AutoZone 2001 Oldsmobile Truck Silhouette 3.4L SFI 6cyl | Repair Guides | Engine Mechanical | Engine Mechanical Components | Timing Belt 1 | AutoZone.com

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    Mazda Car 2002-04

    Timing Belt 1

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    General Information



    Timing belts are typically only used on overhead camshaft engines. Timing belts are used to synchronize the crankshaft with the camshaft, similar to a timing chain on an overhead valve (pushrod) engine. Unlike a timing belt, a timing chain will normally last the life of the engine without needing service or replacement. Timing belts use raised teeth to mesh with sprockets to operate the valvetrain of an overhead camshaft engine.

    Whenever a vehicle with an unknown service history comes into your repair facility or is recently purchased, here are some points that should be asked to help prevent costly engine damage:



    Does the owner know if, or when the belt was replaced-
     
    If the vehicle purchased is used, or the condition and mileage of the last timing belt replacement are unknown, it is recommended to inspect, replace or at least inform the owner that the vehicle is equipped with a timing belt.
     
    Note the mileage of the vehicle. The average replacement interval for a timing belt is approximately 60,000 miles (96,000 km).
     

    Interference Engines

    Engines, chain-or belt-driven, can be classified as either free-running or interference, depending on what would happen if the piston-to-valve timing were disrupted. A free-running engine is designed with enough clearance between the pistons and valves to allow the crankshaft to rotate (pistons still moving) while the camshaft stays in one position (several valves fully open). If this condition occurs normally, no internal engine damage will result. In an interference engine, there is not enough clearance between the pistons and valves to allow the crankshaft to turn without the camshaft being in time.

    An interference engine can suffer extensive internal damage if a timing belt fails. The piston design does not allow clearance for the valve to be fully open and the piston to be at the top of its stroke. If the belt fails, the piston will collide with the valve and will bend or break the valve, damage the piston, and/or bend a connecting rod. When this type of failure occurs, the engine will need to be replaced or disassembled for further internal inspection; either choice costing many times that of replacing the timing belt.

    Inspection




    NOTE
    For manufacturers recommended service interval, refer to the maintenance interval chart located in this manual.

    The average replacement interval for a timing belt is approximately 60,000 miles (96,000km). If, however, the timing belt is inspected earlier or more frequently than suggested, and shows signs of wear or defects, the belt should be replaced at that time.


    WARNING
    Never allow antifreeze, oil or solvents to come into with a timing belt. If this occurs immediately wash the solution from the timing belt. Also, never excessive bend or twist the timing belt; this can damage the belt so that its lifetime is severely shortened.



    Click image to see an enlarged view

    Fig. Never bend or twist a timing belt excessively, and do not allow solvents, antifreeze, gasoline, acid or oil to come into contact with the belt

    Inspect both sides of the timing belt. Replace the belt with a new one if any of the following conditions exist:



    Hardening of the rubber-back side is glossy without resilience and leaves no indentation when pressed with a fingernail
     
    Cracks on the rubber backing
     
    Cracks or peeling of the canvas backing
     
    Cracks on rib root
     
    Cracks on belt sides
     
    Missing teeth or chunks of teeth
     
    Abnormal wear of belt sides-the sides are normal if they are sharp, as if cut by a knife
     

    If none of these conditions exist, the belt does not need replacement unless it is at the recommended interval. The belt MUST be replaced at the recommended interval.


    WARNING
    On interference engines, it is very important to replace the timing belt at the recommended intervals, otherwise expensive engine damage will likely result if the belt fails.



    Click image to see an enlarged view

    Fig. Broken tooth may be due to a damaged pulley



    Click image to see an enlarged view

    Fig. Back surface worn or cracked from a possible overheated engine or interference with the belt cover



    Click image to see an enlarged view

    Fig. Side wear from improper installation



    Click image to see an enlarged view

    Fig. Worn teeth from excessive belt tension, camshaft or distributor not turning properly, or fluid leaking on the belt

    Removal & Installation




    NOTE
    The radio may have a coded theft protection circuit. Obtain the code before disconnecting the battery, removing the radio fuse, or removing the radio.


    CAUTION
    Timing belt maintenance is extremely important. All Hyundai models use interference-type non-freewheeling engines. Should the timing belt break in these engines, the valves in the cylinder head will come in contact with the pistons, causing major engine damage. The recommended replacement interval for timing belts is 60,000 miles.


    CAUTION
    On models with an air bag, wait at least 90 seconds from the time that the ignition switch is turned to the LOCK position and the battery is disconnected before performing any further work.

    1.5L (Z5d) And 1.8L (Bpd) Engines
    1. Remove all necessary components for access to the timing belt covers, then remove the covers.
    2.  
    3. Turn the crankshaft until the timing mark on the crankshaft sprocket aligns with the timing mark on the oil pump and the camshaft sprocket timing marks align on the camshaft sprockets.
    4.  
    5. Remove the crankshaft pulley lockbolt and pulley boss.
    6.  
    7. Lower the vehicle. Insert a camshaft sprocket holding tool between the camshaft sprockets.
    8.  
    9. Loosen the tensioner pulley lockbolt. Pull the tensioner pulley away from the center of the engine to reduce the tension on the timing belt.
    10.  
    11. If the timing belt is to be reused, mark the direction of rotation on the timing belt. Remove the timing belt.
    12.  
    13. To remove the tensioner, unhook the tensioner spring, and remove the pulley lockbolt and tensioner.

      Click image to see an enlarged view

      Fig. Proper timing belt sprocket mark alignment for belt installation-Mazda 1.5L (Z5D) engine



      Click image to see an enlarged view

      Fig. When properly positioning the timing belt sprocket marks, be sure the two I-s are aligned and the two E-s are aligned as indicated-Mazda Protégé and Miata 1.8L (BPD) engines

    14.  

    To install:

    1. Install the crankshaft sprocket bolt. Install the flywheel locking tool, if equipped with automatic transaxle, or place the shift lever in 4th gear and apply the parking brake, if equipped with manual transaxle. Tighten the bolt to 108-116 ft. lbs. (147-157 Nm).
    2.  
    3. Be sure the timing marks on the camshaft and crankshaft sprockets are still aligned.
    4.  
    5. If removed, position the tensioner with the spring fully extended, and install the lockbolt tightening the mounting bolt to 28-38 ft. lbs. (38-51 Nm).
    6.  
    7. Install the timing belt. If reusing the original timing belt, be sure it is installed in the same direction of rotation.
    8.  
    9. Rotate the crankshaft clockwise 1 5 / 6 turns and align the timing marks. Be sure all marks are still correctly aligned.
    10.  
    11. Loosen the tensioner lockbolt to apply tension to the timing belt. Tighten the tensioner lockbolt to 28-38 ft. lbs. (38-51 Nm). Remove the holding tool from between the camshaft sprockets.
    12.  
    13. Rotate the crankshaft clockwise 2 1 / 6 turns and be sure all marks are still correctly aligned.
    14.  
    15. Raise and safely support the vehicle. Install the crankshaft pulley lockbolt and boss. Tighten the bolt to 116-122 ft. lbs. (157-166 Nm).
    16.  
    17. Install the timing belt covers.
    18.  

    1.6L (Zm) 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
       
      Camshaft Position (CMP) sensor
       
      Ignition coils
       
      Drive belt
       
      Crankshaft pulley and plate
       
      Water pump pulley
       
      Rocker arm cover and discard the gasket
       

    6.  
    7. Support the engine with a suitable support device and remove the number 3 engine mount.

      Timing belt cover
       
      Pulley using tool 49 D011 102 to prevent crankshaft rotation and remove the pulley boss
       

    8.  
    9. Install the pulley boss on the crankshaft and tighten the bolt.
    10.  
    11. Turn the crankshaft until the timing marks on the crankshaft and camshaft sprockets are aligned. Face the camshaft pulley marks I and E straight up, then align the timing marks with the horizontal surface on the cylinder head. The pin on the pulley boss must face upward. Hold the crankshaft pulley boss with a suitable tool and remove the pulley lockbolt, being careful not to rotate the crankshaft. Remove the crankshaft pulley boss.
      NOTE
      Protect the tensioner with a shop towel before prying on it. Do not rotate the crankshaft after the timing belt has been removed.

    12.  
    13. Mark the direction of rotation on the timing belt. Loosen the tensioner lockbolt and pry the tensioner outward. Tighten the lockbolt with the tensioner spring fully extended. Remove the timing belt.
    14.  
    15. Remove the tensioner and spring. If necessary, remove the idler pulley.
    16.  
    17. Inspect the belt for wear, peeling, cracking, hardening or signs of oil contamination. Inspect the tensioner for free and smooth rotation. Check the tensioner spring free length; it should not exceed 2.43 inch (68mm). Inspect the sprocket teeth for wear or damage. Replace parts, as necessary.

      Click image to see an enlarged view

      Fig. Exploded view of the timing belt assembly-1.6L (ZM) engines



      Click image to see an enlarged view

      Fig. Remove pulley bolt and boss by using tool 49 D011 102 to prevent crankshaft rotation-1.6L (ZM) engines



      Click image to see an enlarged view

      Fig. Turn the crankshaft until the timing marks on the crankshaft and camshaft sprockets are aligned. The pin on the pulley boss must face upward-1.6L (ZM) engines



      Click image to see an enlarged view

      Fig. Loosen the tensioner lockbolt and pry the tensioner outward-1.6L (ZM) engines



      Click image to see an enlarged view

      Fig. Do not to bend, twist or get oil or other contaminates on the belt as this will damage the belt, if reusing the belt; mark the direction of rotation prior to removal-1.6L (ZM) engines



      Click image to see an enlarged view

      Fig. Check the tensioner spring free length; it should not exceed 2.43 inch (68mm)-1.6L (ZM) engines

    18.  

    To install:

    1. Install the crankshaft sprocket bolt and temporarily tighten.
    2.  
    3. Install the tensioner and tensioner spring. Install the spring with the damper rubber closing face on the right side. Temporarily tighten the tensioner lockbolt with the tensioner spring fully extended.
    4.  
    5. Face the I and E marks of the camshaft pulley marks straight up, then align the timing marks with the horizontal surface on the cylinder head. Refer to the illustration for timing mark alignment.
    6.  
    7. Install the timing belt so there is no looseness, refer to the illustration for location as follows:

      Crankshaft pulley
       
      Idler pulley
       
      Exhaust camshaft pulley
       
      Intake camshaft pulley
       
      Tensioner
       

    8.  
    9. Make sure no pressure other than the tensioner spring is applied to the belt. If reusing the old belt, be sure it is installed in the same direction of rotation.
    10.  
    11. Temporarily install the pulley boss and lockbolt.
    12.  
    13. Turn the crankshaft 1 5 / 6 turns clockwise and align the crankshaft sprocket timing mark with the tension set mark for proper belt tension adjustment. Remove the lockbolt and pulley boss.
      CAUTION
      Do not let the tensioner move with the tensioner lock bolt as it is turned.



      Remove the pulley bolt and boss. and verify the timing belt pulley mark is still aligned with the tensioner set mark.
       

    14.  
    15. Tighten the tensioner lock bolt.
    16.  
    17. Temporarily install the pulley boss and lockbolt.
    18.  
    19. Turn the crankshaft 2 1 / 6 turns clockwise and face the pin on the pulley boss upright. Be sure the camshaft sprocket timing marks are aligned. If they are not, repeat the alignment steps.
      NOTE
      The timing marks are aligned normally if the camshaft pulley marks I and E are facing straight up, the timing marks are aligned to the horizontal surface on the cylinder head.



      Click image to see an enlarged view

      Fig. Install the tensioner and tensioner spring-1.6L (ZM) engines



      Click image to see an enlarged view

      Fig. Verify the timing marks are aligned as shown before installing the belt-1.6L (ZM) engines



      Click image to see an enlarged view

      Fig. Install the timing belt in this order-1.6L (ZM) engines



      Click image to see an enlarged view

      Fig. Turn the crankshaft 15/6turns clockwise and align the crankshaft sprocket timing mark with the tension set mark for proper belt tension adjustment-1.6L (ZM) engines



      Click image to see an enlarged view

      Fig. The belt should deflect 0.24-0.29 inch (6-7.5mm)-1.6L (ZM) engines

    20.  
    21. Apply approximately 22 lbs. (10 kg) pressure to the timing belt at a point midway between the camshaft sprockets. The belt should deflect 0.24-0.29 inch (6-7.5mm). If the deflection is not correct, repeat the alignment and tensioning procedure.
    22.  
    23. Install the pulley boss and lockbolt. Tighten the bolt to 116-122 ft. lbs. (157-166 Nm).
    24.  
    25. Install the timing belt covers and tighten the bolts to 95 inch lbs. (11 Nm).
    26.  
    27. Install the number 3 mount and remove the engine support device.
    28.  
    29. Install or connect the following:

      Rocker arm cover with a new gasket
       
      Water pump pulley
       
      Plate
       
      Crankshaft pulley and tighten the bolts to 109-151 inch lbs. (12-17 Nm)
       
      Drive belt
       
      Ignition coils
       
      CMP sensor and check the air gap between the sensor and the plate teeth using a brass feeler gauge. If the gap is not 0.020-0.059 inch (0.5-1.5mm) adjust the sensor until the proper gap is reached.
       
      Negative battery cable
       

    30.  

     
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