2002 MAZDA 6 engine

G–2
OUTLINE
OUTLINE OF CONSTRUCTIONA6E470202000201•The construction and operation of the engine electrical system for the new Mazda6 (GG, GY) MZR-CD (RF
Turbo) engine model is the same as the current Mazda 323 (BJ) RF engine model. (European specs.) (See
Mazda 323 Training Manual 3324-10-98E.)
•The construction and operation of the engine electrical system for the new Mazda6 (GG, GY) L8, LF, and L3
engine models is the same as the current Mazda6 (GG) L8, LF, and L3 engine models. (See Mazda6 Training
Manual 3359-1*-02C, Mazda6 Workshop Manual 1730-1*-02C.)
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SPECIFICATIONSA6E470202000203Gasoline engine
* : Cold area or intensely hot area
Diesel engine
Bold frames:New specifications
* : Cold area
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OUTLINE
ItemSpecification
New
Mazda6
(GG, GY)Current
Mazda6
(GG)New
Mazda6
(GG, GY)Current
Mazda6
(GG)New
Mazda6
(GG, GY)Current
Mazda6
(GG)
L8 LF L3
BatteryType and capacity
(5-hour rate)50D20L (40),
75D26L (52)
*50D20L (40),
75D26L (52) *50D20L (40),
80D26L (55)*
Voltage (V) 12
GeneratorOutput (V-A) 12-90
Regulated voltage
Controlled by PCM
Self-diagnosis
function
Ignition
systemType DEI (Double Electronic Ignition)
Spark advance Electronic
Firing order 1—3—4—2
Spark
plugType NGK ITR6F-13
StarterType Coaxial reduction
Output (kW) 1.0 1.4
ItemSpecification
New Mazda6 (GG, GY) Current Mazda 323 (BJ)
MZR-CD (RF Turbo) RF
BatteryType and capacity
(5-hour rate)95D31L (64),
115D31L (70)
*
Voltage (V) 12
GeneratorOutput (V-A) 12-90 12-80
Regulated voltage 14.1—14.7
Self-diagnosis function Equipped
StarterType Coaxial reduction
Output (kW) 2.2

G–4
OUTLINE
SUPPLEMENTAL SERVICE INFORMATIONA6E470202000204•The following changes and/or additions have been made since publication of the Mazda6 Workshop Manual
(1730-1*-02C).
Battery
•Removal/Installation procedure has been added. (MZR-CD (RF Turbo) engine model)
•Inspection procedure has been added. (MZR-CD (RF Turbo) engine model)
•Recharging procedure has been added. (MZR-CD (RF Turbo) engine model)
Generator
•Removal/Installation procedure has been added. (MZR-CD (RF Turbo) engine model)
•Inspection procedure has been added. (MZR-CD (RF Turbo) engine model)
Starter
•Removal/Installation procedure has been added.
•Inspection procedure has been added. (MZR-CD (RF Turbo) engine model)
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LOCATION INDEXA6E470202000206MZR-CD (RF Turbo)
.
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OUTLINE
3
1
2
A6E4702W100
1 Battery
(See G–5 BATTERY REMOVAL/INSTALLATION)
(See G–6 BATTERY INSPECTION)
(See G–6 BATTERY RECHARGING)2 Generator
(See G–7 GENERATOR REMOVAL/
INSTALLATION)
(See G–7 GENERATOR INSPECTION)
3Starter
(See G–9 STARTER REMOVAL/INSTALLATION)
(See G–11 STARTER INSPECTION)

G–6
CHARGING SYSTEM
BATTERY INSPECTIONA6E471018520202MZR-CD (RF Turbo)
Battery
1. Inspect the battery with the following procedure.
Load test chart
Battery positive voltage with load
Back-up Current
1. Verify that the engine switch is off and that the engine key has been removed.
2. Disconnect the negative battery cable.
Caution
•Operating electrical loads while measuring the back-up current can damage the circuit tester.
3. Measure the back-up current between the negative battery terminal and the negative battery cable.
(1) If the current exceeds the maximum, remove the fuses in the main fuse block and the fuse block one by
one while measuring the back-up current.
(2) Inspect and repair harnesses and connectors on the fuse where the current has been reduced.
Back-up current
20 mA max.
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BATTERY RECHARGINGA6E471018520203MZR-CD (RF Turbo)
Caution
•To avoid damage to the battery, do not quick charge for over 30 min.
•When disconnecting the battery, remove the negative cable first and install it last to prevent
damage to electrical components or the battery.
•To avoid deformation or damage to the battery, remove the battery plugs while charging the
battery.
Step Inspection Result Action
1Measure open circuit
voltage of battery.Above
12.4 VGo to Step
3.
Below
12.4 VGo to next
step.
2Quick-charge for 30 min.
and recheck voltage.Above
12.4 VGo to next
step.
Below
12.4 VReplace
battery.
3Apply load test (see load
test chart) to battery using a
battery load tester and
record battery voltage after
15 s. Is voltage more than
specification?YesBattery
okay.
NoReplace
battery.
Battery Load (A)
95D31L (64) 250
115D31L (70) 320
Approximate battery temp. Minimum voltage (V)
21°C {70°F} 9.6
15°C {60°F} 9.5
10°C {50°F} 9.4
4°C {40°F} 9.3
–1°C {30°F} 9.1
–7°C {20°F} 8.9
–12°C {10°F} 8.7
–18°C {0°F} 8.5

CHARGING SYSTEM
G–7
G
1. Remove the battery from vehicle and place it in a pan of water.
2. Connect a battery charger to the battery.
3. Adjust the charging current as follows.
4. After the battery has been recharged, measure
the battery positive voltage and verify that the
battery keeps specified voltage for more than 1 h.
•If not as specified, replace the battery.
Specification
Above 12.4 V
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GENERATOR REMOVAL/INSTALLATIONA6E471018300202MZR-CD (RF Turbo)
Warning
•When the battery cables are connected, touching the vehicle body with generator terminal B will
generate sparks. This can cause personal injury, fire, and damage to the electrical components.
Always disconnect the battery before performing the following operation.
1. Disconnect the negative battery cable.
2. Remove the radiator.
3. Remove the drive belt. (See B2–4 DRIVE BELT REPLACEMENT.)
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.
End Of SieGENERATOR INSPECTIONA6E471018300203MZR-CD (RF Turbo)
Generator Warning Light
1. Verify that the battery is fully charged.
•Charge if necessary. (See G–6 BATTERY RECHARGING.)
2. Verify that the drive belt deflection/tension is correct. (See B2–4 DRIVE BELT INSPECTION.)
•Replace if necessary. (See B2–4 DRIVE BELT REPLACEMENT.)
3. Turn the engine switch ON position and verify that the generator warning light turns on.
•If not, inspect the generator warning light, and the wiring harnesses between the battery, generator warning
light, and generator terminal L.
4. Verify that the generator warning light goes out after the engine is started.
•If not, inspect the generator.
Battery type
(5-hour rate)Slow-charge
(A)Quick-charge
(A/30 min)
95D31L (64) 6.5—8.0 40
115D31L (70) 7.0—8.5 45BATTERY CHARGER
BATTERY
A6E4710W100
1 Terminal B wire
2 Connector
3 Generator
3
12
A
B
A
B
9.8—14.7
{1.0—1.4,
8—10}
N·m {kgf·m, ft·lbf}
37—52
{38—53, 28—38}
9.8—11.7 N·m
{100—120 kgf·cm,
87—104 in·lbf}
A6E4710W101

G–8
CHARGING SYSTEM
Generator
Voltage
1. Verify that the battery is fully charged.
•Charge if necessary. (See G–6 BATTERY RECHARGING.)
2. Inspect the drive belt deflection/tension.
(See B2–4 DRIVE BELT INSPECTION.)
•Replace if necessary. (See B2–4 DRIVE BELT REPLACEMENT.)
3. Turn off all electrical loads.
4. Turn the engine switch to start the engine and verify that the generator rotates smoothly without any noise
while the engine is running.
5. Measure the voltage at the terminals shown in the table.
•If not as specified, repair or replace the generator if necessary.
Standard voltage
Current
1. Verify that the battery is fully charged.
•Charge if necessary. (See G–6 BATTERY RECHARGING.)
2. Verify that the drive belt deflection/tension is correct. (See B2–4 DRIVE BELT INSPECTION.)
•Replace if necessary. (See B2–4 DRIVE BELT REPLACEMENT.)
3. Disconnect the negative battery cable.
4. Connect an ammeter, capable of reading 120 A or more, between generator terminal B and the wiring harness.
5. Connect the negative battery cable.
6. Turn off all electrical loads.
7. Start the engine and increase the engine speed to 2,000—2,500 rpm.
8. Turn the following electrical loads on and verify that the current reading increases.
(1) Headlights
(2) Blower motor
(3) Rear window defroster
Note
•Current required for generating power varies with electrical loads applied.
Standard current (reference)
Measuring conditions
Room temperature: 20°C {68°F}
Voltage: 13.5 V
Engine hot
* : Must not be 0 A.
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Terminal Engine switch ON (V)Idle (V)
[20°C {68°F}]
BB+
14.1—14.7 LApprox. 1
SB+
SL
A6E4710W102
Engine speed
(rpm)Terminal B current (A)*
1,000 0—80
2,000 0—90

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

STARTING SYSTEM
G–11
G
STARTER INSPECTIONA6E471418400203MZR-CD (RF Turbo)
On-vehicle Inspection
1. Verify that the battery is fully charged.
•Charge if necessary. (See G–6 BATTERY RECHARGING.)
2. Crank the engine and verify that the starter rotates smoothly without any noise.
•If not as specified, inspect the following:
—Remove the starter, and inspect the magnetic switch and the starter.
—Inspect the related wiring harness and the engine switch.
No Load Test
1. Verify that the battery is fully charged.
•Charge if necessary. (See G–6 BATTERY RECHARGING.)
2. Connect the starter, battery, voltmeter and
ammeter as shown.
3. Operate the starter and verify that it rotates
smoothly.
4. Measure the voltage and current while the starter
is operating.
•If not as specified, replace the starter.
Specification
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Voltage (V)11
Current (A)Below 130
ENGINE
SWITCH
TERMINAL SB
M
STARTERVA
VOLTMETER
BATTERY
AMMETER
A6E4714W101

H–2
OUTLINE
OUTLINE OF CONSTRUCTIONA6E490216003201•The construction and operation of the clutch is essentially carried over from that of the current MPV (LW)
models, except for the following features. (See Mazda MPV Training Manual 3340-1*-99F.)
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FEATURESA6E490216003202Adoption of the A65M-R manual transaxle models
•The specifications for the A65M-R manual transaxle models have been added.
Increased torque transmission capacity
•Increased clutch cover set load.
Reduced noise
•The flywheel with a damper has been adopted for the A65M-R manual transaxle model.
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SPECIFICATIONSA6E490216003203
Bold frames:New specifications
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SUPPLEMENTAL SERVICE INFORMATIONA6E490216003204•The following changes have been made since publication of the Mazda6 Workshop Manual (1730-1*-02C).
CLUTCH RELEASE CYLINDER
•Removal/installation procedure has been modified.
•Disassembly/assembly procedure has been modified.
CLUTCH UNIT
•Removal/installation procedure has been modified.
•Clutch cover inspection procedure has been modified.
FLYWHEEL
•Flywheel inspection procedure has been modified.
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OUTLINE
Item New Mazda6 (GG, GY) Current MPV (LW)
EngineMZR-CD (RF Turbo)
Manual transaxle type A65M-R
Clutch control Hydraulic
Clutch coverSpring type Diaphragm
Set load (N {kgf, lbf}) 6,550 {668, 1,472}
Clutch discOuter diameter (mm {in}) 239 {9.41}
Inner diameter (mm {in}) 160 {6.30}
Clutch pedalType Suspended
Pedal ratio 5.9 6.41
Full stroke (mm {in}) 140 {5.51} 148 {5.83}
Clutch master cylinder inner diameter (mm {in}) 15.87 {0.625}
Clutch release cylinder inner diameter (mm {in}) 19.05 {0.750}
Clutch fluid type SAE J1703, FMVSS116 DOT-3 or DOT-4
OUTLINE