diagram MAZDA 6 2002 Workshop Manual Suplement

VEHICLE IDENTIFICATION NUMBERS (VIN)
U.K. specs.
JMZ GG12R20# 100001—
JMZ GG12T20# 100001—
JMZ GG14R20# 100001—
JMZ GG14T20# 100001—
JMZ GY19320# 100001—
JMZ GY19820# 100001—
JMZ GY19F20# 100001—
JMZ GY19F50# 100001—
JMZ GY19R20# 100001—
JMZ GY19T20# 100001—
JMZ GY89370# 100001—
European (L.H.D.) specs.
JMZ GG12R2✻# 100001—
JMZ GG12T2✻# 100001—
JMZ GG14R2✻# 100001—
JMZ GG14T2✻# 100001—JMZ GY1932✻# 100001—
JMZ GY1982✻# 100001—
JMZ GY19F2✻# 100001—
JMZ GY19F5✻# 100001—
JMZ GY19R2✻# 100001—
JMZ GY19T2✻# 100001—
JMZ GY8937✻# 100001—
GCC specs.
JM7 GG32F✻✻# 100001—
JM7 GG42F✻✻# 100001—
JM7 GG34F✻✻# 100001—
JM7 GG44F✻✻# 100001—
JM7 GY49F✻✻# 100001—
JM7 GY39F✻✻# 100001—
JM7 GY49F✻0# 100001—
JM7 GY39F✻0# 100001—
RELATED MATERIALS
Mazda6 Training Manual
(European (L.H.D. U.K.), GCC specs.) . . . . . . . . . . . . 3359–1*–02C
Mazda6 Workshop Manual
(European (L.H.D. U.K.), GCC specs.) . . . . . . . . . . . . 1730–1*–02C
Engine Workshop Manual L8, LF, L3 . . . . . . . . . . . . . . 1731–1*–02C
Engine Workshop Manual MZR–CD (RF Turbo) . . . . . 1744–1E–02D
Manual Transaxle Workshop Manual G35M–R . . . . . . 1732–1*–02C
Manual Transaxle Workshop Manual A65M–R . . . . . . 1739–1E–02D
Automatic Transaxle Workshop Manual FN4A–EL . . . 1623–10–98E
Automatic Transaxle Workshop Manual
Supplement FN4A–EL . . . . . . . . . . . . . . . . . . . . . . . . . 1746–1*–02C
Automatic Transaxle Workshop Manual JA5A–EL . . . 1738–1E–02D
Automatic Transaxle Workshop Manual
Supplement JA5AX–EL . . . . . . . . . . . . . . . . . . . . . . . . 1765–1*–02H
Mazda6 Wiring Diagram
(European (L.H.D.), GCC specs.) . . . . . . . . . . . . . . . . 5558–1*–02G
Mazda6 Wiring Diagram
(U.K. specs.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5559–1*–02G
Mazda6 Bodyshop Manual
(European (L.H.D. U.K.), GCC specs.) . . . . . . . . . . . . 3360–1*–02C
Mazda6 Bodyshop Manual Supplement
(European (L.H.D. U.K.), GCC specs.) . . . . . . . . . . . . 3368–1*–02I
EOBD Training Manual
(European (L.H.D. U.K.), Australian specs.) . . . . . . . 3345–1*–00B
* : Indicates the printing location
E: Europe
0: Japan

E–1
E
ECOOLING SYSTEM
OUTLINE................................................................ E-2
OUTLINE OF CONSTRUCTION.......................... E-2
FEATURES .......................................................... E-2
SPECIFICATIONS ............................................... E-3
COOLING SYSTEM................................................ E-4
STRUCTURAL VIEW ........................................... E-4
COOLING FLOW DIAGRAM ............................... E-5
COOLING FAN .................................................... E-5
OUTLINE................................................................ E-6
SUPPLEMENTAL SERVICE INFORMATION ..... E-6
LOCATION INDEX ............................................... E-6
RADIATOR CAP..................................................... E-7
RADIATOR CAP INSPECTION ........................... E-7
ENGINE COOLANT................................................ E-8
ENGINE COOLANT LEAKAGE INSPECTION .... E-8
THERMOSTAT....................................................... E-9
THERMOSTAT REMOVAL/INSTALLATION ....... E-9
THERMOSTAT INSPECTION ........................... E-10
WATER PUMP...................................................... E-11
WATER PUMP REMOVAL/INSTALLATION...... E-11
FAN MOTOR........................................................ E-12
COOLING FAN MOTOR
REMOVAL/INSTALLATION ............................ E-12
COOLING FAN MOTOR INSPECTION ............. E-13 FEATURES
SERVICE

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
End Of Sie
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

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

F1–4
OUTLINE
CONTROL SYSTEM WIRING DIAGRAM (4WD)A6E390218881205With Immobilizer System
.
2Y
2Z
2AC
1AB
1Y
2K
2A
1J
1G
1M
2E
1P
2H
2U
2R
2P
2S
2D
2G
2J
2M4Z
4W
4AD
4AA
4G
4J
4A
4D
2X
4O
4B
4L
4F
4Q
2T
2Q
2W
4I
9
87
5
4
3
10
19
18
17
15
16
14
13
11
12
20
29
28
27
25
26
24
23
21
22
30
6
1
2
3132
A6E39022001
1 HO2S (front)
2 HO2S (rear)
3 TP sensor
4 MAP sensor
5 BARO sensor6ECT sensor
7 MAF/IAT sensor
8 IAT sensor
9 MAF sensor
10 Controller area network (CAN)

F1–10
FUEL SYSTEM
SYSTEM DIAGRAMA6E391201006203
.
End Of Sie
FUEL PUMP (TRANSFER)A6E391213350201Function
•The fuel tank for 4WD is saddle type. Fuel in the fuel gauge sender sub-unit side (right side) is pumped to the
left side of the fuel tank using the fuel pump (transfer).
Structure
•The fuel pump (transfer) is integrated into the fuel pump unit and it cannot be separately disassembled.
•The fuel pump (transfer) is composed of a relief valve and fuel jet pump.
87
5
4
3
6
1
2
:
9
10
A6E39122002
1 Filler cap
2 Pressure regulator
3 Fuel pump (transfer)
4 Fuel filter (high-pressure)
5Fuel pump6 Fuel filter (low-pressure)
7 Fuel pump unit
8 Pulsation damper
9 Fuel injector
10 Fuel flow

CONTROL SYSTEM
F1–17
F1
BLOCK DIAGRAMA6E394018880203
.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
1832
31
30
29
28
27
26
25
24
23
22
21
20
1933
34
35
36
37
38
39
40
41
42
43
44
45
46
A6E3940T001

F2–1
F2
F2FUEL AND EMISSION CONTROL SYSTEMS
[MZR-CD (RF Turbo)]
OUTLINE.............................................................. F2-3
OUTLINE OF CONSTRUCTION ....................... F2-3
FEATURES ........................................................ F2-3
SPECIFICATIONS ............................................. F2-3
CONTROL SYSTEM DIAGRAM ........................ F2-4
CONTROL SYSTEM WIRING DIAGRAM.......... F2-5
INTAKE-AIR SYSTEM.......................................... F2-8
OUTLINE ........................................................... F2-8
STRUCTURAL VIEW......................................... F2-9
FUEL SYSTEM................................................... F2-10
OUTLINE ......................................................... F2-10
STRUCTURAL VIEW....................................... F2-11
EXHAUST SYSTEM........................................... F2-13
OUTLINE ......................................................... F2-13
STRUCTURAL VIEW....................................... F2-13
EMISSION SYSTEM........................................... F2-14
OUTLINE ......................................................... F2-14
STRUCTURAL VIEW....................................... F2-15
WARM UP OXIDATION CATALYTIC
CONVERTER DESCRIPTION ...................... F2-16
CONTROL SYSTEM........................................... F2-16
OUTLINE ......................................................... F2-16
STRUCTURAL VIEW....................................... F2-18
BLOCK DIAGRAM ........................................... F2-20
CONTROL DEVICE AND CONTROL
RELATIONSHIP CHART .............................. F2-22
CRUISE CONTROL SYSTEM ......................... F2-23
CONTROLLER AREA NETWORK (CAN) ....... F2-24
ON-BOARD DIAGNOSTIC................................. F2-24
OUTLINE ......................................................... F2-24
DTC.................................................................. F2-24
KOEO/KOER SELF-TEST ............................... F2-26
PID/DATA MONITOR AND RECORD ............. F2-27
SIMULATION TEST ......................................... F2-27
LOCATION INDEX............................................. F2-28
INTAKE-AIR SYSTEM ..................................... F2-28
FUEL SYSTEM ................................................ F2-29
EMISSION SYSTEM........................................ F2-31
CONTROL SYSTEM........................................ F2-32
ENGINE TUNE-UP............................................. F2-34
ENGINE TUNE-UP PREPARATION ............... F2-34
IDLE SPEED INSPECTION ............................. F2-34
CORRECTION PROCEDURE ......................... F2-34
INTAKE-AIR SYSTEM........................................ F2-35
VACUUM TUBE ROUTING DIAGRAM............ F2-35
INTAKE-AIR SYSTEM
REMOVAL/INSTALLATION .......................... F2-36
AIR CLEANER ELEMENT INSPECTION ........ F2-37
TURBOCHARGER INSPECTION ................... F2-38
GUIDE BLADE ACTUATOR INSPECTION ..... F2-39
VARIABLE BOOST CONTROL (VBC)
SOLENOID VALVE INSPECTION ................ F2-40VARIABLE BOOST CONTROL (VBC)
CHECK VALVE INSPECTION ...................... F2-41
VARIABLE SWIRL CONTROL (VSC)
VALVE ACTUATOR INSPECTION ............... F2-41
VARIABLE SWIRL CONTROL (VSC)
SOLENOID VALVE INSPECTION ................ F2-42
GLOW PLUG REMOVAL/INSTALLATION ...... F2-42
GLOW PLUG INSPECTION ............................ F2-43
GLOW PLUG LEAD INSPECTION .................. F2-43
ACCELERATOR PEDAL COMPONENT
REMOVAL/INSTALLATION .......................... F2-44
ACCELERATOR PEDAL COMPONENT
DISASSEMBLY/ASSEMBLY ........................ F2-44
FUEL SYSTEM................................................... F2-45
BEFORE REPAIR PROCEDURE .................... F2-45
AFTER REPAIR PROCEDURE ....................... F2-45
FUEL TANK REMOVAL/INSTALLATION ........ F2-45
FUEL TANK INSPECTION .............................. F2-49
NONRETURN VALVE INSPECTION............... F2-50
FUEL FILTER COMPONENT
REMOVAL/INSTALLATION .......................... F2-50
FUEL FILTER COMPONENT
DISASSEMBLY/ASSEMBLY ........................ F2-51
FUEL WARMER INSPECTION........................ F2-51
SEDIMENTOR WATER DRAINING................. F2-52
SEDIMENTOR SWITCH INSPECTION ........... F2-52
SUPPLY PUMP REMOVAL/INSTALLATION .. F2-53
SUPPLY PUMP INSPECTION......................... F2-54
SUCTION CONTROL VALVE INSPECTION ... F2-54
COMMON RAIL INSPECTION ........................ F2-54
FUEL INJECTOR REMOVAL/INSTALLATION F2-55
FUEL INJECTOR INSPECTION ...................... F2-56
EXHAUST SYSTEM........................................... F2-57
EXHAUST SYSTEM INSPECTION ................. F2-57
EXHAUST SYSTEM
REMOVAL/INSTALLATION .......................... F2-57
EMISSION SYSTEM........................................... F2-59
EGR VALVE REMOVAL/INSTALLATION........ F2-59
EGR VALVE INSPECTION .............................. F2-59
EGR SOLENOID VALVE (VACUUM)
INSPECTION ................................................ F2-60
EGR SOLENOID VALVE (VENT)
INSPECTION ................................................ F2-60
EGR CONTROL SOLENOID VALVE
INSPECTION ................................................ F2-61
INTAKE SHUTTER VALVE ACTUATOR
INSPECTION ................................................ F2-62
INTAKE SHUTTER SOLENOID VALVE
INSPECTION ................................................ F2-63
CONTROL SYSTEM........................................... F2-64
PCM REMOVAL/INSTALLATION .................... F2-64
PCM INSPECTION .......................................... F2-65
PCM CONFIGURATION .................................. F2-68
CLUTCH SWITCH INSPECTION .................... F2-68
NEUTRAL SWITCH INSPECTION .................. F2-69
IDLE SWITCH INSPECTION ........................... F2-70
IDLE SWITCH ADJUSTMENT ......................... F2-71
ACCELERATOR POSITION SENSOR
INSPECTION ................................................ F2-72
ACCELERATOR POSITION SENSOR
ADJUSTMENT .............................................. F2-73 FEATURES
SERVICE

F2–4
OUTLINE
CONTROL SYSTEM DIAGRAMA6E400218881204
.
End Of Sie
5
4
3
6
1
2
8
7
910
13
11
12
19
18
17
1516
14
202928
27
25
26
24
2321
22
30
393837
35
3633
31
32
40
34
494847
45
464443
4142
50
54
515253
A
A
BB
A6E40022001
1 Air cleaner
2 Vacuum chamber
3 VBC check valve
4 MAF/IAT sensor
5 VBC solenoid valve
6 Vacuum damper
7 Guide blade actuator
8 Turbocharger
9 Charge air cooler
10 IAT sensor No.2
11 Boost sensor
12 Intake shutter valve actuator
13 Intake shutter solenoid valve (half)
14 Intake shutter solenoid valve (full)
15 EGR solenoid valve (vacuum)
16 EGR solenoid valve (vent)
17 EGR control solenoid valve
18 EGR valve
19 EGR water cooler
20 VSC valve actuator
21 VSC solenoid valve
22 Fuel tank
23 Fuel filter
24 Fuel warmer
25 Supply pump
26 Suction control valve
27 Fuel temperature sensor28 Common rail
29 Fuel pressure sensor
30 Fuel pressure limiter
31 Glow plug
32 Fuel injector
33 ECT sensor
34 Calibration resistor
35 CMP sensor
36 Warm up oxidation catalytic converter
37 Oxidation catalytic converter
38 Silencer
39 Vacuum pump
40 CKP sensor
41 Idle switch
42 Accelerator position sensor
43 Glow plug relay
44 IDM
45 PCM
46 BARO sensor
47 PCM control relay
48 Engine switch
49 Starter (starter signal)
50 Neutral switch
51 Clutch switch
52 A/C switch
53 CAN bus
54 To PCM