clutch MAZDA 6 2002 Workshop Manual Suplement

M–8
ELECTRONIC 4WD CONTROL SYSTEM
Components and Functions
System Diagram
.
Part name Function
Electronic control coupling
(4WD solenoid)•Based on a signal from the 4WD CM, it operates the electromagnetic clutch and
transmits drive torque to the rear wheels.
Differential oil temperature
sensor•Informs the 4WD CM of the rear differential oil temperature.
4WD CM•Controls operation of the electronic control coupling (4WD solenoid) based on signals
input from the throttle opening angle, speed, differential oil temperature and other
sensors.
•Outputs coupling control condition and 4WD warning control information as a CAN
signal.
•Controls the on-board diagnostic system and the fail-safe system if there is a malfunction
in the 4WD system.
4WD warning light•Illuminates or flashes to alert driver of a malfunction or control failure in the 4WD system.
PCM•Sends the throttle opening angle and engine speed signals, as CAN signals, to the 4WD
CM.
TCM•Sends the selector lever position and gear position signals, as CAN signals, to the 4WD
CM.
DSC HU/CM•Sends the four-wheel speed and DSC operating condition signals, as CAN signals, to the
4WD CM.
•Sends the coupling torque request signal, as a CAN signal, to the 4WD CM.
KO
P I
A
C
NH G
9
8
7
5
4
3
10
13
11
12
6
1
2
A6E63222002
1 Battery
2 Ignition switch
3 Differential oil temperature sensor
4 4WD control modure (4WD CM)
5 Electronic control coupling
6 4WD solenoid
7 Instrument cluster8 DSC HU/CM
9TCM
10 PCM
11 CAN-H
12 CAN-L
13 CAN driver

ELECTRONIC 4WD CONTROL SYSTEM
M–9
M
End Of SieELECTRONIC CONTROL COUPLINGA6E632227100202Outline
Features
•An electromagnetic clutch, which operates smoothly due to the lack influence from the front and rear wheel
traction force, has been adopted for the electronic control coupling system.
•The construction of the coupling enables the torque formed by the pilot clutch to be amplified by the cam
mechanism, thus allowing the main clutch to obtain a high degree of torque. Due to this, size and weight
reduction of the component parts has been achieved.
Construction
•The electronic control coupling basically consists of an electromagnetic clutch, a cam mechanism and a torque
transmission system.
•The electromagnetic clutch consists of a 4WD solenoid (electromagnetic coil), rear-housing that forms a
magnetic path, pilot clutch, and armature. The cam mechanism consists of a pilot cam, balls, and main cam.
The torque transmission system consists of a main clutch and hydraulic oil (ATF).
.
9
8
7
5
43
10
13
1112
6
12
A6E63222003
1 Front wheel side
2 Rear wheel side
3 Torque transmission system
4 Electromagnetic clutch
5 Rear housing
6 4WD solenoid (Electromagnetic coil)
7 Cam mechanism8Ball
9 Main clutch
10 Main cam
11 Armature
12 Pilot clutch
13 Pilot cam

M–10
ELECTRONIC 4WD CONTROL SYSTEM
Operation
4WD solenoid control current is OFF
•When the 4WD solenoid control current is OFF, no torque is generated in the pilot clutch because there is no
current flowing to the 4WD solenoid. At the same time, the pilot cam and the main cam rotate in the same
direction via the balls, and the main cam does not exert any push force on the main clutch side. Therefore, the
traction from the front wheels is not transmitted to the rear wheels.
.
8
7
5
4
3
6
12
56
7
A6E63222004
1 Main clutch
2 Pilot clutch
3 4WD solenoid (Electromagnetic coil)
4 4WD control modure (4WD CM)5Main cam
6Pilot cam
7Ball
8 Armature

ELECTRONIC 4WD CONTROL SYSTEM
M–11
M
4WD solenoid control current is ON
•When the 4WD solenoid control current is ON, current flows from the 4WD CM to the 4WD solenoid, and the
coupling operates in the following manner.
1. Magnetic flux forms at the electromagnetic coil of the 4WD solenoid.
2. Due to the magnetic flux in the armature, the pilot clutch is suctioned towards the magnetic coil side and
made to engage. This causes frictional torque to generate in the pilot clutch.
3. The torque is transmitted to the pilot cam, which is engaged with the pilot clutch.
4. A rotational difference is created between the pilot cam and the main cam. Due to this relative torsion, the
cam mechanism operates, transmitting torque from the pilot cam to the ball and then to the main cam. In
this way, the push force exerted on the main clutch is amplified.
5. As the main clutch engages, the drive torque from the front wheels is transmitted to the rear wheels.
•The amount of push force exerted on the main clutch by the main cam (that is, the strength of the drive torque
transmitted to the rear wheels) changes in accordance with the proportion of the force acting upon the pilot
cam, engaged with the pilot clutch. Therefore, by changing the periodicity of the electric current from the 4WD
CM to the 4WD solenoid (ON/OFF rate of the 4WD solenoid = force acting on the pilot cam), the module
controls the transmission of drive torque to the rear wheels.
.
End Of Sie
98
75
4
3
10
11
6
12
56
7
12
A6E63222005
1 Main clutch
2Pilot clutch
3 4WD solenoid (Electromagnetic coil)
4 4WD control modure (4WD CM)
5Main cam
6Pilot cam7Ball
8Armature
9 Drive torque
10 Magnetic flux
11 Input
12 Output

ELECTRONIC 4WD CONTROL SYSTEM
M–13
M
4WD CONTROL MODUREA6E632227100205Function
•The 4WD control modure (4WD CM) calculates the optimal amount of torque distribution for the rear wheels
and outputs a corresponding electric current to the electronic control coupling (4WD solenoid). This calculation
is based on the throttle angle, four-wheel speed, engine speed, selector lever position, and other related input
signals, matched with the vehicle driving and road surface conditions.
Functions
Construction
•The 4WD CM is installed to the left of the brake pedal (clutch pedal position).
Block diagram
.
Function name Contents
4WD system control
function•Based on each input signal, the electronic control current sent to the electronic control coupling
(4WD solenoid) is optimally controlled.
Diagnostic system•If the self-diagnostic system detects a malfunction, the 4WD warning light illuminates to alert
the driver, and at the same time the system suspends control or performs other measures to
prevent a loss of driving stability and protect the system.
•The detected malfunction is stored as a DTC in the 4WD CM.
987
5
43
10
19
18
17
15
16
14
131112
6
1
2
A6E63222008
1Front
2PCM
3TCM
4 DSC HU/CM
5 4WD control modure (4WD CM)
6 4WD solenoid
7Transaxle
8Transfer
9 Propeller shaft
10 Front drive shaft11 Pilot clutch/pilot cam
12 Ball/main cam
13 Main clutch
14 Electronic control coupling
15 Rear differential
16 Rear drive shaft
17 Torque transmission path
18 Electric signal path
19 Solenoid activation

U–2
OUTLINE
OUTLINE OF CONSTRUCTIONA6E850201038201•The construction and operation of the air conditioner system is essentially carried over from that of the previous
Mazda6 (GG) model, except for the following features. (See Mazda6 Training Manual 3359-1*-02C.)
End Of Sie
FEATURESA6E850201038202Improved Comfort
•The water heater system has been adopted. (For MZR-CD (RF Turbo) European (L.H.D.) specs.)
End Of Sie
SPECIFICATIONSA6E850201038203Manual Air Conditioner
OUTLINE
ItemSpecification
L3, L8, LF MZR-CD (RF Turbo)
Heating capacity (kW {kcal/h}) 4.400 {3,784}4.400 {3,784} (L.H.D.)
5.120 {4,403} (R.H.D.)
Airflow volume
(during heater operation)Blower motor
(m
3/h)310 (L.H.D.)
300 (R.H.D.)
Electricity consumption
(during heater operation)Blower motor (W) 184
Cooling capacity (kW {kcal/h}) 4.200 {3,612}
Airflow volume (during air
conditioner operation)Blower motor
(m
3/h)460
Electricity consumption
(during air conditioner
operation)Blower motor (W) 225
Magnetic clutch (W) 46 45
Fan type Blower motor Sirocco fan
RefrigerantType R-134a
Regular amount
(approximate quantity)470 {16.6} (L.H.D.)
430 {15.2} (R.H.D.)
(g {oz})
A/C compressorType Vane-rotary
Discharge capacity
120 {120, 4.06}
(ml {cc, fl oz})
Max. allowable speed
6,400
(rpm)
Lube
oilType ATMOS GU10
Sealed volume
(approximate quantity)
120 {120, 4.06} 150 {150, 5.07}
(ml {cc, fl oz})
Magnetic clutch clearance
0.3—0.5 {0.012—0.019}
(mm {in})
CondenserType Multiflow (sub-cooling type)
Radiated heat (kW {kcal/h})4.69 {4,030}: European (L.H.D.) specs.
5.96 {5,130}: European (U.K.), GCC specs.
Receiver/drier
capacity(ml {cc, fl oz}) 190 {190, 6.42}
Desiccant Synthetic zeolite
Expansion valve Type Block type
Evaporator Type Double-tank drawn cup

U–4
OUTLINE
Full-auto Air Conditioner
ItemSpecification
L3, L8, LF MZR-CD (RF Turbo)
Heating capacity (kW {kcal/h}) 4.400 {3,784}4.400 {3,784} (L.H.D.)
5.120 {4,403} {R.H.D.)
Airflow volume
(during heater operation)Blower motor
(m
3/h)310 (L.H.D.)
300 (R.H.D.)
Electricity consumption
(during heater operation)Blower motor (W) 184
Cooling capacity (kW {kcal/h}) 4.200 {3,612}
Airflow volume (during air
conditioner operation)Blower motor
(m
3/h)460
Electricity consumption
(during air conditioner
operation)Blower motor (W) 225
Magnetic clutch (W) 46 45
Fan type Blower motor Sirocco fan
RefrigerantType R-134a
Regular amount
(approximate quantity)470 {16.6} (L.H.D.)
430 {15.2} (R.H.D.)
(g {oz})
A/C compressorType Vane-rotary
Discharge capacity
120 {120, 4.06}
(ml {cc, fl oz})
Max. allowable speed
6,400
(rpm)
Lube
oilType ATMOS GU10
Sealed volume
(approximate quantity)
120 {120, 4.06} 150 {150, 5.07}
(ml {cc, fl oz})
Magnetic clutch clearance
0.3—0.5 {0.012—0.019}
(mm {in})
CondenserType Multiflow (sub-cooling type)
Radiated heat (kW {kcal/h})4.69 {4,030}: European (L.H.D.) specs.
5.96 {5,130}: European (U.K.), GCC specs.
Receiver/drier
capacity(ml {cc, fl oz}) 190 {190, 6.42}
Desiccant Synthetic zeolite
Expansion valve Type Block type
Evaporator Type Double-tank drawn cup

BASIC SYSTEM
U–11
U
7. Install in the reverse order of removal.
8. Perform the refrigerant system performance test.
A/C Unit Installation Note
1. When installing a new A/C unit or evaporator, add a supplemental amount of ATMOS GU10 compressor oil into
the refrigerant cycle.
Supplemental amount (approximate quantity)
40 ml {40 cc, 1.4 fl oz}
End Of Sie
A/C COMPRESSOR REMOVAL/INSTALLATIONA6E8516614502011. Disconnect the negative battery cable.
2. Discharge the refrigerant from the system.
3. Remove the right side splash shield.
4. Loosen the drive belt and remove it.
Caution
•If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and
abnormal noise will occur. Always immediately plug open fittings after removing any refrigeration
cycle parts to keep moisture or foreign material out of the cycle.
5. Remove in the order indicated in the table. Do not
allow compressor oil to spill.
.
6. Install in the reverse order of removal.
7. Adjust the drive belt.
8. Perform the refrigerant system performance test.
A/C Compressor Installation Note
1. Remove the following amount of compressor oil from the new A/C compressor when replacing the A/C
compressor.
Compressor oil to be removed (approximate quantity)
150 ml {150 cc, 5.07 fl oz} – [compressor oil from old A/C compressor + 15 ml {15 cc, 0.5 fl oz}]
End Of Sie
1 Cooler hose (HI)
(See U–13 REFRIGERANT LINES REMOVAL/
INSTALLATION)
2 Cooler hose (LO)
(See U–13 REFRIGERANT LINES REMOVAL/
INSTALLATION)
3 Magnetic clutch connector
4A/C compressor
(See U–11 A/C Compressor Installation Note)
4
3
1
2
N·m {kgf·cm, in·lbf} 6.86—9.80
{70.0—99.9,
60.8—86.7}
R
R
6.86—9.80
{70.0—99.9,
60.8—86.7}
17.6—26.5 N·m
{1.80—2.70 kgf·m,
13.0—19.5 ft·lbf}
A6E85162005

TD–1
TD
TDTECHNICAL DATA
TECHNICAL DATA............................................. TD-2
ENGINE ............................................................ TD-2
LUBRICATION SYSTEM .................................. TD-2
COOLING SYSTEM .......................................... TD-3
FUEL AND EMISSION CONTROL
SYSTEM ........................................................ TD-3
ENGINE ELECTRICAL SYSTEM ..................... TD-4
CLUTCH............................................................ TD-4
MANUAL TRANSAXLE ..................................... TD-4
AUTOMATIC TRANSAXLE............................... TD-5
PROPELLER SHAFT ........................................ TD-5
FRONT AND REAR AXLE ................................ TD-6
STEERING SYSTEM ........................................ TD-6
BRAKING SYSTEM .......................................... TD-7
SUSPENSION................................................... TD-7
BODY ELECTRICAL SYSTEM ......................... TD-8
HEATER AND AIR CONDITIONER
SYSTEMS ...................................................... TD-9

TD–4
TECHNICAL DATA
ENGINE ELECTRICAL SYSTEMA6E931001001205
*1: Back-up current is the constant flow of current present (for the audio unit, clock, PCM, etc.) when the engine
switch is off and with the key removed.
*
2: Must not be 0 A.
*3: Cold area
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CLUTCHA6E931001024201
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MANUAL TRANSAXLEA6E931001024202
ItemSpecification
Diesel engine
MZR-CD (RF Turbo)
BatteryElectrolyte gravity 1.27—1.29
Back-up current*
1(mA) Max.20
Type
95D31L, 115D31L
*3
Test load chart (A) Battery type95D31L (64) 250
115D31L (70) *3320
Slow-charge (A)Battery type
(5-hour rate)95D31L (64) 6.5—8.0
115D31L (70)
*37.0—8.5
Quick-charge
Battery type
(5-hour rate)95D31L (64) 40
(A/30 min)
115D31L (70)
*345
GeneratorStandard voltage (V)Ignition switch ON TerminalBB+
L Approx. 1
SB+
Idle [20°C {68°F}] TerminalB
14.1—14.7 L
S
Generated current*
2
(reference) (A) Engine speed (rpm)1,000 0—80
2,000 0—90
Starter No load testVoltage (V) 11
Current (A) Below 130
Item Specification
Clutch coverDiaphragm
spring fingersDepth mm {in} 0.6 {0.024}
Misalignment mm {in} 0.6 {0.024}
Maximum clearance of flatness of the
pressure platemm {in} 0.3 {0.012}
Flywheel Run out limit mm {in} 0.3 {0.012}
Item Specification
Manual transaxle typeA65M-R
Transaxle controlFloor-shift
Operation systemCable
Shift assistSynchromesh
Gear ratio1st 3.416
2nd 1.944
3rd 1.258
4th 0.902
5th 0.659
Reverse 3.252
Final gear ratio3.588
Transaxle oilGrade API service GL-4 or GL-5
Viscosity (All-season) SAE 75W-90
Capacity (approximate quantity)
2.30 {2.40, 2.00}
(L {US qt, Imp qt})