General Information: Other Mazda 6 GJ

Range of Topics

1. Mazda Service Information 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
2. 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.

Scheme 23

1. 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. (Scheme 23): Inspecting Cooling System Cap

Scheme 24

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. (Scheme 24): Repair Procedure Chart

Scheme 25

1. There are eight symbols indicating oil, grease, fluids, sealant, and the use of SST or equivalent. These symbols show application points or use of these materials during service. (Scheme 25): Symbols Chart

Advisory Messages

1. You will find several Warnings, Cautions, Notes, Specifications and Upper and Lower Limits in this manual.

Note. A Note provides added information that will help you to complete a particular procedure.

Specification

1. The values indicate the allowable range when performing inspections or adjustments.

Upper and lower limits

1. The values indicate the upper and lower limits that must not be exceeded when performing inspections or adjustments.

Troubleshooting Basic Flow Chart. Scheme 26

UNITS

Conversion from SI Units (Systeme International d'Unites)

1. All numerical values in this manual are based on SI units. Numbers shown in conventional units are converted from these values.

Number Of Digits For Converted Values

1. The number digits for converted values is the same as the number of significant figures *1 of the SI unit.
2. For the torque value, the number of significant figures is, in principle, is 2 digits, in consideration of market practicalities. However, if the number of decimal places at the upper and lower limits of the converted value differs, the one with least number of decimal places is used. In addition, if the integer part is 3 digits or more, the integer part becomes the significant number of figures.

*1 The number of significant figures is the number of digits from the left-most non-zero digit to the right-most digit including 0. (Example: 0.12 is 2 digits, 41.0 is 3 digits)

Converted Value Rounding Off And Rounding Up/down

1. If there is no tolerance in the SI unit value, after conversion, rounding off is to within the number of significant digits.
2. If there is tolerance in the SI unit value and the figure after conversion indicates the upper limit, the number of digits is rounded down to within the number of significant figures. If it indicates the lower limit, they are rounded up to within the number of significant figures.
3. Even if the SI unit value is the same, the converted value may differ based on whether that value is the upper or lower limit.

Injury/Damage Prevention Precautions

1. Depending on the vehicle, the cooling fan may operate suddenly even when the ignition is switched to off. Therefore, keep hands and tools away from the cooling fan even if the cooling fan is not operating to prevent injury to personnel or damage to the cooling fan. Always disconnect the negative battery cable when servicing the cooling fan or parts near the cooling fan.

Scheme 27

1. Always be sure to cover fenders, seats and floor areas before starting work. (Scheme 27): Protection Of Vehicle

Scheme 28

1. Be sure that all necessary tools and measuring equipment are available before starting any work. (Scheme 28): Preparation Of Tools And Measuring Equipment

Scheme 29

1. Use special service tools or equivalent when they are required. (Scheme 29): Identifying Special Service Tools

Negative Battery Cable Disconnection/connection

Negative battery cable disconnection/required procedures after connecting

Using UV light (black light)

1. Remove any oil on the engine or transmission/transaxle. NOTE: Referring to the fluorescent dye instruction manual, mix the specified amount of dye into the engine oil or transmission/transaxle oil.
2. Pour the fluorescent dye into the engine oil or transmission/transaxle oil.
3. Allow the engine to run for 30 min .
4. Inspect for dye leakage by irradiating with UV light (black light), and identify the type of oil that is leaking.
5. If no dye leakage is found, allow the engine to run for another 30 min . or drive the vehicle then reinspect.
6. Find where the oil is leaking from, then make necessary repairs. NOTE: To determine whether it is necessary to replace the oil after adding the fluorescent dye, refer to the fluorescent dye instruction manual.

Scheme 30

1. Gather sample of the leaking oil using an absorbent white tissue.
2. Then, gather some samples of engine and transmission/transaxle oil onto a white cloth or piece of paper. MT vehicles: Transmission/transaxle oil AT vehicles: ATF
3. Compare the appearance and smell, and identify the type of oil that is leaking. (Scheme 30): Identifying Engine Oil Leaking Area
4. Remove any oil on the engine or transmission/transaxle.
5. Allow the engine to run for 30 min.
6. Check the area where the oil is leaking, then make necessary repairs.

Scheme 31

1. While correcting a problem, also try to determine its cause. Begin work only after first learning which parts and subassemblies must be removed and disassembled for replacement or repair. After removing the part, plug all holes and ports to prevent foreign material from entering. (Scheme 31): Troubleshooting Procedure

Scheme 32

1. 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. (Scheme 32): Identifying Typical Mark Location

Scheme 33

1. When removed, each part should be carefully inspected for malfunction, deformation, damage and other problems. (Scheme 33): Inspecting Components

Scheme 34

1. All disassembled parts should be carefully arranged for reassembly. (Scheme 34): Identifying Arrangement Of Parts
2. Be sure to separate or otherwise identify the parts to be replaced from those that will be reused.

Scheme 35

1. All parts to be reused should be carefully and thoroughly cleaned in the appropriate method. (Scheme 35): Cleaning Of Parts

Scheme 36

Scheme 37

1. Standard values, such as torques and certain adjustments, must be strictly observed in the reassembly of all parts. (Scheme 36): Tightening Bolts Using Torque Wrench
2. If removed, these parts should be replaced with new ones: Oil seals Gaskets O-rings Lockwashers Cotter pins Nylon nuts
3. Depending on location: (Scheme 37): Identifying Sealant Application Area 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.

Scheme 38

1. Use suitable gauges and testers when making adjustments. (Scheme 38): Caution For Making Adjustments

Scheme 39

1. Prevent gasoline or oil from getting on rubber parts or tubing. (Scheme 39): Caution For Rubber Parts And Tubing

Scheme 40

1. 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. (Scheme 40): Identifying Hose Clamp Position

Scheme 41

1. 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 by using the following formulas. Choose the formula that applies to you. (Scheme 41): Changes In Applied Torque Due To Torque Wrench Length

A The length of the SST past the torque wrench drive.

L The length of the torque wrench.

Scheme 42

1. When using a vise, put protective plates in the jaws of the vise to prevent damage to parts. (Scheme 42): Vise Protective Plates

Dynamometer

1. When inspecting and servicing the power train on the dynamometer or speed meter tester, pay attention to the following: Place a fan, preferably a vehicle-speed proportional type, in front of the vehicle. Make sure the vehicle is in a facility with an exhaust gas ventilation system. Keep the rear bumper cool by placing a cooling fan near the exhaust pipe so that the rear bumper does not get deformed by the heat from the exhaust. Keep the area around the vehicle uncluttered so that heat does not build up. Watch the water temperature gauge and don't overheat the engine. Avoid added load to the engine and maintain normal driving conditions as much as possible. NOTE: When only the front or rear wheels are rotated on a chassis dynamometer or equivalent, the DSC HU/CM determines that there is a malfunction in the DSC and illuminates the following lights: ABS warning light Brake system warning light DSC indicator light
2. If the above lights are illuminated, dismount the vehicle from the chassis dynamometer and switch the ignition OFF (LOCK). Then, switch the ignition ON, run the vehicle at 10 km/h {6.2 mph} or more and verify that the warning lights go out. In this case, a DTC will be stored in the memory. Clear the DTC from the memory by following the memory clearing procedure [DSC] in the on-board diagnostic system. (See «ON-BOARD DIAGNOSIS [DYNAMIC STABILITY CONTROL (DSC)]»(ref-581612-S35041327492013101400000) .)

SST

1. Some global SST or equivalent are used as SSTs necessary for engine repair. Note that these SSTs are marked with global SST numbers.
2. Note that a global SST number is written together with a corresponding Mazda SST number as shown below.

Identifying SST List Example. Scheme 43

Identifying SST In Text Example. Scheme 44

Direction of View for Connector

1. The viewing direction of connectors is indicated with a symbol.
2. The figures showing the viewing direction are the same as those used in Wiring Diagrams.
3. The viewing directions are shown in the following three ways

Part-side connector

The viewing direction of part-side connectors is from the terminal side.

Identifying Part-Side Connector. Scheme 45

* Part names are shown only when there are multiple connector drawings.

Other

When it is necessary to show the terminal side of vehicle harness-side connectors, such as the following connectors, the viewing direction is from the terminal side.

Identifying Terminal Side Of Vehicle Harness-Side Connectors. Scheme 46

1. Main fuse block and the main fuse block relays
2. Data link connector
3. Check connector
4. Relay box

Identifying Jumper Wire. Scheme 47

Scheme 48

1. The DC voltmeter is used to measure circuit voltage. A voltmeter with a range of 15 V or more is used by connecting the positive (+) probe (red lead wire) to the point where voltage will be measured and the negative (-) probe (black lead wire) to a body ground. (Scheme 48): Measuring Circuit Voltage Using DC Voltmeter

Caution - Do Not Connect Ohmmeter To Any Circuit Where Voltage Is Applied. Scheme 49

Precautions Before Welding

A vehicle has various electrical parts. To protect the parts from excessive current generated when welding, be sure to perform the following procedure.

Scheme 50

Scheme 51

1. Switch the ignition to OFF (LOCK).
2. Disconnect the battery cables. (Scheme 50): Disconnecting Battery Cables
3. Securely connect the welding machine ground near the welding area. (Scheme 51): Connecting Welding Machine Ground Near Welding Area
4. Cover the peripheral parts of the welding area to protect them from weld spatter.

Jacking Positions

Front

Note. To prevent obstruction between the jack body and front bumper when the jack body is inserted, use a low-floor type jack. Near the center of the front crossmember.

Scheme 52

1. Near the center of the rear crossmember. (Scheme 52): Identifying Front And Rear Jacking Points

Front and rear

Identifying Vehicle Side Sills. Scheme 53

Scheme 54

1. Proper lifting and towing are necessary to prevent damage to the vehicle. Government and local laws must be followed.
2. A towed vehicle usually should have its drive wheels (front wheels) off the ground. If excessive damage or other conditions prevent this, use wheel dollies.
3. When towing with the rear wheels on the ground, release the parking brake. (Scheme 54): Identifying Vehicle Towing

Caution - Do Not Tow Vehicle Pointed Backward With Driving Wheels On Ground. Scheme 55

Caution - Do Not Tow With Sling-Type Equipment. Scheme 56

Scheme 57

1. When transporting the vehicle by flat bed tow truck or trailer, secure the vehicle to the trailer using the holes and left tiedown loop shown in the figure. (Scheme 57): Identifying Holes And Left Tiedown Loop

Scheme 58

Scheme 59

1. The VIN marking position is located on the floor on the front passenger-side. (Scheme 58): Locating VIN Marking Position On Floor Of Front Passenger-Side
2. If the VIN plate is adhered to the dashboard, it is located in the position shown in the figure. (Scheme 59): Locating VIN Plate

Identifying Engine Type/Number. Scheme 60

SAE STANDARDS

1. In accordance with new regulations, SAE (Society of Automotive Engineers) standard names and abbreviations are now used in this manual. The table below lists the names and abbreviations that have been used in Mazda manuals up to now and their SAE equivalents.

Exterior

INSPECT and ADJUST , if necessary, the following items to specification

[] Glass, exterior bright metal and paint for damage

[] Wheel lug nuts

[] All weatherstrips for damage or detachment

[] Tire pressures

[] Operation of hood release and lock

[] Operation of trunk lid and fuel-filler lid opener

[] Door operation and alignment including side door and back door

[] Headlight aiming

INSTALL the following parts

[] Flap (front)

[] Wheel caps or rings (if equipped)

Under hood-engine off

INSPECT and ADJUST , if necessary, the following items to specification

[] Fuel, engine coolant, and hydraulic lines, fittings, connections, and components for leaks

[] Engine oil level

[] Power steering fluid level

[] Brake and clutch fluid level

[] Windshield washer reservoir fluid level

[] Radiator coolant level and specific gravity

[] Tightness of water hose clamps

[] Tightness of battery terminals, electrolyte level and specific gravity

Interior

INSTALL the following items

[] Fuse for accessories

INSPECT the operations of the following items

[] Seat controls (slide and recline) and headrests

[] Folding rear seat

[] Door locks, including childproof door locks

[] Seat belts and warning system

[] Ignition switch and steering lock

[] Transaxle range switch

[] Warning buzzers

[] Ignition key reminder alarm

[] Air bag system using warning light

[] Cruise control system (if equipped)

[] Power door lock

[] Shift-lock system (if equipped)

[] Starter interlock

[] All lights including warning, and indicator lights

[] Horn, wipers, and washers

[] Wiper blades performance Clean wiper blades and windshield, if necessary

[] Antenna

[] Audio system

[] Cigarette lighter and clock

[] Power windows (if equipped)

[] Heater, defroster, and air conditioner at various mode selections (if equipped)

INSPECT the following items

[] Presence of spare fuse

[] Upholstery and interior finish

INSPECT and ADJUST , if necessary, the following items

[] Operation and fit of windows

[] Pedal height and free play of clutch pedal

[] Parking brake

Under hood-engine running at operating temperature

INSPECT the following items

[] Automatic transaxle fluid level

[] Operation of idle-up system for electrical load, air conditioner or power steering (if equipped)

[] Ignition timing

[] Idle speed

[] Operation of throttle position sensor

[] Operation of EGR valve

On hoist

INSPECT the following items

[] Manual transaxle oil level

[] Underside fuel, coolant and hydraulic lines, fittings, connections, and components for leaks

[] Tires for cuts or bruises

[] Steering linkage, suspension, exhaust system, and all underside hardware for looseness or damage

Schedule 1 (Normal Driving Conditions) for USA

1. The vehicle is mainly operated where none of the "unique driving conditions" apply.

Chart symbols

1. I: Inspect: Inspect and clean, repair, adjust, fill up, or replace if necessary.
2. R: Replace
3. C: Clean
4. L: Lubricate
5. T: Tighten

Remarks

1. After the prescribed period, continue to follow the described maintenance at the recommended intervals.
2. Refer below for a description of items marked* in the maintenance chart. *1: Use FL22 type coolant in vehicles with the inscription "FL22" on the radiator cap itself or the surrounding area. Use FL22 when replacing the coolant. *2: According to state/provincial and federal regulations, failure to perform maintenance on these items will not void your emissions warranties. However, Mazda recommends that all maintenance services be performed at the recommended time or mileage/kilometer period to ensure long-term reliability.

Schedule 2 CANADA, Puerto Rico, and (Unique Driving Conditions) for USA

1. Repeated short-distance driving
2. Driving in dusty conditions
3. Driving with extended use of brakes
4. Driving in areas where salt or other corrosive materials are used
5. Driving on rough or muddy roads
6. Extended periods of idling or low-speed operation
7. Driving for long periods in cold temperatures or extremely humid climates
8. Driving in extremely hot conditions
9. Driving in mountainous conditions continually

Chart symbols

1. I: Inspect: Inspect and clean, repair, adjust, fill up, or replace if necessary.
2. R: Replace
3. C: Clean
4. L: Lubricate
5. T: Tighten

1. After the prescribed period, continue to follow the described maintenance at the recommended intervals.
2. Refer below for a description of items marked* in the maintenance chart. *1: Use FL22 type coolant in vehicles with the inscription "FL22" on the radiator cap itself or the surrounding area. Use FL22 when replacing the coolant. *2: According to state/provincial and federal regulations, failure to perform maintenance on these items will not void your emissions warranties. However, Mazda recommends that all maintenance services be performed at the recommended time or mileage/kilometer period to ensure long-term reliability. *3: If the vehicle is operated primarily under any of the following conditions, replace the spark plugs at every 96,000 km (60,000 miles) or shorter. Repeated short-distance driving Extended periods of idling or low-speed operation Driving for long periods in cold temperatures or extremely humid climates

Schedule 1 (Normal Driving Conditions) for Mexico

1. The vehicle is mainly operated where none of the "unique driving conditions" apply.

Chart symbols

1. I: Inspect: Inspect and clean, repair, adjust, fill up, or replace if necessary.
2. R: Replace
3. C: Clean
4. L: Lubricate
5. T: Tighten

Remarks

1. After the prescribed period, continue to follow the described maintenance at the recommended intervals.
2. Refer below for a description of items marked* in the maintenance chart. *1: Use FL22 type coolant in vehicles with the inscription "FL22" on the radiator cap itself or the surrounding area. Use FL22 when replacing the coolant. *2: According to state/provincial and federal regulations, failure to perform maintenance on these items will not void your emissions warranties. However, Mazda recommends that all maintenance services be performed at the recommended time or kilometer period to ensure long-term reliability.

Schedule 2 (Unique Driving Conditions) for Mexico

1. Repeated short-distance driving
2. Driving in dusty conditions
3. Driving with extended use of brakes
4. Driving in areas where salt or other corrosive materials are used
5. Driving on rough or muddy roads
6. Extended periods of idling or low-speed operation
7. Driving for long periods in cold temperatures or extremely humid climates
8. Driving in extremely hot conditions
9. Driving in mountainous conditions continually

Chart symbols

1. I: Inspect: Inspect and clean, repair, adjust, fill up, or replace if necessary.
2. R: Replace
3. C: Clean
4. L: Lubricate
5. T: Tighten

Remarks

1. After the prescribed period, continue to follow the described maintenance at the recommended intervals.
2. Refer below for a description of items marked* in the maintenance chart. *1: Use FL22 type coolant in vehicles with the inscription "FL22" on the radiator cap itself or the surrounding area. Use FL22 when replacing the coolant. *2: According to state/provincial and federal regulations, failure to perform maintenance on these items will not void your emissions warranties. However, Mazda recommends that all maintenance services be performed at the recommended time or kilometer period to ensure long-term reliability.