Mazda 6 2002 Training Manual

Full download: http://manualplace.com/download/mazda-6-2002-training-manual/

Mazda6 CONTENTS

Training Title Section

Manual General Information

Engine
GI

Lubrication System D

FOREWORD Cooling System E

This manual explains each component or
system operation and function for Fuel and Emission Control Systems F
the Mazda6.
Engine Electrical System G
For proper repair and maintenance,
a thorough familiarization with this manual Clutch H
is important, and it should always be kept
in a handy place for quick and easy Manual Transaxle J
reference.
Automatic Transaxle K
All the contents of this manual, including Front and Rear Axles M
drawings and specifications, are the latest
available at the time of printing. Steering System N
As modifications affecting repair or
maintenance occur, relevant information Braking System P
supplementary to this volume will be made
available at Mazda dealers. This manual Suspension R
should be kept up-to-date.
Body S
Mazda Motor Corporation reserves
the right to alter the specifications and Body Electrical System T
contents of this manual without obligation
or advance notice. Heater and Air Conditioner Systems U
All rights reserved. No part of this book
may be reproduced or used in any form or © 2002 Mazda Motor Corporation
by any means, electronic or PRINTED IN The Netherlands, MARCH 2002
mechanical—including photocopying and 3359–1E–02C
recording and the use of any kind of
information storage and retrieval
system—without permission in writing.

Mazda Motor Corporation

HIROSHIMA, JAPAN

APPLICATION:
This manual is applicable to vehicles
beginning with the Vehicle Identification
Numbers (VIN) shown on the following
page.

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 VEHICLE IDENTIFICATION NUMBERS (VIN)

U.K. specs.
JMZ GG12820# 100001—
JMZ GG14320# 100001—
JMZ GG14820# 100001—
JMZ GG12F20# 100001—
JMZ GG12F50# 100001—
JMZ GG14F20# 100001—
JMZ GG14F50# 100001—

European (L.H.D.) specs.

JMZ GG1232✻# 100001—
JMZ GG1282✻# 100001—
JMZ GG1432✻# 100001—
JMZ GG1482✻# 100001—
JMZ GG12F2✻# 100001—
JMZ GG12F5✻# 100001—
JMZ GG14F2✻# 100001—
JMZ GG14F5✻# 100001—

GCC specs.
JM7 GG32F✻✻# 100001—
JM7 GG34F✻✻# 100001—
JM7 GG42F✻✻# 100001—
JM7 GG44F✻✻# 100001—

RELATED MATERIALS

Engine Workshop Manual L8, LF, L3 . . . . . . . . . . . . . . 1731–1*–02C

Manual Transaxle Workshop Manual
G35M–R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1732–1*–02C
Automatic Transaxle Workshop Manual
FN4A–EL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1623–10–98E
Automatic Transaxle Workshop Manual
Supplement FN4A–EL . . . . . . . . . . . . . . . . . . . . . . . . . 1746–1*–02C
Mazda6 Wiring Diagram
(European (L.H.D.), GCC specs.) . . . . . . . . . . . . . . . . 5539–1*–02C
Mazda6 Wirinig Diagram
(U.K. specs.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5540–1*–02C
Mazda6 Bodyshop Manual
(European (L.H.D. U.K.), GCC specs.) . . . . . . . . . . . . 3360–1*–02C
* : Indicates the printing location
E: Europe
0: Japan
GENERAL INFORMATION
G
I
GI

HOW TO USE THIS MANUAL ............................. GI-2

VIN CODE.......................................................... GI-2
UNITS ................................................................... GI-4
UNITS TABLE .................................................... GI-4
NEW STANDARDS .............................................. GI-5
NEW STANDARDS TABLE ............................... GI-5

GI–1
 HOW TO USE THIS MANUAL

HOW TO USE THIS MANUAL

VIN CODE
A6E201000001T01
European (L.H.D. U.K.) specs.

A6E2021T001

GI–2
 HOW TO USE THIS MANUAL
GCC specs.

GI

A6E2021T002

End Of Sie

GI–3
 UNITS

UNITS
UNITS TABLE
A6E201200002T01

Electrical current A (ampere)

Electric power W (watt)
Electric resistance ohm
Electric voltage V (volt)
mm (millimeter)
Length
in (inch)
kPa (kilo pascal)
Negative pressure mmHg (millimeters of mercury)
inHg (inches of mercury)
kPa (kilo pascal)

Positive pressure kgf/cm2 (kilogram force per square

centimeter)
psi (pounds per square inch)
N·m (Newton meter)
kgf·m (kilogram force meter)
Torque kgf·cm (kilogram force centimeter)
ft·lbf (foot pound force)
in·lbf (inch pound force)
L (liter)
US qt (U.S. quart)
Imp qt (Imperial quart)
Volume ml (milliliter)
cc (cubic centimeter)
cu in (cubic inch)
fl oz (fluid ounce)
g (gram)
Weight
oz (ounce)

Conversion to SI Units (Système International d'Unités)

• All numerical values in this manual are based on SI units. Numbers shown in conventional units are converted
from these values.

Rounding Off
• Converted values are rounded off to the same number of places as the SI unit value. For example, if the SI unit
value is 17.2 and the value after conversion is 37.84, the converted value will be rounded off to 37.8.

Upper and Lower Limits

• When the data indicates upper and lower limits, the converted values are rounded down if the SI unit value is
an upper limit and rounded up if the SI unit value is a lower limit. Therefore, converted values for the same SI
unit value may differ after conversion. For example, consider 2.7 kgf/cm2 in the following specifications:

210—260 kPa {2.1—2.7 kgf/cm2, 30—38 psi}

270—310 kPa {2.7—3.2 kgf/cm2, 39—45 psi}

• The actual converted values for 2.7 kgf/cm2 are 265 kPa and 38.4 psi. In the first specification, 2.7 is used as
an upper limit, so the converted values are rounded down to 260 and 38. In the second specification, 2.7 is
used as a lower limit, so the converted values are rounded up to 270 and 39.
End Of Sie

GI–4
 NEW STANDARDS

NEW STANDARDS
GI
NEW STANDARDS TABLE
A6E202800020T01
• Following is a comparison of the previous standard and the new standard.
New Standard Previous Standard
Abbrevi- Abbrevi- Remark
Name Name
ation ation
AP Accelerator Pedal — Accelerator Pedal
ACL Air Cleaner — Air Cleaner
A/C Air Conditioning — Air Conditioning
BARO Barometric Pressure — Atmospheric Pressure
B+ Battery Positive Voltage Vb Battery Voltage
— Brake Switch — Stoplight Switch
— Calibration Resistor — Corrected Resistance #6
CMP sensor Camshaft Position Sensor — Crank Angle Sensor
CAC Charge Air Cooler — Intercooler
CLS Closed Loop System — Feedback System
CTP Closed Throttle Position — Fully Closed
CPP Clutch Pedal Position — Clutch Position
CIS Continuous Fuel Injection System EGI Electronic Gasoline Injection System
CS sensor Control Sleeve Sensor CSP sensor Control Sleeve Position Sensor #6
CKP sensor Crankshaft Position Sensor — Crank Angle Sensor 2
DLC Data Link Connector — Diagnosis Connector
DTM Diagnostic Test Mode — Test Mode #1
DTC Diagnostic Trouble Code(s) — Service Code(s)
DI Distributor Ignition — Spark Ignition
DLI Distributorless Ignition — Direct Ignition
EI Electronic Ignition — Electronic Spark Ignition #2
ECT Engine Coolant Temperature — Water Thermo
EM Engine Modification — Engine Modification
— Engine Speed Input Signal — Engine RPM Signal
EVAP Evaporative Emission — Evaporative Emission
EGR Exhaust Gas Recirculation — Exhaust Gas Recirculation
FC Fan Control — Fan Control
FF Flexible Fuel — Flexible Fuel
4GR Fourth Gear — Overdrive
— Fuel Pump Relay — Circuit Opening Relay #3
FSO
Fuel Shut Off Solenoid FCV Fuel Cut Valve #6
solenoid
GEN Generator — Alternator
GND Ground — Ground/Earth
HO2S Heated Oxygen Sensor — Oxygen Sensor With heater
IAC Idle Air Control — Idle Speed Control
— IDM Relay — Spill Valve Relay #6
— Incorrect Gear Ratio — —
— Injection Pump FIP Fuel Injection Pump #6
— Input/Turbine Speed Sensor — Pulse Generator
IAT Intake Air Temperature — Intake Air Thermo
KS Knock Sensor — Knock Sensor
MIL Malfunction Indicator Lamp — Malfunction Indicator Light
MAP Manifold Absolute Pressure — Intake Air Pressure
MAF sensor Mass Air Flow Sensor — Airflow Sensor
MFL Multiport Fuel Injection — Multiport Fuel Injection
OBD On-Board Diagnostic — Diagnosis/SelfDiagnosis
OL Open Loop — Open Loop

GI–5
 NEW STANDARDS
New Standard Previous Standard
Abbrevi- Abbrevi- Remark
Name Name
ation ation
— Output Speed Sensor — Vehicle Speed Sensor 1
OC Oxidation Catalytic Converter — Catalytic Converter
O2S Oxygen Sensor — Oxygen Sensor
PNP Park/Neutral Position — Park/Neutral Range
— PCM Control Relay — Main Relay #6
PSP Power Steering Pressure — Power Steering Pressure
PCM Powertrain Control Module ECU Engine Control Unit #4
— Pressure Control Solenoid — Line Pressure Solenoid Valve
Pulsed
PAIR Pulsed Secondary Air Injection — Secondary Air Injection System
injection
— Pump Speed Sensor — NE Sensor #6
Injection
AIR Secondary Air Injection — Secondary Air Injection System with air
pump
SAPV Secondary Air Pulse Valve — Reed Valve
SFI Sequential Multipoint Fuel Injection — Sequential Fuel Injection
— 1-2 Shift Solenoid Valve
— Shift Solenoid A
— Shift A Solenoid Valve
— 2-3 Shift Solenoid Valve
— Shift Solenoid B
— Shift B Solenoid Valve
— Shift Solenoid C — 3-4 Shift Solenoid Valve
3GR Third Gear — 3rd Gear
TWC Three Way Catalytic Converter — Catalytic Converter
TB Throttle Body — Throttle Body
TP sensor Throttle Position Sensor — Throttle Sensor
TCV Timer Control Valve TCV Timing Control Valve #6
TCC Torque Converter Clutch — Lockup Position
Transmission (Transaxle) Control
TCM — ECAT Control Unit
Module
Transmission (Transaxle) Fluid
— — ATF Thermosensor
Temperature Sensor
TR Transmission (Transaxle) Range — Inhibitor Position
TC Turbocharger — Turbocharger
VSS Vehicle Speed Sensor — Vehicle Speed Sensor
VR Voltage Regulator — IC Regulator
VAF sensor Volume Air Flow Sensor — Air flow Sensor
Warm Up Three Way Catalytic
WUTWC — Catalytic Converter #5
Converter
WOT Wide Open Throttle — Fully Open

#1 : Diagnostic trouble codes depend on the diagnostic test mode

#2 : Controlled by the PCM
#3 : In some models, there is a fuel pump relay that controls pump speed. That relay is now called the fuel pump
relay (speed).
#4 : Device that controls engine and powertrain
#5 : Directly connected to exhaust manifold
#6 : Part name of diesel engine

End Of Sie

GI–6
ENGINE
B

ABBREVIATIONS ..................................................B-2
ABBREVIATIONS ................................................ B-2
OUTLINE ................................................................ B-2
OUTLINE OF CONSTRUCTION.......................... B-2
FEATURES .......................................................... B-2
ENGINE PERFORMANCE CURVE..................... B-3
SPECIFICATIONS ............................................... B-4
STRUCTURAL VIEW...........................................B-4
ENGINE .................................................................. B-5
CYLINDER HEAD COVER .................................. B-5
CYLINDER HEAD ............................................... B-5
CYLINDER HEAD GASKET ................................ B-6
CYLINDER BLOCK ............................................. B-6
CRANKSHAFT, MAIN BEARING......................... B-8
BALANCER UNIT ................................................ B-9
CRANKSHAFT PULLEY .................................... B-11
ENGINE FRONT COVER .................................. B-12
PISTON, PISTON RING, PISTON PIN .............. B-13
CONNECTING ROD,
CONNECTING ROD BEARING...................... B-14
DRIVE BELT ...................................................... B-15
ENGINE MOUNT ............................................... B-16
VALVE MECHANISM ........................................... B-19
VALVE MECHANISM......................................... B-19
CAMSHAFT ....................................................... B-20
CAMSHAFT SPROCKET................................... B-22
CRANKSHAFT SPROCKET .............................. B-23
TIMING CHAIN, CHAIN TENSIONER ............... B-24
VALVE, VALVE SPRING, VALVE SEAL,
VALVE GUIDE ................................................ B-25
TAPPET ............................................................. B-26
VALVE MECHANISM......................................... B-27
VARIABLE VALVE TIMING ACTUATOR........... B-33
OIL CONTROL VALVE (OCV) ........................... B-33

B–1
 ABBREVIATIONS , OUTLINE

ABBREVIATIONS
ABBREVIATIONS
A6E220102000T01

A/C Air conditioner

ABDC After bottom dead center
ATDC After top dead center
BBDC Before bottom dead center
BTDC Before bottom dead center
DOHC Double overhead camshaft
EX Exhaust
IN Intake
OCV Oil control valve
P/S Power steering
PCV Positive crankcase ventilation
SST Special service tool
TDC Top dead center

End Of Sie

OUTLINE
OUTLINE OF CONSTRUCTION
A6E220202000T01
• The new L8 engine models (1.8L) has been adopted for European specs.
• The new LF engine models (2.0L) has been adopted.
• The new L3 (with variable valve timing mechanism) engine models (2.3L) has been adopted for European
specs.
End Of Sie
FEATURES
A6E220202000T02
Improved engine performance
• The variable valve timing mechanism has been adopted for L3 engine models (2.3L).

Reduced engine weight

• Main parts (cylinder head and cylinder block) made of aluminum alloy.

Reduced engine noise and vibration

• The cylinder head is made of aluminum alloy.
• The cassette type balancer unit has been adopted for the L3 engine models (2.3L).
• Silent timing chain has been adopted.
• A deep skirt type and forms the ladder frame structure with the integrated main bearing cap has been adopted
for the cylinder block.
• The crankshaft pulley with torsional damper has been adopted.
• The engine mount of pendulum type has been adopted.

Improved serviceability
• The drive belt of serpentine type has been adopted.
• Tension of the drive belt is adjusted automatically with an auto-tensioner.
• Timing chains have been adopted to eliminate the need for replacement.
• The engine front cover with service hole has been adopted. (for unlocking the chain adjust ratchet, and
securing the tensioner arm).
End Of Sie

B–2
 OUTLINE
ENGINE PERFORMANCE CURVE
A6E220202000T04

AME2202N001

1 Engine speed 2 Output

3 Torque

B–3
 OUTLINE
End Of Sie
SPECIFICATIONS
A6E220202000T03

Specification
Item
L8 LF L3
Type Gasoline, 4-cycle
Cylinder arrangement and number In-line, 4-cylinder
Combustion chamber Pentroof
Valve system DOHC, timing chain driven, 16 valves
1,798 1,999 2,261
Displacement (ml {cc, cu in})
{1,798, 109.7} {1,999, 121.9} {2,261, 137.9}
83.0 × 83.1 87.5 × 83.1 87.5 × 94.0
Bore × stroke (mm {in})
{3.27 ×3.27} {3.44 ×3.27} {3.44 × 3.70}
Compression ratio 10.8:1 10.8:1 10.6:1
1,750 {17.85, 253.8} 1,720 {17.54, 1,430 {14.58, 207.4}
Compression pressure (kPa {kgf/cm2, psi} [rpm]) [300] 249.5} [300] [290]
Open BTDC (°) 4 4 0—25
IN
Close ABDC (°) 33 52 0—37
Valve timing
Open BBDC (°) 37 37 42
EX
Close ATDC (°) 4 4 5
Valve IN 0.22 {0.0087}— 0.28 {0.011} [Engine cold]
(mm {in})
clearance EX 0.27 {0.011}— 0.33 {0.012} [Engine cold]

End Of Sie
STRUCTURAL VIEW
A6E220202000T05

AME2202N002

End Of Sie

B–4
 ENGINE

ENGINE
CYLINDER HEAD COVER
A6E222410100T01
Structure B
• The cylinder head cover is made of integrated aluminum alloy, which is lightweight and sound absorbent.
• The oil filler cap is a screw-in type. The boss for installing the camshaft position (CMP) sensor is provided at
the rear of the cylinder head cover.
• L3 engine models has a hole for installing the oil control (OCV) valve.

AME2224N001
.

1 Camshaft position (CMP) sensor 3 Oil filler cap

2 Oil control (OCV) valve attachment hole (L3)

End Of Sie
CYLINDER HEAD
A6E222410100T02
Structure
• The cylinder head is made of a high heat conductive, lightweight aluminum alloy, which has been quenched.
• Compact, pentroof-type combustion chambers have been adopted. The spark plugs are mounted at the top of
the combustion chambers to improve combustion efficiency.
• The intake/exhaust port layout is a cross flow type, (the angle between two valves is 39°, the two intake valves
and the two exhaust valves per cylinder) which improves air intake/exhaust efficiency.
• The cylinder head bolt is a plastic region tightening bolt, which is tightened in five motions. It insures a stable
axis during tightening.

AME2224N002
.

1 Cylinder head bolt 5 The angle between two valves

2 Exhaust side 6 Intake port
3 Intake side 7 Exhaust port
4 Engine front side
B–5
 ENGINE
End Of Sie HEAD GASKET
CYLINDER
A6E222410271T01
Structure
• Cylinder head gaskets are 2 layer-metal gaskets.

AME2224N400
.

1 Beat plate 3 A-A sectional view

2 Shim

End Of Sie
CYLINDER BLOCK
A6E222410300T01
Structure
• The cylinder block is made of aluminum alloy, which is cast with the cast iron liner, improving heat radiation and
decreasing weight.
• The cylinder block is a deep skirt type and forms the ladder frame structure with the integrated main bearing
cap. The water jacket of the cylinder block is a closed deck type. Its higher rigidity reduces vibration and noise.
• The cylinder block has the oil separator cover on the opposite side of the fresh air intake, the PCV (positive
crankcase ventilation) valve and the oil separator function with an part for installing the PCV valve, to improve
blow-by gas ventilation efficiency.
• The tab for alignment, used to install the upper main journal and the lower main bearing, has been
decommissioned.
• The main bearing cap bolt is a plastic region tightening bolt, which is to be tightened in two motions. It insures
a stable axis during tightening.

B–6
 ENGINE

AME2224N003
.

1 Oil separator cover 4 Oil separator cover attachment part

2 PCV valve 5 Cylinder block
3 Main bearing cap

• The service hole for installing the SST, which is used for detect the No.1 cylinder's TDC position, is located at
the right side of the cylinder block. The TDC position can be detected when the SST edge touches the cutting
surface of the No.1 counter weight.
.

1 Cylinder block
2 No.1 cylinder
3 Service hole
4 SST
5 No.1 cylinder TDC position
6 No.1 piston
7 Crankshaft counter

AME2224N004

B–7
 ENGINE
End Of Sie
CRANKSHAFT, MAIN BEARING
A6E222411301T01
Structure
• Cast iron 5 axle-hole 4 counter weight has been adopted for the L8 engine models and LF engine models
crankshafts.
• Cast iron 5 axle-hole 8 counter weight has been adopted for the L3 engine models crankshaft. The shrinkage
fitted drive gear is attached to the crankshaft and the crankshaft drives the balance shaft.
• The conventional positioning key has been decommissioned and the tightening pressure of the crankshaft
pulley tightening bolt secures the installation part of the crankshaft sprocket. When installing the crankshaft
sprocket, always use the SST and align the No.1 cylinder to TDC.

AME2224N005
.

1 Drive gear

• The oil line for supplying oil to each journal is provided in the crankshaft. And the crank pin and the fillets on
both sides of journal are rolled so that they bear the heavy loads.

AME2224N006
.

1 Oil passage 2 Fillet roll area

• The upper and lower main bearings are made of aluminum alloy and the upper side No.3 journal bearing is
integrated with the thrust bearing. The upper main bearing has the oil grooves and the oil holes.
• The upper and lower bearings' positioning tabs for installing the main journal have been decommissioned.
• Measure and attach the main bearings (upper and lower) so that they are positioned at the center the main
bearing cap.

B–8
 ENGINE

AME2224N007
.

1 Upper main bearing 5 2 holes Supplying engine oil

2 Lower main bearing 6 Main bearing cap
3 Thrust bearing 7 Main bearing
4 Supplying engine oil

• Three kinds of main bearings are available depending on the oil clearance.

(mm {in})
Bearing
Color Bearing thickness
size
Standard Green 2.506—2.509 {0.0987—0.0988}
0.25 {0.01}
2.628—2.634 {0.1035—0.1037}
Oversize
0.50 {0.02}
2.753—2.759 {0.1084—0.1086}
Oversize

End Of Sie
BALANCER UNIT
A6E222411301T02
Outline
• The cassette type balancer, which is separated
from the engine, has been adopted for the L3
engine models to reduce vibration from the
engine. .

1 Cassette type balancer unit

2 balance shaft

AME2224N401

B–9
 ENGINE
Structure
• The balancer unit is configured with two balancer shafts (No.1 and No.2) with weights, the balancer unit case
and the adjust shim which adjusts the amount of backlash in the crankshaft.
• The two balancer shafts (No.1 and No.2) are driven by the drive gear which is attached to the crankshaft.
• The balancer unit cannot be disassembled because it is a precision unit.

Operation
• The rotary motion is transmitted from the drive gear, which is between the back of the No.3 cylinder and the
No.4 main journal, directly to the No.1 balance shaft with driven gear. Then the balance unit transmits the
rotation motion to the No.2 balance shaft. The ratio of gears, which are attached to No.1 and No. 2 balancer
shafts, has been set so that the gear rotates at twice the velocity of the crankshaft. The balancer shaft's rotation
velocity counterbalances (generate the force in the opposite direction) the rotation inertial force (secondary
inertial rotation force) from the crankshaft.

AME2224N402
.

1 Adjust shim 5 Weights

2 Crankshaft 6 No.2 balance shaft
3 Engine front 7 Drive gear
4 Balancer unit case 8 No.1 balance shaft with driven gear

• Replace the adjust shim to adjust backlash. There are 40 kinds of adjuster shim depending on the thickness.
To determine the kind, check the engraved identification mark (2 digits) on the adjust shim.

B–10
 ENGINE

AME2224N403
.

1 Cylinder block 2 Engraved identification mark (2 digits)

End Of Sie
CRANKSHAFT PULLEY
A6E222411371T01
Structure
• The crankshaft position (CKP) signal detecting blade has been adopted for the crankshaft pulley. And the
torsional damper, which prevents the crankshaft from wobbling, has also been adopted for the crankshaft.
• The positioning key slot, which is used for attaching the pulley to the crankshaft, has been decommissioned.
For aligning the crankshaft pulley to the crankshaft, use the positioning hole on the engine front cover and the
crankshaft pulley.
• Crankshaft pulley rock bolt is the plastic region tightening bolt, which can be tightened in 2 motions. It insures a
stable axis during tightening.
.

1 Elevation view
2 Sectional view
3 Braid for CKP sensor signal detection
4 Hole for pulley positioning
5 Torsional damper

AME2224N012

End Of Sie

B–11
Mazda 6 2002 Training Manual
Full download: http://manualplace.com/download/mazda-6-2002-training-manual/

ENGINE
ENGINE FRONT COVER
A6E222401001T01
Structure
• The engine front cover is made of aluminum alloy, and is integrated with the No.3 engine-mounting bracket, to
improve noise absorption and decrease weight.
• The hole for crankshaft pulley positioning bolt, the service hole for unlocking the chain adjuster ratchet, and the
service hole for securing the tensioner arm when loosening the timing chain, are on the engine front cover.
• The oil line and the integrated oil filter are on the L3 engine front cover.

AME2224N011
.

1 Elevational view 5 Bolt hole crankshaft pulley positioning

2 Service hole for tensioner arm fixation 6 Back view
3 Service hole for chain tensioner lock release 7 Oil filter
4 No.3 engine mount bracket 8 Oil passage to OCV

End Of Sie

B–12

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