oil MAZDA 6 2002 Workshop Manual Suplement

EXTERIOR ATTACHMENT
S–11
S
EXTRACTOR CHAMBER REMOVAL/INSTALLATIONA6E772851920201WGN
1. Remove the rear bumper.
2. Remove the left side trunk side trim.
3. Squeeze the clips with your fingers and remove
the extractor chamber from the vehicle side.
4. Install in the reverse order of removal.
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REAR SPOILER REMOVAL/INSTALLATIONA6E772851920202WGN
1. Disconnect the negative battery cable.
2. Remove the liftgate upper trim. (SeeS–23 LIFTGATE UPPER TRIM REMOVAL/INSTALLATION)
3. Remove the bolts and nuts.
4. Disconnect the high-mount brake light connector.
5. Disengage the pin A from the body, then remove
the rear spoiler.
6. Install in the reverse order of removal.
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ROOF RAIL REMOVAL/INSTALLATIONA6E7728517202011. Remove the headliner.
2. Remove the nuts.
3. Remove the roof rail.
4. Install in the reverse order of removal.
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EXTERIOR ATTACHMENT
EXTRACTOR
CHAMBER CLIP AA
A
A6E77281103
BOLT REAR SPOILER
HIGH-MOUNT BRAKE
LIGHT CONNECTOR
NUTPIN A
AA
N·m {kgf·cm, in·lbf} 7.8—9.8
{79—100, 68.8—86.7} 8.9—12.7 {90—130, 79—112}
A6A7728W104
ROOF RAIL
6.9—9.8 N·m
{70—100 kgf·cm,
60.8—86.7 in·lbf}NUT
A6A7728W105

TRIM
S–23
S
TRUNK END TRIM REMOVAL/INSTALLATIONA6E774468890201WGN
1. Pull the trunk end trim upward, then disengage
clips A and pins B from the body.
2. Remove the trunk end trim.
3. Install in the reverse order of removal.
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LIFTGATE UPPER TRIM REMOVAL/INSTALLATIONA6E774468930201WGN
Without rear spoiler
Caution
•Removing the liftgate upper trim by pulling on the middle section of the trim could damage the
high-mount brake light. When removing the trim, be sure to pull on the side edges of the trim only.
1. Pull the liftgate upper trim on the side edges
towards you, then disengage pins A from the
body.
2. Pull the middle section of the trim towards you
and disengage clips B and pin C from the body.
3. Remove the liftgate upper trim.
4. Install in the reverse order of removal.
With rear spoiler
1. Pull the liftgate upper trim toward you, then
disengage the pin A, C and clip B from the body.
2. Remove the liftgate upper trim.
3. Install in the reverse order of removal.
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AB
A
A
B
A
A
A B
TRUNK END TRIM
PIN B
CLIP A
A6A7744W108
AC B
AB
CLIP B
PIN A LIFTGATE UPPER TRIM
PIN C
A6A7744W109
ABAB
C
CLIP BPIN C LIFTGATE UPPER TRIM
PIN A
A6A7744W110

T–8
EXTERIOR LIGHTING SYSTEM, INTERIOR LIGHTING SYSTEM
OUTLINEA6E811201052201•In-vehicle-type high-mount brake light and rear spoiler type high-mount brake light have been adopted. (WGN)
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STRUCTURAL VIEWA6E811201052202
.
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STRUCTURAL VIEWA6E811401052201
.
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EXTERIOR LIGHTING SYSTEM
2
1
A6E8112T101
1 High-mount brake light (in-vehicle-type)2 High-mount brake light (rear spoiler type)
INTERIOR LIGHTING SYSTEM
FRONT
1
A6E81141001
1 Cargo compartment light

EXTERIOR LIGHTING SYSTEM, INTERIOR LIGHTING SYSTEM
T–21
T
Rear spoiler type
1. Disconnect the negative battery cable.
2. Remove the rear spoiler.
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.
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CARGO COMPARTMENT LIGHT REMOVAL/INSTALLATIONA6E8114514412011. Disconnect the negative battery cable.
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.
Lens Removal Note
1. Insert a tape-wrapped flathead screwdriver into
the service hole.
2. Twist the flathead screwdriver as indicated by the
arrow to remove the lens.
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1Bolt
2 Cover
3 Connector
4 High-mount brake light
4
12
3
A6J81121004
INTERIOR LIGHTING SYSTEM
1Lens
(See T–21 Lens Removal Note)
2 Cargo compartment light bulb
3 Screw (if equipped)
4 Cargo compartment light
5 Connector
12
33
4
5
A6J81141102
SERVICE HOLE
A6A8114W104

T–34
AIR BAG SYSTEM
Side Air Bag Sensor Handling
•Disconnecting the side air bag sensor connector or removing the side air bag sensor with the ignition
switch at ON position can cause the side air bag sensor to operate and the side air bag module to
deploy, which may seriously injure you. Before disconnecting the side air bag sensor connector or
removing the side air bag sensor, always turn the ignition switch to LOCK position, then disconnect the
negative battery cable and wait for more than 1 minute to allow the backup power supply of the SAS
control module to deplete its stored power.
•If the side air bag sensor is subjected to shock or the sensor is disassembled, the side air bag module
may operate (deploy) suddenly and cause injury, or it may fail to operate normally and cause a serious
accident. Do not subject the side air bag sensor to shock or disassemble the sensor.
•Because a sensor is built into the side air bag sensor, when the side air bag module operates (deploys),
there may be a problem, such as an internal malfunction, even if there is not any external damage or
deformation. If the side air bag sensor is reused, the side air bag module may fail to operate normally
and cause a serious injury. Always replace the side air bag sensor with a new part. The side air bag
sensor cannot be bench-checked or self-checked.
Pre-tensioner Seat Belt Inspection
•Inspecting a pre-tensioner seat belt using an
ohmmeter can deploy the pre-tensioner seat
belt, which can cause serious injury. Do not
use an ohmmeter to inspect the pre-tensioner
seat belt. Always use the on-board diagnostic
to diagnose the pre-tensioner seat belt for
malfunctions.
Component Handling
•Oil, grease, water, etc on components may cause the air bag modules and pre-tensioner seat belts to
fall to deploy in an accident, which may cause serious injury. Do not allow oil, grease, water, etc., on
components.
•Inserting a screwdriver, etc., into the
connector of an air bag module or a pre-
tensioner seat belt may damage the connector
and cause the air bag module or the pre-
tensioner seat belt to deploy improperly,
which may cause serious injury. Do not insert
any foreign objects into the connector.
Component Reuse
•Even if an air bag module or a pre-tensioner seat belt does not deploy in a collision and does not have
any external signs of damage, it may have been damaged internally, which may cause improper
operation. Improper operation may cause serious injury. Always self-check the undamaged air bag
module or pre-tensioner seat belt to determine whether it can be reused.
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A6E8130W025
A6E8130W023

U–2
OUTLINE
OUTLINE OF CONSTRUCTIONA6E850201038201•The construction and operation of the air conditioner system is essentially carried over from that of the previous
Mazda6 (GG) model, except for the following features. (See Mazda6 Training Manual 3359-1*-02C.)
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FEATURESA6E850201038202Improved Comfort
•The water heater system has been adopted. (For MZR-CD (RF Turbo) European (L.H.D.) specs.)
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SPECIFICATIONSA6E850201038203Manual Air Conditioner
OUTLINE
ItemSpecification
L3, L8, LF MZR-CD (RF Turbo)
Heating capacity (kW {kcal/h}) 4.400 {3,784}4.400 {3,784} (L.H.D.)
5.120 {4,403} (R.H.D.)
Airflow volume
(during heater operation)Blower motor
(m
3/h)310 (L.H.D.)
300 (R.H.D.)
Electricity consumption
(during heater operation)Blower motor (W) 184
Cooling capacity (kW {kcal/h}) 4.200 {3,612}
Airflow volume (during air
conditioner operation)Blower motor
(m
3/h)460
Electricity consumption
(during air conditioner
operation)Blower motor (W) 225
Magnetic clutch (W) 46 45
Fan type Blower motor Sirocco fan
RefrigerantType R-134a
Regular amount
(approximate quantity)470 {16.6} (L.H.D.)
430 {15.2} (R.H.D.)
(g {oz})
A/C compressorType Vane-rotary
Discharge capacity
120 {120, 4.06}
(ml {cc, fl oz})
Max. allowable speed
6,400
(rpm)
Lube
oilType ATMOS GU10
Sealed volume
(approximate quantity)
120 {120, 4.06} 150 {150, 5.07}
(ml {cc, fl oz})
Magnetic clutch clearance
0.3—0.5 {0.012—0.019}
(mm {in})
CondenserType Multiflow (sub-cooling type)
Radiated heat (kW {kcal/h})4.69 {4,030}: European (L.H.D.) specs.
5.96 {5,130}: European (U.K.), GCC specs.
Receiver/drier
capacity(ml {cc, fl oz}) 190 {190, 6.42}
Desiccant Synthetic zeolite
Expansion valve Type Block type
Evaporator Type Double-tank drawn cup

U–4
OUTLINE
Full-auto Air Conditioner
ItemSpecification
L3, L8, LF MZR-CD (RF Turbo)
Heating capacity (kW {kcal/h}) 4.400 {3,784}4.400 {3,784} (L.H.D.)
5.120 {4,403} {R.H.D.)
Airflow volume
(during heater operation)Blower motor
(m
3/h)310 (L.H.D.)
300 (R.H.D.)
Electricity consumption
(during heater operation)Blower motor (W) 184
Cooling capacity (kW {kcal/h}) 4.200 {3,612}
Airflow volume (during air
conditioner operation)Blower motor
(m
3/h)460
Electricity consumption
(during air conditioner
operation)Blower motor (W) 225
Magnetic clutch (W) 46 45
Fan type Blower motor Sirocco fan
RefrigerantType R-134a
Regular amount
(approximate quantity)470 {16.6} (L.H.D.)
430 {15.2} (R.H.D.)
(g {oz})
A/C compressorType Vane-rotary
Discharge capacity
120 {120, 4.06}
(ml {cc, fl oz})
Max. allowable speed
6,400
(rpm)
Lube
oilType ATMOS GU10
Sealed volume
(approximate quantity)
120 {120, 4.06} 150 {150, 5.07}
(ml {cc, fl oz})
Magnetic clutch clearance
0.3—0.5 {0.012—0.019}
(mm {in})
CondenserType Multiflow (sub-cooling type)
Radiated heat (kW {kcal/h})4.69 {4,030}: European (L.H.D.) specs.
5.96 {5,130}: European (U.K.), GCC specs.
Receiver/drier
capacity(ml {cc, fl oz}) 190 {190, 6.42}
Desiccant Synthetic zeolite
Expansion valve Type Block type
Evaporator Type Double-tank drawn cup

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–11
U
7. Install in the reverse order of removal.
8. Perform the refrigerant system performance test.
A/C Unit Installation Note
1. When installing a new A/C unit or evaporator, add a supplemental amount of ATMOS GU10 compressor oil into
the refrigerant cycle.
Supplemental amount (approximate quantity)
40 ml {40 cc, 1.4 fl oz}
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A/C COMPRESSOR REMOVAL/INSTALLATIONA6E8516614502011. Disconnect the negative battery cable.
2. Discharge the refrigerant from the system.
3. Remove the right side splash shield.
4. Loosen the drive belt and remove it.
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.
5. Remove in the order indicated in the table. Do not
allow compressor oil to spill.
.
6. Install in the reverse order of removal.
7. Adjust the drive belt.
8. Perform the refrigerant system performance test.
A/C Compressor Installation Note
1. Remove the following amount of compressor oil from the new A/C compressor when replacing the A/C
compressor.
Compressor oil to be removed (approximate quantity)
150 ml {150 cc, 5.07 fl oz} – [compressor oil from old A/C compressor + 15 ml {15 cc, 0.5 fl oz}]
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1 Cooler hose (HI)
(See U–13 REFRIGERANT LINES REMOVAL/
INSTALLATION)
2 Cooler hose (LO)
(See U–13 REFRIGERANT LINES REMOVAL/
INSTALLATION)
3 Magnetic clutch connector
4A/C compressor
(See U–11 A/C Compressor Installation Note)
4
3
1
2
N·m {kgf·cm, in·lbf} 6.86—9.80
{70.0—99.9,
60.8—86.7}
R
R
6.86—9.80
{70.0—99.9,
60.8—86.7}
17.6—26.5 N·m
{1.80—2.70 kgf·m,
13.0—19.5 ft·lbf}
A6E85162005

U–12
BASIC SYSTEM
CONDENSER REMOVAL/INSTALLATIONA6E8516614802011. Disconnect the negative battery cable.
2. Discharge the refrigerant from the system.
3. Remove the shroud panel.
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.
4. Remove in the order indicated in the table. Do not
allow compressor oil to spill.
.
5. Install in the reverse order of removal.
6. Perform the refrigerant system performance test.
Condenser Installation Note
1. When installing a new condenser, add a supplemental amount of ATMOS GU10 compressor oil inlet the
refrigerant cycle.
Supplemental amount (approximate quantity)
35 ml {35 cc, 1.2 fl oz}
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1 Cooler pipe No.1
(See U–13 REFRIGERANT LINES REMOVAL/
INSTALLATION)
(See U–13 REFRIGERANT LINES REMOVAL/
INSTALLATION)
2 Cooler pipe No.2
(See U–13 REFRIGERANT LINES REMOVAL/
INSTALLATION)
(See U–13 REFRIGERANT LINES REMOVAL/
INSTALLATION)
3 Condenser
(See U–12 Condenser Installation Note)
N·m {kgf·cm, in·lbf}
R
3
1
2
6.86—9.80
{70.0—99.9, 60.8—86.7}
R
A6E8516W013