engine MAZDA 6 2002 Suplement User Guide

SCHEDULED MAINTENANCE
GI–11
GI
For GCC
Chart symbols:
I : Inspect and clean, repair, adjust, or replace if necessary.
R : Replace
T:Tighten
C : Clean
Remarks:
End Of Sie
Steering operation & linkages IIIII I
Manual transaxle oil R R
Automatic transaxle fluid level IIIII I
Front & rear suspension & ball joints IIIII
Driveshaft dust boots IIIII
Exhaust system & heat shields IIIII I
Bolts & nuts on seats IIIII I
Body condition (for rust, corrosion & perforation) Inspect annually
Cabin air filter (if installed) R R R R R R R R R R R RMaintenance ItemMaintenance Interval (Number of months or km (miles), whichever comes first)
Months 12 24 36 48 60 72 84 96 108 120 132 144
×1000 km 15 30 45 60 75 90 105 120 135 150 165 180
×1000 miles 9 18 27 36 45 54 63 72 81 90 99 108
•To ensure efficient operation of the engine and all systems related to emission control, the ignition and fuel systems must
be serviced regularly. It is strongly recommended that all servicing related to these systems be done by an authorized
Mazda Dealer.
•After the described period, continue to follow the described maintenance at the recommended intervals.
•Refer below for a description of items marked* in the maintenance chart.
*1: If the vehicle is operated under any of the following conditions, change the engine oil and oil filter more often than
recommended intervals.
a. Driving in dusty conditions.
b. Extended periods of idling or low speed operation.
c. Driving for long period in cold temperatures or driving regularly at short distance only.
*2: Also inspect and adjust the power steering and air conditioner drive belts, if installed.
*3: If the brakes are used extensively (for example, continuous hard driving or mountain driving) or if the vehicle is
operated in extremely humid climates, change the brake fluid annually.
*4: If the vehicle is operated in very dusty or sandy areas, clean and if necessary, replace the air cleaner element more
often than the recommended intervals.
*5: This is a full function check of electrical systems such as lights, wiper and washer systems (including wiper blades),
and power windows.
*6: If the vehicle is operated under any of the following conditions, change the rear differential oil
every 45,000 km (27,000 miles).
a. Towing a trailer or using a car - top carrier
b. Driving in dusty, sandy or wet condition
c. Extended periods of idling or low speed operation
d. Repeated short trips of less than 16 km (10 miles)
*7: If this component has been submerged in water, the oil should be changed.
Maintenance ItemMaintenance Interval (Number of months or km (miles), whichever comes first)
Months 6 121824303642485460667278849096
×1000 km
10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160
×1000 miles6.25 12.5 18.75 25 31.25 37.5 43.75 50 56.25 62.5 68.75 75 81.25 87.5 93.75 100
ENGINE
Engine valve clearance (leaded fuel) I I I I
Drive belts *2IIIIIIIIIIIIIIII
Engine oil *1RRRRRRRRRRRRRRRR
Engine oil filter *1RRRRRRRRRRRRRRRR
COOLING SYSTEM
Cooling system IIIIIIII
Engine coolant Replace every 2 years

GI–12
SCHEDULED MAINTENANCE
GIGENE RAL INFORMATION
For Europe (L.H.D. U.K.)
Applied VIN (assumed):
JMZ GG12820# 202316-, JMZ GG12F20# 202316-, JMZ GG12F50# 202316-, JMZ GG14320# 202316-
JMZ GG14820# 202316-, JMZ GG14F20# 202316-, JMZ GG14F50# 202316-, JMZ GG12350# 202316-
JMZ GG14350# 202316-, JMZ GG1232✻
✻✻ ✻
# 202316-, JMZ GG1282✻
✻✻ ✻
# 202316-, JMZ GG12F2✻
✻✻ ✻
# 202316-
JMZ GG12F5✻
✻✻ ✻
# 202316-, JMZ GG1432✻
✻✻ ✻
# 202316-, JMZ GG1482✻
✻✻ ✻
# 202316-, JMZ GG14F2✻
✻✻ ✻
# 202316-
JMZ GG14F5✻
✻✻ ✻
# 202316-, JMZ GY19320# 146118-, JMZ GY19820# 146118-, JMZ GY19F20# 146118-
JMZ GY19F50# 146118-, JMZ GY89370# 146118-, JMZ GY19350# 146118-, JMZ GY1932✻
✻✻ ✻
# 146118-
JMZ GY1982✻
✻✻ ✻
# 146118-, JMZ GY8937✻
✻✻ ✻
# 146118-
Chart symbols:
I : Inspect and clean, repair, adjust, or replace if necessary.
R:Replace
C : Clean
Remarks:
S CHEDULED MAINTE NANCE
•The ignition and fuel systems are highly important to the emission control system and to efficient engine operation. All
inspections and adjustments must be made by an expert repairer, we recommend an Authorized Mazda Repairer.
•After the described period, continue to follow the described maintenance at the recommended intervals.
•Refer below for a description of items marked* in the maintenance chart.
*1: If the vehicle is operated under any of the following conditions, change the engine oil and oil filter every 10,000 km
(6,250 miles) or shorter.
a. Driving in dusty conditions.
b. Extended periods of idling or low speed operation.
c. Driving for long period in cold temperatures or driving regularly at short distance only.
*2: Also inspect and adjust the power steering and air conditioner drive belts, if installed.
*3: If the brakes are used extensively (for example, continuous hard driving or mountain driving) or if the vehicle is
operated in extremely humid climates, change the brake fluid annually.
*4: If the vehicle is operated in very dusty or sandy areas, clean and if necessary, replace the air cleaner element more
often than the recommended intervals.
*5: Replacement of the timing belt is required at every 100,000 km (62,500 miles).
Failure to replace the timing belt may result in damage to the engine.
*6: Replacement of the timing belt is required at every 120,000 km (75,000 miles).
Failure to replace the timing belt may result in damage to the engine.
*7: If the vehicle is operated under any of the following conditions, change the rear differential oil every 45,000 km (27,000
miles).
a. Towing a trailer or using a car - top carrier
b. Driving in dusty, sandy or wet condition
c. Extended periods of idling or low speed operation
d. Repeated short trips of less than 16 km (10 miles)
*8: If this component has been submerged in water, the oil should be changed.
Maintenance ItemMaintenance Interval (Number of months or km (miles), whichever comes first)
Months 12 24 36 48 60 72 84 96 108
×1000 km 20 40 60 80 100 120 140 160 180
×1000 miles 12.5 25 37.5 50 62.5 75 87.5 100 112.5
GASOLINE ENGINE
Engine valve clearance Audible inspect every 120,000 km (75,000 miles), if noisy, adjust
Spark plugs Replace every 100,000 km (62,500 miles)
Air cleaner element *4 R R R
Evaporative system (if installed) I I I
DIESEL ENGINE
Engine valve clearance I I
Engine timing beltFinland, Sweden, Norway*5 Replace every 100,000 km (62,500 miles)
Others*6 Replace every 120,000 km (75,000 miles)
Fuel filter R R R
Fuel injection system I I I I
Air cleaner element *4 C C R C C R C C R
E.G.R. system I I I
GASOLINE and DIESEL ENGINE

SCHEDULED MAINTENANCE
GI–13
GI
For Israel
Applied VIN (assumed):
JMZ GG1235✻
✻✻ ✻
# 202316-, JMZ GG1435✻
✻✻ ✻
# 202316-, JMZ GY19F2✻
✻✻ ✻
# 146118-, JMZ GY19F5✻
✻✻ ✻
# 146118-
Chart symbols:
I : Inspect and clean, repair, adjust, or replace if necessary.
R : Replace
C : Clean
Remarks:
Engine oil *1 R R R R R R R R R
Engine oil filter *1RRRRRRRRR
Drive belts *2 I I I
Cooling system (including coolant level adjustment) I I I I
Engine coolantReplace at first 4 years or 100,000 km (62,500 miles);
after that, every 2 years
Fuel lines and hoses I I I I
Battery electrolyte level and specific gravity IIIIIIIII
Brake fluid *3 R R R R
Brake lines, hoses and connections IIIIIIIII
Parking brake IIIIIIIII
Power brake unit and hoses IIIIIIIII
Disc brakes IIIIIIIII
Power steering fluid, lines, hoses, and connections IIIIIIIII
Steering operation and linkages I I I I
Manual transaxle oil R
Automatic transaxle fluid level I I I
Rear differential oil (for 4WD)
*7*8
Transfer oil (for 4WD)
*8
Front and rear suspension and ball joints I I I I
Driveshaft dust boots I I I I
Exhaust system and heat shields I I
Cabin air filter (if installed) (pollen filter) R R R R
Body condition
(for rust, corrosion and perforation)Inspect annually
Tires (including spare tyre)
(with inflation pressure adjustment)IIIIIIIII Maintenance ItemMaintenance Interval (Number of months or km (miles), whichever comes first)
Months 12 24 36 48 60 72 84 96 108
×1000 km 20 40 60 80 100 120 140 160 180
×1000 miles 12.5 25 37.5 50 62.5 75 87.5 100 112.5
•The ignition and fuel systems are highly important to the emission control system and to efficient engine operation. All
inspections and adjustments must be made by an Authorized Mazda Dealer.
•After the prescribed period, continue to follow the described maintenance at the recommended intervals.
•Refer below for a description of items marked* in the maintenance chart.
*1: If the vehicle is operated under any of the following conditions, change the engine oil and oil filter every 10,000 km
(6,250 miles) or shorter.
a. Driving in dusty conditions.
b. Extended periods of idling or low speed operation.
c. Driving for long period in cold temperatures or driving regularly at short distance only.
*2: Also inspect and adjust the power steering and air conditioner drive belts, if installed.
*3: If the brakes are used extensively (for example, continuous hard driving or mountain driving) or if the vehicle is
operated in extremely humid climates, change the brake fluid annually.
*4: If the vehicle is operated in very dusty or sandy areas, clean and if necessary, replace the air cleaner element more
often than the recommended intervals.
*5: This is a full function check of electrical systems such as lights, wiper and washer systems (including wiper blades),
and power windows.

GI–14
SC HE DU LE D MAI NTE NA NCE
Mai nten ance I temM ain tenan ce I nter val (Nu mber o f mo nths or km (mil es), whi chever co mes fi rst)
Mo nth s 12 24 36 48 60 72 84 96 108 120 132 144
×1000 km 15 30 45 60 75 90 105 120 135 150 165 180
×1000 mil es 9 18 27 36 45 54 63 72 81 90 99 108
EN GIN E
Engine valve clearanc e Audible inspec t every 120, 000 k m (75, 000 m iles), if nois y, adjus t
Drive belts *2III II II II II I
Engine oil *1RRR RR RR RR RR R
Engine oil filter *1RRR RR RR RR RR R
C OOLI NG SYSTEM
C ooling s ys tem
(I ncluding coolant level adjust ment )IIIIII
Engine coolantReplac e at f irst 4 years or 90,000 km (54,000 miles );
af ter that , ev ery 2 y ears
F UEL SYST EM
Air cleaner element *4 C C C R C C C R C C C R
F uel f ilter R eplace ev ery 105,000 km (63, 000 m iles)
F uel lines and hosesIIIIII
I GNI TI ON SYSTEM
Spark plugs Replac e every 90, 000 k m (54,000 miles )
EM ISSI ON CON TROL SYST EM
Ev aporat ive sy st em I I I
EL ECT RI CA L SYSTEM
Bat ter y elec troly te level and spec ific grav ity I I I I I I I I I I I I
All electrical system *5III II II II II I
C HA S S IS AN D BO DY
Brake lines, hos es and c onnect ions I I I I I I I I I I I I
Brake fluid *3IRI RI RI RI RI R
Parking brake III II II II II I
Power brak e unit and hoses I I I I I I I I I I I I
Disc brakes III II II II II I
Power st eering f luid, lines, hoses , and
c onnect ionsIII II II II II I
St eering operat ion and linkagesIIIIII
M anual t ransax le oil R R
Automatic transaxle fluid level IIIIII
Front and rear s uspens ion and ball joint s I I I I I
D rives haft dus t boots I I I I I
Ex haust s ys tem and heat shields Ins pect every 75, 000 k m (45,000 miles )
Body c ondition (for r ust , corros ion and
perforat ion)Ins pect annually
C abin air filt er (if ins talled) R R R R R R R R R R R R
Tyres (inc luding s pare t yre)
(w ith inflat ion pres sure adjust ment )III II II II II I

SCHEDULED MAINTENANCE
GI–15
GI
For GCC
Applied VIN (assumed):
JM7 GG323✻✻
✻✻✻✻ ✻✻
# 128767-, JM7 GG423✻✻
✻✻✻✻ ✻✻
# 128767-, JM7 GG343✻✻
✻✻✻✻ ✻✻
# 128767-
JM7 GG443✻✻
✻✻✻✻ ✻✻
# 128767-, JM7 GG32F✻✻
✻✻✻✻ ✻✻
# 128767-, JM7 GG42F✻✻
✻✻✻✻ ✻✻
# 128767-
JM7 GG34F✻
✻✻ ✻✻
✻✻ ✻
# 128767-, JM7 GG44F✻
✻✻ ✻✻
✻✻ ✻
# 128767-, JM7 GY49F✻✻
✻✻✻✻ ✻✻
# 101432-
JM7 GY39F✻✻
✻✻✻✻ ✻✻
# 101432-, JM7 GY49F✻
✻✻ ✻
0# 101432-, JM7 GY39F✻
✻✻ ✻
0# 101432-
Chart symbols:
I : Inspect and clean, repair, adjust, or replace if necessary.
R : Replace
T:Tighten
C : Clean
Remarks:
•The ignition and fuel systems are highly important to the emission control system and to efficient engine operation. All
inspections and adjustments must be made by an Authorized Mazda Dealer.
•After the prescribed period, continue to follow the described maintenance at the recommended intervals.
•Refer below for a description of items marked* in the maintenance chart.
*1: If the vehicle is operated under any of the following conditions, change the engine oil and oil filter more often than
recommended intervals.
a. Driving in dusty conditions.
b. Extended periods of idling or low speed operation.
c. Driving for long period in cold temperatures or driving regularly at short distance only.
*2: Also inspect and adjust the power steering and air conditioner drive belts, if installed.
*3: If the brakes are used extensively (for example, continuous hard driving or mountain driving) or if the vehicle is
operated in extremely humid climates, change the brake fluid annually.
*4: If the vehicle is operated in very dusty or sandy areas, clean and if necessary, replace the air cleaner element more
often than the recommended intervals.
*5: This is a full function check of electrical systems such as lights, wiper and washer systems (including wiper blades),
and power windows.
*6: If the vehicle is operated under any of the following conditions, change the rear differential oil
every 45,000 km (27,000 miles).
a. Towing a trailer or using a car - top carrier
b. Driving in dusty, sandy or wet condition
c. Extended periods of idling or low speed operation
d. Repeated short trips of less than 16 km (10 miles)
*7: If this component has been submerged in water, the oil should be changed.
Maintenance ItemMaintenance Interval (Number of months or km (miles), whichever comes first)
Months 6 121824303642485460667278849096
×1000 km
10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160
×1000 miles6.25 12.5 18.75 25 31.25 37.5 43.75 50 56.25 62.5 68.75 75 81.25 87.5 93.75 100
ENGINE
Engine valve clearance Unleaded fuel Audible inspect every 120,000 km (75,000 miles), if noisy, adjust
leaded fuel I I I I
Drive belts *2IIIIIIIIIIIIIIII
Engine oil *1RRRRRRRRRRRRRRRR
Engine oil filter *1RRRRRRRRRRRRRRRR
COOLING SYSTEM
Cooling system IIIIIIII
Engine coolant Replace every 2 years
FUEL SYSTEM
Air cleaner element *4CCRCCRCC
Fuel filter R R R R
Fuel lines and hoses IIIIIIII
IGNITION SYSTEM
Spark plugs Unleaded fuel Replace every 100,000 km (62,500 miles)
Leaded fuel IIIIIIII
EMISSION CONTROL SYSTEM
Idle mixture (leaded fuel) IIIIIIII

SCHEDULED MAINTENANCE
GI–17
GI
Scheduled Maintenance Service (Specific Work Required)
•The specific work required for each maintenance item is listed in the following table. (Please refer to the section
applicable to the model serviced.)
For Europe (L.H.D. U.K.)
Bold frames: New item
Maintenance Item Specific Work Required
ENGINE
Engine valve clearance Measure clearance
Drive beltsInspect for wear, cracks and fraying, and check tension.
Replace drive belt.
Engine timing belt Replace engine timing belt.
Engine oil Replace engine oil and inspect for leakage.
Oil filter Replace oil filter and inspect for leakage.
COOLING SYSTEM
Cooling system
(including coolant level adjustment)Check coolant level and quality, and inspect for leakage.
Engine coolant Replace coolant.
FUEL SYSTEM
Air cleaner elementInspect for dirt, oil and damage.
Clean air cleaner element (by blowing air).
Replace air cleaner element.
Fuel filter Replace fuel filter.
Fuel lines and hoses Inspect for cracks, leakage and loose connection.
Fuel injection system (for MZR-CD (RF Turbo)) Update to injection amount correction with WDS. (see W/M)
IGNITION SYSTEM (FOR GASOLINE)
Spark plugsInspect for wear, damage, carbon, high-tension lead condition and measure
plug gap.
Replace spark plugs.
EMISSION CONTROL SYSTEM
Evaporative system (for gasoline)Check system operation (see W/M), vapor lines, vacuum fitting hoses and
connection.
E.G.R. system (MZR-CR (RF Turbo))Check system operation (see W/M), vacuum fitting hoses and connection.
Update to MAF correction for E.G.R control with WDS. (see W/M)
ELECTRICAL SYSTEM
Battery electrolyte level and specific gravity Check level and specific gravity.
CHASSIS AND BODY
Brake fluidCheck fluid level and inspect for leakage.
Replace brake fluid.
Brake lines, hoses and connectionsInspect for cracks, damage, chafing, corrosion, scars, swelling and fluid
leakage.
Parking brake Check lever stroke.
Power brake unit and hosesCheck vacuum lines, connections and check valve for improper attachment,
air tightness, cracks chafing and deterioration.
Disc brakesTest for judder and noise. Inspect caliper for correct operation and fluid
leakage, brake pads for wear. Check disc plate condition and thickness.
Power steering fluid and linesCheck fluid level and lines for improper attachment, leakage, cracks,
damage, loose connections, chafing and deterioration.
Power steering fluid Check fluid level.
Power steering system and hosesCheck lines for improper attachment, leakage, cracks, damage, loose
connections, chafing and deterioration.
Steering operation and gear housingCheck that the steering wheel has the specified play. Be sure to check for
changes, such as excessive play, hard steering or strange noises.
Check gear housing and boots for looseness, damage and grease/gear oil
leakage.
Steering linkages tie rod ends and armsCheck ball joint, dust cover and other components for looseness, wear,
damage and grease leakage.
Front and rear suspension and ball joints Inspect for grease leakage, cracks, damage and looseness.
Manual transmission/transaxle oilCheck oil level and inspect for leakage.
Replace manual transmission/transaxle oil.
Automatic transmission/transaxle fluid level Check fluid level.

B1–1
B1
B1ENGINE [L8, LF, L3]
OUTLINE.............................................................. B1-2
OUTLINE OF CONSTRUCTION........................ B1-2
FEATURES ........................................................ B1-2
ENGINE PERFORMANCE CURVE ................... B1-2
SPECIFICATIONS ............................................. B1-3
OUTLINE.............................................................. B1-4
SUPPLEMENTAL SERVICE INFORMATION ... B1-4
ENGINE................................................................ B1-4
ENGINE REMOVAL/INSTALLATION (4WD) ..... B1-4 FEATURES
SERVICE

B1–2
OUTLINE
OUTLINE OF CONSTRUCTIONA6E220202000201•The construction and operation of the new Mazda6 (GG, GY) L8, LF, and L3 engine is the same as that of the
current Mazda6 (GG) L8, LF, and L3 engine models except for the following features. (See Mazda6 training
Manual 3359-1*-02C.)
End Of Sie
FEATURESA6E220202000202Modification to the engine performance
•Engine performance curve has been changed. (4WD model)
End Of Sie
ENGINE PERFORMANCE CURVEA6E220202000203
End Of Sie
OUTLINE
1 Engine speed
2Output
3Torque
4 Current 2WD model (L3)
5 New 4WD model (L3)
0
7,000 6,000 5,000 4,000 3,000 2,000 1,000 10 20
30
40
50
60
70
80
90 100
110
120
130270
200
180
160
140
1200
7,000 6,000 5,000 4,000 3,000 2,000 1,000 10 20
30
40
50
60
70
80
90 100
110
120
130270
200
180
160
140
120 205N·m/4,000rpm
119kW/6,500rpm
3
1
2
(rpm) (kw)(N
·m)
5
207N·m/4000rpm
122kW/6500rpm
3
1
2
(rpm) (kw)(N
·m)
4
A6E2202N201

OUTLINE
B1–3
B1
SPECIFICATIONSA6E220202000204
End Of Sie
ItemSpecification
New
Mazda6
(GG, GY)Current
Mazda6
(GG)New
Mazda6
(GG, GY)Current
Mazda6
(GG)New
Mazda6
(GG, GY)Current
Mazda6
(GG)
L8 LF L3
Type Gasoline, 4-cycle
Cylinder arrangement and number In-line, 4-cylinder
Combustion chamber Pentroof
Valve systemDOHC,
Timing chain driven, 16 valves
Displacement (ml {cc, cu in})1,798
{1,798, 109.7}1,999
{1,999, 121.9}2,261
{2,261, 137.9}
Bore × stroke (mm {in})83.0 × 83.1
{3.27 ×3.27}87.5 × 83.1
{3.44 ×3.27}87.5 × 94.0
{3.44 × 3.70}
Compression ratio 10.8:1 10.6:1
Compression pressure(kPa {kgf/cm
2,
psi}) [rpm]1,750
{17.85, 253.8}
[300]1,720
{17.54, 249.5}
[300]1,430
{14.58, 207.4}
[290]
Valve timingINOpenBTDC
(°)40—25
CloseABDC
(°)33 52 62—37
EXOpenBBDC
(°)37 42
CloseATDC
(°)45
Valve
clearance
[engine cold](mm {in})IN 0.22—0.28 {0.0087—0.0110} (0.25±0.03 {0.0098±0.0011})
EX 0.27—0.33 {0.0106 —0.0130} (0.30±0.03 {0.0118±0.0011})

B1–4
OUTLINE, ENGINE
SUPPLEMENTAL SERVICE INFORMATIONA6E220202000205•The following changes and/or additions have been made since publication of the Mazda6 Workshop Manual
(1730-1*-02C).
Engine
•Removal/Installation procedure for 4WD has been adopted.
End Of Sie
ENGINE REMOVAL/INSTALLATION (4WD)A6E222401001201
Warning
•Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel.
•Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line
Safety Procedure”.
1. Remove the battery.
2. Remove the battery tray.
3. Remove the radiator.
4. Drain the transaxle oil.
5. Remove the P/S oil pump with the oil hose still connected. Position the P/S oil pump so that it is out of the way.
Use wire or rope to secure.
6. Remove the A/C compressor with the pipes still connected. Position the A/C compressor so that it is out of the
way. Use wire or rope to secure.
7. Remove the propeller shaft from the transfer.
8. Remove the joint shaft. (See M–31 JOINT SHAFT (4WD) DISASSEMBLY/ASSEMBLY.)
9. Remove the front drive shaft (LH) from the transaxle. (See M–39 FRONT DRIVE SHAFT (4WD)
DISASSEMBLY/ASSEMBLY.)
10. Remove the air cleaner, intake air duct, accelerator cable and bracket, and vacuum hose.
11. Remove the ATF hose and selector cable.
12. Remove the vacuum hose and heater hose.
13. Disconnect the fuel hose. (See F1–27 Plastic Fuel Hose Removal Note.) (See F1–28 Plastic Fuel Hose
Installation Note.)
14. Disconnect the wiring harness from the engine side.
15. Remove the three way catalyst (TWC). (See F1–30 EXHAUST SYSTEM REMOVAL/INSTALLATION.)
16. Remove in the order indicated in the table.
17. Install in the reverse order of removal.
18. Start the engine and:
•Inspect for the engine oil, engine coolant, transaxle oil and fuel leakage.
•Verify the ignition timing, idle speed and idle mixture. (See F1–22 IDLE SPEED INSPECTION (4WD).)
19. Perform a road test.
OUTLINE
ENGINE