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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