2002 MAZDA 6 display

F1–62
TROUBLESHOOTING
NO.14 POOR FUEL ECONOMYA6E398018881203
Diagnostic procedure
14 POOR FUEL ECONOMY
DESCRIPTIONFuel economy is unsatisfactory.
POSSIBLE CAUSE•Contaminated air cleaner element
•VIS malfunction (if equipped)
•Engine cooling system malfunction
•Improper ATF level (ATX)
•Weak spark
•Poor fuel quality
•Erratic or no signal from CMP sensor
•Clutch slippage (MTX)
•VTCS malfunction
•Improper variable valve timing control system operation (if equipped)
•Improper coolant level
•Inadequate fuel pressure
•Spark plug malfunction
•PCV valve malfunction
•Brake dragging
•Improper valve timing due to jumping out of timing belt
•Contaminated MAF sensor
•Improper engine compression
•Exhaust system clogging
•Improper electrically controlled 4WD system operation
Warning
The following troubleshooting flow chart contains fuel system diagnosis and repair
procedures. Read following warnings before performing 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 injuries 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.
Caution
•Disconnecting/connecting quick release connector without cleaning it may possibly cause
damage to fuel pipe and quick release connector. Always clean quick release connector
joint area before disconnecting/connecting, and make sure that it is free of foreign material.
STEP INSPECTION RESULTS ACTION
1 Inspect for following:
•Air cleaner element for contamination
•ATF level
•Fuel quality
•Coolant level
•Brake dragging
•Clutch slippage
Are all items okay?Yes Go to next step.
No Service as necessary.
Repeat Step 1.
2 Connect WDS or equivalent to DLC-2.
Retrieve any continuous memory, KOEO and
KOER DTCs.
Are there any DTCs displayed?YesDTC is displayed:
Go to appropriate DTC test.
NoNo DTC is displayed:
Go to next step.
3 Access ECT PID.
Drive vehicle while monitoring PID.
(See F1–33 PCM INSPECTION (4WD).)
Is PID within specification?Yes Go to next step.
No Inspect for coolant leakage, cooling fan and condenser
fan operations or thermostat operation.

F2–174
TROUBLESHOOTING
NO.2 MIL ILLUMINATESA6E408018881204
Diagnostic procedure
End Of Sie
NO.3 WILL NOT CRANKA6E408018881205
Diagnostic procedure
2 MIL ILLUMINATES
DESCRIPTION•MIL illuminates incorrectly.
POSSIBLE
CAUSE•PCM illuminates for emission-related concern (DTC is stored in PCM)
•Instrument cluster malfunction
Note
•If MIL blinks at steady rate, misfire condition could possibly exist.
STEP INSPECTION RESULTS ACTION
1 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.
NoNo DTC is displayed:
•Inspect instrument cluster operation.
2 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)
3 WILL NOT CRANK
DESCRIPTION•Starter does not work.
POSSIBLE
CAUSE•Open starter circuit between engine switch and starter
•Starter malfunction
•Seized/hydrolocked engine, flywheel
•Immobilizer system (PATS) and/or circuit malfunction (if equipped)
•Low or dead battery
•Charging system malfunction
STEP INSPECTION RESULTS ACTION
1Note
•The following test should be perform for
vehicles with immobilizer system. Go to
Step 10 for vehicles without immobilizer
system.
Connect WDS or equivalent to DLC-2.
Do following conditions appear?
•Engine is not completely started.
•DTC B1681 is displayed.YesBoth conditions appear:
Go to Step 4.
NoEither or other condition appears:
Go to next step.
2 Is coil connector securely connected to coil? Yes Go to next step.
No Connect coil connector securely.
Return to Step 1.
3 Does security light illuminate? Yes Go to next step.
No Inspect instrument cluster and wiring harness.
4 Connect WDS or equivalent to DLC-2 and
retrieve DTC.
DTC
B1213, B1342, B1600, B1601, B1602, B1681,
B2103, B2431Yes Go to appropriate DTC test.
No Go to next step.

TROUBLESHOOTING
F2–175
F2
End Of Sie
5 Is there continuity between PCM GND terminals
65, 85, 103, 104 and GND?Yes Go to next step.
No Repair or replace wiring harness.
6 Measure voltage between PCM GND terminals
65, 85, 103, 104 and coil terminal C.
Is the voltage below 1.0?Yes Go to next step.
No Repair or replace wiring harness.
7 Turn engine switch to ON.
Access VPWR PID.
Is VPWR PID okay?
Specification
Battery voltageYes Go to next step.
No Repair or replace wiring harness.
8 Disconnect coil connector.
Turn engine switch to ON.
Is there battery voltage at coil connector terminal
D (harness-side)?Yes Inspect for following:
•Open or short circuit between coil terminal A and
PCM terminal 80
•Open or short circuit between coil terminal B and
PCM terminal 28
No Repair or replace wiring harness between coil
connector terminal D and fuse panel.
9 Is there continuity between PCM terminal 57 and
starter relay?Yes Go to next step.
No Repair replace wiring harness.
10 Inspect following:
•Battery connection
•Battery condition
•Fuses
Are all items okay?Yes Go to next step.
No Service as necessary.
Repeat Step 10.
11 Is clicking sound heard from starter when engine
switch is turned to START?Yes Go to Step 13.
No Go to next step.
12 Inspect starting system.
Is starting system okay?Yes Inspect for seized/hydrolocked engine, flywheel.
No Repair or replace components as required.
13 Do any other electrical accessories work? Yes Go to next step.
No Inspect charging system.
14 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 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:
Inspect for following:
•START circuit in engine switch
•Open circuit between engine switch and starter
15 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

F2–176
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.

F2–178
TROUBLESHOOTING
End Of Sie
NO.5 ENGINE STALLS-AFTER START/AT IDLEA6E408018881207
Diagnostic Procedure
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
5 ENGINE STALLS-AFTER START/AT IDLE
DESCRIPTION•Engine stops unexpectedly.
POSSIBLE
CAUSE•Poor fuel quality
•Intake-air system restriction or clogging
•Engine overheating
•A/C system improper operation
•Immobilizer system (PATS) and/or circuit malfunction (if equipped)
•PCM control relay malfunction
•Glow system malfunction
•Inadequate fuel pressure
•Fuel pressure sensor related circuit malfunction
•Suction control valve malfunction (built-in supply pump)
•Fuel pressure limiter malfunction (built-in common rail)
•Fuel leakage
•Fuel line clogging or restriction
•Fuel filter clogging or restriction
•Incorrect fuel injection timing
•Erratic signal from CKP sensor
•Erratic signal from CMP sensor
•Supply pump malfunction
•Fuel injector malfunction
•Low engine compression
•Improper valve timing
•Exhaust system and/or catalyst converter restriction or clogging
•EGR system malfunction
•ECT sensor or related circuit malfunction
•Accelerator positions sensor or related circuit malfunction
•Accelerator positions sensor misadjustment
•MAF/IAT sensor or related circuit malfunction
•V-reference voltage supply circuit malfunction
•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
1Note
•The following test should be perform for
vehicles with immobilizer system. Go to
Step 10 for vehicles without immobilizer
system.
Connect WDS or equivalent to DLC-2.
Do following conditions appear?
•Engine is not completely started.
•DTC B1681 is displayed.YesBoth conditions appear:
Go to Step 4.
NoEither or other condition appears:
Go to next step.
2 Is coil connector securely connected to coil? Yes Go to next step.
No Connect coil connector securely.
Return to Step 1.
3 Does security light illuminate? Yes Go to next step.
No Inspect instrument cluster and wiring harness.

TROUBLESHOOTING
F2–179
F2
4 Connect WDS or equivalent to DLC-2 and
retrieve DTC.
DTC
B1213, B1342, B1600, B1601, B1602, B1681,
B2103, B2431Yes Go to appropriate DTC test.
No Go to next step.
5 Is there continuity between PCM GND terminals
65, 85, 103, 104 and GND?Yes Go to next step.
No Repair or replace wiring harness.
6 Measure voltage between PCM GND terminals
65, 85, 103, 104 and coil terminal C.
Is the voltage below 1.0?Yes Go to next step.
No Repair or replace wiring harness.
7 Turn engine switch to ON.
Access VPWR PID.
Is VPWR PID okay?
Specification
Battery voltageYes Go to next step.
No Repair or replace wiring harness.
8 Disconnect coil connector.
Turn engine switch to ON.
Is there battery voltage at coil connector terminal
D (harness-side)?Yes Inspect for following:
•Open or short circuit between coil terminal A and
PCM terminal 80
•Open or short circuit between coil terminal B and
PCM terminal 28
No Repair or replace wiring harness between coil
connector terminal D and fuse panel.
9 Is there continuity between PCM terminal 57 and
starter relay?Yes Go to next step.
No Repair replace wiring harness.
10 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 10.
11 Is engine overheating? Yes Go to symptom troubleshooting “NO.17 COOLING
SYSTEM CONCERNS-OVERHEATING”.
No Go to next step.
12Note
•Ignore DTC P0122, P0123, P0222 or
P0223 while performing this test.
Disconnect accelerator position sensor
connector.
Measure voltage at accelerator position sensor
connector VREF terminal (terminal D) with
engine switch ON.
Specification
4.5—5.5 V
Is voltage okay?Yes Go to next step.
No Go to symptom troubleshooting “NO.26 CONSTANT
VOLTAGE”.
13 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 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.
14 Does engine start normally after warm-up? Yes Inspect glow system operation.
(See T–19 RELAY INSPECTION)
Replace any malfunctioning part as necessary.
If glow system is okay, go to next step.
No Go to next step. STEP INSPECTION RESULTS ACTION

TROUBLESHOOTING
F2–181
F2
End Of Sie
NO.6 CRANKS NORMALLY BUT WILL NOT STARTA6E408018881208
Diagnostic Procedure
28 Inspect IDM.
(See F2–84 INJECTOR DRIVER MODULE
(IDM) INSPECTION)
Is IDM okay?Yes Go to next step.
No Repair or replace as necessary.
29 Inspect EGR system operation.
Is EGR system operation normal?Yes Remove and inspect supply pump and common rail.
No Repair or replace malfunctioning part according to
EGR system operation results.
30 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
6 CRANKS NORMALLY BUT WILL NOT START
DESCRIPTION•Starter cranks engine at normal speed but engine will not run.
•Refer to symptom troubleshooting “No.5 Engine stalls” if this symptom appears after engine stall.
•Fuel is in fuel tank.
•Battery is in normal condition.
POSSIBLE
CAUSE•Poor fuel quality
•Intake-air system restriction
•Fuel line restriction
•EGR system malfunction
•Glow system malfunction
•Fuel pressure sensor or related circuit malfunction
•Suction control valve malfunction (built-in supply pump)
•Fuel pressure limiter malfunction (built-in common rail)
•Fuel leakage
•Fuel filter clogging
•Incorrect fuel injection timing
•Erratic signal from CKP sensor
•Erratic signal from CMP sensor
•V-reference supply circuit malfunction
•ECT sensor or related circuit malfunction
•Supply pump malfunction
•Fuel injector malfunction
•Immobilizer system (PATS) and/or circuit malfunction (if equipped)
•Low engine compression
•Improper valve timing
•IDM or related circuit malfunction
•PCM control repay 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
1Note
•The following test should be perform for
vehicles with immobilizer system. Go to
Step 10 for vehicles without immobilizer
system.
Connect WDS or equivalent to DLC-2.
Do following conditions appear?
•Engine is not completely started.
•DTC B1681 is displayed.YesBoth conditions appear:
Go to Step 4.
NoEither or other condition appears:
Go to next step.
2 Is coil connector securely connected to coil? Yes Go to next step.
No Connect coil connector securely.
Return to Step 1.

F2–182
TROUBLESHOOTING
3 Does security light illuminate? Yes Go to next step.
No Inspect instrument cluster and wiring harness.
4 Connect WDS or equivalent to DLC-2 and
retrieve DTC.
DTC
B1213, B1342, B1600, B1601, B1602, B1681,
B2103, B2431Yes Go to appropriate DTC test.
No Go to next step.
5 Is there continuity between PCM GND terminals
65, 85, 103, 104 and GND?Yes Go to next step.
No Repair or replace wiring harness.
6 Measure voltage between PCM GND terminals
65, 85, 103, 104 and coil terminal C.
Is the voltage below 1.0?Yes Go to next step.
No Repair or replace wiring harness.
7 Turn engine switch to ON.
Access VPWR PID.
Is VPWR PID okay?
Specification
Battery voltageYes Go to next step.
No Repair or replace wiring harness.
8 Disconnect coil connector.
Turn engine switch to ON.
Is there battery voltage at coil connector terminal
D (harness-side)?Yes Inspect for following:
•Open or short circuit between coil terminal A and
PCM terminal 80
•Open or short circuit between coil terminal B and
PCM terminal 28
No Repair or replace wiring harness between coil
connector terminal D and fuse panel.
9 Is there continuity between PCM terminal 57 and
starter relay?Yes Go to next step.
No Repair replace wiring harness.
10 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 10.
11Note
•Ignore DTC P0122, P0123, P0222 or
P0223 while performing this test.
Disconnect accelerator position sensor
connector.
Measure voltage at accelerator position sensor
connector VREF terminal (terminal D) with
engine switch ON.
Specification
4.5—5.5 V
Is voltage okay?Yes Go to next step.
No Go to symptom troubleshooting “NO.26 CONSTANT
VOLTAGE”.
12 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 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. STEP INSPECTION RESULTS ACTION