2002 MAZDA 6 warning

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)

RADIATOR CAP
E–7
E
RADIATOR CAP INSPECTIONA6E361415201201MZR-CD (RF Turbo)
Warning
•Never remove the radiator cap while the engine is running, or when the engine and radiator are
hot. Scalding coolant and steam may shoot out and cause serious injury. It may also damage the
engine and cooling system.
•Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap.
Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while
the pressure escapes.
•When you are sure all the pressure is gone, press down on the cap using the cloth, turn it, and
remove it.
1. Clean the radiator cap negative pressure valve and the sealed part.
2. Inspect the crack or turn over on the sealed part of the radiator cap.
•If not as specified, repace the radiator cap.
3. Fill the SST with the water or the engine coolant to the full level and attach the radiator cap to the SST.
4. Hold the radiator cap downward and apply pressure gradually. Verify that the pressure become held for 10 s
within the specification.
•If the pressure is not held stable within the specification, replace the radiator cap.
Pressure
94—122 kPa
{0.96—1.24 kgf/cm
2, 13.7—17.6 psi}
End Of Sie
RADIATOR CAP
RADIATOR CAP49 9200 145
A6E3614W201

E–8
ENGINE COOLANT
ENGINE COOLANT LEAKAGE INSPECTIONA6E361215201201MZR-CD (RF Turbo)
Warning
•Never remove the radiator cap while the engine is running, or when the engine and radiator are
hot. Scalding coolant and steam may shoot out and cause serious injury. It may also damage the
engine and cooling system.
•Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap.
Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while
the pressure escapes.
•When you are sure all the pressure is gone, press down on the cap using the cloth, turn it, and
remove it.
1. Inspect the coolant level.
2. Remove the radiator cap.
3. Clean the mounting surface of the rediator cap and the upper radiator hose.
4. Connect the SST to the reservoir filler port.
5. Apply specified pressure to the radiator.
Pressure
122 kPa { 1.24 kgf/cm
2, 17.6 psi}
6. Verify that the pressure is held.
•If not, inspect the system for coolant leakage.
—If the coolant leaks from the upper hose
attachment part, replace the upper hose
and the clamp.
—If the coolant leaks from the main body of
the radiator (caulked part), replace the
radiator.
End Of Sie
ENGINE COOLANT
49 9200 145
A6E3612W200

CONTROL SYSTEM
F1–21
F1
CONTROLLER AREA NETWORK (CAN)A6E394018880205•PCM transmit/received the information in the CAN. For detail information of the CAN, see the “MULTIPLEX
COMMUNICATION SYSTEM.” (See T–3 OUTLINE.)
Transmit Information (4WD ATX Model)
•Engine control condition
•Torque reduction inhibit
•Engine speed
•Vehicle Speed
•TP
•Engine torque (without torque reduction)
•Engine torque (with torque reduction)
•Battery reconnection
•Engine loss torque
•ECT
•Travelled distance
•Fuel injection information
•MIL condition
•Generator warning light conditions
•Engine displacement
•Number of cylinders
•Air induction type
•Fuel type and delivery
•Country
•Transmission/axle type
•Tire circumference (front/rear)
Received Information (4WD ATX Model)
From ABS HU/CM, ABS/TCS HU/CM, or DSC HU/CM
•Wheel speed
—Front left, Front right, Rear left, and Rear right
•Travelled distance
•Brake system status
•Torque reduction request
•Brake system configuration
From TCM
•Desired torque
•Upper torque limit
•Turbineshaft speed
•Vehicle speed
•Torque reduction request
•Idle speed up request
•Racing select determination
•MIL indicate request
•Desired gear/selector lever position
•AT warning indicator light condition
•TCC condition
End Of Sie

FUEL SYSTEM
F1–23
F1
FUEL TANK REMOVAL/INSTALLATIONA6E391242110201
Warning
•Repairing a fuel tank that has not been properly steam cleaned can be dangerous. Explosion or
fire may cause death or serious injury. Always properly steam clean a fuel tank before repairing it.
•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.
1. Level the vehicle.
2. Complete the “BEFORE REPAIR PROCEDURE”.
3. Disconnect the negative battery cable.
4. Remove the fuel pump unit. (See F1–26 FUEL PUMP UNIT REMOVAL/INSTALLATION.)
5. Remove the fuel gauge sender sub-unit. (See T–27 Fuel Gauge Sender Sub-Unit.)
6. Siphon the fuel from the service hole.
7. Remove the presilencer. (See F1–30 EXHAUST SYSTEM REMOVAL/INSTALLATION.)
8. Remove the TWC. (See F1–30 EXHAUST SYSTEM REMOVAL/INSTALLATION.)
9. Remove the propeller shaft. (See L–5 PROPELLER SHAFT REMOVAL/INSTALLATION.)
FUEL SYSTEM

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

FUEL SYSTEM
F1–29
F1
FUEL HOSE (FUEL TANK SIDE, TRANSFER HOSE PART) REMOVAL/INSTALLATIONA6E391242692202
Warning
•Repairing a fuel tank that has not been properly steam cleaned can be dangerous. Explosion or
fire may cause death or serious injury. Always properly steam clean a fuel tank before repairing it.
•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.
Removal
1. Complete the “BEFORE REPAIR PROCEDURE”.
2. Disconnect the negative battery cable.
Note
•Squeezing the tab while lightly pushing the fuel hose on the fuel pipe side will make removal easier.
3. Squeeze the tabs on the quick release connector
and disconnect the quick release connector from
the fuel pipe by pulling it straight back.
4. Cover the disconnected quick release connector
and fuel pipe with vinyl sheets or the like to
prevent them from being scratched or
contaminated with foreign material.
Installation
Caution
•If the quick release connector O-ring is damaged, replace the plastic fuel hose. A fuel leak may be
caused.
1. Inspect the fuel hose and fuel pipe sealing surface for damage and deformation, and replace as necessary.
2. Slightly apply clean engine oil to the sealing surface of the fuel pump unit.
3. Align the fuel pipe and quick release connector. Push the quick release connector straight into the fuel pipe
until a click is heard.
4. Lightly pull and push the quick release connector a few times by hand and verify that it can move 2.0—3.0 mm
{0.08—0.11 in} and it is connected securely.
•If the quick release connector does not move at all, verify that O-ring is not damaged and slipped, and
reconnect the quick release connector.
5. Complete the “AFTER REPAIR PROCEDURE”.
End Of Sie
QUICK RELEASE
CONNECTOR TA BDISCONNECT
FUEL PIPE
A6E39122007
A6E39122014

F1–30
EXHAUST SYSTEM
EXHAUST SYSTEM REMOVAL/INSTALLATIONA6E391440000203
Warning
•When the engine and exhaust system are hot, they can badly burn. Turn off the engine and wait
until they are cool before removing the exhaust system.
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
.
EXHAUST SYSTEM
R
37.3—52.0
{3.9—5.3, 28—38} 40—55
{4.1—5.6, 30—40} 43—64
{4.4—6.5, 32—47}
2
1
R
R
R
7
4
36
5
8
RA
SST
29—49 {3.0—4.9, 22—36}SST
R
A
10
38—51 {3.9—5.2, 29—37}N·m {kgf·m, ft·lbf} 38—51 {3.9—5.2, 29—37} 38—51 {3.9—5.2, 29—37} 38—51 {3.9—5.2, 29—37} 7.8—10.8 N·m
{80—110 kgf·cm, 70—95 in·lbf}
7.8—10.8 N·m
{80—110 kgf·cm, 70—95 in·lbf} 7.8—10.8 N·m
{80—110 kgf·cm, 70—95 in·lbf} 29—49 {3.0—4.9, 22—36}
9
A6E39142004