Mazda SPEED6 User Manual

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01 ENGINE10Direct InjectionDiesels were the fi rst engines to use direct injection, but they use compression ignition rather than spark ignition. Direc

01 ENGINE11DISI Fuel SystemFuel pressure from the in-tank pump is controlled at two voltages; low voltage for idle when less fuel volume is required a

01 ENGINE12In-Tank Low Pressure Fuel Pump Operation: Battery Voltage Off IdleFuel pressure is inspected in the traditional manner in the engine compar

01 ENGINE13High Pressure Fuel RailHigh Pressure High Pressure pumppumpFuel RailFuel RailPressure SensorPressure SensorHigh Pressure Fuel PumpThe PCM m

01 ENGINE14High Pressure Fuel RailThe fuel rail supplies fuel to the injectors. The fuel rail pressure sensor supplies pressure information to the PC

01 ENGINE15Injector Driver ModuleThe PCM fi res the injectors with the injector driver module. Because the fuel system is running at up to 1885 PSI, i

01 ENGINE16The #3 injector requires cutting the corner off of the PCV catch tank to allow more clearance.

01 ENGINE17TurbochargerThe main components of the turbocharging system are:Air ducts and charge air cooler (Intercooler)TurbochargerWaste gateWaste ga

01 ENGINE18Air Ducts and Charge Air CoolerAir cleaner to turbo inlet (low pressure/low temperature)Turbo outlet to charge air cooler (high pressure/hi

01 ENGINE19TurboTurbochargers consist of a housing, a blade assembly, inlet ducts for low pressure air and outlet ducts for high pressure air, an inte

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01 ENGINE20Turbocharger Inlet and Outlet Pressures and TemperaturesWaste Gate SolenoidExhaust to spin the turbineHigh pressure hot air to intercoolerL

01 ENGINE21Waste GateThe waste gate is a valve that allows exhaust pressure to bypass the turbocharger turbine and dump directly into the exhaust. Th

01 ENGINE22Waste Gate Regulator Solenoid An intake manifold connection to the waste gate actuator opens the waste gate. The waste gate regulator sole

01 ENGINE232. Solenoid off, waste gate open, releasing boostWhen boost pressure is high in the intake, the boost pressure from the intake manifold act

01 ENGINE243. Solenoid on, waste gate closed, building maximum boostThe waste gate regulator solenoid tunes the opening rate of the waste gate to help

01 ENGINE25Air Bypass ValveThe air bypass valve protects the intake manifold air ducts, passages, and sealing gaskets from damage due to over-boost.

01 ENGINE26 Turbocharger DiagnosisBlack SmokeDirty air fi lter system Suction and pressure line distorted or leaking Excessive fl ow resistance in exhau

01 ENGINE27Black Blue SmokeCompressor/Turbine Wheel FailureTurbocharger bearing damageBlack Blue SmokeHigh Oil ConsumptionCompressor/Turbine Wheel Fai

01 ENGINE28Turbocharger Diagnosis by Symptom Possible CauseSymptomsBlack smokeBlue smokeHigh Boost PressureCompressor/ turbine wheel damageHigh oil co

01 ENGINE29Lubrication Routing DiagramCoolant Routing DiagramThe coolant lines run from the cylinder head to the EGR valve and turbocharger.

300 GENERAL INFORMATIONCONTENTS01 ENGINE ...7Engine Modi

01 ENGINE30Fuel OctaneThe MZR 2.3L L3T engine has a high compression ratio for a turbocharged vehicle of 9.5:1. Typically turbocharged engine compres

02 SUSPENSION31Suspension Modifi cations 18” X 7” Alloy wheels with 215/45/18Vehicle overall height reduced 0.4”Shock dampers tunedSpring rates increas

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03 DRIVELINE/AXLE33ObjectivesAfter completing this section, you will be able to:Explain Active Torque Control AWD•

03 DRIVELINE/AXLE34All Wheel Drive (AWD)Front/rear wheel torque varies between 100/0 and 50/50 through an electronic torque coupling mounted in front

03 DRIVELINE/AXLE35The 4WD ECU uses real-time data to manage torque.PCM: VSS, RPM, TP angle, neutral switch, brake pedal position, selector lever posi

03 DRIVELINE/AXLE36Transfer UnitWater Cooling

03 DRIVELINE/AXLE37Torque always goes to the front wheels and the rear drive shaft.

03 DRIVELINE/AXLE38Electronic Control CouplingThe electronic control coupling switches power to the rear wheels the rear differential. Internal Compon

03 DRIVELINE/AXLE39Electromagnetic Clutch OFFElectromagnetic solenoid off, pilot clutch releasedNo power to rear differential and the rear wheels are

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03 DRIVELINE/AXLE40Power to Electromagnetic ClutchElectromagnetic solenoid energized, pilot clutch appliedA slight difference in speed between the fro

03 DRIVELINE/AXLE41Tochigi-Fuji Limited Slip Differential (LSD)

03 DRIVELINE/AXLE42Differential EffectLSD Effect

03 DRIVELINE/AXLE43LSD Torque Transfer

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04 BRAKES45ObjectivesAfter completing this section, you will be able to:Explain Brake Assist ControlExplain Oversteer and UndersteerExplain Dynamic St

04 BRAKES46Braking System Modifi cationsLarger brakes:Front- 12.6” (vs 11.8”) ventilated discs Rear-12.4” (vs 10”) solid discs ABSAnti-lock Braking Sys

04 BRAKES47DSCDSC is designed to help correct understeer and oversteer.Understeer Is described by drivers as plowing or pushing. Understeer occurs wh

04 BRAKES48↕Forward G-force↔Lateral G-forceYaw Angle

04 BRAKES49Combined SensorAll combined sensor readings (yaw, forward and lateral G-force) read 2.5 volts while the vehicle is at rest. The voltage o

500 GENERAL INFORMATIONMazdaspeed6 Vehicle Walk AroundExteriorHood scoop for intercooler concealed inside hoodGrillFront bumper with fog lightsDark fi

04 BRAKES50Part name FunctionNormal PositionPressure-retention solenoid valveAdjusts the fl uid pressure in each brake system according to DSC HU/CM si

04 BRAKES51Normal Braking Fluid pressure passes from the master cylinder through all HU/CM solenoids directly to the front and rear brake calipers.The

04 BRAKES52ABS/EBD Application• Right Front Pressure Increases• Left Front Pressure Maintains• Both Rear Wheels Pressure Decreases. During pressure

04 BRAKES53DSC: Oversteer Correction• Left turn, the right front wheel is slipping, resulting in oversteer• The pump, traction switching and stabili

04 BRAKES54DSC: Understeer Correction• Left turn• Understeer is detected• DSC applies ABS pump, traction switching and stability control solenoids

04 BRAKES55TCSTCS will back off the electronic throttle to brake engine torque and prevent wheel slip, which is a uniform correction to all wheels sim

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5705 TRANSAXLEManual Transaxle ChangesA26 MX-R6-Speed Manual TransmissionCompact 3-shaft design keeps overall length the same as the 5-speed manual tr

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06 STEERING59Steering System ChangesThe steering rack stroke has been increased from 135.4 to 141.6mm to accommodate the 18 inch wheels. This also in

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6107 HVACHVAC ChangesAuto ACThis has been available on MAZDA6 since 2003. Changes include combining the condenser and receiver drier together. In de

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6308 RESTRAINTSRestraint System ChangesThis system is the same as MAZDA6 and MAZDASPEED6 both receive the following DTCs:DTC Flash Code Malfunction Lo

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09 BODY & ACCESSORIES65ObjectivesAfter completing this section, you will be able to:Explain the following body and electrical changes: Power Windo

09 BODY & ACCESSORIES66Power WindowsOne touch operationAll power windows have one touch up and down capability from the master switch and the sub-

09 BODY & ACCESSORIES67Power window initialize procedure Any time battery power to the power window circuit is lost several power window automatic

09 BODY & ACCESSORIES68Power Window Main SwitchPower Window Sub Switches

09 BODY & ACCESSORIES69Advanced Keyless System This system allows a customer to enter and start the vehicle without using a transmitter button or

01 ENGINE7ObjectivesAfter completing this section, you will be able to:Explain DISI (Direct Injection Spark IgnitionExplain turbocharger controls and

09 BODY & ACCESSORIES70Reception RangeTransmitterAdvanced Keyless Back-up If the transmitter battery fails, the advanced keyless system fails or t

09 BODY & ACCESSORIES71Advanced Keyless System OperationDriver Request Switch (person must have the transmitter)Entering the vehicle Exiting the v

09 BODY & ACCESSORIES72Automatic RelockingIf the keyless transmitter moves outside the reception zone, all doors will automatically re-lock after

09 BODY & ACCESSORIES73Immobilizer (iPATS) The PCM, ignition coil, and keys are the main components. When a key or transmitter is recognized the

09 BODY & ACCESSORIES74High Intensity Discharge (HID) Headlights The high intensity discharge headlights are Xenon gas charged with 25,000 volts.

09 BODY & ACCESSORIES75Wiper Washer: Speed Sensing WipersIn the intermittent position, the windshield wiper motor changes frequency of wipes based

09 BODY & ACCESSORIES76AudioStandard BOSE® modular audio with: In-dash 6-CD changer2-tweeters4-speakersTrunk mounted subwooferSirius® satellite ra

09 BODY & ACCESSORIES777. Remove bolt hidden behind the driver side of the dash (use protective tape to prevent cuts from sharp metal edges

09 BODY & ACCESSORIES78NAVI (DVD Satellite Navigation System)Similar to MAZDA3 and RX-8 (does not support voice commands)The remote control can be

09 BODY & ACCESSORIES79Chassis Stiffening to Improve Body RigidityTorsional rigidity has been improved by approximately 50% over MAZDA6Local reinf

01 ENGINE8L3T: 2.3L DISI, VVT, TurboThe engine block is the same Mazda L3 engine family used since 2001:2001 B2300 2003 MAZDA62004 MAZDA3 (2.0L &am

09 BODY & ACCESSORIES80Body ExteriorHoodGrilleSide sillsRear lip spoilerRear bumper with exhaust diffusersFront fendersFront bumper with fog light

09 BODY & ACCESSORIES81Body InteriorStainless steel scuff plates•Alloy pedals•Front sport seats with longer seat bottom and enlarged side bolsters

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01 ENGINE9Engine Modifi cations To Handle The Increased PowerNew precision engine block and cylinder head casting processForged steel crankshaft and co