2002 MAZDA 6 lock

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
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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

ABBREVIATIONS
GI–7
GIABBREVIATIONS TABLEA6E203000011202
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ABBREVIATIONS
A/C Air conditioner
ABS Antilock brake system
ACC Accessories
ABDC After bottom dead center
ATDC After top dead center
ATF Automatic transaxle fluid
ATX Automatic transaxle
BBDC Before bottom dead center
BDC Bottom dead center
BTDC Before top dead center
CAN Controller area network
CM Control module
DEI Double electronic ignition
DOHC Double overhead camshaft
DSC Dynamic stability control
ESA Electronic spark advance
EX Exhaust
HI High
HU Hydraulic unit
IDM Injector driver module
IG Ignition
IN Intake
KOEO Key on engine off
KOER Key off engine running
LH Left hand
L.H.D. Left hand drive
LO Low
LR Left rear
M Motor
MAX Maximum
MTX Manual transaxle
MIN Minimum
O/D Overdrive
OCV Oil control valveOFF Switch off
ON Switch on
P/S Power steering
PATS Passive anti-theft system
PCV Positive crankcase ventilation
PID Parameter identification
RF Right front
RH Right hand
R.H.D. Right hand drive
RR Right rear
SST Special service tool
SW Switch
TCC Torque converter clutch
TCM Transaxle control module
TDC Top dead center
TFT Transaxle fluid temperature
TNS Tail number side lights
TR Transaxle range
TWC Three way catalytic converter
VAD Variable air duct
VBC Variable boost control
VIS Variable intake-air system
VSC Variable swirl control
VSS Vehicle speedometer sensor
VTCS Variable tumble control system
WGN Wagon
WDS Worldwide diagnostic system
1GR 1st gear
2GR 2nd gear
4GR 4th gear
5GR 5th gear
4SD 4 door sedan
5HB 5 door hatchback
4WD 4 wheel drive

B2–2
OUTLINE
OUTLINE OF CONSTRUCTIONA6E230202000201•MZR-CD (RF Turbo) engine is newly adopted as Mazda6 (GG, GY).
•The construction of MZR-CD (RF Turbo) engine and operation which were newly adopted for the Mazda6 (GG,
GY) are the same as the current Mazda MPV(LW) MZR-CD (RF Turbo) engine model and current Mazda 323
(BJ) RF Turbo engine model except for the following components. (See Mazda MPV Workshop Manual
Supplement 1737-1*-02C.), (See Mazda 323 Workshop Manual Supplement 1633-10-98G.)
—Engine mount
•The construction and the operation of the engine mount for the new Mazda6 (GG, GY) MZR-CD (RF Turbo)
engine model is the same as the current Mazda6 (GG). (See Mazda6 Training Manual 3359-1*-02C)
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FEATURESA6E230202000202Improved engine performance
•Coated pistons have been adopted.
Reduced engine noise and vibration
•An aluminium alloy oil pan upper block has been adopted.
•An eight counter weight crankshaft has been adopted.
•A crankshaft pulley cover has been adopted.
•An engine cover with insulator has been adopted.
•A pendulum type engine mount has been adopted.
Improved serviceability
•A serpentine type drive belt has been adopted.
•An auto tensioner that automatically adjusts the drive belt tension has been adopted.
Improved design
•An engine cover has been adopted.
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SPECIFICATIONSA6E230202000203
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OUTLINE
ItemSpecifications
New Mazda6 (GG, GY) Current Mazda MPV (LW)
MZR-CD (RF Turbo) MZR-CD (RF Turbo)
TypeDiesel, 4-cycle
Cylinder arrangement and number In-line, 4-cylinder
Combustion chamber Direct injection
Valve system SOHC, belt-driven, 16-valve
Displacement (ml {cc, cu in}) 1,998 {1.998, 122.9}
Bore × stroke (mm {in}) 86.0 × 86.0 {3.39 × 3.39}
Compression ratio 18.4
Compression pressure
(kPa {kgf/cm
2, psi} [rpm])3,500 {35.7, 507.7} [250]
Valve timingINOpen BTDC (°)6
Close ABDC (°)30
EXOpen BBDC (°)41
Close ATDC (°)8
Valve clearance
[engine cold]IN (mm {in}) 0.12 —0.18 {0.005—0.007} (0.15±0.03 {0.006±0.0011})
EX (mm {in}) 0.32—0.38 {0.013—0.014} (0.35±0.03 {0.014±0.0011})

B2–4
DRIVE BELT
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DRIVE BELT INSPECTIONA6E231015800201
Note
•Drive belt deflection/tension inspection is not necessary because of the use of the drive belt auto
tensioner.
1. Remove the washer tank.
2. Verify that the drive belt auto tensioner indicator
mark does not exceeds the limit.
•If it exceeds the limit, replace the drive belt.
(See B2–4 DRIVE BELT REPLACEMENT.)
3. Install the washer tank.
End Of SieDRIVE BELT REPLACEMENTA6E2310158002021. Remove the splash shield (RH).
2. Remove the under cover.
3. Turn the center of the tensioner pulley clockwise
to release tension to the drive belt.
4. Remove the drive belt.
5. Reinstall the drive belt or install a new drive belt.
6. Verify that the drive belt auto tensioner indicator
mark does not exceed the limit. (See B2–4
DRIVE BELT INSPECTION.)
•If it exceeds the limit, replace the drive belt.
7. Install the under cover.
8. Install the splash shield (RH).
End Of SieDRIVE BELT AUTO TENSIONER INSPECTIONA6E2310159802011. Remove the drive belt. (See B2–4 DRIVE BELT REPLACEMENT.)
2. Verify that the drive belt auto tensioner moves smoothly in the operational direction.
•Replace the drive belt auto tensioner if necessary.
DRIVE BELT
INDICATOR
MARKNORMAL
A6E2310W100
MALFUNCTION
INDICATOR
MARK
A6E2310W101
A6E2310W102

B2–6
VALVE CLEARANCE
8. Install the timing belt cover bolt as shown.
Tightening torque
7.9—10.7 N·m {80—110 kgf·cm, 69.5—95.4
in·lbf}
9. Install the engine cover. (See B2–9 TIMING BELT
REMOVAL/INSTALLATION.)
End Of SieVALVE CLEARANCE ADJUSTMENTA6E2312121112021. Remove the engine cover. (See B2–9 TIMING BELT REMOVAL/INSTALLATION.)
2. Remove the timing belt cover bolt as shown.
3. Remove the cylinder head cover. (See B2–15
CYLINDER HEAD GASKET REPLACEMENT.)
4. Turn the crankshaft clockwise and set the No.1
cylinder to compression TDC.
5. Remove the fuel injector. (See F2–55 FUEL
INJECTOR REMOVAL/INSTALLATION.)
6. Adjust the valve clearance A with the No.1
cylinder at TDC of compression, and those of B
with the No.4 cylinder at TDC of compression.
(1) Hold the rocker bridge using the SST (49
G012 006).
(2) Loosen the locknut (d) using the SST (49
G012 004), and then turn the adjusting screw
(c) using the SST (49 G012 005) until it is
separated from the valve stem completely.
TIMING BELT
COVER BOLT
UPPER TIMING BELT COVER
A6E2312W200
TIMING BELT
COVER BOLT
UPPER TIMING BELT COVER
A6E2312W200
A
A B
B
A6E2312W201
49 G012 006
49 G012 005
49 G012 004
ADJUSTING
SCREW(c)
ROCKER BRIDGELOCKNUT(d)
NORMAL
A6E2312W202

VALVE CLEARANCE
B2–7
B2
(3) Loosen the rocker arm locknut (b) using the
SST (49 G012 004), and then turn the
adjusting screw (a) using the SST (49 G012
005) until it is separated from the rocker
bridge completely.
(4) Insert a feeler gauge between the rocker arm
and rocker bridge (e).
Standard valve clearance [Engine cold]
IN: 0.12—0.18 mm {0.005—0.007 in}
(0.15±0.03 mm {0.006±0.0011 in})
EX: 0.32—0.38 mm {0.013—0.014 in}
(0.35±0.03 mm {0.014±0.0011 in})
(5) Adjust the valve clearance by turning the
adjuster (a) using the SST (49 G012 005).
Then temporarily tighten locknut (b) using the
SST (49 G012 004).
(6) With the feeler gauge inserted between the
rocker arm and rocker bridge, verify that the feeler gauge remains firmly in place even when the adjusting
screw (c) is loosened.
•If the feeler gauge does not remain firmly in place, repeat procedures from Step 1.
(7) Turn the adjusting screw (c) using the SST (49 G012 005) until it reaches the valve stem and the feeler
gauge fits more firmly. Then tighten the locknut (d) using the SST (49 G012 004) to specified torque.
Tightening torque
16—20 N·m {1.6—2.1 kgf·m, 12—15 ft·lbf}
(8) Loosen the locknut (b) using the SST (49 G012 004) and readjust the valve clearance (e).
Standard valve clearance [Engine cold]
IN: 0.12—0.18 mm {0.005—0.007 in} (0.15±0.03 mm {0.006±0.0011 in})
EX: 0.32—0.38 mm {0.013—0.014 in} (0.35±0.03 mm {0.014±0.0011 in})
(9) Tighten the locknut (b) using the SST (49 G012 004) to specified torque.
Tightening torque
16—20 N·m {1.6—2.1 kgf·m, 12—15 ft·lbf}
(10)Verify the valve clearance at (e).
Standard valve clearance [Engine cold]
IN: 0.12—0.18 mm {0.005—0.007 in} (0.15±0.03 mm {0.006±0.0011 in})
EX: 0.32—0.38 mm {0.013—0.014 in} (0.35±0.03 mm {0.014±0.0011 in})
7. Turn the crankshaft one full turn and adjust the remaining valve clearances.
8. Install the fuel injector. (See F2–55 FUEL INJECTOR REMOVAL/INSTALLATION.)
9. Install the cylinder head cover. (See B2–21 Cylinder Head Cover Installation Note.)
49 G012 00549 G012 004
LOCKNUT(b) ADJUSTING
SCREW(a)
A6E2312W203
(e)
A6E2312W204

TIMING BELT
B2–11
B2
No.3 Engine Joint Bracket Removal Note
1. Suspend the engine using the SST.
2.
Lower Timing Belt Cover Removal Note
Caution
•The timing belt cover could be damaged
easily. Hold the timing belt cover at the
locations indicated in the figure and
remove the crankshaft position sensor
harness slowly.
Timing Belt, Timing Belt Auto Tensioner Removal Note
1. Turn the crankshaft clockwise and align the timing
marks as shown.
Caution
•Forcefully twisting the belt, turning it
inside out, or allowing oil or grease on it
will damage the belt and shorten its life.
•After removing the timing belt, do not
move the crankshaft and/or camshaft
from this position because it can cause
the valve and piston to come into
contact.
2. Remove the timing belt auto tensioner.
3. Mark the timing belt rotation on the belt for proper
reinstallation.
49 E017 5A0
A6E2316W101
A6E2316W102
TIMING MARK TIMING MARK
TIMING MARK
A6E2316W103
25 mm {1.0 in} MIN.
FAULTY FAULTY
FAULTY
FAULTY ROTATION
ARROW
A6E2316W104

TIMING BELT
B2–13
B2
Caution
•To prevent the bolts (M8 x 1.25) from damaging the fuel injection pump and pulley, do not fully
tighten the fixing bolts. If it contacts the pulley surface, it will damage the pulley.
4. Verify that all timing marks are correctly aligned.
•If not, align all timing marks according to the
procedure below.
5. Fix the camshaft pulley to the cylinder head using
bolt (M8 x1.25).
6. Fix the injection pump pulley to the bracket using
two bolts (M8 x1.25).
Caution
•Turn the crankshaft in the direction
which will prevent the TDC and BDC from
being passed. Otherwise it can cause the
valve and piston to come into contact.
(1) Turn the crankshaft and set it at an angle of 45° or more away from the TDC and BDC.
(2) Align the timing marks of the camshaft pulley.
(3) Align the timing marks of the injection pump pulley.
(4) Turn the crankshaft and align the timing marks of the timing belt pulley.
7. Install the timing belt on the pulleys in the order
shown below.
(1) Timing belt pulley
(2) Idler
(3) Supply pump pulley
(4) Camshaft pulley
(5) Water pump pulley
(6) Tensioner
8. Remove the supply pump pulley fixing bolts and
camshaft pulley fixing bolt (M8 x 1.25).
9. Hand tighten the timing belt auto tensioner bolts
in the order A to B as indicated in the figure.
10. Tighten the timing belt auto tensioner bolts in the
order A to B as indicated in the figure.
Tightening torque
19—25 N·m {1.9—2.6 kgf·m, 14—18 ft·lbf}
11. Remove the pin from the timing belt auto
tensioner to apply tension to the belt.
12. Turn the crankshaft clockwise twice, and align the
timing marks.
13. Verify that all timing marks are correctly aligned.
•If not as specified, repeat from Timing Belt,
Timing Belt Auto Tensioner Removal Note.
TIMING MARK
TIMING MARKTIMING MARK
M8 1.25
BOLT
M8 1.25
BOLT
CAMSHAFT
PULLEYINJECTION
PUMP
PULLEY
A6E2316W107
5
43
1
2
6
A6E2316W108
A
B
A6E2316W109