2002 MAZDA 6 catalytic converter

F2–14
EMISSION SYSTEM
OUTLINEA6E401601007201•The emission system is essentially carried over from that of the current MPV (LW) MZR-CD (RF Turbo) engine
model. (See MPV Workshop Manual Supplement 1737-1*-02D.)
×:Applicable
End Of Sie
EMISSION SYSTEM
ItemMazda6
(GG,GY)Current
MPV (LW)
Remark for new model
MZR-CD (RF Turbo)
Rollover valve×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Shape has been changed
Check valve (two-way)×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Shape has been changed
Intake shutter valve actuator×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Intake shutter solenoid valve
(half) (full)×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
EGR valve×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
EGR solenoid valve (vacuum)
(vent)×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
EGR control solenoid valve×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
EGR water cooler×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Warm up oxidation catalytic
converter×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Oxidation catalytic converter×Same function as MPV (LW) MZR-CD (RF Turbo) engine model

EMISSION SYSTEM
F2–15
F2
STRUCTURAL VIEWA6E401601007202Engine room side
.
Fuel tank side
.
9
8
7
5
4
3
10
6
2
1
A6E40162018
1EGR water cooler
2EGR valve
3 Intake shutter solenoid valve (full)
4 Intake shutter solenoid valve (half)
5 EGR solenoid valve (vacuum)6 Warm up oxidation catalytic converter
7 Intake shutter valve actuator
8 Oxidation catalytic converter
9 EGR solenoid valve (vent)
10 EGR control solenoid valve
1
2
A6E40162019
1 Rollover valve2 Check valve (two-way)

F2–16
EMISSION SYSTEM, CONTROL SYSTEM
End Of SieWARM UP OXIDATION CATALYTIC CONVERTER DESCRIPTIONA6E401601007203•The warm up oxidation catalytic converter capacity has been increased to 1,920 ml {1,920 cc, 117 cu in} in
order to improve emission performance.
End Of Sie
OUTLINEA6E404018881201•The control system is essentially carried over from that of the current MPV (LW) MZR-CD (RF Turbo) engine
models. (See MPV Workshop Manual Supplement 1737-1*-02C.)
Input Device
×:Applicable –: Not applicable
CONTROL SYSTEM
ItemMazda6
(GG, GY)Current
MPV (LW)
Remark for new model
MZR-CD (RF Turbo)
Battery×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Starter (starter signal)×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Starter relay×–Newly adopted
Clutch switch×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Neutral switch×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Brake switch×Same function as Mazda6 (GG) L series engine model
Idle switch×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
A/C switch×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Refrigerant pressure switch×Same function as 626 (GF, GW) RF Turbo engine model
Cruise control switch×Same function as Mazda6 (GG) L series engine model
Accelerator position sensor×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
MAF/IAT sensor×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
IAT sensor No.2×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
ECT sensor×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Fuel temperature sensor×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
BARO sensor (integrated in PCM)×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Boost sensor×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Fuel pressure sensor×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
CMP sensor×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
CKP sensor×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
VSS×Vehicle speed signal is received by CAN
Calibration resistor×Same function as MPV (LW) MZR-CD (RF Turbo) engine model
Immobilizer unit (integrated in
PCM)×Immobilizer unit equipped into PCM

INTAKE-AIR SYSTEM
F2–39
F2
Turbine Wheel Inspection
1. Remove the warm up oxidation catalytic converter between the flexible pipe and the turbocharger. (See F2–57
EXHAUST SYSTEM REMOVAL/INSTALLATION.)
2. Visually inspect the turbine wheel from view B and verify that all fins are free from damage, cracks or bends.
•If there are damaged fins, cracks or bends, replace the turbocharger.
Note
•To make the inspection easier, set a small
mirror as shown in the figure and use a
penlight.
•If the turbine wheel is interfering with the
turbine housing, it is likely that the fin edges
are cracked, damaged, or bent.
•If the turbine wheel is damaged, check the
following before replacing the turbocharger
to avoid reoccurrence of the problem.
—Foreign material in intake air/exhaust
system.
—Oil pipe clogging.
End Of Sie
GUIDE BLADE ACTUATOR INSPECTIONA6E4010137002021. Disconnect the vacuum hose from the guide blade actuator.
2. Connect the vacuum pump to the guide blade
actuator.
3. Apply vacuum and verify that the rod moves as
specified.
•If not as specified, replace the turbocharger.
Specification
End Of Sie
MIRRORB
GRINDING MARK
A6E40102010
Vacuum (kPa {mmHg, inHg}) Rod movement
Below –14.5 {–108, –4.27} Starts to move
Above –44.9 {–337, –13.3} Fully pulled
VACUUM PUMP
ROD
A6E40102011

EXHAUST SYSTEM
F2–57
F2
EXHAUST SYSTEM INSPECTIONA6E4014400002031. Start the engine and inspect each exhaust system component for exhaust gas leakage.
•If leakage is found, repair or replace as necessary.
End Of Sie
EXHAUST SYSTEM REMOVAL/INSTALLATIONA6E401440000204
Warning
•When the engine and exhaust system are hot, they can cause severe burns or injury. Turn off the
engine and wait until they are cool before removing the exhaust system.
1. Disconnect the negative battery cable.
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.
.
EXHAUST SYSTEM
13
B
B
A
A
N·m {kgf·m, ft·lbf} 7.9—10.7 N
·m
{80—110 kgf·cm,
70—94 in·lbf}
7.9—10.7 N
·m
{80—110 kgf·cm,
70—94 in·lbf}
38—51
{3.9—5.2,
29—37} 7.9—10.7 N·m
{80—110 kgf·cm,
70—94 in·lbf}
38—51
{3.9—5.2,
29—37} 38—51
{3.9—5.2,
29—37} 21.6—26.5
{2.2—2.7,
16.0—19.5} 8.9—12.7 N
·m
{90—130 kgf·cm,
79—112 in·lbf}
8.9—12.7 N·m
{90—130 kgf·cm,
79—112 in·lbf}
43—60
{4.3—6.1, 31—44} 40.3—54.7
{4.11—5.57,
29.8—40.3}
43—60
{4.3—6.1, 31—44}9.1—14.3 N·m
{93—145 kgf·cm,
81—126 in·lbf} 11.8—17.6
{1.2—1.7, 8.7—12.9} 15.7—23.5
{1.6—2.3, 11.6—17.3}
7.9—10.7 N·m
{80—110 kgf·cm,
70—94 in·lbf}
38.2—46.1
{3.9—4.7, 28—34}
R
R
RR
R
R
R
R
RR
R
R
R
9
8
7
5
4
310
11
12
6
1
2
14
R
R
A6E40142006
1 Main silencer
2 Middle pipe
3 Oxidation catalytic converter
4 Front pipe5 Warm up oxidation catalytic converter
(See F2–58 Warm Up Oxidation Catalytic Converter
Removal Note)
6 Turbocharger insulator No. 1
7 Turbocharger insulator No. 2

F2–58
EXHAUST SYSTEM
Warm Up Oxidation Catalytic Converter Removal Note
1. Support the crossmember using a jack before
removing the crossmember bracket.
2. Loosen the jack and lower the crossmember.
3. Remove the warm up oxidation catalytic
converter.
Water Hose Removal Note
1. Drain the engine coolant.
Turbocharger Removal Note
1. Remove the air pipe and the air hose before
removing the turbocharger. (See F2–36
INTAKE-AIR SYSTEM REMOVAL/
INSTALLATION.)
Exhaust Manifold Removal Note
1. Remove the EGR pipe before removing the exhaust manifold. (See F2–59 EGR VALVE REMOVAL/
INSTALLATION.)
Exhaust Manifold Installation Note
1. Tighten the exhaust manifold installation nuts in
the order shown.
Water Pipe Installation Note
1. Install the connector bolt before installing the
water pipe bracket.
Oil Pipe (Supply) Installation Note
1. Install the connector bolt before installing the
water pipe bracket.
End Of Sie
8 Exhaust manifold insulator
9 Oil pipe (supply)
(See F2–58 Oil Pipe (Supply) Installation Note)
10 Oil pipe (return)
11 Water hose
(See F2–58 Water Hose Removal Note)12 Water pipe
(See F2–58 Water Pipe Installation Note)
13 Turbocharger
(See F2–58 Turbocharger Removal Note)
14 Exhaust manifold
(See F2–58 Exhaust Manifold Removal Note)
(See F2–58 Exhaust Manifold Installation Note)
FRONT
CROSSMEMBER
CROSSMEMBER
BRACKET FRONT
A6E0612W107
87
5436
12
A6E40142003

REAR DIFFERENTIAL
M–51
M
REAR DIFFERENTIAL REMOVAL/INSTALLATIONA6E6319271002071. Drain the rear differential oil into a container.
2. Remove the after silencer, presilencer, and catalytic converter. (See F1–30 EXHAUST SYSTEM REMOVAL/
INSTALLATION.)
3. Remove the propeller shaft. (See L–5 PROPELLER SHAFT REMOVAL/INSTALLATION.)
4. Remove the rear drive shaft. (See M–43 REAR DRIVE SHAFT REMOVAL/INSTALLATION.)
5. Remove in the order indicated in the table.
6. Install in the reverse order of removal.
7. Add the specified rear differential oil.
.
SEALANTSEALANT
5
3
12
6
86.2—116.6
{8.8—11.9,
63.6—85.9}
74.5—104.9
{7.6—10.6, 55.0—77.3}
43.1—60.8
{4.4—6.1,
31.8—44.8}
22.6—26.4
{2.4—2.6,
16.7—19.4}
4
N·m {kgf·m, ft·lbf}
A6E63192201
1 Differential oil temperature sensor connector
2 4WD solenoid connector
3 Coupling component and rear differential
component
(See M–52 Coupling Component and Rear
Differential Component Removal/installation Note)
4 Rear differential bracket 5 Coupling component
(See M–68 COUPLING COMPONENT REMOVAL/
INSTALLATION)
6 Rear differential

M–68
ELECTRONIC 4WD CONTROL SYSTEM
COUPLING COMPONENT REMOVAL/INSTALLATIONA6E6322271002141. Drain the differential oil into a container.
2. Remove the after silencer, presilencer, and the catalytic converter. (See F1–30 EXHAUST SYSTEM
REMOVAL/INSTALLATION.)
3. Remove the propeller shaft. (See L–5 PROPELLER SHAFT REMOVAL/INSTALLATION.)
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.
6. Add differential oil.
.
Coupling Component Removal Note
1. Support the coupling unit with a transmission jack.
2. Cut away the coupling unit using an oil pan seal
cutter.
Coupling Component Installation Note
Note
•Clean away the old sealant before applying the new sealant.
•Install the coupling unit within 10 minutes after applying sealant.
•Allow the sealant to set at least 30 minutes after installation before filling the differential with the specified
oil.
3
12
SEALANTSEALANT
74.5—104.9
{7.6—10.6, 55.0—77.3}22.6—26.4
{2.4—2.6, 16.7—19.4}
N·m {kgf·m, ft·lbf}
A6E63222106
1 4WD solenoid connector
2Bolt3 Coupling component
(See M–68 Coupling Component Removal Note)
(See M–68 Coupling Component Installation Note)
OIL PAN
SEAL CUTTER
A6E63222107