service MAZDA 6 2002 Workshop Manual Suplement

CONTENTSMazda6
Workshop
Manual
Supplement
FOREWORD
This manual contains on-vehicle service
and diagnosis for the Mazda6.
For proper repair and maintenance,
a thorough familiarization with this manual
is important, and it should always be kept
in a handy place for quick and easy
reference.
All the contents of this manual, including
drawings and specifications, are the latest
available at the time of printing.
As modifications affecting repair or
maintenance occur, relevant information
supplementary to this volume will be made
available at Mazda dealers. This manual
should be kept up-to-date.
Mazda Motor Corporation reserves
the right to alter the specifications and
contents of this manual without obligation
or advance notice.
All rights reserved. No part of this book
may be reproduced or used in any form or
by any means, electronic or
mechanical—including photocopying and
recording and the use of any kind of
information storage and retrieval
system—without permission in writing.
Mazda Motor Corporation
HIROSHIMA, JAPAN
APPLICATION:
This manual is applicable to vehicles
beginning with the Vehicle Identification
Numbers (VIN), and related materials shown
on the following page.There are explanation given only for the sections
marked with shadow ( ).
© 2002 Mazda Motor Corporation
PRINTED IN THE NETHERLANDS, JULY 2002
1749–1E–02G
Title Section
General Information
GI
EngineL8, LF, L3
B1
MZR–CD (RF Turbo)B2
Lubrication System
D
Cooling System
E
Fuel and Emission Control
SystemsL8, LF, L3
F1
MZR–CD (RF Turbo)F2
Engine Electrical System
G
Clutch
H
Manual TransaxleG35M
–RJ1
A65M
–RJ2
Automatic TransaxleFN4A
–ELK1
JA5AX
–ELK2
Propeller Shaft
L
Front and Rear Axles
M
Steering System
N
Braking System
P
Suspension
R
Body
S
Body Electrical System
T
Heater and Air Conditioner Systems
U
Technical Data
TD
Special Tools
ST

WARNING
Servicing a vehicle can be dangerous. If you have not received
service-related training, the risks of injury, property damage, and
failure of servicing increase. The recommended servicing procedures
for the vehicle in this workshop manual were developed with
Mazda-trained technicians in mind. This manual may be useful to
non-Mazda trained technicians, but a technician with our
service-related training and experience will be at less risk when
performing service operations. However, all users of this manual are
expected to at least know general safety procedures.
This manual contains "Warnings" and "Cautions" applicable to risks
not normally encountered in a general technician's experience.
They should be followed to reduce the risk of injury and the risk that
improper service or repair may damage the vehicle or render it unsafe.
It is also important to understand that the "Warnings" and "Cautions"
are not exhaustive. It is impossible to warn of all the hazardous
consequences that might result from failure to follow the procedures.
The procedures recommended and described in this manual are
effective methods of performing service and repair. Some require tools
specifically designed for a specific purpose. Persons using procedures
and tools which are not recommended by Mazda Motor Corporation
must satisfy themselves thoroughly that neither personal safety nor
safety of the vehicle will be jeopardized.
The contents of this manual, including drawings and specifications, are
the latest available at the time of printing, and
Mazda Motor Corporation
reserves the right to change the vehicle designs and alter the contents
of this manual without notice and without incurring obligation.
Parts should be replaced with genuine Mazda replacement parts or
with parts which match the quality of genuine Mazda replacement
parts. Persons using replacement parts of lesser quality than that of
genuine Mazda replacement parts must satisfy themselves thoroughly
that neither personal safety nor safety of the vehicle will be
jeopardized.
Mazda Motor Corporation is not responsible for any problems which
may arise from the use of this manual. The cause of such problems
includes but is not limited to insufficient service-related training, use of
improper tools, use of replacement parts of lesser quality than that of
genuine Mazda replacement parts, or not being aware of any revision
of this manual.

GI–2
HOW TO USE THIS MANUAL
RANGE OF TOPICSA6E201000001206•This manual indicates only changes/additions, as it is supplemental to the related materials. Therefore it may
not contain the necessary reference service procedures to perform the service indicated in this manual.
End Of Sie
HOW TO USE THIS MANUAL

NEW STANDARDS
GI–5
GINEW STANDARDS TABLEA6E202800020201•The following is a comparison of the previous standard and the new standard.
NEW STANDARDS
New Standard Previous Standard
Remark
Abbrevi-
ationNameAbbrevi-
ationName
AP Accelerator Pedal—Accelerator Pedal
ACL Air Cleaner—Air Cleaner
A/C Air Conditioning—Air Conditioning
BARO Barometric Pressure—Atmospheric Pressure
B+ Battery Positive VoltageV
BBattery Voltage
—Brake Switch—Stoplight Switch
—Calibration Resistor—Corrected Resistance #6
CMP sensor Camshaft Position Sensor—Crank Angle Sensor
CAC Charge Air Cooler—Intercooler
CLS Closed Loop System—Feedback System
CTP Closed Throttle Position—Fully Closed
—Closed Throttle Position Switch—Idle Switch
CPP Clutch Pedal Position—Clutch Position
CIS Continuous Fuel Injection System EGI Electronic Gasoline Injection System
CS sensor Control Sleeve Sensor CSP sensor Control Sleeve Position Sensor #6
CKP sensor Crankshaft Position Sensor—Crank Angle Sensor 2
DLC Data Link Connector—Diagnosis Connector
DTM Diagnostic Test Mode—Test Mode #1
DTC Diagnostic Trouble Code—Service Code(s)
DI Distributor Ignition—Spark Ignition
DLI Distributorless Ignition—Direct Ignition
EI Electronic Ignition—Electronic Spark Ignition #2
ECT Engine Coolant Temperature—Water Thermo
EM Engine Modification—Engine Modification
—Engine Speed Input Signal—Engine RPM Signal
EVAP Evaporative Emission—Evaporative Emission
EGR Exhaust Gas Recirculation—Exhaust Gas Recirculation
FC Fan Control—Fan Control
FF Flexible Fuel—Flexible Fuel
4GR Fourth Gear—Overdrive
—Fuel Pump Relay—Circuit Opening Relay #3
FSO
solenoidFuel Shut Off Solenoid FCV Fuel Cut Valve #6
GEN Generator—Alternator
GND Ground—Ground/Earth
HO2S Heated Oxygen Sensor—Oxygen Sensor With heater
IAC Idle Air Control—Idle Speed Control
—IDM Relay—Spill Valve Relay #6
—Incorrect Gear Ratio——
—Injection Pump FIP Fuel Injection Pump #6
—Input/Turbine Speed Sensor—Pulse Generator
IAT Intake Air Temperature—Intake Air Thermo
KS Knock Sensor—Knock Sensor
MIL Malfunction Indicator Lamp—Malfunction Indicator Light
MAP Manifold Absolute Pressure—Intake Air Pressure
MAF sensor Mass Air Flow Sensor—Airflow Sensor
MFI Multiport Fuel Injection—Multiport Fuel Injection
OBD On Board Diagnostic—Diagnosis/Self Diagnosis

ABBREVIATIONS
GI–7
GIABBREVIATIONS TABLEA6E203000011202
End Of Sie
ABBREVIATIONS
A/C Air conditioner
ABS Antilock brake system
ACC Accessories
ABDC After bottom dead center
ATDC After top dead center
ATF Automatic transaxle fluid
ATX Automatic transaxle
BBDC Before bottom dead center
BDC Bottom dead center
BTDC Before top dead center
CAN Controller area network
CM Control module
DEI Double electronic ignition
DOHC Double overhead camshaft
DSC Dynamic stability control
ESA Electronic spark advance
EX Exhaust
HI High
HU Hydraulic unit
IDM Injector driver module
IG Ignition
IN Intake
KOEO Key on engine off
KOER Key off engine running
LH Left hand
L.H.D. Left hand drive
LO Low
LR Left rear
M Motor
MAX Maximum
MTX Manual transaxle
MIN Minimum
O/D Overdrive
OCV Oil control valveOFF Switch off
ON Switch on
P/S Power steering
PATS Passive anti-theft system
PCV Positive crankcase ventilation
PID Parameter identification
RF Right front
RH Right hand
R.H.D. Right hand drive
RR Right rear
SST Special service tool
SW Switch
TCC Torque converter clutch
TCM Transaxle control module
TDC Top dead center
TFT Transaxle fluid temperature
TNS Tail number side lights
TR Transaxle range
TWC Three way catalytic converter
VAD Variable air duct
VBC Variable boost control
VIS Variable intake-air system
VSC Variable swirl control
VSS Vehicle speedometer sensor
VTCS Variable tumble control system
WGN Wagon
WDS Worldwide diagnostic system
1GR 1st gear
2GR 2nd gear
4GR 4th gear
5GR 5th gear
4SD 4 door sedan
5HB 5 door hatchback
4WD 4 wheel drive

GI–8
SCHEDULED MAINTENANCE
SCHEDULED MAINTENANCE TABLEA6E203400013202For Europe (L.H.D. U.K.)
Chart symbols:
I : Inspect and clean, repair, adjust, or replace if necessary.
R:Replace
C : Clean
Remarks:
SCHEDULED MAINTENANCE
•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 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 40,000 km (25,000 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 12.52537.55062.57587.5100112.5
GASOLINE ENGINE
Spark plugs Replace every 100,000 km (62,500 miles)
Air cleaner element *4 R R R
E.G.R. system 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 *4CCRCCRCCR
E.G.R. system I I I
GASOLINE and DIESEL ENGINE
Engine oil *1RRRRRRRRR
Engine oil filter *1RRRRRRRRR
Drive belts *2 I I I
Cooling system (including coolant level adjustment) I I I I

GI–10
SCHEDULED MAINTENANCE
For Israel
Chart symbols:
I : Inspect and clean, repair, adjust, or replace if necessary.
R:Replace
C : Clean
Remarks:
•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 every 10,000 km
(6,000 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.
Maintenance 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
ENGINE
Drive belts *2IIIIIIIIIII I
Engine oil *1RRRRRRRRRRR R
Engine oil filter *1RRRRRRRRRRR R
COOLING SYSTEM
Cooling system
(Including coolant level adjustment)IIIII I
Engine coolantReplace at first 4 years or 90,000 km (54,000 miles);
after that, every 2 years
FUEL SYSTEM
Air cleaner element *4CCCRCCCRCCC R
Fuel filter R R
Fuel lines & hoses IIIII I
IGNITION SYSTEM
Spark plugs Replace every 90,000 km (54,000 miles)
EMISSION CONTROL SYSTEM
Evaporative system I I I
E.G.R. system (if installed) I I I
ELECTRICAL SYSTEM
Battery electrolyte level & specific gravity I I I I I I I I I I I I
All electrical system *5IIIIIIIIIII I
CHASSIS & BODY
Brake & clutch pedals IIIIIIIIIII I
Brake lines, hoses & connections I I I I I I I I I I I I
Brake fluid *3IRIRIRIRIRI R
Parking brake IIIIIIIIIII I
Power brake unit & hoses IIIIIIIIIII I
Disc brakes IIIIIIIIIII I
Power steering fluid, lines, hoses, and
connectionsIIIIIIIIIII I

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

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