2002 MAZDA 6 service

T–32
AIR BAG SYSTEM
SERVICE WARNINGSA6E813001046202Component Disassembly
•Disassembling and reassembling the
components of the air bag system can render
the system inoperative, which may result in
serious injury or death in the event of an
accident. Do not disassemble any air bag
system components.
Wiring Harness Repair
•Incorrectly repairing an air bag system wiring
harness can accidentally deploy the air bag
module or pre-tensioner seat belt, which can
cause serious injury. If a problem is found in
the system wiring, replace the wiring harness.
Do not try to repair it.
Air Bag Module Inspection
•Inspecting an air bag module using an
ohmmeter can deploy the air bag module,
which may cause serious injury. Do not use an
ohmmeter to inspect an air bag module.
Always use the on-board diagnostic to
diagnose the air bag module for malfunctions.
Air Bag Module Handling
•A live (undeployed) air bag module may
accidentally deploy when it is handled and
cause serious injury. When carrying a live
(undeployed) air bag module, point the front
surface away from your body to lessen the
chance of injury in case it deploys.
AIR BAG SYSTEM
A6E8130W044
A6E8130W045
A6E8130W024
A6E8130W022

AIR BAG SYSTEM
T–33
T
•A live (undeployed) air bag module placed
face down on a surface is dangerous. If the air
bag module deploys, the motion of the
module can cause serious injury. Always face
the front surface up to reduce the motion of
the module in case it accidentally deploys.
Side Air Bag Module Handling
•When the side air bag module deploys due to a collision, the interior of the seat back (pad, frame, etc.)
may become damaged. If the seat back is reused and the side air bag module does not deploy properly,
a serious accident may result. When the side air bag module deploys, always replace both the side air
bag module and the seat back (pad, frame, trim) with new parts. After service, confirm that the seat
operates normally and that the harness is positioned properly.
SAS Unit Handling
•Disconnecting the SAS unit connector or removing the SAS unit with the ignition switch at ON position
can cause the air bag modules to deploy, which may seriously injure you. Before disconnecting the
SAS unit connector or removing the SAS unit, turn the ignition switch to LOCK position, then
disconnect the negative battery cable and wait for more than 1 minute to allow the backup power
supply of the SAS unit to deplete its stored power.
•Connecting the SAS unit connector without firmly installing the SAS unit to the vehicle is dangerous.
The crash sensor inside the control module may send an electrical signal to the air bag modules. This
will deploy the air bag modules, which may result in serious injury. Therefore, before connecting the
connector, firmly mount the control module to the vehicle.
•For vehicles with a single point sensor, once an air bag module is deployed due to an accident or other
causes, the SAS unit must be replaced with a new one even if the used one does not have any external
signs of damage. The used SAS unit may have been damaged internally which may cause improper
operation, resulting in major injuries or even death. The used single point SAS unit cannot be
bench-checked or self-checked.
Crash Zone Sensor Handling
•Disconnecting the crash zone sensor connector or removing the crash zone sensor with the ignition
switch at ON position can cause the crash zone sensor to operate and the air bag modules and pre-
tensioner seat belts to deploy, which may seriously injure you. Before disconnecting the crash zone
sensor connector or removing the crash zone sensor, always turn the ignition switch to LOCK position,
then disconnect the negative battery cable and wait for more than 1 minute to allow the backup power
supply of the SAS control module to deplete its stored power.
•If the crash zone sensor is subjected to shock or the sensor is disassembled, the air bag modules and
pre-tensioner seat belts may operate (deploy) suddenly and cause injury, or it may fail to operate
normally and cause a serious accident. Do not subject the crash zone sensor to shock or disassemble
the sensor.
•Because a sensor is built into the crash zone sensor, when the air bag modules and pre-tensioner seat
belts operates (deploys), there may be a problem, such as an internal malfunction, even if there is not
any external damage or deformation. If the crash zone sensor is reused, the air bag modules and pre-
tensioner seat belts may fail to operate normally and cause a serious injury. Always replace the crash
zone sensor with a new part. The crash zone sensor cannot be bench-checked or self-checked.
A6E8130W021

AIR BAG SYSTEM
T–35
T
CURTAIN AIR BAG MODULE REMOVAL/INSTALLATIONA6E813000171201
Warning
•Handling the air bag module improperly can accidentally deploy the air bag module, which may
seriously injure you. Read AIR BAG SYSTEM SERVICE WARNINGS before handling the air bag
module. (See T–32 SERVICE WARNINGS.)
1. Turn the ignition switch to LOCK position.
2. Disconnect the negative battery cable and wait for more than 1 minute.
3. Remove the headliner.
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.
6. Turn the ignition switch to ON position.
7. Verify that the air bag system warning light
illuminates for approximately 6 seconds and
then goes off.
•If the air bag system warning light does not
operate in the manner described above, there
are malfunctions in the system. Inspect the system using the on-board diagnostic.
Connector Removal Note
1. Using a flathead screwdriver, pry out the
connector's stopper plate.
2. Disconnect the connector.
End Of SieAIR BAG MODULE AND PRE-TENSIONER SEAT BELT DEPLOYMENT PROCEDURESA6E813057000201
Warning
•A live (undeployed) air bag module and pre-tensioner seat belt may accidentally deploy when it is
disposed of and cause serious injury. Do not dispose of a live (undeployed) air bag module and
pre-tensioner seat belt. If the SSTs (Deployment tool and Adapter harness) are not available,
consult the nearest Mazda representative for assistance.
Caution
•Deploying the air bag modules and pre-tensioner seat belts inside the vehicle may cause damage
to the vehicle interior. When the vehicle is not to be scrapped, always deploy the air bag modules
and pre-tensioner seat belts outside the vehicle.
•When the vehicle is to be scrapped, deploy the air bag modules and pre-tensioner seat belts inside the vehicle.
(See T–36 Deployment Procedure for Inside of Vehicle (Only When Vehicle Is To Be Scrapped).)
•When the vehicle is not to be scrapped, deploy the air bag modules and pre-tensioner seat belts outside the
vehicle. (See T–36 Deployment Procedure for Outside of Vehicle.)
Note
•When disposing of deployed air bag module and pre-tensioner seat belt, refer to the disposal procedure.
•The deployment procedures are the same as those of the current 4SD and 5HB models, except for the
curtain air bag module.
1 Connector
(See T–35 Connector Removal Note)
2Bolt
3 Curtain air bag module3
1
2
N·m {kgf·cm, in·lbf} 7.9—11.7
{80—120, 70—104}
A6E81301126
A6E8130W002

U–1
U
UHEATER AND AIR CONDITIONER SYSTEMS
OUTLINE................................................................ U-2
OUTLINE OF CONSTRUCTION.......................... U-2
FEATURES .......................................................... U-2
SPECIFICATIONS ............................................... U-2
CONTROL SYSTEM............................................... U-6
WATER HEATER SYSTEM................................. U-6
OUTLINE................................................................ U-7
SUPPLEMENTAL SERVICE INFORMATION .....U-7
LOCATION INDEX.................................................U-8
BASIC SYSTEM................................................... U-8
CONTROL SYSTEM ............................................ U-9
BASIC SYSTEM................................................... U-10
A/C UNIT REMOVAL/INSTALLATION...............U-10
A/C COMPRESSOR
REMOVAL/INSTALLATION ............................U-11
CONDENSER REMOVAL/INSTALLATION ....... U-12
REFRIGERANT LINES
REMOVAL/INSTALLATION ............................U-13
CONTROL SYSTEM............................................. U-15
WATER HEATER UNIT
REMOVAL/INSTALLATION ............................U-15
FUEL PUMP (WATER HEATER SYSTEM)
INSPECTION .................................................. U-16
CLIMATE CONTROL UNIT INSPECTION.........U-16
ON-BOARD DIAGNOSTIC...................................U-22
FOREWORD ......................................................U-22
DTC TABLE ................................................... U-22-2
PID/DATA MONITOR AND RECORD ........... U-22-2
DTC B1317 .................................................... U-22-3
DTC B1318 ........................................................ U-23
DTC B1342, B2463, B2537, B2538, B2547 ....... U-23
DTC B2449, B2450 ............................................ U-24
DTC B2451, B2452 ............................................ U-24
DTC B2453, B2454 ............................................ U-25
DTC B2548 ........................................................ U-25
TROUBLESHOOTING.......................................... U-26
FOREWORD ......................................................U-26
TROUBLESHOOTING INDEX ...........................U-26 FEATURES
SERVICE

OUTLINE
U–7
U
SUPPLEMENTAL SERVICE INFORMATIONA6E850201038204•The following additions have been made for the MZR-CD (RF Turbo) since the publication of the Mazda6
Workshop Manual (1730-1*-02C).
A/C unit
•Removal/installation procedure has been modified.
A/C compressor
•Removal/installation procedure has been modified.
Condenser
•Removal/installation procedure has been modified.
Refrigerant lines
•Removal/installation procedure has been modified.
Water heater unit
•Removal/installation procedure has been added.
Fuel pump (water heater system)
•Inspection procedure has been added.
Climate control unit
•Inspection procedure has been modified.
Water heater system
•On-board diagnostic system has been added.
End Of Sie
OUTLINE

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
End Of Sie
CLUTCHA6E931001024201
End Of Sie
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})

TECHNICAL DATA
TD–5
TD
End Of SieAUTOMATIC TRANSAXLEA6E931001024203
End Of Sie
PROPELLER SHAFTA6E931001024204
End Of Sie
Item Specification
Transaxle typeJA5AX-EL
Line pressure
(kPa {kgf/cm
2, psi})D range, M range (2GR)Idle 290—490 {3.0—5.0, 42—71}
Stall 1,550—1,750 {15.8—17.8, 225—254}
M range (1GR), R positionIdle 550—750 {5.6—7.6, 80—109}
Stall 1,550—1,750 {15.8—17.8, 225—254}
Engine stall speed
D, M (1GR, 2GR), R 2,200—2,600
(rpm)
Time lag (second)N-D Approx. 0.5—1.0
N-R Approx. 0.6—1.0
Transaxle fluid
temperature (TFT)
sensor-20 °C {−4 °F} 15.87—17.54
0 °C {32 °F} 5.73—6.33
20 °C {68 °F} 2.38—2.63
40 °C {104 °F} 1.10—1.22
60 °C {140 °F} 0.56—0.62
80 °C {176 °F} 0.31—0.34
(kilohm) 100 °C {212 °F} 0.18—0.20
120 °C {248 °F} 0.11—0.12
130 °C {266 °F} 0.09—0.10
Input/turbine
speed sensor(ohm) ATF temperature: 20 °C {68 °F} 513—627
Intermediate
sensor(ohm) ATF temperature: 20 °C {68 °F} 513—627
Vehicle
speedometer
sensor(ohm) ATF temperature: 20 °C {68 °F} 513—627
Solenoid valves (ohm)Shift solenoid A 14—18
Shift solenoid B 14—18
Shift solenoid C 14—18
Neutral shift solenoid valve 14—18
Reduction timing solenoid valve 14—18
TCC solenoid valve 12.0—13.2
2-4 brake solenoid valve 2.6—3.2
High clutch solenoid valve 2.6—3.2
Pressure control solenoid 2.6—3.2
Automatic transaxle fluid
(ATF)Type
M-
III or equivalent (e.g. Dexron ® III )
Capacity (Approximate quantity) (L {US qt, Imp qt}) 8.3 {8.8, 7.3}
Transfer oilGrade API service GL-5
Viscosity SAE 80W-90
Capacity (Approximate quantity) (L {US qt, Imp qt}) 0.62 {0.65, 0.54}
Item Specification
Runout limit mm {in} 0.3 {0.01}
Starting torqueN·m
{kgf·cm}0.29—0.78 {3.0—7.9}

TD–6
TECHNICAL DATA
FRONT AND REAR AXLEA6E931001018201
End Of Sie
STEERING SYSTEMA6E931001034201
End Of Sie
Item Specification
FRONT DRIVE SHAFT
Shaft length
(Air in boot at atmospheric
pressure)(mm {in})Left sideMZR-CD (RF Turbo): 666.1—676.1 {26.23—26.61}
4WD: 667—677 {26.26—26.65}
Right sideMZR-CD (RF Turbo): 615.9—625.9 {24.25—24.64}
4WD: 631—641 {24.85—25.23}
REAR DRIVE SHAFT (4WD)
Shaft length
(Air in boot at atmospheric
pressure)(mm {in})Left side 805.4—815.4 {31.71—32.10}
Right side 852.4—862.4 {33.56—33.95}
REAR DIFFERENTIAL (4WD)
Pinion height (mm {in})–0.025—0.025 {–0.001—0.001}
Backlash of side gear and differential pinion (mm {in}) 0.1 {0.004} or less
Drive pinion preload (N·m kgf·cm, in·lbf) 1.3—1.8 {13.3—18.3, 11.5—15.9}
Backlash of drive pinion and
ring gear(mm {in})Standard 0.09—0.11 {0.0036—0.0043}
Minimum 0.05 {0.002}
Differential oilGrade API service GL-5
ViscosityAbove –18°C {0°F}: SAE 90
Below –18°C {0°F}: SAE 80
Capacity
(Approximate quantity)(L {US qt, lmp qt}) 1.00 {1.06, 0.88}
ELECTRONIC 4WD CONTROL SYSTEM
Differential oil temperature
sensor(kilohm)0°C {32°F} 91—100
10°C {50°F} 56—61
20°C {68°F} 35—39
30°C {86°F} 23—25
40°C {104°F} 14—17
50°C {122°F} 10—11
60°C {140°F} 7.1—7.9
70°C {158°F} 5.0—5.6
80°C {176°F} 3.6—4.0
4WD solenoid
(Rear differential oil temperature
at 20°C {68°F})(ohm) 1.5—2.0
Item Specification
ENGINE SPEED SENSING POWER STEERING
Power
steering oil
pumpOil pump fluid pressure 2WD (Except MZR-CD (RF Turbo)):
10.80—11.29 {110.2—115.1, 1,567—1,637}
MZR-CD (RF Turbo):
11.31—11.80 {115.4—120.3, 1,641—1,711}
4WD: 10.30—10.79 {105.1—110.0, 1,490—1,564} (MPa {kgf·cm
2, psi})
Gear housing fluid pressure 2WD (Except MZR-CD (RF Turbo)):
10.80—11.29 {110.2—115.1, 1,567—1,637}
MZR-CD (RF Turbo):
11.31—11.80 {115.4—120.3, 1,641—1,711}
4WD: 10.30—10.79 {105.1—110.0, 1,490—1,564} (MPa {kgf·cm
2, psi})
Power
steering
systemFluid type
ATF M-
III or equivalent (e.g. Dexron®II)
Capacity (Approximate quantity) MTX (Except MZR-CD (RF Turbo)): 0.80 {0.85, 0.70}
ATX (Except 4WD): 0.87 {0.92, 0.77}
MZR-CD (RF Turbo): 0.86 {0.91, 0.76}
4WD: 0.89 {0.94, 0.78} (L {US qt, Imp qt})