MAZDA 6 2002 Workshop Manual Suplement

LOCATION INDEX
F2–29
F2
End Of Sie
FUEL SYSTEMA6E400001006201Engine room side
1 Air cleaner
(See F2–36 INTAKE-AIR SYSTEM REMOVAL/
INSTALLATION)
(See F2–37 AIR CLEANER ELEMENT
INSPECTION)
2 Turbocharger
(See F2–38 TURBOCHARGER INSPECTION)
3 Charge air cooler
(See F2–36 INTAKE-AIR SYSTEM REMOVAL/
INSTALLATION)
4 Intake manifold
(See F2–36 INTAKE-AIR SYSTEM REMOVAL/
INSTALLATION)
5 Guide blade actuator
(See F2–39 GUIDE BLADE ACTUATOR
INSPECTION)
6 VBC solenoid valve
(See F2–40 VARIABLE BOOST CONTROL (VBC)
SOLENOID VALVE INSPECTION)7 VBC check valve
(See F2–41 VARIABLE BOOST CONTROL (VBC)
CHECK VALVE INSPECTION)
8 VSC valve actuator
(See F2–41 VARIABLE SWIRL CONTROL (VSC)
VALVE ACTUATOR INSPECTION)
9 VSC solenoid valve
(See F2–42 VARIABLE SWIRL CONTROL (VSC)
SOLENOID VALVE INSPECTION)
10 Accelerator pedal component
(See F2–44 ACCELERATOR PEDAL
COMPONENT REMOVAL/INSTALLATION)
(See F2–44 ACCELERATOR PEDAL
COMPONENT DISASSEMBLY/ASSEMBLY)
11 Glow plug
(See F2–42 GLOW PLUG REMOVAL/
INSTALLATION)
(See F2–43 GLOW PLUG INSPECTION)
12 Glow plug lead
(See F2–43 GLOW PLUG LEAD INSPECTION)
9
8
7
5
4
3
6
10
6
4
3
L.H.D.
R.H.D.
A6E40002003

F2–30
LOCATION INDEX
Fuel tank side
.
End Of Sie
21
A6E40002004
1 Fuel tank
(See F2–45 FUEL TANK REMOVAL/
INSTALLATION)
(See F2–49 FUEL TANK INSPECTION)
2 Nonreturn valve
(See F2–50 NONRETURN VALVE INSPECTION)
3 Sedimentor switch
(See F2–52 SEDIMENTOR SWITCH INSPECTION)
4 Fuel filter
(See F2–50 FUEL FILTER COMPONENT
REMOVAL/INSTALLATION)
(See F2–51 FUEL FILTER COMPONENT
DISASSEMBLY/ASSEMBLY)
5 Fuel warmer
(See F2–51 FUEL WARMER INSPECTION)6 Priming pump
(See F2–52 SEDIMENTOR WATER DRAINING)
7 Supply pump
(See F2–53 SUPPLY PUMP REMOVAL/
INSTALLATION)
(See F2–54 SUPPLY PUMP INSPECTION)
8 Suction control valve
(See F2–54 SUCTION CONTROL VALVE
INSPECTION)
9 Common rail
(See F2–54 COMMON RAIL INSPECTION)
10 Fuel injector
(See F2–55 FUEL INJECTOR REMOVAL/
INSTALLATION)
(See F2–56 FUEL INJECTOR INSPECTION)

LOCATION INDEX
F2–31
F2
EMISSION SYSTEMA6E400001007201
.
End Of Sie
7
5
4
3
6
1
2
A6E40002005
1EGR valve
(See F2–59 EGR VALVE REMOVAL/
INSTALLATION)
(See F2–59 EGR VALVE INSPECTION)
2 EGR control solenoid valve
(See F2–61 EGR CONTROL SOLENOID VALVE
INSPECTION)
3 EGR solenoid valve (vacuum)
(See F2–60 EGR SOLENOID VALVE (VACUUM)
INSPECTION)4 EGR solenoid valve (vent)
(See F2–60 EGR SOLENOID VALVE (VENT)
INSPECTION)
5 Intake shutter valve actuator
(See F2–62 INTAKE SHUTTER VALVE
ACTUATOR INSPECTION)
6 Intake shutter solenoid valve (half)
(See F2–63 INTAKE SHUTTER SOLENOID VALVE
INSPECTION)
7 Intake shutter solenoid valve (full)
(See F2–63 INTAKE SHUTTER SOLENOID VALVE
INSPECTION)

F2–32
LOCATION INDEX
CONTROL SYSTEMA6E400018881201
.
9
8
7
5
4
10
15
14
1311
12
6
1
2
1
2
3
4
5
L.H.D.R.H.D.
A6E40002001

LOCATION INDEX
F2–33
F2
End Of Sie
1 PCM (with built-in BARO sensor and immobilizer
unit)
(SeeF2–64 PCM REMOVAL/INSTALLATION)
(SeeF2–65 PCM INSPECTION)
(SeeF2–68 PCM CONFIGURATION)
2 Clutch switch
(SeeF2–68 CLUTCH SWITCH INSPECTION)
3 Neutral switch
(SeeF2–69 NEUTRAL SWITCH INSPECTION)
4 Idle switch
(SeeF2–70 IDLE SWITCH INSPECTION)
(SeeF2–71 IDLE SWITCH ADJUSTMENT)
5 Accelerator position sensor
(SeeF2–72 ACCELERATOR POSITION SENSOR
INSPECTION)
(SeeF2–73 ACCELERATOR POSITION SENSOR
ADJUSTMENT)
6 MAF/IAT sensor
(SeeF2–74 MASS AIR FLOW (MAF)/INTAKE AIR
TEMPERATURE (IAT) SENSOR INSPECTION)
7 IAT sensor No.2
(SeeF2–75 INTAKE AIR TEMPERATURE (IAT)
SENSOR NO.2 INSPECTION)
8ECT sensor
(SeeF2–76 ENGINE COOLANT TEMPERATURE
(ECT) SENSOR REMOVAL/INSTALLATION)
(SeeF2–76 ENGINE COOLANT TEMPERATURE
(ECT) SENSOR INSPECTION)
9 Fuel temperature sensor
(SeeF2–77 FUEL TEMPERATURE SENSOR
INSPECTION)
10 Boost sensor
(SeeF2–78 BOOST SENSOR INSPECTION)
11 Fuel pressure sensor
(SeeF2–79 FUEL PRESSURE SENSOR
INSPECTION)
12 CMP sensor
(SeeF2–80 CAMSHAFT POSITION (CMP)
SENSOR REMOVAL/INSTALLATION)
(SeeF2–80 CAMSHAFT POSITION (CMP)
SENSOR INSPECTION)
13 CKP sensor
(SeeF2–81 CRANKSHAFT POSITION (CKP)
SENSOR REMOVAL/INSTALLATION)
(SeeF2–82 CRANKSHAFT POSITION (CKP)
SENSOR INSPECTION)
14 Calibration resistor
(SeeF2–83 CALIBRATION RESISTOR
INSPECTION)
15 IDM
(SeeF2–84 INJECTOR DRIVER MODULE (IDM)
INSPECTION)

F2–34
ENGINE TUNE-UP
ENGINE TUNE-UP PREPARATIONA6E4008020002011. Start the engine and warm up completely.
2. Verify that the gear is in neutral position.
3. Verify that the accelerator pedal is released.
4. Turn off the A/C switch.
5. Turn off all electrical loads.
6. Verify that no DTC is present.
7. Connect the WDS or equivalent to the DLC-2.
8. Wait until the electrical fan stops.
End Of Sie
IDLE SPEED INSPECTIONA6E4008020002021. Perform “Engine Tune-up Preparation”. (See F2–34 ENGINE TUNE-UP PREPARATION.)
2. Monitor the RPM PID using the WDS or equivalent.
3. Verify that engine speed is within specification.
•If not as specified, inspect the following.
—Suction control valve
—Fuel injector
—Accelerator position sensor
—ECT sensor
—Fuel pressure sensor
—CMP sensor
—CKP sensor
Specification
End Of Sie
CORRECTION PROCEDUREA6E400802000203
Note
•Perform each procedure by selecting the corresponding menu on the WDS screen. These procedures
appear when “Powertrain” in the “Toolbox tab” is selected.
Correction after Parts Installation
Note
•Perform this procedure after replacing the PCM and/or fuel injectors.
1. Perform “Engine Tune-up Preparation”. (See F2–34 ENGINE TUNE-UP PREPARATION.)
2. Perform “Correction after Parts Installation” using the WDS or equivalent.
ENGINE TUNE-UP
DLC-2
A6E40702001
Load condition Engine speed (rpm)
No load 725—825 (775±50)
A/C switch is on 725—825 (775±50)

ENGINE TUNE-UP, INTAKE-AIR SYSTEM
F2–35
F2
Injection Amount Correction
Note
•Perform this procedure at the recommended interval as described under “Fuel injection system” in
“SCHEDULED MAINTENANCE.”
1. Perform “Engine Tune-up Preparation”. (See F2–34 ENGINE TUNE-UP PREPARATION.)
2. Perform “Injection Amount Correction” using the WDS or equivalent.
MAF Correction
Note
•Perform this procedure after replacing the MAF/IAT sensor or at the recommended interval as described
under “E.G.R. system” in “SCHEDULED MAINTENANCE.”
1. Perform “Engine Tune-up Preparation”. (See F2–34 ENGINE TUNE-UP PREPARATION.)
2. Perform “MAF Correction” using the WDS or equivalent.
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VACUUM TUBE ROUTING DIAGRAMA6E401020030201
End Of Sie
INTAKE-AIR SYSTEM
EGR CONTROL SOLENOID
VA LV E
VBC SOLENOID VALVE
VBC CHECK VALVE
EGR SOLENOID VALVE
(VACUUM)EGR SOLENOID VALVE
(VENT) VSC SOLENOID VALVE
VSC SHUTTER VALVE
ACTUATOR
INTAKE SHUTTER VALVE
ACTUATOREGR VALVE
INTAKE SHUTTER
SOLENOID VALVE
(HALF)
INTAKE SHUTTER
SOLENOID VALVE
(FULL)VBC VACUUM DAMPER GUIDE BLADE ACTUATOR
A6E40102007

F2–36
INTAKE-AIR SYSTEM
INTAKE-AIR SYSTEM REMOVAL/INSTALLATIONA6E401001005203
Warning
•When the engine and intake-air system are hot, they can cause severe burns or injury. Turn off the
engine and wait until they are cool before removing or installing the intake-air system.
•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 the following “Fuel
Line Safety Procedure”. (See F2–45 Fuel Line Safety Procedures.)
Note
•Perform “ MAF Correction” after replacing the MAF/IAT sensor. (See F2–35 MAF Correction.)
1. Disconnect the negative battery cable.
2. Remove the front bumper.
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.
.
A
A
C
C
B
B
20—30
{2.1—3.1, 15—22}
19—25
{1.9—2.6, 14—18}6.9—9.8 N·m
{70—100 kgf·cm,
61—86 in·lbf}
2.5—3.4 N·m
{25—35 kgf·cm,
22—30 in·lbf}
6.9—9.8 N·m
{70—100 kgf·cm,
61—86 in·lbf} 7.8—11.8 N·m
{80—120 kgf·cm,
70—104 in·lbf}
6.9—9.8 N·m
{70—100 kgf·cm,
61—86 in·lbf} 17.6—26.5
{1.8—2.7,
13.0—19.8}6.9—9.8 N·m
{70—100 kgf·cm,
61—86 in·lbf}
6.9—9.8 N·m
{70—100 kgf·cm,
61—86 in·lbf}
2.5—3.4 N·m
{25—35 kgf·cm,
22—30 in·lbf}
TO EGR CONTROL SOLENOID VALVE
AND EGR SOLENOID VALVE (VENT)
TO VBC
CHECK VALVE
TO INTAKE SUTTER
SOLENOID VALVE (HALF)
9
10
19
17
11
20
21
1
2
3
5
4
7
6
8
12
14
13
15
16
18
0.55—0.85 N·m
{5.6—8.6 kgf·cm,
4.9—7.5 in·lbf}
N·m {kgf·m, ft·lbf}
R
RR
R
17.6—26.5
{1.8—2.7,
13.0—19.8}17.6—26.5
{1.8—2.7,
13.0—19.8}
4.9 N·m
{50 kgf·cm, 43 in·lbf}
4.9 N·m
{50 kgf·cm,
43 in·lbf}
4.9 N·m
{50 kgf·cm, 43 in·lbf}4.9 N·m
{50 kgf·cm,
43 in·lbf}
4.9 N·m
{50 kgf·cm,
43 in·lbf}
4.9 N·m
{50 kgf·cm,
43 in·lbf}
RUBBER MOUNT
(FRAME SIDE) RUBBER MOUNT
(ENGINE SIDE)
TO VBC
SOLENOID
VA LV E
A6E4010L030

INTAKE-AIR SYSTEM
F2–37
F2Air Pipe Removal Note
1. Remove the battery and the battery tray before removing the air pipe. (See G–5 BATTERY REMOVAL/
INSTALLATION.)
Intake Manifold Removal Note
1. Remove the supply pump before removing the intake manifold. (See F2–53 SUPPLY PUMP REMOVAL/
INSTALLATION.)
2. Remove the EGR valve before removing the intake manifold. (See F2–59 EGR VALVE REMOVAL/
INSTALLATION.)
Air Cleaner Case Installation Note
Note
•Before assembling the air cleaner, verify that the rubber mounts have not fallen off from the air cleaner
bracket (3 locations).
•Always install the air cleaner case using the following procedure.
•When inserting the rubber mounts into the air cleaner case, soapy water can be applied.
1. Verify that the rubber mounts are set in the air cleaner bracket (3 locations).
2. Install the projections on the frame side (2 locations).
3. Verify that the projections on the frame side are installed securely.
4. Install the projection on the engine side (remaining location).
5. Verify that the projection on the engine side installed securely.
End Of Sie
AIR CLEANER ELEMENT INSPECTIONA6E4010010052041. Remove the air cleaner element. (See F2–36 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.)
2. Verify that the air cleaner element surface is free of dirt.
•If there is dirt present, use an air gun or similar tool to clean the element.
•If the replacement time limit has passed, replace the element.
End Of Sie
1 Vacuum hose
2 Air hose
3 Air cleaner cover
4 Air cleaner element
5Air cleaner case
(See F2–37 Air Cleaner Case Installation Note)
6 MAF/IAT sensor
7Air pipe
(See F2–37 Air Pipe Removal Note)
8 Vacuum pipe
9 Air hose
10 Air pipe11 Air hose
12 Air pipe
13 Boost sensor
14 IAT sensor No. 2
15 Air pipe
16 Air hose
17 Air duct
18 Charge air cooler
19 Vacuum hose (Intake shutter valve actuator)
20 Vacuum hose (VSC shutter valve actuator)
21Intake manifold
(See F2–37 Intake Manifold Removal Note)

F2–38
INTAKE-AIR SYSTEM
TURBOCHARGER INSPECTIONA6E401013700201
Note
•If the following problems exist, diagnosis the turbocharger using the following symptom troubleshooting
procedures.
1. Lack of power: perform “NO.12 LACK/LOSS OF POWER”. (See F2–195 NO.12 LACK/LOSS OF POWER-
ACCELERATION/CRUISE.)
2. Oil leak: perform “NO.16 HIGH OIL CONSUMPTION/LEAKAGE”. (See F2–209 NO.16 HIGH OIL
CONSUMPTION/LEAKAGE.)
3. Noise: perform “NO. 21 ENGINE NOISE”. (See F2–217 NO.21 ENGINE NOISE.)
Compressor Wheel Inspection
1. Remove the air pipe between the air cleaner and the turbocharger. (See F2–36 INTAKE-AIR SYSTEM
REMOVAL/INSTALLATION.)
2. Visually inspect the compressor wheel from view A and verify that all fins are free from damage, cracks or
bends.
•If there are damaged fins, cracks or bends, replace the turbocharger.
Note
•To make the inspection easier, set a small
mirror as shown in the figure and use a
penlight.
•If the compressor wheel is interfering with
the compressor housing, it is likely that the
fin edges are cracked, damaged, or bent.
•If the compressor wheel is damaged, check
the following before replacing the
turbocharger to avoid reoccurrence of the
problem.
—Foreign material in intake air/exhaust
system.
—Oil pipe clogging.
MIRROR
A
A6E40102009