2002 MAZDA 6 service

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.

B1–1
B1
B1ENGINE [L8, LF, L3]
OUTLINE.............................................................. B1-2
OUTLINE OF CONSTRUCTION........................ B1-2
FEATURES ........................................................ B1-2
ENGINE PERFORMANCE CURVE ................... B1-2
SPECIFICATIONS ............................................. B1-3
OUTLINE.............................................................. B1-4
SUPPLEMENTAL SERVICE INFORMATION ... B1-4
ENGINE................................................................ B1-4
ENGINE REMOVAL/INSTALLATION (4WD) ..... B1-4 FEATURES
SERVICE

B1–4
OUTLINE, ENGINE
SUPPLEMENTAL SERVICE INFORMATIONA6E220202000205•The following changes and/or additions have been made since publication of the Mazda6 Workshop Manual
(1730-1*-02C).
Engine
•Removal/Installation procedure for 4WD has been adopted.
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ENGINE REMOVAL/INSTALLATION (4WD)A6E222401001201
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 injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line
Safety Procedure”.
1. Remove the battery.
2. Remove the battery tray.
3. Remove the radiator.
4. Drain the transaxle oil.
5. Remove the P/S oil pump with the oil hose still connected. Position the P/S oil pump so that it is out of the way.
Use wire or rope to secure.
6. Remove the A/C compressor with the pipes still connected. Position the A/C compressor so that it is out of the
way. Use wire or rope to secure.
7. Remove the propeller shaft from the transfer.
8. Remove the joint shaft. (See M–31 JOINT SHAFT (4WD) DISASSEMBLY/ASSEMBLY.)
9. Remove the front drive shaft (LH) from the transaxle. (See M–39 FRONT DRIVE SHAFT (4WD)
DISASSEMBLY/ASSEMBLY.)
10. Remove the air cleaner, intake air duct, accelerator cable and bracket, and vacuum hose.
11. Remove the ATF hose and selector cable.
12. Remove the vacuum hose and heater hose.
13. Disconnect the fuel hose. (See F1–27 Plastic Fuel Hose Removal Note.) (See F1–28 Plastic Fuel Hose
Installation Note.)
14. Disconnect the wiring harness from the engine side.
15. Remove the three way catalyst (TWC). (See F1–30 EXHAUST SYSTEM REMOVAL/INSTALLATION.)
16. Remove in the order indicated in the table.
17. Install in the reverse order of removal.
18. Start the engine and:
•Inspect for the engine oil, engine coolant, transaxle oil and fuel leakage.
•Verify the ignition timing, idle speed and idle mixture. (See F1–22 IDLE SPEED INSPECTION (4WD).)
19. Perform a road test.
OUTLINE
ENGINE

B2–1
B2
B2ENGINE [MZR-CD (RF Turbo)]
OUTLINE.............................................................. B2-2
OUTLINE OF CONSTRUCTION........................ B2-2
FEATURES ........................................................ B2-2
SPECIFICATIONS ............................................. B2-2
LOCATION INDEX............................................... B2-3
LOCATION INDEX ............................................. B2-3
DRIVE BELT......................................................... B2-4
DRIVE BELT INSPECTION ............................... B2-4
DRIVE BELT REPLACEMENT .......................... B2-4
DRIVE BELT AUTO TENSIONER
INSPECTION .................................................. B2-5
VALVE CLEARANCE........................................... B2-5
VALVE CLEARANCE INSPECTION.................. B2-5
VALVE CLEARANCE ADJUSTMENT ............... B2-6
COMPRESSION PRESSURE.............................. B2-8
COMPRESSION INSPECTION ......................... B2-8
TIMING BELT....................................................... B2-9
TIMING BELT REMOVAL/INSTALLATION ....... B2-9
CYLINDER HEAD GASKET............................... B2-15
CYLINDER HEAD GASKET REPLACEMENT B2-15
FRONT OIL SEAL.............................................. B2-24
FRONT OIL SEAL REPLACEMENT ................ B2-24
REAR OIL SEAL................................................ B2-26
REAR OIL SEAL REPLACEMENT .................. B2-26
ENGINE.............................................................. B2-27
ENGINE REMOVAL/INSTALLATION .............. B2-27
ENGINE DISASSEMBLY/ASSEMBLY............. B2-32 FEATURES
SERVICE

B2–2
OUTLINE
OUTLINE OF CONSTRUCTIONA6E230202000201•MZR-CD (RF Turbo) engine is newly adopted as Mazda6 (GG, GY).
•The construction of MZR-CD (RF Turbo) engine and operation which were newly adopted for the Mazda6 (GG,
GY) are the same as the current Mazda MPV(LW) MZR-CD (RF Turbo) engine model and current Mazda 323
(BJ) RF Turbo engine model except for the following components. (See Mazda MPV Workshop Manual
Supplement 1737-1*-02C.), (See Mazda 323 Workshop Manual Supplement 1633-10-98G.)
—Engine mount
•The construction and the operation of the engine mount for the new Mazda6 (GG, GY) MZR-CD (RF Turbo)
engine model is the same as the current Mazda6 (GG). (See Mazda6 Training Manual 3359-1*-02C)
End Of Sie
FEATURESA6E230202000202Improved engine performance
•Coated pistons have been adopted.
Reduced engine noise and vibration
•An aluminium alloy oil pan upper block has been adopted.
•An eight counter weight crankshaft has been adopted.
•A crankshaft pulley cover has been adopted.
•An engine cover with insulator has been adopted.
•A pendulum type engine mount has been adopted.
Improved serviceability
•A serpentine type drive belt has been adopted.
•An auto tensioner that automatically adjusts the drive belt tension has been adopted.
Improved design
•An engine cover has been adopted.
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SPECIFICATIONSA6E230202000203
End Of Sie
OUTLINE
ItemSpecifications
New Mazda6 (GG, GY) Current Mazda MPV (LW)
MZR-CD (RF Turbo) MZR-CD (RF Turbo)
TypeDiesel, 4-cycle
Cylinder arrangement and number In-line, 4-cylinder
Combustion chamber Direct injection
Valve system SOHC, belt-driven, 16-valve
Displacement (ml {cc, cu in}) 1,998 {1.998, 122.9}
Bore × stroke (mm {in}) 86.0 × 86.0 {3.39 × 3.39}
Compression ratio 18.4
Compression pressure
(kPa {kgf/cm
2, psi} [rpm])3,500 {35.7, 507.7} [250]
Valve timingINOpen BTDC (°)6
Close ABDC (°)30
EXOpen BBDC (°)41
Close ATDC (°)8
Valve clearance
[engine cold]IN (mm {in}) 0.12 —0.18 {0.005—0.007} (0.15±0.03 {0.006±0.0011})
EX (mm {in}) 0.32—0.38 {0.013—0.014} (0.35±0.03 {0.014±0.0011})

D–1
D
DLUBRICATION SYSTEM
OUTLINE................................................................ D-2
OUTLINE OF CONSTRUCTION.......................... D-2
SPECIFICATIONS ............................................... D-2
STRUCTURAL VIEW ...........................................D-4
LUBRICATION SYSTEM........................................ D-5
LUBRICATION FLOW CHART ............................ D-5
OUTLINE................................................................ D-6
SUPPLEMENTAL SERVICE INFORMATION .....D-6
LUBRICATION SYSTEM........................................ D-6
LOCATION INDEX ............................................... D-6
OIL PRESSURE INSPECTION..............................D-7
OIL PRESSURE INSPECTION............................ D-7
ENGINE OIL........................................................... D-8
ENGINE OIL INSPECTION.................................. D-8
ENGINE OIL REPLACEMENT.............................D-8
OIL FILTER............................................................. D-9
OIL FILTER REPLACEMENT ..............................D-9
OIL COOLER.......................................................... D-9
OIL COOLER REMOVAL/INSTALLATION ..........D-9
OIL PAN................................................................ D-10
OIL PAN REMOVAL/INSTALLATION................ D-10 FEATURES
SERVICE

D–6
OUTLINE, LUBRICATION SYSTEM
SUPPLEMENTAL SERVICE INFORMATIONA6E330202000204•The following changes and/or additions have been made since publication of the Mazda6 Workshop Manual
(1730-1*-02C).
Oil pressure
•Inspection procedure has been adopted. (MZR-CD (RF Turbo) engine model)
Engine oil
•Inspection procedure has been adopted. (MZR-CD (RF Turbo) engine model)
•Replacement procedure has been adopted. (MZR-CD (RF Turbo) engine model)
Oil filter
•Replacement procedure has been adopted. (MZR-CD (RF Turbo) engine model)
Oil cooler
•Removal/Installation procedure has been adopted. (MZR-CD (RF Turbo) engine model)
Oil pan
•Removal/Installation procedure has been adopted. (MZR-CD (RF Turbo) engine model)
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LOCATION INDEXA6E333014100201MZR-CD (RF Turbo)
.
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OUTLINE
LUBRICATION SYSTEM
4
3
1
2
A6E3300W003
1 Oil pressure switch
(See D–7 OIL PRESSURE INSPECTION)
2 Oil filter
(See D–9 OIL FILTER REPLACEMENT)3 Oil cooler
(See D–9 OIL COOLER REMOVAL/
INSTALLATION)
4 Oil pan
(See D–10 OIL PAN REMOVAL/INSTALLATION)

E–1
E
ECOOLING SYSTEM
OUTLINE................................................................ E-2
OUTLINE OF CONSTRUCTION.......................... E-2
FEATURES .......................................................... E-2
SPECIFICATIONS ............................................... E-3
COOLING SYSTEM................................................ E-4
STRUCTURAL VIEW ........................................... E-4
COOLING FLOW DIAGRAM ............................... E-5
COOLING FAN .................................................... E-5
OUTLINE................................................................ E-6
SUPPLEMENTAL SERVICE INFORMATION ..... E-6
LOCATION INDEX ............................................... E-6
RADIATOR CAP..................................................... E-7
RADIATOR CAP INSPECTION ........................... E-7
ENGINE COOLANT................................................ E-8
ENGINE COOLANT LEAKAGE INSPECTION .... E-8
THERMOSTAT....................................................... E-9
THERMOSTAT REMOVAL/INSTALLATION ....... E-9
THERMOSTAT INSPECTION ........................... E-10
WATER PUMP...................................................... E-11
WATER PUMP REMOVAL/INSTALLATION...... E-11
FAN MOTOR........................................................ E-12
COOLING FAN MOTOR
REMOVAL/INSTALLATION ............................ E-12
COOLING FAN MOTOR INSPECTION ............. E-13 FEATURES
SERVICE