2002 MAZDA 6 clutch

ENGINE
B2–27
B2
ENGINE REMOVAL/INSTALLATIONA6E232401001201
Warning
•Fuel vapor is hazardous. It can very 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 injures or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line
Safety Procedure”. (See F2–45 Fuel Line Safety Procedures.)
1. Disconnect the negative battery cable.
2. Drain the engine coolant, engine oil, and transaxle oil.
3. Remove the radiator.
4. Remove the engine cover. (See B2–9 TIMING BELT REMOVAL/INSTALLATION.)
5. Remove the air cleaner and air hose. (See F2–36 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.)
6. Disconnect the fuel hose. (See F2–45 BEFORE REPAIR PROCEDURE.)
7. Remove the front pipe. (See F2–57 EXHAUST SYSTEM REMOVAL/INSTALLATION.)
8. Remove the battery and tray. (See G–5 BATTERY REMOVAL/INSTALLATION.)
9. Remove the shift cable, select cable and clutch release cylinder related to the transaxle. (See J2–7 MANUAL
TRANSAXLE REMOVAL/INSTALLATION.)
10. Remove the clutch release cylinder.
11. Remove the vacuum hose and the heater hose.
12. Disconnect the P/S oil pump pressure pipe and P/S oil pump relief hose from the P/S oil pump side. (See N–16
POWER STEERING OIL PUMP (MZR-CD (RF Turbo)) REMOVAL/INSTALLATION.)
Note
•The P/S oil pump will not be removed from the engine.
13. Remove the A/C compressor with the pipe still connected. Position the A/C compressor so that it is out of the
way. Use wire or rope to secure it. (See U–11 A/C COMPRESSOR REMOVAL/INSTALLATION.)
14. Remove the joint shaft.
15. Remove the front drive shaft (LH) from the transaxle.
16. Remove in the order indicated in the table.
17. Install in the reverse order of removal.
18. Fill the engine coolant, engine oil, and transaxle oil.
19. Bleed the air from the fuel line. (See F2–45 AFTER REPAIR PROCEDURE.)
20. Start the engine and:
•Inspect the pulleys and the drive belt for runout and contact.
•Inspect the engine oil, engine coolant transaxle oil, P/S fluid, and fuel for leakage.
•Inspect the idle speed. (See F2–34 IDLE SPEED INSPECTION.)
21. Perform a road test.
22. Reinspect the engine oil, engine coolant, transaxle oil, and P/S fluid levels.
ENGINE

B2–32
ENGINE
No.1 Engine Mount Bracket Installation Note
1. Tighten No.1 engine mount bracket bolt A.
Tightening torque
93.1—116.6 N·m {9.5—11.8 kgf·m,
68.7—85.9 ft·lbf}
2. Tighten No.1 engine mount bracket bolt B.
Tightening torque
93.1—116.6 N·m {9.5—11.8 kgf·m,
68.7—85.9 ft·lbf}
No.1 Engine Mount Rubber Installation Note
1. Tighten through-bolt A on the No.1 engine mount
bracket.
Tightening torque
85.3—116.6 N·m {8.7—11.8 kgf·m,
62.9—85.9 ft·lbf}
2. Tighten through-bolt B on the front crossmember
side.
Tightening torque
93.1—116.6 N·m {9.5—11.8 kgf·m,
68.7—85.9 ft·lbf}
End Of SieENGINE DISASSEMBLY/ASSEMBLYA6E2324010012021. Disconnect the engine and transaxle. (See J2–7 MANUAL TRANSAXLE REMOVAL/INSTALLATION.)
2. Remove the intake-air system. (See F2–36 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.)
3. Remove the exhaust system. (See F2–57 EXHAUST SYSTEM REMOVAL/INSTALLATION.)
4. Remove the generator. (See G–7 GENERATOR REMOVAL/INSTALLATION.)
5. Remove the clutch. (See H–5 CLUTCH UNIT REMOVAL/INSTALLATION (A65M-R manual transaxle
models).)
6. Remove the vacuum pump. (See P–13 VACUUM PUMP REMOVAL/INSTALLATION (MZR-CD (RF
TURBO)).)
7. Remove the P/S oil pump. (See N–16 POWER STEERING OIL PUMP (MZR-CD (RF Turbo)) REMOVAL/
INSTALLATION.)
8. Disassemble in the order indicated in the table.
9. Assemble in the reverse order of disassembly.
A
B
A6E2324W207
A B
A6E2324W201

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

F1–18
CONTROL SYSTEM
*1: For MTX model
*2: For 2WD ATX model
*3: For L3 engine
End Of Sie
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, rear)
9 PSP switch
10 Vehicle speedometer sensor
11
Clutch switch*
1
12
Neutral switch*1
13
TR switch*2
14 Brake switch
15 A/C switch
16 Refrigerant pressure switch
17 Generator (terminal P: generation voltage)
18 Battery
19
VAD control solenoid valve*
3
20 IAC valve
21
VIC solenoid valve*
3
22 Variable tumble control solenoid valve
23
OCV*
3
24 Fuel injector
25 Fuel pump relay
26 Ignition coil
27 Purge solenoid valve
28 EGR valve
29 Oxygen sensor heater (front, rear)
30 A/C relay
31 Cooling fan relay
32 Generator (terminal D: field coil)
33
VAD control*
3
34 IAC
35
VIC*
3
36 VTCS
37
Variable valve timing control*
3
38 Fuel injection control
39 Fuel pump control
40 Electronic spark advance (ESA) control
41 Purge control
42 EGR control
43 Oxygen sensor heater control
44 A/C cut-off control
45 Electrical fan control
46 Generator control

CONTROL SYSTEM
F1–19
F1
CONTROL DEVICE AND CONTROL RELATIONSHIP CHARTA6E394018880204Input devices
x: Applicable
*
1: For unleaded fuel (RON 90 or above) model
*2: For MTX model
*3: For 2WD ATX model
Component
IAT sensor x x x xxxx×
MAF sensor x xx xxxxx
TP sensor x x x x x x x x
MAP sensor x x
ECT sensor xx xxx xxxxx x
CMP sensor x x
CKP sensor xxxxxxxxxxxxx
Knock sensor x
Front HO2S x x
Rear HO2S x
BARO sensor*
1x
Neutral switch*
2xxxx
Clutch switch*
2xxxxx
TR switch*
3xxxxx
Brake switch
PSP switch x x x
VSS×
A/C switch, refrigerant
pressure switch (high,
low pressure)xxx××
Refrigerant pressure
switch (middle pressure)×
Battery voltage x x x×
Generator terminal P
(Generation voltage)xxx×
ABS/TCS HU/CM×
Coil×
Idle air control (IAC)Variable air duct (VAD)
controlVariable intake-air
control (VIC)Variable tumble
control system (VTCS)Variable valve timing controlFuel injection controlFuel pump controlElectronic spark advance
(ESA) controlPurge controlEGR controlFront HO2S heater controlRear HO2S heater controlA/C cut-off controlElectrical fan controlGenerator controlTraction controlImmobilizer system

F1–34
CONTROL SYSTEM
BARO*7
(Barometric pressure)kPa, inHgIgnition switch ON (at sea level):
approx. 101 kPa {29.8 inHg}
Inspect BARO sensor. 1G
VIgnition switch ON (at sea level):
approx. 4.1 V
BOO
(Brake switch)ON/OFFBrake pedal depressed: ON
Brake pedal released: OFFInspect brake switch. 1K
CHRGLP (Generator
warning light)ON/OFFIgnition switch ON: ON
Idle: OFFPerform applicable DTC
troubleshooting.
(See F1–54 DTC TABLE)—
COLP*
4 (Refrigerant
pressure switch
(middle))ON/OFFRefrigerant pressure switch (middle)
ON *2 at idle: ON
Refrigerant pressure switch (middle)
OFF
*3 at idle: OFFInspect refrigerant pressure switch. 1Q
CPP*
8
(Clutch pedal position)ON/OFFClutch pedal depressed: ON
Clutch pedal released: OFFInspect clutch switch. 1R
CPP/PNP*
8 (Shift
lever position)Drive/
NeutralNeutral position: Neutral
Others: DriveInspect neutral switch. 1W
DTCCNT (Number of
DTC detected)——Perform applicable DTC
troubleshooting.
(See F1–54 DTC TABLE)—
ECT (Engine coolant
temperature)°C°FECT 20 °C {68 °F}: 20 °C {68 °F}
ECT 60 °C {140 °F}: 60 °C {140 °F}
Inspect ECT sensor. 1M
VECT 20 °C {68 °F}: 3.04—3.14 V
ECT 60 °C {140 °F}: 1.29—1.39 V
EVAPCP (Purge
solenoid valve duty
value)%Ignition switch ON: 0%
Idle: 0%Inspect following PIDs: IAT, RPM,
ECT, MAF, O2S11,BARO, INGEAR,
TR, VPWR.4U
FAN1
(Cooling fan control)ON/OFFECT below 100 °C {212 °F}: OFF
Others: ONInspect following PIDs: RPM, TP,
ECT, ACSW, COLP, TEST.
Inspect cooling fan relay.4L
FAN2
(Cooling fan control)ON/OFFECT below 108 °C {226 °F}: OFF
A/C operating, refrigerant pressure
switch (middle) is OFF, and ECT
below 108 °C {226 °F}: OFF
Others: ONInspect following PIDs: RPM, TP,
ECT, ACSW, COLP, TEST.
Inspect cooling fan relay.4F
FAN3
(Cooling fan control)ON/OFFECT below 100 °C {212 °F}: OFF
A/C operating, refrigerant pressure
switch (middle) is ON, and ECT
below 108 °C {226 °F}: OFF
Other: ONInspect following PIDs: RPM, TP,
ECT, ACSW, COLP, TEST.
Inspect cooling fan relay.4B
FDPDTC
(Pending code caused
FFD storage)——Perform applicable DTC
troubleshooting.
(See F1–54 DTC TABLE)—
FP (Fuel pump relay) ON/OFFIgnition switch ON: OFF
Idle: ON
Cranking: ONInspect following PIDs: RPM.
Inspect fuel pump relay.4P
*5
4Q*6
FUELPW (Fuel
injector duration)msIgnition switch ON: 0 ms
Idle (after warm up): approx. 2.5 msInspect following PIDs: IAT, MAF, TP,
MAP, ECT, RPM, O2S11, O2S12,
INGEAR, TR, PSP, ACSW, VPWR,
ALTT V.
Inspect fuel injector.4W, 4Z,
4AA,
4AD
FUELSYS
(Fuel system status)OL_Drive/
OL/
CL_Fault/
OL_Fault/CLIgnition switch ON: OL
Idle (after warm up): CLInspect following PIDs: IAT, MAF, TP,
MAP, ECT, RPM, O2S11, O2S12,
INGEAR, TR, PSP, ACSW, VPWR,
ALTT V.
Inspect fuel injector.—
GENVDSD
(Generator voltage
desired)VIgnition switch ON: 0 V
Idle: Approx. 14.9 V
*1 (E/L not
operating)Perform applicable DTC
troubleshooting.
(See F1–54 DTC TABLE)—
HTR11
(HO2S heater (front))ON/OFF Idle (after warm up): ON⇔OFFInspect following PIDs: IAT, MAF, TP,
ECT, RPM, ACSW.4A Monitor item
(Definition)Unit/
ConditionCondition/Specification
(Reference)ActionPCM
terminal

F1–38
CONTROL SYSTEM
1QRefrigerant
pressure switch
(middle)Refrigerant
pressure switch
(middle)A/C ONRefrigerant
pressure is
above 1.52
MPaBelow 1.0
•Inspect refrigerant
pressure switch
•Inspect related
harness Refrigerant
pressure is
below 1.23
MPaB+
1RClutch operation*
2Clutch switchClutch pedal depressed Below 1.0•Inspect clutch switch
•Inspect related
harness Clutch pedal released B+
—*
3————
1S—— — ——
1T—— — ——
1U—— — ——
1V—— — ——
1WNeutral position*
2Neutral switchShift lever is at neutral position Below 1.0
•Inspect neutral switch
•Inspect related
harness Shift lever is not at neutral
positionB+
Selector lever
position*
11TR switch
(terminal C)Ignition switch
ONP rangeApprox.
4.6
•Inspect TR switch
•Inspect related
harness R rangeApprox.
3.9
N rangeApprox.
3.2
D range*4
M range*5Approx.
2.5
S range*
4Approx.
1.7
L range*
4Approx.
0.94
—*
12————
1X—— — ——
1Y HO2S (rear) HO2S (rear)Ignition switch ON Approx. 0•Inspect HO2S (rear)
•Inspect related
harness Idle (after warm up) 0—1.0
1Z PSP PSP switch IdleSteering wheel
at straight
ahead positionB+•Inspect PSP switch
•Inspect power
steering system
•Inspect related
harness While turning
steering wheelBelow 1.0
1AAGenerator output
voltageGenerator
(terminal P)•Inspect using the wave profile.
(See F1–44 Inspection Using An
Oscilloscope (Reference).)•Inspect generator
•Inspect related
harness
1AB HO2S (front) HO2S (front)•Inspect using the wave profile.
(See F1–44 Inspection Using An
Oscilloscope (Reference).)•Inspect HO2S (front)
•Inspect related
harness
1AC A/C on signalRefrigerant
pressure switchIdleA/C switch and
fan switch onBelow 1.0•Inspect refrigerant
pressure switch
•Inspect related
harness A/C switch off B+
1ADGenerator field coil
controlGenerator
(terminal D)•Inspect using the wave profile.
(See F1–44 Inspection Using An
Oscilloscope (Reference).)•Inspect generator
•Inspect related
harness
2A Throttle position TP sensorIgnition switch
ONCTP0.65—
1.15•Inspect TP sensor
•Inspect related
harness
WOT 4.3—4.8
2B—— — ——
2C—— — —— Terminal Signal Connected to Test conditionVoltage
(V)Action

ON-BOARD DIAGNOSTIC
F1–51
F1
P0112 IAT circuit low input ON 1 CCM×
P0113 IAT circuit high input ON 1 CCM×
P0117 ECT circuit low input ON 1 CCM×
P0118 ECT circuit high input ON 1 CCM×
P0121 TP stuck closed ON 2 CCM×
P0122 TP circuit low input ON 1 CCM×
P0123 TP circuit high input ON 1 CCM×
P0125 Excessive time to enter closed loop fuel control ON 2 CCM×
P0131 Front HO2S no inversion (stuck low) ON 2 CCM×
P0132 Front HO2S no inversion (stuck high) ON 2 CCM×
P0133 Front HO2S circuit malfunction ON 2O
2 sensor
×
P0134 Front HO2S circuit no activity detected ON 2 CCM×
P0138 Rear HO2S circuit high input ON 2 CCM×
P0140 Rear HO2S circuit no activity detected ON 2 CCM×
P0171 Fuel trim system too lean ON 2 Fuel×
P0172 Fuel trim system too rich ON 2 Fuel×
P0300 Random misfire detected Flash / ON 1 or 2 Misfire×
P0301 Cylinder No.1 misfire detected Flash / ON 1 or 2 Misfire×
P0302 Cylinder No.2 misfire detected Flash / ON 1 or 2 Misfire×
P0303 Cylinder No.3 misfire detected Flash / ON 1 or 2 Misfire×
P0304 Cylinder No.4 misfire detected Flash / ON 1 or 2 Misfire×
P0327 Knock sensor circuit low input ON 1 CCM×
P0328 Knock sensor circuit high input ON 1 CCM×
P0335 CKP sensor circuit malfunction ON 1 CCM×
P0340 CMP sensor circuit malfunction ON 1 CCM×
P0403 EGR valve motor coils open or short ON 2 CCM×
P0420 Catalyst system efficiency below threshold ON 2 Catalyst×
P0443Evaporative emission control system purge control
valve circuit malfunctionON 2 CCM×
P0480 Fan relay control circuit malfunction OFF 2 Other×
P0500 Vehicle speed sensor (VSS) circuit malfunction ON 2 CCM×
P0505 Idle control system malfunction OFF—Other—
P0506 Idle control system RPM lower than expected ON 2 CCM×
P0507 Idle control system RPM higher than expected ON 2 CCM×
P0511 Idle control system circuit malfunction ON 1 CCM×
P0550 PSP switch circuit malfunction ON 2 CCM×
P0602 PCM programming error ON 1 CCM×
P0610 Control module vehicle options error ON 1 CCM×
P0661 VIS control circuit low input OFF 2 Other×
P0662 VIS control circuit high input OFF 2 Other×
P0703 Brake switch input malfunction ON 2 CCM×
P0704 Clutch switch input malfunction ON 2 CCM×
P0850 Neutral switch input malfunction ON 2 CCM×
P1410 Variable air duct valve circuit malfunction OFF 2 Other×
P1562 PCM +BB voltage low ON 1 CCM×
P2006 Variable tumble control shutter valve stuck closed ON 2 CCM×
P2009 Variable tumble control solenoid circuit low input ON 2 CCM×
P2010 Variable tumble control solenoid circuit high input ON 2 CCM×
P2228 BARO sensor circuit low input ON 1 CCM×
P2229 BARO sensor circuit high input ON 1 CCM×
P2502 Generator output voltage signal no electricity OFF 1 Other—
P2503 Battery overcharge OFF 1 Other—
P2504 Generator terminal B circuit open OFF 1 Other—
U0073 CAN bus off OFF 1 Other— DTC No. Condition MIL DC Monitor itemMemory
function