2002 MAZDA 6 Workshop Manual Suplement

CONTROL SYSTEM
F2–65
F2
End Of SiePCM INSPECTIONA6E404018881208Using WDS or Equivalent
Caution
•The PCM terminal voltage vary with change in measuring conditions and vehicle conditions.
Always carry out a total inspection of the input systems, output systems, and PCM to determine
the cause of trouble. Otherwise, diagnosis will be incorrect.
Note
•For replace the PCM, setup the WDS and perform the following.
—“PCM configuration” (See F2–68 PCM CONFIGURATION.)
—“Correction after Parts Installation” (See F2–34 Correction after Parts Installation.)
1. Connect the WDS or equivalent to the DLC-2. (See F2–85 ON-BOARD DIAGNOSTIC TEST.)
2. Turn the engine switch to ON.
3. Measure the PID value.
•If PID value is not within the specification, follow the instructions in ACTION column.
PID Monitor Table
Monitor item (Definition)Unit/
ConditionCondition/Specification
(Reference)ActionPCM
terminal
ACCS
(A/C relay)ON/OFF•A/C operating: ON
•Engine switch is on: OFFInspect A/C relay.
(See T–19 RELAY
INSPECTION)73
ACSW
(A/C switch)ON/OFF•A/C switch is on: ON
•A/C switch is off: OFFInspect A/C switch. 84
APS1
(Accelerator position sensor
No.1 signal voltage)V•Accelerator pedal depressed:
3.35—4.03 V
•Accelerator pedal released: 0.4—
0.7 VInspect accelerator position
sensor.
(See F2–72
ACCELERATOR POSITION
SENSOR INSPECTION)10
APS2
(Accelerator position sensor
No.2 signal voltage)V•Accelerator pedal depressed:
3.35—4.03 V
•Accelerator pedal released: 0.4—
0.7 VInspect accelerator position
sensor.
(See F2–72
ACCELERATOR POSITION
SENSOR INSPECTION)88
BARO
(BARO)kPa inHg•Elevation 0—400 m {0—1310 ft}:
100—103 kPa {29.5—30.4 inHg}Replace PCM.
(See F2–64 PCM
REMOVAL/INSTALLATION)–
BARO
(BARO signal voltage)V•Elevation 0—400 m {0—1310 ft}:
approx. 4.0 V
BOO
(Brake switch)ON/OFF•Brake pedal depressed: ON
•Brake pedal released: OFFInspect brake switch. 7
CPP
(Clutch switch)ON/OFF•Clutch pedal depressed: ON
•Clutch pedal released: OFFInspect clutch switch.
(See F2–68 CLUTCH
SWITCH INSPECTION)33
CPP/PNP
(neutral switch)Neutral/Drive•Gear is neutral position: Neutral
•Gear is not neutral position: DriveInspect neutral switch.
(See F2–69 NEUTRAL
SWITCH INSPECTION)56
CRUISESW
(Cruise control switch)ON/OFF•Cruise control switch is on: ON
•Cruise control switch is off: OFFInspect cruise control switch. 64
DTCCNT
(DTC count)–•Number of output DTCFollow DTC inspection.
(See F2–87 DTC TABLE)–
ECT
(ECT)°C°F•ECT is 20°C {68°F}: 20°C
{68°F}
•ECT is 85°C {185°F}: 85°C
{185°F}Inspect ECT sensor.
(See F2–76 ENGINE
COOLANT TEMPERATURE
(ECT) SENSOR
INSPECTION)87
ECT
(ECT signal voltage)V•ECT is 20°C {68°F}: 3.0—3.2 V
•ECT is 85°C {185°F}: 0.7—0.9 V
FAN2
(Cooling fan relay No.2)ON/OFF•Engine coolant temperature is
above 100°C {212°F}: ON
•Others: OFFInspect cooling fan relay
No.2.76
FAN3
(Cooling fan relay No.1)ON/OFF•Engine coolant temperature is
above 108°C {226°F}: ON
•A/C switch is on: ON
•Others: OFFInspect cooling fan relay
No.1.102

F2–66
CONTROL SYSTEM
IAT
(IAT)°C°F•IAT is 20°C {68°F}: 20°C {68°F}
•IAT is 30°C {86°F}: 30°C {86°F}Inspect IAT sensor No.1.
(See F2–74 MASS AIR
FLOW (MAF)/INTAKE AIR
TEMPERATURE (IAT)
SENSOR INSPECTION)60
IAT
(IAT signal voltage)V•IAT is 20°C {68°F}: 2.2—2.5 V
•IAT is 30°C {86°F}: 1.7—2.0 V
IMRC
(VSC solenoid valve)ON/OFF•Idle: ON
•Engine speed is above approx.
2,500 rpm: OFFInspect following PIDs:
BARO, ECT, IAT, RPM, VSS101
INGEAR
(In gear)ON/OFF•Gear is not neutral position and
clutch pedal released: ON
•Gear is neutral position: OFF
•Clutch pedal depressed: OFFInspect following PIDs:
CPP, CPP/PNP33, 56
INJ_LRN_DIS
(Distance from the last
injector learning)Km Mile•Distance from the last injector
learning––
MAF
(Mass air flow amount)g/s•Engine switch is on: approx. 0 g/s
•Idle: 6.8—7.4 g/sInspect MAF/IAT sensor.
(See F2–74 MASS AIR
FLOW (MAF)/INTAKE AIR
TEMPERATURE (IAT)
SENSOR INSPECTION)9
MAF
(Mass air flow signal voltage)V•Engine switch is on: 0.0—1.0 V
•Idle: 1.5—2.1 V
MAF_LRN_DIS
(Distance from the last MAF
learning)Km Mile•Distance from the last MAF
learning––
MAINRLY
(PCM control relay)ON/OFF•Engine switch is on: ONInspect PCM control relay.
(See T–19 RELAY
INSPECTION)69
MAP
(MAP)kPa inHg•Engine switch is on: 100—103
kPa {29.5—30.4 inHg}
•Idle: 100—103 kPa {29.5—30.4
inHg}Inspect boost sensor.
(See F2–78 BOOST
SENSOR INSPECTION)36
MAP
(MAP signal voltage)V•Engine switch is on: 2.1—2.5 V
•Idle: 2.1—2.5 V
MIL
(MIL)ON/OFF•Engine switch is on: ON
•DTC output: ON
•Others: OFFInspect instrument cluster.
Inspect CAN system.
(See T–39 MULTIPLEX
COMMUNICATION
SYSTEM)13, 39
NUMKEYS
(Number of keys stored in
module)–•Number of keys stored in module––
RPM
(Engine speed)rpm•Idle: 725—825 rpmInspect CKP sensor.
(See F2–80 CAMSHAFT
POSITION (CMP) SENSOR
INSPECTION)3, 29
VPWR
(Battery positive voltage)V•Engine switch is ON: B+Inspect Battery.
Inspect fuse.4
VSS
(Vehicle speed)km/h mph•Vehicle speed is 20 km/h {12.5
mph}: 20 km/h {12.5 mph}
•Vehicle speed is 40 km/h {25
mph}: 40 km/h {25 mph}Inspect CAN system.
(See T–39 MULTIPLEX
COMMUNICATION
SYSTEM)13, 39 Monitor item (Definition)Unit/
ConditionCondition/Specification
(Reference)ActionPCM
terminal

CONTROL SYSTEM
F2–67
F2
Not Using WDS or Equivalent
Constant voltage terminal inspection
1. Turn the engine switch to ON.
2. Measure the voltage between the accelerator
position sensor terminal A (vehicle side) and body
GND using a voltmeter.
(1) Measurement voltage is below 1.0 V.
1)Turn the engine switch to OFF.
2)Disconnect the accelerator position
sensor connector.
3)Verify there is no continuity between the
accelerator position sensor terminal A
(vehicle side) and body GND using an
ohmmeter.
•If there is continuity, repair or replace
the related harness.
4)Inspect for continuity between the PCM
terminal 90 (vehicle side) and accelerator position sensor terminal A (vehicle side) using an ohmmeter.
•If there is no continuity, repair or replace the related harness.
(2) Measurement voltage is B+.
1)Turn the engine switch to OFF.
2)Disconnect the battery negative cable and battery positive cable.
3)Verify there is no continuity between the accelerator position sensor terminal A (vehicle side) and
battery positive cable using an ohmmeter.
•If there is continuity, repair or replace the related harness.
(3) Measurement voltage is approx. 5 V.
•Constant voltage terminal of PCM is okay.
GND terminal inspection
1. Turn the engine switch to OFF.
2. Disconnect the PCM connector.
3. Inspect for continuity between the PCM GND terminals and body GND using an ohmmeter.
•If there is no continuity, repair or replace the related harness.
Power supply terminal inspection
1. Disconnect the PCM connector.
2. Turn the engine switch to ON.
3. Measure the voltage between the PCM battery power terminal and body GND using a voltmeter.
•If not as specified, repair or replace the related harness.
Specification
B+
End Of Sie
ACCELERATOR POSITION SENSOR
HARNESS SIDE CONNECTOR
A B
C D
A6E40702042
PCM GND terminal
65
85
103
104
PCM power supply terminal
27

F2–68
CONTROL SYSTEM
PCM CONFIGURATIONA6E4040188812091. Connect the WDS to DLC-2.
2. Set up the WDS (including the vehicle
recognition).
3. Select “Module programming.”
4. Select “Programmable module installation.”
5. Select “PCM” and perform procedures according
to directions on the WDS screen.
Note
•If the PCM is replaced with a new one, the
PCM stores DTC P0602 and illuminates the
MIL even though no malfunction is detected.
After completing the "PCM
CONFIGURATION" procedure, clear DTC
P0602 using the WDS or equivalent.
6. Retrieve DTC’s by the WDS or equivalent, then verify that there in no DTC present.
•If DTC is present, perform applicable DTC inspection.
End Of Sie
CLUTCH SWITCH INSPECTIONA6E404018660201
Note
•Perform the following test only when directed.
Continuity Inspection
1. Inspect continuity between the clutch switch
terminals using an ohmmeter.
•If the clutch switch is okay, but the CPP PID is
out of specification, perform the “Circuit Open/
Short Inspection”
•If not as specified, replace the clutch switch.
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
•Signal circuit
—Clutch switch terminal C and PCM terminal 33
•GND circuit
—Clutch switch terminal E and GND
Short circuit
•Signal circuit
—Clutch switch terminal C and PCM terminal 33 to GND.
End Of Sie
DLC-2
A6E40702001
PUSH
ROD
A
B
C
D E
A6E40702034
A6E40702033
ConditionClutch pedalTerminal
CE
Rod pushed
Except aboveReleased
Depressed
O
O
O
O: Continuity

CONTROL SYSTEM
F2–69
F2
NEUTRAL SWITCH INSPECTIONA6E404017640201
Note
•Perform the following test only when directed.
Continuity Inspection
1. Inspect for continuity between the neutral switch
terminals using an ohmmeter.
•If the neutral switch is okay, but the CPP/PNP
PID is out of specification, perform the “Circuit
Open/Short Inspection”
•If not as specified, replace the neutral switch.
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
•Signal circuit
—Neutral switch terminal A and PCM terminal 56
•GND circuit
—Neutral switch terminal B and GND
Short circuit
•Signal circuit
—Neutral switch terminal A and PCM terminal 56 to GND
End Of Sie
PUSH
RODB
A
A6E40702036
Condition
TransmissionTerminal
O
O: Continuity
A
B
Rod pushed
Except aboveIn neutral
Other
O
O
A6E40702035

F2–70
CONTROL SYSTEM
IDLE SWITCH INSPECTIONA6E404041600201
Note
•Perform the following test only when directed.
1. Verify that the accelerator position sensor is normal.
2. Visually inspect all accelerator pedal components for looseness.
3. Verify that the idle switch is installed to the accelerator pedal properly.
4. Verify that the power circuit voltage.
(1) Verify that the voltage between the PCM terminals 90 (power circuit) and 91(GND circuit) is 4.75—5.25 V.
Note
•Voltage at the PCM terminal 10 may deviate when the power circuit voltage is abnormal.
5. Verify that the voltage at the PCM terminal 31
(idle signal) is 1 V or less with the accelerator
pedal fully released.
6. Depress the accelerator pedal gradually and hold
the pedal when the PCM terminal 31 voltage
changes to approximately 10 V.
7. Verify that the voltage between the PCM
terminals 10 (accelerator position detection
signal) and 91 is within the specification.
•If the circuit is okay, replace the idle switch.
Specification
0.85—1.15 V (Target value: 1.0 V)
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
•Signal circuit
—Idle switch terminal A and PCM terminal 31
•GND circuit
—Idle switch terminal B and GND
Short circuit
•Signal circuit
—Idle switch terminal A and PCM terminal 31 to
GND
End Of Sie
ACCELERATOR POSITION SENSOR
IDLE SWITCHPCM B
A
C
D
A
B31 10
90
88
91
A6E40702037
IDLE SWITCH
HARNESS SIDE CONNECTOR
A
B
A6E40702038

CONTROL SYSTEM
F2–71
F2
IDLE SWITCH ADJUSTMENTA6E404041600202
Caution
•Adjusting the idle switch unnecessarily may adversely affect engine control. Therefore, adjust the
idle switch only when it is replaced.
1. Verify that the accelerator position sensor is normal.
2. Visually inspect all accelerator pedal components for looseness.
3. Loosen the locknut that secures the idle switch.
4. Verify that the power circuit voltage.
(1) Verify that the voltage between the PCM terminals 90 (power circuit) and 91(GND circuit) is 4.75—5.25 V.
Note
•Voltage at the PCM terminal 10 may deviate when the power circuit voltage is abnormal.
5. Depress the accelerator pedal by hand and
secure it when the voltage between the PCM
terminals 10 (accelerator position detection
signal) and 91 is within the range specified below.
Voltage range
0.9—1.1V (Target value: 1.0 V)
6. Turn the idle switch under the condition in Step 5.
Secure the idle switch when the continuity turns
from OFF to ON, and tighten the locknut.
7. Release the accelerator pedal. Depress the
accelerator pedal again and verify that the idle
switch continuity changes from OFF to ON when
the PCM terminal 10 voltage is within 0.9—1.1 V.
•If the continuity does not change, repeat Step
6.
End Of Sie
ACCELERATOR POSITION SENSOR
IDLE SWITCHPCM B
A
C
D
A
B31 10
90
88
91
A6E40702037
ACCELERATOR PEDAL
A6E40702039
IDLE SWITCH
LOCKNUTA
B
A6E40702040

F2–72
CONTROL SYSTEM
ACCELERATOR POSITION SENSOR INSPECTIONA6E404041602201
Note
•Perform the following test only when directed.
1. Visually inspect all accelerator pedal components for looseness.
2. Verify that the accelerator position sensor is installed to the accelerator pedal properly.
3. Verify the power circuit voltage.
(1) Verify that the voltage between the PCM terminal 90 (power circuit) and 91 (GND circuit) is 4.75—5.25 V.
Note
•Voltage at the PCM terminal 10 may deviate when the power circuit voltage is abnormal.
4. Verify that the voltage between the PCM
terminals 10 (accelerator position detection
signal) and 91 is as shown below according to the
accelerator pedal conditions.
•If the circuit is okay, replace the accelerator
position sensor.
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
•Power circuit
—Accelerator position sensor terminal A and
PCM terminal 90
•Signal circuit
—Accelerator position sensor terminal B and
PCM terminal 10
—Accelerator position sensor terminal C and
PCM terminal 88
•GND circuit
—Accelerator position sensor terminal D and PCM terminal 91
Short circuit
•Power circuit
—Accelerator position sensor terminal A and PCM terminal 90 to GND
•Signal circuit
—Accelerator position sensor terminal B and PCM terminal 10 to power circuit
—Accelerator position sensor terminal B and PCM terminal 10 to GND
—Accelerator position sensor terminal C and PCM terminal 88 to power circuit
—Accelerator position sensor terminal C and PCM terminal 88 to GND
End Of Sie
Accelerator pedal
conditionOutput voltage (V)
Fully released 0.45—0.75 (Target value: 0.6)
Gradually depressed Increases linearly
Fully depressed 3.35—4.03 (Target value: 3.6)
ACCELERATOR POSITION SENSOR
PCM
B
A
C
D10
90
88
91
A6E40702041
ACCELERATOR POSITION SENSOR
HARNESS SIDE CONNECTOR
A B
C D
A6E40702042