Mazda 6 Facelift 2005 Installation guide

TRAINING MANUAL
Mazda6 Facelift

No part of this hardcopy may be reproduced in any form without prior permission of
Mazda Motor Europe GmbH.
The illustrations, technical information, data and descriptive text in this issue, to the best
of our knowledge, were correct at the time of going to print.
No liability can be accepted for any inaccuracies or omissions in this publication,
although every possible care has been taken to make it as complete and accurate as
possible.
©2005
Mazda Motor Europe GmbH
Training Services

Contents
General Information 00
Engine 01
Suspension 02
Brakes 04
Transmission / Transaxle 05
Restraints 08
Body & Accessories 09
SectionTitle
Service Training Mazda6 Facelift

Service Training Mazda6 Facelift

00
General Information

00 General Information
Vehicle Identification Number (VIN) Code.........................................................1
Applicable VIN ................................................................................................1
Engine / Transaxle Combinations......................................................................2
Scheduled Maintenance .....................................................................................3
Europe ............................................................................................................3
Table of Contents 00 Service Training Mazda6 Facelift

General Information
Vehicle Identification Number (VIN) Code
JMZ GG 1 2 3 2 0 1 1 2 3 4 5 6
Serial No.
Plant 0= Hiroshima
1= Hofu
Dummy 0, 6 to 9, A to Z
Transmission
2= 5MTX
6= 6MTX
7= 5ATX
Engine Type
3= 2.3L (L3)
8= 1.8L (L8)
F= 2.0L (LF)
R= MZR-CD (RF Turbo)-Hi
T= MZR-CD (RF Turbo)-Standard
Body style
2= 4SD
4= 5HB
9= WAGON
Remarks 8= 4WD
1= 2WD
Vehicle type GG= Mazda6 (4SD, 5HB)
GY= Mazda6 (WAGON)
World manufacturer indication JMZ= European (L.H.D. U.K.)
M6FL_00T001
Applicable VIN
JMZ GG1236*# 600001—
JMZ GG12360# 600001—
JMZ GG1282*# 600001—
JMZ GG12820# 600001—
JMZ GG12F6*# 600001—
JMZ GG12F60# 600001—
JMZ GG12R6*# 600001—
JMZ GG12R60# 600001—
JMZ GG12T6*# 600001—
JMZ GG12T60# 600001—
JMZ GG1436*# 600001—
JMZ GG14360# 600001—
JMZ GG1482*# 600001—
JMZ GG14820# 600001—
JMZ GG14F6*# 600001—
JMZ GG14F60# 600001—
JMZ GG14R6*# 600001—
JMZ GG14R60# 600001—
JMZ GG14T6*# 600001—
JMZ GG14T60# 600001—
JMZ GY1936*# 400001—
JMZ GY1982*# 400001—
JMZ GY19820# 400001—
JMZ GY19F6*# 400001—
JMZ GY19F60# 400001—
JMZ GY19R6*# 400001—
JMZ GY19R60# 400001—
JMZ GY19T6*# 400001—
JMZ GY19T60# 400001—
JMZ GY8937*# 400001—
JMZ GY89370# 400001—
Service Training Mazda6 Facelift 00-1

General Information
Engine / Transaxle Combinations
• All engines have been revised. New transaxles have been added to the range. The
following engine/transaxle combinations are available:
G35M-R
5-speed
manual
transaxle
G66M-R
6-speed
manual
transaxle
A26M-R
6-speed
manual
transaxle
FS5A-EL
5-speed
automatic
transaxle
(front wheel drive)
JA5AX-EL
5-speed
automatic
transaxle
(All Wheel
Drive (AWD))
M6FL_00T002
L8 1.8L
88 KW (120 HP)
at 5,500 rpm
165 Nm
at 4,300 rpm
L3 2.3L
122 KW (166 HP)
at 6,500 rpm
207 Nm
at 4,000 rpm
RF Turbo STD 2.0L
89 KW (121 HP)
at 3,500 rpm
320 Nm
at 2,000 rpm
X
XX
X
RF Turbo HI 2.0L
105 KW (143 HP)
at 3,500 rpm
360 Nm
at 2,000 rpm
LF 2.0L
108 KW (147 HP)
at 6,500 rpm
184 Nm
at 4,000 rpm
X
X
X
X
00-2 Service Training Mazda6 Facelift

General Information
Scheduled Maintenance
Europe
Months 12 24 36 48 60 72 84 96 108
X1000 km 20 40 60 80 100 120 140 160 180
X1000 miles 12,5 25 37,5 50 62,5 75 87,5 100 112,5
RRR
III
II
RRR
IIII
DDDDDDDDD
CCRCCRCCR
RRRRRRRRR
RRRRRRRRR
III
IIII
FL 22 type *5
Others
IIII
IIIIIIIII
IIIIIIIII
RRRR
IIIIIIIII
IIIIIIIII
IIIIIIIII
R
III
IIII
IIII
RRRR
M6FL_00T003
IIIIIIII
Replace at first 100,000 km (62,500 miles) or 4 years;
after that, every 2years
Inspect every 80,000 km (50,000 miles) or 5 years
Body condtion
(for rust, corrosion and perforation) Inspect annualy
Parking brake
Fuel lines and hoses
Disc brakes
Transfer oil (for 4 WD)
Brake fluid *6
Maintenance items
Maintenance interval (number of momths or km (miles) which ever comes first)
I
*7 *8
*8
PETROL AND DIESEL ENGINE
Drive belt *4
Engine coolant
Front and rear suspension and ball joints
Drive shaft dus boots
Replace every 120,000 km (75,000 miles)
Replace every 200,000 km (125,000 miles) 0r 11 years
Tires (including spare tire)
(with inflation pressure adjustment)
Exhaust system and heat shields
Battery electrolyte level and specific gravity
Brakes lines hoses and connections
Steering operation and linkages
Manual transaxle oil
Automatic transaxle fluid level
Rear differential oil (for 4 WD)
Engine oil filter *3
Engine oil*3
Air cleaner element*1
Fuel system (Drain water)
Fuel injection system
Fuel filter
Engine timing belt *2
Engine valve clearance
Cabin air filter (if installed)
Cooling system (including coolant level
adjustment)
DIESEL ENGINE
PETROL ENGINE
Engine valve clearance
Spark plugs
Air cleaner element
Evaporation system(if installed)
Replace every 100,000km (62,500miles)
Audible inspect every 120,000km (75,000 miles), if noisy adjust
I: Inspect: Inspect and clean, repair, adjust, or replace if necessary.
R: Replace
C: Clean
D: Drain
Service Training Mazda6 Facelift 00-3

General Information
Remarks:
*1 If the vehicle is operated in very dusty or sandy areas, clean and if necessary, replace the
air filter more often than the recommended intervals.
*2 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.
*3 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
*4 Also inspect and adjust the power steering and air conditioner drive belts, if installed.
*5 Use FL22 type coolant in vehicles with the inscription “FL22” on the radiator cap itself or
the surrounding area. Use FL22 when replacing the coolant.
*6 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.
*7 If the vehicle is operated under any of the following conditions, change the rear differential
oil every 45,000 km (28,100 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.
00-4 Service Training Mazda6 Facelift

01
Engines

01 Engine
Table of Contents
Petrol Engines
Mechanics............................................................................................................1
Cylinder Head Cover.......................................................................................1
Valve Mechanism............................................................................................2
Lubrication ......................................................................................................3
Intake-Air System................................................................................................4
Electronic Throttle Control...............................................................................5
Exhaust System...................................................................................................6
Charging System.................................................................................................7
Generator Design............................................................................................7
Generator Electrical Diagram ...................................................................8
Ignition System....................................................................................................9
Engine Control System.....................................................................................10
Structural View..............................................................................................10
Powertrain Control Module (PCM)................................................................11
PCM Connector (Harness Side Shown) .................................................11
Overview.......................................................................................................12
Wiring Diagram.............................................................................................14
Accelerator Pedal Position (APP) Sensor.....................................................18
Throttle Valve Actuator .................................................................................20
Throttle Position (TP) Sensor........................................................................21
TP Sensor Voltage Characteristics.........................................................22
Heated Oxygen Sensors (HO2S)..................................................................23
Front HO2S ............................................................................................24
Rear HO2S.............................................................................................25
Crankshaft Position (CKP) Sensor................................................................26
Camshaft Position (CMP) Sensor.................................................................28
Diesel Engines
Mechanics..........................................................................................................29
Pistons..........................................................................................................30
Cylinder Head...............................................................................................31
Lubrication.........................................................................................................32
Specification..................................................................................................32
Engine Oil...............................................................................................32
Parts Location...............................................................................................33
Engine Oil .....................................................................................................34
Table of Contents 01 Service Training Mazda6 Facelift

01 Engine
Table of Contents (continued)
Oil Dipstick....................................................................................................35
Oil Dilution Calculation..................................................................................36
Oil Cooler and Oil Filter.................................................................................37
Cooling System.................................................................................................39
Specifications................................................................................................39
Parts Location...............................................................................................40
Intake-air System...............................................................................................41
Parts Location...............................................................................................41
Turbocharger ................................................................................................42
Manifold Absolute Pressure Sensor..............................................................43
Fuel System.......................................................................................................44
Parts Location...............................................................................................44
Common Rail................................................................................................45
Injectors ........................................................................................................46
Injector Correction Factors .....................................................................48
Injection Amount Learning Function .......................................................49
Emission System...............................................................................................50
Parts Location...............................................................................................50
Exhaust System.................................................................................................51
Parts Location...............................................................................................51
Exhaust Gas Recirculation System .................................................................52
EGR Valve....................................................................................................52
EGR Cooler...................................................................................................55
Intake Shutter Valve......................................................................................56
Diesel Particulate Filter System.......................................................................59
Diesel Particulates ........................................................................................59
Diesel Particulate Filter.................................................................................60
DPF Differential Pressure Sensor.................................................................63
Diagnostics.............................................................................................66
Exhaust Gas Temperature Sensors..............................................................68
Heated Oxygen Sensor.................................................................................70
DPF Indicator Light.......................................................................................72
Regeneration Control....................................................................................73
Soot Amount Calculation........................................................................73
Regeneration Process............................................................................75
Regeneration Intervals............................................................................76
Service Training Mazda6 Facelift Table of Contents 01

01 Engine
Table of Contents (continued)
Charging System...............................................................................................77
Specifications................................................................................................77
Parts Location...............................................................................................77
Smart Charging System................................................................................78
Control System..................................................................................................79
Parts Location...............................................................................................79
Wiring Diagram.............................................................................................82
Powertrain Control Module............................................................................86
Crankshaft Position Sensor...........................................................................87
Camshaft Position Sensor.............................................................................88
Accelerator Pedal Position Sensor................................................................89
Power Steering Pressure Switch...................................................................92
Service And Repair.......................................................................................93
Replacing the Engine Oil........................................................................93
Manual Regeneration .............................................................................93
Replacing the MAF Sensor.....................................................................94
Replacing the High-Pressure Pump........................................................94
Replacing Injectors.................................................................................94
Replacing the EGR Valve Or The ISV....................................................95
Replacing the DPF..................................................................................95
Replacing the DPF Differential Pressure Sensor....................................95
Replacing the HO2S...............................................................................96
Replacing the PCM.................................................................................96
On-board Diagnostic System...........................................................................97
Self Test........................................................................................................97
PID Monitor...................................................................................................98
Simulation Test...........................................................................................101
Table of Contents 01 Service Training Mazda6 Facelift

Engine Petrol Engines
Mechanics
M6FL_01057
Cylinder Head Cover
• The cylinder head cover is made of plastic. On LF and L3 engines a hole is provided for
installation of the OCV (Oil Control Valve).
• A dipstick insertion hole has been equipped to the cylinder head cover.
M6FL_01001
1 CMP (Camshaft Position) sensor
attachment part 3 OCV attachment hole (LF, L3)
2 Dipstick insertion hole
Service Training Mazda6 Facelift 01-1

Petrol Engines Engine
Valve Mechanism
• For the LF engine the variable valve timing system has been carried over from the L3
engine.
• All engines use a sensor ring with 6 reference cams for the CMP Sensor on the intake
camshaft.
M6FL_01002
1 Timing chain 7 Valve assembly
2 Camshaft sprocket 8 Tappet
3 Tensioner arm 9 Camshafts
4 Chain tensioner 10 OCV
5 Crankshaft sprocket 11 Variable valve timing actuator
6 Chain guide
01-2 Service Training Mazda6 Facelift

Engine Petrol Engines
Lubrication
• The lubrication system has been carried over from the previous engines. Depending on
specification, both spin-on and cartridge type oil filters are available.
• The oil cooler is now installed on both the L3 and the LF engine.
M6FL_01003
1 Oil pump chain tensioner 11 Oil jet valve
2 Oil pump chain guide 12 Oil cooler (LF, L3)
3 Oil pump chain 13 Gasket
4 Oil pump sprocket 14 Oil pressure switch
5 Oil pump 15 Oil filter adapter
6 O-ring 16 Oil filter
7 Oil strainer 17 Oil filter cover
8 Washer 18 Oil filter drain plug
9 Oil pan drain plug 19 Cartridge type oil filter
10 Oil pan 20 Spin-on type oil filter
Service Training Mazda6 Facelift 01-3

Petrol Engines Engine
Intake-Air System
• The intake-air system has been basically carried over from the previous engines. It
comprises:
– VTCS (Variable Tumble Control System) (L8, LF, L3)
– VIS (Variable Intake-air System) (LF, L3)
– VAD (Variable Air Duct) (L3)
• All petrol engines now use an electronic throttle control.
• For the LF engine the VIS has been carried over from the L3 engine.
M6FL_01004
1 Air cleaner 8 VIS shutter valve actuator (LF, L3)
2 Accelerator pedal 9 Throttle body
3 VAD solenoid valve (L3) 10 VAD check valve (one-way) (L3)
4 VAD shutter valve (L3) 11 Intake manifold
5 Resonance chamber 12 VIS solenoid valve (LF, L3)
6 VAD vacuum chamber (L3) 13 VTCS solenoid valve
7 VTCS shutter valve actuator
01-4 Service Training Mazda6 Facelift

Engine Petrol Engines
Electronic Throttle Control
• All engines are using an electronically controlled throttle body, which is quite similar to
the one on RX-8. This supersedes the IAC (Idle Air Control) valve.
• To keep moisture from freezing inside the throttle body, and thus to prevent the throttle
valve from getting stuck, engine coolant is circulated through the throttle body.
• The throttle body cannot be disassembled.
• When the throttle actuator is not energized, the throttle valve is maintained slightly open
by the force of the return spring. This allows limited operation of the engine in case of a
malfunction.
M6FL_01005
1 Throttle body 3 TP (Throttle Position) sensor
2 Throttle actuator 4 Throttle valve
Service Training Mazda6 Facelift 01-5

Petrol Engines Engine
Exhaust System
• The exhaust system has been carried over from the previous Mazda6.
• Vehicles specified with LF engine are now using the exhaust system with two main
silencers (previously used on L3 engines only).
M6FL_01006
1 Main silencer 5 HO2S (front)
2 Middle pipe 6 Exhaust manifold
3 HO2S (Heated Oxygen Sensor) (rear) 7 LF, L3
4 TWC (Three-Way Catalyst)
01-6 Service Training Mazda6 Facelift