2002 MAZDA 6 engine oil

TIMING BELT
B2–11
B2
No.3 Engine Joint Bracket Removal Note
1. Suspend the engine using the SST.
2.
Lower Timing Belt Cover Removal Note
Caution
•The timing belt cover could be damaged
easily. Hold the timing belt cover at the
locations indicated in the figure and
remove the crankshaft position sensor
harness slowly.
Timing Belt, Timing Belt Auto Tensioner Removal Note
1. Turn the crankshaft clockwise and align the timing
marks as shown.
Caution
•Forcefully twisting the belt, turning it
inside out, or allowing oil or grease on it
will damage the belt and shorten its life.
•After removing the timing belt, do not
move the crankshaft and/or camshaft
from this position because it can cause
the valve and piston to come into
contact.
2. Remove the timing belt auto tensioner.
3. Mark the timing belt rotation on the belt for proper
reinstallation.
49 E017 5A0
A6E2316W101
A6E2316W102
TIMING MARK TIMING MARK
TIMING MARK
A6E2316W103
25 mm {1.0 in} MIN.
FAULTY FAULTY
FAULTY
FAULTY ROTATION
ARROW
A6E2316W104

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

B2–20
CYLINDER HEAD GASKET
3. Install the rocker arm shaft plane side upward.
Caution
•Because there is little camshaft thrust
clearance, the camshaft must be held
horizontally while it is installed.
Otherwise, excessive force will be
applied to the thrust area, causing burrs
on the thrust receiving area of the
cylinder head journal. To avoid this, the
following procedure must be observed.
4. Tighten the bolts in two or three steps in the order
shown.
Tightening torque
25—30 N·m {2.5—3.1 kgf·m, 18—22 ft·lbf}
5. Apply clean engine oil to the new oil seal.
6. Push the oil seal slightly in by hand.
7. Tap the oil seal into the cylinder head using the
SST and a hammer.
Side Wall Installation Note
1. Apply silicone sealant as shown in the figure.
Thickness
2 mm {0.079 in}
A6E2318W112
9
8
75
4
3
10126
1
2
11
A6E2318W113
49 B010 002
0.5—1.5 mm {0.020—0.059 in}
OIL SEAL CYLINDER
HEAD HAMMER
A6E2318W114
SEALANTSEALANT
A6E2318W115

FRONT OIL SEAL
B2–25
B2
Front Oil Seal Removal Note
1. Cut the oil seal lip using a razor knife.
2. Remove the oil seal using a screwdriver protected
with a rag.
Front Oil Seal Installation Note
1. Apply clean engine oil to the oil seal lip.
2. Push the oil seal slightly in by hand.
3. Tap the oil seal in evenly using the SST and a
hammer. The oil seal must be tapped in until it is
flush with the edge of the oil pump body.
End Of Sie
OIL SEAL LIP
A6E2320W103
RAG
A6E2320W104
49 U027 003
0—0.5 mm {0—0.019 in}
HAMMEROIL PUMP BODY
FRONT OIL SEAL
A6E2320W105

B2–26
REAR OIL SEAL
REAR OIL SEAL REPLACEMENTA6E2322113992011. Remove the flywheel. (See H–5 CLUTCH UNIT REMOVAL/INSTALLATION (A65M-R manual transaxle
models).)
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.
.
Rear Oil Seal Removal Note
1. Cut the oil seal lip using a razor knife.
2. Remove the oil seal using a screwdriver protected
with a rag.
Rear Oil Seal Installation Note
1. Apply clean engine oil to the oil seal lip.
2. Push the oil seal slightly in by hand.
3. Tap the oil seal in evenly using the SST and a
hammer.
End Of Sie
REAR OIL SEAL
1 Rear oil seal
(See B2–26 Rear Oil Seal Removal Note)
(See B2–26 Rear Oil Seal Installation Note)
SST
R
OILOIL1
A6E2322W100
OIL SEAL LIP
A6E2322W101
RAG
A6E2322W102
0—0.5 mm
{0—0.019 in}
HAMMERREAR COVER
REAR OIL SEAL
49 G033 107A
A6E2322W103

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

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