2002 MAZDA 6 battery

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
F2–19
F2
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1PCM (with built-in BARO sensor and immobilizer
unit)
2Battery
3Starter
4 Starter relay
5 Clutch switch
6 Neutral switch
7 Brake switch
8 Idle switch
9 Cruise control switch
10 Accelerator position sensor
11 MAF/IAT sensor
12 IAT sensor No.2
13 ECT sensor
14 Fuel temperature sensor
15 Boost sensor
16 Fuel pressure sensor
17 CMP sensor
18 CKP sensor
19 VSS
20 Calibration resistor
21 Suction control valve
22 IDM
23 VSC solenoid valve
24 VBC solenoid valve
25 EGR control solenoid valve
26 EGR solenoid valve (vacuum)
27 EGR solenoid valve (vent)
28 Intake shutter solenoid valve (half)
29 Intake shutter solenoid valve (full)
30 Glow indicator light
31 Cruise main indicator light
32 Cruise set indicator light
33 Glow plug relay
34 Cooling fan relay No.1
35 Cooling fan relay No.2
36 A/C relay
37 PCM control relay
38 L.H.D.
39 R.H.D.

CONTROL SYSTEM
F2–21
F2
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1PCM
2 Idle speed control
3Glow control
4 VSC
5 Boost pressure control
6 Fuel injection amount control
7 Fuel injection timing control
8 Multiple fuel injection control
9 Fuel pressure control
10 EGR control
11 Cruise control system
12 Electrical fan control
13 A/C cut-off control
14 Immobilizer system
15 Battery
16 Starter (starter signal)
17 Starter relay
18 Clutch switch
19 Neutral switch
20 Brake switch
21 Idle switch
22 A/C switch
23 Refrigerant pressure switch
24 Cruise control switch
25 Accelerator position sensor
26 MAF/IAT sensor
27 IAT sensor No.2
28 ECT sensor
29 Fuel temperature sensor
30 BARO sensor (integrated in PCM)
31 Boost sensor
32 Fuel pressure sensor
33 CMP sensor
34 CKP sensor
35 VSS
36 Calibration resistor
37 Immobilizer unit (integrated in PCM)
38 Suction control valve
39 IDM
40 VSC solenoid valve
41 VBC solenoid valve
42 EGR control solenoid valve
43 EGR solenoid valve (vacuum)
44 EGR solenoid valve (vent)
45 Intake shutter solenoid valve (half)
46 Intake shutter solenoid valve (full)
47 Glow indicator light
48 Cruise main indicator light
49 Cruise set indicator light
50 Glow plug relay
51 Cooling fan relay No.1
52 Cooling fan relay No.2
53 A/C relay

F2–22
CONTROL SYSTEM
CONTROL DEVICE AND CONTROL RELATIONSHIP CHARTA6E404018881204
×: Applicable
End Of Sie
Item
Input device
Battery××
Starter (starter signal)××××××××× ×
Starter relay××××××××× ×
Clutch switch× × ××× ×× ×
Neutral switch× × ××× ×× ×
Brake switch×
Idle switch× × ××× × ×
A/C switch×××××
Refrigerant pressure switch×××××
Cruise control switch×
Accelerator position sensor××××××××
MAF/IAT sensor× ××××
IAT sensor No.2××
ECT sensor××× ××××× ××
Fuel temperature sensor×
BARO sensor (integrated in PCM)×××
Boost sensor××× ×
Fuel pressure sensor×× ××
CMP sensor×××××
CKP sensor× ××××××× ×
VSS××× ××× ××
Calibration resistor××
Immobilizer unit (integrated in PCM)×
Output device
Suction control valve××
IDM× ××× × ×
VSC solenoid valve×
VBC solenoid valve×
EGR control solenoid valve×
EGR solenoid valve (vacuum)×
EGR solenoid valve (vent)×
Intake shutter solenoid valve (half)×
Intake shutter solenoid valve (full)×
Glow indicator light×
Cruise main indicator light×
Cruise set indicator light×
Glow plug relay×
Cooling fan relay No.1×
Cooling fan relay No.2×
A/C relay×
Idle speed controlGlow controlVSCBoost pressure controlFuel injection amount controlFuel injection timing controlMultiple fuel injection controlFuel pressure controlEGR controlCruise control systemElectrical fan controlA/C cut-off controlImmobilizer system

ON-BOARD DIAGNOSTIC
F2–27
F2
PID/DATA MONITOR AND RECORDA6E407018881204PID monitoring item table
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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

F2–36
INTAKE-AIR SYSTEM
INTAKE-AIR SYSTEM REMOVAL/INSTALLATIONA6E401001005203
Warning
•When the engine and intake-air system are hot, they can cause severe burns or injury. Turn off the
engine and wait until they are cool before removing or installing the intake-air system.
•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 injuries or death and
damage, Fuel can also irritate skin and eyes. To prevent this, always complete the following “Fuel
Line Safety Procedure”. (See F2–45 Fuel Line Safety Procedures.)
Note
•Perform “ MAF Correction” after replacing the MAF/IAT sensor. (See F2–35 MAF Correction.)
1. Disconnect the negative battery cable.
2. Remove the front bumper.
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.
.
A
A
C
C
B
B
20—30
{2.1—3.1, 15—22}
19—25
{1.9—2.6, 14—18}6.9—9.8 N·m
{70—100 kgf·cm,
61—86 in·lbf}
2.5—3.4 N·m
{25—35 kgf·cm,
22—30 in·lbf}
6.9—9.8 N·m
{70—100 kgf·cm,
61—86 in·lbf} 7.8—11.8 N·m
{80—120 kgf·cm,
70—104 in·lbf}
6.9—9.8 N·m
{70—100 kgf·cm,
61—86 in·lbf} 17.6—26.5
{1.8—2.7,
13.0—19.8}6.9—9.8 N·m
{70—100 kgf·cm,
61—86 in·lbf}
6.9—9.8 N·m
{70—100 kgf·cm,
61—86 in·lbf}
2.5—3.4 N·m
{25—35 kgf·cm,
22—30 in·lbf}
TO EGR CONTROL SOLENOID VALVE
AND EGR SOLENOID VALVE (VENT)
TO VBC
CHECK VALVE
TO INTAKE SUTTER
SOLENOID VALVE (HALF)
9
10
19
17
11
20
21
1
2
3
5
4
7
6
8
12
14
13
15
16
18
0.55—0.85 N·m
{5.6—8.6 kgf·cm,
4.9—7.5 in·lbf}
N·m {kgf·m, ft·lbf}
R
RR
R
17.6—26.5
{1.8—2.7,
13.0—19.8}17.6—26.5
{1.8—2.7,
13.0—19.8}
4.9 N·m
{50 kgf·cm, 43 in·lbf}
4.9 N·m
{50 kgf·cm,
43 in·lbf}
4.9 N·m
{50 kgf·cm, 43 in·lbf}4.9 N·m
{50 kgf·cm,
43 in·lbf}
4.9 N·m
{50 kgf·cm,
43 in·lbf}
4.9 N·m
{50 kgf·cm,
43 in·lbf}
RUBBER MOUNT
(FRAME SIDE) RUBBER MOUNT
(ENGINE SIDE)
TO VBC
SOLENOID
VA LV E
A6E4010L030

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.
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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.
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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)

F2–42
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
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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