Mazda Car 2002-04

Oil Pan 2

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Removal & Installation



2.5L (Kl) Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Right hand splash shield on Millenia models

    Click image to see an enlarged view

    Fig. Exploded view of the oil pan and related components-2.5L (KL) engines, 626 model shown Millenia similar

     
    Oxygen (O 2 S) sensor
     
    Front exhaust pipe
     
    Oil pan bolts and the oil pan
     

  6.  

To install:

  1. Clean the oil pan. Clean all dirt, oil and old sealant from the oil pan and cylinder block contact surfaces.
  2.  
  3. Apply a continuous bead of silicone sealant around the oil pan, going on the inside of the bolt holes.
  4.  
  5. Install or connect the following:

    Oil pan. Torque the long bolts to 14-18 ft. lbs. (19-25 Nm) and the short bolts to 70-95 inch lbs. (8-11 Nm).
     
    Front pipe
     
    O 2 S connector
     
    Right hand splash shield on Millenia models
     
    Negative battery cable
     

  6.  
  7. Fill the engine with clean oil.
  8.  
  9. Start the engine, check for leaks and repair if necessary.
  10.  

3.0L (Aj) Engine


Click image to see an enlarged view

Fig. Exploded view of the oil pan and related components-Mazda 6 with the 3.0L (AJ) engine

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the right hand three way converter.
  8.  
  9. Remove the end plate cover.
  10.  
  11. Remove the oil pan-to-transaxle bolts.
  12.  
  13. Loosen the oil pan retainers using 2-3 passes in the order illustrated.
  14.  
  15. Thoroughly clean the gasket mating surfaces.

    Click image to see an enlarged view

    Fig. Loosen the oil pan retainers using 2-3 passes in the order shown-Mazda 6 with the 3.0L (AJ) engine

  16.  

To install:

  1. Apply a 0.39 inch (10mm) bead of silicone sealer to the oil pan at the locations illustrated.
  2.  
  3. Install the oil pan retainers and hand tighten.
  4.  
  5. Install the oil pan-to-transaxle bolts.
  6.  
  7. Tighten the oil pan retainers in the sequence illustrated to 15-22 ft. lbs. (20-30 Nm).
  8.  
  9. Tighten the oil pan-to-transaxle bolts to 28-38 ft. lbs. (38-51 Nm)
  10.  
  11. Install the remaining components in the reverse order of removal.
  12.  
  13. Fill the engine with clean oil.
  14.  
  15. Start the vehicle, check for leaks and repair if necessary.

    Click image to see an enlarged view

    Fig. Apply a 0.39 inch (10mm) bead of silicone sealer to the oil pan at the locations shown-Mazda 6 with the 3.0L (AJ) engine



    Click image to see an enlarged view

    Fig. Location of the oil pan stud bolts-Mazda 6 with the 3.0L (AJ) engine



    Click image to see an enlarged view

    Fig. Oil pan torque sequence-Mazda 6 with the 3.0L (AJ) engine

  16.  

Mazdaspeed6
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the engine under cover.
  6.  
  7. Remove the right front wheel.
  8.  
  9. Drain the engine oil.
  10.  
  11. Remove the engine front cover. Refer to the timing chain removal procedure in this section.
  12.  
  13. Remove the dipstick tube pipe and O-ring.
  14.  
  15. Remove the oil pan bolts and use a separator tool to separate the oil pan from the block.
  16.  
  17. Remove the oil pan.
  18.  

To install:

  1. Clean the oil pan mating surfaces.
  2.  
  3. Apply a 0.087-126 inch (2.2-3.2mm) bead of sealant around the perimeter of the oil pan as illustrated.
  4.  
  5. Use a square ruler to align the oil pan and the block junction side on the engine front cover side.
  6.  
  7. Install the oil pan within 5 minutes of applying the sealant.
  8.  
  9. Install the lower oil pan bolts and tighten in sequence to 12.6-17 ft. lbs. (17-23 Nm) and the oil pan-to-transaxle bolts to 28-38 ft. lbs. (37-52 Nm).
  10.  
  11. Install the remaining components in the reverse order of removal.
  12.  
  13. Fill the engine with clean oil.
  14.  
  15. Start the vehicle, check for leaks and repair if necessary.

    Click image to see an enlarged view

    Fig. Apply a 0.087-126 inch (2.2-3.2mm) bead of sealant around the perimeter of the oil pan-Mazdaspeed6

  16.  

 
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