Removal and installation the timing belt / adjusting the timing drive (Mazda Familia BG)

Usually the timing gear drive is adjusted only in case of repairs in which the timing belt is removed or the engine is disassembled. If the timing gear drive only needs to be checked, all work steps should be performed except for replacing the timing belt.

Removal

1. Disconnect the ground cable from the battery.

Warning! This will erase the engine fault memory or the radio security code. Before disconnecting the battery, read the instructions in Section Removal and installation the battery.

2. Raise the vehicle and remove the right front wheel, see Chapter Introduction.

3. Remove the lower engine shield in the right wheel arch.

4. If equipped, remove the servo pump V-belt, see Chapter Petrol engines, Chapter Removal and installation/tensioning the V-belt.

5. Loosen the water pump belt pulley mounting bolts.

6. Remove the alternator V-belt, see Chapter Petrol engines, Chapter Removal and installation/tensioning the V-belt.



7. Loosen the crankshaft belt pulley mounting bolts and remove the pulley.

Up to 2/91 issue.

1. Block the engine and unscrew the crankshaft belt pulley mounting bolts.

2. To lock the crankshaft, engage 5th gear and ask an assistant to press the brake pedal.

3. Remove the washer, crankshaft pulley, and outer and inner timing belt guide discs.

Since 3/91 issue.

1. Unscrew the crankshaft belt pulley mounting bolts. Hold the belt pulley journal with a special tool MAZDA SST 49D011102.

2. Remove the oil dipstick.



3. Unscrew the lower and upper toothed belt covers.

4. Remove the glow plugs, see Section Checking the preheating system.



5. Set the piston of the 1st cylinder to the ignition position. To do this, turn the crankshaft so that the marks on the crankshaft belt pulley coincide with the marks on the cylinder head cover.



6. To turn the crankshaft, remove the front wheel, engage 5th gear and turn the wheel by hand. Another way to turn the crankshaft: Apply the handbrake and set the gearbox to neutral. Turn the crankshaft wheel through the right wheel arch using a socket head.

Caution! Never turn the crankshaft with a toothed belt on the camshaft gear or the injection pump, as the toothed belt will be overloaded.

Attention! After the piston of the 1st cylinder is in the ignition position, set the gearbox to neutral and check again whether the marks on the camshaft belt pulley and the valve cover match, adjust if necessary.

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



8. Loosen the tension roller bolt and use an Allen key to press the roller away from the toothed belt until the belt is unloaded. Tighten the tension roller bolt again.

9. Remove the toothed belt, after this do not change the position of the toothed wheels.

Attention! Before removing, set the gearbox to neutral and check again whether the mark on the camshaft wheel matches the edge of the cylinder head, correct if necessary.

Caution! If the camshaft is turned with the timing belt removed, none of the pistons should be at TDC. Otherwise, serious damage to the pistons or valves may occur. If it is necessary to turn the camshaft, set all pistons to half level. To do this, draw a line with chalk on top of the crankshaft belt pulley (provided that the crankshaft is in the TDC position of the 1st cylinder), then turn the crankshaft belt pulley 1/4 turn (90°) to the right or left. The mark will now face right or left.

Installation

Attention! Do not bend or twist the toothed belt. Replace dirty, damaged or worn belts in any case. Check the evenness and ease of movement of the tension roller.

1. Check that all gears are in the correct position, install if necessary. Observe the instructions in the section Removing to turn the shafts.





2. Secure the fuel injection pump belt pulley with two 35 mm long bolts.

3. Install the toothed belt. If the old belt is being installed, install it according to the mark applied.

4. Apply the toothed belt.

Caution: Make sure that the belt fits perfectly into the gears.

5. Unscrew the fixing bolts from the fuel injection pump.

Tension

1. Loosen the tension roller bolt until it begins to press on the belt due to the spring force.

2. Turn the crankshaft two turns clockwise until the camshaft gear and cylinder head cover lines are aligned again. Check that all marks are aligned.

3. Tighten the tension roller bolt with force 25 Nm.

Attention! Do not move the roller mount.

4. Turn the crankshaft two turns in the direction of rotation and check the adjustment again.

5. Check the tension of the toothed belt. When applying a force of 10 kg between the camshaft belt pulley and the fuel injection pump pulley, the belt should be pressed through by 9.5-11.5 mm. Otherwise, loosen the tension roller mounting bolt again and tighten it again.

6. Screw the lower and upper toothed belt covers with force 10 Nm.

7. Up to 2/91 issue: Install the crankshaft pulley and washer and tighten the mounting bolts to torque 15 Nm.



8. Since 3/91 issue: Install the crankshaft belt pulley mounting bolts. Hold the belt pulley journal with the special tool MAZDA SST 49D011102 and tighten the bolt with force 165 Nm.

9. Install the water pump belt pulley and tighten the mounting bolts by hand.

10. Install the V-belt, see Chapter Petrol engines, Chapter Removal and installation/tensioning the V-belt.

11. Tighten the water pump belt pulley with force 10 Nm.

12. Install glow plugs.

13. Install and tension the V-belt, see Chapter Petrol engines, Chapter Removal and installation/tensioning the V-belt.

14. If available, install the servo pump, see Chapter Suspension and steering system.

15. Screw the shield into the right wheel arch.

16. Insert the oil dipstick.

17. It is recommended to check the start of the injection pump feed (is done in the workshop).

18. Connect the ground cable to the battery.

19. If available, set the time on the clock and set the security code for the radio receiver.