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 Engine / Transaxle Combinations 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 L 600001 Serial No Plant = Hiroshima, = Hofu Dummy 0,6 to 9, A to Z Transmission = 6MTX Engine Type L = 2.3L (L3 Turbo) Body style = 4SD Remarks = 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 – Acceleration from 60 80 km/h (4th gear): 3.0 seconds (under Mazda test conditions) Max torque: 380Nm / 3,000rpm Acceleration from 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) M6-MPS_00001 00-2 Power output Torque Engine speed Service Training Mazda6 MPS Supplement 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 12 24 36 48 60 72 84 96 108 120 132 144 15 30 45 60 75 90 105 120 135 150 165 180 46.9 56.3 65.6 75.0 84.4 103.1 112.5 18.8 28.1 37.5 9.4 93.8 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 COOLING SYSTEM I Cooling system (including coolant level adjustment) Engine coolant I FL 22 type *4 Others I I I I I I I Replace every 195,000 km (121,900 miles) or 11 years Replace at first 90,000Km (56,300 miles) or years, after that every years FUEL SYSTEM Air cleaner element*1 Fuel lines and hoses Replace every 60,000Km (37,500 miles) or 36 months 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 I I I I I I I I I I CHASSIS and BODY Brakes lines hoses and connections I Brake fluid *6 R R R R R I R Parking brake I I I I I I I I I I I I Power brake unit (Brake booster) and hoses Disc brakes I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I Power steering fluid, lines, hoses and connections Steering operation and linkages I I I Manual transaxle oil I I I R Rear differential oil R *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 Body condtion (for rust, corrosion and perforation) Tires (including spare tire) (with inflation pressure adjustment) I Inspect annualy I I I I I I I I I I I I AIR CONDITIONER SYSTEM (if installed Air filter (if installed) Replace every 40,000Km (25,000 miles) or 24 months M6-MPS_00T002 I: R: Inspect: Inspect and clean, repair, adjust, or replace if necessary Replace Service Training Mazda6 MPS Supplement 00-3 I 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 00-4 Service Training Mazda6 MPS Supplement 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 • 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 Torque transmission system Electromagnetic clutch Rear housing 4WD solenoid (electromagnetic coil) Cam mechanism Ball Rear wheel side 03-18 10 11 12 13 Pilot cam Pilot clutch Armature Main cam Main clutch Front wheel side Service Training Mazda6 MPS Supplement 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 Therefore, the traction from the front wheels is not transmitted to the rear wheels M6-MPS_03015 Main clutch Pilot clutch 4WD solenoid (electromagnetic coil) 4WD CM Pilot cam Ball Main cam Armature Service Training Mazda6 MPS Supplement 03-19 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 This causes friction that generates torque in the pilot clutch The torque is transmitted to the pilot cam, which is engaged with the pilot clutch 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 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 03-20 Service Training Mazda6 MPS Supplement Driveline/Axle M6-MPS_03016 Main clutch Pilot clutch 4WD solenoid (electromagnetic coil) 4WD CM Pilot cam Ball 10 11 12 Main cam Drive torque Armature Magnetic flux Input Output Service Training Mazda6 MPS Supplement 03-21 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 The resistance grows smaller as the oil temperature rises and vice-versa, as shown M6-MPS_03025 Differential oil temperature sensor Differential Oil Temperature Sensor Characteristics M6-MPS_03017 03-22 Service Training Mazda6 MPS Supplement 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 M6-MPS_03019 4WD control module 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 Service Training Mazda6 MPS Supplement 03-23 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 • The 4WD CM controls the operation of the warning light M6-MPS_03018 03-24 Service Training Mazda6 MPS Supplement Driveline/Axle 4-Wheel Drive Control System Block Diagram M6-MPS_03020 PCM DSC HU/CM 4WD CM 4WD solenoid Front Transaxle Transfer case Propeller shaft Front drive shaft 10 11 12 13 14 15 16 17 18 Pilot clutch/pilot cam Ball/main cam Main clutch Electronic control coupling Rear differential Rear drive shaft Torque transmission path Electric signal path Solenoid activation Service Training Mazda6 MPS Supplement 03-25 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) • The 4WD CM controls the current to the 4WD solenoid by changing the rate of the ON/OFF timing (duty signal) • PCM: – – – • Four-wheel speed * DSC operating condition * Coupling torque request * Steering wheel angle * Back-up light switch position * Yaw rate * Lateral-G * Rear differential oil temperature Parking brake switch: – • Transaxle neutral position * Differential oil temperature sensor: – • Engine speed * DSC HU/CM: – – – – – – – • Accelerator pedal position * 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 03-26 Service Training Mazda6 MPS Supplement 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 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 Service Training Mazda6 MPS Supplement 03-27 Driveline/Axle 4-Wheel Drive Control System Wiring Diagram M6-MPS_03013 Ignition switch 4WD CM Electronic control coupling 4WD solenoid Instrument cluster (4WD warning light) DSC HU/CM PCM CAN_L 03-28 10 11 12 13 14 15 16 CAN_H Data Link Connector CAN driver Parking brake switch Battery Fuse ENG+B 10A Fuse METER 15A Differential oil temperature sensor Service Training Mazda6 MPS Supplement 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 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 P1887 System wiring P1888 Differential oil temperature sensor U0073 CAN system communication error U0100 PCM communication system U0121 DSC communication system 4WD Warning Light Condition Illuminated Illuminated DTC Stored in Control Memory Condition X Stop X Stop Illuminated X Stop Illuminated X Stop Illuminated *1 X Stop *2 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 Service Training Mazda6 MPS Supplement 03-29 Driveline/Axle Notes: 03-30 Service Training Mazda6 MPS Supplement 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 NTC Negative Temperature Coefficient OCV Oil Control Valve PCM Powertrain Control Module PCV Positive Crankcase Ventilation PID Parameter Identification DSC/HU/CM Dynamic Stability Control/Hydraulic Unit/Control Module DTC Diagnostic Trouble Code EBA Electronic Brake Assistance ECT Engine Coolant Temperature EGR Exhaust Gas Recirculation 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 ... 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... 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... member mounts (increased thickness of sheet metal) Service Training Mazda6 MPS Supplement 00-7 General Information Notes: 00-8 Service Training Mazda6 MPS Supplement 01 Engine 01 Engine Table of Contents