Mazda Car 2002-04

Timing Belt 6

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Removal & Installation



2.5L (KL) Engine
  1. Remove the timing belt covers. Temporarily reinstall the crankshaft pulley bolt.
  2.  
  3. On Millenia models, support the engine, and remove the nuts and through-bolt from the right side (No. 3) engine mount sub bracket. Remove the sub bracket.
  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 number one idler pulley. Remove the timing belt.

    Click image to see an enlarged view

    Fig. Timing belt sprocket positioning for proper timing belt installation-Mazda 626/MX6 2.5L (KL) engines



    Click image to see an enlarged view

    Fig. Position the crankshaft and camshaft sprockets as shown for belt installation-Mazda Millennia 2.5L (KL) engine

  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 suitable 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 0.060 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 counterclockwise until the timing sprocket is aligned.
  8.  
  9. With the No. 1 idler pulley removed, 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, tensioner pulley and right-hand camshaft sprocket.
  10.  
  11. Install the No. 1 idler pulley while applying pressure on the timing belt. Tighten the bolt to 28-38 ft. lbs. (38-51 Nm).
  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 2 turns in the normal direction of rotation and align the timing marks. Be sure all marks are still correctly aligned.
  18.  
  19. 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.
  20.  
  21. On Millenia models, install the right side (No. 3) engine mount sub-bracket. Tighten the nuts to 55-77 ft. lbs. (75-104 Nm) and the through-bolt to 63-86 ft. lbs. (86-116 Nm). Remove the engine support.
  22.  
  23. Remove the crankshaft damper bolt and install the timing belt covers.
  24.  

  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.  

  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
     
    Splash shield from the right hand side
     
    Drive belt
     
    Water pump pulley
     
    Idler pulley and bracket
     
    Power steering pump, leave the lines attached and position the pump aside
     



    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
     
    CKP sensor
     
    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 auto tensioner bolts, hold the tensioner so that the threads are aligned or the threads can be damaged.

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

  12.  
  13. Remove the number 1 idler pulley
    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-Millenia 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 0.0.512-0.551 inch (13-14mm) on type A tensioners or 0.563-0.594 inch (14.3-15.1mm) 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 pin whose diameter is 0.055 inch (1.4mm) on type A tensioners or 0.079 inch (2mm) on type B tensioners 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.
     
    CKP sensor
     
    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).
     
    Power steering pump
     
    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
     
    Splash shield
     
    Negative battery cable
     

  18.  

 
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