wheel MAZDA 6 2002 Suplement Service Manual

TROUBLESHOOTING
F2–219
F2
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14 Inspect if turbocharger compressor wheel
locknut is loose or has fallen down inside
turbocharger.
Is there any problem?Yes Replace turbocharger.
No Go to next step.
15 Turn turbocharger compressor wheel by hand.
Does wheel turn easily and smoothly?Yes Go to next step.
No Replace turbocharger.
16 Inspect if turbocharger turbine wheel is
damaged, cracked or interfering with housing on
vehicle.
Note
•Inspect all fins on each turbine wheel.
Is there any problem?Yes Replace turbocharger.
No Go to next step.
17 Is any engine oil found inside turbocharger
turbine housing?YesExcessive amount of oil is found:
Replace turbocharger.
Small amount of oil is found:
Wipe oil off of vehicle, then go to next step.
No Go to next step.
18 Is any engine oil found inside turbocharger
compressor housing?Yes Wipe oil off of vehicle, then go to next step.
No Go to next step.
19 Is any exhaust gas leakage found around
location where turbocharger is attached to
exhaust manifold?Yes Remove turbocharger.
Inspect for cracks on center housing inlet surface.
If cracks are found, replace turbocharger.
No Go to next step.
20 Are any center housing and turbine housing
attaching bolts loose?Yes Retighten loose bolts.
If a bolt is found to be missing, attach appropriate new
bolts.
No Turbocharger is okay.
Install all parts removed in Step 13.
Go to next step.
21 Inspect suction control valve.
(See F2–54 SUCTION CONTROL VALVE
INSPECTION)
Is suction control valve okay?Yes Go to next step.
No Repair supply pump.
(See F2–54 SUPPLY PUMP INSPECTION)
22 Inspect fuel injector and fuel injector gasket.
(See F2–56 FUEL INJECTOR INSPECTION)
Is fuel injector okay?Yes Inspect for following:
•Metal flow
•Bent connecting rod
•Damaged valve seat
•Incorrect valve clearance
No Repair or replace as necessary.
23 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

F2–220
TROUBLESHOOTING
NO.22 VIBRATION CONCERNS (ENGINE)A6E408018881224
Diagnostic Procedure
22 VIBRATION CONCERNS (ENGINE)
DESCRIPTION•Vibration from under hood or driveline.
POSSIBLE
CAUSE•Loose attaching bolts or worn parts
•Cooling fan No.1 or cooling fan No.2 seat are improper
•Engine or transaxle mounts are improperly installed
•Components malfunction such as worn parts
•Erratic signal from CMP sensor
•ECT sensor or related circuit malfunction
•Accelerator position sensor or related circuit malfunction
•MAF/IAT sensor or related circuit malfunction
•Idle switch or related circuit malfunction
•Incorrect adjustment of accelerator position sensor and/or idle switch
•Fuel injector malfunction
•Vacuum leakage
•Improper tension or damaged drive belts
•Improper balance of wheels or tires
•Driveline malfunction
•Suspension 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 following components for loose attaching
bolts or worn parts:
•Cooling fan No.1
•Cooling fan No.2
•Cooling fan No.1 and cooling fan No.2 seat
•Drive belt and pulley
•Engine mounts
•Exhaust system
Are all items okay?Yes Go to next step.
No Readjust or retighten engine mount installation
position.
Service as necessary for other parts.
2 Inspect vacuum leakage.
Are vacuum hoses okay?Yes Go to next step.
No Service as necessary.
Repeat Step 2.

TROUBLESHOOTING
F2–221
F2
End Of Sie
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.
4 Inspect adjustment of accelerator position
sensor and idle switch.
(See F2–72 ACCELERATOR POSITION
SENSOR INSPECTION)
(See F2–70 IDLE SWITCH INSPECTION)
Are accelerator position sensor and idle switch
adjusted correctly?Yes Go to next step.
No Adjust accelerator position sensor and idle switch
correctly.
(See F2–73 ACCELERATOR POSITION SENSOR
ADJUSTMENT)
(See F2–71 IDLE SWITCH ADJUSTMENT)
5 Inspect adjustment of neutral switch.
(See F2–69 NEUTRAL SWITCH INSPECTION)
Is neutral switch adjusted correctly?Yes Go to next step.
No Adjust neutral switch correctly.
6 Visually inspect CMP sensor and teeth of pulse
wheel.
Are CMP sensor and teeth of pulse wheel okay?Yes Inspect following PIDs:
(See F2–65 PCM INSPECTION)
•ECT
•IAT
•MAF
•RPM
If PID value is not as specified, repair or replace
malfunctioning parts.
If PID value is okay, go to next step.
No Replace malfunctioning parts.
7 Inspect fuel injector.
(See F2–56 FUEL INJECTOR INSPECTION)
Is fuel injector okay?Yes Inspect following systems:
•Wheels
•Transaxle and mounts
•Driveline
•Suspension
Service as necessary.
No Repair or replace as necessary.
8 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

H–1
H
HCLUTCH
OUTLINE................................................................ H-2
OUTLINE OF CONSTRUCTION.......................... H-2
FEATURES .......................................................... H-2
SPECIFICATIONS ............................................... H-2
OUTLINE................................................................ H-2
SUPPLEMENTAL SERVICE INFORMATION .....H-2
CLUTCH RELEASE CYLINDER............................ H-3
CLUTCH RELEASE CYLINDER
REMOVAL/INSTALLATION
(A65M-R MANUAL TRANSAXLE MODELS) ....H-3
CLUTCH RELEASE CYLINDER
DISASSEMBLY/ASSEMBLY (A65M-R
MANUAL TRANSAXLE MODELS) ................... H-4
CLUTCH UNIT........................................................H-5
CLUTCH UNIT REMOVAL/INSTALLATION
(A65M-R MANUAL TRANSAXLE MODELS) ....H-5
CLUTCH COVER INSPECTION (A65M-R
MANUAL TRANSAXLE MODELS) ................... H-7
FLYWHEEL............................................................ H-8
FLYWHEEL INSPECTION (A65M-R MANUAL
TRANSAXLE MODELS) ................................... H-8 FEATURES
SERVICE

H–2
OUTLINE
OUTLINE OF CONSTRUCTIONA6E490216003201•The construction and operation of the clutch is essentially carried over from that of the current MPV (LW)
models, except for the following features. (See Mazda MPV Training Manual 3340-1*-99F.)
End Of Sie
FEATURESA6E490216003202Adoption of the A65M-R manual transaxle models
•The specifications for the A65M-R manual transaxle models have been added.
Increased torque transmission capacity
•Increased clutch cover set load.
Reduced noise
•The flywheel with a damper has been adopted for the A65M-R manual transaxle model.
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SPECIFICATIONSA6E490216003203
Bold frames:New specifications
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SUPPLEMENTAL SERVICE INFORMATIONA6E490216003204•The following changes have been made since publication of the Mazda6 Workshop Manual (1730-1*-02C).
CLUTCH RELEASE CYLINDER
•Removal/installation procedure has been modified.
•Disassembly/assembly procedure has been modified.
CLUTCH UNIT
•Removal/installation procedure has been modified.
•Clutch cover inspection procedure has been modified.
FLYWHEEL
•Flywheel inspection procedure has been modified.
End Of Sie
OUTLINE
Item New Mazda6 (GG, GY) Current MPV (LW)
EngineMZR-CD (RF Turbo)
Manual transaxle type A65M-R
Clutch control Hydraulic
Clutch coverSpring type Diaphragm
Set load (N {kgf, lbf}) 6,550 {668, 1,472}
Clutch discOuter diameter (mm {in}) 239 {9.41}
Inner diameter (mm {in}) 160 {6.30}
Clutch pedalType Suspended
Pedal ratio 5.9 6.41
Full stroke (mm {in}) 140 {5.51} 148 {5.83}
Clutch master cylinder inner diameter (mm {in}) 15.87 {0.625}
Clutch release cylinder inner diameter (mm {in}) 19.05 {0.750}
Clutch fluid type SAE J1703, FMVSS116 DOT-3 or DOT-4
OUTLINE

CLUTCH UNIT
H–5
H
CLUTCH UNIT REMOVAL/INSTALLATION (A65M-R MANUAL TRANSAXLE MODELS)A6E4920160002011. Remove in the order indicated in the table.
2. Install in the reverse order oremoval.
.
CLUTCH UNIT
SST
SST
SSTSEALANT
25—33
{2.6—3.3, 19—24}
151.3—161.1
{15.43—16.42, 111.6—118.8} 18.6—25.5
{1.90—2.60, 13.8—18.8}
1
GREASE
GREASE
GREASE
GREASE
GREASE
5
6
7
8
4
3
2
(MOLYBDENUM SULFIDE) TRANSAXLE SIDE ENGINE SIDE
N·m {kgf·m, ft·lbf}
A6E4920W010
1 Clutch release cylinder
2 Manual transaxle
(See J2–7 MANUAL TRANSAXLE REMOVAL/
INSTALLATION)
3Boot
4 Clutch release collar
5 Clutch release fork6 Clutch cover
(See H–6 Clutch Cover and Disc Removal Note)
(See H–7 Clutch Cover Installation Note)
7Clutch disc
(See H–6 Clutch Cover and Disc Removal Note)
(See H–7 Clutch Disc Installation Note)
8 Flywheel
(See H–6 Flywheel Removal Note)
(See H–6 Flywheel Installation Note)

H–6
CLUTCH UNIT
Clutch Cover and Disc Removal Note
1. Install the SSTs.
2. Loosen each bolt one turn at a time in a crisscross pattern until spring tension is released.
3. Remove the clutch cover and disc.
Flywheel Removal Note
1. Hold the flywheel using the SST.
2. Remove the bolts evenly and gradually in a crisscross pattern.
3. Remove the flywheel.
Flywheel Installation Note
1. Install the flywheel to the crankshaft.
2. When reusing the bolts, clean threads and hole, then apply locking compound to the threads.
Note
•No locking compound is needed when using new bolts.
3. Hand-tighten the flywheel lock bolts.
4. Install the SST to the flywheel.
5. Gradually tighten the flywheel lock bolts in a
crisscross pattern.
Tightning torque
151.3—161.1 N·m
{15.43—16.42 kgf·m, 111.6—118.8 ft·lbf}
49 SE01 310A
49 E011 1A0
A6E4920W011
49 E011 1A0
5
4
3
61
2
8
7
A6E4920W012
49 E011 1A0
5
4
3
61
2
8
7
A6E4920W013

H–8
CLUTCH UNIT, FLYWHEEL
4. Rotate the flywheel and check for misaligned
diaphragm spring fingers.
•If not as specified, replace the clutch cover.
Misalignment
0.6 mm {0.024 in} max.
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FLYWHEEL INSPECTION (A65M-R MANUAL TRANSAXLE MODELS)A6E4922115002011. Install a dial gauge on the cylinder block.
2. Measure the flywheel runout using a dial
indicator.
•If the runout is excessive, replace the
flywheel.
Runout
0.3 mm {0.012 in} max.
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A6E4920W016
FLYWHEEL
A6E4922W001

MANUAL TRANSAXLE
J2–5
J2
OIL SEAL (DIFFERENTIAL) REPLACEMENTA6E5212192402011. On level ground, jack up the vehicle and support it evenly on safety stands.
2. Drain the oil from the transaxle.
3. Remove the front wheels and splash shields.
4. Separate the drive shaft and joint shaft from the transaxle. (See Section M.)
5. Remove the oil seals using a screwdriver.
6. Using the SSTs and a hammer, tap each new oil
seal in evenly until the SSTs contact the transaxle
case.
7. Coat the lip of each oil seal with transaxle oil.
8. Insert the drive shaft and joint shaft into the
transaxle. (See Section M.)
9. Install the wheels and splash shields.
10. Add the specified amount and type of oil. (See
J2–4 TRANSAXLE OIL REPLACEMENT.)
End Of SieREVERSE SWITCH INSPECTIONA6E5212190102011. Disconnect the reverse switch connector.
2. Shift the shift lever to each position, and inspect
for continuity between terminals A and B.
•If not as specified, replace the reverse switch.
(See J2–6 REVERSE SWITCH REMOVAL/
INSTALLATION.)
3. Connect the reverse switch connector.
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AME5212W005
49 G030 797
49 U027 003
A6E5212W011
REVERSE SWITCH
A6E5212W012
BA REVERSE SWITCH
PART SIDE CONNENTOR
A6E5212W013
Shift positionConnector terminal
AB:
Continuity
Reverse
Others
A6E5212W014

MANUAL TRANSAXLE
J2–7
J2
NEUTRAL SWITCH REMOVAL/INSTALLATIONA6E5212190102041. Remove the neutral switch.
2. Apply a light coat of silicone sealant to the screw
of the neutral switch.
Sealant
Three Bond product: TB1215
3. Install the neutral switch to the transaxle case.
Tightening torque
22.5—33.3 N·m
{2.29—3.40 kgf·m, 16.6—24.6 ft·lbf}
End Of Sie
MANUAL TRANSAXLE REMOVAL/INSTALLATIONA6E5212010292011. Remove the battery and battery tray.
2. Remove the air cleaner compornent. (See F2–36 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.)
3. Remove the air hose above the transaxle. (See F2–36 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.)
4. Remove the air pipe above the transaxle. (See F2–36 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.)
5. Remove the solenoid bracket.
6. Remove the wheels, tires and splash shields.
7. Remove the under cover.
8. Separate the steering hose.
9. Remove the steering gear and linkage, and pipe assembly installation bolts from the front crossmember, then
suspend the steering gear and linkage with a cable. (See N–8 STEERING GEAR AND LINKAGE (MZR-CD
(RF Turbo)) REMOVAL/INSTALLATION.)
Tightening torque
•Pipe assembly: 7.8—10.8 N·m {79.6—110.0 kgf·cm, 69.1—95.5 in·lbf}
10. Remove the front auto leveling sensor. (See Section T.)
11. Drain the transaxle oil into a suitable container.
12. Remove in the order indicated in the table.
13. Install in the reverse order of removal.
14. Adjust the headlight zeroset. (See Section T.)
15. Add the specified amount of specified transaxle oil. (See J2–4 TRANSAXLE OIL REPLACEMENT.)
16. Warm up the engine and transaxle, inspect for oil leakage, and inspect the transaxle operation.
NEUTRAL
SWITCH
A6E5212W015