626 1999-2001

Timing Belt

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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



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



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Fig. Side wear from improper installation



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

Removal & Installation



1.8L (Fp) & 2.0L (Fs) Engines

Specific to:

Mazda 626 1999-2002

Mazda Protege 1999-2003

Mazda Protege5 2002-2003

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Refer to the illustration of the exploded view of the timing belt assembly for component location and torque specifications.
  4.  
  5. Remove or disconnect the following:
    CAUTION
    The CKP sensor rotor is on the rear of the crankshaft pulley and can be damaged if the pulley is not removed carefully.



    Negative battery cable
     
    Crankshaft Position (CKP) sensor
     
    Camshaft Position (CMP) sensor on Protégé models
     
    Spark plugs
     
    Power steering pump and bracket, leave the lines attached and position the pump aside on 2.0L (FS) engines
     
    Drive belt
     
    Water pump pulley
     



    Crankshaft pulley using special tools 49 G011 103, 49 E011 1A1 and 49 S120 710. Refer to the illustration for tool positioning.
     
    Guide plate from behind the crankshaft pulley
     
    Rocker arm cover
     
    Oil dipstick and tube
     
    Timing belt cover
     

  6.  
  7. Support the engine assembly with a hoist and remove the number 3 engine mount rubber.
  8.  
  9. 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 E and I align on the camshaft sprockets. Refer to the illustration for proper timing mark alignment.
  10.  
  11. Lower the vehicle. Insert a camshaft sprocket holding tool between the camshaft sprockets.
  12.  
  13. Turn the timing belt tensioner with an Allen wrench and remove the tensioner spring from the hook pinch
    CAUTION
    Be careful not to bend, twist or get oil or other contaminates on the belt as this will damage the belt.

  14.  
  15. If the timing belt is to be reused, mark the direction of rotation on the timing belt. Remove the timing belt.
  16.  
  17. Rotate the tensioner, if the tension rotates with no resistance or does not rotate; replace the tensioner

    Click image to see an enlarged view

    Fig. Exploded view of the timing belt assembly-2.0L (FS) engines shown, 1.8L (FP) engines are similar



    Click image to see an enlarged view

    Fig. Remove the crankshaft pulley using special tools 49 G011 v103, 49 E011 1A1 and 49 S120 710-1.8L (FP) and 2.0L (FS) engines



    Click image to see an enlarged view

    Fig. When properly aligned for belt removal, the cam gear marks should face each other-1.8L (FP) and 2.0L (FS) engines



    Click image to see an enlarged view

    Fig. Remove the tensioner spring from the hook pin-1.8L (FP) and 2.0L (FS) 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-1.8L (FP) and 2.0L (FS) engines



    Click image to see an enlarged view

    Fig. Rotate the tensioner, if the tension rotates with no resistance or does not rotate; replace the tensioner-1.8L (FP) and 2.0L (FS) engines

  18.  

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 116-122 ft. lbs. (157-166 Nm).
  2.  
  3. Be sure the timing marks on the camshaft and crankshaft sprockets are still aligned.
  4.  
  5. Install the timing belt. If reusing the original timing belt, be sure it is installed in the same direction of rotation. Make sure there is no looseness on the idler side.
  6.  
  7. Rotate the crankshaft 2 turns in the normal direction of rotation and align the timing marks. Be sure all marks are still correctly aligned. If the marks are not aligned, remove the belt and then reinstall it and make sure the marks are properly aligned.
  8.  
  9. Check the tensioner spring length, if the free length is not 1.44 inch (36.5mm), replace the spring.
    CAUTION
    Do not use tension other than that supplied by the tension spring or damage could occur

  10.  
  11. Turn the tensioner clockwise with an Allen wrench and install the tensioner spring. Remove the holding tool from between the camshaft sprockets.
  12.  
  13. Rotate the crankshaft 2 turns in the normal direction of rotation and align the timing marks. Be sure all marks are still correctly aligned.
  14.  
  15. Install the number 3 engine mount rubber and tighten the fasteners to the specifications shown in the illustration. Remove the engine hoist.

    Click image to see an enlarged view

    Fig. Be sure the timing marks on the camshaft and crankshaft sprockets are still aligned-1.8L (FP) and 2.0L (FS) engines



    Click image to see an enlarged view

    Fig. Make sure there is no looseness on the idler side when the belt is installed-1.8L (FP) and 2.0L (FS) engines



    Click image to see an enlarged view

    Fig. Check the tensioner spring length, if the free length is not 1.44 inch (36.5mm); replace the spring-1.8L (FP) and 2.0L (FS) engines

  16.  
  17. Install or connect the following:
    CAUTION
    The CKP sensor rotor is on the rear of the crankshaft pulley and can be damaged if the pulley is not installed carefully.



    Timing belt cover. Refer to the exploded view of the timing belt components for torque specifications.
     
    Oil dipstick and tube. Refer to the exploded view of the timing belt components for torque specifications.
     
    Rocker arm cover
     
    Guide plate
     



    Crankshaft pulley using special tools 49 G011 v103, 49 E011 1A1 and 49 S120 710 and tighten the bolt to 116-122 ft. lbs. (157-166 Nm).
     
    Water pump pulley. Refer to the exploded view of the timing belt components for torque specifications.
     
    Drive belt
     
    Power steering bracket and pump, if removed
     
    Spark plugs
     
    CKP sensor
     
    Negative battery cable
     

  18.  

2.5L (KL) Engine

Specific to:

Mazda 626 1999-2002

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Refer to the illustration of the exploded view of the timing belt assembly for component location and torque specifications.
  4.  
  5. Remove or disconnect the following:
    CAUTION
    The CKP sensor rotor is on the rear of the crankshaft pulley and can be damaged if the pulley is not removed carefully.



    Negative battery cable
     
    Crankshaft Position (CKP) sensor
     
    Spark plugs
     
    Power steering pump, leave the lines attached and position the pump aside
     
    Drive belt
     
    Water pump pulley
     
    Idler pulley bracket
     



    Crankshaft pulley using special tools 49 E011 1A1 and 49 S120 710. Refer to the illustration for tool positioning.
     
    Rocker arm cover
     
    Oil dipstick and tube
     
    Timing belt cover
     

  6.  
  7. Support the engine assembly with a hoist and remove the number 3 engine mount rubber.
  8.  
  9. Install the crankshaft pulley bolt and turn the crankshaft clockwise and align the timing marks as illustrated. The number 1 piston should be at Top Dead Center (TDC) of the compression stroke.
    CAUTION
    When removing the number 1 idler pulley bolt, hold the pulley so that the threads are aligned or the threads can be damaged.

  10.  
  11. Remove the number 1 idler pulley
    CAUTION
    When removing the auto tensioner bolts, hold the tensioner so that the threads are aligned or the threads can be damaged.

  12.  
  13. Loosen the auto tensioner bolts and remove the lower bolt.
    CAUTION
    Be careful not to bend, twist or get oil or other contaminates on the belt as this will damage the belt.

  14.  
  15. If the timing belt is to be reused, mark the direction of rotation on the timing belt. Remove the timing belt.
  16.  
  17. Remove the belt.
  18.  
  19. If necessary, remove the auto tensioner.

    Click image to see an enlarged view

    Fig. Exploded view of the timing belt assembly-2.5L (KL) engines-626 models



    Click image to see an enlarged view

    Fig. Remove the crankshaft pulley using special tools 49 E011 1A1 and 49 S120 710-2.5L (KL) engines



    Click image to see an enlarged view

    Fig. Turn the crankshaft clockwise and align the timing marks as illustrated. The number 1 piston should be at Top Dead Center (TDC) of the compression stroke.-2.5L (KL) engines



    Click image to see an enlarged view

    Fig. Remove the number 1 idler pulley.-2.5L (KL) engines



    Click image to see an enlarged view

    Fig. Loosen the auto tensioner bolts and remove the lower bolt-2.5L (KL) 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-2.5L (KL) engines

  20.  

To install:


CAUTION
There are two type of auto tensioners and they are interchangeable.

  1. If removed install the auto tensioner as follows:
    1. Measure the tensioner rod projection length. If the length exceeds 0.563-0.594 inch (14.3-15.1mm) on type A tensioners or 0.473-0.511 inch (12-13mm) on type B tensioners replace the tensioner. Refer to the illustration to distinguish tensioner type.
    2.  
    3. Inspect the tensioner for leakage and replace if defective.
      CAUTION
      Do not apply pressure of more than 2,200 ft. lbs. (9.8 Kn) to the tensioner or damage will occur.

    4.  
    5. Using a press, slowly press in the tensioner rod.
    6.  
    7. Insert a 0.055 inch (1.4mm) diameter pin to hold the rod in position.
    8.  
    9. Install the tensioner and hand tighten the bolt.
    10.  

  2.  
  3. Turn the camshafts clockwise and align the timing marks as illustrated.
  4.  
  5. Install the crankshaft pulley bolt and turn the crankshaft clockwise and align the marks as illustrated.
  6.  
  7. With the number 1 idler pulley removed, install the belt on the pulleys in this order:
    CAUTION
    Make sure the belt has no looseness at the tension side.



    Click image to see an enlarged view

    Fig. There are two type of auto tensioners and they are interchangeable-2.5L (KL) engines



    Click image to see an enlarged view

    Fig. Measure the tensioner rod projection length and replace if it exceeds specification-2.5L (KL) engines



    Click image to see an enlarged view

    Fig. Using a press, slowly press in the tensioner rod and insert a 0.055 inch (1.4mm) diameter pin to hold the rod in position-2.5L (KL) engines



    Click image to see an enlarged view

    Fig. Install the tensioner and hand tighten the bolt-2.5L (KL) engines



    Click image to see an enlarged view

    Fig. Turn the camshafts clockwise and align the timing marks-2.5L (KL) engines



    Click image to see an enlarged view

    Fig. Make sure there is tension between pulleys (3) and (1) and pulleys (1) and (5)-2.5L (KL) engines



    Timing belt pulley
     
    Number 2 idler pulley
     
    Left hand camshaft pulley
     
    Tensioner pulley
     
    Right hand camshaft pulley
     

  8.  
  9. Make sure there is tension between pulleys (3) and (1) and pulleys (1) and (5). Refer to the illustration for location of the pulleys.
  10.  
  11. Install the number 1 idler pulley while applying the pressure on the timing belt. Tighten the bolt to 28-38 ft. lbs. (38-51 Nm).
  12.  
  13. Push the auto tensioner in the direction of arrow (refer to illustration) and hand tighten the lower bolt, then tighten the bolts. Refer to the exploded view of the timing belt components for torque specifications. Then remove the retaining pin.

    Click image to see an enlarged view

    Fig. Push the auto tensioner in the direction of arrow and hand tighten the lower bolt-2.5L (KL) engine

  14.  
  15. Turn the crankshaft clockwise and align the timing marks. Make sure the timing marks are aligned, if not remove the belt and repeat the installation process.
  16.  
  17. Install or connect the following:
    CAUTION
    The CKP sensor rotor is on the rear of the crankshaft pulley and can be damaged if the pulley is not removed carefully.



    Number 3 engine mount rubber. Refer to the exploded view of the timing belt components for torque specifications. Remove the engine hoist.
     
    Timing belt cover. Refer to the exploded view of the timing belt components for torque specifications.
     
    Oil dipstick and tube. Refer to the exploded view of the timing belt components for torque specifications.
     
    Rocker arm cover
     



    Crankshaft pulley using special tools 49 E011 1A1 and 49 S120 710. Refer to the illustration for tool positioning. Tighten the bolt to 16-122 ft. lbs. (157-166 Nm).
     
    Idler pulley bracket. Refer to the exploded view of the timing belt components for torque specifications.
     
    Water pump pulley. Refer to the exploded view of the timing belt components for torque specifications.
     
    Drive belt
     
    Power steering pump
     
    Spark plugs
     
    CKP sensor
     
    Negative battery cable
     

  18.  

 
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