Mazda 6 MPS 2005 Installation guide

TRAINING MANUAL
Mazda6 MPS Supplement

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
Driveline/Axle 03
SectionTitle
Service Training Mazda6 MPS Supplement

Service Training Mazda6 MPS Supplement

00
General Information

00 General Information
VIN (Vehicle Identification Number) Code.........................................................1
Applicable VIN ................................................................................................1
Engine / Transaxle Combinations......................................................................2
Scheduled Maintenance .....................................................................................3
Features ...............................................................................................................5
Body .....................................................................................................................6
Table of Contents 00 Service Training Mazda6 MPS Supplement

General Information
VIN (Vehicle Identification Number) Code
M6-MPS_00T001
pplicable VIN
0001—
JMZ GG 8 2 L 6 0 1 600001
Serial No.
Plant 0 = Hiroshima, 1 = Hofu
Dummy 0,6 to 9, A to Z
Transmission 6 = 6MTX
Engine Type L = 2.3L (L3 Turbo)
Body style 2 = 4SD
Remarks 8 = 4WD
Vehicle type GG = Mazda6 MPS, Mazda6 (4SD, 5HB)
World manufacturer indication JMZ = Mazda (Europe)
A
European specs:
JMZGG82L60# 60
Service Training Mazda6 MPS Supplement 00-1

General Information
Engine / Transaxle Combinations
• The Mazda6 MPS (Mazda Performance Series) fitted with the L3 Turbo engine is
available in Europe exclusively with the A26MX-R transaxle.
• Power and torque output of the L3 Turbo engine are significantly increased in
comparison to the standard L3 engine:
– Max. output: 191kW (260PS) / 5,500rpm
– Max. torque: 380Nm / 3,000rpm
– Acceleration from 0...100 km/h: 6.6 seconds (under Mazda test conditions)
– Acceleration from 50...100 km/h (3rd gear): 5.9 seconds (under Mazda test
conditions)
– Acceleration from 60...80 km/h (4th gear): 3.0 seconds (under Mazda test conditions)
M6-MPS_00001
1 Power output 3 Engine speed
2 Torque
00-2 Service Training Mazda6 MPS Supplement

General Information
Scheduled Maintenance
Months 12 24 36 48 60 72 84 96 108 120 132 144
X1000 km 5 15 30 45 60 75 90 105 120 135 150 165 180
X1000 miles 3.1 9.4 18.8 28.1 37.5 46.9 56.3 65.6 75.0 84.4 93.8 103.1 112.5
RRRRRRRR R R R R R
RRRRRRRR R R R R R
II
II I I I
FL 22 type *4
Others
II I I I
II
IIII I I I I I I I I
IIII I I I I I I I I
RR R R R R
IIII I I I I I I I I
IIII I I I I I I I I
IIII I I I I I I I I
II I I I
RR
II I I I
II I I I
II
Air filter (if installed)
Replace every 195,000 km (121,900 miles) or 11 years
Replace at first 90,000Km (56,300 miles) or 4 years, after that every 2 years
Replace every 60,000Km (37,500 miles) or 36 months
AIR CONDITIONER SYSTEM (if installed
Brakes lines hoses and connections
Steering operation and linkages
Manual transaxle oil
Rear differential oil
Parking brake
Front and rear suspension and ball joints
Drive shaft dust boots
Power steering fluid, lines, hoses
and connections
Tires (including spare tire)
(with inflation pressure adjustment)
Exhaust system and heat shields
CHASSIS and BODY
Maintenance
interval
Drive belt *3
Engine coolant
Battery electrolyte level and specific gravity
Engine valve clearance
Spark plugs
Evaporation system(if installed)
Engine oil filter *2
Engine oil*2
Disc brakes
Transfer oil
Brake fluid *6
Power brake unit (Brake booster)
and hoses
Maintenance interval (number of momths or km (miles) which ever comes first)
Replace every 75,000 Km (46,900 miles)
EMISSION CONTROL SYSTEM
IGNITION SYSTEM
Fuel lines and hoses
Air cleaner element*1
Cooling system (including coolant level adjustment)
Audible inspect every 120,000km (75,000 miles), if noisy adjust
ENGINE
COOLING SYSTEM
Inspect annualy
FUEL SYSTEM
ELECTRICAL SYSTEM
IIII I I
Body condtion
(for rust, corrosion and perforation)
IIII I I
*6 *7
*7
IIIIIIII I
Replace every 40,000Km (25,000 miles) or 24 months
IIII
I
I
I
I
I
I
I
M6-MPS_00T002
I: Inspect: Inspect and clean, repair, adjust, or replace if necessary.
R: Replace
Service Training Mazda6 MPS Supplement 00-3

General Information
Remarks: Emission control and related systems
• The ignition and fuel systems are highly important to the emission control system and to
efficient engine operation. All inspections and adjustments must be made by an
Authorized Mazda Dealer.
• After the prescribed period, continue to follow the described maintenance at the
recommended intervals.
• Refer below for a description of items marked* in the maintenance chart.
*1: Also inspect and adjust the power steering and air conditioner drive belts, if installed.
*2: If the vehicle is operated under any of the following conditions, change the engine oil and
oil filter more often than recommended intervals:
– Driving in dusty conditions.
– Extended periods of idling or low speed operation.
– Driving for long period in cold temperatures or driving regularly at short distance only.
*3: 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.
*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: 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.
*6: If the vehicle is operated under any of the following conditions, change the rear differential
oil every 45,000 km (28,100 miles):
– Towing a trailer or using a car-top carrier.
– Driving in dusty, sandy or wet condition.
– Extended periods of idling or low speed operation.
– Repeated short trips of less than 16 km (10 miles).
*7: If this component has been submerged in water, the oil should be changed.
*8: This is a full function check of electrical systems such as lights, wiper and washer
systems (including wiper blades), and power windows.
00-4 Service Training Mazda6 MPS Supplement

General Information
Features
• Powertrain
– MZR 2.3 DISI TURBO engine with DISI (Direct Injection Spark Ignition) technology
– 6-speed manual transaxle with active torque split all-wheel drive
– relocated charcoal canister under spare wheel recess
– limited slip differential
• Suspension
– increased spring and damper rates
– larger stabilizer bar diameters
– revised rubber bushings to match sporty suspension settings
– high-pressure gas charged rear shock absorbers
– 18 x 7J wheels with 215/45R 18 93Y tires
• Brakes
– brake hardware carried over from Mazda6 Facelift with 18'' wheels
– DSC (Dynamic Stability Control), TCS (Traction Control System) and EBA
(Emergency Brake Assistant)
• Accessories
– new front fog lamps
– black leather seats and leather-wrapped gear knob
– driver’s seat memory function
– alloy pedal set
– stainless steel scuff plates
– unique instrument cluster including black and red instrument dials
– anti-theft protection system
– navigation system (optional)
– Bose audio system
Service Training Mazda6 MPS Supplement 00-5

General Information
Body
• Exterior design:
– unique bonnet with integral air duct for charge air cooler
– relocated washer jets in cowl panel
– newly designed sports grille
– front and rear spoilers, unique rear bumper and side skirts
– metallic or mica paint as standard: Titanium Gray II metallic, Black mica, Velocity
Red mica, new body colour Moist Silver metallic
• Torsional rigidity has been improved by approximately 50 percent over the Mazda6.
Specific actions taken to increase body rigidity include:
– A diagonal brace structure was added behind the rear seatbacks, with four angled
members that suppress diagonal displacement and displacement of the rear damper
mount (no load-through provision).
– The cross members atop the floor that join the left and right sides of the cabin serve
to support the rear damper mounts for the suspension.
– The strength of the suspension mounts at the rear of the body was increased to
support the greater damping force of the new rear dampers.
– Increased size of the reinforcements for the inside of the bumper section is used to
strengthen the joint to the body.
– The plane cross section of the cowl member has been lengthened on both ends and
connected directly to stiffeners on the front damper mounts.
– The number of joints between the instrument panel members and body was
increased from three to four to create a stronger, more rigid assembly.
– The body mounts for the perimeter frame to which the front suspension and engine
are mounted were also strengthened.
– Reinforcing gussets were added to strengthen the left and right roof rails and header
sections of the upper body, while creating a synergistic effect with the diagonal brace
system behind the rear seatbacks for even greater rigidity.
00-6 Service Training Mazda6 MPS Supplement

General Information
M6-MPS_00002
1 Cowl member (extended and connected
to side body) 4 Strengthened cross member mounts (increased number of joints)
2 Added reinforcement gussets 5 Reinforced cross member mounts
(increased thickness of sheet metal)
3 Diagonal brace structure
Service Training Mazda6 MPS Supplement 00-7

General Information
Notes:
00-8 Service Training Mazda6 MPS Supplement

01
Engine

01 Engine
Table of Contents
L3 Turbo
Mechanics............................................................................................................1
Specifications..................................................................................................2
Cylinder Head Construction............................................................................2
Cylinder Head Structural View........................................................................3
Cylinder Head Gasket Construction................................................................4
Cylinder Block Construction............................................................................5
Pistons............................................................................................................7
Crankshaft.......................................................................................................8
Balancer Unit ..................................................................................................8
Valve Mechanism............................................................................................9
Timing Chain.................................................................................................10
Chain Tensioner............................................................................................11
Camshafts.....................................................................................................12
Camshaft Sprocket .......................................................................................14
Valve Timing.................................................................................................15
Lubrication System...........................................................................................16
Specifications................................................................................................17
Lubrication System Flow Diagram ................................................................18
Oil Cooler......................................................................................................19
Oil Jet Valve..................................................................................................19
Cooling System.................................................................................................20
Cooling System Flow Diagram......................................................................20
Cooling Fan Operation..................................................................................21
Cooling Fan Wiring Diagram.........................................................................22
Intake-Air System..............................................................................................23
Intake-Air System Flow Diagram...................................................................24
Intake-Air System Hose Routing Diagram.....................................................25
Air Charging System.....................................................................................26
Turbocharger Construction/Operation...........................................................26
Air Bypass Valve Function............................................................................28
Variable Swirl System...................................................................................30
Table of Contents 01 Service Training Mazda6 MPS Supplement

01 Engine
Fuel System.......................................................................................................32
Specifications................................................................................................32
Fuel System Structural View.........................................................................33
Returnless Fuel System................................................................................34
Direct Fuel Injection System .........................................................................35
Fuel Pump Unit.............................................................................................36
Fuel Pump Resistor ......................................................................................37
Fuel Pump Relay and Fuel Pump Speed Relay............................................38
High Pressure Fuel Pump.............................................................................41
High Pressure Fuel Pump Structural View....................................................42
High Pressure Fuel Pump Operation ............................................................42
Fuel Delivery Pipe.........................................................................................46
Fuel Injector..................................................................................................47
Exhaust System.................................................................................................49
Control System..................................................................................................50
PCM..............................................................................................................50
Control System Structural View ....................................................................51
Control System Wiring Diagram....................................................................52
Injector Driver Module...................................................................................56
Injector Driver Module Wiring Diagram .........................................................58
L3 TURBO Specific DTCs.............................................................................59
L3 Turbo Specific PIDs .................................................................................60
Service Training Mazda6 MPS Supplement Table of Contents 01

01 Engine
Notes:
Table of Contents 01 Service Training Mazda6 MPS Supplement

Engine L3 Turbo
Mechanics
• The engine is basically carried over from the Mazda6 L3 engine.
M6-MPS_01001
M6-MPS_01002
1 CMP (Camshaft Position) sensor
attachment hole 3 Oil filler cap
2 OCV (Oil Control Valve) attachment hole
Service Training Mazda6 MPS Supplement 01-1

L3 Turbo Engine
Specifications
M6-MPS_01T006
Cylinder Head Construction
ction, the structure of the cylinder head now has
e injectors to reach the combustion chambers.
Displacement
Compression pressure Open BTDC (°)
Close ABDC (°)
Open BBDC (°)
Close ATDC(°)
IN
EX
cc
Compression ratio
Bore x stroke
IN
EX
Item
Type
Cylinder arrangement and number
Combustion chamber
Valve system
mm
MECHANICAL
Kpa [rpm]
42
5
0.27-0.33 (eng. cold)
0.22-028 (eng. cold)
9.5 : 1
1280 [250]
0-30
62-32
Specification
L3 Turbo
Gasoline 4-cycle
In-line, 4- cylinder
Pentroof
DOHC, timing chain driven, 16 valves
2261
87.5 x 94.0
Valve timing
Valve clearance mm
• With the adoption of direct inje
installation holes that allow th
M6-MPS_01003
1 Parting angle between valves 3 Exhaust port
2 Intake port
01-2 Service Training Mazda6 MPS Supplement