engine oil MAZDA 6 2002 Workshop Manual Suplement

REAR SUSPENSION
R–5
R
SUSPENSION CONTROL SYSTEMA6E741601013201Outline
•The self-leveling suspension is a system that adjusts the vehicle height according the amount of vehicle load.
This system will raise the rear of a vehicle, lowered due to a load placed on it, to the designated load level
* after
the vehicle has been driven a certain distance.
•The vehicle height adjustment is performed using a gas-pressurized pump function built into the rear shock
absorber.
•For the vehicle height to return to the designated load level, the vehicle must be driven approx. 5—6 km {3.1—
3.7 miles} in city driving conditions. (Distance will vary due to load and road conditions.)
•A load amount of approx. 140—300 kg {308—660 lb} at the rear axle will cause the vehicle height to be raised,
and any weight over that will prevent the vehicle from returning to the designated load level.
*: Designated load level is defined as the level at which the vehicle is with: a full fuel tank; engine coolant and oil at
specified levels; spare tire, jack and tools in designated positions; and four people, weighing 55 kg {121 lb} each,
riding in the vehicle.
Construction
.
REAR SUSPENSION
5
4
3
6
1
2
A6E74162001
1 Outlet check valve
2 Pump chamber
3 Low-pressure chamber4 High-pressure chamber
5Piston
6 Inlet check valve

R–8
WHEEL ALIGNMENT
FRONT WHEEL ALIGNMENT (WGN)A6E741201015201Specification (Unloaded)*1
2WD
*
1: Engine coolant and engine oil are at specified level. Spare tire, jack and tools are in designated position.
*2: Difference between left and right must not exceed 1 °30'.*3: Distance between wheel center and fender brim is 405 mm {15.94 in} (reference value).
4WD
*
1: Engine coolant and engine oil are at specified level. Spare tire, jack and tools are in designated position.
*2: Difference between left and right must not exceed 1 °30'.
Maximum Steering Angle Adjustment 1. Loosen the tie-rod end locknuts.
2. Remove the steering gear boot clamp.
3. Turn the tie rods to equalize the length L.
Maximum left/right difference3 mm {0.12 in}
4. Turn the tie rods equally to provide the correct maximum steering angle.
5. Tighten the tie-rod end locknuts.
Tightening torque68.6—98.0 N·m {7.00—9.99 kgf·m, 50.6—72.2 ft·lbf}
6. Verify that the boot is not twisted, and install the boot clamp.
7. Adjust the toe-in after adjusting the steering angle.
WHEEL ALIGNMENT
Item Fuel gauge indication
Empty 1/4 1/2 3/4 Full
Maximum steering angle Inner
18 inch wheel specification vehicles: 36
°±3°
Except for above: 39 °±3°
Outer 18 inch wheel specification vehicles: 30
°±3°
Except for above: 31 °±3°
Total toe-in (mm {in}) Tire: 2
±4 {0.08 ±0.16}, Rim inner: 1 ±3 {0.04 ±0.12}
(degree) 0 °11 ′±0°22 ′
Caster angle
*2
(Reference value) normal 3
°30' ±1 ° 3°32' ±1 ° 3°34' ±1° 3°37' ±1° 3°40' ±1 °
elevated*33 °25' ±1 ° 3°27' ±1 ° 3°29' ±1° 3°32' ±1° 3°35' ±1 °
Camber angle
*2
(Reference value) normal -0
°14' ±1 ° -0°15' ±1°
elevated*3-0 °07' ±1 ° -0°08' ±1°
Steering axis inclination
(Reference value) normal 5
°24'
elevated
*35 °15' 5 °16'
Item Fuel gauge indication
Empty 1/4 1/2 3/4 Full
Maximum steering angle Inner 39
°±3°
Outer 31 °±3°
Total toe-in (mm {in}) Tire: 2
±4 {0.08 ±0.16}, Rim inner: 1 ±3 {0.04 ±0.12}
(degree) 0 °11 ′±0°22 ′
Caster angle*
2 (reference value) 3
°25' ±1 ° 3°27' ±1 ° 3°29' ±1 ° 3°32' ±1 ° 3°35' ±1 °
Camber angle*
2(reference value) -0
°07' ±1 ° -0°08' ±1°
Steering axis inclination (reference value) 5 °15' 5 °16'
LEFT AND RIGHT DIFFERENCE
L
LESS THAN 3 mm {0.12 in}
A6E7412W002

WHEEL ALIGNMENT
R–9
R
Total Toe-in Adjustment
1. Center the steering wheel and confirm that the vehicle wheels/tires are pointing straight.
2. Loosen the left and right tie-rod end locknuts and turn the tie-rods equally. Both tie rods are right threaded, so
turning the right tie-rod toward the front of the vehicle and the left toward the rear increases toe-in.
Note
•Turning both tie-rods one complete turn changes toe-in by about 6 mm {0.24 in} (0°36').
3. Tighten the tie-rod end locknuts to the specified torque.
Tightening torque
68.6—98.0 N·m {7.00—9.99 kgf·m, 50.6—72.2 ft·lbf}
4. Verify that the boot is not twisted, and install the boot clamp.
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REAR WHEEL ALIGNMENT (WGN)A6E741201016201Specification (Unloaded)*1
2WD
*
1: Engine coolant and engine oil are at specified level. Spare tire, jack and tools are in designated position.
*2: Difference between left and right must not exceed 1°30'.*3: Distance between wheel center and fender brim is 407 mm {16.02 in} (reference value).
4WD
*
1: Engine coolant and engine oil are at specified level. Spare tire, jack and tools are in designated position.
*2: Difference between left and right must not exceed 1°30'.
Note
•Adjust the toe-in after adjusting the camber.
Camber Adjustment
1. Loosen the cam nut on the lower arm.
2. Turn the adjusting cam bolt to provide the correct
camber angles as indicated.
3. Tighten the cam nut.
Tightening torque
86.2—116.6 N·m {8.80—11.88 kgf·m, 63.58—
85.99 ft·lbf}
ItemFuel gauge indication
Empty 1/4 1/2 3/4 Full
Total toe-in(mm {in}) Tire: 2±4 {0.08±0.16}, Rim inner: 1±3 {0.04±0.12}
(degree) 0°11′±0°22′
Camber angle
*2 normal–0°59′±1°–1°00′±1°–1°02′±1°–1°04′±1°–1°06′±1°
elevated
*3–0°52′±1°–0°53′±1°–0°55′±1°–0°56′±1°–0°58′±1°
Thrust angle 0°±0°48′
ItemFuel gauge indication
Empty 1/4 1/2 3/4 Full
Total toe-in(mm {in}) Tire: 2±4 {0.08±0.16}, Rim inner: 1±3 {0.04±0.12}
(degree) 0°11′±0°22′
Camber angle*
2 –0°55′±1°–0°57′±1°–0°59′±1°–1°01′±1°–1°03′±1°
Thrust angle (degree) 0°±0°48′
Left wheel Right wheel
Positive direction ClockwiseCounter-
clockwise
Negative directionCounter-
clockwiseClockwise
LEFT SIDE
(VIEW FROM
FRONT OF THE
VEHICLE)
ADJUSTING
CAM BOLT
A6E7412W003

U–10
BASIC SYSTEM
A/C UNIT REMOVAL/INSTALLATIONA6E8516611302011. Disconnect the negative battery cable.
2. Discharge the refrigerant from the system.
3. Drain the engine coolant.
4. Remove the dashboard.
5. Remove the theft-deterrent control module.
Caution
•If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and
abnormal noise will occur. Always immediately plug open fittings after removing any refrigeration
cycle parts to keep moisture or foreign material out of the cycle.
6. Remove in the order indicated in the table. Do not allow compressor oil to spill.
.
BASIC SYSTEM
1
L.H.D.R.H.D.
3
2
R
R
N·m {kgf·cm, in·lbf} 6.86—9.80
{70.0—99.9,
60.8—86.7}
R
R
3
2
1
4
A6E85162001
1 Heater hose
2 Cooler pipe No.4 (L.H.D.) or cooler pipe No.5
(R.H.D.)
(See U–13 REFRIGERANT LINES REMOVAL/
INSTALLATION) (R.H.D.)
(See U–13 REFRIGERANT LINES REMOVAL/
INSTALLATION)3 Cooler pipe No.3
(See U–13 REFRIGERANT LINES REMOVAL/
INSTALLATION) (R.H.D.)
(See U–13 REFRIGERANT LINES REMOVAL/
INSTALLATION)
4A/C unit
(See U–11 A/C Unit Installation Note)

BASIC SYSTEM
U–13
U
REFRIGERANT LINES REMOVAL/INSTALLATIONA6E8516614602011. Remove the battery.
2. Discharge the refrigerant from the system.
3. Remove the washer tank.
4. Remove the air cleaner cover, air cleaner element and air cleaner case. (See F2–36 INTAKE-AIR SYSTEM
REMOVAL/INSTALLATION.)
5. Remove the sedimentor.
6. Remove the No.3 engine mount.
7. Remove the water heater unit.
8. Remove the shroud panel.
9. Remove the right splash shield.
Caution
•If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and
abnormal noise will occur. Always immediately plug all open fittings after removing any
refrigeration cycle parts to keep moisture or foreign material out of the cycle.
10. Remove in the order indicated in the table. Do not allow compressor oil to spill.
11. Install in the reverse order of removal.

TD–2
TECHNICAL DATA
ENGINEA6E931001001201
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LUBRICATION SYSTEMA6E931001001202
TECHNICAL DATA
ItemSpecification
Diesel engine
MZR-CD (RF Turbo)
MECHANICAL
Valve clearance
[engine cold](mm {in})IN0.12—0.18
{0.005—0.007}
(0.15±0.03 {0.006±0.0011})
EX0.32—0.38
{0.013—0.014}
(0.35±0.03 {0.014±0.0011})
Compression pressure(kPa {kgf/cm
2, psi}) [rpm]Standard3,500
{35.7, 507.7}
[250]
Minimum3,100
{31.6, 449.4}
[250]
Maximum difference
between cylinders196.1 {1.999, 28.44}
Cylinder head bolt length (mm {in})Standard 159.7—160.3 {6.288—6.311}
Maximum 161.0 {6.338}
Pushing distance of the front oil seal
(from the edge of the oil pump body)(mm {in})0—0.5
{0—0.019}
Pushing distance of the rear oil seal
(from the edge of the rear cover)(mm {in})0—0.5
{0—0.019}
Pushing distance of the camshaft oil seal
(from the edge of the cylinder head)(mm {in})0.5—1.5
{0.020—0.059}
Timing belt auto tensioner rod projection (free length) (mm {in})12.9—14.6
{0.508—0.574}
ItemSpecification
Diesel engine
MZR-CD (RF Turbo)
Oil pressure
(approximate quantity)
[oil temperature: 100°C {212°F}](kPa {kgf/cm
2, psi}) min [rpm]147 {1.5, 21} [1,000],
343 {3.5, 50} [3,000]
Oil capacity
(approximate quantity)Total (dry engine)
5.5 {5.8, 4.8}
(L {US qt, Imp qt})
Oil replacement
4.8 {5.1, 4.2}
(L {US qt, Imp qt})
Oil and oil filter replacement
5.0 {5.3, 4.4}
(L {US qt, Imp qt})

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})

TECHNICAL DATA
TD–5
TD
End Of SieAUTOMATIC TRANSAXLEA6E931001024203
End Of Sie
PROPELLER SHAFTA6E931001024204
End Of Sie
Item Specification
Transaxle typeJA5AX-EL
Line pressure
(kPa {kgf/cm
2, psi})D range, M range (2GR)Idle 290—490 {3.0—5.0, 42—71}
Stall 1,550—1,750 {15.8—17.8, 225—254}
M range (1GR), R positionIdle 550—750 {5.6—7.6, 80—109}
Stall 1,550—1,750 {15.8—17.8, 225—254}
Engine stall speed
D, M (1GR, 2GR), R 2,200—2,600
(rpm)
Time lag (second)N-D Approx. 0.5—1.0
N-R Approx. 0.6—1.0
Transaxle fluid
temperature (TFT)
sensor-20 °C {−4 °F} 15.87—17.54
0 °C {32 °F} 5.73—6.33
20 °C {68 °F} 2.38—2.63
40 °C {104 °F} 1.10—1.22
60 °C {140 °F} 0.56—0.62
80 °C {176 °F} 0.31—0.34
(kilohm) 100 °C {212 °F} 0.18—0.20
120 °C {248 °F} 0.11—0.12
130 °C {266 °F} 0.09—0.10
Input/turbine
speed sensor(ohm) ATF temperature: 20 °C {68 °F} 513—627
Intermediate
sensor(ohm) ATF temperature: 20 °C {68 °F} 513—627
Vehicle
speedometer
sensor(ohm) ATF temperature: 20 °C {68 °F} 513—627
Solenoid valves (ohm)Shift solenoid A 14—18
Shift solenoid B 14—18
Shift solenoid C 14—18
Neutral shift solenoid valve 14—18
Reduction timing solenoid valve 14—18
TCC solenoid valve 12.0—13.2
2-4 brake solenoid valve 2.6—3.2
High clutch solenoid valve 2.6—3.2
Pressure control solenoid 2.6—3.2
Automatic transaxle fluid
(ATF)Type
M-
III or equivalent (e.g. Dexron ® III )
Capacity (Approximate quantity) (L {US qt, Imp qt}) 8.3 {8.8, 7.3}
Transfer oilGrade API service GL-5
Viscosity SAE 80W-90
Capacity (Approximate quantity) (L {US qt, Imp qt}) 0.62 {0.65, 0.54}
Item Specification
Runout limit mm {in} 0.3 {0.01}
Starting torqueN·m
{kgf·cm}0.29—0.78 {3.0—7.9}

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})