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

Title Section

General Information 00

Engine 01

Driveline/Axle 03

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

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)

M6-MPS_00T001
Applicable VIN
European specs:

JMZGG82L60# 600001—

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

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General Information

Scheduled Maintenance

Maintenance interval (number of momths or km (miles) which ever comes first)

Maintenance Months 12 24 36 48 60 72 84 96 108 120 132 144
interval 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
ENGINE
Engine valve clearance Audible inspect every 120,000km (75,000 miles), if noisy adjust
Engine oil*2 R R R R R R R R R R R R R
Engine oil filter *2 R R R R R R R R R R R R R
Drive belt *3 I I I
COOLING SYSTEM

Cooling system (including coolant level adjustment) I I I I I I

FL 22 type *4 Replace every 195,000 km (121,900 miles) or 11 years

Engine coolant
Others Replace at first 90,000Km (56,300 miles) or 4 years, after that every 2 years
FUEL SYSTEM
Air cleaner element*1 Replace every 60,000Km (37,500 miles) or 36 months
Fuel lines and hoses I I I I I I
IGNITION SYSTEM
Spark plugs Replace every 75,000 Km (46,900 miles)
EMISSION CONTROL SYSTEM
Evaporation system(if installed) I I I
ELECTRICAL SYSTEM
Battery electrolyte level and specific gravity I I I I I I I I I I I I
CHASSIS and BODY
Brakes lines hoses and connections I I I I I I I I I I I I
Brake fluid *6 R R R R R R
Parking brake I I I I I I I I I I I I
Power brake unit (Brake booster) I I I I I I I I I I I I
and hoses
Disc brakes I I I I I I I I I I I I
Power steering fluid, lines, hoses I I I I I I I I I I I I
and connections
Steering operation and linkages I I I I I I
Manual transaxle oil R R
Rear differential oil *6 *7
Transfer oil *7
Front and rear suspension and ball joints I I I I I I
Drive shaft dust boots I I I I I I
Exhaust system and heat shields I I
Body condtion
Inspect annualy
(for rust, corrosion and perforation)
Tires (including spare tire)
I I I I I I I I I I I I I
(with inflation pressure adjustment)
AIR CONDITIONER SYSTEM (if installed
Air filter (if installed) Replace every 40,000Km (25,000 miles) or 24 months

M6-MPS_00T002
I: Inspect: Inspect and clean, repair, adjust, or replace if necessary.
R: Replace

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 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.

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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.

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General Information

M6-MPS_00002

1 Cowl member (extended and connected 4 Strengthened cross member mounts

to side body) (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:

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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 3 Oil filler cap

attachment hole
2 OCV (Oil Control Valve) attachment hole

Service Training Mazda6 MPS Supplement 01-1

L3 Turbo Engine

Specifications
Specification
Item
L3 Turbo
MECHANICAL
Type Gasoline 4-cycle
Cylinder arrangement and number In-line, 4- cylinder
Combustion chamber Pentroof
Valve system DOHC, timing chain driven, 16 valves
Displacement cc 2261
Bore x stroke mm 87.5 x 94.0
Compression ratio 9.5 : 1
Compression pressure Kpa [rpm] 1280 [250]
Open BTDC (°) 0-30
IN
Close ABDC (°) 62-32
Valve timing
Open BBDC (°) 42
EX
Close ATDC(°) 5
IN 0.22-028 (eng. cold)
Valve clearance mm
EX 0.27-0.33 (eng. cold)
M6-MPS_01T006

Cylinder Head Construction

• With the adoption of direct injection, the structure of the cylinder head now has
installation holes that allow the injectors to reach the combustion chambers.

M6-MPS_01003

1 Parting angle between valves 3 Exhaust port

2 Intake port

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Engine L3 Turbo

Cylinder Head Structural View

M6-MPS_01004

1 Fuel injector installation hole 2 Combustion chamber

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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

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Engine L3 Turbo

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

2 PCV valve 5 Main bearing cap
3 Cylinder block

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L3 Turbo Engine
• 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

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

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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

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L3 Turbo Engine

Crankshaft

• A five axle-hole, 8 counter weight cast iron L3 Turbo crankshaft has been adopted. The
shrinkage fitted drive gear is attached to the 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

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Engine L3 Turbo

Valve Mechanism

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

L3 Turbo Engine

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

1 Camshaft sprockets 5 Chain guide

2 Timing chain 6 Crankshaft sprocket
3 Pitch size 7 Chain tensioner
4 Pin 8 Tensioner arm

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Engine L3 Turbo

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
arm.

M6-MPS_01012

1 Cam spring 4 Piston

2 Ratchet 5 Spring
3 Rack 6 Body

Service Training Mazda6 MPS Supplement 01-11

L3 Turbo Engine

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

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

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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

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L3 Turbo Engine

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

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Engine L3 Turbo

Valve Timing

• 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

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L3 Turbo Engine

Lubrication System

M6-MPS_01018

1 Oil cooler 10 Washer

2 Gasket 11 Oil pan drain plug
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

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Engine L3 Turbo

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:

Item Europe
Grade API SL or ACEA A3 / A5 API SL or ACEA A3
Viscosity (SAE) 5W-30 10W-40
Remarks Mazda genuine Dexelia oil e.g.

M6-MPS_01T001

Oil Pressure Reference Value (100°C)

• 297-551 kPa (3000 rpm)

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L3 Turbo Engine

Lubrication System Flow Diagram

M6-MPS_01019

1 OCV 13 Orifice
2 Variable valve timing actuator 14 Timing chain
3 Tappet 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

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Engine L3 Turbo

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.

M6-MPS_01021

1 Engine front side 3 Oil jet valve

2 Oil 4 Cylinder block

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L3 Turbo Engine

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

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Engine L3 Turbo

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
3 Fan control module 7 Cooling fan No.2
4 Cooling fan motor No.1

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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

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Engine L3 Turbo

Intake-Air System

M6-MPS_01024

1 Charge air cooler 7 Variable 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

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L3 Turbo Engine

Intake-Air System Flow Diagram

M6-MPS_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)

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Engine L3 Turbo

Intake-Air System 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

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L3 Turbo Engine

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.

Turbocharger Construction/Operation

• The turbocharger consists of the turbine wheel, compressor 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, which results in decreased intake air
pressure.

M6-MPS_01027

1 To charge air cooler 4 From exhaust manifold

2 Intake air side 5 To WU-TWC
3 Exhaust gas side 6 From air cleaner

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Engine L3 Turbo

Wastegate operation

• The wastegate controls the exhaust pressure on the exhaust side turbine, thereby
controlling the speed of the intake turbine.
• The wastegate is operated using a diaphragm-type actuator.The overpressure to operate
the diaphragm is produced by the intake turbine.
• As long as the wastegate control solenoid valve, which is controlled by the PCM, is
closed, the wastegate will be opened by the overpressure of approx. 0.7 bar.
• If the wastegate solenoid is opened by the PCM, the 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 is opened, there is an
orifice in the pressure pipe to the wastegate actuator.

M6-MPS_01056
1 Wastegate control solenoid valve 6 To WU-Catalyst
2 Orifice 7 Wastegate
3 To charge air cooler 8 Wastegate control diaphragm
4 From air cleaner 9 Air flow
5 Turbine

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L3 Turbo Engine

Air Bypass Valve Function

M6-MPS_01028

1 Charge air cooler 2 Air bypass valve

• Too high overpressure in the air charging system can cause the air hose to come off or
damage the air charging 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.

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Engine L3 Turbo

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

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L3 Turbo Engine

Variable Swirl System

• The variable swirl system functions to lower emissions at cold-engine start (ECT lower
than 60° C) and at low engine speed (lower than 3750 rpm)
• If both these conditions are met, the variable swirl system increases intake airflow speed
by closing the shutter valve and narrowing the 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 cleaner

2 Variable swirl solenoid valve 4 Variable swirl shutter valve

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Engine L3 Turbo

M6-MPS_01031

1 Variable swirl shutter valve open 3 Variable swirl shutter valve closed
2 Intake air ports

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L3 Turbo Engine

Fuel System

Specifications:
Item Specification
Type Electro-magnetic (1.0...1.2 Ohm)
Injector Type of fuel delivery Top-feed
Type of drive Voltage
Pressure regulator control pressure
(within the fuel tank) kPa Approx. 430
Relief valve control pressure
(within the fuel delivery pipe) Mpa Approx. 13
Pre delivery fuel pump type Electric
High pressure fuel pump type Mechanic
Fuel tank capacity L 60

M6_MPS_01T002

NOTE: The L3 Turbo engine was designed to consume 98 octane (RON (Research
Octane Number)) fuel. If 98 octane (RON) fuel is not availabel the vehicle can
be operated using 95 octane (RON) fuel which will result in decreased power
output. Using fuel with lower octane can cause engine knocking an serious
engine damage.

NOTE: Working on the high pressure fuel system can be dangerous. Always release
fuel pressure before opening the high pressure fuel system. To release the
pressure remove the fuel pump relay, start engine and allow engine to stop.
Then crank engine with the starter until fuel pressure is discharged.

01-32 Service Training Mazda6 MPS Supplement

Engine L3 Turbo

Fuel System Structural 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

L3 Turbo Engine

Fuel Tank Side

M6-MPS_01033

1 Fuel tank 3 Fuel pump unit

2 Rollover valves 4 Pressure regulator

Returnless Fuel System

• Fuel is pumped out through the fuel pump, filtered by the fuel filter, and then regulated to
a specified pressure by the pressure 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 suppressed.
End Of Sie

01-34 Service Training Mazda6 MPS Supplement

Engine L3 Turbo

Direct Fuel Injection System

• High engine output and response are obtained through direct control with no time lag in
the amount of fuel in the combustion chamber.
• A fine mist of fuel is injected due to the enhanced fuel pressure obtained via the high
pressure fuel pump. The temperature of the air intake from the turbocharger increases
due to the rise in pressure, but the temperature of the combustion chamber decreases
as a result of vaporization heat caused by refined atomization 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 pressure fuel pump 6 Connected to injector driver module
3 Fuel injector 7 Fuel pump
4 Relief valve 8 Pressure regulator

Operation

• Fuel is injected during the intake process and diffused uniformly in the combustion
chamber by the flow of intake air.

Service Training Mazda6 MPS Supplement 01-35

L3 Turbo Engine

Fuel Pump Unit

• The fuel pump draws fuel from the fuel tank and pumps it to the high pressure fuel pump.
• The fuel pump unit mainly consists of a fuel filter, pressure regulator, fuel pump, fuel
reservoir cup, suction filter, and jet pump.
• A pressure regulator has been built in the fuel pump unit due to the adoption of a
returnless fuel system.
• A hard-plastic fuel pump unit, with an integrated fuel filter (top side) and fuel pump, has
been adopted to simplify the fuel line.
• The fuel pump 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 pressure that is used to transfer fuel from the reserve to the main tank.

Pressure Regulator

• The pressure regulator is built into the fuel pump unit due to the adoption of a returnless
fuel system.
• The regulator mainly consists of a spring and diaphragm.

01-36 Service Training Mazda6 MPS Supplement

Engine L3 Turbo

Fuel Pump Resistor

• On L3 Turbo the fuel pump relay supplies voltage to the fuel pump via the 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

L3 Turbo Engine

Fuel Pump Relay and Fuel Pump Speed Relay

• The fuel pump relay controls the fuel pump operation according to control 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

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Engine L3 Turbo

Fuel Pump Speed Relay Operation

• The fuel pump speed relay reduces the voltage by routing it through the fuel 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

L3 Turbo Engine

Fuel Pump Check Connector

• To operate 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

Engine L3 Turbo

High Pressure Fuel Pump

• The high pressure fuel pump is located on the rear side of the cylinder head and consists
of a spill valve control solenoid, spill 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

L3 Turbo Engine

High Pressure Fuel Pump Structural View

M6-MPS_01052

1 Springloaded rod 5 Plunger

2 Spill valve control solenoid 6 Check valve
3 Spill valve 7 Pulsation damper
4 Camshaft

High Pressure Fuel Pump Operation

• Fuel is drawn and pumped due to the up and down movement of the piston caused by
the rotation of the 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 by the piston is discharged to the fuel delivery pipe, and fuel pressure rises.

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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

L3 Turbo Engine
Note: If the high pressure fuel pump joint nut is loosened, fuel leakage may occur resulting
in death or serious injury, or damage to the equipment or the vehicle. Fuel can also
irritate the skin and eyes.

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 Mazda6 MPS Supplement

Engine L3 Turbo

Fuel Delivery Pipe

• The fuel delivery pipe distributes the pressurized fuel to the injectors.
• A fuel pressure sensor is installed at the end of the fuel delivery pipe.
• A relief valve is installed at the other end of the fuel delivery pipe.
• If the fuel pressure 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 delivery pipe 4 Relief valve

Service Training Mazda6 MPS Supplement 01-45

L3 Turbo Engine

Fuel Injector

• The fuel injectors are located under the intake manifold, installed directly to the cylinder
head.
• They consist of a coil, spring, needle valve, filter and o-ring.
• The filter inside the injector can not be removed.
• The drive 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

01-46 Service Training Mazda6 MPS Supplement

Engine L3 Turbo

SST to Remove the Injector

• To remove the potentially 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

L3 Turbo Engine

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

Engine L3 Turbo

Control System
Specification
Item Specification
Neutral switch ON/OFF
CPP (Clutch Pedal Position) switch ON/OFF
ECT (Engine Coolant Temperature) sensor Thermistor
IAT (Intake Air Temperature) sensor (Inside Thermistor
MAF)
Boost air temperature sensor (Inside MAP) Thermistor
TP (Throttle Position) sensor Hall 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 Piezoelectric element
PCM)
KS (Knock Sensor) Piezoelectric element
MAP (Manifold Absolute Pressure) sensor Piezoelectric element
Fuel pressure sensor Piezoelectric element
CKP (Crankshaft Position) sensor GMR (Giant Magneto Resistive) sensor
CMP sensor GMR sensor
Brake switch ON/OFF

M6-MPS_T01003
PCM

• A PCM with integral BARO sensor and 117-pin (four-block) connector has been adopted.

M6-MPS_01043

1 PCM 3 PCM cover

2 PCM connector

Service Training Mazda6 MPS Supplement 01-49

L3 Turbo Engine

Control System Structural View

M6-MPS_01044

1 HO2S 11 Injector driver module

2 ECT sensor 12 Neutral switch
3 CMP sensor 13 CKP sensor
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

Engine L3 Turbo

NOTES:

Service Training Mazda6 MPS Supplement 01-51

L3 Turbo Engine
Control System Wiring Diagram

M6-MPS_01045

01-52 Service Training Mazda6 MPS Supplement

Engine L3 Turbo

1 Injector driver module 16 Main relay

2 Fuel injector No.1 17 Starter relay
3 Fuel injector No.2 18 Ignition switch
4 Fuel injector No.3 19 Battery
5 Fuel injector No.4 20 HO2S (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

L3 Turbo Engine

Control System Wiring Diagram (Continued)

M6-MPS_01046

01-54 Service Training Mazda6 MPS Supplement

Engine L3 Turbo

1 Drive-by-wire-relay 17 Generator
2 EGR (Exhaust Gas Recirculation)valve 18 CAN (Controller Area Network)
3 Purge solenoid valve 19 Cruise control switch
4 Wastegate control solenoid valve 20 CPP switch
5 Variable swirl solenoid valve 21 Neutral switch
6 OCV 22 PSP switch
7 Spill valve control solenoid valve (High 23 Refrigerant pressure switch (Middle)
pressure pump)
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 Throttle actuator 31 CKP sensor
16 TP sensor 32 PCM

Service Training Mazda6 MPS Supplement 01-55

L3 Turbo Engine

Injector Driver Module

• The injector driver module is located on the side frame under the battery tray.
• The injector driver module can provide high voltage to drive 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

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Engine L3 Turbo

• The fuel injectors are controlled by switching the ground connection.

• The 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

L3 Turbo Engine

Injector Driver Module Wiring Diagram

M6-MPS_01049

1 PCM 10 Fuel injector check

2 Injector driver module 11 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

Engine L3 Turbo

L3 Turbo Specific DTCs

• The list below shows the DTCs, which have been added to the DTC list of the naturally
aspirated L3 engine.

DTC Condition MIL

No.
P0069 Manifold absolute pressure/atmospheric pressure correlation ON
P0089 Fuel pressure regulator performance OFF
P0091 Fuel pressure regulator control circuit low ON
P0092 Fuel pressure regulator control circuit high ON
P0096 IAT sensor 2 circuit range/performance problem ON
P0097 IAT sensor 2 circuit low ON
P0098 IAT sensor 2 circuit high ON
P0192 Fuel rail pressure sensor circuit low input ON
P0193 Fuel rail pressure sensor circuit high input ON
P0201 Injector circuit/open 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
P2006 Variable swirl control system shutter valve stuck closed ON
P2009 Variable swirl solenoid valve control circuit low ON
P2010 Variable swirl solenoid valve control circuit high ON
P2228 BARO sensor circuit low input ON
P2229 BARO sensor circuit high input ON
P2245 Front HO2S sensor reference voltage circuit low input ON
P2246 Front HO2S sensor reference voltage circuit high input ON

M6-MPS_01T004

Service Training Mazda6 MPS Supplement 01-59

L3 Turbo Engine

L3 Turbo Specific PIDs

• The list below shows the PIDs, which have been added to the PID list of the naturally
aspirated L3 engine.

PID Unit / Condition Condition / Specification

AFR - Target air-fuel ratio is displayed
AFR_ACT - Actual air-fuel ratio is displayed
BARO (Barometric pressure) Pa / V Ignition switch ON: Indicate the atmospheric pressure
BAT °C Boost air temperature is displayed
BAT_V V Boost air temperature 20° C: 2.4...2.6 V
Boost air temperature 30° C: 1.7...1.9 V
ECT less than 98° C: 0%
FAN_DUTY % ECT 100° C: 30%
ECT 106° C: 70%
ECT 110° C: 100%
FIA (Fuel injection amount) mg/cylinder Indicate the fuel injection amount
FP_Hi_PRES Spill valve control solenoid valve work: On
On/Off
Spill valve control solenoid valve does not work: Off
Idle: Approx. 3 MPa
FUEL_PRES Pa
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) On/Off 3,750 rpm and ECT is below 60° C: On
Others: Off
Wastegate control:
WGC % Racing with the accelerator pedal fully depressed: 100%
Fully closed: 0%

M6-MPS_01T005

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 03
Driveline/Axle
03 Driveline/Axle

Table of Contents
Clutch ...................................................................................................................1
A26MX-R Manual Transaxle................................................................................1
A26MX-R Manual Transaxle Cross-Sectional View ........................................2
Transfer Case ......................................................................................................3
Transfer Case Cross-Sectional View ..............................................................4
Transfer Case Power Flow..............................................................................5
Transfer Case Oil Cooler ................................................................................6
Transfer Case Oil............................................................................................6
Adjustment Procedures Necessary For Transfer Case Assembly ..................7
4-Wheel Drive.......................................................................................................8
Specifications..................................................................................................8
Drive Shafts .........................................................................................................9
Propeller Shaft...................................................................................................10
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-Wheel Drive Control System Operation .....................................................26
4-Wheel Drive Control System Wiring Diagram ............................................28
Diagnostics ........................................................................................................29
DTC Table.....................................................................................................29

Table of Contents 03 Service Training Mazda6 MPS Supplement

 Driveline/Axle

Clutch
• The clutch mechanism and shift mechanism are carried over from the A26M-R manual
transaxle of the MZR-CD (RF Turbo) engine.
• A self-adjusting clutch cover maintains the set load of the clutch cover unchanged even
as the clutch disc becomes worn, thereby extending disc life.
• A dual-mass flywheel has separated primary and secondary flywheel, and a torsional
damper that is located inside the flywheel. Due to this structure, the transaxle primary
shaft rotation can be stabilized, decreasing noise inside the transaxle (gear teeth rattling)
created by engine speed fluctuation, and thereby 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.

Item Specification
Operation system Cable
Transaxle Control Floor-shift
Forward Synchromesh
Shift assist Reverse Synchromesh (Lever type)
1GR 3.538
2GR 2.238
3GR 1.535
Gear ratios 4GR 1.171
5GR 1.085
6GR 0.853
Reverse 3.831
1GR-4GR 3.941
Final gear ratio
5GR, 6GR, Reverse 3.350
Grade API service GL-4 or GL-5
Oil Viscosity SAE 75W-90
Capacity 2.55 litre
M6-MPS_03T003

Service Training Mazda6 MPS Supplement 03-1

Driveline/Axle

A26MX-R Manual Transaxle Cross-Sectional View

M6-MPS_03026

1 A26MX-R manual transaxle 2 Transfer case

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 Driveline/Axle

Transfer Case
• The transfer case is mounted to the differential housing of the A26MX-R transaxle and
ensures power flow to the rear wheels.
• To ensure proper 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

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Driveline/Axle

Transfer Case Cross-Sectional 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

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 Driveline/Axle

Transfer Case Power Flow

• The transfer case is driven by the hollow drive gear shaft, which is connected to the
differential cage.
• The joint shaft, which drives the front right driveshaft, independently 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 Supplement 03-5

Driveline/Axle

Transfer Case Oil Cooler

M6-MPS_03007

1 Water in 2 Water out

Transfer Case Oil

• The transfer case is filled with 1.2 litre transmission oil. The transmission oil must comply
with SAE 80 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

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 Driveline/Axle

Transfer Case Oil Level Inspection

M6-MPS_03011

Adjustment Procedures Necessary For Transfer Case Assembly

– drive gear shaft axial play and preload (adjustment shim)

– ring gear shaft axial play and preload (left and right 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 Training Mazda6 MPS Supplement 03-7

Driveline/Axle

4-Wheel Drive
Specifications

Item Specification
Front axle Bearing type Angular ball bearing
Rear axle Bearing type Angular ball bearing
Joint type wheel side Bell joint
Front drive shaft Joint type differential side Double offset joint
Shaft diameter 27.0 mm
Joint shaft diameter 28.0 mm
Joint type wheel side Bell joint
Rear drive shaft Joint type differential side Double offset joint
Shaft diameter 24.0 mm
Rear and front wheel torque distribution unit Electronic control coupling
Reduction gear Hypoid gear
Differential gear Straight bevel gear
Ring gear size 7.4 inches
Rear differential
Final gear ratio 2.928
Number of teeth: drive pinion 14
Number of teeth: ring gear 41
Grade API service GL-5
Differential oil Viscosity SAE 80W-90
Capacity 1.0 litre

M6-MPS_03T001

Note: When towing a 4WD vehicle, where all the wheels are connected to the drive train,
proper transporting of the vehicle is absolutely essential to avoid damaging the drive
system. A towed 4WD vehicle must have all its wheels off or on the ground.

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 Driveline/Axle

Drive Shafts
• Double offset joint type front and rear drive shafts have been used for 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

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Driveline/Axle

Propeller Shaft
• The propeller shaft transmits drive force from the transfer case to the rear differential.
• The propeller shaft is made of steel and 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

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 Driveline/Axle

Rear Differential
• The rear differential comprises an integrated coupling 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

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Driveline/Axle

Coupling Component

• The coupling case can be removed from the rear differential assembly, after the rear
differential oil has been drained and the exhaust system and 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

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 Driveline/Axle

• To get access to the actual coupling 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

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Driveline/Axle

Super-LSD

• The super-LSD is a torque-sensing type limited slip differential that provides improved
traction and driving stability due to the following characteristics:
– low torque bias ratio provides improved controllability
(torque bias ratio: 2.0 <=> 33.3% locking factor)
– creation of initial torque provides improved starting from a standstill and
acceleration/deceleration response, and driving straight-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 positioned between the right and left bevel gears to provide
initial torque to the taper rings.

M6-MPS_03005

1 Pinion gear 4 Taper ring

2 Bevel gear 5 Retainer
3 Cone 6 Spring

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 Driveline/Axle

Rear Differential Oil

• The rear differential is filled with 1.0 litre transmission oil. The transmission oil must
comply with SAE 80W-90 (API service GL-5) specification.
• The rear differential is filled with oil 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

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Driveline/Axle

4-Wheel Drive Control

• An electronic 4WD (4-Wheel Drive) control system, which automatically optimizes
traction distribution to the front and rear wheels improves mobility, handling stability,
operability, fuel economy and marketability.
• Based on the input signals from each sensor, the 4WD CM (Control Module) determines
vehicle 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 sensor 6 PCM
3 Rear differential 7 DSC HU/CM
Electronic control coupling (4WD
4 solenoid)

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Components

• Electronic control coupling (4WD solenoid):

– Based on a signal from the 4WD CM, it operates the electromagnetic clutch and
transmits drive torque to the rear wheels.
• Differential oil temperature sensor:
– Informs the 4WD CM of the rear differential oil temperature.
• 4WD CM:
– Controls operation of the electronic control coupling (4WD solenoid) mainly based on
signals indicating accelerator pedal position, wheel speed and differential oil
temperature.
– Outputs coupling control condition 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 available for the 4WD CM.
• DSC HU/CM (Dynamic Stability Control Hydraulic Unit/Control Module):
– Provides data about four-wheel speed, DSC operating condition, steering wheel
angle and the coupling torque request signal on the CAN data bus available for the
4WD CM.

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Electronic Control Coupling

• An electromagnetic clutch, which operates smoothly due to the lack of influence from the
front and rear wheel traction force, has been used for the electronic control coupling
system.
• The construction of the coupling enables the torque formed by the pilot clutch to be
amplified by the cam mechanism, thus allowing the main clutch to obtain a high degree
of torque.
• The electronic control coupling basically consists of 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 transmission system 8 Pilot cam

2 Electromagnetic clutch 9 Pilot clutch
3 Rear housing 10 Armature
4 4WD solenoid (electromagnetic coil) 11 Main cam
5 Cam mechanism 12 Main clutch
6 Ball 13 Front wheel side
7 Rear wheel side

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Electronic Control Coupling Operation

4WD Solenoid Control Current Is OFF

• When the 4WD solenoid control current is OFF, no torque is generated in the pilot clutch
because there is no current flowing to the 4WD 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

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4WD Solenoid Control Current Is ON

• When the 4WD solenoid control current is ON, current flows from the 4WD CM to the
4WD solenoid, and the coupling operates in the following manner.
1. Magnetic flux forms at the electromagnetic coil of the 4WD solenoid.
2. Due to the magnetic flux in the armature, the pilot clutch is pulled towards the magnetic
coil side and engages. This causes friction that generates torque in the pilot clutch.
3. The torque is transmitted to the pilot cam, which is engaged with the pilot clutch.
4. Wheel slip at the front axle creates a rotational difference between the pilot cam and the
main cam. 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 drive torque transmitted to the rear wheels) changes in accordance with
the proportion of the force acting upon the pilot cam, engaged with the pilot clutch.
Therefore, by changing the periodicity of the electric current from the 4WD CM to the
4WD solenoid (ON/OFF rate of the 4WD solenoid = force acting on the pilot cam), the
module controls the transmission of drive torque to the rear wheels.

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M6-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

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Differential Oil Temperature Sensor

• The differential oil temperature sensor is installed in the rear differential carrier.
• The differential oil temperature sensor detects the rear differential oil temperature and
inputs it 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

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4WD Control Module

• The 4WD CM calculates the optimal amount of torque distribution for the rear wheels
and sends a corresponding electric current to the electronic control coupling (4WD
solenoid). This calculation is mainly based on the accelerator pedal position, four-wheel
speed, engine speed and transaxle neutral position, matched with the vehicle driving and
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 suspends control to prevent a
loss of driving stability and protect the system.
– The detected malfunction is stored as a DTC in the 4WD CM.

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4WD Warning Light

• The 4WD warning light is built into the instrument cluster.

• If the self-diagnostic function stores a DTC (Diagnostic Trouble Code), 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

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4-Wheel Drive Control System Block Diagram

M6-MPS_03020

1 PCM 10 Pilot clutch/pilot cam

2 DSC HU/CM 11 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

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4-Wheel Drive Control System Operation

• Based on the signals listed below, the 4WD CM calculates the optimal amount of torque
distribution for the rear wheels and outputs a corresponding electric control current to the
electronic control coupling (4WD solenoid).
• The 4WD CM controls the current to the 4WD solenoid by changing the rate of the
ON/OFF timing (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 about coupling torque and 4WD
system condition (warning light information) using the CAN system.

* Transmitted as a CAN signal

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Normal Control

• When starting off or accelerating during straight-ahead driving, torque transmitted to the
rear wheels is optimally controlled to ensure sufficient acceleration performance. Due to
this, standing-start and acceleration performance is improved.
• Also, in order to improve fuel economy when driving at a stable, consistent speed, torque
transmitted to the rear wheels is damped.
Tight Cornering Control

• When the 4WD CM determines, based on the four-wheel speed and steering wheel
angle information, that the vehicle is in tight cornering, it reduces the torque transmitted
to the rear wheels.
Integrated DSC Control

• If a signal from the DSC HU/CM input to the 4WD CM indicates that ABS (Antilock Brake
System) control is activated, the module controls the torque transmitted to the rear
wheels to 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 case the rear differential oil temperature exceeds the specified amount, or when there
is an unusually large variation in the rotation speed of the front and rear wheels (ex.
when trying to get unstuck), control is temporarily suspended in order to protect the 4WD
system. When this occurs the 4WD warning light flashes to indicate the situation to the
driver.
• The software inside the 4WD control module can recognize the driver´s input and wheel
slip condition. Accordingly, it automatically selects an appropriate control map to facilitate
normal, sport or snow 4WD control.

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4-Wheel Drive Control System Wiring Diagram

M6-MPS_03013

1 Ignition switch 9 CAN_H

2 4WD 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

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Diagnostics
• When the ignition key is turned to the ON position, the 4WD CM begins operation, and
the 4WD warning light illuminates for 3 seconds while the system checks for open
circuits, monitors the condition of the power supply voltage and checks for internal
malfunctions.
• Then, once the system is running, the system checks the operating conditions of the
4WD solenoid and the differential oil temperature sensor at regular intervals to determine
whether there is any malfunction.
• If any malfunction is detected during these diagnostic tests, the warning light illuminates
according to the malfunction to alert the driver and fail-safe functions are applied as well
as a DTC is stored in the 4WD CM.
• Once a DTC is stored, it is not cleared even if the input/output signal system malfunction
returns to normal when the ignition key is turned to the LOCK position (engine OFF).
• Since DTCs are stored in the non-volatile memory inside the 4WD CM, they are not
cleared even if the 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 4WD CM inspection
has to be done with the aid of a Terminal Voltage List for reference which can be found
in the Workshop Manual.

DTC Table

DTC Malfunction Location 4WD Warning Light DTC Stored in Control

Condition Memory Condition
P1887 System wiring Illuminated X Stop
P1888 Differential oil Illuminated X Stop
temperature sensor
U0073 CAN system Illuminated X Stop
communication error
U0100 PCM communication Illuminated X Stop
system
U0121 DSC communication Illuminated *1 X Stop *2
system

M6-MPS_03T002

*1 : Does not illuminate when only the coupling torque request signal from the DSC HU/CM cannot be
received.
*2 : Only integrated DSC control is prohibited when only the coupling torque request signal from the
DSC HU/CM cannot be received.

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Notes:

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 List of Abbreviations
4WD 4-Wheel Drive F/L Facelift

A/C Air Conditioning GMR Gigant Magnetic Resistive

ABS Antilock Brake System GPS Global Positioning System

APP Accelerator Pedal Position GND Ground

ATF Automatic Transmission Fluid HO2S Heated Oxygen Sensor

BARO Barometric Pressure IAT Intake Air Temperature

BDC Bottom Dead Center KS Knock Sensor

CAN Controller Area Network LHD Left Hand Drive

CMP Camshaft Position LSD Limited Slip Differential

CPP Clutch Pedal Position MAF Mass Air Flow

DISI Direct Injection Spark Ignition MAP Manifold Absolute Pressure

DSC Dynamic Stability Control MPS Mazda Performance Series

DSC/HU/CM Dynamic Stability NTC Negative Temperature

Control/Hydraulic Coefficient
Unit/Control Module

OCV Oil Control Valve

DTC Diagnostic Trouble Code

PCM Powertrain Control Module

EBA Electronic Brake Assistance

PCV Positive Crankcase

ECT Engine Coolant Temperature Ventilation

EGR Exhaust Gas Recirculation PID Parameter Identification

Service Training Mazda6 MPS Supplement

List of Abbreviations
PSP Power Steering Pressure

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