2002 MAZDA 6 fuse

TROUBLESHOOTING
F1–57
F1
ENGINE SYMPTOM TROUBLESHOOTINGA6E398018881201•Confirm trouble symptom using the following diagnostic index, then go to appropriate troubleshooting chart.
Diagnostic Index
End Of Sie
TROUBLESHOOTING
No. TROUBLESHOOTING ITEM DESCRIPTION
1 Melting of main or other fuses—
2 MIL illuminates MIL is illuminated incorrectly.
3 Will not crank Starter does not work.
4Hard to start/long crank/erratic start/erratic
crankStarter cranks engine at normal speed but engine requires excessive
cranking time before starting.
5 Engine stalls. After start/at idle Engine stops unexpectedly at idle and/or after start.
6 Cranks normally but will not start Starter cranks engine at normal speed but engine will not run.
7 Slow return to idle Engine takes more time than normal to return to idle speed.
8 Engine runs rough/rolling idleEngine speed fluctuates between specified idle speed and lower
speed and engine shakes excessively.
9 Fast idle/runs onEngine speed continues at fast idle after warm-up.
Engine runs after ignition switch is turned to off.
10 Low idle/stalls during decelerationEngine stops unexpectedly at beginning of deceleration or recovery
from deceleration.
11Engine stalls/quits. Acceleration/cruiseEngine stops unexpectedly at beginning of acceleration or during
acceleration.
Engine stops unexpectedly while cruising.
Engine runs rough. Acceleration/cruise Engine speed fluctuates during acceleration or cruising.
Misses Acceleration/cruise Engine misses during acceleration or cruising.
Buck/jerkAcceleration/cruise/
decelerationVehicle bucks/jerks during acceleration, cruising, or deceleration.
Hesitation/stumble Acceleration Momentary pause at beginning of acceleration or during acceleration
Surges Acceleration/cruise Momentary minor irregularity in engine output
12 Lack/loss of power Acceleration/cruisePerformance is poor under load.
(e.g., power down when climbing hills)
13 Knocking/pinging Acceleration/cruiseSound is produced when air/fuel mixture is ignited by something other
than spark plug. (e.g., hot spot in combustion chamber)
14 Poor fuel economy Fuel economy is unsatisfactory.
15 Emission compliance Fails emissions test.
16 High oil consumption/leakage Oil consumption is excessive.
17Cooling system
concernsOverheating Engine runs at higher than normal temperature/overheats.
18Cooling system
concernsRuns cold Engine does not reach normal operating temperature.
19 Exhaust smoke Blue, black, or white smoke from exhaust system
20 Fuel odor (in engine compartment) Gasoline fuel smell or visible leakage
21 Engine noise Engine noise from under hood
22 Vibration concerns (engine) Vibration from under hood or driveline
23 A/C does not work sufficiently.A/C compressor magnetic clutch does not engage when A/C is turned
on.
24A/C is always on or A/C compressor runs
continuously.A/C compressor magnetic clutch does not disengage.
25 A/C is not cut off under WOT conditions. A/C compressor magnetic clutch does not disengage under WOT.
26 Exhaust sulphur smell Rotten egg smell (sulphur) from exhaust
27 Constant voltage Incorrect constant voltage
28 Spark plug condition Incorrect spark plug condition
29 ATX concernsUpshift/downshift/
engagementATX concerns not related to engine performance

F1–58
TROUBLESHOOTING
QUICK DIAGNOSTIC CHARTA6E398018881202
X: Applicable
Possible factor
Troubleshooting item
Starter motor malfunction (Mechanical or electrical)
Starter circuit including ignition switch is open.
Starter interlock switch malfunction (MTX with starter
interlock system)
Improper engine oil level
Low or dead battery
Charging system malfunction
Improper engine compression
Improper valve timing
Hydrolocked engine
Improper engine oil viscosity
Improper dipstick
Base engine malfunction
Drive plate or flywheel are seized.
Improper tension or damaged drive belts
Improper engine coolant level
Water and anti-freeze mixture is improper.
Cooling system malfunction (Radiator, hoses,
overflow system, thermostat, etc.)
Cooling fan system malfunction
Engine or transaxle mounts are improperly installed.
Cooling fan or condenser fan seat are improper.
Accelerator cable free play misadjustment
Cruise control cable misadjustment
Fuel quality
1 Melting of main or other fuses2 MIL illuminates x x x x x x x3 Will not crank4 Hard to start/long crank/erratic start/erratic
crankx
5 Engine stalls. After start/at idle x x x x6 Cranks normally but will not start x x x x7 Slow return to idlex8 Engine runs rough/rolling idle x x x9 Fast idle/runs onxx10 Low idle/stalls during decelerationEngine stalls/quits. Acceleration/cruise x x xEngine runs rough. Acceleration/cruise x x xMissesAcceleration/cruise x x xBuck/jerk Acceleration/cruise/
decelerationxx x
Hesitation/stumble Acceleration x x x
11
Surges Acceleration/cruis
exx x12 Lack/loss of powerAcceleration/cruisexx x13 Knocking/pingingAcceleration/cruisexx14 Poor fuel economy x x x x x x15 Emission compliance x x x x16 High oil consumption/leakage x x x17 Cooling system concerns Overheatingxx x x x18 Cooling system concernsRuns cold x x19 Exhaust smoke x x x20 Fuel odor (in engine compartment)21 Engine noise x x x22 Vibration concerns (engine) x x 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 smellx27 Constant voltage28 Spark plug condition x x29 ATX concernsUpshift/downshift
engagementSee Section K, TROUBLESHOOTING
A6E39802001

TROUBLESHOOTING
F1–59
F1
X: Applicable
Possible factor
Troubleshooting itemVariable valve timing system malfunction (L3 engine
model)
VICS malfunction
Engine overheating
Air cleaner element clogging or restriction
Air leakage from intake-air system (Loose tubes,
cracks, gaskets breakage)
IAC valve improper operation
Throttle body malfunction
VICS malfunction (L3 engine model)
VACS malfunction (L3 engine model)
Vacuum leakage (Vacuum hose damage, misrouting)
Ignition coil malfunction (e.g. open, short or cracks)
Initial ignition timing misadjustment (CKP sensor &
crankshaft pulley misadjustment)
Spark plug malfunction
High-tension leads malfunction (Cracks, open, low
resistance)
CKP sensor is damaged. (e.g. open or short circuits )
Crankshaft pulley is damaged
Improper gap between CKP sensor and crankshaft
Fuel pump malfunction (Mechanically or electrically)
Pressure regulator malfunction
Fuel hoses restriction or clogging
1 Melting of main or other fuses2 MIL illuminates x x x x x3 Will not crank4 Hard to start/long crank/erratic start/erratic
crankx x x x x x xxxxxx
5 Engine stalls. x x x x x xxxxxxxxxxx6 Cranks normally but will not start x x x x xxxxxxxxxxx7 Slow return to idle x8 Engine runs rough/rolling idle x x x x x x x x xxxxxxx9 Fast idle/runs on x x10 Low idle/stalls during deceleration x x xEngine stalls/quits. Acceleration/cruise x x x x x x x x xxxxxxxEngine runs rough. Acceleration/cruise x x x x x x x x xxxxxxxMissesAcceleration/cruise x x x x x x x x xxxxxxxBuck/jerk Acceleration/cruise/dece
lerationxxx x xx x x x xxxxxx
Hesitation/stumble Acceleration x x x x x x x x xxxxxxx
11
Surges Acceleration/cruise x x x x x x x x xxxxxxx
12 Lack/loss of powerAcceleration/cruise x x x x x x x x xxxxxxx13 Knocking/pingingAcceleration/cruise x x x14 Poor fuel economy x x x x x x x15 Emission compliance x x x x x x x x x16 High oil consumption/leakage17 Cooling system
concernsOverheating
18 Cooling system
concernsRuns cold
19 Exhaust smoke x x x x x x20 Fuel odor (in engine compartment)x21 Engine noise x x x22 Vibration concerns (engine)23 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 x x x27 Constant voltage28 Spark plug condition x x x x x x29 ATX concernsUpshift/downshift
engagementSee Section K, TROUBLESHOOTING
A6E39802002

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

TROUBLESHOOTING
F1–61
F1
End Of Sie
X: Applicable
Possible factor
Troubleshooting itemIAT sensor and related circuit malfunction
Barometric pressure sensor malfunction
Neutral or clutch switch and related circuit
malfunction (MTX)
MAF sensor and related circuit malfunction
Knock sensor and related circuit malfunction
TP sensor and related circuit malfunction
TP sensor misadjustment (including looseness)
P/S pressure switch and related circuit
malfunction
Improper refrigerant charging amount
A/C relay (A/C control signal circuit malfunction
A/C compressor magnetic clutch malfunction
Condenser fan system malfunction
Improper load signal input
Clutch slippage
ATX related parts malfunction
VSS and related circuit malfunction
Improper ATF level
Brake dragging
Loose parts
Improper balance of wheels and tires
Drive line malfunction
Suspension malfunction
PATS operating (if equipped)
1 Melting of main or other fuses2 MIL illuminates x x x x x x x x3 Will not crankx4 Hard to start/long crank/erratic
start/erratic crankx
5 Engine stalls. After start/at idle x x x x6 Cranks normally but will not startx7 Slow return to idle8 Engine runs rough/rolling idle x x x x x x9 Fast idle/runs onx10 Low idle/stalls during deceleration x x x x x xEngine stalls/quits.Acceleration/cruisex x xx xx xxxEngine runs rough. Acceleration/cruisex x xx xx xxxMissesAcceleration/cruisex xx xx xxxBuck/jerk Acceleration/cruise
/decelerationx xx xx xxx
Hesitation/stumble Acceleration x x x x x x x x x
11
Surges Acceleration/cruise x x x x x x x x
12 Lack/loss of power Acceleration/cruise x x x x x x x x13 Knocking/pingingAcceleration/cruise x x x14 Poor fuel economy x x x x x15 Emission compliance x16 High oil consumption/leakage17 Cooling system
concernsOverheating x x x
18 Cooling system
concernsRuns cold x
19 Exhaust smoke20 Fuel odor (in engine compartment)21 Engine noisex22 Vibration concerns (engine)xxxx23 A/C does not work sufficiently. x x x24 A/C is always on or A/C compressorruns continuously.xx25 A/C is not cut off under WOT conditions x x26 Exhaust sulfur smell27 Constant voltage x x x x x x28 Spark plug condition x x29 ATX concernsUpshift/downshift/e
ngagementSee Section K, TROUBLESHOOTING
A6E39802004

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

F2–40
INTAKE-AIR SYSTEM
VARIABLE BOOST CONTROL (VBC) SOLENOID VALVE INSPECTIONA6E401013710201Air Tightness Inspection
1. Connect a vacuum pump to the VBC solenoid
valve port A, and apply vacuum.
Note
•Even if there is vacuum leakage, the VBC
solenoid valve is okay if vacuum increases
to –47 kPa {–353 mmHg, –14 inHg} or
more.
2. Verify that the vacuum increases to –47 kPa {–
353 mmHg, –14 inHg} or more.
•If not as specified, replace the VBC solenoid
valve.
•If VBC solenoid valve is okay, perform the
“Operation Inspection”.
Operation Inspection
1. Connect a vacuum pump to the VBC solenoid valve port A, and apply vacuum.
2. Turn the engine switch to ON.
3. Simulate the VBCV PID to 100 % using the WDS or equivalent.
4. Verify that the vacuum is decreased.
•If not as specified, replace the VBC solenoid valve.
•If VBC solenoid valve is okay, perform the “Resistance Inspection”.
Resistance Inspection
Note
•Perform the following test only when directed.
1. Measure the resistance between the VBC
solenoid valve terminals using an ohmmeter.
•If not as specified, replace the VBC solenoid
valve.
•If VBC solenoid valve is okay, perform the
“Circuit Open/Short Inspection”.
Specification
11—13 kilohms [20°C {68°F}]
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.
A
A6E40102012
A B
A6E40102031
AA
BC
DE VBC SOLENOID VALVE
HARNESS SIDE CONNECTORFUSE BOX
(PCM CONTROL RELAY)
A6E40102014

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