2002 MAZDA 6 Workshop Manual Suplement

OUTLINE
B1–3
B1
SPECIFICATIONSA6E220202000204
End Of Sie
ItemSpecification
New
Mazda6
(GG, GY)Current
Mazda6
(GG)New
Mazda6
(GG, GY)Current
Mazda6
(GG)New
Mazda6
(GG, GY)Current
Mazda6
(GG)
L8 LF L3
Type Gasoline, 4-cycle
Cylinder arrangement and number In-line, 4-cylinder
Combustion chamber Pentroof
Valve systemDOHC,
Timing chain driven, 16 valves
Displacement (ml {cc, cu in})1,798
{1,798, 109.7}1,999
{1,999, 121.9}2,261
{2,261, 137.9}
Bore × stroke (mm {in})83.0 × 83.1
{3.27 ×3.27}87.5 × 83.1
{3.44 ×3.27}87.5 × 94.0
{3.44 × 3.70}
Compression ratio 10.8:1 10.6:1
Compression pressure(kPa {kgf/cm
2,
psi}) [rpm]1,750
{17.85, 253.8}
[300]1,720
{17.54, 249.5}
[300]1,430
{14.58, 207.4}
[290]
Valve timingINOpenBTDC
(°)40—25
CloseABDC
(°)33 52 62—37
EXOpenBBDC
(°)37 42
CloseATDC
(°)45
Valve
clearance
[engine cold](mm {in})IN 0.22—0.28 {0.0087—0.0110} (0.25±0.03 {0.0098±0.0011})
EX 0.27—0.33 {0.0106 —0.0130} (0.30±0.03 {0.0118±0.0011})

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.
End Of Sie
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

ENGINE
B1–5
B1
6
5
4
3
1
2
74.5—104.9
{7.6—10.6, 55.0—76.6}
N·m {kgf·m, ft·lbf} 85.3—116.6
{8.7—11.8, 62.9—85.9}58.8—80.4
{6.0—8.1, 43.3—58.5} 74.5—104.9
{7.6—10.6,
55.0—76.6}66.6—93.1
{6.8—9.4, 49.2—67.9}
66.6—93.1
{6.8—9.4,
49.2—67.9}58.8—80.4
{6.0—8.1, 43.3—58.5}
8.0—11.5 N·m
{81.6—117.2 kgf·cm,
70.9—101.7 in·lbf}
A6E2213W001
1 No.1 Engine mount rubber
(See B1–6 No.1 Engine Mount Rubber Removal
Note)
(See B1–9 No.1 Engine Mount Rubber Installation
Note)
2 No.1 Engine mount bracket
(See B1–9 No.1 Engine Mount Bracket Installation
Note)
3 No.4 Engine mount bracket and No.4 Engine mount
rubber
(See B1–6 No.4 Engine Mount Bracket and No.4
Engine Mount Rubber Removal Note)
(See B1–8 No.4 Engine Mount Bracket and No.4
Engine Mount Rubber Installation Note)4 Engine ground
5 No.3 Engine joint bracket
(See B1–8 No.3 Engine Joint Bracket Installation
Note)
6 Engine, transaxle

B1–6
ENGINE
No.1 Engine Mount Rubber Removal Note
1. Suspend the engine using the SST.
2. Remove through-bolt A on the No.1 engine mount
bracket side.
3. Loosen through-bolt B on the front crossmember
side until approximately three pitches are
showing.
Note
•Do not remove the No.1 engine mount
rubber from the front crossmember.
No.4 Engine Mount Bracket and No.4 Engine Mount Rubber Removal Note
1. Secure the engine and the transaxle using an
engine jack and attachment as shown.
A6E2215W004
A B
A6E2324W201
A6E2324W202
A6E2324W209

ENGINE
B1–7
B1
2. Remove the SST.
3. Secure the engine and the transaxle using a
hoist.
4. Remove the No.4 engine mount bracket and
engine mount rubber together as a unit.
A6E2215W004
A6E2324W203
A6E2324W204

B1–8
ENGINE
No.3 Engine Joint Bracket Installation Note
1. Tighten the No.3 engine mount bracket stud bolt.
Tightening torque
7.0—13 N·m {71.4—132.5 kgf·cm, 62.0—115.0
in·lbf}
2. Tighten the No.3 engine joint bracket bolt and nut
in the order as shown.
Tightening torque
74.5—104.9 N·m {7.6—10.6 kgf·m, 55.0—76.6
ft·lbf}
No.4 Engine Mount Bracket and No.4 Engine Mount Rubber Installation Note
1. Tighten the No.4 engine mount bracket and No.4
engine mount rubber bolt and nut in the order as
shown.
2. Secure the engine and the transaxle using an
engine jack and attachment as shown.
No.3
ENGINE
MOUNT
BRACKET
STUD
BOLT
A6E2215W011
12
A6E2316W111
Bolt or nut No.Tightening torque
(N·m {kgf·m, ft·lbf})
1, 2, 358.8—80.4 {6.0—8.1, 43.3—58.5}
4, 5, 666.6—93.1 {6.8—9.4, 49.2—67.9}
5431
2
6
A6E2324W206
A6E2324W209

ENGINE
B1–9
B1
3. Remove the hoist and secure the engine and
transaxle using SST.
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 Sie
A6E2215W004
A
B
A6E2324W207
A B
A6E2324W201

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