2002 MAZDA 6 engine

RADIATOR CAP
E–7
E
RADIATOR CAP INSPECTIONA6E361415201201MZR-CD (RF Turbo)
Warning
•Never remove the radiator cap while the engine is running, or when the engine and radiator are
hot. Scalding coolant and steam may shoot out and cause serious injury. It may also damage the
engine and cooling system.
•Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap.
Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while
the pressure escapes.
•When you are sure all the pressure is gone, press down on the cap using the cloth, turn it, and
remove it.
1. Clean the radiator cap negative pressure valve and the sealed part.
2. Inspect the crack or turn over on the sealed part of the radiator cap.
•If not as specified, repace the radiator cap.
3. Fill the SST with the water or the engine coolant to the full level and attach the radiator cap to the SST.
4. Hold the radiator cap downward and apply pressure gradually. Verify that the pressure become held for 10 s
within the specification.
•If the pressure is not held stable within the specification, replace the radiator cap.
Pressure
94—122 kPa
{0.96—1.24 kgf/cm
2, 13.7—17.6 psi}
End Of Sie
RADIATOR CAP
RADIATOR CAP49 9200 145
A6E3614W201

E–8
ENGINE COOLANT
ENGINE COOLANT LEAKAGE INSPECTIONA6E361215201201MZR-CD (RF Turbo)
Warning
•Never remove the radiator cap while the engine is running, or when the engine and radiator are
hot. Scalding coolant and steam may shoot out and cause serious injury. It may also damage the
engine and cooling system.
•Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap.
Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while
the pressure escapes.
•When you are sure all the pressure is gone, press down on the cap using the cloth, turn it, and
remove it.
1. Inspect the coolant level.
2. Remove the radiator cap.
3. Clean the mounting surface of the rediator cap and the upper radiator hose.
4. Connect the SST to the reservoir filler port.
5. Apply specified pressure to the radiator.
Pressure
122 kPa { 1.24 kgf/cm
2, 17.6 psi}
6. Verify that the pressure is held.
•If not, inspect the system for coolant leakage.
—If the coolant leaks from the upper hose
attachment part, replace the upper hose
and the clamp.
—If the coolant leaks from the main body of
the radiator (caulked part), replace the
radiator.
End Of Sie
ENGINE COOLANT
49 9200 145
A6E3612W200

THERMOSTAT
E–9
E
THERMOSTAT REMOVAL/INSTALLATIONA6E361815171201MZR-CD (RF Turbo)
1. Disconnect the negative battery cable.
2. Remove the under cover.
3. Drain the engine coolant.
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.
6. Fill the radiator with the specified amount and type of engine coolant.
7. Inspect the engine coolant leakage. (See E–8 ENGINE COOLANT LEAKAGE INSPECTION.)
Thermostat Installation Note
1. Verify that the positions of the jiggle pin and the projection on the gasket are as shown.
2. Install the thermostat into the thermostat case, aligning the projection on the gasket to the thermostat cover.
End Of Sie
THERMOSTAT
1 Lower radiator hose
2 Thermostat cover
3Thermostat
(See E–9 Thermostat Installation Note )
3
1
2
7.9—10.7 N·m
{80—110 kgf·cm,
69.5—95.4 in·lbf}
A6E3618W100
THERMOSTAT
COVER
GASKET
PROJECTIONJIGGLE PIN
A6A3618W101

WATER PUMP
E–11
E
WATER PUMP REMOVAL/INSTALLATIONA6E362015010201MZR-CD (RF Turbo)
1. Disconnect the negative battery cable.
2. Remove the under cover.
3. Drain the engine coolant.
4. Remove the timing belt. (See B2–9 TIMING BELT REMOVAL/INSTALLATION.)
5. Remove the thermostat. (See E–9 THERMOSTAT REMOVAL/INSTALLATION.)
6. Remove in the order indicated in the table.
7. Install in the reverse order of removal.
8. Insect the drive belt. (See B2–4 DRIVE BELT INSPECTION.)
9. Fill the radiator with the specified amount and type of engine coolant.
10. Inspect the engine coolant leakage. (See E–8 ENGINE COOLANT LEAKAGE INSPECTION.)
End Of Sie
WATER PUMP
3
1
2
1
19—25
{1.9—2.6, 14—18}
N·m {kgf·m, ft·lbf} 38—51
{3.8—5.3, 28—38}
7.9—10.7 N·m
{80—110 kgf·cm, 69.5—95.4 in·lbf} 38—51
{3.8—5.3, 28—38}
R
R
A6E3620W100
1Hose
2 Water pump
3 Thermostat case

F1–1
F1
F1FUEL AND EMISSION CONTROL SYSTEM
[L8, LF, L3]
OUTLINE.............................................................. F1-2
OUTLINE OF CONSTRUCTION ....................... F1-2
FEATURES ........................................................ F1-2
SPECIFICATIONS ............................................. F1-2
CONTROL SYSTEM DIAGRAM (4WD)............. F1-3
CONTROL SYSTEM WIRING DIAGRAM
(4WD).............................................................. F1-4
FUEL SYSTEM..................................................... F1-9
OUTLINE ........................................................... F1-9
STRUCTURAL VIEW......................................... F1-9
SYSTEM DIAGRAM ........................................ F1-10
FUEL PUMP (TRANSFER).............................. F1-10
QUICK RELEASE CONNECTOR (FUEL TANK
SIDE, TRANSFER HOSE PART) ................. F1-12
EXHAUST SYSTEM........................................... F1-13
OUTLINE ......................................................... F1-13
STRUCTURAL VIEW....................................... F1-13
CONTROL SYSTEM........................................... F1-14
OUTLINE ......................................................... F1-14
STRUCTURAL VIEW (4WD) ........................... F1-16
BLOCK DIAGRAM ........................................... F1-17
CONTROL DEVICE AND CONTROL
RELATIONSHIP CHART .............................. F1-19
CONTROLLER AREA NETWORK (CAN) ....... F1-21
OUTLINE............................................................ F1-22
SUPPLEMENTAL SERVICE
INFORMATION ............................................. F1-22
ENGINE TUNE-UP............................................. F1-22
IDLE SPEED INSPECTION (4WD) ................. F1-22
FUEL SYSTEM................................................... F1-23
FUEL TANK REMOVAL/INSTALLATION ........ F1-23
FUEL PUMP UNIT
REMOVAL/INSTALLATION .......................... F1-26
FUEL HOSE (FUEL TANK SIDE,
TRANSFER HOSE PART)
REMOVAL/INSTALLATION .......................... F1-29
EXHAUST SYSTEM........................................... F1-30
EXHAUST SYSTEM
REMOVAL/INSTALLATION .......................... F1-30
CONTROL SYSTEM........................................... F1-33
PCM INSPECTION (4WD)............................... F1-33
ON-BOARD DIAGNOSTIC................................. F1-50
OUTLINE ......................................................... F1-50
CONTROL DEVICE AND MONITORING
SYSTEM RELATIONSHIP CHART .............. F1-50
DIAGNOSTIC TEST MODE (4WD) ................. F1-50
DTC (4WD) ...................................................... F1-52
OBD DRIVE MODE ......................................... F1-52
DTC TABLE ..................................................... F1-54
TROUBLESHOOTING........................................ F1-57ENGINE SYMPTOM
TROUBLESHOOTING .................................. F1-57
QUICK DIAGNOSTIC CHART ......................... F1-58
NO.14 POOR FUEL ECONOMY ..................... F1-62
NO.22 VIBRATION CONCERNS
(ENGINE) ...................................................... F1-64 FEATURES
SERVICE

OUTLINE
F1–3
F1
CONTROL SYSTEM DIAGRAM (4WD)A6E390218881204
.
* : Equipped for L3 engine modelEnd Of Sie
9
8
7
54
3
10
19
18
17
15
16
14
13
11
12
20
29
28
27
25
26
24
23
21
22
30
3938
3735
33
36
31
32
40
6
1
2
3441
A6E39022000
1PCM
2 Ignition coil
3 Generator
4* VAD shutter valve
5 Air cleaner
6 MAF sensor
7* VAD shutter valve actuator
8* VAD control solenoid valve
9* Vacuum chamber
10* VAD check valve (one-way)
11 IAC valve
12 Purge solenoid valve
13 TP sensor
14 MAP sensor
15* VIS control solenoid valve
16 Variable tumble control solenoid valve
17* VIS shutter valve actuator
18* VIS shutter valve
19 VTCS shutter valve actuator
20 VTCS shutter valve
21 Fuel injector22* OCV
23 CMP sensor
24 EGR valve
25 Knock sensor
26 ECT sensor
27 PCV valve
28 CKP sensor
29 HO2S (front)
30 HO2S (rear)
31 Charcoal canister
32 Check valve (two-way)
33 Pressure regulator
34 Fuel filter (high-pressure)
35 Fuel pump
36 Fuel filter (low-pressure)
37 Fuel tank
38 Rollover valve
39 Pulsation damper
40 Fuel pump (transfer)
41 To PCM

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

CONTROL SYSTEM
F1–15
F1
Output Device
×:Applied
—: Not applied
* : For L3 engine only
End Of Sie
Item SignalMazda6 (GG, GY)
Remark for new model
4WD ATX Unleaded
(RON 90
or above)Current
model
IAC valve IAC×Same as current model
VIC solenoid valve* VIC×—×Same as current model
Variable tumble control
solenoid valveVTCS×Same as current model
Oil control valve (OCV)*Variable valve
timing control×—×Same as current model
Fuel injectorFuel injection
control×Same as current model
Fuel pump relayFuel pump
control×Same as current model
Ignition coil ESA control×Same as current model
EGR valve EGR control×Same as current model
Purge solenoid valve Purge control×Same as current model
BARO factor for Purge control has been
eliminated.
Heated oxygen sensor
heater
(Front, rear)O2S heater
control×Same as current model
Field coil
(Generator terminal D)Generator
control×Same as current model
Cooling fan relayElectric fan
control×Same as current model
A/C relayA/C cut-off
control×Same as current model
Controller area network
(CAN)Information
function×Same as current model
TCM (ATX) information have been
adopted for 4WD ATX model.