engine MAZDA MODEL 6 HATCHBACK 2004 (in English) Repair Manual

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lConnect the other end to a solid,
stationary, exposed metallic point
(for example, the strut mounting
bolt) away from the discharged
battery (4).
Connect cables in
numerical order and
disconnect in reverse
order.
Discharged
batteryJumper cables
Booster battery
4. Start the engine of the booster vehicle
and run it a few minutes. Then start the
engine of the other vehicle.
5. When finished, carefully disconnect the
cables in the reverse order described in
Step 3.
Push-Starting
WARNING
Towing a Vehicle to Start It:
Towing a vehicle to start it is
dangerous. The vehicle being towed
could surge forward when its engine
starts, causing the two vehicles to
collide. The occupants could be
injured. Never tow a vehicle to start it.
You can't start a vehicle with an automatic
transaxle by pushing it.
CAUTION
You shouldn't push-start a vehicle that
has a manual transaxle. It can damage
the emission control system.
In Case of an Emergency
Emergency Starting
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8Maintenance and Care
How to keep your Mazda in top condition.
Introduction .................................................................................. 8-2
Introduction ............................................................................... 8-2
Scheduled Maintenance ................................................................ 8-3
Scheduled Maintenance ............................................................ 8-3
Owner Maintenance ..................................................................... 8-7
Owner Maintenance Schedule .................................................. 8-7
Owner Maintenance Precautions ............................................... 8-8
Engine Compartment Overview ................................................ 8-9
Engine Oil ............................................................................... 8-10
Engine Coolant ....................................................................... 8-12
Brake/Clutch Fluid .................................................................. 8-15
Power Steering Fluid ............................................................... 8-16
Automatic Transaxle Fluid (ATF) ........................................... 8-17
Washer Fluid ........................................................................... 8-18
Body Lubrication .................................................................... 8-19
Air Filter .................................................................................. 8-20
Wiper Blades ........................................................................... 8-21
Battery ..................................................................................... 8-26
Tires ........................................................................................ 8-27
Light Bulbs ............................................................................. 8-31
Fuses ....................................................................................... 8-38
Appearance Care ........................................................................ 8-43
How to Minimize Environmental Paint Damage .................... 8-43
Exterior Care ........................................................................... 8-45
Interior Care ............................................................................ 8-48
8-1
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qSchedule 1
Maintenance IntervalNumber of months or kilometers (miles), whichever comes first
Months 6 12 18 24 30 36 42 48
×1000 km 12 24 36 48 60 72 84 96
×1000 miles 7.5 15 22.5 30 37.5 45 52.5 60
ENGINE
Drive belts (tension)2.3-liter engine I
3.0-liter engine I I
Engine valve clearance (2.3-liter engine)Audible inspect every 120,000km (75,000miles), if noisy,
adjust
Engine oil R R R R R R R R
Engine oil filter R R R R R R R R
COOLING SYSTEM
Cooling system I I
Engine coolantReplace at first 168,000km (105,000miles) or 60 months ;
after that, every 48,000km (30,000miles) or 24 months
FUEL SYSTEM
Air filter R
Fuel lines and hoses
*1II
Hoses and tubes for emission*1I
IGNITION SYSTEM
Spark plugs Replace every 120,000km (75,000miles)
CHASSIS and BODY
Brake lines, hoses and connections I I
Disc brakes I I I I
Tire (Rotation) Rotate every 12,000km (7,500miles)
Steering operation and linkages I I
Front suspension ball joints I I
Driveshaft dust boots I I
Exhaust system and heat shields Inspect every 72,000km (45,000miles) or 60 months
All locks and hinges L L L L L L L L
AIR CONDITIONER SYSTEM (if installed)
Cabin air filter Replace every 40,000kms (25,000miles) or 24 months
Chart symbols
I:Inspect and repair, clean, adjust, or replace if necessary.
R:Replace
L:Lubricate
Remarks
*1: According to state/provincial and federal regulations, failure to perform maintenance on these items will not
void your emissions warranties. However, Mazda recommends that all maintenance services be performed at
the recommended time or mileage/kilometer period to ensure long-term reliability.
8-4
Maintenance and Care
Scheduled Maintenance
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qSchedule 2
Maintenance IntervalNumber of months or kilometers (miles), whichever comes first
Months 4 8 12 16 20 24 28 32 36 40 44 48
×1000 km 8 16 24 32 40 48 56 64 72 80 88 96
×1000 miles 5 10 15 20 25 30 35 40 45 50 55 60
ENGINE
Drive belts (tension)2.3-liter engine I
3.0-liter engine I I
Engine valve clearance (2.3-liter engine) Audible inspect every 120,000km (75,000miles), if noisy, adjust
Engine oilPuerto Rico Replace every 5,000km (3,000miles) or 3 months
Others R R R R R R RRRRRR
Engine oil filter R R R R R R RRRRRR
COOLING SYSTEM
Cooling system I I
Engine coolantReplace at first 168,000km (105,000miles) or 60 months ;
after that, every 48,000km (30,000miles) or 24 months
Engine coolant level I I I I I I IIIIII
FUEL SYSTEM
Air filterPuerto Rico R R
Others R
Fuel lines and hoses
*1II
Hoses and tubes for emission*1I
IGNITION SYSTEM
Spark plugsUSA Replace every 96,000km (60,000miles)
Others
*2Replace every 120,000km (75,000miles)
ELECTRICAL SYSTEM
Function of all lights I I I I I I IIIIII
CHASSIS and BODY
Brake lines, hoses and connections I I
Brake and clutch fluid level I I I I I I IIIIII
Disc brakesIIII
Tire (Rotation) Rotate every 8,000km (5,000miles)
Tire inflation pressure and tire wear I I I I I I IIIIII
Steering operation and linkages I I
Power steering fluid level I I I I I I IIIIII
Front suspension ball joints I I
Driveshaft dust boots I I
Exhaust system and heat shields Inspect every 72,000km (45,000miles) or 60 months
All locks and hinges L L L L L LLLLLLL
Washer fluid level I I I I I I IIIIII
Maintenance and Care
Scheduled Maintenance
8-5
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Owner Maintenance Schedule
The owner or a qualified service technician should make these vehicle inspections at the
indicated intervals to ensure safe and dependable operation.
Bring any problem to the attention of an Authorized Mazda Dealer or qualified service
technician as soon as possible.
qWhen Refueling
lBrake and clutch fluid level (page 8-15)
lEngine coolant level (page 8-12)
lEngine oil level (page 8-10)
lWasher fluid level (page 8-18)
qAt Least Monthly
Tire inflation pressures (page 8-28)
qAt Least Twice a Year (For Example, Every Spring and Fall)
lAutomatic transaxle fluid level (page 8-17)
lPower steering fluid level (page 8-16)
You can do the following scheduled maintenance items if you have some mechanical
ability and a few basic tools and if you closely follow the directions in this manual.
lAir filter (page 8-20)
lEngine coolant (page 8-12)
lEngine oil (page 8-11)
Maintenance and Care
Owner Maintenance
8-7
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Owner Maintenance Precautions
Improper or incomplete service may result in problems. This section gives instructions only
for items that are easy to perform.
As explained in the Introduction (page 8-2), several procedures can be done only by a
qualified service technician with special tools.
Improper owner maintenance during the warranty period may affect warranty coverage.
For details, read the separate Mazda Warranty statement provided with the vehicle. If
you're unsure about any servicing or maintenance procedure, have it done by an
Authorized Mazda Dealer.
There are strict environmental laws regarding the disposal of waste oil and fluids. Please
dispose of your waste properly and with due regard to the environment.
We recommend that you entrust the oil and fluid changes of your vehicle to an Authorized
Mazda Dealer.
WARNING
Maintenance Procedures:
Performing maintenance work on a vehicle is dangerous if not done properly. You can
be seriously injured while performing some maintenance procedures. If you lack
sufficient knowledge and experience or the proper tools and equipment to do the work,
have it done by a qualified technician.
Running the Engine:
Working under the hood with the engine running is dangerous. It becomes even more
dangerous when you wear jewelry or loose clothing.
Either can become entangled in moving parts and result in injury.
Therefore, if you must run the engine while working under the hood, make certain
that you remove all jewelry (especially rings, bracelets, watches, and necklaces) and
all neckties, scarves, and similar loose clothing before getting near the engine or
cooling fan which may turn on unexpectedly.
Electrical Fan and Engine Inspection:
Inspecting the engine with the ignition switch in the ON position is dangerous. The
cooling fan could come on unexpectedly even when the engine isn't running. You
could be seriously injured by the fan. Turn the ignition switch off and remove the key
from the ignition switch when you inspect the engine.
8-8
Maintenance and Care
Owner Maintenance
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Engine Compartment Overview
Power steering
fluid reservoirWindshield washer
fluid reservoir
Fuse block
Air filter Brake/Clutch fluid reservoir Engine coolant
reservoir
Engine coolant
reservoirAutomatic transaxle fluid-level dipstick
(only for automatic transaxle) Automatic transaxle fluid-level dipstick
(only for automatic transaxle) 2.3-liter engine
3.0-liter engine
Battery Engine oil dipstick
Windshield washer
fluid reservoir
Power steering
fluid reservoir Cooling system capEngine oil-filler cap
Brake/Clutch fluid reservoir
Air filter
Fuse blockBattery
Engine oil-filler cap Engine oil dipstickCooling system cap
Maintenance and Care
Owner Maintenance
8-9
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Engine Oil
qRecommended Oil
Oil container labels provide important
information.
ENGINESGASOLINE
(ILSAC)
FOR
The quality designationSLorILSAC
must be on the label.
5W-20
120 100 80
60 40
20
0 –20
50 40 30
20 10
0 –10
–20 –30
Energy conserving oils are recommended.
A chief contribution they make to fuel
economy is reducing the amount of fuel
necessary to overcome engine friction.
qInspecting Engine Oil Level
1. Be sure the vehicle is on a level
surface.
2. Warm up the engine to normal
operating temperature.
3. Turn it off and wait at least 5 minutes
for the oil to return to the oil pan.
4. Pull out the dipstick, wipe it clean, and
reinsert it fully.
2.3-liter engine
Full
OK
Low
3.0-liter engine
Full
OK
Low
5. Pull it out again and examine the level.
It's OK between MIN and MAX.
But if it's near or below MIN, add
enough oil to bring the level to MAX.
8-10
Maintenance and Care
Owner Maintenance
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CAUTION
Don't add engine oil over MAX. This
may cause engine damage.
6. Make sure the O-ring on the dipstick is
positioned properly before reinserting
the dipstick.
qChanging Engine Oil and Filter
Change engine oil and filter according to
Scheduled Maintenance (page 8-3).
Please act responsibly—protect the
environment and take used oil to a
recycling facility. Ask your dealer or a
service station for information.
WARNING
Handling Used Engine Oil:
Continuous contact with used engine
oil is dangerous. It could cause skin
cancer. Always wash with soap and
water immediately after changing oil
and filter.
CAUTION
Remove any oil splatter from the
exhaust manifold, the exhaust pipe and
the shield. Oil left on these areas will
smoke when the engine is running.
Changing engine oil
WARNING
Checking or Changing Engine Oil:
Hot engine oil is dangerous. If the
engine has been running, the engine
oil becomes very hot. You could be
seriously burned. Don't check or
change the engine oil when the engine
is hot.
1. Warm up the engine for a few minutes
and turn it off. Remove the oil-filler
cap.
2. Remove the drain plug and drain the
oil into a suitable container.
3. Replace the drain plug washer after the
oil has thoroughly drained.
4. Reinstall the plug tightly.
5. Fill the engine with new oil to the
MAX mark on the dipstick.
6. Securely reinstall the oil-filler cap.
2.3-liter engine
Loosen
Tighten
Drain plug Front
Maintenance and Care
Owner Maintenance
8-11
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Drain plug Front LoosenTighten 3.0-liter engine
7. Start the engine and inspect around the
drain plug for leaks.
8. Turn it off and wait 5 minutes for the
oil to return to the oil pan.
Check the oil level and fill to the MAX
mark if necessary.
Oil capacity (General reference only,
refer to Specifications section for
capacities.)
NOTE
lThe indicated engine oil capacities
are for general reference purposes
only. When adding or changing oil,
verify the engine oil level with the
oil dipstick.
lUse only specified engine oil (page
10-3).
Changing oil filter
Because you need a special tool to
retighten the filter, an Authorized Mazda
Dealer should do the work.
Engine Coolant
qInspecting Coolant Level
WARNING
Hot Engine:
A hot engine is dangerous. If the
engine has been running, parts of the
engine compartment can become very
hot. You could be burned. Carefully
inspect the engine coolant in the
coolant reservoir, but do not open it.
Do not use a match or live flame in the
engine compartment. DO NOT ADD
COOLANT WHEN THE ENGINE IS
HOT.
Cooling Fan and EngineInspection:
Inspecting the engine with the ignition
switch in the ON position is
dangerous. The cooling fan could turn
on unexpectedly even when the engine
isn't running. You could be seriously
injured by the fan. Turn the ignition
switch off and remove the key from the
ignition switch when you inspect the
engine.
Cooling System Cap:
When the engine and radiator are hot,
scalding coolant and steam may shoot
out under pressure and cause serious
injury. Don't remove the cooling
system cap when the engine and
radiator are hot.
8-12
Maintenance and Care
Owner Maintenance
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