2002 MAZDA 6 catalytic converter

GI–6
NEW STANDARDS
#1 : Diagnostic trouble codes depend on the diagnostic test mode.
#2 : Controlled by the PCM
#3 : In some models, there is a fuel pump relay that controls pump speed. That relay is now called the fuel pump
relay (speed).
#4 : Device that controls engine and powertrain
#5 : Directly connected to exhaust manifold
#6 : Part name of diesel engine
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OL Open Loop—Open Loop
—Output Speed Sensor—Vehicle Speed Sensor 1
OC Oxidation Catalytic Converter—Catalytic Converter
O2S Oxygen Sensor—Oxygen Sensor
PNP Park/Neutral Position—Park/Neutral Range
—PCM Control Relay—Main Relay #6
PSP Power Steering Pressure—Power Steering Pressure
PCM Powertrain Control Module ECU Engine Control Unit #4
—Pressure Control Solenoid—Line Pressure Solenoid Valve
PAIR Pulsed Secondary Air Injection—Secondary Air Injection SystemPulsed
injection
—Pump Speed Sensor—NE Sensor #6
AIR Secondary Air Injection—Secondary Air Injection SystemInjection
with air
pump
SAPV Secondary Air Pulse Valve—Reed Valve
SFI Sequential Multiport Fuel Injection—Sequential Fuel Injection
—Shift Solenoid A—1–2 Shift Solenoid Valve
—Shift A Solenoid Valve
—Shift Solenoid B—2–3 Shift Solenoid Valve
—Shift B Solenoid Valve
—Shift Solenoid C—3–4 Shift Solenoid Valve
3GR Third Gear—3rd Gear
TWC Three Way Catalytic Converter—Catalytic Converter
TB Throttle Body—Throttle Body
TP sensor Throttle Position Sensor—Throttle Sensor
TCV Timer Control Valve TCV Timing Control Valve #6
TCC Torque Converter Clutch—Lockup Position
TCMTransmission (Transaxle) Control
Module—EC-AT Control Unit
—Transmission (Transaxle) Fluid
Temperature Sensor—ATF Thermosensor
TR Transmission (Transaxle) Range—Inhibitor Position
TC Turbocharger—Turbocharger
VSS Vehicle Speed Sensor—Vehicle Speed Sensor
VR Voltage Regulator—IC Regulator
VAF sensor Volume Air Flow Sensor —Airflow Meter
WU-TWCWarm Up Three Way Catalytic
Converter—Catalytic Converter #5
WOT Wide Open Throttle—Fully Open New Standard Previous Standard
Remark
Abbrevi-
ationNameAbbrevi-
ationName

ABBREVIATIONS
GI–7
GIABBREVIATIONS TABLEA6E203000011202
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ABBREVIATIONS
A/C Air conditioner
ABS Antilock brake system
ACC Accessories
ABDC After bottom dead center
ATDC After top dead center
ATF Automatic transaxle fluid
ATX Automatic transaxle
BBDC Before bottom dead center
BDC Bottom dead center
BTDC Before top dead center
CAN Controller area network
CM Control module
DEI Double electronic ignition
DOHC Double overhead camshaft
DSC Dynamic stability control
ESA Electronic spark advance
EX Exhaust
HI High
HU Hydraulic unit
IDM Injector driver module
IG Ignition
IN Intake
KOEO Key on engine off
KOER Key off engine running
LH Left hand
L.H.D. Left hand drive
LO Low
LR Left rear
M Motor
MAX Maximum
MTX Manual transaxle
MIN Minimum
O/D Overdrive
OCV Oil control valveOFF Switch off
ON Switch on
P/S Power steering
PATS Passive anti-theft system
PCV Positive crankcase ventilation
PID Parameter identification
RF Right front
RH Right hand
R.H.D. Right hand drive
RR Right rear
SST Special service tool
SW Switch
TCC Torque converter clutch
TCM Transaxle control module
TDC Top dead center
TFT Transaxle fluid temperature
TNS Tail number side lights
TR Transaxle range
TWC Three way catalytic converter
VAD Variable air duct
VBC Variable boost control
VIS Variable intake-air system
VSC Variable swirl control
VSS Vehicle speedometer sensor
VTCS Variable tumble control system
WGN Wagon
WDS Worldwide diagnostic system
1GR 1st gear
2GR 2nd gear
4GR 4th gear
5GR 5th gear
4SD 4 door sedan
5HB 5 door hatchback
4WD 4 wheel drive

F1–52
ON-BOARD DIAGNOSTIC
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DTC (4WD)A6E397018881204•Detection logics and conditions are as shown below.
Controller Area Network (CAN)
PCM cannot receive any signals from TCM (U0101)
•PCM cannot receive any signals from TCM.
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OBD DRIVE MODEA6E397018881205•Performing the Drive Mode inspects the OBD system for proper operation. The Drive Mode must be performed
to ensure that no additional DTCs are present.
•During Drive Mode, the following systems are inspected:
—Oxygen sensor (HO2S)
—Oxygen sensor heater
—Catalytic converter (TWC)
Caution
•While performing the Drive Mode, always operate the vehicle in a safe and lawful manner.
•When the WDS or equivalent is used to observe monitor system condition while driving, be sure to
have another technician with you, or record the data in the WDS or equivalent using the PID/DATA
MONITOR AND RECORD function and inspect later.
Note
•Vehicle speed and engine speed detected by the PCM may differ from that indicated by the speedometer
and tachometer. Use the WDS or equivalent to monitor vehicle speed.
•If the OBD system inspection is not completed during the Drive Mode, the following causes are
considered:
1. The OBD system detects the malfunction.
2. The Drive Mode procedure is not completed correctly.
•Disconnecting the battery will reset the memory. Do not disconnect the battery during and after Drive
Mode.
PCM Adaptive Memory Procedure Drive Mode
Note
•The PCM adaptive memory condition can be confirmed with RFCFLAG PID.
•If RFCFLAG PID is “Learnt”, PCM Adaptive Memory Procedure Drive Mode is not necessary, because
PCM already has adaptive memory.
•If RFCFLAG PID is “Not Learnt”, PCM Adaptive Memory Procedure Drive should be performed before
HO2S Heater, HO2S, and TWC Repair Verification Drive Mode.
1. Start the engine and warm it up completely.
2. Verify all accessory loads (A/C, headlights, blower fan, rear window defroster) are off.
U0101 PCM cannot receive any signals from TCM ON 1 Other×
U0121PCM cannot receive any signals from ABS, ABS/TCS
or DSC HU/CMON 1 Other×
U0155PCM cannot receive any signals from instrument
clusterON 1 Other× DTC No. Condition MIL DC Monitor itemMemory
function

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

F2–1
F2
F2FUEL AND EMISSION CONTROL SYSTEMS
[MZR-CD (RF Turbo)]
OUTLINE.............................................................. F2-3
OUTLINE OF CONSTRUCTION ....................... F2-3
FEATURES ........................................................ F2-3
SPECIFICATIONS ............................................. F2-3
CONTROL SYSTEM DIAGRAM ........................ F2-4
CONTROL SYSTEM WIRING DIAGRAM.......... F2-5
INTAKE-AIR SYSTEM.......................................... F2-8
OUTLINE ........................................................... F2-8
STRUCTURAL VIEW......................................... F2-9
FUEL SYSTEM................................................... F2-10
OUTLINE ......................................................... F2-10
STRUCTURAL VIEW....................................... F2-11
EXHAUST SYSTEM........................................... F2-13
OUTLINE ......................................................... F2-13
STRUCTURAL VIEW....................................... F2-13
EMISSION SYSTEM........................................... F2-14
OUTLINE ......................................................... F2-14
STRUCTURAL VIEW....................................... F2-15
WARM UP OXIDATION CATALYTIC
CONVERTER DESCRIPTION ...................... F2-16
CONTROL SYSTEM........................................... F2-16
OUTLINE ......................................................... F2-16
STRUCTURAL VIEW....................................... F2-18
BLOCK DIAGRAM ........................................... F2-20
CONTROL DEVICE AND CONTROL
RELATIONSHIP CHART .............................. F2-22
CRUISE CONTROL SYSTEM ......................... F2-23
CONTROLLER AREA NETWORK (CAN) ....... F2-24
ON-BOARD DIAGNOSTIC................................. F2-24
OUTLINE ......................................................... F2-24
DTC.................................................................. F2-24
KOEO/KOER SELF-TEST ............................... F2-26
PID/DATA MONITOR AND RECORD ............. F2-27
SIMULATION TEST ......................................... F2-27
LOCATION INDEX............................................. F2-28
INTAKE-AIR SYSTEM ..................................... F2-28
FUEL SYSTEM ................................................ F2-29
EMISSION SYSTEM........................................ F2-31
CONTROL SYSTEM........................................ F2-32
ENGINE TUNE-UP............................................. F2-34
ENGINE TUNE-UP PREPARATION ............... F2-34
IDLE SPEED INSPECTION ............................. F2-34
CORRECTION PROCEDURE ......................... F2-34
INTAKE-AIR SYSTEM........................................ F2-35
VACUUM TUBE ROUTING DIAGRAM............ F2-35
INTAKE-AIR SYSTEM
REMOVAL/INSTALLATION .......................... F2-36
AIR CLEANER ELEMENT INSPECTION ........ F2-37
TURBOCHARGER INSPECTION ................... F2-38
GUIDE BLADE ACTUATOR INSPECTION ..... F2-39
VARIABLE BOOST CONTROL (VBC)
SOLENOID VALVE INSPECTION ................ F2-40VARIABLE BOOST CONTROL (VBC)
CHECK VALVE INSPECTION ...................... F2-41
VARIABLE SWIRL CONTROL (VSC)
VALVE ACTUATOR INSPECTION ............... F2-41
VARIABLE SWIRL CONTROL (VSC)
SOLENOID VALVE INSPECTION ................ F2-42
GLOW PLUG REMOVAL/INSTALLATION ...... F2-42
GLOW PLUG INSPECTION ............................ F2-43
GLOW PLUG LEAD INSPECTION .................. F2-43
ACCELERATOR PEDAL COMPONENT
REMOVAL/INSTALLATION .......................... F2-44
ACCELERATOR PEDAL COMPONENT
DISASSEMBLY/ASSEMBLY ........................ F2-44
FUEL SYSTEM................................................... F2-45
BEFORE REPAIR PROCEDURE .................... F2-45
AFTER REPAIR PROCEDURE ....................... F2-45
FUEL TANK REMOVAL/INSTALLATION ........ F2-45
FUEL TANK INSPECTION .............................. F2-49
NONRETURN VALVE INSPECTION............... F2-50
FUEL FILTER COMPONENT
REMOVAL/INSTALLATION .......................... F2-50
FUEL FILTER COMPONENT
DISASSEMBLY/ASSEMBLY ........................ F2-51
FUEL WARMER INSPECTION........................ F2-51
SEDIMENTOR WATER DRAINING................. F2-52
SEDIMENTOR SWITCH INSPECTION ........... F2-52
SUPPLY PUMP REMOVAL/INSTALLATION .. F2-53
SUPPLY PUMP INSPECTION......................... F2-54
SUCTION CONTROL VALVE INSPECTION ... F2-54
COMMON RAIL INSPECTION ........................ F2-54
FUEL INJECTOR REMOVAL/INSTALLATION F2-55
FUEL INJECTOR INSPECTION ...................... F2-56
EXHAUST SYSTEM........................................... F2-57
EXHAUST SYSTEM INSPECTION ................. F2-57
EXHAUST SYSTEM
REMOVAL/INSTALLATION .......................... F2-57
EMISSION SYSTEM........................................... F2-59
EGR VALVE REMOVAL/INSTALLATION........ F2-59
EGR VALVE INSPECTION .............................. F2-59
EGR SOLENOID VALVE (VACUUM)
INSPECTION ................................................ F2-60
EGR SOLENOID VALVE (VENT)
INSPECTION ................................................ F2-60
EGR CONTROL SOLENOID VALVE
INSPECTION ................................................ F2-61
INTAKE SHUTTER VALVE ACTUATOR
INSPECTION ................................................ F2-62
INTAKE SHUTTER SOLENOID VALVE
INSPECTION ................................................ F2-63
CONTROL SYSTEM........................................... F2-64
PCM REMOVAL/INSTALLATION .................... F2-64
PCM INSPECTION .......................................... F2-65
PCM CONFIGURATION .................................. F2-68
CLUTCH SWITCH INSPECTION .................... F2-68
NEUTRAL SWITCH INSPECTION .................. F2-69
IDLE SWITCH INSPECTION ........................... F2-70
IDLE SWITCH ADJUSTMENT ......................... F2-71
ACCELERATOR POSITION SENSOR
INSPECTION ................................................ F2-72
ACCELERATOR POSITION SENSOR
ADJUSTMENT .............................................. F2-73 FEATURES
SERVICE

OUTLINE
F2–3
F2
OUTLINE OF CONSTRUCTIONA6E400218881201•The common rail injection system has been adopted for Mazda6 (GG, GY) MZR-CD (RF Turbo) engine
models.
•The fuel and emission control system is essentially carried over from that of the current MPV (LW) MZR-CD
(RF Turbo) engine models, except for the following features. (See MPV Workshop Manual Supplement 1737-
1*-02C.)
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FEATURESA6E400218881202Improved Emission Performance
•Warm up oxidation catalytic converter capacity has been increased.
System Simplification
•Immobilizer unit has been equipped into PCM
•Cruise control system has been adopted.
•Electrical fan control has been changed.
•CAN has been changed.
Improved Serviceability
•DTCs, PID monitoring items, and simulation test items have been changed.
•KOEO/KOER self-test items have been changed.
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SPECIFICATIONSA6E400218881203
Bold frames: New specifications
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OUTLINE
ItemNew Mazda6 (GG, GY) Current MPV (LW)
MZR-CD (RF Turbo)
Air cleaner element Type Non woven fabric (dry)
Supercharger Type Turbocharger
Glow plug Type Metal
Pump Type Supply pump
Fuel tankCapacity
64 {16.9, 14.1} 75 {19.8, 16.5}
(L {US gal, lmp gal})
Catalyst Type Warm up oxidation catalyst, Oxidation catalyst
EGR control Type Duty control
PCV system Type Closed

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

EXHAUST SYSTEM
F2–13
F2
OUTLINEA6E401440000201•The exhaust system is essentially carried over from that of the current 626 (GF)/626 Station Wagon (GW) RF
Turbo engine models. (See 626 626 Station Wagon Workshop Manual Supplement 1688-1*-00G.)
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STRUCTURAL VIEWA6E401440000202
.
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EXHAUST SYSTEM
5
4
3
6
1
2
A6E40142005
1 Exhaust manifold
2 Warm up oxidation catalytic converter
3 Front pipe4 Oxidation catalytic converter
5 Middle pipe
6 Main silencer