Mazda6 training manual

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.. Replace every 6

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

General Information 00

Section Title

Service Training Mazda6 MPS Supplement

00

General Information

VIN (Vehicle Identification Number) Code 1

Applicable VIN 1

Engine / Transaxle Combinations 2

Scheduled Maintenance 3

Features 5

Body 6

VIN (Vehicle Identification Number) Code

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

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

Replace every 60,000Km (37,500 miles) or 36 months

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

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

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

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

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

2 Added reinforcement gussets 5 Reinforced cross member mounts

(increased thickness of sheet metal)

3 Diagonal brace structure

Notes:

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

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

Notes:

Mechanics

• The engine is basically carried over from the Mazda6 L3 engine

M6-MPS_01001

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

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

Cylinder Head Structural View

M6-MPS_01004

1 Fuel injector installation hole 2 Combustion chamber

Cylinder Head Gasket Construction

• A four-layer, metal cylinder head gasket has been adopted

Cylinder Block Construction

• The cylinder block is made of aluminium alloy, which is cast with the cast iron liners,

improving 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

3 Cylinder block

• The service hole for installing the SST (Service Special Tool), which is used for detecting the No.1 cylinder TDC (Top Dead Center) position, 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

2 No.1 cylinder TDC position 6 Service hole

4 Crankshaft counter weight

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

1 Cassette type balancer unit 2 Balancer shafts

Valve Mechanism

• For the L3 turbo engine the variable valve timing system has been basically carried over

from the L3 engine

M6-MPS_01010

4 Variable valve timing actuator 10 Timing chain

6 Crankshaft sprocket

Timing Chain

• A roller chain and respective sprockets have been adopted in order to improve durability against high output and heavy loads

M6-MPS_01011

Chain Tensioner

• The L3 Turbo uses a different chain tensioner, but the principle of operation 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

Camshafts

• The fuel pump drive cam and new designed CMP sensor detection lobes are located at the rear of the intake camshaft

M6-MPS_01013

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

Camshaft Sprocket

• The sintered alloy, which has high rigidity, has been adopted for the camshaft sprocket 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

Valve Timing

• The adjustment range of the variable valve timing actuator has been extended

M6-MPS_01017

Lubrication System

M6-MPS_01018

7 Oil filter drain plug 16 Oil pump chain tensioner

Specifications

Engine oil capacity:

• Oil replacement: 5.3 L

• Oil and oil filter replacement: 5.7 L

• Total (dry engine): 6.4 L

Recommended engine oil:

Lubrication System Flow Diagram

M6-MPS_01019

2 Variable valve timing actuator 14 Timing chain

12 Oil pressure switch

Oil Cooler

• A water-cooled type oil cooler has been adopted to reduce engine oil degradation

• The oil cooler is attached to the oil filter adapter

M6-MPS_01020

1 Engine coolant flow direction

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

Cooling System

• The cooling system has been carried over basically from the Mazda6 F/L (Facelift) with

L3 engine

• The coolant system of the Mazda6 MPS contains 8,0 L coolant

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

Cooling Fan Operation

• On the L3 Turbo the fan control module drives both fan motors based on the cooling fan

control signal sent by the PCM (Powertrain Control Module) according 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

4 Cooling fan motor No.1

Cooling Fan Wiring Diagram

M6-MPS_01023

1 Fan control module 4 Cooling fan motor No.1

3 Cooling fan motor No.2

Intake-Air System

M6-MPS_01024

Intake-Air System Flow Diagram

M6-MPS_01025

2 Charge air cooler 7 Wastegate control solenoid valve

5 WU-TWC (Warm Up Three-Way Catalyst)

Intake-Air System Hose Routing Diagram

Air Charging System

• A wastegate type turbocharger supplied by Hitachi has been adopted for the air charging pressure system, which utilizes exhaust gas pressure to pressurize the intake air and forcefully blow the air to the cylinder Thereby power efficiency, driveability, and fuel economy have been improved

M6-MPS_01027

1 To charge air cooler 4 From exhaust manifold