Mazda 6 MPS 2005 Training Manual Supplement
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Mazda 6 MPS 2005 Training Manual Supplement

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TRAINING MANUAL
Mazda6 MPS Supplement

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  • Page 1 TRAINING MANUAL Mazda6 MPS Supplement...
  • Page 2 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.
  • Page 3 Contents Title Section General Information Engine Driveline/Axle Service Training Mazda6 MPS Supplement...
  • Page 4 Service Training Mazda6 MPS Supplement...

  • Page 5: General Information

    General Information...

  • Page 6: Table Of Contents

    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...

  • Page 7: Vin (Vehicle Identification Number) Code

    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 pplicable VIN European specs: JMZGG82L60# 60 0001—...

  • Page 8: Engine / Transaxle Combinations

    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: –...

  • Page 9: Scheduled Maintenance

    General Information Scheduled Maintenance Maintenance interval (number of momths or km (miles) which ever comes first) Months Maintenance interval X1000 km X1000 miles 3.1 9.4 18.8 28.1 37.5 46.9 56.3 65.6 75.0 84.4 103.1 112.5 93.8 ENGINE Engine valve clearance Audible inspect every 120,000km (75,000 miles), if noisy adjust Engine oil* Engine oil filter...
  • Page 10 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.

  • Page 11: Features

    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 •...

  • Page 12: Body

    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 –...
  • Page 13 General Information M6-MPS_00002 Cowl member (extended and connected Strengthened cross member mounts to side body) (increased number of joints) Added reinforcement gussets Reinforced cross member mounts (increased thickness of sheet metal) Diagonal brace structure Service Training Mazda6 MPS Supplement 00-7...
  • Page 14 General Information Notes: 00-8 Service Training Mazda6 MPS Supplement...
  • Page 15 Engine...
  • Page 16 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...
  • Page 17 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...
  • Page 18 01 Engine Notes: Table of Contents 01 Service Training Mazda6 MPS Supplement...

  • Page 19: Mechanics

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

  • Page 20: Specifications

    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 2261 Bore x stroke 87.5 x 94.0 Compression ratio 9.5 : 1 Compression pressure Kpa [rpm]...

  • Page 21: Cylinder Head Structural View

    Engine L3 Turbo Cylinder Head Structural View M6-MPS_01004 Fuel injector installation hole Combustion chamber Service Training Mazda6 MPS Supplement 01-3...

  • Page 22: Cylinder Head Gasket Construction

    L3 Turbo Engine Cylinder Head Gasket Construction • A four-layer, metal cylinder head gasket has been adopted. M6-MPS_01005 Bead plate Bead plate Shim 01-4 Service Training Mazda6 MPS Supplement...

  • Page 23: Cylinder Block Construction

    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.
  • Page 24 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.

  • Page 25: Pistons

    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. •...

  • Page 26: Crankshaft

    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 Drive gear Balancer Unit • The cassette-type balancer unit is adopted from the L3 engine to reduce vibration from the engine.

  • Page 27: Valve Mechanism

    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 Camshafts Chain tensioner Tappet Tensioner arm Valve assembly Camshaft sprockets Variable valve timing actuator Timing chain Chain guide Oil control valve (OCV)

  • Page 28: Timing Chain

    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 Camshaft sprockets Chain guide Timing chain Crankshaft sprocket Pitch size Chain tensioner Tensioner arm 01-10 Service Training Mazda6 MPS Supplement...

  • Page 29: Chain Tensioner

    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.

  • Page 30: Camshafts

    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 Exhaust camshaft Thrust collar Thrust collar Cam nose Cam nose CMP sensor detection lobes Cam heel Fuel pump drive cam Cam journal...
  • Page 31 Engine L3 Turbo M6-MPS_01014 Fuel pump drive cam CMP sensor detection lobes New SST for Camshaft Alignment M6-MPS_01015 SST 49 UN30 310610 Service Training Mazda6 MPS Supplement 01-13...

  • Page 32: Camshaft Sprocket

    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.

  • Page 33: Valve Timing

    Engine L3 Turbo Valve Timing • The adjustment range of the variable valve timing actuator has been extended. M6-MPS_01017 BDC (Bottom Dead Center) Variable domain Variable domain Intake air Exhaust air Service Training Mazda6 MPS Supplement 01-15...

  • Page 34: Lubrication System

    L3 Turbo Engine Lubrication System M6-MPS_01018 Oil cooler Washer Gasket Oil pan drain plug Oil pressure switch Oil pump Oil filter adapter Oil pump sprocket Oil filter Oil pump chain Oil filter cover Oil pump chain guide Oil filter drain plug Oil pump chain tensioner O-ring Oil strainer...

  • Page 35: Specifications

    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) Service Training Mazda6 MPS Supplement 01-17...

  • Page 36: Lubrication System Flow Diagram

    L3 Turbo Engine Lubrication System Flow Diagram M6-MPS_01019 Orifice Variable valve timing actuator Timing chain Tappet Chain tensioner Camshaft Piston Turbocharger Oil jet valve Balancer shaft Main Bearing Oil pan Crankshaft Oil strainer Connecting rod bearing Oil pump Oil passage Oil cooler Oil relief passage Oil filter...

  • Page 37: Oil Cooler

    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 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.

  • Page 38: Cooling System

    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 Coolant reserve tank Throttle body...

  • Page 39: Cooling Fan Operation

    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 –...

  • Page 40: Cooling Fan Wiring Diagram

    L3 Turbo Engine Cooling Fan Wiring Diagram M6-MPS_01023 Fan control module Cooling fan motor No.1 Battery Cooling fan motor No.2 01-22 Service Training Mazda6 MPS Supplement...

  • Page 41: Intake-Air System

    Engine L3 Turbo Intake-Air System M6-MPS_01024 Charge air cooler Variable swirl shutter valve actuator Turbocharger Throttle body Air cleaner Variable swirl solenoid valve Accelerator pedal Wastegate actuator Resonance chamber Wastegate control solenoid valve Air bypass valve Service Training Mazda6 MPS Supplement 01-23...

  • Page 42: Intake-Air System Flow Diagram

    L3 Turbo Engine Intake-Air System Flow Diagram M6-MPS_01025 Air bypass valve Wastegate actuator Charge air cooler Wastegate control solenoid valve Air cleaner Variable Swirl valve Turbocharger Throttle body WU-TWC (Warm Up Three-Way Catalyst) 01-24 Service Training Mazda6 MPS Supplement...

  • Page 43: Intake-Air System Hose Routing Diagram

    Engine L3 Turbo Intake-Air System Hose Routing Diagram M6-MPS_01026 Charge air cooler Intake manifold Turbocharger Variable swirl solenoid valve Air cleaner Variable swirl shutter valve actuator Throttle body Service Training Mazda6 MPS Supplement 01-25...

  • Page 44: Air Charging System

    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.
  • Page 45 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. •...

  • Page 46: Air Bypass Valve Function

    L3 Turbo Engine Air Bypass Valve Function M6-MPS_01028 Charge air cooler 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.
  • Page 47 Engine L3 Turbo M6-MPS_01029 Throttle valve: open Throttle valve: closed Air bypass valve Positive pressure Vacuum Charge air cooler To upstream of the turbocharger Service Training Mazda6 MPS Supplement 01-29...

  • Page 48: Variable Swirl System

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

  • Page 50: Fuel System

    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) Approx. 430 Relief valve control pressure (within the fuel delivery pipe) Approx.

  • Page 51: Fuel System Structural View

    Engine L3 Turbo Fuel System Structural View Engine Compartment Side M6-MPS_01032 High pressure fuel pump Fuel delivery pipe Fuel pump speed control relay Fuel injectors Fuel pump relay Fuel pressure sensor Service Training Mazda6 MPS Supplement 01-33...

  • Page 52: Returnless Fuel System

    L3 Turbo Engine Fuel Tank Side M6-MPS_01033 Fuel tank Fuel pump unit Rollover valves 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. •...

  • Page 53: Direct Fuel Injection System

    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.

  • Page 54: Fuel Pump Unit

    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.

  • Page 55: Fuel Pump Resistor

    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).

  • Page 56: Fuel Pump Relay And Fuel Pump Speed Relay

    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.
  • Page 57 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.
  • Page 58 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 Fuel pump check connector Main fuse block 01-40 Service Training Mazda6 MPS Supplement...

  • Page 59: High Pressure Fuel Pump

    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.

  • Page 60: High Pressure Fuel Pump Structural View

    L3 Turbo Engine High Pressure Fuel Pump Structural View M6-MPS_01052 Springloaded rod Plunger Spill valve control solenoid Check valve Spill valve Pulsation damper 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).
  • Page 61 Engine L3 Turbo Spill valve energized: inflow: thrust out: M6-MPS_01053 Spill valve deenergized: inflow: reverse flow: M6-MPS_01054 Fuel flow Plunger movement Service Training Mazda6 MPS Supplement 01-43...
  • Page 62 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.

  • Page 63: Fuel Delivery Pipe

    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. •...

  • Page 64: Fuel Injector

    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. •...
  • Page 65 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 SST 49 G013 101 Service Training Mazda6 MPS Supplement...

  • Page 66: Exhaust System

    L3 Turbo Engine Exhaust System M6-MPS_01042 Exhaust manifold Front pipe Turbocharger WU-TWC TWC (Three Way Catalyst) Front HO2S Rear HO2S (Heated Oxygen Sensor) Main silencer 01-48 Service Training Mazda6 MPS Supplement...

  • Page 67: Control System

    Engine L3 Turbo Control System Specification Item Specification Neutral switch ON/OFF ON/OFF CPP (Clutch Pedal Position) switch Thermistor ECT (Engine Coolant Temperature) sensor Thermistor IAT (Intake Air Temperature) sensor (Inside MAF) Boost air temperature sensor (Inside MAP) Thermistor Hall element TP (Throttle Position) sensor APP (Accelerator Pedal Position) sensor Hall element...

  • Page 68: Control System Structural View

    L3 Turbo Engine Control System Structural View M6-MPS_01044 HO2S Injector driver module ECT sensor Neutral switch CMP sensor CKP sensor Clutch switch APP sensor PSP (Power Steering Pressure) switch CMP sensor Fuel pressure sensor ECT sensor Variable swirl shutter valve switch MAF / IAT sensor TP sensor and throttle actuator PCM (RHD (Right Hand Drive))
  • Page 69 Engine L3 Turbo NOTES: Service Training Mazda6 MPS Supplement 01-51...

  • Page 70: Control System Wiring Diagram

    L3 Turbo Engine Control System Wiring Diagram M6-MPS_01045 01-52 Service Training Mazda6 MPS Supplement...
  • Page 71 Engine L3 Turbo Injector driver module Main relay Fuel injector No.1 Starter relay Fuel injector No.2 Ignition switch Fuel injector No.3 Battery Fuel injector No.4 HO2S (Front) Injector driver relay HO2S (Rear) HO2S heater (Front) Boost air temperature sensor HO2S heater (Rear) MAP sensor Fan control module ECT sensor...
  • Page 72 L3 Turbo Engine Control System Wiring Diagram (Continued) M6-MPS_01046 01-54 Service Training Mazda6 MPS Supplement...
  • Page 73 Engine L3 Turbo Drive-by-wire-relay Generator EGR (Exhaust Gas Recirculation)valve CAN (Controller Area Network) Purge solenoid Cruise control switch valve Wastegate control solenoid valve CPP switch Variable swirl solenoid valve Neutral switch PSP switch Spill valve control solenoid valve (High Refrigerant pressure switch (Middle) pressure pump) Instrument cluster Refrigerant pressure switch (High and...

  • Page 74: Injector Driver Module

    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). •...
  • Page 75 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 PCM output Excess exciting current Fuel injector operation period PCM input Close current Injector driver module output Hold current...

  • Page 76: Injector Driver Module Wiring Diagram

    L3 Turbo Engine Injector Driver Module Wiring Diagram M6-MPS_01049 Fuel injector check Injector driver module Injectorsignal No.1 Fuel injectors Injectorsignal No.2 Output circuit Injectorsignal No.3 Booster circuit Injectorsignal No.4 Input circuit Valve open transistor Battery GND (Ground)transistor Ignition switch Hold transistor Injector driver relay 01-58 Service Training Mazda6 MPS Supplement...

  • Page 77: L3 Turbo Specific Dtcs

    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. Condition P0069 Manifold absolute pressure/atmospheric pressure correlation P0089 Fuel pressure regulator performance P0091 Fuel pressure regulator control circuit low P0092...

  • Page 78: L3 Turbo Specific Pids

    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. Unit / Condition Condition / Specification Target air-fuel ratio is displayed AFR_ACT Actual air-fuel ratio is displayed BARO (Barometric pressure) Pa / V...
  • Page 79 Driveline/Axle...
  • Page 80 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...

  • Page 81: Clutch

    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. •...

  • Page 82: A26Mx-R Manual Transaxle Cross-Sectional View

    Driveline/Axle A26MX-R Manual Transaxle Cross-Sectional View M6-MPS_03026 A26MX-R manual transaxle Transfer case 03-2 Service Training Mazda6 MPS Supplement...

  • Page 83: Transfer Case

    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. •...

  • Page 84: Transfer Case Cross-Sectional View

    Driveline/Axle Transfer Case Cross-Sectional View M6-MPS_03008 Drive gear Front carrier Drive gear case Drive pinion gear Drive gear shaft Ring gear on ring gear shaft Oil pump Bolt (left-hand thread) Oil level plug 03-4 Service Training Mazda6 MPS Supplement...

  • Page 85: Transfer Case Power Flow

    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. •...

  • Page 86: Transfer Case Oil Cooler

    Driveline/Axle Transfer Case Oil Cooler M6-MPS_03007 Water in 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.

  • Page 87: Adjustment Procedures Necessary For Transfer Case Assembly

    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) –...

  • Page 88: 4-Wheel Drive

    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 Joint type differential side Double offset joint Front drive shaft Shaft diameter 27.0 mm Joint shaft diameter 28.0 mm...

  • Page 89: Drive Shafts

    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 Joint shaft Front drive shaft...

  • Page 90: Propeller Shaft

    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 •...

  • Page 91: Rear Differential

    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 Coupling component section Rear differential section Service Training Mazda6 MPS Supplement 03-11...

  • Page 92: Coupling Component

    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 Coupling case 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.
  • Page 93 Driveline/Axle • To get access to the actual coupling component, the coupling case must be dismantled. M6-MPS_03023 Locknut Retaining ring Washer Bearing Companion flange Coupling case Oil seal Output shaft Shim Coupling component Service Training Mazda6 MPS Supplement 03-13...

  • Page 94: Super Lsd

    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) –...

  • Page 95: Rear Differential Oil

    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.

  • Page 96: 4-Wheel Drive Control

    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.

  • Page 97: Components

    Driveline/Axle 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. •...

  • Page 98: Electronic Control Coupling

    Driveline/Axle 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.

  • Page 99: Electronic Control Coupling Operation

    Driveline/Axle 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.
  • Page 100 Driveline/Axle 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. Magnetic flux forms at the electromagnetic coil of the 4WD solenoid. Due to the magnetic flux in the armature, the pilot clutch is pulled towards the magnetic coil side and engages.
  • Page 101 Driveline/Axle M6-MPS_03016 Main clutch Main cam Pilot clutch Drive torque 4WD solenoid (electromagnetic coil) Armature 4WD CM Magnetic flux Pilot cam Input Ball Output Service Training Mazda6 MPS Supplement 03-21...

  • Page 102: Differential Oil Temperature Sensor

    Driveline/Axle 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.

  • Page 103: 4Wd Control Module

    Driveline/Axle 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.

  • Page 104: 4Wd Warning Light

    Driveline/Axle 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.

  • Page 105: 4-Wheel Drive Control System Block Diagram

    Driveline/Axle 4-Wheel Drive Control System Block Diagram M6-MPS_03020 Pilot clutch/pilot cam DSC HU/CM Ball/main cam 4WD CM Main clutch 4WD solenoid Electronic control coupling Front Rear differential Transaxle Rear drive shaft Transfer case Torque transmission path Propeller shaft Electric signal path Front drive shaft Solenoid activation Service Training Mazda6 MPS Supplement...

  • Page 106: 4-Wheel Drive Control System Operation

    Driveline/Axle 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). •...
  • Page 107 Driveline/Axle 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.

  • Page 108: 4-Wheel Drive Control System Wiring Diagram

    Driveline/Axle 4-Wheel Drive Control System Wiring Diagram M6-MPS_03013 Ignition switch CAN_H 4WD CM Data Link Connector Electronic control coupling CAN driver 4WD solenoid Parking brake switch Instrument cluster (4WD warning light) Battery DSC HU/CM Fuse ENG+B 10A Fuse METER 15A CAN_L Differential oil temperature sensor 03-28...

  • Page 109: Diagnostics

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

  • Page 111: List Of Abbreviations

    Controller Area Network Limited Slip Differential Camshaft Position Mass Air Flow Clutch Pedal Position Manifold Absolute Pressure DISI Direct Injection Spark Ignition Mazda Performance Series Dynamic Stability Control Negative Temperature DSC/HU/CM Dynamic Stability Coefficient Control/Hydraulic Unit/Control Module Oil Control Valve...
  • Page 112 List of Abbreviations Power Steering Pressure Right Hand Drive Research Octane Number Traction Control System Top Dead Center Throttle Position Three-Way Catalyst Vehicle Identification Number WU-TWC Warm-Up Three-Way Catalyst Service Training Mazda6 MPS Supplement...

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