Mazda Car 2002-04

Timing Belt 5

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Removal & Installation



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:
    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.  

2.0L (FS) Engine
  1. Remove the timing belt covers. Temporarily reinstall the crankshaft pulley bolt.
  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 E and I align on the camshaft sprockets.
  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 pin.
  8.  
  9. If the timing belt is to be reused, mark the direction of rotation on the timing belt. Remove the timing belt.

    Click image to see an enlarged view

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

  10.  

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. Install the timing belt. If reusing the original timing belt, be sure it is installed in the same direction of rotation.
  6.  
  7. Turn the tensioner clockwise with an Allen wrench and install the tensioner spring. Remove the holding tool from between the camshaft sprockets.
  8.  
  9. Rotate the crankshaft 2 turns in the normal direction of rotation and align the timing marks. Be sure all marks are still correctly aligned.
  10.  
  11. Raise and safely support the vehicle. Remove the crankshaft pulley bolt and install the timing belt covers.
  12.  

2.3L (KJ) Engine
  1. Remove the timing belt covers. Temporarily reinstall the crankshaft pulley bolt.
  2.  
  3. Remove the power steering auto-tensioner and pulley.
  4.  
  5. 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 with the marks on the cylinder head. The No. 1 piston should be at Top Dead Center (TDC) of the compression stroke.
  6.  
  7. Remove the two bolts from the automatic tensioner, removing the lower one first. Keep the bolt holes aligned by holding the tensioner to reduce the chance of stripping the threads on the bolts.
  8.  
  9. If the timing belt is to be reused, mark the direction of rotation on the timing belt.
  10.  
  11. Remove the timing belt.

    Click image to see an enlarged view

    Fig. Proper crankshaft and camshaft timing belt sprocket alignment mark positioning-Mazda 2.3L (KJ) engines

  12.  

To install:

  1. Install the crankshaft sprocket bolt. Install the flywheel locking tool. Tighten the bolt to 116-122 ft. lbs. (157-166 Nm). Remove the flywheel locking tool.
  2.  
  3. Position the automatic tensioner in a press. Set a flat washer under the tensioner body to prevent damage to the body plug.
  4.  
  5. Compress the tensioner until the hole in the piston is aligned with the 2nd hole in the tensioner case. Insert a 0.063 in. (1.6mm) diameter wire or pin through the 2nd hole to keep the piston compressed.
  6.  
  7. Be sure the camshaft sprocket timing marks are still aligned. Turn the crankshaft clockwise until the timing sprocket is aligned.
  8.  
  9. Install the timing belt. If the original belt is being reused, be sure it is installed in the same direction of rotation. The order of installation is: timing belt (crankshaft) sprocket, No. 2 idler pulley, left-hand camshaft sprocket, both No. 1 idler pulleys, right-hand camshaft sprocket and the tensioner pulley.
  10.  
  11. Install the automatic belt tensioner and tighten the bolts to 14-18 ft. lbs. (19-25 Nm). Remove the wire or pin from the tensioner.
  12.  
  13. Turn the crankshaft clockwise, until the crankshaft sprocket timing mark is again at TDC. This should place all of the belt slack in the automatic tensioner portion of the belt.
  14.  
  15. Rotate the crankshaft two turns in the normal direction of rotation and align the timing marks. Be sure all marks are still correctly aligned.
  16.  
  17. Inspect timing belt deflection, 0.24-0.31 in. (6-8mm), between the crankshaft sprocket and the tensioner pulley. If it is out of specification, replace the auto-tensioner.
  18.  
  19. Install the power steering auto-tensioner and tighten the bolts to 14-18 ft. lbs. (19-25 Nm). Install the pulley, and tighten the bolt to 29-34 ft. lbs. (40-47 Nm).
  20.  
  21. Remove the crankshaft damper bolt and install the timing belt covers.
  22.  

  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 Crankshaft Position (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
     
    Right front wheel
     
    Splash shield from the right hand side
     
    Dust cover
     
    Drive belt
     

  6.  
  7. Turn the crankshaft pulley clockwise until the pin on the pulley is facing down.

    Crankshaft pulley using special tools 49 E120 710. Refer to the illustration for tool positioning.

    Click image to see an enlarged view

    Fig. Remove the crankshaft pulley using special tools 49 E120 710-2.3L (KJ) engines

     
    Power steering pump, leave the lines attached and position the pump aside
     
    Water pump pulley
     
    Alternator drive belt tensioner
     
    Camshaft Position (CMP) sensor
     
    Oil dipstick and tube
     
    Vacuum pipe
     
    Upper radiator hose
     

  8.  
  9. Support the engine assembly with a hoist and remove the number 3 engine mount rubber.

    Number 3 engine mount sub bracket, rubber and bracket

    Click image to see an enlarged view

    Fig. Remove the number 3 engine mount sub bracket, rubber and bracket-2.3L (KJ) engines

     
    Timing belt cover
     
    Power steering pump drive belt tensioner
     

  10.  
  11. 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 with the marks on the cylinder head. The No. 1 piston should be at Top Dead Center (TDC) of the compression stroke.
  12.  
  13. Remove the two bolts from the automatic tensioner, removing the lower one first. Keep the bolt holes aligned by holding the tensioner to reduce the chance of stripping the threads on the bolts.
  14.  
  15. If the timing belt is to be reused, mark the direction of rotation on the timing belt.
  16.  
  17. Remove the timing belt.

    Click image to see an enlarged view

    Fig. Exploded view of the timing belt assembly-2.3L (KJ) engines

  18.  

To install:

  1. Install the crankshaft sprocket bolt. Install the flywheel locking tool. Tighten the bolt to 116-122 ft. lbs. (157-166 Nm).
  2.  
  3. Check the tension rod projection, it should be 0.563-0.594 inch (14.3-15.1mm), if not, replace the tensioner

    Click image to see an enlarged view

    Fig. Check the tension rod projection, it should be 0.563-0.594 inch (14.3-15.1mm)-2.3L (KJ) engines

  4.  
  5. Position the automatic tensioner in a press. Set a flat washer under the tensioner body to prevent damage to the body plug.
  6.  
  7. Compress the tensioner until the hole in the piston is aligned with the 2nd hole in the tensioner case. Insert a 0.055 inch (1.4mm) diameter wire or pin through the 2nd hole to keep the piston compressed.
  8.  
  9. Be sure the camshaft sprocket timing marks are still aligned. Turn the crankshaft clockwise until the timing sprocket is aligned.

    Click image to see an enlarged view

    Fig. Be sure the camshaft sprocket timing marks are still aligned-2.3L (KJ) engines

  10.  
  11. Install the timing belt. If the original belt is being reused, be sure it is installed in the same direction of rotation. The order of installation is: timing belt (crankshaft) sprocket, No. 2 idler pulley, left-hand camshaft sprocket, both No. 1 idler pulleys, right-hand camshaft sprocket and the tensioner pulley.
  12.  
  13. Install the automatic belt tensioner and tighten the bolts to 14-18 ft. lbs. (19-25 Nm). Remove the wire or pin from the tensioner.
  14.  
  15. Turn the crankshaft clockwise, until the crankshaft sprocket timing mark is again at TDC. This should place all of the belt slack in the automatic tensioner portion of the belt.
  16.  
  17. Rotate the crankshaft two turns in the normal direction of rotation and align the timing marks. Be sure all marks are still correctly aligned.

    Click image to see an enlarged view

    Fig. Check the timing belt mark alignment once all the components are installed-2.3L (KJ) engines



    Click image to see an enlarged view

    Fig. Turn the crankshaft clockwise, until the crankshaft sprocket timing mark is again at TDC-2.3L (KJ) engines

  18.  
  19. Inspect timing belt deflection, 0.24-0.31 inch (6-8mm), between the crankshaft sprocket and the tensioner pulley. If it is out of specification, replace the auto-tensioner.
  20.  
  21. Install or connect the following:

    Power steering pump drive belt tensioner
     
    Upper timing belt cover and tighten the bolts to 95 inch lbs. (11 Nm) in the sequence illustrated
     
    Right and left hand timing belt cover and tighten the bolts to 95 inch lbs. (11 Nm) in the sequence illustrated

    Click image to see an enlarged view

    Fig. Tighten the upper timing belt cover in this sequence-2.3L (KJ) engine



    Click image to see an enlarged view

    Fig. Tighten the right and left hand timing belt cover in this sequence-2.3L (KJ) engine

     
    Number 3 engine mount rubber, bracket and sub bracket. Tighten bolts A to 44 ft. lbs. (60 Nm) and bolts B to 77 ft. lbs. (104 Nm).

    Click image to see an enlarged view

    Fig. Install the number 3 engine mount rubber, bracket and sub bracket and tighten to specification-2.3L (KJ) engine

     
    Upper radiator hose
     
    Vacuum pipe
     
    Oil dipstick and tube
     
    CMP sensor
     
    Alternator drive belt tensioner
     
    Water pump pulley
     
    Power steering pump
     

  22.  
  23. Remove the timing belt pulley A , install the crankshaft pulley. Hand tighten bolts A and B . Tighten the bolt A to 116-122 ft. lbs. (157-166 Nm) and bolt B to 22 ft. lbs. (30 Nm).

    Drive belt
     
    Dust cover
     
    Splash shield from the right hand side
     
    Right front wheel
     
    Negative battery cable
     

  24.  

 
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