1730-1E-02C.pdf

Mazda6

Workshop

Manual

CONTENTS

Title

Section

General Information

Engine

Lubrication System

FOREWORD

This manual contains on-vehicle service

and diagnosis for the Mazda6.

Cooling System

Fuel and Emission Control Systems

Engine Electrical System

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.

Clutch

Manual Transaxle

Automatic Transaxle

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.

Front and Rear Axles

Steering System

Braking System

Suspension

Mazda Motor Corporation reserves

the right to alter the specifications and

contents of this manual without obligation

or advance notice.

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.

Body

Body Electrical System

Heater and Air Conditioner Systems

Technical Data

Special Tools

PRINTED IN The Netherlands, MARCH 2002

1730–1E–02C

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.

VEHICLE IDENTIFICATION NUMBERS (VIN)

U.K. specs.

JMZ GG12820#

100001—

JMZ GG14320#

100001—

JMZ GG14820#

100001—

JMZ GG12F20#

100001—

JMZ GG12F50#

100001—

JMZ GG14F20#

100001—

JMZ GG14F50#

100001—

European (L.H.D.) specs.

JMZ GG1232

✻ #

100001—

JMZ GG1282

✻ #

100001—

JMZ GG1432

✻ #

100001—

JMZ GG1482

✻ #

100001—

JMZ GG12F2

✻ #

100001—

JMZ GG12F5

✻ #

100001—

JMZ GG14F2

✻ #

100001—

JMZ GG14F5

✻ #

100001—

GCC specs.

JM7 GG32F ✻✻

✻✻ #

100001—

✻✻✻

JM7 GG34F ✻✻

✻✻ #

100001—

✻✻✻

JM7 GG42F ✻✻

✻✻ #

100001—

✻✻✻

JM7 GG44F ✻✻

✻✻ #

100001—

✻✻✻

RELATED MATERIALS

Mazda6 Training Manual

(European (L.H.D.), GCC Specs.) . . . . . . . . . . . . . . . . 3359–1*–02C

Engine Workshop Manual L8, LF, L3 . . . . . . . . . . . . . . 1731–1*–02C

Manual Transaxle Workshop Manual

G35M–R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1732–1*–02C

Automatic Transaxle Workshop Manual

FN4A–EL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1623–10–98E

Automatic Transaxle Workshop Manual

Supplement FN4A–EL . . . . . . . . . . . . . . . . . . . . . . . . . 1746–1*–02C

Mazda6 Wiring Diagram

(European (L.H.D.), GCC specs.) . . . . . . . . . . . . . . . . 5539–1*–02C

Mazda6 Wirinig Diagram

(U.K. specs.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5540–1*–02C

Mazda6 Bodyshop Manual

(European (L.H.D. U.K.), GCC specs.) . . . . . . . . . . . . 3360–1*–02C

* : Indicates the printing location

E: Europe

0: Japan

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.

GENERAL INFORMATION

HOW TO USE THIS MANUAL ..............................GI-2

RANGE OF TOPICS ...........................................GI-2

SERVICE PROCEDURE ....................................GI-2

SYMBOLS...........................................................GI-4

ADVISORY MESSAGES ....................................GI-4

TROUBLESHOOTING PROCEDURE ................GI-5

UNITS ..................................................................GI-11

UNITS ...............................................................GI-11

FUNDAMENTAL PROCEDURES .......................GI-12

PROTECTION OF VEHICLE ............................GI-12

PREPARATION OF TOOLS AND

MEASURING EQUIPMENT...........................GI-12

SPECIAL SERVICE TOOLS .............................GI-12

OIL LEAKAGE INSPECTION ...........................GI-12

DISCONNECTION OF THE NEGATIVE

BATTERY CABLE..........................................GI-13

REMOVAL OF PARTS .....................................GI-13

DISASSEMBLY.................................................GI-13

INSPECTION DURING REMOVAL,

DISASSEMBLY..............................................GI-14

ARRANGEMENT OF PARTS ...........................GI-14

CLEANING OF PARTS.....................................GI-14

REASSEMBLY..................................................GI-14

ADJUSTMENT ..................................................GI-15

RUBBER PARTS AND TUBING .......................GI-15

HOSE CLAMPS ................................................GI-16

TORQUE FORMULAS......................................GI-16

VISE ..................................................................GI-16

DYNAMOMETER..............................................GI-17

SST ...................................................................GI-17

INSTALLATION OF RADIO SYSTEM ............... GI-17

INSTALLATION OF RADIO SYSTEM ............. GI-17

ELECTRICAL SYSTEM ...................................... GI-18

ELECTRICAL PARTS ...................................... GI-18

CONNECTORS................................................ GI-18

ELECTRICAL TROUBLESHOOTING

TOOLS .......................................................... GI-22

PRECAUTIONS BEFORE WELDING.............. GI-23

JACKING POSITIONS ,VEHICLE LIFT

(2 SUPPORTS),SAFETY STANDS

(RIGID RACK) POSITIONS ............................. GI-24

JACKING POSITIONS, VEHICLE LIFT

(2 SUPPORTS) AND SAFETY STAND

(RIGID RACK) POSITIONS .......................... GI-24

TOWING ............................................................. GI-26

TOWING .......................................................... GI-26

TOWING HOOKS ............................................ GI-26

IDENTIFICATION NUMBER LOCATIONS ........ GI-28

VEHICLE IDENTIFICATION

NUMBER(VIN) .............................................. GI-28

ENGINE IDENTIFICATION NUMBER ............. GI-28

NEW STANDARDS ............................................ GI-29

NEW STANDARDS.......................................... GI-29

ABBREVIATIONS .............................................. GI-31

ABBREVIATIONS ............................................ GI-31

PRE-DELIVERY INSPECTION ........................... GI-32

PRE-DELIVERY INSPECTION........................ GI-32

SCHEDULED MAINTENANCE .......................... GI-33

SCHEDULED MAINTENANCE TABLE ........... GI-33

GI–1

HOW TO USE THIS MANUAL

RANGE OF TOPICS

A6E201000001W01

•

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

•

A6E201000001W02

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 s hown in the illustrations.

XME2010001

GI–2

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