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Mazda Mazda6 Workshop Manual Supplement

Mazda Mazda6 Workshop Manual Supplement

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Mazda6

Workshop

Manual

Supplement

FOREWORD

This manual contains on-vehicle service

and diagnosis for the Mazda6.

For proper repair and maintenance,

a thorough familiarization with this manual

is important, and it should always be kept

in a handy place for quick and easy

reference.

All the contents of this manual, including

drawings and specifications, are the latest

available at the time of printing.

As modifications affecting repair or

maintenance occur, relevant information

supplementary to this volume will be made

available at Mazda dealers. This manual

should be kept up-to-date.

Mazda Motor Corporation reserves

the right to alter the specifications and

contents of this manual without obligation

or advance notice.

All rights reserved. No part of this book

may be reproduced or used in any form or

by any means, electronic or

mechanical—including photocopying and

recording and the use of any kind of

information storage and retrieval

system—without permission in writing.

Mazda Motor Corporation

HIROSHIMA, JAPAN

APPLICATION:

This manual is applicable to vehicles

beginning with the Vehicle Identification

Numbers (VIN), and related materials shown

on the following page.

CONTENTS

Title

General Information

Engine

Lubrication System

Cooling System

Fuel and Emission Control

Systems

Engine Electrical System

Clutch

Manual Transaxle

Automatic Transaxle

Propeller Shaft

Front and Rear Axles

Steering System

Braking System

Suspension

Body

Body Electrical System

Heater and Air Conditioner Systems

Technical Data

Special Tools

There are explanation given only for the sections

marked with shadow (

© 2002 Mazda Motor Corporation

PRINTED IN THE NETHERLANDS, JULY 2002

1749–1E–02G

L8, LF, L3

MZR–CD (RF Turbo)

L8, LF, L3

MZR–CD (RF Turbo)

G35M–R

A65M–R

FN4A–EL

JA5AX–EL

).

Section

GI

B1

B2

D

E

F1

F2

G

H

J1

J2

K1

K2

L

M

N

P

R

S

T

U

TD

ST

Table of Contents

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Chapters

Table of Contents

Troubleshooting

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Summary of Contents for Mazda Mazda6

Page 1 Lubrication System Cooling System FOREWORD This manual contains on-vehicle service L8, LF, L3 Fuel and Emission Control and diagnosis for the Mazda6. Systems MZR–CD (RF Turbo) For proper repair and maintenance, Engine Electrical System a thorough familiarization with this manual...
Page 2 (European (L.H.D. U.K.), GCC specs.) ... . 3360–1*–02C Mazda6 Bodyshop Manual Supplement (European (L.H.D. U.K.), GCC specs.) ... . 3368–1*–02I EOBD Training Manual (European (L.H.D.
Page 3 The contents of this manual, including drawings and specifications, are the latest available at the time of printing, and Mazda Motor Corporation reserves the right to change the vehicle designs and alter the contents of this manual without notice and without incurring obligation.
Page 4: Table Of Contents
G ENERAL INFORMATION HOW TO USE THIS MANUAL ......GI-2 RANGE OF TOPICS .......... GI-2 VIN CODE ............. GI-3 VIN CODE............GI-3 FUNDAMENTAL PROCEDURES ......GI-4 DYNAMOMETER..........GI-4 NEW STANDARDS ..........GI-5 NEW STANDARDS TABLE ....... GI-5 ABBREVIATIONS ..........GI-7 ABBREVIATIONS TABLE........
Page 5: How To Use This Manual
HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL RANGE OF TOPICS A6E201000001206 • This manual indicates only changes/additions, as it is supplemental to the related materials. Therefore it may not contain the necessary reference service procedures to perform the service indicated in this manual. End Of Sie GI–2...
Page 6: Vin Code
F= 2.0L (LF) 2= 4SD 4= 5HB Body style 9= WAGON 3= Without side air bag Restraint system 4= With side air bag GG= MAZDA6 (4SD, 5HB) Vehicle type GY= MAZDA6 (WAGON) World manufacturer identification JM7= General (L.H.D.) A6E2010T102 GI–3...
Page 7: Fundamental Procedures
FUNDAMENTAL PROCEDURES FUNDAMENTAL PROCEDURES DYNAMOMETER A6E201400004217 4WD 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).
Page 8: New Standards
NEW STANDARDS NEW STANDARDS NEW STANDARDS TABLE A6E202800020201 • The following is a comparison of the previous standard and the new standard. New Standard Previous Standard Remark Abbrevi- Abbrevi- Name Name ation ation Accelerator Pedal — Accelerator Pedal Air Cleaner —...
Page 9 NEW STANDARDS New Standard Previous Standard Remark Abbrevi- Abbrevi- Name Name ation ation Open Loop — Open Loop — Output Speed Sensor — Vehicle Speed Sensor 1 Oxidation Catalytic Converter — Catalytic Converter Oxygen Sensor — Oxygen Sensor Park/Neutral Position —...
Page 10: Abbreviations
ABBREVIATIONS ABBREVIATIONS ABBREVIATIONS TABLE A6E203000011202 Switch off Air conditioner Switch on Antilock brake system Power steering Accessories PATS Passive anti-theft system ABDC After bottom dead center Positive crankcase ventilation ATDC After top dead center Parameter identification Automatic transaxle fluid Right front Automatic transaxle Right hand BBDC...
Page 11: Scheduled Maintenance
• To ensure efficient operation of the engine and all systems related to emission control, the ignition and fuel systems must be serviced regularly. It is strongly recommended that all servicing related to these systems be done by an authorized Mazda Dealer. • After the described period, continue to follow the described maintenance at the recommended intervals.
Page 12 SCHEDULED MAINTENANCE Maintenance Interval (Number of months or km (miles), whichever comes first) Months Maintenance Item ×1000 km ×1000 miles 12.5 37.5 62.5 87.5 112.5 Replace at first 4 years or 100,000 km (62,500 miles); Engine coolant after that, every 2 years Fuel lines &...
Page 13 • To ensure efficient operation of the engine and all systems related to emission control, the ignition and fuel systems must be serviced regularly. It is strongly recommended that all servicing related to these systems be done by an authorized Mazda Dealer. • After the described period, continue to follow the described maintenance at the recommended intervals.
Page 14 • To ensure efficient operation of the engine and all systems related to emission control, the ignition and fuel systems must be serviced regularly. It is strongly recommended that all servicing related to these systems be done by an authorized Mazda Dealer. • After the described period, continue to follow the described maintenance at the recommended intervals.
Page 15 SCHEDULED MAINTENANCE SCHEDULED MAINTENANCE G I – 1 1 G ENERAL INFORMATION Maintenance Interval (Number of months or km (miles), whichever comes first) Months 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 Maintenance Item ×1000 km 100 110 120 130 140 150 160 ×1000 miles...
Page 16 • The ignition and fuel systems are highly important to the emission control system and to efficient engine operation. All inspections and adjustments must be made by an expert repairer, we recommend an Authorized Mazda Repairer. • After the described period, continue to follow the described maintenance at the recommended intervals.
Page 17 • The ignition and fuel systems are highly important to the emission control system and to efficient engine operation. All inspections and adjustments must be made by an Authorized Mazda Dealer. • After the prescribed period, continue to follow the described maintenance at the recommended intervals.
Page 18 SCHEDULED MAINTENANCE Maintenance Interval (Number of months or km (miles), whichever comes first) Months Maintenance Item ×1000 km ×1000 miles ENGINE Engine valve clearance Audible inspect every 120,000 km (75,000 miles), if noisy, adjust Drive belts Engine oil Engine oil filter COOLING SYSTEM Cooling system (Including coolant level adjustment)
Page 19 • The ignition and fuel systems are highly important to the emission control system and to efficient engine operation. All inspections and adjustments must be made by an Authorized Mazda Dealer. • After the prescribed period, continue to follow the described maintenance at the recommended intervals.
Page 20 SCHEDULED MAINTENANCE Maintenance Interval (Number of months or km (miles), whichever comes first) Months 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 Maintenance Item ×1000 km 100 110 120 130 140 150 160 ×1000 miles 6.25 12.5...
Page 21 SCHEDULED MAINTENANCE 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...
Page 22 SCHEDULED MAINTENANCE Maintenance Item Specific Work Required Check oil level and inspect for leakage. Rear differential oil Replace rear differential oil. Check oil level and inspect for leakage. Transfer oil (for 4×4) Replace transfer oil. Driveshaft dust boots Inspect for grease leakage, cracks, damage and looseness. Body condition Inspect body surface for paint damage, rust, corrosion and perforation.
Page 23 E NGINE [L8, LF, L3] FEATURES OUTLINE .............. B1-2 OUTLINE OF CONSTRUCTION......B1-2 FEATURES ............B1-2 ENGINE PERFORMANCE CURVE....B1-2 SPECIFICATIONS ..........B1-3 SERVICE OUTLINE .............. B1-4 SUPPLEMENTAL SERVICE INFORMATION ... B1-4 ENGINE ..............B1-4 ENGINE REMOVAL/INSTALLATION (4WD)..B1-4 B1–1...
Page 24: Outline
A6E220202000201 • The construction and operation of the new Mazda6 (GG, GY) L8, LF, and L3 engine is the same as that of the current Mazda6 (GG) L8, LF, and L3 engine models except for the following features. (See Mazda6 training Manual 3359-1*-02C.)
Page 25: Specifications
OUTLINE SPECIFICATIONS A6E220202000204 Specification Current Current Current Item Mazda6 Mazda6 Mazda6 Mazda6 Mazda6 Mazda6 (GG, GY) (GG) (GG, GY) (GG) (GG, GY) (GG) Type Gasoline, 4-cycle Cylinder arrangement and number In-line, 4-cylinder Combustion chamber Pentroof DOHC, Valve system Timing chain driven, 16 valves...
Page 26: Outline
OUTLINE, ENGINE OUTLINE SUPPLEMENTAL SERVICE INFORMATION A6E220202000205 • 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 ENGINE REMOVAL/INSTALLATION (4WD)
Page 27 ENGINE 8.0—11.5 N·m {81.6—117.2 kgf·cm, 70.9—101.7 in·lbf} 66.6—93.1 66.6—93.1 {6.8—9.4, 49.2—67.9} {6.8—9.4, 74.5—104.9 58.8—80.4 49.2—67.9} {7.6—10.6, 74.5—104.9 {6.0—8.1, 43.3—58.5} 55.0—76.6} {7.6—10.6, 55.0—76.6} 58.8—80.4 {6.0—8.1, 43.3—58.5} 85.3—116.6 {8.7—11.8, 62.9—85.9} N·m {kgf·m, ft·lbf} A6E2213W001 Engine ground No.1 Engine mount rubber (See B1–6 No.1 Engine Mount Rubber Removal No.3 Engine joint bracket Note) (See...
Page 28 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. A6E2215W004 3. Loosen through-bolt B on the front crossmember side until approximately three pitches are showing.
Page 29 ENGINE 2. Remove the SST. A6E2215W004 3. Secure the engine and the transaxle using a hoist. A6E2324W203 4. Remove the No.4 engine mount bracket and engine mount rubber together as a unit. A6E2324W204 B1–7...
Page 30 ENGINE No.3 Engine Joint Bracket Installation Note 1. Tighten the No.3 engine mount bracket stud bolt. No.3 Tightening torque ENGINE 7.0—13 N·m {71.4—132.5 kgf·cm, 62.0—115.0 MOUNT BRACKET in·lbf} STUD BOLT A6E2215W011 2. Tighten the No.3 engine joint bracket bolt and nut in the order as shown.
Page 31 ENGINE 3. Remove the hoist and secure the engine and transaxle using SST. A6E2215W004 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}...
Page 32 E NGINE [MZR-CD (RF Turbo)] FEATURES OUTLINE .............. B2-2 OUTLINE OF CONSTRUCTION......B2-2 FEATURES ............B2-2 SPECIFICATIONS ..........B2-2 SERVICE LOCATION INDEX ..........B2-3 LOCATION INDEX..........B2-3 DRIVE BELT ............B2-4 DRIVE BELT INSPECTION ....... B2-4 DRIVE BELT REPLACEMENT ......B2-4 DRIVE BELT AUTO TENSIONER INSPECTION ..........
Page 33: Outline
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)
Page 34: Location Index
LOCATION INDEX LOCATION INDEX LOCATION INDEX A6E230001002201 A6E2500W100 Drive belt Timing Belt (See B2–9 TIMING BELT REMOVAL/ (See B2–4 DRIVE BELT INSPECTION) INSTALLATION) (See B2–4 DRIVE BELT REPLACEMENT) (See B2–4 DRIVE BELT AUTO TENSIONER Cylinder head gasket INSPECTION) (See B2–15 CYLINDER HEAD GASKET REPLACEMENT) Rocker arm (See...
Page 35: Drive Belt
DRIVE BELT End Of Sie DRIVE BELT DRIVE BELT INSPECTION A6E231015800201 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.
Page 36: Valve Clearance
DRIVE BELT, VALVE CLEARANCE 3. Turn the drive belt auto tensioner pulley by hand and verify that it rotates smoothly. • Replace the drive belt auto tensioner if necessary. 4. Install the drive belt. A6E2310W103 End Of Sie VALVE CLEARANCE VALVE CLEARANCE INSPECTION A6E231212111201 1.
Page 37: Valve Clearance Adjustment
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 TIMING BELT in·lbf} COVER BOLT 9. Install the engine cover. (See B2–9 TIMING BELT REMOVAL/INSTALLATION.) UPPER TIMING BELT COVER A6E2312W200 End Of Sie VALVE CLEARANCE ADJUSTMENT A6E231212111202 1.
Page 38 VALVE CLEARANCE (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 49 G012 005 49 G012 004 005) until it is separated from the rocker ADJUSTING bridge completely.
Page 39: Compression Pressure
VALVE CLEARANCE, COMPRESSION PRESSURE 10. Install the timing belt cover bolt as shown. Tightening torque 7.9—10.7 N·m {80—110 kgf·cm, 69.5—95.4 TIMING BELT in·lbf} COVER BOLT 11. Install the engine cover. (See B2–9 TIMING BELT REMOVAL/INSTALLATION.) UPPER TIMING BELT COVER A6E2312W200 End Of Sie COMPRESSION PRESSURE COMPRESSION INSPECTION...
Page 40: Timing Belt
COMPRESSION PRESSURE, TIMING BELT 7. Install the SSTs into the glow plug hole. 8. Crank the engine and note the maximum gauge 49 S010 1A0 reading. 9. Inspect each cylinder as above. • If the compression in one or more cylinders is 49 S013 102 low, pour a small amount of clean engine oil into the cylinder and reinspect the...
Page 41 TIMING BELT 7.6—10.8 N·m {80—110 kgf·cm, 69.1—95.5 in·lbf} 74.5—104.9 {7.6—10.6, 55.0—76.6} 7.9—10.7 N·m 19—25 {80—110 kgf·cm, {1.9—2.6, 14—18} 69.5—95.4 in·lbf} 23—32 N·m {kgf·m, ft·lbf} {2.3—3.3, 17—23} A6E2316W100 Engine cover Lower timing belt cover (See B2–11 Lower Timing Belt Cover Removal No.3 engine joint bracket Note) (See...
Page 42 TIMING BELT No.3 Engine Joint Bracket Removal Note 1. Suspend the engine using the SST. 49 E017 5A0 A6E2316W101 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.
Page 43 TIMING BELT Timing Belt, Timing Belt Auto Tensioner Installation Note 1. Measure the tensioned rod projection length. • If not as specified, replace the timing belt auto tensioner. 2. Inspect the timing belt auto tensioner for oil leakage. • If not as specified, replace the timing belt auto tensioner.
Page 44 TIMING BELT 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. TIMING MARK •...
Page 45 TIMING BELT Crankshaft Pulley Installation Note 1. Tighten the bolts in the order shown. Tightening torque 23—32 N·m {2.3—3.3 kgf·m, 17—23 ft·lbf} A6E2316W110 No.3 Engine Joint Bracket Installation Note 1. Tighten the No.3 engine joint bracket bolt and nut in the order shown. Tightening torque 74.5—104.9 N·m {7.6—10.6 kgf·m, 55.0—76.6 ft·lbf}...
Page 46: Cylinder Head Gasket
CYLINDER HEAD GASKET End Of Sie CYLINDER HEAD GASKET CYLINDER HEAD GASKET REPLACEMENT A6E231810271201 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.
Page 47 CYLINDER HEAD GASKET 7.9—10.7 N·m {80—110 kgf·cm, SEALANT SEALANT 69.5—95.4 in·lbf} 7.9—10.7 N·m {80—110 kgf·cm, 25—30 69.5—95.4 in·lbf} {2.5—3.1, 18—22} 55—64 {5.6—6.6, 41—47} 7.9—10.7 N·m {80—110 kgf·cm, SEALANT SEALANT SEALANT SEALANT 69.5—95.4 in·lbf} SEALANT SEALANT 38—51 {3.8—5.3, 28—38} 19—25 {1.9—2.6, 14—18} 52—61 7.9—10.7 N·m...
Page 48 CYLINDER HEAD GASKET Camshaft Cylinder head (See B2–18 Cylinder Head Removal Note) Breather pipe (See B2–19 Cylinder Head Installation Note) Cylinder head gasket Supply Pump Pulley Removal Note 1. Verify that timing marks are correctly aligned. Caution • To prevent the bolts (M8 x 1.25) from damaging the supply pump and pulley, do not fully tighten the fixing bolts.
Page 49: Front
CYLINDER HEAD GASKET Camshaft Pulley Removal Note 1. Hold the camshaft using the SST. 2. Remove the camshaft pulley lock bolt. 49 S120 710 A6E2318W104 3. Remove the camshaft pulley using the SST. 49 G011 106 A6E2318W105 Seal Plate Removal Note 1.
Page 50 CYLINDER HEAD GASKET Cylinder Head Installation Note 1. Measure the length of each cylinder head bolt. • Replace any that exceeds maximum length. Length 159.7—160.3 mm {6.288—6.311 in} Maximum 161.0 mm {6.338 in} LENGTH A6E2318W108 2. Tighten the bolts in two or three steps in the order shown.
Page 51 CYLINDER HEAD GASKET 3. Install the rocker arm shaft plane side upward. Caution • Because there is little camshaft thrust clearance, the camshaft must be held horizontally while it is installed. Otherwise, excessive force will be applied to the thrust area, causing burrs on the thrust receiving area of the cylinder head journal.
Page 52 CYLINDER HEAD GASKET Fuel Injection Pipe Installation Note Caution • Fuel injection pipes can be removed and reinstalled up to five times. If removing them for the sixth time, be sure to replace them with new ones. Cylinder Head Cover Installation Note 1.
Page 53 CYLINDER HEAD GASKET Camshaft Pulley Installation Note 1. Hold the camshaft using the SST. 49 S120 710 A6E2318W104 Gear Case Installation Note 1. Apply silicone sealant as shown in the figure. Thickness SEALANT SEALANT 1.5—2.5 mm {0.060—0.098 in} 2. Tighten the bolts in clockwise order. A6E2318W119 Drive Gear Installation Note 1.
Page 54 CYLINDER HEAD GASKET Supply Pump Pulley Installation Note Caution • To prevent the bolts (M8 x1.25) from damaging the supply pump and pulley, do not fully tighten the fixing bolts. If they contact the pulley surface, they will damage the pulley. 1.
Page 55: Front Oil Seal
FRONT OIL SEAL FRONT OIL SEAL FRONT OIL SEAL REPLACEMENT A6E232010602201 1. Remove the timing belt. (See B2–9 TIMING BELT REMOVAL/INSTALLATION.) 2. Remove in the order shown in the table. 3. Install in the reverse order of removal. Timing belt pulley lock bolt (See B2–24 Timing Belt Pulley Lock Bolt Removal/ Installation...
Page 56 FRONT OIL SEAL Front Oil Seal Removal Note 1. Cut the oil seal lip using a razor knife. OIL SEAL LIP A6E2320W103 2. Remove the oil seal using a screwdriver protected with a rag. A6E2320W104 Front Oil Seal Installation Note 1.
Page 57: Rear Oil Seal
REAR OIL SEAL REAR OIL SEAL REAR OIL SEAL REPLACEMENT A6E232211399201 1. Remove the flywheel. (See H–5 CLUTCH UNIT REMOVAL/INSTALLATION (A65M-R manual transaxle models).) 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. Rear oil seal (See B2–26 Rear Oil Seal Removal...
Page 58: Engine
ENGINE ENGINE ENGINE REMOVAL/INSTALLATION A6E232401001201 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 injures or death and damage.
Page 59 ENGINE 74.5—104.9 {7.6—10.6, 55.0—76.6} 66.6—93.1 66.6—93.1 {6.8—9.4, 49.2—67.9} {6.8—9.4, 49.2—67.9} 58.8—80.4 74.5—104.9 {6.0—8.1, 43.3—58.5} {7.6—10.6, 55.0—76.6} 58.8—80.4 {6.0—8.1, 43.3—58.5} 85.3—116.6 {8.7—11.8, 62.9—85.9} N·m {kgf·m, ft·lbf} A6E2324W200 No.3 Engine joint bracket No.1 Engine mount rubber (See B2–30 No.3 Engine Joint Bracket Installation (See B2–29 No.1 Engine Mount Rubber Removal Note)
Page 60 ENGINE No.1 Engine Mount Rubber Removal Note 1. Suspend the engine using the SST. 49 E017 5A0 2. Remove through-bolt A on the No.1 engine mount bracket side. A6E2316W101 3. Loosen through-bolt B on the front crossmember side until approximately three pitches are showing.
Page 61 ENGINE 2. Remove the SST. 49 E017 5A0 A6E2316W101 3. Secure the engine and the transaxle using a hoist. A6E2324W203 4. Remove the No.4 engine mount bracket and engine mount rubber together as a unit. A6E2324W304 No.3 Engine Joint Bracket Installation Note 1.
Page 62 ENGINE 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} A6E2316W111 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.
Page 63: Engine Disassembly/Assembly
ENGINE 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} A6E2324W207 No.1 Engine Mount Rubber Installation Note 1.
Page 64 ENGINE 38—51 {3.8—5.3, 28—38} N·m { kgf·m, ft·lbf} A6E2324W105 A/C compressor bracket Seal plate (See B2–33 A/C Compressor Bracket Installation Note) A/C Compressor Bracket Installation Note 1. Tighten the A/C compressor bracket bolts in the order shown. Tightening torque 38—51 N·m {3.8—5.3 kgf·m, 28—38 ft·lbf} A6E2324W106 End Of Sie B2–33...
Page 65 L UBRICATION SYSTEM FEATURES OUTLINE ..............D-2 OUTLINE OF CONSTRUCTION......D-2 SPECIFICATIONS ..........D-2 STRUCTURAL VIEW...........D-4 LUBRICATION SYSTEM........D-5 LUBRICATION FLOW CHART ......D-5 SERVICE OUTLINE ..............D-6 SUPPLEMENTAL SERVICE INFORMATION ..D-6 LUBRICATION SYSTEM........D-6 LOCATION INDEX..........D-6 OIL PRESSURE INSPECTION ......D-7 OIL PRESSURE INSPECTION......D-7 ENGINE OIL ............D-8 ENGINE OIL INSPECTION........D-8 ENGINE OIL REPLACEMENT......D-8 OIL FILTER.............D-9...
Page 66: Outline
A6E330202000201 • The construction and the operation of the oil cooler and the oil filter for the new Mazda6 (GG, GY) MZR-CD (RF Turbo) engine model is the same as the current Mazda MPV (LW) MZR-CD (RF Turbo) engine model. (See Mazda MPV Workshop Manual Supplement 1737-1*-02D.)
Page 67 OUTLINE Diesel engine Specification Current Current New Mazda6 Mazda 626, 626 Mazda MPV Item (GG, GY) Station Wagon (LW) (GF, GW) MZR-CD (RF MZR-CD (RF Turbo) RF Turbo Turbo) Lubrication system Force-fed type — Oil cooler Water-cooled — Oil pressure 147 {1.5, 21} [1,000],...
Page 68: Structural View
OUTLINE STRUCTURAL VIEW A6E330202000203 MZR-CD (RF Turbo) A6E330W001 Oil pressure switch Oil pump Oil filter Oil strainer Oil cooler Turbocharger Oil pan Vaccum pump Oil filter adapter End Of Sie D–4...
Page 69: Lubrication System
LUBRICATION SYSTEM LUBRICATION SYSTEM LUBRICATION FLOW CHART A6E333014100202 MZR-CD (RF Turbo) A6E3300W002 Oil pan Piston Oil strainer Oil pressure switch Oil pump Orifice Oil cooler Camshaft Oil filter Rocker arm shaft Main bearing Rocker arm, rocker arm bridge Crankshaft Vaccum pump Connecting rod bearing Turbocharger Oil jet valve...
Page 70: Outline
OUTLINE, LUBRICATION SYSTEM OUTLINE SUPPLEMENTAL SERVICE INFORMATION A6E330202000204 • The following changes and/or additions have been made since publication of the Mazda6 Workshop Manual (1730-1*-02C). Oil pressure • Inspection procedure has been adopted. (MZR-CD (RF Turbo) engine model) Engine oil •...
Page 71: Oil Pressure Inspection
OIL PRESSURE INSPECTION OIL PRESSURE INSPECTION OIL PRESSURE INSPECTION A6E331001003201 MZR-CD (RF Turbo) Warning • Continuous exposure to USED engine oil has caused skin cancer in laboratory mice. Protect your skin by washing with soap and water immediately after working with engine oil. •...
Page 72: Engine Oil
5W-30 10W-40 5W-30, 10W-30 Remarks Mazda genuine Dexelia oil e.g. — 8. Start the engine and inspect for oil leakage. • If the oil leaks, specify the faulty part and repair or replace it. 9. Inspect the oil level .
Page 73: Oil Filter
OIL FILTER, OIL COOLER OIL FILTER OIL FILTER REPLACEMENT A6E331414300201 MZR-CD (RF Turbo) 1. Disconnect the negative battery cable. 2. Remove the under cover. 3. Remove the oil filter using the oil filter wrench. 4. Use a clean rag to wipe off the mounting surface OIL FILTER on the oil filter.
Page 74: Oil Pan
OIL PAN OIL PAN OIL PAN REMOVAL/INSTALLATION A6E332010040201 MZR-CD (RF Turbo) Warning • Hot engines and engines oil can cause severe burns. Turn off the engine and wait until it and the engine oil have cooled. 1. Disconnect the negative battery cable. 2.
Page 75 OIL PAN 3. Screw an oil pan bolt into the weldnut to make a small gap between the cylinder block and the oil pan. WELD NUT A6E3320W101 4. Remove the oil pan using the separator tool. A6E3320W102 Oil Pan Installation Note Caution •...
Page 76 C OOLING SYSTEM FEATURES OUTLINE ..............E-2 OUTLINE OF CONSTRUCTION......E-2 FEATURES ............E-2 SPECIFICATIONS ..........E-3 COOLING SYSTEM..........E-4 STRUCTURAL VIEW...........E-4 COOLING FLOW DIAGRAM ....... E-5 COOLING FAN ............ E-5 SERVICE OUTLINE ..............E-6 SUPPLEMENTAL SERVICE INFORMATION ..E-6 LOCATION INDEX..........E-6 RADIATOR CAP.............
Page 77: Outline
(See Mazda6 Training Manual 3359-1*-02C.) • The construction and operation of the engine cooling 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.)
Page 78: Specifications
Cooling fan No.1: 5 Cooling fan No.1: 7 (sheet) blade Cooling fan No.2: 7 Cooling fan No.2: 5 Bold frames: New specifications Diesel engine Specification New Mazda6 Current Mazda 323 Item (GG, GY) (BJ) MZR-CD (RF Turbo) RF Turbo Cooling system Water-cooled...
Page 79: Cooling System
COOLING SYSTEM COOLING SYSTEM STRUCTURAL VIEW A6E363002000201 MZR-CD (RF Turbo) A6E3602W201 To water heater system Engine oil cooler Radiator EGR water cooler Coolant reservoir tank To cylinder head Thermostat To cylinder block Water pump Turbocharger Cylinder head Water outlet Cylinder block End Of Sie E–4...
Page 80: Cooling Flow Diagram
COOLING SYSTEM COOLING FLOW DIAGRAM A6E363002000202 MZR-CD (RF Turbo) A6E3600W300 Radiator Turbocharger Coolant reservoir tank Water pump Water outlet Thermostat case EGR water cooler Thermostat cover Engine oil cooler Water heater system Cylinder head Heater core Cylinder block End Of Sie COOLING FAN A6E363002000204 MZR-CD (RF Turbo)
Page 81: Outline
OUTLINE OUTLINE SUPPLEMENTAL SERVICE INFORMATION A6E360202000208 • The following changes and/or additions have been made since publication of the Mazda6 Workshop Manual (1730-1*-02C). Radiator cap • Inspection procedure has been added. (MZR-CD (RF Turbo) engine model) Thermostat • Removal/Installation procedure has been added. (MZR-CD (RF Turbo) engine model) •...
Page 82: Radiator Cap Inspection
RADIATOR CAP RADIATOR CAP RADIATOR CAP INSPECTION A6E361415201201 MZR-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.
Page 83: Engine Coolant
ENGINE COOLANT ENGINE COOLANT ENGINE COOLANT LEAKAGE INSPECTION A6E361215201201 MZR-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.
Page 84: Thermostat
THERMOSTAT THERMOSTAT THERMOSTAT REMOVAL/INSTALLATION A6E361815171201 MZR-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.
Page 85: Thermostat Inspection
THERMOSTAT THERMOSTAT INSPECTION A6E361815171202 MZR-CD (RF Turbo) 1. Inspect the thermostat for the following. • Closed valve at room temperature • Opening temperature and lift of the valve — If not as specified, replace the thermostat. Condition Specification Initial-opening temperature 80—84 {176—183} (°C {°F}) Full-open temperature...
Page 86: Water Pump
WATER PUMP WATER PUMP WATER PUMP REMOVAL/INSTALLATION A6E362015010201 MZR-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.
Page 87: Fan Motor
FAN MOTOR FAN MOTOR COOLING FAN MOTOR REMOVAL/INSTALLATION A6E362215025201 MZR-CD (RF Turbo) 1. Remove the cooling fan component. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. 3.9—4.9 N·m {39.7—50.0 kgf·cm, 34.7—43.4 in·lbf} 3.9—4.9 N·m {39.7—50.0 kgf·cm, 34.7—43.4 in·lbf}...
Page 88: Cooling Fan Motor Inspection
FAN MOTOR COOLING FAN MOTOR INSPECTION A6E362215025202 MZR-CD (RF Turbo) 1. Verify that the battery is fully charged. • Charge if necessary. (See G–6 BATTERY RECHARGING.) 2. Connect battery positive voltage and an ammeter to the cooling fan motor connector. 3.
Page 89 F UEL AND EMISSION CONTROL SYSTEM [L8, LF, L3] ENGINE SYMPTOM FEATURES TROUBLESHOOTING ........F1-57 QUICK DIAGNOSTIC CHART ......F1-58 OUTLINE .............. F1-2 NO.14 POOR FUEL ECONOMY ..... F1-62 OUTLINE OF CONSTRUCTION ....... F1-2 NO.22 VIBRATION CONCERNS FEATURES ............F1-2 (ENGINE) ............
Page 90: Outline
OUTLINE OUTLINE OUTLINE OF CONSTRUCTION A6E390218881201 • The fuel and emission control systems are essentially carried over from the current Mazda6 (GG), except for the following features. (See Mazda6 Training Manual 3359-1*-02C.) End Of Sie FEATURES A6E390218881202 System simplification • Controller area network has been adopted with TCM communication (4WD).
Page 91: Control System Diagram (4Wd)
OUTLINE CONTROL SYSTEM DIAGRAM (4WD) A6E390218881204 A6E39022000 Ignition coil CMP sensor Generator EGR valve VAD shutter valve Knock sensor Air cleaner ECT sensor MAF sensor PCV valve VAD shutter valve actuator CKP sensor VAD control solenoid valve HO2S (front) Vacuum chamber HO2S (rear) VAD check valve (one-way) Charcoal canister...
Page 92: Control System Wiring Diagram
OUTLINE CONTROL SYSTEM WIRING DIAGRAM (4WD) A6E390218881205 With Immobilizer System A6E39022001 HO2S (front) ECT sensor HO2S (rear) MAF/IAT sensor TP sensor IAT sensor MAP sensor MAF sensor BARO sensor Controller area network (CAN) F1–4...
Page 93 OUTLINE Knock sensor Cooling fan relay CKP sensor Cooling fan relay CMP sensor Cooling fan relay Fuel injector No.1 TR switch Fuel injector No.2 Fuel pump relay Fuel injector No.3 Coil Fuel injector No.4 Security light IAC valve Ignition switch Oxygen sensor heater (front) Main relay Oxygen sensor heater (rear)
Page 94 OUTLINE A6E39022002 Generator Ignition coil Refrigerant pressure switch (middle) Generator PSP switch Purge solenoid valve Blower motor VAD control solenoid valve Refrigerant pressure switch (high and low) EGR valve A/C switch Variable tumble control solenoid valve Brake switch VIS control solenoid valve Brake light F1–6...
Page 95 OUTLINE Without Immobilizer system A6E39022003 HO2S (front) IAT sensor HO2S (rear) MAF sensor TP sensor Controller area network (CAN) MAP sensor Knock sensor BARO sensor CKP sensor ECT sensor CMP sensor MAF/IAT sensor Fuel injector No.1 F1–7...
Page 96 OUTLINE Fuel injector No.2 Cooling fan relay Fuel injector No.3 Cooling fan relay Fuel injector No.4 Cooling fan relay IAC valve Cooling fan relay Oxygen sensor heater (front) Fuel pump relay Oxygen sensor heater (rear) Ignition switch A/C relay Main relay A6E39022004 Generator Ignition coil...
Page 97: Fuel System
FUEL SYSTEM OUTLINE A6E391201006201 • 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.
Page 98 FUEL SYSTEM SYSTEM DIAGRAM A6E391201006203 A6E39122002 Filler cap Fuel filter (low-pressure) Pressure regulator Fuel pump unit Fuel pump (transfer) Pulsation damper Fuel filter (high-pressure) Fuel injector Fuel pump Fuel flow End Of Sie FUEL PUMP (TRANSFER) A6E391213350201 Function • The fuel tank for 4WD is saddle type. Fuel in the fuel gauge sender sub-unit side (right side) is pumped to the left side of the fuel tank using the fuel pump (transfer).
Page 99 FUEL SYSTEM Operation • The fuel jet pump (venturi) is installed in the return passage from the pressure regulator, and fuel in the fuel tank is pumped to the left side from the right side using the vacuum generated in the passage. •...
Page 100: Quick Release Connector
FUEL SYSTEM QUICK RELEASE CONNECTOR (FUEL TANK SIDE, TRANSFER HOSE PART) A6E391242692201 Function • The quick release connector makes disconnecting and connecting of fuel hoses and fuel pipes easy. Structure • The quick release connector is adopted for the transfer hose part of the fuel tank side. •...
Page 101: Exhaust System
OUTLINE A6E391440000201 • The exhaust system is essentially carried over from that of the current Mazda6 (GG), except for the following. (See Mazda6 Training Manual 3359-1*-02C.) — The TWC and the presilencer have been become separate parts, and removal/installation procedure has been changed.
Page 102: Control System
CONTROL SYSTEM CONTROL SYSTEM OUTLINE A6E394018880201 • 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).
Page 103 CONTROL SYSTEM Output Device ×:Applied —: Not applied Mazda6 (GG, GY) Unleaded Item Signal Remark for new model Current 4WD ATX (RON 90 model or above) × IAC valve Same as current model × × VIC solenoid valve* — Same as current model Variable tumble control ×...
Page 104: Structural View (4Wd)
CONTROL SYSTEM STRUCTURAL VIEW (4WD) A6E394018880202 A6E39402000 MAF/IAT sensor VIC solenoid valve TP sensor Variable tumble control solenoid valve MAP sensor CMP sensor Fuel injector CKP sensor Ignition coil ECT sensor Purge solenoid valve Knock sensor EGR valve HO2S (front) BARO sensor HO2S (rear) PCM (R.H.D.)
Page 105: Block Diagram
CONTROL SYSTEM BLOCK DIAGRAM A6E394018880203 A6E3940T001 F1–17...
Page 106 CONTROL SYSTEM MAF/IAT sensor Fuel pump relay TP sensor Ignition coil MAP sensor Purge solenoid valve CMP sensor EGR valve CKP sensor Oxygen sensor heater (front, rear) ECT sensor A/C relay Knock sensor Cooling fan relay HO2S (front, rear) Generator (terminal D: field coil) PSP switch VAD control* Vehicle speedometer sensor...
Page 107: Control Device And Control Relationship Chart
CONTROL SYSTEM CONTROL DEVICE AND CONTROL RELATIONSHIP CHART A6E394018880204 Input devices x: Applicable Component × IAT sensor MAF sensor TP sensor MAP sensor ECT sensor CMP sensor CKP sensor Knock sensor Front HO2S Rear HO2S BARO sensor* Neutral switch* Clutch switch* TR switch* Brake switch PSP switch...
Page 108 CONTROL SYSTEM Output devices ×: Applicable Component × IAC valve × VAD control solenoid valve* × VIC solenoid valve* Variable tumble control × solenoid valve × Oil control valve (OCV)* × × Fuel injectors × Fuel pump relay × × Ignition coil ×...
Page 109: Controller Area Network (Can)
CONTROL SYSTEM 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 •...
Page 110: Outline
OUTLINE, ENGINE TUNE-UP OUTLINE SUPPLEMENTAL SERVICE INFORMATION A6E390218881206 • The following changes and/or additions have been made since publication of the Mazda6 Workshop Manual (1621-10-98E). Idle speed • Adjustment procedure has been modified. Fuel tank • Removal/installation procedure has been modified.
Page 111: Fuel System
FUEL SYSTEM FUEL SYSTEM FUEL TANK REMOVAL/INSTALLATION A6E391242110201 Warning • Repairing a fuel tank that has not been properly steam cleaned can be dangerous. Explosion or fire may cause death or serious injury. Always properly steam clean a fuel tank before repairing it. •...
Page 112 FUEL SYSTEM 10. Remove in the order indicated in the table. 11. Install in the reverse order of removal. 12. Complete the “AFTER REPAIR PROCEDURE”. 8.9—12.7 N·m {91—120 kgf·cm, 79—110 in·lbf} 8.9—12.7 N·m {91—120 kgf·cm, 79—110 in·lbf} 44—60 {4.5—6.1, 33—44} 44—60 {4.5—6.1, 33—44} 44—60...
Page 113 FUEL SYSTEM Evaporative Hose Installation Note 1. Fit the evaporative hose until it hits the check valve as shown. CHECK VALVE EVAPORATIVE HOSE A6E39122006 Breather Hose Installation Note 1. Fit the breather hose onto the respective fittings, and install clamps as shown. 10 {0.39} UPPER SIDE VIEW FROM A...
Page 114: Fuel Pump Unit
FUEL SYSTEM FUEL PUMP UNIT REMOVAL/INSTALLATION A6E391213350202 Warning • 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, do not damage the sealing surface of the fuel pump unit when removing or installing.
Page 115 FUEL SYSTEM Plastic Fuel Hose Removal Note Caution • The quick release connector may be damaged if the tab is bent excessively. Do not expand the tab over the stopper. 1. Disconnect the quick release connector. FUEL PIPE (1) Push the tab on the locking coupler 90 degrees until it stops.
Page 116 FUEL SYSTEM Fuel Pump Cap Installation Note 1. Verify that the fuel tank mark is aligned with the fuel pump unit mark as shown. 2. Using the SST, tighten the fuel pump cap without shifting the mark. Tightening torque 80—90 N·m {8.2—9.1 kgf·m, 60—66 ft·lbf} A6E39122013 Plastic Fuel Hose Installation Note Note...
Page 117: Fuel Hose
FUEL SYSTEM FUEL HOSE (FUEL TANK SIDE, TRANSFER HOSE PART) REMOVAL/INSTALLATION A6E391242692202 Warning • Repairing a fuel tank that has not been properly steam cleaned can be dangerous. Explosion or fire may cause death or serious injury. Always properly steam clean a fuel tank before repairing it. •...
Page 118: Exhaust System
EXHAUST SYSTEM EXHAUST SYSTEM EXHAUST SYSTEM REMOVAL/INSTALLATION A6E391440000203 Warning • When the engine and exhaust system are hot, they can badly burn. Turn off the engine and wait until they are cool before removing the exhaust system. 1. Remove in the order indicated in the table. 2.
Page 119 EXHAUST SYSTEM Main silencer Exhaust manifold gasket Presilencer Exhaust manifold insulator (lower) (See F1–31 Exhaust Manifold Insulator (Lower) Installation Note) Exhaust manifold insulator (upper) HO2S (front) (See F1–32 Exhaust Manifold Insulator (Upper) (See F1–31 HO2S Removal Note) Installation Note) HO2S (rear) Bracket (See F1–31 HO2S Removal...
Page 120 EXHAUST SYSTEM Exhaust Manifold Installation Note 1. Tighten the exhaust manifold installation nuts in the order shown. A6J3914W003 Bracket Installation Note 1. Temporarily tighten the bracket installation bolt by the side of the exhaust manifold. 2. Verify that there is 2.0—4.0 mm {0.08—0.15 in} gap between the exhaust manifold and the bracket.
Page 121: Control System
CONTROL SYSTEM CONTROL SYSTEM PCM INSPECTION (4WD) A6E394018880207 Using SST (WDS or equivalent) Note • PIDs for the following parts are not available on this model. Go to the appropriate part inspection page. — CMP sensor — Main relay 1. Connect the SST (WDS or equivalent) to the DLC-2.
Page 122 CONTROL SYSTEM Monitor item Unit/ Condition/Specification Action (Definition) Condition (Reference) terminal Ignition switch ON (at sea level): kPa, inHg approx. 101 kPa {29.8 inHg} BARO* Inspect BARO sensor. (Barometric pressure) Ignition switch ON (at sea level): approx. 4.1 V Brake pedal depressed: ON ON/OFF Inspect brake switch.
Page 123 CONTROL SYSTEM Monitor item Unit/ Condition/Specification Action (Definition) Condition (Reference) terminal Ignition switch ON: ON (HO2S HTR12 Inspect following PIDs: IAT, MAF, ON/OFF heater operated) (HO2S heater (rear)) ECT, RPM, ACSW. Idle: ON (HO2S heater operated) Inspect following PIDs: IAT, RPM, Ignition switch ON: 0% MAP, ECT, MAF, TP, INGEAR, TR, IAC (IAC valve)
Page 124 CONTROL SYSTEM Monitor item Unit/ Condition/Specification Action (Definition) Condition (Reference) terminal RO2FT1 (Rear oxygen Idle (after warm up): approx. – Perform applicable DTC — — sensor fuel trim) 0.03—0.03 troubleshooting. LF Unleaded fuel (RON 90 or above) model No load: 600—700 rpm E/L operating: 650—750 rpm P/S operating: 650—750 rpm A/C ON: 700—800 rpm...
Page 125 CONTROL SYSTEM Without Using the SST Caution • The PCM terminal voltages vary with change in measuring conditions and vehicle conditions. Always carry out a total inspection of the input systems, output systems, and PCM to determine the cause of trouble. Otherwise, a wrong diagnosis will be made. 1.
Page 126 CONTROL SYSTEM Voltage Terminal Signal Connected to Test condition Action Refrigerant pressure is Below 1.0 • Inspect refrigerant above 1.52 Refrigerant Refrigerant pressure switch pressure switch pressure switch A/C ON • Inspect related Refrigerant (middle) (middle) harness pressure is below 1.23 Below 1.0 •...
Page 127 CONTROL SYSTEM Voltage Terminal Signal Connected to Test condition Action • Inspect using the wave profile. • Inspect CKP sensor • Inspect related CKP (+) CKP sensor (See F1–44 Inspection Using An Oscilloscope (Reference).) harness IAT 20 °C • Inspect IAT sensor 2.4—2.6 {68 °F} Ignition switch...
Page 128 CONTROL SYSTEM Voltage Terminal Signal Connected to Test condition Action • Inspect coil Because this terminal is for communication, Coil* (Immobilizer • Inspect related Coil good/no good judgment by terminal voltage system) is not possible. harness — — — — —* Instrument cluster, ABS HU/CM,...
Page 129 CONTROL SYSTEM Voltage Terminal Signal Connected to Test condition Action Detects down- Below 1.0 • Inspect down switch shift operation Ignition switch • Inspect related 5, 11 of selector lever Down switch Manual down* in M range harness Others — —...
Page 130 CONTROL SYSTEM Voltage Terminal Signal Connected to Test condition Action • Inspect cooling fan ECT below 100 °C {212 °F} relay Cooling fan control Cooling fan relay Idling • Inspect related A/C operating Below 1.0 harness Engine speed • Inspect VAD control below 5,800 VAD control Ignition switch...
Page 131 CONTROL SYSTEM Voltage Terminal Signal Connected to Test condition Action • Inspect fuel pump Ignition switch ON relay Cranking Below 1.0 Fuel pump relay Fuel pump control* • Inspect related Idle Below 1.0 harness — — — — —* • Inspect VIC solenoid Engine speed: above 4,500 rpm VIC control valve...
Page 132 CONTROL SYSTEM : Unleaded fuel (RON 90 or above) models : Exclude L3 engine models : MTX, without ABS models : Immobilizer system equipped : Immobilizer system not equipped : 2WD ATX models : 4WD ATX models : Exclude MTX models without ABS : Exclude 2WD ATX models Inspection Using An Oscilloscope (Reference) IGT1, IGT2 control signals...
Page 133 CONTROL SYSTEM Generator field coil control signal PCM terminals • 1AD(+)—1C(–) Oscilloscope setting • 0.5 V/DIV (Y), 1 ms/DIV (X), DC range Vehicle condition • Idle after warm up (engine speed approx. 650 rpm [MTX] or 700 rpm [ATX], no load, P/S off, A/C off) A6A3940W006 CKP sensor signal...
Page 134 CONTROL SYSTEM CMP sensor signal L3 engine (+) PCM terminals • 2J(+)—2H(–) Oscilloscope setting • 1 V/DIV (Y), 10 ms/DIV (X), DC range Vehicle condition • Idle after warm up (engine speed approx. 650 rpm [MTX] or 700 rpm [ATX], no load, P/S off, A/C off) A6A3940W012 LF engine (+)
Page 135 CONTROL SYSTEM Input/turbine speed sensor signal PCM terminals • 3G(+)—2AC(–) Oscilloscope setting • 500 mV/DIV (Y), 1 ms/DIV (X), DC range Vehicle condition • Idle after warm up (engine speed approx. 650 rpm [MTX] or 700 rpm [ATX], no load, P/S off, A/C off) A6A3940W016 Pressure control solenoid signal...
Page 136 CONTROL SYSTEM IAC signal PCM terminals • 4G(+)—1C(–) Oscilloscope setting • 2 V/DIV (Y), 0.4 ms/DIV (X), DC range Vehicle condition • Idle after warm up (engine speed approx. 650 rpm [MTX] or 700 rpm [ATX], no load, P/S off, A/C off) A6A3940W020 (–)
Page 137 CONTROL SYSTEM Fuel injection control PCM terminals • Fuel Injection No.1: 4Z(+)—1C(–) • Fuel Injection No.1: 4W(+)—1C(–) • Fuel Injection No.1: 4AD(+)—1C(–) • Fuel Injection No.1: 4AA(+)—1C(–) Oscilloscope setting • 4 V/DIV (Y), 10 ms/DIV (X), DC range Vehicle condition •...
Page 138: Outline
A6E397018881201 • The construction and operation of the on-board diagnostic system is essentially carried over from that of the current Mazda6 (GG), except for the following. (See Mazda6 Training Manual 3359-1*-02C.) 4WD ATX model — DTCs, PID monitoring items, and simulation items have been deleted to match the vehicle characteristics.
Page 139 ON-BOARD DIAGNOSTIC Memory DTC No. Condition Monitor item function × P0112 IAT circuit low input × P0113 IAT circuit high input × P0117 ECT circuit low input × P0118 ECT circuit high input × P0121 TP stuck closed × P0122 TP circuit low input ×...
Page 140: Dtc (4Wd)
ON-BOARD DIAGNOSTIC Memory DTC No. Condition Monitor item function × U0101 PCM cannot receive any signals from TCM Other PCM cannot receive any signals from ABS, ABS/TCS × U0121 Other or DSC HU/CM PCM cannot receive any signals from instrument ×...
Page 141 ON-BOARD DIAGNOSTIC 3. Perform no load racing at the engine speed shown in the graph, then idle the engine for more than 30 s after the cooling fan is stopped. If possible, monitor RPM PID for engine speed and 2,800 3,200 rpm —...
Page 142: Dtc Table
ON-BOARD DIAGNOSTIC For L3 engine ATX Vehicle Speed Time Zone Range km/h {mph} km/h {mph} Sec. T1: Above 100 {62} P or N M (3rd) 40—65 {25—41} T2: Above 30 M (3rd) 65—80 {41—49} 50 {31} M (2nd) 60—75 {38—46} T3: Above 20 M (3rd) 80—95 {50—59}...
Page 143 ON-BOARD DIAGNOSTIC Memory DTC No. Condition Monitor item Page function × sensor P0133 Front HO2S circuit malfunction — Front HO2S circuit no activity × P0134 — detected × P0138 Rear HO2S circuit high input — Rear HO2S circuit no activity ×...
Page 144 ON-BOARD DIAGNOSTIC Memory DTC No. Condition Monitor item Page function Generator terminal B circuit P2504 Other — — open U0073 CAN bus off Other — — (See T–39 MULTIPLEX PCM cannot receive any × U0101 Other COMMUNICATION signals from TCM SYSTEM) PCM cannot receive any ×...
Page 145: Troubleshooting
TROUBLESHOOTING TROUBLESHOOTING ENGINE SYMPTOM TROUBLESHOOTING A6E398018881201 • Confirm trouble symptom using the following diagnostic index, then go to appropriate troubleshooting chart. Diagnostic Index TROUBLESHOOTING ITEM DESCRIPTION Melting of main or other fuses — MIL illuminates MIL is illuminated incorrectly. Will not crank Starter does not work.
Page 146 TROUBLESHOOTING QUICK DIAGNOSTIC CHART A6E398018881202 Applicable Possible factor Troubleshooting item Melting of main or other fuses MIL illuminates Will not crank Hard to start/long crank/erratic start/erratic crank Engine stalls. After start/at idle x x x Cranks normally but will not start x x x Slow return to idle Engine runs rough/rolling idle...
Page 147 TROUBLESHOOTING Applicable Possible factor Troubleshooting item Melting of main or other fuses MIL illuminates Will not crank Hard to start/long crank/erratic start/erratic crank Engine stalls. Cranks normally but will not start Slow return to idle Engine runs rough/rolling idle Fast idle/runs on 10 Low idle/stalls during deceleration Engine stalls/quits.
Page 148 TROUBLESHOOTING Applicable Possible factor Troubleshooting item Melting of main or other fuses MIL illuminates Will not crank Hard to start/long crank/erratic start/erratic crank Engine stalls. After start/at idle Cranks normally but will not start Slow return to idle Engine runs rough/rolling idle Fast idle/runs on 10 Low idle/stalls during deceleration Engine stalls/quits.
Page 149 TROUBLESHOOTING Applicable Possible factor Troubleshooting item 1 Melting of main or other fuses 2 MIL illuminates 3 Will not crank 4 Hard to start/long crank/erratic start/erratic crank 5 Engine stalls. After start/at idle 6 Cranks normally but will not start 7 Slow return to idle 8 Engine runs rough/rolling idle 9 Fast idle/runs on...
Page 150 TROUBLESHOOTING NO.14 POOR FUEL ECONOMY A6E398018881203 POOR FUEL ECONOMY DESCRIPTION Fuel economy is unsatisfactory. • Contaminated air cleaner element • VIS malfunction (if equipped) • Engine cooling system malfunction • Improper ATF level (ATX) • Weak spark • Poor fuel quality •...
Page 151 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Is strong blue spark visible at each disconnected Inspect for following: • Spark plugs malfunction high-tension lead while cranking engine? • CMP sensor is improperly installed. • Trigger wheel damage on camshaft • Open or short circuit on CMP sensor •...
Page 152 TROUBLESHOOTING NO.22 VIBRATION CONCERNS (ENGINE) A6E398018881204 VIBRATION CONCERNS (ENGINE) • Vibration from under hood or driveline DESCRIPTION • Loose attaching bolts or worn parts POSSIBLE CAUSE • Components malfunction such as worn parts Diagnostic procedure STEP INSPECTION RESULTS ACTION Inspect following components for loose attaching Inspect following systems: •...
Page 153 F UEL AND EMISSION CONTROL SYSTEMS [MZR-CD (RF Turbo)] VARIABLE BOOST CONTROL (VBC) FEATURES CHECK VALVE INSPECTION ...... F2-41 VARIABLE SWIRL CONTROL (VSC) OUTLINE .............. F2-3 VALVE ACTUATOR INSPECTION....F2-41 VARIABLE SWIRL CONTROL (VSC) OUTLINE OF CONSTRUCTION ....... F2-3 SOLENOID VALVE INSPECTION ....F2-42 FEATURES ............
Page 154 MASS AIR FLOW (MAF)/INTAKE AIR DTC P0606............. F2-155 TEMPERATURE (IAT) SENSOR DTC P0610............. F2-155 INSPECTION ..........F2-74 DTC P0661............. F2-156 INTAKE AIR TEMPERATURE (IAT) DTC P0662............. F2-158 SENSOR NO.2 INSPECTION....... F2-75 DTC P0850............. F2-160 ENGINE COOLANT TEMPERATURE (ECT) DTC P1190............. F2-162 SENSOR REMOVAL/INSTALLATION..
Page 155: Outline
OUTLINE OF CONSTRUCTION A6E400218881201 • The common rail injection system has been adopted for Mazda6 (GG, GY) MZR-CD (RF Turbo) engine models. • The fuel and emission control system is essentially carried over from that of the current MPV (LW) MZR-CD (RF Turbo) engine models, except for the following features.
Page 156: Control System Diagram
OUTLINE CONTROL SYSTEM DIAGRAM A6E400218881204 29 28 A6E40022001 Air cleaner Common rail Vacuum chamber Fuel pressure sensor VBC check valve Fuel pressure limiter MAF/IAT sensor Glow plug VBC solenoid valve Fuel injector Vacuum damper ECT sensor Guide blade actuator Calibration resistor Turbocharger CMP sensor Charge air cooler...
Page 157: Control System Wiring Diagram
OUTLINE CONTROL SYSTEM WIRING DIAGRAM A6E400218881205 2A 2B 2C 2D 2E 2F 2G 2H 1A 1B 1C 1D 1E 1F 1G 1H 1A 1B 1C 1D 1E 1F 30 42 44 45 43 13 39 7 34 64 104 103 85 65 91 69 53 79 80 28 9 14 60...
Page 158 OUTLINE C B D C B D C B D C B D 81 55 29 3 86 68 94 93 A6E40022003 DLC-2 Battery Water heater unit Engine switch Fuel pump Starter relay Other unit Starter F2–6...
Page 159 OUTLINE Generator Intake shutter solenoid valve (full) Oil pressure switch VBC solenoid valve Sedimentor switch EGR control solenoid valve Instrument cluster Boost sensor Neutral switch Accelerator position sensor Clutch switch Idle switch Coil Fuel pressure sensor Brake switch ECT sensor Brake switch 2 Fuel temperature sensor Cruise control switch...
Page 160: Intake-Air System
OUTLINE A6E401001005201 • The intake-air system is essentially carried over from that of the current MPV (LW) MZR-CD (RF Turbo) engine model. (See MPV Workshop Manual Supplement 1737-1*-02D.) ×:Applicable Mazda6 Current (GG, GY) MPV (LW) Item Remark for new model...
Page 161: Structural View
INTAKE-AIR SYSTEM STRUCTURAL VIEW A6E401001005202 A6E40102029 Glow plug VSC solenoid valve Intake manifold VBC solenoid valve VSC valve actuator VBC check valve Charge air cooler Air cleaner Vacuum damper Glow plug relay Glow plug lead Accelerator pedal component Guide blade actuator L.H.D.
Page 162: Fuel System
OUTLINE A6E401201006201 • The fuel system is essentially carried over from that of the current MPV (LW) MZR-CD (RF Turbo) engine model. (See MPV Wordshop Manual Supplement 1737-1*-02D.) ×:Applicable Mazda6 Current (GG, GY) MPV (LW) Item Remark for new model...
Page 163: Structural View
FUEL SYSTEM STRUCTURAL VIEW A6E401201006202 Engine room side A6E40122031 Fuel warmer L.H.D. Sedimentor switch Fuel injector Supply pump Priming pump Suction control valve Fuel filter Common rail R.H.D. Priming pump Sedimentor switch F2–11...
Page 164 FUEL SYSTEM Fuel tank side A6E40122032 Fuel tank Nonreturn valve Fuel pump Fuel filler cap End Of Sie F2–12...
Page 165: Exhaust System
EXHAUST SYSTEM EXHAUST SYSTEM OUTLINE A6E401440000201 • The exhaust system is essentially carried over from that of the current 626 (GF)/626 Station Wagon (GW) RF Turbo engine models. (See 626 626 Station Wagon Workshop Manual Supplement 1688-1*-00G.) End Of Sie STRUCTURAL VIEW A6E401440000202 A6E40142005...
Page 166: Emission System
EMISSION SYSTEM OUTLINE A6E401601007201 • The emission system is essentially carried over from that of the current MPV (LW) MZR-CD (RF Turbo) engine model. (See MPV Workshop Manual Supplement 1737-1*-02D.) ×:Applicable Mazda6 Current (GG,GY) MPV (LW) Item Remark for new model...
Page 167: Structural View
EMISSION SYSTEM STRUCTURAL VIEW A6E401601007202 Engine room side A6E40162018 EGR water cooler Warm up oxidation catalytic converter EGR valve Intake shutter valve actuator Intake shutter solenoid valve (full) Oxidation catalytic converter Intake shutter solenoid valve (half) EGR solenoid valve (vent) EGR solenoid valve (vacuum) EGR control solenoid valve Fuel tank side...
Page 168: Warm Up Oxidation Catalytic Converter Description
× Neutral switch Same function as MPV (LW) MZR-CD (RF Turbo) engine model × Brake switch Same function as Mazda6 (GG) L series engine model × Idle switch Same function as MPV (LW) MZR-CD (RF Turbo) engine model × A/C switch Same function as MPV (LW) MZR-CD (RF Turbo) engine model ×...
Page 169 Same function as MPV (LW) MZR-CD (RF Turbo) engine model × Cruise main indicator light – Same function as Mazda6 (GG) L series engine model × Cruise set indicator light – Same function as Mazda6 (GG) L series engine model ×...
Page 170: Structural View
CONTROL SYSTEM STRUCTURAL VIEW A6E404018881202 A6E40402024 F2–18...
Page 171 CONTROL SYSTEM PCM (with built-in BARO sensor and immobilizer unit) Battery Starter Starter relay Clutch switch Neutral switch Brake switch Idle switch Cruise control switch Accelerator position sensor MAF/IAT sensor IAT sensor No.2 ECT sensor Fuel temperature sensor Boost sensor Fuel pressure sensor CMP sensor CKP sensor...
Page 172: Block Diagram
CONTROL SYSTEM BLOCK DIAGRAM A6E404018881203 CRUISE MAIN CRUISE A6E40402017 F2–20...
Page 173 CONTROL SYSTEM Idle speed control Glow control Boost pressure control Fuel injection amount control Fuel injection timing control Multiple fuel injection control Fuel pressure control EGR control Cruise control system Electrical fan control A/C cut-off control Immobilizer system Battery Starter (starter signal) Starter relay Clutch switch Neutral switch...
Page 174: Control Device And Control Relationship Chart
CONTROL SYSTEM CONTROL DEVICE AND CONTROL RELATIONSHIP CHART A6E404018881204 ×: Applicable Item Input device × × Battery × × × × × × × × × × Starter (starter signal) × × × × × × × × × × Starter relay ×...
Page 175: Cruise Control System
• Cruise control module has been equipped into the PCM. Due to this, the PCM controls cruise control system. • Function of the cruise control system is basically the same as that of the Mazda6 (GG) L series engine model, except for the following: —...
Page 176: Controller Area Network (Can)
CONTROL SYSTEM, ON-BOARD DIAGNOSTIC CONTROLLER AREA NETWORK (CAN) A6E404018881206 Outline • 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 •...
Page 177 ON-BOARD DIAGNOSTIC Memory Condition Detection condition function × × P0112 IAT sensor No.2 circuit low input Input voltage from IAT sensor No.2 is below 0.1 V. × × P0113 IAT sensor No.2 circuit high input Input voltage from IAT sensor No.2 is above 5.0 V. ×...
Page 178: Koeo/Koer Self-Test
ON-BOARD DIAGNOSTIC Memory Condition Detection condition function × × P0610 Control module vehicle options error PCM data configuration error. Input voltage from VSC solenoid valve is below 0.1 × P0661 VSC solenoid valve circuit low input – × P0662 VSC solenoid valve circuit high input Input voltage from VSC solenoid valve is above B+.
Page 179: Pid/Data Monitor And Record
ON-BOARD DIAGNOSTIC PID/DATA MONITOR AND RECORD A6E407018881204 PID monitoring item table Item Definition Condition/unit PCM terminal ACCS A/C relay ON/OFF ACSW A/C switch ON/OFF APS1 Accelerator position sensor No.1 signal voltage APS2 Accelerator position sensor No.2 signal voltage Barometric pressure kPa, inHg BARO Barometric pressure signal voltage...
Page 180: Location Index
LOCATION INDEX End Of Sie LOCATION INDEX INTAKE-AIR SYSTEM A6E400001005201 R.H.D. L.H.D. A6E40002002 F2–28...
Page 181 LOCATION INDEX Air cleaner VBC check valve (See F2–36 INTAKE-AIR SYSTEM REMOVAL/ (See F2–41 VARIABLE BOOST CONTROL (VBC) INSTALLATION) CHECK VALVE INSPECTION) (See F2–37 AIR CLEANER ELEMENT VSC valve actuator INSPECTION) (See F2–41 VARIABLE SWIRL CONTROL (VSC) Turbocharger VALVE ACTUATOR INSPECTION) (See F2–38 TURBOCHARGER...
Page 182 LOCATION INDEX Fuel tank side A6E40002004 Fuel tank Priming pump (See F2–45 FUEL TANK REMOVAL/ (See F2–52 SEDIMENTOR WATER DRAINING) INSTALLATION) Supply pump (See F2–49 FUEL TANK INSPECTION) (See F2–53 SUPPLY PUMP REMOVAL/ Nonreturn valve INSTALLATION) (See F2–50 NONRETURN VALVE INSPECTION) (See F2–54 SUPPLY PUMP...
Page 183: Emission System
LOCATION INDEX EMISSION SYSTEM A6E400001007201 A6E40002005 EGR valve EGR solenoid valve (vent) (See F2–59 EGR VALVE REMOVAL/ (See F2–60 EGR SOLENOID VALVE (VENT) INSTALLATION) INSPECTION) (See F2–59 EGR VALVE INSPECTION) Intake shutter valve actuator EGR control solenoid valve (See F2–62 INTAKE SHUTTER VALVE (See F2–61 EGR CONTROL SOLENOID VALVE ACTUATOR...
Page 184: Control System
LOCATION INDEX CONTROL SYSTEM A6E400018881201 L.H.D. R.H.D. A6E40002001 F2–32...
Page 185 LOCATION INDEX PCM (with built-in BARO sensor and immobilizer unit) (SeeF2–64 PCM REMOVAL/INSTALLATION) (SeeF2–65 PCM INSPECTION) (SeeF2–68 PCM CONFIGURATION) Clutch switch (SeeF2–68 CLUTCH SWITCH INSPECTION) Neutral switch (SeeF2–69 NEUTRAL SWITCH INSPECTION) Idle switch (SeeF2–70 IDLE SWITCH INSPECTION) (SeeF2–71 IDLE SWITCH ADJUSTMENT) Accelerator position sensor (SeeF2–72 ACCELERATOR POSITION SENSOR...
Page 186: Engine Tune-Up
ENGINE TUNE-UP ENGINE TUNE-UP ENGINE TUNE-UP PREPARATION A6E400802000201 1. Start the engine and warm up completely. 2. Verify that the gear is in neutral position. 3. Verify that the accelerator pedal is released. 4. Turn off the A/C switch. 5. Turn off all electrical loads. 6.
Page 187: Intake-Air System
ENGINE TUNE-UP, INTAKE-AIR SYSTEM Injection Amount Correction Note • Perform this procedure at the recommended interval as described under “Fuel injection system” in “SCHEDULED MAINTENANCE.” 1. Perform “Engine Tune-up Preparation”. (See F2–34 ENGINE TUNE-UP PREPARATION.) 2. Perform “Injection Amount Correction” using the WDS or equivalent. MAF Correction Note •...
Page 188: Intake-Air System Removal/Installation
INTAKE-AIR SYSTEM INTAKE-AIR SYSTEM REMOVAL/INSTALLATION A6E401001005203 Warning • When the engine and intake-air system are hot, they can cause severe burns or injury. Turn off the engine and wait until they are cool before removing or installing the intake-air system. •...
Page 189: Air Cleaner Element Inspection
INTAKE-AIR SYSTEM Vacuum hose Air hose Air hose Air pipe Air cleaner cover Boost sensor Air cleaner element IAT sensor No. 2 Air cleaner case Air pipe (See F2–37 Air Cleaner Case Installation Note) Air hose MAF/IAT sensor Air duct Air pipe Charge air cooler (See...
Page 190: Turbocharger Inspection
INTAKE-AIR SYSTEM TURBOCHARGER INSPECTION A6E401013700201 Note • If the following problems exist, diagnosis the turbocharger using the following symptom troubleshooting procedures. 1. Lack of power: perform “NO.12 LACK/LOSS OF POWER”. (See F2–195 NO.12 LACK/LOSS OF POWER- ACCELERATION/CRUISE.) 2. Oil leak: perform “NO.16 HIGH OIL CONSUMPTION/LEAKAGE”. (See F2–209 NO.16 HIGH OIL CONSUMPTION/LEAKAGE.) 3.
Page 191: Guide Blade Actuator Inspection
INTAKE-AIR SYSTEM Turbine Wheel Inspection 1. Remove the warm up oxidation catalytic converter between the flexible pipe and the turbocharger. (See F2–57 EXHAUST SYSTEM REMOVAL/INSTALLATION.) 2. Visually inspect the turbine wheel from view B and verify that all fins are free from damage, cracks or bends. •...
Page 192: Variable Boost Control (Vbc) Solenoid Valve Inspection
INTAKE-AIR SYSTEM VARIABLE BOOST CONTROL (VBC) SOLENOID VALVE INSPECTION A6E401013710201 Air Tightness Inspection 1. Connect a vacuum pump to the VBC solenoid valve port A, and apply vacuum. Note • Even if there is vacuum leakage, the VBC solenoid valve is okay if vacuum increases to –47 kPa {–353 mmHg, –14 inHg} or more.
Page 193: Variable Boost Control (Vbc) Check Valve Inspection
INTAKE-AIR SYSTEM Open circuit • If there is no continuity, the circuit is open. Repair or replace the harness. — VBC solenoid valve terminal A (harness-side) and PCM control relay terminal C — VBC solenoid valve terminal B (harness-side) and PCM connector terminal 67 Short circuit •...
Page 194: Variable Swirl Control (Vsc) Solenoid Valve Inspection
INTAKE-AIR SYSTEM VARIABLE SWIRL CONTROL (VSC) SOLENOID VALVE INSPECTION A6E401013110202 Note • Perform the following test only when directed. 1. Inspect airflow between the ports under the following conditions. • If not as specified, replace the VSC solenoid valve. • If VSC solenoid valve is okay, perform the “Circuit Open/Short Inspection”.
Page 195: Glow Plug Inspection
INTAKE-AIR SYSTEM Glow Plug Removal Note 1. When removing the glow plug, first loosen it at least one pitch using a tool, then loosen by hand. Glow Plug Installation Note 1. Tighten the glow plug at least one pitch by hand, and continue tightening with a tool. End Of Sie GLOW PLUG INSPECTION A6E401018601202...
Page 196: Accelerator Pedal Component Removal/Installation
INTAKE-AIR SYSTEM End Of Sie ACCELERATOR PEDAL COMPONENT REMOVAL/INSTALLATION A6E401041600201 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. Accelerator position sensor connector Idle switch connector Pedal component 3. Install in the reverse order of removal. 7.8—10.8 N·m {80—110 kgf·m, 69—95 in·lbf}...
Page 197: Fuel System
FUEL SYSTEM FUEL SYSTEM BEFORE REPAIR PROCEDURE A6E401201006203 Warning • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leads are dangerous. Fuel can ignite and cause serious injuries or death and damage.
Page 198 FUEL SYSTEM 1. Verify that vehicle is level. 2. Complete the “BEFORE REPAIR PROCEDURE”. (See F2–45 BEFORE REPAIR PROCEDURE.) 3. Disconnect the negative battery cable. 4. Remove the rear seat cushion. 5. Remove the service hole cover. 6. Remove the plastic fuel hose from the fuel gauge sender unit. (See F2–47 Plastic Fuel Hose Removal Note.) (See...
Page 199 FUEL SYSTEM Plastic Fuel Hose Removal Note Caution • The quick release connector may be damaged if the tab is bent excessively. Do not expand the tab over the stopper. 1. Disconnect the quick release connector. (1) Push the tab on the locking coupler 90 degrees until it stops. (2) Pull the fuel hose straight back.
Page 200 FUEL SYSTEM Breather Hose Installation Note 1. Fit the breather hose onto the respective fittings, FUEL TANK SIDE and install clamps as shown. 10 mm {0.39 in} A6E3912W038 Joint Hose Installation Note 1. Fit the joint hose onto the respective fittings, and FUEL TANK SIDE install clamps as shown.
Page 201: Fuel Tank Inspection
FUEL SYSTEM (2) Apply a slight amount of clean engine oil to the sealing surface of the fuel pump unit. QUICK RELEASE SEALING CONNECTOR (3) Align the fuel pipe on the fuel pump unit and SURFACE quick release connector so that the tabs of the retainer are correctly fitted into the quick release connector.
Page 202: Nonreturn Valve Inspection
FUEL SYSTEM NONRETURN VALVE INSPECTION A6E401242270201 Note • Nonreturn valve is integrated in the fuel tank. Therefore, before inspecting the nonreturn valve perform the follwing: 1. Remove the fuel gauge sender unit. (See F2–45 FUEL TANK REMOVAL/INSTALLATION.) 2. Siphon the fuel from the fuel tank. Note •...
Page 203: Fuel Filter Component Disassembly/Assembly
FUEL SYSTEM FUEL FILTER COMPONENT DISASSEMBLY/ASSEMBLY A6E401234802202 1. Disassemble in the order indicated in the table. Connector Fuel hose Priming pump 17.6—26.5 Fuel filter {1.8—2.7, (See F2–51 Fuel Filter Installation Note) 13.0—19.8} Sedimentor switch (See F2–51 Sedimentor Switch Installation Note) Drain plug Fuel warmer 2.
Page 204: Sedimentor Water Draining
FUEL SYSTEM SEDIMENTOR WATER DRAINING A6E401234802204 1. Disconnect the negative battery cable. 2. Complete the “BEFORE REPAIR PROCEDURE”. (See F2–45 BEFORE REPAIR PROCEDURE.) 3. Loosen the drain plug located at the bottom of the fuel filter. 4. Pump the priming pump and drain the water. 5.
Page 205: Supply Pump Removal/Installation
FUEL SYSTEM SUPPLY PUMP REMOVAL/INSTALLATION A6E401213350201 Caution • Fuel line spills and leakage on the parts are dangerous. Fuel can ignite and also deteriorate the parts. To prevent this, always cover the mouths of the removed parts in the fuel system with rags to soak up the fuel.
Page 206: Supply Pump Inspection
FUEL SYSTEM SUPPLY PUMP INSPECTION A6E401213350202 Caution • The supply pump is sealed to maintain proper function. Special tools and testers are required when disassembling the supply pump. Disassembling the supply pump without special tools and testers will cause a malfunction. •...
Page 207: Fuel Injector Removal/Installation F2-55
FUEL SYSTEM FUEL INJECTOR REMOVAL/INSTALLATION A6E401213250201 Caution • Fuel line spills and leakage on the parts are dangerous. Fuel can ignite and also deteriorate the parts. To prevent this, always cover the mouths of the removed parts in the fuel system with rags to soak up the fuel.
Page 208: Fuel Injector Inspection
FUEL SYSTEM End Of Sie FUEL INJECTOR INSPECTION A6E401213250202 Resistance Inspection Note • Perform the following test only when directed. • Perform “Correction after Parts Installation” after replacing the fuel injector. (See F2–34 Correction after Parts Installation.) 1. Disconnect the negative battery cable. 2.
Page 209: Exhaust System
EXHAUST SYSTEM EXHAUST SYSTEM EXHAUST SYSTEM INSPECTION A6E401440000203 1. Start the engine and inspect each exhaust system component for exhaust gas leakage. • If leakage is found, repair or replace as necessary. End Of Sie EXHAUST SYSTEM REMOVAL/INSTALLATION A6E401440000204 Warning •...
Page 210 EXHAUST SYSTEM Exhaust manifold insulator Water pipe (See F2–58 Water Pipe Installation Note) Oil pipe (supply) (See F2–58 Oil Pipe (Supply) Installation Note) Turbocharger (See F2–58 Turbocharger Removal Note) Oil pipe (return) Exhaust manifold Water hose (See F2–58 Exhaust Manifold Removal Note) (See F2–58 Water Hose Removal...
Page 211: Emission System
EMISSION SYSTEM EMISSION SYSTEM EGR VALVE REMOVAL/INSTALLATION A6E401620300201 1. Disconnect the negative battery cable. 2. Remove the air cleaner. (See F2–36 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.) 3. Remove the common rail. (See F2–53 SUPPLY PUMP REMOVAL/INSTALLATION.) 4. Remove in the order indicated in the table. 22—26 {2.2—2.7, Air pipe...
Page 212: Egr Solenoid Valve (Vacuum) Inspection
EMISSION SYSTEM EGR SOLENOID VALVE (VACUUM) INSPECTION A6E401618741201 Note • Perform the following inspection only when directed. 1. Inspect airflow between the ports under the following conditions. • If not as specified, replace the EGR solenoid valve (vacuum). • If as specified, carry out the “Circuit Open/ Short Inspection”.
Page 213: Egr Control Solenoid Valve Inspection
EMISSION SYSTEM Circuit Open/Short Inspection 1. Inspect the following wiring harness for an open FUSE BOX EGR SOLENOID VALVE(VENT) or short circuit (continuity check). (PCM CONTROL RELAY) HARNESS SIDE CONNECTOR Open circuit • If there is no continuity, the circuit is open, Repair or replace the harness.
Page 214: Intake Shutter Valve Actuator Inspection
EMISSION SYSTEM INTAKE SHUTTER VALVE ACTUATOR INSPECTION A6E401620100201 1. Disconnect the vacuum hose from the intake shutter valve actuator. 2. Connect a vacuum pump to port A. 3. Apply vacuum and verify that the rod moves. • If the rod does not move, replace the intake manifold.
Page 215: Intake Shutter Solenoid Valve Inspection
EMISSION SYSTEM INTAKE SHUTTER SOLENOID VALVE INSPECTION A6E401613937201 Note • Perform the following inspection only when directed. • The inspection includes both intake shutter solenoid valve (half) and intake shutter solenoid valve (full). 1. Inspect airflow between the ports under the following conditions. •...
Page 216: Control System
CONTROL SYSTEM CONTROL SYSTEM PCM REMOVAL/INSTALLATION A6E404018881207 Note • For replace the PCM, setup the WDS and perform the following. — “PCM configuration” (See F2–68 PCM CONFIGURATION.) — “Correction after Parts Installation” (See F2–34 Correction after Parts Installation.) European (L.H.D.) Specs. 1.
Page 217: Pcm Inspection
CONTROL SYSTEM End Of Sie PCM INSPECTION A6E404018881208 Using WDS or Equivalent Caution • The PCM terminal voltage vary with change in measuring conditions and vehicle conditions. Always carry out a total inspection of the input systems, output systems, and PCM to determine the cause of trouble.
Page 218 CONTROL SYSTEM Unit/ Condition/Specification Monitor item (Definition) Action Condition (Reference) terminal • IAT is 20°C {68°F}: 20°C {68°F} Inspect IAT sensor No.1. °C °F • IAT is 30°C {86°F}: 30°C {86°F} (IAT) (See F2–74 MASS AIR FLOW (MAF)/INTAKE AIR • IAT is 20°C {68°F}: 2.2—2.5 V TEMPERATURE (IAT) •...
Page 219 CONTROL SYSTEM Not Using WDS or Equivalent Constant voltage terminal inspection 1. Turn the engine switch to ON. 2. Measure the voltage between the accelerator ACCELERATOR POSITION SENSOR position sensor terminal A (vehicle side) and body HARNESS SIDE CONNECTOR GND using a voltmeter. (1) Measurement voltage is below 1.0 V.
Page 220: Pcm Configuration
CONTROL SYSTEM PCM CONFIGURATION A6E404018881209 1. Connect the WDS to DLC-2. 2. Set up the WDS (including the vehicle recognition). 3. Select “Module programming.” 4. Select “Programmable module installation.” 5. Select “PCM” and perform procedures according DLC-2 to directions on the WDS screen. Note •...
Page 221: Neutral Switch Inspection
CONTROL SYSTEM NEUTRAL SWITCH INSPECTION A6E404017640201 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”...
Page 222: Idle Switch Inspection
CONTROL SYSTEM IDLE SWITCH INSPECTION A6E404041600201 Note • Perform the following test only when directed. 1. Verify that the accelerator position sensor is normal. 2. Visually inspect all accelerator pedal components for looseness. 3. Verify that the idle switch is installed to the accelerator pedal properly. 4.
Page 223: Idle Switch Adjustment
CONTROL SYSTEM IDLE SWITCH ADJUSTMENT A6E404041600202 Caution • Adjusting the idle switch unnecessarily may adversely affect engine control. Therefore, adjust the idle switch only when it is replaced. 1. Verify that the accelerator position sensor is normal. 2. Visually inspect all accelerator pedal components for looseness. 3.
Page 224: Accelerator Position Sensor Inspection
CONTROL SYSTEM ACCELERATOR POSITION SENSOR INSPECTION A6E404041602201 Note • Perform the following test only when directed. 1. Visually inspect all accelerator pedal components for looseness. 2. Verify that the accelerator position sensor is installed to the accelerator pedal properly. 3. Verify the power circuit voltage. (1) Verify that the voltage between the PCM terminal 90 (power circuit) and 91 (GND circuit) is 4.75—5.25 V.
Page 225: Accelerator Position Sensor Adjustment
CONTROL SYSTEM ACCELERATOR POSITION SENSOR ADJUSTMENT A6E404041602202 Caution • Adjusting the accelerator position sensor unnecessarily may adversely affect engine control. Therefore, adjust accelerator position sensor only when it is replaced. Note • Accelerator position sensor adjustment is based on the output voltage with the accelerator pedal fully released.
Page 226: Mass Air Flow (Maf)/Intake Air Temperature (Iat) Sensor Inspection
CONTROL SYSTEM MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR INSPECTION A6E404013210201 Note • Perform the following test only when directed. • Perform “MAF Correction” after replacing the MAF/IAT sensor. (See F2–35 MAF Correction.) MAF Sensor Voltage Inspection 1. Turn the engine switch to ON. 2.
Page 227: Intake Air Temperature (Iat) Sensor No.2 Inspection
CONTROL SYSTEM IAT Sensor No.1 Resistance Inspection 1. Disconnect the MAF/IAT sensor connector. 2. Measure the resistance between MAF/IAT sensor terminals D and E using an ohmmeter. • If not as specified, replace the MAF/IAT sensor. Specification Ambient temperature (°C Resistance (kilohm) {°F}) 20 {68}...
Page 228: Engine Coolant Temperature (Ect) Sensor Removal/Installation
CONTROL SYSTEM ENGINE COOLANT TEMPERATURE (ECT) SENSOR REMOVAL/INSTALLATION A6E404018840201 Warning • When the engine is hot, it can badly burn. Turn off the engine and wait until it is cool before removing the ECT sensor. 1. Disconnect the negative battery cable. 2.
Page 229: Fuel Temperature Sensor Inspection
CONTROL SYSTEM FUEL TEMPERATURE SENSOR INSPECTION A6E404013350201 Note • Perform the following test only when directed. Resistance Inspection 1. Disconnect the negative battery cable. 2. Remove the supply pump. (See F2–53 SUPPLY PUMP REMOVAL/INSTALLATION.) 3. Measure the resistance between the fuel temperature sensor terminals using an ohmmeter.
Page 230: Boost Sensor Inspection
CONTROL SYSTEM BOOST SENSOR INSPECTION A6E404013214201 Note • Perform the following test only when directed. Visual Inspection 1. Inspect the boost sensor for damage and cracks. • If not as specified, replace the boost sensor. 2. Inspect vacuum hose for improper routing, kinks or leakage. •...
Page 231: Fuel Pressure Sensor Inspection
CONTROL SYSTEM FUEL PRESSURE SENSOR INSPECTION A6E404013015201 Note • Perform the following test only when directed. Voltage Inspection 1. Start the engine and warm up the engine completely. 2. Measure the voltage between fuel pressure sensor terminals A and B using a voltmeter at idle. •...
Page 232: Camshaft Position (Cmp) Sensor Removal/Installation
CONTROL SYSTEM CAMSHAFT POSITION (CMP) SENSOR REMOVAL/INSTALLATION A6E404018200201 Caution • When foreign material, such as iron chips, gets on the CMP sensor, it can cause abnormal output from the sensor because of flux turbulence and adversely affect engine control. Be sure there is no foreign material on the CMP sensor when replacing.
Page 233: Crankshaft Position (Ckp) Sensor Removal/Installation
CONTROL SYSTEM Resistance Inspection 1. Disconnect the negative battery cable. 2. Remove the engine cover. 3. Disconnect the CMP sensor connector. 4. Inspect the resistance between the terminals under the following condition. • If not as specified, replace the CMP sensor. Specification Atmospheric Resistance...
Page 234: Crankshaft Position (Ckp) Sensor Inspection
CONTROL SYSTEM CRANKSHAFT POSITION (CKP) SENSOR INSPECTION A6E404018230202 Note • Perform the following test only when directed. Caution • When foreign material, such as iron chips, gets on the CKP sensor, it can cause abnormal output from the sensor because of flux turbulence and adversely affect engine control. Be sure there is no foreign material on the CKP sensor when replacing.
Page 235: Calibration Resistor Inspection
CONTROL SYSTEM CALIBRATION RESISTOR INSPECTION A6E404013050201 Note • Perform the following test only when directed. Resistance Inspection 1. Remove the calibration resistor. 2. Verify the calibration resistor rank number. FUEL INJECTOR 3. Refer to the table below and verify the resistance corresponding to the resistor rank number.
Page 236: Injector Driver Module (Idm) Inspection
CONTROL SYSTEM 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 — Calibration resistor No.1 terminal A and PCM terminal 37 —...
Page 237: On-Board Diagnostic
ON-BOARD DIAGNOSTIC ON-BOARD DIAGNOSTIC ON-BOARD DIAGNOSTIC TEST A6E407018881206 DTCs Retrieving Procedure 1. Perform the necessary vehicle preparation and visual inspection. 2. Connect the WDS or equivalent to the vehicle DLC-2 16-pin connector. 3. Retrieve DTC using the WDS or equivalent. PID/DATA Monitor and Record Procedure 1.
Page 238: Koeo/Koer Self-Test Procedure
ON-BOARD DIAGNOSTIC KOEO/KOER SELF-TEST PROCEDURE A6E407018881208 1. Connect the WDS or equivalent to the vehicle DLC-2 16-pin connector. 2. Perform KOEO/KOER self-test. DLC-2 A6E40702001 End Of Sie AFTER REPAIR PROCEDURE A6E407018881209 1. Connect the WDS or equivalent to the vehicle DLC-2 16-pin connector.
Page 239: Dtc Table
ON-BOARD DIAGNOSTIC End Of Sie DTC TABLE A6E407018881210 ×: Applicable –: Not applicable Memory Condition Page function × × P0016 Crankshaft position-camshaft position correlation malfunction (See F2–88 DTC P0016) × P0088 Fuel pressure system too high – (See F2–89 DTC P0088) ×...
Page 240: Dtc P0016
ON-BOARD DIAGNOSTIC End Of Sie DTC P0016 A6E407001082201 DTC P0016 Crankshaft position-camshaft position correlation malfunction • PCM monitors input signals from CKP sensor and CMP sensor while engine is running. If input signals DETECTION from CKP sensor and CMP sensor are misaligned, PCM determines crankshaft position-camshaft position CONDITION correlation malfunction.
Page 241: Dtc P0088
ON-BOARD DIAGNOSTIC DTC P0088 A6E407001082202 DTC P0088 Fuel pressure system too high • PCM monitors fuel pressure in common rail from fuel pressure sensor while engine running. If fuel pressure DETECTION CONDITION is higher than preprogrammed criteria, PCM determines fuel pressure system too high. •...
Page 242: Dtc P0091
ON-BOARD DIAGNOSTIC DTC P0091 A6E407001082203 DTC P0091 Suction control valve circuit low input • PCM monitors input voltage from suction control valve while engine is running. If input voltage from suction DETECTION CONDITION control valve does not change from off to on, PCM determines suction control valve circuit low input. •...
Page 243 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT POOR CONNECTION OF SUCTION Yes Repair or replace suspected terminal, go to Step 7. CONTROL VALVE CONNECTOR Go to next step. • Turn engine switch to OFF. • Inspect for poor connection (damaged, pulled- out terminals, corrosion, etc.).
Page 244: Dtc P0092
ON-BOARD DIAGNOSTIC DTC P0092 A6E407001082204 DTC P0092 Suction control valve circuit high input • PCM monitors input voltage from suction control valve while engine is running. If input voltage from suction DETECTION CONDITION control valve does not change from on to off, PCM determines suction control valve circuit high input. •...
Page 245 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT POOR CONNECTION OF SUCTION Yes Repair or replace suspected terminal, go to Step 6. CONTROL VALVE CONNECTOR Go to next step. • Turn engine switch to OFF. • Inspect for poor connection (damaged, pulled- out terminals, corrosion, etc.).
Page 246: Dtc P0093
ON-BOARD DIAGNOSTIC DTC P0093 A6E407001082205 DTC P0093 Fuel system leak detection • PCM monitors fuel pressure in common rail from fuel pressure sensor while engine running. If fuel pressure DETECTION CONDITION is lower after fuel injection than preprogrammed criteria, PCM determines fuel system leak detection. •...
Page 247: Dtc P0097
ON-BOARD DIAGNOSTIC DTC P0097 A6E407001082206 DTC P0097 IAT sensor No.1 circuit low input • PCM monitors input voltage from IAT sensor No.1 while engine is running. If input voltage from IAT sensor DETECTION CONDITION No.1 is below 0.1 V, PCM determines IAT sensor No.1 circuit low input. •...
Page 248 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT IAT SENSOR NO.1 CIRCUIT FOR Yes Repair or replace harness for short with each other, go to Step 7. SHORT WITH EACH OTHER • Turn engine switch to OFF. Go to next step. • Inspect continuity between MAF/IAT sensor terminals D and E.
Page 249: Dtc P0098
ON-BOARD DIAGNOSTIC DTC P0098 A6E407001082207 DTC P0098 IAT sensor No.1 circuit high input • PCM monitors input voltage from IAT sensor No.1 while engine is running. If input voltage from IAT sensor DETECTION CONDITION No.1 is above 5.0 V, PCM determines IAT sensor No.1 circuit high input. •...
Page 250 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT IAT SENSOR NO.1 SIGNAL CIRCUIT Yes Go to next step. FOR SHORT TO POWER Repair or replace harness for short to power, go to Step 7. • Turn engine switch to ON (Engine OFF). •...
Page 251: Dtc P0102
ON-BOARD DIAGNOSTIC DTC P0102 A6E407001082208 DTC P0102 MAF sensor circuit low input • PCM monitors input voltage from MAF sensor while engine is running. If input voltage from MAF sensor is DETECTION CONDITION below 0.2 V, PCM determines MAF sensor circuit low input. •...
Page 252 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT MAF SENSOR SIGNAL CIRCUIT FOR Yes Repair or replace harness for short to GND, go to Step 9. SHORT TO GND Go to next step. • Turn engine switch to OFF. • Inspect continuity between MAF/IAT sensor terminal C and body GND.
Page 253: Dtc P0103
ON-BOARD DIAGNOSTIC DTC P0103 A6E407001082209 DTC P0103 MAF sensor circuit high input • PCM monitors input voltage from MAF sensor while engine is running. If input voltage from MAF sensor is DETECTION CONDITION above 4.9 V, PCM determines MAF sensor circuit high input. •...
Page 254 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT MAF SENSOR Yes Replace MAF/IAT sensor, go to Step 8. • Inspect MAF sensor. (See F2–36 INTAKE-AIR SYSTEM REMOVAL/ INSTALLATION) (See F2–74 MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR Go to next step. INSPECTION) •...
Page 255: Dtc P0107
ON-BOARD DIAGNOSTIC DTC P0107 A6E407001082210 DTC P0107 Boost sensor circuit low input • PCM monitors input voltage from boost sensor while engine is running. If input voltage from boost sensor is DETECTION below 1.9 V when engine speed is 2,400 rpm or above and accelerator opening angle is 50% or above, CONDITION PCM determines boost sensor circuit low input.
Page 256 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT BOOST SENSOR POWER CIRCUIT Yes Repair or replace harness for open, go to Step 9. FOR OPEN Go to next step. • Turn engine switch to ON. (Engine OFF) • Inspect voltage at boost sensor terminal C (harness side).
Page 257: Dtc P0108
ON-BOARD DIAGNOSTIC DTC P0108 A6E407001082211 DTC P0108 Boost sensor circuit high input • PCM monitors input voltage from boost sensor while engine is running. If input voltage from boost sensor is DETECTION CONDITION above 4.9 V, PCM determines boost sensor circuit high input. •...
Page 258 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT POOR CONNECTION OF PCM Yes Repair or replace suspected terminal, go to Step 7. CONNECTOR Go to next step. • Turn engine switch to OFF. • Inspect for poor connection (damaged, pulled- out terminals, corrosion, etc.). •...
Page 259: Dtc P0112
ON-BOARD DIAGNOSTIC DTC P0112 A6E407001082212 DTC P0112 IAT sensor No.2 circuit low input • PCM monitors input voltage from IAT sensor No.2 while engine is running. If input voltage from IAT sensor DETECTION CONDITION No.2 is below 0.1 V, PCM determines IAT sensor No.2 circuit low input. •...
Page 260 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT IAT SENSOR NO.2 Yes Replace IAT sensor No.2, go to next Step 7. • Inspect IAT sensor No.2. (See F2–36 INTAKE-AIR SYSTEM REMOVAL/ INSTALLATION) (See F2–75 INTAKE AIR TEMPERATURE (IAT) SENSOR NO.2 INSPECTION) Go to next step. •...
Page 261: Dtc P0113
ON-BOARD DIAGNOSTIC DTC P0113 A6E407001082213 DTC P0113 IAT sensor No.2 circuit high input • PCM monitors input voltage from IAT sensor No.2 while engine is running. If input voltage from IAT sensor DETECTION CONDITION No.2 is above 5.0 V, PCM determines IAT sensor No.2 circuit high input. •...
Page 262 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT POOR CONNECTION OF PCM Yes Repair or replace suspected terminal, go to Step 7. CONNECTOR Go to next step. • Turn engine switch to OFF. • Inspect for poor connection (damaged, pulled- out terminals, corrosion, etc.). •...
Page 263: Dtc P0117
ON-BOARD DIAGNOSTIC DTC P0117 A6E407001082214 DTC P0117 ECT sensor circuit low input • PCM monitors input voltage from ECT sensor while engine is running. If input voltage from ECT sensor is DETECTION CONDITION below 0.1 V, PCM determines ECT sensor circuit low input. •...
Page 264 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT ECT SENSOR CIRCUIT FOR SHORT Yes Repair or replace harness for short with each other, go to Step 7. WITH EACH OTHER • Turn engine switch to OFF. Go to next step. • Inspect continuity between ECT sensor terminals A and B.
Page 265: Dtc P0118
ON-BOARD DIAGNOSTIC DTC P0118 A6E407001082215 DTC P0118 ECT sensor circuit high input • PCM monitors input voltage from ECT sensor while engine is running. If input voltage from ECT sensor is DETECTION CONDITION above 5.0 V, PCM determines ECT sensor circuit high input. •...
Page 266 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT ECT SENSOR SIGNAL CIRCUIT FOR Yes Go to next step. SHORT TO POWER Repair or replace harness for short to power, go to Step 7. • Turn engine switch to ON (Engine OFF). • Inspect voltage between ECT sensor terminal A and body GND.
Page 267: Dtc P0121
ON-BOARD DIAGNOSTIC DTC P0121 A6E407001082216 DTC P0121 Accelerator position sensor No.1 circuit performance problem • PCM monitors input voltage from accelerator position sensor No.1 while engine is running. If input voltage DETECTION from accelerator position sensor No.1 is above 1.3 V when accelerator pedal is depressed, PCM CONDITION determines accelerator position sensor No.1 circuit performance problem.
Page 268: Dtc P0122
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT POOR CONNECTION OF PCM Yes Repair or replace suspected terminal, go to next step. CONNECTOR Go to next step. • Turn engine switch to OFF. • Inspect for poor connection (damaged, pulled- out terminals, corrosion, etc.). •...
Page 269 ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION PERFORM DTC CONFIRMATION PROCEDURE Yes Go to next step. • Perform “DTC Confirmation Procedure”. Intermittent concern exists. Go to “Intermittent Concern (See F2–85 DTC CONFIRMATION Troubleshooting”. PROCEDURE) (See F2–227 INTERMITTENT CONCERN • Is same DTC present during KOEO or KOER TROUBLESHOOTING) self-test? INSPECT POOR CONNECTION OF...
Page 270: Dtc P0123
ON-BOARD DIAGNOSTIC DTC P0123 A6E407001082218 DTC P0123 Accelerator position sensor No.1 circuit high input • PCM monitors input voltage from accelerator position sensor No.1 while engine is running. If input voltage DETECTION from accelerator position sensor No.1 is above 4.7 V, PCM determines accelerator position sensor No.1 CONDITION circuit high input.
Page 271 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT POOR CONNECTION OF Yes Repair or replace suspected terminal, go to Step 7. ACCELERATOR POSITION SENSOR NO.1 Go to next step. CONNECTOR • Turn engine switch to OFF. • Inspect for poor connection (damaged, pulled- out terminals, corrosion, etc.).
Page 272: Dtc P0182
ON-BOARD DIAGNOSTIC DTC P0182 A6E407001082219 DTC P0182 Fuel temperature sensor circuit low input • PCM monitors input voltage from fuel temperature sensor while engine is running. If input voltage from fuel DETECTION CONDITION temperature sensor is below 0.1 V, PCM determines fuel temperature sensor circuit low input. •...
Page 273 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT POOR CONNECTION OF FUEL Yes Repair or replace suspected terminal, go to Step 7. TEMPERATURE SENSOR CONNECTOR Go to next step. • Turn engine switch to OFF. • Inspect for poor connection (damaged, pulled- out terminals, corrosion, etc.).
Page 274: Dtc P0183
ON-BOARD DIAGNOSTIC DTC P0183 A6E407001082220 DTC P0183 Fuel temperature sensor circuit high input • PCM monitors input voltage from fuel temperature sensor while engine is running. If input voltage from fuel DETECTION CONDITION temperature sensor is above 5.0 V, PCM determines fuel temperature sensor circuit high input. •...
Page 275 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT POOR CONNECTION OF FUEL Yes Repair or replace suspected terminal, go to Step 7. TEMPERATURE SENSOR CONNECTOR Go to next step. • Turn engine switch to OFF. • Inspect for poor connection (damaged, pulled- out terminals, corrosion, etc.).
Page 276: Dtc P0191
ON-BOARD DIAGNOSTIC DTC P0191 A6E407001082221 DTC P0191 Fuel pressure sensor circuit performance problem • PCM monitors fuel pressure in common rail from fuel pressure sensor while engine is running. PCM DETECTION calculates difference between actual fuel pressure and target fuel pressure. If pressure difference exceeds CONDITION preprogrammed criteria, PCM determines fuel pressure sensor circuit performance problem.
Page 277: Dtc P0192
ON-BOARD DIAGNOSTIC DTC P0192 A6E407001082222 DTC P0192 Fuel pressure sensor circuit low input • PCM monitors input voltage from fuel pressure sensor while engine is running. If input voltage from fuel DETECTION CONDITION pressure sensor is below 0.4 V, PCM determines fuel pressure sensor circuit low input. •...
Page 278 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT FUEL PRESSURE SENSOR SIGNAL Yes Repair or replace harness for short to GND, go to Step 9. CIRCUIT FOR SHORT TO GND Go to next step. • Turn engine switch to OFF. • Inspect continuity between fuel pressure sensor terminal B and body GND.
Page 279: Dtc P0193
ON-BOARD DIAGNOSTIC DTC P0193 A6E407001082223 DTC P0193 Fuel pressure sensor circuit high input • PCM monitors input voltage from fuel pressure sensor while engine is running. If input voltage from fuel DETECTION CONDITION pressure sensor is above 4.8 V, PCM determines fuel pressure sensor circuit high input. •...
Page 280 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT POOR CONNECTION OF PCM Yes Repair or replace suspected terminal, go to Step 7. CONNECTOR Go to next step. • Turn engine switch to OFF. • Inspect for poor connection (damaged, pulled- out terminals, corrosion, etc.). •...
Page 281: Dtc P0200
ON-BOARD DIAGNOSTIC DTC P0200 A6E407001082224 DTC P0200 Fuel injector circuit malfunction • PCM monitors injection confirmation signal from IDM while engine is running. If injection confirmation DETECTION CONDITION signal is not input normally, PCM determines fuel injector circuit malfunction. • IDM •...
Page 282 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT POOR CONNECTION OF IDM Yes Repair or replace suspected terminal, go to Step 9. CONNECTOR Go to next step. • Turn engine switch to OFF. • Inspect for poor connection (damaged, pulled- out terminals, corrosion, etc.). •...
Page 283: Dtc P0221
ON-BOARD DIAGNOSTIC DTC P0221 A6E407001082225 DTC P0221 Accelerator position sensor No.2 circuit performance problem • PCM monitors input voltage from accelerator position sensor No.1 and accelerator position sensor No.2 DETECTION while engine is running. If voltage difference exceeds 0.9 V, PCM determines accelerator position sensor CONDITION No.2 circuit performance problem.
Page 284: Dtc P0222
ON-BOARD DIAGNOSTIC DTC P0222 A6E407001082226 DTC P0222 Accelerator position sensor No.2 circuit low input • PCM monitors input voltage from accelerator position sensor No.2 while engine is running. If input voltage DETECTION from accelerator position sensor No.2 is below 0.3 V, PCM determines accelerator position sensor No.2 CONDITION circuit low input.
Page 285 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT POOR CONNECTION OF Yes Repair or replace suspected terminal, go to Step 8. ACCELERATOR POSITION SENSOR NO.2 Go to next step. CONNECTOR • Turn engine switch to OFF. • Inspect for poor connection (damaged, pulled- out terminals, corrosion, etc.).
Page 286: Dtc P0223
ON-BOARD DIAGNOSTIC DTC P0223 A6E407001082227 DTC P0223 Accelerator position sensor No.2 circuit high input • PCM monitors input voltage from accelerator position sensor No.2 while engine is running. If input voltage DETECTION from accelerator position sensor No.2 is above 4.7 V, PCM determines accelerator position sensor No.2 CONDITION circuit high input.
Page 287 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT POOR CONNECTION OF Yes Repair or replace suspected terminal, go to Step 7. ACCELERATOR POSITION SENSOR NO.2 Go to next step. CONNECTOR • Turn engine switch to OFF. • Inspect for poor connection (damaged, pulled- out terminals, corrosion, etc.).
Page 288: Dtc P0300
ON-BOARD DIAGNOSTIC DTC P0300 A6E407001082228 DTC P0300 Random misfire detection • PCM monitors CKP sensor input signal interval time. PCM calculates change of interval time for each DETECTION CONDITION cylinder. If the interval time exceeds preprogrammed criteria, PCM determines random misfire detection. •...
Page 289: Dtc P0336
ON-BOARD DIAGNOSTIC DTC P0336 A6E407001082229 DTC P0336 CKP sensor circuit performance problem • PCM monitors input signal from CKP sensor while engine is running. If input signal from CKP sensor is not DETECTION CONDITION proper pulse number, PCM determines CKP sensor circuit performance problem. •...
Page 290: Dtc P0337
ON-BOARD DIAGNOSTIC DTC P0337 A6E407001082230 DTC P0337 CKP sensor circuit low input • PCM monitors input signal from CKP sensor while engine is running. If input signal from CKP sensor is not DETECTION CONDITION input at 12 crankshaft revolutions, PCM determines CKP sensor circuit low input. •...
Page 291 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT POOR CONNECTION OF CKP Yes Repair or replace suspected terminal, go to Step 7. SENSOR CONNECTOR Go to next step. • Turn engine switch to OFF. • Inspect for poor connection (damaged, pulled- out terminals, corrosion, etc.). •...
Page 292: Dtc P0341
ON-BOARD DIAGNOSTIC DTC P0341 A6E407001082231 DTC P0341 CMP sensor circuit performance problem • PCM monitors input signal from CMP sensor while engine is running. If input signal from CMP sensor is not DETECTION CONDITION proper pulse number, PCM determines CMP sensor circuit performance problem. •...
Page 293: Dtc P0342
ON-BOARD DIAGNOSTIC DTC P0342 A6E407001082232 DTC P0342 CMP sensor circuit low input • PCM monitors input signal from CMP sensor while engine is running. If input signal from CMP sensor is not DETECTION CONDITION input at 12 crankshaft revolutions, PCM determines CMP sensor circuit low input. •...
Page 294 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT CMP SENSOR Yes Replace CMP sensor, go to Step 7. • Inspect CMP sensor. (See F2–80 CAMSHAFT POSITION (CMP) SENSOR REMOVAL/INSTALLATION) (See F2–80 CAMSHAFT POSITION (CMP) SENSOR INSPECTION) Go to next step. • Is there any malfunction? INSPECT POOR CONNECTION OF PCM Yes Repair or replace suspected terminal, go to Step 7.
Page 295: Dtc P0380
ON-BOARD DIAGNOSTIC DTC P0380 A6E407001082233 DTC P0380 Glow plug relay circuit malfunction • PCM monitors input voltage from glow plug relay while engine is running. PCM determines glow plug relay DETECTION circuit malfunction if input voltage from glow plug relay is as following: CONDITION —...
Page 296 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT GLOW PLUG RELAY CIRCUIT FOR Yes Repair or replace harness for short to GND, go to Step 9. SHORT TO GND Go to next step. • Turn engine switch to OFF. • Inspect continuity between following harnesses: —...
Page 297 ON-BOARD DIAGNOSTIC DTC P0504 A6E407001082234 DTC P0504 Brake switch signal correlation malfunction • PCM monitors input signal from brake switch 1 and brake switch 2 while engine is running. PCM determines brake switch signal correlation malfunction if input signal from brake switch 1 brake switch 2 is DETECTION as following: CONDITION...
Page 298 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT POOR CONNECTION OF BRAKE Yes Repair or replace suspected terminal, go to Step 21. SWITCH 1 CONNECTOR Go to next step. • Turn engine switch to OFF. • Inspect for poor connection (damaged, pulled- out terminals, corrosion, etc.).
Page 299 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT POOR CONNECTION OF PCM Yes Repair or replace suspected terminal, go to Step 21. CONNECTOR Go to Step 21. • Turn engine switch to OFF. • Inspect for poor connection (damaged, pulled- out terminals, corrosion, etc.). •...
Page 300: Dtc P0504
ON-BOARD DIAGNOSTIC DTC P0510 A6E407001082235 DTC P0510 Idle switch circuit malfunction • PCM monitors input voltage from idle switch while engine is running. If input voltage from idle switch is B+ DETECTION when accelerator position sensor No.1 voltage is below 0.7 V, PCM determines idle switch circuit CONDITION malfunction.
Page 301 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT POOR CONNECTION OF IDLE Yes Repair or replace suspected terminal, go to Step 7. SWITCH CONNECTOR Go to next step. • Turn engine switch to OFF. • Inspect for poor connection (damaged, pulled- out terminals, corrosion, etc.). •...
Page 302: Dtc P0512
ON-BOARD DIAGNOSTIC DTC P0512 A6E407001082236 DTC P0512 Engine switch circuit malfunction • PCM monitors input voltage from engine switch while engine is running. If input voltage from engine switch DETECTION CONDITION is B+ when engine speed is 1,200 rpm or above, PCM determines engine switch circuit malfunction. •...
Page 303 ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to available Service Information. AVAILABILITY • If vehicle is not repaired, go to next step. • Check for related Service Information availability. Go to next step. •...
Page 304: Dtc P0564
ON-BOARD DIAGNOSTIC DTC P0564 A6E407001082237 DTC P0564 Cruise control signal malfunction • PCM monitors input voltage from cruise control switch while engine is running. PCM determines cruise control signal malfunction if input voltage from cruise control switch is as following for 120 s: DETECTION —...
Page 305 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT POOR CONNECTION OF CRUISE Yes Repair or replace suspected terminal, go to Step 9. CONTROL SWITCH CONNECTOR Go to next step. • Turn engine switch to OFF. • Inspect for poor connection (damaged, pulled- out terminals, corrosion, etc.).
Page 306: Dtc P0602
ON-BOARD DIAGNOSTIC DTC P0602 A6E407001082238 DTC P0602 PCM programming error • No configuration data in PCM Note DETECTION • If “PCM CONFIGURATION” is successful, the PCM stored DTC P0602 and illuminates the MIL CONDITION (System i s normal). Clear the DTC P0602 using WDS or equivalent after “PCM CONFIGURATION”. •...
Page 307: Dtc P0606
ON-BOARD DIAGNOSTIC DTC P0606 A6E407001082239 DTC P0606 PCM malfunction DETECTION • PCM does not read DTC from output devices. CONDITION POSSIBLE • PCM internal malfunction CAUSE Diagnostic procedure STEP INSPECTION ACTION Replace PCM. – – (See F2–64 PCM REMOVAL/INSTALLATION) End Of Sie DTC P0610 A6E407001082240 DTC P0610...
Page 308: Dtc P0661
ON-BOARD DIAGNOSTIC DTC P0661 A6E407001082241 DTC P0661 VSC solenoid valve circuit low input • PCM monitors input voltage from VSC solenoid valve while engine is running. If input voltage from VSC DETECTION CONDITION solenoid valve is below 0.1 V, PCM determines suction control valve circuit low input. •...
Page 309 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT POOR CONNECTION OF VSC Yes Repair or replace suspected terminal, go to Step 7. SOLENOID VALVE CONNECTOR Go to next step. • Turn engine switch to OFF. • Inspect for poor connection (damaged, pulled- out terminals, corrosion, etc.).
Page 310: Dtc P0662
ON-BOARD DIAGNOSTIC DTC P0662 A6E407001082242 DTC P0662 VSC solenoid valve circuit high input • PCM monitors input voltage from VSC solenoid valve while engine is running. If input voltage from VSC DETECTION CONDITION solenoid valve is above B+, PCM determines suction control valve circuit high input. •...
Page 311 ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION PERFORM DTC CONFIRMATION PROCEDURE Yes Go to next step. • Perform “DTC Confirmation Procedure”. Intermittent concern exists. Go to “Intermittent Concern (See F2–85 DTC CONFIRMATION Troubleshooting”. PROCEDURE) (See F2–227 INTERMITTENT CONCERN • Is same DTC present during KOEO or KOER TROUBLESHOOTING) self-test? INSPECT POOR CONNECTION OF VSC...
Page 312: Dtc P0850
ON-BOARD DIAGNOSTIC DTC P0850 A6E407001082243 DTC P0850 Neutral switch circuit malfunction • PCM monitors input voltage from neutral switch while engine is running. If input voltage from neutral switch DETECTION does not change when vehicle stops after accelerating to above 60 km/h {37 mph} and decelerating to 0 CONDITION km/h {0 mph} two times, PCM determines neutral switch circuit malfunction.
Page 313 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT NEUTRAL SWITCH FOR CLOSE Yes Replace neutral switch, go to Step 10. STUCK Go to next step. • Turn engine switch to ON (Engine OFF). • Disconnect neutral switch connector. • Access CPP/PNP PID using WDS or equivalent.
Page 314: Dtc P1190
ON-BOARD DIAGNOSTIC DTC P1190 A6E407001083201 DTC P1190 Calibration resistor circuit malfunction • PCM monitors input voltage from calibration resistor while engine is running. If input voltage from DETECTION CONDITION calibration resistor is below 0.2 V or above 4.8 V, PCM determines calibration resistor circuit malfunction. •...
Page 315 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT POOR CONNECTION OF Yes Repair or replace suspected terminal, go to Step 8. CALIBRATION RESISTOR CONNECTOR Go to next step. • Turn engine switch to OFF. • Inspect for poor connection (damaged, pulled- out terminals, corrosion, etc.). •...
Page 316: Dtc P2228
ON-BOARD DIAGNOSTIC DTC P2228 A6W407001082244 DTC P2228 BARO sensor circuit low input • PCM monitors input voltage from BARO sensor while engine is running. If input voltage from BARO sensor DETECTION CONDITION is below 0.7 V, PCM determines BARO sensor circuit low input. •...
Page 317: Troubleshooting
TROUBLESHOOTING TROUBLESHOOTING SYMPTOM DIAGNOSTIC INDEX A6E408018881201 TROUBLESHOOTING ITEM DESCRIPTION PAGE (See F2–173 NO.1 MELTING Melting of main or other fuses — OF MAIN OR OTHER FUSES) (See F2–174 NO.2 MIL MIL illuminates MIL is illuminated incorrectly. ILLUMINATES) (See F2–174 NO.3 WILL NOT Will not crank Starter does not work.
Page 318: 23 A/C Does Not Work
TROUBLESHOOTING TROUBLESHOOTING ITEM DESCRIPTION PAGE (See F2–212 NO.18 COOLING Cooling system Engine does not reach normal operating Runs cold SYSTEM CONCERNS-RUNS concerns temperature. COLD) Excessive black smoke is observed in (See F2–213 NO.19 Excessive black smoke exhaust gas. EXCESSIVE BLACK SMOKE) (See F2–216 NO.20 FUEL...
Page 319 TROUBLESHOOTING SYMPTOM QUICK DIAGNOSIS CHART A6E408018881202 ×: Applicable Troubleshooting item Melting of main or other fuses MIL illuminates × × × × × × Will not crank × × × Hard start/long crank/erratic start/erratic crank × × Engine stalls After start/at idle ×...
Page 320 TROUBLESHOOTING ×: Applicable Troubleshooting item Melting of main or other fuses MIL illuminates Will not crank × × × Hard start/long crank/erratic start/erratic crank × × × Engine stalls After start/at idle × × Cranks normally but will not start ×...
Page 321 TROUBLESHOOTING ×: Applicable Troubleshooting item Melting of main or other fuses × × × × MIL illuminates Will not crank × × × × × × × × × Hard start/long crank/erratic start/erratic crank × × × × × × ×...
Page 322 TROUBLESHOOTING ×: Applicable Troubleshooting item Melting of main or other fuses × × MIL illuminates Will not crank × × × × × × × × Hard start/long crank/erratic start/erratic crank × × × × × × × × × Engine stalls After start/at idle ×...
Page 323 TROUBLESHOOTING ×: Applicable Troubleshooting item Melting of main or other fuses × × × × × × × × × × MIL illuminates Will not crank × × × × × Hard start/long crank/erratic start/erratic crank × × × × ×...
Page 324 TROUBLESHOOTING ×: Applicable Troubleshooting item Melting of main or other fuses MIL illuminates × Will not crank Hard start/long crank/erratic start/erratic crank × × × Engine stalls After start/at idle × Cranks normally but will not start Slow return to idle ×...
Page 325 TROUBLESHOOTING NO.1 MELTING OF MAIN OR OTHER FUSES A6E408018881203 Melting of main or other fuses [TROUBLESHOOTING HINTS] Inspect condition of fuse. Deterioration Shorted harness Repair shorted harness and replace fuse Fuse Replace fuse Damaged fuse Related wiring harness MAIN MAIN fuse •...
Page 326 TROUBLESHOOTING NO.2 MIL ILLUMINATES A6E408018881204 MIL ILLUMINATES • MIL illuminates incorrectly. DESCRIPTION • PCM illuminates for emission-related concern (DTC is stored in PCM) • Instrument cluster malfunction POSSIBLE CAUSE Note • If MIL blinks at steady rate, misfire condition could possibly exist. Diagnostic procedure STEP INSPECTION...
Page 327 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Is there continuity between PCM GND terminals Go to next step. 65, 85, 103, 104 and GND? Repair or replace wiring harness. Measure voltage between PCM GND terminals Go to next step. 65, 85, 103, 104 and coil terminal C. Repair or replace wiring harness.
Page 328 TROUBLESHOOTING NO.4 HARD START/LONG CRANK/ERRATIC START/ERRATIC CRANK A6E408018881206 HARD START/LONG CRANK/ERRATIC START/ERRATIC CRANK • Starter cranks engine at normal speed but engine requires excessive cranking time before starting. DESCRIPTION • Battery is in normal condition. • Poor fuel quality • Intake-air system restriction or clogging •...
Page 329 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Does engine start normally after warm-up? Inspect glow system operation. (See T–19 RELAY INSPECTION) Replace any malfunctioning part as necessary. If glow system is okay, go to next step. Go to next step. Is there any restriction in exhaust system or Repair or replace as necessary.
Page 330 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Verify test results. • If okay, return to diagnostic index to service any additional symptoms. • If malfunction remains, replace PCM. (See F2–64 PCM REMOVAL/INSTALLATION) End Of Sie NO.5 ENGINE STALLS-AFTER START/AT IDLE A6E408018881207 ENGINE STALLS-AFTER START/AT IDLE •...
Page 331 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Connect WDS or equivalent to DLC-2 and Go to appropriate DTC test. retrieve DTC. Go to next step. B1213, B1342, B1600, B1601, B1602, B1681, B2103, B2431 Is there continuity between PCM GND terminals Go to next step. 65, 85, 103, 104 and GND? Repair or replace wiring harness.
Page 332 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Is there any restriction in exhaust system or Repair or replace as necessary. catalyst converter? Go to next step. Access RPM PID. Go to next step. Is RPM PID indicating engine speed during Go to Step 19. cranking engine? Note Go to next step.
Page 333 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Inspect IDM. Go to next step. (See F2–84 INJECTOR DRIVER MODULE Repair or replace as necessary. (IDM) INSPECTION) Is IDM okay? Inspect EGR system operation. Remove and inspect supply pump and common rail. Is EGR system operation normal? Repair or replace malfunctioning part according to EGR system operation results.
Page 334 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Does security light illuminate? Go to next step. Inspect instrument cluster and wiring harness. Connect WDS or equivalent to DLC-2 and Go to appropriate DTC test. retrieve DTC. Go to next step. B1213, B1342, B1600, B1601, B1602, B1681, B2103, B2431 Is there continuity between PCM GND terminals Go to next step.
Page 335 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Inspect glow system operation. Go to next step. (See T–19 RELAY INSPECTION) Repair or replace malfunctioning part according to Is glow system operation normal? glow system operation results. Inspect for fuel leakage from fuel pipe. Repair or replace as necessary.
Page 336 TROUBLESHOOTING NO.7 SLOW RETURN TO IDLE A6E408018881209 SLOW RETURN TO IDLE • Engine takes more time than normal to return to idle speed. DESCRIPTION • Engine speed continues at fast idle after warm-up. • Thermostat is stuck open • Fuel injection timing is incorrect •...
Page 337 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Inspect idle speed. Go to next step. (See F2–34 IDLE SPEED INSPECTION) Repair or replace malfunctioning part according to idle Is idle speed correct? speed inspection results. Inspect cooling fan No.2 control system Go to next step. operation.
Page 338 TROUBLESHOOTING NO.8 ENGINE RUNS ROUGH/ROLLING IDLE A6E408018881210 ENGINE RUNS ROUGH/ROLLING IDLE • Engine speed fluctuates between specified idle speed and lower speed and engine shakes excessively. DESCRIPTION • Idle speed is too slow and engine shakes excessively. • Poor fuel quality •...
Page 339 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Connect WDS or equivalent to DLC-2. DTC is displayed: Turn engine switch to ON. Go to appropriate DTC test. Retrieve any DTC. Communication error message is displayed: Is DTC displayed? Inspect for following: • Open circuit between PCM control relay and PCM terminal 53 or 79 •...
Page 340 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Is engine compression correct? Go to next step. (See B2–8 COMPRESSION INSPECTION) Inspect for following: • Damaged valve seat • Worn valve stem and valve guide • Worn or stuck piston ring • Worn piston, piston ring or cylinder •...
Page 341 TROUBLESHOOTING NO.9 FAST IDLE/RUNS ON A6E408018881211 RUNS IDLE/RUNS ON • Engine speed continues at fast idle after warm-up. DESCRIPTION • Engine runs after engine key turned off. • ECT sensor or related circuit malfunction • Incorrect adjustment accelerator position sensor and/or idle switch •...
Page 342 TROUBLESHOOTING NO.10 LOW IDLE/STALLS DURING DECELERATION A6E408018881212 LOW IDLE/STALLS DURING DECELERATION • Engine stops unexpectedly at beginning of deceleration or recovery from deceleration. DESCRIPTION • Intake-air system restriction or clogging • Poor fuel quality • A/C system improper operation • Inadequate fuel pressure •...
Page 343 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Inspect adjustment of accelerator position Go to next step. sensor and idle switch. Adjust accelerator position sensor and idle switch (See F2–72 ACCELERATOR POSITION correctly. SENSOR INSPECTION) (See F2–73 ACCELERATOR POSITION SENSOR (See F2–70 IDLE SWITCH INSPECTION) ADJUSTMENT) Are accelerator position sensor and idle switch...
Page 344 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Inspect IDM. Remove and inspect supply pump and common rail. (See F2–84 INJECTOR DRIVER MODULE Repair or replace as necessary. (IDM) INSPECTION) Is IDM okay? Verify test results. • If okay, return to diagnostic index to service any additional symptoms. •...
Page 345 TROUBLESHOOTING Diagnostic Procedure STEP INSPECTION RESULTS ACTION Is idle speed stable? Go to next step. Go to symptom troubleshooting “NO.8 ENGINE RUNS ROUGH/ROLLING IDLE”. Is engine overheating? Go to symptom troubleshooting “NO.17 COOLING SYSTEM CONCERNS—OVERHEATING”. Go to next step. Perform self-test function using WDS or DTC is displayed: equivalent.
Page 346 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Inspect adjustment of accelerator position Go to next step. sensor and idle switch. Adjust accelerator position sensor and idle switch (See F2–72 ACCELERATOR POSITION correctly. SENSOR INSPECTION) (See F2–73 ACCELERATOR POSITION SENSOR (See F2–70 IDLE SWITCH INSPECTION) ADJUSTMENT) Are accelerator position sensor and idle switch...
Page 347 TROUBLESHOOTING NO.12 LACK/LOSS OF POWER-ACCELERATION/CRUISE A6E408018881214 LACK/LOSS OF POWER-ACCELERATION CRUISE • Performance is poor under load (e.g., power down when climbing hills). DESCRIPTION • Poor fuel quality • Air leakage from intake-air system • Intake-air system restriction or clogging • Engine overheating •...
Page 348: Engine Control System Operation Inspection
TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Perform self-test function using WDS or DTC is displayed: equivalent. Go to appropriate DTC test. Turn engine switch to ON. Communication error message is displayed: Retrieve any DTC. Inspect for following: • Open circuit between PCM control relay and PCM Is DTC displayed? terminal 53 or 79 •...
Page 349 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Inspect if turbocharger turbine wheel is Replace turbocharger. damaged, cracked or interfering with housing on Go to next step. vehicle. Note • Inspect all fins on each turbine wheel. Is there any problem? Is any engine oil found inside turbocharger Excessive amount of oil is found: turbine housing? Replace turbocharger.
Page 350 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Is engine compression correct? Go to next step. (See B2–8 COMPRESSION INSPECTION) Inspect for following: • Damaged valve seat • Worn valve stem and valve guide • Worn or stuck piston ring • Worn piston, piston ring or cylinder •...
Page 351 TROUBLESHOOTING NO.13 KNOCKING/PINGING A6E408018881215 KNOCKING/PINGING • Excessive shrilly knocking sound from engine. DESCRIPTION • Poor fuel quality • Air leakage from intake-air system • Intake-air system restriction or clogging • Variable swirl control (VSC) system malfunction • Variable boost control (VBC) system malfunction •...
Page 352 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Perform self-test function using WDS or DTC is displayed: equivalent. Go to appropriate DTC test. Turn engine switch to ON. Communication error message is displayed: Retrieve any DTC. Inspect for following: • Open circuit between PCM control relay and PCM Is DTC displayed? terminal 53 or 79 •...
Page 353 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Is any engine oil found inside turbocharger Wipe oil off of vehicle and install all removed parts in compressor hosing? Step 10. Then, go to next step. Turbocharger is okay. Install all parts removed in Step10. Then, go to next step.
Page 354 TROUBLESHOOTING NO.14 POOR FUEL ECONOMY A6E408018881216 POOR FUEL ECONOMY • Fuel economy is unsatisfactory. DESCRIPTION • Incorrect idle speed • A/C system improper operation • Intake -air system clogging or restriction • Engine cooling system malfunction • Poor fuel quality •...
Page 355 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Perform self-test function using WDS or DTC is displayed: equivalent. Go to appropriate DTC test. Turn engine switch to ON. Communication error message is displayed: Retrieve any DTC. Inspect for following: • Open circuit between PCM control relay and PCM Is DTC displayed? terminal 53 or 79 •...
Page 356 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Measure gap between CKP sensor and teeth of Go to next step. pulse wheel. Adjust CKP sensor position. Specification 1.5—2.5 mm {0.059—0.098 in} Is gap within specification? Visually inspect CMP sensor and teeth of pulse Inspect following PIDs: wheel.
Page 357 TROUBLESHOOTING NO.15 EMISSION COMPLIANCE A6E408018881217 EMISSION COMPLIANCE • Fails emissions test. DESCRIPTION • Poor fuel quality • Vacuum leakage • Air leakage from intake-air system • Intake-air system restriction or clogging • Variable swirl control (VSC) system malfunction • Variable boost control (VBC) system malfunction •...
Page 358 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Connect WDS or equivalent to DLC-2. DTC is displayed: Perform self-test function using WDS or Go to appropriate DTC test. equivalent. Communication error message is displayed: Turn engine switch to ON. Inspect for following: • Open circuit between PCM control relay and PCM Retrieve any DTC.
Page 359 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Inspect if turbocharger compressor wheel Replace turbocharger. locknut is loose or has fallen down inside Go to next step. turbocharger. Is there any problem? Inspect turbocharger compressor wheel by Go to next step. hand. Replace turbocharger. Does wheel turn easily and smoothly? Inspect if turbocharger turbine wheel is Replace turbocharger.
Page 360 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Is engine compression correct? Go to next step. (See B2–8 COMPRESSION INSPECTION) Inspect for following: • Damaged valve seat • Worn valve stem and valve guide • Worn or stuck piston ring • Worn piston, piston ring or cylinder •...
Page 361 TROUBLESHOOTING NO.16 HIGH OIL CONSUMPTION/LEAKAGE A6E408018881218 HIGH OIL CONSUMPTION/LEAKAGE • Oil consumption is excessive. DESCRIPTION • Improper engine oil level • Improper dipstick • Improper engine oil viscosity POSSIBLE • Engine internal parts malfunction CAUSE • Oil leakage • Turbocharger malfunction Diagnostic Procedure STEP INSPECTION...
Page 362 TROUBLESHOOTING End Of Sie NO.17 COOLING SYSTEM CONCERNS-OVERHEATING A6E408018881219 COOLING SYSTEM CONCERNS-OVERHEATING • Engine runs at higher than normal temperature/overheats. DESCRIPTION • Cooling fan No.2 malfunction • Cooling fan No.1 malfunction • Low drive belt tension • Drive belt damage •...
Page 363 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Note Go to next step. • The following test should be performed on Go to symptom troubleshooting “NO.24 A/C ALWAYS the vehicles with A/C system. Go to next ON OR A/C COMPRESSOR RUNS step for vehicles without A/C system CONTINUOUSLY”.
Page 364 TROUBLESHOOTING NO.18 COOLING SYSTEM CONCERNS-RUNS COLD A6E408018881220 COOLING SYSTEM CONCERNS-RUNS COLD • Engine takes excessive period for reaching normal operating temperature. DESCRIPTION • Thermostat malfunction • Cooling fan No.2 system malfunction POSSIBLE • Cooling fan No.1 system malfunction CAUSE • Coolant heater system malfunction Diagnostic Procedure STEP INSPECTION...
Page 365 TROUBLESHOOTING NO.19 EXCESSIVE BLACK SMOKE A6E408018881221 EXCESSIVE BLACK SMOKE • Excessive black smoke is observed in exhaust gas. DESCRIPTION • Intake-air system clogging or restriction • Air leakage from Intake-air system • Incorrect fuel injection timing • Erratic signal from CKP sensor •...
Page 366 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Inspect intake shutter valve and VSC valve Repair or replace as necessary. operations. Go to next step. (See F2–229 ENGINE CONTROL SYSTEM OPERATION INSPECTION) Is there any problem? Inspect guide blade valve operation. Repair or replace as necessary. (See F2–229 ENGINE CONTROL SYSTEM Go to next step.
Page 367 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Inspect if turbocharger compressor wheel Replace turbocharger. locknut is loose or has fallen down inside Go to next step. turbocharger. Is there any problem? Inspect if turbocharger compressor wheel by Go to next step. hand. Replace turbocharger.
Page 368 TROUBLESHOOTING NO.20 FUEL ODOR (IN ENGINE COMPARTMENT) A6E408018881222 FUEL ODOR (IN ENGINE COMPARTMENT) • Fuel smell or visible leakage. DESCRIPTION • Excessive fuel pressure • Suction control valve malfunction (built-in supply pump) • Fuel pressure limiter malfunction (built-in common rail) •...
Page 369 TROUBLESHOOTING NO.21 ENGINE NOISE A6E408018881223 ENGINE NOISE • Engine noise under hood. DESCRIPTION • Engine internal damage • Timing belt displacement • Fuel injector malfunction • Loose attaching bolts or worn parts • Improper drive belt tension • Air leakage from intake-air system •...
Page 370 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Perform self-test function using WDS or DTC is displayed: equivalent. Go to appropriate DTC test. Turn engine switch to ON. Communication error message is displayed: Retrieve any DTC. Inspect for following: • Open circuit between PCM control relay and PCM Is DTC displayed? terminal 53 or 79 •...
Page 371 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Inspect if turbocharger compressor wheel Replace turbocharger. locknut is loose or has fallen down inside Go to next step. turbocharger. Is there any problem? Turn turbocharger compressor wheel by hand. Go to next step. Does wheel turn easily and smoothly? Replace turbocharger.
Page 372 TROUBLESHOOTING NO.22 VIBRATION CONCERNS (ENGINE) A6E408018881224 VIBRATION CONCERNS (ENGINE) • Vibration from under hood or driveline. DESCRIPTION • Loose attaching bolts or worn parts • Cooling fan No.1 or cooling fan No.2 seat are improper • Engine or transaxle mounts are improperly installed •...
Page 373 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Connect WDS or equivalent to DLC-2. DTC is displayed: Turn engine switch to ON. Go to appropriate DTC test. Retrieve any DTC. Communication error message is displayed: Is DTC displayed? Inspect following: • Open circuit between PCM control relay and PCM terminal 53 or 79 •...
Page 374 TROUBLESHOOTING NO.23 A/C DOES NOT WORK SUFFICIENTLY A6E408018881225 A/C DOES NOT WORK SUFFICIENTLY • A/C compressor magnetic clutch does not engage when A/C switch is turned on. DESCRIPTION • Improper refrigerant charge amount • Open A/C switch magnetic clutch • Open circuit between A/C relay and A/C magnetic clutch •...
Page 375 TROUBLESHOOTING NO.24 A/C ALWAYS ON OR A/C COMPRESSOR RUNS CONTINUOUSLY A6E408018881226 A/C ALWAYS ON OR A/C COMPRESSOR RUNS CONTINUOUSLY • A/C compressor magnetic clutch does not disengage. DESCRIPTION • A/C compressor magnetic clutch stuck engagement • A/C relay is stuck closed •...
Page 376 TROUBLESHOOTING NO.25 A/C DOES NOT CUT OFF UNDER WIDE OPEN THROTTLE CONDITIONS A6E408018881227 A/C DOES NOT CUT OFF UNDER WIDE OPEN THROTTLE CONDITIONS • A/C compressor magnetic clutch does not disengage under wide open throttle. DESCRIPTION • Accelerator position sensor malfunction POSSIBLE •...
Page 377 TROUBLESHOOTING NO.26 CONSTANT VOLTAGE A6E408018881228 CONSTANT VOLTAGE • Incorrect constant voltage. DESCRIPTION • Constant voltage circuit malfunction • Accelerator positions sensor or related circuit malfunction • Fuel pressure sensor or related circuit malfunction • Boost sensor or related circuit malfunction •...
Page 378 TROUBLESHOOTING STEP INSPECTION RESULTS ACTION Note Go to next step. • Purpose of this step is to determine if Go to Step 11. WDS or equivalent is communicating with PCM. Reconnect appropriate sensor connector. Turn engine switch to ON. Attempt to access ECT PID. Can ECT PID be accessed? Are DTCs present for two or more sensors Go to next step.
Page 379 TROUBLESHOOTING INTERMITTENT CONCERN TROUBLESHOOTING A6E408018881229 Vibration Method 1. If a malfunction occurs or becomes worse while driving on a rough road, or due to engine vibration, perform the steps below. Note • There are several reasons vehicle or engine vibration could cause an electrical malfunction. Some of the things to check for are: —...
Page 380 TROUBLESHOOTING Inspection Method for Sensors 1. Connect the WDS or equivalent to the DLC-2. 2. Turn the engine switch to ON (Engine OFF). Note • If the engine starts and runs, perform the following steps at idle. 3. Access PIDs for the switch you are inspecting. 4.
Page 381 TROUBLESHOOTING ENGINE CONTROL SYSTEM OPERATION INSPECTION A6E408018881230 Intake Shutter Valve Operation Inspection 1. Start the engine and warm up completely. 2. Turn off the A/C switch. 3. Connect the WDS or equivalent to the DLC-2. 4. Monitor the following PIDs using the WDS or equivalent. —...
Page 382 TROUBLESHOOTING Cooling Fan No.1/Cooling Fan No.2 Control System Inspection Cooling fan No.1/cooling fan No.2 system operation Cooling fan Cooling fan Engine condition relay No.2 relay No.1 ECT below 100°C {212°F} ECT above 100°C {212°F} (until below 97°C {207°F}) ECT above 108°C {228°F} (until below 105°C {230°F}) A/C and fan switches...
Page 383 TROUBLESHOOTING 6. Turn the A/C switch and fan switch off. • If the cooling fan No.1 does not operate but operation sound of A/C compressor magnetic clutch is heard, inspect for the following. — Open circuit between ignition switch and cooling fan relay No.1 —...
Page 384 E NGINE ELECTRICAL SYSTEM FEATURES OUTLINE ............... G-2 OUTLINE OF CONSTRUCTION......G-2 SPECIFICATIONS ..........G-2 STRUCTURAl VIEW ........... G-3 SERVICE OUTLINE ............... G-4 SUPPLEMENTAL SERVICE INFORMATION ..G-4 LOCATION INDEX..........G-4 CHARGING SYSTEM..........G-5 BATTERY REMOVAL/INSTALLATION ....G-5 BATTERY INSPECTION........G-6 BATTERY RECHARGING ........
Page 385: Outline
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.)
Page 386: Structural View
OUTLINE STRUCTURAL VIEW A6E470202000205 MZR-CD (RF Turbo) A6E4702W100 Battery Starter Generator End Of Sie G–3...
Page 387: Supplemental Service Information
OUTLINE OUTLINE SUPPLEMENTAL SERVICE INFORMATION A6E470202000204 • 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) •...
Page 388: Charging System
CHARGING SYSTEM CHARGING SYSTEM BATTERY REMOVAL/INSTALLATION A6E471018520201 MZR-CD (RF Turbo) 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. 4.0—6.8 N·m {40.8—69.3 kgf·cm, 35.5—60.1 in·lbf} 7.9—11.7 N·m {80.6—119.3 kgf·cm, 70.0—103.5 in·lbf} A6E4710W103 Battery Negative battery cable Battery tray...
Page 389: Battery Inspection
CHARGING SYSTEM BATTERY INSPECTION A6E471018520202 MZR-CD (RF Turbo) Battery 1. Inspect the battery with the following procedure. Step Inspection Result Action Above Go to Step 12.4 V Measure open circuit voltage of battery. Below Go to next 12.4 V step. Above Go to next 12.4 V...
Page 390: Generator Removal/Installation
CHARGING SYSTEM 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. Battery type Slow-charge Quick-charge BATTERY CHARGER (5-hour rate) (A/30 min) 95D31L (64) 6.5—8.0 BATTERY...
Page 391 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.
Page 392: Starting System
STARTING SYSTEM STARTING SYSTEM STARTER REMOVAL/INSTALLATION A6E471418400202 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.
Page 393 STARTING SYSTEM L8, LF, L3 9.8—11.7 N·m {100—120 kgf·cm, 87—104 in·lbf} 9.8—11.7 N·m {100—120 kgf·cm, 87—104 in·lbf} FRONT 38—51 9.8—11.7 N·m {3.8—5.3, 28—38} {100—120 kgf·cm, 87—104 in·lbf} HEATER HOSE MZR-CD (RF TURBO) 64—89 {6.5—9.1, 48—65} 9.8—11.7 N·m {100—120 kgf·cm, 87—104 in·lbf} N·m {kgf·m, ft·lbf} A6E4714W100 Terminal B wire...
Page 394: Starter Inspection
STARTING SYSTEM STARTER INSPECTION A6E471418400203 MZR-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. •...
Page 395 C LUTCH FEATURES OUTLINE ..............H-2 OUTLINE OF CONSTRUCTION......H-2 FEATURES ............H-2 SPECIFICATIONS ..........H-2 SERVICE OUTLINE ..............H-2 SUPPLEMENTAL SERVICE INFORMATION ..H-2 CLUTCH RELEASE CYLINDER ......H-3 CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION (A65M-R MANUAL TRANSAXLE MODELS) ..H-3 CLUTCH RELEASE CYLINDER DISASSEMBLY/ASSEMBLY (A65M-R MANUAL TRANSAXLE MODELS) ....H-4 CLUTCH UNIT ............H-5 CLUTCH UNIT REMOVAL/INSTALLATION (A65M-R MANUAL TRANSAXLE MODELS) ..H-5...
Page 396: Outline
End Of Sie OUTLINE SUPPLEMENTAL SERVICE INFORMATION A6E490216003204 • 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 •...
Page 397: Clutch Release Cylinder
CLUTCH RELEASE CYLINDER CLUTCH RELEASE CYLINDER CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION (A65M-R MANUAL TRANSAXLE MODELS) A6E491841920201 1. Remove the under cover. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. 12.7—21.6 N·m {130—220 kgf·cm, 113—190 in·lbf} (MOLYBDENUM SULFIDE) 18.6—25.5 {1.90—2.60,13.8—18.8}...
Page 398: Clutch Release Cylinder Disassembly/Assembly (A65M-Rmanual Transaxle Models
CLUTCH RELEASE CYLINDER CLUTCH RELEASE CYLINDER DISASSEMBLY/ASSEMBLY (A65M-R MANUAL TRANSAXLE MODELS) A6E491841920202 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. 5.9—8.8 N . m {60—90 kgf . cm,53—78 in . lbf} BRAKE FLUID BRAKE...
Page 399: Clutch Unit
CLUTCH UNIT CLUTCH UNIT CLUTCH UNIT REMOVAL/INSTALLATION (A65M-R MANUAL TRANSAXLE MODELS) A6E492016000201 1. Remove in the order indicated in the table. 2. Install in the reverse order oremoval. TRANSAXLE SIDE ENGINE SIDE 25—33 {2.6—3.3, 19—24} 18.6—25.5 {1.90—2.60, 13.8—18.8} 151.3—161.1 {15.43—16.42, 111.6—118.8} SEALANT (MOLYBDENUM SULFIDE) N·m {kgf·m, ft·lbf}...
Page 400 CLUTCH UNIT Clutch Cover and Disc Removal Note 1. Install the SSTs. 2. Loosen each bolt one turn at a time in a crisscross pattern until spring tension is released. 3. Remove the clutch cover and disc. 49 SE01 310A 49 E011 1A0 A6E4920W011 Flywheel Removal Note...
Page 401: Clutch Cover Inspection (A65M-Rmanual Transaxle Models
CLUTCH UNIT Clutch Disc Installation Note 1. Hold the clutch disc position using the SST. 49 SE01 310A A6E4920W014 Clutch Cover Installation Note 1. Install the SSTs. 2. Tighten the bolts evenly and gradually in a crisscross pattern. Tightening torque 49 E011 1A0 25—33 N·m {2.6—3.3 kgf·m, 19—24 ft·lbf} 49 SE01 310A...
Page 402: Flywheel
CLUTCH UNIT, FLYWHEEL 4. Rotate the flywheel and check for misaligned diaphragm spring fingers. • If not as specified, replace the clutch cover. Misalignment 0.6 mm {0.024 in} max. A6E4920W016 End Of Sie FLYWHEEL FLYWHEEL INSPECTION (A65M-R MANUAL TRANSAXLE MODELS) A6E492211500201 1.
Page 403 M ANUAL TRANSAXLE [A65M-R] FEATURES OUTLINE .............. J2-2 OUTLINE OF CONSTRUCTION......J2-2 FEATURES ............J2-2 SPECIFICATIONS ..........J2-2 SERVICE LOCATION INDEX ..........J2-3 MANUAL TRANSAXLE LOCATION INDEX ..J2-3 MANUAL TRANSAXLE........J2-4 TRANSAXLE OIL INSPECTION ......J2-4 TRANSAXLE OIL REPLACEMENT ....J2-4 OIL SEAL (DIFFERENTIAL) REPLACEMENT ..
Page 404: Outline
(See MPV Workshop Manual supplement 1737-1*-02D.) End Of Sie FEATURES A6E520201025201 Improved drivability • The gear ratio has been changed. End Of Sie SPECIFICATIONS A6E520201025202 Item New Mazda6 (GG, GY) Current MPV (LW) Transaxle type A65M-R Transaxle control Floor-shift Operation system Cable Forward Shift assist...
Page 405: Location Index
LOCATION INDEX LOCATION INDEX MANUAL TRANSAXLE LOCATION INDEX A6E520001036201 A6E5200W001 Manual transaxle Oil seal (differential) (See J2–7 MANUAL TRANSAXLE REMOVAL/ (See J2–5 OIL SEAL (DIFFERENTIAL) INSTALLATION) REPLACEMENT) Shift mechanism Reverse switch (See J2–12 SHIFT MECHANISM REMOVAL/ (See J2–5 REVERSE SWITCH INSPECTION) INSTALLATION) (See...
Page 406: Manual Transaxle
MANUAL TRANSAXLE MANUAL TRANSAXLE TRANSAXLE OIL INSPECTION A6E521227001201 1. Park the vehicle on level ground. 2. Remove the filler plug and gasket. 3. Verify that the oil is near the brim of the plug port. • If the oil level is low, add the specified amount and type of oil through the filler plug hole.
Page 407: Oil Seal (Differential) Replacement
MANUAL TRANSAXLE OIL SEAL (DIFFERENTIAL) REPLACEMENT A6E521219240201 1. On level ground, jack up the vehicle and support it evenly on safety stands. 2. Drain the oil from the transaxle. 3. Remove the front wheels and splash shields. 4. Separate the drive shaft and joint shaft from the transaxle. (See Section M.) 5.
Page 408: Reverse Switch Removal/Installation
MANUAL TRANSAXLE REVERSE SWITCH REMOVAL/INSTALLATION A6E521219010202 1. Remove the reverse switch. 2. Apply a light coat of silicone sealant to the screw REVERSE SWITCH of the reverse switch. Sealant Three Bond product: TB1215 3. Install the reverse switch to the transaxle case. Tightening torque 22.5—33.3 N·m {2.29—3.40 kgf·m, 16.6—24.6 ft·lbf}...
Page 409: Neutral Switch Removal/Installation
MANUAL TRANSAXLE NEUTRAL SWITCH REMOVAL/INSTALLATION A6E521219010204 1. Remove the neutral switch. 2. Apply a light coat of silicone sealant to the screw of the neutral switch. NEUTRAL SWITCH Sealant Three Bond product: TB1215 3. Install the neutral switch to the transaxle case. Tightening torque 22.5—33.3 N·m {2.29—3.40 kgf·m, 16.6—24.6 ft·lbf}...
Page 410 MANUAL TRANSAXLE 33.0—44.1 {3.21—4.49, 23.2—32.5} 38—51 {3.9—5.2, 28—37} 93.1—126.4 {9.50—12.88, 68.67—93.22} 66.6—93.1 {6.80—9.49, 49.2—68.6} 43—61 {4.6—6.3, 32—45} 85.3—116.6 {8.70—11.88, 62.91—85.98} 58.8—80.4 {6.00—8.19, 43.4—59.2} 27.4—40.2 {2.80—4.09, 20.2—29.6} 58.8—80.4 18.6—25.5 {6.00—8.19, 43.4—59.2} {1.90—2.60, 13.8—18.8} 43.1—60.8 {4.40—6.19, 31.8—44.8} 93.1—116.6 {9.50—11.88, 68.66—85.98} 89.3—116 {9.1—11.8, 65.9—85.5} 166.6—200.0 {16.99—20.39, 122.9—147.5}...
Page 411 MANUAL TRANSAXLE Lower arm (front, rear) ball joint No.1 engine mount (See Section R) (See J2–9 No.1 Engine Mount Bracket Removal Note) Damper fork (See J2–11 No.1 Engine Mount Installation Note) Tie-rod end ball joint Crossmember bracket (See N–8 STEERING GEAR AND LINKAGE (MZR-CD (RF Turbo)) REMOVAL/INSTALLATION) Crossmember, steering pipe...
Page 412 MANUAL TRANSAXLE Manual Transaxle Installation Note 1. Set the transaxle on a jack and lift into place. 2. Install the transaxle mounting bolts. A6E5212W022 3. Install the stud of the No.4 engine mount. Tightening torque 27.4—40.2 N·m {2.80—4.09 kgf·m, 20.2—29.6 ft·lbf} STUD 4.
Page 413 MANUAL TRANSAXLE 12. Tighten the bolt E. Tightening torque E: 85.3—116.6 N·m {8.70—11.88 kgf·m, 62.91—85.98 ft·lbf} F,G,H: 66.6—93.1 N·m {6.80—9.49 kgf·m, 49.2—68.6 ft·lbf} A6E5212W024 No.1 Engine Mount Installation Note 1. Tighten the bolt A, then bolt B. Tightening torque 93.1—116.6 N·m {9.50—11.88 kgf·m, 68.66—85.98 ft·lbf} 2.
Page 414: Shift Mechanism
SHIFT MECHANISM SHIFT MECHANISM SHIFT MECHANISM REMOVAL/INSTALLATION A6E521446010201 1. Remove the battery and battery tray. 2. Remove the air cleaner component. (See F2–36 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.) 3. Remove the dashboard compleat. (See Section S.) 4. Remove the SAS control module. (See Section T.) 5.
Page 415 SHIFT MECHANISM Select Cable Installation Note 1. Remove the center console. 2. Make sure that the shift lever (transaxle side) is in neutral. 3. Unlock the lock pice of the select cable (shift lever side) in the order shown in the figure. 4.
Page 416 A UTOMATIC TRANSAXLE [JA5AX-EL] AUTOMATIC TRANSAXLE FLUID FEATURES (ATF) INSPECTION ........K2-78 AUTOMATIC TRANSAXLE FLUID OUTLINE .............. K2-3 (ATF) REPLACEMENT ......... K2-80 FEATURES ............K2-3 TRANSAXLE RANGE (TR) SWITCH SPECIFICATIONS ..........K2-3 INSPECTION ..........K2-80 AUTOMATIC TRANSAXLE........K2-4 TRANSAXLE RANGE (TR) SWITCH OUTLINE ............
Page 417 AUTOMATIC TRANSAXLE ON-BOARD NO.17 EXCESSIVE SHIFT SHOCK DIAGNOSTIC FUNCTION ......K2-123 FROM N TO D OR N TO R AFTER REPAIR PROCEDURE ..... K2-124 POSITION/RANGE ........K2-196 DTC TABLE ........... K2-126 NO.18 EXCESSIVE SHIFT SHOCK IS DTC P0705 ............ K2-127 GIVEN WHEN UPSHIFTING AND DTC P0706 ............
Page 418: Features
• A plate-type clutch pack replaces the band brake in the 2-4 brake. High efficiency, compactness, and light weight • Miniature trochoid gear type oil pump with torque converter direct drive has been adopted. End Of Sie SPECIFICATIONS A6E570201030202 New Mazda6 (GY) Current MPV (LW) Except for For General Item General –...
Page 419: Automatic Transaxle
AUTOMATIC TRANSAXLE Bold frames:New specifications End Of Sie AUTOMATIC TRANSAXLE OUTLINE A6E571401030201 • Adopted new JA5AX-EL automatic transaxle. • Newly designed FF type five-speed automatic transaxle. — Use of 3 sets of planetary gears, and a wider gear ratio setting realizes improvement of acceleration-from- standing-start performance, fuel economy, and quietness.
Page 420 AUTOMATIC TRANSAXLE EC-AT Operation Chart Solenoid valve Mode Gear position R INH : Operation : Transmits the torque only when driving A6E5714W009 End Of Sie K2–5...
Page 421: Cross-Sectional View
AUTOMATIC TRANSAXLE CROSS-SECTIONAL VIEW A6E571401030202 A6E5714W006 K2–6...
Page 422 AUTOMATIC TRANSAXLE Output gear Rear planetary gear Low one-way clutch Reduction planetary gear Low and reverse brake Reduction one-way clutch Low clutch Direct clutch 2-4 brake Reduction brake Reverse clutch Idler gear High clutch Reduction gear Front planetary gear Transfer End Of Sie K2–7...
Page 423: Electronic Control System Structural View
AUTOMATIC TRANSAXLE ELECTRONIC CONTROL SYSTEM STRUCTURAL VIEW A6E571401030203 • The TCM control the automatic transaxle operations. The TCM outputs a control signal to the transaxle according to the signal from other sensors and/or switches. A6E5714W010 DLC-2 Brake light switch Selector lever AT warning light M range switch Selector indicator light...
Page 424 AUTOMATIC TRANSAXLE A6E5714W011 Cruise control module (In cluise actuator) Input/turbine speed sensor Solenoid valve Intermediate sensor TFT sensor TR switch Oil cooler End Of Sie K2–9...
Page 425: Automatic Transaxle Control System Wiring Diagram
AUTOMATIC TRANSAXLE AUTOMATIC TRANSAXLE CONTROL SYSTEM WIRING DIAGRAM A6E571401030204 A6E5714W008 Down switch R position (TR switch) Selector lever D range (TR switch) Cruise control module (In cruise actuator) N position (TR switch) TFT sensor P position (TR switch) Brake switch Input/turbine speed sensor M range switch Intermediate sensor...
Page 426: Automatic Transaxle Block Diagram
AUTOMATIC TRANSAXLE 2-4 brake solenoid valve Neutral shift solenoid valve High clutch solenoid valve CAN_L TCC solenoid valve CAN_H Shift solenoid A Instrument cluster Shift solenoid B Shift solenoid C ABS HU/CM or DSC HU/CM Reduction timing solenoid valve End Of Sie AUTOMATIC TRANSAXLE BLOCK DIAGRAM A6E571401030205 A6E5714W012...
Page 427 AUTOMATIC TRANSAXLE Electronic Control Item and Control Control item Contents • Detects engine load condition and vehicle speed. Shifts to the best gear Shift control position according to the programmed automatic shift diagram. • Generates line pressure matching the engine load condition and driving Line pressure control conditions.
Page 428: Automatic Transaxle Device Relationship Chart
AUTOMATIC TRANSAXLE Part name Function • Switches ON and OFF based on electric signals from the Output system ON/OFF Shift solenoid A type TCM, changes hydraulic circuit to control shifting • Switches ON and OFF based on electric signals from the Shift solenoid B TCM, changes hydraulic circuit to control shifting •...
Page 429 AUTOMATIC TRANSAXLE Control item Line Reverse Shift Slope Component Shift Feedbac pressure inhibition transient select mode control k control control system control control control control control Throttle signal position signal Engine torque signal (without torque down) Engine torque signal (with torque down) Engine...
Page 430: Powertrain Description
AUTOMATIC TRANSAXLE Control item Line Reverse Shift Slope Component Shift Feedbac pressure inhibition transient select mode control k control control system control control control control control Duty Pressure type control solenoid 2-4 brake solenoid valve High clutch solenoid valve solenoid valve Reduce signal...
Page 431 AUTOMATIC TRANSAXLE A6E5714W071 Rear pinion gear Rear sun gear Rear internal gear Reduction brake Low one-way clutch Direct clutch Low and reverse brake Reduction one-way clutch Low clutch Idler gear 2-4 brake Reduction gear Front internal gear Reduction sun gear Reverse clutch Reduction pinion gear High clutch...
Page 432 AUTOMATIC TRANSAXLE Operation Note • All rotation are viewed from the side cover. Component description Component Function • Transmits rotation of low clutch drum to rear internal gear Low clutch • Operates in 1GR, 2GR, or 3GR position • Prevents rotation of front sun gear 2-4 brake •...
Page 433 AUTOMATIC TRANSAXLE 1GR (D range) AMU0517S007 K2–18...
Page 434 AUTOMATIC TRANSAXLE AMU0517S008 K2–19...
Page 435 AUTOMATIC TRANSAXLE 1GR (M range) LOW ONE-WAY CLUTCH CLUTCH LOW AND REVERSE BRAKE OUTPUT GEAR BRAKE REVERSE CLUTCH REAR PINION GEAR HIGH REAR CLUTCH INTERNAL FRONT GEAR PINION GEAR FRONT INTERNAL REDUCTION GEAR GEAR REAR GEAR FRONT GEAR IDLER GEAR REDUCTION REDUCTION INTERNAL...
Page 436 AUTOMATIC TRANSAXLE LOW AND REVERSE BRAKE LOW CLUTCH 2-4 BRAKE LOW ONE-WAY CLUTCH FRONT REAR INTERNAL INTERNAL REVERSE GEAR GEAR CLUTCH REAR PINION GEAR HIGH CLUTCH FRONT PINION GEAR FRONT REDUCTION REAR SUN GEAR BRAKE GEAR OUTPUT GEAR DIRECT REDUCTION CLUTCH INTERNAL GEAR REDUCTION...
Page 437 AUTOMATIC TRANSAXLE 2GR (D range) AMU0517S009 K2–22...
Page 438 AUTOMATIC TRANSAXLE AMU0517S010 K2–23...
Page 439 AUTOMATIC TRANSAXLE 2GR (M range) AMU0517S011 K2–24...
Page 440 AUTOMATIC TRANSAXLE AMU0517S012 K2–25...
Page 441 AUTOMATIC TRANSAXLE 3GR (D range) AMU0517S013 K2–26...
Page 442 AUTOMATIC TRANSAXLE AMU0517S049 K2–27...
Page 443 AUTOMATIC TRANSAXLE 3GR (M range) AMU0517S050 K2–28...
Page 444 AUTOMATIC TRANSAXLE AMU0517S051 K2–29...
Page 445 AUTOMATIC TRANSAXLE 4GR (D range) AMU0517S052 K2–30...
Page 446 AUTOMATIC TRANSAXLE AMU0517S053 K2–31...
Page 447 AUTOMATIC TRANSAXLE 4GR (M range) AMU0517S054 K2–32...
Page 448 AUTOMATIC TRANSAXLE AMU0517S055 K2–33...
Page 449 AUTOMATIC TRANSAXLE AMU0517S056 K2–34...
Page 450 AUTOMATIC TRANSAXLE AMU0517S057 K2–35...
Page 451 AUTOMATIC TRANSAXLE R position AMU0517S058 K2–36...
Page 452 AUTOMATIC TRANSAXLE AMU0517S059 K2–37...
Page 453 AUTOMATIC TRANSAXLE R position (Reverse inhibition control) AMU0517S060 K2–38...
Page 454 AUTOMATIC TRANSAXLE AMU0517S061 End Of Sie K2–39...
Page 455: Torque Converter Description
AUTOMATIC TRANSAXLE TORQUE CONVERTER DESCRIPTION A6E571419100201 Outline • The JA5AX-EL uses a three-element, single-gear, two-phase torque converter with torque converter clutch (TCC) mechanism. • The torque converter efficiently matches the output characteristic of AJ engine. • By matching the output characteristics of the engine in order to optimize the configuration of the impellers, the torque converter increases the capacity coefficient in the practical range, thereby improving drivability and fuel economy.
Page 456: Oil Pump Description
AUTOMATIC TRANSAXLE OIL PUMP DESCRIPTION A6E571419220201 Outline • The light-weight, compact, and quiet trochoid type oil pump reduces pump driving torque. • The direct drive type oil pump is placed behind the torque converter. AMU0517S015 Structure/Operation • The outer rotor and inner rotor are installed in the oil pump housing. •...
Page 457: Centrifugal Balance Clutch Description
AUTOMATIC TRANSAXLE CENTRIFUGAL BALANCE CLUTCH DESCRIPTION A6E571401030208 Function • The centrifugal balance clutch, which replaces the conventional piston check ball, cancels centrifugal oil pressure generated during clutch drum rotation to prevent the clutch drag-engagement and to stabilize piston pressure during full rotation. Construction/Operation •...
Page 458: Control Valve Body Description
AUTOMATIC TRANSAXLE When the clutch pressure is not applied • When the clutch drum rotates, centrifugal force acts on the residual ATF in the clutch chamber to push against the piston. However, centrifugal force also acts on the ATF filled in the centrifugal balance clutch chamber to push back the piston.
Page 459 AUTOMATIC TRANSAXLE AMU0517S064 End Of Sie K2–44...
Page 460: Transaxle Fluid Temperature (Tft) Sensor Description
AUTOMATIC TRANSAXLE TRANSAXLE FLUID TEMPERATURE (TFT) SENSOR DESCRIPTION A6E571419010201 • The TFT sensor, which is installed in the transaxle case, detects the ATF temperature in the transaxle case, and sends the control signal to the TCM. The TCM controls the driving pattern and the torque converter clutch based on the signal from the TFT sensor.
Page 461: Intermediate Sensor Description
AUTOMATIC TRANSAXLE INTERMEDIATE SENSOR DESCRIPTION A6E571419550201 Function • A intermediate sensor is located in the transaxle case and detects the rotating speed of the output gear. Construction/Operation • The magnetic pickup type of intermediate sensor is mounted in the transaxle case, next to the output gear. It generates a 54-pulse signal for each rotation of the output gear, and sends this signal to the TCM.
Page 462: Solenoid Valve Description
AUTOMATIC TRANSAXLE SOLENOID VALVE DESCRIPTION A6E571421280201 Function AMU0517S024 K2–47...
Page 463 AUTOMATIC TRANSAXLE Function chart Solenoid Type Characteristics Function Controls pressure regulator Pressure control solenoid Normal high valve, regulates line pressure Torque converter clutch Controls TCC engagement Normal low (TCC) solenoid valve and disengagement Repeats ON and OFF at 50 Control 2-4 brake Hz (20 ms cycle);...
Page 464 AUTOMATIC TRANSAXLE ON/OFF type (two-way) Normal low • De-energized (OFF) — The TCM does not apply an electric current to the solenoid valves. The rod moves upward by hydraulic pressure and the drain port opens. • Energized (ON) — The TCM applies an electric current to the solenoid valves. This excites the coil and forces the rod to move downward to retain hydraulic pressure.
Page 465: Controller Area Network (Can) Description
AUTOMATIC TRANSAXLE CONTROLLER AREA NETWORK (CAN) DESCRIPTION A6E571418901201 Outline • The TCM transmits/receives information using the CAN system. See Section T for detailed information regarding the CAN system. Structure/Operation • The PCM inputs throttle opening angle, engine speed, engine torque, engine coolant temperature. to the TCM. •...
Page 466 AUTOMATIC TRANSAXLE TRANSAXLE CONTROL MODULE (TCM) DESCRIPTION A6E571418901202 Outline • The TCM controls the automatic transaxle operations. The TCM outputs a control signal to the transaxle according to the signal from other sensors and/or switches. • In driving mode, there are three mode selections: NORMAL, high temp, and SLOPE. The TCM automatically selects the proper mode according to driving condition.
Page 467: Manual Mode Shift Control Description
AUTOMATIC TRANSAXLE Operation Range determination • Each range is determined by operating the selector lever, and switching ON/OFF the switch in the TR switch internal circuit. The present range is detected according to the ON/OFF signal of the switch. • The following switches are built into the TR switch, and determine each range when the switch is on. P position switch R position switch N position switch...
Page 468 AUTOMATIC TRANSAXLE Instrument cluster Selector lever component Input -M range switch -Up switch -Down switch TR switch ABS HU/CM or DSC HU/CM TFT sensor Operation Manual mode shift • When the selector lever is shifted over from the D to M range position, the M range switch in the selector lever component turns on, sending a manual mode command signal to the PCM which activates the manual mode shift control.
Page 469 AUTOMATIC TRANSAXLE Shift diagram 0{0} 20{12} 40{25} 60{37} 80{50} 100{62} 120{74} 140{87} 160{99} 180{112} 200{124} 220{136} A6E5714W070 TCC operation available Vehicle speed (km/h {mph}) Throttle opening Down shifting is inhibited until vehicle reaches speed possible for downshifting TCC operation OFF When decelerating below set vehicle speed, TCC operation ON executes automatic downshifting...
Page 470 AUTOMATIC TRANSAXLE Construction (System diagram) A6E5714W019 Intermediate sensor TR switch Pressure control solenoid Input/turbine speed sensor M range switch Throttle position signal Up switch Engine torque signal Down switch TFT sensor Cruise control module K2–55...
Page 471 AUTOMATIC TRANSAXLE Basic Line Pressure Control • Control at vehicle-start or during normal driving. The pressure control solenoid is controlled so that the line pressure is optimal according to the throttle opening angle. The pressure characteristic is as shown in the graph at below. During normal driving (only in shift ranges for forward travel), the line pressure is set lower than that of at vehicle-start;...
Page 472: Feedback Control Description
AUTOMATIC TRANSAXLE Line Pressure Control at Extremely Low Temperatures • When the ATF temperature is approximately –30 °C {–22 °F} or below, the period when the pressure control solenoid is ON (duty ratio) is set at 3 % to maintain line pressure at maximum regardless of the throttle opening angle.
Page 473 AUTOMATIC TRANSAXLE Construction (system diagram) A6E5714W020 Throttle position signal Input/turbine speed sensor Torque reduce signal Intermediate sensor Engine torque signal Input Output Reduce torque signal K2–58...
Page 474: N-D Select Control Description
AUTOMATIC TRANSAXLE High clutch solenoid valve TFT sensor GND return TR switch Pressure control solenoid 2-4 brake solenoid valve Operation Upshift clutch engagement pressure feedback • Clutch pressure (2) is learned so that gear shift time (1) becomes a predetermined target value, and thus changes in performance and changes in the transaxle over time are minimized based on past gear shift results.
Page 475 AUTOMATIC TRANSAXLE Construction (system diagram) A6E5714W021 Input/turbine speed sensor TR switch Engine speed signal TCC solenoid valve Throttle position signal TCC signal TFT sensor K2–60...
Page 476 AUTOMATIC TRANSAXLE Operation Torque converter clutch (TCC) release operation • The TCM sends an OFF signal to TCC solenoid valve to release the TCC. In this condition, the TCC control valve is pushed to the up side by spring force and line pressure, and torque converter pressure acts on the torque converter front chamber, releasing the TCC from the converter cover.
Page 477 AUTOMATIC TRANSAXLE Torque converter clutch (TCC) engaging operation • The TCM determines smooth TCC operation. It sends an ON signal to the TCC solenoid valve to push the TCC control valve to the down side. Consequently, the hydraulic pressure applied to the torque converter front chamber is drained through the TCC control valve, engaging torque converter clutch.
Page 478 AUTOMATIC TRANSAXLE Determination of Torque Converter Clutch (TCC) Cancellation The TCC control is canceled when any of the following condition are met: • Engine coolant temperature is low. • ATF temperature is low. • Brake switch is on (when depressing the brake pedal). •...
Page 479: On-Board Diagnostic (Obd) System Description
AUTOMATIC TRANSAXLE ON-BOARD DIAGNOSTIC (OBD) SYSTEM DESCRIPTION A6E571418901210 • The OBD system has the following functions: — Failure detection function: detects failure of the input/output devices and system components of the ATX. — Memory function: stores the DTC when a failure is detected. —...
Page 480 AUTOMATIC TRANSAXLE Memory Function • The memory function stores failure information detected in the failure detection function. Once failure information is stored, the memory will not be cleared even when the ignition switch is turned off (LOCK position) or the malfunction is repaired. •...
Page 481 AUTOMATIC TRANSAXLE On-board diagnostic function Detection condition Fail-safe • TFT sensor signal stays Transaxle fluid temperature (TFT) P0711 outside normal temperature — Available sensor malfunction (stuck) range for 10 minute or more • Signals form TFT sensor are Transaxle fluid temperature (TFT) 155 °C {311 °F} or greater P0712 sensor circuit malfunction (short...
Page 482 AUTOMATIC TRANSAXLE On-board diagnostic function Detection condition Fail-safe • Open or short in shift solenoid B circuit (Voltage • Stops driving all ON/OFF different from on/off signal Shift solenoid B malfunction P0758 relayed by CPU in TCM is type solenoids (OFF) and Inhibition (open/short) detected while TCM is...
Page 483: Tcm
AUTOMATIC TRANSAXLE Parameter Identification (PID) Access Monitor item table Display on the Unit/ Definition tester Condition terminal 2-4 B Duty 2-4 brake solenoid valve control signal in TCM ON/OFF Brake switch ON/OFF DWN_SW Down switch ON/OFF 1ST/2ND/ GEAR Calculated gear range in TCM –...
Page 484: Cooling System Description
AUTOMATIC TRANSAXLE COOLING SYSTEM DESCRIPTION A6E571419900201 Outline AME5714W017 End Of Sie K2–69...
Page 485: Location Index
LOCATION INDEX LOCATION INDEX AUTOMATIC TRANSAXLE LOCATION INDEX A6E570001074201 9 11 A6E5700W001 K2–70...
Page 486 LOCATION INDEX Automatic transaxle fluid (ATF) Transfer oil (See K2–78 AUTOMATIC TRANSAXLE FLUID (See K2–114 TRANSFER OIL INSPECTION) (ATF) INSPECTION) (See K2–114 TRANSFER OIL REPLACEMENT) (See K2–80 AUTOMATIC TRANSAXLE FLUID Automatic transaxle (ATF) REPLACEMENT) (See K2–99 AUTOMATIC TRANSAXLE AND Transaxle range (TR) switch TRANSFER REMOVAL/INSTALLATION) (See...
Page 487: Automatic Transaxle
AUTOMATIC TRANSAXLE AUTOMATIC TRANSAXLE MECHANICAL SYSTEM TEST A6E571401030209 Mechanical System Test Preparation 1. Apply the parking brake and use wheel chocks at the front and rear of the wheels. 2. Inspect the engine coolant. (See Section E.) 3. Inspect the engine oil. (See D–8 ENGINE OIL INSPECTION.) 4.
Page 488 AUTOMATIC TRANSAXLE (3) Connect the SSTs (49 L019 014, 49 B019 901B, and 49 0378 400C) to the low clutch D,M RANGES pressure inspection port (D and M range line 49 B019 901B pressures) or reverse clutch pressure inspection port (R position line pressure). (4) Start the engine and warm it up until the ATF reaches 60—70 °C {140—158 °F}.
Page 489 AUTOMATIC TRANSAXLE Evaluation of line pressure test Condition Possible cause Worn oil pump Poor operation of each solenoid Fluid leaking from oil strainer, oil pump, pressure regulator Low pressure in all ranges valve, torque converter relief valve, and/or pressure relief valve Pressure regulator valve or pilot valve sticking Damaged pressure regulator valve spring or pilot valve spring Below specification...
Page 490: Road Test
AUTOMATIC TRANSAXLE Time Lag Test 1. Perform mechanical system test preparation. (See K2–72 Mechanical System Test Preparation.) 2. Start the engine. 3. Warm up the engine until the ATF temperature reaches 60—70°C {140—158°F}. Shift the selector lever from N position to D range. 4.
Page 491 AUTOMATIC TRANSAXLE D Range Test Note • The NORMAL mode and SLOPE mode are automatically selected by the TCM in D range. The TCM shifts to SLOPE mode when the upgrade is approx. 5 % or more, and shifts to NORMAL mode when the upgrade is approx.
Page 492 AUTOMATIC TRANSAXLE M Range Test 1. Perform road test preparation. (See K2–75 Road Test Preparation.) 2. Shift the selector lever to M range. 3. Verify that 1→2, 2→3, 3→4, and 4→5 upshifts and 5→4, 4→3, 3→2, and 2→1 downshifts are obtained by manual shifting of the selector lever forward and back.
Page 493: Automatic Transaxle Fluid (Atf) Inspection
AUTOMATIC TRANSAXLE Evaluation Condition Possible Cause Stuck shift solenoid C Stuck shift valve C No 1-2 up- or downshift Wore 2-4 brake Trouble intermediate sensor Stuck shift solenoid A No 2-3 up- or downshift Stuck shift valve A Wore high clutch Stuck shift solenoid B No 3-4 up- or downshift Stuck shift valve B...
Page 494 AUTOMATIC TRANSAXLE Automatic Transaxle Fluid (ATF) Level Inspection Caution • The ATF amount varies according to ATF's temperature. Therefore, when checking the ATF level or replacing the ATF, use a thermometer to measure the temperature then adjust the ATF amount to the specified level according to the specified temperature.
Page 495: Automatic Transaxle Fluid (Atf) Replacement
AUTOMATIC TRANSAXLE AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT A6E571419001202 Warning • When the transaxle and ATF are hot, they can badly burn you. Turn off the engine and wait until they are cool before changing the ATF. 1. Remove the oil dipstick. 2.
Page 496: Transaxle Range (Tr) Switch Removal/Installation
AUTOMATIC TRANSAXLE 3. Connect the TR switch connector. A6E5714W109 End Of Sie TRANSAXLE RANGE (TR) SWITCH REMOVAL/INSTALLATION A6E571419440202 1. Disconnect the negative battery cable. 2. Remove the air cleaner component. (See Section F.) Caution • Water or foreign objects entering the connector can cause a poor connection or corrosion. Be sure not to drop water or foreign objects on the connector when disconnecting it.
Page 497 AUTOMATIC TRANSAXLE 11. Using the SST and by turning the TR switch, adjust the positions of the manual shaft and the 49 L019 013 TR switch neutral hole. 12. Tighten the TR switch mounting bolts. Tightening torque 4.9—6.9 N·m {50—70 kgf·cm, 44—61 in·lbf} A6E5714W113 13.
Page 498: Transaxle Range (Tr) Switch Adjustment
AUTOMATIC TRANSAXLE End Of Sie TRANSAXLE RANGE (TR) SWITCH ADJUSTMENT A6E571419440203 Caution • Water or foreign objects entering the connector can cause a poor connection or corrosion. Be sure not to drop water or foreign objects on the connector when disconnecting it. 1.
Page 499: Transaxle Fluid Temperature (Tft) Sensor Inspection
AUTOMATIC TRANSAXLE TRANSAXLE FLUID TEMPERATURE (TFT) SENSOR INSPECTION A6E571419010202 1. Disconnect the terminal component No.2 TERMINAL COMPONENT No.2 connector. 2. Remove the oil dipstick. A6E5714W117 3. Insert the thermistor probe into the filler tube. 4. Start the engine. A6E5614W003 5. Measure resistance between the terminals G and A6E5714W118 •...
Page 500: Transaxle Fluid Temperature
AUTOMATIC TRANSAXLE TRANSAXLE FLUID TEMPERATURE (TFT) SENSOR REMOVAL/INSTALLATION A6E571419010203 1. Remove the automatic transaxle. (See K2–99 AUTOMATIC TRANSAXLE AND TRANSFER REMOVAL/ INSTALLATION.) 2. Disassemble the automatic transaxle, and then remove the TFT sensor. (See Automatic Transaxle Workshop Manual JA5A-EL) 3. Install a TFT sensor, and then assemble the automatic transaxle. (See Automatic Transaxle Workshop Manual JA5A-EL) 4.
Page 501: Input/Turbine Speed Sensor Removal/Installation
AUTOMATIC TRANSAXLE INPUT/TURBINE SPEED SENSOR REMOVAL/INSTALLATION A6E571421550203 1. Remove the automatic transaxle. (See K2–99 AUTOMATIC TRANSAXLE AND TRANSFER REMOVAL/ INSTALLATION.) 2. Remove the input/turbine speed sensor. (See Automatic Transaxle Workshop Manual JA5A-EL.) 3. Install the input/turbine speed sensor. (See Automatic Transaxle Workshop Manual JA5A-EL.) 4.
Page 502: Vehicle Speedometer Sensor (Vss) Inspection
AUTOMATIC TRANSAXLE VEHICLE SPEEDOMETER SENSOR (VSS) INSPECTION A6E571417400204 On-Vehicle Inspection 1. Disconnect the terminal component No.2 TERMINAL COMPONENT No.2 connector. A6E5714W117 2. Measure resistance between the terminals A and • If not as specified, inspect the VSS sensor. (See K2–87 Inspection of Individual Part.) Resistance (ATF temperature: 20 °C {68 °F}) 513—627 ohms...
Page 503: Solenoid Valve Inspection
AUTOMATIC TRANSAXLE SOLENOID VALVE INSPECTION A6E571421280202 Resistance Inspection (On-Vehicle) 1. Disconnect the negative battery cable. 2. Disconnect the terminal component No.1 TERMINAL COMPONENT No.1 connector. A6E5714W120 3. Measure the resistance between the following terminals. • If not as specified, inspect each solenoid valve.
Page 504 AUTOMATIC TRANSAXLE Resistance Inspection (Off-Vehicle) 1. Remove each solenoid valve. (See K2–90 SOLENOID VALVE REMOVAL/INSTALLATION.) 2. Measure the resistance of each solenoid valve individually. • If not specified, replace the solenoid valve. • If it is normal, replace the harness. Pressure control solenoid, 2-4 brake solenoid valve, and high clutch solenoid valve Resistance: 2.6—3.2 ohms (20 °C {68 °F}) AMU0517W034...
Page 505: Solenoid Valve Removal/Installation
AUTOMATIC TRANSAXLE SOLENOID VALVE REMOVAL/INSTALLATION A6E571421280203 1. Remove the control valve body. (See K2–105 CONTROL VALVE BODY REMOVAL/INSTALLATION.) 2. Remove the solenoid valves and manual valve. A6E5714W122 Manual valve Shift solenoid B 2-4 brake solenoid valve Reduction timing solenoid valve Neutral shift solenoid valve Shift solenoid A TCC solenoid valve...
Page 506 AUTOMATIC TRANSAXLE AMJ5814W078 Terminal Signal Connected to Test Condition Voltage (V) Action — — — — — • Inspect TFT sensor TFT sensor TFT sensor Constant Continuity (GND) (See K2–84 TRANSAXLE FLUID TEMPERATURE (TFT) SENSOR INSPECTION) • Inspect related harness •...
Page 507 AUTOMATIC TRANSAXLE Terminal Signal Connected to Test Condition Voltage (V) Action • Inspect battery Back-up power Battery Constant supply (See G–6 BATTERY INSPECTION) • Inspect related harness — — — — — • Inspect selector lever Down switch Down switch Down shift at M range component...
Page 508 AUTOMATIC TRANSAXLE Terminal Signal Connected to Test Condition Voltage (V) Action — — — — — • Inspect Input/turbine Input/turbine speed Input/turbine speed Constant sensor sensor speed sensor (GND) (See K2–85 INPUT/ TURBINE SPEED SENSOR INSPECTION) • Inspect related harness •...
Page 509 AUTOMATIC TRANSAXLE Terminal Signal Connected to Test Condition Voltage (V) Action • Inspect pressure control Pressure control Pressure control N position solenoid control solenoid solenoid D position stall (See K2–88 SOLENOID VALVE INSPECTION) • Inspect related harness • Inspect main relay Power supply Main relay Ignition switch ON...
Page 510 AUTOMATIC TRANSAXLE Pressure control solenoid signal • TCM terminal: 2Y (+)—2P (–) • Oscilloscope setting: 5 V/DIV (Y) 5 ms/DIV (X) • Measuring condition: Idle after warm-up AMU0517W060 2-4 brake solenoid valve signal • TCM terminal: 2V (+)—2P (–) • Oscilloscope setting: 5 V/DIV (Y) 5 ms/DIV (X) •...
Page 511: Tcm Removal/Installation
AUTOMATIC TRANSAXLE TCC solenoid valve signal (lock up on) • TCM terminal: 2S (+)—2P (–) • Oscilloscope setting: 5 V/DIV (Y) 5 ms/DIV (X) • Measuring condition: Drive the vehicle with lock AMU0517W059 End Of Sie TCM REMOVAL/INSTALLATION A6E571418901212 1. Disconnect the negative battery cable. 2.
Page 512 AUTOMATIC TRANSAXLE European (L.H.D.) specs. 7.8—10.8 N·m {80—110 kgf·cm, 69.5—95.4 in·lbf} 7.8—10.8 N·m {80—110 kgf·cm, 69.5—95.4 in·lbf} A6E5714W124 4WD control module connector 4WD control module TCM connector Set Nut/bolt Removal Note 1. Using a chisel and hammer, cut a groove on the head of the set nut/bolt so that a screwdriver can be inserted. 2.
Page 513 AUTOMATIC TRANSAXLE THIS PAGE IS INTENTIONALLY LEFT BLANK End Of Sie K2–98...
Page 514: Automatic Transaxle And Transfer Removal/Installation
AUTOMATIC TRANSAXLE AUTOMATIC TRANSAXLE AND TRANSFER REMOVAL/INSTALLATION A6E571419090201 1. Disconnect the negative battery cable. 2. Remove the battery and battery tray. 3. Remove the aircleaner component. (See Sectin F.) 4. Remove the front tires and splash shield. 5. Remove the under cover. 6.
Page 515 AUTOMATIC TRANSAXLE 33.0—44.1 {3.21—4.49, 23.2—32.5} 34.3—60.5 {3.50—6.16, 25.3—44.6} 93.1—126.4 {9.50—12.88, 68.67—93.22} 66.6—93.1 {6.80—9.49, 49.2—68.6} 37—52 85.3—116.6 {3.8—5.3, 28—38} {8.70—11.88, 62.91—85.98} 6.9—9.8 42—62 {71—99 kgf·cm, {4.3—6.3, 31—45} 62—86 in·lbf} — 43.1—60.8 {4.40—6.19, 31.8—44.8} 37—52 {3.8—5.3, 28—38} 85.3—116.6 {8.70—11.88, 62.91—85.98} 166.6—200.0 {16.99—20.39, 122.9—147.5} 119.6—154.8 {12.20—15.78,...
Page 516 AUTOMATIC TRANSAXLE sensor connector Drive shaft (right side) (See Section M) Joint shaft (See Section M) Terminal component No.1, No.2 connector No.1 engine mount TR switch connector (See K2–101 No.1 Engine Mount Bracket Removal GND harness Note) Selector cable (See K2–103 No.1 Engine Mount Installation Note) (See...
Page 517 AUTOMATIC TRANSAXLE Transaxle Installation Note 1. Set the transaxle on a jack and lift it. 2. Install the transaxle mounting bolts. Tightening torque 37—52 N·m {3.8—5.3 kgf·m, 28—38 ft·lbf} A6E5714W135 Torque Converter Nuts Removal Note 1. Hold the cankshaft pulley to prevent drive plate from rotating.
Page 518 AUTOMATIC TRANSAXLE 2. Tighten the torque converter mounting nuts. Tightening torque 34.3—60.5 N·m {3.50—6.16 kgf·m, 25.3—44.6 ft·lbf} A6E5714W136 No.4 Engine Mount Installation Note 1. Verify that the No.4 engine mount bracket are installed as shown. 2. Lightly tighten the bolt D. A6E5112W005 3.
Page 519: Oil Seal Removal/Installation
AUTOMATIC TRANSAXLE 4. Tighten the bolt A. Tightening torque A: 93.1—116.6 N·m {9.50—11.88 kgf·m, 68.66—85.98 ft·lbf} B: 85.3—116.6 N·m {8.70—11.88 kgf·m, 62.91—85.98 ft·lbf} A6E5714W138 Selector Cable Installation Note 1. Install the selector lever to the manual shaft lever in such a way that the selector cable does not SPRING UPWARD bear a load.
Page 520: Control Valve Body Removal/Installation
AUTOMATIC TRANSAXLE 4. Coat the oil seal with transfer oil and grease as shown in the figure. Caution • The oil seal is easily damaged by the sharp edges of the drive shaft splines. Do not let the splines contact the oil seal. 5.
Page 521: Oil Cooler Flushing
AUTOMATIC TRANSAXLE 5. Install the control valve body cover. Tightening torque 6.9—8.8 N·m {0.70—0.90 kgf·m, 5.1—6.5 ft·lbf} 6. Install the oil hose and oil pipe. (See K2–108 OIL COOLER REMOVAL/INSTALLATION.) 7. Install the radiator. (See Section E.) 8. Install the shroud panel. (See Section S.) CONTROL VALVE BODY 9.
Page 522 AUTOMATIC TRANSAXLE Back flushing 1. Using the power flushing equipment FLUSHING FLUID IN manufacturer's instructions, connect equipment FLUSHING FLUID OUT so the flushing fluid flows in the opposite direction of normal fluid flow. 2. Flush oil cooler/lines until discharge fluid is clean. Caution •...
Page 523: Oil Cooler Removal/Installation
AUTOMATIC TRANSAXLE OIL COOLER REMOVAL/INSTALLATION A6E571419900203 1. Disconnect the negative battery cable. 2. Drain the ATF into a container. (See K2–80 AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT.) 3. Remove the radiator. (See Section E.) 4. Remove in the order indicated in the table. 5.
Page 524 AUTOMATIC TRANSAXLE Oil Pipe, Hose Clamp, Oil Hose Installation Note 1. Apply compressed air to cooler-side opening, and blow any remaining grime and foreign material from the cooler pipes. Compressed air should be applied for no less than one minute. A6E5614W070 2.
Page 525: Oil Cooler Disassembly/Assembly
AUTOMATIC TRANSAXLE OIL COOLER DISASSEMBLY/ASSEMBLY A6E571419900204 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. 0.78—1.56 N·m {7.96—15.9 kgf·cm, 7—14 in·lbf} A6E5614W072 Mount rubber Drain cock Radiator outer tank (in tank oil cooler) ATF cooler (See K2–110 Radiator Outer Tank (In Tank Oil...
Page 526 AUTOMATIC TRANSAXLE 3. Pivot the screwdriver to pry the tab away from the tank and repeat the procedure for each tab. 4. Remove the radiator outer tank and O-ring (gasket) from the core header when all of the tabs SCREWDRIVER are opened.
Page 527: Drive Plate Removal/Installation
AUTOMATIC TRANSAXLE 4. Squeeze the header tabs down in order as shown against the lip of radiator outer tank base with RADIATOR LOWER TANK locking-type pliers while rotating the pliers toward the tank. LOCKING TYPE PLIERS A6E5614W076 5. Verify the height of the header tabs is same as the height before removal.
Page 528 AUTOMATIC TRANSAXLE Drive Plate Mounting Bolts Removal Note 1. Set the SST or equivalent against the drive plate. 2. Remove the bolts and the drive plate. 49 E011 1A0 A6E5614W079 Drive Plate Installation Note Caution • If the bolts are reused, remove the oil sealant from the bolt threads. Tightening a bolt that has old sealant on it can cause thread damage.
Page 529: Transfer
TRANSFER TRANSFER TRANSFER OIL INSPECTION A6E571817001201 1. Park the vehicle on level ground. 2. Remove the PTO heat shield. 3. Remove the filler plug. 4. Verify that the oil is near the brim of the plug port. • If the oil level is low, add the specified amount TRANSFER and type of oil through the filler plug hole.
Page 530: Transfer Removal/Installation
TRANSFER End Of Sie TRANSFER REMOVAL/INSTALLATION A6E571817001204 1. Disconnect the negative battery cable. 2. Remove the propeller shaft. (See L–5 PROPELLER SHAFT REMOVAL/INSTALLATION.) 3. Remove the TWC. (See F1–30 EXHAUST SYSTEM REMOVAL/INSTALLATION.) 4. Remove the front tires and splash shield of right side. 5.
Page 531: Breather Plug Removal/Installation
TRANSFER No.1 Engine Mount Installation Bolt Installation Note 1. Tighten the bolt C and D. 2. Lightly tighten the bolt B, then bolt A. 3. Tighten the bolt B and A. Tightening torque A, C, D: 93.1—116.6 N·m {9.50—11.88 kgf·m, 68.66—85.98 ft·lbf} B: 85.3—116.6 N·m {8.70—11.88 kgf·m, 62.91—85.98 ft·lbf} A6E5714W138...
Page 532: Automatic Transaxle Shift Mechanism
AUTOMATIC TRANSAXLE SHIFT MECHANISM AUTOMATIC TRANSAXLE SHIFT MECHANISM SELECTOR LEVER INSPECTION A6E571646102201 1. Turn the ignition switch to the ON position (engine off). 2. With the brake pedal depressed, verify that a “click” sound is heard at each range when shifted in the pattern shown.
Page 533: Selector Cable Adjustment
AUTOMATIC TRANSAXLE SHIFT MECHANISM SELECTOR CABLE ADJUSTMENT A6E571646500201 1. Remove the center console. 2. Shift the selector lever to P position. 3. Unlock the lock piece of the selector cable (selector lever side) in the order shown in the SAFETY LOCK LOCK PIECE figure.
Page 534: Selector Lever Removal/Installation
AUTOMATIC TRANSAXLE SHIFT MECHANISM SELECTOR LEVER REMOVAL/INSTALLATION A6E571646102202 1. Disconnect the negative battery cable. 2. Remove the battery and battery tray. 3. Remove the air cleaner compornent. (See Section F.) 4. Remove the console. 5. Remove the dashboard compleat. (See Section S.) 6.
Page 535 AUTOMATIC TRANSAXLE SHIFT MECHANISM Selector Cable Removal Note 1. Remove the spring. 2. Remove the selector cable. SELECTOR CABLE SPRING A6E5716W105 Selector Cable Installation Note 1. Install the selector cable to the selector lever certainly. 2. Install the selector cable to the bracket certainly. Note •...
Page 536 AUTOMATIC TRANSAXLE SHIFT MECHANISM Caution SPRING • Bending the selector cable in the manner UPWARD shown in the figure will damage the cable and it may become loose when shifted. When installing the selector cable, hold it straight. Note SELECTOR CABLE •...
Page 537: Selector Lever Disassembly/Assembly
AUTOMATIC TRANSAXLE SHIFT MECHANISM SELECTOR LEVER DISASSEMBLY/ASSEMBLY A6E571646102203 1. Disassemble in the order shown in the figure. 2. Assemble in the reverse order of disassembly. A6E5716W106 Selector lever knob Selector illumination light Indicator panel Selector lever End Of Sie K2–122...
Page 538: On-Board Diagnostic
ON-BOARD DIAGNOSTIC ON-BOARD DIAGNOSTIC FOREWORD A6E577018901201 • When the customer reports vehicle malfunction, check the malfunction indicator lamp (MIL) indication, AT warning indication, and diagnostic trouble code (DTC), then diagnose the malfunction according to following flowchart. — If the DTC exists, diagnose the applicable DTC inspection. (See K2–126 DTC TABLE.) —...
Page 539: After Repair Procedure
ON-BOARD DIAGNOSTIC AFTER REPAIR PROCEDURE A6E577018901203 Caution • After repairing a malfunction, perform this procedure to verify that the malfunction has been corrected. • When this procedure is carried out, be sure to drive the vehicle at lawful speed and pay attention to the other vehicles.
Page 540 ON-BOARD DIAGNOSTIC • For P0740 i. Start the engine. ii. Warm up the engine and ATX. iii. Drive vehicle under the following conditions for 10 seconds or more. — Vehicle speed (VSS PID): 76 km/h {47 mph} — Selector lever position: D range —...
Page 541 ON-BOARD DIAGNOSTIC DTC TABLE A6E577018901204 *Monitor Memory DTC No. Condition warning Page item function light Transaxle range (TR) switch circuit malfunction (See K2–127 P0705 (power short circuit) P0705) Transaxle range (TR) switch circuit malfunction (See K2–129 P0706 (Open/ground short circuit) P0706) Transaxle fluid temperature (TFT) sensor (See...
Page 542: Dtc P0705
ON-BOARD DIAGNOSTIC DTC P0705 A6E577018901205 DTC P0705 Transaxle range (TR) switch circuit malfunction (short circuit) • Two or more range signals are input from TR switch for 5 seconds or more. Diagnostic support note: • This is a continuous monitor (CCM). •...
Page 543 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION VERIFY CURRENT INPUT SIGNAL STATUS-IS Yes Go to next step. CONCERN INTERMITTENT OR CONSTANT? Go to intermittent concern troubleshooting procedure. • Connect volt meter to TCM. (See section F1.) • Turn ignition key to ON (engine OFF). •...
Page 544: Dtc P0706
ON-BOARD DIAGNOSTIC DTC P0706 A6E577018901206 DTC P0706 Transaxle range (TR) switch circuit malfunction (open/ground short circuit) • No range signal is input from TR switch for 100 seconds or more. Diagnostic support note: • This is a continuous monitor (CCM). •...
Page 545 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to available repair information. AVAILABILITY • If vehicle is not repaired, go to next step. • Check for related Service Bulletins and/or on- line repair information availability. Go to next step.
Page 546 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT PCM CONNECTOR FOR POOR Yes Go to next step. CONNECTION Repair terminals, then go to Step 12. • Turn ignition key to OFF. • Check for poor connection (damaged pulled- out terminals, corrosion, etc.). •...
Page 547: Dtc P0711
ON-BOARD DIAGNOSTIC DTC P0711 A6E577018901207 DTC P0711 Transaxle fluid temperature (TFT) sensor malfunction (stuck) • TFT sensor signal stays outside normal temperature range for 10 minute or more. Diagnostic support note: • This is a continuous monitor (CCM). • MIL illuminates if TCM detects the above malfunction conditions in two consecutive drive cycles. DETECTION •...
Page 548: Dtc P0712
ON-BOARD DIAGNOSTIC DTC P0712 A6E577018901208 DTC P0712 Transaxle fluid temperature (TFT) sensor circuit malfunction (short to ground) • Signal from TFT sensor is 0.088 V or less for 20 seconds or more. Diagnostic support note: • This is a continuous monitor (CCM). •...
Page 549 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT TERMINAL CONDITION Yes Repair or replace terminals, then go to Step 9. • If terminals cannot be repaired, replace harness, then • Turn ignition key to OFF. • Disconnect terminal component No.2. go to Step 9. •...
Page 550: Dtc P0713
ON-BOARD DIAGNOSTIC DTC P0713 A6E577018901209 DTC P0713 Transaxle fluid temperature (TFT) sensor circuit malfunction (open circuit) • Vehicle speed is 20 km/h {12.4 mph} or greater, and signal from TFT sensor is 2.4 V or above for 300 seconds or more. Diagnostic support note: •...
Page 551 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT TERMINAL COMPONENT NO.2 (8- Yes Go to next step. PIN) FOR POOR CONNECTION Repair or replace connector and/or terminal, then go to • Turn ignition key to OFF. Step 11. • Inspect terminal component No.2 (8-pin) connection.
Page 552: Dtc P0715
ON-BOARD DIAGNOSTIC DTC P0715 A6E577018901210 DTC P0715 Input/turbine speed sensor circuit malfunction • The following condition is detected twice: — Input/turbine speed sensor signal is 600 rpm or less while engine speed is 1,500 rpm or greater and vehicle speed is 40 km/h {24.8 mph} or greater in D range. Diagnostic support note: •...
Page 553 ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to next step. RECORDED Record FREEZE FRAME PID DATA on repair order, then • Has FREEZE FRAME PID DATA been go to next step. recorded? VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to available repair information.
Page 554: Dtc P0720
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT INPUT/TURBINE SPEED SENSOR Yes Go to next step. CONNECTOR FOR POOR CONNECTION Repair terminals, then go to Step 12. • Disassemble the transaxle. • Disconnect input/turbine speed sensor connector. • Check for poor connection (damaged, pulled- out terminals, corrosion, etc.).
Page 555 ON-BOARD DIAGNOSTIC DTC P0720 Vehicle speedometer sensor (VSS) malfunction (open/short) TERMINAL COMPONENT HARNESS SIDE CONNECTOR NO.2(8-PIN) HARNESS SIDE CONNECTOR COUPLER COMPONENT (8-PIN) HARNESS SIDE CONNECTOR PART SIDE CONNECTOR Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to next step. RECORDED Record FREEZE FRAME PID DATA on repair order, then •...
Page 556 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT VEHICLE SPEEDOMETER SENSOR Yes Go to next step. RESISTANCE Go to Step 8 • Measure resistance between terminal component No.2 (8-pin) (transaxle case side). • Is resistance within 513—627 ohms between terminal component No.2 (8-pin) terminal A and B (transaxle case side)? INSPECT TCM CONNECTOR FOR POOR Yes Go to next step.
Page 557: Dtc P0740
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION VERIFY TROUBLESHOOTING OF DTC P0720 Yes Replace TCM, then go to next step. (See K2–96 TCM REMOVAL/INSTALLATION.) COMPLETED • Make sure to reconnect all disconnected Go to next step. connectors. • Clear DTC from memory using WDS or equivalent.
Page 558 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT LINE PRESSURE Yes Go to next step. • Start engine. All ranges: Replace or overhaul oil pump or control valve • Measure line pressure. body, then go to Step 10. Specification Any ranges: Replace or overhaul automatic transaxle, then —...
Page 559: Dtc P0743
ON-BOARD DIAGNOSTIC DTC P0743 A6E577018901213 DTC P0743 Torque converter clutch (TCC) solenoid valve circuit malfunction (open/short) • Open or short in TCC solenoid signal system (while TCM monitors solenoid output voltage, the voltage that differs from the ON/OFF signal output by CPU in TCM is detected). Diagnostic support note: •...
Page 560 ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to next step. RECORDED Record FREEZE FRAME PID DATA on repair order, then • Has FREEZE FRAME PID DATA been go to next step. recorded? VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to available repair information.
Page 561: Dtc P0748
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT TERMINAL COMPONENT NO.1 (12- Yes Go to next step. PIN) CIRCUIT FOR SHORT TO POWER Repair or replace harness, then go to Step 13. • Turn ignition key to ON (engine OFF). • Check voltage at terminal component No.1 (12- pin) terminal H (harness-side).
Page 562 ON-BOARD DIAGNOSTIC DTC P0748 Pressure control solenoid circuit malfunction (open/short) PRESSURE CONTROL SOLENOID TERMINAL COMPONENT NO.1(12-PIN) HARNESS SIDE CONNECTOR HARNESS SIDE CONNECTOR COUPLER COMPONENT PRESSURE CONTROL (10-PIN) SOLENOID PART SIDE CONNECTOR HARNESS SIDE CONNECTOR Diagnostic procedure STEP INSPECTION ACTION VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to available repair information.
Page 563 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT RESISTANCE Yes Go to Step 8. • Check resistance between terminal component Go to next step. No.1 (12-pin) terminal D (transaxle case side) and body ground. • Is resistance within 2.6—3.2 ohms? (See K2–88 SOLENOID VALVE INSPECTION.) INSPECT COUPLER COMPONENT (10-PIN) Yes Go to next step.
Page 564: Dtc P0751
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION VERIFY AFTER REPAIR PROCEDURE Yes Go to applicable DTC inspection. • Perform “After Repair Procedure”. Troubleshooting completed. (See K2–124 AFTER REPAIR PROCEDURE.) • Is there any DTC present? End Of Sie DTC P0751 A6E577018901215 DTC P0751 Shift solenoid A malfunction (stuck off) •...
Page 565: Dtc P0752
ON-BOARD DIAGNOSTIC DTC P0752 A6E577018901216 DTC P0752 Shift solenoid A malfunction (stuck on) • Difference between actual gear ratio and gear ratio set in TCM is large. Diagnostic support note: • This is a continuous monitor (CCM). • MIL illuminates if TCM detects the above malfunction. DETECTION •...
Page 566: Dtc P0753
ON-BOARD DIAGNOSTIC DTC P0753 A6E577018901217 DTC P0753 Shift solenoid A circuit malfunction (open/short) • Open or short in shift solenoid A signal system (while TCM monitors solenoid output voltage, the voltage that differs from the ON/OFF signal output by CPU in TCM is detected). Diagnostic support note: •...
Page 567 ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to next step. RECORDED Record FREEZE FRAME PID DATA on repair order, then • Has FREEZE FRAME PID DATA been go to next step. recorded? VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to available repair information.
Page 568: Dtc P0756
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT TERMINAL COMPONENT NO.1 (12- Yes Go to next step. PIN) CIRCUIT FOR SHORT TO POWER Repair or replace harness, then go to Step 13. • Turn ignition key to ON (engine OFF). • Check voltage at terminal component No.1 (12- pin) terminal I (harness-side).
Page 569: Dtc P0757
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION CHECK ATF CONDITION Yes replace control valve body, then go to next step. • Turn ignition key to OFF. If ATF color milky or reddish brown, reaper or replace ATX, • Check ATF condition. then go to next step. —...
Page 570: Dtc P0758
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION VERIFY TROUBLESHOOTING OF DTC P0757 Yes Replace TCM, then go to next step. (See K2–96 TCM REMOVAL/INSTALLATION.) COMPLETED. • Make sure to reconnect all disconnected Go to next step. connectors. • Clear DTC from memory using WDS or equivalent.
Page 571 ON-BOARD DIAGNOSTIC DTC P0758 Shift solenoid B circuit malfunction (open/short) SHIFT SOLENOID B TERMINAL COMPONENT HARNESS SIDE CONNECTOR NO.1(12-PIN) HARNESS SIDE CONNECTOR COUPLER COMPONENT SHIFT SOLENOID B (10-PIN) HARNESS SIDE CONNECTOR PART SIDE CONNECTOR Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to next step.
Page 572 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT TERMINAL COMPONENT NO.1 (12- Yes Go to next step. PIN) FOR POOR CONNECTION Repair or replace terminals, then go to Step 13. • Turn ignition key to OFF. • Disconnect terminal component No.1 (12-pin). •...
Page 573: Dtc P0761
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION VERIFY TROUBLESHOOTING OF DTC P0758 Yes Replace TCM, then go to next step. (See K2–96 TCM REMOVAL/INSTALLATION.) COMPLETED • Make sure to reconnect all disconnected Go to next step. connectors. • Clear DTC from memory using WDS or equivalent.
Page 574: Dtc P0762
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION VERIFY AFTER REPAIR PROCEDURE Yes Go to applicable DTC inspection. • Perform “After Repair Procedure”. Troubleshooting completed. (See K2–124 AFTER REPAIR PROCEDURE.) • Is there any DTC present? End Of Sie DTC P0762 A6E577018901222 DTC P0762 Shift solenoid C malfunction (stuck on) •...
Page 575: Dtc P0763
ON-BOARD DIAGNOSTIC DTC P0763 A6E577018901223 DTC P0763 Shift solenoid C circuit malfunction (open/short) • Open or short in shift solenoid C signal system (while TCM monitors solenoid output voltage, the voltage that differs from the ON/OFF signal output by CPU in TCM is detected). Diagnostic support note: •...
Page 576 ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to next step. RECORDED No Record FREEZE FRAME PID DATA on repair order, then • Has FREEZE FRAME PID DATA been go to next step. recorded? VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to available repair...
Page 577 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT TERMINAL COMPONENT NO.1 (12- Yes Go to next step. PIN) CIRCUIT FOR SHORT TO POWER No Repair or replace harness, then go to Step 13. • Turn ignition key to ON (engine OFF). • Check voltage at terminal component No.1 (12- pin) terminal F (harness-side).
Page 578: Dtc P0768
ON-BOARD DIAGNOSTIC DTC P0768 A6E577018901224 DTC P0768 Reduction timing solenoid valve circuit malfunction (open/short) • Open or short in reduction timing solenoid signal system (while TCM monitors solenoid output voltage, the voltage that differs from the ON/OFF signal output by CPU in TCM is detected.) Diagnostic support note: •...
Page 579 ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to available repair information. AVAILABILITY • If vehicle is not repaired, go to next step. • Check for related Service Bulletins and/or on- line repair information availability.
Page 580 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT TCM CIRCUIT FOR SHORT TO Yes Repair or replace harness, then go to next step. GROUND Go to next step. • Turn ignition key to OFF. • Check continuity between TCM terminal 2G (harness-side) and body ground. •...
Page 581: Dtc P0773
ON-BOARD DIAGNOSTIC DTC P0773 A6E577018901225 DTC P0773 Neutral shift solenoid valve circuit malfunction (open/short) • Open or short in neutral shift solenoid signal system (while TCM monitors solenoid output voltage, the voltage that differs from the ON/OFF signal output by CPU in TCM is detected). Diagnostic support note: •...
Page 582 ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to available repair information. AVAILABILITY • If vehicle is not repaired, go to next step. • Check for related Service Bulletins and/or on- line repair information availability.
Page 583 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT TCM CIRCUIT FOR SHORT TO Yes Repair or replace harness, then go to next step. GROUND Go to next step. • Turn ignition key to OFF. • Check continuity between TCM terminal 2D (harness-side) and body ground. •...
Page 584: Dtc P0778
ON-BOARD DIAGNOSTIC DTC P0778 A6E577018901226 DTC P0778 2-4 brake solenoid valve circuit malfunction (open/short) • Open or short in 2-4 brake solenoid signal system (while TCM monitors solenoid output voltage, the voltage that differs from the ON/OFF signal output by CPU in TCM is detected). Diagnostic support note: •...
Page 585 ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to available repair information. AVAILABILITY • If vehicle is not repaired, go to next step. • Check for related Service Bulletins and/or on- line repair information availability.
Page 586 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT TCM CIRCUIT FOR SHORT TO Yes Repair or replace harness, then go to next step. GROUND Go to next step. • Turn ignition key to OFF. • Check continuity between TCM terminal 2V (harness-side) and body ground. •...
Page 587: Dtc P0791
ON-BOARD DIAGNOSTIC DTC P0791 A6E577018901227 DTC P0791 Intermediate sensor circuit malfunction (open/short) • Rotation speed of output gear (intermediate sensor) is low when vehicle speed and engine speed exceed the preprogrammed value. Diagnostic support note: • This is continuous monitor (CCM). DETECTION •...
Page 588 ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to next step. RECORDED Record FREEZE FRAME PID DATA on repair order, then • Has FREEZE FRAME PID DATA been go to next step. recorded? VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to available repair information.
Page 589 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT INTERMEDIATE SENSOR Yes Go to next step. CONNECTOR FOR POOR CONNECTION Repair terminals, then go to Step 12. • Disassemble the transaxle. • Disconnect intermediate sensor connector. • Check for poor connection (damaged, pulled- out terminals, corrosion, etc.).
Page 590: Dtc P0798
ON-BOARD DIAGNOSTIC DTC P0798 A6E577018901228 DTC P0798 High clutch solenoid valve circuit malfunction (open/short) • Open or short is high clutch solenoid signal system (while TCM monitors solenoid output voltage, the voltage that differs from the ON/OFF signal output by CPU in TCM is detected). Diagnostic support note: •...
Page 591 ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to available repair information. AVAILABILITY • If vehicle is not repaired, go to next step. • Check for related Service Bulletins and/or on- line repair information availability.
Page 592 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT TCM CIRCUIT FOR SHORT TO Yes Repair or replace harness, then go to next step. GROUND Go to next step. • Turn ignition key to OFF. • Check continuity between TCM terminal 2U (harness-side) and body ground. •...
Page 593: Dtc P1710
ON-BOARD DIAGNOSTIC DTC P1710 A6E577018901229 DTC P1710 GND return circuit malfunction • TCM detects open circuit in GND return signal line from solenoid valve. Diagnostic support note: • This is a diagnostic support DTC (monitored one per key cycle). • MIL does not illuminate. DETECTION •...
Page 594 ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to available repair information. AVAILABILITY • If vehicle is not repaired, go to next step. • Check for related Service Bulletins and/or on- line repair information availability.
Page 595: Pid/Data Monitor Inspection
ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION VERIFY AFTER REPAIR PROCEDURE Yes Go to applicable DTC inspection. • Perform “After Repair Procedure”. Troubleshooting completed. (See K2–124 AFTER REPAIR PROCEDURE.) • Is there any DTC present? End Of Sie PID/DATA MONITOR INSPECTION A6E577018901230 1.
Page 596 ON-BOARD DIAGNOSTIC Monitor item Unit/ Condition/Specification Action (Definition) Condition terminal SSB/SS2 Inspect shift solenoid B. N position: ON (Shift solenoid ON/OFF (See K2–88 SOLENOID VALVE – D range 4GR: OFF INSPECTION.) SSC/SS3 Inspect shift solenoid C. N position: ON (Shift solenoid ON/OFF (See K2–88 SOLENOID VALVE...
Page 597: Troubleshooting
TROUBLESHOOTING TROUBLESHOOTING FOREWORD A6E578001030201 • Refer to Section GI and thoroughly read and understand the basic flow of troubleshooting in order to properly perform the procedure. End Of Sie AUTOMATIC TRANSAXLE BASIC INSPECTION A6E578001030202 STEP INSPECTION ACTION • Turn ignition switch to ON. Yes Go to next step.
Page 598: Automatic Transaxle Symptom Troubleshooting
TROUBLESHOOTING AUTOMATIC TRANSAXLE SYMPTOM TROUBLESHOOTING A6E578001030203 Diagnostic Index • Use the chart below to verify the symptoms of the trouble in order to diagnose the appropriate area. TROUBLESHOOTING ITEM DESCRIPTION PAGE • Vehicle does not move in D range, • Vehicle does not move when accelerator (See K2–188 NO.1 VEHICLE or in R position...
Page 599: 17 Excessive Shift Shock
TROUBLESHOOTING TROUBLESHOOTING ITEM DESCRIPTION PAGE • Excessive shift shock from N to D • Strong shock felt when shifting from N to (See K2–196 NO.17 or N to R position/range D or N to R position/range at idle. EXCESSIVE SHIFT SHOCK FROM N TO D OR N TO R POSITION/RANGE.) •...
Page 600 TROUBLESHOOTING Quick Diagnosis Chart Vehicle dose not move in D range, or in R position Vehicle moves in N position Vehicle moves in P position, or parking gear does not disengage when P is disengaged Excessive creep No creep at all Low maximum speed and poor acceleration No shifting Does not shift to fifth gear (5GR)
Page 601 TROUBLESHOOTING Vehicle dose not move in D range, or in R position Vehicle moves in N position Vehicle moves in P position, or parking gear does not disengage when P is disengaged Excessive creep No creep at all Low maximum speed and poor acceleration X X X No shifting Does not shift to fifth gear (5GR)
Page 602 TROUBLESHOOTING Vehicle dose not move in D range, or in R position Vehicle moves in N position Vehicle moves in P position, or parking gear does not disengage when P is disengaged Excessive creep No creep at all Low maximum speed and poor acceleration X X X No shifting Does not shift to fifth gear (5GR)
Page 603 TROUBLESHOOTING NO.1 VEHICLE DOES NOT MOVE IN D RANGE, OR IN R POSITION A6E578001030204 Vehicle does not move in D range, or in R position • Vehicle does not move when accelerator pedal depressed. DESCRIPTION • If vehicle does not move in D range or R position, basically, malfunction is in ATX. (Vehicle will move even with a malfunction in TCM.) Since a malfunction in sensor circuit or output circuit is cause of malfunction in ATX, inspect sensors, output circuit, and related harnesses.
Page 604 TROUBLESHOOTING Diagnostic procedure STEP INSPECTION ACTION • Does vehicle creep when selector lever • Overhaul control valve body and repair or replace any moved slightly in N position? defective parts. (See ATX Workshop Manual.) — If problem remains, replace or overhaul transaxle and repair or replace any defective parts.
Page 605 TROUBLESHOOTING Diagnostic procedure STEP INSPECTION ACTION • Does vehicle creep in P and/or N position? Yes Inspect or adjust the selector lever. (See K2–117 SELECTOR LEVER INSPECTION.) (See K2–118 SELECTOR CABLE ADJUSTMENT.) Go to next step. • Stop engine. Yes Go to next step. •...
Page 606 TROUBLESHOOTING STEP INSPECTION ACTION • Stop engine. Yes Go to next step. • Inspect shift solenoid A, B, or C. • Inspect for shift solenoid mechanical stuck. • Are they okay? (See K2–88 SOLENOID VALVE INSPECTION.) — If shift solenoids okay, inspect for open or short circuit between TCM connector terminals 2W, 2T, 2X and pressure control solenoid connector terminals I, G, or •...
Page 607 TROUBLESHOOTING NO.8 DOES NOT SHIFT TO FIFTH GEAR (5GR) A6E578001030211 Does not shift to fifth gear (5GR) • Vehicle does not upshift from 4GR to 5GR even though vehicle speed increased. DESCRIPTION • Vehicle does not shift to 5GR even though accelerator pedal released in D range at 60 km/h {37 mph}. •...
Page 608 TROUBLESHOOTING STEP INSPECTION ACTION • Verify test results. — If okay, return to diagnostic index to service any additional symptoms. — If malfunction remains, inspect related Service Informations and perform repair or diagnosis. — If vehicle repaired, troubleshooting completed. — If vehicle not repaired or additional diagnostic information not available, replace TCM. End Of Sie NO.9 ABNORMAL SHIFTING A6E578001030212...
Page 609 TROUBLESHOOTING NO.11 SHIFT POINT IS HIGH OR LOW A6E578001030214 Shift point is high or low • Shift point considerably different from automatic shift diagram. • Shift delays when accelerating. DESCRIPTION • Shift occurs quickly when accelerating and engine speed does not increase. •...
Page 610 TROUBLESHOOTING End Of Sie NO.13 NO KICKDOWN A6E578001030216 No kickdown • Does not downshift when accelerator pedal fully depressed within kickdown range. DESCRIPTION • If transaxle does not downshift though shifting is normal, malfunction is in TP sensor circuit (including sensor ground, sensor harness and connector).
Page 611 TROUBLESHOOTING NO.15 ENGINE FLARES UP OR SLIPS WHEN ACCELERATING VEHICLE A6E578001030218 Engine flares up or slips when accelerating vehicle • Engine flares up when accelerator pedal depressed for upshifting. DESCRIPTION • Engine flares up suddenly when accelerator pedal depressed for downshifting. •...
Page 612 TROUBLESHOOTING STEP INSPECTION ACTION • Is line pressure okay? Yes Go to next step. (See K2–72 Line Pressure Test.) Repair or replace any defective parts according to inspection results. • Is stall speed okay? Yes Go to next step. (See K2–74 Stall Speed Test.) Go to Step 6.
Page 613: No.21 Noise Occurs At Idle When Vehicle Is Stopped In D Range, Or In R Position
TROUBLESHOOTING NO.20 NOISE OCCURS AT IDLE WHEN VEHICLE IS STOPPED IN ALL POSITIONS/RANGES A6E578001030223 Noise occurs at idle when vehicle is stopped in all positions/ranges • Transaxle noisy in all positions and ranges when vehicle idling. DESCRIPTION • Malfunction is in pressure solenoid or oil pump which causes a high-pitched noise to be emitted from transaxle at idle.
Page 614: No.23 Transaxle Overheats
TROUBLESHOOTING STEP INSPECTION ACTION • Do following symptoms concurrently occur? Yes Go to symptom troubleshooting No.14 “Engine flares up or — Engine flares up or slips during slips when upshifting or downshifting” or No.15 “Engine acceleration flares up or slips when accelerating vehicle”. —...
Page 615: No.25 Engine Stalls When Driving At Slow Speed Or Stopping
TROUBLESHOOTING Diagnostic procedure STEP INSPECTION ACTION • Go to symptom troubleshooting No.4 Yes Go to next step. “Engine stalls-after start/at idle”. Repair or replace any defective parts according to (See Section F.) inspection results. • Is engine control system okay? •...
Page 616: No.28 Gear Position Indicator Light Illuminates In D Range Or In P, N, R Positions
TROUBLESHOOTING STEP INSPECTION ACTION • Inspect MNL SW PID value using WDS or Yes Inspect instrument cluster. equivalent. Inspect M range switch. • Are these PIDs okay? If M range switch is okay, inspect for continuity between M range switch and TCM terminal 1AA. •...
Page 617 P ROPELLER SHAFT FEATURES OUTLINE ..............L-2 OUTLINE OF CONSTRUCTION......L-2 FEATURES ............L-2 SPECIFICATIONS ..........L-2 SERVICE LOCATION INDEX ..........L-3 PROPELLER SHAFT INDEX....... L-3 PROPELLER SHAFT ..........L-4 PROPELLER SHAFT INSPECTION ON VEHICLE ......L-4 PROPELLER SHAFT REMOVAL/INSTALLATION ......L-5 PROPELLER SHAFT DISASSEMBLY/ASSEMBLY ......
Page 618 • The Mazda6 4WD model has been adopted for European specs. End Of Sie FEATURES A6E610225002203 Reduced noise and vibration • The four-joint type propeller shaft with two bearing support has been adopted for the Mazda6 4WD model. End Of Sie SPECIFICATIONS A6E610225002202 Item Specification 720.5...
Page 619 LOCATION INDEX LOCATION INDEX PROPELLER SHAFT INDEX A6E610001036201 A6E6100W001 Propeller shaft (See L–4 PROPELLER SHAFT INSPECTION ON VEHICLE) (See L–5 PROPELLER SHAFT REMOVAL/ INSTALLATION) (See L–7 PROPELLER SHAFT DISASSEMBLY/ ASSEMBLY) (See L–14 PROPELLER SHAFT INSPECTION) End Of Sie L–3...
Page 620 PROPELLER SHAFT PROPELLER SHAFT PROPELLER SHAFT INSPECTION ON VEHICLE A6E611025002204 Joint Play Inspection 1. Move the joint shaft by hand, and verify that there is no play. If there is play, perform the following service operations. • Yoke : Universal joint replacement (See L–7 PROPELLER SHAFT DISASSEMBLY/ASSEMBLY.) •...
Page 621 PROPELLER SHAFT End Of Sie PROPELLER SHAFT REMOVAL/INSTALLATION A6E611025002201 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. 49—58 {4.2—5.9, 36—42} 37.3—52.0 {3.81—5.30, 27.6—38.3} 49—58 {4.2—5.9, 36—42} 37.3—52.0 {3.81—5.30, 27.6—38.3} N·m {kgf·m, ft·lbf} A6E6110W001 Propeller shaft heat shield (See...
Page 622 PROPELLER SHAFT Nut Removal Note Caution • Do not mark with the ponch to prevent unbalance. 1. Before removing the nut, put marks on the front companion flange, tripod joint and the rear companion flange, rear universal joint yoke for proper reinstallation.
Page 623 PROPELLER SHAFT Propeller Shaft Installation Note 1. Align the mark made during removal, and install the propeller shaft. Front side A6J6110W006 2. Installing a new propeller shaft, align the differential companion flange precast marking with the tag on the propeller shaft. MARK A6E6110W002 End Of Sie...
Page 624 PROPELLER SHAFT 157—177 {16.1—18.0, 116—130} 157—177 {16.1—18.0, 116—130} N·m {kgf·m, ft·lbf} A6E6110W003 Snap ring Center yoke (See L–9 Snap Ring Disassembly Note) (See L–10 Center Yoke Disassembly Note) (See L–12 Bearing Cup and Snap Ring Assembly Bearing support Note) (See L–10 Bearing support Disassembly Note) Bearing cup...
Page 625 PROPELLER SHAFT Snap Ring Disassembly Note 1. Mark the yoke and flont propeller shaft or york and rear propeller shaft for proper reassembly. 2. Clamp the propeller shaft in a vise. MARK A6E6110W004 3. Remove the snap ring using a screwdriver. YTA6110W107 Bearing Cup Disassembly Note 1.
Page 626 PROPELLER SHAFT Center Yoke Disassembly Note 1. Remove the center yoke using the SST. Center yoke (front side) 49 0839 425C A6J6110W017 Center yoke (rear side) 49 0839 425C 49 H027 002 A6J6110W011 Bearing support Disassembly Note 1. Remove the bearing support using the SST. 49 0839 425C 49 G030 370 A6J6110W012...
Page 627 PROPELLER SHAFT Bearing Assembly Note 1. Install the bearing onto the bearing support using the SST and a press. 49 G030 797 49 H033 101 49 U027 005 A6J6110W014 Dust Cover Assembly Note 1. Install the dust cover onto the bearing support using the SST and a press.
Page 628 PROPELLER SHAFT Locknut Assembly Note 1. Align the mark on the center yoke and shaft, and MARK install the center yoke. Tightening torque 137—177 N·m {16.1—18.0 kgf·m, 116—130 ft·lbf} A6E6110W005 Bearing Cup and Snap Ring Assembly Note 1. Apply the grease to the bearing rollers inside the bearing cups.
Page 629 PROPELLER SHAFT 5. Measure the bearing cup groove width, and select a new snap ring that thickness is same as the groove to install. Snap ring thickness mm {in} Snap ring Part number Thickness T010 25 071 1.21 {0.0476} T010 25 071B 1.22 {0.0480} T010 25 072 1.23 {0.0484}...
Page 630 PROPELLER SHAFT PROPELLER SHAFT INSPECTION A6E611025002203 1. Disassemble the propeller shaft. 2. Measure the propeller shaft runout with a dial indicator. • If the runout is excessive, replace the propeller shaft. Runout limit 0.3 mm {0.01 in} A6E6110W015 3. Move the universal joint in the direction shown, and inspect joint play.
Page 631: 4Wd Control Modure (4Wd Cm)
FRONT AND REAR AXLES REAR DRIVE SHAFT .......... M-42 FEATURES REAR DRIVE SHAFT PRE-INSPECTION..M-42 REAR DRIVE SHAFT OUTLINE ............... M-2 REMOVAL/INSTALLATION ......M-43 OUTLINE OF CONSTRUCTION ......M-2 REAR DRIVE SHAFT FEATURES ............M-2 DISASSEMBLY/ASSEMBLY ......M-45 SPECIFICATIONS ..........M-2 REAR DIFFERENTIAL ........
Page 632 OUTLINE OUTLINE OF CONSTRUCTION A6E630201018201 • The construction and operation of the front and rear axles is the same as that of the current Mazda6 (GG) model, except for the following features. (See Mazda6 Training Manual 3359-1*-02C.) End Of Sie...
Page 633 OUTLINE Specification Item New Mazda6 (GY)(Wagon 4WD) Engine Transaxle Front axle Bearing type Angular ball bearing Rear axle Bearing type Angular ball bearing Wheel side Bell joint Joint type Front drive shaft Differential side Tripod joint (With free ring) Shaft diameter (mm {in}) 24.0 {0.94}...
Page 634 REAR AXLE REAR AXLE REAR AXLE OUTLINE A6E631401018201 Features Improved drivability • An angular ball bearing, with a low rotational resistance, has been adopted. Improved serviceability • A unit bearing that does not require pre-load setting has been adopted. End Of Sie CROSS-SECTIONAL VIEW A6E631401018202 A6E63142001...
Page 635 DRIVE SHAFT DRIVE SHAFT DRIVE SHAFT OUTLINE A6E631625500201 Features Improved drivability, reduced noise and vibration • Concurrent with the MZR-CD (RF Turbo) engine and 4WD system, the configuration of the front drive shaft and the joint shaft has been optimized. •...
Page 636 REAR DIFFERENTIAL End Of Sie REAR DIFFERENTIAL REAR DIFFERENTIAL OUTLINE A6E631927100201 Features Size and weight reduction • A rear differential with an integrated coupling component has been adopted. • An aluminum differential carrier has been adopted. End Of Sie CROSS-SECTIONAL VIEW A6E631927100202 A6E63192001 Coupling component section...
Page 637 ELECTRONIC 4WD CONTROL SYSTEM ELECTRONIC 4WD CONTROL SYSTEM OUTLINE A6E632227100201 Features Improved off-road mobility, handling stability, operability, fuel economy and marketability • An electronic 4WD control system, which automatically optimizes traction distribution to the front and rear wheels, has been adopted. Improved serviceability •...
Page 638 ELECTRONIC 4WD CONTROL SYSTEM Components and Functions Part name Function • Based on a signal from the 4WD CM, it operates the electromagnetic clutch and Electronic control coupling (4WD solenoid) transmits drive torque to the rear wheels. Differential oil temperature •...
Page 639 ELECTRONIC 4WD CONTROL SYSTEM ELECTRONIC CONTROL COUPLING End Of Sie A6E632227100202 Outline Features • An electromagnetic clutch, which operates smoothly due to the lack influence from the front and rear wheel traction force, has been adopted for the electronic control coupling system. •...
Page 640 ELECTRONIC 4WD CONTROL SYSTEM Operation 4WD solenoid control current is OFF • When the 4WD solenoid control current is OFF, no torque is generated in the pilot clutch because there is no current flowing to the 4WD solenoid. At the same time, the pilot cam and the main cam rotate in the same direction via the balls, and the main cam does not exert any push force on the main clutch side.
Page 641 ELECTRONIC 4WD CONTROL SYSTEM 4WD solenoid control current is ON • When the 4WD solenoid control current is ON, current flows from the 4WD CM to the 4WD solenoid, and the coupling operates in the following manner. 1. Magnetic flux forms at the electromagnetic coil of the 4WD solenoid. 2.
Page 642 ELECTRONIC 4WD CONTROL SYSTEM DIFFERENTIAL OIL TEMPERATURE SENSOR A6E632227100203 Function • The differential oil temperature sensor detects the rear differential oil temperature based on the resistance of the thermistor, and inputs it to the 4WD control modure (4WD CM). Construction/Operation •...
Page 643 ELECTRONIC 4WD CONTROL SYSTEM 4WD CONTROL MODURE A6E632227100205 Function • The 4WD control modure (4WD CM) calculates the optimal amount of torque distribution for the rear wheels and outputs a corresponding electric current to the electronic control coupling (4WD solenoid). This calculation is based on the throttle angle, four-wheel speed, engine speed, selector lever position, and other related input signals, matched with the vehicle driving and road surface conditions.
Page 644 ELECTRONIC 4WD CONTROL SYSTEM 4WD SYSTEM CONTROL End Of Sie A6E632227100206 Outline Features • Based on the inputted signals listed below, the 4WD CM calculates the optimal amount of torque distribution for the rear wheels and outputs a corresponding electric control current to the electronic control coupling (4WD solenoid).
Page 645 ELECTRONIC 4WD CONTROL SYSTEM Operation Normal control • When starting off or accelerating during straight-ahead driving, torque transmitted to the rear wheels is optimally controlled to ensure sufficient acceleration performance. Due to this, standing-start and acceleration performance is improved. • Also, in order to improve fuel economy when driving at a stable, consistent speed, torque transmitted to the rear wheels is damped, and rear-wheel drive is controlled to maintain it close to that of the front wheels.
Page 646 ELECTRONIC 4WD CONTROL SYSTEM ON-BOARD DIAGNOSTIC A6E632227100208 Outline • The on-board diagnostic function allows for detecting malfunctions in the input/output signals when the ignition key is at the ON position. • The DLC-2, which combines the failure detection and detection maintenance connectors, has been adopted to improve serviceability.
Page 647 ELECTRONIC 4WD CONTROL SYSTEM Memory function • This function stores DTCs for malfunctions of the input/output signal systems as determined by the failure detection function. Once a DTC is stored, it is not cleared even if the input/output signal system malfunction returns to normal when the ignition key is turned to the LOCK position (engine OFF).
Page 648 OUTLINE OUTLINE SUPPLEMENTAL SERVICE INFORMATION A6E630201018204 • The following additions have been made since publication of the Mazda6 Workshop Manual (1730-1*-02C). Rear wheel hub bolt • Replacement procedure has been added. Wheel hub, knuckle • Removal/installation procedure has been added.
Page 649: Front Drive Shaft
LOCATION INDEX LOCATION INDEX AXLE/DRIVE SHAFT LOCATION INDEX A6E630025500201 A6J63002001 Wheel hub bolt Front drive shaft (See M–22 WHEEL HUB BOLT REPLACEMENT) (See M–34 FRONT DRIVE SHAFT (MZR-CD (RF Turbo)) DISASSEMBLY/ASSEMBLY) Wheel hub, knuckle (See M–39 FRONT DRIVE SHAFT (4WD) (See M–22 WHEEL HUB, KNUCKLE REMOVAL/ DISASSEMBLY/ASSEMBLY)
Page 650 LOCATION INDEX REAR DIFFERENTIAL/ELECTRONIC 4WD CONTROL SYSTEM LOCATION INDEX A6E630027100201 L.H.D. R.H.D. A6J63002002 Differential oil Differential oil temperature sensor (See M–48 DIFFERENTIAL OIL INSPECTION) (See M–65 DIFFERENTIAL OIL TEMPERATURE (See M–48 DIFFERENTIAL OIL REPLACEMENT) SENSOR INSPECTION) (See M–65 DIFFERENTIAL OIL TEMPERATURE Oil seal (side gear) SENSOR REMOVAL/INSTALLATION)
Page 651 GENERAL PROCEDURES GENERAL PROCEDURES PRECAUTION (FRONT AND REAR AXLE) A6E631001018201 Wheel and Tire Removal/Installation 1. The removal and installation procedures for the wheels and tires are not mentioned in this section. When a wheel is removed, tighten it to 88—118 N·m {9.0—12.0 kgf·m, 65.0—87.0 ft·lbf} Brake Line Disconnection/Connection Caution •...
Page 652 REAR AXLE REAR AXLE WHEEL HUB BOLT REPLACEMENT A6E631405000201 1. Remove the brake caliper component and the disc plate. 2. Remove the wheel hub bolt using the SST as shown in the figure. Note • If the dust cover interferes with the wheel hub bolt and the wheel hub bolt cannot be removed, tap the part shown in the figure with a chisel lightly and bend the process...
Page 653 REAR AXLE 43.1—60.8 {4.4—6.1, 31.8—44.8} 51.0—66.7 {5.3—6.8, 37.7—49.1} 75.5—94.5 {7.7—9.6, 55.7—69.6} 18.6—25.5 {1.90—2.63, 13.8—18.8} 93.2—131.4 {9.6—13.3, 68.8—96.9} 86.2—116.6 {8.8—11.9, 63.6—85.9} 86.2—116.6 {8.8—11.9, 63.6—85.9} 75.5—94.5 {7.7—9.6, 55.7—69.6} 235.2—318.5 {24.0—32.4, 173.5—234.9} 86.2—116.6 {8.8—11.9, 63.6—85.9} N·m {kgf·m, ft·lbf} A6E63142101 Bolt (lateral link (outer)) ABS wheel-speed sensor (See M–24 Bolt (Lateral Link (Outer)) Removal...
Page 654 REAR AXLE Dust cover Wheel hub bolt (See M–26 Dust Cover Removal Note) (See M–26 Wheel Hub Bolt Removal Note) (See M–27 Dust Cover Installation Note) (See M–26 Wheel Hub Bolt Installation Note) Knuckle Locknut Removal Note 1. Knock the crimped portion of the locknut outward using a small chisel and a hammer.
Page 655 REAR AXLE Bolt (Trailing Link (Front)) Removal Note Warning • Be sure that the trailing link and the knuckle component are supported securely with a jack. Otherwise, the trailing link and/or the knuckle component may fall, causing death or injury, or vehicle damage.
Page 656 REAR AXLE Dust Cover Removal Note Note • The dust cover does not need to be removed unless it is being replaced. 1. Mark the dust cover and knuckle for proper installation. 2. Remove the dust cover from the knuckle using a chisel.
Page 657 REAR AXLE Dust Cover Installation Note 1. Mark the new dust cover in the same way as the removed one. 2. Align the marks of the new dust cover and the knuckle. A6J63142107 3. Install the new dust cover to the knuckle using the STEEL SSTs.
Page 658 REAR AXLE Bolt (Trailing Link (Front)) Installation Note Warning • Be sure that the trailing link and the knuckle component are supported securely with a jack. Otherwise, the trailing link and/or the knuckle component may fall, causing death or injury, or vehicle damage.
Page 659: Front Drive Shaft
FRONT DRIVE SHAFT FRONT DRIVE SHAFT JOINT SHAFT (MZR-CD (RF TURBO)) DISASSEMBLY/ASSEMBLY A6E631525700201 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. A6E63152001 Joint shaft Dust seal (Left) (See M–29 Joint Shaft Disassembly Note) (See M–30 Dust Seal (Differential Side) Assembly...
Page 660 FRONT DRIVE SHAFT Dust Seal (Wheel Side) Assembly Note 1. Apply grease to the new dust seal lip. 2. Install the new dust seal (wheel side) using the SSTs. 49 F027 003 49 B025 004 A6E63152004 Bearing Assembly Note 1. Install the new bearing using the SSTs. 49 F027 003 49 F027 005 49 S231 626...
Page 661 FRONT DRIVE SHAFT JOINT SHAFT (4WD) DISASSEMBLY/ASSEMBLY A6E631525700202 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. A6J63152001 Dust seal (Differential side) Joint shaft (See M–32 Dust Seal (Differential Side) Assembly (See M–31 Joint Shaft Disassembly Note) Note)
Page 662 FRONT DRIVE SHAFT When the bearing remains on the shaft 1. Remove the bearing from the joint shaft using the SST. 49 H027 002 A6J63152003 Dust Seal (Wheel Side) Assembly Note 1. Apply grease to the new dust seal lip. 2.
Page 663 FRONT DRIVE SHAFT Joint Shaft Assembly Note 1. Assemble the joint shaft using a press and the SST. JOINT SHAFT 49 S231 626 A6E0313W029 End Of Sie M–33...
Page 664 FRONT DRIVE SHAFT FRONT DRIVE SHAFT (MZR-CD (RF TURBO)) DISASSEMBLY/ASSEMBLY A6E631525500201 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. A6E6316W009 Boot band (wheel side) Inner Ring (See M–35 Boot Band (Wheel Side) Disassembly (See M–36 Balls, Inner Ring, Cage Disassembly Note)
Page 665 FRONT DRIVE SHAFT Boot Band (Wheel Side) Disassembly Note Note • The boot band does not need to be removed unless it is being replaced. 1. Remove the boot clamp with end clamp pliers as shown and discard the clamp. A6E6316W004 Boot Band (Transaxle Side) Disassembly Note 1.
Page 666 FRONT DRIVE SHAFT Balls, Inner Ring, Cage Disassembly Note 1. Mark the inner ring and cage. Caution • Mark with paint; do not use a punch. 2. Remove the snap ring using snap-ring pliers. 3. Turn the cage approximately 22.5 degree and 22.5°...
Page 667 FRONT DRIVE SHAFT Dynamic Damper Assembly Note 1. Install the dynamic damper as shown in the figure. Standard length 334.7—340.7 mm {13.2—13.4 in} 2. Install the new boot band onto the dynamic damper. DYNAMIC DAMPER A6E6316W006 Boot Assembly Note Note •...
Page 668 FRONT DRIVE SHAFT Standard length mm {in} Left side Right side 666.3—676.3 615.6—625.6 {26.24—26.62} {24.24—24.62} 6. Release any trapped air from the boots by carefully lifting up the small end of each boot with a cloth wrapped screwdriver. Caution • Be careful not to allow the grease to leak. •...
Page 669 FRONT DRIVE SHAFT 4. Fill the boot with the repair kit grease. 5. Adjust clearance A by turning the adjusting bolt of the SST. Clearance A 3.2 mm {0.13 in} 6. Crimp the wheel side big boot band using the SST. 7.
Page 670 FRONT DRIVE SHAFT Outer Ring Disassembly Note 1. Mark the outer ring and the shaft for proper assembly. MARK 2. Remove the outer ring. A6E0313W046 Snap Ring, Tripod Joint Disassembly Note 1. Mark the shaft and tripod joint for proper assembly. 2.
Page 671 FRONT DRIVE SHAFT Dynamic Damper Assembly Note 1. Install the dynamic damper as shown in the figure. DYNAMIC DAMPER Standard length Left side: 281.7—287.7 mm {11.10—11.32 in} Right side: 334.7—340.7 mm {13.2—13.4 in} 2. Install a new boot band onto the dynamic damper. A6E6316W006 Boot Assembly Note Note...
Page 672: Rear Drive Shaft
FRONT DRIVE SHAFT, REAR DRIVE SHAFT Standard length mm {in} Left side Right side 667—677 631—641 {26.26—26.65} {24.85—25.23} 4. Release any trapped air from the boots by carefully lifting up the small end of each boot with a cloth wrapped screwdriver. Caution •...
Page 673: Rear Drive Shaft Removal/Installation
REAR DRIVE SHAFT REAR DRIVE SHAFT REMOVAL/INSTALLATION A6E631725500202 Caution • Performing the following procedures without first removing the ABS wheel-speed sensor may possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the following procedures, remove the ABS wheel-speed sensor (wheel side) and fix it to an appropriate place where the sensor will not be pulled by mistake while the vehicle is being serviced.
Page 674 REAR DRIVE SHAFT Rear Drive Shaft Removal Note 1. Deform the metal cover of the oil seal using a bar, and disengage the drive shaft. Note • Oil seal cannot be reused. Always replace the oil seal with a new one. A6J63172201 Clip Installation Note 1.
Page 675 REAR DRIVE SHAFT REAR DRIVE SHAFT DISASSEMBLY/ASSEMBLY A6E631725500203 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. A6J63172003 Boot band (wheel side) Balls (See M–35 Boot Band (Wheel Side) Disassembly (See M–46 Balls, Inner Ring, Cage Disassembly Note) Note) (See...
Page 676 REAR DRIVE SHAFT Clip Disassembly Note 1. Mark the drive shaft and outer ring for proper MARK assembly. Caution • Mark with paint; do not use a punch. 2. Remove the clip. A6E6316W010 Snap Ring Disassembly Note 1. Mark the drive shaft end and inner ring for proper reassembly.
Page 677 REAR DRIVE SHAFT Boot Assembly Note Note • The wheel side and differential side boots are different. 1. Fill the wheel side boot with the specified grease. Caution • Do not touch grease with your hand. Apply it from the tube to prevent foreign matter from entering the boot.
Page 678 REAR DRIVE SHAFT, REAR DIFFERENTIAL 5. Release any trapped air from the boots by carefully lifting up the small end of each boot with a cloth wrapped screwdriver. Caution • Do not let grease leak. • Do not damage the boot. 6.
Page 679 REAR DIFFERENTIAL OIL SEAL (SIDE GEAR) REPLACEMENT End Of Sie A6E631927100205 1. Remove the drain plug and the drain differential oil into a container. 2. Install a new washer and the drain plug, and tighten. 3. Remove the rear drive shaft. (See M–43 REAR DRIVE SHAFT REMOVAL/INSTALLATION.) 4.
Page 680 REAR DIFFERENTIAL 5. After removing the front side of the differential mount, gradually lower the jack and tilt the front side of the differential downward. DIFFERENTIAL JACK A6E63192042 6. Pull the companion flange off using the SST. 7. Remove the oil seal from the differential carrier 49 0839 425C using a screwdriver or similar tool.
Page 681: Rear Differential Removal/Installation
REAR DIFFERENTIAL REAR DIFFERENTIAL REMOVAL/INSTALLATION A6E631927100207 1. Drain the rear differential oil into a container. 2. Remove the after silencer, presilencer, and catalytic converter. (See F1–30 EXHAUST SYSTEM REMOVAL/ INSTALLATION.) 3. Remove the propeller shaft. (See L–5 PROPELLER SHAFT REMOVAL/INSTALLATION.) 4.
Page 682 REAR DIFFERENTIAL Coupling Component and Rear Differential Component Removal/installation Note Warning • Make sure that the coupling component and rear differential component are securely supported by the jack. If the coupling component and rear differential component fall, it could cause death, serious injury, or vehicle damage.
Page 683 REAR DIFFERENTIAL Differential oil temperature sensor Bearing inner race (rear bearing) (See M–54 Bearing Inner Race (Rear Bearing) Rear cover Disassembly Note) (See M–53 Rear Cover Disassembly Note) Spacer Bearing cap (See M–53 Bearing Cap Disassembly Note) Bearing outer race (See M–55 Bearing Outer Race Disassembly Note)
Page 684 REAR DIFFERENTIAL Rear Differential Component Disassembly Note 1. Remove the rear differential component using the SSTs. 49 T032 317 2. Mark or otherwise distinguish between the removed left and right adjusting shims, spacers and side bearing outer races so that they are not 49 T032 316 mixed up at the time of reassembly.
Page 685 REAR DIFFERENTIAL Bearing Outer Race Disassembly Note 1. Remove the bearing outer races using the 2 grooves in the carrier and alternately tapping the sides of the races with a brass bar. A6A63192016 Ring Gear Disassembly Note 1. Secure the gear case in a vice and remove the bolts.
Page 686 REAR DIFFERENTIAL REAR DIFFERENTIAL ASSEMBLY A6E631927100209 Warning • The engine stand is equipped with a self-lock mechanism, however, if the rear differential is in a tilted condition, the self-lock mechanism could become inoperative. If the rear differential unexpectedly rotates it could cause injury, therefore do not maintain the rear differential in a tilted condition.
Page 687 REAR DIFFERENTIAL Adjusting shim (L) Bearing cap (See M–61 Adjusting Shim Assembly Note) (See M–63 Bearing Cap Assembly Note) Spacer Rear cover (See M–64 Rear Cover Assembly Note) Side bearing outer race Differential oil temperature sensor Rear differential component Oil seal Adjusting shim (R) (See M–64 Oil Seal Assembly...
Page 688 REAR DIFFERENTIAL Ring Gear Assembly Note Caution • The differential gear and ring gear could be damaged if the ring gear is installed with old thread- locking compound remaining on the bolt threads. Before installing the ring gear, completely remove the old thread-locking compound from the bolt threads. 1.
Page 689 REAR DIFFERENTIAL Spacer, Bearing Inner Race Assembly Note Pinion height adjustment Note • Use the same spacer. • Install the spacer with the chamfer on the SST side. 1. Assemble the spacer, the bearing inner race (rear bearing), and the SST O-ring to the SST (49 8531 49 G027 004 565) as shown in the figure.
Page 690 REAR DIFFERENTIAL 9. Add the two (left and right) values obtained by the measurements taken in Step 8 and then divide the total by 2. From this result, subtract the result obtained by dividing the number inscribed on the end surface of the drive pinion by 100. (If there is no figure inscribed, use 0.) This is the pinion height adjustment value.
Page 691 REAR DIFFERENTIAL Locknut Assembly Note Drive pinion preload adjustment 1. Apply differential oil to a new locknut. 2. Assemble a new collapsible spacer, bearing inner race (front bearing), and locknut to the drive pinion, and temporarily tighten the locknut. 3. Turn the serrated part of the drive pinion by hand to seat the bearing. 4.
Page 692 REAR DIFFERENTIAL Adjusting shim thickness Identification mark Thickness (mm {in}) Identification mark Thickness (mm {in}) 7.00 {0.276} 7.50 {0.295} 7.05 {0.278} 7.55 {0.297} 7.10 {0.279} 7.60 {0.299} 7.15 {0.281} 7.65 {0.301} 7.20 {0.283} 7.70 {0.303} 7.25 {0.285} 7.75 {0.305} 7.30 {0.287} 7.80 {0.307} 7.35 {0.289} 7.85 {0.309}...
Page 693 REAR DIFFERENTIAL Bearing Cap Assembly Note 1. Align the bearing cap alignment marks to assemble the bearing cap. Tightening torque 37—51 N·m {3.8—5.2 kgf·m, 28—37 ft·lbf} 2. Inspect the drive pinion and ring gear teeth contact points. MARK A6E63192037 (1) Coat both surfaces of the ring gear uniformly with a thin red lead coating.
Page 694 REAR DIFFERENTIAL Rear Cover Assembly Note Caution • Clean away the old sealant before applying the new sealant. • Install the rear differential within 10 minutes after applying sealant. • Allow the sealant to set at least 30 minutes after installation before filling the differential with the specified oil.
Page 695 ELECTRONIC 4WD CONTROL SYSTEM ELECTRONIC 4WD CONTROL SYSTEM DIFFERENTIAL OIL TEMPERATURE SENSOR INSPECTION A6E632227100209 Warning • Hot differential oil may cause severe burns. Do not perform maintenance while differential oil is hot. 1. Disconnect the negative (-) battery cable. 2. Disconnect the differential oil temperature sensor connector and remove the differential oil temperature sensor. 3.
Page 696 ELECTRONIC 4WD CONTROL SYSTEM 4WD SOLENOID INSPECTION A6E632227100211 1. Disconnect the negative (-) battery cable. 2. Disconnect the 4WD solenoid connector. 3. Measure resistance between 4WD solenoid connector terminals A and B. • If the resistance is not within the specification, replace the coupling unit.
Page 697 ELECTRONIC 4WD CONTROL SYSTEM Input/ Connected Measuring Voltage (V)/ Inspection location Terminal Signal Test condition output item Continuity in case of failure • Inspect fuse Power supply Ignition key ON • Inspect related (Ignition Input Ignition key Voltage Ignition key OFF 1.0 or below switch) harness...
Page 698 ELECTRONIC 4WD CONTROL SYSTEM COUPLING COMPONENT REMOVAL/INSTALLATION A6E632227100214 1. Drain the differential oil into a container. 2. Remove the after silencer, presilencer, and the catalytic converter. (See F1–30 EXHAUST SYSTEM REMOVAL/INSTALLATION.) 3. Remove the propeller shaft. (See L–5 PROPELLER SHAFT REMOVAL/INSTALLATION.) 4.
Page 699: Coupling Component Disassembly
ELECTRONIC 4WD CONTROL SYSTEM 1. Apply sealant to the coupling case surface that contacts the rear differential case. 2. Install the coupling unit to the rear differential so that the two tabs on the coupling unit engage the rear differential grooves (two locations). Tightening torque 22.6—26.4 N·m {2.4—2.6 kgf·m, 16.7—19.4 ft·lbf}...
Page 700 ELECTRONIC 4WD CONTROL SYSTEM Locknut Disassembly Note 1. Assemble the SSTs to the engine stand. 49 L027 0A2 49 0107 680A A6J63222110 2. Install the coupling unit to the SSTs as shown. 49 L027 0A2 A6J63222111 3. Secure the companion flange using the SST, and remove the locknut.
Page 701 ELECTRONIC 4WD CONTROL SYSTEM Output Shaft Disassembly Note 1. Remove the coupling unit from the SST. 2. Install the coupling unit to the press as shown, and remove the output shaft together with the coupling unit. 3. Install the companion flange to the output shaft. A6J63222114 4.
Page 702: Coupling Component Assembly
ELECTRONIC 4WD CONTROL SYSTEM COUPLING COMPONENT ASSEMBLY A6E632227100216 Warning • The engine stand is equipped with a self-lock mechanism, however, if the coupling unit is in a tilted condition, the self-lock mechanism could become inoperative. If the coupling unit unexpectedly rotates it could cause injury, therefore do not maintain the coupling unit in a tilted condition.
Page 703 ELECTRONIC 4WD CONTROL SYSTEM Output Shaft Assembly Note 1. Install the output shaft to the coupling unit and partially tighten the bolts. 2. Install the companion flange to the output shaft. 3. Secure the companion flange using the SST, and tighten the bolts.
Page 704 ELECTRONIC 4WD CONTROL SYSTEM Oil Seal Assembly Note 1. Apply the specified oil to a new oil seal lip. 2. Install the oil seal to the coupling case using the SST. "' 9 A6J63222121 Companion Flange Assembly Note 1. Install the coupling case to the SSTs as shown. 2.
Page 705: On-Board Diagnostic
ON-BOARD DIAGNOSTIC ON-BOARD DIAGNOSTIC WIRING DIAGRAM A6E637027100201 ELECTRONIC CONTROL COUPLING IGNITION SWITCH 4WD SOLENOID INSTRUMENT CLUSTER 4WD CM DSC HU/CM BATTERY DIFFERENTIAL OIL TEMPERATURE SENSOR CAN-H CAN-L CAN DRIVER A6E63702002 End Of Sie M–75...
Page 706: Electronic 4Wd Control System On-Board Diagnosis
ON-BOARD DIAGNOSTIC ELECTRONIC 4WD CONTROL SYSTEM ON-BOARD DIAGNOSIS A6E637027100202 Reading DTCs Procedure 1. Connect WDS or equivalent to the vehicle DLC-2 L.H.D. 16-pin connector. 2. Retrieve DTC by WDS or equivalent. • If a DTC is displayed, proceed with inspection steps for that DTC.
Page 707 ON-BOARD DIAGNOSTIC DTC P1887 A6E637027100203 P1887 System wiring • Current detection circuit in 4WD CM detects current above specification for more than specified period. • 4WD CM detects that 4WD solenoid control signal differs from current detected at current detection DETECTION circuit for more than specified period.
Page 708 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT 4WD SOLENOID TO 4WD CM Yes Repair or replace harness for short to ground between 4WD CM and 4WD solenoid, then go to Step 9. (POWER SUPPLY CIRCUIT) FOR SHORT TO GROUND Go to next step. •...
Page 709 ON-BOARD DIAGNOSTIC DTC P1888 A6E637027100204 P1888 Differential oil temperature sensor DETECTION • Differential oil temperature sensor voltage monitor circuit detects abnormal input voltage. CONDITION • Open circuit, or short to battery or GND between 4WD CM terminal A and differential oil temperature sensor terminal A •...
Page 710 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT 4WD CM TO DIFFERENTIAL OIL Yes Repair or replace harness for short to ground between 4WD CM and differential oil temperature sensor, then go to Step TEMPERATURE SENSOR FOR SHORT TO GROUND • Inspect for continuity between 4WD CM Go to next step.
Page 711: System Wiring Diagram
TROUBLESHOOTING TROUBLESHOOTING SYSTEM WIRING DIAGRAM A6E638027100201 ELECTRONIC CONTROL COUPLING IGNITION SWITCH 4WD SOLENOID INSTRUMENT CLUSTER 4WD CM DSC HU/CM BATTERY DIFFERENTIAL OIL TEMPERATURE SENSOR CAN-H CAN-L CAN DRIVER A6E63702002 End Of Sie M–81...
Page 712: Foreword
TROUBLESHOOTING FOREWORD A6E638027100202 Malfunction vehicle delivered Confirm all customer problems using a questionnaire. Questionnaire Confirm malfunction on actual vehicle. Verify malfunction symptoms DTC inspection Inspect for DTCs using WDS or equivalent. Symptom troubleshooting Perform applicable troubleshooting inspection according to diagnostic index. Verify that malfunctions have been repaired Troubleshooting completed A6E63802001...
Page 713: No.2 Tight Corner Braking
TROUBLESHOOTING Diagnostic procedure STEP INSPECTION ACTION VERIFY DSC, PCM, TCM, AND 4WD SYSTEM Yes Go to applicable DTC inspection. DTCs Go to next step. • Verify DSC, PCM, TCM, and 4WD system DTCs using WDS or equivalent. • Are there any DTCs present? VERIFY TIRE AIR PRESSURE Yes Go to next step.
Page 714: No.3 Abnormal Noise And/Or Vibration From Coupling Component
TROUBLESHOOTING STEP INSPECTION ACTION INSPECT 4WD SOLENOID Yes Inspect harness between 4WD solenoid and 4WD CM, then • Inspect 4WD solenoid. go to next step. (See M–66 4WD SOLENOID INSPECTION) Replace coupling component. • Is it okay? End Of Sie NO.3 ABNORMAL NOISE AND/OR VIBRATION FROM COUPLING COMPONENT A6E638027100206 Abnormal noise and/or vibration from coupling component...
Page 715 S TEERING SYSTEM FEATURES OUTLINE ..............N-2 OUTLINE OF CONSTRUCTION......N-2 FEATURES ............N-2 SPECIFICATIONS ..........N-2 STRUCTURAL VIEW...........N-3 SERVICE OUTLINE ..............N-5 SUPPLEMENTAL SERVICE INFORMATION ..........N-5 ENGINE SPEED SENSING POWER STEERING............N-6 POWER STEERING FLUID INSPECTION..N-6 STEERING GEAR AND LINKAGE (MZR-CD (RF TURBO)) REMOVAL/INSTALLATION ......N-8 STEERING GEAR AND LINKAGE (4WD) REMOVAL/INSTALLATION ......N-13 POWER STEERING OIL PUMP...
Page 716 • Due to the addition of the MZR-CD (RF Turbo) engine, a gear-driven power steering oil pump has been adopted. The operation of the oil pump is the same as that of the current Mazda6 (GG). • The disassembly/assembly procedures for the steering gear and linkage of the newly equipped MZR-CD (RF Turbo) engine, wagon and 4WD models are the same as that of the current Mazda6 (GG).
Page 717 OUTLINE STRUCTURAL VIEW A6E660201036204 MZR-CD (RF Turbo) A6E63162001 L.H.D. Steering gear R.H.D. Power steering oil pump Steering wheel Fluid reservoir Steering column and shaft N–3...
Page 718 OUTLINE A6E63162002 L.H.D. Steering gear R.H.D. Power steering oil pump Steering wheel Fluid reservoir Steering column and shaft Cooling pipe End Of Sie N–4...
Page 719 OUTLINE OUTLINE SUPPLEMENTAL SERVICE INFORMATION A6E660201034201 • The following changes have been made since publication of the Mazda6 Workshop Manual (1730-1*-02C). Power steering fluid • Inspection procedure has been modified. Steering gear and linkage (MZR-CD (RF Turbo)) • Removal/installation procedure has been added.
Page 720 ENGINE SPEED SENSING POWER STEERING ENGINE SPEED SENSING POWER STEERING POWER STEERING FLUID INSPECTION A6E661432040201 Fluid Level Inspection 1. Inspect the power steering fluid level. • Add fluid to the specified level as necessary. Fluid specification ® ATF M-III or equivalent (e.g. Dexron Fluid Leakage Inspection Caution •...
Page 721 ENGINE SPEED SENSING POWER STEERING Fluid Pressure Inspection 1. Assemble the SSTs as shown in the figure. 49 1232 670B 49 H002 671 A6E0612W101 2. Disconnect the pressure pipe from the oil pump, MZR-CD (RF Turbo) and connect the SSTs. 49 G032 351 Tightening torque 29.4—44.1 N·m {3.0—4.4 kgf·m, 22—32 ft·lbf}...
Page 722 ENGINE SPEED SENSING POWER STEERING 8. Open the gauge valve fully and increase the GAUGE engine speed to 1,000—1,500 rpm. 9. Turn the steering wheel fully to the left and right, OPEN VALVE COMPLETELY then measure the fluid pressure generated at the THERMOMETER °...
Page 723 ENGINE SPEED SENSING POWER STEERING 18.6—26.5 {1.9—2.7, 13.8—19.5} 74.4—104.8 33.0—44.1 {7.6—10.6, 74.4—104.8 {3.3—4.4, 54.9—77.2} 33.0—44.1 {7.6—10.6, 21.7—32.5} {3.3—4.4, 54.9—77.23} 21.7—32.5} 29.4—44.1 {3.0—4.4, 21.7—32.5} 7.8—10.8 {0.8—1.1, 5.8—7.9} 7.8—10.8 {0.8—1.1, 5.8—7.9} 93.1—116.6 {9.5—11.8, 68.7—85.9} 7.8—10.8 {0.8—1.1, 5.8—7.9} 93.1—131.3 {9.5—13.3, 68.7—96.8} 119.6—154.8 119.6—154.8 93.1—131.3 {9.5—15.7, {9.5—15.7,...
Page 724 ENGINE SPEED SENSING POWER STEERING Bolt (intermediate shaft) removal note 1. Mark the pinion shaft and gear housing for proper installation. MARK A6E0612W084 Tie-rod end ball joint removal note 1. Remove the tie rod-nut. 2. Separate the tie-rod end from the steering knuckle using the SSTs.
Page 725 ENGINE SPEED SENSING POWER STEERING Crossmember bracket removal note Warning • Removing the crossmember is dangerous. The crossmember component could fall and cause serious injury or death. Verify that the jack securely supports the crossmember component before removing the crossmember bracket. 1.
Page 726 ENGINE SPEED SENSING POWER STEERING R.H.D. 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. 3. After installation, inspect the toe-in. 18.6—26.5 {1.9—2.7, 74.4—104.8 13.8—19.5} {7.6—10.6, 54.9—77.2} 7.8—10.8 {0.8—1.1, 5.8—7.9} 33.0—44.1 {3.3—4.4, 33.0—44.1 21.7—32.5} {3.3—4.4,...
Page 727 ENGINE SPEED SENSING POWER STEERING STEERING GEAR AND LINKAGE (4WD) REMOVAL/INSTALLATION A6E661432960202 Caution • Performing the following procedures without first removing the ABS wheel-speed sensor may possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate place where the sensor will not be pulled by mistake while servicing the vehicle.
Page 728 ENGINE SPEED SENSING POWER STEERING 74.4—104.8 L.H.D {7.6—10.6, 54.9—77.2} 7.8—10.8 {0.8—1.1, 5.8—7.9} 7.8—10.8 {0.8—1.1, 29.4—44.1 5.8—7.9} {3.0—4.4, 21.7—32.5} 74.4—104.8 18.6—26.5 R.H.D {7.6—10.6, {1.9—2.7, 54.9—77.2} 13.8—19.5} 29.4—44.1 7.8—10.8 {3.0—4.4, {0.8—1.1, 21.7—32.5} 5.8—7.9} 33.0—44.1 {3.4—4.4, 24.4—32.5} 33.0—44.1 {3.4—4.4, 74.4—104.8 24.4—32.5} {7.6—10.6, 54.9—77.2} 93.1—116.6 {9.5—11.8, 68.7—85.9}...
Page 729 ENGINE SPEED SENSING POWER STEERING Bolt (intermediate shaft) No.1 engine mount center bolt (See N–10 Bolt (intermediate shaft) removal note) (See N–15 No.1 Engine Mount Center Bolt Removal (See N–11 Bolt (intermediate shaft) installation Note) note) Crossmember bracket Cotter pin (See N–11 Crossmember bracket removal note)
Page 730 ENGINE SPEED SENSING POWER STEERING POWER STEERING OIL PUMP (MZR-CD (RF TURBO)) REMOVAL/INSTALLATION A6E661432650201 1. Remove the air cleaner. 2. Remove the battery and battery tray. 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal. 18.6—25.5 {1.90—2.60, 13.8—18.8}...
Page 731 ENGINE SPEED SENSING POWER STEERING POWER STEERING OIL PUMP (MZR-CD (RF TURBO)) DISASSEMBLY/ASSEMBLY A6E661432650202 Note • The following procedure is for replacement of the O-ring and oil seal only. Replace the pump component if other repairs are necessary. 1. Disassemble in the order indicated in the table. 2.
Page 732 ENGINE SPEED SENSING POWER STEERING Rear pump body Rotor (See N–19 Rear Pump Body Assembly Note) Vane Gasket (See N–18 Vane Assembly Note) Cam ring Side plate (See N–19 Cam Ring Assembly Note) Power steering oil pump Power Steering Oil Pump Component Disassembly Note 1.
Page 733 ENGINE SPEED SENSING POWER STEERING Cam Ring Assembly Note 1. Install the cam ring in the front pump body with the mark facing upward. A6E6316W014 Rear Pump Body Assembly Note 1. After installing the rear body, manually turn the shaft to verify that it rotates smoothly. Clip Assembly Note 1.
Page 734 B RAKING SYSTEM FEATURES OUTLINE ..............P-2 OUTLINE OF CONSTRUCTION......P-2 FEATURES ............P-2 SPECIFICATIONS ..........P-2 STRUCTURAL VIEW...........P-3 ABS/TCS ..............P-4 OUTLINE..............P-4 DYNAMIC STABILITY CONTROL ......P-6 OUTLINE..............P-6 COMBINE SENSOR (FORWARD-G SENSOR) ......... P-8 CONTROLLER AREA NETWORK (CAN) ...P-8 ON-BOARD DIAGNOSTIC ........P-9 OUTLINE..............P-9 SERVICE...
Page 735: Outline
OUTLINE OF CONSTRUCTION A6E690201020201 • The construction and operation of the braking system is the same as that of the current Mazda6 (GG) L8, LF, L3 engine 2WD model, except for the following features. (See Mazda6 Training Manual 3359-1*-02C.) End Of Sie...
Page 736 OUTLINE STRUCTURAL VIEW A6E690201020204 A6E6902W201 L.H.D. Without ABS R.H.D. Dual proportioning valve Brake pedal ABS (ABS/TCS) or DSC HU/CM Master cylinder ABS wheel-speed sensor (front) Power brake unit ABS sensor rotor (front) Front brake (disc) ABS wheel-speed sensor (rear) Rear brake (disc) ABS sensor rotor (rear) Vacuum pump Combine sensor...
Page 737: Outline
OUTLINE A6E692146444201 • The construction and operation of ABS (ABS/TCS) is the same as that of the current Mazda6 (GG) L8, LF, L3 engine 2WD model, except for the following. (See Mazda6 Training Manual 3359-1*-02C.) — Due to adoption of TCM, ABS (ABS/TCS) HU/CM sends 4-wheel speed signal to the TCM through CAN.
Page 738 ABS/TCS System Diagram ABS/TCS HU/CM A6E6921W201 IG switch Cruise actuator SUS 15 A fuse TCS OFF switch ABS 60 A fuse DLC-2 Meter CAN-H ABS warning light CAN-L Brake system warning light ABS Wheel-speed sensor TCS OFF light Battery TCS indicator light Brake switch CAN driver Audio unit, Wiper and washer switch, Car-navigation...
Page 739 DYNAMIC STABILITY CONTROL DYNAMIC STABILITY CONTROL OUTLINE A6E692067650201 • The construction and operation of DSC is the same as that of the current Mazada6 2WD model, except for the following: — Due to the addition the 4WD model, DSC HU/CM uses the foward-G signal from the combine sensor to control DSC.
Page 740 DYNAMIC STABILITY CONTROL Wiring Diagram DSC HU/CM A6E6921W203 IG switch DLC-2 SUS 15A fuse CAN-H ABS 60 A fuse CAN-L Meter Wheel-speed sensor ABS warning light Combine sensor Brake system warning light Steering angle sensor DSC OFF light Brake switch DSC indicator light Brake light CAN driver...
Page 741: Combine Sensor
DYNAMIC STABILITY CONTROL End Of Sie COMBINE SENSOR (FORWARD-G SENSOR) A6E692067650202 Function • The forward-G sensor is integrated with the combine sensor to detect and calculate the vehicle forward-G force and change in voltage to the DSC HU/CM. Structure/Operation • The drive train of 4WD vehicles delivers driving force to all four wheels, and due to this interlocking, the speed of all wheels during braking is the same.
Page 742: On-Board Diagnostic
A6E697043000201 • The operation of the on-board diagnostic system for ABS (ABS/TCS) or DSC is the same as that of the current Mazda6 (GG) L8, LF, L3 engine 2WD model, except for the following. (See Mazda6 Training Manual 3359-1*-02C.) — Due to the addition of the 4WD model, DTCs and PID data monitor has been added.
Page 743: Supplemental Service Information
OUTLINE , GENERAL PROCEDURES OUTLINE SUPPLEMENTAL SERVICE INFORMATION A6E690201020205 • The following changes have been made since publication of the Mazda6 Workshop Manual (1730-1*-02C). Power brake unit • Removal/installation procedure has been modified. Vacuum switch (MZR-CD (RF Turbo)) • Inspection procedure has been added.
Page 744: Conventional Brake System
CONVENTIONAL BRAKE SYSTEM CONVENTIONAL BRAKE SYSTEM POWER BRAKE UNIT REMOVAL/INSTALLATION A6E691243800201 1. Remove the master cylinder. 2. Remove the wiper arm. 3. Remove the cowl grille. 4. Remove the wiper motor. 5. Remove the cowl panel. 6. For L.H.D. and R.H.D. (MZR-CD (RF Turbo) only), remove the A/C bracket. 7.
Page 745: Vacuum Switch Removal/Installation
CONVENTIONAL BRAKE SYSTEM VACUUM SWITCH REMOVAL/INSTALLATION (MZR-CD (RF TURBO)) A6E691266390202 1. Remove in the order indicated in the table. Connector Vacuum switch (See P–12 Vacuum Switch Installation Note) 2. Install in the reverse order of removal. 19.6—24.5 {2.00—2.49, 14.5—18.0} SEALANT SEALANT N·m {kgf·m, ft·lbf} A6E6912W205...
Page 746: Vacuum Pump Removal/Installation
CONVENTIONAL BRAKE SYSTEM VACUUM PUMP REMOVAL/INSTALLATION (MZR-CD (RF TURBO)) A6E691218777202 1. Remove in the order indicated in the table. Vacuum hose Bolt Vacuum pump (See P–13 Vacuum Pump Installation Note) O-ring 18.6—25.5 2. Install in the reverse order of removal. {1.90—2.60, 13.8—18.8} N·m {kgf·cm, in·lbf}...
Page 747: Front Brake (Disc) Removal/Installation
CONVENTIONAL BRAKE SYSTEM FRONT BRAKE (DISC) REMOVAL/INSTALLATION A6E691233980202 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. 3. After installation, depress the pedal a few times, rotate the wheel by hand, and verify that the brake does not drag.
Page 748 CONVENTIONAL BRAKE SYSTEM Disc Plate Removal Note 1. Mark the wheel hub bolt and disc plate before removal for reference during installation. MARK A6E6912W037 Disc Plate Installation Note 1. Remove any rust or grime on the contact face of the disc plate and wheel hub. 2.
Page 749: Disc Pad (Front) Replacement
CONVENTIONAL BRAKE SYSTEM DISC PAD (FRONT) REPLACEMENT A6E691233630201 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. 18.5—25.5 {1.89—2.60, 13.7—18.8} 18.5—25.5 {1.89—2.60, 13.7—18.8} RUBBER GREASE L8, LF (GCC SPECS.): 44.1—49.0 {4.47—4.99, 32.4—36.1} LF (EUROPEAN (L.H.D.
Page 750: Parking Brake (Lever Type) Adjustment
DYNAMIC STABILITY CONTROL PARKING BRAKE SYSTEM, PARKING BRAKE SYSTEM PARKING BRAKE (LEVER TYPE) ADJUSTMENT A6E691444000201 1. Start the engine and depress the brake pedal several times. 2. Stop the engine. 3. For the 2WD model, remove the rear ashtray case behind the center console 4.
Page 751 DYNAMIC STABILITY CONTROL Terminal Signal Connected to Test condition Voltage (V) Action Vehicle is stopped 0 (AC) • Inspect related harness • Inspect using the wave profile. RR wheel- • Inspect wheel-speed RR wheel-speed speed sensor (See P–19 Inspection Using An sensor Oscilloscope (Reference))
Page 752 DYNAMIC STABILITY CONTROL Terminal Signal Connected to Test condition Voltage (V) Action • Inspect related harness When auto cruise is ON Below 1.0 Auto cruise set Auto cruise unit • Inspect DSC HU/CM signal output When auto cruise is OFF —...
Page 753: Combine Sensor
DYNAMIC STABILITY CONTROL Vehicle speed output • DSC HU/CM terminal: AE (+) — A(-) • Oscilloscope setting: 1 V/DIV (Y), 5 ms/DIV (X), DC range • Vehicle condition: Driving 30 km/h (18.6 mph) Note • As vehicle speed increases, period of wave shortens.
Page 754: On-Board Diagnostic
ON-BOARD DIAGNOSTIC ON-BOARD DIAGNOSTIC DSC ON-BOARD DIAGNOSIS A6E697067650201 DTC Table Note • There is no change except for the code marked with an asterisk * Diagnosis system component WDS or equivalent B1318 DSC power supply B1342 DSC HU/CM B1483 Stop switch signal (with DSC only) B1484 Stop switch signal (with DSC only) B1486...
Page 755 ON-BOARD DIAGNOSTIC Diagnosis system component WDS or equivalent C1730 Combine sensor (with DSC only) C1949* Combine sensor (with DSC only) C1950* Combine sensor (with DSC only) C1951 Combine sensor (with DSC only) C1952 Combine sensor (with DSC only) C1953 Brake fluid pressure sensor (with DSC only) C1954 Brake fluid pressure sensor (with DSC only) C1955...
Page 756 ON-BOARD DIAGNOSTIC ABS (ABS/ PID Name TCS) HU/CM or Unit/Condition Condition/Specification Action (Definition) DSC HU/CM terminal • Pump motor is activated: Inspect DSC HU/CM PMPSTAT ON/OFF — • Pump motor is deactivated: (Pump motor output state) • Brake fluid is above LOW: Inspect brake fluid BRK_FLUID (with DSC only) level.
Page 757 ON-BOARD DIAGNOSTIC ABS (ABS/ PID Name TCS) HU/CM or Unit/Condition Condition/Specification Action (Definition) DSC HU/CM terminal • During ABS control: ON/ Internal fault of ABS (ABS/TCS) or DSC ABSRF_I (solenoid valve is activated/ HU/CM. Replace ABS (Right front ABS pressure ON/OFF deactivated) (ABS/TCS) or DSC...
Page 758 ON-BOARD DIAGNOSTIC ABS (ABS/ PID Name TCS) HU/CM or Unit/Condition Condition/Specification Action (Definition) DSC HU/CM terminal • Torque reduction is not Inspect DSC HU/CM. TCSOUTD requested: 0 % • Torque reduction is (Torque reduction request PERCENTAGE — value) requested: Changes between 0 % and 100 % •...
Page 759 ON-BOARD DIAGNOSTIC DTC C1119 A6E697067650202 C1119 Engine control system, torque reduction inhibit signal line • Engine RPM information through CAN is out of specification • Throttle information through CAN is out of specification DETECTION • Fuel injection information through CAN is invalid or out of specification (for MZR-CD (RF Turbo) only). CONDITION •...
Page 760: Dtc C1949, C1950
ON-BOARD DIAGNOSTIC Diagnostic procedure STEP INSPECTION ACTION CHECK FOR PCM FOR DTCs Yes Follow inspection procedures for engine control system. • Turn ignition key to OFF. Go to next step. • Connect WDS or equivalent to DLC-2 • Turn ignition key to ON (engine OFF). •...
Page 761 ON-BOARD DIAGNOSTIC DSC HU/CM COMBINE SENSOR REGULATOR DSC HU/CM HARNESS SIDE CONNECTOR SST (49 G066 004) B C D E F G H I J COMBINE SENSOR HARNESS SIDE CONNECTOR Diagnostic procedure STEP INSPECTION ACTION INSPECT COMBINE SENSOR POWER Yes Go to next step. SUPPLY CIRCUIT FOR OPEN CIRCUIT Repair or replace harness for open circuit between combine •...
Page 762 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT FORWARD-G SENSOR PART Yes Go to next step. SIGNAL CIRCUIT FOR OPEN CIRCUIT Repair or replace harness for open circuit between DSC • Inspect continuity between DSC HU/CM HU/CM terminal V and combine sensor terminal A, then go terminal V (harness side) and combine to Step 8.
Page 763 SUSPENSION FEATURES OUTLINE ..............R-2 OUTLINE OF CONSTRUCTION......R-2 FEATURES ............R-2 SPECIFICATIONS ..........R-3 STRUCTURAL VIEW...........R-4 REAR SUSPENSION ..........R-5 SUSPENSION CONTROL SYSTEM ....R-5 SERVICE OUTLINE ..............R-7 SUPPLEMENTAL SERVICE INFORMATION ..R-7 WHEEL ALIGNMENT..........R-8 FRONT WHEEL ALIGNMENT (WGN)....R-8 REAR WHEEL ALIGNMENT (WGN) ....R-9 REAR SUSPENSION ...........R-11 SUSPENSION CONTROL SYSTEM ON-VEHICLE INSPECTION (WGN) ....R-11 REAR SHOCK ABSORBER...
Page 764 OUTLINE OUTLINE OF CONSTRUCTION A6E740201013201 • The construction and operation of suspension system is essentially carried over from that of the current Mazda6 (GG), except for the following features. (See Mazda6 Training Manual 3359-1*-02C.) End Of Sie FEATURES A6E740201013202 Improved Handling Stability and Riding Comfort •...
Page 765 OUTLINE SPECIFICATIONS A6E740201013203 Specification Current Item New Mazda6 Mazda6 GG (4SD, 5HB) GY (WGN 2WD) GY (WGN 4WD) GG (4SD, 5HB) L8, LF, L3, LF, MZR-CD Engine type MZR-CD (RF L8, LF, L3 (RF Turbo) Turbo) Type High-mount double wishbone (with double-pivoted lower arm(s))
Page 766 OUTLINE STRUCTURAL VIEW A6E740201013204 REAR SUSPENSION (4WD) A6E74162013 Rear crossmember mounting bushing Rear lateral link Rear crossmember Rear stabilizer Rear shock absorber View from vehicle rear side Rear upper arm Rear coil spring Bound stopper (body side) Bound stopper (spring side) Rear trailing arm Rear lower arm End Of Sie...
Page 767 REAR SUSPENSION REAR SUSPENSION SUSPENSION CONTROL SYSTEM A6E741601013201 Outline • The self-leveling suspension is a system that adjusts the vehicle height according the amount of vehicle load. This system will raise the rear of a vehicle, lowered due to a load placed on it, to the designated load level after the vehicle has been driven a certain distance.
Page 768 REAR SUSPENSION Operation During leveling operation • During shock absorber expansion, the inlet check valve opens due to negative pressure created in the pump chamber, and oil is drawn into the pump chamber from the low-pressure chamber. During shock absorber contraction, oil pressure in the pump chamber forces the outlet check valve to open, and oil in the pump chamber flows through the pump cylinder into the high-pressure chamber.
Page 769 End Of Sie OUTLINE SUPPLEMENTAL SERVICE INFORMATION A6E740201013205 • The following changes have been made since publication of the Mazda6 Workshop Manual (1730-1*-02C). Front wheel alignment (WGN) • Specifications have been added. Rear wheel alignment (WGN) • Specifications have been added.
Page 770 WHEEL ALIGNMENT WHEEL ALIGNMENT FRONT WHEEL ALIGNMENT (WGN) A6E741201015201 Specification (Unloaded)* Fuel gauge indication Item Empty Full Inner 39°±3° Maximum steering angle Outer 31°±3° (mm {in}) Tire: 2±4 {0.08±0.16}, Rim inner: 1±3 {0.04±0.12} Total toe-in (degree) 0°11′±0°22′ normal 3°30'±1° 3°32'±1° 3°34'±1°...
Page 771 WHEEL ALIGNMENT Total Toe-in Adjustment 1. Center the steering wheel and confirm that the vehicle wheels/tires are pointing straight. 2. Loosen the left and right tie-rod end locknuts and turn the tie-rods equally. Both tie rods are right threaded, so turning the right tie-rod toward the front of the vehicle and the left toward the rear increases toe-in.
Page 772 WHEEL ALIGNMENT Total Toe-in Adjustment 1. Loosen the locknut of the lateral link. A6E7412W004 2. Adjust the toe-in turning the adjusting link. Specification Total Toe-in: 2±4 mm {0.08±0.16 in} Note • Toe change amount: 0°43′ / one rotation A6E7412W005 3. Tighten the locknut. Tightening torque 68.6—98.1 N·m {7.0—10.0 kgf·m, 50.6—72.3 ft·lbf}...
Page 773 REAR SUSPENSION REAR SUSPENSION SUSPENSION CONTROL SYSTEM ON-VEHICLE INSPECTION (WGN) A6E741601013202 1. Pull up the dust boot and visually inspect the piston rod for oil leakage. 2. Remove all cargo and drive the vehicle, with only the driver aboard, for 1 km {0.62 miles} or more. After driving, verify that the rear vehicle height (distance measured from the fender brim to the center of the wheel) is 360 mm {14.2 in} or more .
Page 774 REAR SUSPENSION Bracket Installation Note 1. Install the bracket as shown in the figure. ° 106.5—112.5 A6J74162006 End Of Sie REAR SHOCK ABSORBER DISPOSAL (WGN) A6E741628700202 1. Lay the shock absorber on a level, horizontal surface. 2. Using a 2—3 mm {0.08—0.12 in} drill bit, drill a hole in the high-pressure side (area indicated by A), and allow the gas to escape.
Page 775 REAR SUSPENSION REAR STABILIZER REMOVAL/INSTALLATION (4WD) A6E741628100201 1. Remove the rear auto leveling sensor. (See T–20 REAR AUTO LEVELING SENSOR REMOVAL/INSTALLATION.) 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. 4. Adjust the headlight zeroset. 43.1—60.8 {4.40—6.19, 43.1—60.8...
Page 776 REAR SUSPENSION Bolt (Differential Front Side) Installation Note 1. Support the differential with a jack, and then install the bolt. JACK 2. Connect differential oil temperature sensor connector and 4WD solenoid connector. A6E74162011 End Of Sie TRAILING LINK REMOVAL/INSTALLATION (4WD) A6E741628200201 Caution •...
Page 777 REAR SUSPENSION 18.6—25.5 {1.90—2.60, 13.8—18.8} 18.6—25.5 {1.90—2.60, 13.8—18.8} 93.2—131.4 {9.51—13.39, 68.75—96.91} 86.2—116.6 {8.80—11.88, 63.58—85.99} 86.2—116.6 86.2—116.6 {8.80—11.88, {8.80—11.88, 63.58—85.99} 63.58—85.99} N·m {kgf·m, ft·lbf} A6E74162008 ABS wheel-speed sensor Bolt (Lateral link outer side) (See R–16 Bolt (Lateral Link Outer Side) Removal Parking brake cable Note) Bolt (shock absorber lower side)
Page 778 REAR SUSPENSION Bolt (Trailing Link Front Side) Removal Note 1. Support the trailing link with a jack. Caution • Removing the trailing link is dangerous. The trailing link could fall and cause serious injury or death. Verify that the jack securely supports the trailing link. 2.
Page 779 REAR SUSPENSION 43.1—60.8 {4.40—6.19, 31.8—44.8} RUBBER GREASE 86.2—116.6 43.1—60.8 {8.80—11.88, 63.58—85.99} 93.1—131.3 {4.40—6.19, 31.8—44.8} {9.50—13.38, 86.2—116.6 68.67—96.84} {8.80—11.88, 63.58—85.99} 75.5—94.5 {7.70—9.63, 55.7—69.6} 86.2—116.6 {8.80—11.88, 63.58—85.99} 93.1—131.3 {9.50—13.38, 86.2—116.6 68.67—96.84} 86.2—116.6 {8.80—11.88, {8.80—11.88, 63.58—85.99} 63.58—85.99} 43.1—60.8 {4.40—6.19, 31.8—44.8} 86.2—116.6 {8.80—11.88, 63.58—85.99} 86.2—116.6 {8.80—11.88, N·m {kgf·m, ft·lbf}...
Page 780 REAR SUSPENSION Crossmember component, Differential And Drive Shaft Removal Note 1. Support the differential with a jack, and remove the nut. Warning • Removing the crossmember component, differential and drive shaft is dangerous. The crossmember component, differential and drive shaft could fall and JACK cause serious injury or death.
Page 781 REAR SUSPENSION 2. Tap the bushing onto the rear crossmember using the SSTs. 49 G033 102 49 G033 106 A6E7416W002 End Of Sie R–19...
Page 782 B ODY TONNEAU COVER ANCHOR FEATURES REMOVAL/INSTALLATION ......S-25 HEADLINER ............S-26 OUTLINE ..............S-2 HEADLINER REMOVAL/INSTALLATION ..S-26 OUTLINE OF CONSTRUCTION ......S-2 FLOOR COVERING ..........S-27 FEATURES ............S-2 FRONT FLOOR COVERING EXTERIOR ATTACHMENT........S-2 REMOVAL/INSTALLATION ......S-27 OUTLINE .............
Page 783 OUTLINE OUTLINE OF CONSTRUCTION A6E770201086201 • The construction and operation of the body system is essentially carried over from that of the current Mazda6 (GG) model, except for the following features. (See Mazda6 Training Manual 3359-1*-02C) End Of Sie FEATURES...
Page 784 TRIM TRIM OUTLINE A6E774468320202 • A tonneau cover with an attached net has been adopted. By extending this cover and net, the privacy of the cargo compartment can be maintained, the cargo and passenger compartments can be partioned, and cargo or luggage can be kept from falling into the passenger compartment.
Page 785 SEAT End Of Sie SEAT OUTLINE A6E775257100201 • A fixed rear seat cushion has been adopted. (4WD WGN) End Of Sie STRUCTURAL VIEW A6E775257100202 A6E77521101 Full flat fold down function (except 4WD WGN) Rear seat back Fold down function (4WD WGN) Rear seat cushion End Of Sie S–4...
Page 786 OUTLINE OUTLINE SUPPLEMENTAL SERVICE INFORMATION A6E770201086203 • The following changes and/or additions have been made since publication of the Mazda6 Workshop Manual (1730-1*-02C). Liftgate • Removal/Installation procedure has been modified. • Disassembly/Assembly procedure has been modified. • Adjustment procedure has been modified.
Page 787 LOCATION INDEX LOCATION INDEX EXTERIOR A6E770001086201 A6E77001102 Rear spoiler Rear drain hose (See S–11 REAR SPOILER REMOVAL/ (See S–20 REAR DRAIN HOSE REMOVAL) INSTALLATION) Side window glass Rear window glass (See S–14 SIDE WINDOW GLASS REMOVAL) (See S–16 REAR WINDOW GLASS REMOVAL) (See S–14 SIDE WINDOW GLASS...
Page 788 LOCATION INDEX INTERIOR A6E770001086202 A6E77001104 Liftgate side trim Rear seat (See S–24 LIFTGATE SIDE TRIM REMOVAL/ (See S–29 REAR SEAT REMOVAL/ INSTALLATION) INSTALLATION) (See S–30 REAR SEAT DISASSEMBLY/ C-pillar trim ASSEMBLY) (See S–21 C-PILLAR TRIM REMOVAL/ INSTALLATION) Floor covering (See S–27 FRONT FLOOR COVERING D-pillar trim REMOVAL/INSTALLATION)
Page 789 LIFTGATE LIFTGATE LIFTGATE REMOVAL/INSTALLATION A6E772262010201 Warning • Removing the stay damper without supporting the liftgate can be dangerous. The liftgate may fall and injure you. Open the liftgate fully and support it before removing the stay damper. 1. Disconnect the negative battery cable. 2.
Page 790 LIFTGATE 9. To remove the stay damper, remove the bolt B. 10. Install in the reverse order of removal. BOLT B 8.8—12.7 HINGE {90—130, 78—112} STAY DAMPER BOLT A 32.4—48.5 N·m 7.8—10.8 {3.3—4.9 kgf·m, {80—110, 70—95} 24—35 ft·lbf} N·m {kgf·cm, in·lbf} A6E77221102 End Of Sie LIFTGATE DISASSEMBLY/ASSEMBLY...
Page 791 LIFTGATE End Of Sie LIFTGATE ADJUSTMENT A6E772262010203 1. Measure the gap and height between the liftgate and the body. 2. If not as specified, loosen the liftgate hinge installation bolts or the liftgate striker installation screws, and reposition the liftgate. Clearance a: 0—2.0 mm {0—0.07 in} b: 4.8—6.8 mm {0.19—0.26 in}...
Page 792 EXTERIOR ATTACHMENT EXTERIOR ATTACHMENT EXTRACTOR CHAMBER REMOVAL/INSTALLATION A6E772851920201 1. Remove the rear bumper. 2. Remove the left side trunk side trim. 3. Squeeze the clips with your fingers and remove the extractor chamber from the vehicle side. 4. Install in the reverse order of removal. CLIP A EXTRACTOR CHAMBER...
Page 793 MOLDING MOLDING ROOF MOLDING REMOVAL A6E773050620201 With Roof Rail 1. Remove the roof rail. 2. Detach the clips which secure A section of roof moldings, using a screwdriver or equivalent tool. 3. Remove the roof molding No.2 and No.3. ROOF ROOF MOLDING No.1 MOLDING No.3...
Page 794 MOLDING 3. Align the front end-face of roof molding No.2 at a position 216 mm {8.5 in} from the rear end-face of roof molding No.1. ROOF MOLDING No.1 4. Press in roof molding No.2 along the direction (1) shown in the figure and attach it to clips B at the B section.
Page 795 WINDOW GLASS WINDOW GLASS SIDE WINDOW GLASS REMOVAL A6E773862580201 1. Apply protective tape along the edge of the body to protect it from damage. 2. Make a hole through the sealant, avoiding pins, from the inside of the vehicle using an awl. FASTENER A6A7738W102 3.
Page 796 WINDOW GLASS 4. Insert the spacer into the body. SPACER SEC. A — A6A7738W104 5. Use only glass primer on the glass, and body primer on the body and the molding. Allow it to dry for approximately 30 minutes. Caution •...
Page 797 WINDOW GLASS 7. Set the side window glass in place and insert the pins and fastener into the body. Install the side window glass. 8. Allow the sealant to harden completely. Sealant hardening time: 24 hours FASTENER A6A7738W102 End Of Sie REAR WINDOW GLASS REMOVAL A6E773863931201 1.
Page 798 WINDOW GLASS Reusing Glass Note • Before removing the rear window glass from the body, mark the position of the glass by affixing tape to the glass and body panel. 1. Make a hole through the sealant, avoiding pins, from the inside of the vehicle using an awl. A6E77381108 2.
Page 799 WINDOW GLASS 4. Install the molding as shown in the figure. SIDE 45˚ REAR WINDOW MOLDING LOWER 3 mm — {-0.12 0.12 in} — REAR WINDOW MOLDING A6E77381110 5. Use only glass primer on the glass, and body primer on the body and the molding. Allow it to dry for approximately 30 minutes.
Page 800 WINDOW GLASS 6. Apply sealant to the area of the glass surface as shown in the figure. {0.43} APPLY SEALANT 5 {0.20} TO THIS AREA. mm {in} A6A7738W113 7. Set the position of the front windshield glass and insert a pin into the body. Install the glass. A6E77381114 8.
Page 801 SLIDING SUNROOF SLIDING SUNROOF REAR DRAIN HOSE REMOVAL A6E774069922201 1. Remove the headliner. 2. Remove the trunk side upper trim and trunk side trim. 3. Disconnect the rear drain hose from the sunroof frame. 4. Remove the rear drain hose from the clips. 5.
Page 802 TRIM TRIM C-PILLAR TRIM REMOVAL/INSTALLATION A6E774468240201 1. Remove the trunk side upper trim. 2. Turn the seaming welt over. HOOK 3. Remove the fastener. C-PILLAR TRIM 4. Pull the C-pillar trim forward, then disengage the FRONT clip A and pin B from the body. 5.
Page 803 TRIM 3. Remove the screw, then remove the bracket. 4. Remove the cargo hooks. 5. Remove the fasteners, then remove the trunk SCREW FRONT side trim. 6. Install in the reverse order of removal. FASTENER BRACKET TRUNK SIDE TRIM CARGO HOOK A6E77441106 End Of Sie TRUNK SIDE UPPER TRIM REMOVAL/INSTALLATION...
Page 804 TRIM TRUNK END TRIM REMOVAL/INSTALLATION A6E774468890201 1. Pull the trunk end trim upward, then disengage clips A and pins B from the body. 2. Remove the trunk end trim. TRUNK END TRIM 3. Install in the reverse order of removal. PIN B CLIP A A6A7744W108...
Page 805 TRIM LIFTGATE SIDE TRIM REMOVAL/INSTALLATION A6E774468940201 1. Remove the liftgate upper trim. (SeeS–23 LIFTGATE UPPER TRIM REMOVAL/INSTALLATION) 2. Remove the fastener. 3. Pull the liftgate side trim toward you, then disengage the clips A and hook B, C from the body.
Page 806 TRIM TONNEAU COVER ANCHOR REMOVAL/INSTALLATION A6E774468320201 1. Remove the trunk side upper trim. 2. Remove the screws. 3. Remove the tonneau cover anchor. TONNEAU COVER ANCHOR 4. Install in the reverse order of removal. SCREW A6A7744W114 End Of Sie S–25...
Page 807 HEADLINER HEADLINER HEADLINER REMOVAL/INSTALLATION A6E774668030201 1. Disconnect the negative battery cable. 2. Turn the seaming welt and weatherstrip over. 3. Remove the sunroof seaming welt. (vehicles with sunroof only) 4. Remove the A-pillar trims. 5. Remove the B-pillar upper trims. 6.
Page 808 FLOOR COVERING FLOOR COVERING FRONT FLOOR COVERING REMOVAL/INSTALLATION A6E774868670201 1. Disconnect the negative battery cable. 2. Remove the front seats. 3. Remove the rear seat. (SeeS–29 REAR SEAT REMOVAL/INSTALLATION) 4. Remove the front scuff plates. 5. Remove the rear scuff plates. 6.
Page 809 SEAT BELT SEAT BELT REAR SIDE SEAT BELT REMOVAL/INSTALLATION A6E775057730201 Caution • The rear side seat belt for 4WD models is equipped with a silencer to reduce abnormal noise while driving. If the silencer is not installed in the proper position, the push knob may not function properly.
Page 810 SEAT SEAT REAR SEAT REMOVAL/INSTALLATION A6E775257200201 4WD (WGN) 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. A: 36.3—53.9 N·m {3.71—5.49 kgf·m, 26.8—39.7 ft·lbf} B: 38.3—78.4 N·m {3.91—7.99 kgf·m, 28.3—57.8 ft·lbf} A6E77521102 Remote wire Rear seat cushion (See...
Page 811 SEAT REAR SEAT DISASSEMBLY/ASSEMBLY A6E775257200202 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.. A6E77521015 Headrest Cup holder Hinge cover (2WD) Armrest hinge Seat cushion trim Armrest trim Seat cushion pad Armrest pad Seat cushion frame (2WD) Seat back trim Remote button cover...
Page 812 B ODY ELECTRICAL SYSTEM HIGH-MOUNT BRAKE LIGHT FEATURES REMOVAL/INSTALLATION ......T-20 INTERIOR LIGHTING SYSTEM ......T-21 OUTLINE ..............T-2 CARGO COMPARTMENT LIGHT OUTLINE OF CONSTRUCTION ......T-2 REMOVAL/INSTALLATION ......T-21 FEATURES ............T-2 CARGO COMPARTMENT LIGHT POWER SYSTEM........... T-2 INSPECTION ..........T-22 STRUCTURAL VIEW...........
Page 813 OUTLINE OF CONSTRUCTION A6E810201088201 • The construction and operation of the body electrical system is essentially carried over from that of the current Mazda6 (GG) model, except for the following features. (See Mazda6 Training Manual 3359-1*-02C) End Of Sie FEATURES...
Page 814 MULTIPLEX COMMUNICATION SYSTEM MULTIPLEX COMMUNICATION SYSTEM OUTLINE A6E811155430201 • A TCM and a 4WD control module have been adopted for the CAN system-related module. End Of Sie STRUCTRURAL VIEW A6E811155430202 A6E81111101 ABS (ABS/TCS) HU/CM (with ABS (ABS/TCS)) DSC HU/CM (with DSC) Instrument cluster 4WD control module End Of Sie...
Page 815 MULTIPLEX COMMUNICATION SYSTEM SYSTEM WIRING DIAGRAM A6E811155430203 AF AG CAN_L CAN_H 2M 2J A6E81111102 4WD control module (4WD) DSC HU/CM (with DSC) Twist pair ABS (ABS/TCS) HU/CM (with ABS (ABS/TCS)) 2R (except MZR-CD (RF Turbo)) Data link connector-2 39 (MZR-CD (RF Turbo)) Instrument cluster 2U (except MZR-CD (RF Turbo)) TCM (JA5AX-EL)
Page 816 MULTIPLEX COMMUNICATION SYSTEM Multiplex module ABS (ABS/TCS) Signal 4WD control Instrument HU/CM or module cluster DSC HU/CM Cruise main indicator light conditions (MZR-CD (RF – – – Turbo)) Cruise set indicator light conditions (MZR-CD (RF – – – Turbo)) Desired gear/ FN4A-EL –...
Page 817 CAN system malfunction locations. • Due to the adoption of the TCM and the 4WD CM, some DTCs and PID/data monitor items have been added. Other functions are the same as those of the current Mazda6 (GG) model. Block Diagram...
Page 818 MULTIPLEX COMMUNICATION SYSTEM Self-Malfunction Diagnostic Function • The self-malfunction diagnostic function determines that there is a malfunction, and outputs a signal, as a DTC, to the DLC-2. The DTC can be read out using an SST (WDS or equivalent). DTC table Malfunction location Related module •...
Page 819 EXTERIOR LIGHTING SYSTEM, INTERIOR LIGHTING SYSTEM EXTERIOR LIGHTING SYSTEM OUTLINE A6E811201052201 • In-vehicle-type high-mount brake light and rear spoiler type high-mount brake light have been adopted. (WGN) End Of Sie STRUCTURAL VIEW A6E811201052202 A6E8112T101 High-mount brake light (in-vehicle-type) High-mount brake light (rear spoiler type) End Of Sie INTERIOR LIGHTING SYSTEM STRUCTURAL VIEW...
Page 820 WIPER AND WASHER WIPER AND WASHER OUTLINE A6E811601052201 • Due to the adoption of the WGN, the following have been changed: — Installation positions of the rear wiper arm and blade, rear wiper motor, rear washer nozzle and intermittent rear wiper relay —...
Page 821 WARNING AND INDICATOR SYSTEM WARNING AND INDICATOR SYSTEM OUTLINE A6E811801069201 • In accordance with the 4WD setting, the following indicator light has been added: — 4WD indicator light • In accordance with the MZR-CD (RF Turbo) setting, the following indicator lights have been added: —...
Page 822 OUTLINE A6E812050000201 • An intruder sensor has been adopted on the rear part of the roof. (WGN) • The construction and operation of the theft-deterrent system is the same as that of the current Mazda6 (GG) model. End Of Sie...
Page 823 THEFT-DETERRENT SYSTEM Structural View A6E81201103 Front intruder sensor (with sliding sunroof) Rear intruder sensor (WGN) Center intruder sensor (without sliding sunroof) System Wiring Diagram A6E81201101 Theft-deterrent control module Front intruder sensor (with sliding sunroof) Rear intruder sensor (WGN) Center intruder sensor (without sliding sunroof) End Of Sie T–12...
Page 824 AUDIO AND NAVIGATION SYSTEM, CRUISE CONTROL SYSTEM, AIR BAG SYSTEM AUDIO AND NAVIGATION SYSTEM OUTLINE A6E812401052201 • Due to the adoption of the WGN, the following have been changed: — Installation positions of the condenser and the noise filter — Antenna feeder routing End Of Sie STRUCTURAL VIEW A6E812401052202...
Page 825 OUTLINE OUTLINE SUPPLEMENTAL SERVICE INFORMATION A6E810201088203 • The following changes and/or additions have been made since publication of the Mazda6 Workshop Manual (1730-1*-02C). Relay • Location has been changed. • Inspection procedure has been modified. Rear auto leveling sensor • Removal/Installation procedure has been modified.
Page 826 LOCATION INDEX LOCATION INDEX POWER SYSTEM A6E810001072201 A6E81101124 Main fuse block (See T–19 RELAY LOCATION) (See T–19 RELAY INSPECTION) End Of Sie EXTERIOR LIGHTING SYSTEM A6E810001052201 A6E81121162 High-mount brake light Rear auto leveling sensor (4WD) (See T–20 HIGH-MOUNT BRAKE LIGHT (See T–20 REAR AUTO LEVELING SENSOR REMOVAL/INSTALLATION)
Page 827 LOCATION INDEX End Of Sie INTERIOR LIGHTING SYSTEM A6E810001052202 FRONT A6E81141130 Cargo compartment light (See T–21 CARGO COMPARTMENT LIGHT REMOVAL/INSTALLATION) (See T–22 CARGO COMPARTMENT LIGHT INSPECTION) End Of Sie WIPER AND WASHER SYSTEM A6E810001052203 A6E81161107 Rear washer hose Rear wiper arm and blade (See T–25 REAR WASHER HOSE REMOVAL/ T–23 REAR WIPER ARM AND BLADE REMOVAL/...
Page 828 LOCATION INDEX End Of Sie WARNING AND INDICATOR SYSTEM A6E810001067201 A6E81181112 Fuel gauge sender sub-unit Fuel gauge sender unit (See T–27 FUEL GAUGE SENDER UNIT (See T–27 FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION) REMOVAL/INSTALLATION) (See T–28 FUEL GAUGE SENDER UNIT (See T–28 FUEL GAUGE SENDER UNIT INSPECTION) INSPECTION)
Page 829 LOCATION INDEX AUDIO AND NAVIGATION SYSTEM A6E810001066201 A6A8124W144 Antenna feeder Noise filter (See T–31 ANTENNA FEEDER LOCATION) (See T–30 NOISE FILTER REMOVAL/ (See T–31 REAR ANTENNA FEEDER INSTALLATION) INSPECTION) Condenser (See T–30 CONDENSER REMOVAL/ INSTALLATION) End Of Sie AIR BAG SYSTEM A6E810001046201 A6E81301150 Curtain air bag module...
Page 830 POWER SYSTEM POWER SYSTEM RELAY LOCATION A6E811067730202 A6E81101102 Seat warmer relay (with seat warmer) Glow relay (MZR-CD (RF Turbo) only) End Of Sie RELAY INSPECTION A6E811067730203 Relay Type Terminal type Part name • Seat warmer relay Type A Four-terminal • Glow relay Type B Four-terminal Type A...
Page 831 EXTERIOR LIGHTING SYSTEM EXTERIOR LIGHTING SYSTEM REAR AUTO LEVELING SENSOR REMOVAL/INSTALLATION A6E811251030201 1. Disconnect the negative battery cable. 2. Jack up the vehicle. 3. Remove in the order indicated in the table. REAR STABILIZER Connector Bolt Bracket Rear auto leveling sensor 4.
Page 832 EXTERIOR LIGHTING SYSTEM, INTERIOR LIGHTING SYSTEM Rear spoiler type 1. Disconnect the negative battery cable. 2. Remove the rear spoiler. 3. Remove in the order indicated in the table. Bolt Cover Connector High-mount brake light 4. Install in the reverse order of removal. A6J81121004 End Of Sie INTERIOR LIGHTING SYSTEM...
Page 833 INTERIOR LIGHTING SYSTEM, WIPER AND WASHER CARGO COMPARTMENT LIGHT INSPECTION A6E811451441202 1. Remove the cargo compartment light. (See T–21 CARGO COMPARTMENT LIGHT REMOVAL/ INSTALLATION) 2. Inspect for continuity between the cargo compartment light terminals using an ohmmeter. • If not as specified, replace the cargo compartment light.
Page 834 WIPER AND WASHER 5. Verify that the rear wiper motor operates. 6. Disconnect the ground to the terminal B while the rear wiper is operating. AUTOSTOP SWITCH A6E81161119 7. Verify that the rear wiper stops in the park position. • If not as specified, replace the rear wiper motor.
Page 835 WIPER AND WASHER Rear Wiper Arm Installation Note 1. Clean the rear wiper arm connector shaft using a wire brush before installing the rear wiper arm. REAR WIPER ARM CONNECTOR SHAFT A6E81161103 End Of Sie REAR WIPER ARM AND BLADE ADJUSTMENT A6E811667420202 1.
Page 836 WIPER AND WASHER REAR WASHER NOZZLE ADJUSTMENT A6E811667511202 1. Insert a needle or an equivalent tool into the spray hole of the rear washer nozzle and adjust the GLASS END LINE nozzle direction as shown. 13 {0.5} 7 {0.3} GLASS 28 {1.1} END LINE mm {in}...
Page 837 WIPER AND WASHER 13. Remove rear washer hose No.3 from clip C. 14. Remove rear washer hose No.3 and joint pipe D. 15. Remove the headliner. (See S–26 HEADLINER REMOVAL/INSTALLATION) CLIP C JOINT PIPE D REAR WASHER HOSE NO.3 A6E81161150 16.
Page 838: Transfer
WARNING AND INDICATOR SYSTEM WARNING AND INDICATOR SYSTEM FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION A6E811860960201 Fuel Gauge Sender Unit • There are no changes from the current fuel gauge sender unit removal/installation procedure. 1. Remove the fuel gauge sender unit. (See F1–26 FUEL PUMP UNIT REMOVAL/INSTALLATION.) 2.
Page 839 WARNING AND INDICATOR SYSTEM Fuel gauge sender cap removal note 1. Using the SST, remove the fuel gauge sender cap. 49 T042 001A A6J81182105 Fuel Gauge Sender Cap Installation Note 1. Verify that the fuel tank mark is aligned with the MARK fuel gauge sender sub-unit mark as shown.
Page 840 THEFT-DETERRENT SYSTEM THEFT-DETERRENT SYSTEM INTRUDER SENSOR REMOVAL/INSTALLATION A6E812000172201 Front Intruder Sensor (With Sliding Sunroof) • There are no changes from the current front intruder sensor removal/installation procedure. Center Intruder Sensor (Without Sliding Sunroof) • There are no changes from the current center intruder sensor removal/installation procedure. Rear Intruder Sensor (WGN) 1.
Page 841 AUDIO AND NAVIGATION SYSTEM AUDIO AND NAVIGATION SYSTEM NOISE FILTER REMOVAL/INSTALLATION A6E812466869201 Brake Light Noise Filter 1. Remove the noise filter according to the NOISE FILTER REMOVAL/INSTALLATION procedure for the 4SD. 2. Install in the reverse order of removal. Rear Window Defroster Noise Filter 1.
Page 842 AUDIO AND NAVIGATION SYSTEM ANTENNA FEEDER LOCATION A6E812466941201 A6E81241138 Rear antenna feeder End Of Sie REAR ANTENNA FEEDER INSPECTION A6E812466942201 1. Verify that there is no continuity between antenna feeder terminals A and B using an ohmmeter. 2. Inspect for continuity between the antenna feeder terminals using an ohmmeter.
Page 843 AIR BAG SYSTEM AIR BAG SYSTEM SERVICE WARNINGS A6E813001046202 Component Disassembly • Disassembling and reassembling the components of the air bag system can render the system inoperative, which may result in serious injury or death in the event of an accident.
Page 844 AIR BAG SYSTEM • A live (undeployed) air bag module placed face down on a surface is dangerous. If the air bag module deploys, the motion of the module can cause serious injury. Always face the front surface up to reduce the motion of the module in case it accidentally deploys.
Page 845 AIR BAG SYSTEM Side Air Bag Sensor Handling • Disconnecting the side air bag sensor connector or removing the side air bag sensor with the ignition switch at ON position can cause the side air bag sensor to operate and the side air bag module to deploy, which may seriously injure you.
Page 846 Do not dispose of a live (undeployed) air bag module and pre-tensioner seat belt. If the SSTs (Deployment tool and Adapter harness) are not available, consult the nearest Mazda representative for assistance. Caution • Deploying the air bag modules and pre-tensioner seat belts inside the vehicle may cause damage to the vehicle interior.
Page 847 AIR BAG SYSTEM Deployment Procedure for Inside of Vehicle (Only When Vehicle Is To Be Scrapped) 1. Inspect the SST (Deployment tool). 2. Move the vehicle to an open space, away from strong winds, and close all the doors and windows. 3.
Page 848 AIR BAG SYSTEM Curtain air bag module (WGN) 1. Remove the curtain air bag module. (See T–35 CURTAIN AIR BAG MODULE REMOVAL/INSTALLATION.) 2. Secure the curtain air bag module in a vise, and cut off the deployment section, as shown in the figure.
Page 849 AIR BAG SYSTEM 6. Tie all tires together with wire. A6E8130W034 7. Connect the SST (Deployment tool) to the SST (Adapter harness). 8. Connect the red clip of the SST (Deployment tool) to the positive battery terminal and the black clip to the negative battery terminal.
Page 850 ON-BOARD DIAGNOSTIC [MULTIPLEX COMMUNICATION SYSTEM] ON-BOARD DIAGNOSTIC [MULTIPLEX COMMUNICATION SYSTEM] MULTIPLEX COMMUNICATION SYSTEM A6E816255430201 Outline • If the controller area network (CAN) system is malfunctioning, read the DTCs of the following modules, using the SST (WDS or equivalent) to determine the malfunctioning system. —...
Page 851 ON-BOARD DIAGNOSTIC [MULTIPLEX COMMUNICATION SYSTEM] Flowchart • Use the following flowchart to verify the cause of the trouble. START Using the SST (WDS or equivalent), verify if DTCs are displayed for PCM, TCM, ABS (ABS/TCS) HU/CM (with ABS (ABS/TCS)), DSC HU/CM (with DSC), 4WD control module and instrument cluster. Are any DTCs displayed? Are any DTCs other than the following displayed? Is there a response from the PCM, TCM, ABS (ABS/TCS) HU/CM,...
Page 852 ON-BOARD DIAGNOSTIC [MULTIPLEX COMMUNICATION SYSTEM] ON-BOARD DIAGNOSTIC [MULTIPLEX COMMUNICATION SYSTEM] T – 4 0 B ODY ELECTRICAL SYSTEM Connect each unit connector. Turn the ignition switch to the ON position. Measure the voltage between DLC-2 terminals CAN_L and CAN_H. Is the voltage 2.0—3.0 V? Turn the ignition switch to the LOCK position.
Page 853 ON-BOARD DIAGNOSTIC [MULTIPLEX COMMUNICATION SYSTEM] ON-BOARD DIAGNOSTIC [MULTIPLEX COMMUNICATION SYSTEM] T B ODY ELECTRICAL SYSTEM DTC TABLE A6E816255430202 Malfunction location Related module Page • PCM (See T–45 DTC U0073, U0073 CAN system communication error • TCM U1900, U2516) • TCM U0100 Communication error to PCM •...
Page 854 ON-BOARD DIAGNOSTIC [MULTIPLEX COMMUNICATION SYSTEM] PROCEDURES FOR DETERMINING THE LOCATION OF A MALFUNCTION A6E816255430204 System Wiring Diagram ABS (ABS/TCS) HU/CM DSC HU/CM WIRING HARNESS A WIRING HARNESS B INSTRUMENT CLUSTER WIRING HARNESS C ABS (ABS/TCS) HU/CM DSC HU/CM WIRING WIRING WIRING HARNESS C HARNESS G...
Page 855 ON-BOARD DIAGNOSTIC [MULTIPLEX COMMUNICATION SYSTEM] X: Normal —: Communication error Communication status Module Malfunction location ABS (ABS/TCS) HU/CM Instrument cluster DSC HU/CM • Wiring harness A — — — • PCM • Wiring harness B — • TCM • Wiring harness D •...
Page 856 ON-BOARD DIAGNOSTIC [MULTIPLEX COMMUNICATION SYSTEM] X: Normal —: Communication error Communication status Module Malfunction location 4WD control Instrument cluster module • Wiring harness D • ABS (ABS/TCS) — — — — HU/CM • DSC HU/CM • Wiring harness A — •...
Page 857 ON-BOARD DIAGNOSTIC [MULTIPLEX COMMUNICATION SYSTEM] X: Normal —: Communication error Communication status Module Malfunction location ABS (ABS/TCS) HU/CM DSC HU/CM • Wiring harness C — — • Instrument cluster • Wiring harness A — • PCM Instrument cluster • Wiring harness B •...
Page 858 ON-BOARD DIAGNOSTIC [MULTIPLEX COMMUNICATION SYSTEM] ABS (ABS/TCS) HU/CM DSC HU/CM WIRING HARNESS A WIRING HARNESS B INSTRUMENT CLUSTER WIRING HARNESS C ABS (ABS/TCS) HU/CM DSC HU/CM WIRING WIRING WIRING HARNESS C HARNESS G HARNESS A WIRING HARNESS D INSTRUMENT CLUSTER WIRING WIRING WIRING...
Page 859 ON-BOARD DIAGNOSTIC [MULTIPLEX COMMUNICATION SYSTEM] STEP INSPECTION ACTION INSPECT INSTRUMENT CLUSTER Yes Go to next step. CONNECTOR Replace wiring harness. • Disconnect negative battery cable. • Disconnect instrument cluster connector. • Are poor connection detection bars of instrument cluster connector okay? •...
Page 860 ON-BOARD DIAGNOSTIC [MULTIPLEX COMMUNICATION SYSTEM] STEP INSPECTION ACTION • Is vehicle equipped with DSC? Yes Go to next step. Go to step 16. INSPECT WIRING HARNESS BETWEEN PCM Yes Replace PCM, then go to Step 17. AND DSC HU/CM Replace wiring harness. •...
Page 861 ON-BOARD DIAGNOSTIC [MULTIPLEX COMMUNICATION SYSTEM] STEP INSPECTION ACTION DETERMINING THE LOCATION OF A Yes Go to Step 36. MALFUNCTION Go to next step. • Is the malfunctioning part the wiring harness DETERMINING THE LOCATION OF A Yes Go to Step 39. MALFUNCTION Go to next step.
Page 862 ON-BOARD DIAGNOSTIC [MULTIPLEX COMMUNICATION SYSTEM] STEP INSPECTION ACTION INSPECT WIRING HARNESS BETWEEN ABS Yes Go to Step 45. (ABS/TCS) HU/CM AND 4WD CONTROL Replace wiring harness. MODULE • Disconnect ABS (ABS/TCS) HU/CM connector. • Inspect the following wiring harness between ABS (ABS/TCS) HU/CM and 4WD control module terminals for short to ground, short power supply, and open circuit:...
Page 863 ON-BOARD DIAGNOSTIC [MULTIPLEX COMMUNICATION SYSTEM] STEP INSPECTION ACTION INSPECT TCM CONNECTOR Yes Go to next step. • Disconnect negative battery cable. Replace wiring harness. • Disconnect TCM connector. • Is the connector for the TCM connected correctly? • Is vehicle equipped with DSC? Yes Go to next step.
Page 864 H EATER AND AIR CONDITIONER SYSTEMS FEATURES OUTLINE ..............U-2 OUTLINE OF CONSTRUCTION......U-2 FEATURES ............U-2 SPECIFICATIONS ..........U-2 CONTROL SYSTEM..........U-6 WATER HEATER SYSTEM.........U-6 SERVICE OUTLINE ..............U-7 SUPPLEMENTAL SERVICE INFORMATION ..U-7 LOCATION INDEX ..........U-8 BASIC SYSTEM...........U-8 CONTROL SYSTEM..........U-9 BASIC SYSTEM ...........U-10 A/C UNIT REMOVAL/INSTALLATION....U-10 A/C COMPRESSOR REMOVAL/INSTALLATION ......U-11 CONDENSER REMOVAL/INSTALLATION ..U-12...
Page 865 OUTLINE OF CONSTRUCTION A6E850201038201 • The construction and operation of the air conditioner system is essentially carried over from that of the previous Mazda6 (GG) model, except for the following features. (See Mazda6 Training Manual 3359-1*-02C.) End Of Sie FEATURES...
Page 866 OUTLINE Specification Item L3, L8, LF MZR-CD (RF Turbo) Type Dual-pressure: General area Operating pressure 0.166—0.226 2.94—3.34 (MPa {kgf/cm , psi}) {1.693—2.304, {30.0—34.0, 24.08—32.77} 427—483} 0.02 0.39—0.79 {3.98—8.05, {0.20, 2.84} or less 56.6—114} 0.195—0.250 {1.989—2.549, 28.30—36.24} Triple-pressure: L3 engine, Type intensely hot area Operating pressure •...
Page 867 OUTLINE Full-auto Air Conditioner Specification Item L3, L8, LF MZR-CD (RF Turbo) 4.400 {3,784} (L.H.D.) Heating capacity (kW {kcal/h}) 4.400 {3,784} 5.120 {4,403} {R.H.D.) Airflow volume 310 (L.H.D.) Blower motor (during heater operation) 300 (R.H.D.) Electricity consumption Blower motor (during heater operation) Cooling capacity (kW {kcal/h}) 4.200 {3,612}...
Page 868 OUTLINE Specification Item L3, L8, LF MZR-CD (RF Turbo) Type Dual-pressure: General area Operating pressure 0.166—0.226 2.94—3.34 (MPa {kgf/cm , psi}) {1.693—2.304, {30.0—34.0, 24.08—32.77} 427—483} 0.02 0.39—0.79 {3.98—8.05, {0.20, 2.84} or less 56.6—114} 0.195—0.250 {1.989—2.549, 28.30—36.24} Triple-pressure: L3 engine, Type intensely hot area Operating pressure •...
Page 869 CONTROL SYSTEM CONTROL SYSTEM WATER HEATER SYSTEM A6E854000169201 Outline • The function, structure and operation of the water heater system is essentially carried over from that of the current MPV (LW) model, except for following: — Full/half switching temperature has been changed. Structural View A6E85402002 Water heater unit...
Page 870 OUTLINE OUTLINE SUPPLEMENTAL SERVICE INFORMATION A6E850201038204 • The following additions have been made for the MZR-CD (RF Turbo) since the publication of the Mazda6 Workshop Manual (1730-1*-02C). A/C unit • Removal/installation procedure has been modified. A/C compressor • Removal/installation procedure has been modified.
Page 871 LOCATION INDEX LOCATION INDEX BASIC SYSTEM A6E850001040201 L.H.D. A6E85002001 R.H.D. A6E85002002 Blower unit Condenser (See U–12 CONDENSER REMOVAL/ Air filter INSTALLATION) A/C unit Heater hose (See U–10 A/C UNIT REMOVAL/INSTALLATION) Refrigerant lines Rear heat duct (See U–13 REFRIGERANT LINES REMOVAL/ A/C compressor INSTALLATION) (See...
Page 872 LOCATION INDEX CONTROL SYSTEM A6E850001040202 A6E85002003 Water heater unit Climate control unit (See U–15 WATER HEATER UNIT REMOVAL/ (See U–16 CLIMATE CONTROL UNIT INSTALLATION) INSPECTION) Fuel pump (water heater system) (See U–16 FUEL PUMP (WATER HEATER SYSTEM) INSPECTION) End Of Sie U–9...
Page 873 BASIC SYSTEM BASIC SYSTEM A/C UNIT REMOVAL/INSTALLATION A6E851661130201 1. Disconnect the negative battery cable. 2. Discharge the refrigerant from the system. 3. Drain the engine coolant. 4. Remove the dashboard. 5. Remove the theft-deterrent control module. Caution • If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and abnormal noise will occur.
Page 874 BASIC SYSTEM 7. Install in the reverse order of removal. 8. Perform the refrigerant system performance test. A/C Unit Installation Note 1. When installing a new A/C unit or evaporator, add a supplemental amount of ATMOS GU10 compressor oil into the refrigerant cycle.
Page 875 BASIC SYSTEM CONDENSER REMOVAL/INSTALLATION A6E851661480201 1. Disconnect the negative battery cable. 2. Discharge the refrigerant from the system. 3. Remove the shroud panel. Caution • If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and abnormal noise will occur.
Page 876 BASIC SYSTEM REFRIGERANT LINES REMOVAL/INSTALLATION A6E851661460201 1. Remove the battery. 2. Discharge the refrigerant from the system. 3. Remove the washer tank. 4. Remove the air cleaner cover, air cleaner element and air cleaner case. (See F2–36 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.) 5.
Page 877 BASIC SYSTEM 12. Perform the refrigerant system performance test. L.H.D. A:6.86—9.80 N·m {70.0—99.9 kgf·cm, 60.8—86.7 in·lbf} A6E85162006 R.H.D. A:6.86—9.80 N·m {70.0—99.9 kgf·cm, 60.8—86.7 in·lbf} A6E85162007 U–14...
Page 878 BASIC SYSTEM, CONTROL SYSTEM Cooler pipe No.1 Cooler pipe No.5 (R.H.D. only) Cooler pipe No.2 Cooler hose (HI) Cooler pipe No.3 Cooler hose (LO) Cooler pipe No.4 End Of Sie CONTROL SYSTEM WATER HEATER UNIT REMOVAL/INSTALLATION A6E854000170201 Caution • If the negative battery cable is disconnected during the purge cycle of the water heater unit, the gas in the unit may not be properly scavenged, causing white smoke (unburnt gas) to emit from the exhaust pipe.
Page 879 CONTROL SYSTEM FUEL PUMP (WATER HEATER SYSTEM) INSPECTION A6E854013350201 1. Inspect for continuity between fuel pump terminal A and B using an ohmmeter. • If not as specified, replace the fuel pump (water heater system). AME8540W007 End Of Sie CLIMATE CONTROL UNIT INSPECTION A6E854061190201 Full-auto Air Conditioner 1.
Page 880 CONTROL SYSTEM Terminal Signal Connected to Test condition Voltage (V) Action • Air mix actuator • Inspect for short circuit +5 V Ignition switch at ON • Airflow mode position (Climate control unit— air actuator mix actuator, airflow mode • Solar radiation actuator, solar radiation sensor sensor: 1B—B, B, A)
Page 881 CONTROL SYSTEM Terminal Signal Connected to Test condition Voltage (V) Action • Inspect for continuity Ambient Ambient Depends on temperature temperature temperature sensor surrounding sensor (Climate control unit— sensor input ambient temperature sensor: 1K—B, 1I—A) • Inspect for short circuit See Figure (Climate control unit—...
Page 882 CONTROL SYSTEM Terminal Signal Connected to Test condition Voltage (V) Action • Inspect for continuity Evaporator Evaporator Depends on temperature temperature temperature sensor surrounding sensor (Climate control unit— sensor input evaporator temperature signal sensor: 1Q—B, 1I—A) • Inspect for short circuit See Figure (Climate control unit—...
Page 883 CONTROL SYSTEM Terminal Signal Connected to Test condition Voltage (V) Action • Inspect for short circuit TNS signal TNS relay Headlight switch OFF (Climate control unit—TNS Below 1.0 relay: 2B—D) • Inspect TNS relay • Inspect headlight switch • Inspect for continuity or Headlight switch ON short circuit (Climate control unit—TNS relay: 2B—D)
Page 884 CONTROL SYSTEM Figure 1 (Evaporator temperature sensor) Figure 2 (Ambient temperature sensor) {86} {32} {50} {68} {104} {122} {-4} {14} {14} {32} {50} {68} {86} {104} {122} {-4} TEMPERATURE °C {°F} °C {°F} TEMPERATURE Figure 3 (Cabin temperature sensor) Figure 4 (Water temperature sensor) {-4} {14} {32}...
Page 885 ON-BOARD DIAGNOSTIC ON-BOARD DIAGNOSTIC FOREWORD A6E857001038201 Outline • When the customer reports a vehicle malfunction, verify the DTC, then diagnose the malfunction according to following flowchart. — If a DTC exists, diagnose according to the applicable DTC inspection (See U–22–2 DTC TABLE.) —...
Page 886 ON-BOARD DIAGNOSTIC U – 2 2 H EATER AND AIR CONDITIONER SYSTEMS ON-BOARD DIAGNOSTIC After Repair Procedure 1. Connect the SST (WDS or equivalent) to the vehicle DLC-2 16-pin connector located as shown in the figure. 2. Turn the ignition switch to the ON position. 3.
Page 887 ON-BOARD DIAGNOSTIC PID/Data Monitor and Record Procedure 1. Connect SST (WDS or equivalent) to the vehicle DLC-2 16-pin connector located as shown in the figure. 2. Access and monitor PIDs by WDS or equivalent. DLC-2 A6E3970W002 End Of Sie DTC TABLE A6E857001038202 Possible cause Page...
Page 888 ON-BOARD DIAGNOSTIC Water PID Name Unit/ Condition/Specification Action Heater Unit (Definition) Condition (Reference) terminal • Water heater unit is not operating: Off On/Off — — • Water heater unit is operating: On (Fuel pump) • Water heater unit is not operating: Off WATER_PMP On/Off —...
Page 889 ON-BOARD DIAGNOSTIC U H EATER AND AIR CONDITIONER SYSTEMS ON-BOARD DIAGNOSTIC DTC B1318 A6E857001038204 DTC B1318 Input voltage low DETECTION • Voltage detected at water heater unit terminals A is less than 9 V. CONDITION • Generator malfunction POSSIBLE • Battery malfunction CAUSE WATER HEATER UNIT CONNECTOR Diagnostic procedure...
Page 890 ON-BOARD DIAGNOSTIC DTC B2449, B2450 A6E857001038206 B2449 Glow plug circuit short to ground B2450 Glow plug circuit open DETECTION • CPU detects malfunction in glow plug circuit CONDITION POSSIBLE • Water heater unit malfunction CAUSE Diagnostic procedure STEP INSPECTION ACTION INSPECT WATER HEATER UNIT Yes Go to the applicable DTC troubleshooting.
Page 891 ON-BOARD DIAGNOSTIC STEP INSPECTION ACTION INSPECT WATER HEATER UNIT Yes Replace the water heater unit. • Clear the DTC. (See U–15 WATER HEATER UNIT REMOVAL/ • Perform the KOEO Self Test. (See INSTALLATION) U–22 KOEO Self Test/Combustion Test.) Go to the next step. •...
Page 892 TROUBLESHOOTING TROUBLESHOOTING FOREWORD A6E858001038201 • Confirm the symptom using the following troubleshooting index and carry out the appropriate action. End Of Sie TROUBLESHOOTING INDEX A6E858001038202 TROUBLESHOOTING ITEM ACTION • Inspect the water heater system in the vehicle fuel Fuel odor system.
Page 893 T ECHNICAL DATA TECHNICAL DATA ..........TD-2 ENGINE ............TD-2 LUBRICATION SYSTEM ........TD-2 COOLING SYSTEM.......... TD-3 FUEL AND EMISSION CONTROL SYSTEM ............TD-3 ENGINE ELECTRICAL SYSTEM ..... TD-4 CLUTCH............TD-4 MANUAL TRANSAXLE........TD-4 AUTOMATIC TRANSAXLE....... TD-5 PROPELLER SHAFT........TD-5 FRONT AND REAR AXLE ........
Page 894 TECHNICAL DATA TECHNICAL DATA ENGINE A6E931001001201 Specification Item Diesel engine MZR-CD (RF Turbo) MECHANICAL 0.12—0.18 {0.005—0.007} (0.15±0.03 {0.006±0.0011}) Valve clearance (mm {in}) [engine cold] 0.32—0.38 {0.013—0.014} (0.35±0.03 {0.014±0.0011}) 3,500 Standard {35.7, 507.7} [250] 3,100 (kPa {kgf/cm , psi}) [rpm] Compression pressure Minimum {31.6, 449.4} [250]...
Page 895 Grade ACEA B1 or B3 B3 or B4 Engine oil Viscosity (SAE) 5W-30 10W-40 5W-30, 10W-30 Remarks Mazda genuine Dexelia oil e.g. — End Of Sie COOLING SYSTEM A6E931001001203 Specification Item Diesel engine MZR-CD (RF Turbo) Coolant capacity (L {US qt, Imp qt}) 9.0 {9.5, 7.9}...
Page 896 TECHNICAL DATA ENGINE ELECTRICAL SYSTEM A6E931001001205 Specification Item Diesel engine MZR-CD (RF Turbo) Electrolyte gravity 1.27—1.29 (mA) Max.20 Back-up current* Type 95D31L, 115D31L 95D31L (64) Test load chart (A) Battery type Battery 115D31L (70) 95D31L (64) 6.5—8.0 Battery type Slow-charge (5-hour rate) 7.0—8.5 115D31L (70)
Page 897: Propeller Shaft
TECHNICAL DATA AUTOMATIC TRANSAXLE End Of Sie A6E931001024203 Item Specification Transaxle type JA5AX-EL Idle 290—490 {3.0—5.0, 42—71} D range, M range (2GR) Line pressure Stall 1,550—1,750 {15.8—17.8, 225—254} (kPa {kgf/cm , psi}) Idle 550—750 {5.6—7.6, 80—109} M range (1GR), R position Stall 1,550—1,750 {15.8—17.8, 225—254} Engine stall speed...
Page 898: Front Drive Shaft
TECHNICAL DATA FRONT AND REAR AXLE A6E931001018201 Item Specification FRONT DRIVE SHAFT MZR-CD (RF Turbo): 666.1—676.1 {26.23—26.61} Left side Shaft length 4WD: 667—677 {26.26—26.65} (Air in boot at atmospheric (mm {in}) MZR-CD (RF Turbo): 615.9—625.9 {24.25—24.64} pressure) Right side 4WD: 631—641 {24.85—25.23} REAR DRIVE SHAFT (4WD) Shaft length Left side...
Page 899 TECHNICAL DATA BRAKING SYSTEM A6E931001020201 Item Specification CONVENTIONAL BRAKE SYSTEM L8, LF (GCC specs.): 22 mm {0.87 in} Minimum disc pad (mm {in}) LF (European (L.H.D. U.K.) specs.), L3, MZR-CD (RF Turbo): thickness 23 mm {0.91 in} Front disc brake L8, LF (GCC specs.): 22.8 mm {0.90 in} Minimum disc plate (mm {in})
Page 900 TECHNICAL DATA Wheel and Tires Item Specification Standard tire and wheel 15 × 6JJ 16 × 7JJ 17 × 7JJ Size Offset (mm {in}) 50 {1.97} 55 {2.17} Wheel Pitch circle diameter (mm {in}) 114.3 {4.50} Material Steel Aluminum alloy 215/45R17 91W Size 195/65R15 91V...
Page 901 TECHNICAL DATA HEATER AND AIR CONDITIONER SYSTEMS A6E931001038201 Specification Item MZR–CD (RF Turbo) REFRIGERANT SYSTEM Type R–134a Refrigerant Regular amount L.H.D. 470 {16.6} (g {oz}) R.H.D. 430 {15.2} BASIC SYSTEM Type ATMOS GU10 A/C compressor Lubricating oil Sealed volume 150 {150, 5.07} (ml {cc, fl oz}) CONTROL SYSTEM Magnetic clutch...
Page 902 S PECIAL TOOLS SPECIAL TOOLS ..........ST-2 ENGINE .............ST-2 LUBRICATION SYSTEM ........ST-2 COOLING SYSTEM...........ST-2 FUEL AND EMISSION CONTROL SYSTEM ..ST-3 CLUTCH.............ST-3 MANUAL TRANSAXLE........ST-3 AUTOMATIC TRANSAXLE........ST-3 PROPELLER SHFT ...........ST-4 FRONT AND REAR AXLE .........ST-4 STEERING SYSTEM .........ST-7 BRAKING SYSTEM ...........ST-7 SUSPENSION............ST-7 BODY ..............ST-7 BODY ELECTRICAL SYSTEM ......ST-8 ST–1...
Page 903 SPECIAL TOOLS SPECIAL TOOLS ENGINE A6E941001001205 49 S120 710 49 G033 107A 49 S120 215B Coupling flange Dust cover Pulley puller holder installer 49 G011 106 49 S013 1A1 49 B010 002 Camshaft pulley Compression Oil seal installer puller gauge set 49 G012 0A0 49 G011 105 49 U027 003...
Page 904 SPECIAL TOOLS FUEL AND EMISSION CONTROL SYSTEM A6E941001001204 49 T042 001A 49 L018 001 Union wrench sensor wrench 49 D015 001 Box wrench End Of Sie CLUTCH A6E941001024201 49 0259 770B 49 SE01 310A 49 E011 1A0 Flare Nut Clutch Disc Ring Gear Wrench Centering Tool...
Page 905 SPECIAL TOOLS 49 L019 013 49 E017 5A0 49 E011 1A0 Adapter Engine Support Ring gear brake — — End Of Sie PROPELLER SHFT A6E941001024204 49 0839 425C 49 H027 002 49 G030 370 Bearing puller Bearing Removing Plate Remover 49 F015 002 49 0636 145 49 G030 797...
Page 906 SPECIAL TOOLS 49 F026 103 49 G030 797 49 F027 005 Attachment φ 62 Wheel hub Handle puller 49 G033 107A 49 H026 104 49 F027 004 Attachment φ 80 Dust cover Guide block installer 49 B014 001 49 W034 301 49 G030 370 Oil seal installer Support block...
Page 907 SPECIAL TOOLS 49 0107 680A 49 T032 317 49 T032 316 Engine stand Weight Shaft 49 L027 004 49 L027 0A0 49 L027 006 Gear case Locknut Serrate socket remover replacer set (Part of 49 L027 0A0) 49 L027 007 49 F401 366A 49 B027 003 Hex socket...
Page 908 SPECIAL TOOLS STEERING SYSTEM A6E941001034201 49 1232 670B 49 H002 671 49 G032 3A4 Power steering Adapter Power steering gauge set gauge adapter 49 T028 3A0 49 F032 301 49 E017 5A0 Ball joint puller Power steering Engine support pump hanger End Of Sie BRAKING SYSTEM A6E941001020201...
Page 909 SPECIAL TOOLS BODY ELECTRICAL SYSTEM A6E941001047202 49 H066 002 49 L066 002 Deployment tool Adapter harness 49 T042 001A Union wrench – – End Of Sie ST–8...

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