Mazda 6 MPS 2005 Training Manual Supplement Download Page 25

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Engine L3

Turbo

Pistons

•

The shape of pistons has been changed due to the different requirements of direct
injecting petrol engines.

•

The piston top is recessed to improve the mixture formation.

•

The piston skirt was redesigned to fit to the new oil jet valves.

•

The pistons are coated partially to reduce friction between piston and cylinder wall.

M6-MPS_01007a

1 Oil jet release width

Piston Ring Assembly

M6-MPS_01007b

Service Training Mazda6 MPS Supplement

01-7

Summary of Contents for 6 MPS 2005

Page 1: ...TRAINING MANUAL Mazda6 MPS Supplement ...

Page 2: ...rmation 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 ...

Page 3: ...Contents General Information 00 Engine 01 Driveline Axle 03 Section Title Service Training Mazda6 MPS Supplement ...

Page 4: ...Service Training Mazda6 MPS Supplement ...

Page 5: ...00 General Information ...

Page 6: ...eral 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 ...

Page 7: ... 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 ...

Page 8: ...nificantly 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 ...

Page 9: ...ts 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 Po...

Page 10: ...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 vehi...

Page 11: ...ings 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 ...

Page 12: ...pport 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 directl...

Page 13: ...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 ...

Page 14: ...General Information Notes 00 8 Service Training Mazda6 MPS Supplement ...

Page 15: ...01 Engine ...

Page 16: ...procket 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 ...

Page 17: ...ssure 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 Suppl...

Page 18: ...01 Engine Notes Table of Contents 01 Service Training Mazda6 MPS Supplement ...

Page 19: ...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 ...

Page 20: ... 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...

Page 21: ...Engine L3 Turbo Cylinder Head Structural View M6 MPS_01004 1 Fuel injector installation hole 2 Combustion chamber Service Training Mazda6 MPS Supplement 01 3 ...

Page 22: ...L3 Turbo Engine Cylinder Head Gasket Construction A four layer metal cylinder head gasket has been adopted M6 MPS_01005 1 Bead plate 3 Bead plate 2 Shim 01 4 Service Training Mazda6 MPS Supplement ...

Page 23: ...ng heat radiation and decreasing weight The cylinder block has an oil separator cover with integrated PCV Positive Crankcase Ventilation valve on the side of the fresh air intake M6 MPS_01006 1 Oil separator cover 4 Oil separator cover attachment 2 PCV valve 5 Main bearing cap 3 Cylinder block Service Training Mazda6 MPS Supplement 01 5 ...

Page 24: ... is located at the exhaust side of the cylinder block The TDC position can be detected when the SST edge touches the cutting surface of the No 1 counter weight M6 MPS_01007 1 Cylinder block 5 SST 49 JE01 061 2 No 1 cylinder TDC position 6 Service hole 3 No 1 piston 7 No 1 cylinder 4 Crankshaft counter weight 01 6 Service Training Mazda6 MPS Supplement ...

Page 25: ...es The piston top is recessed to improve the mixture formation The piston skirt was redesigned to fit to the new oil jet valves The pistons are coated partially to reduce friction between piston and cylinder wall M6 MPS_01007a 1 Oil jet release width Piston Ring Assembly M6 MPS_01007b Service Training Mazda6 MPS Supplement 01 7 ...

Page 26: ...e crankshaft for driving the balancer unit M6 MPS_01008 1 Drive gear Balancer Unit The cassette type balancer unit is adopted from the L3 engine to reduce vibration from the engine The balancer unit must not be disassembled because it is a precision unit M6 MPS_01009 1 Cassette type balancer unit 2 Balancer shafts 01 8 Service Training Mazda6 MPS Supplement ...

Page 27: ...asically carried over from the L3 engine M6 MPS_01010 1 Camshafts 7 Chain tensioner 2 Tappet 8 Tensioner arm 3 Valve assembly 9 Camshaft sprockets 4 Variable valve timing actuator 10 Timing chain 5 Chain guide 11 Oil control valve OCV 6 Crankshaft sprocket Service Training Mazda6 MPS Supplement 01 9 ...

Page 28: ...s have been adopted in order to improve durability against high output and heavy loads M6 MPS_01011 1 Camshaft sprockets 5 Chain guide 2 Timing chain 6 Crankshaft sprocket 3 Pitch size 7 Chain tensioner 4 Pin 8 Tensioner arm 01 10 Service Training Mazda6 MPS Supplement ...

Page 29: ...stayed the same The oil pressure chain tensioner consists of a ratchet and rack that fixes the piston in place when the engine is started and a piston and spring that push against the tensioner arm M6 MPS_01012 1 Cam spring 4 Piston 2 Ratchet 5 Spring 3 Rack 6 Body Service Training Mazda6 MPS Supplement 01 11 ...

Page 30: ...e located at the rear of the intake camshaft M6 MPS_01013 1 Exhaust camshaft 7 Thrust collar 2 Thrust collar 8 Cam nose 3 Cam nose 9 CMP sensor detection lobes 4 Cam heel 10 Fuel pump drive cam 5 Cam journal 11 Cam journal 6 Intake camshaft 12 Cam heel 01 12 Service Training Mazda6 MPS Supplement ...

Page 31: ...Engine L3 Turbo M6 MPS_01014 1 Fuel pump drive cam 2 CMP sensor detection lobes New SST for Camshaft Alignment M6 MPS_01015 1 SST 49 UN30 310610 Service Training Mazda6 MPS Supplement 01 13 ...

Page 32: ...et and is quenched to improve the abrasion resistance at the contact point with the timing chain The intake camshaft sprocket is integrated with the variable valve timing actuator and must not be disassembled M6 MPS01016 1 Camshaft sprocket 2 Variable valve timing actuator 01 14 Service Training Mazda6 MPS Supplement ...

Page 33: ... The adjustment range of the variable valve timing actuator has been extended M6 MPS_01017 1 TDC 4 BDC Bottom Dead Center 2 Variable domain 5 Variable domain 3 Intake air 6 Exhaust air Service Training Mazda6 MPS Supplement 01 15 ...

Page 34: ...ug 3 Oil pressure switch 12 Oil pump 4 Oil filter adapter 13 Oil pump sprocket 5 Oil filter 14 Oil pump chain 6 Oil filter cover 15 Oil pump chain guide 7 Oil filter drain plug 16 Oil pump chain tensioner 8 O ring 17 Oil strainer 9 Oil pan 18 Oil jet valve 01 16 Service Training Mazda6 MPS Supplement ...

Page 35: ...lacement 5 7 L Total dry engine 6 4 L Recommended engine oil Item Grade API SL or ACEA A3 A5 API SL or ACEA A3 Viscosity SAE 5W 30 10W 40 Remarks Europe Mazda genuine Dexelia oil e g M6 MPS_01T001 Oil Pressure Reference Value 100 C 297 551 kPa 3000 rpm Service Training Mazda6 MPS Supplement 01 17 ...

Page 36: ... 15 Chain tensioner 4 Camshaft 16 Piston 5 Turbocharger 17 Oil jet valve 6 Balancer shaft 18 Main Bearing 7 Oil pan 19 Crankshaft 8 Oil strainer 20 Connecting rod bearing 9 Oil pump 21 Oil passage 10 Oil cooler 22 Oil relief passage 11 Oil filter 23 Oil bypass passage 12 Oil pressure switch 01 18 Service Training Mazda6 MPS Supplement ...

Page 37: ...n Oil Jet Valve New oil jet valves to cool the pistons are installed in the cylinder block The oil jet valve nozzles are installed pointed toward the back surface of each piston The oil jet valves are designed to inhibit oil draining from the lubrication system when the engine is stopped M6 MPS_01021 1 Engine front side 3 Oil jet valve 2 Oil 4 Cylinder block Service Training Mazda6 MPS Supplement ...

Page 38: ...nt Cooling System Flow Diagram The turbocharger and the transfer case cooler have been added to the coolant system M MPS_01050 1 Coolant reserve tank 8 Throttle body 2 Radiator 9 Turbocharger 3 Thermostat 10 Transfer case oil cooler 4 Water pump 11 Heater 5 Cylinder block 12 Oil cooler 6 Cylinder head 13 Coolant flow direction 7 EGR valve 01 20 Service Training Mazda6 MPS Supplement ...

Page 39: ...ccording to the following Engine coolant temperature Vehicle speed Whether A C Air Conditioning middle pressure switch is on or off Whether the A C magnetic clutch is on or off M6 MPS_01022 1 Coolant reserve tank 5 Radiator cowling 2 Cooling fan motor No 2 6 Cooling fan No 1 3 Fan control module 7 Cooling fan No 2 4 Cooling fan motor No 1 Service Training Mazda6 MPS Supplement 01 21 ...

Page 40: ...L3 Turbo Engine Cooling Fan Wiring Diagram M6 MPS_01023 1 Fan control module 4 Cooling fan motor No 1 2 PCM 5 Battery 3 Cooling fan motor No 2 01 22 Service Training Mazda6 MPS Supplement ...

Page 41: ...iable swirl shutter valve actuator 2 Turbocharger 8 Throttle body 3 Air cleaner 9 Variable swirl solenoid valve 4 Accelerator pedal 10 Wastegate actuator 5 Resonance chamber 11 Wastegate control solenoid valve 6 Air bypass valve Service Training Mazda6 MPS Supplement 01 23 ...

Page 42: ...PS_01025 1 Air bypass valve 6 Wastegate actuator 2 Charge air cooler 7 Wastegate control solenoid valve 3 Air cleaner 8 Variable Swirl valve 4 Turbocharger 9 Throttle body 5 WU TWC Warm Up Three Way Catalyst 01 24 Service Training Mazda6 MPS Supplement ...

Page 43: ... Hose Routing Diagram M6 MPS_01026 1 Charge air cooler 5 Intake manifold 2 Turbocharger 6 Variable swirl solenoid valve 3 Air cleaner 7 Variable swirl shutter valve actuator 4 Throttle body Service Training Mazda6 MPS Supplement 01 25 ...

Page 44: ...or wheel wastegate valve and wastegate actuator When exhaust gas flows to the turbocharger turbine wheel the coaxial compressor wheel rotates and intake air is pressurized The wastegate actuator opens the wastegate valve according to the overpressure at the diaphragm When the wastegate is open the exhaust gas pressure at the turbine is lowered and this lowers the speed and force of the turbine whi...

Page 45: ...e wastegate cannot open any more because the overpressure sent to the actuator is leaking through the wastegate control solenoid valve to the intake system Though the wastegate control solenoid valve can inhibit the opening of the wastgate To control charge air pressure exactly the PCM operates the wastegate solenoid with a duty signal To reduce the pressure loss when the wastegate solenoid valve ...

Page 46: ...ging system To prevent this if the air pressure in the air charging system exceeds a specified value approx 1 4 bar the bypass valve opens and the pressure is released upstream of the turbocharger When the throttle is closed vacuum applied to the air bypass valve diaphragm opens the valve directly and the pressure is released upstream of the turbocharger 01 28 Service Training Mazda6 MPS Supplemen...

Page 47: ...bo M6 MPS_01029 1 Throttle valve open 5 Throttle valve closed 2 Air bypass valve 6 Positive pressure 3 Rod 7 Vacuum 4 Charge air cooler 8 To upstream of the turbocharger Service Training Mazda6 MPS Supplement 01 29 ...

Page 48: ... intake passage As a result the air fuel mixture quality is improved Additionally the creation of a powerful air swirl in the combustion chamber promotes the atomization of the air fuel mixture Due to this exhaust emission quality is improved A variable swirl switch monitors the opening of the valve and is connected to the PCM for feedback M6 MPS_01030 1 Variable swirl shutter valve actuator 3 Air...

Page 49: ...Engine L3 Turbo M6 MPS_01031 1 Variable swirl shutter valve open 3 Variable swirl shutter valve closed 2 Intake air ports Service Training Mazda6 MPS Supplement 01 31 ...

Page 50: ...he fuel delivery pipe Mpa Approx 13 Pre delivery fuel pump type Electric High pressure fuel pump type Mechanic Fuel tank capacity L 60 Item Injector N Research be operated using 95 octane RON fuel which will result in decreased powe output Using fuel with lower octane can cause engine knocking an serious engine damage Working on the high pressure fuel system can be dangerous Always release fuel pr...

Page 51: ...ructural View Engine Compartment Side M6 MPS_01032 1 High pressure fuel pump 4 Fuel delivery pipe 2 Fuel pump speed control relay 5 Fuel injectors 3 Fuel pump relay 6 Fuel pressure sensor Service Training Mazda6 MPS Supplement 01 33 ...

Page 52: ...ure regulator The pressure regulated fuel is sent to the high pressure fuel pump The returnless fuel system reduces fuel evaporation in the fuel tank The pressure regulator located in the fuel tank prevents fuel return from the engine compartment side thereby maintaining a low fuel temperature in the fuel tank Due to this formation of evaporative gas produced by a rise in fuel temperature is suppr...

Page 53: ...zation of the injected fuel Due to this engine knocking is reduced and high engine output is obtained Uniform combustion in all areas regardless of load conditions is obtained End Of Construction The direct fuel injection system consists of a high pressure fuel pump fuel injectors injector driver module fuel pressure sensor and a relief valve M6 MPS_01034 1 Fuel tank 5 Fuel pressure sensor 2 High ...

Page 54: ... unit located in the fuel tank can be removed and installed through the service hole in the bottom of the rear seat Fuel in the fuel reservoir cup is drawn through the suction filter by the fuel pump and pumped to the fuel filter Return fuel is sent back to the fuel reservoir cup or send to the jet pump A venturi located in the path of fuel returning from the pressure regulator creates negative pr...

Page 55: ...fuel pump resistor to protect the fuel pump when the injection amount is low when engine speed is low The fuel pump resistor has a resistance of 0 304 0 336 ohms 20 C The resistor is located below the air cleaner housing M6 MPS_01035 1 Fuel pump resistor End Of Sie Service Training Mazda6 MPS Supplement 01 37 ...

Page 56: ...rol signals from the PCM The fuel pump speed relay controls the fuel pump speed by conducting the current directly to the fuel pump or through the fuel pump resistor according to the control signals from the PCM M6 MPS_01036 1 Fuel pump relay 3 Main fuse block 2 Fuel pump speed relay 01 38 Service Training Mazda6 MPS Supplement ...

Page 57: ... pump resistor to protect the fuel pump when the required fuel amount is low due to low engine speed M6 MPS_01037 1 Fuel pump speed relay off 5 Fuel pump speed control relay 2 PCM 6 Fuel pump relay 3 Fuel pump 7 Current flow 4 Fuel pump resistor 8 Fuel pump speed control relay on Service Training Mazda6 MPS Supplement 01 39 ...

Page 58: ...ate the electric fuel pump manually for test the check connector can be used to operate the fuel pump permanently when the ignition is switched on M6 MPS_01051 1 Fuel pump check connector 2 Main fuse block 01 40 Service Training Mazda6 MPS Supplement ...

Page 59: ...ll valve camshaft piston and spring The high pressure fuel pump is supplied with fuel 430 kPa 4 3 bar by the fuel pump unit inside the tank The high pressure fuel pump applies pressure up to 11 5 MPa 115 bar to the fuel and pumps it to the fuel delivery pipe The high pressure fuel pump must not be disassembled M6 MPS_01038 Service Training Mazda6 MPS Supplement 01 41 ...

Page 60: ... 3 head cam installed to the rear end of the camshaft intake side Fuel pressure is adjusted by the spill valve control solenoid When the spill valve control solenoid is off the spill valve is kept open and fuel pushed out by the piston is returned to upstream thus fuel cannot be pressurized When the spill valve control solenoid is on the spill valve can operate as a check valve and fuel pushed out...

Page 61: ...Engine L3 Turbo Spill valve energized inflow thrust out M6 MPS_01053 Spill valve deenergized inflow reverse flow M6 MPS_01054 1 Fuel flow 2 Plunger movement Service Training Mazda6 MPS Supplement 01 43 ...

Page 62: ...s Note When removing the high pressure line pipe always unscrew the high pressure line pipe installation nut while fixing the high pressure fuel pump joint nut with a wrench If the high pressure fuel pump joint nut has rotated replace the high pressure fuel pump with a new one M6 MPS_01039 1 Joint nut 3 High pressure line pipe 2 High pressure line pipe installation nut 01 44 Service Training Mazda...

Page 63: ... in the fuel delivery pipe reaches 13 MPa 130 bar the relief valve opens and fuel is returned upstream by the high pressure fuel pump The fuel pressure sensor monitors the fuel pressure in the fuel delivery pipe Note The fuel pressure sensor must not be detached from the fuel delivery pipe It can only be renewed by renewing the whole unit M6 MPS_01040 1 Fuel injectors 3 Fuel pressure sensor 2 Fuel...

Page 64: ...ive current is sent from the injector driver module causing excitation current to pass through the coil and thereby pull in the needle valve Due to this the injection nozzle opens and fuel is injected The amount of injection is determined by the open time of the needle valve i e the energization time of the coil M6 MPS_01041 1 Coil 5 Spring 2 O ring 6 Needle valve 3 High pressure 7 Gasket 4 Filter...

Page 65: ...otentially seized injector out of the cylinder head the new SST 49 G013 101 can be used to loosen it Complete rotation move is not possible because this would break away the connector M6 MPS_01055 1 SST 49 G013 101 Service Training Mazda6 MPS Supplement 01 47 ...

Page 66: ... Exhaust System M6 MPS_01042 1 Exhaust manifold 5 Front pipe 2 Turbocharger 6 WU TWC 3 TWC Three Way Catalyst 7 Front HO2S 4 Rear HO2S Heated Oxygen Sensor 8 Main silencer 01 48 Service Training Mazda6 MPS Supplement ...

Page 67: ...element APP Accelerator Pedal Position sensor Hall element Throttle valve actuator DC motor MAF Mass Air Flow sensor Hot wire Front HO2S All range air fuel ratio sensor Rear HO2S Jump type air fuel ratio sensor BARO Barometric Pressure sensor Inside PCM Piezoelectric element KS Knock Sensor Piezoelectric element MAP Manifold Absolute Pressure sensor Piezoelectric element Fuel pressure sensor Piezo...

Page 68: ...r 4 Clutch switch 14 KS 5 APP sensor 15 PSP Power Steering Pressure switch 6 CMP sensor 16 Fuel pressure sensor 7 ECT sensor 17 Variable swirl shutter valve switch 8 MAF IAT sensor 18 TP sensor and throttle actuator 9 PCM RHD Right Hand Drive 19 MAP Boost air temperature sensor 10 PCM LHD Left Hand Drive 01 50 Service Training Mazda6 MPS Supplement ...

Page 69: ...Engine L3 Turbo NOTES Service Training Mazda6 MPS Supplement 01 51 ...

Page 70: ...L3 Turbo Engine Control System Wiring Diagram M6 MPS_01045 01 52 Service Training Mazda6 MPS Supplement ...

Page 71: ...2S Front 6 Injector driver relay 21 HO2S Rear 7 HO2S heater Front 22 Boost air temperature sensor 8 HO2S heater Rear 23 MAP sensor 9 Fan control module 24 ECT sensor 10 Fan relay Main 25 Fuel pressure sensor 11 A C relay 26 APP sensor 12 Fuel pump speed relay 27 MAF sensor 13 Fuel pump resistor 28 IAT sensor 14 Fuel pump 29 PCM 15 Fuel pump relay Service Training Mazda6 MPS Supplement 01 53 ...

Page 72: ...L3 Turbo Engine Control System Wiring Diagram Continued M6 MPS_01046 01 54 Service Training Mazda6 MPS Supplement ...

Page 73: ...l valve control solenoid valve High pressure pump 23 Refrigerant pressure switch Middle 8 Instrument cluster 24 Refrigerant pressure switch High and low 9 Coil immobilizer system 25 A C switch 10 Ignition coil No 1 26 Variable swirl shutter valve switch 11 Ignition coil No 2 27 Brake switch 12 Ignition coil No 3 28 Brake light 13 Ignition coil No 4 29 KS 14 Generator Field coil 30 CMP sensor 15 Th...

Page 74: ...ive the fuel injectors which corresponds to a base high fuel pressure of 3 11 5 MPa 30 115 bar The injector driver module provides the boosted voltage to the fuel injector according to the fuel injection signal from the PCM M6 MPS_01047 1 Injector driver module 3 Connector bracket 2 Injector driver module bracket 4 Wiring harness 01 56 Service Training Mazda6 MPS Supplement ...

Page 75: ...e figure below shows injector voltage measutred at both connections of the injector M6 MPS_01048 1 PCM output 5 Excess exciting current 2 Fuel injector operation period 6 PCM input 3 Close current 7 Injector driver module output 4 Hold current Service Training Mazda6 MPS Supplement 01 57 ...

Page 76: ...1 Injectorsignal No 1 3 Fuel injectors 12 Injectorsignal No 2 4 Output circuit 13 Injectorsignal No 3 5 Booster circuit 14 Injectorsignal No 4 6 Input circuit 15 Valve open transistor 7 Battery 16 GND Ground transistor 8 Ignition switch 17 Hold transistor 9 Injector driver relay 01 58 Service Training Mazda6 MPS Supplement ...

Page 77: ... cylinder No 1 ON P0202 Injector circuit open cylinder No 2 ON P0203 Injector circuit open cylinder No 3 ON P0204 Injector circuit open cylinder No 4 ON P0234 Turbo supercharger overboost condition OFF P0245 Turbocharger wastegate solenoid low OFF P0246 Turbocharger wastegate solenoid high OFF P0421 Catalyst system efficiency below threshold ON P0611 Fuel injector control module performance OFF P2...

Page 78: ...ature 30 C 1 7 1 9 V ECT less than 98 C 0 ECT 100 C 30 ECT 106 C 70 ECT 110 C 100 FIA Fuel injection amount mg cylinder Indicate the fuel injection amount Spill valve control solenoid valve work On Spill valve control solenoid valve does not work Off Idle Approx 3 MPa Load 60 or more Approx 11 5 MPa FUEL_PRES_V V Idle Approx 1 4 V IMRC Variable swirl Engine speed is below Approx solenoid valve 3 7...

Page 79: ...03 Driveline Axle ...

Page 80: ...0 Rear Axle Cross Sectional View 10 Rear Differential 11 Rear Differential Cross Sectional View 11 Coupling Component 12 Super LSD 14 Rear Differential Oil 15 4 Wheel Drive Control 16 Components 17 Electronic Control Coupling 18 Electronic Control Coupling Operation 19 Differential Oil Temperature Sensor 22 4WD Control Module 23 4WD Warning Light 24 4 Wheel Drive Control System Block Diagram 25 4 ...

Page 81: ...hereby greatly reducing vehicle booming noise also A26MX R Manual Transaxle The A26MX R six speed manual transaxle consists of an A26M R manual transaxle and a transfer case which is bolted to the differential housing The transaxle itself is similar to the one used in conjunction with the MZR CD RF Turbo engine but has revised gear ratios The transfer case facilitates 4 wheel drive Specification C...

Page 82: ...Driveline Axle A26MX R Manual Transaxle Cross Sectional View M6 MPS_03026 1 A26MX R manual transaxle 2 Transfer case 03 2 Service Training Mazda6 MPS Supplement ...

Page 83: ... lubrication of all gears the transfer case is equipped with an oil pump To shorten the warm up period and to prevent overheating the transfer case is equipped with an oil cooler which is connected to the engine cooling system M6 MPS_03006 1 Oil cooler 4 Drive gear shaft 2 Drive pinion gear 5 Drive gear 3 Ring gear 6 Oil pump Service Training Mazda6 MPS Supplement 03 3 ...

Page 84: ...ctional View M6 MPS_03008 1 Drive gear 6 Front carrier 2 Drive gear case 7 Drive pinion gear 3 Drive gear shaft 8 Ring gear on ring gear shaft 4 Oil pump 9 Bolt left hand thread 5 Oil level plug 03 4 Service Training Mazda6 MPS Supplement ...

Page 85: ...tly rotates inside the drive gear shaft and is driven by the right differential bevel gear The drive gear is fixed to the drive gear shaft and drives the ring gear shaft The ring gear drives the drive pinion gear which rotates the flange that is attached to the propeller shaft M6 MPS_03009 1 Front left drive shaft 3 Transfer case 2 Front differential 4 Joint shaft Service Training Mazda6 MPS Suppl...

Page 86: ...or SAE 90 API service GL 5 specification The transfer case is filled with oil for lifetime and there is generally no need for replacement or a level check during scheduled maintenance Nevertheless if there are traces of oil leaks a level check is recommended If the transfer case has been submerged in water the oil must be changed M6 MPS_03010 1 Drain plug 03 6 Service Training Mazda6 MPS Supplemen...

Page 87: ...ht adjustment shims drive pinion height and preload spacer drive pinion backlash sliding the ring gear in shaft direction by varying the thicknesses of the left and right adjustment shims while maintaining total thickness of both drive pinion and ring gear tooth contact drive pinion height and backlash by spacers For the detailed procedures please refer to the current Workshop Manual Service Train...

Page 88: ...ear Differential gear Straight bevel gear Ring gear size 7 4 inches Final gear ratio 2 928 Number of teeth drive pinion 14 Number of teeth ring gear 41 Grade API service GL 5 Viscosity SAE 80W 90 Capacity 1 0 litre Rear differential Differential oil Item Front drive shaft Rear drive shaft Rear and front wheel torque distribution unit M6 MPS_03T001 Note When towing a 4WD vehicle where all the wheel...

Page 89: ...r the Mazda6 MPS The drive shafts are equipped with bell joints on the wheel side and double offset joints with low slide resistance on the differential side of the constant velocity joints M6 MPS_03003 1 Joint shaft 3 Front drive shaft 2 Rear drive shaft Service Training Mazda6 MPS Supplement 03 9 ...

Page 90: ...d is 60 5 mm in diameter It comprises one constant velocity tripod double offset joint and three cross shaped joints M6 MPS_03001 Rear Axle Cross Sectional View The rear axle uses cartridge type angular ball bearings that allow the installation of drive shafts for the rear wheels M6 MPS_03002 1 Angular ball bearing 03 10 Service Training Mazda6 MPS Supplement ...

Page 91: ...ing component and a super LSD Limited Slip Differential A differential carrier of aluminium alloy has been used for weight reduction Rear Differential Cross Sectional View M6 MPS_03004 1 Coupling component section 2 Rear differential section Service Training Mazda6 MPS Supplement 03 11 ...

Page 92: ...d the propeller shaft have been removed M6 MPS_03021 1 Coupling case 2 Rear differential The installation position of the coupling component to the rear differential is determined by two tabs on the coupling component that engage with grooves in the rear differential M6 MPS_03022 A Rear differential B Coupling unit 1 Grooves 2 Tabs 03 12 Service Training Mazda6 MPS Supplement ...

Page 93: ...upling component the coupling case must be dismantled M6 MPS_03023 1 Locknut 6 Retaining ring 2 Washer 7 Bearing 3 Companion flange 8 Coupling case 4 Oil seal 9 Output shaft 5 Shim 10 Coupling component Service Training Mazda6 MPS Supplement 03 13 ...

Page 94: ...ahead initial torque 49 Nm simplified construction provides weight reduction The gear cage component of the super LSD must not be disassembled Inside the super LSD taper rings that are fixed to the differential gear cage have been placed between the differential gear cage and the bevel gears Additionally a cone is provided around the outer surface of the bevel gear Springs and retainers are positi...

Page 95: ...l for lifetime and there is generally no need for replacement or a level check during scheduled maintenance Nevertheless if the vehicle is operated under severe conditions see Scheduled Maintenance Remarks the oil should be changed every 45 000 km 28 100 miles If the rear differential has been submerged in water the oil must be changed M6 MPS_03024 1 Filler plug 2 Drain plug Service Training Mazda...

Page 96: ...icle driving and road conditions and controls output current to the electronic control coupling 4WD solenoid inside the rear differential This control allows for optimal distribution of the drive torque from the engine to the rear wheels A self diagnostic function improves serviceability of the electronic 4WD control system M6 MPS_03012 1 4WD warning light 5 4WD CM 2 Differential oil temperature s...

Page 97: ...ion and 4WD warning control information as a CAN signal Controls the on board diagnostic system and the fail safe system if there is a malfunction in the 4WD system 4WD warning light Illuminates or flashes to alert the driver of a malfunction or control failure in the 4WD system PCM Provides data about accelerator pedal position engine speed and transaxle neutral position on the CAN data bus avail...

Page 98: ...an electromagnetic clutch a cam mechanism and a torque transmission system The electromagnetic clutch consists of a 4WD solenoid electromagnetic coil rear housing that forms a magnetic path pilot clutch and armature The cam mechanism consists of a pilot cam balls and main cam The torque transmission system consists of a main clutch and ATF Automatic Transmission Fluid M6 MPS_03014 1 Torque transmi...

Page 99: ...solenoid At the same time the pilot cam and the main cam rotate in the same direction via the balls and the main cam does not exert any push force on the main clutch side Therefore the traction from the front wheels is not transmitted to the rear wheels M6 MPS_03015 1 Main clutch 5 Pilot cam 2 Pilot clutch 6 Ball 3 4WD solenoid electromagnetic coil 7 Main cam 4 4WD CM 8 Armature Service Training M...

Page 100: ...Due to this relative torsion the cam mechanism operates transmitting torque from the pilot cam to the ball and then to the main cam In this way the push force exerted on the main clutch is amplified 5 As the main clutch engages the drive torque from the front wheels is transmitted to the rear wheels The amount of push force exerted on the main clutch by the main cam that is the strength of the dri...

Page 101: ...MPS_03016 1 Main clutch 7 Main cam 2 Pilot clutch 8 Drive torque 3 4WD solenoid electromagnetic coil 9 Armature 4 4WD CM 10 Magnetic flux 5 Pilot cam 11 Input 6 Ball 12 Output Service Training Mazda6 MPS Supplement 03 21 ...

Page 102: ... to the 4WD CM The differential oil temperature sensor uses an NTC Negative Temperature Coefficient resistor whose resistance changes according to changes in the rear differential oil temperature The resistance grows smaller as the oil temperature rises and vice versa as shown M6 MPS_03025 1 Differential oil temperature sensor Differential Oil Temperature Sensor Characteristics M6 MPS_03017 03 22 ...

Page 103: ... road surface conditions M6 MPS_03019 1 4WD control module 2 PCM Operation 4WD system control function Based on each input signal the electronic control current sent to the electronic control coupling 4WD solenoid is optimally controlled Diagnostic system If the self diagnostic system detects a malfunction the 4WD warning light illuminates to alert the driver and at the same time the system suspen...

Page 104: ... the warning light illuminates to alert the driver of the malfunction If the system control is temporarily suspended due to the rear differential oil temperature becoming abnormally hot or similar cause the warning light flashes to alert the driver The 4WD CM controls the operation of the warning light M6 MPS_03018 03 24 Service Training Mazda6 MPS Supplement ...

Page 105: ... Ball main cam 3 4WD CM 12 Main clutch 4 4WD solenoid 13 Electronic control coupling 5 Front 14 Rear differential 6 Transaxle 15 Rear drive shaft 7 Transfer case 16 Torque transmission path 8 Propeller shaft 17 Electric signal path 9 Front drive shaft 18 Solenoid activation Service Training Mazda6 MPS Supplement 03 25 ...

Page 106: ...ing duty signal PCM Accelerator pedal position Engine speed Transaxle neutral position DSC HU CM Four wheel speed DSC operating condition Coupling torque request Steering wheel angle Back up light switch position Yaw rate Lateral G Differential oil temperature sensor Rear differential oil temperature Parking brake switch Parking brake position In addition to that the 4WD CM transmits information a...

Page 107: ... prevent undue influence on ABS control Also when a coupling torque request signal is received from the DSC HU CM the module controls the torque transmitted to the rear wheels to match the amount of requested torque Torque can also be transmitted to the rear wheels in order to distribute engine braking force to all the wheels to achieve better driving stability when decelerating Other Control In c...

Page 108: ... CM 10 Data Link Connector 3 Electronic control coupling 11 CAN driver 4 4WD solenoid 12 Parking brake switch 5 Instrument cluster 4WD warning light 13 Battery 6 DSC HU CM 14 Fuse ENG B 10A 7 PCM 15 Fuse METER 15A 8 CAN_L 16 Differential oil temperature sensor 03 28 Service Training Mazda6 MPS Supplement ...

Page 109: ...he battery is disconnected Therefore it is necessary to clear the memory when maintenance has been completed When the failure detection function determines that there is a malfunction the 4WD warning light illuminates to alert the driver At this time the fail safe function suspends control to ensure that driving stability is not lost Certain DTCs are provided to make diagnostics easier A complete ...

Page 110: ...Driveline Axle Notes 03 30 Service Training Mazda6 MPS Supplement ...

Page 111: ... Module DTC Diagnostic Trouble Code EBA Electronic Brake Assistance ECT Engine Coolant Temperature EGR Exhaust Gas Recirculation F L Facelift GMR Gigant Magnetic Resistive GPS Global Positioning System GND Ground HO2S Heated Oxygen Sensor IAT Intake Air Temperature KS Knock Sensor LHD Left Hand Drive LSD Limited Slip Differential MAF Mass Air Flow MAP Manifold Absolute Pressure MPS Mazda Performan...

Page 112: ...re RHD Right Hand Drive RON Research Octane Number TCS Traction Control System TDS Top Dead Center TP Throttle Position TWC Three Way Catalyst VIN Vehicle Identification Number WU TWC Warm Up Three Way Catalyst Service Training Mazda6 MPS Supplement ...

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Mazda 6 MPS 2005, Training Manual Supplement

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