Mazda Car 2002-04

Timing Belt, Cover, Sprockets, & Seal 2

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Removal & Installation



2.5L (KL) 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
     
    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
     

  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 E011 1A1 and 49 S120 710. Refer to the illustration for tool positioning.
 
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. 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.
  4.  


CAUTION
When removing the number 1 idler pulley bolt, hold the pulley so that the threads are aligned or the threads can be damaged.

  1. Remove the number 1 idler pulley
  2.  


CAUTION
When removing the auto tensioner bolts, hold the tensioner so that the threads are aligned or the threads can be damaged.

  1. Loosen the auto tensioner bolts and remove the lower bolt.
  2.  


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. Remove the belt.
  4.  
  5. If necessary, remove the auto tensioner.
  6.  


    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


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 typeAB
    2.  
    3. Inspect the tensioner for leakage and replace if defective.
    4.  

  2.  


CAUTION
Do not apply pressure of more than 2,200 lbf. (9.8 Kn) to the tensioner or damage will occur.

  1. Using a press, slowly press in the tensioner rod.
  2.  
  3. Insert a 0.055 inch (1.4mm) diameter pin to hold the rod in position.
  4.  
  5. Install the tensioner and hand tighten the bolt.
  6.  

  1. Turn the camshafts clockwise and align the timing marks as illustrated.
  2.  
  3. Install the crankshaft pulley bolt and turn the crankshaft clockwise and align the marks as illustrated.
  4.  
  5. With the number 1 idler pulley removed, install the belt on the pulleys in this order:

    Timing belt pulley
     
    Number 2 idler pulley
     
    Left hand camshaft pulley
     
    Tensioner pulley
     
    Right hand camshaft pulley
     



    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

  6.  


CAUTION
Make sure the belt has no looseness at the tension side.

  1. Make sure there is tension between pulleys (3) and (1) and pulleys (1) and (5). Refer to the illustration for location of the pulleys.
  2.  
  3. 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).
  4.  
  5. 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.
  6.  
  7. 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.
  8.  
  9. Install or connect the following:

    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
     

  10.  


    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



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 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
 

  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
     
    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
     

  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.



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
 

  1. Support the engine assembly with a hoist and remove the number 3 engine mount rubber.
  2.  
  3. 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.
  4.  


CAUTION
When removing the auto tensioner bolts, hold the tensioner so that the threads are aligned or the threads can be damaged.

  1. Loosen the auto tensioner bolts and remove the lower bolt.
  2.  


CAUTION
When removing the number 1 idler pulley bolt, hold the pulley so that the threads are aligned or the threads can be damaged.

  1. Remove the number 1 idler pulley
  2.  


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. Remove the belt.
  4.  
  5. If necessary, remove the auto tensioner.
  6.  


    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


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 typeAB
    2.  
    3. Inspect the tensioner for leakage and replace if defective.
    4.  

  2.  


CAUTION
Do not apply pressure of more than 2,200 lbf. (9.8 Kn) to the tensioner or damage will occur.

  1. Using a press, slowly press in the tensioner rod.
  2.  
  3. Insert a pin whose diameter is 0.055 inch (1.4mm) on typeAB
  4.  
  5. Install the tensioner and hand tighten the bolt.
  6.  

  1. Turn the camshafts clockwise and align the timing marks as illustrated.
  2.  
  3. Install the crankshaft pulley bolt and turn the crankshaft clockwise and align the marks as illustrated.
  4.  
  5. With the number 1 idler pulley removed, install the belt on the pulleys in this order:

    Timing belt pulley
     
    Number 2 idler pulley
     
    Left hand camshaft pulley
     
    Tensioner pulley
     
    Right hand camshaft pulley
     



    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

  6.  


CAUTION
Make sure the belt has no looseness at the tension side.

  1. Make sure there is tension between pulleys (3) and (1) and pulleys (1) and (5). Refer to the illustration for location of the pulleys.
  2.  
  3. 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).
  4.  
  5. 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.
  6.  
  7. 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.
  8.  
  9. Install or connect the following:

    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
     

  10.  


    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



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 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
 

 
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