Mazda 2002 Millenia User manual

CONTENTS

Mazda6

Training

Manual

FOREWORD

This manual explains each component or

system operation and function 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.

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) shown on the following

page.

PRINTED IN The Netherlands, MARCH 2002

33591E02C

Title Section

General Information

GI

Engine

B

Lubrication System

D

Cooling System

E

Fuel and Emission Control Systems

F

Engine Electrical System

G

Clutch

H

Manual Transaxle

J

Automatic Transaxle

K

Front and Rear Axles

M

Steering System

N

Braking System

P

Suspension

R

Body

S

Body Electrical System

T

Heater and Air Conditioner Systems

U

VEHICLE IDENTIFICATION NUMBERS (VIN)

U.K. specs.

JMZ GG12820# 100001

JMZ GG14320# 100001

JMZ GG14820# 100001

JMZ GG12F20# 100001

JMZ GG12F50# 100001

JMZ GG14F20# 100001

JMZ GG14F50# 100001

European (L.H.D.) specs.

JMZ GG1232✻# 100001

JMZ GG1282✻# 100001

JMZ GG1432✻# 100001

JMZ GG1482✻# 100001

JMZ GG12F2✻# 100001

JMZ GG12F5✻# 100001

JMZ GG14F2✻# 100001

JMZ GG14F5✻# 100001

GCC specs.

JM7 GG32F✻✻# 100001

JM7 GG34F✻✻# 100001

JM7 GG42F✻✻# 100001

JM7 GG44F✻✻# 100001

RELATED MATERIALS

Engine Workshop Manual L8, LF, L3 . . . . . . . . . . . . . . 17311*02C

Manual Transaxle Workshop Manual

G35MR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17321*02C

Automatic Transaxle Workshop Manual

FN4AEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16231098E

Automatic Transaxle Workshop Manual

Supplement FN4AEL . . . . . . . . . . . . . . . . . . . . . . . . . 17461*02C

Mazda6 Wiring Diagram

(European (L.H.D.), GCC specs.) . . . . . . . . . . . . . . . . 55391*02C

Mazda6 Wirinig Diagram

(U.K. specs.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55401*02C

Mazda6 Bodyshop Manual

(European (L.H.D. U.K.), GCC specs.) . . . . . . . . . . . . 33601*02C

* : Indicates the printing location

E: Europe

0: Japan

GI1

GI

GIGENERAL INFORMATION

HOW TO USE THIS MANUAL ............................. GI-2

VIN CODE.......................................................... GI-2

UNITS ................................................................... GI-4

UNITS TABLE .................................................... GI-4

NEW STANDARDS .............................................. GI-5

NEW STANDARDS TABLE ............................... GI-5

GI2

HOW TO USE THIS MANUAL

VIN CODE

A6E201000001T01

European (L.H.D. U.K.) specs.

HOW TO USE THIS MANUAL

A6E2021T001

HOW TO USE THIS MANUAL

GI3

GI

GCC specs.

End Of Sie

A6E2021T002

GI4

UNITS

UNITS TABLE

A6E201200002T01

Conversion to SI Units (Système International d'Unités)

• All numerical values in this manual are based on SI units. Numbers shown in conventional units are converted

from these values.

Rounding Off

• Converted values are rounded off to the same number of places as the SI unit value. For example, if the SI unit

value is 17.2 and the value after conversion is 37.84, the converted value will be rounded off to 37.8.

Upper and Lower Limits

• When the data indicates upper and lower limits, the converted values are rounded down if the SI unit value is

an upper limit and rounded up if the SI unit value is a lower limit. Therefore, converted values for the same SI

unit value may differ after conversion. For example, consider 2.7 kgf/cm

2

in the following specifications:

210260 kPa {2.12.7 kgf/cm

2

, 3038 psi}

270310 kPa {2.73.2 kgf/cm

2

, 3945 psi}

• The actual converted values for 2.7 kgf/cm

2

are 265 kPa and 38.4 psi. In the first specification, 2.7 is used as

an upper limit, so the converted values are rounded down to 260 and 38. In the second specification, 2.7 is

used as a lower limit, so the converted values are rounded up to 270 and 39.

End Of Sie

UNITS

Electrical current A (ampere)

Electric power W (watt)

Electric resistance ohm

Electric voltage V (volt)

Length

mm (millimeter)

in (inch)

Negative pressure

kPa (kilo pascal)

mmHg (millimeters of mercury)

inHg (inches of mercury)

Positive pressure

kPa (kilo pascal)

kgf/cm

2

(kilogram force per square

centimeter)

psi (pounds per square inch)

Torque

N·m (Newton meter)

kgf·m (kilogram force meter)

kgf·cm (kilogram force centimeter)

ft·lbf (foot pound force)

in·lbf (inch pound force)

Volume

L (liter)

US qt (U.S. quart)

Imp qt (Imperial quart)

ml (milliliter)

cc (cubic centimeter)

cu in (cubic inch)

fl oz (fluid ounce)

Weight

g (gram)

oz (ounce)

NEW STANDARDS

GI5

GI

NEW STANDARDS TABLE

A6E202800020T01

• Following is a comparison of the previous standard and the new standard.

NEW STANDARDS

New Standard Previous Standard

Remark

Abbrevi-

ation

Name

Abbrevi-

ation

Name

AP Accelerator Pedal  Accelerator Pedal

ACL Air Cleaner  Air Cleaner

A/C Air Conditioning  Air Conditioning

BARO Barometric Pressure  Atmospheric Pressure

B+ Battery Positive Voltage Vb Battery Voltage

 Brake Switch  Stoplight Switch

 Calibration Resistor  Corrected Resistance #6

CMP sensor Camshaft Position Sensor  Crank Angle Sensor

CAC Charge Air Cooler  Intercooler

CLS Closed Loop System  Feedback System

CTP Closed Throttle Position  Fully Closed

CPP Clutch Pedal Position  Clutch Position

CIS Continuous Fuel Injection System EGI Electronic Gasoline Injection System

CS sensor Control Sleeve Sensor CSP sensor Control Sleeve Position Sensor #6

CKP sensor Crankshaft Position Sensor  Crank Angle Sensor 2

DLC Data Link Connector  Diagnosis Connector

DTM Diagnostic Test Mode  Test Mode #1

DTC Diagnostic Trouble Code(s)  Service Code(s)

DI Distributor Ignition  Spark Ignition

DLI Distributorless Ignition  Direct Ignition

EI Electronic Ignition  Electronic Spark Ignition #2

ECT Engine Coolant Temperature  Water Thermo

EM Engine Modification  Engine Modification

 Engine Speed Input Signal  Engine RPM Signal

EVAP Evaporative Emission  Evaporative Emission

EGR Exhaust Gas Recirculation  Exhaust Gas Recirculation

FC Fan Control  Fan Control

FF Flexible Fuel  Flexible Fuel

4GR Fourth Gear  Overdrive

 Fuel Pump Relay  Circuit Opening Relay #3

FSO

solenoid

Fuel Shut Off Solenoid FCV Fuel Cut Valve #6

GEN Generator  Alternator

GND Ground  Ground/Earth

HO2S Heated Oxygen Sensor  Oxygen Sensor With heater

IAC Idle Air Control  Idle Speed Control

 IDM Relay  Spill Valve Relay #6

 Incorrect Gear Ratio  

 Injection Pump FIP Fuel Injection Pump #6

 Input/Turbine Speed Sensor  Pulse Generator

IAT Intake Air Temperature  Intake Air Thermo

KS Knock Sensor  Knock Sensor

MIL Malfunction Indicator Lamp  Malfunction Indicator Light

MAP Manifold Absolute Pressure  Intake Air Pressure

MAF sensor Mass Air Flow Sensor  Airflow Sensor

MFL Multiport Fuel Injection  Multiport Fuel Injection

OBD On-Board Diagnostic  Diagnosis/SelfDiagnosis

OL Open Loop  Open Loop

GI6

NEW STANDARDS

#1 : Diagnostic trouble codes depend on the diagnostic test mode

#2 : Controlled by the PCM

#3 : In some models, there is a fuel pump relay that controls pump speed. That relay is now called the fuel pump

relay (speed).

#4 : Device that controls engine and powertrain

#5 : Directly connected to exhaust manifold

#6 : Part name of diesel engine

End Of Sie

 Output Speed Sensor  Vehicle Speed Sensor 1

OC Oxidation Catalytic Converter  Catalytic Converter

O2S Oxygen Sensor  Oxygen Sensor

PNP Park/Neutral Position  Park/Neutral Range

 PCM Control Relay  Main Relay #6

PSP Power Steering Pressure  Power Steering Pressure

PCM Powertrain Control Module ECU Engine Control Unit #4

 Pressure Control Solenoid  Line Pressure Solenoid Valve

PAIR Pulsed Secondary Air Injection  Secondary Air Injection System

Pulsed

injection

 Pump Speed Sensor  NE Sensor #6

AIR Secondary Air Injection  Secondary Air Injection System

Injection

with air

pump

SAPV Secondary Air Pulse Valve  Reed Valve

SFI Sequential Multipoint Fuel Injection  Sequential Fuel Injection

 Shift Solenoid A

 1-2 Shift Solenoid Valve

 Shift A Solenoid Valve

 Shift Solenoid B

 2-3 Shift Solenoid Valve

 Shift B Solenoid Valve

 Shift Solenoid C  3-4 Shift Solenoid Valve

3GR Third Gear  3rd Gear

TWC Three Way Catalytic Converter  Catalytic Converter

TB Throttle Body  Throttle Body

TP sensor Throttle Position Sensor  Throttle Sensor

TCV Timer Control Valve TCV Timing Control Valve #6

TCC Torque Converter Clutch  Lockup Position

TCM

Transmission (Transaxle) Control

Module

 ECAT Control Unit



Transmission (Transaxle) Fluid

Temperature Sensor

 ATF Thermosensor

TR Transmission (Transaxle) Range  Inhibitor Position

TC Turbocharger  Turbocharger

VSS Vehicle Speed Sensor  Vehicle Speed Sensor

VR Voltage Regulator  IC Regulator

VAF sensor Volume Air Flow Sensor  Air flow Sensor

WUTWC

Warm Up Three Way Catalytic

Converter

 Catalytic Converter #5

WOT Wide Open Throttle  Fully Open

New Standard Previous Standard

Remark

Abbrevi-

ation

Name

Abbrevi-

ation

Name

B1

B

BENGINE

ABBREVIATIONS ..................................................B-2

ABBREVIATIONS ................................................ B-2

OUTLINE ................................................................B-2

OUTLINE OF CONSTRUCTION..........................B-2

FEATURES .......................................................... B-2

ENGINE PERFORMANCE CURVE..................... B-3

SPECIFICATIONS ...............................................B-4

STRUCTURAL VIEW...........................................B-4

ENGINE .................................................................. B-5

CYLINDER HEAD COVER .................................. B-5

CYLINDER HEAD ............................................... B-5

CYLINDER HEAD GASKET ................................ B-6

CYLINDER BLOCK ............................................. B-6

CRANKSHAFT, MAIN BEARING.........................B-8

BALANCER UNIT ................................................B-9

CRANKSHAFT PULLEY .................................... B-11

ENGINE FRONT COVER ..................................B-12

PISTON, PISTON RING, PISTON PIN .............. B-13

CONNECTING ROD,

CONNECTING ROD BEARING......................B-14

DRIVE BELT ......................................................B-15

ENGINE MOUNT ............................................... B-16

VALVE MECHANISM ...........................................B-19

VALVE MECHANISM.........................................B-19

CAMSHAFT ....................................................... B-20

CAMSHAFT SPROCKET................................... B-22

CRANKSHAFT SPROCKET .............................. B-23

TIMING CHAIN, CHAIN TENSIONER ...............B-24

VALVE, VALVE SPRING, VALVE SEAL,

VALVE GUIDE ................................................ B-25

TAPPET ............................................................. B-26

VALVE MECHANISM.........................................B-27

VARIABLE VALVE TIMING ACTUATOR........... B-33

OIL CONTROL VALVE (OCV) ........................... B-33

B2

ABBREVIATIONS , OUTLINE

ABBREVIATIONS

A6E220102000T01

End Of Sie

OUTLINE OF CONSTRUCTION

A6E220202000T01

• The new L8 engine models (1.8L) has been adopted for European specs.

• The new LF engine models (2.0L) has been adopted.

• The new L3 (with variable valve timing mechanism) engine models (2.3L) has been adopted for European

specs.

End Of Sie

FEATURES

A6E220202000T02

Improved engine performance

• The variable valve timing mechanism has been adopted for L3 engine models (2.3L).

Reduced engine weight

• Main parts (cylinder head and cylinder block) made of aluminum alloy.

Reduced engine noise and vibration

• The cylinder head is made of aluminum alloy.

• The cassette type balancer unit has been adopted for the L3 engine models (2.3L).

• Silent timing chain has been adopted.

• A deep skirt type and forms the ladder frame structure with the integrated main bearing cap has been adopted

for the cylinder block.

• The crankshaft pulley with torsional damper has been adopted.

• The engine mount of pendulum type has been adopted.

Improved serviceability

• The drive belt of serpentine type has been adopted.

• Tension of the drive belt is adjusted automatically with an auto-tensioner.

• Timing chains have been adopted to eliminate the need for replacement.

• The engine front cover with service hole has been adopted. (for unlocking the chain adjust ratchet, and

securing the tensioner arm).

End Of Sie

ABBREVIATIONS

A/C Air conditioner

ABDC After bottom dead center

ATDC After top dead center

BBDC Before bottom dead center

BTDC Before bottom dead center

DOHC Double overhead camshaft

EX Exhaust

IN Intake

OCV Oil control valve

P/S Power steering

PCV Positive crankcase ventilation

SST Special service tool

TDC Top dead center

OUTLINE

B3

B

ENGINE PERFORMANCE CURVE

A6E220202000T04

AME2202N001

1 Engine speed

2Output

3Torque

B4

OUTLINE

End Of Sie

SPECIFICATIONS

A6E220202000T03

End Of Sie

STRUCTURAL VIEW

A6E220202000T05

End Of Sie

Item

Specification

L8 LF L3

Type Gasoline, 4-cycle

Cylinder arrangement and number In-line, 4-cylinder

Combustion chamber Pentroof

Valve system DOHC, timing chain driven, 16 valves

Displacement (ml {cc, cu in})

1,798

{1,798, 109.7}

1,999

{1,999, 121.9}

2,261

{2,261, 137.9}

Bore × stroke (mm {in})

83.0 × 83.1

{3.27 ×3.27}

87.5 × 83.1

{3.44 ×3.27}

87.5 × 94.0

{3.44 × 3.70}

Compression ratio 10.8:1 10.8:1 10.6:1

Compression pressure

(kPa {kgf/cm

2

, psi} [rpm])

1,750 {17.85, 253.8}

[300]

1,720 {17.54,

249.5} [300]

1,430 {14.58, 207.4}

[290]

Valve timing

IN

Open BTDC (°) 4 4 025

Close ABDC (°) 33 52 037

EX

Open BBDC (°)37 37 42

Close ATDC (°)4 4 5

Valve

clearance

(mm {in})

IN 0.22 {0.0087} 0.28 {0.011} [Engine cold]

EX 0.27 {0.011} 0.33 {0.012} [Engine cold]

AME2202N002

ENGINE

B5

B

CYLINDER HEAD COVER

A6E222410100T01

Structure

• The cylinder head cover is made of integrated aluminum alloy, which is lightweight and sound absorbent.

• The oil filler cap is a screw-in type. The boss for installing the camshaft position (CMP) sensor is provided at

the rear of the cylinder head cover.

• L3 engine models has a hole for installing the oil control (OCV) valve.

.

End Of Sie

CYLINDER HEAD

A6E222410100T02

Structure

• The cylinder head is made of a high heat conductive, lightweight aluminum alloy, which has been quenched.

• Compact, pentroof-type combustion chambers have been adopted. The spark plugs are mounted at the top of

the combustion chambers to improve combustion efficiency.

• The intake/exhaust port layout is a cross flow type, (the angle between two valves is 39°, the two intake valves

and the two exhaust valves per cylinder) which improves air intake/exhaust efficiency.

• The cylinder head bolt is a plastic region tightening bolt, which is tightened in five motions. It insures a stable

axis during tightening.

.

ENGINE

AME2224N001

1 Camshaft position (CMP) sensor

2 Oil control (OCV) valve attachment hole (L3)

3 Oil filler cap

AME2224N002

1 Cylinder head bolt

2 Exhaust side

3 Intake side

4 Engine front side

5 The angle between two valves

6 Intake port

7 Exhaust port

B6

ENGINE

End Of Sie

CYLINDER HEAD GASKET

A6E222410271T01

Structure

• Cylinder head gaskets are 2 layer-metal gaskets.

.

End Of Sie

CYLINDER BLOCK

A6E222410300T01

Structure

• The cylinder block is made of aluminum alloy, which is cast with the cast iron liner, improving heat radiation and

decreasing weight.

• The cylinder block is a deep skirt type and forms the ladder frame structure with the integrated main bearing

cap. The water jacket of the cylinder block is a closed deck type. Its higher rigidity reduces vibration and noise.

• The cylinder block has the oil separator cover on the opposite side of the fresh air intake, the PCV (positive

crankcase ventilation) valve and the oil separator function with an part for installing the PCV valve, to improve

blow-by gas ventilation efficiency.

• The tab for alignment, used to install the upper main journal and the lower main bearing, has been

decommissioned.

• The main bearing cap bolt is a plastic region tightening bolt, which is to be tightened in two motions. It insures

a stable axis during tightening.

AME2224N400

1 Beat plate

2Shim

3 A-A sectional view

ENGINE

B7

B

.

• The service hole for installing the SST, which is used for detect the No.1 cylinder's TDC position, is located at

the right side of the cylinder block. The TDC position can be detected when the SST edge touches the cutting

surface of the No.1 counter weight.

.

AME2224N003

1 Oil separator cover

2PCV valve

3 Main bearing cap

4 Oil separator cover attachment part

5 Cylinder block

1 Cylinder block

2 No.1 cylinder

3 Service hole

4 SST

5 No.1 cylinder TDC position

6 No.1 piston

7 Crankshaft counter

AME2224N004

B8

ENGINE

End Of Sie

CRANKSHAFT, MAIN BEARING

A6E222411301T01

Structure

• Cast iron 5 axle-hole 4 counter weight has been adopted for the L8 engine models and LF engine models

crankshafts.

• Cast iron 5 axle-hole 8 counter weight has been adopted for the L3 engine models crankshaft. The shrinkage

fitted drive gear is attached to the crankshaft and the crankshaft drives the balance shaft.

• The conventional positioning key has been decommissioned and the tightening pressure of the crankshaft

pulley tightening bolt secures the installation part of the crankshaft sprocket. When installing the crankshaft

sprocket, always use the SST and align the No.1 cylinder to TDC.

.

• The oil line for supplying oil to each journal is provided in the crankshaft. And the crank pin and the fillets on

both sides of journal are rolled so that they bear the heavy loads.

.

• The upper and lower main bearings are made of aluminum alloy and the upper side No.3 journal bearing is

integrated with the thrust bearing. The upper main bearing has the oil grooves and the oil holes.

• The upper and lower bearings' positioning tabs for installing the main journal have been decommissioned.

• Measure and attach the main bearings (upper and lower) so that they are positioned at the center the main

bearing cap.

AME2224N005

1Drive gear

AME2224N006

1Oil passage 2 Fillet roll area

ENGINE

B9

B

.

• Three kinds of main bearings are available depending on the oil clearance.

(mm {in})

End Of Sie

BALANCER UNIT

A6E222411301T02

Outline

• The cassette type balancer, which is separated

from the engine, has been adopted for the L3

engine models to reduce vibration from the

engine.

.

AME2224N007

1 Upper main bearing

2 Lower main bearing

3 Thrust bearing

4 Supplying engine oil

5 2 holes Supplying engine oil

6 Main bearing cap

7 Main bearing

Bearing

size

Color Bearing thickness

Standard Green 2.5062.509 {0.09870.0988}

0.25 {0.01}

Oversize

2.6282.634 {0.10350.1037}

0.50 {0.02}

Oversize

2.7532.759 {0.10840.1086}

1 Cassette type balancer unit

2 balance shaft

AME2224N401

B10

ENGINE

Structure

• The balancer unit is configured with two balancer shafts (No.1 and No.2) with weights, the balancer unit case

and the adjust shim which adjusts the amount of backlash in the crankshaft.

• The two balancer shafts (No.1 and No.2) are driven by the drive gear which is attached to the crankshaft.

• The balancer unit cannot be disassembled because it is a precision unit.

Operation

• The rotary motion is transmitted from the drive gear, which is between the back of the No.3 cylinder and the

No.4 main journal, directly to the No.1 balance shaft with driven gear. Then the balance unit transmits the

rotation motion to the No.2 balance shaft. The ratio of gears, which are attached to No.1 and No. 2 balancer

shafts, has been set so that the gear rotates at twice the velocity of the crankshaft. The balancer shaft's rotation

velocity counterbalances (generate the force in the opposite direction) the rotation inertial force (secondary

inertial rotation force) from the crankshaft.

.

• Replace the adjust shim to adjust backlash. There are 40 kinds of adjuster shim depending on the thickness.

To determine the kind, check the engraved identification mark (2 digits) on the adjust shim.

AME2224N402

1 Adjust shim

2 Crankshaft

3 Engine front

4 Balancer unit case

5Weights

6 No.2 balance shaft

7 Drive gear

8 No.1 balance shaft with driven gear

ENGINE

B11

B

.

End Of Sie

CRANKSHAFT PULLEY

A6E222411371T01

Structure

• The crankshaft position (CKP) signal detecting blade has been adopted for the crankshaft pulley. And the

torsional damper, which prevents the crankshaft from wobbling, has also been adopted for the crankshaft.

• The positioning key slot, which is used for attaching the pulley to the crankshaft, has been decommissioned.

For aligning the crankshaft pulley to the crankshaft, use the positioning hole on the engine front cover and the

crankshaft pulley.

• Crankshaft pulley rock bolt is the plastic region tightening bolt, which can be tightened in 2 motions. It insures a

stable axis during tightening.

.

End Of Sie

AME2224N403

1 Cylinder block 2 Engraved identification mark (2 digits)

1 Elevation view

2 Sectional view

3 Braid for CKP sensor signal detection

4 Hole for pulley positioning

5 Torsional damper

AME2224N012

B12

ENGINE

ENGINE FRONT COVER

A6E222401001T01

Structure

• The engine front cover is made of aluminum alloy, and is integrated with the No.3 engine-mounting bracket, to

improve noise absorption and decrease weight.

• The hole for crankshaft pulley positioning bolt, the service hole for unlocking the chain adjuster ratchet, and the

service hole for securing the tensioner arm when loosening the timing chain, are on the engine front cover.

• The oil line and the integrated oil filter are on the L3 engine front cover.

.

End Of Sie

AME2224N011

1 Elevational view

2 Service hole for tensioner arm fixation

3 Service hole for chain tensioner lock release

4 No.3 engine mount bracket

5 Bolt hole crankshaft pulley positioning

6 Back view

7 Oil filter

8 Oil passage to OCV

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