2002 MAZDA 6 load capacity

H–2
OUTLINE
OUTLINE OF CONSTRUCTIONA6E490216003201•The construction and operation of the clutch is essentially carried over from that of the current MPV (LW)
models, except for the following features. (See Mazda MPV Training Manual 3340-1*-99F.)
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FEATURESA6E490216003202Adoption of the A65M-R manual transaxle models
•The specifications for the A65M-R manual transaxle models have been added.
Increased torque transmission capacity
•Increased clutch cover set load.
Reduced noise
•The flywheel with a damper has been adopted for the A65M-R manual transaxle model.
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SPECIFICATIONSA6E490216003203
Bold frames:New specifications
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SUPPLEMENTAL SERVICE INFORMATIONA6E490216003204•The following changes have been made since publication of the Mazda6 Workshop Manual (1730-1*-02C).
CLUTCH RELEASE CYLINDER
•Removal/installation procedure has been modified.
•Disassembly/assembly procedure has been modified.
CLUTCH UNIT
•Removal/installation procedure has been modified.
•Clutch cover inspection procedure has been modified.
FLYWHEEL
•Flywheel inspection procedure has been modified.
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OUTLINE
Item New Mazda6 (GG, GY) Current MPV (LW)
EngineMZR-CD (RF Turbo)
Manual transaxle type A65M-R
Clutch control Hydraulic
Clutch coverSpring type Diaphragm
Set load (N {kgf, lbf}) 6,550 {668, 1,472}
Clutch discOuter diameter (mm {in}) 239 {9.41}
Inner diameter (mm {in}) 160 {6.30}
Clutch pedalType Suspended
Pedal ratio 5.9 6.41
Full stroke (mm {in}) 140 {5.51} 148 {5.83}
Clutch master cylinder inner diameter (mm {in}) 15.87 {0.625}
Clutch release cylinder inner diameter (mm {in}) 19.05 {0.750}
Clutch fluid type SAE J1703, FMVSS116 DOT-3 or DOT-4
OUTLINE

TECHNICAL DATA
TD–3
TD
Recommended engine oil
Note
•The maintenance intervals on scheduled maintenance table (See GI–8 SCHEDULED MAINTENANCE
TABLE) can only be supported with the use of following oils.
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COOLING SYSTEMA6E931001001203
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FUEL AND EMISSION CONTROL SYSTEMA6E931001001204
*1: Excludes temporary idle speed drop just after the electrical loads are turned on.
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ItemSpecification
Diesel engine
MZR-CD (RF Turbo)
Engine oil GradeAPI CF CD, CE, CF-4
ACEA B1 or B3
B3B3 or B4
Viscosity (SAE) 5W-30 10W-40 5W-30, 10W-30
RemarksMazda genuine Dexelia oil e.g. —
ItemSpecification
Diesel engine
MZR-CD (RF Turbo)
Coolant capacity (L {US qt, Imp qt}) 9.0 {9.5, 7.9}
Radiator capCap valve opening pressure
94—122
{0.96—1.24, 13.7—17.6}
(kPa {kgf/cm
2, psi})
ThermostatType Wax, bottom-bypass
Initial-opening temperature (°C {°F})80—84
{176—183}
Full-opening temperature (°C {°F}) 95 {203}
Full-open lift (mm {in}) More than 8.5 {0.33}
Cooling fan Motor Current (A)4.4—7.4 (Cooling fan motor No.1)
6.3—9.3 (Cooling fan motor No.2)
ItemEngine
L3 (4WD)
Idle speed
*1(rpm) 650—750 (700±50)
ItemEngine
MZR-CD (RF Turbo)
Idle speed (rpm) 725—825 (775±50)
Idle-up speed (rpm) When A/C is operated 725—825 (775±50)
Boost relief pressure (kPa {mmHg, inHg}) Approx. –14.5 {–108, –4.27}

TD–4
TECHNICAL DATA
ENGINE ELECTRICAL SYSTEMA6E931001001205
*1: Back-up current is the constant flow of current present (for the audio unit, clock, PCM, etc.) when the engine
switch is off and with the key removed.
*
2: Must not be 0 A.
*3: Cold area
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CLUTCHA6E931001024201
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MANUAL TRANSAXLEA6E931001024202
ItemSpecification
Diesel engine
MZR-CD (RF Turbo)
BatteryElectrolyte gravity 1.27—1.29
Back-up current*
1(mA) Max.20
Type
95D31L, 115D31L
*3
Test load chart (A) Battery type95D31L (64) 250
115D31L (70) *3320
Slow-charge (A)Battery type
(5-hour rate)95D31L (64) 6.5—8.0
115D31L (70)
*37.0—8.5
Quick-charge
Battery type
(5-hour rate)95D31L (64) 40
(A/30 min)
115D31L (70)
*345
GeneratorStandard voltage (V)Ignition switch ON TerminalBB+
L Approx. 1
SB+
Idle [20°C {68°F}] TerminalB
14.1—14.7 L
S
Generated current*
2
(reference) (A) Engine speed (rpm)1,000 0—80
2,000 0—90
Starter No load testVoltage (V) 11
Current (A) Below 130
Item Specification
Clutch coverDiaphragm
spring fingersDepth mm {in} 0.6 {0.024}
Misalignment mm {in} 0.6 {0.024}
Maximum clearance of flatness of the
pressure platemm {in} 0.3 {0.012}
Flywheel Run out limit mm {in} 0.3 {0.012}
Item Specification
Manual transaxle typeA65M-R
Transaxle controlFloor-shift
Operation systemCable
Shift assistSynchromesh
Gear ratio1st 3.416
2nd 1.944
3rd 1.258
4th 0.902
5th 0.659
Reverse 3.252
Final gear ratio3.588
Transaxle oilGrade API service GL-4 or GL-5
Viscosity (All-season) SAE 75W-90
Capacity (approximate quantity)
2.30 {2.40, 2.00}
(L {US qt, Imp qt})

TD–6
TECHNICAL DATA
FRONT AND REAR AXLEA6E931001018201
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STEERING SYSTEMA6E931001034201
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Item Specification
FRONT DRIVE SHAFT
Shaft length
(Air in boot at atmospheric
pressure)(mm {in})Left sideMZR-CD (RF Turbo): 666.1—676.1 {26.23—26.61}
4WD: 667—677 {26.26—26.65}
Right sideMZR-CD (RF Turbo): 615.9—625.9 {24.25—24.64}
4WD: 631—641 {24.85—25.23}
REAR DRIVE SHAFT (4WD)
Shaft length
(Air in boot at atmospheric
pressure)(mm {in})Left side 805.4—815.4 {31.71—32.10}
Right side 852.4—862.4 {33.56—33.95}
REAR DIFFERENTIAL (4WD)
Pinion height (mm {in})–0.025—0.025 {–0.001—0.001}
Backlash of side gear and differential pinion (mm {in}) 0.1 {0.004} or less
Drive pinion preload (N·m kgf·cm, in·lbf) 1.3—1.8 {13.3—18.3, 11.5—15.9}
Backlash of drive pinion and
ring gear(mm {in})Standard 0.09—0.11 {0.0036—0.0043}
Minimum 0.05 {0.002}
Differential oilGrade API service GL-5
ViscosityAbove –18°C {0°F}: SAE 90
Below –18°C {0°F}: SAE 80
Capacity
(Approximate quantity)(L {US qt, lmp qt}) 1.00 {1.06, 0.88}
ELECTRONIC 4WD CONTROL SYSTEM
Differential oil temperature
sensor(kilohm)0°C {32°F} 91—100
10°C {50°F} 56—61
20°C {68°F} 35—39
30°C {86°F} 23—25
40°C {104°F} 14—17
50°C {122°F} 10—11
60°C {140°F} 7.1—7.9
70°C {158°F} 5.0—5.6
80°C {176°F} 3.6—4.0
4WD solenoid
(Rear differential oil temperature
at 20°C {68°F})(ohm) 1.5—2.0
Item Specification
ENGINE SPEED SENSING POWER STEERING
Power
steering oil
pumpOil pump fluid pressure 2WD (Except MZR-CD (RF Turbo)):
10.80—11.29 {110.2—115.1, 1,567—1,637}
MZR-CD (RF Turbo):
11.31—11.80 {115.4—120.3, 1,641—1,711}
4WD: 10.30—10.79 {105.1—110.0, 1,490—1,564} (MPa {kgf·cm
2, psi})
Gear housing fluid pressure 2WD (Except MZR-CD (RF Turbo)):
10.80—11.29 {110.2—115.1, 1,567—1,637}
MZR-CD (RF Turbo):
11.31—11.80 {115.4—120.3, 1,641—1,711}
4WD: 10.30—10.79 {105.1—110.0, 1,490—1,564} (MPa {kgf·cm
2, psi})
Power
steering
systemFluid type
ATF M-
III or equivalent (e.g. Dexron®II)
Capacity (Approximate quantity) MTX (Except MZR-CD (RF Turbo)): 0.80 {0.85, 0.70}
ATX (Except 4WD): 0.87 {0.92, 0.77}
MZR-CD (RF Turbo): 0.86 {0.91, 0.76}
4WD: 0.89 {0.94, 0.78} (L {US qt, Imp qt})

TD–8
TECHNICAL DATA
Wheel and Tires
*
1: Total weight exceeds 160 g {5.65 oz}.
*2: One balance weight: 60 g {2.12 oz} max. If the total weight exceeds 100 g {3.53 oz} on one side, rebalance after moving the tire around on the rim. Do not use 3 or more balance weights.
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BODY ELECTRICAL SYSTEMA6E931001047201
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Item Specification
Standard tire and wheel
Wheel Size 15
× 6JJ 16 × 7JJ 17 × 7JJ 18 × 7J
Offset (mm {in}) 50 {1.97} 55 {2.17} 55 {2.17}
Pitch circle diameter (mm {in}) 114.3 {4.50} 114.3 {4.50}
Material Steel Aluminum alloy Aluminum alloy
Tire Size 195/65R15 91V 205/55R16 91V
215/45R17
87W 215/45R17
91W
(reinforced) 215/45R18 89W
Air pressure
(kPa {kgf/
cm
2, psi}) Front
Up to 4
persons
220 {2.2, 32} 2WD: 230
{2.3, 33}
4WD: 250 {2.5, 36} 220 {2.2, 32}
Full load 240 {2.4, 35} 2WD: 240
{2.4, 35}
4WD: 250 {2.5, 36} 240 {2.4, 35}
Rear Up to 4
persons
220 {2.2, 32} 2WD: 230
{2.3, 33}
4WD: 250 {2.5, 36} 220 {2.2, 32}
Full load 300 {3.1, 44} 270 {2.8, 39} 270 {2.8, 39}
Remaining tread (mm {in}) 1.6 {0.06} 1.6 {0.06}
Wheel
and
tire Wheel and tire
runout
Radial
direction
1.5 {0.06} max. 1.5 {0.06} max.
(mm {in}) Lateral direction 2.5 {0.10} max. 2.0 {0.08} max. 2.0 {0.08} max.
Wheel imbalance (g {oz}) Knock-type*
2:
9 {0.32} max. Adhesive-type*
1:
13 {0.46} max.
Knock-type*
2:
8 {0.28} max. Adhesive-type*
1:
11 {0.39} max.
Knock-type*
2:
7 {0.25} max. Adhesive-type*
1:
10 {0.35} max.
Knock-type*
2:
6 {0.21} max.
Temporary spare tire
Wheel Size 15
×4T
Offset (mm {in}) 40 {1.57}
Pitch circle diameter (mm {in}) 114.3 {4.50}
Material Steel
Tire Size T115/70 D15 T135/90 D15
Air pressure
(kPa {kgf/cm
2,
psi}) 420 {4.2, 60}
Wheel
and
tire Wheel and tire
runout
Radial
direction
2.0 {0.08} max.
(mm {in}) Lateral direction 2.5 {0.10} max.
Item Specifications
Exterior light bulb capacity (W) High-mount brake
lightWGNIn-vehicle-type 18.4
× 1
Rear spoiler
type 4
× 1 (LED)
Interior light bulb capacity (W) Cargo compartment light 10 × 1