2002 MAZDA 6 oil type

K2–106
AUTOMATIC TRANSAXLE
5. Install the control valve body cover.
Tightening torque
6.9—8.8 N·m
{0.70—0.90 kgf·m, 5.1—6.5 ft·lbf}
6. Install the oil hose and oil pipe. (See K2–108 OIL
COOLER REMOVAL/INSTALLATION.)
7. Install the radiator. (See Section E.)
8. Install the shroud panel. (See Section S.)
9. Install the front bumper. (See Section S.)
10. Connect the negative battery cable.
11. Fill the transaxle with the specified ATF. (See K2–
80 AUTOMATIC TRANSAXLE FLUID (ATF)
REPLACEMENT.)
12. Inspect for leakage of ATF from the oil pan or the oil hose connecting points.
13. Carry out the mechanical system test. (See K2–72 MECHANICAL SYSTEM TEST.)
14. Carry out the road test. (See K2–75 ROAD TEST.)
End Of Sie
OIL COOLER FLUSHINGA6E571419900202
Caution
•Power flushing should be performed very carefully when removing the accumulated debris from
the fluid baffle, otherwise the debris cannot be removed or the problem becomes even worse.
Note
•The contaminated cooler line (oil pipes and hoses) and auxiliary cooler (if equipped) must be flushed
completely when ATX is overhauled or replaced.
•Performing back and reverse power flushing two times each does not work because debris or particles
flow out from the feed pipe side of ATX.
Recommended power-flushing manufacturer
Power Flushing
Repair procedure
1. Before power flushing, inspect the hoses/lines and clamps. Power flushing must begin with back flushing
followed by forward flushing to quickly dislodge the restriction. If back flushing is not performed before forward
flushing, the restriction could further reduce the ATF flow through the internal mesh type baffle of the cooler and
flushing will not be effective or possible.
Inspecting oil lines & clamps
1. Be sure to inspect the lines (hoses/pipes) for cuts, crimps (pinched), cracks or any other damage before
reusing them. If any problem exists replace it.
Caution
•Always use new clamps when replacing hoses.
CONTROL
VALVE BODY
COVER
A6E5714W143
Manufacturer Part number Description
Kent Moore J35944-AMAZFlushing kit or
equivalent
OTC 60081Portable torque
converter, oil cooler
cleaner or equivalent

AUTOMATIC TRANSAXLE
K2–111
K2
3. Pivot the screwdriver to pry the tab away from the
tank and repeat the procedure for each tab.
4. Remove the radiator outer tank and O-ring
(gasket) from the core header when all of the tabs
are opened.
Note
•If any header tabs are missing from the core,
replace the radiator.
5. Inspect the gasket surface of the radiator core
header to ensure it is clean and free of foreign
material or damage.
6. Inspect the radiator outer tank for warping. If it is
warped, replace radiator tank.
Radiator Outer Tank (In Tank Oil Cooler) Installation Note
1. Install a new O-ring and ensure it is not twisted.
Note
•The old O-ring must be replaced.
2. Position the radiator tank in the original direction
to the core using care not to scratch the tank
sealing surface with the header tabs.
Note
•Step 3 will set jaw opening to the correct
specification.
3. With the jaws of locking-type pliers (vise grips)
closed and locked, turn the adjusting screw to
position the jaws against the drill bit with the
diameter measured (height) in removal procedure
1. Tighten the lock nut on the adjusting screw
against the handle to lock the adjustment in place.
SCREWDRIVER
A6E5614W074
O-RING
A6E5614W075
LOCKING TYPE PLIERS
(VISE PLIERS)
LOCKNUTADJUSTING
SCREW
DRILL BIT
A6E5614W093

K2–114
TRANSFER
TRANSFER OIL INSPECTIONA6E5718170012011. Park the vehicle on level ground.
2. Remove the PTO heat shield.
3. Remove the filler plug.
4. Verify that the oil is near the brim of the plug port.
•If the oil level is low, add the specified amount
and type of oil through the filler plug hole.
Specified oil grade
API Service GL-5
Specified oil viscosity
SAE 80W-90
5. Apply a sealant to the thread area of filler plug.
Specified sealant
TB1215
6. Install the filler plug.
Tightening torque
9.8—19.6 N·m
{100—199 kgf·cm, 116—175 in·lbf}
7. Install the PTO heat shield. (See K2–116 PTO Heat Shield Installation Note.)
End Of Sie
TRANSFER OIL REPLACEMENTA6E5718170012021. Remove the drain plug.
2. Drain the oil into a suitable container.
3. Apply a sealant to the thread area of drain plug.
Specified sealant
TB1215
4. Install the drain plug.
Tightening torque
9.8—19.6 N·m
{100—199 kgf·cm, 116—175 in·lbf}
5. Remove the PTO heat shield.
6. Remove the filler plug and add the specified amount and type of oil through the filler plug hole until the level
reaches the bottom of the filler plug hole.
Specified oil grade
API Service GL-5
Specified oil viscosity
SAE 80W-90
Capacity (approximate quantity)
0.62 L {0.65 US qt, 0.54 lmp qt}
7. Apply a sealant to the thread area of filler plug.
Specified sealant
TB1215
8. Install the filler plug.
Tightening torque
9.8—19.6 N·m
{100—199 kgf·cm, 116—175 in·lbf}
9. Install the PTO heat shield. (See K2–116 PTO Heat Shield Installation Note.)
TRANSFER
TRANSFER
FILLER PLUG
DRAIN PLUG
A6E5718W101
TRANSFER
FILLER PLUG
DRAIN PLUG
A6E5718W101

OUTLINE
M–3
M
4WD
Bold frames:New specifications
End Of Sie
ItemSpecification
New Mazda6 (GY)(Wagon 4WD)
EngineL3
TransaxleATX
Front axle Bearing type Angular ball bearing
Rear axle Bearing type Angular ball bearing
Front drive shaftJoint typeWheel side Bell joint
Differential side Tripod joint (With free ring)
Shaft diameter (mm {in}) 24.0 {0.94}
Joint shaft Shaft diameter (mm {in}) 29.0 {1.14}
Rear drive shaftJoint typeWheel side Bell joint
Differential side Double offset joint
Shaft diameter (mm {in}) 22.0 {0.87}
Rear and front wheel torque distribution unit Electronic control coupling
Rear differentialReduction gear Hypoid gear
Differential gear Straight bevel gear
Ring gear size (Inches) 6.5
Final gear ratio 2.928
Gears:
Number of teethDrive pinion 14
Ring gear 41
Differential oilTypeGrade API service GL-5
ViscosityAbove –18°C {0°F}: SAE 90
Below –18°C {0°F}: SAE 80
Amount
(Approximate quantity)(L {US qt, lmp qt}) 1.0 {1.1, 0.9}

M–48
REAR DRIVE SHAFT, REAR DIFFERENTIAL
5. Release any trapped air from the boots by
carefully lifting up the small end of each boot with
a cloth wrapped screwdriver.
Caution
•Do not let grease leak.
•Do not damage the boot.
6. Set the drive shaft to the standard length.
Standard length
mm {in}
7. Verify that the drive shaft length is within the standard.
•If not, repeat from Step 5.
End Of Sie
DIFFERENTIAL OIL INSPECTIONA6E6319271002031. Place the vehicle on level ground.
2. Remove the filler plug and washer.
3. Verify that the oil is at the brim of the filler plug
hole.
4. If it is low, add the specified oil.
5. Install a new washer and the filler plug, and
tighten.
Tightening torque
39.2—53.9 N·m {4.0—5.4 kgf·m, 29.0—39.7
ft·lbf}
End Of SieDIFFERENTIAL OIL REPLACEMENTA6E6319271002041. Place the vehicle on level ground.
2. Remove the filler plug.
3. Remove the drain plug and drain the differential
oil into a container.
4. Install a new washer and the drain plug, and
tighten.
Tightening torque
39—53 N·m {4.0—5.4 kgf·m, 29—39 ft·lbf}
5. Add the specified differential oil from the filler plug
until the level reaches the brim of the plug hole.
Specified oil
Type (API service GL-5)
Above -18°C {0°F}: SAE 90
Below -18°C {0°F}: SAE 80
Capacity (Approximate quantity):
1.00 L {1.06 US qt, 0.88 Imp qt}
6. After filling with differential oil, perform oil level inspection.
7. Install a new washer and the drain plug, and tighten.
Tightening torque
39.2—53.9 N·m {4.0—5.4 kgf·m, 29.0—39.7 ft·lbf}
Left side Right side
805.4—815.4
{31.71—32.10}852.4—862.4
{33.56—33.95}A6E6316W007
REAR DIFFERENTIAL
FILLER PLUG
A6E63192101
FILLER PLUG
DRAIN PLUG
A6E63192102

N–2
OUTLINE
OUTLINE OF CONSTRUCTIONA6E660201036201•The construction and operation of the steering system is essentially carried over from that of the current
Mazda6 (GG), except for the following features. (See Mazda6 Training Manual 3359-1*-02C.)
• Due to the addition of the MZR-CD (RF Turbo) engine, a gear-driven power steering oil pump has been
adopted. The operation of the oil pump is the same as that of the current Mazda6 (GG).
• The disassembly/assembly procedures for the steering gear and linkage of the newly equipped MZR-CD (RF
Turbo) engine, wagon and 4WD models are the same as that of the current Mazda6 (GG).
End Of Sie
FEATURESA6E660201036202Improved Steering Feel
• The fluid pressure characteristics of the power steering system has been optimized (MZR-CD (RF Turbo) and
4WD models).
End Of Sie
SPECIFICATIONSA6E660201036203
* : When reservoir tank is at maximum volume
Bold frame:New specifications
End Of Sie
OUTLINE
Item New Mazda6
(GG) (4SD, 5HB) New Mazda6 (GY) (Wagon) Current Mazda6
(GG) (4SD, 5HB)
Drive train 2WD 4WD 2WD
Steering
wheel Outer diameter
370 {14.6}
(mm {in})
Lock-to-lock 18 inch wheel specification vehicles: 2.65
Except for above: 2.75 2.75
(turns)
Steering gear
and linkage Type Rack-and-pinion
Rack stroke 18 inch wheel specification vehicles:
141.6—143.6 {5.57—5.65}
Except for above:146.8—148.8
{5.78—5.85} 146.8—148.8 {5.78—5.85}
(mm {in})
Steering
column and
shaft Shaft type Collapsible
Joint type 2-cross joint
Amount of tilt
45 {1.8}
(mm {in})
Amount of telescope
(If equipped) 50 {2.0}
(mm {in})
Powe r
steering
system Power assist type Engine speed sensing
Pow er
steering
fluid
Ty p e
M-
III or equivalent (e.g. Dexron®II)
Fluid capacity
*
(approximate
quantity) MTX (except MZR-CD (RF Turbo)):
0.80 {0.85, 0.70}
ATX: 0.87 {0.92, 0.77} MZR-CD (RF Turbo):
0.86 {0.91, 0.76} 0.89 {0.94, 0.78}
MTX:
0.80 {0.85, 0.70}
AT X :
0.87 {0.92, 0.77}
(L {US qt, Imp qt})

ENGINE SPEED SENSING POWER STEERING
N–7
N
Fluid Pressure Inspection
1. Assemble the SSTs as shown in the figure.
2. Disconnect the pressure pipe from the oil pump,
and connect the SSTs.
Tightening torque
29.4—44.1 N·m {3.0—4.4 kgf·m, 22—32 ft·lbf}
3. Bleed the air from the system.
4. Open the gauge valve fully.
5. Start the engine and turn the steering wheel fully
left and right to raise the fluid temperature to 50—
60 °C {122—140 °F}.
6. Close the gauge valve completely.
7. Increase the engine speed to 1,000—1,500 rpm
and measure the fluid pressure generated by the
oil pump.
•If the pressure is not within the specification,
repair or replace the oil pump component.
Caution
•If the valve is left closed for more than 5
seconds, the fluid temperature will rise
excessively and adversely affect the oil
pump.
Oil pump fluid pressure
(MPa {kgf/cm
2, psi})
Type Oil pump fluid pressure
2WD
(Except MZR-CD
(RF Turbo))10.80—11.29
{110.2—115.1, 1,567—1637}
MZR-CD
(RF Turbo)11.31—11.80
{115.4—120.3, 1,641—1,711}
4WD10.30—10.79
{105.1—110.0, 1,490—1,564}
49 1232 670B
49 H002 671
A6E0612W101
49 G032 351
49 G032 353
49 G032 352
49 G032 352
49 G032 351
49 G032 353
MZR-CD (RF Turbo)
EXCEPT MZR-CD (RF Turbo)
A6E66142002
THERMOMETER50—60
{122—140 }°
°F
GAUGE
CLOSE VALVE
COMPLETELY
A6E0612W081

N–8
ENGINE SPEED SENSING POWER STEERING
8. Open the gauge valve fully and increase the
engine speed to 1,000—1,500 rpm.
9. Turn the steering wheel fully to the left and right,
then measure the fluid pressure generated at the
gear housing.
•If the pressure is not within the specification,
repair or replace the steering gear
component.
Caution
•If the steering wheel is kept in the fully
turned position for more than 5 seconds,
the fluid temperature will rise excessively
and adversely affect the oil pump.
Gear housing fluid pressure
(MPa {kgf/cm
2, psi})
10. Remove the SSTs. Install and tighten the pressure pipe to the specified torque.
Tightening torque
29.4—44.1 N·m {3.0—4.4 kgf·m, 22—32 ft·lbf}
11. Bleed the air from the system.
End Of Sie
STEERING GEAR AND LINKAGE (MZR-CD (RF TURBO)) REMOVAL/INSTALLATIONA6E661432960201
Caution
•Performing the following procedures without first removing the ABS wheel-speed sensor may
possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the
following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate
place where the sensor will not be pulled by mistake while servicing the vehicle.
L.H.D.
1. Remove the under cover and mud guard. (Left side)
2. Remove the front auto leveling sensor.
3. Separate the stabilizer control link. (shock absorber side)
4. Separate the front lower arm (front and rear) ball joint.
5. Remove the shock absorber bolt. (lower side)
6. Remove in the order indicated in the table.
7. Install in the reverse order of removal.
8. Inspect the toe-in.
9. Adjust the headlight zeroset.
Type Oil pump fluid pressure
2WD
(Except MZR-CD
(RF Turbo))10.80—11.29
{110.2—115.1, 1,567—1637}
MZR-CD
(RF Turbo)11.31—11.80
{115.4—120.3, 1,641—1,711}
4WD10.30—10.79
{105.1—110.0, 1,490—1,564}
THERMOMETER50—60
{122—140 }°
°F
GAUGE
OPEN VALVE
COMPLETELY
A6E0612W080