2002 MAZDA 6 oil

TROUBLESHOOTING
F2–215
F2
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15 Inspect if turbocharger compressor wheel
locknut is loose or has fallen down inside
turbocharger.
Is there any problem?Yes Replace turbocharger.
No Go to next step.
16 Inspect if turbocharger compressor wheel by
hand.
Does wheel turn easily and smoothly?Yes Go to next step.
No Replace turbocharger.
17 Inspect if turbocharger turbine wheel is
damaged, cracked or interfering with housing on
vehicle.
Note
•Inspect all fins on each turbine wheel.
Is there any problem?Yes Replace turbocharger.
No Go to next step.
18 Is any engine oil found inside turbocharger
compressor housing?Yes Wipe oil off of vehicle and install all removed parts in
Step 15. Then, go to next step.
No Turbocharger is okay.
Install all parts removed is Step 15. Then, go to next
step.
19 Inspect suction control valve.
(See F2–54 SUCTION CONTROL VALVE
INSPECTION)
Is suction control valve okay?Yes Go to next step.
No Repair supply pump.
(See F2–54 SUPPLY PUMP INSPECTION)
20 Is engine compression correct?
(See B2–8 COMPRESSION INSPECTION)Yes Go to next step.
No Inspect for following:
•Damaged valve seat
•Worn valve stem and valve guide
•Worn or stuck piston ring
•Worn piston, piston ring or cylinder
•Improper valve timing
Service as necessary.
21 Inspect IDM.
(See F2–84 INJECTOR DRIVER MODULE
(IDM) INSPECTION)
Is IDM okay?Yes Go to next step.
No Repair or replace as necessary.
22 Inspect fuel injector.
(See F2–56 FUEL INJECTOR INSPECTION)
Is fuel injector okay?Yes Inspect following:
•Boost sensor
•Fuel pressure limiter (built-in common rail)
•Fuel pressure sensor
•Fuel return line restriction or clogging
Service as necessary.
No Repair or replace as necessary.
23 Verify test results.
•If okay, return to diagnostic index to service any additional symptoms.
•If malfunction remains, replace PCM. (See F2–64 PCM REMOVAL/INSTALLATION) STEP INSPECTION RESULTS ACTION

TROUBLESHOOTING
F2–217
F2
NO.21 ENGINE NOISEA6E408018881223
Diagnostic Procedure
21 ENGINE NOISE
DESCRIPTION•Engine noise under hood.
POSSIBLE
CAUSE•Engine internal damage
•Timing belt displacement
•Fuel injector malfunction
•Loose attaching bolts or worn parts
•Improper drive belt tension
•Air leakage from intake-air system
•Incorrect injection timing
•Erratic signal from CKP sensor
•Erratic signal from CMP sensor
•Fuel pressure sensor or related circuit malfunction
•Boost sensor or related circuit malfunction
•Accelerator position sensor or related circuit malfunction
•MAF/IAT sensor or related circuit malfunction
•ECT sensor or related circuit malfunction
•EGR system or malfunction
•IAT sensor No.2 or related circuit malfunction
•Vacuum leakage
•Suction control valve malfunction (built-in supply pump)
•Air leakage from intake-air system
•Air in power steering fluid line
•Turbocharger operating noise
•Solenoid valve operating noise
Warning
The following troubleshooting flow chart contains the fuel system diagnosis and repair
procedures. Read the following warnings before performing the fuel system services:
•Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel.
•Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injury or death
and damage. Fuel can also irritate skin and eyes. To prevent this, always complete “BEFORE
REPAIR PROCEDURE” and “AFTER REPAIR PROCEDURE” described in this manual.
Note
•PCM checks fuel injection amount during a set interval while idling, and automatically corrects it to
maintain engine efficiency. It is normal that engine noise and vibration might be a little louder during
this process.
STEP INSPECTION RESULTS ACTION
1 Is squeal, click or chirp sound present? Yes Inspect engine oil level, solenoid valves installation or
drive belt.
No Go to next step.
2 Is rumble or grind sound present? Yes Inspect drive belt tension or power steering system
fluid level.
If okay, perform power steering fluid line air bleed.
No Go to next step.
3 Is rattle sound present? Yes Inspect location of rattle for loose parts.
No Go to next step.
4 Is hiss sound present? Yes Inspect for vacuum leakage and intake-air system
leakage.
No Go to next step.
5 Is rap or roar sound present? Yes Inspect exhaust system or loose parts.
No Go to next step.

TROUBLESHOOTING
F2–219
F2
End Of Sie
14 Inspect if turbocharger compressor wheel
locknut is loose or has fallen down inside
turbocharger.
Is there any problem?Yes Replace turbocharger.
No Go to next step.
15 Turn turbocharger compressor wheel by hand.
Does wheel turn easily and smoothly?Yes Go to next step.
No Replace turbocharger.
16 Inspect if turbocharger turbine wheel is
damaged, cracked or interfering with housing on
vehicle.
Note
•Inspect all fins on each turbine wheel.
Is there any problem?Yes Replace turbocharger.
No Go to next step.
17 Is any engine oil found inside turbocharger
turbine housing?YesExcessive amount of oil is found:
Replace turbocharger.
Small amount of oil is found:
Wipe oil off of vehicle, then go to next step.
No Go to next step.
18 Is any engine oil found inside turbocharger
compressor housing?Yes Wipe oil off of vehicle, then go to next step.
No Go to next step.
19 Is any exhaust gas leakage found around
location where turbocharger is attached to
exhaust manifold?Yes Remove turbocharger.
Inspect for cracks on center housing inlet surface.
If cracks are found, replace turbocharger.
No Go to next step.
20 Are any center housing and turbine housing
attaching bolts loose?Yes Retighten loose bolts.
If a bolt is found to be missing, attach appropriate new
bolts.
No Turbocharger is okay.
Install all parts removed in Step 13.
Go to next step.
21 Inspect suction control valve.
(See F2–54 SUCTION CONTROL VALVE
INSPECTION)
Is suction control valve okay?Yes Go to next step.
No Repair supply pump.
(See F2–54 SUPPLY PUMP INSPECTION)
22 Inspect fuel injector and fuel injector gasket.
(See F2–56 FUEL INJECTOR INSPECTION)
Is fuel injector okay?Yes Inspect for following:
•Metal flow
•Bent connecting rod
•Damaged valve seat
•Incorrect valve clearance
No Repair or replace as necessary.
23 Verify test results.
•If okay, return to diagnostic index to service any additional symptoms.
•If malfunction remains, replace PCM. (See F2–64 PCM REMOVAL/INSTALLATION) STEP INSPECTION RESULTS ACTION

F2–222
TROUBLESHOOTING
NO.23 A/C DOES NOT WORK SUFFICIENTLYA6E408018881225
Diagnostic Procedure
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23 A/C DOES NOT WORK SUFFICIENTLY
DESCRIPTION•A/C compressor magnetic clutch does not engage when A/C switch is turned on.
POSSIBLE
CAUSE•Improper refrigerant charge amount
•Open A/C switch magnetic clutch
•Open circuit between A/C relay and A/C magnetic clutch
•Poor GND of A/C magnetic clutch
•Improper A/C magnetic clutch clearance
•Refrigerant pressure switch is stuck open
•A/C relay is stuck open
•Improper A/C cut-off control
•Open circuit between A/C switch and PCM through both refrigerant pressure switch and A/C amplifier
STEP INSPECTION RESULTS ACTION
1 Perform self-test function using WDS or
equivalent.
Turn engine switch to ON.
Retrieve any DTC.
Is DTC displayed?YesDTC is displayed:
Go to appropriate DTC test.
Communication error message is displayed:
Inspect for following:
•Open circuit between PCM control relay and PCM
terminal 53 or 79
•Open circuit PCM control relay and PCM terminal
69
•PCM control relay stuck open
•Open or poor GND circuit (PCM terminal 65, 85,
103 or 104)
•Poor connection vehicle body GND
YesNo DTC is displayed:
Go to appropriate DTC test.
2 Disconnect A/C compressor connector.
Start engine and turn A/C switch to ON.
Is there correct voltage at terminal of A/C
compressor magnetic clutch connector?
Specification
More than 10.5 VYes Inspect for GND condition of magnetic clutch on A/C
compressor.
If GND condition is okay, inspect magnetic clutch coil
for open circuit.
No Go to next step.
3 Disconnect refrigerant pressure switch
connector.
Connect jumper wire between terminals of
refrigerant pressure switch connector.
Turn engine switch to ON.
Turn A/C switch on and set blower fan at any
speed.
Measure PCM terminal 84 voltage.
Is voltage below 1.0 V?Yes Inspect refrigerant pressure switch operation.
If switch is okay, go to next step.
No Inspect for following:
•A/C switch is stuck open
•Open circuit between refrigerant pressure switch
and PCM terminal 84
•Open circuit of blower motor fan switch and
resistor (if blower motor does not operate)
•Evaporator temperature sensor and A/C amplifier
4 Inspect A/C cut-off operation.
Does A/C cut-off work properly?Yes Go to next step.
No Repair or replace malfunctioning part according to A/C
cut-off system inspection results.
5 Remove jumper wire from switch connector.
Reconnect connector to refrigerant pressure
switch.
Start engine and turn A/C switch on.
Does fan operate?Yes Inspect for stuck open A/C relay.
Replace if necessary.
No Inspect following and repair or replace as necessary:
•Refrigerant charging amount
•Seized A/C compressor
6 Verify test results.
•If okay, return to diagnostic index to service any additional symptoms.
•If malfunction remains, replace PCM. (See F2–64 PCM REMOVAL/INSTALLATION)

STARTING SYSTEM
G–9
G
STARTER REMOVAL/INSTALLATIONA6E471418400202
Warning
•When the battery cables are connected, touching the vehicle body with starter terminal B will
generate sparks. This can cause personal injury, fire, and damage to the electrical components.
Always disconnect the battery negative cables before performing the following operation.
1. Disconnect the negative battery cable.
2. Remove the plug hole plate. (L8, LF, and L3 engine models)
3. Remove the engine cover. (MZR-CD (RF Turbo) engine model) (See B2–9 TIMING BELT REMOVAL/
INSTALLATION.)
4. Remove the air cleaner assembly. (L8, LF, and L3 engine models).
5. Remove the under cover.
6. Remove the oil filter and oil cooler component with the cooling hose connected. Position the oil filter and oil
cooler component so that it is out of the way. (L3 engine model (4WD))
7. Remove the solenoid valve assembly with the vacuum hose and the connector connected. Position the
solenoid valve assembly so that it is out of the way. (MZR-CD (RF Turbo) engine model)
8. Remove the release cylinder with the oil pipe connected. Position the release cylinder so that it is out of the
way. (MTX)
9. Remove in the order indicated in the table.
10. Install in the reverse order of removal.
STARTING SYSTEM

J2–1
J2
J2MANUAL TRANSAXLE [A65M-R]
OUTLINE.............................................................. J2-2
OUTLINE OF CONSTRUCTION........................ J2-2
FEATURES ........................................................ J2-2
SPECIFICATIONS ............................................. J2-2
LOCATION INDEX............................................... J2-3
MANUAL TRANSAXLE LOCATION INDEX ...... J2-3
MANUAL TRANSAXLE........................................ J2-4
TRANSAXLE OIL INSPECTION ........................ J2-4
TRANSAXLE OIL REPLACEMENT ................... J2-4
OIL SEAL (DIFFERENTIAL) REPLACEMENT .. J2-5
REVERSE SWITCH INSPECTION .................... J2-5
REVERSE SWITCH
REMOVAL/INSTALLATION ............................ J2-6
NEUTRAL SWITCH INSPECTION .................... J2-6
NEUTRAL SWITCH
REMOVAL/INSTALLATION ............................ J2-7
MANUAL TRANSAXLE
REMOVAL/INSTALLATION ............................ J2-7
SHIFT MECHANISM........................................... J2-12
SHIFT MECHANISM
REMOVAL/INSTALLATION .......................... J2-12 FEATURES
SERVICE

J2–2
OUTLINE
OUTLINE OF CONSTRUCTIONA6E520201025203•The construction and operation of the manual transaxle is the same as those of the current A65M-R type
manual transaxle, except for the following features. (See MPV Workshop Manual supplement 1737-1*-02D.)
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FEATURESA6E520201025201Improved drivability
•The gear ratio has been changed.
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SPECIFICATIONSA6E520201025202
Bold frames:New specifications
End Of Sie
OUTLINE
Item New Mazda6 (GG, GY) Current MPV (LW)
Transaxle typeA65M-R
Transaxle control Floor-shift
Operation system Cable
Shift assistForward
Synchromesh
Reverse
Gear ratio1st 3.416
2nd 1.944 1.789
3rd 1.258 1.193
4th 0.902
5th 0.659
Reverse 3.252
Final gear ratio 3.588 4.133
OilGrade API service GL-4 or GL-5
Viscosity (All season) SAE 75W-90
Capacity (approximate quantity)
(L {US qt, Imp qt})2.30 {2.40, 2.00}

LOCATION INDEX
J2–3
J2
MANUAL TRANSAXLE LOCATION INDEXA6E520001036201
.
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LOCATION INDEX
2
5
36
4
1
A6E5200W001
1 Manual transaxle
(See J2–7 MANUAL TRANSAXLE REMOVAL/
INSTALLATION)
2 Shift mechanism
(See J2–12 SHIFT MECHANISM REMOVAL/
INSTALLATION)
3 Transaxle oil
(See J2–4 TRANSAXLE OIL INSPECTION)
(See J2–4 TRANSAXLE OIL REPLACEMENT)4 Oil seal (differential)
(See J2–5 OIL SEAL (DIFFERENTIAL)
REPLACEMENT)
5 Reverse switch
(See J2–5 REVERSE SWITCH INSPECTION)
(See J2–6 REVERSE SWITCH REMOVAL/
INSTALLATION)
6 Neutral switch
(See J2–6 NEUTRAL SWITCH INSPECTION)
(See J2–7 NEUTRAL SWITCH REMOVAL/
INSTALLATION)