·lbf}
A6E40122036
Ambient temperature (°C {°F}) Resistance (ohms)
20 {68} 0.5—1.5
FUEL WARMER
B
A6E40122013
A B FUEL WARMER
HARNESS SIDE CONNECTOR
A6E40122014

F2–52
FUEL SYSTEM
SEDIMENTOR WATER DRAININGA6E4012348022041. Disconnect the negative battery cable.
2. Complete the “BEFORE REPAIR PROCEDURE”. (See F2–45 BEFORE REPAIR PROCEDURE.)
3. Loosen the drain plug located at the bottom of the fuel filter.
4. Pump the priming pump and drain the water.
5. After all the water has been drained, tighten the drain plug.
6. Complete the “AFTER REPAIR PROCEDURE”. (See F2–45 AFTER REPAIR PROCEDURE.)
7. Reconnect the negative battery cable.
End Of Sie
SEDIMENTOR SWITCH INSPECTIONA6E401213840201
Note
•Perform the following test only when directed.
1. Disconnect the negative battery cable.
2. Complete the “BEFORE REPAIR PROCEDURE”. (See F2–45 BEFORE REPAIR PROCEDURE.)
3. Drain fuel from the fuel filter. (See F2–52 SEDIMENTOR WATER DRAINING.)
4. Remove the sedimentor switch.
5. Inspect for continuity of the sedimentor switch
using an ohmmeter.
•If as specified, inspect the following and carry
out the “Circuit Open/Short Inspection.”
•If not as specified, replace the sedimentor
switch.
Specification
6. Install the sedimentor switch.
7. Reconnect the negative battery cable.
8. Complete the “AFTER REPAIR PROCEDURE”.
(See F2–45 AFTER REPAIR PROCEDURE.)
Circuit Open/Short Inspection
1. Inspect the following wiring harnesses for open or
short (continuity check).
Open circuit
•If there is no continuity, the circuit is open.
Repair or replace the harness.
—Sedimentor switch terminal B (harness-
side) and GND.
—Sedimentor switch terminal A (harness-
side) and instrument cluster terminal 1C.
Short circuit
•If there is continuity, the circuit is shorted.
Repair of replace the harness.
—Sedimentor switch terminal A (harness-
side) and GND.
—Sedimentor switch terminal B (harness-
side) and power supply.
End Of Sie
Float Continuity
Up Yes
Down No
UP
DOWN
FLOATA
B
A6E40122015
1O 1M 1K 1I 1G 1E 1C 1A
1P 1N 1L 1J 1H 1F 1D 1B INSTRUMENT CLUSTER CONNECTOR
SEDIMENTOR SWITCH
HARNESS SIDE CONNECTOR
A
B
A6E40122016

F2–54
FUEL SYSTEM
SUPPLY PUMP INSPECTIONA6E401213350202
Caution
•The supply pump is sealed to maintain proper function. Special tools and testers are required
when disassembling the supply pump. Disassembling the supply pump without special tools and
testers will cause a malfunction.
•Consult an authorized DENSO parts distributor for repair if any of the following supply pump parts
are possibly malfunctioning.
1. Supply pump inner parts
2. Suction control valve
3. Fuel temperature sensor
End Of Sie
SUCTION CONTROL VALVE INSPECTIONA6E401213350203
Caution
•The supply pump is sealed to maintain proper function. Special tools and testers are required
when disassembling the supply pump. Disassembling the supply pump without special tools and
testers will cause a malfunction.
•Consult an authorized DENSO parts distributor for repair if suction control valve is possibly
malfunctioning.
Resistance Inspection
1. Disconnect the negative battery cable.
2. Disconnect the suction control valve connector.
3. Measure the resistance between the suction
control valve terminals using an ohmmeter.
•If not as specified, repair the supply pump.
(See F2–54 SUPPLY PUMP INSPECTION.)
•If as specified, carry out the “Circuit Open/
Short Inspection”.
Specification
Circuit Open/Short Inspection
1. Disconnect the PCM connector. (See F2–64 PCM REMOVAL/INSTALLATION.)
2. Inspect the following wiring harnesses for an open or short circuit (continuity check).
Open circuit
•If there is no continuity, the circuit is open. Repair of replace the harness.
—Suction control valve terminal A (harness-side) and PCM terminal 93
—Suction control valve terminal B (harness-side) and PCM terminal 94
Short circuit
•If there is continuity, the circuit is shorted. Repair or replace the harness.
—Suction control valve terminal A (harness-side) and power supply
—Suction control valve terminal A (harness-side) and GND
—Suction control valve terminal B (harness-side) and power supply
—Suction control valve terminal B (harness-side) and GND
End Of Sie
COMMON RAIL INSPECTIONA6E401213015201
Caution
•Do not remove the fuel pressure sensor nor the fuel pressure limiter from the common rail. Since
fuel pressure in the common rail is extremely high, the fuel pressure sensor, fuel pressure limiter,
or the common rail can be damaged, leading to fuel leakage if any of them are removed.
1. Visually inspect the common rail for damage and cracks. Also verify that there is no extreme rust which will
cause fuel leakage.
•If either is observed, replace the common rail.
End Of Sie
Ambient temperature (°C {°F}) Resistance (ohms)
20 {68} Approx. 2.1
SUCTION
CONTROL VALVE A B
A6E40122018

F2–56
FUEL SYSTEM
End Of SieFUEL INJECTOR INSPECTIONA6E401213250202Resistance Inspection
Note
•Perform the following test only when directed.
•Perform “Correction after Parts Installation” after replacing the fuel injector. (See F2–34 Correction after
Parts Installation.)
1. Disconnect the negative battery cable.
2. Disconnect the fuel injector connectors.
3. Measure the resistance of the fuel injector using
an ohmmeter.
•If not as specified, replace the fuel injector.
(See F2–55 FUEL INJECTOR REMOVAL/
INSTALLATION.)
•If as specified, carry out the “Circuit Open/
Short Inspection”.
Resistance
approx. 0.45 ohm
Circuit Open/Short Inspection
1. Disconnect the IDM connector.
2. Inspect the following wiring harnesses for an
open or short circuit (continuity check).
Open circuit
•If there is no continuity, the circuit is open. Repair
or replace the harness.
—No.1 cylinder fuel injector terminal B
(harness-side) and IDM terminal 1E.
—No.2 cylinder fuel injector terminal B
(harness-side) and IDM terminal 1G.
—No.3 cylinder fuel injector terminal B
(harness-side) and IDM terminal 1H.
—No.4 cylinder fuel injector terminal B
(harness-side) and IDM terminal 1F.
—No.1 cylinder fuel injector terminal D
(harness-side) and IDM terminal 1D.
—No.2 cylinder fuel injector terminal D (harness-side) and IDM terminal 1C.
—No.3 cylinder fuel injector terminal D (harness-side) and IDM terminal 1D.
—No.4 cylinder fuel injector terminal D (harness-side) and IDM terminal 1C
Short circuit
•If there is continuity, the circuit is short. Repair or replace the harness.
—No.1 cylinder fuel injector terminal B (harness-side) and GND.
—No.2 cylinder fuel injector terminal B (harness-side) and GND.
—No.3 cylinder fuel injector terminal B (harness-side) and GND.
—No.4 cylinder fuel injector terminal B (harness-side) and GND.
—No.1 cylinder fuel injector terminal D (harness-side) and power supply.
—No.2 cylinder fuel injector terminal D (harness-side) and power supply.
—No.3 cylinder fuel injector terminal D (harness-side) and power supply.
—No.4 cylinder fuel injector terminal D (harness- side) and power supply.
End Of Sie
A B
A6E40122021
A
B C
D
A6E40122020

F2–60
EMISSION SYSTEM
EGR SOLENOID VALVE (VACUUM) INSPECTIONA6E401618741201
Note
•Perform the following inspection only when directed.
1. Inspect airflow between the ports under the
following conditions.
•If not as specified, replace the EGR solenoid
valve (vacuum).
•If as specified, carry out the “Circuit Open/
Short Inspection”.
Circuit Open/Short Inspection
1. Inspect the following wiring harness for open or
short (continuity check).
Open circuit
•If there is no continuity, the circuit is open. Repair
or replace the harness.
—EGR solenoid valve (vacuum) terminal A
(harness-side) and PCM control relay
terminal C (harness-side)
—EGR solenoid valve (vacuum) terminal B
(harness-side) and PCM terminal 99
Short circuit
•If there is continuity, the circuit is shorted. Repair
or replace the harness.
—EGR solenoid valve (vacuum) terminal A (harness-side) and GND
—EGR solenoid valve (vacuum) terminal B (harness-side) and power supply
End Of Sie
EGR SOLENOID VALVE (VENT) INSPECTIONA6E401618741202
Note
•Perform the following inspection only when directed.
1. Inspect airflow between the ports under the
following conditions.
•If not as specified, replace the EGR solenoid
valve.
•If as specified, carry out the “Circuit Open/
Short Inspection”.
BAA B
A6E40162001
StepTerminal
ABAB Por t
1
2
B+GND: Airflow
: Continuity
A6E40162020
EGR SOLENOID VALVE
HARNESS SIDE CONNECTORFUSE BOX
(PCM CONTROL RELAY)
A
BA
E
C
D
A6E40162002
BA
CBA
A6E40162003
Step
1
2
A
BAB
C Por t
Terminal
: Airflow
B+
GND: Continuity
A6E40162021

EMISSION SYSTEM
F2–61
F2
Circuit Open/Short Inspection
1. Inspect the following wiring harness for an open
or short circuit (continuity check).
Open circuit
•If there is no continuity, the circuit is open, Repair
or replace the harness.
—EGR solenoid valve (vent) terminal A
(harness-side) and PCM control relay
terminal C (harness-side)
—EGR solenoid valve (vent) terminal B
(harness-side) and PCM terminal 72
Short circuit
•If there is continuity, the circuit is shorted. Repair
or replace the harness.
—EGR solenoid valve (vent) terminal A (harness-side) and GND
—EGR solenoid valve (vent) terminal B (harness-side) and power supply
End Of Sie
EGR CONTROL SOLENOID VALVE INSPECTIONA6E401618741203
Note
•Perform the following inspection only when directed.
1. Inspect airflow between the ports under the
following conditions.
•If not as specified, replace the EGR control
solenoid valve.
•If as specified, carry out the “Circuit Open/
Short Inspection”.
Circuit Open/Short inspection
1. Inspect the following wiring harness for an open
or short circuit (continuity check).
Open circuit
•If there is no continuity, the circuit is open. Repair
or replace the harness.
—EGR control solenoid valve terminal A
(harness-side) and PCM control relay
terminal C (harness-side)
—EGR control solenoid valve terminal B
(harness-side) and PCM terminal 77
Short circuit
•If there is continuity, the circuit is shorted. Repair
or replace the harness.
—EGR control solenoid valve terminal A (harness-side) and GND
—EGR control solenoid valve terminal B (harness-side) and power supply
End Of Sie
EGR SOLENOID VALVE(VENT)
HARNESS SIDE CONNECTORFUSE BOX
(PCM CONTROL RELAY)
BAA
C
DE
A6E40162004
B
AA
B
A6E40162005
StepTerminalPor t
: Airflow
ABAB
GND
B+
1
2
: Continuity
A6E40162022
EGR CONTROL SOLENOID VALVE
HARNESS SIDE CONNECTORFUSE BOX
(MAIN RELAY)
BAAE
C
D
A6E40162006

EMISSION SYSTEM
F2–63
F2
INTAKE SHUTTER SOLENOID VALVE INSPECTIONA6E401613937201
Note
•Perform the following inspection only when directed.
•The inspection includes both intake shutter solenoid valve (half) and intake shutter solenoid valve (full).
1. Inspect airflow between the ports under the following conditions.
•If not as specified, replace the intake shutter solenoid valve.
•If as specified, carry out the “Circuit Open/Short Inspection”.
Intake Shutter Solenoid Valve (Half) Circuit Open/
Short Inspection
1. Disconnect the PCM connector. (See F2–64 PCM
REMOVAL/INSTALLATION.)
2. Inspect the following wiring harness for an open
or short circuit (continuity check).
Open circuit
•If there is no continuity, the circuit is open. Repair
or replace the harness.
—Intake shutter solenoid valve (half) terminal A
(harness-side) and PCM control relay
terminal C (harness-side)
—Intake shutter solenoid valve (half) terminal B
(harness-side) and PCM terminal 74
Short circuit
•If there is continuity, the circuit is shorted. Repair or replace the harness.
—Intake shutter solenoid valve (half) terminal A (harness-side) and GND
—Intake shutter solenoid valve (half) terminal B (harness-side) and power supply
Intake Shutter Solenoid Valve (Full) Circuit Open/Short Inspection
1. Disconnect the PCM connector. (See F2–64 PCM REMOVAL/INSTALLATION.)
2. Inspect the following wiring harness for an open
or short circuit (continuity check).
Open circuit
•If there is no continuity, the circuit is open. Repair
or replace the harness.
—Intake shutter solenoid valve (full) terminal A
(harness-side) and PCM control relay
terminal C (harness-side)
—Intake shutter solenoid valve (full) terminal B
(harness-side) and PCM terminal 100
Short circuit
•If there is continuity, the circuit is shorted. Repair or replace the harness.
—Intake shutter solenoid valve (full) terminal A (harness-side) and GND
—Intake shutter solenoid valve (full) terminal B (harness-side) and power supply
End Of Sie
B
A
CB
A
A6E40162024
StepTerminal
C B
A B APor t: Airflow
1
2B+ GND
: Continuity
A6E40162023
INTAKE SHUTTER SOLENOID
VALVE (HALF)
HARNESS SIDE CONNECTORFUSE BOX
(PCM CONTROL RELAY)
B
AA
E
C
D
A6E40162010
INTAKE SHUTTER SOLENOID
VALVE (FULL)
HARNESS SIDE CONNECTORFUSE BOX
(PCM CONTROL RELAY)
B
AA
C
DE
A6E40162011