2002 MAZDA 6 lock

CYLINDER HEAD GASKET
B2–17
B2
Supply Pump Pulley Removal Note
1. Verify that timing marks are correctly aligned.
Caution
•To prevent the bolts (M8 x 1.25) from damaging the supply pump and pulley, do not fully tighten
the fixing bolts. If it contacts the pulley surface, it will damage the pulley.
2. Fix the supply pump pulley to the bracket using
two bolts (M8 x 1.25).
3. Loosen the supply pump pulley lock nut.
4. Separate the supply pump pulley from the supply
pump shaft using the SST.
5. Remove the supply pump pulley fixed bolts
(M8 x 1.25).
Drive Gear Removal Note
1. Hold the camshaft using the SST.
2. Remove the drive gear lock bolt.
22 Camshaft
23 Breather pipe24 Cylinder head
(See B2–18 Cylinder Head Removal Note)
(See B2–19 Cylinder Head Installation Note)
25 Cylinder head gasket
M8 1.25
BOLT
A6E2318W101
49 S120 215B
A6E2318W102
49 S120 710
A6E2318W103

B2–18
CYLINDER HEAD GASKET
Camshaft Pulley Removal Note
1. Hold the camshaft using the SST.
2. Remove the camshaft pulley lock bolt.
3. Remove the camshaft pulley using the SST.
Seal Plate Removal Note
1. Remove the seal plate from the engine component. However, the seal plate cannot be removed completely.
Separate the seal plate from the engine component by removing the fitting bolts so that the cylinder head can
be removed.
Rocker Arm and Rocker Arm Shaft Removal Note
1. Loosen the bolts in two or three steps in the order
shown.
Cylinder Head Removal Note
1. Loosen the cylinder head bolts in two or three
steps in the order shown.
49 S120 710
A6E2318W104
49 G011 106
A6E2318W105
9
8
75
4
3
10
11
1262
1
A6E2318W106
98
7
54
3106
1
2
ENGINE
FRONT
A6E2318W107

CYLINDER HEAD GASKET
B2–21
B2
Fuel Injection Pipe Installation Note
Caution
•Fuel injection pipes can be removed and reinstalled up to five times. If removing them for the sixth
time, be sure to replace them with new ones.
Cylinder Head Cover Installation Note
1. Apply silicone sealant to the shaded areas.
Thickness
2 mm {0.079 in}
2. Tighten the bolts in the order shown.
Tightening torque
7.9—10.7 N·m {80—110 kgf·cm, 69.5—95.4
in·lbf}
Seal Plate Installation Note
1. Install the seal plate and hand tighten the bolt in
the order A to B.
2. Tighten the bolts in the order shown.
Tightening torque
7.9—10.7 N·m {80—110 kgf·cm, 69.5—95.4
in·lbf}
Idler Installation Note
Caution
•The idler has a front and back relative to
the engine, therefore when installing
make sure that the longer projection of
the shaft is on the engine side as
indicated in the figure.
SEALANTSEALANTSEALANTSEALANT
SEALANTSEALANT20 mm
{0.79 in}
MIN.VIEW AVIEW A
A6E2318W116
9
8
7
5
4
36
1
2
A6E2318W117
1
2B
A
3
3
A6E2318W118
SHAFTCYLINDER
BLOCK
BOLT
A6E2318W121

B2–22
CYLINDER HEAD GASKET
Camshaft Pulley Installation Note
1. Hold the camshaft using the SST.
Gear Case Installation Note
1. Apply silicone sealant as shown in the figure.
Thickness
1.5—2.5 mm {0.060—0.098 in}
2. Tighten the bolts in clockwise order.
Drive Gear Installation Note
1. Hold the camshaft using the SST.
2. Tighten the drive gear lock bolt.
Tightening torque
55—64 N·m {5.6—6.6 kgf·m, 41—47 ft·lbf}
Gear Cover Installation Note
1. Apply silicone sealant as shown in the figure.
Thickness
1.5—2.5 mm {0.060—0.098 in}
2. Tighten the bolts in clockwise order.
49 S120 710
A6E2318W104
SEALANTSEALANT
A6E2318W119
49 S120 710
A6E2318W103
SEALANTSEALANT
A6E2318W120

B2–24
FRONT OIL SEAL
FRONT OIL SEAL REPLACEMENTA6E2320106022011. Remove the timing belt. (See B2–9 TIMING BELT REMOVAL/INSTALLATION.)
2. Remove in the order shown in the table.
3. Install in the reverse order of removal.
.
Timing Belt Pulley Lock Bolt Removal/Installation Note
1. Hold the timing belt pulley using the SSTs.
Timing Belt Pulley Removal Note
1. Remove the timing belt pulley using the SST.
FRONT OIL SEAL
1 Timing belt pulley lock bolt
(See B2–24 Timing Belt Pulley Lock Bolt Removal/
Installation Note)
2 Timing belt pulley
(See B2–24 Timing Belt Pulley Removal Note)
3Key
4 Front oil seal
(See B2–25 Front Oil Seal Removal Note)
(See B2–25 Front Oil Seal Installation Note)
SST
SST
SST
R
OILOIL
167—176 {17.0—18.0, 123—130}
N·m {kgf·m, ft·lbf}
3
1
2
4
A6E2320W100
49 G011 105
49 S120 710
A6E2320W101
49 S120 215B
A6E2320W102

OIL PAN
D–11
D
3. Screw an oil pan bolt into the weldnut to make a
small gap between the cylinder block and the oil
pan.
4. Remove the oil pan using the separator tool.
Oil Pan Installation Note
Caution
•If the bolts are reused, remove the old sealant from the bolt threads. Tightening a bolt that has old
sealant on it can cause bolt hole damage.
1. Apply silicone sealant to the oil pan along the
inside of the bolt holes and overlap the ends.
Thickness
2.5—3.5 mm {0.099—0.137 in}
2. Install the oil pan.
3. Hand tighten the flangeless bolts and tighten the
flanged bolts
Tightening torque
7.9—10.7 N·m
{80—110 kgf·cm, 69.5—95.4 in·lbf}
End Of Sie
WELD NUT
A6E3320W101
A6E3320W102
OLD SEALANTCRACKS
A6E3320W103
SEALANTSEALANT
A6E3320W104

E–4
COOLING SYSTEM
STRUCTURAL VIEWA6E363002000201MZR-CD (RF Turbo)
.
End Of Sie
COOLING SYSTEM
8
75
4
3
1
2
6
10
11
11
9
1312
A6E3602W201
1 To water heater system
2 Radiator
3 Coolant reservoir tank
4Thermostat
5 Water pump
6 Cylinder head
7 Cylinder block8 Engine oil cooler
9EGR water cooler
10 To cylinder head
11 To cylinder block
12 Turbocharger
13 Water outlet

COOLING SYSTEM
E–5
E
COOLING FLOW DIAGRAMA6E363002000202MZR-CD (RF Turbo)
.
End Of SieCOOLING FANA6E363002000204 MZR-CD (RF Turbo)
Structure
•Electric cooling fans No.1 and No.2, operated according to a cooling fan control signal from the PCM, have
been adopted. Due to this, engine noise is reduced and rapid warm-up is possible.
•Cooling fans No.1 and No.2 are attached to the radiator cowling.
•The cooling fan motor output has been changed.
Cooling fan, Fan motor specification
End Of Sie
9
8
7
5
4
3
1
2
10
13
11
12
6
A6E3600W300
1Radiator
2 Coolant reservoir tank
3 Water outlet
4EGR water cooler
5 Engine oil cooler
6 Cylinder head
7 Cylinder block8 Turbocharger
9 Water pump
10 Thermostat case
11 Thermostat cover
12 Water heater system
13 Heater core
ITEM Specification
Cooling fan No.1Fan Number of blades (sheet) 7
Motor Motor output (W) 70
Cooling fan No.2Fan Number of blades (sheet) 5
Motor Motor output (W) 80