2002-2014 Mazda6 Service & Repair Manual

CONTENTS Engine Workshop Manual MZR–CD (RF Turbo) FOREWORD This manual explains the disassembly, inspection, repair, and reassembly procedures for the above-indicated engine. In order to do these procedures safely, quickly, and correctly, you must first read this manual and any other relevant service materials carefully. The information in this manual is current up to April, 2002. Any changes that occur after that time will not be reflected in this particular manual. Therefore, the contents of this manual may not exactly match the mechanism that you are currently servicing. Mazda Motor Corporation HIROSHIMA, JAPAN © 2002 Mazda Motor Corporation PRINTED IN THE NETHERLANDS, APRIL 2002 1744–1E–02D Title Section General Information GI Engine B 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–1 GI GIGENERAL INFORMATION HOW TO USE THIS MANUAL ............................. GI-2 RANGE OF TOPICS .......................................... GI-2 SERVICE PROCEDURE ................................... GI-2 SYMBOLS .......................................................... GI-3 ADVISORY MESSAGES ................................... GI-4 UNITS ................................................................... GI-5 UNITS ................................................................ GI-5 FUNDAMENTAL PROCEDURES ........................ GI-6 PREPARATION OF TOOLS AND MEASURING EQUIPMENT ................................................... GI-6 SPECIAL SERVICE TOOLS .............................. GI-6 DISASSEMBLY .................................................. GI-6 INSPECTION DURING REMOVAL, DISASSEMBLY ............................................... GI-7 ARRANGEMENT OF PARTS ............................ GI-7 CLEANING OF PARTS ...................................... GI-7 REASSEMBLY ................................................... GI-7 ADJUSTMENT ................................................... GI-8 RUBBER PARTS AND TUBING ........................ GI-8 HOSE CLAMPS ................................................. GI-8 TORQUE FORMULAS ....................................... GI-9 VISE ................................................................... GI-9 ELECTRICAL SYSTEM...................................... GI-10 ELECTRICAL PARTS ...................................... GI-10 CONNECTORS................................................ GI-10 NEW STANDARDS ............................................ GI-13 NEW STANDARDS.......................................... GI-13 ABBREVIATIONS .............................................. GI-15 ABBREVIATIONS ............................................ GI-15

GI–2 HOW TO USE THIS MANUAL RANGE OF TOPICS AME201000001101 • This manual contains procedures for performing all required service operations. The procedures are divided into the following five basic operations: — Removal/Installation — Disassembly/Assembly — Replacement — Inspection — Adjustment • Simple operations which can be performed easily just by looking at the vehicle (i.e., removal/installation of parts, jacking, vehicle lifting, cleaning of parts and visual inspection) have been omitted. End Of Sie SERVICE PROCEDURE AME201000001102 Inspection, adjustment • Inspection and adjustment procedures are divided into steps. Important points regarding the location and contents of the procedures are explained in detail and shown in the illustrations. Repair procedure 1. Most repair operations begin with an overview illustration. It identifies the components, shows how the parts fit together and describes visual part inspection. However, only removal/installation procedures that need to be performed methodically have written instructions. 2. Expendable parts, tightening torques and symbols for oil, grease, and sealant are shown in the overview illustration. In addition, symbols indicating parts requiring the use of special service tools or equivalent are also shown. HOW TO USE THIS MANUAL XME2010001

HOW TO USE THIS MANUAL GI–3 GI 3. Procedure steps are numbered and the part that is the main point of that procedure is shown in the illustration with the corresponding number. Occasionally, there are important points or additional information concerning a procedure. Refer to this information when servicing the related part. End Of Sie SYMBOLS AME201000001103 • There are eight symbols indicating oil, grease, fluids, sealant, and SST or equivalent use. These symbols show application points or use of these materials during service. XME2010010 Symbol Meaning Kind Apply oil New appropriate engine oil or gear oil Apply brake fluid New appropriate brake fluid

GI–4 HOW TO USE THIS MANUAL End Of Sie ADVISORY MESSAGES AME201000001104 • You'll find several Warnings, Cautions, Notes, Specifications and Upper and Lower Limits in this manual. Warning • A Warning indicates a situation in which serious injury or death could result if the warning is ignored. Caution • A Caution indicates a situation in which damage to the vehicle or parts could result if the caution is ignored. Note • A Note provides added information that will help you to complete a particular procedure. Specification • The values indicate the allowable range when performing inspections or adjustments. Upper and lower limits • The values indicate the upper and lower limits that must not be exceeded when performing inspections or adjustments. End Of Sie Apply automatic transaxle/ transmission fluid New appropriate automatic transaxle/ transmission fluid Apply grease Appropriate grease Apply sealant Appropriate sealant Apply petroleum jelly Appropriate petroleum jelly Replace part O-ring, gasket, etc. Use SST or equivalent Appropriate tools Symbol Meaning Kind

UNITS GI–5 GI UNITS AME201200002101 Conversion to SI Units (Système International d'Unités) • All numerical values in this manual are based on SI units. Numbers shown in conventional units are converted from these values. Rounding Off • Converted values are rounded off to the same number of places as the SI unit value. For example, if the SI unit value is 17.2 and the value after conversion is 37.84, the converted value will be rounded off to 37.8. Upper and Lower Limits • When the data indicates upper and lower limits, the converted values are rounded down if the SI unit value is an upper limit and rounded up if the SI unit value is a lower limit. Therefore, converted values for the same SI unit value may differ after conversion. For example, consider 2.7 kgf/cm 2 in the following specifications: 210—260 kPa {2.1—2.7 kgf/cm 2 , 30—38 psi} 270—310 kPa {2.7—3.2 kgf/cm 2 , 39—45 psi} • The actual converted values for 2.7 kgf/cm 2 are 264 kPa and 38.4 psi. In the first specification, 2.7 is used as an upper limit, so the converted values are rounded down to 260 and 38. In the second specification, 2.7 is used as a lower limit, so the converted values are rounded up to 270 and 39. End Of Sie UNITS Electrical current A (ampere) Electric power W (watt) Electric resistance ohm Electric voltage V (volt) Length mm (millimeter) in (inch) Negative pressure kPa (kilo pascal) mmHg (millimeters of mercury) inHg (inches of mercury) Positive pressure kPa (kilo pascal) kgf/cm 2 (kilogram force per square centimeter) psi (pounds per square inch) Torque N·m (Newton meter) kgf·m (kilogram force meter) kgf·cm (kilogram force centimeter) ft·lbf (foot pound force) in·lbf (inch pound force) Volume L (liter) US qt (U.S. quart) Imp qt (Imperial quart) ml (milliliter) cc (cubic centimeter) cu in (cubic inch) fl oz (fluid ounce) Weight g (gram) oz (ounce)

GI–6 FUNDAMENTAL PROCEDURES PREPARATION OF TOOLS AND MEASURING EQUIPMENT AME201400004101 • Be sure that all necessary tools and measuring equipment are available before starting any work. End Of Sie SPECIAL SERVICE TOOLS AME201400004102 • Use special service tools or equivalent when they are required. End Of Sie DISASSEMBLY AME201400004103 • If the disassembly procedure is complex, requiring many parts to be disassembled, all parts should be marked in a place that will not affect their performance or external appearance and identified so that reassembly can be performed easily and efficiently. End Of Sie FUNDAMENTAL PROCEDURES X3U000WAH X3U000WAJ X3U000WAL

FUNDAMENTAL PROCEDURES GI–7 GI INSPECTION DURING REMOVAL, DISASSEMBLY AME201400004104 • When removed, each part should be carefully inspected for malfunction, deformation, damage, and other problems. End Of Sie ARRANGEMENT OF PARTS AME201400004105 • All disassembled parts should be carefully arranged for reassembly. • Be sure to separate or otherwise identify the parts to be replaced from those that will be reused. End Of Sie CLEANING OF PARTS AME201400004106 • All parts to be reused should be carefully and thoroughly cleaned in the appropriate method. Warning • Using compressed air can cause dirt and other particles to fly out causing injury to the eyes. Wear protective eye wear whenever using compressed air. End Of Sie REASSEMBLY AME201400004107 • Standard values, such as torques and certain adjustments, must be strictly observed in the reassembly of all parts. • If removed, these parts should be replaced with new ones: — Oil seals — Gaskets — O-rings — Lockwashers — Cotter pins — Nylon nuts X3U000WAM X3U000WAN WGIWXX0030J WGIWXX0031J

GI–8 FUNDAMENTAL PROCEDURES • Depending on location: — Sealant and gaskets, or both, should be applied to specified locations. When sealant is applied, parts should be installed before sealant hardens to prevent leakage. — Oil should be applied to the moving components of parts. — Specified oil or grease should be applied at the prescribed locations (such as oil seals) before reassembly. End Of Sie ADJUSTMENT AME201400004108 • Use suitable gauges and/or testers when making adjustments. End Of Sie RUBBER PARTS AND TUBING AME201400004109 • Prevent gasoline or oil from getting on rubber parts or tubing. End Of Sie HOSE CLAMPS AME201400004110 • When reinstalling, position the hose clamp in the original location on the hose and squeeze the clamp lightly with large pliers to ensure a good fit. End Of Sie WGIWXX0032J X3U000WAS WGIWXX0034E WGIWXX0035J

2002-2014 Mazda6 Service & Repair Manual

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