Mazda Car 2002-04

Timing Belt 4

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Removal & Installation



1.8L (Bp) 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
     
    Front suspension lower bar
     
    Air pipe
     
    Drive belt
     
    Crankshaft Position (CKP) sensor
     
    High tension lead and the ignition coil
     
    Spark plugs
     
    Upper radiator hose
     
    Water hose
     
    Oil pipe
     
    Oil Control Valve (OCV)
     
    Rocker arm cover and discard the gasket
     
    Water pump pulley
     
    Crankshaft pulley and plate
     
    Pulley bolt and boss by using tool 49 D011 102 to prevent crankshaft rotation
     
    Timing belt cover
     

  6.  
  7. Install the pulley boss on the crankshaft and tighten the bolt.
  8.  
  9. Turn the crankshaft until the timing marks on the crankshaft and camshaft sprockets are aligned. 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.
  10.  


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 2.31 inch (59.2mm). 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-1.8L (BP) engines



    Click image to see an enlarged view

    Fig. Remove pulley bolt and boss by using tool 49 D011 102 to prevent crankshaft rotation-1.8L (BP) 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-1.8L (BP) engines



    Click image to see an enlarged view

    Fig. Loosen the tensioner lockbolt and pry the tensioner outward-1.8L (BP) 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 (BP) engines



    Click image to see an enlarged view

    Fig. Check the tensioner spring free length; it should not exceed 2.31 inch (59.2mm)-1.8L (BP) engines


To install:

  1. Install the crankshaft sprocket bolt and temporarily tighten.
  2.  
  3. If removed, install the idler pulley and tighten the bolt to 37 ft. lbs. (51 Nm).
  4.  
  5. Install the tensioner and tensioner spring. Pry the tensioner outward and temporarily tighten the tensioner lockbolt with the tensioner spring fully extended.
  6.  
  7. Be sure the crankshaft sprocket timing mark is aligned with the mark on the oil pump housing. Be sure the camshaft sprocket timing marks are aligned with the marks on the seal plate. Refer to the illustration for timing mark alignment.
  8.  
  9. Install the timing belt so there is no looseness at the idler pulley side or between the camshaft sprockets. 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 2 turns clockwise and align the crankshaft sprocket timing mark. 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.
  14.  
  15. Turn the crankshaft 156
  16.  
  17. Be sure the crankshaft sprocket timing mark is aligned with the tension set mark. Loosen the tensioner lockbolt, and allow the spring to apply tension to the belt. Tighten the tensioner lockbolt to 37 ft. lbs. (51 Nm).
  18.  
  19. Install the pulley boss and lockbolt.
  20.  
  21. Turn the crankshaft 216
  22.  
  23. Apply approximately 22 lbs. (10kg) pressure to the timing belt at a point midway between the camshaft sprockets. The belt should deflect 0.35-0.45 inch (9.0-11.5mm). If the deflection is not correct, repeat the alignment and tensioning procedure.
  24.  
  25. Install the timing belt covers and tighten the bolts in sequence to 95 inch lbs. (11 Nm).
  26.  
  27. Install the valve cover and spark plugs, along with all other applicable components.
  28.  
  29. Hold the pulley boss with a suitable tool, and tighten the lockbolt to 116-130 ft. lbs. (157-167 Nm).
  30.  
  31. Install or connect the following:

    Crankshaft plate and pulley
     
    Water pump pulley
     
    Rocker arm cover with a new gasket
     
    Rocker arm cover with a new gasket.
     
    Temporarily tighten the cover boltsA
     

  32.  


    Click image to see an enlarged view

    Fig. Install the tensioner and tensioner spring-1.8L (BP) engines



    Click image to see an enlarged view

    Fig. Be sure the crankshaft sprocket timing mark is aligned with the mark on the oil pump housing. Be sure the camshaft sprocket timing marks are aligned with the marks on the seal plate-1.8L (BP) engines



    Click image to see an enlarged view

    Fig. Install the timing belt so there is no looseness at the idler pulley side or between the camshaft sprockets-1.8L (BP) 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-1.8L (BP) engines



    Click image to see an enlarged view

    Fig. The belt should deflect 0.35-0.45 inch (9.0-11.5mm)-1.8L (BP) engines



    Click image to see an enlarged view

    Fig. Tighten the timing belt cover using this sequence-1.8L (BP) engines



CAUTION
When installing the OCV valve, be careful not to damage the O-ring, if damaged it may cause leaking.



OCV and tighten the bolts in the sequence illustrated
 

  1. Install the oil pipe as follows:
    1. Oil pipe. 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. Coat the new washer with clean engine oil and temporarily install the upper and side oil pipe and position the pipe.
    2.  
    3. using several passes to 95 inch lbs. (11 Nm).A
    4.  
    5. Tighten oil pipe boltsB
    6.  
    7. Tighten oil pipe boltsC
    8.  
    9. Tighten oil pipe bolts 1, 2, 3, 4 and 7 using several passes to 95 inch lbs. (11 Nm).
    10.  
    11. Tighten oil pipe bolt 5 using several passes to 17 ft. lbs. (23 Nm).
    12.  
    13. Tighten oil pipe bolt 6 using several passes to 34 ft. lbs. (47 Nm).
    14.  

  2.  
  3. Install or connect the following:

    Water hose
     
    Upper radiator hose
     
    Spark plugs
     
    High tension lead and the ignition coil
     
    CKP sensor
     
    Drive belt
     
    Air pipe
     
    Front suspension lower bar
     
    Negative battery cable
     

  4.  


    Click image to see an enlarged view

    Fig. Tighten oil pipe bolts A and B using several passes to the specification in the text-1.8L (BP) engine



    Click image to see an enlarged view

    Fig. Tighten oil pipe bolts C using several passes to the specification in the text-1.8L (BP) engine



    Click image to see an enlarged view

    Fig. Tighten oil pipe bolts using several passes to the specification in the text-1.8L (BP) engine


1.8L (Bpd) Engine
  1. Remove all necessary components for access to the valve cover, then remove the cover.
  2.  
  3. Remove the spark plugs.
    NOTE
    Spark plugs are removed to make it easier to rotate the engine.

  4.  
  5. Remove the upper, middle and lower timing belt covers.
  6.  
  7. Turn the crankshaft until the timing marks on the crankshaft and camshaft sprockets are aligned. 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.
  8.  
  9. 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.
    NOTE
    Protect the tensioner with a shop towel before prying on it. Do not rotate the crankshaft after the timing belt has been removed.

  10.  
  11. Remove the tensioner and spring. If necessary, remove the idler pulley.
  12.  
  13. 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 2.315 in. (58.8mm). Inspect the sprocket teeth for wear or damage. Replace parts, as necessary.
  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. If removed, install the idler pulley and tighten the bolt to 38 ft. lbs. (52 Nm).
  4.  
  5. Install the tensioner and tensioner spring. Pry the tensioner outward and temporarily tighten the tensioner lockbolt with the tensioner spring fully extended.
  6.  
  7. Be sure the crankshaft sprocket timing mark is aligned with the mark on the oil pump housing. Be sure the camshaft sprocket timing marks are aligned with the marks on the seal plate.
  8.  
  9. Install the timing belt so there is no looseness at the idler pulley side or between the camshaft sprockets. 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 2 turns clockwise and align the crankshaft sprocket timing mark. 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.
  14.  
  15. 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.
  16.  
  17. Be sure the crankshaft sprocket timing mark is aligned with the tension set mark. Loosen the tensioner lockbolt, and allow the spring to apply tension to the belt. Tighten the tensioner lockbolt to 28-38 ft. lbs. (38-52 Nm).
  18.  
  19. Install the pulley boss and lockbolt.
  20.  
  21. Turn the crankshaft 2 1 / 6 turns clockwise and be sure the timing marks are correctly aligned.
  22.  
  23. Apply approximately 22 lbs. (10kg) pressure to the timing belt at a point midway between the camshaft sprockets. The belt should deflect 0.35-0.45 in. (9.0-11.5mm). If the deflection is not correct, repeat the alignment and tensioning procedure.
  24.  
  25. Hold the pulley boss with a suitable tool, and tighten the lockbolt to 123 ft. lbs. (167 Nm).
  26.  
  27. Install the timing belt covers and tighten the bolts to 95 inch lbs. (11 Nm).
  28.  
  29. Install the valve cover and spark plugs, along with all other applicable components.
  30.  

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

    Negative battery cable
     
    Crankshaft Position (CKP) sensor
     
    Camshaft Position (CMP) sensor on Protege 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
     

  6.  


CAUTION
The CKP sensor rotor is on the rear of the crankshaft pulley and can be damaged if the pulley is not removed carefully.



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
 

  1. Support the engine assembly with a hoist and remove the number 3 engine mount rubber.
  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 marksEI
  4.  
  5. Lower the vehicle. Insert a camshaft sprocket holding tool between the camshaft sprockets.
  6.  
  7. Turn the timing belt tensioner with an Allen wrench and remove the tensioner spring from the hook pinch
  8.  


CAUTION
Be careful not to bend, twist or get oil or other contaminates on the belt as this will damage the belt.

  1. If the timing belt is to be reused, mark the direction of rotation on the timing belt. Remove the timing belt.
  2.  
  3. Rotate the tensioner, if the tension rotates with no resistance or does not rotate; replace the tensioner
  4.  


    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


To install:

  1. Install the crankshaft sprocket bolt. Install the flywheel locking tool, if equipped with automatic transaxle, or place the shift lever in4th
  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.
  10.  


CAUTION
Do not use tension other than that supplied by the tension spring or damage could occur

  1. Turn the tensioner clockwise with an Allen wrench and install the tensioner spring. Remove the holding tool from between the camshaft sprockets.
  2.  
  3. Rotate the crankshaft 2 turns in the normal direction of rotation and align the timing marks. Be sure all marks are still correctly aligned.
  4.  
  5. Install the number 3 engine mount rubber and tighten the fasteners to the specifications shown in the illustration. Remove the engine hoist.
  6.  
  7. Install or connect the following:

    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
     

  8.  


    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



CAUTION
The CKP sensor rotor is on the rear of the crankshaft pulley and can be damaged if the pulley is not installed carefully.



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
 

 
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