2002 MAZDA 6 relay

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

F2–4
OUTLINE
CONTROL SYSTEM DIAGRAMA6E400218881204
.
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5
4
3
6
1
2
8
7
910
13
11
12
19
18
17
1516
14
202928
27
25
26
24
2321
22
30
393837
35
3633
31
32
40
34
494847
45
464443
4142
50
54
515253
A
A
BB
A6E40022001
1 Air cleaner
2 Vacuum chamber
3 VBC check valve
4 MAF/IAT sensor
5 VBC solenoid valve
6 Vacuum damper
7 Guide blade actuator
8 Turbocharger
9 Charge air cooler
10 IAT sensor No.2
11 Boost sensor
12 Intake shutter valve actuator
13 Intake shutter solenoid valve (half)
14 Intake shutter solenoid valve (full)
15 EGR solenoid valve (vacuum)
16 EGR solenoid valve (vent)
17 EGR control solenoid valve
18 EGR valve
19 EGR water cooler
20 VSC valve actuator
21 VSC solenoid valve
22 Fuel tank
23 Fuel filter
24 Fuel warmer
25 Supply pump
26 Suction control valve
27 Fuel temperature sensor28 Common rail
29 Fuel pressure sensor
30 Fuel pressure limiter
31 Glow plug
32 Fuel injector
33 ECT sensor
34 Calibration resistor
35 CMP sensor
36 Warm up oxidation catalytic converter
37 Oxidation catalytic converter
38 Silencer
39 Vacuum pump
40 CKP sensor
41 Idle switch
42 Accelerator position sensor
43 Glow plug relay
44 IDM
45 PCM
46 BARO sensor
47 PCM control relay
48 Engine switch
49 Starter (starter signal)
50 Neutral switch
51 Clutch switch
52 A/C switch
53 CAN bus
54 To PCM

F2–6
OUTLINE
.
a
b
c
d
e
f
gCBD
A
CBD
ACBD
ACBD
A
3762
89 11C
BABABABABABABABABA
81 55 29 3 99 72
1017410067 77
h
i
j
k
l
m
n
oA
B
C36
10
A
BCD8831
90
A B CA
BA
B
A B 6135
87 94 93 8
A
B76
E
C
A D
M84
10273 8668
AB
C D
M
M A B
29282725262430
1
393837353633
31
3240
49
48
47454644
4341
42
50
59
58
57
55
5654
60
64
63
61
62
34
51
5253
A6E40022003
1PCM
2DLC-2
3 Water heater unit
4Fuel pump
5 Other unit6IDM
7Battery
8 Engine switch
9 Starter relay
10 Starter

OUTLINE
F2–7
F2
End Of Sie
11 Generator
12 Oil pressure switch
13 Sedimentor switch
14 Instrument cluster
15 Neutral switch
16 Clutch switch
17 Coil
18 Brake switch
19 Brake switch 2
20 Cruise control switch
21 With cruise control system
22 PCM control relay
23 MAF/IAT sensor
24 Calibration resistor No.1
25 Fuel injector No.1
26 Calibration resistor No.2
27 Fuel injector No.2
28 Calibration resistor No.3
29 Fuel injector No.3
30 Calibration resistor No.4
31 Fuel injector No.4
32 CMP sensor
33 CKP sensor
34 EGR solenoid valve (vacuum)
35 EGR solenoid valve (vent)
36 VSC solenoid valve
37 Intake shutter solenoid valve (half)38 Intake shutter solenoid valve (full)
39 VBC solenoid valve
40 EGR control solenoid valve
41 Boost sensor
42 Accelerator position sensor
43 Idle switch
44 Fuel pressure sensor
45 ECT sensor
46 Fuel temperature sensor
47 Suction control valve
48 IAT sensor No.2
49 Cooling fan relay No.2
50 Cooling fan No.1
51 Refrigerant pressure switch (middle)
52 A/C switch
53 A/C amplifier
54 Cooling fan relay No.1
55 Cooling fan No.2
56 A/C relay
57 Refrigerant pressure switch (HI and LO)
58 Magnetic clutch
59 With A/C
60 Glow plug relay
61 Glow plug
62 Vacuum switch
63 Fuel warmer
64 With fuel warmer

F2–8
INTAKE-AIR SYSTEM
OUTLINEA6E401001005201•The intake-air system is essentially carried over from that of the current MPV (LW) MZR-CD (RF Turbo) engine
model. (See MPV Workshop Manual Supplement 1737-1*-02D.)
×:Applicable
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INTAKE-AIR SYSTEM
Item Mazda6
(GG, GY)Current
MPV (LW)
Remark for new model
MZR-CD (RF Turbo)
Fresh-air duct ×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Shape has been changed
Air cleaner×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Shape has been changed
Turbocharger×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Charge air cooler×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Shape has been changed
Intake manifold×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
VBC system×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
VSC system×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Glow plug×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Glow plug lead×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Glow plug relay×Same function as MPV (LW) MZR-CD (RF Turbo) engine model

INTAKE-AIR SYSTEM
F2–9
F2
STRUCTURAL VIEWA6E401001005202
.
9
8
7
5
4
3
10
14
13
11
12
6
1
2
1516
14
A6E40102029
1 Glow plug
2 Intake manifold
3 VSC valve actuator
4 Charge air cooler
5 Vacuum damper
6 Glow plug lead
7 Guide blade actuator
8 Turbocharger9 VSC solenoid valve
10 VBC solenoid valve
11 VBC check valve
12 Air cleaner
13 Glow plug relay
14 Accelerator pedal component
15 L.H.D.
16 R.H.D.

F2–16
EMISSION SYSTEM, CONTROL SYSTEM
End Of SieWARM UP OXIDATION CATALYTIC CONVERTER DESCRIPTIONA6E401601007203•The warm up oxidation catalytic converter capacity has been increased to 1,920 ml {1,920 cc, 117 cu in} in
order to improve emission performance.
End Of Sie
OUTLINEA6E404018881201•The control system is essentially carried over from that of the current MPV (LW) MZR-CD (RF Turbo) engine
models. (See MPV Workshop Manual Supplement 1737-1*-02C.)
Input Device
×:Applicable –: Not applicable
CONTROL SYSTEM
ItemMazda6
(GG, GY)Current
MPV (LW)
Remark for new model
MZR-CD (RF Turbo)
Battery×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Starter (starter signal)×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Starter relay×–Newly adopted
Clutch switch×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Neutral switch×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Brake switch×Same function as Mazda6 (GG) L series engine model
Idle switch×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
A/C switch×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Refrigerant pressure switch×Same function as 626 (GF, GW) RF Turbo engine model
Cruise control switch×Same function as Mazda6 (GG) L series engine model
Accelerator position sensor×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
MAF/IAT sensor×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
IAT sensor No.2×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
ECT sensor×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Fuel temperature sensor×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
BARO sensor (integrated in PCM)×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Boost sensor×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Fuel pressure sensor×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
CMP sensor×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
CKP sensor×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
VSS×Vehicle speed signal is received by CAN
Calibration resistor×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Immobilizer unit (integrated in
PCM)×Immobilizer unit equipped into PCM

CONTROL SYSTEM
F2–17
F2
Output Device
×:Applicable –: Not applicable
Control System
×:Applicable –: Not applicable
End Of Sie
ItemMazda6
(GG, GY)Current
MPV (LW)
Remark for new model
MZR-CD (RF Turbo)
Suction control valve×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
IDM×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
VSC solenoid valve×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
VBC solenoid valve×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
EGR control solenoid valve×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
EGR solenoid valve (vacuum)×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
EGR solenoid valve (vent)×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Intake shutter solenoid valve (half)×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Intake shutter solenoid valve (full)×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Glow indicator light×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Cruise main indicator light×–Same function as Mazda6 (GG) L series engine model
Cruise set indicator light×–Same function as Mazda6 (GG) L series engine model
Glow plug relay×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Cooling fan relay No.1×–Same function as cooling fan relay of 626 (GF, GW) RF Turbo
engine model
Cooling fan relay No.2×–Same function as condenser fan relay of 626 (GF, GW) RF
Turbo engine model
A/C relay×Same function as 626 (GF, GW) RF Turbo engine model
ItemMazda6
(GG, GY)Current
MPV (LW)
Remark for new model
MZR-CD (RF Turbo)
Idle speed control×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Glow control×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
VSC×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Boost pressure control×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Fuel injection amount control×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Fuel injection timing control×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Multiple fuel injection control×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Fuel pressure control×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
EGR control×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Cruise control system×–Newly adopted
Electrical fan control×Same function as 626 (GF, GW) RF Turbo engine model
A/C cut-off control×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Immobilizer system×Same function as Mazda6 (GG) L series engine model