2002 MAZDA 6 ABS

F1–56
ON-BOARD DIAGNOSTIC
End Of Sie
P2504Generator terminal B circuit
openOFF 1 Other——
U0073 CAN bus off OFF 1 Other——
U0101PCM cannot receive any
signals from TCMON 1 Other×(See T–39 MULTIPLEX
COMMUNICATION
SYSTEM)
U0121PCM cannot receive any
signals from ABS, ABS/TCS or
DSC HU/CMON 1 Other×—
U0155PCM cannot receive any
signals from combination meterON 1 Other×— DTC No. Condition MIL DC Monitor itemMemory
functionPage

F1–60
TROUBLESHOOTING
X: Applicable
Possible factor
Troubleshooting item
Injectors malfunction (Leakage or clogging, inope-rative
Fuel leakage from fuel system (including insulator,
injector O-ring)
Fuel filters restriction or clogging
CMP sensor is damaged. (e.g. open or short circuit)
Camshaft is damaged.
Improper air/fuel mixture ratio control
Exhaust system restriction or clogging
Catalytic converter malfunction
EGR system malfunction (Unleaded gasoline models)
EVAP control system malfunction
PCV valve malfunction
Constant voltage supply circuit malfunction
Main relay malfunction (Mechanically or electrically)
ECT sensor malfunction
TR sensor misadjustment (ATX)
TR sensor malfunction (ATX)
Break switch and related circuit malfunction
Manifold absolute pressure sensor and related circuit
malfunction
HO2S and related circuit malfunction (Unleaded
gasoline models)
Variable resistor misadjustment (Leaded gasoline
models)
Improper electrically controlled 4WD system operation
1 Melting of main or other fuses2 MIL illuminates x x x x x x x3 Will not crankxx4 Hard to start/long crank/erratic start/erratic
crankx xx xxx x
5 Engine stalls. After start/at idle x x x x x x x x x6 Cranks normally but will not start x x x xxxxxx x7 Slow return to idlex8 Engine runs rough/rolling idle xxxxxx xxx x9 Fast idle/runs onx10 Low idle/stalls during deceleration x x x x xEngine stalls/quits.Acceleration/cruisex xxxxx xxxxx xEngine runs rough. Acceleration/cruisex xxxxx xxxxx xMissesAcceleration/cruisex xxxxx xxxxx xBuck/jerk Acceleration/cruise/
decelerationx xxxxx xxxxx x
Hesitation/stumble Acceleration xxxxxx xxxxx x
11
Surges Acceleration/cruise xxxxxx xxxxx x
12 Lack/loss of power Acceleration/cruise x x x x x x x x13 Knocking/pingingAcceleration/cruise x14 Poor fuel economy x x x x x x15 Emission compliancexxxxxxxxx x16 High oil consumption/leakage x17 Cooling system concerns Overheating18 Cooling system concernsRuns cold19 Exhaust smoke x x20 Fuel odor (in engine compartment) x x21 Engine noise22 Vibration concerns (engine)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 smell x x27 Constant voltage x x x x x28 Spark plug condition x x x x29 ATX concernsUpshift/downshift/en
gagementSee Section K, TROUBLESHOOTING
A6E39802003

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
End Of Sie
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.××

F2–26
ON-BOARD DIAGNOSTIC
End Of Sie
KOEO/KOER SELF-TESTA6E407018881203KOEO/KOER self-test function table
×: Applicable –: Not applicable
End Of Sie
P0610 Control module vehicle options error PCM data configuration error.××
P0661 VSC solenoid valve circuit low inputInput voltage from VSC solenoid valve is below 0.1
V.–×
P0662 VSC solenoid valve circuit high input Input voltage from VSC solenoid valve is above B+.–×
P0850 Neutral switch circuit malfunctionInput voltage from neutral switch does not change
when vehicle stops after accelerating to above 60
km/h {37 mph} and decelerating to 0 km/h {0 mph}
2 times.××
P1190 Calibration resistor circuit malfunctionInput voltage from calibration resistor is below 0.2 V
or above 4.8 V.××
P2228 BARO sensor circuit low input Input voltage from BARO sensor is below 0.7 V.××
P2229 BARO sensor circuit high input Input voltage from BARO sensor is above 4.5 V.××
U0073 CAN bus off CAN controller is damaged.–×
U0121PCM cannot receive any signals from
ABS, ABS/TCS or DSC HU/CMPCM cannot receive any signals from ABS, ABS/
TCS or DSC HU/CM.××
U0155PCM cannot receive any signals from
instrument clusterPCM cannot receive any signals from instrument
cluster.×× DTC Condition Detection condition MILMemory
function
DTC Condition KOEO KOER
P0097 IAT sensor No.1 circuit low input××
P0098 IAT sensor No.1 circuit high input××
P0102 MAF sensor circuit low input××
P0103 MAF sensor circuit high input××
P0107 Boost sensor circuit low input××
P0108 Boost sensor circuit high input××
P0112 IAT sensor No.2 circuit low input××
P0113 IAT sensor No.2 circuit high input××
P0117 ECT sensor circuit low input××
P0118 ECT sensor circuit high input××
P0122 Accelerator position sensor No.1 circuit low input××
P0123 Accelerator position sensor No.1 circuit high input××
P0222 Accelerator position sensor No.2 circuit low input××
P0223 Accelerator position sensor No.2 circuit high input××
P0602 PCM programming error××
P0610 Control module vehicle options error××
P0661 VSC solenoid valve circuit low input××
P0662 VSC solenoid valve circuit high input××
P2228 BARO sensor circuit low input××
P2229 BARO sensor circuit high input××
U0073 CAN bus off××
U0121 PCM cannot receive any signals from ABS, ABS/TCS or DSC HU/CM××
U0155 PCM cannot receive any signals from instrument cluster××

ON-BOARD DIAGNOSTIC
F2–27
F2
PID/DATA MONITOR AND RECORDA6E407018881204PID monitoring item table
End Of Sie
SIMULATION TESTA6E407018881205Simulation test item table
×: Applicable
Item Definition Condition/unit PCM terminal
ACCS A/C relay ON/OFF 73
ACSW A/C switch ON/OFF 84
APS1 Accelerator position sensor No.1 signal voltage V 10
APS2 Accelerator position sensor No.2 signal voltage V 88
BAROBarometric pressure kPa, inHg
-
Barometric pressure signal voltage V
BOO Brake switch ON/OFF 7
CPP Clutch switch ON/OFF 33
CPP/PNP Neutral switch Neutral/Drive 56
CRUISESW Cruise control switch ON/OFF 64
DTCCNT DTC count - -
ECTEngine coolant temperature°C, °F
87
Engine coolant temperature signal voltage V
FAN2 Cooling fan relay No.2 ON/OFF 76
FAN3 Cooling fan relay No.1 ON/OFF 102
IATIntake air temperature°C, °F
60
Intake air temperature signal voltage V
IMRC VSC solenoid valve ON/OFF 101
INGEAR In gear ON/OFF 33, 56
INJ_LRN_DIS Distance from the last injector learning Km, Mile -
MAFMass air flow amount g/s
9
Mass air flow signal voltage V
MAF_LRN_DIS Distance from the last MAF learning Km, Mile -
MAINRLY PCM control relay ON/OFF 69
MAPManifold absolute pressure kPa, inHg
36
Manifold absolute pressure signal voltage V
MIL Malfunction indicator lamp ON/OFF 71
NUMKEYS Number of keys stored in module - -
RPM Engine speed rpm 3, 29
VPWR Battery positive voltage V 27
VSS Vehicle speed km/h, mph 13, 39
Item Definition OperationTest condition
PCM
terminal
Key ON Idle
ACCS A/C relay ON or OFF××73
EGRA EGR solenoid valve (vent)Actuated by any duty value
(0—100%)××72
EGRV EGR solenoid valve (vacuum)Actuated by any duty value
(0—100%)××99
EGRV2 EGR control solenoid valve ON or OFF××77
FAN Cooling fan No.2 ON or OFF××76
FAN3 Cooling fan No.1 ON or OFF××102
GP_LMP Glow indicator light ON or OFF××97
GPC Glow plug relay ON or OFF××68
IASV Intake shutter solenoid valve (half) ON or OFF××74
IASV2 Intake shutter solenoid valve (full) ON or OFF××100
IMRC VSC solenoid valve ON or OFF××101
VBCV VBC solenoid valveActuated by any duty value
(0—100%)××67

FUEL SYSTEM
F2–47
F2
Plastic Fuel Hose Removal Note
Caution
•The quick release connector may be damaged if the tab is bent excessively. Do not expand the tab
over the stopper.
1. Disconnect the quick release connector.
(1) Push the tab on the locking coupler 90 degrees until it stops.
(2) Pull the fuel hose straight back.
Note
•The stopper may be removed from the quick
connector. Take care not to lose it.
Reinstall it to the quick release connector
before reconnecting the fuel line.
•The locking coupler has two internal locking
tabs which retain the fuel pipe. Be sure that
the tab on the locking coupler is rotated until
it stops to release two internal locking tabs.
2. Cover the disconnected quick release connector
and fuel pipe with vinyl sheets or the like to
prevent them from being scratched or
contaminated with foreign material.
Fuel Tank Gauge Cap Removal Note
1. Using the SST, remove the fuel tank gauge cap.
FUEL PIPE
STOPPER TAB
A6E3912W001
LOCKING TAB
A6E3912W002
A6E3912W039
49 T042 001A
A6A3912W007

FUEL SYSTEM
F2–49
F2
(2) Apply a slight amount of clean engine oil to
the sealing surface of the fuel pump unit.
(3) Align the fuel pipe on the fuel pump unit and
quick release connector so that the tabs of the
retainer are correctly fitted into the quick
release connector. Push the quick release
connector straight into the retainer until a click
is heard.
(4) Lightly pull and push the quick release
connector a few times by hand and verify that
it can move 2.0—3.0 mm {0.08—0.11 in} and
it is connected securely.
•If the quick release connector does not
move at all, verify that O-ring is not
damaged of that is has not slipped, and reconnect the quick release connector.
2. When the retainer is removed, perform the following procedure.
End Of Sie
FUEL TANK INSPECTIONA6E401242110202
Caution
•Disconnecting/connecting the quick release connector without cleaning it may possibly cause
damage to the fuel pipe and quick release connector. Always clean the quick release connector
joint area before disconnecting/connecting using a cloth or soft brush, and make sure that it is
free of foreign material.
Note
•This inspection is for two rollover valves and check valve (two-way) integrated in the fuel tank.
1. Remove the fuel tank with the fuel gauge sender unit. (See F2–45 FUEL TANK REMOVAL/INSTALLATION.)
2. Plug the fuel pipe of the fuel gauge sender unit.
3. Plug port C.
4. Connect the pump to port B.
5. Level the fuel tank.
6. Apply pressure of +2.0 kpa {+34 mmHg, +1.3
inHg} to port B.
(1) Verify there is airflow from port A.
•If there is no airflow, replace the fuel tank.
7. Apply pressure of –5.9 kPa {–44 mmHg, –1.7
inHg} to port B.
•If there is no vacuum, replace the fuel tank.
•If there is vacuum, turn the fuel tank
upside-down and proceed to next step.
8. Apply pressure of +2.0 kPa {+15 mmHg, +0.6
inHg} to port B.
(1) Verify there is no airflow from port A.
•If there is airflow, replace the fuel tank.
End Of Sie
OILOIL
PLASTIC FUEL HOSE QUICK RELEASE
CONNECTOR SEALING
SURFACE
A6E3912W006
B
C
APLUG
PLUG
CHECK VALVE
(TWO-WAY)
FUEL GAUGE SENDER UNIT
ROLLOVER VALVE
A6E40122034
B CA
PLUGPLUG
CHECK VALVE
(TWO-WAY)
FUEL GAUGE SENDER UNIT
ROLLOVER VALVE
A6E40122035

ON-BOARD DIAGNOSTIC
F2–87
F2
End Of SieDTC TABLEA6E407018881210
×: Applicable –: Not applicable
DTC Condition MILMemory
functionPage
P0016 Crankshaft position-camshaft position correlation malfunction××(See F2–88 DTC P0016)
P0088 Fuel pressure system too high–×(See F2–89 DTC P0088)
P0091 Suction control valve circuit low input××(See F2–90 DTC P0091)
P0092 Suction control valve circuit high input××(See F2–92 DTC P0092)
P0093 Fuel system leak detection××(See F2–94 DTC P0093)
P0097 IAT sensor No.1 circuit low input××(See F2–95 DTC P0097)
P0098 IAT sensor No.1 circuit high input××(See F2–97 DTC P0098)
P0102 MAF sensor circuit low input××(See F2–99 DTC P0102)
P0103 MAF sensor circuit high input××(See F2–101 DTC P0103)
P0107 Boost sensor circuit low input××(See F2–103 DTC P0107)
P0108 Boost sensor circuit high input××(See F2–105 DTC P0108)
P0112 IAT sensor No.2 circuit low input××(See F2–107 DTC P0112)
P0113 IAT sensor No.2 circuit high input××(See F2–109 DTC P0113)
P0117 ECT sensor circuit low input××(See F2–111 DTC P0117)
P0118 ECT sensor circuit high input××(See F2–113 DTC P0118)
P0121 Accelerator position sensor No.1 circuit performance problem××(See F2–115 DTC P0121)
P0122 Accelerator position sensor No.1 circuit low input××(See F2–116 DTC P0122)
P0123 Accelerator position sensor No.1 circuit high input××(See F2–118 DTC P0123)
P0182 Fuel temperature sensor circuit low input××(See F2–120 DTC P0182)
P0183 Fuel temperature sensor circuit high input××(See F2–122 DTC P0183)
P0191 Fuel pressure sensor circuit performance problem××(See F2–124 DTC P0191)
P0192 Fuel pressure sensor circuit low input××(See F2–125 DTC P0192)
P0193 Fuel pressure sensor circuit high input××(See F2–127 DTC P0193)
P0200 Fuel injector circuit malfunction××(See F2–129 DTC P0200)
P0221 Accelerator position sensor No.2 circuit performance problem××(See F2–131 DTC P0221)
P0222 Accelerator position sensor No.2 circuit low input××(See F2–132 DTC P0222)
P0223 Accelerator position sensor No.2 circuit high input××(See F2–134 DTC P0223)
P0300 Random misfire detection××(See F2–136 DTC P0300)
P0336 CKP sensor circuit performance problem××(See F2–137 DTC P0336)
P0337 CKP sensor circuit low input××(See F2–138 DTC P0337)
P0341 CMP sensor circuit performance problem××(See F2–140 DTC P0341)
P0342 CMP sensor circuit low input××(See F2–141 DTC P0342)
P0380 Glow plug relay circuit malfunction××(See F2–143 DTC P0380)
P0504 Brake switch signal correlation malfunction××(See F2–145 DTC P0504)
P0510 Idle switch circuit malfunction××(See F2–148 DTC P0510)
P0512 Engine switch circuit malfunction××(See F2–150 DTC P0512)
P0564 Cruise control signal malfunction–×(See F2–152 DTC P0564)
P0602 PCM programming error××(See F2–154 DTC P0602)
P0606 PCM malfunction××(See F2–155 DTC P0606)
P0610 Control module vehicle options error××(See F2–155 DTC P0610)
P0661 VSC solenoid valve circuit low input–×(See F2–156 DTC P0661)
P0662 VSC solenoid valve circuit high input–×(See F2–158 DTC P0662)
P0850 Neutral switch circuit malfunction××(See F2–160 DTC P0850)
P1190 Calibration resistor circuit malfunction××(See F2–162 DTC P1190)
P2228 BARO sensor circuit low input××(See F2–164 DTC P2228)
P2229 BARO sensor circuit high input××(See F2–164 DTC P2229)
U0073 CAN bus off–×(See T–39 MULTIPLEX
COMMUNICATION SYSTEM)
U0121PCM cannot receive any signals from ABS, ABS/TCS or DSC
HU/CM××(See T–39 MULTIPLEX
COMMUNICATION SYSTEM)
U0155 PCM cannot receive any signals from instrument cluster××(See T–39 MULTIPLEX
COMMUNICATION SYSTEM)