2002 MAZDA 6 transmission

VIN CODE
GI–3
GIVIN CODEA6E200800021201European (L.H.D. U.K.) specs.GCC specs.End Of Sie
VIN CODE
Serial No.
0=Hiroshima
2=5MT For Europe(U.K.): Dummy
For Europe(L.H.D.): Dummy
For Israel: Model year0
3 to 9
3=2003
3=2.3L (L3)
8=1.8L (L8)
F=2.0L (LF)
R=MZR-CD(RF-Turbo)-Hi
T=MZR-CD(RF-Turbo)-Low5=4EAT
7=5EAT
8=4WD
1=2WD
GG=MAZDA6 (4SD, 5HB)
GY=MAZDA6 (WAGON)
JMZ=Europe(L.H.D. U.K.)2=4SD
4=5HB
9=WAGON 1=Hofu Plant
Engine typeWorld manufacturer identification
Body style
Remarks
Vehicle type
Transmission
A6E2021T101
J M 7 G Y 3 9 F * 3 # 1 2 3 4 5 6
Serial No.
0= Hiroshima
1= Hofu
0 to 9, X
F= 2.0L (LF)
9= WAGON 4= 5HB 2= 4SD
JM7= General (L.H.D.) 3= Without side air bag
4= With side air bag
GY= MAZDA6 (WAGON) GG= MAZDA6 (4SD, 5HB) Plant
For Saudi: Model year
For Model year: Dummy
Body style Engine typeCheck digit3
0 - 9
Restraint system
Vehicle type
World manufacturer identification
A6E2010T102

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

SCHEDULED MAINTENANCE
GI–17
GI
Scheduled Maintenance Service (Specific Work Required)
•The specific work required for each maintenance item is listed in the following table. (Please refer to the section
applicable to the model serviced.)
For Europe (L.H.D. U.K.)
Bold frames: New item
Maintenance Item Specific Work Required
ENGINE
Engine valve clearance Measure clearance
Drive beltsInspect for wear, cracks and fraying, and check tension.
Replace drive belt.
Engine timing belt Replace engine timing belt.
Engine oil Replace engine oil and inspect for leakage.
Oil filter Replace oil filter and inspect for leakage.
COOLING SYSTEM
Cooling system
(including coolant level adjustment)Check coolant level and quality, and inspect for leakage.
Engine coolant Replace coolant.
FUEL SYSTEM
Air cleaner elementInspect for dirt, oil and damage.
Clean air cleaner element (by blowing air).
Replace air cleaner element.
Fuel filter Replace fuel filter.
Fuel lines and hoses Inspect for cracks, leakage and loose connection.
Fuel injection system (for MZR-CD (RF Turbo)) Update to injection amount correction with WDS. (see W/M)
IGNITION SYSTEM (FOR GASOLINE)
Spark plugsInspect for wear, damage, carbon, high-tension lead condition and measure
plug gap.
Replace spark plugs.
EMISSION CONTROL SYSTEM
Evaporative system (for gasoline)Check system operation (see W/M), vapor lines, vacuum fitting hoses and
connection.
E.G.R. system (MZR-CR (RF Turbo))Check system operation (see W/M), vacuum fitting hoses and connection.
Update to MAF correction for E.G.R control with WDS. (see W/M)
ELECTRICAL SYSTEM
Battery electrolyte level and specific gravity Check level and specific gravity.
CHASSIS AND BODY
Brake fluidCheck fluid level and inspect for leakage.
Replace brake fluid.
Brake lines, hoses and connectionsInspect for cracks, damage, chafing, corrosion, scars, swelling and fluid
leakage.
Parking brake Check lever stroke.
Power brake unit and hosesCheck vacuum lines, connections and check valve for improper attachment,
air tightness, cracks chafing and deterioration.
Disc brakesTest for judder and noise. Inspect caliper for correct operation and fluid
leakage, brake pads for wear. Check disc plate condition and thickness.
Power steering fluid and linesCheck fluid level and lines for improper attachment, leakage, cracks,
damage, loose connections, chafing and deterioration.
Power steering fluid Check fluid level.
Power steering system and hosesCheck lines for improper attachment, leakage, cracks, damage, loose
connections, chafing and deterioration.
Steering operation and gear housingCheck that the steering wheel has the specified play. Be sure to check for
changes, such as excessive play, hard steering or strange noises.
Check gear housing and boots for looseness, damage and grease/gear oil
leakage.
Steering linkages tie rod ends and armsCheck ball joint, dust cover and other components for looseness, wear,
damage and grease leakage.
Front and rear suspension and ball joints Inspect for grease leakage, cracks, damage and looseness.
Manual transmission/transaxle oilCheck oil level and inspect for leakage.
Replace manual transmission/transaxle oil.
Automatic transmission/transaxle fluid level Check fluid level.

FUEL SYSTEM
F1–9
F1
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OUTLINEA6E391201006201•The fuel system is essentially carried over from that of the current Mazda6 (GG), except for the following. (See
Mazda6 Training Manual 3359-1*-02C.)
—A saddle type fuel tank has been adopted.
—A fuel pump (transfer) for fuel transmission has been added.
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STRUCTURAL VIEWA6E391201006202
.
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FUEL SYSTEM
7
5
4
3
6
1
2
A6E39122001
1 Fuel gauge sender sub-unit
2 Quick release connector (fuel tank side, transfer
hose part)
3 Non-return valve4 Quick release connector (fuel tank side, main fuel
pipe part)
5 Fuel tank
6 Fuel pump unit
7 Filler cap

CONTROL SYSTEM
F1–21
F1
CONTROLLER AREA NETWORK (CAN)A6E394018880205•PCM transmit/received the information in the CAN. For detail information of the CAN, see the “MULTIPLEX
COMMUNICATION SYSTEM.” (See T–3 OUTLINE.)
Transmit Information (4WD ATX Model)
•Engine control condition
•Torque reduction inhibit
•Engine speed
•Vehicle Speed
•TP
•Engine torque (without torque reduction)
•Engine torque (with torque reduction)
•Battery reconnection
•Engine loss torque
•ECT
•Travelled distance
•Fuel injection information
•MIL condition
•Generator warning light conditions
•Engine displacement
•Number of cylinders
•Air induction type
•Fuel type and delivery
•Country
•Transmission/axle type
•Tire circumference (front/rear)
Received Information (4WD ATX Model)
From ABS HU/CM, ABS/TCS HU/CM, or DSC HU/CM
•Wheel speed
—Front left, Front right, Rear left, and Rear right
•Travelled distance
•Brake system status
•Torque reduction request
•Brake system configuration
From TCM
•Desired torque
•Upper torque limit
•Turbineshaft speed
•Vehicle speed
•Torque reduction request
•Idle speed up request
•Racing select determination
•MIL indicate request
•Desired gear/selector lever position
•AT warning indicator light condition
•TCC condition
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F2–24
CONTROL SYSTEM, ON-BOARD DIAGNOSTIC
CONTROLLER AREA NETWORK (CAN)A6E404018881206Outline
•The PCM transmit/received the information other units using CAN to simplify the system.
Transmit Information
•Engine speed
•Vehicle speed
•Accelerator pedal position
•Fuel injection information
•Torque reduction inhibit
•Intake air temperature
•Engine coolant temperature
•Travelled distance
•Glow indicator light conditions
•Engine displacement
•Number of cylinders
•Air induction type
•Fuel type and delivery
•Country
•Transmission/axle type
•Tire circumference (front/rear)
•Cruise main indicator light conditions
•Cruise set indicator light conditions
Received Information
•Torque reduction request from DSC HU/CM
•Wheel speed from ABS HU/CM or DSC HU/CM
—Front left
—Front right
•Travelled distance from ABS HU/CM or DSC HU/CM
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OUTLINEA6E407018881201•The on-board diagnostic system is essentially carried over from that of the current MPV (LW) MZR-CD (RF
Turbo) engine models, except for the following. (See MPV Workshop Manual Supplement 1737-1*-02C.)
—DTCs, PID monitoring items, and simulation items have been changed.
—KOEO/KOER self-test items have been changed.
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DTCA6E407018881202
×: Applicable –: Not applicable
ON-BOARD DIAGNOSTIC
DTC Condition Detection condition MILMemory
function
P0016Crankshaft position-camshaft position
correlation malfunctionInput signals from CKP sensor and CMP sensor
are misaligned.××
P0088 Fuel pressure system too highFuel pressure is higher than preprogrammed
criteria.–×
P0091 Suction control valve circuit low inputInput voltage from suction control valve does not
change from off to on.××
P0092 Suction control valve circuit high inputInput voltage from suction control valve does not
change from on to off.××
P0093 Fuel system leak detectionFuel pressure after fuel injection is lower than
preprogrammed criteria.××
P0097 IAT sensor No.1 circuit low input Input voltage from IAT sensor No.1 is below 0.1 V.××
P0098 IAT sensor No.1 circuit high input Input voltage from IAT sensor No.1 is above 5.0 V.××
P0102 MAF sensor circuit low input Input voltage from MAF sensor is below 0.2 V.××
P0103 MAF sensor circuit high input Input voltage from MAF sensor is above 4.9 V.××
P0107 Boost sensor circuit low inputInput voltage from boost sensor is below 1.9 V
when engine speed is 2,400 rpm or above and
accelerator opening angle is 50% or above.××
P0108 Boost sensor circuit high input Input voltage from boost sensor is above 4.9 V.××

CONTROL SYSTEM
F2–69
F2
NEUTRAL SWITCH INSPECTIONA6E404017640201
Note
•Perform the following test only when directed.
Continuity Inspection
1. Inspect for continuity between the neutral switch
terminals using an ohmmeter.
•If the neutral switch is okay, but the CPP/PNP
PID is out of specification, perform the “Circuit
Open/Short Inspection”
•If not as specified, replace the neutral switch.
Specification
Circuit Open/Short Inspection
1. Inspect for open/short circuit in the following wiring harnesses.
•If there is open/short circuit, repair or replace wiring harnesses.
Open circuit
•Signal circuit
—Neutral switch terminal A and PCM terminal 56
•GND circuit
—Neutral switch terminal B and GND
Short circuit
•Signal circuit
—Neutral switch terminal A and PCM terminal 56 to GND
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PUSH
RODB
A
A6E40702036
Condition
TransmissionTerminal
O
O: Continuity
A
B
Rod pushed
Except aboveIn neutral
Other
O
O
A6E40702035

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