gas type MAZDA 6 2002 Workshop Manual Suplement

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})

D–2
OUTLINE
OUTLINE OF CONSTRUCTIONA6E330202000201•The construction and the operation of the oil cooler and the oil filter for the new Mazda6 (GG, GY) MZR-CD (RF
Turbo) engine model is the same as the current Mazda MPV (LW) MZR-CD (RF Turbo) engine model. (See
Mazda MPV Workshop Manual Supplement 1737-1*-02D.)
•The construction and the operation of the lubrication system except for the oil cooler and oil filter for the new
Mazda6 (GG, GY) MZR-CD (RF Turbo) engine model is the same as the current Mazda 626, 626 Station
Wagon (GF, GW) RF Turbo engine model. (European specs.) (See Mazda 626, 626 Station Wagon RF Turbo
Workshop Manual Supplement 1614-10-98D.)
•The construction and the operation of the lubrication system for the new Mazda6 (GG, GY) L8, LF, and L3
engine models is the same as the current Mazda6 (GG) engine model L8, LF, and L3 engine models. (See
Mazda6 Training Manual 3359-1*-02C, Mazda6 Workshop Manual 1730-1*-02C.)
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SPECIFICATIONSA6E330202000202Gasoline engine
* : Always verify the oil level with the dipsticks since the engine oil capacity differs according to dipstick
specifications. (See Mazda6 Workshop Manual 1730-1*-02C Section D.)
Recommended Engine Oil (Gasoline Engine)
•The maintenance intervals on the scheduled maintenance table (See GI–8 SCHEDULED MAINTENANCE
TABLE) can only be supported with the use of following oils.
OUTLINE
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*
Lubrication system Force-fed type
Oil coolerWater-cooled
Oil pressure
(approximate quantity)
[oil temperature: 100°C
{212°F}](kPa {kgf/cm
2, psi})
min [rpm]234—521
{2.39—5.31, 33.9—75.5}
[3,000]395—649
{4.03—6.61,
57.3—94.1}
[3,000]
Oil pumpType Trochoid gear type
Relief pressure
(approximate
quantity) (kPa {kgf/cm
2,
psi})500—600
{5.09—6.11, 72.6—87.0}
Oil filterType Full-flow, Paper element
Bypass pressure
(approximate
quantity)(kPa kgf/cm
2, psi})80—120
{0.9—1.2, 12.8—17.0}
Oil capacity
(approximate
quantity)Total
(dry engine)(L {US qt, lmp qt}) 4.6 {4.8, 4.0} Dipstick A: 4.2 {4.4, 3.7}
Dipstick B: 5.1 {5.4, 4.5}
Oil replacement (L {US qt, lmp qt}) 3.9 {4.0, 3.4} Dipstick A: 3.1 {3.3, 2.7}
Dipstick B: 4.0 {4.2, 3.5}
Oil and oil filter
replacement(L {US qt, lmp qt}) 4.3 {4.5, 3.8} Dipstick A: 3.5 {3.7, 3.1}
Dipstick B: 4.4 {4.6, 3.9}
ItemSpecification
New Mazda6
(GG, GY), Current Mazda6
(GG)New Mazda6
(GG, GY), Current Mazda6
(GG)
L8, LF, L3
Engine oil GradeAPI SL
ACEA A3
Viscosity (SAE) 5W-30, 10W-40 5W-20
RemarksMazda genuine Dexelia oil e.g. —

OUTLINE
E–3
E
SPECIFICATIONSA6E360202000209Gasoline engine
Bold frames: New specifications
Diesel engine
Bold frames: New specifications
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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
Cooling system Water-cooled
Coolant capacity
(approximate quantity)(L {US qt, lmp qt}) 7.5 {7.9, 6.6}
Water pump TypeCentrifugal,
V-ribbed belt-driven
ThermostatTypeWax,
Bottom-bypass
Opening temperature (°C {°F}) 80—84 {176—183}
Full-open temperature (°C {°F}) 97 {206}
Full-open lift (mm {in}) More than 8.0 {0.31}
RadiatorType Corrugated fin
Cap valve opening pressure
113—142
{1.15—1.44, 16.4—20.4}
(kPa {kgf/cm
2, psi})
Cooling fanType Electric
BladeOuter
diameter(mm {in}) 300 {11.8} 320 {12.6}
Number of
blade(sheet)Cooling fan No.1: 5
Cooling fan No.2: 7Cooling fan No.1: 7
Cooling fan No.2: 5
ItemSpecification
New Mazda6
(GG, GY)Current Mazda 323
(BJ)
MZR-CD (RF Turbo) RF Turbo
Cooling system Water-cooled
Coolant capacity
(approximate quantity)(L {US qt, lmp qt}) 9.0 {9.5, 7.9}
Water pump TypeCentrifugal,
Timing-belt driven
ThermostatType Wax, Bottom-bypass
Opening temperature (°C {°F}) 80—84 {176—183}
Full-open temperature (°C {°F}) 95 {203}
Full-open lift (mm {in}) More than 8.5 {0.33}
RadiatorType Corrugated fin
Cap valve opening pressure
94—122
{0.96—1.24, 13.7—17.6}
(kPa {kgf/cm
2, psi})
Cooling fanType Electric
BladeOuter
diameter(mm {in}) 320 {12.6} 300 {11.9}
Number of
blade(sheet)Cooling fan No.1: 7
Cooling fan No.2: 54

THERMOSTAT
E–9
E
THERMOSTAT REMOVAL/INSTALLATIONA6E361815171201MZR-CD (RF Turbo)
1. Disconnect the negative battery cable.
2. Remove the under cover.
3. Drain the engine coolant.
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.
6. Fill the radiator with the specified amount and type of engine coolant.
7. Inspect the engine coolant leakage. (See E–8 ENGINE COOLANT LEAKAGE INSPECTION.)
Thermostat Installation Note
1. Verify that the positions of the jiggle pin and the projection on the gasket are as shown.
2. Install the thermostat into the thermostat case, aligning the projection on the gasket to the thermostat cover.
End Of Sie
THERMOSTAT
1 Lower radiator hose
2 Thermostat cover
3Thermostat
(See E–9 Thermostat Installation Note )
3
1
2
7.9—10.7 N·m
{80—110 kgf·cm,
69.5—95.4 in·lbf}
A6E3618W100
THERMOSTAT
COVER
GASKET
PROJECTIONJIGGLE PIN
A6A3618W101

G–2
OUTLINE
OUTLINE OF CONSTRUCTIONA6E470202000201•The construction and operation of the engine electrical system for the new Mazda6 (GG, GY) MZR-CD (RF
Turbo) engine model is the same as the current Mazda 323 (BJ) RF engine model. (European specs.) (See
Mazda 323 Training Manual 3324-10-98E.)
•The construction and operation of the engine electrical system for the new Mazda6 (GG, GY) L8, LF, and L3
engine models is the same as the current Mazda6 (GG) L8, LF, and L3 engine models. (See Mazda6 Training
Manual 3359-1*-02C, Mazda6 Workshop Manual 1730-1*-02C.)
End Of Sie
SPECIFICATIONSA6E470202000203Gasoline engine
* : Cold area or intensely hot area
Diesel engine
Bold frames:New specifications
* : Cold area
End Of Sie
OUTLINE
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
BatteryType and capacity
(5-hour rate)50D20L (40),
75D26L (52)
*50D20L (40),
75D26L (52) *50D20L (40),
80D26L (55)*
Voltage (V) 12
GeneratorOutput (V-A) 12-90
Regulated voltage
Controlled by PCM
Self-diagnosis
function
Ignition
systemType DEI (Double Electronic Ignition)
Spark advance Electronic
Firing order 1—3—4—2
Spark
plugType NGK ITR6F-13
StarterType Coaxial reduction
Output (kW) 1.0 1.4
ItemSpecification
New Mazda6 (GG, GY) Current Mazda 323 (BJ)
MZR-CD (RF Turbo) RF
BatteryType and capacity
(5-hour rate)95D31L (64),
115D31L (70)
*
Voltage (V) 12
GeneratorOutput (V-A) 12-90 12-80
Regulated voltage 14.1—14.7
Self-diagnosis function Equipped
StarterType Coaxial reduction
Output (kW) 2.2

J2–4
MANUAL TRANSAXLE
TRANSAXLE OIL INSPECTIONA6E5212270012011. Park the vehicle on level ground.
2. Remove the filler plug and gasket.
3. Verify that the oil is near the brim of the plug port.
•If the oil level is low, add the specified amount
and type of oil through the filler plug hole.
Specified oil grade
API Service GL-4 or GL-5
Specified oil viscosity
SAE 75W-90
4. Install a new gasket and the filler plug.
Tightening torque
30.0—39.0 N·m
{3.06—3.98 kgf·m, 22.1—28.8 in·lbf}
End Of Sie
TRANSAXLE OIL REPLACEMENTA6E5212270012021. Remove the drain plug with the gasket.
2. Drain the oil into a suitable container.
3. Install a new gasket and the drain plug.
Tightening torque
30.0—39.0 N·m
{3.06—3.98 kgf·m, 22.1—28.8 in·lbf}
4. Remove the filler plug with gasket and add the
specified amount and type of oil through the filler
plug hole until the level reaches the bottom of the
filler plug hole.
Specified oil grade
API Service GL-4 or GL-5
Specified oil viscosity
SAE 75W-90
Capacity (approximate quantity)
2.30 L {2.40 US qt, 2.00 lmp qt}
5. Install a new gasket and the filler plug.
Tightening torque
30.0—39.0 N·m
{3.06—3.98 kgf·m, 22.1—28.8 in·lbf}
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MANUAL TRANSAXLE
DRAIN PLUG FILLER PLUG
A6E5212W010
DRAIN PLUG FILLER PLUG
A6E5212W010

AUTOMATIC TRANSAXLE
K2–111
K2
3. Pivot the screwdriver to pry the tab away from the
tank and repeat the procedure for each tab.
4. Remove the radiator outer tank and O-ring
(gasket) from the core header when all of the tabs
are opened.
Note
•If any header tabs are missing from the core,
replace the radiator.
5. Inspect the gasket surface of the radiator core
header to ensure it is clean and free of foreign
material or damage.
6. Inspect the radiator outer tank for warping. If it is
warped, replace radiator tank.
Radiator Outer Tank (In Tank Oil Cooler) Installation Note
1. Install a new O-ring and ensure it is not twisted.
Note
•The old O-ring must be replaced.
2. Position the radiator tank in the original direction
to the core using care not to scratch the tank
sealing surface with the header tabs.
Note
•Step 3 will set jaw opening to the correct
specification.
3. With the jaws of locking-type pliers (vise grips)
closed and locked, turn the adjusting screw to
position the jaws against the drill bit with the
diameter measured (height) in removal procedure
1. Tighten the lock nut on the adjusting screw
against the handle to lock the adjustment in place.
SCREWDRIVER
A6E5614W074
O-RING
A6E5614W075
LOCKING TYPE PLIERS
(VISE PLIERS)
LOCKNUTADJUSTING
SCREW
DRILL BIT
A6E5614W093

OUTLINE
R–3
R
SPECIFICATIONSA6E740201013203
*1: Engine coolant and engine oil are at specified level. Fuel is full. 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 following. 4SD and 5HB front: 402 mm {15.82 in} (reference
value) 4SD and 5HB rear: 401 mm {15.78 in} (reference value), WGN (2WD) front: 405 mm {15.94 in}
(reference value) WGN (2WD) rear: 407 mm {16.02 in} (reference value)
Bold frames: New specifications
End Of Sie
Item Specification
New Mazda6 Current
Mazda6
GG (4SD, 5HB) GY (WGN 2WD) GY (WGN 4WD) GG (4SD, 5HB)
Engine type LF, MZR-CD
(RF Turbo) L8, LF, L3,
MZR-CD (RF Turbo) L3 L8, LF, L3
Fr o nt
suspension Type High-mount double wishbone (with double-pivoted lower arm(s))
Spring type Coil spring
Shock absorber type
Cylindrical, double-acting
(Low-pressure gas charged with rebound spring)
Stabilizer Type Torsion bar
Diameter (mm {in}) 23 {0.91}
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 ′
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°
Caster
angle*
2
(reference
value) normal 3
°47 ′±1° 3°40 ′±1° 3°35 ′±1° 3°47 ′±1°
elevated*33 °42' ±1° 3°35 ′±1° —3 °42' ±1 °
Camber
angle*
2
(reference
value) normal –0
°17 ′±1° –0°15 ′±1° –0°08 ′±1° –0°17 ′±1°
elevated*3–0 °10' ±1° –0°08 ′±1° —–0 °10' ±1°
Steering
axis
inclination
(reference
value) normal 5
°28 ′ 5°24 ′ 5°16 ′ 5°28 ′
elevated
*35 °18' 5 °16 ′ —5 °18'
Rear
suspension Type E-type multi-link
Spring type Coil spring
Stabilizer
Type Torsion bar
Diameter (mm {in})
4SD: 19 {0.75}
5HB: 18 {0.71}18 {0.71} 21 {0.83}
4SD: 19 {0.75}
5HB: 18 {0.71}
Shock absorber type Cylindrical,
double-acting
(Low-pressure gas charged) Cylindrical,
double-acting
(Low-pressure gas charged)/
(High-pressure
gas charged) Cylindrical,
double-acting
(High-pressure gas charged) Cylindrical,
double-acting
(Low-pressure gas charged)
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 –1 °13 ′±1° –1°06 ′±1° –1°03 ′±1° –1°13 ′±1°
elevated
*3–1 °05 ′±1° –0°58 ′±1° —–1 °05 ′±1°
Thrust angle (degree) 0 °±0°48 ′