2002 MAZDA 6 air filter

SCHEDULED MAINTENANCE
GI–15
GI
For GCC
Applied VIN (assumed):
JM7 GG323✻✻
✻✻✻✻ ✻✻
# 128767-, JM7 GG423✻✻
✻✻✻✻ ✻✻
# 128767-, JM7 GG343✻✻
✻✻✻✻ ✻✻
# 128767-
JM7 GG443✻✻
✻✻✻✻ ✻✻
# 128767-, JM7 GG32F✻✻
✻✻✻✻ ✻✻
# 128767-, JM7 GG42F✻✻
✻✻✻✻ ✻✻
# 128767-
JM7 GG34F✻
✻✻ ✻✻
✻✻ ✻
# 128767-, JM7 GG44F✻
✻✻ ✻✻
✻✻ ✻
# 128767-, JM7 GY49F✻✻
✻✻✻✻ ✻✻
# 101432-
JM7 GY39F✻✻
✻✻✻✻ ✻✻
# 101432-, JM7 GY49F✻
✻✻ ✻
0# 101432-, JM7 GY39F✻
✻✻ ✻
0# 101432-
Chart symbols:
I : Inspect and clean, repair, adjust, or replace if necessary.
R : Replace
T:Tighten
C : Clean
Remarks:
•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: If the vehicle is operated under any of the following conditions, change the engine oil and oil filter more often than
recommended intervals.
a. Driving in dusty conditions.
b. Extended periods of idling or low speed operation.
c. Driving for long period in cold temperatures or driving regularly at short distance only.
*2: Also inspect and adjust the power steering and air conditioner drive belts, if installed.
*3: 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.
*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: This is a full function check of electrical systems such as lights, wiper and washer systems (including wiper blades),
and power windows.
*6: If the vehicle is operated under any of the following conditions, change the rear differential oil
every 45,000 km (27,000 miles).
a. Towing a trailer or using a car - top carrier
b. Driving in dusty, sandy or wet condition
c. Extended periods of idling or low speed operation
d. Repeated short trips of less than 16 km (10 miles)
*7: If this component has been submerged in water, the oil should be changed.
Maintenance ItemMaintenance Interval (Number of months or km (miles), whichever comes first)
Months 6 121824303642485460667278849096
×1000 km
10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160
×1000 miles6.25 12.5 18.75 25 31.25 37.5 43.75 50 56.25 62.5 68.75 75 81.25 87.5 93.75 100
ENGINE
Engine valve clearance Unleaded fuel Audible inspect every 120,000 km (75,000 miles), if noisy, adjust
leaded fuel I I I I
Drive belts *2IIIIIIIIIIIIIIII
Engine oil *1RRRRRRRRRRRRRRRR
Engine oil filter *1RRRRRRRRRRRRRRRR
COOLING SYSTEM
Cooling system IIIIIIII
Engine coolant Replace every 2 years
FUEL SYSTEM
Air cleaner element *4CCRCCRCC
Fuel filter R R R R
Fuel lines and hoses IIIIIIII
IGNITION SYSTEM
Spark plugs Unleaded fuel Replace every 100,000 km (62,500 miles)
Leaded fuel IIIIIIII
EMISSION CONTROL SYSTEM
Idle mixture (leaded fuel) IIIIIIII

GI–16
SCHEDULED MAINTENANCE
Evaporative system (if installed) IIIIIIII
ELECTRICAL SYSTEM
Battery electrolyte level and specific gravity IIIIIIII
All electrical system *5IIIIIIII
CHASSIS AND BODY
Brake lines, hoses and connections IIIIIIII
Brake fluid *3IIIRIIIRIIIRIIIR
Parking brake IIIIIIIIIIIIIIII
Power brake unit and hoses IIIIIIII
Disc brakes IIIIIIIIIIIIIIII
Power steering fluid, lines, hoses, and connections I I I I I I I I I I I I I I I I
Steering operation and linkages IIIIIIII
Manual transaxle oilR
Automatic transaxle fluid level IIIIIIII
Rear differential oil (for 4WD)
*6*7
Transfer oil (for 4WD)
*7
Front and rear suspension and ball joints I I I I
Driveshaft dust boots I I I I
Bolts and nuts on chassis and body TTTTTTTT
Exhaust system and heat shields Inspect every 80,000 km (50,000 miles)
Cabin air filter (if installed) RRRRRRRR
Body condition
(for rust, corrosion and perforation)Inspect annually
Tyres (including spare tyre)
(with inflation pressure adjustment)IIIIIIII Maintenance ItemMaintenance Interval (Number of months or km (miles), whichever comes first)
Months 6 121824303642485460667278849096
×1000 km
10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160
×1000 miles6.25 12.5 18.75 25 31.25 37.5 43.75 50 56.25 62.5 68.75 75 81.25 87.5 93.75 100

SCHEDULED MAINTENANCE
GI–17
GI
Scheduled Maintenance Service (Specific Work Required)
•The specific work required for each maintenance item is listed in the following table. (Please refer to the section
applicable to the model serviced.)
For Europe (L.H.D. U.K.)
Bold frames: New item
Maintenance Item Specific Work Required
ENGINE
Engine valve clearance Measure clearance
Drive beltsInspect for wear, cracks and fraying, and check tension.
Replace drive belt.
Engine timing belt Replace engine timing belt.
Engine oil Replace engine oil and inspect for leakage.
Oil filter Replace oil filter and inspect for leakage.
COOLING SYSTEM
Cooling system
(including coolant level adjustment)Check coolant level and quality, and inspect for leakage.
Engine coolant Replace coolant.
FUEL SYSTEM
Air cleaner elementInspect for dirt, oil and damage.
Clean air cleaner element (by blowing air).
Replace air cleaner element.
Fuel filter Replace fuel filter.
Fuel lines and hoses Inspect for cracks, leakage and loose connection.
Fuel injection system (for MZR-CD (RF Turbo)) Update to injection amount correction with WDS. (see W/M)
IGNITION SYSTEM (FOR GASOLINE)
Spark plugsInspect for wear, damage, carbon, high-tension lead condition and measure
plug gap.
Replace spark plugs.
EMISSION CONTROL SYSTEM
Evaporative system (for gasoline)Check system operation (see W/M), vapor lines, vacuum fitting hoses and
connection.
E.G.R. system (MZR-CR (RF Turbo))Check system operation (see W/M), vacuum fitting hoses and connection.
Update to MAF correction for E.G.R control with WDS. (see W/M)
ELECTRICAL SYSTEM
Battery electrolyte level and specific gravity Check level and specific gravity.
CHASSIS AND BODY
Brake fluidCheck fluid level and inspect for leakage.
Replace brake fluid.
Brake lines, hoses and connectionsInspect for cracks, damage, chafing, corrosion, scars, swelling and fluid
leakage.
Parking brake Check lever stroke.
Power brake unit and hosesCheck vacuum lines, connections and check valve for improper attachment,
air tightness, cracks chafing and deterioration.
Disc brakesTest for judder and noise. Inspect caliper for correct operation and fluid
leakage, brake pads for wear. Check disc plate condition and thickness.
Power steering fluid and linesCheck fluid level and lines for improper attachment, leakage, cracks,
damage, loose connections, chafing and deterioration.
Power steering fluid Check fluid level.
Power steering system and hosesCheck lines for improper attachment, leakage, cracks, damage, loose
connections, chafing and deterioration.
Steering operation and gear housingCheck that the steering wheel has the specified play. Be sure to check for
changes, such as excessive play, hard steering or strange noises.
Check gear housing and boots for looseness, damage and grease/gear oil
leakage.
Steering linkages tie rod ends and armsCheck ball joint, dust cover and other components for looseness, wear,
damage and grease leakage.
Front and rear suspension and ball joints Inspect for grease leakage, cracks, damage and looseness.
Manual transmission/transaxle oilCheck oil level and inspect for leakage.
Replace manual transmission/transaxle oil.
Automatic transmission/transaxle fluid level Check fluid level.

GI–18
SCHEDULED MAINTENANCE
End Of Sie
Rear differential oilCheck oil level and inspect for leakage.
Replace rear differential oil.
Transfer oil (for 4×4)Check oil level and inspect for leakage.
Replace transfer oil.
Driveshaft dust boots Inspect for grease leakage, cracks, damage and looseness.
Body condition
(for rust, corrosion and perforation)Inspect body surface for paint damage, rust, corrosion and perforation.
Exhaust system and heat shields Inspect for damage, corrosion, looseness of connections and gas leakage.
Tires
(including spare tire)
(with inflation pressure adjustment)Check air pressure and inspect tires for tread wear, damage and cracks;
and wheels for damage and corrosion.
AIR CONDITIONER SYSTEM (IF EQUIPPED)
Cabin air filter Replace cabin air filter.Maintenance Item Specific Work Required

D–8
ENGINE OIL
ENGINE OIL INSPECTIONA6E331214001201MZR-CD (RF Turbo)
1. Position the vehicle on level ground.
2. Warm up the engine to normal operating temperature.
3. Stop the engine and wait for 5 min.
4. Verify that the oil level is between the L and F marks on the dipstick and check the engine oil condition.
•If the oil level is below the L mark, add engine oil. (See D–8 ENGINE OIL REPLACEMENT.)
End Of SieENGINE OIL REPLACEMENTA6E331214001202MZR-CD (RF Turbo)
Warning
•Hot engines and engine oil can cause severe burns. Turn off the engine and wait until it and the
engine oil have cooled.
•A vehicle that is lifted but not securely supported on safety stands is dangerous. It can slip or fall,
causing death or serious injury. Never work around or under a lifted vehicle if it is not securely
supported on safety stands.
•Continuous exposure to USED engine oil has caused skin cancer in laboratory mice. Protect your
skin by washing with soap and water immediately after working with engine oil.
Caution
•In case you spill engine oil on the front pipe, wipe it off completely. If you fail to wipe the spilled
oil, it will produce fumes because of the heat.
1. Position the vehicle on level ground.
2. Remove the the oil filler cap.
3. Remove the under cover.
4. Remove the oil pan drain plug.
5. Drain the engine oil into a container.
6. Install the oil pan drain plug with a new the washer.
Tightening torque
12—17 N·m {1.2—1.8 kgf·m, 9—13 ft·lbf}
Note
•The amount of residual oil in the engine can vary with the replacement method, oil temperature, etc. Verify
the oil level after engine oil replacement.
7. Refill the engine oil with the specified type and amount, then install the oil filler cap.
Oil capacity (approximate quantity)
L {US qt, Imp qt}
Note
•The maintenance intervals on scheduled maintenance table (See GI–8 SCHEDULED MAINTENANCE
TABLE) can only be supported with the use of following oils.
Recommended Engine Oil
8. Start the engine and inspect for oil leakage.
•If the oil leaks, specify the faulty part and repair or replace it.
9. Inspect the oil level .
•If the necessary, add oil. (See D–8 ENGINE OIL INSPECTION.)
10. Install the under cover.
End Of Sie
ENGINE OIL
Item Specification
Total (dry engine) 5.5 {5.8, 4.8}
Oil replacement 4.8 {5.1, 4.2}
Oil and oil filter replacement 5.0 {5.3, 4.4}
Item Specification
Engine oil GradeAPI CF CD, CE, CF-4
ACEA B1 or B3 B3 B3 or B4
Viscosity (SAE) 5W-30 10W-40 5W-30, 10W-30
RemarksMazda genuine Dexelia oil e.g. —

OIL FILTER, OIL COOLER
D–9
D
OIL FILTER REPLACEMENTA6E331414300201MZR-CD (RF Turbo)
1. Disconnect the negative battery cable.
2. Remove the under cover.
3. Remove the oil filter using the oil filter wrench.
4. Use a clean rag to wipe off the mounting surface
on the oil filter.
5. Apply clean engine oil to the O-ring of a new oil
filter.
6. Using the oil filter wrench, tighten the filter
according to the installation procedure indicated
on the side of the filter or packing box.
7. Start the engine and inspect for oil leakage.
•If the oil leaks, specify the faulty part and
repair or replace it.
8. Inspect the oil level. (See D–8 ENGINE OIL
INSPECTION.)
9. Install the under cover.
End Of Sie
OIL COOLER REMOVAL/INSTALLATIONA6E331819900201MZR-CD (RF Turbo)
1. Disconnect the negative battery cable.
2. Remove the under cover.
3. Drain the engine coolant.
4. Remove in the order indicated in the table.
5. Install in the reverse order of the removal.
6. Refill the engine coolant.
7. Start the engine and inspect for oil leakage.
•If the oil leaks, specify the faulty part and repair or replace it.
8. Inspect the oil level. (See D–8 ENGINE OIL
INSPECTION.)
.
End Of Sie
OIL FILTER
OIL FILTER
WRENCH
OIL FILTER
A6E3314W100
OIL COOLER
1 Water hose
2 Oil cooler
ROILOIL
34—44
{3.5—4.4,
25.4—31.8}
1
2N·m {kgf·m, ft·lbf}ROILOIL
1
A6E3318W100

OUTLINE
F1–3
F1
CONTROL SYSTEM DIAGRAM (4WD)A6E390218881204
.
* : Equipped for L3 engine modelEnd Of Sie
9
8
7
54
3
10
19
18
17
15
16
14
13
11
12
20
29
28
27
25
26
24
23
21
22
30
3938
3735
33
36
31
32
40
6
1
2
3441
A6E39022000
1PCM
2 Ignition coil
3 Generator
4* VAD shutter valve
5 Air cleaner
6 MAF sensor
7* VAD shutter valve actuator
8* VAD control solenoid valve
9* Vacuum chamber
10* VAD check valve (one-way)
11 IAC valve
12 Purge solenoid valve
13 TP sensor
14 MAP sensor
15* VIS control solenoid valve
16 Variable tumble control solenoid valve
17* VIS shutter valve actuator
18* VIS shutter valve
19 VTCS shutter valve actuator
20 VTCS shutter valve
21 Fuel injector22* OCV
23 CMP sensor
24 EGR valve
25 Knock sensor
26 ECT sensor
27 PCV valve
28 CKP sensor
29 HO2S (front)
30 HO2S (rear)
31 Charcoal canister
32 Check valve (two-way)
33 Pressure regulator
34 Fuel filter (high-pressure)
35 Fuel pump
36 Fuel filter (low-pressure)
37 Fuel tank
38 Rollover valve
39 Pulsation damper
40 Fuel pump (transfer)
41 To PCM

F1–26
FUEL SYSTEM
FUEL PUMP UNIT REMOVAL/INSTALLATIONA6E391213350202
Warning
•Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, do not damage the sealing surface of
the fuel pump unit when removing or installing.
Caution
•Disconnecting/connecting the quick release connector without cleaning it may possibly cause
damage to the fuel pipe and quick release connector. Always clean the quick release connector
joint area before disconnecting/connecting using a cloth or soft brush, and make sure that it is
free of foreign material.
Note
•Since the fuel pump unit is integrated with the fuel filter, it needs to be replaced every 75,000 km.
1. Complete the “BEFORE REPAIR PROCEDURE”.
2. Disconnect the negative battery cable.
3. Complete the following in order to the work area.
(1) Loosen the bolt of the fuel tank strap.
(2) Lower the fuel tank to a position where the SST can be attached from the service hole cover.
4. Remove the rear seat cushion.
5. Remove in the order indicated in the table.
.
6. Install in the reverse order of removal.
7. Complete the “AFTER REPAIR PROCEDURE”.
8. Complete the “Fuel Leak Inspection After Fuel
Pump Unit Installation.“ (See F1–28 Fuel Leak
Inspection After Fuel Pump Unit Installation.)
1 Service hole cover
2 Connector
3 Plastic fuel hose (fuel tank side, main fuel pipe part)
(See F1–27 Plastic Fuel Hose Removal Note)
(See F1–28 Plastic Fuel Hose Installation Note)
4 Plastic fuel hose (fuel tank side, transfer hose part)
(See F1–29 FUEL HOSE (FUEL TANK SIDE,
TRANSFER HOSE PART) REMOVAL/
INSTALLATION)
5Fuel pump cap
(See F1–27 Fuel Pump Cap Removal Note)
(See F1–28 Fuel Pump Cap Installation Note)
6 Packing
7 Fuel pump unit
3
7
1
4
5
2
6
80—90 {8.2—9.1, 60—66}
R
SST
N·m {kgf·m, ft·lbf}
A6E39122009