2002 MAZDA 6 drain bolt

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)

F2–58
EXHAUST SYSTEM
Warm Up Oxidation Catalytic Converter Removal Note
1. Support the crossmember using a jack before
removing the crossmember bracket.
2. Loosen the jack and lower the crossmember.
3. Remove the warm up oxidation catalytic
converter.
Water Hose Removal Note
1. Drain the engine coolant.
Turbocharger Removal Note
1. Remove the air pipe and the air hose before
removing the turbocharger. (See F2–36
INTAKE-AIR SYSTEM REMOVAL/
INSTALLATION.)
Exhaust Manifold Removal Note
1. Remove the EGR pipe before removing the exhaust manifold. (See F2–59 EGR VALVE REMOVAL/
INSTALLATION.)
Exhaust Manifold Installation Note
1. Tighten the exhaust manifold installation nuts in
the order shown.
Water Pipe Installation Note
1. Install the connector bolt before installing the
water pipe bracket.
Oil Pipe (Supply) Installation Note
1. Install the connector bolt before installing the
water pipe bracket.
End Of Sie
8 Exhaust manifold insulator
9 Oil pipe (supply)
(See F2–58 Oil Pipe (Supply) Installation Note)
10 Oil pipe (return)
11 Water hose
(See F2–58 Water Hose Removal Note)12 Water pipe
(See F2–58 Water Pipe Installation Note)
13 Turbocharger
(See F2–58 Turbocharger Removal Note)
14 Exhaust manifold
(See F2–58 Exhaust Manifold Removal Note)
(See F2–58 Exhaust Manifold Installation Note)
FRONT
CROSSMEMBER
CROSSMEMBER
BRACKET FRONT
A6E0612W107
87
5436
12
A6E40142003

MANUAL TRANSAXLE
J2–7
J2
NEUTRAL SWITCH REMOVAL/INSTALLATIONA6E5212190102041. Remove the neutral switch.
2. Apply a light coat of silicone sealant to the screw
of the neutral switch.
Sealant
Three Bond product: TB1215
3. Install the neutral switch to the transaxle case.
Tightening torque
22.5—33.3 N·m
{2.29—3.40 kgf·m, 16.6—24.6 ft·lbf}
End Of Sie
MANUAL TRANSAXLE REMOVAL/INSTALLATIONA6E5212010292011. Remove the battery and battery tray.
2. Remove the air cleaner compornent. (See F2–36 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.)
3. Remove the air hose above the transaxle. (See F2–36 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.)
4. Remove the air pipe above the transaxle. (See F2–36 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.)
5. Remove the solenoid bracket.
6. Remove the wheels, tires and splash shields.
7. Remove the under cover.
8. Separate the steering hose.
9. Remove the steering gear and linkage, and pipe assembly installation bolts from the front crossmember, then
suspend the steering gear and linkage with a cable. (See N–8 STEERING GEAR AND LINKAGE (MZR-CD
(RF Turbo)) REMOVAL/INSTALLATION.)
Tightening torque
•Pipe assembly: 7.8—10.8 N·m {79.6—110.0 kgf·cm, 69.1—95.5 in·lbf}
10. Remove the front auto leveling sensor. (See Section T.)
11. Drain the transaxle oil into a suitable container.
12. Remove in the order indicated in the table.
13. Install in the reverse order of removal.
14. Adjust the headlight zeroset. (See Section T.)
15. Add the specified amount of specified transaxle oil. (See J2–4 TRANSAXLE OIL REPLACEMENT.)
16. Warm up the engine and transaxle, inspect for oil leakage, and inspect the transaxle operation.
NEUTRAL
SWITCH
A6E5212W015

K2–104
AUTOMATIC TRANSAXLE
4. Tighten the bolt A.
Tightening torque
A: 93.1—116.6 N·m
{9.50—11.88 kgf·m, 68.66—85.98 ft·lbf}
B: 85.3—116.6 N·m
{8.70—11.88 kgf·m, 62.91—85.98 ft·lbf}
Selector Cable Installation Note
1. Install the selector lever to the manual shaft lever
in such a way that the selector cable does not
bear a load.
Note
•Install the selector lever to the manual shaft
lever with the spring side of the selector
cable end facing the upward of the vehicle.
2. Confirm that the end of the manual shaft lever
sticks out of the end of the selector cable.
End Of SieOIL SEAL REMOVAL/INSTALLATIONA6E571419240201Differential side
1. Drain the ATF. (See K2–80 AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT.)
2. Remove the drive shaft. (See Section M.)
3. Remove and discard the oil seal using a screwdriver.
4. Using the SSTs and a hammer, tap a new oil seal
in evenly until the SSTs contacts the transaxle
case.
5. Coat the lip of the oil seal with ATF.
Caution
•The oil seal is easily damaged by the
sharp edges of the drive shaft splines. Do
not let the splines contact the oil seal.
6. Install the drive shaft. (See Section M.)
7. Add ATF to the specified level. (See K2–80
AUTOMATIC TRANSAXLE FLUID (ATF)
REPLACEMENT.)
8. Carry out the mechanical system test. (See K2–72 MECHANICAL SYSTEM TEST.)
Transfer side
1. Remove the drive shaft and joint shaft. (See Section M.)
2. Remove and discard the oil seal using a screwdriver.
3. Using the SST and a hammer, tap a new oil seal
in evenly until the SST contacts the transfer case.
AC
B
D
A6E5714W138
SELECTOR CABLE
MANUAL SHAFT LEVERSPRING
UPWARD
A6E5714W115
49 G030 79749 L019 016
-1.1—-0.1 mm
{-0.043—-0.004 in}
A6E5714W142
49 B010 001
A6E5714W129

M–68
ELECTRONIC 4WD CONTROL SYSTEM
COUPLING COMPONENT REMOVAL/INSTALLATIONA6E6322271002141. Drain the differential oil into a container.
2. Remove the after silencer, presilencer, and the catalytic converter. (See F1–30 EXHAUST SYSTEM
REMOVAL/INSTALLATION.)
3. Remove the propeller shaft. (See L–5 PROPELLER SHAFT REMOVAL/INSTALLATION.)
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.
6. Add differential oil.
.
Coupling Component Removal Note
1. Support the coupling unit with a transmission jack.
2. Cut away the coupling unit using an oil pan seal
cutter.
Coupling Component Installation Note
Note
•Clean away the old sealant before applying the new sealant.
•Install the coupling unit within 10 minutes after applying sealant.
•Allow the sealant to set at least 30 minutes after installation before filling the differential with the specified
oil.
3
12
SEALANTSEALANT
74.5—104.9
{7.6—10.6, 55.0—77.3}22.6—26.4
{2.4—2.6, 16.7—19.4}
N·m {kgf·m, ft·lbf}
A6E63222106
1 4WD solenoid connector
2Bolt3 Coupling component
(See M–68 Coupling Component Removal Note)
(See M–68 Coupling Component Installation Note)
OIL PAN
SEAL CUTTER
A6E63222107