2002 MAZDA 6 air condition

CONTROL SYSTEM
F1–35
F1
HTR12
(HO2S heater (rear))ON/OFFIgnition switch ON: ON (HO2S
heater operated)
Idle: ON (HO2S heater operated)Inspect following PIDs: IAT, MAF,
ECT, RPM, ACSW.4D
IAC (IAC valve) %Ignition switch ON: 0%
Idle: Approx. 60% (ECT 90°C {194
°F} and E/L not operating) Inspect following PIDs: IAT, RPM,
MAP, ECT, MAF, TP, INGEAR, TR,
PSP, ACSW.
Inspect IAC valve.4G, 4J
IASV (Variable air duct
control solenoid valve)ON/OFFECT is above 70 °C {158 °F}, engine
speed is above 5,800 rpm, and TP
opening angle is above 50%: ON
Others: OFFInspect following PIDs: ECT, RPM,
TP.
Inspect VAD control solenoid valve.4C
IAT
(Intake air temperature)°C°FIAT 20 °C {68 °F}: 20 °C {68 °F}
IAT 30 °C {86 °F}: 30 °C {86 °F}
Inspect IAT sensor. 2E
VIAT 20 °C {68 °F}: 2.4—2.6 V
IAT 30 °C {86 °F}: 1.7—1.9 V
IMRC (Variable tumble
control solenoid valve)ON/OFFEngine speed is below approx.
3,500 rpm: ON
Others: OFFInspect following PIDs: TP, ECT,
RPM.
Inspect variable tumble control
solenoid valve.4T
IMTV*
7 (Variable
Intake-air control
solenoid valve)ON/OFFEngine speed is below approx.
4,350 rpm: ON
Others: OFFInspect following PIDs: RPM.
Inspect VIC control solenoid valve.4R
INGEAR*
8 (Load/no
load condition)ON/OFFCPP or CPP/PNP is ON: OFF
Others: ONPerform applicable DTC
troubleshooting.1R, 1W
IVS (CTP condition)IDLE/ OFF
IDLECTP: IDLE
Others: OFF IDLEPerform applicable DTC
troubleshooting.2A
KNOCKR (Knocking
retard)°Ignition switch ON: 0°
Idle: 0°Inspect knock sensor. 2P, 2S
LOAD (Engine load) %Ignition switch ON: 0%
Idle (after warm up): approx.19%Inspect MAF sensor.—
LONGFT1 (long term
fuel trim)%Idle (after warm up): approx. –14—
14%Perform applicable DTC
troubleshooting.
(See F1–54 DTC TABLE)—
MAF (Mass airflow)g/sIgnition switch ON: approx. 0 g/s
Idle (after warm up): approx. 1.5 g/s
Inspect MAF sensor. 1P
VIgnition switch ON: approx. 0.7 V
Idle (after warm up): approx. 1.3 V
MAP (Manifold
absolute pressure)kPa, inHgIgnition switch ON (at sea level):
approx 101 kPa {29.8 inHg}
Inspect MAP sensor. 1J
VIgnition switch ON (at sea level):
approx 4.1 V
MIL (Malfunction
indicator lamp)ON/OFFIgnition switch ON: ON
Idle: OFFPerform applicable DTC
troubleshooting.
(See F1–54 DTC TABLE)—
MIL_DIS (Trabelled
distance since the MIL
illuminated)km, mileNo DTC: 0 km {0 mile}
DTC detected: Not 0 km {0 mile}Perform applicable DTC
troubleshooting.
(See F1–54 DTC TABLE)—
O2S11 (Front oxygen
sensor)VIgnition switch ON: 0—1.0 V
Idle (After warm up): 0—1.0 V
Inspect HO2S (front). 1AB
Rich/LeanAcceleration (After warm up): Rich
Deceleration (After warm up): Lean
O2S12 (Rear oxygen
sensor)V Idle (After warm up): approx 0.6 V
Inspect HO2S (rear). 1Y
Rich/Lean Idle (After warm up): Rich
PSP (Power steering
pressure switch)Low/HighSteering wheel in straight ahead
position: Low
Others: HighInspect PSP switch. 1Z
RFCFLAG (Readness
function code)Learnt/Not
LearntBefore running PCM adaptive
memory procedure drive mode: Not
Learnt
After running PCM adaptive memory
procedure drive mode: LearntRun PCM adaptive memory
procedure drive mode.— Monitor item
(Definition)Unit/
ConditionCondition/Specification
(Reference)ActionPCM
terminal

ON-BOARD DIAGNOSTIC
F1–51
F1
P0112 IAT circuit low input ON 1 CCM×
P0113 IAT circuit high input ON 1 CCM×
P0117 ECT circuit low input ON 1 CCM×
P0118 ECT circuit high input ON 1 CCM×
P0121 TP stuck closed ON 2 CCM×
P0122 TP circuit low input ON 1 CCM×
P0123 TP circuit high input ON 1 CCM×
P0125 Excessive time to enter closed loop fuel control ON 2 CCM×
P0131 Front HO2S no inversion (stuck low) ON 2 CCM×
P0132 Front HO2S no inversion (stuck high) ON 2 CCM×
P0133 Front HO2S circuit malfunction ON 2O
2 sensor
×
P0134 Front HO2S circuit no activity detected ON 2 CCM×
P0138 Rear HO2S circuit high input ON 2 CCM×
P0140 Rear HO2S circuit no activity detected ON 2 CCM×
P0171 Fuel trim system too lean ON 2 Fuel×
P0172 Fuel trim system too rich ON 2 Fuel×
P0300 Random misfire detected Flash / ON 1 or 2 Misfire×
P0301 Cylinder No.1 misfire detected Flash / ON 1 or 2 Misfire×
P0302 Cylinder No.2 misfire detected Flash / ON 1 or 2 Misfire×
P0303 Cylinder No.3 misfire detected Flash / ON 1 or 2 Misfire×
P0304 Cylinder No.4 misfire detected Flash / ON 1 or 2 Misfire×
P0327 Knock sensor circuit low input ON 1 CCM×
P0328 Knock sensor circuit high input ON 1 CCM×
P0335 CKP sensor circuit malfunction ON 1 CCM×
P0340 CMP sensor circuit malfunction ON 1 CCM×
P0403 EGR valve motor coils open or short ON 2 CCM×
P0420 Catalyst system efficiency below threshold ON 2 Catalyst×
P0443Evaporative emission control system purge control
valve circuit malfunctionON 2 CCM×
P0480 Fan relay control circuit malfunction OFF 2 Other×
P0500 Vehicle speed sensor (VSS) circuit malfunction ON 2 CCM×
P0505 Idle control system malfunction OFF—Other—
P0506 Idle control system RPM lower than expected ON 2 CCM×
P0507 Idle control system RPM higher than expected ON 2 CCM×
P0511 Idle control system circuit malfunction ON 1 CCM×
P0550 PSP switch circuit malfunction ON 2 CCM×
P0602 PCM programming error ON 1 CCM×
P0610 Control module vehicle options error ON 1 CCM×
P0661 VIS control circuit low input OFF 2 Other×
P0662 VIS control circuit high input OFF 2 Other×
P0703 Brake switch input malfunction ON 2 CCM×
P0704 Clutch switch input malfunction ON 2 CCM×
P0850 Neutral switch input malfunction ON 2 CCM×
P1410 Variable air duct valve circuit malfunction OFF 2 Other×
P1562 PCM +BB voltage low ON 1 CCM×
P2006 Variable tumble control shutter valve stuck closed ON 2 CCM×
P2009 Variable tumble control solenoid circuit low input ON 2 CCM×
P2010 Variable tumble control solenoid circuit high input ON 2 CCM×
P2228 BARO sensor circuit low input ON 1 CCM×
P2229 BARO sensor circuit high input ON 1 CCM×
P2502 Generator output voltage signal no electricity OFF 1 Other—
P2503 Battery overcharge OFF 1 Other—
P2504 Generator terminal B circuit open OFF 1 Other—
U0073 CAN bus off OFF 1 Other— DTC No. Condition MIL DC Monitor itemMemory
function

F1–52
ON-BOARD DIAGNOSTIC
End Of Sie
DTC (4WD)A6E397018881204•Detection logics and conditions are as shown below.
Controller Area Network (CAN)
PCM cannot receive any signals from TCM (U0101)
•PCM cannot receive any signals from TCM.
End Of Sie
OBD DRIVE MODEA6E397018881205•Performing the Drive Mode inspects the OBD system for proper operation. The Drive Mode must be performed
to ensure that no additional DTCs are present.
•During Drive Mode, the following systems are inspected:
—Oxygen sensor (HO2S)
—Oxygen sensor heater
—Catalytic converter (TWC)
Caution
•While performing the Drive Mode, always operate the vehicle in a safe and lawful manner.
•When the WDS or equivalent is used to observe monitor system condition while driving, be sure to
have another technician with you, or record the data in the WDS or equivalent using the PID/DATA
MONITOR AND RECORD function and inspect later.
Note
•Vehicle speed and engine speed detected by the PCM may differ from that indicated by the speedometer
and tachometer. Use the WDS or equivalent to monitor vehicle speed.
•If the OBD system inspection is not completed during the Drive Mode, the following causes are
considered:
1. The OBD system detects the malfunction.
2. The Drive Mode procedure is not completed correctly.
•Disconnecting the battery will reset the memory. Do not disconnect the battery during and after Drive
Mode.
PCM Adaptive Memory Procedure Drive Mode
Note
•The PCM adaptive memory condition can be confirmed with RFCFLAG PID.
•If RFCFLAG PID is “Learnt”, PCM Adaptive Memory Procedure Drive Mode is not necessary, because
PCM already has adaptive memory.
•If RFCFLAG PID is “Not Learnt”, PCM Adaptive Memory Procedure Drive should be performed before
HO2S Heater, HO2S, and TWC Repair Verification Drive Mode.
1. Start the engine and warm it up completely.
2. Verify all accessory loads (A/C, headlights, blower fan, rear window defroster) are off.
U0101 PCM cannot receive any signals from TCM ON 1 Other×
U0121PCM cannot receive any signals from ABS, ABS/TCS
or DSC HU/CMON 1 Other×
U0155PCM cannot receive any signals from instrument
clusterON 1 Other× DTC No. Condition MIL DC Monitor itemMemory
function

ON-BOARD DIAGNOSTIC
F1–53
F1
3. Perform no load racing at the engine speed
shown in the graph, then idle the engine for more
than 30 s after the cooling fan is stopped. If
possible, monitor RPM PID for engine speed and
FAN1 PID for cooling fan condition during this
procedure.
4. Turn ignition key off then on again.
5. Access to RFCFLAG PID to confirm PCM
adaptive memory condition. If RFCFLAG PID is
“Learnt”, PCM Adaptive Memory Procedure Drive
is completed.
6. If RFCFLAGPID is still “Not Learnt”, go back to
Step 1.
HO2S Heater, HO2S, and TWC Repair Verification Drive Mode
1. Access to RFCFLAG PID to confirm PCM adaptive memory condition. If RFCFLAG PID is OFF, perform PCM
Adaptive Memory Procedure Drive first.
2. If RFCFLAG PID is ON, start the engine and warm it up completely.
3. Verify all accessory loads (A/C, headlights, blower fan, rear window defroster) are off.
4. Drive the vehicle as shown in the graph; first drive in zone O, then A or B, followed by C or D, finally E or F.
Driving condition before the constant speed driving is not specified.
For MTX
2,800—3,200 rpm
IDLE
Above
30 sAbove
30 s
ENGINE SPEEDIDLE
A6E3970W003
ZoneShift
PositionVehicle Speed
km/h {mph}Time
Sec.
O Neutral 0 T1: Above 455
A2nd40—50 {25—32}
T2: Above 30
B3rd65—75 {41—47}
C2nd60—75 {38—46}
T3: Above 20
D3rd75—100 {47—62}
E4th50—75 {31—46}
T4: Above 120
F5th75—100 {47—62}
km/h {mph}
100 {62}
50 {31}
0 {0}O
T1 T2 T3 T4A BD
C
E F
A6E3970W004

F1–54
ON-BOARD DIAGNOSTIC
For L3 engine ATX
5. Stop vehicle and access to ON BOARD SYSTEM
READINESS menu of GENERIC OBD
FUNCTION to inspect the Drive Mode completion
condition. If completed, RFC changes from NO to
YES.
6. If not completed, turn the ignition key to OFF, then go back to Step 4.
7. Access DIAGNOSTIC MONITORING TEST RESULTS menu of GENERIC OBD FUNCTIONS to inspect the
monitor results. If MEAS are not within the specification, repair has not completed.
8. Verify no DTC is available.
End Of Sie
DTC TABLEA6E397018881206DTC table
×: Applicable
—: Not applicable
Zone RangeVehicle Speed
km/h {mph}Time
Sec.
OP or N 0T1: Above
455
A M (3rd) 40—65 {25—41}
T2: Above 30
B M (3rd) 65—80 {41—49}
C M (2nd) 60—75 {38—46}
T3: Above 20
D M (3rd) 80—95 {50—59}
EM (4th)50—75 {31—47}
T4: Above
120
FM (5th)75—100 {46—62}km/h {mph}
100 {62}
50 {31}
0 {0}O
T1 T2 T3 T4A BD
C
E F
A6E3970W999
DTC No. Condition MIL DC Monitor itemMemory
functionPage
P0010CMP actuator circuit
malfunctionON 1 CCM×—
P0011 CMP timing over-advanced ON 1 CCM×—
P0012 CMP timing over-retarded ON 1 CCM×—
P0031Front HO2S heater circuit low
inputON 2O
2 sensor heater
×—
P0032Front HO2S heater circuit high
inputON 2O
2 sensor heater
×—
P0037Rear HO2S heater circuit low
inputON 2O
2 sensor heater
×—
P0038Rear HO2S heater circuit high
inputON 2O
2 sensor heater
×—
P0101MAF sensor inconsistent with
TP sensorON 2 CCM×—
P0102 MAF circuit low input ON 1 CCM×—
P0103 MAF circuit high input ON 1 CCM×—
P0107 MAP sensor circuit low input ON 1 CCM×—
P0108 MAP sensor circuit high input ON 1 CCM×—
P0111 IAT circuit performance problem ON 2 CCM×—
P0112 IAT circuit low input ON 1 CCM×—
P0113 IAT circuit high input ON 1 CCM×—
P0117 ECT circuit low input ON 1 CCM×—
P0118 ECT circuit high input ON 1 CCM×—
P0121 TP stuck closed ON 2 CCM×—
P0122 TP circuit low input ON 1 CCM×—
P0123 TP circuit high input ON 1 CCM×—
P0125Excessive time to enter closed
loop fuel controlON 2 CCM×—
P0131Front HO2S no inversion (stuck
low)ON 2 CCM×—
P0132Front HO2S no inversion (stuck
high)ON 2 CCM×—

ON-BOARD DIAGNOSTIC
F1–55
F1
P0133 Front HO2S circuit malfunction ON 2O2 sensor
×—
P0134Front HO2S circuit no activity
detectedON 2 CCM×—
P0138 Rear HO2S circuit high input ON 2 CCM×—
P0140Rear HO2S circuit no activity
detectedON 2 CCM×—
P0171 Fuel trim system too lean ON 2 Fuel×—
P0172 Fuel trim system too rich ON 2 Fuel×—
P0300 Random misfire detected Flash / ON 1 or 2 Misfire×—
P0301 Cylinder No.1 misfire detected Flash / ON 1 or 2 Misfire×—
P0302 Cylinder No.2 misfire detected Flash / ON 1 or 2 Misfire×—
P0303 Cylinder No.3 misfire detected Flash / ON 1 or 2 Misfire×—
P0304 Cylinder No.4 misfire detected Flash / ON 1 or 2 Misfire×—
P0327 Knock sensor circuit low input ON 1 CCM×—
P0328 Knock sensor circuit high input ON 1 CCM×—
P0335 CKP sensor circuit malfunction ON 1 CCM×—
P0340 CMP sensor circuit malfunction ON 1 CCM×—
P0403EGR valve motor coils open or
shortON 2 CCM×—
P0420Catalyst system efficiency
below thresholdON 2 Catalyst×—
P0443Evaporative emission control
system purge control valve
circuit malfunctionON 2 CCM×—
P0480Fan relay control circuit
malfunctionOFF 2 Other×—
P0500Vehicle speed sensor (VSS)
circuit malfunction (MTX)ON 2 CCM×—
P0505 Idle control system malfunction OFF—Other——
P0506Idle control system RPM lower
than expectedON 2 CCM×—
P0507Idle control system RPM higher
than expectedON 2 CCM×—
P0511Idle control system circuit
malfunctionON 1 CCM×—
P0550 PSP switch circuit malfunction ON 2 CCM×—
P0602 PCM programming error ON 1 CCM×—
P0610Control module vehicle options
errorON 1 CCM×—
P0661 VIS control circuit low input OFF 2 Other×—
P0662 VIS control circuit high input OFF 2 Other×—
P0703 Brake switch input malfunction ON 2 CCM×—
P0704 Clutch switch input malfunction ON 2 CCM×—
P0850 Neutral switch input malfunction ON 2 CCM×—
P1410Variable air duct valve circuit
malfunctionOFF 2 Other×—
P1562 PCM +BB voltage low ON 1 CCM×—
P2006Variable tumble control system
shutter valve stuck closedON 2 CCM×—
P2009Variable tumble control solenoid
valve circuit low inputON 2 CCM×—
P2010Variable tumble control solenoid
valve circuit high inputON 2 CCM×—
P2228 BARO sensor circuit low input ON 1 CCM×—
P2229 BARO sensor circuit high input ON 1 CCM×—
P2502Generator output voltage signal
no electricityOFF 1 Other——
P2503 Battery overcharge OFF 1 Other—— DTC No. Condition MIL DC Monitor itemMemory
functionPage

TROUBLESHOOTING
F1–57
F1
ENGINE SYMPTOM TROUBLESHOOTINGA6E398018881201•Confirm trouble symptom using the following diagnostic index, then go to appropriate troubleshooting chart.
Diagnostic Index
End Of Sie
TROUBLESHOOTING
No. TROUBLESHOOTING ITEM DESCRIPTION
1 Melting of main or other fuses—
2 MIL illuminates MIL is illuminated incorrectly.
3 Will not crank Starter does not work.
4Hard to start/long crank/erratic start/erratic
crankStarter cranks engine at normal speed but engine requires excessive
cranking time before starting.
5 Engine stalls. After start/at idle Engine stops unexpectedly at idle and/or after start.
6 Cranks normally but will not start Starter cranks engine at normal speed but engine will not run.
7 Slow return to idle Engine takes more time than normal to return to idle speed.
8 Engine runs rough/rolling idleEngine speed fluctuates between specified idle speed and lower
speed and engine shakes excessively.
9 Fast idle/runs onEngine speed continues at fast idle after warm-up.
Engine runs after ignition switch is turned to off.
10 Low idle/stalls during decelerationEngine stops unexpectedly at beginning of deceleration or recovery
from deceleration.
11Engine stalls/quits. Acceleration/cruiseEngine stops unexpectedly at beginning of acceleration or during
acceleration.
Engine stops unexpectedly while cruising.
Engine runs rough. Acceleration/cruise Engine speed fluctuates during acceleration or cruising.
Misses Acceleration/cruise Engine misses during acceleration or cruising.
Buck/jerkAcceleration/cruise/
decelerationVehicle bucks/jerks during acceleration, cruising, or deceleration.
Hesitation/stumble Acceleration Momentary pause at beginning of acceleration or during acceleration
Surges Acceleration/cruise Momentary minor irregularity in engine output
12 Lack/loss of power Acceleration/cruisePerformance is poor under load.
(e.g., power down when climbing hills)
13 Knocking/pinging Acceleration/cruiseSound is produced when air/fuel mixture is ignited by something other
than spark plug. (e.g., hot spot in combustion chamber)
14 Poor fuel economy Fuel economy is unsatisfactory.
15 Emission compliance Fails emissions test.
16 High oil consumption/leakage Oil consumption is excessive.
17Cooling system
concernsOverheating Engine runs at higher than normal temperature/overheats.
18Cooling system
concernsRuns cold Engine does not reach normal operating temperature.
19 Exhaust smoke Blue, black, or white smoke from exhaust system
20 Fuel odor (in engine compartment) Gasoline fuel smell or visible leakage
21 Engine noise Engine noise from under hood
22 Vibration concerns (engine) Vibration from under hood or driveline
23 A/C does not work sufficiently.A/C compressor magnetic clutch does not engage when A/C is turned
on.
24A/C is always on or A/C compressor runs
continuously.A/C compressor magnetic clutch does not disengage.
25 A/C is not cut off under WOT conditions. A/C compressor magnetic clutch does not disengage under WOT.
26 Exhaust sulphur smell Rotten egg smell (sulphur) from exhaust
27 Constant voltage Incorrect constant voltage
28 Spark plug condition Incorrect spark plug condition
29 ATX concernsUpshift/downshift/
engagementATX concerns not related to engine performance

TROUBLESHOOTING
F1–59
F1
X: Applicable
Possible factor
Troubleshooting itemVariable valve timing system malfunction (L3 engine
model)
VICS malfunction
Engine overheating
Air cleaner element clogging or restriction
Air leakage from intake-air system (Loose tubes,
cracks, gaskets breakage)
IAC valve improper operation
Throttle body malfunction
VICS malfunction (L3 engine model)
VACS malfunction (L3 engine model)
Vacuum leakage (Vacuum hose damage, misrouting)
Ignition coil malfunction (e.g. open, short or cracks)
Initial ignition timing misadjustment (CKP sensor &
crankshaft pulley misadjustment)
Spark plug malfunction
High-tension leads malfunction (Cracks, open, low
resistance)
CKP sensor is damaged. (e.g. open or short circuits )
Crankshaft pulley is damaged
Improper gap between CKP sensor and crankshaft
Fuel pump malfunction (Mechanically or electrically)
Pressure regulator malfunction
Fuel hoses restriction or clogging
1 Melting of main or other fuses2 MIL illuminates x x x x x3 Will not crank4 Hard to start/long crank/erratic start/erratic
crankx x x x x x xxxxxx
5 Engine stalls. x x x x x xxxxxxxxxxx6 Cranks normally but will not start x x x x xxxxxxxxxxx7 Slow return to idle x8 Engine runs rough/rolling idle x x x x x x x x xxxxxxx9 Fast idle/runs on x x10 Low idle/stalls during deceleration x x xEngine stalls/quits. Acceleration/cruise x x x x x x x x xxxxxxxEngine runs rough. Acceleration/cruise x x x x x x x x xxxxxxxMissesAcceleration/cruise x x x x x x x x xxxxxxxBuck/jerk Acceleration/cruise/dece
lerationxxx x xx x x x xxxxxx
Hesitation/stumble Acceleration x x x x x x x x xxxxxxx
11
Surges Acceleration/cruise x x x x x x x x xxxxxxx
12 Lack/loss of powerAcceleration/cruise x x x x x x x x xxxxxxx13 Knocking/pingingAcceleration/cruise x x x14 Poor fuel economy x x x x x x x15 Emission compliance x x x x x x x x x16 High oil consumption/leakage17 Cooling system
concernsOverheating
18 Cooling system
concernsRuns cold
19 Exhaust smoke x x x x x x20 Fuel odor (in engine compartment)x21 Engine noise x x x22 Vibration concerns (engine)23 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 x x x27 Constant voltage28 Spark plug condition x x x x x x29 ATX concernsUpshift/downshift
engagementSee Section K, TROUBLESHOOTING
A6E39802002