Mazda 6 2003 User Manual

Mazda6

CONTENTS

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.

Title Section

General Information

L8, LF, L3

Engine

MZR–CD (RF Turbo)

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

L8, LF, L3

MZR–CD (RF Turbo)

G35M

–

A65M

–

FN4A

–

JA5AX

GI

B1

B2

D

E

F1

F2

G

H

R J1

R J2

EL K1

–

EL K2

L

M

N

P

R

S

T

U

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.

Technical Data

Special Tools

There are explanation given only for the sections marked with shadow ( ).

PRINTED IN THE NETHERLANDS, JULY 2003 1789–1E–03G

TD

ST

VEHICLE IDENTIFICATION NUMBERS (VIN)

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

JMZ GG12R20# 100001— JMZ GG12T20# 100001— JMZ GG14R20# 100001— JMZ GG14T20# 100001— JMZ GY19R20# 100001— JMZ GY19T20# 100001—

RELATED MATERIALS

Mazda6 Training Manual

(European (L.H.D. U.K.), GCC specs.) . . . . . . . . . . . . 3359–1*–02C

Mazda6 Workshop Manual

(European (L.H.D. U.K.), GCC specs.) . . . . . . . . . . . . 1730–1*–02C

Mazda6 Workshop Manual Supplement

(European (L.H.D. U.K.), GCC specs.) . . . . . . . . . . . . 1749–1*–02G

Mazda6 Workshop Manual Supplement

(European (L.H.D. U.K.), GCC specs.) . . . . . . . . . . . . 1776–10–03G

Engine Workshop Manual MZR–CD (RF Turbo) . . . . . 1744–1E–02D

Manual Transaxle Workshop Manual A65M–R . . . . . . 1739–1E–02D

Mazda6 Wiring Diagram

(European (L.H.D.), GCC specs.) . . . . . . . . . . . . . . . . 5558–1*–02G

Mazda6 Wiring Diagram Supplement

(European (L.H.D.), GCC specs.) . . . . . . . . . . . . . . . . 5575–10–03A

Mazda6 Wiring Diagram

(U.K. specs.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5559–1*–02G

Mazda6 Wiring Diagram Supplement

(U.K. specs.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5576–10–03A

Mazda6 Bodyshop Manual

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

Mazda6 Bodyshop Manual Supplement Wagon

(European (L.H.D. U.K.), Australian,

General (L.H.D. R.H.D.) specs.). . . . . . . . . . . . . . . . . . 3368–1*–02I

EOBD Training Manual

(General (L.H.D. R.H.D.) specs.) . . . . . . . . . . . . . . . . . 3345–1*–00B

* : Indicates the printing location

E: Europe

0: Japan

WARNING

Servicing a vehicle can be dangerous. If you have not received service-related training, the risks of injury, property damage, and failure of servicing increase. The recommended servicing procedures for the vehicle in this workshop manual were developed with Mazda-trained technicians in mind. This manual may be useful to non-Mazda trained technicians, but a technician with our service-related training and experience will be at less risk when performing service operations. However, all users of this manual are expected to at least know general safety procedures.

This manual contains "Warnings" and "Cautions" applicable to risks not normally encountered in a general technician's experience. They should be followed to reduce the risk of injury and the risk that improper service or repair may damage the vehicle or render it unsafe. It is also important to understand that the "Warnings" and "Cautions" are not exhaustive. It is impossible to warn of all the hazardous consequences that might result from failure to follow the procedures.

The procedures recommended and described in this manual are effective methods of performing service and repair. Some require tools specifically designed for a specific purpose. Persons using procedures and tools which are not recommended by Mazda Motor Corporation must satisfy themselves thoroughly that neither personal safety nor safety of the vehicle will be jeopardized.

The contents of this manual, including drawings and specifications, are the latest available at the time of printing, and reserves the right to change the vehicle designs and alter the contents of this manual without notice and without incurring obligation.

Parts should be replaced with genuine Mazda replacement parts or with parts which match the quality of genuine Mazda replacement parts. Persons using replacement parts of lesser quality than that of genuine Mazda replacement parts must satisfy themselves thoroughly that neither personal safety nor safety of the vehicle will be jeopardized.

Mazda Motor Corporation is not responsible for any problems which may arise from the use of this manual. The cause of such problems includes but is not limited to insufficient service-related training, use of improper tools, use of replacement parts of lesser quality than that of genuine Mazda replacement parts, or not being aware of any revision of this manual.

Mazda Motor Corporation

GI

GENERAL INFORMATION

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

RANGE OF TOPICS .......................................... GI-2

VIN CODE ............................................................. GI-3

VIN CODE.......................................................... GI-3

NEW STANDARDS .............................................. GI-4

NEW STANDARDS TABLE ............................... GI-4

ABBREVIATIONS ................................................ GI-6

ABBREVIATIONS TABLE .................................. GI-6

SCHEDULED MAINTENANCE ............................ GI-7

SCHEDULED MAINTENANCE TABLE ............. GI-7

GI

GI–1

HOW TO USE THIS MANUAL

RANGE OF TOPICS

• 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

B6E201000001101

GI–2

VIN CODE

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

J M Z GG 1 2 3 2 0 # 1 2 3 4 5 6

End Of Sie

Plant

Dammy Dammy

For Others (Israel etc.) : Model year

Transaxle

Engine

Body style

Remarks

Vehicle type

World manufacturer identification

GI

B6E200800021101

Serial No. 0=Hiroshima

1=Hofu

0 3 to 9 (same as Model year-Israel) 3=2003, 4=2004

2=5MTX 5=4ATX 7=5ATX

3=2.3L (L3)

8=1.8L (L8) F=2.0L (LF)

R=MZR-CD (RF-Turbo)-Hi

T=MZR-CD (RF-Turbo)-Low

2=4SD 4=5HB 9=WAGON

8=4WD 1=2WD

GG=MAZDA6 (4SD, 5HB)

GY=MAZDA6 (WAGON)

JMZ=Europe (L.H.D. U.K.)

B6E2008W001

GI–3

NEW STANDARDS

NEW STANDARDS TABLE

• The following is a comparison of the previous standard and the new standard.

New Standard Previous Standard

Abbrevi-

ation

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

— 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

— Closed Throttle Position Switch — Idle Switch

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 — 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

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

MFI Multiport Fuel Injection — Multiport Fuel Injection

OBD On Board Diagnostic — Diagnosis/Self Diagnosis

Fuel Shut Off Solenoid FCV Fuel Cut Valve #6

Name

Abbrevi-

ation

V

B

Name

Battery Voltage

B6E202800020101

Remark

GI–4

NEW STANDARDS

New Standard Previous Standard

Abbrevi-

ation

OL Open Loop — Open Loop

— Output Speed Sensor — Vehicle Speed Sensor 1

OC Oxidation Catalytic Converter — Catalytic Converter O2S Oxygen Sensor — Oxygen Sensor PNP Park/Neutral Position — Park/Neutral Range

— PCM Control Relay — Main Relay #6

PSP Power Steering Pressure — Power Steering Pressure

PCM Powertrain Control Module ECU Engine Control Unit #4

— Pressure Control Solenoid — Line Pressure Solenoid Valve

PAIR Pulsed Secondary Air Injection — Secondary Air Injection System

— Pump Speed Sensor — NE Sensor #6

AIR Secondary Air Injection — Secondary Air Injection System

SAPV Secondary Air Pulse Valve — Reed Valve

SFI Sequential Multiport Fuel Injection — Sequential Fuel Injection

— Shift Solenoid A

— Shift Solenoid B

— 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

—

TR Transmission (Transaxle) Range — Inhibitor Position TC Turbocharger — Turbocharger

VSS Vehicle Speed Sensor — Vehicle Speed Sensor

VR Voltage Regulator — IC Regulator

VAF sensor Volume Air Flow Sensor — Airflow Meter

WU-TWC

WOT Wide Open Throttle — Fully Open

Transmission (Transaxle) Control Module

Transmission (Transaxle) Fluid Temperature Sensor

Warm Up Three Way Catalytic Converter

Name

Abbrevi-

ation

— 1–2 Shift Solenoid Valve — Shift A Solenoid Valve — 2–3 Shift Solenoid Valve — Shift B Solenoid Valve

— EC-AT Control Unit

— ATF Thermosensor

— Catalytic Converter #5

Name

Remark

GI

Pulsed injection

Injection with air pump

#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

GI–5

ABBREVIATIONS

ABBREVIATIONS TABLE

CAN Controller Area Network IDM Injector Driver Module KOEO Key On Engine Off KOER Key Off Engine Running OFF Switch Off ON Switch On PID Parameter Identification SW Switch TCV Timer Control Valve VBC Variable Boost Control VSC Variable Swirl Control WDS Worldwide Diagnostic System

End Of Sie

B6E203000011101

GI–6

SCHEDULED MAINTENANCE

SCHEDULED MAINTENANCE TABLE

B6E203400013101

For Europe (L.H.D. U.K.) Chart symbols: I : Inspect and clean, repair, adjust, or replace if necessary. R : Replace C : Clean Remarks:

• 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.

• Refer below for a description of items marked* in the maintenance chart.

*1: If the vehicle is operated under any of the following conditions, change the engine oil and oil filter every 10,000 km

(6,250 miles) or shorter.

a. Driving in dusty conditions. b. Extended periods of idling or low speed operation.

c. Driving for long period in cold temperatures or driving regularly at short distance only. *2: Also inspect and adjust the power steering and air conditioner drive belts, if installed. *3: If the brakes are used extensively (for example, continuous hard driving or mountain driving) or if the vehicle is

operated in extremely humid climates, change the brake fluid annually.

*4: If the vehicle is operated in very dusty or sandy areas, clean and if necessary, replace the air cleaner element more

often than the recommended intervals.

*5: Replacement of the timing belt is required at every 100,000 km (62,500 miles).

Failure to replace the timing belt may result in damage to the engine.

*6: Replacement of the timing belt is required at every 120,000 km (75,000 miles).

Failure to replace the timing belt may result in damage to the engine.

*7: If the vehicle is operated under any of the following conditions, change the rear differential oil every 45,000 km (27,000

miles).

a. Towing a trailer or using a car - top carrier

b. Driving in dusty, sandy or wet condition

c. Extended periods of idling or low speed operation

d. Repeated short trips of less than 16 km (10 miles) *8: If this component has been submerged in water, the oil should be changed.

GI

Maintenance Interval (Number of months or km (miles), whichever comes first)

Maintenance Item

GASOLINE ENGINE

Engine valve clearance Audible inspect every 120,000 km (75,000 miles), if noisy, adjust Spark plugs Replace every 100,000 km (62,500 miles) Air cleaner element *4 R R R Evaporative system (if installed) I I I

DIESEL ENGINE

Engine valve clearance I I

Engine timing belt

Fuel filter R R R Fuel injection system I I I I Air cleaner element *4 C C R C C R C C R E.G.R. system I I I

GASOLINE and DIESEL ENGINE

Engine oil *1 R R R R R R R R R Engine oil filter *1RRRRRRRRR Drive belts *2 I I I Cooling system (including coolant level adjustment) I I I I

Engine coolant

Finland, Sweden, Norway*5 Replace every 100,000 km (62,500 miles)

Months 12 24 36 48 60 72 84 96 108

××××1000 km 20 40 60 80 100 120 140 160 180

××××1000 miles 12.5 25 37.5 50 62.5 75 87.5 100 112.5

Others*6 Replace every 120,000 km (75,000 miles)

Replace at first 4 years or 100,000 km (62,500 miles);

after that, every 2 years

GI–7

SCHEDULED MAINTENANCE

Maintenance Interval (Number of months or km (miles), whichever comes first)

Maintenance Item

Fuel lines & hoses I I I I Battery electrolyte level & specific gravity I I I I I I I I I Brake fluid *3 R R R R Brake lines, hoses & connections I I I I I I I I I Parking brake IIIIIIIII Power brake unit & hoses I I I I I I I I I Disc brakes I I I I I I I I I Power steering fluid, lines, hoses, and connections I I I I I I I I I Steering operation & linkages I I I I Manual transaxle oil R Automatic transaxle fluid level I I I

Rear differential oil (for 4WD)

Transfer oil (for 4WD)

Front & rear suspension & ball joints I I I I Drive shaft dust boots I I I I Exhaust system and heat shields I I Cabin air filter (if installed) (pollen filter) R R R R Body condition

(for rust, corrosion & perforation) Tires (including spare tyre)

(with inflation pressure adjustment)

Months 12 24 36 48 60 72 84 96 108

××××1000 km 20 40 60 80 100 120 140 160 180

××××1000 miles 12.5 25 37.5 50 62.5 75 87.5 100 112.5

*7*

8

*

8

Inspect annually

IIIIIIIII

Scheduled Maintenance Service (Specific Work Required)

• The specific work required for each maintenance item is listed in the following table. (Please refer to the section applicable to the model serviced.)

For Europe (L.H.D. U.K.)

Bold frames: New item

Maintenance Item Specific Work Required

ENGINE

Engine valve clearance Measure clearance

Drive belts

Engine timing belt Replace engine timing belt. Engine oil Replace engine oil and inspect for leakage. Oil filter Replace oil filter and inspect for leakage.

COOLING SYSTEM

Cooling system (including coolant level adjustment)

Engine coolant Replace coolant.

FUEL SYSTEM

Air cleaner element

Fuel filter Replace fuel filter. Fuel lines & hoses Inspect for cracks, leakage and loose connection. Fuel injection system (for MZR-CD (RF Turbo)) Update to injection amount correction with WDS. (see W/M)

IGNITION SYSTEM (FOR GASOLINE)

Spark plugs

EMISSION CONTROL SYSTEM

Evaporative system (for gasoline)

E.G.R. system (MZR-CR (RF Turbo))

Inspect for wear, cracks and fraying, and check tension. Replace drive belt.

Check coolant level and quality, and inspect for leakage.

Inspect for dirt, oil and damage. Clean air cleaner element (by blowing air). Replace air cleaner element.

Inspect for wear, damage, carbon, high-tension lead condition and measure plug gap. Replace spark plugs.

Check system operation (see W/M), vapor lines, vacuum fitting hoses and connection.

Check system operation (see W/M), vacuum fitting hoses and connection. Update to MAF correction for E.G.R control with WDS. (see W/M)

GI–8

SCHEDULED MAINTENANCE

Maintenance Item Specific Work Required

ELECTRICAL SYSTEM

Battery electrolyte level & specific gravity Check level and specific gravity.

CHASSIS & BODY

Brake fluid

Brake lines, hoses & connections

Parking brake Check lever stroke.

Power brake unit & hoses

Disc brakes

Power steering fluid & lines

Power steering fluid Check fluid level.

Power steering system & hoses

Steering operation & gear housing

Steering linkages tie rod ends & arms

Front & rear suspension ball joints Inspect for grease leakage, cracks, damage and looseness.

Manual transmission/transaxle oil

Automatic transmission/transaxle fluid level Check fluid level.

Rear differential oil

Transfer oil (for 4×4)

Drive shaft dust boots Inspect for grease leakage, cracks, damage and looseness. Body condition

(for rust, corrosion & perforation) Exhaust system and heat shields Inspect for damage, corrosion, looseness of connections and gas leakage. Tires

(including spare tire) (with inflation pressure adjustment)

AIR CONDITIONER SYSTEM (IF EQUIPPED)

Cabin air filter Replace cabin air filter.

Check fluid level and inspect for leakage. Replace brake fluid.

Inspect for cracks, damage, chafing, corrosion, scars, swelling and fluid leakage.

Check vacuum lines, connections and check valve for improper attachment, air tightness, cracks chafing and deterioration.

Test for judder and noise. Inspect caliper for correct operation and fluid leakage, brake pads for wear. Check disc plate condition and thickness.

Check fluid level and lines for improper attachment, leakage, cracks, damage, loose connections, chafing and deterioration.

Check lines for improper attachment, leakage, cracks, damage, loose connections, chafing and deterioration.

Check that the steering wheel has the specified play. Be sure to check for changes, such as excessive play, hard steering or strange noises. Check gear housing and boots for looseness, damage and grease/gear oil leakage.

Check ball joint, dust cover and other components for looseness, wear, damage and grease leakage.

Check oil level and inspect for leakage. Replace manual transmission/transaxle oil.

Check oil level and inspect for leakage. Replace rear differential oil.

Check oil level and inspect for leakage. Replace transfer oil.

Inspect body surface for paint damage, rust, corrosion and perforation.

Check air pressure and inspect tires for tread wear, damage and cracks; and wheels for damage and corrosion.

GI

End Of Sie

GI–9

F2

FUEL AND EMISSION CONTROL SYSTEMS

[MZR-CD (RF Turbo)]

FEATURES

OUTLINE .............................................................. F2-3

OUTLINE OF CONSTRUCTION ....................... F2-3

FEATURES ........................................................ F2-3

SPECIFICATIONS ............................................. F2-3

CONTROL SYSTEM DIAGRAM........................ F2-4

CONTROL SYSTEM WIRING DIAGRAM.......... F2-6

CONTROL SYSTEM........................................... F2-10

CONTROL SYSTEM OUTLINE ....................... F2-10

STRUCTURAL VIEW....................................... F2-13

BLOCK DIAGRAM ........................................... F2-15

CONTROL DEVICE AND CONTROL

RELATIONSHIP CHART .............................. F2-17

ON-BOARD DIAGNOSTIC................................. F2-18

ON-BOARD DIAGNOSTIC OUTLINE.............. F2-18

DIAGNOSTIC TEST MODE............................. F2-18

DTC DETECTION LOGIC AND

CONDITIONS ............................................... F2-21

PID/DATA MONITOR AND RECORD ............. F2-26

SIMULATION TEST ......................................... F2-28

SERVICE

OUTLINE ............................................................ F2-30

SUPPLEMENTAL SERVICE

INFORMATION............................................. F2-30

CONTROL SYSTEM........................................... F2-31

PCM INSPECTION .......................................... F2-31

EGR VALVE POSITION SENSOR

INSPECTION ................................................ F2-37

ON-BOARD DIAGNOSTIC................................. F2-38

FOREWORD.................................................... F2-38

OBD PENDING TROUBLE CODES ................ F2-38

OBD FREEZE FRAME DATA .......................... F2-38

OBD READ/CLEAR DIAGNOSTIC

TEST RESULTS ........................................... F2-38

OBD PARAMETER IDENTIFICATION

(PID) ACCESS.............................................. F2-38

ON-BOARD DIAGNOSTIC TEST .................... F2-38

OBD DRIVE MODE ......................................... F2-39

DTC TABLE ..................................................... F2-40

DTC P0016 ...................................................... F2-42

DTC P0045 ...................................................... F2-43

DTC P0088 ...................................................... F2-46

DTC P0093 ...................................................... F2-47

DTC P0096 ...................................................... F2-48

DTC P0097 ...................................................... F2-49

DTC P0098 ...................................................... F2-51

DTC P0101 ...................................................... F2-54

DTC P0102 ...................................................... F2-55

DTC P0103 ...................................................... F2-58

DTC P0106 ...................................................... F2-60

DTC P0107 ...................................................... F2-61

DTC P0108 ...................................................... F2-64

DTC P0111 ...................................................... F2-66

DTC P0112 ...................................................... F2-67

DTC P0113 ...................................................... F2-69

DTC P0116 ...................................................... F2-72

DTC P0117 ...................................................... F2-74

DTC P0118 ...................................................... F2-75

DTC P0122 ...................................................... F2-78

DTC P0123 ...................................................... F2-80

DTC P0182 ...................................................... F2-82

DTC P0183 ...................................................... F2-84

DTC P0191 ...................................................... F2-86

DTC P0192 ...................................................... F2-87

DTC P0193 ...................................................... F2-90

DTC P0200 ...................................................... F2-92

DTC P0201 ...................................................... F2-95

DTC P0202 ...................................................... F2-98

DTC P0203 .................................................... F2-101

DTC P0204 .................................................... F2-104

DTC P0222 .................................................... F2-107

DTC P0223 .................................................... F2-110

DTC P0225 .................................................... F2-112

DTC P0301, P0302, P0303, P0304 ............... F2-114

DTC P0336 .................................................... F2-116

DTC P0337 .................................................... F2-117

DTC P0341 .................................................... F2-120

DTC P0342 .................................................... F2-121

DTC P0401 .................................................... F2-124

DTC P0402 .................................................... F2-125

DTC P0404 .................................................... F2-126

DTC P0406 .................................................... F2-127

DTC P0489 .................................................... F2-130

DTC P0490 .................................................... F2-132

DTC P0500 .................................................... F2-134

DTC P0504 .................................................... F2-134

DTC P0512 .................................................... F2-137

DTC P0562 .................................................... F2-140

DTC P0563 .................................................... F2-141

DTC P0564 .................................................... F2-144

DTC P0602 .................................................... F2-146

DTC P0606 .................................................... F2-146

DTC P0610 .................................................... F2-147

DTC P0627 .................................................... F2-147

DTC P0628 .................................................... F2-150

DTC P0629 .................................................... F2-152

DTC P0661 .................................................... F2-154

DTC P0662 .................................................... F2-156

DTC P0664 .................................................... F2-158

DTC P0665 .................................................... F2-160

DTC P0704 .................................................... F2-162

DTC P0850 .................................................... F2-164

DTC P1190 .................................................... F2-166

DTC P1211 .................................................... F2-169

DTC P1391 .................................................... F2-170

DTC P1392 .................................................... F2-173

DTC P2009 .................................................... F2-176

DTC P2010 .................................................... F2-178

DTC P2135 .................................................... F2-180

DTC P2136 .................................................... F2-180

DTC P2141 .................................................... F2-182

F2

F2–1

DTC P2142 .................................................... F2-185

DTC P2144 .................................................... F2-187

DTC P2145 .................................................... F2-189

DTC P2146 .................................................... F2-191

DTC P2149 .................................................... F2-194

DTC P2227 .................................................... F2-197

DTC P2228 .................................................... F2-197

DTC P2229 .................................................... F2-198

TROUBLESHOOTING...................................... F2-200

SYMPTOM QUICK DIAGNOSIS CHART ...... F2-200

NO.5 ENGINE STALLS-AFTER

START/AT IDLE.......................................... F2-205

NO.6 CRANKS NORMALLY BUT WILL

NOT START................................................ F2-209

NO.8 ENGINE RUNS ROUGH/ROLLING

IDLE ............................................................ F2-212

NO.10 LOW IDLE/STALLS DURING

DECELERATION ........................................ F2-214

NO.11 ENGINE STALLS/QUITS, ENGINE

RUNS ROUGH, MISSES, BUCK/LERK,

HESITATION/STUMBLE............................. F2-217

NO.12 LACK/LOSS OF POWER-

ACCELERATION/CRUISE.......................... F2-220

NO.13 KNOCKING/PINGING ........................ F2-224

NO.15 EMISSION COMPLIANCE ................. F2-227

NO.19 EXCESSIVE BLACK SMOKE............. F2-230

ENGINE CONTROL SYSTEM OPERATION

INSPECTION .............................................. F2-232

F2–2

OUTLINE

OUTLINE OF CONSTRUCTION

B6E400218881101

• The fuel and emission control system is essentially carried over from that of the previous Mazda6 (GG, GY) MZR-CD (RF Turbo) engine models, except for the following features. (See Mazda6 Workshop Manual Supplement 1749-1*-02G.)

End Of Sie

FEATURES

Improved Emission Performance

• A EGR valve position sensor has been adopted.

Improved Serviceability

• The number of DTCs has been increased to provide more detail information.

• The DTC troubleshooting procedures have been renewed due to the adoption of the diagnostic test mode and

OBD drive mode.

• The PID item has been added.

• The simulation item has been added.

B6E400218881102

End Of Sie

SPECIFICATIONS

Item

Air cleaner element Type Non woven fabric (dry) Supercharger Type Turbocharger Glow plug Type Metal Pump Type Supply pump

Fuel tank

Catalyst Type Warm up oxidation catalyst, Oxidation catalyst EGR control Type Duty control PCV system Type Closed

Capacity

(L {US gal, lmp gal})

New Mazda6 (GG, GY) Previous Mazda6 (GG, GY)

MZR-CD (RF Turbo)

64 {17, 14}

B6E400218881103

F2

End Of Sie

F2–3

OUTLINE

CONTROL SYSTEM DIAGRAM

.

51

47

48

49

50

52

53

56

45

46

43

44

26

25

24

27

23

22

54

57

15

A

B6E400218881104

5

13

30

16

17

12

14

11

31

10

9

6

55

*

18

19

34

4

8

B

3

2

1

7

29

28

20

35

33

A

21

B

32

39

36

37

42

41

38

40

B6E4002W002

1 Air cleaner 2 Vacuum chamber 3 VBC check valve 4 MAF/IAT sensor 5 VBC solenoid valve 6 Vacuum damper 7 Guide blade actuator 8 Turbocharger

9 Charge air cooler 10 IAT sensor No.2 11 Boost sensor 12 Intake shutter valve actuator 13 Intake shutter solenoid valve (half) 14 Intake shutter solenoid valve (full) 15 EGR solenoid valve (vacuum) 16 EGR solenoid valve (vent) 17 EGR control solenoid valve 18 EGR valve 19 EGR water cooler 20 VSC valve actuator 21 VSC solenoid valve 22 Fuel tank 23 Fuel filter 24 Fuel warmer 25 Supply pump 26 Suction control valve 27 Fuel temperature sensor 28 Common rail 29 Fuel pressure sensor 30 Fuel pressure limiter

F2–4

31 Glow plug 32 Fuel injector 33 ECT sensor 34 Calibration resistor 35 CMP sensor 36 Warm up oxidation catalytic converter 37 Oxidation catalytic converter 38 Silencer 39 Vacuum pump 40 CKP sensor 41 Idle switch 42 APP sensor 43 Glow plug relay 44 IDM 45 PCM 46 BARO sensor 47 PCM control relay 48 Engine switch 49 Starter (starter signal) 50 Neutral switch 51 Clutch switch 52 A/C switch 53 CAN bus 54 To PCM 55 EGR valve position sensor 56 DLC-2 57 Fuel flow

OUTLINE

F2

End Of Sie

F2–5

OUTLINE

CONTROL SYSTEM WIRING DIAGRAM

4

1A

1B 1C 1D 1E 1F

2

13 39

57

E

C

56

3

5

33 1

80

427 734

2878

1A

1B 1C 1D 1E 1F

1

B6E400218881105

6

1H

65 91

2A

2B 2C2D2E2F2G 2H

30 42

44 45

69E53

79 91460

a

b

c

d

e

f

g

43

h

i

j

k

1G

64

104

103

85

8

LOCK ACC ON ST

9

A

D

15

IG1

ACC

B

IG2

ST

16

14

17

21

20

C

A

D

22

DAE

CB

23

l

m

n

o

18

19

A

10

A

B

D

P

M

11

AA

12

B

13

7

.

1PCM

2DLC-2

3 Water heater unit

4Fuel pump

5 Other unit

6IDM

F2–6

A6E40022002

7Battery 8 Engine switch

9 Starter relay 10 Starter 11 Generator 12 Oil pressure switch

13 Sedimentor switch 14 Instrument cluster 15 Neutral switch 16 Clutch switch 17 Coil 18 Brake switch 19 Brake switch 2 20 Cruise control switch 21 With cruise control system 22 PCM control relay 23 MAF/IAT sensor

OUTLINE

F2

F2–7

OUTLINE

.

25

24

BD

C

A

27

26

BD

C

A

29

28

BD

C

ACBD

30

31

A

B

100

3938

A

B

67 77

40

A

B

35

a

b

c

d

e

f

g

37

62

89 11

32

A

81 55 29 3 99 72

B

34

C

A

B

3633

A

B

101

37

A

B

A

74

1

36

h

i

j

k

10

31

88

61

90

35

87 94 93 8

32

A

B

102

76

84

73 86

68

B

C

60

A

B

ABC

A

B

C

41

A

D

BC

43

B

C

AB

A

48

4745 4644

65

A

D

61

l

m

n

o

42

24 Calibration resistor No.1 25 Fuel injector No.1 26 Calibration resistor No.2 27 Fuel injector No.2 28 Calibration resistor No.3 29 Fuel injector No.3

64

63

62

59

E

C

49

AB

50

D

A

51

M

52 53

56 54

57

M

58

M

55

B6E4002W001

F2–8

30 Calibration resistor No.4 31 Fuel injector No.4 32 CMP sensor 33 CKP sensor 34 EGR solenoid valve (vacuum) 35 EGR solenoid valve (vent) 36 VSC solenoid valve 37 Intake shutter solenoid valve (half) 38 Intake shutter solenoid valve (full) 39 VBC solenoid valve 40 EGR control solenoid valve 41 Boost sensor 42 APP sensor 43 Idle switch 44 Fuel pressure sensor 45 ECT sensor 46 Fuel temperature sensor 47 Suction control valve 48 IAT sensor No.2 49 Cooling fan relay No.2 50 Cooling fan No.1 51 Refrigerant pressure switch (middle) 52 A/C switch 53 A/C amplifier 54 Cooling fan relay No.1 55 Cooling fan No.2 56 A/C relay 57 Refrigerant pressure switch (HI and LO) 58 Magnetic clutch 59 With A/C 60 Glow plug relay 61 Glow plug 62 Vacuum switch 63 Fuel warmer 64 With fuel warmer 65 EGR valve position sensor

OUTLINE

F2

End Of Sie

F2–9

CONTROL SYSTEM

CONTROL SYSTEM OUTLINE

B6E404018881101

• The control system is essentially carried over from that of the previous Mazda6 (GG, GY) MZR-CD (RF Turbo) engine models. (See Mazda6 Workshop Manual Supplement 1749-1*-02G.)

Input Device

×:Applicable –: Not applicable

New

Item

Battery ×

Starter (starter signal) ×

Starter relay ×

Clutch switch ×

Neutral switch ×

Brake switch ×

Idle switch ×

A/C switch ×

Refrigerant pressure switch ×

Cruise control switch ×

Accelerator position sensor ×

MAF/IAT sensor ×

IAT sensor No.2 ×

ECT sensor ×

Fuel temperature sensor ×

BARO sensor (integrated in PCM) ×

Boost sensor ×

Fuel pressure sensor ×

CMP sensor ×

CKP sensor ×

VSS ×

Calibration resistor ×

Immobilizer unit (integrated in PCM)

EGR valve position sensor × –

Mazda6

(GG, GY)

MZR-CD (RF Turbo)

(GG, GY)

×

Remark for new model

Same function as previous Mazda6 (GG, GY) MZR-CD (RF Turbo) engine model

Same function as previous Mazda PREMACY (CP) RF Turbo engine model

F2–10

Output Device

New

Item

Suction control valve ×

IDM ×

VSC solenoid valve ×

VBC solenoid valve ×

EGR control solenoid valve ×

EGR solenoid valve (vacuum) ×

EGR solenoid valve (vent) ×

Intake shutter solenoid valve (half) ×

Intake shutter solenoid valve (full) ×

Glow indicator light ×

Cruise main indicator light ×

Cruise set indicator light ×

Glow plug relay ×

Cooling fan relay No.1 ×

Cooling fan relay No.2 ×

A/C relay ×

Mazda6

(GG, GY)

MZR-CD (RF Turbo)

CONTROL SYSTEM

(GG, GY)

Same function as previous Mazda6 (GG, GY) MZR-CD (RF Turbo) engine model

×:Applicable –: Not applicable

Remark for new model

F2

Control System

New

Item

Idle speed control ×

Glow control ×

VSC ×

Boost pressure control ×

Fuel injection amount control ×

Fuel injection timing control ×

Multiple fuel injection control ×

Fuel pressure control ×

Mazda6

(GG, GY)

MZR-CD (RF Turbo)

(GG, GY)

×:Applicable –: Not applicable

Remark for new model

Same function as previous Mazda6 (GG, GY) MZR-CD (RF Turbo) engine model

F2–11

CONTROL SYSTEM

New

Item

EGR control ×

Cruise control system ×

Electrical fan control ×

A/C cut-off control ×

Immobilizer system ×

Mazda6

(GG, GY)

MZR-CD (RF Turbo)

End Of Sie

(GG, GY)

Remark for new model

Same function as previous Mazda6 (GG, GY) MZR-CD (RF Turbo) engine model

F2–12

CONTROL SYSTEM

STRUCTURAL VIEW

.

14

40

20

23

17

24

33

36

4

34

B6E404018881102

35

37

F2

2

38

10

21

18

16

13

28

3

22

11

6

29

32

26

25

27

3031

19

39

31

15

12

32

30

19

9

5

10

1

8

1

7

8

7

PCM (with built-in BARO sensor and immobilizer

1

unit) 2Battery 3Starter

B6E4040W001

F2–13

4 Starter relay 5 Clutch switch 6 Neutral switch 7 Brake switch 8 Idle switch

9 Cruise control switch 10 Accelerator position sensor 11 MAF/IAT sensor 12 IAT sensor No.2 13 ECT sensor 14 Fuel temperature sensor 15 Boost sensor 16 Fuel pressure sensor 17 CMP sensor 18 CKP sensor 19 VSS 20 Calibration resistor 21 Suction control valve 22 IDM 23 VSC solenoid valve 24 VBC solenoid valve 25 EGR control solenoid valve 26 EGR solenoid valve (vacuum) 27 EGR solenoid valve (vent) 28 Intake shutter solenoid valve (half) 29 Intake shutter solenoid valve (full) 30 Glow indicator light 31 Cruise main indicator light 32 Cruise set indicator light 33 Glow plug relay 34 Cooling fan relay No.1 35 Cooling fan relay No.2 36 A/C relay 37 PCM control relay 38 L.H.D. 39 R.H.D. 40 EGR valve position sensor

CONTROL SYSTEM

End Of Sie

F2–14

CONTROL SYSTEM

BLOCK DIAGRAM

.

15

16

17

18

19

20

21

22

23

24

B6E404018881103

1

38

2

39

3

40

4

41

5

6

42

43

F2

44

7

25

26

27

28

29

30

31

32

33

34

35

36

8

9

10

11

12

13

CRUISE MAIN

CRUISE

45

46

47

48

49

50

51

52

37

54

1PCM 2 Idle speed control

14

53

B6E4040W002

F2–15

3 Glow control

4 VSC

5 Boost pressure control

6 Fuel injection amount control

7 Fuel injection timing control

8 Multiple fuel injection control

9 Fuel pressure control 10 EGR control 11 Cruise control system 12 Electrical fan control 13 A/C cut-off control 14 Immobilizer system 15 Battery 16 Starter (starter signal) 17 Starter relay 18 Clutch switch 19 Neutral switch 20 Brake switch 21 Idle switch 22 A/C switch 23 Refrigerant pressure switch 24 Cruise control switch 25 Accelerator position sensor 26 MAF/IAT sensor 27 IAT sensor No.2 28 ECT sensor 29 Fuel temperature sensor 30 BARO sensor (integrated in PCM) 31 Boost sensor 32 Fuel pressure sensor 33 CMP sensor 34 CKP sensor 35 VSS 36 Calibration resistor 37 Immobilizer unit (integrated in PCM) 38 Suction control valve 39 IDM 40 VSC solenoid valve 41 VBC solenoid valve 42 EGR control solenoid valve 43 EGR solenoid valve (vacuum) 44 EGR solenoid valve (vent) 45 Intake shutter solenoid valve (half) 46 Intake shutter solenoid valve (full) 47 Glow indicator light 48 Cruise main indicator light 49 Cruise set indicator light 50 Glow plug relay 51 Cooling fan relay No.1 52 Cooling fan relay No.2 53 A/C relay 54 EGR valve position sensor

CONTROL SYSTEM

End Of Sie

F2–16

CONTROL SYSTEM

CONTROL DEVICE AND CONTROL RELATIONSHIP CHART

B6E404018881104

×: Applicable

Item

Idle speed control

Glow control

VSC

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

Input device

F2

Battery ×× Starter (starter signal) ЧЧЧЧЧЧЧЧЧ × Starter relay ЧЧЧЧЧЧЧЧЧ × Clutch switch × × ××× ×× × Neutral switch × × ××× ×× × Brake switch × Idle switch × × ××× × × A/C switch ××××× Refrigerant pressure switch ××××× Cruise control switch × Accelerator position sensor × ××× × × ×× MAF/IAT sensor × ×××× IAT sensor No.2 ×× ECT sensor ××× ЧЧЧЧЧ ×× Fuel temperature sensor × BARO sensor (integrated in PCM) ××× Boost sensor ××× × Fuel pressure sensor ×× ×× CMP sensor ЧЧЧЧЧ CKP sensor × ЧЧЧЧЧЧЧ × VSS ××× ××× ×× Calibration resistor ×× Immobilizer unit (integrated in PCM) × EGR valve position sensor ×

Output device

Suction control valve ×× IDM × ××× × × VSC solenoid valve × VBC solenoid valve × EGR control solenoid valve × EGR solenoid valve (vacuum) × EGR solenoid valve (vent) × Intake shutter solenoid valve (half) × Intake shutter solenoid valve (full) × Glow indicator light × Cruise main indicator light × Cruise set indicator light × Glow plug relay × Cooling fan relay No.1 × Cooling fan relay No.2 × A/C relay ×

End Of Sie

F2–17

ON-BOARD DIAGNOSTIC

ON-BOARD DIAGNOSTIC OUTLINE

Features

To meet the EOBD regulations • Diagnostic test modes adopted Improved serviceability • DTC troubleshooting modified

• PID/DATA monitor items added

• Simulation items added

• OBD drive mode adopted

Block Diagram

1

2

5

B6E407000102101

3

4

7

6

8

9

.

1PCM

2 OBD system

3 Malfunction indication function

4MIL

5 Memory function

6 Tester communication function

7DLC-2

8CAN

13

10

11 12

15 1614

BHE0102T001

9 WDS or equivalent 10 Detection function 11 PID data monitor function 12 Simulation test function 13 Fail-safe function 14 Input device 15 Engine control system 16 Output device

End Of Sie

DIAGNOSTIC TEST MODE

• To meet EOBD regulations, the following diagnostic test modes have been adopted.

F2–18

B6E407000102102