Engine Controls - Surge While Cruising at 40 - 50 Mph

Engine

01-032/04

2003 -2004 MAZDA6 - SURGING WHILE
CRUISING AT 40-50 MPH

APPLICABLE MODEL(S)/VINS

2003-2004 Mazda6

DESCRIPTION

Some vehicles may exhibit surging when cruising at a steady speed between 40-50 MPH on smooth, paved roads. While the OBDII EGR system is being monitored, the amount of EGR flow is increased in order to improve the failure detection level. During this time, engine combustion worsens which causes surging to be felt.The PCM calibration has been revised to decrease the amount of EGR flow and improve combustion during the EGR monitoring period.

Customers having this concern should have their vehicle repaired using the following repair procedure.

REPAIR PROCEDURE

1. Verify customer concern.

2. Using WDS 1330.6 or later software, reprogram the PCM to the latest calibration (refer to "Calibration Information" table) by following the "Module Reprogramming" procedure.

NOTE:
^ Always update the WDS PTU first, then install the needed calibration file that WDS shows during PCM reprogramming. Go to "WDS Calibration" on ESI and download the "update" file. If the PTU is not updated to the latest WDS calibration level, the calibration file will not install into the PTU.

^ It is not necessary to remove any fuses or relays during PCM reprogramming when the WDS screen prompts you to do so. You may accidentally stop power to one of the PCM terminals and cause the PCM to be blanked, or you may receive error messages during the WDS reprogramming procedure.

^ WDS shows the calibration part numbers afier programming the PCM.

^ Please be aware that PCM calibration part numbers and file names listed in any Service Bulletin may change due to future releases of WDS software, and additional revisions made to those calibrations for service related concerns.

^ When reprogramming a PCM, WDS will always display the "latest" calibration P/N available for that vehicle. If any calibration has been revised/updated to contain new information for a new service concern/issue, it will also contain all previously released calibrations.

^ When performing this procedure, if the WDS PTU is not docked and connected to 115V-120V, we recommend that a battery charger be installed on the vehicle battery and turned ON to a maximum charge of no more than 20 AMPS to keep the vehicle battery up to capacity. If you exceed 20 AMPS, it will damage the WDS PTU.

3. After performing the PCM reprogramming procedure, verify the repair by starting the engine and making sure there are no MIL illumination or abnormal warning lights present.

NOTE:
After PCM reprogramming, it is no longer necessary to road test the vehicle to "relearn" KAM (Keep Alive Memory).

4. Place an "Authorized Modification" label (P/N 9999-95-AMDC-97) with the new calibration information on the "A" pillar above the tear tag in the driver doorjamb.








CALIBRATION INFORMATION








WARRANTY INFORMATION

NOTE:

^ This warranty information applies only to verified customer complaints on vehicles eligible for warranty repair. Refer to the SRT microfiche for warranty term information.

^ Additional diagnostic time cannot be claimed for this repair.