Mazda Car 2002-04

Removal & Installation

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1.5L, 1.6L And 1.8L (BP) Engines



  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the engine coolant.
  6.  
  7. Remove or disconnect the following:

    Timing belt covers and timing belt

    Click image to see an enlarged view

    Fig. Exploded view of the water pump assembly-1.5L, 1.6L and 1.8L (BP) engines

     
    Coolant inlet pipe and gasket
     
    Timing belt with idler pulleys still attached to the water pump
     
    Water pump
     

  8.  

To install:

  1. Clean all gasket mating surfaces.
  2.  
  3. Using a new gasket, install the water pump on the engine. Torque the mounting bolts to 14-18 ft. lbs. (19-25 Nm). Torque the bolt from the water pump to the alternator bracket to 28-38 ft. lbs. (38-51 Nm).
  4.  
  5. Install or connect the following:

    Timing belt idler pulleys
     
    Coolant inlet pipe with a new gasket. Torque the coolant inlet pipe bolts to 14-18 ft. lbs. (19-25 Nm)
     
    Timing belt and the timing belt covers
     
    Negative battery cable
     

  6.  
  7. Fill and bleed the cooling system.
  8.  
  9. Start the engine and bring to normal operating temperature. Check for leaks.
  10.  

1.6L (Zm) Engines





Click image to see an enlarged view

Fig. Exploded view of the water pump assembly-1.6L (ZM) engines

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    negative battery cable
     
    Fresh air duct
     
    Exhaust manifold insulator
     
    timing belt
     
    power steering oil pump with the lines attached and set aside
     
    A/C compressor with the lines attached and set aside
     
    Water inlet pipe
     
    Water pump mounting bolts
     
    Water pump
     

  6.  

To install:

  1. Clean all gasket mating surfaces.
  2.  
  3. Install or connect the following:

    Water pump using a new gasket. Torque the main bolts to 12-17 ft. lbs. (16-23 Nm) and the upper left hand bolt to 28-38 ft. lbs. (38-51 Nm).
     
    Water inlet pipe with new gasket and O-ring and tighten the bolts to 12-17 ft. lbs. (16-23 Nm)
     
    A/C compressor
     
    power steering oil pump
     
    timing belt
     
    Exhaust manifold insulator
     
    Fresh air duct
     
    negative battery cable
     

  4.  
  5. Fill and bleed the cooling system.
  6.  
  7. Start the engine, check for leaks and repair if necessary.
  8.  



Click image to see an enlarged view

Fig. Exploded view of the water pump assembly-1.6L (ZM) engines

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Fresh air duct
     
    Exhaust manifold insulator
     
    Timing belt
     
    Power steering oil pump with the lines attached and set aside
     
    A/C compressor with the lines attached and set aside
     
    Water inlet pipe
     
    Water pump mounting bolts
     
    Water pump
     

  6.  

To install:

  1. Clean all gasket mating surfaces.
  2.  
  3. Install or connect the following:

    Water pump using a new gasket. Torque the main bolts to 12-17 ft. lbs. (16-23 Nm) and the upper left hand bolt to 28-38 ft. lbs. (38-51 Nm).
     
    Water inlet pipe with new gasket and O-ring and tighten the bolts to 12-17 ft. lbs. (16-23 Nm)
     
    A/C compressor
     
    Power steering oil pump
     
    Timing belt
     
    Exhaust manifold insulator
     
    Fresh air duct
     
    Negative battery cable
     

  4.  
  5. Fill and bleed the cooling system.
  6.  
  7. Start the engine, check for leaks and repair if necessary.
  8.  

1.8L (Bp) Engines



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the engine coolant.
  6.  
  7. Remove or disconnect the following:

    Timing belt covers and timing belt
     
    Power steering pump, leaving the lines attached and set aside
     
    Idler, on models not equipped with power steering
     


    Click image to see an enlarged view

    Fig. Exploded view of the water pump assembly-1.8L (BP) engines

    Coolant inlet pipe and gasket
     
    water pump
     

  8.  

To install:

  1. Clean all gasket mating surfaces.
  2.  
  3. Using a new gasket, install the water pump on the engine. Torque the mounting bolts to 14-18 ft. lbs. (19-25 Nm). Torque the bolt from the water pump to the alternator bracket to 28-38 ft. lbs. (38-51 Nm).
  4.  
  5. Install or connect the following:

    coolant inlet pipe with a new gasket. Torque the coolant inlet pipe bolts to 14-18 ft. lbs. (19-25 Nm).
     
    Idler, on models not equipped with power steering
     
    Power steering pump
     
    timing belt and the timing belt covers
     
    Negative battery cable
     

  6.  
  7. Fill and bleed the cooling system.
  8.  
  9. Start the engine and bring to normal operating temperature. Check for leaks.
  10.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the engine coolant.
  6.  
  7. Remove or disconnect the following:

    Timing belt covers and timing belt
     
    Power steering pump, leaving the lines attached and set aside
     
    Idler, on models not equipped with power steering

    Click image to see an enlarged view

    Fig. Exploded view of the water pump assembly-1.8L (BP) engines

     
    Coolant inlet pipe and gasket
     
    Water pump
     

  8.  

To install:

  1. Clean all gasket mating surfaces.
  2.  
  3. Using a new gasket, install the water pump on the engine. Torque the mounting bolts to 14-18 ft. lbs. (19-25 Nm). Torque the bolt from the water pump to the alternator bracket to 28-38 ft. lbs. (38-51 Nm).
  4.  
  5. Install or connect the following:

    Coolant inlet pipe with a new gasket. Torque the coolant inlet pipe bolts to 14-18 ft. lbs. (19-25 Nm).
     
    Idler, on models not equipped with power steering
     
    Power steering pump
     
    Timing belt and the timing belt covers
     
    Negative battery cable
     

  6.  
  7. Fill and bleed the cooling system.
  8.  
  9. Start the engine and bring to normal operating temperature. Check for leaks.
  10.  

1.8L (FP) And 2.0L Engines





Click image to see an enlarged view

Fig. Exploded view of the water pump assembly-1.8L (FP) and 2.0L engines

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Timing belt
     
    Power steering oil pump adjuster
     
    5 water pump mounting bolts
     
    Water pump
     

  6.  

To install:

  1. Clean all gasket mating surfaces.
  2.  
  3. Install or connect the following:

    Water pump using a new gasket. Torque the bolts to 14-18 ft. lbs. (19-25 Nm)
     
    Power steering oil pump adjuster. Torque the bolts to 12-16 ft. lbs. (16-22 Nm)
     
    Timing belt
     
    Negative battery cable
     

  4.  
  5. Fill and bleed the cooling system.
  6.  
  7. Start the engine, check for leaks and repair if necessary.
  8.  

1.8L (Fp) Engines





Click image to see an enlarged view

Fig. Exploded view of the water pump assembly-1.8L (FP) engines

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    negative battery cable
     
    timing belt
     
    Power steering oil pump adjuster
     
    Water pump mounting bolts
     
    Water pump
     

  6.  

To install:

  1. Clean all gasket mating surfaces.
  2.  
  3. Install or connect the following:

    Water pump using a new gasket. Make sure the gasket is installed with the sealing ring facing the pump. Torque the bolts to 14-18 ft. lbs. (19-25 Nm).
     


    Click image to see an enlarged view

    Fig. Make sure the gasket is installed with the sealing ring facing the pump-1.8L (FP) engines

    Power steering oil pump adjuster
     
    timing belt
     
    negative battery cable
     

  4.  
  5. Fill and bleed the cooling system.
  6.  
  7. Start the engine, check for leaks and repair if necessary.
  8.  

2.0L (Fs) Engines



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    negative battery cable
     
    timing belt
     
    power steering oil pump adjuster
     
    Water pump mounting bolts
     
    Water pump
     

  6.  

To install:

  1. Clean all gasket mating surfaces.
  2.  
  3. Install or connect the following:

    Water pump using a new gasket. Torque the bolts to 14-18 ft. lbs. (19-25 Nm).
     
    power steering oil pump adjuster. Torque the bolts to 12-16 ft. lbs. (16-22 Nm).
     
    timing belt
     
    negative battery cable
     

  4.  
  5. Fill and bleed the cooling system.
  6.  
  7. Start the engine, check for leaks and repair if necessary.
  8.  


    Click image to see an enlarged view

    Fig. Exploded view of the water pump assembly-2.0L (FS) engines


  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Timing belt
     
    Power steering oil pump adjuster
     
    Water pump mounting bolts
     
    Water pump
     

  6.  

To install:

  1. Clean all gasket mating surfaces.
  2.  
  3. Install or connect the following:

    Water pump using a new gasket. Torque the bolts to 14-18 ft. lbs. (19-25 Nm).
     
    Power steering oil pump adjuster. Torque the bolts to 12-16 ft. lbs. (16-22 Nm).
     
    Timing belt
     
    Negative battery cable
     

  4.  
  5. Fill and bleed the cooling system.
  6.  
  7. Start the engine, check for leaks and repair if necessary.

    Click image to see an enlarged view

    Fig. Exploded view of the water pump assembly-2.0L (FS) engines

  8.  

2.0L (Lf) & 2.3L (L3) Engines-Mazda 3 & Mazda 6 Models



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the battery cover and disconnect the negative battery cable.
  4.  
  5. Remove the under cover and splash shield as an assembly.
  6.  
  7. Drain the cooling system.
  8.  
  9. Position the coolant reservoir tank aside with the hose still attached.
  10.  
  11. Remove the plug hole plate.
  12.  
  13. Loosen the water pump pulley bolt and position the drive belt aside.
  14.  
  15. Remove the water pump pulley.
  16.  
  17. Remove the water pump bolts, the pump and the O-ring.

    Click image to see an enlarged view

    Fig. Water pump mounting and related components-Mazda 3 and Mazda 6 models equipped with the 2.0L (LF) and 2.3L (L3) engines

  18.  

To install:

  1. Clean the water pump mating surfaces.
  2.  
  3. Install a new O-ring and the water pump. Tighten the bolts to 71-101 inch lbs. (8-11 Nm).
  4.  
  5. Install the water pump pulley and tighten the tighten the bolts to 12-17 ft. lbs. (17-23 Nm).
  6.  
  7. Install the drive belt.
  8.  
  9. Install the plug hole plate
  10.  
  11. Install the coolant reservoir tank.
  12.  
  13. Install the splash shield and under cover.
  14.  
  15. Connect the battery cable and install the cover.
  16.  
  17. Fill the cooling system.
  18.  
  19. Start the engine, check for leaks and repair if necessary.
  20.  

2.3L (Kj) Engine



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    timing belt and water pump together
     

  6.  

To install:

  1. Clean the mating surfaces.
  2.  
  3. Install or connect the following:

    Water pump using a new gasket along with the timing belt. Torque the bolts to 14-18 ft. lbs. (19-25 Nm).
     
    negative battery cable
     

  4.  
  5. Fill the cooling system.
  6.  
  7. Start the engine, check for leaks and repair if necessary.
  8.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Timing belt and water pump together
     

  6.  

To install:

  1. Clean the mating surfaces.
  2.  
  3. Install or connect the following:

    Water pump using a new gasket along with the timing belt. Torque the bolts to 14-18 ft. lbs. (19-25 Nm).
     
    Negative battery cable
     

  4.  
  5. Fill the cooling system.
  6.  
  7. Start the engine, check for leaks and repair if necessary.
  8.  

2.3L Engine



  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the cooling system.

    Timing belt covers and timing belt
     
    Water pump pulley bolts the pulley
     
    Water pump
     

  6.  

To install:

  1. Clean the mating surfaces.
  2.  
  3. Install or connect the following:

    Water pump using a new gasket. Tighten the bolts to 14-18 ft. lbs. (19-25 Nm)
     
    Water pump pulley. Tighten the bolts to 88 inch lbs. (10 Nm)
     
    Timing belt and timing covers
     
    Negative battery cable
     

  4.  
  5. Fill the cooling system.
  6.  
  7. Start the engine and check for leaks.
  8.  

2.5L (Kl) Engine



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the cooling system.

    timing belt
     
    Number 3 engine mount bracket
     
    Water pump bolts
     
    water pump
     

  6.  

To install:

  1. Clean the mating surfaces.
  2.  
  3. Install or connect the following:

    Water pump using a new gasket. Tighten the bolts to 14-18 ft. lbs. (19-25 Nm).
     
    Number 3 engine mount bracket and tighten the bolts to 32-44 ft. lbs. (44-60 Nm)
     
    timing belt
     
    negative battery cable
     

  4.  
  5. Fill the cooling system.
  6.  
  7. Start the engine and check for leaks.
  8.  


    Click image to see an enlarged view

    Fig. Exploded view of the water pump assembly-2.5L (KL) engines


  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the cooling system.

    Timing belt
     
    Number 3 engine mount bracket
     
    Water pump bolts
     
    Water pump
     

  6.  

To install:

  1. Clean the mating surfaces.
  2.  
  3. Install or connect the following:

    Water pump using a new gasket. Tighten the bolts to 14-18 ft. lbs. (19-25 Nm).
     
    Number 3 engine mount bracket and tighten the bolts to 32-44 ft. lbs. (44-60 Nm)
     
    Timing belt
     
    Negative battery cable
     

  4.  
  5. Fill the cooling system.
  6.  
  7. Start the engine and check for leaks.

    Click image to see an enlarged view

    Fig. Exploded view of the water pump assembly-2.5L (KL) engines

  8.  

2.5L Engine



  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Timing belt
     
    No. 3 engine mount bracket
     
    5 water pump mounting bolts
     
    Water pump

    Click image to see an enlarged view

    Fig. Exploded view of the water pump assembly-2.5L engine, 2.3L engine is similar

     

  6.  

To install:

  1. Clean the mating surfaces.
  2.  
  3. Install or connect the following:

    Water pump using a new gasket. Torque the bolts to 14-18 ft. lbs. (19-25 Nm)
     
    Engine mount bracket. Torque the bolts to 32-44 ft. lbs. (44-60 Nm)
     
    Timing belt
     
    Negative battery cable
     

  4.  
  5. Fill the cooling system.
  6.  
  7. Start the engine, check for leaks and repair if necessary.
  8.  

3.0L (Aj) Engine



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Before servicing the vehicle, refer to the Precautions section.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the under cover.
  8.  
  9. Drain the cooling system.
  10.  
  11. Remove the air cleaner.
  12.  
  13. Remove the water pump drive belt pulley as follows:
    1. Replace part of tool 49 UN30 3009 with tool 49 UN30 3457.
    2.  
    3. Install the tools as illustrated and remove the water pump drive pulley.
    4.  

  14.  
  15. Remove the thermostat case, heater hose and the water outlet pipe.
  16.  
  17. Remove the water pump bolts and the pump.
  18.  


    Click image to see an enlarged view

    Fig. Exploded view of the water pump and related components-Mazda 6 models with the 3.0L (AJ) engine



    Click image to see an enlarged view

    Fig. Replace part of tool 49 UN30 3009 with tool 49 UN30 3457-Mazda 6 models with the 3.0L (AJ) engine



    Click image to see an enlarged view

    Fig. Install the tools as illustrated and remove the water pump drive pulley-Mazda 6 models with the 3.0L (AJ) engine


To install:

  1. Install the water pump and tighten the bolts 89 inch lbs. (10 Nm), plus an additional 85-95 degrees.
  2.  
  3. Install the water outlet pipe, heater hose and thermostat case.
  4.  
  5. Install a new water pump drive belt pulley using tool 49 UN21 1185.
  6.  
  7. Install the air cleaner.
  8.  
  9. Fill the cooling system and connect the negative battery cable.
  10.  
  11. Start the vehicle and check for leaks, repair if necessary.
  12.  
  13. Install the under cover if no leaks are found.
  14.  


    Click image to see an enlarged view

    Fig. Install a new water pump drive belt pulley using tool 49 UN21 1185-Mazda 6 models with the 3.0L (AJ) engine


  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Before servicing the vehicle, refer to the Precautions section.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the under cover.
  8.  
  9. Drain the cooling system.
  10.  
  11. Remove the air cleaner.
  12.  
  13. Remove the water pump drive belt pulley as follows:
    1. Replace part of tool 49 UN30 3009 with tool 49 UN30 3457.
    2.  
    3. Install the tools as illustrated and remove the water pump drive pulley.

      Click image to see an enlarged view

      Fig. Exploded view of the water pump and related components-Mazda 6 models with the 3.0L (AJ) engine



      Click image to see an enlarged view

      Fig. Replace part of tool 49 UN30 3009 with tool 49 UN30 3457-Mazda 6 models with the 3.0L (AJ) engine



      Click image to see an enlarged view

      Fig. Install the tools as illustrated and remove the water pump drive pulley-Mazda 6 models with the 3.0L (AJ) engine

    4.  

  14.  
  15. Remove the thermostat case, heater hose and the water outlet pipe.
  16.  
  17. Remove the water pump bolts and the pump.
  18.  

To install:

  1. Install the water pump and tighten the bolts 89 inch lbs. (10 Nm), plus an additional 85-95 degrees.
  2.  
  3. Install the water outlet pipe, heater hose and thermostat case.
  4.  
  5. Install a new water pump drive belt pulley using tool 49 UN21 1185.
  6.  
  7. Install the air cleaner.
  8.  
  9. Fill the cooling system and connect the negative battery cable.
  10.  
  11. Start the vehicle and check for leaks, repair if necessary.
  12.  
  13. Install the under cover if no leaks are found.

    Click image to see an enlarged view

    Fig. Install a new water pump drive belt pulley using tool 49 UN21 1185-Mazda 6 models with the 3.0L (AJ) engine

  14.  

Mazdaspeed6



  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove the battery cover and disconnect the negative battery cable.
  4.  
  5. Drain the cooling system.
  6.  
  7. Loosen the water pump pulley bolt and position the drive belt aside.
  8.  
  9. Remove the water pump pulley.
  10.  
  11. Remove the water pump bolts, the pump and the O-ring.
  12.  

To install:

  1. Clean the water pump mating surfaces.
  2.  
  3. Install a new O-ring and the water pump. Tighten the bolts to 71-101 inch lbs. (8-11 Nm).
  4.  
  5. Install the water pump pulley and tighten the tighten the bolts to 12-17 ft. lbs. (17-23 Nm).
  6.  
  7. Install the drive belt.
  8.  
  9. Connect the battery cable and install the cover.
  10.  
  11. Fill the cooling system.
  12.  
  13. Start the engine, check for leaks and repair if necessary.
  14.  

 
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