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Mazda 6 2002 Engine Workshop Manual

Mazda 6 2002 Engine Workshop Manual

Online PDF Mazda 6 2002 Engine Workshop Manual

This manual contains procedures for performing all required service operations. The procedures are divided into the following five basic operations:

  1. Removal/Installation
  2. Disassembly/Assembly
  3. Replacement
  4. Inspection
  5. 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.

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.

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/cm2 in the following specifications:

  • 210—260 kPa {2.1—2.7 kgf/cm2, 30—38 psi}
  • 270—310 kPa {2.7—3.2 kgf/cm2, 39—45 psi}

The actual converted values for 2.7 kgf/cm2 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.

TORQUE FORMULAS
When using a torque wrench-SST or equivalent combination, the written torque must be recalculated due to the extra length that the SST or equivalent adds to the torque wrench. Recalculate the torque using the following formulas. Choose the formula that applies to you.

Managing the Vehicle Damage Repair Process
In the event that your vehicle requires damage repairs, GM recommends that you take an active role in its repair. If you have a pre-determined repair facility of choice, take your vehicle there, or have it towed there. Specify to the facility that any required replacement collision parts be original equipment parts, either new Genuine GM parts or recycled original GM parts. Remember, recycled parts will not be covered by your GM vehicle warranty.

Insurance pays the bill for the repair, but you must live with the repair. Depending on your policy limits, your insurance company may initially value the repair using aftermarket parts. Discuss this with your repair professional, and insist on Genuine GM parts. Remember if your vehicle is leased you may be obligated to have the vehicle repaired with Genuine GM parts, even if your insurance coverage does not pay the full cost.

If another party’s insurance company is paying for the repairs, you are not obligated to accept a repair valuation based on that insurance company’s collision policy repair limits, as you have no contractual limits with that company. In such cases, you can have control of the repair and parts choices as long as cost stays within reasonable limits.

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