engine MAZDA 6 2002 Suplement Repair Manual

OUTLINE
E–3
E
SPECIFICATIONSA6E360202000209Gasoline engine
Bold frames: New specifications
Diesel engine
Bold frames: New specifications
End Of Sie
ItemSpecification
New
Mazda6
(GG, GY)Current
Mazda6
(GG)New
Mazda6
(GG, GY)Current
Mazda6
(GG)New
Mazda6
(GG, GY)Current
Mazda6
(GG)
L8 LF L3
Cooling system Water-cooled
Coolant capacity
(approximate quantity)(L {US qt, lmp qt}) 7.5 {7.9, 6.6}
Water pump TypeCentrifugal,
V-ribbed belt-driven
ThermostatTypeWax,
Bottom-bypass
Opening temperature (°C {°F}) 80—84 {176—183}
Full-open temperature (°C {°F}) 97 {206}
Full-open lift (mm {in}) More than 8.0 {0.31}
RadiatorType Corrugated fin
Cap valve opening pressure
113—142
{1.15—1.44, 16.4—20.4}
(kPa {kgf/cm
2, psi})
Cooling fanType Electric
BladeOuter
diameter(mm {in}) 300 {11.8} 320 {12.6}
Number of
blade(sheet)Cooling fan No.1: 5
Cooling fan No.2: 7Cooling fan No.1: 7
Cooling fan No.2: 5
ItemSpecification
New Mazda6
(GG, GY)Current Mazda 323
(BJ)
MZR-CD (RF Turbo) RF Turbo
Cooling system Water-cooled
Coolant capacity
(approximate quantity)(L {US qt, lmp qt}) 9.0 {9.5, 7.9}
Water pump TypeCentrifugal,
Timing-belt driven
ThermostatType Wax, Bottom-bypass
Opening temperature (°C {°F}) 80—84 {176—183}
Full-open temperature (°C {°F}) 95 {203}
Full-open lift (mm {in}) More than 8.5 {0.33}
RadiatorType Corrugated fin
Cap valve opening pressure
94—122
{0.96—1.24, 13.7—17.6}
(kPa {kgf/cm
2, psi})
Cooling fanType Electric
BladeOuter
diameter(mm {in}) 320 {12.6} 300 {11.9}
Number of
blade(sheet)Cooling fan No.1: 7
Cooling fan No.2: 54

E–4
COOLING SYSTEM
STRUCTURAL VIEWA6E363002000201MZR-CD (RF Turbo)
.
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COOLING SYSTEM
8
75
4
3
1
2
6
10
11
11
9
1312
A6E3602W201
1 To water heater system
2 Radiator
3 Coolant reservoir tank
4Thermostat
5 Water pump
6 Cylinder head
7 Cylinder block8 Engine oil cooler
9EGR water cooler
10 To cylinder head
11 To cylinder block
12 Turbocharger
13 Water outlet

COOLING SYSTEM
E–5
E
COOLING FLOW DIAGRAMA6E363002000202MZR-CD (RF Turbo)
.
End Of SieCOOLING FANA6E363002000204 MZR-CD (RF Turbo)
Structure
•Electric cooling fans No.1 and No.2, operated according to a cooling fan control signal from the PCM, have
been adopted. Due to this, engine noise is reduced and rapid warm-up is possible.
•Cooling fans No.1 and No.2 are attached to the radiator cowling.
•The cooling fan motor output has been changed.
Cooling fan, Fan motor specification
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9
8
7
5
4
3
1
2
10
13
11
12
6
A6E3600W300
1Radiator
2 Coolant reservoir tank
3 Water outlet
4EGR water cooler
5 Engine oil cooler
6 Cylinder head
7 Cylinder block8 Turbocharger
9 Water pump
10 Thermostat case
11 Thermostat cover
12 Water heater system
13 Heater core
ITEM Specification
Cooling fan No.1Fan Number of blades (sheet) 7
Motor Motor output (W) 70
Cooling fan No.2Fan Number of blades (sheet) 5
Motor Motor output (W) 80

E–6
OUTLINE
SUPPLEMENTAL SERVICE INFORMATIONA6E360202000208•The following changes and/or additions have been made since publication of the Mazda6 Workshop Manual
(1730-1*-02C).
Radiator cap
•Inspection procedure has been added. (MZR-CD (RF Turbo) engine model)
Thermostat
•Removal/Installation procedure has been added. (MZR-CD (RF Turbo) engine model)
•Inspection procedure has been added. (MZR-CD (RF Turbo) engine model)
Water pump
•Removal/Installation procedure has been added. (MZR-CD (RF Turbo) engine model)
Fan motor
•Removal/Installation procedure has been added. (MZR-CD (RF Turbo) engine model)
•Inspection procedure has been added. (MZR-CD (RF Turbo) engine model)
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LOCATION INDEXA6E360202000210MZR-CD (RF Turbo)
.
End Of Sie
OUTLINE
4
3
1
2
A6E3602W202
1 Radiator cap
(See E–7 RADIATOR CAP INSPECTION)
2Thermostat
(See E–9 THERMOSTAT REMOVAL/
INSTALLATION)
(See E–10 THERMOSTAT INSPECTION)3 Water pump
(See E–11 WATER PUMP REMOVAL/
INSTALLATION)
4 Cooling fan motor
(See E–12 COOLING FAN MOTOR REMOVAL/
INSTALLATION)
(See E–13 COOLING FAN MOTOR INSPECTION)

RADIATOR CAP
E–7
E
RADIATOR CAP INSPECTIONA6E361415201201MZR-CD (RF Turbo)
Warning
•Never remove the radiator cap while the engine is running, or when the engine and radiator are
hot. Scalding coolant and steam may shoot out and cause serious injury. It may also damage the
engine and cooling system.
•Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap.
Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while
the pressure escapes.
•When you are sure all the pressure is gone, press down on the cap using the cloth, turn it, and
remove it.
1. Clean the radiator cap negative pressure valve and the sealed part.
2. Inspect the crack or turn over on the sealed part of the radiator cap.
•If not as specified, repace the radiator cap.
3. Fill the SST with the water or the engine coolant to the full level and attach the radiator cap to the SST.
4. Hold the radiator cap downward and apply pressure gradually. Verify that the pressure become held for 10 s
within the specification.
•If the pressure is not held stable within the specification, replace the radiator cap.
Pressure
94—122 kPa
{0.96—1.24 kgf/cm
2, 13.7—17.6 psi}
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RADIATOR CAP
RADIATOR CAP49 9200 145
A6E3614W201

E–8
ENGINE COOLANT
ENGINE COOLANT LEAKAGE INSPECTIONA6E361215201201MZR-CD (RF Turbo)
Warning
•Never remove the radiator cap while the engine is running, or when the engine and radiator are
hot. Scalding coolant and steam may shoot out and cause serious injury. It may also damage the
engine and cooling system.
•Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap.
Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while
the pressure escapes.
•When you are sure all the pressure is gone, press down on the cap using the cloth, turn it, and
remove it.
1. Inspect the coolant level.
2. Remove the radiator cap.
3. Clean the mounting surface of the rediator cap and the upper radiator hose.
4. Connect the SST to the reservoir filler port.
5. Apply specified pressure to the radiator.
Pressure
122 kPa { 1.24 kgf/cm
2, 17.6 psi}
6. Verify that the pressure is held.
•If not, inspect the system for coolant leakage.
—If the coolant leaks from the upper hose
attachment part, replace the upper hose
and the clamp.
—If the coolant leaks from the main body of
the radiator (caulked part), replace the
radiator.
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ENGINE COOLANT
49 9200 145
A6E3612W200

THERMOSTAT
E–9
E
THERMOSTAT REMOVAL/INSTALLATIONA6E361815171201MZR-CD (RF Turbo)
1. Disconnect the negative battery cable.
2. Remove the under cover.
3. Drain the engine coolant.
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.
6. Fill the radiator with the specified amount and type of engine coolant.
7. Inspect the engine coolant leakage. (See E–8 ENGINE COOLANT LEAKAGE INSPECTION.)
Thermostat Installation Note
1. Verify that the positions of the jiggle pin and the projection on the gasket are as shown.
2. Install the thermostat into the thermostat case, aligning the projection on the gasket to the thermostat cover.
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THERMOSTAT
1 Lower radiator hose
2 Thermostat cover
3Thermostat
(See E–9 Thermostat Installation Note )
3
1
2
7.9—10.7 N·m
{80—110 kgf·cm,
69.5—95.4 in·lbf}
A6E3618W100
THERMOSTAT
COVER
GASKET
PROJECTIONJIGGLE PIN
A6A3618W101

WATER PUMP
E–11
E
WATER PUMP REMOVAL/INSTALLATIONA6E362015010201MZR-CD (RF Turbo)
1. Disconnect the negative battery cable.
2. Remove the under cover.
3. Drain the engine coolant.
4. Remove the timing belt. (See B2–9 TIMING BELT REMOVAL/INSTALLATION.)
5. Remove the thermostat. (See E–9 THERMOSTAT REMOVAL/INSTALLATION.)
6. Remove in the order indicated in the table.
7. Install in the reverse order of removal.
8. Insect the drive belt. (See B2–4 DRIVE BELT INSPECTION.)
9. Fill the radiator with the specified amount and type of engine coolant.
10. Inspect the engine coolant leakage. (See E–8 ENGINE COOLANT LEAKAGE INSPECTION.)
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WATER PUMP
3
1
2
1
19—25
{1.9—2.6, 14—18}
N·m {kgf·m, ft·lbf} 38—51
{3.8—5.3, 28—38}
7.9—10.7 N·m
{80—110 kgf·cm, 69.5—95.4 in·lbf} 38—51
{3.8—5.3, 28—38}
R
R
A6E3620W100
1Hose
2 Water pump
3 Thermostat case

F1–1
F1
F1FUEL AND EMISSION CONTROL SYSTEM
[L8, LF, L3]
OUTLINE.............................................................. F1-2
OUTLINE OF CONSTRUCTION ....................... F1-2
FEATURES ........................................................ F1-2
SPECIFICATIONS ............................................. F1-2
CONTROL SYSTEM DIAGRAM (4WD)............. F1-3
CONTROL SYSTEM WIRING DIAGRAM
(4WD).............................................................. F1-4
FUEL SYSTEM..................................................... F1-9
OUTLINE ........................................................... F1-9
STRUCTURAL VIEW......................................... F1-9
SYSTEM DIAGRAM ........................................ F1-10
FUEL PUMP (TRANSFER).............................. F1-10
QUICK RELEASE CONNECTOR (FUEL TANK
SIDE, TRANSFER HOSE PART) ................. F1-12
EXHAUST SYSTEM........................................... F1-13
OUTLINE ......................................................... F1-13
STRUCTURAL VIEW....................................... F1-13
CONTROL SYSTEM........................................... F1-14
OUTLINE ......................................................... F1-14
STRUCTURAL VIEW (4WD) ........................... F1-16
BLOCK DIAGRAM ........................................... F1-17
CONTROL DEVICE AND CONTROL
RELATIONSHIP CHART .............................. F1-19
CONTROLLER AREA NETWORK (CAN) ....... F1-21
OUTLINE............................................................ F1-22
SUPPLEMENTAL SERVICE
INFORMATION ............................................. F1-22
ENGINE TUNE-UP............................................. F1-22
IDLE SPEED INSPECTION (4WD) ................. F1-22
FUEL SYSTEM................................................... F1-23
FUEL TANK REMOVAL/INSTALLATION ........ F1-23
FUEL PUMP UNIT
REMOVAL/INSTALLATION .......................... F1-26
FUEL HOSE (FUEL TANK SIDE,
TRANSFER HOSE PART)
REMOVAL/INSTALLATION .......................... F1-29
EXHAUST SYSTEM........................................... F1-30
EXHAUST SYSTEM
REMOVAL/INSTALLATION .......................... F1-30
CONTROL SYSTEM........................................... F1-33
PCM INSPECTION (4WD)............................... F1-33
ON-BOARD DIAGNOSTIC................................. F1-50
OUTLINE ......................................................... F1-50
CONTROL DEVICE AND MONITORING
SYSTEM RELATIONSHIP CHART .............. F1-50
DIAGNOSTIC TEST MODE (4WD) ................. F1-50
DTC (4WD) ...................................................... F1-52
OBD DRIVE MODE ......................................... F1-52
DTC TABLE ..................................................... F1-54
TROUBLESHOOTING........................................ F1-57ENGINE SYMPTOM
TROUBLESHOOTING .................................. F1-57
QUICK DIAGNOSTIC CHART ......................... F1-58
NO.14 POOR FUEL ECONOMY ..................... F1-62
NO.22 VIBRATION CONCERNS
(ENGINE) ...................................................... F1-64 FEATURES
SERVICE

OUTLINE
F1–3
F1
CONTROL SYSTEM DIAGRAM (4WD)A6E390218881204
.
* : Equipped for L3 engine modelEnd Of Sie
9
8
7
54
3
10
19
18
17
15
16
14
13
11
12
20
29
28
27
25
26
24
23
21
22
30
3938
3735
33
36
31
32
40
6
1
2
3441
A6E39022000
1PCM
2 Ignition coil
3 Generator
4* VAD shutter valve
5 Air cleaner
6 MAF sensor
7* VAD shutter valve actuator
8* VAD control solenoid valve
9* Vacuum chamber
10* VAD check valve (one-way)
11 IAC valve
12 Purge solenoid valve
13 TP sensor
14 MAP sensor
15* VIS control solenoid valve
16 Variable tumble control solenoid valve
17* VIS shutter valve actuator
18* VIS shutter valve
19 VTCS shutter valve actuator
20 VTCS shutter valve
21 Fuel injector22* OCV
23 CMP sensor
24 EGR valve
25 Knock sensor
26 ECT sensor
27 PCV valve
28 CKP sensor
29 HO2S (front)
30 HO2S (rear)
31 Charcoal canister
32 Check valve (two-way)
33 Pressure regulator
34 Fuel filter (high-pressure)
35 Fuel pump
36 Fuel filter (low-pressure)
37 Fuel tank
38 Rollover valve
39 Pulsation damper
40 Fuel pump (transfer)
41 To PCM