2002 MAZDA 6 Workshop Manual Suplement

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
B2–19
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

CYLINDER HEAD GASKET
B2–23
B2
Supply Pump Pulley Installation Note
Caution
•To prevent the bolts (M8 x1.25) from damaging the supply pump and pulley, do not fully tighten
the fixing bolts. If they contact the pulley surface, they will damage the pulley.
1. Fix the supply pump pulley to the bracket using
two bolts (M8 x 1.25).
End Of Sie
M8 1.25
BOLT
A6E2318W101

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

FRONT OIL SEAL
B2–25
B2
Front Oil Seal Removal Note
1. Cut the oil seal lip using a razor knife.
2. Remove the oil seal using a screwdriver protected
with a rag.
Front Oil Seal Installation Note
1. Apply clean engine oil to the oil seal lip.
2. Push the oil seal slightly in by hand.
3. Tap the oil seal in evenly using the SST and a
hammer. The oil seal must be tapped in until it is
flush with the edge of the oil pump body.
End Of Sie
OIL SEAL LIP
A6E2320W103
RAG
A6E2320W104
49 U027 003
0—0.5 mm {0—0.019 in}
HAMMEROIL PUMP BODY
FRONT OIL SEAL
A6E2320W105