Mazda 6 M6 2002 User Manual

Manual

CONTENTS

Transaxle Workshop Manual A65M–R

FOREWORD

This manual explains the structure, operation, and service points for the above-indicated manual transaxle. In order to do these procedures safely, quickly, and correctly, you must first read this manual and any other relevant service materials carefully.

The information in this manual is current up to April, 2002. Any changes that occur after that time will not be reflected in this particular manual. Therefore, the contents of this manual may not exactly match the mechanism that you are currently servicing.

Title Section

General Information GI Overhaul J Technical Data TD Special Tools ST

PRINTED IN THE NETHERLANDS, APRIL 2002 1739–1E–02D

Mazda Motor Corporation

HIROSHIMA, 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

GENERAL INFORMATION

HOW TO USE THIS MANUAL

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

SERVICING PROCEDURE ............................... GI-2

SYMBOLS.......................................................... GI-3

ADVISORY MESSAGES ................................... GI-4

UNITS FUNDAMENTAL PROCEDURES

ELECTRICAL SYSTEM NEW STANDARDS ABBREVIATIONS

................................................................... GI-5

UNITS TABLE.................................................... GI-5

PREPARATION OF TOOLS AND MEASURING

EQUIPMENT................................................... GI-6

SPECIAL SERVICE TOOLS.............................. GI-6

DISASSEMBLY.................................................. GI-6

INSPECTION DURING REMOVAL,

DISASSEMBLY............................................... GI-6

ARRANGEMENT OF PARTS ............................ GI-7

CLEANING OF PARTS...................................... GI-7

REASSEMBLY................................................... GI-7

ADJUSTMENT................................................... GI-8

RUBBER PARTS AND TUBING........................ GI-8

HOSE CLAMPS ................................................. GI-8

TORQUE FORMULAS....................................... GI-8

VISE................................................................... GI-9

........................................ GI-9

CONNECTORS.................................................. GI-9

............................................ GI-12

NEW STANDARDS TABLE ............................. GI-12

.............................................. GI-14

ABBREVIATIONS TABLE................................ GI-14

............................. GI-2

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

GI–1

HOW TO USE THIS MANUAL

RANGE OF TOPICS

• This manual contains procedures for performing all required service operations. The procedures are divided into the following five basic operations: — Removal/Installation — Disassembly/Assembly — Replacement — Inspection — Adjustment

• Simple operations which can be performed easily just by looking at the vehicle (i.e., removal/installation of parts, jacking, vehicle lifting, cleaning of parts and visual inspe ct ion) have been omitted.

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SERVICING PROCEDURE Inspection, Adjustment

• Inspection and adjustment procedures are divided into steps. Important points regarding the location and contents of the procedures are explained in detail and shown in the illustrations.

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Repair Procedure

1. Most repair operations begin with an overview illustration. It identifies the components, shows how the parts fit together, and describes visual part inspection. However, only removal/installation procedures that need to be performed methodically have written instructions.

2. Expendable parts, tightening torque s, and symbols for oil, grease, and sealant are shown in the overview illustration. In addition, symbols indicating parts requiring the use of special service tools or equivalent are also shown.

GI–2

HOW TO USE THIS MANUAL

3. Procedure steps are numbered and the par t that is the main point of the procedure is shown in the illustration with the corresponding number. Occasiona lly, there ar e important p oints or addit ional informat ion concerning a procedure. Refer to this information when servicing the related part.

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SYMBOLS

• There are eight symbols indicating oil, grease, fluids, sealan t, and the use of show application points or use of these materia l s du rin g service.

Symbol Meaning Kind

Apply oil New appropriate engine oil or gear oil

Apply brake fluid New appropriate brake fluid

Apply automatic transaxle/transmission fluid

New appropriate automatic transaxle/transmission fluid

or equivalent. These symbols

SST

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GI–3

HOW TO USE THIS MANUAL

Symbol Meaning Kind

Apply grease Appropriate grease

Apply sealant Appropriate sealant

Apply petroleum jelly Appropriate petroleum jelly

Replace part O-ring, gasket, etc.

Use SST or equivalent Appropriate tools

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ADVISORY MESSAGES

• You will find several manual.

Warning

• A Warning indicates a situation in which serious injury or death could result if the warning is ignored.

Caution

• A Caution indicates a situation in which damage to the vehicle or parts could result if the caution is ignored.

Note

• A Note provides added information that will help you to complete a particular procedure.

Specifications

• The values indicate the allowable range when performing inspections or adjustments.

Upper and Lower Limits

• The values indicate the upper and lower limits that must not be exceeded when perfor ming inspections or adjustments.

Warnings, Cautions, Notes, Specifications

and

Upper and Lower Limits

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in this

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GI–4

UNITS

UNITS TABLE

Electrical current A (ampere) Electric power W (watt) Electric resistance ohm Electric voltage V (volt)

Length

Negative pressure

Number of revolutions

Positive pressure

Torque

Volume

Weight

mm (millimeter) in (inch) kPa (kilo pascal) mmHg (millimeters of mercury) inHg (inches of mercury)

rpm (revolutions per minute) kPa (kilo pascal)

kgf/cm centimeter)

psi (pounds per square inch) N·m (Newton meter) kgf·m (kilogram force meter) kgf·cm (kilogram force centimeter) ft·lbf (foot pound force) in·lbf (inch pound force) L (liter) US qt (U.S. quart) imp qt (Imperial quart) ml (milliliter) cc (cubic centimeter) cu in (cubic inch) fl oz (fluid ounce) N (Newton) g (gram) oz (ounce)

(kilogram force per square

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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 p laces as the SI unit value. For example, if the SI u nit 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. Fo r ex am p l e, co ns ide r 2. 7 kgf /cm

210—260 kPa {2.1—2.7 kgf/cm2, 30—38 psi} 270—310 kPa {2.7—3.2 kgf/cm

• The actual converted values for 2.7 kgf/cm

, 39—45 psi}

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

in the following specifications:

an upper limit, so the converted values are roun ded 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.

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GI–5

FUNDAMENTAL PROCEDURES

PREPARATION OF TOOLS AND MEASURING EQUIPMENT

• Be sure that all necessary tools and measuring equipment are available before starting any work.

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SPECIAL SERVICE TOOLS

• Use special service tools or equivalent when they are required.

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WGIWXX0023E

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DISASSEMBLY

• If the disassembly procedure is complex, requiring many parts to be disassembled, all parts should be marked in a place that will not affect their performance or external appearance and identified so that reassembly can be performed easily and efficiently.

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INSPECTION DURING REMOVAL, DISASSEMBLY

• When removed, each part should be carefully inspected for malfunction, deformatio n, dam a ge , and other problems.

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GI–6

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FUNDAMENTAL PROCEDURES

ARRANGEMENT OF PARTS

• All disassembled parts should be carefully arranged for reassembly.

• Be sure to separate or otherwise identify the par ts to be replaced from those that will be reused.

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CLEANING OF PARTS

• All parts to be reused should be carefully and thoroughly cleaned in the appropriate method.

Warning

••••

Using compressed air can cause dirt and

other particles to fly out cau sing injury t o the eyes. Wear protective eye wear whenever using compressed air.

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WGIWXX0029E

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REASSEMBLY

•

Standard values, such as torques and certain adjustments, must be strictly observed in the reassembly of all parts.

•

If removed, these parts should be replaced with new ones:

— Oil seals — Gaskets — O-rings — Lockwashers — Cotter pins — Nylon nuts

•

Depending on location: — Sealant and gaskets, or both, sho u ld be

applied to specified locations. When sealant is applied, parts should be installed before sealant hardens to prevent leakage.

— Oil should be applied to the moving

components of parts.

— Specified oil or grease should be applied at

the prescribed locations (such as oil seals) before reassembly.

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GI–7

FUNDAMENTAL PROCEDURES

ADJUSTMENT

•

Use suitable gauges and/or testers when making adjustments.

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RUBBER PARTS AND TUBING

•

Prevent gasoline or oil from getting on rubber parts or tubing.

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HOSE CLAMPS

•

When reinstalling, position the hose clamp in the original location on the hose and squeeze the clamp lightly with large pliers to ensure a good fit.

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TORQUE FORMULAS

•

When using a torque wrench-SST or equivalent combination, the written torque must be recalculated due to the extra length that the SST or equivalent adds to the torque wrench. Recalculate the torque using the following formulas. Choose the formula that applies to you.

Torque Unit Formula

N·mN·m × [L/(L+A)]

kgf·mkgf·m × [L/(L+A)]

kgf·cm kgf·cm × [L/(L+A)]

ft·lbf ft·lbf × [L/(L+A)]

in·lbf in·lbf × [L/(L+A)]

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WGIWXX0035E

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A : The length of the SST past the torque wrench drive L : The length of the torque wrench

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GI–8

FUNDAMENTAL PROCEDURES, ELECTRICAL SYSTEM

VISE

•

When using a vise, put protective plates in the jaws of the vise to prevent damage to parts.

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ELECTRICAL SYSTEM

CONNECTORS Data Link Connector

•

Insert the probe into the service hole when connecting a jumper wire to the data link connector.

Caution

•

• Inserting a jumper wire probe into the

••

data link connector terminal may damage the terminal.

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WGIWXX0037E

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Disconnecting Connectors

•

When disconnecting connector, grasp the connectors, not the wires.

•

Connectors can be disconnected by pressing or pulling the lock lever as shown.

X3U000WAY

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GI–9

ELECTRICAL SYSTEM

Locking Connector

•

When locking connectors, listen for a click indicating they are securely locked.

Inspection

•

When a tester is used to inspect for continuity or measuring voltage, insert the tester probe from the wiring harness side.

X3U000WB1

•

Inspect the terminals of waterproof conne c to r s from the connector side since they cannot be accessed from the wiring harness side.

Caution

•

• To prevent damage to the terminal, wrap

••

a thin wire around the tester probe before inserting into terminal.

Terminals Inspection

•

Pull lightly on individual wires to verify that they are secured in the terminal.

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GI–10

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ELECTRICAL SYSTEM

Replacement

•

Use the appropriate tools to remove a terminal as shown. When installing a terminal, be sure to insert it until it locks securely.

•

Insert a thin piece of metal from the terminal side of the connector and with the terminal locking t ab pressed down, pull the terminal out from the connector.

Sensors, Switches, and Relays

•

Handle sensors, switches, and relays carefully. Do not drop them or strike them against other objects.

WGIWXX0046E

Wiring Harness Wiring color codes

•

Two-color wires are indicated by a two-color code symbol.

•

The first letter indicates the base color of the wire and the second the color of the stripe.

CODE COLOR CODE COLOR

B Black O Orange

BR Brown P Pink

GGreenR Red

GY Gray V Violet

L Blue W White

LB Light Blue Y Yellow

LG Light Green

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GI–11

NEW STANDARDS

NEW STANDARDS TABLE

•

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 CPP Clutch Pedal Position — Idle Switch

CIS Continuous Fuel Injection System — Clutch Position

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

CKP sensor Crankshaft Position Sensor — Crank Angl e 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 Distributorle ss 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

MFL Multiport Fuel Injection — Multiport Fuel Injection OBD On-Board Diagnostic — Diagnosis/Self Diagnosis

OL Open Loop — Open Loop

Fuel Shut Off Solenoid FCV Fuel Cut Valve #6

Name

Abbrevi-

ation

Name

Battery Voltage

AME202800020M01

Remark

GI–12

NEW STANDARDS

New Standard Previous Standard

Abbrevi-

ation

— 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 Sole noid 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 Multipoint 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 — Air flow Sensor

WUTWC

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

— ECAT Control Unit

— ATF Thermosensor

— Catalytic Converter #5

Name

Remark

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 exhau st ma n ifold #6 : Part name of diesel engine

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GI–13

ABBREVIATIONS

ABBREVIATIONS TABLE

SST Special service tool

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GI–14

OVERHAUL

MANUAL TRANSAXLE.......................................... J-2

PRECAUTION...................................................... J-2

CLUTCH HOUSING AND TRANSAXLE CASE

COMPONENTS DISASSEMBLY...................... J-3

PRIMARY SHAFT COMPONENTS

PREINSPECTION............................................. J-8

PRIMARY SHAFT COMPONENTS

DISASSEMBLY................................................. J-9

PRIMARY SHAFT COMPONENTS

INSPECTION.................................................. J-11

PRIMARY SHAFT COMPONENTS

ASSEMBLY..................................................... J-13

SECONDARY SHAFT COMPONENTS

PREINSPECTION........................................... J-18

SECONDARY SHAFT COMPONENTS

DISASSEMBLY............................................... J-19

SECONDARY SHAFT COMPONENTS

INSPECTION.................................................. J-20

SECONDARY SHAFT COMPONENTS

ASSEMBLY..................................................... J-24

REVERSE IDLER SHAFT COMPONENTS

DISASSEMBLY/ASSEMBLY .......................... J-30

REVERSE IDLER SHAFT COMPONENTS

INSPECTION.................................................. J-31

DIFFERENTIAL PREINSPECTION ................... J-32

DIFFERENTIAL DISASSEMBLY....................... J-32

DIFFERENTIAL ASSEMBLY............................. J-33

PRIMARY SHAFT END PLAY ADJUSTMENT.. J-35 SECONDARY SHAFT END PLAY

ADJUSTMENT................................................ J-36

REVERSE IDLER GEAR END PLAY

ADJUSTMENT................................................ J-37

DIFFERENTIAL SIDE BEARING PRELOAD

ADJUSTMENT................................................ J-38

CLUTCH HOUSING AND TRANSAXLE CASE

COMPONENTS ASSEMBLY.......................... J-40

J–1

MANUAL TRANSAXLE

PRECAUTION

1. Clean the transaxle exterior thoroughly using a steam cleaner or cleaning solvents before disassembly.

Warning

•

• Using compressed air can cause dirt and other particles to fly out, causing injury to the eyes.

••

Wear protective eye wear whenever using compressed air.

Caution

•

• Cleaning sealed bearings using cleaning fluids or a steam cleaner can wash the grease out of the

••

bearing.

2. Clean the removed parts using cleaning solvent, and dry the m using compressed air.

3. Clean out all holes and passages using compressed air, and check that there are no obstructions.

4. Use a plastic hammer when disassembling the transaxle case and other light alloy metal parts.

5. Make sure each part is cleaned before assembling.

6. Coat all movable parts with the specified oil.

7. Replace parts whenever required.

8. Remove old sealant from contact surfaces before applying new sealant.

9. Assemble the parts within 10 minutes after app lying sealant. Allow all sealant to cure at least 30 minutes after assembly before filling the transaxle with transaxle oil.

Warning

•

• Although the stand has a self-locking brake system, there is a possibility that the bra ke may not

••

hold when the transaxle is he ld in a lopsi ded position on the stand. Th is would cause the transaxle to turn suddenly, causing serious injury. Never keep the transaxle tilted to one side. Always hold the rotating handle firmly when turning the transaxle.

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J–2

MANUAL TRANSAXLE

CLUTCH HOUSING AND TRANSAXLE CASE COMPONENTS DISASSEMBLY Disassembly Components

AME511217010M01

1Drain plug 2 Filler cap 3 Neutral switch 4 Reverse switch 5 Air-bleed plug 6 Bore plug 7 Welt plug 8 Baffle plate 9 Oil pass

10 Transaxle case

AME5112M004

11 Pivot pin 12 Magnet 13 Differential oil seal 14 Knock pin 15 Dowel pin 16 Secondary shaft bearing retainer 17 Secondary shaft front bearing 18 Oil channel 19 Primary shaft oil seal 20 Clutch housing

J–3

MANUAL TRANSAXLE

1 Stopper bolt 2 Shift check bolt 3 Shift control component 4O ring 5 Rod bushing 6 Reverse lever component 7 Reverse fork rod 8Cap

9 Reverse shift fork 10 Retaining pin 11 C ring 12 5th/Reverse fork rod 13 5th shift fork 14 5th/reverse bracket 15 Check plug (5th/reverse) 16 Check spring (5th/reverse)

J–4

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17 Shift check sleeve (5th/reverse) 18 Check ball 19 Inter lock pin 20 3rd/4th fork rod 21 3rd/4th shift fork 22 3rd/4th bracket 23 Shift check sleeve (1st/2nd) 24 1st/2nd fork rod 25 1st/2nd bracket 26 1st/2nd shift fork 27 Clutch housing 28 Transaxle case 29 Check plug (1st/2nd, 3rd/4th) 30 Check spring (1st/2nd) 31 Check spring (3rd/4th)

MANUAL TRANSAXLE

Disassembly Procedure

1. Remove the drain plug and the filler cap.

2. Remove the neutral switch and reverse switch.

3. Remove the shift check bolt and stopper bolt.

4. Remove the shift control component.

5. Remove the check plugs, check springs, check balls, and shift check sleeve as shown in the figure.

AME5112M098

6. Remove the transaxle case installation bolt.

7. Remove the bore plug using screwdriver.

8. Stretch the snap ring of the secondary shaf t rear bearing at the bore plug hole, and remove the transaxle case.

9. Remove the baffle plate and the oil pass.

10. Remove the snap ring, secondary shaft adjust shim, primary shaft rear bearing adjust shim from the transaxle case.

11. Remove the differential side bearing outer race (transaxle case side) using the SST, and remove the adjust shim.

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+ 47 hidden pages