engine MAZDA MODEL 6 2003 (in English) Manual PDF

8-14
Maintenance and Care
Owner Maintenance
Form No. 8R29-EA-02I

Changing Coolant
Change coolant according to Scheduled
Maintenance (page 8-3).
For mixture percentage:To change coolant
1. Remove the cooling system cap. •
Use only soft (demineralized) water
in the coolant mixture. Water that
contains minerals will cut down on
the coolant’s effectiveness.
•
Don’t add only water. Always add a
proper coolant mixture.
•
The engine has aluminum parts and
must be protected by an ethylene-
glycol-based coolant to prevent
corrosion and freezing.
•
DO NOT USE alcohol or methanol
antifreeze. DO NOT MIX alcohol
or methanol with the coolant. This
could damage the cooling system.
•
Don’t use a solution that contains
more than 60 % antifreeze.
This would reduce effectiveness.
ProtectionVo l u m e
Antifreeze
solutionWa t e r
Above
−16
°C (3
°F) 35% 65%
Above
−26
°C (
−15
°F) 45% 55%
Above
−40
°C (
−40
°F) 55% 45%
CAUTIONRemoving the Cooling System Cap:Removing the cooling system cap or
drain plug while the engine is
running or hot is dangerous. This
might lead to cooling system and
engine damage and could result in
serious injury from escaping hot
coolant or steam. Turn off the engine
and wait until it’s cool. Even then, be
very careful when removing the cap
or drain plug. Wrap a thick cloth
around it and slowly turn it
counterclockwise to the first stop.
Step back while the pressure escapes.
When you’re sure all the pressure is
gone, press down on the cap — still
using a cloth — turn the cap, and
remove it.
WARNING
Loosen
Tighten
Loosen Tighten 2.3-liter engine
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8-15
Maintenance and Care
Owner Maintenance
Form No. 8R29-EA-02I
2. Only when the engine is cool, remove
the radiator drain plug and drain the
coolant into a suitable container.
Properly dispose of the used coolant.
3. Flush out the system with running
water.
4. Drain the system completely. Insert
and tighten the plug. Add as much
ethylene-glycol-based coolant and
water as necessary to provide freezing
and corrosion protection.
5. In extremely cold climates, add the
amount recommended in the coolant
manufacturer’s instructions.
6. Run the engine at idle with the cooling
system cap off. Slowly add additional
coolant if necessary.
7. At this point, wait until the engine
reaches normal operating temperature;
then depress the accelerator two or
three times. Add more coolant, if
necessary, until the system is full.
8. Install the cooling system cap. Inspect
all connections for leaks. Inspect the
level in the coolant reservoir one more
time.

Inspecting Brake/Clutch Fluid
Level
The brakes and clutch draw fluid from the
same reservoir.
Inspect the fluid level in the reservoir
regularly. It should be kept at MAX.
The level normally drops with
accumulated distance, a condition
associated with wear of brake and clutch
linings. If it is excessively low, have the
brake/clutch system inspected by an
Authorized Mazda Dealer.
Loosen
Tighten
Loosen Tighten
3.0-liter engine
Brake/Clutch Fluid
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8-16
Maintenance and Care
Owner Maintenance
Form No. 8R29-EA-02I

Adding Brake/Clutch Fluid
If the fluid level is low, add fluid until it
reaches MAX.
Before adding fluid, thoroughly clean the
area around the cap.
Spilled Brake Fluid:Spilled brake fluid is dangerous. If it
gets in your eyes, they could be
seriously injured. If this happens,
immediately flush your eyes with
water and get medical attention.
Brake fluid spilled on a hot engine
could cause a fire. Be careful not to
spill brake fluid on yourselfor on the
engine.
Low Brake/Clutch Fluid Levels:
Low brake/clutch fluid levels are
dangerous. Low levels could signal
brake lining wear or a brake system
leak. Your brakes could fail and cause
an accident. If you find a low fluid
level, have the brakes and clutch
inspected.
WARNING•
Brake and clutch fluid will damage
painted surfaces. If brake or clutch
fluid does get on a painted surface,
wipe it off immediately.
•
Using nonspecified brake and clutch
fluids (page 10-3) will damage the
systems. Mixing different fluids
will also damage them.
If the brake/clutch system
frequently requires new fluid,
consult an Authorized Mazda
Dealer.
CAUTION
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8-17
Maintenance and Care
Owner Maintenance
Form No. 8R29-EA-02I

Inspecting Power Steering Fluid
Level
2.3-liter engine
Inspect the fluid level in the reservoir at
each engine oil change with the engine off
and cold. Add fluid if necessary; it does
not require periodic changing.
The level must be kept between MIN and
MAX.
Visually examine the lines and hoses for
leaks and damage.If new fluid is required frequently, consult
an Authorized Mazda Dealer.
3.0-liter engine
Inspect the fluid level at each engine oil
change. Add fluid if necessary; it does not
require periodic changing.
The level must be kept between the H and
L marks.
Visually examine the lines and hoses for
leaks and damage.
1. Park on a level surface, well off the
right-of-way, and set the parking brake
firmly.
2. Turn off the engine and allow it to cool.
3. Remove the filler cap and attached
dipstick.
4. Wipe them clean and put them back.
5. Remove again and inspect the level.
6. It must be between H and L. Add fluid
if necessary.
Don’t overfill.

If new fluid is required frequently, consult
an Authorized Mazda Dealer.
Power Steering Fluid
To avoid damage to the power steering
pump, don’t operate the vehicle for
long periods when the power steering
fluid level is low.
NOTE
Use specified power steering fluid
(page 10-3).
CAUTION
High
OK
LowTighten
Loosen
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8-18
Maintenance and Care
Owner Maintenance
Form No. 8R29-EA-02I

Inspecting Automatic transaxle
Fluid Level
The automatic transaxle fluid level should
be inspected regularly. Measure it as
described below.
The volume of fluid changes with the
temperature. Fluid must be checked at idle
without driving at normal operating
temperature.
1. Park on a level surface and set the
parking brake firmly.
2. Idle the engine about two minutes.
Push down on the brake pedal.
3. Move the shift lever through all ranges
and set it at P.4. With the engine still idling, pull out the
dipstick, wipe it clean, and put it back.
5. Pull it out again.
The proper fluid level is marked on the
dipstick as follows.
Fluid hot scale A
When the vehicle has been driven and the
fluid is at normal operating temperature,
about 65°
C (150°
F), the level must be
between Full and Low.
Fluid cold scale B
When the engine has not been running
and the outside temperature is about 20°
C
(70°
F), the level must be between Full and
Low.
Automatic transaxle Fluid
(ATF)
•
Low fluid level causes transaxle
slippage. Overfilling can cause
foaming, loss of fluid, and transaxle
malfunction.
•
Use specified fluid (page 10-3). A
nonspecified fluid could result in
transaxle malfunction and failure.
CAUTION
Sudden Vehicle Movement:Shifting the shift lever without first
depressing the brake pedal is
dangerous. The vehicle could move
suddenly and cause an accident.
Make sure the brake pedal is applied
before shifting the shift lever.
WARNING
Full
A
LowFull
B
Low
Full
A
Low
Full
B
Low 2.3-liter engine
3.0-liter engine
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8-19
Maintenance and Care
Owner Maintenance
Form No. 8R29-EA-02I
Fully insert the dipstick. When adding
fluid, inspect with the dipstick to make
sure it doesn’t pass full.

Inspecting Washer Fluid Level
Inspect fluid level in the washer fluid
reservoir; add fluid if necessary.
Use plain water if washer fluid is
unavailable.
But use only washer fluid in cold weather
to prevent it from freezing. •
Use the cold scale only as a
reference.
•
If outside temperature is lower than
about 20°
C (70°
F), start the engine
and inspect the fluid level after the
engine reaches operating
temperature.
•
If the vehicle has been driven for an
extended period at high speeds or in
city traffic in hot weather, inspect
the level only after stopping the
engine and allowing the fluid to
cool for 30 minutes.
NOTE
Inspect the fluid on both sides of the
dipstick in a well lit area for an
accurate reading.
CAUTIONWa s h e r F l u i d
Substitute Washer Fluid:Using radiator antifreeze as washer
fluid is dangerous. If sprayed on the
windshield, it will dirty the
windshield, affect your visibility, and
could result in an accident. Use only
windshield washer fluid or plain
water in the reservoir.
WARNING
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8-20
Maintenance and Care
Owner Maintenance
Form No. 8R29-EA-02I
All moving points of the body, such as
door and hood hinges and locks, should
be lubricated each time the engine oil is
changed. Use a nonfreezing lubricant on
locks during cold weather.
Make sure the engine hood’s secondary
latch keeps the hood from opening when
the primary latch is released.This air filter may be cleaned with
compressed air and reused, or replaced,
depending on its condition. Unless it is
very dirty, simply shake it to remove
foreign particles. Each time you inspect it,
wipe inside the air cleaner housing with a
damp cloth.

Replacing the Air Filter
1. Unfasten the clamps.
Body LubricationAir Filter
Don’t drive without an air filter. This
could result in excessive engine wear.
NOTE
If the vehicle is operated in very dusty
or sandy areas, replace the filter more
often than recommended intervals.
CAUTION
Clamp 2.3-liter engine
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8-21
Maintenance and Care
Owner Maintenance
Form No. 8R29-EA-02I
2. Tilt or lift the air filter cover and
remove the filter.3. Wipe inside the air cleaner housing
with a damp cloth.
4. Clean or replace the filter.
5. Install in the reverse order of removal.
Replace the filter according to Scheduled
Maintenance (page 8-3).
Clamp3.0-liter engine
Air filter cover
Air filter 2.3-liter engine
Air filter cover
Air filter 3.0-liter engine
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8-35
Maintenance and Care
Owner Maintenance
Form No. 8R29-EA-02I
Your vehicle’s electrical system is
protected by fuses.
If any lights, accessories, or controls don’t
work, inspect the appropriate circuit
protector. If a fuse has blown, the inside
element will be melted.
If the same fuse blows again, avoid using
that system and consult an Authorized
Mazda Dealer as soon as possible.

Fuse Replacement
If the electrical system doesn’t work, first
inspect fuses on the vehicle’s left side.
1. Turn off the ignition switch and other
switches.
2. Open the fuse panel cover.3. Pull the fuse straight out with the fuse
puller provided on the fuse block.
4. Inspect it and replace if it’s blown.
5. Push in a new fuse of the same rating,
and make sure it fits tightly. If it
doesn’t, have an Authorized Mazda
Dealer install it.
If you have no spare fuses, borrow one
of the same rating from a circuit not
essential to vehicle operation, such as
the SPARE circuit.
Fuses
Fuse panel cover
Fuse puller
Engine compartment fuse box
Normal Blown
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8-37
Maintenance and Care
Owner Maintenance
Form No. 8R29-EA-02I

Fuse Panel Description
Fuse block (Engine compartment)
*12.3-liter engine*23.0-liter engine
DESCRIPTIONFUSE
RATINGPROTECTED
COMPONENT
1 SPARE 20A—
2 SPARE 15A—
3 SPARE 10A—
4—— —
5—— —
6 INJ 15A Injector
7 ENG BAR10A
*1Air flow sensor,
EGR control
valve 15A
*2
8ENG BAR2*115A O2 sensor
ENG BB*25A Cooling fan
9 HEAD LR 10AHeadlight-low
beam (Right)
10 HEAD LL 10AHeadlight-low
beam (Left)
11 HEAD HL 10AHeadlight-high
beam (Left)
12 HEAD HR 10AHeadlight-high
beam (Right)
13 ETC 7.5AAccelerator
position sensor
DESCRIPTIONFUSE
RATINGPROTECTED
COMPONENT
14 HAZARD 10ATurn signal
lights
15 STOP 15A Brake/Taillights
16TCM
*110A TCM
IG1*215A O2 sensor
17
ENG B7.5A PCM, TCM
18 FUEL PUMP 15A Fuel pump
19 IG KEY 40AWindshield
wiper and
washer, Engine
control unit,
Lighter
20 P.WIND 30A Power window
21—— —
22—— —
23 IG KEY2 30AReverse lights,
Heater control
unit
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