Mazda2004–2009Technical specifications

3 1.6: Technical specifications

Workshop data for the 1.6-litre diesel (engine code Y6). Covers engine, fluids, brakes, service, torques and air conditioning: the figures to check before a job or a parts order.

Common faults & fixes

Summary

Match the engine code (Y6) to the vehicle before ordering parts or applying these figures.

Vehicle specifications

Overview

Make: Mazda
Model: 3
Years: 2004–2009
Fuel: Diesel
Engine code: Y6

Performance & efficiency

Power: 80 kW (109 hp)
Engine size: 1,560 cc
Cylinders: 4 · DOHC
Compression ratio: 18.0:1

Fluids & capacities

Engine oil (with the filter): 3.8 litres

All 95 specifications below

Engine & identification

Vehicle identification

No. of cylinders Type	4/DOHC
Capacity cc	1560
Compression ratio :1	18,0

Injection system

Air metering Type	Mass/MAP
Fuel/injection pump assembly Make	Bosch
Pump type	Common rail
Injector Ohm	0,7

Injection sequence

The injection sequence for the Mazda 3 1.6 (2004–2009) is 1-3-4-2.

Injection sequence	1-3-4-2

Valve clearances

Valve clearances on the Mazda 3 1.6 (2004–2009) are hydraulic — they self-adjust, so no manual clearance figure applies.

Valve clearance - INLET mm	Hydraulic
Valve clearance - EXHAUST mm	Hydraulic

Engine oil & fluids

Engine oil

The Mazda 3 1.6 (2004–2009) takes 3.8 litres of engine oil with the filter.

See the reference table for the complete engine oil entries and their conditions.

Manual gearbox

The manual gearbox has a listed capacity of 1.9 litres.

Coolant

The listed total cooling-system capacity is 8.5 litres.

Grades, filling conditions and capacities

Lubricants and capacities — complete reference
Engine oil options
Ambient temperature range	➞30°C
Engine oil grade SAE	5W-30
Engine oil classification API/ACEA	CF/B1, B3, B4, B5
Ambient temperature range	-15°C➞40°C
Engine oil grade SAE	10W-30
Engine oil classification API/ACEA	CF/B3, B4
Ambient temperature range	-25°C➞45°C
Engine oil grade SAE	10W-40
Engine oil classification API/ACEA	CF/B3
Engine with filter(s) litres	3.8
Other lubricants and capacities
Manual transmission oil grade SAE	—
Manual transmission litres	1.9
Cooling system - total capacity litres	8.5
Brake fluid Type	DOT 3/4
Power steering fluid Type	ATF M-III
Power steering fluid litres	0.8
Diesel particulate filter (DPF) additive Make	Mazda
Diesel particulate filter (DPF) additive Type	Y605-13-SS0
Diesel particulate filter (DPF) additive litres	1.8

Brakes & wear limits

Brake disc thickness

Brake discs on the Mazda 3 1.6 (2004–2009) are replaced at a minimum thickness of 23 mm (ventilated) front and 9 mm rear.

Minimum disc thickness for replacement - ventilated Front	23 mm
Minimum disc thickness for replacement Rear	9 mm

Brake disc and drum dimensions

Disc thickness variation Front	0,015 mm
Disc thickness variation Rear	0,015 mm
Disc runout Front	0,05 mm
Disc runout Rear	0,05 mm
Minimum pad thickness Front	2 mm
Minimum pad thickness Rear	2 mm
Parking brake travel No. of notches	3-6

Service & electrical

Battery

The Mazda 3 1.6 (2004–2009) uses a 12 V, 55 Ah battery.

Battery V/RC(Ah)	12 (55)

Tuning and emissions

Idle speed rpm	750±50
Oil temperature °C	80
Test mode A/B	B
Probe type 1/2	1

Starting and charging

Alternator output A/V/rpm	150/12/-

Service checks and adjustments

Oil pressure bar/rpm	2,3-3,7/2000
Radiator cap bar	1,35-1,55
Thermostat opens °C	80-84

Tightening torques

Cylinder head bolt torque

The cylinder head bolts on the Mazda 3 1.6 (2004–2009) are tightened in 3 stages: 20 Nm, then 40 Nm, then a final 220°.

Cylinder head
Renew bolts	Yes
Tighten	20 Nm
Tighten	40 Nm
Tighten	220°

Other engine tightening torques
Cylinder head instructions	—
Main bearings Renew bolts/nuts	Yes
Main bearings Stage 1	—
Big end bearings Renew bolts/nuts	Yes
Big end bearings Stage 1	—
Oil pump to cylinder block	10 Nm
Sump bolts	10 Nm
Sump drain bolt	25 Nm
Flywheel/driveplate	30 Nm+90°
Clutch pressure plate	29 Nm
Crankshaft pulley/damper centre bolt	30 Nm+180°
Camshaft sprocket/gear	43 Nm
Camshaft carrier/cap	1)5 Nm 2)10 Nm
Camshaft/rocker cover	10 Nm
Inlet manifold to cylinder head	9-12 Nm
Exhaust manifold to cylinder head	25 Nm
Exhaust downpipe to manifold	38-51 Nm
Water pump	1)3 Nm 2)10 Nm
Injector/clamp	4 Nm+75°
Injector pipe unions	10-23 Nm
Fuel/injection pump sprocket/gear	50 Nm
Fuel/injection pump mounting	20 Nm
Glow plugs	8 Nm
Crankshaft position (CKP) sensor/engine speed (RPM) sensor	8 Nm
Camshaft position (CMP) sensor	5 Nm
Engine oil pressure switch	30 Nm
Oil filter	11-16 Nm
Chassis tightening torques
Front hub	—
Rear hub	58±8 Nm
Steering wheel	48±7 Nm
Steering rack/box mounting	90±15 Nm
Steering track rod end	56±19 Nm
Brake caliper to carrier Front	28±2 Nm
Brake caliper/carrier to hub Front	110±8 Nm
Brake caliper to carrier Rear	28±2 Nm
Brake caliper/carrier to hub Rear	68±8 Nm
ABS sensor Front	5±1 Nm
ABS sensor Rear	5±1 Nm
Road wheels	103±15 Nm

Air conditioning

No. of AC service connectors	2
Air conditioning restrictor type	Expansion valve
Compressor clutch/magnetic coupling	Yes
Compressor variable displacement solenoid	No
Air conditioning refrigerant Type	R134a
Air conditioning refrigerant quantity grams	650
Air conditioning oil group	PAG
Air conditioning oil Type	SP10
Air conditioning oil quantity cm³	200
Air conditioning oil viscosity ISO	46

Frequently asked questions

What is the injection sequence of the Mazda 3 1.6?

The injection sequence for the Mazda 3 1.6 (2004–2009) is 1-3-4-2.

How much oil does the Mazda 3 1.6 take?

The Mazda 3 1.6 (2004–2009) takes 3.8 litres of engine oil with the filter. See the reference table for the complete engine oil entries and their conditions.

What are the valve clearances for the Mazda 3 1.6?

Valve clearances on the Mazda 3 1.6 (2004–2009) are hydraulic — they self-adjust, so no manual clearance figure applies.

What is the cylinder head torque for the Mazda 3 1.6?

The cylinder head bolts on the Mazda 3 1.6 (2004–2009) are tightened in 3 stages: 20 Nm, then 40 Nm, then a final 220°.

What is the minimum brake disc thickness for the Mazda 3 1.6?

Brake discs on the Mazda 3 1.6 (2004–2009) are replaced at a minimum thickness of 23 mm (ventilated) front and 9 mm rear.

What battery does the Mazda 3 1.6 use?

The Mazda 3 1.6 (2004–2009) uses a 12 V, 55 Ah battery.