2002 MAZDA 6 Workshop Manual Suplement

ON-BOARD DIAGNOSTIC
U–23
U
UHEATER AND AIR CONDITIONER SYSTEMSDTC B1318A6E857001038204
Diagnostic procedure
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DTC B1342, B2463, B2537, B2538, B2547A6E857001038205
Diagnostic procedure
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ON-BOARD DIAGNOSTIC
DTC B1318 Input voltage low
DETECTION
CONDITION•Voltage detected at water heater unit terminals A is less than 9 V.
POSSIBLE
CAUSE•Generator malfunction
•Battery malfunction
STEP INSPECTION ACTION
1INSPECT BATTERY VOLTAGE
•Measure the battery voltage.
•Is the voltage more than 9 V?Yes Go to the next step.
No The battery is weak.
•Inspect the charging system.
2INSPECT WIRING HARNESS BETWEEN W.HEAT
40 A FUSE AND WATER HEATER UNIT
•Turn the ignition switch to the ON position.
•Measure the voltage at water heater unit
connector terminal A.
•Is the voltage more than 9 V?Yes Go to the next step.
No Repair the wiring harness.
3INSPECT WATER HEATER UNIT
•Clear the DTC.
•Perform the KOEO Self Test. (See U–22 KOEO
Self Test/Combustion Test.)
•Is the same DTC present?Yes Replace the water heater unit.
(See U–15 WATER HEATER UNIT REMOVAL/
INSTALLATION)
No Go to the next step.
4VERIFY AFTER REPAIR PROCEDURE
•Perform the after repair procedure. (See U–22–1
After Repair Procedure.)
•Are any DTCs present?Yes Go to the applicable DTC troubleshooting.
No Troubleshooting completed.
A C E
B
D F WATER HEATER UNIT CONNECTOR
DTCB1342 Malfunction in water heater unit
B2463 Overheat
B2537 Water heater system does not start
B2538 Unstable flame
B2547 Flame prior to operation
DETECTION
CONDITION•CPU detects malfunction in water heater unit
POSSIBLE
CAUSE•Water heater unit malfunction
—CPU malfunction
—Glow plug malfunction
—Flame detection sensor malfunction
STEP INSPECTION ACTION
1INSPECT WATER HEATER UNIT
•Replace the water heater unit. (See U–15
WATER HEATER UNIT REMOVAL/
INSTALLATION)
•Perform the Combustion Test. (See U–22 KOEO
Self Test/Combustion Test.)
•Are any DTCs present?Yes Go to the applicable DTC troubleshooting.
No Troubleshooting completed.

U–24
ON-BOARD DIAGNOSTIC
DTC B2449, B2450A6E857001038206
Diagnostic procedure
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DTC B2451, B2452A6E857001038207
Diagnostic procedure
DTCB2449 Glow plug circuit short to ground
B2450 Glow plug circuit open
DETECTION
CONDITION•CPU detects malfunction in glow plug circuit
POSSIBLE
CAUSE•Water heater unit malfunction
STEP INSPECTION ACTION
1INSPECT WATER HEATER UNIT
•Replace the water heater unit. (See U–15
WATER HEATER UNIT REMOVAL/
INSTALLATION)
•Perform the combustion Test. (See U–22 KOEO
Self Test/Combustion Test.)
•Are any DTCs present?Yes Go to the applicable DTC troubleshooting.
No Troubleshooting completed.
DTCB2451 Fuel pump (water heater system) circuit short to ground
B2452 Fuel pump (water heater system) circuit open
DETECTION
CONDITION•CPU detects malfunction in fuel pump (water heater system) circuit
POSSIBLE
CAUSE•Fuel pump (water heater system) malfunction
•Water heater unit malfunction
•Short to ground between water heater unit terminal B and fuel pump (water heater system) terminal A
•Open circuit between water heater unit terminal B and fuel pump (water heater system) terminal A
•Open circuit between fuel pump (water heater system) terminal B and GND
A C E
B D F WATER HEATER UNIT CONNECTORFUEL PUMP
(WATER HEATER SYSTEM)
CONNECTOR
A
B
STEP INSPECTION ACTION
1INSPECT WIRING HARNESS BETWEEN
WATER HEATER UNIT AND FUEL PUMP
(WATER HEATER SYSTEM) FOR
CONTINUITY
•Start the engine.
•Is the voltage at fuel pump (water heater
system) connector terminal A approximately
12 V?Yes Go to the next step
No Repair the wiring harness.
2INSPECT FUEL PUMP (WATER HEATER
SYSTEM)
•Inspect the fuel pump (water heater system).
(See U–16 FUEL PUMP (WATER HEATER
SYSTEM) INSPECTION)
•Is the fuel pump (water heater system) okay?Yes Go to the next step
No Replace the fuel pump (water heater system).
(See U–15 WATER HEATER UNIT REMOVAL/
INSTALLATION)
3INSPECT WIRING HARNESS BETWEEN
FUEL PUMP (WATER HEATER SYSTEM) AND
GROUND FOR CONTINUITY
•Is there continuity between the fuel pump
(water heater system) connector terminal B
and ground?Yes Go to the next step
No Repair the wiring harness.

ON-BOARD DIAGNOSTIC
U–25
U
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DTC B2453, B2454A6E857001038208
Diagnostic procedure
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DTC B2548A6E857001038210
Diagnostic procedure
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4INSPECT WATER HEATER UNIT
•Clear the DTC.
•Perform the KOEO Self Test. (See U–22
KOEO Self Test/Combustion Test.)
•Is the same DTC present?Yes Replace the water heater unit.
(See U–15 WATER HEATER UNIT REMOVAL/
INSTALLATION)
No Go to the next step.
5VERIFY AFTER REPAIR PROCEDURE
•Perform after repair procedure. (See U–22–1
After Repair Procedure.)
•Are any DTCs present?Yes Go to the applicable DTC troubleshooting.
No Troubleshooting completed. STEP INSPECTION ACTION
DTCB2453 Blower fan circuit short to ground
B2454 Blower fan circuit open
DETECTION
CONDITION•CPU detects Malfunction in blower fan circuit
POSSIBLE
CAUSE•Water heater unit malfunction
ACTION
•Replace the water heater unit.
(See U–15 WATER HEATER UNIT REMOVAL/INSTALLATION)
DTC B2548 Water heater lockout mode
DETECTION
CONDITION•This DTC is stored if the water heater unit detects the same DTC three times and the water heater unit
then suspends system operation for safety reasons.
POSSIBLE
CAUSE•Water heater unit malfunction
•Fuel pump (water heater system) malfunction
•Generator malfunction
•Battery malfunction
•Open or short circuit in related harness
STEP INSPECTION ACTION
1INSPECT WATER HEATER UNIT
•Perform the lockout reset. (See U–22–1 Lockout
Reset.)
•Read DTCs using the SST (WDS or equivalent)
•Are any DTCs present?Yes Go to applicable DTC troubleshooting.
No Troubleshooting completed.

U–26
TROUBLESHOOTING
FOREWORDA6E858001038201•Confirm the symptom using the following troubleshooting index and carry out the appropriate action.
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TROUBLESHOOTING INDEXA6E858001038202
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TROUBLESHOOTING
No. TROUBLESHOOTING ITEM ACTION
1 Fuel odor•Inspect the water heater system in the vehicle fuel
system.
•Inspect the fuel line for leakage, kinks, or blockage.
•If normal, there is an internal water heater leak.
—Replace the water heater unit.
2 The heater does not achieve full load operation•Replace the water heater unit.
3 Continuous white smoke during combustion operation•Replace the water heater unit.
4 Loss of coolant (leakage). Heater develops smoke during
combustion operation; smell of exhaust fumes extremely
sweet•Inspect the coolant hose for leakage, kinks,
looseness, and loose hose clamps.
•If normal, there is an internal water heater leak.
—Replace the water heater unit.
5 Loss of fuel (leakage)•Inspect the water heater system integration in the
vehicle’s fuel system.
•Inspect the fuel line connections for leakage.
•If normal, there is an internal water heater leak.
—Replace the water heater unit.
6 The water heater unit does not communicate with the SST
(WDS or equivalent)•Refer to section T, ON-BOARD DIAGNOSTIC
[MULTIPLEX COMMUNICATION SYSTEM].

TD–1
TD
TDTECHNICAL DATA
TECHNICAL DATA............................................. TD-2
ENGINE ............................................................ TD-2
LUBRICATION SYSTEM .................................. TD-2
COOLING SYSTEM .......................................... TD-3
FUEL AND EMISSION CONTROL
SYSTEM ........................................................ TD-3
ENGINE ELECTRICAL SYSTEM ..................... TD-4
CLUTCH............................................................ TD-4
MANUAL TRANSAXLE ..................................... TD-4
AUTOMATIC TRANSAXLE............................... TD-5
PROPELLER SHAFT ........................................ TD-5
FRONT AND REAR AXLE ................................ TD-6
STEERING SYSTEM ........................................ TD-6
BRAKING SYSTEM .......................................... TD-7
SUSPENSION................................................... TD-7
BODY ELECTRICAL SYSTEM ......................... TD-8
HEATER AND AIR CONDITIONER
SYSTEMS ...................................................... TD-9

TD–2
TECHNICAL DATA
ENGINEA6E931001001201
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LUBRICATION SYSTEMA6E931001001202
TECHNICAL DATA
ItemSpecification
Diesel engine
MZR-CD (RF Turbo)
MECHANICAL
Valve clearance
[engine cold](mm {in})IN0.12—0.18
{0.005—0.007}
(0.15±0.03 {0.006±0.0011})
EX0.32—0.38
{0.013—0.014}
(0.35±0.03 {0.014±0.0011})
Compression pressure(kPa {kgf/cm
2, psi}) [rpm]Standard3,500
{35.7, 507.7}
[250]
Minimum3,100
{31.6, 449.4}
[250]
Maximum difference
between cylinders196.1 {1.999, 28.44}
Cylinder head bolt length (mm {in})Standard 159.7—160.3 {6.288—6.311}
Maximum 161.0 {6.338}
Pushing distance of the front oil seal
(from the edge of the oil pump body)(mm {in})0—0.5
{0—0.019}
Pushing distance of the rear oil seal
(from the edge of the rear cover)(mm {in})0—0.5
{0—0.019}
Pushing distance of the camshaft oil seal
(from the edge of the cylinder head)(mm {in})0.5—1.5
{0.020—0.059}
Timing belt auto tensioner rod projection (free length) (mm {in})12.9—14.6
{0.508—0.574}
ItemSpecification
Diesel engine
MZR-CD (RF Turbo)
Oil pressure
(approximate quantity)
[oil temperature: 100°C {212°F}](kPa {kgf/cm
2, psi}) min [rpm]147 {1.5, 21} [1,000],
343 {3.5, 50} [3,000]
Oil capacity
(approximate quantity)Total (dry engine)
5.5 {5.8, 4.8}
(L {US qt, Imp qt})
Oil replacement
4.8 {5.1, 4.2}
(L {US qt, Imp qt})
Oil and oil filter replacement
5.0 {5.3, 4.4}
(L {US qt, Imp qt})

TECHNICAL DATA
TD–3
TD
Recommended engine oil
Note
•The maintenance intervals on scheduled maintenance table (See GI–8 SCHEDULED MAINTENANCE
TABLE) can only be supported with the use of following oils.
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COOLING SYSTEMA6E931001001203
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FUEL AND EMISSION CONTROL SYSTEMA6E931001001204
*1: Excludes temporary idle speed drop just after the electrical loads are turned on.
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ItemSpecification
Diesel engine
MZR-CD (RF Turbo)
Engine oil GradeAPI CF CD, CE, CF-4
ACEA B1 or B3
B3B3 or B4
Viscosity (SAE) 5W-30 10W-40 5W-30, 10W-30
RemarksMazda genuine Dexelia oil e.g. —
ItemSpecification
Diesel engine
MZR-CD (RF Turbo)
Coolant capacity (L {US qt, Imp qt}) 9.0 {9.5, 7.9}
Radiator capCap valve opening pressure
94—122
{0.96—1.24, 13.7—17.6}
(kPa {kgf/cm
2, psi})
ThermostatType Wax, bottom-bypass
Initial-opening temperature (°C {°F})80—84
{176—183}
Full-opening temperature (°C {°F}) 95 {203}
Full-open lift (mm {in}) More than 8.5 {0.33}
Cooling fan Motor Current (A)4.4—7.4 (Cooling fan motor No.1)
6.3—9.3 (Cooling fan motor No.2)
ItemEngine
L3 (4WD)
Idle speed
*1(rpm) 650—750 (700±50)
ItemEngine
MZR-CD (RF Turbo)
Idle speed (rpm) 725—825 (775±50)
Idle-up speed (rpm) When A/C is operated 725—825 (775±50)
Boost relief pressure (kPa {mmHg, inHg}) Approx. –14.5 {–108, –4.27}

TD–4
TECHNICAL DATA
ENGINE ELECTRICAL SYSTEMA6E931001001205
*1: Back-up current is the constant flow of current present (for the audio unit, clock, PCM, etc.) when the engine
switch is off and with the key removed.
*
2: Must not be 0 A.
*3: Cold area
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CLUTCHA6E931001024201
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MANUAL TRANSAXLEA6E931001024202
ItemSpecification
Diesel engine
MZR-CD (RF Turbo)
BatteryElectrolyte gravity 1.27—1.29
Back-up current*
1(mA) Max.20
Type
95D31L, 115D31L
*3
Test load chart (A) Battery type95D31L (64) 250
115D31L (70) *3320
Slow-charge (A)Battery type
(5-hour rate)95D31L (64) 6.5—8.0
115D31L (70)
*37.0—8.5
Quick-charge
Battery type
(5-hour rate)95D31L (64) 40
(A/30 min)
115D31L (70)
*345
GeneratorStandard voltage (V)Ignition switch ON TerminalBB+
L Approx. 1
SB+
Idle [20°C {68°F}] TerminalB
14.1—14.7 L
S
Generated current*
2
(reference) (A) Engine speed (rpm)1,000 0—80
2,000 0—90
Starter No load testVoltage (V) 11
Current (A) Below 130
Item Specification
Clutch coverDiaphragm
spring fingersDepth mm {in} 0.6 {0.024}
Misalignment mm {in} 0.6 {0.024}
Maximum clearance of flatness of the
pressure platemm {in} 0.3 {0.012}
Flywheel Run out limit mm {in} 0.3 {0.012}
Item Specification
Manual transaxle typeA65M-R
Transaxle controlFloor-shift
Operation systemCable
Shift assistSynchromesh
Gear ratio1st 3.416
2nd 1.944
3rd 1.258
4th 0.902
5th 0.659
Reverse 3.252
Final gear ratio3.588
Transaxle oilGrade API service GL-4 or GL-5
Viscosity (All-season) SAE 75W-90
Capacity (approximate quantity)
2.30 {2.40, 2.00}
(L {US qt, Imp qt})