2002 MAZDA 6 Workshop Manual Suplement

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

EMISSION SYSTEM
F2
F2–59
EGR VALVE REMOVAL/INSTALLATIONA6E4016203002011. Disconnect the negative battery cable.
2. R em ove t he a ir c le a ne r. (S ee F 2–36 IN TA K E-A IR SYS TEM RE MOVA L/I NSTA LL AT IO N.)
3 . R em ove t he co m mon r ai l. (S ee F 2–53 SUPPLY PU MP R EM OVA L/IN STA LLAT IO N.)
4. Remove in the order indicated in the table.
.
5. Install in the reverse order of removal.
EGR Valve Removal Note 1. Remove the EGR pipe flare nut.
2. Remove the EGR valve installation nuts.
3. Remove the EGR valve installation stud bolts.
Note• If the thread length of the stud bolt is smaller
than the two nuts used for stud bolt removal,
shave a nut face 1 mm {0.04 in} to make it
thinner and install two nuts as shown in the
figure.
EGR Valve Installation Note 1. Install the EGR valve in the reverse order of removal.
EGR valve installation stud bolt tightening torque
7.8—11.8 N·m {80—120 kgf·cm, 70—104 in·lbf}
End Of Sie
EGR VALVE INSPECTIONA6E401620300202
Note
• Perform the following test only when directed.
1 . R em ove t h e EG R va lv e . ( See F 2–36 IN TA K E-A IR SYS TEM RE MOVA L/I NSTA LL AT IO N.)
2. Inspect for airflow between 1 and 2 when vacuum is applied using a vacuum pump as shown in the
figure.• If not as specified, replace the EGR valve.
Specification
End Of Sie
EMISSION SYSTEM
1EGR valve (See F 2–5 9 EG R V alv e R em oval N ote )
(See F2 –5 9 E G R V alv e In sta llat ion Not e)
2Air pipe (See F2 –3 6 IN TAKE-AIR SYSTEM RE MOVAL/
INS TA LL ATION )
3 EGR pipe
4 EGR water cooler
CME116EW2002
SHAVED NUT FALSE
TRUE
EGR VALVE
INTAKE
MANIFOLDEGR VALVE
INTAKE
MANIFOLD
NORMAL NUTNORMAL NUT
CME116EW2001
Vacuum
kPa {mmHg, inHg} Airflow
Below –25.0 — – 41.6
{ – 188 — – 312, –7.4 — – 12.3} Ye s
Except above No
12
A6E40122024

F2–60
EMISSION SYSTEM
EGR SOLENOID VALVE (VACUUM) INSPECTIONA6E401618741201
Note
•Perform the following inspection only when directed.
1. Inspect airflow between the ports under the
following conditions.
•If not as specified, replace the EGR solenoid
valve (vacuum).
•If as specified, carry out the “Circuit Open/
Short Inspection”.
Circuit Open/Short Inspection
1. Inspect the following wiring harness for open or
short (continuity check).
Open circuit
•If there is no continuity, the circuit is open. Repair
or replace the harness.
—EGR solenoid valve (vacuum) terminal A
(harness-side) and PCM control relay
terminal C (harness-side)
—EGR solenoid valve (vacuum) terminal B
(harness-side) and PCM terminal 99
Short circuit
•If there is continuity, the circuit is shorted. Repair
or replace the harness.
—EGR solenoid valve (vacuum) terminal A (harness-side) and GND
—EGR solenoid valve (vacuum) terminal B (harness-side) and power supply
End Of Sie
EGR SOLENOID VALVE (VENT) INSPECTIONA6E401618741202
Note
•Perform the following inspection only when directed.
1. Inspect airflow between the ports under the
following conditions.
•If not as specified, replace the EGR solenoid
valve.
•If as specified, carry out the “Circuit Open/
Short Inspection”.
BAA B
A6E40162001
StepTerminal
ABAB Por t
1
2
B+GND: Airflow
: Continuity
A6E40162020
EGR SOLENOID VALVE
HARNESS SIDE CONNECTORFUSE BOX
(PCM CONTROL RELAY)
A
BA
E
C
D
A6E40162002
BA
CBA
A6E40162003
Step
1
2
A
BAB
C Por t
Terminal
: Airflow
B+
GND: Continuity
A6E40162021

EMISSION SYSTEM
F2–61
F2
Circuit Open/Short Inspection
1. Inspect the following wiring harness for an open
or short circuit (continuity check).
Open circuit
•If there is no continuity, the circuit is open, Repair
or replace the harness.
—EGR solenoid valve (vent) terminal A
(harness-side) and PCM control relay
terminal C (harness-side)
—EGR solenoid valve (vent) terminal B
(harness-side) and PCM terminal 72
Short circuit
•If there is continuity, the circuit is shorted. Repair
or replace the harness.
—EGR solenoid valve (vent) terminal A (harness-side) and GND
—EGR solenoid valve (vent) terminal B (harness-side) and power supply
End Of Sie
EGR CONTROL SOLENOID VALVE INSPECTIONA6E401618741203
Note
•Perform the following inspection only when directed.
1. Inspect airflow between the ports under the
following conditions.
•If not as specified, replace the EGR control
solenoid valve.
•If as specified, carry out the “Circuit Open/
Short Inspection”.
Circuit Open/Short inspection
1. Inspect the following wiring harness for an open
or short circuit (continuity check).
Open circuit
•If there is no continuity, the circuit is open. Repair
or replace the harness.
—EGR control solenoid valve terminal A
(harness-side) and PCM control relay
terminal C (harness-side)
—EGR control solenoid valve terminal B
(harness-side) and PCM terminal 77
Short circuit
•If there is continuity, the circuit is shorted. Repair
or replace the harness.
—EGR control solenoid valve terminal A (harness-side) and GND
—EGR control solenoid valve terminal B (harness-side) and power supply
End Of Sie
EGR SOLENOID VALVE(VENT)
HARNESS SIDE CONNECTORFUSE BOX
(PCM CONTROL RELAY)
BAA
C
DE
A6E40162004
B
AA
B
A6E40162005
StepTerminalPor t
: Airflow
ABAB
GND
B+
1
2
: Continuity
A6E40162022
EGR CONTROL SOLENOID VALVE
HARNESS SIDE CONNECTORFUSE BOX
(MAIN RELAY)
BAAE
C
D
A6E40162006

F2–62
EMISSION SYSTEM
INTAKE SHUTTER VALVE ACTUATOR INSPECTIONA6E4016201002011. Disconnect the vacuum hose from the intake shutter valve actuator.
2. Connect a vacuum pump to port A.
3. Apply vacuum and verify that the rod moves.
•If the rod does not move, replace the intake
manifold.
Specification
4. Connect a vacuum pump to port A and B.
5. Apply vacuum and verify that the rod moves.
•If the rod does not move, replace the intake
manifold.
Specification
End Of Sie
Vacuum
kPa {mmHg, inHg}Rod movement
Below –20 {–150, –5.9} Starts to move
Above –66 {–495, –19} Fully pulled
Vacuum
kPa {mmHg, inHg}Rod movement
Above –69.4 {–520, –21} Fully pulled
A6E40162007
A6E40162008

EMISSION SYSTEM
F2–63
F2
INTAKE SHUTTER SOLENOID VALVE INSPECTIONA6E401613937201
Note
•Perform the following inspection only when directed.
•The inspection includes both intake shutter solenoid valve (half) and intake shutter solenoid valve (full).
1. Inspect airflow between the ports under the following conditions.
•If not as specified, replace the intake shutter solenoid valve.
•If as specified, carry out the “Circuit Open/Short Inspection”.
Intake Shutter Solenoid Valve (Half) Circuit Open/
Short Inspection
1. Disconnect the PCM connector. (See F2–64 PCM
REMOVAL/INSTALLATION.)
2. Inspect the following wiring harness for an open
or short circuit (continuity check).
Open circuit
•If there is no continuity, the circuit is open. Repair
or replace the harness.
—Intake shutter solenoid valve (half) terminal A
(harness-side) and PCM control relay
terminal C (harness-side)
—Intake shutter solenoid valve (half) terminal B
(harness-side) and PCM terminal 74
Short circuit
•If there is continuity, the circuit is shorted. Repair or replace the harness.
—Intake shutter solenoid valve (half) terminal A (harness-side) and GND
—Intake shutter solenoid valve (half) terminal B (harness-side) and power supply
Intake Shutter Solenoid Valve (Full) Circuit Open/Short Inspection
1. Disconnect the PCM connector. (See F2–64 PCM REMOVAL/INSTALLATION.)
2. Inspect the following wiring harness for an open
or short circuit (continuity check).
Open circuit
•If there is no continuity, the circuit is open. Repair
or replace the harness.
—Intake shutter solenoid valve (full) terminal A
(harness-side) and PCM control relay
terminal C (harness-side)
—Intake shutter solenoid valve (full) terminal B
(harness-side) and PCM terminal 100
Short circuit
•If there is continuity, the circuit is shorted. Repair or replace the harness.
—Intake shutter solenoid valve (full) terminal A (harness-side) and GND
—Intake shutter solenoid valve (full) terminal B (harness-side) and power supply
End Of Sie
B
A
CB
A
A6E40162024
StepTerminal
C B
A B APor t: Airflow
1
2B+ GND
: Continuity
A6E40162023
INTAKE SHUTTER SOLENOID
VALVE (HALF)
HARNESS SIDE CONNECTORFUSE BOX
(PCM CONTROL RELAY)
B
AA
E
C
D
A6E40162010
INTAKE SHUTTER SOLENOID
VALVE (FULL)
HARNESS SIDE CONNECTORFUSE BOX
(PCM CONTROL RELAY)
B
AA
C
DE
A6E40162011

F2–64
CONTROL SYSTEM
PCM REMOVAL/INSTALLATIONA6E404018881207
Note
•For replace the PCM, setup the WDS and perform the following.
—“PCM configuration” (See F2–68 PCM CONFIGURATION.)
—“Correction after Parts Installation” (See F2–34 Correction after Parts Installation.)
European (L.H.D.) Specs.
1. Disconnect the negative battery cable.
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.
U.K. Specs.
1. Disconnect the negative battery cable.
2. Remove the front side trim (left-side).
3. Partially peek back the flower covering.
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.
Set bolt removal note
1. Using a chisel and a hammer, cut a groove on the head of the set bolt so that a screwdriver can be inserted.
2. Loose the set bolt using an impact screwdriver or
pliers.
Set bolt installation note
1. Install a new set bolt and tighten it until the neck
of the bolt is cut.
CONTROL SYSTEM
1 PCM connector
2PCM
1Set bolt
(See F2–64 Set bolt removal note)
(See F2–64 Set bolt installation note)
2 PCM cover
3 PCM connector
4PCM
1
2
N·m {kgf·cm, in·lbf} 7.8—10.8
{80—110, 69.1—95.5}
3.0—5.4
{31—55, 26.6—47.7}
7.8—10.8
{80—110, 69.1—95.5}
A6E40402022
4
1
2
3
N·m {kgf·cm, in·lbf} 7.8—10.8
{80—110,
69.1—95.5}
3.0—5.4
{31—55, 26.6—47.7}
7.8—10.8
{80—110, 69.1—95.5}
A6E40402023
SET BOLT
CHISEL
A6E40402020
SET BOLT
CUT
A6E40402021