Repairing Manual 1990-1998 Mazda 323/ MX-3/ 626/ MX-6/ Millenia/ Protege Timing Belt Cover Removal & Installation
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REMOVAL & INSTALLATION 1990-94 1.6L and 1.8L (except K8) Engines See Figures 1 and 2 1. Disconnect the negative battery cable. 2. Remove the engine under splash shield. Fig. Fig. 1: Exploded view of the 1990-94 1.6L and 1.8L SOHC timing belt cover assembly Fig. Fig. 2: Exploded view of the 1.8L DOHC timing belt cover assembly 3. Remove the accessory drive belts. Refer to General Information & Maintenance . 4. Remove the crankshaft pulley. 5. Remove the inner and outer timing belt guide plates. 6. Remove the 2 bolts and remove the upper timing belt cover assembly. 7. Remove the 1 bolt and remove the lower timing belt cover assembly and gasket. To install: 8. Install the lower cover gasket and the lower cover. Tighten the bolt to 69-95 inch lbs. (8-11 Nm). 9. Install the upper cover gasket and the upper cover. Tighten the bolts to 69-95 inch lbs. (8-11 Nm). 10. Install the timing belt inner and outer guide plates.
REMOVAL & INSTALLATION 1990-94 1.6L and 1.8L (except K8) Engines See Figures 1 and 2 1. Disconnect the negative battery cable. 2. Remove the engine under splash shield. Fig. Fig. 1: Exploded view of the 1990-94 1.6L and 1.8L SOHC timing belt cover assembly Fig. Fig. 2: Exploded view of the 1.8L DOHC timing belt cover assembly 3. Remove the accessory drive belts. Refer to General Information & Maintenance . 4. Remove the crankshaft pulley. 5. Remove the inner and outer timing belt guide plates. 6. Remove the 2 bolts and remove the upper timing belt cover assembly. 7. Remove the 1 bolt and remove the lower timing belt cover assembly and gasket. To install: 8. Install the lower cover gasket and the lower cover. Tighten the bolt to 69-95 inch lbs. (8-11 Nm). 9. Install the upper cover gasket and the upper cover. Tighten the bolts to 69-95 inch lbs. (8-11 Nm). 10. Install the timing belt inner and outer guide plates.
Make sure that the inner guide plate is installed in the proper direction. 11. Install the crankshaft pulley. Tighten the bolts to 109-152 inch lbs. (12-17 Nm). 12. Install the accessory drive belts. Refer to General Information & Maintenance . 13. Install the under engine splash shield. 14. Connect the negative battery cable. 1.5L and 1995 1.6L DOHC Engines See Figure 3 1. Disconnect the negative battery cable.
2. Remove the engine under splash shield. 3. Drain the cooling
system. 4. Remove the air intake pipe. Fig. Fig. 3: Exploded view of
the timing cover assembly for the 1.5L and 1995 1.6L engines-1995-98
1.8L engine is similar 5. Disconnect the upper radiator hose and the 2 lower coolant hoses from the thermostat housing. 6. Remove the power steering, air conditioning and alternator drive belts.
Refer to General Information & Maintenance . 7. Remove the
retaining bolts and remove the water pump pulley. 8. Remove the
crankshaft pulley bolts and remove the crankshaft pulley. 9. Remove the
inner and outer timing belt guide plates. 10. Disconnect the coil electrical connectors and remove coil assembly. Remove the spark plug wires.
Be certain to record positioning of plug wires for assembly purposes.
11. Remove the spark plugs. 12. Remove the cylinder head cover bolts
and remove the cover.
13. Remove the bolts from the timing belt covers and remove the top, the center and the lower timing belt covers. To install: 14. Install the timing belt
covers with gaskets and tighten the bolts to 69-95 inch lbs. (8-11 Nm).
15. Apply silicone sealant to the corners of the cylinder head cover
and install the cover. Tighten the bolts to 43-78 inch lbs. (5-9 Nm).
16. Install the spark plugs and tighten them to 11-17 ft. lbs. (15-23
Nm). 17. Install the coil assembly and connect the electrical connectors and the spark plug wires. 18. Install the inner and outer timing belt
guide plates. 19. Install the crankshaft pulley and tighten the bolts
to 109-152 inch lbs.(12-17 Nm). 20. Install the water pump pulley and
tighten the bolts to 69-95 inch lbs. (8-11 Nm). 21. Install the power
steering, air conditioning and alternator drive belts. Refer to General
Information & Maintenance . 22. Install the coolant and radiator
hoses and refill the coolant to the proper level. 23. Install the air intake pipe and connect the negative battery cable. 1995-98 1.8L (except K8) DOHC Engines See Figure 3 1. Disconnect the negative battery cable.
2. Remove the engine under splash shield. 3. Remove the power steering, air conditioning and alternator drive belts.
Refer to General Information & Maintenance . 4. Remove the
retaining bolts and remove the water pump pulley. 5. Remove the
crankshaft pulley bolts and remove the crankshaft pulley. 6. Remove the
inner and outer timing belt guide plates. 7. Remove the bolt and remove the upper timing belt cover assembly. 8. Remove the bolts from the middle and lower timing belt cover assembly and remove the covers and the gaskets. To install: 9. Install the upper, the center and the lower timing belt covers. Tighten the bolts to 69-95 inch lbs. (8-11 Nm). 10. Install the timing belt
inner and outer guide plates. Make sure that the inner guide plate is
installed in the proper direction. 11. Install the crankshaft pulley.
Tighten the bolts to 109-152 inch lbs. (12-17 Nm). 12. Install the
water pump pulley and tighten the bolts to 69-95 inch lbs. (8-11 Nm).
13. Install the P/S, A/C and alternator drive belts. Refer to General Information & Maintenance . 14. Install the under engine splash shield. 15. Connect the negative battery cable. 2.0L Engine See Figures 4, 5, 6, 7 and 8 1. Disconnect the negative battery cable. 2. Raise and safely support the vehicle. Remove the right front wheel.
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