2002 MAZDA 6 oil level

CONTROL SYSTEM
F1–37
F1
Without Using the SST
Caution
•The PCM terminal voltages 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, a wrong diagnosis will be made.
1. Measure the voltage at each terminal.
•If any incorrect voltage is detected, inspect the related system(s), wiring harnesses and connector(s)
referring to the Action column in the terminal voltage table.
Terminal voltage table (Reference)
Terminal Signal Connected to Test conditionVoltage
(V)Action
1A IGT1Ignition coil (No. 1,
4 cylinders)•Inspect using the wave profile.
(See F1–44 Inspection Using An
Oscilloscope (Reference).)•Inspect ignition coil
•Inspect related
harness
1B IGT2Ignition coil (No. 2,
3 cylinders)•Inspect using the wave profile.
(See F1–44 Inspection Using An
Oscilloscope (Reference).)•Inspect ignition coil
•Inspect related
harness
1C GND GND Under any condition Below 1.0•Inspect related
harness
1D GND GND Under any condition Below 1.0•Inspect related
harness
1E—— — ——
1F—— — ——
1G BARO BARO sensor Ignition switch ON (at sea level)Approx.
4.1 V•Inspect BARO sensor
•Inspect related
harness
1H—— — ——
1I—— — ——
1JManifold absolute
pressureMAP sensorIgnition switch ON (Engine OFF)Approx.
4.1•Inspect MAP sensor
•Inspect related
harness
IdleApprox.
1.5
1K Brake Brake switchBrake pedal depressed B+•Inspect brake switch
•Inspect related
harness Brake pedal released Below 1.0
1L—— — ——
1M ECT ECT sensorIgnition switch
ONECT 20 °C
{68 °F}3.04—
3.14•Inspect ECT sensor
•Inspect related
harness ECT 60 °C
{140 °F}1.29—
1.39
1N—— — ——
1O—— — ——
1P MAF MAF sensorIgnition switch ONApprox.
0.7•Inspect MAF sensor
•Inspect related
harness
Idle (after warm up)Approx.
1.3
1B 1A
1E 1D
1C 1H 1G 1J
1F 1I 1M
1L 1N 1K 1T 1Q1P 1S
1O 1R 1W1V
1Z 1Y
1X1AC1AB
1AA 1AD1U 2B 2A
2E 2D
2C 2H 2G 2J
2F 2I 2M
2L 2N 2K 2T 2Q2P 2S
2O 2R 2W2V
2Z 2Y
2X2AC2AB
2AA 2AD2U 3B 3A
3E 3D
3C 3H 3G 3J
3F 3I 3M
3L 3N 3K 3T 3Q3P 3S
3O 3R 3W3V
3Z 3Y
3X3AA3U 4B 4A
4E 4D
4C 4H 4G 4J
4F 4I 4M
4L 4N 4K 4T 4Q4P 4S
4O 4R 4W4V
4Z 4Y
4X4AC4AB
4AA 4AD4U
A6A3940W002

F1–58
TROUBLESHOOTING
QUICK DIAGNOSTIC CHARTA6E398018881202
X: Applicable
Possible factor
Troubleshooting item
Starter motor malfunction (Mechanical or electrical)
Starter circuit including ignition switch is open.
Starter interlock switch malfunction (MTX with starter
interlock system)
Improper engine oil level
Low or dead battery
Charging system malfunction
Improper engine compression
Improper valve timing
Hydrolocked engine
Improper engine oil viscosity
Improper dipstick
Base engine malfunction
Drive plate or flywheel are seized.
Improper tension or damaged drive belts
Improper engine coolant level
Water and anti-freeze mixture is improper.
Cooling system malfunction (Radiator, hoses,
overflow system, thermostat, etc.)
Cooling fan system malfunction
Engine or transaxle mounts are improperly installed.
Cooling fan or condenser fan seat are improper.
Accelerator cable free play misadjustment
Cruise control cable misadjustment
Fuel quality
1 Melting of main or other fuses2 MIL illuminates x x x x x x x3 Will not crank4 Hard to start/long crank/erratic start/erratic
crankx
5 Engine stalls. After start/at idle x x x x6 Cranks normally but will not start x x x x7 Slow return to idlex8 Engine runs rough/rolling idle x x x9 Fast idle/runs onxx10 Low idle/stalls during decelerationEngine stalls/quits. Acceleration/cruise x x xEngine runs rough. Acceleration/cruise x x xMissesAcceleration/cruise x x xBuck/jerk Acceleration/cruise/
decelerationxx x
Hesitation/stumble Acceleration x x x
11
Surges Acceleration/cruis
exx x12 Lack/loss of powerAcceleration/cruisexx x13 Knocking/pingingAcceleration/cruisexx14 Poor fuel economy x x x x x x15 Emission compliance x x x x16 High oil consumption/leakage x x x17 Cooling system concerns Overheatingxx x x x18 Cooling system concernsRuns cold x x19 Exhaust smoke x x x20 Fuel odor (in engine compartment)21 Engine noise x x x22 Vibration concerns (engine) x x 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 smellx27 Constant voltage28 Spark plug condition x x29 ATX concernsUpshift/downshift
engagementSee Section K, TROUBLESHOOTING
A6E39802001

TROUBLESHOOTING
F1–61
F1
End Of Sie
X: Applicable
Possible factor
Troubleshooting itemIAT sensor and related circuit malfunction
Barometric pressure sensor malfunction
Neutral or clutch switch and related circuit
malfunction (MTX)
MAF sensor and related circuit malfunction
Knock sensor and related circuit malfunction
TP sensor and related circuit malfunction
TP sensor misadjustment (including looseness)
P/S pressure switch and related circuit
malfunction
Improper refrigerant charging amount
A/C relay (A/C control signal circuit malfunction
A/C compressor magnetic clutch malfunction
Condenser fan system malfunction
Improper load signal input
Clutch slippage
ATX related parts malfunction
VSS and related circuit malfunction
Improper ATF level
Brake dragging
Loose parts
Improper balance of wheels and tires
Drive line malfunction
Suspension malfunction
PATS operating (if equipped)
1 Melting of main or other fuses2 MIL illuminates x x x x x x x x3 Will not crankx4 Hard to start/long crank/erratic
start/erratic crankx
5 Engine stalls. After start/at idle x x x x6 Cranks normally but will not startx7 Slow return to idle8 Engine runs rough/rolling idle x x x x x x9 Fast idle/runs onx10 Low idle/stalls during deceleration x x x x x xEngine stalls/quits.Acceleration/cruisex x xx xx xxxEngine runs rough. Acceleration/cruisex x xx xx xxxMissesAcceleration/cruisex xx xx xxxBuck/jerk Acceleration/cruise
/decelerationx xx xx xxx
Hesitation/stumble Acceleration x x x x x x x x x
11
Surges Acceleration/cruise x x x x x x x x
12 Lack/loss of power Acceleration/cruise x x x x x x x x13 Knocking/pingingAcceleration/cruise x x x14 Poor fuel economy x x x x x15 Emission compliance x16 High oil consumption/leakage17 Cooling system
concernsOverheating x x x
18 Cooling system
concernsRuns cold x
19 Exhaust smoke20 Fuel odor (in engine compartment)21 Engine noisex22 Vibration concerns (engine)xxxx23 A/C does not work sufficiently. x x x24 A/C is always on or A/C compressorruns continuously.xx25 A/C is not cut off under WOT conditions x x26 Exhaust sulfur smell27 Constant voltage x x x x x x28 Spark plug condition x x29 ATX concernsUpshift/downshift/e
ngagementSee Section K, TROUBLESHOOTING
A6E39802004

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

TROUBLESHOOTING
F2–167
F2
SYMPTOM QUICK DIAGNOSIS CHARTA6E408018881202
×: Applicable
Troubleshooting item
1 Melting of main or other fuses
2 MIL illuminates
3 Will not crank×× ×× × ×
4 Hard start/long crank/erratic start/erratic crank×× ×
5 Engine stalls After start/at idle××
6 Cranks normally but will not start××
7 Slow return to idle
8 Engine runs rough/rolling idle××
9 Fast idle/runs on
10 Low idle/stalls during deceleration××
11Engine stalls/quits Acceleration/cruise××
Engine runs rough Acceleration/cruise××
Misses Acceleration/cruise××
Buck/jerk Acceleration/cruise/ deceleration××
Hesitation/stumble Acceleration××
Surges Acceleration/cruise××
12 Lack/loss of power Acceleration/cruise××
13 Knocking/pinging××
14 Poor fuel economy××
15 Emissions compliance×× ×
16 High oil consumption/leakage××××
17 Cooling system concerns Overheating××
18 Cooling system concerns Runs cold
19 Excessive black smoke×
20 Fuel odor (in engine compartment)
21 Engine noise×× × ×
22 Vibration concerns (engine)×
23 A/C does not work sufficiently
24 A/C always on or A/C compressor runs continuously
25 A/C does not cut off under wide open throttle conditions
26 Constant voltage
Starter motor malfunction (Mechanical or electrical)Starter circuit including engine switch is openImproper engine oil levelLow or dead bateryCharging system malfunctionLow engine compressionImproper valve timingHydrolocked egineImproper engine oil viscosityImproper dipstickBase engine malfunctionSeized flywheelImproper tension or damaged drivebelts

F2–168
TROUBLESHOOTING
×: Applicable
Troubleshooting item
1 Melting of main or other fuses
2 MIL illuminates
3 Will not crank
4 Hard start/long crank/erratic start/erratic crank×××
5 Engine stalls After start/at idle×××
6 Cranks normally but will not start××
7 Slow return to idle×
8 Engine runs rough/rolling idle××××
9 Fast idle/runs on×
10 Low idle/stalls during deceleration××
11Engine stalls/quits Acceleration/cruise××××
Engine runs rough Acceleration/cruise×××× ×
Misses Acceleration/cruise××××××
Buck/jerk Acceleration/cruise/ deceleration××××××
Hesitation/stumble Acceleration××××××
Surges Acceleration/cruise××××××
12 Lack/loss of power Acceleration/cruise×××××××
13 Knocking/pinging×××××
14 Poor fuel economy××××
15 Emissions compliance× ××××××
16 High oil consumption/leakage
17 Cooling system concerns Overheating×× × ×
18 Cooling system concerns Runs cold××
19 Excessive black smoke××××
20 Fuel odor (in engine compartment)
21 Engine noise××
22 Vibration concerns (engine)×× ×
23 A/C does not work sufficiently
24 A/C always on or A/C compressor runs continuously
25 A/C does not cut off under wide open throttle conditions
26 Constant voltage
Improper engine coolant levelWater and anti-freeze mixture is improperCooling system malfunction (Radiator, hose,
over-flow system, thermostat, etc.)Cooling fan system malfunctionEngine or transaxle mounts are improperly installedCooling fan No.1 or No.2 seat are improperFuel qualityEngine overheatingIntake-air system clogging or restrictionAir leakage from intake-air systemVSC system malfunctionVacuum leakage

TROUBLESHOOTING
F2–209
F2
NO.16 HIGH OIL CONSUMPTION/LEAKAGEA6E408018881218
Diagnostic Procedure
16 HIGH OIL CONSUMPTION/LEAKAGE
DESCRIPTION•Oil consumption is excessive.
POSSIBLE
CAUSE•Improper engine oil level
•Improper dipstick
•Improper engine oil viscosity
•Engine internal parts malfunction
•Oil leakage
•Turbocharger malfunction
STEP INSPECTION RESULTS ACTION
1 Verify following:
•Proper dipstick
•Proper engine viscosity
•Engine oil level
Are all items okay?Yes Go to next step.
No Service as necessary.
Repeat Step 1.
2 Remove to necessary to inspect turbocharger.
Note
•Do not remove turbocharger.
Inspect if turbocharger compressor wheel is
bent, damaged, or interfering with housing on
vehicle.
Is there any problem?Yes Replace turbocharger.
No Go to next step.
3 Inspect if turbocharger compressor wheel
locknut is loose or has fallen down inside
turbocharger.
Is there any problem?Yes Replace turbocharger.
No Go to next step.
4 Turn turbocharger compressor wheel by hand.
Does wheel turn easily and smoothly?Yes Go to next step.
No Replace turbocharger.
5 Inspect if turbocharger turbine wheel is
damaged, cracked or interfering with housing on
vehicle.
Note
•Inspect all fins on each turbine wheel.
Is there any problem?Yes Replace turbocharger.
No Go to next step.
6 Is any engine oil found inside turbocharger
turbine housing?YesExcessive amount of oil is found:
Replace turbocharger.
Small amount of oil is found:
Wipe oil off of vehicle, then go to next step.
No Go to next step.
7 Is any engine oil found inside turbocharger
compressor housing?Yes Wipe oil off of vehicle, then go to next step.
No Go to next step.
8 Is any engine oil found around oil pipes attached
on turbocharger center housing?Yes If oil leaks from damaged pipe, replace oil pipe.
Then, go to next step.
No Go to next step.
9 Is any engine oil found inside air intake pipes or
hoses?Yes Wipe engine oil off.
No Turbocharger is okay.
Install all parts removed in Step 2.
Then go to next step.
10 Is engine compression correct?
(See B2–8 COMPRESSION INSPECTION)Yes Inspect oil leakage from outside of engine.
No Inspect for following:
•Damaged valve seat
•Worn valve stem and valve guide
•Worn or stuck piston ring
•Worn piston, piston ring or cylinder
Service as necessary.
11 Verify test results.
•If okay, return to diagnostic index to service any additional symptoms.
•If malfunction remains, replace PCM. (See F2–64 PCM REMOVAL/INSTALLATION)

TROUBLESHOOTING
F2–217
F2
NO.21 ENGINE NOISEA6E408018881223
Diagnostic Procedure
21 ENGINE NOISE
DESCRIPTION•Engine noise under hood.
POSSIBLE
CAUSE•Engine internal damage
•Timing belt displacement
•Fuel injector malfunction
•Loose attaching bolts or worn parts
•Improper drive belt tension
•Air leakage from intake-air system
•Incorrect injection timing
•Erratic signal from CKP sensor
•Erratic signal from CMP sensor
•Fuel pressure sensor or related circuit malfunction
•Boost sensor or related circuit malfunction
•Accelerator position sensor or related circuit malfunction
•MAF/IAT sensor or related circuit malfunction
•ECT sensor or related circuit malfunction
•EGR system or malfunction
•IAT sensor No.2 or related circuit malfunction
•Vacuum leakage
•Suction control valve malfunction (built-in supply pump)
•Air leakage from intake-air system
•Air in power steering fluid line
•Turbocharger operating noise
•Solenoid valve operating noise
Warning
The following troubleshooting flow chart contains the fuel system diagnosis and repair
procedures. Read the following warnings before performing the fuel system services:
•Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel.
•Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injury or death
and damage. Fuel can also irritate skin and eyes. To prevent this, always complete “BEFORE
REPAIR PROCEDURE” and “AFTER REPAIR PROCEDURE” described in this manual.
Note
•PCM checks fuel injection amount during a set interval while idling, and automatically corrects it to
maintain engine efficiency. It is normal that engine noise and vibration might be a little louder during
this process.
STEP INSPECTION RESULTS ACTION
1 Is squeal, click or chirp sound present? Yes Inspect engine oil level, solenoid valves installation or
drive belt.
No Go to next step.
2 Is rumble or grind sound present? Yes Inspect drive belt tension or power steering system
fluid level.
If okay, perform power steering fluid line air bleed.
No Go to next step.
3 Is rattle sound present? Yes Inspect location of rattle for loose parts.
No Go to next step.
4 Is hiss sound present? Yes Inspect for vacuum leakage and intake-air system
leakage.
No Go to next step.
5 Is rap or roar sound present? Yes Inspect exhaust system or loose parts.
No Go to next step.