engine MAZDA MODEL 6 HATCHBACK 2004 (in English) Manual PDF

Black plate (255,1)
Inspect the antifreeze protection and
coolant level in the coolant reservoir at
least once a year—at the beginning of the
winter season—and before traveling
where temperatures may drop below
freezing.
Inspect the condition and connections of
all cooling system and heater hoses.
Replace any that are swollen or
deteriorated.
The coolant should be at full in the
radiator and between the FULL or F and
LOW or L marks on the coolant reservoir
when the engine is cool.
2.3-liter engine
3.0-liter engine
If it's at or near LOW or L, add enough
coolant to the coolant reservoir to provide
freezing and corrosion protection and to
bring the level to FULL or F.
CAUTION
Radiator coolant will damage paint.
Rinse it off quickly if spilled.
Do not overfill.
If new coolant is required frequently,
consult an Authorized Mazda Dealer.
qChanging Coolant
Change coolant according to Scheduled
Maintenance (page 8-3).
CAUTION
lUse only soft (demineralized) water
in the coolant mixture. Water that
contains minerals will cut down on
the coolant's effectiveness.
lDon't add only water. Always add a
proper coolant mixture.
lThe engine has aluminum parts and
must be protected by an ethylene-
glycol-based coolant to prevent
corrosion and freezing.
lDO NOT USE alcohol or methanol
antifreeze. DO NOT MIX alcohol or
methanol with the coolant. This
could damage the cooling system.
lDon't use a solution that contains
more than 60 % antifreeze.
This would reduce effectiveness.
For mixture percentage:
ProtectionVolume
Antifreeze
solutionDemineralizedwater
Above–16°C (3°F) 35% 65%
Above–26°C (–15°F) 45% 55%
Above–40°C (–40°F) 55% 45%
Maintenance and Care
Owner Maintenance
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Black plate (256,1)
To change coolant
WARNING
Removing the Cooling System Cap:
Removing the cooling system cap
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.
Wrap a thick cloth around the cap and
slowly turn it counterclockwise to the
first stop (3.0-liter engine) or about
two and a half rotations (2.3-liter
engine).
Step back while the pressure escapes.
When you're sure all the pressure is
gone, press down on the cap (3.0-liter
engine)—still using a cloth—turn
the cap, and remove it.
1. Remove the cooling system cap.
2.3-liter engine
Loosen
Tighten
Loosen Tighten
3.0-liter engine Loosen
Tighten
Tighten
Loosen
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 mixture
and water as necessary to provide
freezing and corrosion protection.
5. In extremely cold climates, add the
mixture percentage recommended in
the coolant mixture percentage table.
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.
8-14
Maintenance and Care
Owner Maintenance
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Black plate (257,1)
Brake/Clutch Fluid
qInspecting 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.
qAdding Brake/Clutch Fluid
WARNING
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 yourself or 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.
If the fluid level is low, add fluid until it
reaches MAX.
Before adding fluid, thoroughly clean the
area around the cap.
CAUTION
lBrake and clutch fluid will damage
painted surfaces. If brake or clutch
fluid does get on a painted surface,
wipe it off immediately.
lUsing 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.
Maintenance and Care
Owner Maintenance
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Black plate (258,1)
Power Steering Fluid
qInspecting Power Steering Fluid
Level
CAUTION
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).
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.
LowOK HighLoosenTighten
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.
8-16
Maintenance and Care
Owner Maintenance
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Black plate (259,1)
Automatic Transaxle Fluid
(ATF)
qInspecting 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.
CAUTION
lLow fluid level causes transaxle
slippage. Overfilling can cause
foaming, loss of fluid, and transaxle
malfunction.
lUse specified fluid (page 10-3). A
nonspecified fluid could result in
transaxle malfunction and failure.
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.
WARNING
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.
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.
Low
B Full A Full
A Full
B Full Low
Low
Low 3.0-liter engine2.3-liter engine
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.
Maintenance and Care
Owner Maintenance
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Black plate (260,1)
CAUTION
lUse the cold scale only as a
reference.
lIf outside temperature is lower than
about 20°C (70°F), start the engine
and inspect the fluid level after the
engine reaches operating
temperature.
lIf 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.
Fully insert the dipstick. When adding
fluid, inspect with the dipstick to make
sure it doesn't pass full.
NOTE
Inspect the fluid on both sides of the
dipstick in a well lit area for an accurate
reading.
Washer Fluid
qInspecting Washer Fluid Level
WARNING
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.
Using Washer Fluid Without Anti-freeze Protection in Cold Weather:
Operating your vehicle in
temperatures below 4 degrees C (40
degrees F) using washer fluid without
anti-freeze protection is dangerous as
it could cause impaired windshield
vision and result in an accident. In
cold weather, always use washer fluid
with anti-freeze protection.
NOTE
State or local regulations may restrict
the use of volatile organic compounds
(VOCs), which are commonly used as
anti-freeze agents in washer fluid. A
washer fluid with limited VOC content
should be used only if it provides
adequate freeze resistance for all
regions and climates in which the
vehicle will be operated.
8-18
Maintenance and Care
Owner Maintenance
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Black plate (261,1)
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.
Body Lubrication
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 hood's secondary latch
keeps the hood from opening when the
primary latch is released.
Maintenance and Care
Owner Maintenance
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Black plate (262,1)
Air Filter
CAUTION
Don't drive without an air filter. This
could result in excessive engine wear.
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.
qReplacing the Air Filter
NOTE
If the vehicle is operated in very dusty
or sandy areas, replace the filter more
often than recommended intervals.
1. Unfasten the clamps .
Clamp 2.3-liter engine
3.0-liter engine
Clamp
2. Tilt or lift the air filter cover and
remove the filter.
2.3-liter engine
Air filter cover
Air filter
3.0-liter engine
Air filter cover
Air 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.
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Maintenance and Care
Owner Maintenance
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Black plate (281,1)
3. Pull the fuse straight out with the fuse
puller provided on the fuse block
located in the engine compartment.
Fuse puller
Engine compartment fuse box
4. Inspect it and replace if it's blown.
NormalBlown
5. Push in a new fuse of the same
amperage 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.
CAUTION
Always replace a fuse with one of the
same rating. Otherwise you may
damage the electric system.
Replacing the fuses under the hood
If the headlights or other electrical
components don't work and the fuses in
the cabin are OK, inspect the fuse block
under the hood. If a fuse is blown, it must
be replaced. Follow these steps:
1. Turn off the ignition switch and all
other switches.
2. Remove the fuse block cover.
Fuse block cover
Tab
3. If a fuse is blown, replace it with a new
oneof the same amperage rating.
Normal
Blown
NOTE
To replace the MAIN fuse, contact an
Authorized Mazda Dealer (page 8-40).
Maintenance and Care
Owner Maintenance
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Black plate (282,1)
qFuse Panel Description
Fuse block (Engine compartment)
DESCRIP-
TIONFUSE
RAT-
INGPROTECTED
COMPONENT
1 SPARE 20A—
2 SPARE 15A—
3 SPARE 10A—
4—— —
5—— —
6 INJ 15A Injector
7ENG
BAR10A
*1Air flow sensor, EGR control
valve
15A*2
8ENG
BAR2*115A O2 sensor
ENG
BB
*25A Cooling fan
9HEAD
LR10A Headlight-low beam (Right)
10HEAD
LL10A Headlight-low beam (Left)
DESCRIP-
TIONFUSE
RAT-
INGPROTECTED
COMPONENT
11HEAD
HL10A Headlight-high beam (Left)
12HEAD
HR10A Headlight-high beam (Right)
13ETC 7.5A Accelerator position sensor
14 HAZARD10A Turn signal lights
15STOP 15A Brake/Taillights
16TCM*110A TCM
IG1*215A O2 sensor
17 ENGB7.5A PCM, TCM
18FUEL
PUMP15A Fuel pump
19IG KEY 40AWindshield wiper and washer,
Engine control unit, Lighter
20P.WIND 30A Power window
21—— —
22—— —
8-40
Maintenance and Care
Owner Maintenance
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