2002 MAZDA 6 length

B2–12
TIMING BELT
Timing Belt, Timing Belt Auto Tensioner Installation Note
1. Measure the tensioned rod projection length.
•If not as specified, replace the timing belt auto
tensioner.
2. Inspect the timing belt auto tensioner for oil
leakage.
•If not as specified, replace the timing belt auto
tensioner.
Projection (free length)
12.9—14.6 mm {0.508—0.574 in}
Caution
•Placing the timing belt auto tensioner
horizontally can cause oil leakage and
damage the timing belt auto tensioner. Place the timing belt auto tensioner vertically when using a
vise.
3. Verify the thrust of the timing belt auto tensioner
rod in the following order:
•If the timing belt auto tensioner rod is rigid
when it is pushed with a force of
approximately 235 N {24 kgf, 53 Ibf}, push it
down slowly and fix the pin in the hole.
•If there is no resistance on the timing belt auto
tensioner rod and it moves slightly when it is
pushed with a force of approximately 235 N
{24 kgf, 53 Ibf};
(1) Push it down slowly two or three times to the
bottom end of the rod.
(2) If the rod protrudes approximately 8.1 mm
{0.32 in}, verify that there is resistance on the
timing belt auto tensioner rod.
Caution
•To prevent damage to the inside of the
timing belt auto tensioner, do not press
down the timing belt auto tensioner rod
with a force greater than the specified
235 N {24 kgf, 53 lbf}.
Be careful that the rod does not touch the
bottom.
•If the timing belt auto tensioner rod
projection is restored, push it down slowly and fix the pin in the hole.
—If the resistance is not restored, replace the timing belt auto tensoner.
A6E2316W105
PIN
A6E2316W106

CYLINDER HEAD GASKET
B2–19
B2
Cylinder Head Installation Note
1. Measure the length of each cylinder head bolt.
•Replace any that exceeds maximum length.
Length
159.7—160.3 mm {6.288—6.311 in}
Maximum
161.0 mm {6.338 in}
2. Tighten the bolts in two or three steps in the order
shown.
Tightening torque
29 N·m {3.0 kgf·m, 22 ft·lbf}
3. Put a paint mark on each bolt head.
4. Using the marks as a reference, tighten the bolts
by turning each 90°—105° in the sequence
shown.
5. Further tighten each bolt by turning another
90°—105°.
6. Then further tighten each bolt by turning another
90°—105°.
Rocker Arm and Rocker Arm Shaft Installation Note
1. Apply sealant as shown in the figure.
Thickness
2 mm {0.079 in}
2. Install the camshaft caps according to the cap
number.
LENGTH
A6E2318W108
98
7
54
3106
1
2ENGINE
FRONT
A6E2318W109
29 N·m
{3.0 kgf·m, 22 ft·lbf}
SECOND
PAINT MARK
FIRST THIRD90 105
90 105
90 105
—
——
A6E2318W110
SEALANTSEALANT
SEALANTSEALANT
SEALANTSEALANT
A6E2318W111

EMISSION SYSTEM
F2
F2–59
EGR VALVE REMOVAL/INSTALLATIONA6E4016203002011. Disconnect the negative battery cable.
2. R em ove t he a ir c le a ne r. (S ee F 2–36 IN TA K E-A IR SYS TEM RE MOVA L/I NSTA LL AT IO N.)
3 . R em ove t he co m mon r ai l. (S ee F 2–53 SUPPLY PU MP R EM OVA L/IN STA LLAT IO N.)
4. Remove in the order indicated in the table.
.
5. Install in the reverse order of removal.
EGR Valve Removal Note 1. Remove the EGR pipe flare nut.
2. Remove the EGR valve installation nuts.
3. Remove the EGR valve installation stud bolts.
Note• If the thread length of the stud bolt is smaller
than the two nuts used for stud bolt removal,
shave a nut face 1 mm {0.04 in} to make it
thinner and install two nuts as shown in the
figure.
EGR Valve Installation Note 1. Install the EGR valve in the reverse order of removal.
EGR valve installation stud bolt tightening torque
7.8—11.8 N·m {80—120 kgf·cm, 70—104 in·lbf}
End Of Sie
EGR VALVE INSPECTIONA6E401620300202
Note
• Perform the following test only when directed.
1 . R em ove t h e EG R va lv e . ( See F 2–36 IN TA K E-A IR SYS TEM RE MOVA L/I NSTA LL AT IO N.)
2. Inspect for airflow between 1 and 2 when vacuum is applied using a vacuum pump as shown in the
figure.• If not as specified, replace the EGR valve.
Specification
End Of Sie
EMISSION SYSTEM
1EGR valve (See F 2–5 9 EG R V alv e R em oval N ote )
(See F2 –5 9 E G R V alv e In sta llat ion Not e)
2Air pipe (See F2 –3 6 IN TAKE-AIR SYSTEM RE MOVAL/
INS TA LL ATION )
3 EGR pipe
4 EGR water cooler
CME116EW2002
SHAVED NUT FALSE
TRUE
EGR VALVE
INTAKE
MANIFOLDEGR VALVE
INTAKE
MANIFOLD
NORMAL NUTNORMAL NUT
CME116EW2001
Vacuum
kPa {mmHg, inHg} Airflow
Below –25.0 — – 41.6
{ – 188 — – 312, –7.4 — – 12.3} Ye s
Except above No
12
A6E40122024

AUTOMATIC TRANSAXLE
K2–79
K2
Automatic Transaxle Fluid (ATF) Level Inspection
Caution
•The ATF amount varies according to ATF's temperature. Therefore, when checking the ATF level or
replacing the ATF, use a thermometer to measure the temperature then adjust the ATF amount to
the specified level according to the specified temperature.
1. Park the vehicle on level ground.
2. Apply the parking brake and position wheel chocks securely to prevent the vehicle from rolling.
3. Adjust the length of the thermistor probe measure to the measure same as the dipstick and hold the probe with
a paper holder.
4. Insert into the filler tube and measure the
temperature.
5. Warm up the engine until the ATF reaches (60—
70 °C {140—158 °F}).
Caution
•Do not warm the transaxle by performing
stalls. This will damage the torque
converter.
Note
•In some cases it may be necessary to
inspect the ATF in the cool range 15—25 °C
{59—77 °F} before warming up the engine.
6. While depressing the brake pedal, shift the selector lever to each range (P—M), pausing momentarily in each
range.
7. Shift back to P position.
Note
•If the ATF level is too high or too low in hot condition, the following problems may be the cause.
8. While the engine is idling, verify that the ATF level
is in the HOT (65 °C {149 °F}) range. Add the
ATF specified type of, if necessary. (See K2–80
AUTOMATIC TRANSAXLE FLUID (ATF)
REPLACEMENT.)
ATF type
ATF M-III or equivalent (e.g. Dexron
®III)
Capacity (Approximate quantity)
8.3 L {8.8 US qt, 7.3 Imp qt}
End Of Sie
ATF level Condition Possible cause
Too lowLine pressure is
lower than the
specificationAir in transaxle oil passage
due to slipping or damaged
clutch mechanism
Too high ATF is hotATF deteriorated due to
slipping clutch or stuck
valve
A6E5614W003
A6E5714W105

L–2
OUTLINE
OUTLINE OF CONSTRUCTIONA6E610225002201•The Mazda6 4WD model has been adopted for European specs.
End Of Sie
FEATURESA6E610225002203Reduced noise and vibration
•The four-joint type propeller shaft with two bearing support has been adopted for the Mazda6 4WD model.
End Of Sie
SPECIFICATIONSA6E610225002202
End Of Sie
OUTLINE
Item Specification
Length (mm)L1 720.5
L2 735.0
L3 503.0
Outer diameter (mm)D1 57.0
D2 57.0
D3 57.0
Joint type Tripod joint, Universal joint
Tripod joint Double offset joint
D3 D2 D1
L3 L2 L1
A6J6110W001

FRONT DRIVE SHAFT
M–37
M
Dynamic Damper Assembly Note
1. Install the dynamic damper as shown in the figure.
Standard length
334.7—340.7 mm {13.2—13.4 in}
2. Install the new boot band onto the dynamic
damper.
Boot Assembly Note
Note
•The wheel side and transaxle side boots are different.
1. Fill the boot (wheel side) with the specified grease.
Caution
•Do not touch grease with your hand. Apply it from the tube to prevent foreign matter from entering
the boot.
Grease amount
105—125 g {3.71—4.40 oz}
2. With the splines of the shaft still wrapped in tape from disassembly, install the boot.
3. Remove the tape.
Cage, Inner Ring, Balls, Snap Ring Assembly Note
1. Align the marks and install the balls and cage to
the inner ring in the direction shown in the figure.
Caution
•Install the cage with the offset facing the
snap ring groove. If incorrectly installed,
the drive shaft may become disengaged.
2. Install a new snap ring.
Outer Ring, Clip Assembly Note
1. Fill the outer ring and boot (transaxle side) with the specified grease.
Caution
•Do not touch grease with your hand. Apply it from the tube to prevent foreign matter from entering
the boot.
Grease amount
120—140 g {4.24—4.93 oz}
2. Align the marks, and install the outer ring on to the shaft.
3. Install a new clip.
4. Install the boot.
5. Set the drive shaft to the standard length.
DYNAMIC DAMPER
A6E6316W006
CAGEBALLS
SNAP RING
GROOVEINNER
RING
MARK
A6E6316W011

M–38
FRONT DRIVE SHAFT
Standard length
mm {in}
6. Release any trapped air from the boots by
carefully lifting up the small end of each boot with
a cloth wrapped screwdriver.
Caution
•Be careful not to allow the grease to leak.
•Do not damage the boot.
7. Verify that the drive shaft length is within the
specification.
•If not, repeat from Step 5.
Boot Band (Transaxle Side) Assembly Note
1. Fold the band in the direction opposite to the
forward revolving direction of the drive shaft and
use pliers to pull it tight.
2. Lock the end of the band by bending the locking
clips.
Caution
•Install the band into the groove securely.
Boot Band (Wheel Side) Assembly Note
1. Adjust clearance A by turning the adjusting bolt of
the SST.
Clearance A
2.9 mm {0.11 in}
2. Crimp the wheel side small boot band using the
SST. Verify that clearance B is within the
specification.
•If clearance B is more than the specification,
reduce clearance A of the SST and crimp the
boot again.
•If clearance B is less than the specification,
replace the boot band, increase clearance A
of the SST, and crimp the new boot.
Clearance B
2.4—2.8 mm {0.095—0.110 in}
3. Verify that the boot band does not protrude from
the boot band installation area.
•If it does, replace the boot band and repeat Steps 2 and 3.
Left side Right side
666.3—676.3
{26.24—26.62}615.6—625.6
{24.24—24.62}
A6E6316W007
A6E6316W008
A
49 T025 001
ADJUSTING BOLT
A6E0350W012
B
49 T025 001
A6E0350W013

FRONT DRIVE SHAFT
M–41
M
Dynamic Damper Assembly Note
1. Install the dynamic damper as shown in the
figure.
Standard length
Left side: 281.7—287.7 mm {11.10—11.32 in}
Right side: 334.7—340.7 mm {13.2—13.4 in}
2. Install a new boot band onto the dynamic damper.
Boot Assembly Note
Note
•The wheel side and transaxle side boots are different.
1. Fill the boot (wheel side) with the specified grease.
Caution
•Do not touch grease with your hand. Apply it from the tube to prevent foreign matter from entering
the boot.
Grease amount
90—110 g {3.18—3.88 oz}
2. With the splines of the shaft still wrapped in tape from disassembly, install the boot.
3. Remove the tape.
Tripod Joint, Snap Ring Assembly Note
1. Align the marks and install the tripod joint using a
bar and a hammer.
Caution
•Do not damage the roller.
2. Install the new snap ring using snap-ring pliers.
Caution
•Be sure the snap ring engages correctly
in the groove of the shaft.
Outer Ring Assembly Note
1. Fill the outer ring and boot (transaxle side) with the specified grease.
Caution
•Do not touch grease with your hand. Apply it from the tube to prevent foreign matter from entering
the boot.
Grease amount
Left side: 185—205 g {6.53—7.23 oz}
Right side: 195—215 g {6.88—7.58 oz}
2. Install the outer ring.
3. Set the drive shaft to the standard length.
DYNAMIC DAMPER
A6E6316W006
MARK
A6E0313W051