Mazda Car 2002-04

Timing Belt 2

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Removal & Installation



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 marksIE
  12.  


NOTE
Protect the tensioner with a shop towel before prying on it. Do not rotate the crankshaft after the timing belt has been removed.

  1. 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.
  2.  
  3. Remove the tensioner and spring. If necessary, remove the idler pulley.
  4.  
  5. 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.
  6.  


    Click image to see an enlarged view

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



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    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


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 theIE
  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 156

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

  14.  


CAUTION
Do not let the tensioner move with the tensioner lock bolt as it is turned.

  1. Tighten the tensioner lock bolt.
  2.  
  3. Temporarily install the pulley boss and lockbolt.
  4.  
  5. Turn the crankshaft 216
  6.  


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



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



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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



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

  1. Apply approximately 22 lbs. (10kg) 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.
  2.  
  3. Install the pulley boss and lockbolt. Tighten the bolt to 116-122 ft. lbs. (157-166 Nm).
  4.  
  5. Install the timing belt covers and tighten the bolts to 95 inch lbs. (11 Nm).
  6.  
  7. Install the number 3 mount and remove the engine support device.
  8.  
  9. Install or connect the following:

    Rocker arm cover with a new gasket
     


    Click image to see an enlarged view

    Fig. Tighten the OCV bolts in the sequence shown-1.8L (BP) engine



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    Fig. Hold the frame of the OCV valve filter and install the OCV so it is aligned with the projected part on the flange end of the oil pipe-1.8L (BP) engine

    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
     

  10.  

 
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