2002 MAZDA 6 steering

GI–12
SCHEDULED MAINTENANCE
GIGENE RAL INFORMATION
For Europe (L.H.D. U.K.)
Applied VIN (assumed):
JMZ GG12820# 202316-, JMZ GG12F20# 202316-, JMZ GG12F50# 202316-, JMZ GG14320# 202316-
JMZ GG14820# 202316-, JMZ GG14F20# 202316-, JMZ GG14F50# 202316-, JMZ GG12350# 202316-
JMZ GG14350# 202316-, JMZ GG1232✻
✻✻ ✻
# 202316-, JMZ GG1282✻
✻✻ ✻
# 202316-, JMZ GG12F2✻
✻✻ ✻
# 202316-
JMZ GG12F5✻
✻✻ ✻
# 202316-, JMZ GG1432✻
✻✻ ✻
# 202316-, JMZ GG1482✻
✻✻ ✻
# 202316-, JMZ GG14F2✻
✻✻ ✻
# 202316-
JMZ GG14F5✻
✻✻ ✻
# 202316-, JMZ GY19320# 146118-, JMZ GY19820# 146118-, JMZ GY19F20# 146118-
JMZ GY19F50# 146118-, JMZ GY89370# 146118-, JMZ GY19350# 146118-, JMZ GY1932✻
✻✻ ✻
# 146118-
JMZ GY1982✻
✻✻ ✻
# 146118-, JMZ GY8937✻
✻✻ ✻
# 146118-
Chart symbols:
I : Inspect and clean, repair, adjust, or replace if necessary.
R:Replace
C : Clean
Remarks:
S CHEDULED MAINTE NANCE
•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 expert repairer, we recommend an Authorized Mazda Repairer.
•After the described 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 every 10,000 km
(6,250 miles) or shorter.
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: Replacement of the timing belt is required at every 100,000 km (62,500 miles).
Failure to replace the timing belt may result in damage to the engine.
*6: Replacement of the timing belt is required at every 120,000 km (75,000 miles).
Failure to replace the timing belt may result in damage to the engine.
*7: 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)
*8: 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 12 24 36 48 60 72 84 96 108
×1000 km 20 40 60 80 100 120 140 160 180
×1000 miles 12.5 25 37.5 50 62.5 75 87.5 100 112.5
GASOLINE ENGINE
Engine valve clearance Audible inspect every 120,000 km (75,000 miles), if noisy, adjust
Spark plugs Replace every 100,000 km (62,500 miles)
Air cleaner element *4 R R R
Evaporative system (if installed) I I I
DIESEL ENGINE
Engine valve clearance I I
Engine timing beltFinland, Sweden, Norway*5 Replace every 100,000 km (62,500 miles)
Others*6 Replace every 120,000 km (75,000 miles)
Fuel filter R R R
Fuel injection system I I I I
Air cleaner element *4 C C R C C R C C R
E.G.R. system I I I
GASOLINE and DIESEL ENGINE

SCHEDULED MAINTENANCE
GI–13
GI
For Israel
Applied VIN (assumed):
JMZ GG1235✻
✻✻ ✻
# 202316-, JMZ GG1435✻
✻✻ ✻
# 202316-, JMZ GY19F2✻
✻✻ ✻
# 146118-, JMZ GY19F5✻
✻✻ ✻
# 146118-
Chart symbols:
I : Inspect and clean, repair, adjust, or replace if necessary.
R : Replace
C : Clean
Remarks:
Engine oil *1 R R R R R R R R R
Engine oil filter *1RRRRRRRRR
Drive belts *2 I I I
Cooling system (including coolant level adjustment) I I I I
Engine coolantReplace at first 4 years or 100,000 km (62,500 miles);
after that, every 2 years
Fuel lines and hoses I I I I
Battery electrolyte level and specific gravity IIIIIIIII
Brake fluid *3 R R R R
Brake lines, hoses and connections IIIIIIIII
Parking brake IIIIIIIII
Power brake unit and hoses IIIIIIIII
Disc brakes IIIIIIIII
Power steering fluid, lines, hoses, and connections IIIIIIIII
Steering operation and linkages I I I I
Manual transaxle oil R
Automatic transaxle fluid level I I I
Rear differential oil (for 4WD)
*7*8
Transfer oil (for 4WD)
*8
Front and rear suspension and ball joints I I I I
Driveshaft dust boots I I I I
Exhaust system and heat shields I I
Cabin air filter (if installed) (pollen filter) R R R R
Body condition
(for rust, corrosion and perforation)Inspect annually
Tires (including spare tyre)
(with inflation pressure adjustment)IIIIIIIII Maintenance ItemMaintenance Interval (Number of months or km (miles), whichever comes first)
Months 12 24 36 48 60 72 84 96 108
×1000 km 20 40 60 80 100 120 140 160 180
×1000 miles 12.5 25 37.5 50 62.5 75 87.5 100 112.5
•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 every 10,000 km
(6,250 miles) or shorter.
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.

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.

CYLINDER HEAD GASKET
B2–15
B2
End Of Sie
CYLINDER HEAD GASKET REPLACEMENTA6E231810271201
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”. (See F2–45 Fuel Line Safety Procedures.)
1. Remove the timing belt. (See B2–9 TIMING BELT REMOVAL/INSTALLATION.)
2. Remove the vacuum pump. (See P–13 VACUUM PUMP REMOVAL/INSTALLATION (MZR-CD (RF
TURBO)).)
3. 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. (See N–16 POWER STEERING OIL PUMP (MZR-CD (RF Turbo)) REMOVAL/
INSTALLATION.)
4. Remove the turbocharger. (See F2–57 EXHAUST SYSTEM REMOVAL/INSTALLATION.)
5. Remove all the glow plugs. (See F2–42 GLOW PLUG REMOVAL/INSTALLATION.)
6. Remove in the order shown in the table.
7. Install in the reverse order of removal.
8. Inspect valve clearance. (See B2–5 VALVE CLEARANCE INSPECTION.)
9. Inspect the engine oil level.
•If necessary, add oil. (See D–8 ENGINE OIL INSPECTION.)
10. Inspect the compression. (See B2–8 COMPRESSION INSPECTION.)
11. Start the engine and:
(1) Inspect the pulleys and the drive belt for runout and contact.
(2) Inspect the engine oil, engine coolant, and fuel leakage.
(3) Inspect the idle speed. (See F2–34 IDLE SPEED INSPECTION.)
CYLINDER HEAD GASKET

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

B2–32
ENGINE
No.1 Engine Mount Bracket Installation Note
1. Tighten No.1 engine mount bracket bolt A.
Tightening torque
93.1—116.6 N·m {9.5—11.8 kgf·m,
68.7—85.9 ft·lbf}
2. Tighten No.1 engine mount bracket bolt B.
Tightening torque
93.1—116.6 N·m {9.5—11.8 kgf·m,
68.7—85.9 ft·lbf}
No.1 Engine Mount Rubber Installation Note
1. Tighten through-bolt A on the No.1 engine mount
bracket.
Tightening torque
85.3—116.6 N·m {8.7—11.8 kgf·m,
62.9—85.9 ft·lbf}
2. Tighten through-bolt B on the front crossmember
side.
Tightening torque
93.1—116.6 N·m {9.5—11.8 kgf·m,
68.7—85.9 ft·lbf}
End Of SieENGINE DISASSEMBLY/ASSEMBLYA6E2324010012021. Disconnect the engine and transaxle. (See J2–7 MANUAL TRANSAXLE REMOVAL/INSTALLATION.)
2. Remove the intake-air system. (See F2–36 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.)
3. Remove the exhaust system. (See F2–57 EXHAUST SYSTEM REMOVAL/INSTALLATION.)
4. Remove the generator. (See G–7 GENERATOR REMOVAL/INSTALLATION.)
5. Remove the clutch. (See H–5 CLUTCH UNIT REMOVAL/INSTALLATION (A65M-R manual transaxle
models).)
6. Remove the vacuum pump. (See P–13 VACUUM PUMP REMOVAL/INSTALLATION (MZR-CD (RF
TURBO)).)
7. Remove the P/S oil pump. (See N–16 POWER STEERING OIL PUMP (MZR-CD (RF Turbo)) REMOVAL/
INSTALLATION.)
8. Disassemble in the order indicated in the table.
9. Assemble in the reverse order of disassembly.
A
B
A6E2324W207
A B
A6E2324W201