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Mazda6 Training Manual 3359-1*-02C)

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Mazda6 Training Manual 3359-1*-02C) Mazda6 CONTENTS Training Title Section General Information GI Manual Engine B Lubrication System D FOREWORD Cooling System E This manual explains each component or system operation and function for Fuel and Emission Control Systems F the Mazda6. Engine Electrical System G For proper repair and maintenance, a thorough familiarization with this manual Clutch H is important, and it should always be kept in a handy place for quick and easy Manual Transaxle J reference. Automatic Transaxle K All the contents of this manual, including Front and Rear Axles M drawings and specifications, are the latest available at the time of printing. Steering System N As modifications affecting repair or maintenance occur, relevant information Braking System P supplementary to this volume will be made available at Mazda dealers. This manual Suspension R should be kept up-to-date. Body S Mazda Motor Corporation reserves the right to alter the specifications and Body Electrical System T contents of this manual without obligation or advance notice. Heater and Air Conditioner Systems U All rights reserved. No part of this book may be reproduced or used in any form or © 2002 Mazda Motor Corporation by any means, electronic or PRINTED IN The Netherlands, MARCH 2002 mechanical—including photocopying and 3359–1E–02C recording and the use of any kind of information storage and retrieval system—without permission in writing. Mazda Motor Corporation HIROSHIMA, JAPAN APPLICATION: This manual is applicable to vehicles beginning with the Vehicle Identification Numbers (VIN) shown on the following page. VEHICLE IDENTIFICATION NUMBERS (VIN) U.K. specs. JMZ GG12820# 100001— JMZ GG14320# 100001— JMZ GG14820# 100001— JMZ GG12F20# 100001— JMZ GG12F50# 100001— JMZ GG14F20# 100001— JMZ GG14F50# 100001— European (L.H.D.) specs. JMZ GG1232✻# 100001— JMZ GG1282✻# 100001— JMZ GG1432✻# 100001— JMZ GG1482✻# 100001— JMZ GG12F2✻# 100001— JMZ GG12F5✻# 100001— JMZ GG14F2✻# 100001— JMZ GG14F5✻# 100001— GCC specs. JM7 GG32F✻✻# 100001— JM7 GG34F✻✻# 100001— JM7 GG42F✻✻# 100001— JM7 GG44F✻✻# 100001— RELATED MATERIALS Engine Workshop Manual L8, LF, L3 . 1731–1*–02C Manual Transaxle Workshop Manual G35M–R . 1732–1*–02C Automatic Transaxle Workshop Manual FN4A–EL. 1623–10–98E Automatic Transaxle Workshop Manual Supplement FN4A–EL . 1746–1*–02C Mazda6 Wiring Diagram (European (L.H.D.), GCC specs.) . 5539–1*–02C Mazda6 Wirinig Diagram (U.K. specs.) . 5540–1*–02C Mazda6 Bodyshop Manual (European (L.H.D. U.K.), GCC specs.) . 3360–1*–02C * : Indicates the printing location E: Europe 0: Japan GI GENERAL INFORMATION GI HOW TO USE THIS MANUAL ............................. GI-2 VIN CODE.......................................................... GI-2 UNITS ................................................................... GI-4 UNITS TABLE .................................................... GI-4 NEW STANDARDS .............................................. GI-5 NEW STANDARDS TABLE ............................... GI-5 GI–1 HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL VIN CODE A6E201000001T01 European (L.H.D. U.K.) specs. A6E2021T001 GI–2 HOW TO USE THIS MANUAL GCC specs. GI A6E2021T002 End Of Sie GI–3 UNITS UNITS UNITS TABLE A6E201200002T01 Electrical current A (ampere) Electric power W (watt) Electric resistance ohm Electric voltage V (volt) mm (millimeter) Length in (inch) kPa (kilo pascal) Negative pressure mmHg (millimeters of mercury) inHg (inches of mercury) kPa (kilo pascal) 2 Positive pressure kgf/cm (kilogram force per square centimeter) psi (pounds per square inch) N·m (Newton meter) kgf·m (kilogram force meter) Torque 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) Volume ml (milliliter) cc (cubic centimeter) cu in (cubic inch) fl oz (fluid ounce) g (gram) Weight oz (ounce) Conversion to SI Units (Système International d'Unités) • All numerical values in this manual are based on SI units. Numbers shown in conventional units are converted from these values. Rounding Off • Converted values are rounded off to the same number of places as the SI unit value. For example, if the SI unit value is 17.2 and the value after conversion is 37.84, the converted value will be rounded off to 37.8. Upper and Lower Limits • When the data indicates upper and lower limits, the converted values are rounded down if the SI unit value is an upper limit and rounded up if the SI unit value is a lower limit. Therefore, converted values for the same SI unit value may differ after conversion. For example, consider 2.7 kgf/cm2 in the following specifications: 210—260 kPa {2.1—2.7 kgf/cm2, 30—38 psi} 270—310 kPa {2.7—3.2 kgf/cm2, 39—45 psi} • The actual converted values for 2.7 kgf/cm2 are 265 kPa and 38.4 psi. In the first specification, 2.7 is used as an upper limit, so the converted values are rounded down to 260 and 38. In the second specification, 2.7 is used as a lower limit, so the converted values are rounded up to 270 and 39. End Of Sie GI–4 NEW STANDARDS NEW STANDARDS GI NEW STANDARDS TABLE A6E202800020T01 • Following is a comparison of the previous standard and the new standard. New Standard Previous Standard Abbrevi- Abbrevi- Remark Name Name ation 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 Vb Battery Voltage — Brake Switch — Stoplight Switch — Calibration Resistor — Corrected Resistance #6 CMP sensor Camshaft Position Sensor — Crank Angle Sensor CAC Charge Air Cooler — Intercooler CLS Closed Loop System — Feedback System CTP Closed Throttle Position — Fully Closed CPP Clutch Pedal Position — Clutch Position CIS Continuous Fuel Injection System EGI Electronic Gasoline Injection System CS sensor Control Sleeve Sensor CSP sensor Control Sleeve Position Sensor #6 CKP sensor Crankshaft Position Sensor — Crank Angle Sensor 2 DLC Data Link Connector — Diagnosis Connector DTM Diagnostic Test Mode — Test Mode #1 DTC Diagnostic Trouble Code(s) — Service Code(s) DI Distributor Ignition — Spark Ignition DLI Distributorless Ignition — Direct Ignition EI Electronic Ignition — Electronic Spark Ignition #2 ECT Engine Coolant Temperature — Water Thermo EM Engine Modification — Engine Modification — Engine Speed Input Signal — Engine RPM Signal EVAP Evaporative Emission — Evaporative Emission EGR Exhaust Gas Recirculation — Exhaust Gas Recirculation FC Fan Control — Fan Control FF Flexible Fuel — Flexible Fuel 4GR Fourth Gear — Overdrive — Fuel Pump Relay — Circuit Opening Relay #3 FSO Fuel Shut Off Solenoid FCV Fuel Cut Valve #6 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/SelfDiagnosis OL Open Loop — Open Loop GI–5 NEW STANDARDS New Standard Previous Standard Abbrevi- Abbrevi- Remark Name Name ation 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 Solenoid Valve Pulsed PAIR Pulsed Secondary Air Injection — Secondary Air Injection System injection — Pump Speed Sensor — NE Sensor #6 Injection AIR Secondary Air Injection — Secondary Air Injection System with air pump SAPV Secondary Air Pulse Valve — Reed Valve SFI Sequential Multipoint Fuel Injection — Sequential Fuel Injection — 1-2 Shift Solenoid Valve — Shift Solenoid A — Shift A Solenoid Valve — 2-3 Shift Solenoid Valve — Shift Solenoid B — Shift B Solenoid Valve — Shift Solenoid C — 3-4 Shift Solenoid Valve 3GR Third Gear — 3rd Gear TWC Three Way Catalytic Converter — Catalytic Converter TB Throttle Body — Throttle Body TP sensor Throttle Position Sensor — Throttle Sensor TCV Timer Control Valve TCV Timing Control Valve #6 TCC Torque Converter Clutch — Lockup Position Transmission (Transaxle) Control TCM — ECAT Control Unit Module Transmission (Transaxle) Fluid — — ATF Thermosensor Temperature Sensor 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 Warm Up Three Way Catalytic WUTWC — Catalytic Converter #5 Converter WOT Wide Open Throttle — Fully Open #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–6 BENGINE B ABBREVIATIONS ..................................................B-2 ABBREVIATIONS ................................................B-2
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