2002 MAZDA 6 ECU

GI–4
FUNDAMENTAL PROCEDURES
DYNAMOMETERA6E2014000042174WD testing/servicing
•Brake tester
Caution
•
To ensure the stability of the drag force of the viscous coupling always perform a brake test after
using the dynamometer or speed meter tester.
Note
•If there is a great amount of brake drag, it is probably due to the viscosity of the viscous coupling or the
center differential (RBC). To remove the influence of the coupling, jack up all four wheels of the vehicle
and verify that each wheel can be rotated freely by hand.
•Chassis dynamometer/speed meter tester
Caution
•
The vehicle may sway or surge forward when on the dynamometer. To prevent possible vehicle
movement, firmly secure it in place using steel retainers (chain, wire or similar) attached to the
front and rear towing hooks or to the tie down hooks.
•
Do not pop the clutch.
•
Do not accelerate suddenly.
Note
•The dynamometer/speed meter tester has two setting modes: propeller shaft removed mode and free
roller mode. After placing the vehicle on the tester and setting the wheels on the free rollers, start the
engine. For MTX vehicles, set the shift lever into second gear and gently, at low idle speed, release the
clutch pedal. For ATX vehicles, set the selector lever to D range, and slowly accelerate.
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FUNDAMENTAL PROCEDURES

GI–6
NEW STANDARDS
#1 : Diagnostic trouble codes depend on the diagnostic test mode.
#2 : Controlled by the PCM
#3 : In some models, there is a fuel pump relay that controls pump speed. That relay is now called the fuel pump
relay (speed).
#4 : Device that controls engine and powertrain
#5 : Directly connected to exhaust manifold
#6 : Part name of diesel engine
End Of Sie
OL Open Loop—Open Loop
—Output Speed Sensor—Vehicle Speed Sensor 1
OC Oxidation Catalytic Converter—Catalytic Converter
O2S Oxygen Sensor—Oxygen Sensor
PNP Park/Neutral Position—Park/Neutral Range
—PCM Control Relay—Main Relay #6
PSP Power Steering Pressure—Power Steering Pressure
PCM Powertrain Control Module ECU Engine Control Unit #4
—Pressure Control Solenoid—Line Pressure Solenoid Valve
PAIR Pulsed Secondary Air Injection—Secondary Air Injection SystemPulsed
injection
—Pump Speed Sensor—NE Sensor #6
AIR Secondary Air Injection—Secondary Air Injection SystemInjection
with air
pump
SAPV Secondary Air Pulse Valve—Reed Valve
SFI Sequential Multiport Fuel Injection—Sequential Fuel Injection
—Shift Solenoid A—1–2 Shift Solenoid Valve
—Shift A Solenoid Valve
—Shift Solenoid B—2–3 Shift Solenoid Valve
—Shift B Solenoid Valve
—Shift Solenoid C—3–4 Shift Solenoid Valve
3GR Third Gear—3rd Gear
TWC Three Way Catalytic Converter—Catalytic Converter
TB Throttle Body—Throttle Body
TP sensor Throttle Position Sensor—Throttle Sensor
TCV Timer Control Valve TCV Timing Control Valve #6
TCC Torque Converter Clutch—Lockup Position
TCMTransmission (Transaxle) Control
Module—EC-AT Control Unit
—Transmission (Transaxle) Fluid
Temperature Sensor—ATF Thermosensor
TR Transmission (Transaxle) Range—Inhibitor Position
TC Turbocharger—Turbocharger
VSS Vehicle Speed Sensor—Vehicle Speed Sensor
VR Voltage Regulator—IC Regulator
VAF sensor Volume Air Flow Sensor —Airflow Meter
WU-TWCWarm Up Three Way Catalytic
Converter—Catalytic Converter #5
WOT Wide Open Throttle—Fully Open New Standard Previous Standard
Remark
Abbrevi-
ationNameAbbrevi-
ationName

B1–4
OUTLINE, ENGINE
SUPPLEMENTAL SERVICE INFORMATIONA6E220202000205•The following changes and/or additions have been made since publication of the Mazda6 Workshop Manual
(1730-1*-02C).
Engine
•Removal/Installation procedure for 4WD has been adopted.
End Of Sie
ENGINE REMOVAL/INSTALLATION (4WD)A6E222401001201
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 injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line
Safety Procedure”.
1. Remove the battery.
2. Remove the battery tray.
3. Remove the radiator.
4. Drain the transaxle oil.
5. Remove the P/S oil pump with the oil hose still connected. Position the P/S oil pump so that it is out of the way.
Use wire or rope to secure.
6. Remove the A/C compressor with the pipes still connected. Position the A/C compressor so that it is out of the
way. Use wire or rope to secure.
7. Remove the propeller shaft from the transfer.
8. Remove the joint shaft. (See M–31 JOINT SHAFT (4WD) DISASSEMBLY/ASSEMBLY.)
9. Remove the front drive shaft (LH) from the transaxle. (See M–39 FRONT DRIVE SHAFT (4WD)
DISASSEMBLY/ASSEMBLY.)
10. Remove the air cleaner, intake air duct, accelerator cable and bracket, and vacuum hose.
11. Remove the ATF hose and selector cable.
12. Remove the vacuum hose and heater hose.
13. Disconnect the fuel hose. (See F1–27 Plastic Fuel Hose Removal Note.) (See F1–28 Plastic Fuel Hose
Installation Note.)
14. Disconnect the wiring harness from the engine side.
15. Remove the three way catalyst (TWC). (See F1–30 EXHAUST SYSTEM REMOVAL/INSTALLATION.)
16. Remove in the order indicated in the table.
17. Install in the reverse order of removal.
18. Start the engine and:
•Inspect for the engine oil, engine coolant, transaxle oil and fuel leakage.
•Verify the ignition timing, idle speed and idle mixture. (See F1–22 IDLE SPEED INSPECTION (4WD).)
19. Perform a road test.
OUTLINE
ENGINE

B1–6
ENGINE
No.1 Engine Mount Rubber Removal Note
1. Suspend the engine using the SST.
2. Remove through-bolt A on the No.1 engine mount
bracket side.
3. Loosen through-bolt B on the front crossmember
side until approximately three pitches are
showing.
Note
•Do not remove the No.1 engine mount
rubber from the front crossmember.
No.4 Engine Mount Bracket and No.4 Engine Mount Rubber Removal Note
1. Secure the engine and the transaxle using an
engine jack and attachment as shown.
A6E2215W004
A B
A6E2324W201
A6E2324W202
A6E2324W209

ENGINE
B1–7
B1
2. Remove the SST.
3. Secure the engine and the transaxle using a
hoist.
4. Remove the No.4 engine mount bracket and
engine mount rubber together as a unit.
A6E2215W004
A6E2324W203
A6E2324W204

B1–8
ENGINE
No.3 Engine Joint Bracket Installation Note
1. Tighten the No.3 engine mount bracket stud bolt.
Tightening torque
7.0—13 N·m {71.4—132.5 kgf·cm, 62.0—115.0
in·lbf}
2. Tighten the No.3 engine joint bracket bolt and nut
in the order as shown.
Tightening torque
74.5—104.9 N·m {7.6—10.6 kgf·m, 55.0—76.6
ft·lbf}
No.4 Engine Mount Bracket and No.4 Engine Mount Rubber Installation Note
1. Tighten the No.4 engine mount bracket and No.4
engine mount rubber bolt and nut in the order as
shown.
2. Secure the engine and the transaxle using an
engine jack and attachment as shown.
No.3
ENGINE
MOUNT
BRACKET
STUD
BOLT
A6E2215W011
12
A6E2316W111
Bolt or nut No.Tightening torque
(N·m {kgf·m, ft·lbf})
1, 2, 358.8—80.4 {6.0—8.1, 43.3—58.5}
4, 5, 666.6—93.1 {6.8—9.4, 49.2—67.9}
5431
2
6
A6E2324W206
A6E2324W209

ENGINE
B1–9
B1
3. Remove the hoist and secure the engine and
transaxle using SST.
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}
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A6E2215W004
A
B
A6E2324W207
A B
A6E2324W201

CYLINDER HEAD GASKET
B2–15
B2
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CYLINDER HEAD GASKET REPLACEMENTA6E231810271201
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 injuries 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. Remove the timing belt. (See B2–9 TIMING BELT REMOVAL/INSTALLATION.)
2. Remove the vacuum pump. (See P–13 VACUUM PUMP REMOVAL/INSTALLATION (MZR-CD (RF
TURBO)).)
3. Remove the P/S oil pump with the oil hose still connected. Position the P/S oil pump so that it is out of the way.
Use wire or rope to secure. (See N–16 POWER STEERING OIL PUMP (MZR-CD (RF Turbo)) REMOVAL/
INSTALLATION.)
4. Remove the turbocharger. (See F2–57 EXHAUST SYSTEM REMOVAL/INSTALLATION.)
5. Remove all the glow plugs. (See F2–42 GLOW PLUG REMOVAL/INSTALLATION.)
6. Remove in the order shown in the table.
7. Install in the reverse order of removal.
8. Inspect valve clearance. (See B2–5 VALVE CLEARANCE INSPECTION.)
9. Inspect the engine oil level.
•If necessary, add oil. (See D–8 ENGINE OIL INSPECTION.)
10. Inspect the compression. (See B2–8 COMPRESSION INSPECTION.)
11. Start the engine and:
(1) Inspect the pulleys and the drive belt for runout and contact.
(2) Inspect the engine oil, engine coolant, and fuel leakage.
(3) Inspect the idle speed. (See F2–34 IDLE SPEED INSPECTION.)
CYLINDER HEAD GASKET