2002 MAZDA 6 Temperature control

CONTROL SYSTEM
F2–19
F2
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1PCM (with built-in BARO sensor and immobilizer
unit)
2Battery
3Starter
4 Starter relay
5 Clutch switch
6 Neutral switch
7 Brake switch
8 Idle switch
9 Cruise control switch
10 Accelerator position sensor
11 MAF/IAT sensor
12 IAT sensor No.2
13 ECT sensor
14 Fuel temperature sensor
15 Boost sensor
16 Fuel pressure sensor
17 CMP sensor
18 CKP sensor
19 VSS
20 Calibration resistor
21 Suction control valve
22 IDM
23 VSC solenoid valve
24 VBC solenoid valve
25 EGR control solenoid valve
26 EGR solenoid valve (vacuum)
27 EGR solenoid valve (vent)
28 Intake shutter solenoid valve (half)
29 Intake shutter solenoid valve (full)
30 Glow indicator light
31 Cruise main indicator light
32 Cruise set indicator light
33 Glow plug relay
34 Cooling fan relay No.1
35 Cooling fan relay No.2
36 A/C relay
37 PCM control relay
38 L.H.D.
39 R.H.D.

CONTROL SYSTEM
F2–21
F2
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1PCM
2 Idle speed control
3Glow control
4 VSC
5 Boost pressure control
6 Fuel injection amount control
7 Fuel injection timing control
8 Multiple fuel injection control
9 Fuel pressure control
10 EGR control
11 Cruise control system
12 Electrical fan control
13 A/C cut-off control
14 Immobilizer system
15 Battery
16 Starter (starter signal)
17 Starter relay
18 Clutch switch
19 Neutral switch
20 Brake switch
21 Idle switch
22 A/C switch
23 Refrigerant pressure switch
24 Cruise control switch
25 Accelerator position sensor
26 MAF/IAT sensor
27 IAT sensor No.2
28 ECT sensor
29 Fuel temperature sensor
30 BARO sensor (integrated in PCM)
31 Boost sensor
32 Fuel pressure sensor
33 CMP sensor
34 CKP sensor
35 VSS
36 Calibration resistor
37 Immobilizer unit (integrated in PCM)
38 Suction control valve
39 IDM
40 VSC solenoid valve
41 VBC solenoid valve
42 EGR control solenoid valve
43 EGR solenoid valve (vacuum)
44 EGR solenoid valve (vent)
45 Intake shutter solenoid valve (half)
46 Intake shutter solenoid valve (full)
47 Glow indicator light
48 Cruise main indicator light
49 Cruise set indicator light
50 Glow plug relay
51 Cooling fan relay No.1
52 Cooling fan relay No.2
53 A/C relay

F2–22
CONTROL SYSTEM
CONTROL DEVICE AND CONTROL RELATIONSHIP CHARTA6E404018881204
×: Applicable
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Item
Input device
Battery××
Starter (starter signal)××××××××× ×
Starter relay××××××××× ×
Clutch switch× × ××× ×× ×
Neutral switch× × ××× ×× ×
Brake switch×
Idle switch× × ××× × ×
A/C switch×××××
Refrigerant pressure switch×××××
Cruise control switch×
Accelerator position sensor××××××××
MAF/IAT sensor× ××××
IAT sensor No.2××
ECT sensor××× ××××× ××
Fuel temperature sensor×
BARO sensor (integrated in PCM)×××
Boost sensor××× ×
Fuel pressure sensor×× ××
CMP sensor×××××
CKP sensor× ××××××× ×
VSS××× ××× ××
Calibration resistor××
Immobilizer unit (integrated in PCM)×
Output device
Suction control valve××
IDM× ××× × ×
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)×
Glow indicator light×
Cruise main indicator light×
Cruise set indicator light×
Glow plug relay×
Cooling fan relay No.1×
Cooling fan relay No.2×
A/C relay×
Idle speed controlGlow controlVSCBoost pressure controlFuel injection amount controlFuel injection timing controlMultiple fuel injection controlFuel pressure controlEGR controlCruise control systemElectrical fan controlA/C cut-off controlImmobilizer system

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.
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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.××

ON-BOARD DIAGNOSTIC
F2–25
F2
P0112 IAT sensor No.2 circuit low input Input voltage from IAT sensor No.2 is below 0.1 V.××
P0113 IAT sensor No.2 circuit high input Input voltage from IAT sensor No.2 is above 5.0 V.××
P0117 ECT sensor circuit low input Input voltage from ECT sensor is below 0.1 V.××
P0118 ECT sensor circuit high input Input voltage from ECT sensor is above 5.0V.××
P0121Accelerator position sensor No.1 circuit
performance problemInput voltage from accelerator position sensor No.1
is above 1.3 V when accelerator pedal is
depressed.××
P0122Accelerator position sensor No.1 circuit
low inputInput voltage from accelerator position sensor No.1
is below 0.3 V.××
P0123Accelerator position sensor No.1 circuit
high inputInput voltage from accelerator position sensor No.1
is above 4.7 V.××
P0182 Fuel temperature sensor circuit low inputInput voltage from fuel temperature sensor is below
0.1 V.××
P0183 Fuel temperature sensor circuit high inputInput voltage from fuel temperature sensor is above
5.0 V.××
P0191Fuel pressure sensor circuit performance
problemPressure difference between actual fuel pressure
and target fuel pressure exceeds preprogrammed
criteria.××
P0192 Fuel pressure sensor circuit low inputInput voltage from fuel pressure sensor is below 0.4
V.××
P0193 Fuel pressure sensor circuit high inputInput voltage from fuel pressure sensor is above
4.8 V.××
P0200 Fuel injector circuit malfunction Injection confirmation signal is not input normally.××
P0221Accelerator position sensor No.2 circuit
performance problemVoltage difference between accelerator position
sensor No.1 and accelerator position sensor No.2
exceeds 0.9 V.××
P0222Accelerator position sensor No.2 circuit
low inputInput voltage from accelerator position sensor No.2
is below 0.3 V.××
P0223Accelerator position sensor No.2 circuit
high inputInput voltage from accelerator position sensor No.2
is above 4.7 V.××
P0300 Random misfire detectionInterval time of CKP sensor input signal exceeds
preprogrammed criteria.××
P0336 CKP sensor circuit performance problemInput signal from CKP sensor is not proper pulse
number.××
P0337 CKP sensor circuit low inputInput signal from CKP sensor is not input at 12
crankshaft revolutions.××
P0341 CMP sensor circuit performance problemInput signal from CMP sensor is not proper pulse
number.××
P0342 CMP sensor circuit low inputInput signal from CMP sensor is not input at 12
crankshaft revolutions.××
P0380 Glow plug relay circuit malfunctionInput voltage from glow plug relay is as following:
—1.0 V or below when glow plug relay is on.
—4.0 V or above when glow plug relay is off.××
P0504Brake switch signal correlation
malfunctionInput signal from brake switch 1 brake switch 2 is as
following:.
—Brake switch 1 is ON and brake switch 2 is ON.
—Brake switch 1 is OFF and brake switch 2 is
OFF.××
P0510 Idle switch circuit malfunctionInput voltage from idle switch is B+ when
accelerator position sensor No.1 voltage is below
0.7 V.××
P0512 Engine switch circuit malfunctionInput voltage from engine switch is B+ when engine
speed is 1,200 rpm or above.××
P0564 Cruise control signal malfunctionInput voltage from cruise control switch is as
following for 120 s:
—Below 0.1 V.
—1.4—1.9 V.
—3.7—3.9 V.
—4.5—4.6 V.××
P0602 PCM programming error No configuration data in PCM.××
P0606 PCM malfunction PCM does not read DTC from output devices.×× DTC Condition Detection condition MILMemory
function

ON-BOARD DIAGNOSTIC
F2–27
F2
PID/DATA MONITOR AND RECORDA6E407018881204PID monitoring item table
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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

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
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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
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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.
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Ambient temperature (°C {°F}) Resistance (ohms)
20 {68} Approx. 2.1
SUCTION
CONTROL VALVE A B
A6E40122018

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