Mazda 6 (Mazda6) Engine Workshop Manual (L8, LF, L3).pdf

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.

Engine

Workshop

Manual

CONTENTS

Title

Section

General Information

Engine

Technical Data

Special Tools

PRINTED IN JAPAN, MARCH 2002

1731–10–02C

FOREWORD

This manual explains the disassembly,

inspection, repair, and reassembly

procedures for the above-indicated engine.

In order to do these procedures safety,

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 March, 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

serving.

Mazda Motor Corporation

HIROSHIMA, JAPAN

GENERAL 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

SST .................................................................... 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–1

HOW TO USE THIS MANUAL

RANGE OF TOPICS

A6E201000001E01

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

A6E201000001E02

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

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.

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.

GI–2

HOW TO USE THIS MANUAL

XME2010010

End Of Sie

SYMBOLS

A6E201000001E03

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 s ervice.

Symbol

Meaning

Kind

Apply oil

New appropriate

engine oil or gear

oil

Apply brake fluid

New appropriate

brake fluid

GI–3

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