2002 MAZDA 6 air condition

F1–60
TROUBLESHOOTING
X: Applicable
Possible factor
Troubleshooting item
Injectors malfunction (Leakage or clogging, inope-rative
Fuel leakage from fuel system (including insulator,
injector O-ring)
Fuel filters restriction or clogging
CMP sensor is damaged. (e.g. open or short circuit)
Camshaft is damaged.
Improper air/fuel mixture ratio control
Exhaust system restriction or clogging
Catalytic converter malfunction
EGR system malfunction (Unleaded gasoline models)
EVAP control system malfunction
PCV valve malfunction
Constant voltage supply circuit malfunction
Main relay malfunction (Mechanically or electrically)
ECT sensor malfunction
TR sensor misadjustment (ATX)
TR sensor malfunction (ATX)
Break switch and related circuit malfunction
Manifold absolute pressure sensor and related circuit
malfunction
HO2S and related circuit malfunction (Unleaded
gasoline models)
Variable resistor misadjustment (Leaded gasoline
models)
Improper electrically controlled 4WD system operation
1 Melting of main or other fuses2 MIL illuminates x x x x x x x3 Will not crankxx4 Hard to start/long crank/erratic start/erratic
crankx xx xxx x
5 Engine stalls. After start/at idle x x x x x x x x x6 Cranks normally but will not start x x x xxxxxx x7 Slow return to idlex8 Engine runs rough/rolling idle xxxxxx xxx x9 Fast idle/runs onx10 Low idle/stalls during deceleration x x x x xEngine stalls/quits.Acceleration/cruisex xxxxx xxxxx xEngine runs rough. Acceleration/cruisex xxxxx xxxxx xMissesAcceleration/cruisex xxxxx xxxxx xBuck/jerk Acceleration/cruise/
decelerationx xxxxx xxxxx x
Hesitation/stumble Acceleration xxxxxx xxxxx x
11
Surges Acceleration/cruise xxxxxx xxxxx x
12 Lack/loss of power Acceleration/cruise x x x x x x x x13 Knocking/pingingAcceleration/cruise x14 Poor fuel economy x x x x x x15 Emission compliancexxxxxxxxx x16 High oil consumption/leakage x17 Cooling system concerns Overheating18 Cooling system concernsRuns cold19 Exhaust smoke x x20 Fuel odor (in engine compartment) x x21 Engine noise22 Vibration concerns (engine)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 smell x x27 Constant voltage x x x x x28 Spark plug condition x x x x29 ATX concernsUpshift/downshift/en
gagementSee Section K, TROUBLESHOOTING
A6E39802003

F2–2

MASS AIR FLOW (MAF)/INTAKE AIR
TEMPERATURE (IAT) SENSOR
INSPECTION ................................................ F2-74
INTAKE AIR TEMPERATURE (IAT)
SENSOR NO.2 INSPECTION....................... F2-75
ENGINE COOLANT TEMPERATURE (ECT)
SENSOR REMOVAL/INSTALLATION .......... F2-76
ENGINE COOLANT TEMPERATURE (ECT)
SENSOR INSPECTION ................................ F2-76
FUEL TEMPERATURE SENSOR
INSPECTION ................................................ F2-77
BOOST SENSOR INSPECTION ..................... F2-78
FUEL PRESSURE SENSOR INSPECTION .... F2-79
CAMSHAFT POSITION (CMP) SENSOR
REMOVAL/INSTALLATION .......................... F2-80
CAMSHAFT POSITION (CMP) SENSOR
INSPECTION ................................................ F2-80
CRANKSHAFT POSITION (CKP) SENSOR
REMOVAL/INSTALLATION .......................... F2-81
CRANKSHAFT POSITION (CKP) SENSOR
INSPECTION ................................................ F2-82
CALIBRATION RESISTOR INSPECTION ....... F2-83
INJECTOR DRIVER MODULE (IDM)
INSPECTION ................................................ F2-84
ON-BOARD DIAGNOSTIC................................. F2-85
ON-BOARD DIAGNOSTIC TEST .................... F2-85
DTC CONFIRMATION PROCEDURE ............. F2-85
KOEO/KOER SELF-TEST PROCEDURE ....... F2-86
AFTER REPAIR PROCEDURE ....................... F2-86
DTC TABLE ..................................................... F2-87
DTC P0016 ...................................................... F2-88
DTC P0088 ...................................................... F2-89
DTC P0091 ...................................................... F2-90
DTC P0092 ...................................................... F2-92
DTC P0093 ...................................................... F2-94
DTC P0097 ...................................................... F2-95
DTC P0098 ...................................................... F2-97
DTC P0102 ...................................................... F2-99
DTC P0103 .................................................... F2-101
DTC P0107 .................................................... F2-103
DTC P0108 .................................................... F2-105
DTC P0112 .................................................... F2-107
DTC P0113 .................................................... F2-109
DTC P0117 .................................................... F2-111
DTC P0118 .................................................... F2-113
DTC P0121 .................................................... F2-115
DTC P0122 .................................................... F2-116
DTC P0123 .................................................... F2-118
DTC P0182 .................................................... F2-120
DTC P0183 .................................................... F2-122
DTC P0191 .................................................... F2-124
DTC P0192 .................................................... F2-125
DTC P0193 .................................................... F2-127
DTC P0200 .................................................... F2-129
DTC P0221 .................................................... F2-131
DTC P0222 .................................................... F2-132
DTC P0223 .................................................... F2-134
DTC P0300 .................................................... F2-136
DTC P0336 .................................................... F2-137
DTC P0337 .................................................... F2-138
DTC P0341 .................................................... F2-140
DTC P0342 .................................................... F2-141
DTC P0380 .................................................... F2-143
DTC P0504 .................................................... F2-145
DTC P0510 .................................................... F2-148
DTC P0512 .................................................... F2-150
DTC P0564 .................................................... F2-152
DTC P0602 .................................................... F2-154DTC P0606..................................................... F2-155
DTC P0610..................................................... F2-155
DTC P0661..................................................... F2-156
DTC P0662..................................................... F2-158
DTC P0850..................................................... F2-160
DTC P1190..................................................... F2-162
DTC P2228..................................................... F2-164
DTC P2229..................................................... F2-164
TROUBLESHOOTING...................................... F2-165
SYMPTOM DIAGNOSTIC INDEX .................. F2-165
SYMPTOM QUICK DIAGNOSIS CHART ...... F2-167
NO.1 MELTING OF MAIN OR
OTHER FUSES ........................................... F2-173
NO.2 MIL ILLUMINATES ............................... F2-174
NO.3 WILL NOT CRANK ............................... F2-174
NO.4 HARD START/LONG CRANK/ERRATIC
START/ERRATIC CRANK .......................... F2-176
NO.5 ENGINE STALLS-AFTER
START/AT IDLE .......................................... F2-178
NO.6 CRANKS NORMALLY BUT WILL NOT
START ........................................................ F2-181
NO.7 SLOW RETURN TO IDLE .................... F2-184
NO.8 ENGINE RUNS ROUGH/ROLLING
IDLE ............................................................ F2-186
NO.9 FAST IDLE/RUNS ON .......................... F2-189
NO.10 LOW IDLE/STALLS DURING
DECELERATION ........................................ F2-190
NO.11 ENGINE STALLS/QUITS, ENGINE RUNS
ROUGH, MISSES, BUCK/JERK,
HESITATION/STUMBLE, SURGES ........... F2-192
NO.12 LACK/LOSS OF
POWER-ACCELERATION/CRUISE ........... F2-195
NO.13 KNOCKING/PINGING......................... F2-199
NO.14 POOR FUEL ECONOMY.................... F2-202
NO.15 EMISSION COMPLIANCE.................. F2-205
NO.16 HIGH OIL
CONSUMPTION/LEAKAGE ....................... F2-209
NO.17 COOLING SYSTEM
CONCERNS-OVERHEATING .................... F2-210
NO.18 COOLING SYSTEM
CONCERNS-RUNS COLD ......................... F2-212
NO.19 EXCESSIVE BLACK SMOKE ............. F2-213
NO.20 FUEL ODOR
(IN ENGINE COMPARTMENT) .................. F2-216
NO.21 ENGINE NOISE .................................. F2-217
NO.22 VIBRATION CONCERNS (ENGINE) .. F2-220
NO.23 A/C DOES NOT WORK
SUFFICIENTLY ........................................... F2-222
NO.24 A/C ALWAYS ON OR A/C
COMPRESSOR RUNS
CONTINUOUSLY........................................ F2-223
NO.25 A/C DOES NOT CUT OFF UNDER
WIDE OPEN THROTTLE CONDITIONS .... F2-224
NO.26 CONSTANT VOLTAGE ...................... F2-225
INTERMITTENT CONCERN
TROUBLESHOOTING ................................ F2-227
ENGINE CONTROL SYSTEM
OPERATION INSPECTION ........................ F2-229

F2–24
CONTROL SYSTEM, ON-BOARD DIAGNOSTIC
CONTROLLER AREA NETWORK (CAN)A6E404018881206Outline
•The PCM transmit/received the information other units using CAN to simplify the system.
Transmit Information
•Engine speed
•Vehicle speed
•Accelerator pedal position
•Fuel injection information
•Torque reduction inhibit
•Intake air temperature
•Engine coolant temperature
•Travelled distance
•Glow indicator light conditions
•Engine displacement
•Number of cylinders
•Air induction type
•Fuel type and delivery
•Country
•Transmission/axle type
•Tire circumference (front/rear)
•Cruise main indicator light conditions
•Cruise set indicator light conditions
Received Information
•Torque reduction request from DSC HU/CM
•Wheel speed from ABS HU/CM or DSC HU/CM
—Front left
—Front right
•Travelled distance from ABS HU/CM or DSC HU/CM
End Of Sie
OUTLINEA6E407018881201•The on-board diagnostic system is essentially carried over from that of the current MPV (LW) MZR-CD (RF
Turbo) engine models, except for the following. (See MPV Workshop Manual Supplement 1737-1*-02C.)
—DTCs, PID monitoring items, and simulation items have been changed.
—KOEO/KOER self-test items have been changed.
End Of Sie
DTCA6E407018881202
×: Applicable –: Not applicable
ON-BOARD DIAGNOSTIC
DTC Condition Detection condition MILMemory
function
P0016Crankshaft position-camshaft position
correlation malfunctionInput signals from CKP sensor and CMP sensor
are misaligned.××
P0088 Fuel pressure system too highFuel pressure is higher than preprogrammed
criteria.–×
P0091 Suction control valve circuit low inputInput voltage from suction control valve does not
change from off to on.××
P0092 Suction control valve circuit high inputInput voltage from suction control valve does not
change from on to off.××
P0093 Fuel system leak detectionFuel pressure after fuel injection is lower than
preprogrammed criteria.××
P0097 IAT sensor No.1 circuit low input Input voltage from IAT sensor No.1 is below 0.1 V.××
P0098 IAT sensor No.1 circuit high input Input voltage from IAT sensor No.1 is above 5.0 V.××
P0102 MAF sensor circuit low input Input voltage from MAF sensor is below 0.2 V.××
P0103 MAF sensor circuit high input Input voltage from MAF sensor is above 4.9 V.××
P0107 Boost sensor circuit low inputInput voltage from boost sensor is below 1.9 V
when engine speed is 2,400 rpm or above and
accelerator opening angle is 50% or above.××
P0108 Boost sensor circuit high input Input voltage from boost sensor is above 4.9 V.××

ON-BOARD DIAGNOSTIC
F2–27
F2
PID/DATA MONITOR AND RECORDA6E407018881204PID monitoring item table
End Of Sie
SIMULATION TESTA6E407018881205Simulation test item table
×: Applicable
Item Definition Condition/unit PCM terminal
ACCS A/C relay ON/OFF 73
ACSW A/C switch ON/OFF 84
APS1 Accelerator position sensor No.1 signal voltage V 10
APS2 Accelerator position sensor No.2 signal voltage V 88
BAROBarometric pressure kPa, inHg
-
Barometric pressure signal voltage V
BOO Brake switch ON/OFF 7
CPP Clutch switch ON/OFF 33
CPP/PNP Neutral switch Neutral/Drive 56
CRUISESW Cruise control switch ON/OFF 64
DTCCNT DTC count - -
ECTEngine coolant temperature°C, °F
87
Engine coolant temperature signal voltage V
FAN2 Cooling fan relay No.2 ON/OFF 76
FAN3 Cooling fan relay No.1 ON/OFF 102
IATIntake air temperature°C, °F
60
Intake air temperature signal voltage V
IMRC VSC solenoid valve ON/OFF 101
INGEAR In gear ON/OFF 33, 56
INJ_LRN_DIS Distance from the last injector learning Km, Mile -
MAFMass air flow amount g/s
9
Mass air flow signal voltage V
MAF_LRN_DIS Distance from the last MAF learning Km, Mile -
MAINRLY PCM control relay ON/OFF 69
MAPManifold absolute pressure kPa, inHg
36
Manifold absolute pressure signal voltage V
MIL Malfunction indicator lamp ON/OFF 71
NUMKEYS Number of keys stored in module - -
RPM Engine speed rpm 3, 29
VPWR Battery positive voltage V 27
VSS Vehicle speed km/h, mph 13, 39
Item Definition OperationTest condition
PCM
terminal
Key ON Idle
ACCS A/C relay ON or OFF××73
EGRA EGR solenoid valve (vent)Actuated by any duty value
(0—100%)××72
EGRV EGR solenoid valve (vacuum)Actuated by any duty value
(0—100%)××99
EGRV2 EGR control solenoid valve ON or OFF××77
FAN Cooling fan No.2 ON or OFF××76
FAN3 Cooling fan No.1 ON or OFF××102
GP_LMP Glow indicator light ON or OFF××97
GPC Glow plug relay ON or OFF××68
IASV Intake shutter solenoid valve (half) ON or OFF××74
IASV2 Intake shutter solenoid valve (full) ON or OFF××100
IMRC VSC solenoid valve ON or OFF××101
VBCV VBC solenoid valveActuated by any duty value
(0—100%)××67

F2–42
INTAKE-AIR SYSTEM
VARIABLE SWIRL CONTROL (VSC) SOLENOID VALVE INSPECTIONA6E401013110202
Note
•Perform the following test only when directed.
1. Inspect airflow between the ports under the
following conditions.
•If not as specified, replace the VSC solenoid
valve.
•If VSC solenoid valve is okay, perform the
“Circuit Open/Short Inspection”.
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 harnesses.
Open circuit
•If there is no continuity, the circuit is open. Repair
or replace the harness.
—VSC solenoid valve terminal A (harness-side)
and PCM control relay terminal C
—VSC solenoid valve terminal B (harness-side)
and PCM terminal 101
Short circuit
•If there is continuity, the circuit is shorted. Repair of replace the harness.
—VSC solenoid valve terminal A (harness-side) and GND.
—VSC solenoid valve terminal B (harness-side) and power supply
End Of Sie
GLOW PLUG REMOVAL/INSTALLATIONA6E401018601201
Caution
•Do not damage the heated section of the glow plug.
•Do not reuse a glow plug that has been dropped over a height of 10 cm, even when there are no
scratches and resistance is normal (approx. 0.6 ohms [20°C {68°F}]).
•Do not remove the glow plug unless you are replacing it.
1. Disconnect the negative battery cable.
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.
A
A B
B
C
A6E40102018
: Airflow
Por t
C B
A
GND B+
ABTerminal
Step
1
2
A6E40102020
BAA
B
C
D VSC SOLENOID VALVE
HARNESS SIDE CONNECTORFUSE BOX
(PCM CONTROL RELAY)
A6E40102021
1 Glow plug lead
2Glow plug
(See F2–43 Glow Plug Removal Note)
(See F2–43 Glow Plug Installation Note)0.8—1.5 N·m
{8—15 kgf·cm,
7—13 in·lbf}
15—20 N·m
{1.5—2.0 kgf·m,
11—14 ft·lbf}
12
A6E40102022

F2–60
EMISSION SYSTEM
EGR SOLENOID VALVE (VACUUM) INSPECTIONA6E401618741201
Note
•Perform the following inspection only when directed.
1. Inspect airflow between the ports under the
following conditions.
•If not as specified, replace the EGR solenoid
valve (vacuum).
•If as specified, carry out the “Circuit Open/
Short Inspection”.
Circuit Open/Short Inspection
1. Inspect the following wiring harness for open or
short (continuity check).
Open circuit
•If there is no continuity, the circuit is open. Repair
or replace the harness.
—EGR solenoid valve (vacuum) terminal A
(harness-side) and PCM control relay
terminal C (harness-side)
—EGR solenoid valve (vacuum) terminal B
(harness-side) and PCM terminal 99
Short circuit
•If there is continuity, the circuit is shorted. Repair
or replace the harness.
—EGR solenoid valve (vacuum) terminal A (harness-side) and GND
—EGR solenoid valve (vacuum) terminal B (harness-side) and power supply
End Of Sie
EGR SOLENOID VALVE (VENT) INSPECTIONA6E401618741202
Note
•Perform the following inspection only when directed.
1. Inspect airflow between the ports under the
following conditions.
•If not as specified, replace the EGR solenoid
valve.
•If as specified, carry out the “Circuit Open/
Short Inspection”.
BAA B
A6E40162001
StepTerminal
ABAB Por t
1
2
B+GND: Airflow
: Continuity
A6E40162020
EGR SOLENOID VALVE
HARNESS SIDE CONNECTORFUSE BOX
(PCM CONTROL RELAY)
A
BA
E
C
D
A6E40162002
BA
CBA
A6E40162003
Step
1
2
A
BAB
C Por t
Terminal
: Airflow
B+
GND: Continuity
A6E40162021

EMISSION SYSTEM
F2–61
F2
Circuit Open/Short Inspection
1. Inspect the following wiring harness for an open
or short circuit (continuity check).
Open circuit
•If there is no continuity, the circuit is open, Repair
or replace the harness.
—EGR solenoid valve (vent) terminal A
(harness-side) and PCM control relay
terminal C (harness-side)
—EGR solenoid valve (vent) terminal B
(harness-side) and PCM terminal 72
Short circuit
•If there is continuity, the circuit is shorted. Repair
or replace the harness.
—EGR solenoid valve (vent) terminal A (harness-side) and GND
—EGR solenoid valve (vent) terminal B (harness-side) and power supply
End Of Sie
EGR CONTROL SOLENOID VALVE INSPECTIONA6E401618741203
Note
•Perform the following inspection only when directed.
1. Inspect airflow between the ports under the
following conditions.
•If not as specified, replace the EGR control
solenoid valve.
•If as specified, carry out the “Circuit Open/
Short Inspection”.
Circuit Open/Short inspection
1. Inspect the following wiring harness for an open
or short circuit (continuity check).
Open circuit
•If there is no continuity, the circuit is open. Repair
or replace the harness.
—EGR control solenoid valve terminal A
(harness-side) and PCM control relay
terminal C (harness-side)
—EGR control solenoid valve terminal B
(harness-side) and PCM terminal 77
Short circuit
•If there is continuity, the circuit is shorted. Repair
or replace the harness.
—EGR control solenoid valve terminal A (harness-side) and GND
—EGR control solenoid valve terminal B (harness-side) and power supply
End Of Sie
EGR SOLENOID VALVE(VENT)
HARNESS SIDE CONNECTORFUSE BOX
(PCM CONTROL RELAY)
BAA
C
DE
A6E40162004
B
AA
B
A6E40162005
StepTerminalPor t
: Airflow
ABAB
GND
B+
1
2
: Continuity
A6E40162022
EGR CONTROL SOLENOID VALVE
HARNESS SIDE CONNECTORFUSE BOX
(MAIN RELAY)
BAAE
C
D
A6E40162006

EMISSION SYSTEM
F2–63
F2
INTAKE SHUTTER SOLENOID VALVE INSPECTIONA6E401613937201
Note
•Perform the following inspection only when directed.
•The inspection includes both intake shutter solenoid valve (half) and intake shutter solenoid valve (full).
1. Inspect airflow between the ports under the following conditions.
•If not as specified, replace the intake shutter solenoid valve.
•If as specified, carry out the “Circuit Open/Short Inspection”.
Intake Shutter Solenoid Valve (Half) Circuit Open/
Short Inspection
1. Disconnect the PCM connector. (See F2–64 PCM
REMOVAL/INSTALLATION.)
2. Inspect the following wiring harness for an open
or short circuit (continuity check).
Open circuit
•If there is no continuity, the circuit is open. Repair
or replace the harness.
—Intake shutter solenoid valve (half) terminal A
(harness-side) and PCM control relay
terminal C (harness-side)
—Intake shutter solenoid valve (half) terminal B
(harness-side) and PCM terminal 74
Short circuit
•If there is continuity, the circuit is shorted. Repair or replace the harness.
—Intake shutter solenoid valve (half) terminal A (harness-side) and GND
—Intake shutter solenoid valve (half) terminal B (harness-side) and power supply
Intake Shutter Solenoid Valve (Full) Circuit Open/Short Inspection
1. Disconnect the PCM connector. (See F2–64 PCM REMOVAL/INSTALLATION.)
2. Inspect the following wiring harness for an open
or short circuit (continuity check).
Open circuit
•If there is no continuity, the circuit is open. Repair
or replace the harness.
—Intake shutter solenoid valve (full) terminal A
(harness-side) and PCM control relay
terminal C (harness-side)
—Intake shutter solenoid valve (full) terminal B
(harness-side) and PCM terminal 100
Short circuit
•If there is continuity, the circuit is shorted. Repair or replace the harness.
—Intake shutter solenoid valve (full) terminal A (harness-side) and GND
—Intake shutter solenoid valve (full) terminal B (harness-side) and power supply
End Of Sie
B
A
CB
A
A6E40162024
StepTerminal
C B
A B APor t: Airflow
1
2B+ GND
: Continuity
A6E40162023
INTAKE SHUTTER SOLENOID
VALVE (HALF)
HARNESS SIDE CONNECTORFUSE BOX
(PCM CONTROL RELAY)
B
AA
E
C
D
A6E40162010
INTAKE SHUTTER SOLENOID
VALVE (FULL)
HARNESS SIDE CONNECTORFUSE BOX
(PCM CONTROL RELAY)
B
AA
C
DE
A6E40162011