2002 MAZDA 6 Workshop Manual Suplement

FUEL SYSTEM
F1–9
F1
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OUTLINEA6E391201006201•The fuel system is essentially carried over from that of the current Mazda6 (GG), except for the following. (See
Mazda6 Training Manual 3359-1*-02C.)
—A saddle type fuel tank has been adopted.
—A fuel pump (transfer) for fuel transmission has been added.
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STRUCTURAL VIEWA6E391201006202
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FUEL SYSTEM
7
5
4
3
6
1
2
A6E39122001
1 Fuel gauge sender sub-unit
2 Quick release connector (fuel tank side, transfer
hose part)
3 Non-return valve4 Quick release connector (fuel tank side, main fuel
pipe part)
5 Fuel tank
6 Fuel pump unit
7 Filler cap

F1–10
FUEL SYSTEM
SYSTEM DIAGRAMA6E391201006203
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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

FUEL SYSTEM
F1–11
F1
Operation
•The fuel jet pump (venturi) is installed in the return passage from the pressure regulator, and fuel in the fuel
tank is pumped to the left side from the right side using the vacuum generated in the passage.
•When the return fuel pressure exceeds a specified value, the relief valve is opened. The relief valve delivers the
return fuel directly to the fuel tank. In this way, pressure of the return fuel passing through the fuel jet pump is
kept constantly below the specified value.
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9
8
7
54
3
10
14
13
11
12
6
1
2
:
:
2
15
A6E39122003
1 Fuel pump unit
2 Fuel pump (transfer)
3 Fuel injector
4 Fuel tank (left side)
5 Fuel tank (right side)
6 Relief valve
7 Discharge outlet
8 From pressure regulator9 From fuel tank (right side)
10 Fuel jet pump
11 To fuel tank (left side)
12 Fuel jet pump
13 From fuel tank (left side)
14 Fuel flow
15 Pumped fuel flow

F1–12
FUEL SYSTEM
QUICK RELEASE CONNECTOR (FUEL TANK SIDE, TRANSFER HOSE PART)A6E391242692201Function
•The quick release connector makes disconnecting and connecting of fuel hoses and fuel pipes easy.
Structure
•The quick release connector is adopted for the transfer hose part of the fuel tank side.
•The quick release connector is composed of a retainer, O-ring and other parts. The quick release connector
and plastic fuel hose are integrated and cannot be disconnected.
•The retainer and quick release connector are integrated and cannot be disconnected.
•An SST is not required to uncouple this type of quick release connector.
.
Operation
•Squeeze the tabs of the retainer to unlock and disconnect the quick release connector from the fuel pipe.
•A click is heard when the tabs of the retainer are pushed correctly into the lock point of the quick release
connector.
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3
1
2
A6E39122010
1Tab
2 Quick release connector3 Disconnect
7
5
4
3
6
1
21
A6E39122011
1 O-ring
2 Lock point
3 Disconnect
4Fuel hose5 Quick release connector
6 Retainer
7 Fuel pipe

EXHAUST SYSTEM
F1–13
F1
OUTLINEA6E391440000201•The exhaust system is essentially carried over from that of the current Mazda6 (GG), except for the following.
(See Mazda6 Training Manual 3359-1*-02C.)
—The TWC and the presilencer have been become separate parts, and removal/installation procedure has
been changed.
—The layout of the front HO2S has been changed.
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STRUCTURAL VIEWA6E391440000202
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EXHAUST SYSTEM
5
4
3
6
1
2
A6E39142001
1 Exhaust manifold
2 HO2S (front)
3 HO2S (rear)4TWC
5 Presilencer
6 Main silencer

F1–14
CONTROL SYSTEM
OUTLINEA6E394018880201•The control system is essentially carried over from the current Mazda6 (GG), except for the following. (See
Mazda6 Training Manual 3359-1*-02C.)
Vehicle Adoption
4WD ATX model
•TCM has been adopted. Due to this the PCM terminal of ATX device has been replaced to TCM. The ATX
device information which is needed by the fuel and emission control systems is communicated to the PCM by
the controller area network (CAN).
Unleaded (RON 90 or above) model
•BARO sensor has been eliminated. Due to this the BARO factor for purge control has been eliminated.
Input Device
×:Applicable
—: Not applicable
*
1: For MTX model
*2: With Immobilizer system
CONTROL SYSTEM
Item SignalMazda6 (GG, GY)
Remark for new model
4WD ATX Unleaded
(RON 90 or
above)Current
model
MAF/IAT sensor MAF and IAT×Same as current model
TP sensor TP×Same as current model
MAP sensor MAP×Same as current model
ECT sensor ECT×Same as current model
CMP sensorCylinder
identification×Same as current model
CKP sensor Engine revolution×Same as current model
Knock sensor Knocking×Same as current model
HO2S (Front, Rear)Oxygen
concentration×Same as current model
BARO sensor BARO×—×Same as current model
Neutral switch*
1Load/no load
distinction×Same as current model
Clutch switch*
1Load/no load
distinction×Same as current model
Brake switchBrake pedal
condition×Same as current model
PSP switchP/S oil pump load
condition×Same as current model
VSS Vehicle speed—×—
A/C switch, refrigerant
pressure switch (high,
low pressure)A/C operational×Same as current model
Refrigerant pressure
switch (middle
pressure)A/C compressor load×—×Same as current model
Battery Battery voltage×Same as current model
Generation voltage
(Generator terminal P)Generation voltage×Same as current model
Immobilizer unit*
2Immobilizer system
communication×—×Same as current model

CONTROL SYSTEM
F1–15
F1
Output Device
×:Applied
—: Not applied
* : For L3 engine only
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Item SignalMazda6 (GG, GY)
Remark for new model
4WD ATX Unleaded
(RON 90
or above)Current
model
IAC valve IAC×Same as current model
VIC solenoid valve* VIC×—×Same as current model
Variable tumble control
solenoid valveVTCS×Same as current model
Oil control valve (OCV)*Variable valve
timing control×—×Same as current model
Fuel injectorFuel injection
control×Same as current model
Fuel pump relayFuel pump
control×Same as current model
Ignition coil ESA control×Same as current model
EGR valve EGR control×Same as current model
Purge solenoid valve Purge control×Same as current model
BARO factor for Purge control has been
eliminated.
Heated oxygen sensor
heater
(Front, rear)O2S heater
control×Same as current model
Field coil
(Generator terminal D)Generator
control×Same as current model
Cooling fan relayElectric fan
control×Same as current model
A/C relayA/C cut-off
control×Same as current model
Controller area network
(CAN)Information
function×Same as current model
TCM (ATX) information have been
adopted for 4WD ATX model.

F1–16
CONTROL SYSTEM
STRUCTURAL VIEW (4WD)A6E394018880202
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9
8
7
5
4
3
10
1817
15
16
14
13
11
12
20
25
24
23
21
22
6
1
2
19
A6E39402000
1 MAF/IAT sensor
2 TP sensor
3 MAP sensor
4 CMP sensor
5 CKP sensor
6 ECT sensor
7 Knock sensor
8 HO2S (front)
9 HO2S (rear)
10 PSP switch
11 Brake switch
12 VAD control solenoid valve
13 IAC valve14 VIC solenoid valve
15 Variable tumble control solenoid valve
16 OCV
17 Fuel injector
18 Ignition coil
19 Purge solenoid valve
20 EGR valve
21 BARO sensor
22 PCM (R.H.D.)
23 TCM (R.H.D)
24 PCM (L.H.D.)
25 TCM (L.H.D)