2002 MAZDA 6 engine coolant

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

LOCATION INDEX
F2–33
F2
End Of Sie
1 PCM (with built-in BARO sensor and immobilizer
unit)
(SeeF2–64 PCM REMOVAL/INSTALLATION)
(SeeF2–65 PCM INSPECTION)
(SeeF2–68 PCM CONFIGURATION)
2 Clutch switch
(SeeF2–68 CLUTCH SWITCH INSPECTION)
3 Neutral switch
(SeeF2–69 NEUTRAL SWITCH INSPECTION)
4 Idle switch
(SeeF2–70 IDLE SWITCH INSPECTION)
(SeeF2–71 IDLE SWITCH ADJUSTMENT)
5 Accelerator position sensor
(SeeF2–72 ACCELERATOR POSITION SENSOR
INSPECTION)
(SeeF2–73 ACCELERATOR POSITION SENSOR
ADJUSTMENT)
6 MAF/IAT sensor
(SeeF2–74 MASS AIR FLOW (MAF)/INTAKE AIR
TEMPERATURE (IAT) SENSOR INSPECTION)
7 IAT sensor No.2
(SeeF2–75 INTAKE AIR TEMPERATURE (IAT)
SENSOR NO.2 INSPECTION)
8ECT sensor
(SeeF2–76 ENGINE COOLANT TEMPERATURE
(ECT) SENSOR REMOVAL/INSTALLATION)
(SeeF2–76 ENGINE COOLANT TEMPERATURE
(ECT) SENSOR INSPECTION)
9 Fuel temperature sensor
(SeeF2–77 FUEL TEMPERATURE SENSOR
INSPECTION)
10 Boost sensor
(SeeF2–78 BOOST SENSOR INSPECTION)
11 Fuel pressure sensor
(SeeF2–79 FUEL PRESSURE SENSOR
INSPECTION)
12 CMP sensor
(SeeF2–80 CAMSHAFT POSITION (CMP)
SENSOR REMOVAL/INSTALLATION)
(SeeF2–80 CAMSHAFT POSITION (CMP)
SENSOR INSPECTION)
13 CKP sensor
(SeeF2–81 CRANKSHAFT POSITION (CKP)
SENSOR REMOVAL/INSTALLATION)
(SeeF2–82 CRANKSHAFT POSITION (CKP)
SENSOR INSPECTION)
14 Calibration resistor
(SeeF2–83 CALIBRATION RESISTOR
INSPECTION)
15 IDM
(SeeF2–84 INJECTOR DRIVER MODULE (IDM)
INSPECTION)

F2–58
EXHAUST SYSTEM
Warm Up Oxidation Catalytic Converter Removal Note
1. Support the crossmember using a jack before
removing the crossmember bracket.
2. Loosen the jack and lower the crossmember.
3. Remove the warm up oxidation catalytic
converter.
Water Hose Removal Note
1. Drain the engine coolant.
Turbocharger Removal Note
1. Remove the air pipe and the air hose before
removing the turbocharger. (See F2–36
INTAKE-AIR SYSTEM REMOVAL/
INSTALLATION.)
Exhaust Manifold Removal Note
1. Remove the EGR pipe before removing the exhaust manifold. (See F2–59 EGR VALVE REMOVAL/
INSTALLATION.)
Exhaust Manifold Installation Note
1. Tighten the exhaust manifold installation nuts in
the order shown.
Water Pipe Installation Note
1. Install the connector bolt before installing the
water pipe bracket.
Oil Pipe (Supply) Installation Note
1. Install the connector bolt before installing the
water pipe bracket.
End Of Sie
8 Exhaust manifold insulator
9 Oil pipe (supply)
(See F2–58 Oil Pipe (Supply) Installation Note)
10 Oil pipe (return)
11 Water hose
(See F2–58 Water Hose Removal Note)12 Water pipe
(See F2–58 Water Pipe Installation Note)
13 Turbocharger
(See F2–58 Turbocharger Removal Note)
14 Exhaust manifold
(See F2–58 Exhaust Manifold Removal Note)
(See F2–58 Exhaust Manifold Installation Note)
FRONT
CROSSMEMBER
CROSSMEMBER
BRACKET FRONT
A6E0612W107
87
5436
12
A6E40142003

CONTROL SYSTEM
F2–65
F2
End Of SiePCM INSPECTIONA6E404018881208Using WDS or Equivalent
Caution
•The PCM terminal voltage 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, diagnosis will be incorrect.
Note
•For replace the PCM, setup the WDS and perform the following.
—“PCM configuration” (See F2–68 PCM CONFIGURATION.)
—“Correction after Parts Installation” (See F2–34 Correction after Parts Installation.)
1. Connect the WDS or equivalent to the DLC-2. (See F2–85 ON-BOARD DIAGNOSTIC TEST.)
2. Turn the engine switch to ON.
3. Measure the PID value.
•If PID value is not within the specification, follow the instructions in ACTION column.
PID Monitor Table
Monitor item (Definition)Unit/
ConditionCondition/Specification
(Reference)ActionPCM
terminal
ACCS
(A/C relay)ON/OFF•A/C operating: ON
•Engine switch is on: OFFInspect A/C relay.
(See T–19 RELAY
INSPECTION)73
ACSW
(A/C switch)ON/OFF•A/C switch is on: ON
•A/C switch is off: OFFInspect A/C switch. 84
APS1
(Accelerator position sensor
No.1 signal voltage)V•Accelerator pedal depressed:
3.35—4.03 V
•Accelerator pedal released: 0.4—
0.7 VInspect accelerator position
sensor.
(See F2–72
ACCELERATOR POSITION
SENSOR INSPECTION)10
APS2
(Accelerator position sensor
No.2 signal voltage)V•Accelerator pedal depressed:
3.35—4.03 V
•Accelerator pedal released: 0.4—
0.7 VInspect accelerator position
sensor.
(See F2–72
ACCELERATOR POSITION
SENSOR INSPECTION)88
BARO
(BARO)kPa inHg•Elevation 0—400 m {0—1310 ft}:
100—103 kPa {29.5—30.4 inHg}Replace PCM.
(See F2–64 PCM
REMOVAL/INSTALLATION)–
BARO
(BARO signal voltage)V•Elevation 0—400 m {0—1310 ft}:
approx. 4.0 V
BOO
(Brake switch)ON/OFF•Brake pedal depressed: ON
•Brake pedal released: OFFInspect brake switch. 7
CPP
(Clutch switch)ON/OFF•Clutch pedal depressed: ON
•Clutch pedal released: OFFInspect clutch switch.
(See F2–68 CLUTCH
SWITCH INSPECTION)33
CPP/PNP
(neutral switch)Neutral/Drive•Gear is neutral position: Neutral
•Gear is not neutral position: DriveInspect neutral switch.
(See F2–69 NEUTRAL
SWITCH INSPECTION)56
CRUISESW
(Cruise control switch)ON/OFF•Cruise control switch is on: ON
•Cruise control switch is off: OFFInspect cruise control switch. 64
DTCCNT
(DTC count)–•Number of output DTCFollow DTC inspection.
(See F2–87 DTC TABLE)–
ECT
(ECT)°C°F•ECT is 20°C {68°F}: 20°C
{68°F}
•ECT is 85°C {185°F}: 85°C
{185°F}Inspect ECT sensor.
(See F2–76 ENGINE
COOLANT TEMPERATURE
(ECT) SENSOR
INSPECTION)87
ECT
(ECT signal voltage)V•ECT is 20°C {68°F}: 3.0—3.2 V
•ECT is 85°C {185°F}: 0.7—0.9 V
FAN2
(Cooling fan relay No.2)ON/OFF•Engine coolant temperature is
above 100°C {212°F}: ON
•Others: OFFInspect cooling fan relay
No.2.76
FAN3
(Cooling fan relay No.1)ON/OFF•Engine coolant temperature is
above 108°C {226°F}: ON
•A/C switch is on: ON
•Others: OFFInspect cooling fan relay
No.1.102

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

ON-BOARD DIAGNOSTIC
F2–111
F2
DTC P0117A6E407001082214
Diagnostic procedure
DTC P0117 ECT sensor circuit low input
DETECTION
CONDITION•PCM monitors input voltage from ECT sensor while engine is running. If input voltage from ECT sensor is
below 0.1 V, PCM determines ECT sensor circuit low input.
POSSIBLE
CAUSE•ECT sensor malfunction
•Connector or terminal malfunction
•Short to GND in wiring between ECT sensor terminal A and PCM terminal 87
•ECT sensor signal and GND circuits short each other
•PCM malfunction
ECT SENSOR
A
B
562
546287
91
B
APCM
91
87 ECT SENSOR
HARNESS SIDE CONNECTORPCM
HARNESS SIDE CONNECTOR
STEP INSPECTION ACTION
1PERFORM DTC CONFIRMATION PROCEDURE
•Perform “DTC Confirmation Procedure”.
(See F2–85 DTC CONFIRMATION
PROCEDURE)
•Is same DTC present during KOEO or KOER
self-test?Yes Go to next step.
No Intermittent concern exists. Go to “Intermittent Concern
Troubleshooting”.
(See F2–227 INTERMITTENT CONCERN
TROUBLESHOOTING)
2INSPECT POOR CONNECTION OF ECT
SENSOR CONNECTOR
•Turn engine switch to OFF.
•Inspect for poor connection (damaged, pulled-
out terminals, corrosion, etc.).
•Is there any malfunction?Yes Repair or replace suspected terminal, go to Step 7.
No Go to next step.
3CLASSIFY ECT SENSOR MALFUNCTION OR
HARNESS MALFUNCTION
•Turn engine switch to ON (Engine OFF).
•Disconnect ECT sensor connector.
•Access ECT PID using WDS or equivalent.
•Is ECT PID below 0.1 V?Yes Go to next step.
No Replace ECT sensor, go to Step 7.
(See F2–76 ENGINE COOLANT TEMPERATURE (ECT)
SENSOR REMOVAL/INSTALLATION)
4INSPECT ECT SENSOR SIGNAL CIRCUIT FOR
SHORT TO GND
•Turn engine switch to OFF.
•Inspect continuity between ECT sensor
terminal A and body GND.
•Is there continuity?Yes Repair or replace harness for short to GND, go to Step 7.
No Go to next step.