2002 MAZDA 6 engine

N–1
N
NSTEERING SYSTEM
OUTLINE................................................................ N-2
OUTLINE OF CONSTRUCTION.......................... N-2
FEATURES .......................................................... N-2
SPECIFICATIONS ............................................... N-2
STRUCTURAL VIEW ...........................................N-3
OUTLINE................................................................ N-5
SUPPLEMENTAL SERVICE
INFORMATION .................................................N-5
ENGINE SPEED SENSING POWER
STEERING........................................................... N-6
POWER STEERING FLUID INSPECTION ..........N-6
STEERING GEAR AND LINKAGE
(MZR-CD (RF TURBO))
REMOVAL/INSTALLATION ..............................N-8
STEERING GEAR AND LINKAGE (4WD)
REMOVAL/INSTALLATION ............................N-13
POWER STEERING OIL PUMP
(MZR-CD (RF TURBO))
REMOVAL/INSTALLATION ............................N-16
POWER STEERING OIL PUMP
(MZR-CD (RF TURBO))
DISASSEMBLY/ASSEMBLY .......................... N-17 FEATURES
SERVICE

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})

N–6
ENGINE SPEED SENSING POWER STEERING
POWER STEERING FLUID INSPECTIONA6E661432040201Fluid Level Inspection
1. Inspect the power steering fluid level.
•Add fluid to the specified level as necessary.
Fluid specification
ATF M-III or equivalent (e.g. Dexron
®II)
Fluid Leakage Inspection
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.
1. Start the engine and let it idle.
2. Turn the steering wheel fully to the left and right to apply fluid pressure.
Note
•The points where fluid leakage may occur are indicated in the figure.
3. Inspect for fluid leakage.
•If fluid leakage is found, replace the related pipe or hose.
ENGINE SPEED SENSING POWER STEERING
L.H.D.
ATX
MTX
R.H.D.
ATX
MTX MZR-CD (RF Turbo)
EXCEPT MZR-CD (RF Turbo)L.H.D
R.H.D
A6E66142001

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

ENGINE SPEED SENSING POWER STEERING
N–9
N
.
9
6
88
4
4
3
3
6
2
2
10
SST
SST
7
SST
R
R
R
R
R
1
18.6—26.5
{1.9—2.7,
13.8—19.5}
33.0—44.1
{3.3—4.4,
21.7—32.5} 74.4—104.8
{7.6—10.6,
54.9—77.23} 74.4—104.8
{7.6—10.6,
54.9—77.2}
33.0—44.1
{3.3—4.4,
21.7—32.5}
29.4—44.1
{3.0—4.4,
21.7—32.5}
7.8—10.8
{0.8—1.1,
5.8—7.9}
7.8—10.8
{0.8—1.1,
5.8—7.9}93.1—116.6
{9.5—11.8,
68.7—85.9}
93.1—131.3
{9.5—13.3,
68.7—96.8}119.6—154.8
{9.5—15.7,
68.7—114.1}119.6—154.8
{9.5—15.7,
68.7—114.1}93.1—131.3
{9.5—13.3,
68.7—96.8}
N·m {kgf·m, ft·lbf}
7.8—10.8
{0.8—1.1,
5.8—7.9}
5
R
A6E66142003
1 Bolt (intermediate shaft)
(See N–10 Bolt (intermediate shaft) removal note)
(See N–11 Bolt (intermediate shaft) installation
note)
2 Cotter pin
3 Nut (tie-rod end ball joint)
4 Tie-rod end ball joint
(See N–10 Tie-rod end ball joint removal note)
5 Pressure pipe
6 Return hose7 No.1 engine mount center bolt
(See N–10 No.1 engine mount center bolt removal
note)
8 Crossmember bracket
(See N–11 Crossmember bracket removal note)
9 Crossmember component, steering gear and
linkage
(See N–11 Crossmember component, steering gear
and linkage removal note)
10 Steering gear and linkage
(See N–11 Steering gear and linkage installation
note)

N–10
ENGINE SPEED SENSING POWER STEERING
Bolt (intermediate shaft) removal note
1. Mark the pinion shaft and gear housing for proper
installation.
Tie-rod end ball joint removal note
1. Remove the tie rod-nut.
2. Separate the tie-rod end from the steering
knuckle using the SSTs.
No.1 engine mount center bolt removal note
1. Suspend the engine using the SST.
2. Remove the No.1 engine mount center bolt.
MARK
A6E0612W084
49 T028 3A0
A6E0612W085
49 E017 5A0
A6E2316W101

ENGINE SPEED SENSING POWER STEERING
N–11
N
Crossmember bracket removal note
Warning
•Removing the crossmember is dangerous. The crossmember component could fall and cause
serious injury or death. Verify that the jack securely supports the crossmember component before
removing the crossmember bracket.
1. Support the crossmember component with a jack
and remove the nuts.
2. Remove the crossmember bracket.
Crossmember component, steering gear and linkage removal note
Warning
•Removing the crossmember is dangerous. The crossmember component could fall and cause
serious injury or death. Verify that the jack securely supports the crossmember component before
removing the crossmember bracket.
1. Remove the crossmember component, steering gear and linkage.
Steering gear and linkage installation note
1. Loosely tighten bolts.
2. Tighten the mounting bracket bolts to the
specified torque in the order shown.
Tightening torque
74.4—104.8 N·m
{7.6—10.6 kgf·m, 55—77 ft·lbf}
Bolt (intermediate shaft) installation note
1. Align the marks and install the intermediate shaft and bolt.
JACK
A6E7414W036
3
3
1
1
2
2
L.H.D.
R.H.D.
A6E0612W027