belt MAZDA 6 2002 Suplement User Guide

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)

B2–4
DRIVE BELT
End Of Sie
DRIVE BELT INSPECTIONA6E231015800201
Note
•Drive belt deflection/tension inspection is not necessary because of the use of the drive belt auto
tensioner.
1. Remove the washer tank.
2. Verify that the drive belt auto tensioner indicator
mark does not exceeds the limit.
•If it exceeds the limit, replace the drive belt.
(See B2–4 DRIVE BELT REPLACEMENT.)
3. Install the washer tank.
End Of SieDRIVE BELT REPLACEMENTA6E2310158002021. Remove the splash shield (RH).
2. Remove the under cover.
3. Turn the center of the tensioner pulley clockwise
to release tension to the drive belt.
4. Remove the drive belt.
5. Reinstall the drive belt or install a new drive belt.
6. Verify that the drive belt auto tensioner indicator
mark does not exceed the limit. (See B2–4
DRIVE BELT INSPECTION.)
•If it exceeds the limit, replace the drive belt.
7. Install the under cover.
8. Install the splash shield (RH).
End Of SieDRIVE BELT AUTO TENSIONER INSPECTIONA6E2310159802011. Remove the drive belt. (See B2–4 DRIVE BELT REPLACEMENT.)
2. Verify that the drive belt auto tensioner moves smoothly in the operational direction.
•Replace the drive belt auto tensioner if necessary.
DRIVE BELT
INDICATOR
MARKNORMAL
A6E2310W100
MALFUNCTION
INDICATOR
MARK
A6E2310W101
A6E2310W102

DRIVE BELT, VALVE CLEARANCE
B2–5
B2
3. Turn the drive belt auto tensioner pulley by hand
and verify that it rotates smoothly.
•Replace the drive belt auto tensioner if
necessary.
4. Install the drive belt.
End Of Sie
VALVE CLEARANCE INSPECTIONA6E2312121112011. Remove the engine cover. (See B2–9 TIMING BELT REMOVAL/INSTALLATION.)
2. Remove the timing belt cover bolt as shown.
3. Remove the cylinder head cover. (See B2–15
CYLINDER HEAD GASKET REPLACEMENT.)
4. Turn the crankshaft and align the timing mark so
that the piston of the No.1 or No.4 cylinder is at
TDC of compression.
5. Measure valve clearances A with the No.1
cylinder at TDC of compression, and those of B
with the No.4 cylinder at TDC of compression.
•If the valve clearance is not within the
specification, adjust the valves. (See B2–6
VALVE CLEARANCE ADJUSTMENT.)
Standard valve clearance [Engine cold]
IN: 0.12—0.18 mm {0.005—0.007 in}
(0.15±0.03 mm {0.006±0.0011 in})
EX: 0.32—0.38 mm {0.013—0.014 in}
(0.35±0.03 mm {0.014±0.0011 in})
6. Turn the crankshaft one full turn and measure the
remaining valve clearances.
•Adjust if necessary. (See B2–6 VALVE
CLEARANCE ADJUSTMENT.)
7. Install the cylinder head cover. (See B2–21 Cylinder Head Cover Installation Note.)
A6E2310W103
VALVE CLEARANCE
TIMING BELT
COVER BOLT
UPPER TIMING BELT COVER
A6E2312W200
A
A B
B
A6E2312W201
MEASURING
POINT
A6E2312W101

B2–6
VALVE CLEARANCE
8. 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}
9. Install the engine cover. (See B2–9 TIMING BELT
REMOVAL/INSTALLATION.)
End Of SieVALVE CLEARANCE ADJUSTMENTA6E2312121112021. Remove the engine cover. (See B2–9 TIMING BELT REMOVAL/INSTALLATION.)
2. Remove the timing belt cover bolt as shown.
3. Remove the cylinder head cover. (See B2–15
CYLINDER HEAD GASKET REPLACEMENT.)
4. Turn the crankshaft clockwise and set the No.1
cylinder to compression TDC.
5. Remove the fuel injector. (See F2–55 FUEL
INJECTOR REMOVAL/INSTALLATION.)
6. Adjust the valve clearance A with the No.1
cylinder at TDC of compression, and those of B
with the No.4 cylinder at TDC of compression.
(1) Hold the rocker bridge using the SST (49
G012 006).
(2) Loosen the locknut (d) using the SST (49
G012 004), and then turn the adjusting screw
(c) using the SST (49 G012 005) until it is
separated from the valve stem completely.
TIMING BELT
COVER BOLT
UPPER TIMING BELT COVER
A6E2312W200
TIMING BELT
COVER BOLT
UPPER TIMING BELT COVER
A6E2312W200
A
A B
B
A6E2312W201
49 G012 006
49 G012 005
49 G012 004
ADJUSTING
SCREW(c)
ROCKER BRIDGELOCKNUT(d)
NORMAL
A6E2312W202

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

B2–10
TIMING BELT
.
N·m {kgf·m, ft·lbf} 7.6—10.8 N·m
{80—110 kgf·cm,
69.1—95.5 in·lbf}
7.9—10.7 N·m
{80—110 kgf·cm,
69.5—95.4 in·lbf}
23—32
{2.3—3.3, 17—23}19—25
{1.9—2.6, 14—18} 74.5—104.9
{7.6—10.6,
55.0—76.6}
9
8
75
4
3
1
2
10
6
A6E2316W100
1 Engine cover
2 No.3 engine joint bracket
(See B2–11 No.3 Engine Joint Bracket Removal
Note)
(See B2–14 No.3 Engine Joint Bracket Installation
Note)
3 Upper timing belt cover
4Drive belt
(See B2–4 DRIVE BELT REPLACEMENT)
5 Crankshaft pulley cover
6 Crankshaft pulley
(See B2–14 Crankshaft Pulley Installation Note)7 Lower timing belt cover
(See B2–11 Lower Timing Belt Cover Removal
Note)
8 Guide plate
9 Timing belt
(See B2–11 Timing Belt, Timing Belt Auto Tensioner
Removal Note)
(See B2–12 Timing Belt, Timing Belt Auto Tensioner
Installation Note)
10 Timing belt auto tensioner
(See B2–11 Timing Belt, Timing Belt Auto Tensioner
Removal Note)
(See B2–12 Timing Belt, Timing Belt Auto Tensioner
Installation Note)

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

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