2002 MAZDA 6 Workshop Manual Suplement

CONTENTSMazda6
Workshop
Manual
Supplement
FOREWORD
This manual contains on-vehicle service
and diagnosis for the Mazda6.
For proper repair and maintenance,
a thorough familiarization with this manual
is important, and it should always be kept
in a handy place for quick and easy
reference.
All the contents of this manual, including
drawings and specifications, are the latest
available at the time of printing.
As modifications affecting repair or
maintenance occur, relevant information
supplementary to this volume will be made
available at Mazda dealers. This manual
should be kept up-to-date.
Mazda Motor Corporation reserves
the right to alter the specifications and
contents of this manual without obligation
or advance notice.
All rights reserved. No part of this book
may be reproduced or used in any form or
by any means, electronic or
mechanical—including photocopying and
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), and related materials shown
on the following page.There are explanation given only for the sections
marked with shadow ( ).
© 2002 Mazda Motor Corporation
PRINTED IN THE NETHERLANDS, JULY 2002
1749–1E–02G
Title Section
General Information
GI
EngineL8, LF, L3
B1
MZR–CD (RF Turbo)B2
Lubrication System
D
Cooling System
E
Fuel and Emission Control
SystemsL8, LF, L3
F1
MZR–CD (RF Turbo)F2
Engine Electrical System
G
Clutch
H
Manual TransaxleG35M
–RJ1
A65M
–RJ2
Automatic TransaxleFN4A
–ELK1
JA5AX
–ELK2
Propeller Shaft
L
Front and Rear Axles
M
Steering System
N
Braking System
P
Suspension
R
Body
S
Body Electrical System
T
Heater and Air Conditioner Systems
U
Technical Data
TD
Special Tools
ST

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

WARNING
Servicing a vehicle can be dangerous. If you have not received
service-related training, the risks of injury, property damage, and
failure of servicing increase. The recommended servicing procedures
for the vehicle in this workshop manual were developed with
Mazda-trained technicians in mind. This manual may be useful to
non-Mazda trained technicians, but a technician with our
service-related training and experience will be at less risk when
performing service operations. However, all users of this manual are
expected to at least know general safety procedures.
This manual contains "Warnings" and "Cautions" applicable to risks
not normally encountered in a general technician's experience.
They should be followed to reduce the risk of injury and the risk that
improper service or repair may damage the vehicle or render it unsafe.
It is also important to understand that the "Warnings" and "Cautions"
are not exhaustive. It is impossible to warn of all the hazardous
consequences that might result from failure to follow the procedures.
The procedures recommended and described in this manual are
effective methods of performing service and repair. Some require tools
specifically designed for a specific purpose. Persons using procedures
and tools which are not recommended by Mazda Motor Corporation
must satisfy themselves thoroughly that neither personal safety nor
safety of the vehicle will be jeopardized.
The contents of this manual, including drawings and specifications, are
the latest available at the time of printing, and
Mazda Motor Corporation
reserves the right to change the vehicle designs and alter the contents
of this manual without notice and without incurring obligation.
Parts should be replaced with genuine Mazda replacement parts or
with parts which match the quality of genuine Mazda replacement
parts. Persons using replacement parts of lesser quality than that of
genuine Mazda replacement parts must satisfy themselves thoroughly
that neither personal safety nor safety of the vehicle will be
jeopardized.
Mazda Motor Corporation is not responsible for any problems which
may arise from the use of this manual. The cause of such problems
includes but is not limited to insufficient service-related training, use of
improper tools, use of replacement parts of lesser quality than that of
genuine Mazda replacement parts, or not being aware of any revision
of this manual.

GI–1
GIGIGENERAL INFORMATION
HOW TO USE THIS MANUAL............................. GI-2
RANGE OF TOPICS .......................................... GI-2
VIN CODE............................................................. GI-3
VIN CODE .......................................................... GI-3
FUNDAMENTAL PROCEDURES........................ GI-4
DYNAMOMETER ............................................... GI-4
NEW STANDARDS.............................................. GI-5
NEW STANDARDS TABLE ............................... GI-5
ABBREVIATIONS................................................ GI-7
ABBREVIATIONS TABLE .................................. GI-7
SCHEDULED MAINTENANCE............................ GI-8
SCHEDULED MAINTENANCE TABLE ............. GI-8

GI–2
HOW TO USE THIS MANUAL
RANGE OF TOPICSA6E201000001206•This manual indicates only changes/additions, as it is supplemental to the related materials. Therefore it may
not contain the necessary reference service procedures to perform the service indicated in this manual.
End Of Sie
HOW TO USE THIS MANUAL

VIN CODE
GI–3
GIVIN CODEA6E200800021201European (L.H.D. U.K.) specs.GCC specs.End Of Sie
VIN CODE
Serial No.
0=Hiroshima
2=5MT For Europe(U.K.): Dummy
For Europe(L.H.D.): Dummy
For Israel: Model year0
3 to 9
3=2003
3=2.3L (L3)
8=1.8L (L8)
F=2.0L (LF)
R=MZR-CD(RF-Turbo)-Hi
T=MZR-CD(RF-Turbo)-Low5=4EAT
7=5EAT
8=4WD
1=2WD
GG=MAZDA6 (4SD, 5HB)
GY=MAZDA6 (WAGON)
JMZ=Europe(L.H.D. U.K.)2=4SD
4=5HB
9=WAGON 1=Hofu Plant
Engine typeWorld manufacturer identification
Body style
Remarks
Vehicle type
Transmission
A6E2021T101
J M 7 G Y 3 9 F * 3 # 1 2 3 4 5 6
Serial No.
0= Hiroshima
1= Hofu
0 to 9, X
F= 2.0L (LF)
9= WAGON 4= 5HB 2= 4SD
JM7= General (L.H.D.) 3= Without side air bag
4= With side air bag
GY= MAZDA6 (WAGON) GG= MAZDA6 (4SD, 5HB) Plant
For Saudi: Model year
For Model year: Dummy
Body style Engine typeCheck digit3
0 - 9
Restraint system
Vehicle type
World manufacturer identification
A6E2010T102

GI–4
FUNDAMENTAL PROCEDURES
DYNAMOMETERA6E2014000042174WD testing/servicing
•Brake tester
Caution
•
To ensure the stability of the drag force of the viscous coupling always perform a brake test after
using the dynamometer or speed meter tester.
Note
•If there is a great amount of brake drag, it is probably due to the viscosity of the viscous coupling or the
center differential (RBC). To remove the influence of the coupling, jack up all four wheels of the vehicle
and verify that each wheel can be rotated freely by hand.
•Chassis dynamometer/speed meter tester
Caution
•
The vehicle may sway or surge forward when on the dynamometer. To prevent possible vehicle
movement, firmly secure it in place using steel retainers (chain, wire or similar) attached to the
front and rear towing hooks or to the tie down hooks.
•
Do not pop the clutch.
•
Do not accelerate suddenly.
Note
•The dynamometer/speed meter tester has two setting modes: propeller shaft removed mode and free
roller mode. After placing the vehicle on the tester and setting the wheels on the free rollers, start the
engine. For MTX vehicles, set the shift lever into second gear and gently, at low idle speed, release the
clutch pedal. For ATX vehicles, set the selector lever to D range, and slowly accelerate.
End Of Sie
FUNDAMENTAL PROCEDURES

NEW STANDARDS
GI–5
GINEW STANDARDS TABLEA6E202800020201•The following is a comparison of the previous standard and the new standard.
NEW STANDARDS
New Standard Previous Standard
Remark
Abbrevi-
ationNameAbbrevi-
ationName
AP Accelerator Pedal—Accelerator Pedal
ACL Air Cleaner—Air Cleaner
A/C Air Conditioning—Air Conditioning
BARO Barometric Pressure—Atmospheric Pressure
B+ Battery Positive VoltageV
BBattery 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
—Closed Throttle Position Switch—Idle Switch
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—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
solenoidFuel Shut Off Solenoid FCV Fuel Cut Valve #6
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
MFI Multiport Fuel Injection—Multiport Fuel Injection
OBD On Board Diagnostic—Diagnosis/Self Diagnosis