2002 MAZDA 6 battery

B2–8
VALVE CLEARANCE, COMPRESSION PRESSURE
10. Install the timing belt cover bolt as shown.
Tightening torque
7.9—10.7 N·m {80—110 kgf·cm, 69.5—95.4
in·lbf}
11. Install the engine cover. (See B2–9 TIMING BELT
REMOVAL/INSTALLATION.)
End Of Sie
COMPRESSION INSPECTIONA6E231402000201
Warning
•When the engine and the oil are hot, they can badly burn. Be careful not to burn yourself during
removal/installation of each component.
1. Verify that the battery is fully charged.
•Recharge it if necessary. (See G–6 BATTERY INSPECTION.)
2. Warm up the engine to the normal operating system temperature.
3. Stop the engine and allow it to cool off for about 10 min.
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 fuel from spurting out of the glow plug
hole, do not ground the fuel injector terminal. (See F2–45 Fuel Line Safety Procedures.)
4. Disconnect the fuel injector connector.
Warning
•If the glow plug harness connector is connected, the glow plug harness and engine component
can come into contact and cause a short when the engine switch is ON. Disconnect the glow plug
harness connector before turning the engine switch on.
5. Remove the engine cover. (See B2–9 TIMING BELT REMOVAL/INSTALLATION.)
6. Remove all the glow plugs. (See F2–42 GLOW
PLUG REMOVAL/INSTALLATION.)
TIMING BELT
COVER BOLT
UPPER TIMING BELT COVER
A6E2312W200
COMPRESSION PRESSURE
GLOW PLUG HARNESS CONNECTOR
A6E2314W100

COMPRESSION PRESSURE, TIMING BELT
B2–9
B2
7. Install the SSTs into the glow plug hole.
8. Crank the engine and note the maximum gauge
reading.
9. Inspect each cylinder as above.
•If the compression in one or more cylinders is
low, pour a small amount of clean engine oil
into the cylinder and reinspect the
compression.
—If the compression increases, the piston,
the piston rings, or cylinder wall may be
worn and overhaul is required.
—If the compression stays low, a valve may
be stuck or improperly seated and
overhaul is required.
—If the compression in adjacent cylinders stays low, the cylinder head gasket may be damaged or the
cylinder head may be distorted and overhaul is required.
Compression
kPa {kgf/cm
2, psi} [rpm]
10. Remove the SSTs.
11. Install the glow plug. (See F2–42 GLOW PLUG REMOVAL/INSTALLATION.)
12. Instal the engine cover. (See B2–9 TIMING BELT REMOVAL/INSTALLATION.)
13. Reconnect the fuel injector connector.
14. Erase DTC from PCM memory using the SST. (WDS or equivalent).
End Of Sie
TIMING BELT REMOVAL/INSTALLATIONA6E231612040201
Warning
•Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel.
•Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injures or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line
Safety Procedure”. (See F2–45 Fuel Line Safety Procedures.)
1. Disconnect the negative battery cable.
2. Remove the front tire (RH).
3. Remove the splash shield (RH).
4. Remove the washer tank.
5. Remove the drive belt. (See B2–4 DRIVE BELT REPLACEMENT.)
6. Remove the fuel filter with the fuel hose still connected and position the fuel filter so that it is out of the way.
( L.H.D.) (See F2–50 FUEL FILTER COMPONENT REMOVAL/INSTALLATION.)
7. Remove in the order shown in the table.
8. Install in the reverse order of removal.
9. Start the engine and inspect the pulleys and the drive belt for runout and contact.
Item Specification
Standard 3,500 {35.7, 507.7} [250]
Minimum 3,100 {31.6, 449.4} [250]
Maximum difference
between cylinders196.1 {1.999, 28.44}
49 S010 1A0
49 S013 102
A6E2314W101
TIMING BELT

ENGINE
B2–27
B2
ENGINE REMOVAL/INSTALLATIONA6E232401001201
Warning
•Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel.
•Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injures or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line
Safety Procedure”. (See F2–45 Fuel Line Safety Procedures.)
1. Disconnect the negative battery cable.
2. Drain the engine coolant, engine oil, and transaxle oil.
3. Remove the radiator.
4. Remove the engine cover. (See B2–9 TIMING BELT REMOVAL/INSTALLATION.)
5. Remove the air cleaner and air hose. (See F2–36 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.)
6. Disconnect the fuel hose. (See F2–45 BEFORE REPAIR PROCEDURE.)
7. Remove the front pipe. (See F2–57 EXHAUST SYSTEM REMOVAL/INSTALLATION.)
8. Remove the battery and tray. (See G–5 BATTERY REMOVAL/INSTALLATION.)
9. Remove the shift cable, select cable and clutch release cylinder related to the transaxle. (See J2–7 MANUAL
TRANSAXLE REMOVAL/INSTALLATION.)
10. Remove the clutch release cylinder.
11. Remove the vacuum hose and the heater hose.
12. Disconnect the P/S oil pump pressure pipe and P/S oil pump relief hose from the P/S oil pump side. (See N–16
POWER STEERING OIL PUMP (MZR-CD (RF Turbo)) REMOVAL/INSTALLATION.)
Note
•The P/S oil pump will not be removed from the engine.
13. Remove the A/C compressor with the pipe still connected. Position the A/C compressor so that it is out of the
way. Use wire or rope to secure it. (See U–11 A/C COMPRESSOR REMOVAL/INSTALLATION.)
14. Remove the joint shaft.
15. Remove the front drive shaft (LH) from the transaxle.
16. Remove in the order indicated in the table.
17. Install in the reverse order of removal.
18. Fill the engine coolant, engine oil, and transaxle oil.
19. Bleed the air from the fuel line. (See F2–45 AFTER REPAIR PROCEDURE.)
20. Start the engine and:
•Inspect the pulleys and the drive belt for runout and contact.
•Inspect the engine oil, engine coolant transaxle oil, P/S fluid, and fuel for leakage.
•Inspect the idle speed. (See F2–34 IDLE SPEED INSPECTION.)
21. Perform a road test.
22. Reinspect the engine oil, engine coolant, transaxle oil, and P/S fluid levels.
ENGINE

OIL PRESSURE INSPECTION
D–7
D
OIL PRESSURE INSPECTIONA6E331001003201MZR-CD (RF Turbo)
Warning
•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.
•Hot engines and engine oil can cause severe burns. Turn off the engine and wait until it and the
engine oil have cooled.
1. Disconnect the negative battery cable.
2. Remove the under cover.
3. Remove the oil pressure switch.
4. Screw the SST into the oil pressure switch
installation hole.
5. Warm up the engine to normal operating
temperature.
6. Run the engine at the specified speed, and note
the gauge readings.
•If the pressure is not as specified, inspect for
the cause and repair or replace if necessary.
Oil pressure (approximate quantity) [oil
temperature: 100°C {212°F}]
147 kPa {1.5 kgf/cm
2, 21psi} min [1,000 rpm]
343 kPa {3.5 kgf/cm2, 50 psi} min [3,000 rpm]
Note
•The oil pressure can vary with oil viscosity and temperature.
7. Stop the engine and wait until it is cool.
8. Remove the SST.
Caution
•Any sealant stuck at the end of the oil pressure switch can cause operation malfunction of the oil
pressure switch.
Be sure there is no sealant at the end of the oil pressure switch.
9. Apply silicone sealant to the oil pressure switch
threads as shown.
10. Install the oil pressure switch.
Tightening torque
12—17 N·m {1.2—1.8 kgf·m, 9—13 ft·lbf}
11. Install the intake manifold bracket.
12. Start the engine and inspect for oil leakage.
•If the oil leaks, specify the faulty part and
repair or replace it.
13. Install the under cover.
End Of Sie
OIL PRESSURE INSPECTION
49 0187 280A
A6E3310W100
1.0—2.0 {0.04—0.07}
4.0—6.0 {0.16—0.23}
mm {in}
SEALANTSEALANT
A6E3310W101

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

D–10
OIL PAN
OIL PAN REMOVAL/INSTALLATIONA6E332010040201MZR-CD (RF Turbo)
Warning
•Hot engines and engines oil can cause severe burns. Turn off the engine and wait until it and the
engine oil have cooled.
1. Disconnect the negative battery cable.
2. Remove the under cover.
3. Drain the engine oil. (See D–8 ENGINE OIL REPLACEMENT.)
4. Remove the lower radiator hose assembly under the oil pan with the cooling hose still connected. Position the
lower radiator hose assembly so that it is out of the way.
5. Remove in the order indicated in the table.
6. Install in the reverse order of removal.
7. Refill the engine oil with the specified type and amount. (See D–8 ENGINE OIL REPLACEMENT.)
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. (See D–8 ENGINE OIL INSPECTION.)
.
Oil Pan Removal Note
Caution
•Pry tools can easily scratch the oil pan mounting surfaces. Prying off the oil pan can easily bend
the oil pan flange.
Refer to the following instructions before removing the oil pan.
1. Remove the oil pan mounting bolts.
2. Remove the sealant from the bolt threads.
OIL PAN
7.9—10.7
{80—110, 69.5—95.4}
N·m {kgf·cm, in·lbf}
1
SEALANTSEALANT
A6E3320W100
1Oil pan
(See D–10 Oil Pan Removal Note)
(See D–11 Oil Pan Installation Note)

THERMOSTAT
E–9
E
THERMOSTAT REMOVAL/INSTALLATIONA6E361815171201MZR-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 removal.
6. Fill the radiator with the specified amount and type of engine coolant.
7. Inspect the engine coolant leakage. (See E–8 ENGINE COOLANT LEAKAGE INSPECTION.)
Thermostat Installation Note
1. Verify that the positions of the jiggle pin and the projection on the gasket are as shown.
2. Install the thermostat into the thermostat case, aligning the projection on the gasket to the thermostat cover.
End Of Sie
THERMOSTAT
1 Lower radiator hose
2 Thermostat cover
3Thermostat
(See E–9 Thermostat Installation Note )
3
1
2
7.9—10.7 N·m
{80—110 kgf·cm,
69.5—95.4 in·lbf}
A6E3618W100
THERMOSTAT
COVER
GASKET
PROJECTIONJIGGLE PIN
A6A3618W101

WATER PUMP
E–11
E
WATER PUMP REMOVAL/INSTALLATIONA6E362015010201MZR-CD (RF Turbo)
1. Disconnect the negative battery cable.
2. Remove the under cover.
3. Drain the engine coolant.
4. Remove the timing belt. (See B2–9 TIMING BELT REMOVAL/INSTALLATION.)
5. Remove the thermostat. (See E–9 THERMOSTAT REMOVAL/INSTALLATION.)
6. Remove in the order indicated in the table.
7. Install in the reverse order of removal.
8. Insect the drive belt. (See B2–4 DRIVE BELT INSPECTION.)
9. Fill the radiator with the specified amount and type of engine coolant.
10. Inspect the engine coolant leakage. (See E–8 ENGINE COOLANT LEAKAGE INSPECTION.)
End Of Sie
WATER PUMP
3
1
2
1
19—25
{1.9—2.6, 14—18}
N·m {kgf·m, ft·lbf} 38—51
{3.8—5.3, 28—38}
7.9—10.7 N·m
{80—110 kgf·cm, 69.5—95.4 in·lbf} 38—51
{3.8—5.3, 28—38}
R
R
A6E3620W100
1Hose
2 Water pump
3 Thermostat case