Mazda Protege 5. Manual - part 119

 

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Mazda Protege 5. Manual - part 119

 

 

MECHANICAL [ZM]

01–10A–10

No.3 Engine Mount Removal Note

1. Suspend the engine using the SST.

Pulley Lock Bolt Removal/Installation Note

1. Remove the crankshaft using the SST.

Timing Belt Removal Note

1. Install the pulley boss and pulley lock bolt.
2. Turn the crankshaft clockwise and align the timing 

marks.

Note

Face the marks (I) and (E) of the camshaft 
pulley straight up, then align the timing 
marks with the horizontal surface on the 
cylinder head.

The pulley boss position pin on the 
crankshaft should be facing straight up.

3. Loosen the tensioner lock bolt.
4. Push the tensioner in the direction of the arrow 

and hand-tighten the lock bolt.

Caution

••••

Forcefully twisting is the timing belt 
turning it inside out, or allowing oil or 
grease on it will damage the belt and 
shorten its life.

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MECHANICAL [ZM]

01–10A–11

01–10A

Note

Mark the timing belt rotation on the belt for 
proper reinstallation.

Tensioner, Tensioner Spring Installation Note

1. Measure the tensioner spring free length.

If not as specified, replace the tensioner 
spring.

Free length

61.8 mm {2.43 in}

2. Install the tensioner.

3. Install the tensioner spring with the damper 

rubber closing face on the right side.

4. Temporarily secure the tensioner with the spring 

fully extended.

Timing Belt Installation Note

1. Verify that the timing belt pulley mark and 

camshaft pulley marks are aligned with the timing 
marks as shown.

Note

Face the marks (I) and (E) of the camshaft 
pulley straight up, then align the timing 
marks with the horizontal surface on the 
cylinder head.

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MECHANICAL [ZM]

01–10A–12

2. Install the timing belt in the order shown to 

prevent looseness.

Caution

••••

Be sure not to apply tension other than 
that of the tensioner spring.

3. Install the pulley boss and pulley lock bolt.
4. Loosen the tensioner lock bolt to apply tension to 

timing belt.

5. Turn the crankshaft clockwise 1 and 5/6 times

and align the timing belt pulley mark with the 
tensioner set mark.

6. Hold the crankshaft using the SST, and remove 

the pulley lock bolt and the pulley boss.

7. Verify that the timing belt pulley mark is aligned 

with the tensioner set mark.

Caution

••••

Prevent the tensioner from moving with 
the tensioner lock bolt as it is turned.

8. Tighten the tensioner lock bolt.
9. Install the pulley boss and the pulley lock bolt.

10. Turn the crankshaft 2 and 1/6 times, and face the 

pin on the pulley boss straight up.

11. Verify that the camshaft pulley marks are aligned 

with the timing marks as shown.

If not, repeat from Timing Belt Removal 
Note
 and reinstall the timing belt. (See 01–
10A–10 Timing Belt Removal Note.)

Note

Timing is normal if: the pulley boss position 
pin and the camshaft pulley marks (I) and 
(E) are facing straight up. the timing marks 
are aligned to the horizontal surface on 
cylinder head.

12. Inspect the timing belt deflection at the point 

indicated by applying moderate pressure 98 N 
{10 kgf, 22 lbf}
.

If not as specified, remove the timing belt and 
repeat from Step 1.

Timing belt deflection

6.0—7.5 mm {0.24—0.29 in}

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MECHANICAL [ZM]

01–10A–13

01–10A

No.3 Engine Mount Installation Note

1. Install the No.3 engine mount. (See 01–10A–22 No.3 Engine Mount Installation Note.)
2. Remove the SST (engine support).

Cylinder Head Cover Installation Note

1. Verify that the grooves on the cylinder head cover are free of oil, water and other foreign material.
2. Install the cylinder head cover gasket into the cylinder head cover.
3. Apply silicone sealant to the cylinder head as 

shown.

Thickness

3.0—4.0 mm {0.12—0.15 in}

4. Tighten the cylinder head cover bolts a few turns 

in the order shown.

End Of Sie

CYLINDER HEAD GASKET REPLACEMENT [ZM]

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Warning

••••

Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep 
sparks and flames away from fuel.

••••

Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and 
damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line 
Safety Procedure”. (See 01–14–4 BEFORE REPAIR PROCEDURE.)

1. Disconnect the negative battery cable.
2. Drain the engine coolant. (See 01–12–2 COOLING SYSTEM SERVICE WARNINGS.) (See 01–12–3 ENGINE 

COOLANT REPLACEMENT.)

3. Remove the timing belt. (See 01–10A–9 TIMING BELT REMOVAL/INSTALLATION [ZM].)
4. Remove the front pipe, exhaust manifold insulator, and EGR pipe. (See 01–15–1 EXHAUST SYSTEM 

REMOVAL/INSTALLATION.)

5. Remove the air cleaner, and fresh-air duct.
6. Disconnect the accelerator cable, and bracket.
7. Disconnect the vacuum hose, and engine harness connector.
8. Disconnect the plastic fuel hoses. (See 01–14–11 Plastic Fuel Hose Removal Note.) (See 01–14–12 Plastic 

Fuel Hose Installation Note.)

9. Remove the intake manifold bracket.

10. Remove the heater hoses.
11. Remove in the order indicated in the table.
12. Install in the reverse order of removal.
13. Inspect for fuel leakage.
14. Inspect the compression. (See 01–10A–8 COMPRESSION INSPECTION [ZM].)
15. Start the engine and

(1) Inspect the pulleys and drive belt for runout and contact.
(2) Inspect the ignition timing. (See 01–10A–25 Ignition Timing Inspection.)
(3) Inspect the idle speed. (See 01–10A–26 Idle Speed Adjustment.)

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