TRAINING MANUAL Mazda6 Facelift Mazda 6 Facelift Technical Training
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The illustrations, technical information, dataand descriptive text in this issue, to the best of our knowledge, were correct at the time of going to print.
No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible.
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Mazda Motor Europe GmbH Training Services
Contents General Information 00 Engine 01 Suspension 02 Brakes 04 Transmission / Transaxle 05 Restraints 08 Body & Accessories 09 Section Title Service Training Mazda6 Facelift
Service Training Mazda6 Facelift
General Information
00
00 General Information Vehicle Identification Number (VIN) Code.........................................................1 Applicable VIN................................................................................................1 Engine / Transaxle Combinations......................................................................2 Scheduled Maintenance.....................................................................................3 Europe ............................................................................................................3 Table of Contents 00 Service Training Mazda6 Facelift
Vehicle Identification Number (VIN) Code
JMZGG1232011 2 3 4 5 6
Serial No. Plant 0= Hiroshima 1= Hofu
Dummy0, 6 to 9, A to Z
Transmission
2= 5MTX 6= 6MTX 7= 5ATX
Engine Type
3= 2.3L (L3) 8= 1.8L (L8) F= 2.0L (LF) R= MZR-CD (RF Turbo)-Hi T= MZR-CD (RF Turbo)-Standard
Body style
2= 4SD 4= 5HB 9= WAGON Remarks 8= 4WD 1= 2WD
Vehicle type
GG= Mazda6 (4SD, 5HB) GY= Mazda6 (WAGON)
World manufacturer indication JMZ= European (L.H.D. U.K.)
Applicable VIN
JMZ GG1236*# 600001—
JMZ GG12360# 600001—
JMZ GG1282*# 600001—
JMZ GG12820# 600001—
JMZ GG12F6*# 600001—
JMZ GG12F60# 600001—
JMZ GG12R6*# 600001—
JMZ GG12R60# 600001—
JMZ GG12T6*# 600001—
JMZ GG12T60# 600001—
JMZ GG1436*# 600001—
JMZ GG14360# 600001—
JMZ GG1482*# 600001—
JMZ GG14820# 600001—
JMZ GG14F6*# 600001—
JMZ GG14F60# 600001—
JMZ GG14R6*# 600001—
JMZ GG14R60# 600001—
JMZ GG14T6*# 600001—
JMZ GG14T60# 600001—
JMZ GY1936*# 400001—
JMZ GY1982*# 400001—
JMZ GY19820# 400001—
JMZ GY19F6*# 400001—
JMZ GY19F60# 400001—
JMZ GY19R6*# 400001—
JMZ GY19R60# 400001—
JMZ GY19T6*# 400001—
JMZ GY19T60# 400001—
JMZ GY8937*# 400001—
JMZ GY89370# 400001—
General Information
M6FL_00T001
Service Training Mazda6 Facelift 00-1
Engine / Transaxle Combinations
• All engines have been revised. New transaxles have been added to the range. The following engine/transaxle combinations are available:
G35M-R 5-speed manual transaxle
G66M-R 6-speed manual transaxle
A26M-R 6-speed manual transaxle
L8 1.8L
88 KW (120 HP) at 5,500 rpm
165 Nm at 4,300 rpm
LF 2.0L
108 KW (147 HP) at 6,500 rpm
L3 2.3L
122 KW (166 HP) at 6,500 rpm
207 Nm at 4,000 rpm
RF Turbo STD 2.0L
89 KW (121 HP) at 3,500 rpm
320 Nm at 2,000 rpm
RF Turbo HI 2.0L
105 KW (143 HP) at 3,500 rpm
360 Nm at 2,000 rpm
FS5A-EL 5-speed automatic transaxle (front wheel drive)
JA5AX-EL 5-speed automatic transaxle (All Wheel Drive (AWD))
X X X
X X X
X
Information
General
M6FL_00T002
184 Nm at 4,000 rpm X 00-2 Service Training Mazda6 Facelift
ENGINE
DIESEL ENGINE
General Information Scheduled Maintenance
RRR
II RRR
DDDDDDDDD CCRCCRCCR RRRRRRRRR RRRRRRRRR III IIII
IIII IIIIIIIII IIIIIIIII RRRR IIIIIIIII IIIIIIIII IIIIIIIII R III IIII IIII RRRR M6FL_00T003 IIII
Maintenance items
Europe Months 1224364860728496108 X1000 km 20406080100120140160180 X1000 miles 12,52537,55062,57587,5100112,5
III
IIII
FL 22 type *5 Others
IIII Replace at first 100,000 km (62,500 miles) or 4 years; after that, every 2years Inspect every 80,000 km (50,000 miles) or 5 years Body condtion (for rust, corrosion and perforation) Inspect annualy Parking brake Fuel lines and hoses Disc brakes Transfer oil (for 4 WD) Brake fluid *6
Maintenance interval (number of momths or km (miles) which ever comes first) I *7 *8 *8
PETROL AND DIESEL ENGINE Drive belt *4 Engine coolant Front and rear suspension and ball joints Drive shaft dus boots Replace every 120,000 km (75,000 miles) Replace every 200,000 km (125,000 miles) 0r 11 years Tires (including spare tire) (with inflation pressure adjustment) Exhaust system and heat shields
Battery electrolyte level and specific gravity Brakes lines hoses and connections Steering operation and linkages Manual transaxle oil Automatic transaxle fluid level Rear differential oil (for 4 WD)
Engine oil filter *3 Engine oil*3 Air cleaner element*1 Fuel system (Drain water) Fuel injection system Fuel filter Engine timing belt *2
Engine valve clearance Cabin air filter (if installed) Cooling system (including coolant level adjustment)
I: Inspect: Inspect and clean, repair, adjust, or replace if necessary. R: Replace C: Clean D: Drain Service Training Mazda6 Facelift 00-3
PETROL
Engine valve clearance Spark plugs Air cleaner element Evaporation system(if installed) Replace every 100,000km (62,500miles) Audible inspect every 120,000km (75,000 miles), if noisy adjust
Remarks:
*1 If the vehicle is operated in very dusty or sandy areas, clean and if necessary, replace the air filter more often than the recommended intervals.
*2 Replacement of the timing belt is required at every 120,000 km (75,000 miles). Failure to replace the timing belt may result in damage to the engine.
*3 If the vehicle is operated under any of the following conditions, change the engine oil and oil filter every 10,000 km (6,250 miles) or shorter.
a) Driving in dusty conditions
b) Extended periods of idling or low speed operation
c) Driving for long period in cold temperatures or driving regularly at short distance only
*4 Also inspect and adjust the power steering and air conditioner drive belts, if installed.
*5 Use FL22 type coolant in vehicles with the inscription “FL22” on the radiator cap itself or the surrounding area. Use FL22 when replacing the coolant.
*6 If the brakes are used extensively (for example, continuous hard driving or mountain driving) or if the vehicle is operated in extremely humid climates, change the brake fluid annually.
*7 If the vehicle is operated under any of the following conditions, change the rear differential oil every 45,000 km (28,100 miles).
a) Towing a trailer or using a car-top carrier
b) Driving in dusty, sandy or wet condition
c) Extended periods of idling or low speed operation
d) Repeated short trips of less than 16 km (10 miles)
*8 If this component has been submerged in water, the oil should be changed.
General Information
00-4 Service Training Mazda6 Facelift
01 Engines
01 Engine Table of Contents Petrol Engines Mechanics............................................................................................................1 Cylinder Head Cover.......................................................................................1 Valve Mechanism ............................................................................................2 Lubrication......................................................................................................3 Intake-Air System................................................................................................4 Electronic Throttle Control...............................................................................5 Exhaust System...................................................................................................6 Charging System.................................................................................................7 Generator Design............................................................................................7 Generator Electrical Diagram ...................................................................8 Ignition System....................................................................................................9 Engine Control System.....................................................................................10 Structural View ..............................................................................................10 Powertrain Control Module (PCM)................................................................11 PCM Connector (Harness Side Shown) .................................................11 Overview.......................................................................................................12 Wiring Diagram.............................................................................................14 Accelerator Pedal Position (APP) Sensor .....................................................18 Throttle Valve Actuator.................................................................................20 Throttle Position (TP) Sensor ........................................................................21 TP Sensor Voltage Characteristics.........................................................22 Heated Oxygen Sensors (HO2S)..................................................................23 Front HO2S............................................................................................24 Rear HO2S.............................................................................................25 Crankshaft Position (CKP) Sensor ................................................................26 Camshaft Position (CMP) Sensor .................................................................28 Diesel Engines Mechanics..........................................................................................................29 Pistons ..........................................................................................................30 Cylinder Head...............................................................................................31 Lubrication.........................................................................................................32 Specification..................................................................................................32 Engine Oil...............................................................................................32 Parts Location...............................................................................................33 Engine Oil.....................................................................................................34 Table of Contents 01 Service Training Mazda6 Facelift
01 Engine Table of Contents (continued) Oil Dipstick....................................................................................................35 Oil Dilution Calculation..................................................................................36 Oil Cooler and Oil Filter.................................................................................37 Cooling System.................................................................................................39 Specifications................................................................................................39 Parts Location...............................................................................................40 Intake-air System...............................................................................................41 Parts Location...............................................................................................41 Turbocharger................................................................................................42 Manifold Absolute Pressure Sensor ..............................................................43 Fuel System.......................................................................................................44 Parts Location...............................................................................................44 Common Rail................................................................................................45 Injectors........................................................................................................46 Injector Correction Factors.....................................................................48 Injection Amount Learning Function.......................................................49 Emission System...............................................................................................50 Parts Location...............................................................................................50 Exhaust System.................................................................................................51 Parts Location...............................................................................................51 Exhaust Gas Recirculation System.................................................................52 EGR Valve....................................................................................................52 EGR Cooler...................................................................................................55 Intake Shutter Valve......................................................................................56 Diesel Particulate Filter System .......................................................................59 Diesel Particulates ........................................................................................59 Diesel Particulate Filter.................................................................................60 DPF Differential Pressure Sensor.................................................................63 Diagnostics.............................................................................................66 Exhaust Gas Temperature Sensors..............................................................68 Heated Oxygen Sensor .................................................................................70 DPF Indicator Light .......................................................................................72 Regeneration Control....................................................................................73 Soot Amount Calculation........................................................................73 Regeneration Process............................................................................75 Regeneration Intervals............................................................................76 Service Training Mazda6 Facelift Table of Contents 01
01 Engine Table of Contents (continued) Charging System...............................................................................................77 Specifications................................................................................................77 Parts Location...............................................................................................77 Smart Charging System................................................................................78 Control System..................................................................................................79 Parts Location...............................................................................................79 Wiring Diagram.............................................................................................82 Powertrain Control Module............................................................................86 Crankshaft Position Sensor...........................................................................87 Camshaft Position Sensor.............................................................................88 Accelerator Pedal Position Sensor ................................................................89 Power Steering Pressure Switch ...................................................................92 Service And Repair .......................................................................................93 Replacing the Engine Oil........................................................................93 Manual Regeneration .............................................................................93 Replacing the MAF Sensor.....................................................................94 Replacing the
Pump........................................................94 Replacing Injectors.................................................................................94 Replacing the
Valve Or The ISV ....................................................95 Replacing the DPF..................................................................................95 Replacing
DPF Differential Pressure Sensor....................................95 Replacing
...............................................................................96 Replacing
PCM .................................................................................96 On-board Diagnostic System...........................................................................97 Self Test........................................................................................................97 PID Monitor...................................................................................................98 Simulation Test...........................................................................................101 Table of Contents 01 Service Training Mazda6 Facelift
High-Pressure
EGR
the
the HO2S
the
Mechanics
M6FL_01057
Cylinder Head Cover
• The cylinder head cover is made of plastic. On LF and L3 engines a hole is provided for installation of the OCV (Oil Control Valve).
• A dipstick insertion hole has been equipped to the cylinder head cover.
M6FL_01001
Engine Petrol Engines
1 CMP (Camshaft Position) sensor attachment part 3 OCV attachment hole (LF,
2 Dipstick insertion hole Service Training Mazda6 Facelift 01-1
L3)
Petrol
Valve Mechanism
• For the LF engine the variable valve timing system has been carried over from the L3 engine. • All engines use a sensor ring with 6 reference cams for the CMP Sensor on the intake camshaft.
Engines Engine
M6FL_01002 1 Timing chain 7 Valve assembly 2 Camshaft sprocket 8 Tappet 3 Tensioner arm 9 Camshafts 4 Chain tensioner 10 OCV 5 Crankshaft sprocket 11 Variable valve timing actuator 6 Chain guide 01-2 Service Training Mazda6 Facelift
Lubrication
lubrication system has been carried over from the previous engines. Depending on specification, both spin-on and cartridge type oil filters are available.
The oil cooler is now installed on both the L3 and the LF engine.
Engine Petrol Engines
M6FL_01003 1 Oil pump chain tensioner 11 Oil jet valve 2 Oil pump chain guide 12 Oil cooler (LF,
3 Oil pump chain 13 Gasket 4 Oil pump sprocket 14 Oil pressure switch 5 Oil pump 15 Oil filter adapter 6 O-ring 16 Oil filter 7 Oil strainer 17 Oil filter cover 8 Washer 18 Oil filter drain plug 9 Oil pan drain plug 19 Cartridge type oil filter 10 Oil pan 20 Spin-on type oil filter Service Training Mazda6 Facelift 01-3
• The
•
L3)
Petrol Engines Engine
Intake-Air System
• The intake-air system has been basically carried over from the previous engines. It comprises: – VTCS (Variable Tumble Control System) (L8, LF, L3) – VIS (Variable Intake-air System) (LF, L3)
VAD (Variable Air Duct) (L3)
• All petrol engines now use an electronic throttle control. • For the LF engine the VIS has been carried over from the L3 engine.
–
M6FL_01004 1 Air
8 VIS
2 Accelerator
9 Throttle
3 VAD
10 VAD
4 VAD
11 Intake
5 Resonance
12 VIS
6 VAD
13 VTCS
7 VTCS
01-4 Service Training Mazda6 Facelift
cleaner
shutter valve actuator (LF, L3)
pedal
body
solenoid valve (L3)
check valve (one-way) (L3)
shutter valve (L3)
manifold
chamber
solenoid valve (LF, L3)
vacuum chamber (L3)
solenoid valve
shutter valve actuator
Electronic Throttle Control
• All engines are using an electronically controlled throttle body, which is quite similar to the one on RX-8. This supersedes the IAC (Idle Air Control) valve.
• To keep moisture from freezing inside the throttle body, and thus to prevent the throttle valve from getting stuck, engine coolant is circulated through the throttle body.
• The throttle body cannot be disassembled.
• When the throttle actuator is not energized, the throttle valve is maintained slightly open by the force of the return spring. This allows limited operation of the engine in case of a malfunction.
Engine Petrol Engines
M6FL_01005
Service Training Mazda6 Facelift 01-5
1 Throttle body 3 TP (Throttle Position) sensor 2 Throttle actuator 4 Throttle valve
Petrol Engines Engine
Exhaust System
The exhaust system has been carried over from the previous Mazda6.
Vehicles specified with LF engine are now using the exhaust system with two main silencers (previously used on L3 engines only).
•
•
M6FL_01006 1 Main silencer 5 HO2S (front) 2 Middle pipe 6 Exhaust manifold 3 HO2S (Heated Oxygen Sensor) (rear) 7 LF, L3 4 TWC (Three-Way Catalyst) 01-6 Service Training Mazda6 Facelift Mazda 6 Facelift Technical Training Full download:
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