2002 MAZDA 6 water pump

INTAKE-AIR SYSTEM
F2–37
F2Air Pipe Removal Note
1. Remove the battery and the battery tray before removing the air pipe. (See G–5 BATTERY REMOVAL/
INSTALLATION.)
Intake Manifold Removal Note
1. Remove the supply pump before removing the intake manifold. (See F2–53 SUPPLY PUMP REMOVAL/
INSTALLATION.)
2. Remove the EGR valve before removing the intake manifold. (See F2–59 EGR VALVE REMOVAL/
INSTALLATION.)
Air Cleaner Case Installation Note
Note
•Before assembling the air cleaner, verify that the rubber mounts have not fallen off from the air cleaner
bracket (3 locations).
•Always install the air cleaner case using the following procedure.
•When inserting the rubber mounts into the air cleaner case, soapy water can be applied.
1. Verify that the rubber mounts are set in the air cleaner bracket (3 locations).
2. Install the projections on the frame side (2 locations).
3. Verify that the projections on the frame side are installed securely.
4. Install the projection on the engine side (remaining location).
5. Verify that the projection on the engine side installed securely.
End Of Sie
AIR CLEANER ELEMENT INSPECTIONA6E4010010052041. Remove the air cleaner element. (See F2–36 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.)
2. Verify that the air cleaner element surface is free of dirt.
•If there is dirt present, use an air gun or similar tool to clean the element.
•If the replacement time limit has passed, replace the element.
End Of Sie
1 Vacuum hose
2 Air hose
3 Air cleaner cover
4 Air cleaner element
5Air cleaner case
(See F2–37 Air Cleaner Case Installation Note)
6 MAF/IAT sensor
7Air pipe
(See F2–37 Air Pipe Removal Note)
8 Vacuum pipe
9 Air hose
10 Air pipe11 Air hose
12 Air pipe
13 Boost sensor
14 IAT sensor No. 2
15 Air pipe
16 Air hose
17 Air duct
18 Charge air cooler
19 Vacuum hose (Intake shutter valve actuator)
20 Vacuum hose (VSC shutter valve actuator)
21Intake manifold
(See F2–37 Intake Manifold Removal Note)

F2–52
FUEL SYSTEM
SEDIMENTOR WATER DRAININGA6E4012348022041. Disconnect the negative battery cable.
2. Complete the “BEFORE REPAIR PROCEDURE”. (See F2–45 BEFORE REPAIR PROCEDURE.)
3. Loosen the drain plug located at the bottom of the fuel filter.
4. Pump the priming pump and drain the water.
5. After all the water has been drained, tighten the drain plug.
6. Complete the “AFTER REPAIR PROCEDURE”. (See F2–45 AFTER REPAIR PROCEDURE.)
7. Reconnect the negative battery cable.
End Of Sie
SEDIMENTOR SWITCH INSPECTIONA6E401213840201
Note
•Perform the following test only when directed.
1. Disconnect the negative battery cable.
2. Complete the “BEFORE REPAIR PROCEDURE”. (See F2–45 BEFORE REPAIR PROCEDURE.)
3. Drain fuel from the fuel filter. (See F2–52 SEDIMENTOR WATER DRAINING.)
4. Remove the sedimentor switch.
5. Inspect for continuity of the sedimentor switch
using an ohmmeter.
•If as specified, inspect the following and carry
out the “Circuit Open/Short Inspection.”
•If not as specified, replace the sedimentor
switch.
Specification
6. Install the sedimentor switch.
7. Reconnect the negative battery cable.
8. Complete the “AFTER REPAIR PROCEDURE”.
(See F2–45 AFTER REPAIR PROCEDURE.)
Circuit Open/Short Inspection
1. Inspect the following wiring harnesses for open or
short (continuity check).
Open circuit
•If there is no continuity, the circuit is open.
Repair or replace the harness.
—Sedimentor switch terminal B (harness-
side) and GND.
—Sedimentor switch terminal A (harness-
side) and instrument cluster terminal 1C.
Short circuit
•If there is continuity, the circuit is shorted.
Repair of replace the harness.
—Sedimentor switch terminal A (harness-
side) and GND.
—Sedimentor switch terminal B (harness-
side) and power supply.
End Of Sie
Float Continuity
Up Yes
Down No
UP
DOWN
FLOATA
B
A6E40122015
1O 1M 1K 1I 1G 1E 1C 1A
1P 1N 1L 1J 1H 1F 1D 1B INSTRUMENT CLUSTER CONNECTOR
SEDIMENTOR SWITCH
HARNESS SIDE CONNECTOR
A
B
A6E40122016

EMISSION SYSTEM
F2
F2–59
EGR VALVE REMOVAL/INSTALLATIONA6E4016203002011. Disconnect the negative battery cable.
2. R em ove t he a ir c le a ne r. (S ee F 2–36 IN TA K E-A IR SYS TEM RE MOVA L/I NSTA LL AT IO N.)
3 . R em ove t he co m mon r ai l. (S ee F 2–53 SUPPLY PU MP R EM OVA L/IN STA LLAT IO N.)
4. Remove in the order indicated in the table.
.
5. Install in the reverse order of removal.
EGR Valve Removal Note 1. Remove the EGR pipe flare nut.
2. Remove the EGR valve installation nuts.
3. Remove the EGR valve installation stud bolts.
Note• If the thread length of the stud bolt is smaller
than the two nuts used for stud bolt removal,
shave a nut face 1 mm {0.04 in} to make it
thinner and install two nuts as shown in the
figure.
EGR Valve Installation Note 1. Install the EGR valve in the reverse order of removal.
EGR valve installation stud bolt tightening torque
7.8—11.8 N·m {80—120 kgf·cm, 70—104 in·lbf}
End Of Sie
EGR VALVE INSPECTIONA6E401620300202
Note
• Perform the following test only when directed.
1 . R em ove t h e EG R va lv e . ( See F 2–36 IN TA K E-A IR SYS TEM RE MOVA L/I NSTA LL AT IO N.)
2. Inspect for airflow between 1 and 2 when vacuum is applied using a vacuum pump as shown in the
figure.• If not as specified, replace the EGR valve.
Specification
End Of Sie
EMISSION SYSTEM
1EGR valve (See F 2–5 9 EG R V alv e R em oval N ote )
(See F2 –5 9 E G R V alv e In sta llat ion Not e)
2Air pipe (See F2 –3 6 IN TAKE-AIR SYSTEM RE MOVAL/
INS TA LL ATION )
3 EGR pipe
4 EGR water cooler
CME116EW2002
SHAVED NUT FALSE
TRUE
EGR VALVE
INTAKE
MANIFOLDEGR VALVE
INTAKE
MANIFOLD
NORMAL NUTNORMAL NUT
CME116EW2001
Vacuum
kPa {mmHg, inHg} Airflow
Below –25.0 — – 41.6
{ – 188 — – 312, –7.4 — – 12.3} Ye s
Except above No
12
A6E40122024

F2–76
CONTROL SYSTEM
ENGINE COOLANT TEMPERATURE (ECT) SENSOR REMOVAL/INSTALLATIONA6E404018840201
Warning•When the engine is hot, it can badly burn. Turn off the engine and wait until it is cool before
removing the ECT sensor.
1. Disconnect the negative battery cable.
2. Drain the engine coolant. (See Section E ENGINE COOLANT REPLACEMENT.)
3. Remove the common rail. (See F2–53 SUPPLY PUMP REMOVAL/INSTALLATION .)
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.
End Of Sie
ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTIONA6E404018840202
Note
• Perform the following test only when directed.
Resistance Inspection 1. Place the ECT sensor in water with a thermometer, and heat the water gradually.
2. Measure the resistance between the ECT sensor terminals using an ohmmeter.
• If not as specified, replace the ECT sensor.
Specification
Circuit Open/Short Inspection 1. Inspect for open/short circuit in the following
wiring harnesses.• If there is open/short circuit, repair or replace
wiring harness.
Open circuit • Signal circuit
— ECT sensor terminal A and PCM terminal 87
• GND circuit
— ECT sensor terminal B and PCM terminal 91
Short circuit • Signal circuit
— ECT sensor terminal A and PCM terminal 87 to power circuit
— ECT sensor terminal A and PCM terminal 87 to GND
End Of Sie
1ECT sensor
2Gasket149 D015 001
N·m {kgf·m, ft·lbf}
16—23
{1.6—2.4, 12—17}2R
A6E40702045
Water temperature (
°C { °F}) Resistance (kilohm)
20 {68} 2.21—2.69
80 {176} 0.29—0.34A
B
A6E40702046

F2–176
TROUBLESHOOTING
NO.4 HARD START/LONG CRANK/ERRATIC START/ERRATIC CRANKA6E408018881206
Diagnostic Procedure
4 HARD START/LONG CRANK/ERRATIC START/ERRATIC CRANK
DESCRIPTION•Starter cranks engine at normal speed but engine requires excessive cranking time before starting.
•Battery is in normal condition.
POSSIBLE
CAUSE•Poor fuel quality
•Intake-air system restriction or clogging
•Starting system malfunction
•Inadequate fuel pressure
•Fuel pressure limiter malfunction (built-in common rail)
•Suction control valve malfunction (built-in supply pump)
•Engine overheating
•Glow system malfunction
•Fuel filter clogging or restriction
•Fuel line clogging or restriction
•Fuel leakage
•Exhaust system and/or catalyst converter restriction or clogging
•Incorrect fuel injection timing
•Erratic signal from CKP sensor
•Erratic signal from CMP sensor
•ECT sensor or related circuit malfunction
•Accelerator position sensor or related circuit malfunction
•Accelerator position sensor misadjustment
•MAF/IAT sensor or related circuit malfunction
•Fuel pressure sensor or related circuit malfunction
•Supply pump malfunction
•Fuel injector malfunction
•Low engine compression
•IDM or related circuit malfunction
•EGR system malfunction
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.
STEP INSPECTION RESULTS ACTION
1 Inspect for following:
•Fuel quality (e.g.: include water
contamination, winter/summer blend)
•Fuel line/fuel filter clogging
•Intake-air system restriction
Are all items okay?Yes Go to next step.
No Service as necessary.
Repeat Step 1.
2 Is engine overheating? Yes Go to symptom troubleshooting “NO.17 COOLING
SYSTEM CONCERNS-OVERHEATING”.
No Go to next step.
3 Connect WDS or equivalent to DLC-2.
Turn engine switch to ON.
Retrieve any DTC.
Is DTC displayed?YesDTC is displayed:
Go to appropriate DTC test.
Communication error message is displayed:
Inspect following:
•Open circuit between PCM control relay and PCM
terminal 53 or 79
•Open circuit PCM control relay and PCM terminal
69
•PCM control relay stuck open
•Open or poor GND circuit (PCM terminal 65, 85,
103 or 104)
•Poor connection vehicle body GND
NoNo DTC is displayed:
Go to next step.

F2–186
TROUBLESHOOTING
NO.8 ENGINE RUNS ROUGH/ROLLING IDLEA6E408018881210
Diagnostic Procedure
8 ENGINE RUNS ROUGH/ROLLING IDLE
DESCRIPTION•Engine speed fluctuates between specified idle speed and lower speed and engine shakes excessively.
•Idle speed is too slow and engine shakes excessively.
POSSIBLE
CAUSE•Poor fuel quality
•Air leakage from intake-air system
•Intake-air system restriction
•Incorrect idle speed
•Engine overheating
•Cooling fan No.1 system malfunction
•A/C system improper operation
•EGR system improper operation
•EGR water cooler malfunction
•Fuel leakage
•Inadequate fuel pressure
•Fuel pressure sensor or related circuit malfunction
•Suction control valve malfunction (built-in supply pump)
•Fuel pressure limiter malfunction (built-in common rail)
•Fuel filter clogging
•Fuel line restriction
•Incorrect fuel injection timing
•Erratic signal from CKP sensor
•Erratic signal from CMP sensor
•ECT sensor or related circuit malfunction
•Idle switch misadjustment
•Idle switch or related circuit malfunction
•Accelerator position sensor misadjustment
•Accelerator position sensor or related circuit malfunction
•MAF/IAT sensor malfunction
•Neutral switch or related circuit malfunction
•Supply pump malfunction
•Fuel injector malfunction
•Low engine compression
•Improper valve timing
•Engine compression excessive unbalance for each cylinder
•Unbalanced fuel injection amount for each cylinder
•IDM or related circuit malfunction
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.
STEP INSPECTION RESULTS ACTION
1 Inspect for following:
•Fuel quality (e.g.: including water
contamination, winter/summer blend)
•Fuel line/fuel filter clogging
•Loose bands on intake-air system
•Cracks on intake-air system parts
•Intake-air system restriction
•Vacuum leakage
•Cooling fan No.1 system operation
Are all items okay?Yes Go to next step.
No Service as necessary
Repeat Step 1.
2 Is engine overheating? Yes Go to symptom troubleshooting “NO.17 COOLING
SYSTEM CONCERNS—OVERHEATING.”
No Go to next step.

F2–188
TROUBLESHOOTING
End Of Sie
13 Is engine compression correct?
(See B2–8 COMPRESSION INSPECTION)Yes Go to next step.
No Inspect for following:
•Damaged valve seat
•Worn valve stem and valve guide
•Worn or stuck piston ring
•Worn piston, piston ring or cylinder
•Improper valve timing
Service as necessary.
14 Inspect fuel injector.
(See F2–56 FUEL INJECTOR INSPECTION)
Is fuel injector okay?Yes Go to next step.
No Repair or replace as necessary.
15 Inspect EGR system operation.
Is EGR system operation normal?Yes Go to next step.
No Repair or replace malfunctioning part according to
EGR system operation results.
16 Inspect EGR water cooler for following:
•Coolant passage clogging/restriction
•Exhaust gas clogging/restriction
Is EGR water cooler okay?Yes Go to next step.
No Service as necessary.
17 Inspect IDM.
(See F2–84 INJECTOR DRIVER MODULE
(IDM) INSPECTION)
Is IDM okay?Yes Remove and inspect supply pump and common rail.
No Repair or replace as necessary.
18 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) STEP INSPECTION RESULTS ACTION

F2–190
TROUBLESHOOTING
NO.10 LOW IDLE/STALLS DURING DECELERATIONA6E408018881212
Diagnostic Procedure
10 LOW IDLE/STALLS DURING DECELERATION
DESCRIPTION•Engine stops unexpectedly at beginning of deceleration or recovery from deceleration.
POSSIBLE
CAUSE•Intake-air system restriction or clogging
•Poor fuel quality
•A/C system improper operation
•Inadequate fuel pressure
•Suction control valve malfunction (built-in supply pump)
•Fuel pressure limiter malfunction (built-in common rail)
•Fuel leakage
•Fuel line restriction or clogging
•Fuel filter restriction or clogging
•Incorrect fuel injection timing
•Incorrect idle speed
•Erratic signal from CKP sensor
•Erratic signal from CMP sensor
•Supply pump malfunction
•Fuel injector malfunction
•Low engine compression
•Improper valve timing
•Glow system malfunction
•EGR system malfunction
•MAF/IAT sensor or related circuit malfunction
•ECT sensor or related circuit malfunction
•Fuel pressure sensor or related circuit malfunction
•Neutral switch malfunction or related circuit malfunction
•Accelerator position sensor or related circuit malfunction
•Idle switch or related circuit malfunction
•Incorrect adjustment accelerator position sensor and/or idle switch
•IDM or related circuit malfunction
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.
STEP INSPECTION RESULTS ACTION
1 Does engine idle rough? Yes Go to symptom troubleshooting “NO.8 ENGINE RUNS
ROUGH/ROLLING IDLE”.
No Go to next step.
2 Inspect for following:
•Fuel line/fuel filter clogging or restriction
•Intake-air system restriction or clogging
•Fuel quality (e.g.: include water
contamination, winter/summer blend)
Are all items okay?Yes Go to next step.
No Service as necessary.
Repeat Step 2.
3 Perform self-test function using WDS or
equivalent.
Turn engine switch to ON.
Retrieve any DTC.
Is DTC displayed?YesDTC is displayed:
Go to appropriate DTC test.
Communication error message is displayed:
Inspect for following:
•Open circuit between PCM control relay and PCM
terminal 53 or 79
•Open circuit PCM control relay and PCM terminal
69
•PCM control relay stuck open
•Open or poor GND circuit (PCM terminal 65, 85,
103 or 104)
•Poor connection vehicle body GND
NoNo DTC is displayed:
Go to next step.
4 Inspect idle speed.
(See F2–34 IDLE SPEED INSPECTION)
Is idle speed correct?Yes Go to next step.
No Repair or replace malfunctioning part according to idle
speed inspection results.