engine MAZDA 6 2002 Workshop Manual Suplement

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
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PROPELLER SHAFTA6E931001024204
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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})

TECHNICAL DATA
TD–7
TD
BRAKING SYSTEMA6E931001020201
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SUSPENSIONA6E931001013201Suspension
WGN (2WD)
*1: Engine coolant and engine oil are at specified level. Spare tire, jack, and tools are in designated position. Adjust to the median when carrying out wheel alignment.
*2: Difference between left and right must not exceed 1 ° 30 ′.*3: Distance between wheel center and fender brim is following. Front: 405 mm {15.94 in} (reference value) Rear:
407 mm {16.02 in} (reference value)
WGN (4WD)
*1: Engine coolant and engine oil are at specified level. Spare tire, jack, and tools are in designated position. Adjust to the median when carrying out wheel alignment.
*2: Difference between left and right must not exceed 1 ° 30 ′.
Item Specification
CONVENTIONAL BRAKE SYSTEM
Front disc
brake Minimum disc pad
thickness
(mm {in})L8, LF (GCC specs.): 22 mm {0.87 in}
LF (European (L.H.D. U.K.) specs.), L3, MZR-CD (RF Turbo):
23 mm {0.91 in}
Minimum disc plate
thickness (mm {in})L8, LF (GCC specs.): 22.8 mm {0.90 in}
LF (European (L.H.D. U.K.) specs.), L3, MZR-CD (RF Turbo): 23.8 mm {0.94 in}
Item Fuel gauge indication
Empty 1/4 1/2 3/4 Full
Fr o nt wh ee l
alignment
(Unloaded)
*1
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'
Rear wheel
alignment
(Unloaded)
*1
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 ′
Item Fuel gauge indication
Empty 1/4 1/2 3/4 Full
Fr o nt wh ee l
alignment
(Unloaded)
*1
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'
Rear wheel
alignment
(Unloaded)
*1
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 0 °±0°48 ′

ST–1
ST
STSPECIAL TOOLS
SPECIAL TOOLS................................................. ST-2
ENGINE .............................................................ST-2
LUBRICATION SYSTEM ...................................ST-2
COOLING SYSTEM ........................................... ST-2
FUEL AND EMISSION CONTROL SYSTEM .... ST-3
CLUTCH.............................................................ST-3
MANUAL TRANSAXLE ...................................... ST-3
AUTOMATIC TRANSAXLE................................ ST-3
PROPELLER SHFT ........................................... ST-4
FRONT AND REAR AXLE ................................. ST-4
STEERING SYSTEM .........................................ST-7
BRAKING SYSTEM ........................................... ST-7
SUSPENSION.................................................... ST-7
BODY ................................................................. ST-7
BODY ELECTRICAL SYSTEM .......................... ST-8

ST–2
SPECIAL TOOLS
ENGINEA6E941001001205
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LUBRICATION SYSTEMA6E941001001206
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COOLING SYSTEMA6E941001001207
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SPECIAL TOOLS
49 S120 710
Coupling flange
holder 49 G033 107A
Dust cover
installer49 S120 215B
Pulley puller
49 G011 106
Camshaft pulley
puller49 S013 1A1
Compression
gauge set49 B010 002
Oil seal installer
49 G012 0A0
Tappet adjust
wrench set49 G011 105
Crankshaft lock
tool49 U027 003
Oil seal installer
WDS 49 E017 5A0
Engine support
set
—
49 0187 280A
Oil pressure
gauge
——
49 9200 145
Radiator cap
tester adapter
set——

SPECIAL TOOLS
ST–3
ST
FUEL AND EMISSION CONTROL SYSTEMA6E941001001204
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CLUTCHA6E941001024201
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MANUAL TRANSAXLEA6E941001024202
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AUTOMATIC TRANSAXLEA6E941001024203
WDS 49 T042 001A
Union wrench49 L018 001
O
2 sensor
wrench
49 D015 001
Box wrench
--
49 0259 770B
Flare Nut
Wrench49 SE01 310A
Clutch Disc
Centering Tool49 E011 1A0
Ring Gear
Brake Set
49 U027 003
Oil Seal Installer49 G030 797
Handle49 E017 5A0
Engine Support
Set
49 0378 400C
Oil pressure
gauge set49 B019 901B
Oil pressure
gauge49 L019 014
Adapter
49 L019 016
Installer49 G030 797
Handle49 B010 001
Oil Seal Installer

ST–4
SPECIAL TOOLS
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PROPELLER SHFTA6E941001024204
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FRONT AND REAR AXLEA6E941001018201
49 L019 013
Adapter49 E017 5A0
Engine Support
Set49 E011 1A0
Ring gear brake
set
WDS
——
49 0839 425C
Bearing puller
set49 H027 002
Bearing
Remover49 G030 370
Removing Plate
49 F015 002
Water seal
installer49 0636 145
Water pump
pulley boss
puller49 G030 797
Handle
49 H033 101
Bearing
remover49 U027 005
Bearing installer49 F401 331
Body
49 B034 201
Support block49 F401 335A
Attachment A
—
49 T028 3A0
Ball joint puller
set49 G033 102
Handle49 G033 105
Attachment

ST–6
SPECIAL TOOLS
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49 0107 680A
Engine stand49 T032 317
Weight49 T032 316
Shaft
49 L027 004
Gear case
remover49 L027 0A0
Locknut
replacer set49 L027 006
Serrate socket
(Part of 49 L027
0A0)
49 L027 007
Hex socket
(Part of 49 L027
0A0)49 F401 366A
Plate49 B027 003
Attachment M
49 F401 331
Body49 F401 337A
Attachment C49 M005 797
Handle
49 F027 007
Attachment
φ 7249 G027 004
Gauge block49 8531 565
Drive pinion
model
49 8531 567
Collar A
(Part of 49 8531
565)49 8531 568
Collar B
(Part of 49 8531
565)49 G032 347
Oil seal installer
49 0727 570
Pinion height
gauge body49 S033 108
Bearing installer49 W010 107A
Installer
49 S032 333
Bearing installer49 E027 002
AttachmentWDS