Mazda Car 2002-04

Timing Belt, Cover, Sprockets, & Seal 1

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Removal & Installation



2.3L (Kj) Engine
  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
     
    Right front wheel
     
    Splash shield from the right hand side
     
    Dust cover
     
    Drive belt
     

  6.  


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.

  1. 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
     

  2.  
  3. 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
     

  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.
  12.  


    Click image to see an enlarged view

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


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
  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.
  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.
  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 boltsAB
     


    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 pulleyAABAB

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

  24.  


    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



    Click image to see an enlarged view

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



    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


 
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