2002 MAZDA 6 ignition

F1–16
CONTROL SYSTEM
STRUCTURAL VIEW (4WD)A6E394018880202
.
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9
8
7
5
4
3
10
1817
15
16
14
13
11
12
20
25
24
23
21
22
6
1
2
19
A6E39402000
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)
9 HO2S (rear)
10 PSP switch
11 Brake switch
12 VAD control solenoid valve
13 IAC valve14 VIC solenoid valve
15 Variable tumble control solenoid valve
16 OCV
17 Fuel injector
18 Ignition coil
19 Purge solenoid valve
20 EGR valve
21 BARO sensor
22 PCM (R.H.D.)
23 TCM (R.H.D)
24 PCM (L.H.D.)
25 TCM (L.H.D)

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

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

CONTROL SYSTEM
F1–33
F1
PCM INSPECTION (4WD)A6E394018880207Using SST (WDS or equivalent)
Note
•PIDs for the following parts are not available on this model. Go to the appropriate part inspection page.
—CMP sensor
—Main relay
1. Connect the SST (WDS or equivalent) to the
DLC-2.
2. Turn the ignition switch to ON position.
3. Measure the PID value.
•If PID value is not within the specification,
follow the instructions in Action column.
Note
•The PID/DATA MONITOR function monitors
the calculated value of the input/output
signals in the PCM. Therefore, an output
device malfunction is not directly indicated
as a malfunction of the monitored value for
the output device. If a monitored value of an
output device is out of specification, inspect the monitored value of the input device related to the output
control.
•For input/output signals except those of the monitoring items, use a voltmeter to measure the PCM
terminal voltage.
•The simulation items that are used in the ENGINE CONTROL SYSTEM OPERATION INSPECTION are
as follows.
—ACCS, ALTF, EVAPCP, FAN1, FAN2, FAN3, FP, HTR11, HTR12, IAC, IASV, IMRC, IMTV, VT DUTY1
PID/DATA monitor table (reference)
CONTROL SYSTEM
DLC-2
A6E3970W002
Monitor item
(Definition)Unit/
ConditionCondition/Specification
(Reference)ActionPCM
terminal
ACCS (A/C relay) ON/OFFIgnition switch ON: OFF
A/C switch ON and fan switch ON at
idle: ONInspect following PIDs: RPM, TP,
ECT, ACSW, TR.
Inspect A/C relay.4O
ACSW (A/C switch) ON/OFFA/C switch and fan switch ON at
ignition switch ON: OFF
A/C switch OFF at ignition switch
ON: OFFInspect A/C switch. 1AC
ALTF (Generator field
coil control duty value)%Ignition switch ON: 0%
Idle: 0—100%
Just after A/C switch ON and fan
switch ON at idle: Duty value risesInspect following PIDs: IAT, ECT,
RPM, VPWR, ALTT V.
Inspect generator.1AD
ALTT V (Generator
output voltage)VIgnition switch ON: 0 V
Idle: Approx. 14.9 V
*1 (E/L not
operating)Inspect generator. 1AA
ARPMDES
(Target engine speed)RPM
LF Unleaded fuel (RON 90 or
above) model
No load: 650 rpm
E/L operating: 700 rpm
P/S operating: 700 rpm
A/C ON: 750 rpm
L3 4WD ATX model
No load: 700 rpm
E/L operating: 700 rpm
P/S operating: 700 rpm
A/C ON: 700 rpm*
2, 750 rpm*3
Inspect following PIDs: IAT, RPM,
MAP, ECT, MAF, TP, INGEAR,
ACSW, TR, PSP, ALTT V.
Inspect IAC valve.
Inspect CKP sensor.—
AST (After start timer) Sec———

F1–34
CONTROL SYSTEM
BARO*7
(Barometric pressure)kPa, inHgIgnition switch ON (at sea level):
approx. 101 kPa {29.8 inHg}
Inspect BARO sensor. 1G
VIgnition switch ON (at sea level):
approx. 4.1 V
BOO
(Brake switch)ON/OFFBrake pedal depressed: ON
Brake pedal released: OFFInspect brake switch. 1K
CHRGLP (Generator
warning light)ON/OFFIgnition switch ON: ON
Idle: OFFPerform applicable DTC
troubleshooting.
(See F1–54 DTC TABLE)—
COLP*
4 (Refrigerant
pressure switch
(middle))ON/OFFRefrigerant pressure switch (middle)
ON *2 at idle: ON
Refrigerant pressure switch (middle)
OFF
*3 at idle: OFFInspect refrigerant pressure switch. 1Q
CPP*
8
(Clutch pedal position)ON/OFFClutch pedal depressed: ON
Clutch pedal released: OFFInspect clutch switch. 1R
CPP/PNP*
8 (Shift
lever position)Drive/
NeutralNeutral position: Neutral
Others: DriveInspect neutral switch. 1W
DTCCNT (Number of
DTC detected)——Perform applicable DTC
troubleshooting.
(See F1–54 DTC TABLE)—
ECT (Engine coolant
temperature)°C°FECT 20 °C {68 °F}: 20 °C {68 °F}
ECT 60 °C {140 °F}: 60 °C {140 °F}
Inspect ECT sensor. 1M
VECT 20 °C {68 °F}: 3.04—3.14 V
ECT 60 °C {140 °F}: 1.29—1.39 V
EVAPCP (Purge
solenoid valve duty
value)%Ignition switch ON: 0%
Idle: 0%Inspect following PIDs: IAT, RPM,
ECT, MAF, O2S11,BARO, INGEAR,
TR, VPWR.4U
FAN1
(Cooling fan control)ON/OFFECT below 100 °C {212 °F}: OFF
Others: ONInspect following PIDs: RPM, TP,
ECT, ACSW, COLP, TEST.
Inspect cooling fan relay.4L
FAN2
(Cooling fan control)ON/OFFECT below 108 °C {226 °F}: OFF
A/C operating, refrigerant pressure
switch (middle) is OFF, and ECT
below 108 °C {226 °F}: OFF
Others: ONInspect following PIDs: RPM, TP,
ECT, ACSW, COLP, TEST.
Inspect cooling fan relay.4F
FAN3
(Cooling fan control)ON/OFFECT below 100 °C {212 °F}: OFF
A/C operating, refrigerant pressure
switch (middle) is ON, and ECT
below 108 °C {226 °F}: OFF
Other: ONInspect following PIDs: RPM, TP,
ECT, ACSW, COLP, TEST.
Inspect cooling fan relay.4B
FDPDTC
(Pending code caused
FFD storage)——Perform applicable DTC
troubleshooting.
(See F1–54 DTC TABLE)—
FP (Fuel pump relay) ON/OFFIgnition switch ON: OFF
Idle: ON
Cranking: ONInspect following PIDs: RPM.
Inspect fuel pump relay.4P
*5
4Q*6
FUELPW (Fuel
injector duration)msIgnition switch ON: 0 ms
Idle (after warm up): approx. 2.5 msInspect following PIDs: IAT, MAF, TP,
MAP, ECT, RPM, O2S11, O2S12,
INGEAR, TR, PSP, ACSW, VPWR,
ALTT V.
Inspect fuel injector.4W, 4Z,
4AA,
4AD
FUELSYS
(Fuel system status)OL_Drive/
OL/
CL_Fault/
OL_Fault/CLIgnition switch ON: OL
Idle (after warm up): CLInspect following PIDs: IAT, MAF, TP,
MAP, ECT, RPM, O2S11, O2S12,
INGEAR, TR, PSP, ACSW, VPWR,
ALTT V.
Inspect fuel injector.—
GENVDSD
(Generator voltage
desired)VIgnition switch ON: 0 V
Idle: Approx. 14.9 V
*1 (E/L not
operating)Perform applicable DTC
troubleshooting.
(See F1–54 DTC TABLE)—
HTR11
(HO2S heater (front))ON/OFF Idle (after warm up): ON⇔OFFInspect following PIDs: IAT, MAF, TP,
ECT, RPM, ACSW.4A Monitor item
(Definition)Unit/
ConditionCondition/Specification
(Reference)ActionPCM
terminal

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

F1–36
CONTROL SYSTEM
*1: Calculated value; differs from terminal voltage
*2: Refrigerant pressure switch (middle) turns on when the refrigerant pressure is 1.69—1.84 MPa {17.3—18.7
kgf/cm2, 247—265 psi}
*3: Refrigerant pressure switch (middle) turns off when the refrigerant pressure is 1.26—1.49 MPa {12.9—15.1
kgf/cm2, 184—214 psi}
*4: L3 and L8, LF (Intensely hot area) engine models
*5: Immobilizer system equipped model
*6: Immobilizer system not equipped
*7: L3 engine model only
*8: MTX model only
•Following PIDs are for the ATX models. If inspects for following PIDs, see K2–180 PID/DATA MONITOR
INSPECTION.
PIDs for the ATX models
—GEAR, LINEDES, LPS, OP_SW_B, SSA/SS1, SSB/SS2, SSC/SS3, TCS, TFT, TFTV, THOP, TR,
TR_SENS, TSS
RO2FT1 (Rear oxygen
sensor fuel trim)—Idle (after warm up): approx. –
0.03—0.03Perform applicable DTC
troubleshooting.—
RPM (Engine speed) rpm
LF Unleaded fuel (RON 90 or
above) model
No load: 600—700 rpm
E/L operating: 650—750 rpm
P/S operating: 650—750 rpm
A/C ON: 700—800 rpm
L3 4WD ATX model
No load: 650—750 rpm
E/L operating: 650—750 rpm
P/S operating: 650—750 rpm
A/C ON: 650—750 rpm*
2, 700—
800 rpm*3
Inspect CKP sensor. 2D, 2G
SEGRP (EGR valve
(stepping motor)
position)StepIgnition switch ON: 0 step
Idle: 0 step
Cranking: 0—60 stepsInspect following PIDs: MAF, TP,
ECT, RPM, VSS.
Inspect EGR valve.4E, 4H,
4K, 4N
SHRTFT1 (Short term
fuel trim)%Idle (after warm up): approx.–30—
25%Perform applicable DTC
troubleshooting.
(See F1–54 DTC TABLE)—
SPARKADV (Ignition
timing)°Ignition switch ON: BTDC 0°
Idle: BTDC approx. 10°Inspect following PIDs: MAF, TP,
ECT, RPM, INGEAR, TR, PSP,
ACSW, VPWR.
Inspect ignition timing.2J, 2M
TEST (Test mode) ON/OFF———
TP (TP)%CTP: 13—23%
WOT: 86—96%
Inspect TP sensor. 2A
VCTP: 0.65—1.15 V
WOT: 4.3—4.8 V
TPCT
(TP sensor voltage at
CTP )V0.65—1.15 V Inspect TP sensor. 2A
VPWR (Battery positive
voltage)V Ignition switch ON: B+Inspect main relay.
Inspect battery.2Y, 2Z
VSS (Vehicle speed) kph, mphVehicle speed 20 kph {12 mph}:
20 kph {12 mph}
Vehicle speed 40 kph {25 mph}:
20 kph {12 mph}Perform applicable DTC
troubleshooting.
(See F1–54 DTC TABLE)—
VT DUTY1*
7% Idle: 0%Inspect following PIDs: TP, ECT,
RPM.
Inspect OCV.2I, 2L Monitor item
(Definition)Unit/
ConditionCondition/Specification
(Reference)ActionPCM
terminal