2002 MAZDA 6 fuel pump

CONTROL SYSTEM
F1–15
F1
Output Device
×:Applied
—: Not applied
* : For L3 engine only
End Of Sie
Item SignalMazda6 (GG, GY)
Remark for new model
4WD ATX Unleaded
(RON 90
or above)Current
model
IAC valve IAC×Same as current model
VIC solenoid valve* VIC×—×Same as current model
Variable tumble control
solenoid valveVTCS×Same as current model
Oil control valve (OCV)*Variable valve
timing control×—×Same as current model
Fuel injectorFuel injection
control×Same as current model
Fuel pump relayFuel pump
control×Same as current model
Ignition coil ESA control×Same as current model
EGR valve EGR control×Same as current model
Purge solenoid valve Purge control×Same as current model
BARO factor for Purge control has been
eliminated.
Heated oxygen sensor
heater
(Front, rear)O2S heater
control×Same as current model
Field coil
(Generator terminal D)Generator
control×Same as current model
Cooling fan relayElectric fan
control×Same as current model
A/C relayA/C cut-off
control×Same as current model
Controller area network
(CAN)Information
function×Same as current model
TCM (ATX) information have been
adopted for 4WD ATX model.

F1–18
CONTROL SYSTEM
*1: For MTX model
*2: For 2WD ATX model
*3: For L3 engine
End Of Sie
1 MAF/IAT sensor
2 TP sensor
3 MAP sensor
4 CMP sensor
5 CKP sensor
6 ECT sensor
7 Knock sensor
8 HO2S (front, rear)
9 PSP switch
10 Vehicle speedometer sensor
11
Clutch switch*
1
12
Neutral switch*1
13
TR switch*2
14 Brake switch
15 A/C switch
16 Refrigerant pressure switch
17 Generator (terminal P: generation voltage)
18 Battery
19
VAD control solenoid valve*
3
20 IAC valve
21
VIC solenoid valve*
3
22 Variable tumble control solenoid valve
23
OCV*
3
24 Fuel injector
25 Fuel pump relay
26 Ignition coil
27 Purge solenoid valve
28 EGR valve
29 Oxygen sensor heater (front, rear)
30 A/C relay
31 Cooling fan relay
32 Generator (terminal D: field coil)
33
VAD control*
3
34 IAC
35
VIC*
3
36 VTCS
37
Variable valve timing control*
3
38 Fuel injection control
39 Fuel pump control
40 Electronic spark advance (ESA) control
41 Purge control
42 EGR control
43 Oxygen sensor heater control
44 A/C cut-off control
45 Electrical fan control
46 Generator control

CONTROL SYSTEM
F1–19
F1
CONTROL DEVICE AND CONTROL RELATIONSHIP CHARTA6E394018880204Input devices
x: Applicable
*
1: For unleaded fuel (RON 90 or above) model
*2: For MTX model
*3: For 2WD ATX model
Component
IAT sensor x x x xxxx×
MAF sensor x xx xxxxx
TP sensor x x x x x x x x
MAP sensor x x
ECT sensor xx xxx xxxxx x
CMP sensor x x
CKP sensor xxxxxxxxxxxxx
Knock sensor x
Front HO2S x x
Rear HO2S x
BARO sensor*
1x
Neutral switch*
2xxxx
Clutch switch*
2xxxxx
TR switch*
3xxxxx
Brake switch
PSP switch x x x
VSS×
A/C switch, refrigerant
pressure switch (high,
low pressure)xxx××
Refrigerant pressure
switch (middle pressure)×
Battery voltage x x x×
Generator terminal P
(Generation voltage)xxx×
ABS/TCS HU/CM×
Coil×
Idle air control (IAC)Variable air duct (VAD)
controlVariable intake-air
control (VIC)Variable tumble
control system (VTCS)Variable valve timing controlFuel injection controlFuel pump controlElectronic spark advance
(ESA) controlPurge controlEGR controlFront HO2S heater controlRear HO2S heater controlA/C cut-off controlElectrical fan controlGenerator controlTraction controlImmobilizer system

F1–20
CONTROL SYSTEM
Output devices
×: Applicable
* : For L3 engine
End Of Sie
Component
IAC valve×
VAD control solenoid valve*×
VIC solenoid valve*×
Variable tumble control
solenoid valve×
Oil control valve (OCV)*×
Fuel injectors××
Fuel pump relay×
Ignition coil××
Purge solenoid valve×
EGR valve×
HO2S heaters××
A/C relay×
Cooling fan relay×
Generator (terminal D: field
coil)×
ABS/TCS HU/CM×
Idle air control (IAC)Variable air duct (VAD)
controlVariable intake-air
control (VIC)Variable tumble
control system (VTCS)Variable valve timing controlFuel injection controlFuel pump controlElectronic spark advance
(ESA) controlPurge controlEGR controlFront HO2S heater controlRear HO2S heater controlA/C cut-off controlElectrical fan controlGenerator controlTraction controlImmobilizer system

F1–22
OUTLINE, ENGINE TUNE-UP
SUPPLEMENTAL SERVICE INFORMATIONA6E390218881206•The following changes and/or additions have been made since publication of the Mazda6 Workshop Manual
(1621-10-98E).
Idle speed
•Adjustment procedure has been modified.
Fuel tank
•Removal/installation procedure has been modified.
Fuel pump unit
•Removal/installation procedure has been modified.
Quick release connector (fuel tank side, transfer hose part)
•Removal/installation procedure has been added.
Exhaust system
•Removal/installation procedure has been modified.
PCM
•Inspection procedure has been modified.
On-board diagnostic
•Inspection procedure has been modified.
Troubleshooting
•Inspection procedure has been modified.
End Of Sie
IDLE SPEED INSPECTION (4WD)A6E390802000201
Note
•Ignition timing is not adjustable.
•Ignition timing verification requires WDS or equivalent.
1. Turn off the electrical loads.
2. Warm up the engine as follows.
(1) Start the engine.
(2) Maintain the engine speed at approx. 3,000 rpm until the cooling fans start to operate.
(3) Release the accelerator pedal.
(4) Wait until the cooling fans stop.
3. Verify that the idle speed (WDS: RPM PID) is within the specification using WDS or equivalent.
Idle speed
*1 : Excludes temporary idle speed drop just after the electrical loads are turned on.
*2 : Blower motor is operating at high speed. Headlight switch is turned on. Rear window defroster switch is turned
on. Cooling fans are operating.
End Of Sie
OUTLINE
ENGINE TUNE-UP
Condition
Engine speed (rpm)*1
No load 650—750
Electrical loads*
2 ON650—750
P/S ON 650—750
A/C ON and refrigerant
pressure switch (middle) OFF650—750
A/C ON and refrigerant
pressure switch (middle) ON700—800

FUEL SYSTEM
F1–23
F1
FUEL TANK REMOVAL/INSTALLATIONA6E391242110201
Warning
•Repairing a fuel tank that has not been properly steam cleaned can be dangerous. Explosion or
fire may cause death or serious injury. Always properly steam clean a fuel tank before repairing it.
•Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, do not damage the sealing surface of
the fuel pump unit when removing or installing.
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.
1. Level the vehicle.
2. Complete the “BEFORE REPAIR PROCEDURE”.
3. Disconnect the negative battery cable.
4. Remove the fuel pump unit. (See F1–26 FUEL PUMP UNIT REMOVAL/INSTALLATION.)
5. Remove the fuel gauge sender sub-unit. (See T–27 Fuel Gauge Sender Sub-Unit.)
6. Siphon the fuel from the service hole.
7. Remove the presilencer. (See F1–30 EXHAUST SYSTEM REMOVAL/INSTALLATION.)
8. Remove the TWC. (See F1–30 EXHAUST SYSTEM REMOVAL/INSTALLATION.)
9. Remove the propeller shaft. (See L–5 PROPELLER SHAFT REMOVAL/INSTALLATION.)
FUEL SYSTEM

F1–26
FUEL SYSTEM
FUEL PUMP UNIT REMOVAL/INSTALLATIONA6E391213350202
Warning
•Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, do not damage the sealing surface of
the fuel pump unit when removing or installing.
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
•Since the fuel pump unit is integrated with the fuel filter, it needs to be replaced every 75,000 km.
1. Complete the “BEFORE REPAIR PROCEDURE”.
2. Disconnect the negative battery cable.
3. Complete the following in order to the work area.
(1) Loosen the bolt of the fuel tank strap.
(2) Lower the fuel tank to a position where the SST can be attached from the service hole cover.
4. Remove the rear seat cushion.
5. Remove in the order indicated in the table.
.
6. Install in the reverse order of removal.
7. Complete the “AFTER REPAIR PROCEDURE”.
8. Complete the “Fuel Leak Inspection After Fuel
Pump Unit Installation.“ (See F1–28 Fuel Leak
Inspection After Fuel Pump Unit Installation.)
1 Service hole cover
2 Connector
3 Plastic fuel hose (fuel tank side, main fuel pipe part)
(See F1–27 Plastic Fuel Hose Removal Note)
(See F1–28 Plastic Fuel Hose Installation Note)
4 Plastic fuel hose (fuel tank side, transfer hose part)
(See F1–29 FUEL HOSE (FUEL TANK SIDE,
TRANSFER HOSE PART) REMOVAL/
INSTALLATION)
5Fuel pump cap
(See F1–27 Fuel Pump Cap Removal Note)
(See F1–28 Fuel Pump Cap Installation Note)
6 Packing
7 Fuel pump unit
3
7
1
4
5
2
6
80—90 {8.2—9.1, 60—66}
R
SST
N·m {kgf·m, ft·lbf}
A6E39122009

FUEL SYSTEM
F1–27
F1
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 Pump Cap Removal Note
1. Using the SST, remove the fuel pump cap.
FUEL PIPE
STOPPER TAB
A6E3912W001
LOCKING TAB
A6E3912W002
A6E39122015
49 T042 001A
A6E39122012