Removing and installing toothed belt / adjusting timing gear

1. Disconnect earth cable from the battery.

This data is erased from the memory of malfunctions of the engine or a protective code of a radio receiver. Before disconnecting the battery should read instructions in Section Removal and installation of the battery.

2. To lift the car and remove the right front wheel, see. Chapter Introduction.
3. Remove the bottom cover of the engine in the right wheel arch.
4. If there is, remove the V-belt pumps', see. Chapter Gasoline engines, Section Removal and installation / belt tension.
5. Loosen the bolts of the water pump pulley.
6. Remove the alternator V-belt, see. Chapter Gasoline engines, Section Removal and installation / belt tension.
7. Release screws on the crankshaft pulley and remove the pulley.

1. Block the engine and unscrew the bolts of the crankshaft pulley.
2. To lock the crankshaft include 5th transfer and ask the assistant to press the brake pedal.
3. Remove the washer, the crankshaft pulley, and internal and external guide wheels toothed belt.

1. Unscrew the bolts of the crankshaft pulley. Hold the pin pulley special tool MAZDA SST 49D011102.
2. Remove the dipstick.

Unscrew the upper and lower casings of a gear belt.

4. Remove the glow plug. See Section Checking the preheat.

To establish the piston of 1st cylinder in the ignition position. To do this, rotate the crankshaft so that matched the marks on the crankshaft belt pulley with the marks on the cylinder head cover.

6. For turning the crankshaft remove the front wheel, turn 5th gear and turn the wheel by hand. Another possibility Crank: Tighten the hand brake and the gearbox in neutral. Turn the wheel of the crankshaft through the right wheel arch using the socket wrench.

Never turn the crankshaft timing belt on the camshaft gear or injection pump, as the toothed belt is overloaded.

After the piston of 1st cylinder will be in the ignition, set the transmission to neutral and again, check whether the label on a belt pulley camshaft and valve cover and adjust if necessary.

7. If it is installed the old timing belt, it should be marked. On the belt should be applied to the arrow indicating the direction of rotation. The motor rotates clockwise.

Loosen the bolt of a tension roller and the squeeze roller with the Allen key from the toothed belt until the belt is not unloaded. Tighten the tensioner pulley bolt again.

9. Remove the timing belt, then the situation is not changing gears.

Before removing the gearbox in neutral and again, check whether the label on a cam-wheel with the edge of the cylinder head, correct if necessary.

If the camshaft rotates at the removed gear belt, any piston should not be in the TDC. Otherwise, you may cause serious damage to the pistons or valves. If you want to rotate the camshaft, to establish all pistons at half level. For this cause a chalk line on top of the crankshaft pulley (provided that the crankshaft is in the TDC position of cylinder 1), and then rotate the crankshaft pulley 1/4 turn (90 ?�) to the right or left. Mark will now turn to the right or to the left.

Toothed belt bend, or twist. Soiled, damaged or worn belts in any way replace. Check the uniformity and ease of movement of the tension roller.

Check that all the gears are in the right position, if necessary, install it. Follow instructions in Section to crank shafts.

Secure the injection pump pulley two bolts 35 mm long.

3. Apply the toothed belt. If you install the old belt, apply it according to the applied mark.
4. Apply the toothed belt.

Make sure that the belt is perfectly entered in the gears.

5. Unscrew the fixing bolts from the pump.

1. Loosen the bolt of the tension roller, until it begins to put pressure on the belt by spring force.
2. Turn the engine on two turns clockwise until the line gear and camshaft cylinder head cover again coincide. Check coincidence of all labels.
3. Tighten the bolt tensioning pulley with a force of 25 Nm.

Fixing roller is not moving.

4. Turn the engine on two turns in the direction of rotation and re-check the adjustment.
5. Check toothed belt tension. When exposed to a force of 10 kg between the camshaft pulley and injection pump pulley belt should be forced 9.5 - 11.5 mm. Otherwise, once again loosen the bolt of a tension roller and tighten again.
6. Screw the upper and lower casings of a gear belt with a force of 10 Nm.
7. Before 2/91 MY .: Install the crankshaft pulley and the washer and tighten the bolts with a torque of 15 Nm.
8. Since 3/91 MY .: Set bolts of the crankshaft pulley. Hold the pin pulley special tool MAZDA SST 49D011102, tighten the bolts to 165 Nm.
9. Install the water pump pulley and tighten the screws by hand.
10. Install the V-belt, see. Chapter Gasoline engines, Section Removal and installation / belt tension.
11. Tighten the water pump pulley with a force of 10 Nm.
12. Install the glow plug.
13. Install and tighten the V-belt, see. Chapter Gasoline engines, Section Removal and installation / belt tension.
14. If there is, install pumps', see. Chapter suspension and steering system.
15. Screw the panel on the right wheel arch.
16. Insert dipstick.
17. It is recommended to check the beginning of the feed pump (performed in the workshop).
18. Connect the earth cable to the battery.
19. If available, set the clock and set the security code radio.