2002 MAZDA 6 oil

LOCATION INDEX
B2–3
B2
LOCATION INDEXA6E230001002201
.
LOCATION INDEX
7
5
4
3
1
2
6
A6E2500W100
1Drive belt
(See B2–4 DRIVE BELT INSPECTION)
(See B2–4 DRIVE BELT REPLACEMENT)
(See B2–4 DRIVE BELT AUTO TENSIONER
INSPECTION)
2 Rocker arm
(See B2–5 VALVE CLEARANCE INSPECTION)
(See B2–6 VALVE CLEARANCE ADJUSTMENT)
3 Engine
(See B2–8 COMPRESSION INSPECTION)
(See B2–27 ENGINE REMOVAL/INSTALLATION)
(See B2–32 ENGINE DISASSEMBLY/ASSEMBLY)
4 Timing Belt
(See B2–9 TIMING BELT REMOVAL/
INSTALLATION)
5 Cylinder head gasket
(See B2–15 CYLINDER HEAD GASKET
REPLACEMENT)
6 Front oil seal
(See B2–24 FRONT OIL SEAL REPLACEMENT)
7 Rear oil seal
(See B2–26 REAR OIL SEAL REPLACEMENT)

B2–8
VALVE CLEARANCE, COMPRESSION PRESSURE
10. Install the timing belt cover bolt as shown.
Tightening torque
7.9—10.7 N·m {80—110 kgf·cm, 69.5—95.4
in·lbf}
11. Install the engine cover. (See B2–9 TIMING BELT
REMOVAL/INSTALLATION.)
End Of Sie
COMPRESSION INSPECTIONA6E231402000201
Warning
•When the engine and the oil are hot, they can badly burn. Be careful not to burn yourself during
removal/installation of each component.
1. Verify that the battery is fully charged.
•Recharge it if necessary. (See G–6 BATTERY INSPECTION.)
2. Warm up the engine to the normal operating system temperature.
3. Stop the engine and allow it to cool off for about 10 min.
Warning
•Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent fuel from spurting out of the glow plug
hole, do not ground the fuel injector terminal. (See F2–45 Fuel Line Safety Procedures.)
4. Disconnect the fuel injector connector.
Warning
•If the glow plug harness connector is connected, the glow plug harness and engine component
can come into contact and cause a short when the engine switch is ON. Disconnect the glow plug
harness connector before turning the engine switch on.
5. Remove the engine cover. (See B2–9 TIMING BELT REMOVAL/INSTALLATION.)
6. Remove all the glow plugs. (See F2–42 GLOW
PLUG REMOVAL/INSTALLATION.)
TIMING BELT
COVER BOLT
UPPER TIMING BELT COVER
A6E2312W200
COMPRESSION PRESSURE
GLOW PLUG HARNESS CONNECTOR
A6E2314W100

COMPRESSION PRESSURE, TIMING BELT
B2–9
B2
7. Install the SSTs into the glow plug hole.
8. Crank the engine and note the maximum gauge
reading.
9. Inspect each cylinder as above.
•If the compression in one or more cylinders is
low, pour a small amount of clean engine oil
into the cylinder and reinspect the
compression.
—If the compression increases, the piston,
the piston rings, or cylinder wall may be
worn and overhaul is required.
—If the compression stays low, a valve may
be stuck or improperly seated and
overhaul is required.
—If the compression in adjacent cylinders stays low, the cylinder head gasket may be damaged or the
cylinder head may be distorted and overhaul is required.
Compression
kPa {kgf/cm
2, psi} [rpm]
10. Remove the SSTs.
11. Install the glow plug. (See F2–42 GLOW PLUG REMOVAL/INSTALLATION.)
12. Instal the engine cover. (See B2–9 TIMING BELT REMOVAL/INSTALLATION.)
13. Reconnect the fuel injector connector.
14. Erase DTC from PCM memory using the SST. (WDS or equivalent).
End Of Sie
TIMING BELT REMOVAL/INSTALLATIONA6E231612040201
Warning
•Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel.
•Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injures or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line
Safety Procedure”. (See F2–45 Fuel Line Safety Procedures.)
1. Disconnect the negative battery cable.
2. Remove the front tire (RH).
3. Remove the splash shield (RH).
4. Remove the washer tank.
5. Remove the drive belt. (See B2–4 DRIVE BELT REPLACEMENT.)
6. Remove the fuel filter with the fuel hose still connected and position the fuel filter so that it is out of the way.
( L.H.D.) (See F2–50 FUEL FILTER COMPONENT REMOVAL/INSTALLATION.)
7. Remove in the order shown in the table.
8. Install in the reverse order of removal.
9. Start the engine and inspect the pulleys and the drive belt for runout and contact.
Item Specification
Standard 3,500 {35.7, 507.7} [250]
Minimum 3,100 {31.6, 449.4} [250]
Maximum difference
between cylinders196.1 {1.999, 28.44}
49 S010 1A0
49 S013 102
A6E2314W101
TIMING BELT

TIMING BELT
B2–11
B2
No.3 Engine Joint Bracket Removal Note
1. Suspend the engine using the SST.
2.
Lower Timing Belt Cover Removal Note
Caution
•The timing belt cover could be damaged
easily. Hold the timing belt cover at the
locations indicated in the figure and
remove the crankshaft position sensor
harness slowly.
Timing Belt, Timing Belt Auto Tensioner Removal Note
1. Turn the crankshaft clockwise and align the timing
marks as shown.
Caution
•Forcefully twisting the belt, turning it
inside out, or allowing oil or grease on it
will damage the belt and shorten its life.
•After removing the timing belt, do not
move the crankshaft and/or camshaft
from this position because it can cause
the valve and piston to come into
contact.
2. Remove the timing belt auto tensioner.
3. Mark the timing belt rotation on the belt for proper
reinstallation.
49 E017 5A0
A6E2316W101
A6E2316W102
TIMING MARK TIMING MARK
TIMING MARK
A6E2316W103
25 mm {1.0 in} MIN.
FAULTY FAULTY
FAULTY
FAULTY ROTATION
ARROW
A6E2316W104

B2–12
TIMING BELT
Timing Belt, Timing Belt Auto Tensioner Installation Note
1. Measure the tensioned rod projection length.
•If not as specified, replace the timing belt auto
tensioner.
2. Inspect the timing belt auto tensioner for oil
leakage.
•If not as specified, replace the timing belt auto
tensioner.
Projection (free length)
12.9—14.6 mm {0.508—0.574 in}
Caution
•Placing the timing belt auto tensioner
horizontally can cause oil leakage and
damage the timing belt auto tensioner. Place the timing belt auto tensioner vertically when using a
vise.
3. Verify the thrust of the timing belt auto tensioner
rod in the following order:
•If the timing belt auto tensioner rod is rigid
when it is pushed with a force of
approximately 235 N {24 kgf, 53 Ibf}, push it
down slowly and fix the pin in the hole.
•If there is no resistance on the timing belt auto
tensioner rod and it moves slightly when it is
pushed with a force of approximately 235 N
{24 kgf, 53 Ibf};
(1) Push it down slowly two or three times to the
bottom end of the rod.
(2) If the rod protrudes approximately 8.1 mm
{0.32 in}, verify that there is resistance on the
timing belt auto tensioner rod.
Caution
•To prevent damage to the inside of the
timing belt auto tensioner, do not press
down the timing belt auto tensioner rod
with a force greater than the specified
235 N {24 kgf, 53 lbf}.
Be careful that the rod does not touch the
bottom.
•If the timing belt auto tensioner rod
projection is restored, push it down slowly and fix the pin in the hole.
—If the resistance is not restored, replace the timing belt auto tensoner.
A6E2316W105
PIN
A6E2316W106

CYLINDER HEAD GASKET
B2–15
B2
End Of Sie
CYLINDER HEAD GASKET REPLACEMENTA6E231810271201
Warning
•Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel.
•Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line
Safety Procedure”. (See F2–45 Fuel Line Safety Procedures.)
1. Remove the timing belt. (See B2–9 TIMING BELT REMOVAL/INSTALLATION.)
2. Remove the vacuum pump. (See P–13 VACUUM PUMP REMOVAL/INSTALLATION (MZR-CD (RF
TURBO)).)
3. Remove the P/S oil pump with the oil hose still connected. Position the P/S oil pump so that it is out of the way.
Use wire or rope to secure. (See N–16 POWER STEERING OIL PUMP (MZR-CD (RF Turbo)) REMOVAL/
INSTALLATION.)
4. Remove the turbocharger. (See F2–57 EXHAUST SYSTEM REMOVAL/INSTALLATION.)
5. Remove all the glow plugs. (See F2–42 GLOW PLUG REMOVAL/INSTALLATION.)
6. Remove in the order shown in the table.
7. Install in the reverse order of removal.
8. Inspect valve clearance. (See B2–5 VALVE CLEARANCE INSPECTION.)
9. Inspect the engine oil level.
•If necessary, add oil. (See D–8 ENGINE OIL INSPECTION.)
10. Inspect the compression. (See B2–8 COMPRESSION INSPECTION.)
11. Start the engine and:
(1) Inspect the pulleys and the drive belt for runout and contact.
(2) Inspect the engine oil, engine coolant, and fuel leakage.
(3) Inspect the idle speed. (See F2–34 IDLE SPEED INSPECTION.)
CYLINDER HEAD GASKET

B2–16
CYLINDER HEAD GASKET
.
SST
SST
SSTR
R
R
R
R
SEALANTSEALANT
SEALANTSEALANT
SEALANTSEALANT
SEALANTSEALANT
SEALANTSEALANT
OILOIL
OILOIL
7.9—10.7 N·m
{80—110 kgf·cm,
69.5—95.4 in·lbf}
7.9—10.7 N·m
{80—110 kgf·cm,
69.5—95.4 in·lbf}
7.9—10.7 N·m
{80—110 kgf·cm,
69.5—95.4 in·lbf} 7.9—10.7 N·m
{80—110 kgf·cm,
69.5—95.4 in·lbf}
7.9—10.7 N·m
{80—110 kgf·cm,
69.5—95.4 in·lbf}55—64
{5.6—6.6, 41—47}
38—51
{3.8—5.3,
28—38}
52—61
{5.3—6.3,
39—45}
29 {3.0, 22}
+90 105
+90 105
+90 105
50—60
{5.0—6.0,
37—44}
19—25
{1.9—2.6,
14—18}
50—60 {5.0—6.0, 37—44}
46—58 {4.6—6.0, 34—43} 59—68
{6.0—7.0, 44—50}25—30
{2.5—3.1, 18—22}
38—51
{3.8—5.3,
28—38}19—25
{1.9—2.6,
14—18}
N·m {kgf·m, ft·lbf}
98
7
54
3
1
2
10
19
18
17
15
16
14
13
11
12
20
25
24
2321
22
6
SST
55—64
{5.6—6.6, 41—47}
—
— —
39—44
{4.0—4.4,
28.8—32.4}
22—26
{2.2—2.7,
16—19}
SEALANTSEALANT
A6E2318W100
1 Supply pump pulley
(See B2–17 Supply Pump Pulley Removal Note)
(See B2–23 Supply Pump Pulley Installation Note)
2 Gear cover
(See B2–22 Gear Cover Installation Note)
3 Drive gear
(See B2–17 Drive Gear Removal Note)
(See B2–22 Drive Gear Installation Note)
4 Gear case
(See B2–22 Gear Case Installation Note)
5 Camshaft pulley
(See B2–18 Camshaft Pulley Removal Note)
(See B2–22 Camshaft Pulley Installation Note)
6 Idler
(See B2–21 Idler Installation Note)
7 Seal plate
(See B2–18 Seal Plate Removal Note)
(See B2–21 Seal Plate Installation Note)
8 Insulator
9 Fuel return hose
10 Injector harness bracket11 Cylinder head cover
(See B2–21 Cylinder Head Cover Installation Note)
12 Fuel Injection pipe (Fuel injector side)
(See B2–21 Fuel Injection Pipe Installation Note)
13 Fuel Injection pipe (Fuel supply pump side)
(See B2–21 Fuel Injection Pipe Installation Note)
14 Common rail
(See F2–53 Common Rail Installation Note)
15 EGR water cooler
16 Nozzle seal
17 Side wall
(See B2–20 Side Wall Installation Note)
18 Fuel injector bracket
19 Fuel injector
(See F2–55 Fuel Injector Installation Note)
20 Rocker arm and rocker arm shaft
(See B2–18 Rocker Arm and Rocker Arm Shaft
Removal Note)
(See B2–19 Rocker Arm and Rocker Arm Shaft
Installation Note)
21 Rocker bridge

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