2002 MAZDA 6 torque

TIMING BELT
B2–13
B2
Caution
•To prevent the bolts (M8 x 1.25) from damaging the fuel injection pump and pulley, do not fully
tighten the fixing bolts. If it contacts the pulley surface, it will damage the pulley.
4. Verify that all timing marks are correctly aligned.
•If not, align all timing marks according to the
procedure below.
5. Fix the camshaft pulley to the cylinder head using
bolt (M8 x1.25).
6. Fix the injection pump pulley to the bracket using
two bolts (M8 x1.25).
Caution
•Turn the crankshaft in the direction
which will prevent the TDC and BDC from
being passed. Otherwise it can cause the
valve and piston to come into contact.
(1) Turn the crankshaft and set it at an angle of 45° or more away from the TDC and BDC.
(2) Align the timing marks of the camshaft pulley.
(3) Align the timing marks of the injection pump pulley.
(4) Turn the crankshaft and align the timing marks of the timing belt pulley.
7. Install the timing belt on the pulleys in the order
shown below.
(1) Timing belt pulley
(2) Idler
(3) Supply pump pulley
(4) Camshaft pulley
(5) Water pump pulley
(6) Tensioner
8. Remove the supply pump pulley fixing bolts and
camshaft pulley fixing bolt (M8 x 1.25).
9. Hand tighten the timing belt auto tensioner bolts
in the order A to B as indicated in the figure.
10. Tighten the timing belt auto tensioner bolts in the
order A to B as indicated in the figure.
Tightening torque
19—25 N·m {1.9—2.6 kgf·m, 14—18 ft·lbf}
11. Remove the pin from the timing belt auto
tensioner to apply tension to the belt.
12. Turn the crankshaft clockwise twice, and align the
timing marks.
13. Verify that all timing marks are correctly aligned.
•If not as specified, repeat from Timing Belt,
Timing Belt Auto Tensioner Removal Note.
TIMING MARK
TIMING MARKTIMING MARK
M8 1.25
BOLT
M8 1.25
BOLT
CAMSHAFT
PULLEYINJECTION
PUMP
PULLEY
A6E2316W107
5
43
1
2
6
A6E2316W108
A
B
A6E2316W109

B2–14
TIMING BELT
Crankshaft Pulley Installation Note
1. Tighten the bolts in the order shown.
Tightening torque
23—32 N·m {2.3—3.3 kgf·m, 17—23 ft·lbf}
No.3 Engine Joint Bracket Installation Note
1. Tighten the No.3 engine joint bracket bolt and nut
in the order shown.
Tightening torque
74.5—104.9 N·m {7.6—10.6 kgf·m,
55.0—76.6 ft·lbf}
7
5
4
3
6
1
2
A6E2316W110
12
A6E2316W111

CYLINDER HEAD GASKET
B2–19
B2
Cylinder Head Installation Note
1. Measure the length of each cylinder head bolt.
•Replace any that exceeds maximum length.
Length
159.7—160.3 mm {6.288—6.311 in}
Maximum
161.0 mm {6.338 in}
2. Tighten the bolts in two or three steps in the order
shown.
Tightening torque
29 N·m {3.0 kgf·m, 22 ft·lbf}
3. Put a paint mark on each bolt head.
4. Using the marks as a reference, tighten the bolts
by turning each 90°—105° in the sequence
shown.
5. Further tighten each bolt by turning another
90°—105°.
6. Then further tighten each bolt by turning another
90°—105°.
Rocker Arm and Rocker Arm Shaft Installation Note
1. Apply sealant as shown in the figure.
Thickness
2 mm {0.079 in}
2. Install the camshaft caps according to the cap
number.
LENGTH
A6E2318W108
98
7
54
3106
1
2ENGINE
FRONT
A6E2318W109
29 N·m
{3.0 kgf·m, 22 ft·lbf}
SECOND
PAINT MARK
FIRST THIRD90 105
90 105
90 105
—
——
A6E2318W110
SEALANTSEALANT
SEALANTSEALANT
SEALANTSEALANT
A6E2318W111

B2–20
CYLINDER HEAD GASKET
3. Install the rocker arm shaft plane side upward.
Caution
•Because there is little camshaft thrust
clearance, the camshaft must be held
horizontally while it is installed.
Otherwise, excessive force will be
applied to the thrust area, causing burrs
on the thrust receiving area of the
cylinder head journal. To avoid this, the
following procedure must be observed.
4. Tighten the bolts in two or three steps in the order
shown.
Tightening torque
25—30 N·m {2.5—3.1 kgf·m, 18—22 ft·lbf}
5. Apply clean engine oil to the new oil seal.
6. Push the oil seal slightly in by hand.
7. Tap the oil seal into the cylinder head using the
SST and a hammer.
Side Wall Installation Note
1. Apply silicone sealant as shown in the figure.
Thickness
2 mm {0.079 in}
A6E2318W112
9
8
75
4
3
10126
1
2
11
A6E2318W113
49 B010 002
0.5—1.5 mm {0.020—0.059 in}
OIL SEAL CYLINDER
HEAD HAMMER
A6E2318W114
SEALANTSEALANT
A6E2318W115

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

B2–30
ENGINE
2. Remove the SST.
3. Secure the engine and the transaxle using a
hoist.
4. Remove the No.4 engine mount bracket and
engine mount rubber together as a unit.
No.3 Engine Joint Bracket Installation Note
1. Tighten the No.3 engine mount bracket stud bolt.
Tightening torque
7.0—13 N·m {71.4—132.5 kgf·cm,
62.0—115.0 in·lbf}49 E017 5A0
A6E2316W101
A6E2324W203
A6E2324W304
No.3 ENGINE
MOUNT
BRACKET
STUD
BOLT
A6E2316W200

ENGINE
B2–31
B2
2. Tighten the No.3 engine joint bracket bolt and nut
in the order as shown.
Tightening torque
74.5—104.9 N·m {7.6—10.6 kgf·m,
55.0—76.6 ft·lbf}
No.4 Engine Mount Bracket and No.4 Engine Mount Rubber Installation Note
1. Tighten the No.4 engine mount bracket and No.4
engine mount rubber bolt and nut in the order as
shown.
2. Secure the engine and the transaxle using an
engine jack and attachment as shown.
3. Remove the hoist and secure the engine and
transaxle using SST.12
A6E2316W111
Bolt or nut No.Tightening torque
(N·m {kgf·m, ft·lbf})
1, 2, 358.8—80.4 {6.0—8.1, 43.3—58.5}
4, 5, 666.6—93.1 {6.8—9.4, 49.2—67.9}
5431
2
6
A6E2324W306
A6E2324W209
49 E017 5A0
A6E2316W101