Protege 1999-2000

Timing Belt

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Removal & Installation



1.6L (Zm) Engine

Specific to:

Mazda Protege 1999-2001

  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
     
    Camshaft Position (CMP) sensor
     
    Ignition coils
     
    Drive belt
     
    Crankshaft pulley and plate
     
    Water pump pulley
     
    Rocker arm cover and discard the gasket
     

  6.  
  7. Support the engine with a suitable support device and remove the number 3 engine mount.

    Timing belt cover
     
    Pulley using tool 49 D011 102 to prevent crankshaft rotation and remove the pulley boss
     

  8.  
  9. Install the pulley boss on the crankshaft and tighten the bolt.
  10.  
  11. Turn the crankshaft until the timing marks on the crankshaft and camshaft sprockets are aligned. Face the camshaft pulley marks I and E straight up, then align the timing marks with the horizontal surface on the cylinder head. 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.
    NOTE
    Protect the tensioner with a shop towel before prying on it. Do not rotate the crankshaft after the timing belt has been removed.

  12.  
  13. 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.
  14.  
  15. Remove the tensioner and spring. If necessary, remove the idler pulley.
  16.  
  17. 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 2.43 inch (68mm). Inspect the sprocket teeth for wear or damage. Replace parts, as necessary.

    Click image to see an enlarged view

    Fig. Exploded view of the timing belt assembly-1.6L (ZM) engines



    Click image to see an enlarged view

    Fig. Remove pulley bolt and boss by using tool 49 D011 102 to prevent crankshaft rotation-1.6L (ZM) 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-1.6L (ZM) engines



    Click image to see an enlarged view

    Fig. Loosen the tensioner lockbolt and pry the tensioner outward-1.6L (ZM) 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-1.6L (ZM) engines



    Click image to see an enlarged view

    Fig. Check the tensioner spring free length; it should not exceed 2.43 inch (68mm)-1.6L (ZM) engines

  18.  

To install:

  1. Install the crankshaft sprocket bolt and temporarily tighten.
  2.  
  3. Install the tensioner and tensioner spring. Install the spring with the damper rubber closing face on the right side. Temporarily tighten the tensioner lockbolt with the tensioner spring fully extended.
  4.  
  5. Face the I and E marks of the camshaft pulley marks straight up, then align the timing marks with the horizontal surface on the cylinder head. Refer to the illustration for timing mark alignment.
  6.  
  7. Install the timing belt so there is no looseness, refer to the illustration for location as follows:

    Crankshaft pulley
     
    Idler pulley
     
    Exhaust camshaft pulley
     
    Intake camshaft pulley
     
    Tensioner
     

  8.  
  9. Make sure no pressure other than the tensioner spring is applied to the belt. 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 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.
    CAUTION
    Do not let the tensioner move with the tensioner lock bolt as it is turned.



    Remove the pulley bolt and boss. and verify the timing belt pulley mark is still aligned with the tensioner set mark.
     

  14.  
  15. Tighten the tensioner lock bolt.
  16.  
  17. Temporarily install the pulley boss and lockbolt.
  18.  
  19. Turn the crankshaft 2 1 / 6 turns clockwise and 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.
    NOTE
    The timing marks are aligned normally if the camshaft pulley marks I and E are facing straight up, the timing marks are aligned to the horizontal surface on the cylinder head.



    Click image to see an enlarged view

    Fig. Install the tensioner and tensioner spring-1.6L (ZM) engines



    Click image to see an enlarged view

    Fig. Verify the timing marks are aligned as shown before installing the belt-1.6L (ZM) engines



    Click image to see an enlarged view

    Fig. Install the timing belt in this order-1.6L (ZM) 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-1.6L (ZM) engines



    Click image to see an enlarged view

    Fig. The belt should deflect 0.24-0.29 inch (6-7.5mm)-1.6L (ZM) engines

  20.  
  21. Apply approximately 22 lbs. (10 kg) pressure to the timing belt at a point midway between the camshaft sprockets. The belt should deflect 0.24-0.29 inch (6-7.5mm). If the deflection is not correct, repeat the alignment and tensioning procedure.
  22.  
  23. Install the pulley boss and lockbolt. Tighten the bolt to 116-122 ft. lbs. (157-166 Nm).
  24.  
  25. Install the timing belt covers and tighten the bolts to 95 inch lbs. (11 Nm).
  26.  
  27. Install the number 3 mount and remove the engine support device.
  28.  
  29. Install or connect the following:

    Rocker arm cover with a new gasket
     
    Water pump pulley
     
    Plate
     
    Crankshaft pulley and tighten the bolts to 109-151 inch lbs. (12-17 Nm)
     
    Drive belt
     
    Ignition coils
     
    CMP sensor and check the air gap between the sensor and the plate teeth using a brass feeler gauge. If the gap is not 0.020-0.059 inch (0.5-1.5mm) adjust the sensor until the proper gap is reached.
     
    Negative battery cable
     

  30.  

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

Specific to:

Mazda 626 1999-2002

Mazda Protege 1999-2003

Mazda Protege5 2002-2003

  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.  

 
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