Repairing Manual 2002 Mazda Protege LX Timing Belt Removal

Repairing Manual 2002 Mazda Protege LX Timing Belt Removal

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1. Disconnect negative battery cable. Remove Crankshaft Position (CKP) and Camshaft Position (CMP) sensors from front of engine (if equipped). See Fig. 1 . Remove spark plugs. 2. Remove accessory drive belts. Leaving hoses attached, remove power steering pump and position aside. Remove the water pump pulley. See Fig. 2 . Rotate crankshaft so No. 1 cylinder is on TDC of compression stroke. CAUTION: On models with a crankshaft position sensor, rotor is on rear of crankshaft pulley. DO NOT damage rotor when removing crankshaft pulley. 3. Using Coupling Flange Holder (49 S120 710) and Adapter (49 E011 1A1), or equivalent, hold the crankshaft and remove crankshaft pulley bolt. See Fig. 3 . Remove crankshaft pulley and guide plate (large washer). 4. Loosen valve cover bolts in 2-3 steps in order shown. See Fig. 4 . Remove valve cover and gasket. 5. Remove dipstick tube. Remove upper and lower timing belt covers.

Support engine from above. Remove No. 3 engine mount at timing belt end of engine. 6. If reusing timing belt, mark arrow on belt to indicate direction of rotation. Install crankshaft pulley bolt finger-tight to retain crankshaft sprocket. Rotate crankshaft clockwise (as viewed from timing belt end of engine) until cylinder No. 1 piston is at TDC of compression stroke and timing marks are aligned. See Fig. 5 . 7. Turn tensioner clockwise using a Allen wrench to relieve spring tension, and then disconnect spring from the hook pin. See Fig. 6 . Remove timing belt. Remove crankshaft sprocket, tensioner and idler pulley (if necessary). Inspection CAUTION: Forcefully twisting the belt, turning it inside out, or allowing oil or grease on it will damage the belt and shorten its life. Check timing belt for cracks, peeling, abrasion or other damage. See Fig. 7 . Check tensioner bearing for looseness or roughness of rotation.

Inspect tensioner spring for stretching. Tensioner spring free length should be 1.44″ (36.6 mm). Measure spring free length from inside edge to inside edge of hooked portion of spring. See Fig. 8 . Replace parts as necessary. Install the tensioner. Rotate tensioner. See Fig. 9 . If tensioner rotates with no resistance or does not rotate, replace tensioner. Installation 1. Ensure all timing marks are aligned. See Fig. 10 . 2. Install timing belt around crankshaft sprocket, water pump sprocket, idler pulley, and camshaft sprockets. Ensure slack does not exist on idler pulley side of timing belt. 3. Complete timing belt installation on slack (tensioner) side. With tensioner spring removed, allow tensioner to ride against timing belt. Turn crankshaft 2 revolutions in normal direction of rotation (clockwise). Ensure camshaft and crankshaft timing marks are still correctly aligned. See Fig. 5 . If not correctly aligned, timing belt will have to be removed and repositioned.

4. If all timing marks are okay, turn tensioner clockwise using an Allen wrench. Connect tensioner spring to pin on engine block. See Fig. 11 . Turn crankshaft 2 revolutions. Ensure camshaft and crankshaft timing marks are still aligned. See Fig. 5 . 5. To install remaining components, reverse removal procedure. When installing valve cover gasket, apply small amount of silicone sealer to 4 corners of gasket where the front of both camshafts go through cylinder head. See Fig. 12 . Tighten valve cover bolts to specification in correct sequence. See Fig. 13 . Adjust drive belts to proper tension. 6. Inspect crankshaft position sensor air gap. Air gap between outer edge of crankshaft pulley rotor tooth and center of CKP sensor should be 0.029-0.059″ (0.5-1.5 mm). See Fig. 14 . Air gap is not adjustable. If gap is incorrect, check for damaged parts.