1 - V-belt, servo pump; 2 - V-belt, generator; 3 - belt pulley of the water pump; 4 - belt pulley of the crankshaft; 5 - upper casing of the toothed belt; 6 - lower casing of the toothed belt; 7 - toothed belt; 8 - tension roller and spring
Typically, the timing drive is adjusted only in the event of a repair, in which the toothed belt is removed or the engine is disassembled. If the timing drive only needs to be checked, all work steps must be carried out except for replacing the toothed belt.
Removing
1. Disconnect the ground cable from the battery.
Attention! This erases the data from the engine fault memory or the radio's security code. Before disconnecting the battery, read the instructions in Section Removing and installing the battery.
2. Raise the car and remove the right front wheel, see Chapter Introduction.
3. Remove the lower engine shield in the right wheel arch.
4. If available, remove the servo pump V-belt, see Chapter Gasoline engines, Chapter Removing and installing/tensioning the V-belt.
5. Loosen the water pump pulley bolts.
6. Remove the alternator V-belt, see Chapter Gasoline engines, Chapter Removing and installing/tensioning the V-belt.
7. To turn out bolts of fastening of a belt pulley of a crankshaft and to remove a pulley.
Until 2/91, issue.
1. Block the engine and unscrew the bolts securing the crankshaft belt pulley.
2. To block the crankshaft, turn on the 5th gear and ask the assistant to depress the brake pedal.
3. Remove the washer, crankshaft pulley, and outer and inner toothed belt guide discs.
Since 3/91, issue.
1. Unscrew the bolts securing the crankshaft belt pulley. Hold the belt pulley pin with the MAZDA SST 49D011102 special tool.
2. Remove the oil dipstick.
3. Unscrew the lower and upper toothed belt covers.
4. Remove glow plugs, see Section Checking the preheat 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 rotate the crankshaft, remove the front wheel, engage 5th gear and turn the wheel by hand. Another possibility to crank the crankshaft: Apply the handbrake and place the transmission in neutral. Turn the crankshaft wheel through the right wheel arch using a socket.
Attention! Never turn the crankshaft with the toothed belt on the camshaft or 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 the neutral position and once again check whether the marks on the camshaft pulley and the valve cover match, adjust if necessary.
7. If an old toothed belt is to be installed, it should be marked. An arrow should be marked on the belt to indicate the direction of rotation. The motor rotates clockwise.
8. Loosen the bolt of the tension roller and press the roller with an Allen key from the toothed belt until the belt is unloaded. Tighten the idler pulley bolt again.
9. Remove the toothed belt, then do not change the position of the gear wheels.
Attention! Before removing, set the gearbox to neutral and check again that the mark on the camshaft wheel coincides with the edge of the cylinder head, correct if necessary.
Attention! If the camshaft turns with the toothed belt removed, neither piston should be at TDC. Otherwise serious damage to pistons or valves may occur. If it is necessary to rotate 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 pulley 1/4 turn (90°) right or left. The mark will now face right or left.
Installation
Attention! Do not kink or twist the toothed belt. Replace dirty, damaged or worn belts in any case. Check the uniformity 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 paragraph Removing to rotate the shafts.
2. Fasten the injection pump belt pulley with two bolts 35 mm long.
3. Fit toothed belt. If the old belt is installed, apply it according to the marked mark.
4. Fit toothed belt.
Attention! Make sure the belt fits perfectly into the gears.
5. Unscrew the fixing bolts from the injection pump.
Tension
1. Loosen the idler pulley bolt until it begins to press on the belt due to the force of the spring.
2. Rotate the crankshaft two turns clockwise until the lines of the camshaft gear and cylinder head cover are aligned again. Check if all labels match.
3. Tighten the tension roller bolt with force 25 Nm.
Attention! Do not move the roller holder.
4. Turn the crankshaft two turns in the direction of rotation and check the adjustment again.
5. Check toothed belt tension. When exposed to a force of 10 kg between the camshaft belt pulley and the injection pump pulley, the belt should be pressed through by 9.5-11.5 mm. Otherwise, loosen the tensioner bolt again and tighten again.
6. Screw the lower and upper toothed belt covers firmly 10 Nm.
7. Until 2/91 issue: Install the crankshaft pulley and washer and tighten the mounting bolts 15 Nm.
8. Since 3/91 issue: Install the crankshaft pulley bolts. While holding the belt pulley trunnion with the MAZDA SST 49D011102 special tool, tighten the bolt with force 165 Nm.
9. Install the water pump pulley and tighten the mounting bolts by hand.
10. Install the V-belt, see Chapter Gasoline engines, Chapter Removing and installing/tensioning the V-belt.
11. Tighten the water pump pulley with force 10 Nm.
12. Install glow plugs.
13. Install and tension the V-belt, see Chapter Gasoline engines, Chapter Removing and installing/tensioning the V-belt.
14. If available, install a servo pump, see Chapter Suspension and steering system.
15. Screw the shield in the right wheel arch.
16. Insert oil dipstick.
17. It is recommended to check the start of injection pump supply (performed in the workshop).
18. Connect the mass cable to the battery.
19. If available, set the clock and set the radio security code.