1993-1U-10E

Title Section

GENERAL INFORMATION 00

ENGINE 01

CONTENTSEngineWorkshopManualMZR 1.5

FOREWORD

This manual explains the service points for the above-indicated automotive system. This manual covers all models with the above-indicated automotive system, not any one specific model.

In order to do these procedures safely, quickly, and correctly, you must first read this manual and any other relevant service materials carefully.

All the contents of this manual, including drawings and specifications, are the latest available at the time of printing. As modifications affecting repair or maintenance occur, relevant information supplementary to this volume will be made available at Mazda dealers. This manual should be kept up-to-date.

Mazda Motor Corporation reserves the right to alter the specifications and contents of this manual without obligation or advance notice.

All rights reserved. No part of this book may be reproduced or used in any form or by any means, electronic or mechanical—including photocopying and recording and the use of any kind of information storage and retrieval system—without permission in writing.

Mazda Motor CorporationHIROSHIMA, JAPAN

© 2010 Mazda Motor CorporationPRINTED IN U.S.A., MAY 2010Form No. 1993–1U–10EPart No. 9999–95–MZR–11

1993-1U-10E(INDEX).fm 1 ページ２０１０年５月１２日　水曜日　午後２時１４分

WARNINGServicing a vehicle can be dangerous. If you have not received service-related training, the risks of injury, property damage, and failure of servicing increase. The recommended servicing procedures for the vehicle in this workshop manual were developed with Mazda-trained technicians in mind. This manual may be useful to non-Mazda trained technicians, but a technician with our service-related training and experience will be at less risk when performing service operations. However, all users of this manual are expected to at least know general safety procedures.

This manual contains "Warnings" and "Cautions" applicable to risks not normally encountered in a general technician's experience. They should be followed to reduce the risk of injury and the risk that improper service or repair may damage the vehicle or render it unsafe. It is also important to understand that the "Warnings" and "Cautions" are not exhaustive. It is impossible to warn of all the hazardous consequences that might result from failure to follow the procedures.

The procedures recommended and described in this manual are effective methods of performing service and repair. Some require tools specifically designed for a specific purpose. Persons using procedures and tools which are not recommended by Mazda Motor Corporation must satisfy themselves thoroughly that neither personal safety nor safety of the vehicle will be jeopardized.

The contents of this manual, including drawings and specifications, are the latest available at the time of printing, and Mazda Motor Corporation reserves the right to change the vehicle designs and alter the contents of this manual without notice and without incurring obligation.

Parts should be replaced with genuine Mazda replacement parts or with parts which match the quality of genuine Mazda replacement parts. Persons using replacement parts of lesser quality than that of genuine Mazda replacement parts must satisfy themselves thoroughly that neither personal safety nor safety of the vehicle will be jeopardized.

Mazda Motor Corporation is not responsible for any problems which may arise from the use of this manual. The cause of such problems includes but is not limited to insufficient service-related training, use of improper tools, use of replacement parts of lesser quality than that of genuine Mazda replacement parts, or not being aware of any revision of this manual.

WARNING(US).fm 1 ページ２０１０年３月１１日　木曜日　午後１時２８分

00GENERAL INFORMATION

00-00–1

SECTION00-00

Toc of SCTGENERAL INFORMATION . . . .00-00

Toc of SCT

00-00 GENERAL INFORMATIONUNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-00–1

Conversion to SI Units (Système International d'Unités) . . . . . 00-00–2

Rounding Off . . . . . . . . . . . . . . . . . . . . . 00-00–2Upper and Lower Limits . . . . . . . . . . . . 00-00–2

HOW TO USE THIS MANUAL . . . . . . . . . 00-00–2Range of Topics . . . . . . . . . . . . . . . . . . 00-00–2Service Procedure . . . . . . . . . . . . . . . . 00-00–2Symbols . . . . . . . . . . . . . . . . . . . . . . . . 00-00–3Advisory Messages . . . . . . . . . . . . . . . . 00-00–4

ELECTRICAL SYSTEM . . . . . . . . . . . . . . 00-00–5Connectors . . . . . . . . . . . . . . . . . . . . . . 00-00–5

ABBREVIATIONS. . . . . . . . . . . . . . . . . . . 00-00–6FUNDAMENTAL PROCEDURES. . . . . . . 00-00–6

Preparation of Tools and Measuring Equipment . . . . . . . . . . . . 00-00–6

Special Service Tools . . . . . . . . . . . . . . 00-00–6Disassembly . . . . . . . . . . . . . . . . . . . . . 00-00–7Inspection During Removal,

Disassembly . . . . . . . . . . . . . . . . . . . . 00-00–7Arrangement of Parts . . . . . . . . . . . . . . 00-00–7Cleaning of Parts . . . . . . . . . . . . . . . . . 00-00–7Reassembly . . . . . . . . . . . . . . . . . . . . . 00-00–8Adjustment . . . . . . . . . . . . . . . . . . . . . . 00-00–8Rubber Parts and Tubing . . . . . . . . . . . 00-00–8Hose Clamps . . . . . . . . . . . . . . . . . . . . 00-00–9Torque Formulas . . . . . . . . . . . . . . . . . 00-00–9Vise . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-00–9

NEW STANDARDS . . . . . . . . . . . . . . . . . 00-00–9

End of TocNG: GENERAL INFORMATION

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GENERAL INFORMATION

00-00–2

UNITSid000000100400

Conversion to SI Units (Système International d"Unités)• All numerical values in this manual are based on SI units. Numbers shown in conventional units are converted

from these values.

Rounding Off• Converted values are rounded off to the same number of places as the SI unit value. For example, if the SI unit

value is 17.2 and the value after conversion is 37.84, the converted value will be rounded off to 37.8.

Upper and Lower Limits• When the data indicates upper and lower limits, the converted values are rounded down if the SI unit value is

an upper limit and rounded up if the SI unit value is a lower limit. Therefore, converted values for the same SI unit value may differ after conversion. For example, consider 2.7 kgf/cm2 in the following specifications:

210—260 kPa {2.1—2.7 kgf/cm2, 30—38 psi}270—310 kPa {2.7—3.2 kgf/cm2, 39—45 psi}

• The actual converted values for 2.7 kgf/cm2 are 264 kPa and 38.4 psi. In the first specification, 2.7 is used as an upper limit, so the converted values are rounded down to 260 and 38. In the second specification, 2.7 is used as a lower limit, so the converted values are rounded up to 270 and 39.

End Of SieWM: GENERAL INFORMATION

Electric current A (ampere)Electric power W (watt)Electric resistance ohmElectric voltage V (volt)

Lengthmm (millimeter)in (inch)

Negative pressurekPa (kilo pascal)mmHg (millimeters of mercury)inHg (inches of mercury)

Positive pressure

kPa (kilo pascal)

kgf/cm2 (kilogram force per square centimeter)psi (pounds per square inch)

Number of revolutions rpm (revolutions per minute)

Torque

N·m (Newton meter)kgf·m (kilogram force meter)kgf·cm (kilogram force centimeter)ft·lbf (foot pound force)in·lbf (inch pound force)

Volume

L (liter)US qt (U.S. quart)Imp qt (Imperial quart)ml (milliliter)cc (cubic centimeter)cu in (cubic inch)fl oz (fluid ounce)

Weightg (gram)oz (ounce)


GENERAL INFORMATION

00-00–3

00-00

HOW TO USE THIS MANUALid000000000100

Range of Topics• This manual contains procedures for performing all required service operations. The procedures are divided

into the following five basic operations:— Removal/Installation— Disassembly/Assembly— Replacement— Inspection— Adjustment

• Simple operations which can be performed easily just by looking at the vehicle (i.e., removal/installation of parts, jacking, vehicle lifting, cleaning of parts, and visual inspection) have been omitted.

Service ProcedureInspection, adjustment• Inspection and adjustment procedures are

divided into steps. Important points regarding the location and contents of the procedures are explained in detail and shown in the illustrations.

49 H002 671

49 H032 322

49 1232 670A

SHOWS PROCEDURE ORDERFOR SERVICE

Fluid Pressure Inspection1. Assemble the SSTs as shown in the figure.

Tightening torque

SHOWS TIGHTENINGTORQUESPECIFICATIONS

CautionConnect the gauge set from underthe vehicle to prevent contact withthe drive belt and the cooling fan.

39—49 N·m {4.0—5.0 kgf·m, 29—36 ft·lbf}

WGIWXX0009E


GENERAL INFORMATION

00-00–4

Repair procedure1. Most repair operations begin with an overview illustration. It identifies the components, shows how the parts fit

together, and describes visual part inspection. However, only removal/installation procedures that need to be performed methodically have written instructions.

2. Expendable parts, tightening torques, and symbols for oil, grease, and sealant are shown in the overview illustration. In addition, symbols indicating parts requiring the use of special service tools or equivalent are also shown.

3. Procedure steps are numbered and the part that is the main point of that procedure is shown in the illustration with the corresponding number. Occasionally, there are important points or additional information concerning a procedure. Refer to this information when servicing the related part.

GR

EA

SE

GR

EA

SE

GR

EA

SE

SHOWS NON-REUSEABLE PARTS

SHOWS DETAILS

KNUCKLE

UPPER TRAILING LINK

LOWER TRAILING LINK

SST

SST

SST

SST

R

R

R

R

9

2

1

4

53

6

1

2

8

7

12

10

11

N·m {kgf·m, ft·lbf}

118—156 {12.0—16.0, 87—115}94—116 {9.5—11.9, 69—86}

43—56 {4.3—5.8, 32—41}

49 T028 30449 T028 305

49 T028 303

Procedure

LOWER TRAILING LINK, UPPER TRAILING LINK REMOVAL/INSTALLATION1. Jack up the rear of the vehicle and support it with safety stands.2. Remove the undercover. (See 01-10-4 Undercover Removal)3. Remove in the order indicated in the table.4. Install in the reverse order of removal.5. Inspect the rear wheel alignment and adjust it if necessary.

1 Split pin2 Nut

3 Lower trailing link ball joint

4

(See 02-14-5 Lower Trailing Link Ball Joint Removal Note)

Bolt5 Lower trailing link 6 Dust boot (lower trailing link)

7 Split pin8 Nut9 Upper trailing link ball joint

(See 02-14-5 Upper Trailing Link Ball Joint Removal Note)10 Nut11 Upper trailing link12 Dust boot (upper trailing link)

Lower Trailing Link Ball Joint, Upper Trailing LinkBall Joint Removal Note

Remove the ball joint using the SSTs.

— 44—60 {4.4—6.2, 32—44}

"Removal/Installation" Portion

"Inspection After Installation" Portion

INSTALL THE PARTS BY PERFORMING STEPS 1—3 IN REVERSE ORDER

SHOWS PROCEDURE ORDER FOR SERVICE

SHOWS TIGHTENING TORQUE SPECIFICATIONS

SHOWS SERVICE ITEM (S)

INDICATES ANY RELEVANT REFERENCES WHICH NEED TO BE FOLLOWED DURING INSTALLATION

SHOWS SPECIAL SERVICE TOOL (SST) FOR SERVICE OPERATION

SHOWS APPLICATION POINTS OF GREASE, ETC.

SHOWS TIGHTENING TORQUE UNITS

SHOWS SPECIAL SERVICE TOOL (SST) NO.

SHOWS REFERRAL NOTES FOR SERVICE

SHOWS THERE ARE REFERRAL NOTES FOR SERVICE

BHE0000W104


GENERAL INFORMATION

00-00–5

00-00

Symbols• There are eight symbols indicating oil, grease, fluids, sealant, and the use of SST or equivalent. These symbols

show application points or use of these materials during service.

Advisory Messages• You will find several Warnings, Cautions, Notes, Specifications and Upper and Lower Limits in this

manual.

Warning• A Warning indicates a situation in which serious injury or death could result if the warning is ignored.

Caution• A Caution indicates a situation in which damage to the vehicle or parts could result if the caution is ignored.

Note• A Note provides added information that will help you to complete a particular procedure.

Specification• The values indicate the allowable range when performing inspections or adjustments.

Upper and lower limits• The values indicate the upper and lower limits that must not be exceeded when performing inspections or

adjustments.End Of Sie

Symbol Meaning Kind

Apply oilNew appropriate engine oil or gear oil

Apply brake fluid New appropriate brake fluid

Apply automatic transaxle/transmission fluid

New appropriate automatic transaxle/transmission fluid

Apply grease Appropriate grease

Apply sealant Appropriate sealant

Apply petroleum jelly

Appropriate petroleum jelly

Replace part O-ring, gasket, etc.

Use SST or equivalent Appropriate tools

OIL

BRAKEFLUID

AATFTF

GR

EA

SE

SEALANT

P

R

SST


GENERAL INFORMATION

00-00–6

ELECTRICAL SYSTEMid000000000500

ConnectorsDisconnecting connectors• When disconnecting connector, grasp the

connectors, not the wires.

• Connectors can be disconnected by pressing or pulling the lock lever as shown.

Locking connector• When locking connectors, listen for a click

indicating they are securely locked.

GOOD NO GOOD

CHU0000W014

WGIWXX0042E

WGIWXX0043E


GENERAL INFORMATION

00-00–7

00-00

Inspection• When a tester is used to inspect for continuity or

measuring voltage, insert the tester probe from the wiring harness side.

• Inspect the terminals of waterproof connectors from the connector side since they cannot be accessed from the wiring harness side.

Caution• To prevent damage to the terminal, wrap

a thin wire around the tester probe before inserting into terminal.

End Of Sie

ABBREVIATIONSid000000010100

End Of SieGAIHAN: -

GOOD NO GOOD

CHU0000W011

GOOD NO GOOD

CHU0000W012

ATX Automatic TransaxleCMP Camshaft PositionEX ExhaustIN IntakeMTX Manual TransaxleOCV Oil Control ValveOS Over SizeSST Special Service ToolSTD StandardTDC Top Dead Center


GENERAL INFORMATION

00-00–8

FUNDAMENTAL PROCEDURESid000000750100

Preparation of Tools and Measuring Equipment• Be sure that all necessary tools and measuring

equipment are available before starting any work.

Special Service Tools• Use special service tools or equivalent when they

are required.

Disassembly• If the disassembly procedure is complex,

requiring many parts to be disassembled, all parts should be marked in a place that will not affect their performance or external appearance and identified so that reassembly can be performed easily and efficiently.

Inspection During Removal, Disassembly• When removed, each part should be carefully

inspected for malfunction, deformation, damage and other problems.

CHU0014W003

49 SE01 310

WGIWXX0024E

WGIWXX0027E

WGIWXX0028E


GENERAL INFORMATION

00-00–9

00-00

Arrangement of Parts• All disassembled parts should be carefully

arranged for reassembly.• Be sure to separate or otherwise identify the parts

to be replaced from those that will be reused.

Cleaning of Parts• All parts to be reused should be carefully and

thoroughly cleaned in the appropriate method.

Warning• Using compressed air can cause dirt and

other particles to fly out causing injury to the eyes. Wear protective eye wear whenever using compressed air.

Reassembly• Standard values, such as torques and certain

adjustments, must be strictly observed in the reassembly of all parts.

• If removed, the following parts should be replaced with new ones:— Oil seals— Gaskets— O-rings— Lockwashers— Cotter pins— Nylon nuts

• Depending on location:— Sealant and gaskets, or both, should be

applied to specified locations. When sealant is applied, parts should be installed before sealant hardens to prevent leakage.

— Oil should be applied to the moving components of parts.

— Specified oil or grease should be applied at the prescribed locations (such as oil seals) before reassembly.

WGIWXX0029E

WGIWXX0030E

WGIWXX0031E

CHU0014W006


GENERAL INFORMATION

00-00–10

Adjustment• Use suitable gauges and testers when making

adjustments.

Rubber Parts and Tubing• Prevent gasoline or oil from getting on rubber

parts or tubing.

Hose Clamps• When reinstalling, position the hose clamp in the

original location on the hose and squeeze the clamp lightly with large pliers to ensure a good fit.

Torque Formulas• When using a torque wrench-SST or equivalent

combination, the written torque must be recalculated due to the extra length that the SST or equivalent adds to the torque wrench. Recalculate the torque by using the following formulas. Choose the formula that applies to you.

A : The length of the SST past the torque wrench drive. L : The length of the torque wrench.

CHU0014W005

WGIWXX0034E

WGIWXX0035E

Torque Unit FormulaN·m N·m × [L/(L+A)]

kgf·m kgf·m × [L/(L+A)]kgf·cm kgf·cm × [L/(L+A)]ft·lbf ft·lbf × [L/(L+A)]in·lbf in·lbf × [L/(L+A)]

01

12

2

33

SST

A L

WGIWXX0036E


GENERAL INFORMATION

00-00–11

00-00

Vise• When using a vise, put protective plates in the

jaws of the vise to prevent damage to parts.End Of SieEN: GENERAL INFORMATION

NEW STANDARDSid000000157100

• Following is a comparison of the previous standard and the new standard.

PROTECTIVE PLATES

CHU0014W010

New Standard Previous StandardRemark

Abbrevi-ation Name Abbrevi-ation NameAP Accelerator Pedal — Accelerator Pedal

ACL Air Cleaner — Air CleanerA/C Air Conditioning — Air Conditioning

BARO Barometric Pressure — Atmospheric PressureB+ Battery Positive Voltage Vb Battery Voltage— Brake Switch — Stoplight Switch— Calibration Resistor — Corrected Resistance #6

CMP sensor Camshaft Position Sensor — Crank Angle SensorCAC Charge Air Cooler — IntercoolerCLS Closed Loop System — Feedback SystemCTP Closed Throttle Position — Fully ClosedCPP Clutch Pedal Position — Idle SwitchCIS Continuous Fuel Injection System — Clutch Position

CS sensor Control Sleeve Sensor CSP sensor Control Sleeve Position Sensor #6CKP sensor Crankshaft Position Sensor — Crank Angle Sensor 2

DLC Data Link Connector — Diagnosis ConnectorDTM Diagnostic Test Mode — Test Mode #1DTC Diagnostic Trouble Code(s) — Service Code(s)DI Distributor Ignition — Spark IgnitionDLI Distributorless Ignition — Direct IgnitionEI Electronic Ignition — Electronic Spark Ignition #2

ECT Engine Coolant Temperature — Water ThermoEM Engine Modification — Engine Modification— Engine Speed Input Signal — Engine RPM Signal

EVAP Evaporative Emission — Evaporative EmissionEGR Exhaust Gas Recirculation — Exhaust Gas RecirculationFC Fan Control — Fan ControlFF Flexible Fuel — Flexible Fuel

4GR Fourth Gear — Overdrive— Fuel Pump Relay — Circuit Opening Relay #3

FSO solenoid Fuel Shut Off Solenoid FCV Fuel Cut Valve #6GEN Generator — AlternatorGND Ground — Ground/EarthHO2S Heated Oxygen Sensor — Oxygen Sensor With heaterIAC Idle Air control — Idle Speed Control— IDM Relay — Spill Valve Relay #6— Incorrect Gear Ratio — —— Injection Pump FIP Fuel Injection Pump #6— Input/Turbine Speed Sensor — Pulse Generator


GENERAL INFORMATION

00-00–12

#1: Diagnostic trouble codes depend on the diagnostic test mode #2: Controlled by the PCM #3: In some models, there is a fuel pump relay that controls pump speed. That relay is now called the fuel pump

relay (speed). #4: Device that controls engine and powertrain #5: Directly connected to exhaust manifold #6: Part name of diesel engineEnd Of Sie

IAT Intake Air Temperature — Intake Air ThermoKS Knock Sensor — Knock SensorMIL Malfunction Indicator Lamp — Malfunction Indicator LightMAP Manifold Absolute Pressure — Intake Air Pressure

MAF sensor Mass Air Flow Sensor — Airflow SensorMFL Multiport Fuel Injection — Multiport Fuel InjectionOBD On-Board Diagnostic — Diagnosis/Self-DiagnosisOL Open Loop — Open Loop— Output Speed Sensor — Vehicle Speed Sensor 1OC Oxidation Catalytic Converter — Catalytic ConverterO2S Oxygen Sensor — Oxygen SensorPNP Park/Neutral Position — Park/Neutral Range— PCM Control Relay — Main Relay #6

PSP Power Steering Pressure — Power Steering PressurePCM Powertrain Control Module ECU Engine Control Unit #4

— Pressure Control Solenoid — Line Pressure Solenoid Valve

PAIR Pulsed Secondary Air Injection — Secondary Air Injection System Pulsed injection

— Pump Speed Sensor — NE Sensor #6

AIR Secondary Air Injection — Secondary Air Injection SystemInjection with air pump

SAPV Secondary Air Pulse Valve — Reed ValveSFI Sequential Multipoint Fuel Injection — Sequential Fuel Injection

— Shift Solenoid A— 12 Shift Solenoid Valve— Shift A Solenoid Valve

— Shift Solenoid B— 23 Shift Solenoid Valve— Shift B Solenoid Valve

— Shift Solenoid C — 34 Shift Solenoid Valve3GR Third Gear — 3rd GearTWC Three Way Catalytic Converter — Catalytic ConverterTB Throttle Body — Throttle Body

TP sensor Throttle Position Sensor — Throttle SensorTCV Timer Control Valve TCV Timing Control Valve #6TCC Torque Converter Clutch — Lockup Position

TCM Transmission (Transaxle) Control Module — EC-AT Control Unit

— Transmission (Transaxle) Fluid Temperature Sensor — ATF Thermo-sensor

TR Transmission (Transaxle) Range — Inhibitor PositionTC Turbocharger — Turbocharger

VSS Vehicle Speed Sensor — Vehicle Speed Sensor VR Voltage Regulator — IC Regulator

VAF sensor Volume Air Flow Sensor — Air flow Sensor

WUTWC Warm Up Three Way Catalytic Converter — Catalytic Converter #5

WOT Wide Open Throttle — Fully Open

New Standard Previous StandardRemark

Abbrevi-ation Name Abbrevi-ation Name


01-10–1

01ENGINESECTION

01-10

Toc of SCTMECHANICAL. . . . . . . . . . . . . .01-10TECHNICAL DATA . . . . . . . . . .01-50

SERVICE TOOLS . . . . . . . . . . . 01-60

Toc of SCT

01-10 MECHANICALENGINE OVERHAUL

SERVICE WARNING . . . . . . . . . . . . . . . 01-10–1ENGINE

MOUNTING/DISMOUNTING . . . . . . . . . 01-10–2Mounting . . . . . . . . . . . . . . . . . . . . . . . . 01-10–2Dismounting . . . . . . . . . . . . . . . . . . . . . 01-10–3

TIMING CHAIN DISASSEMBLY. . . . . . . . 01-10–3Crankshaft Pulley Installation Bolt

Disassembly Note . . . . . . . . . . . . . . . . 01-10–4Engine Front Cover

Disassembly Note . . . . . . . . . . . . . . . . 01-10–4Timing Chain Tensioner

Disassembly Note . . . . . . . . . . . . . . . . 01-10–4CYLINDER HEAD DISASSEMBLY (I) . . . 01-10–5

Camshaft Sprocket, Variable Valve Timing Actuator Disassembly Note . . . 01-10–6

Camshaft Cap Disassembly Note . . . . . 01-10–6Tappet Disassembly Note . . . . . . . . . . . 01-10–6Cylinder Head Disassembly Note . . . . . 01-10–6

CYLINDER HEAD DISASSEMBLY (II) . . . . . . . . . . . . . . . . . 01-10–7

Valve Keeper Disassembly Note . . . . . . 01-10–8Valve Seal Disassembly Note . . . . . . . . 01-10–8

CYLINDER BLOCK DISASSEMBLY (I) . . . . . . . . . . . . . . . . . 01-10–8

Knock Sensor Disassembly Note . . . . . 01-10–10Drive Plate (ATX), Flywheel (MTX)

Disassembly Note . . . . . . . . . . . . . . . . 01-10–10Oil Filter Disassembly Note . . . . . . . . . . 01-10–10Oil Pan Disassembly Note. . . . . . . . . . . 01-10–10

CYLINDER BLOCK DISASSEMBLY (II) . . . . . . . . . . . . . . . . . 01-10–10

Connecting Rod Cap Disassembly Note . . . . . . . . . . . . . . . . 01-10–11

Piston Pin Disassembly Note . . . . . . . . 01-10–12Lower Cylinder Block

Disassembly Note . . . . . . . . . . . . . . . . 01-10–13CYLINDER HEAD INSPECTION . . . . . . . 01-10–14VALVE SEAT INSPECTION/REPAIR . . . . 01-10–15VALVE, VALVE GUIDE INSPECTION . . . 01-10–15VALVE GUIDE REPLACEMENT . . . . . . . 01-10–17

Removal . . . . . . . . . . . . . . . . . . . . . . . . 01-10–17Installation . . . . . . . . . . . . . . . . . . . . . . . 01-10–17

VALVE SPRING INSPECTION . . . . . . . . . 01-10–18TAPPET INSPECTION . . . . . . . . . . . . . . . 01-10–18VARIABLE VALVE TIMING ACTUATOR

INSPECTION . . . . . . . . . . . . . . . . . . . . . 01-10–19

OIL CONTROL VALVE (OCV) INSPECTION . . . . . . . . . . . . . . . . . . . . . 01-10–19

Coil Resistance Inspection . . . . . . . . . . 01-10–19Spool Valve Operation Inspection . . . . 01-10–19

CAMSHAFT INSPECTION . . . . . . . . . . . 01-10–20CYLINDER BLOCK INSPECTION . . . . . 01-10–21OIL JET VALVE INSPECTION . . . . . . . . 01-10–21PISTON, PISTON RING, PISTON PIN

INSPECTION . . . . . . . . . . . . . . . . . . . . . 01-10–22CONNECTING ROD INSPECTION . . . . . 01-10–23CRANKSHAFT INSPECTION . . . . . . . . . 01-10–24BOLT INSPECTION. . . . . . . . . . . . . . . . . 01-10–26OIL PUMP INSPECTION. . . . . . . . . . . . . 01-10–26VALVE CLEARANCE INSPECTION . . . . 01-10–27VALVE CLEARANCE

ADJUSTMENT. . . . . . . . . . . . . . . . . . . . 01-10–27CYLINDER BLOCK ASSEMBLY (I) . . . . 01-10–31

Main Bearing Assembly Note . . . . . . . . 01-10–32Lower Cylinder Block

Assembly Note . . . . . . . . . . . . . . . . . . 01-10–33Piston Pin Assembly Note . . . . . . . . . . 01-10–34Piston Ring Assembly Note . . . . . . . . . 01-10–36Piston, Connecting Rod Component

Assembly Note . . . . . . . . . . . . . . . . . . 01-10–36Connecting Rod Bearing

Assembly Note . . . . . . . . . . . . . . . . . . 01-10–36Connecting Rod Cap

Assembly Note . . . . . . . . . . . . . . . . . . 01-10–37CYLINDER BLOCK ASSEMBLY (II) . . . . 01-10–37

Inner Rotor, Outer Rotor Assembly Note . . . . . . . . . . . . . . . . . . 01-10–39

Oil Pan Assembly Note. . . . . . . . . . . . . 01-10–39Oil Filter Assembly Note. . . . . . . . . . . . 01-10–39Rear Oil Seal Assembly Note . . . . . . . . 01-10–39Drive Plate (ATX), Flywheel (MTX)

Assembly Note . . . . . . . . . . . . . . . . . . 01-10–40Oil Pump Assembly Note . . . . . . . . . . . 01-10–40Knock Sensor Assembly Note . . . . . . . 01-10–41

CYLINDER HEAD ASSEMBLY (I). . . . . . 01-10–41Valve Seal Assembly Note . . . . . . . . . . 01-10–41Valve Keeper Assembly Note . . . . . . . . 01-10–42

CYLINDER HEAD ASSEMBLY (II) . . . . . 01-10–42Cylinder Head Assembly Note . . . . . . . 01-10–43Camshaft Assembly Note. . . . . . . . . . . 01-10–44Camshaft Sprocket, Variable Valve

Timing Actuator Assembly Note . . . . . 01-10–44TIMING CHAIN ASSEMBLY . . . . . . . . . . 01-10–44

Timing Chain Assembly Note . . . . . . . . 01-10–46

MECHANICAL

01-10–2

Engine Front Cover Assembly Note . . . 01-10–46Crankshaft Pulley Installation Bolt

Assembly Note . . . . . . . . . . . . . . . . . . 01-10–48

Cylinder Head Cover Assembly Note . . . . . . . . . . . . . . . . . . 01-10–48

End of TocEN: ENGINE COMPLETEENGINE OVERHAUL SERVICE WARNING

id011000503900

WarningContinuous exposure to USED engine oil has caused skin cancer in laboratory mice. Protect your skin by washing with soap and water immediately after this work.

End Of SieENGINE MOUNTING/DISMOUNTING

id011000507000

Mounting1. Install the SSTs (arms) to the specified position

as shown, and hand-tighten the SST bolts.

2. Assemble the SSTs (bolts, nuts, and plate) to the specified position as shown.

3. Assemble the SSTs (arms and bolts) in Step 1 to the SSTs (bolts, nuts, and plate) in Step 2.

49 L010 102 49 L010 106

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49 L010 10149 L010 104

49 L010 105

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MECHANICAL

01-10–3

01-10

4. Adjust the bolts so that approx. 20 mm {0.79 in}of thread is exposed from the side of the plate.

5. Adjust the bolts and nuts so that the plate and arms are parallel.

6. Mount the engine on the SST.

WarningThe self-locking brake system of the engine stand may not be effective when the engine is held in an unbalanced position. This could lead to sudden, rapid movement of the engine and the mounting stand handle causing serious injury. Never keep the engine in an unbalanced position, and always hold the rotating handle firmly when turning the engine.

7. Remove the oil drain plug and drain the engine oil.

8. Install the drain plug and a new washer.

Tightening torque30—41 N·m {3.1—4.1 kgf·m, 23—30 ft·lbf}

Dismounting1. Dismount in the reverse order of mounting.

End Of Sie

49 L010 101

49 L010 102

49 L010 104 49 L010 103

49 L010 105

PARALLEL

APPROX. 20 mm {0.79 in}

ENGINE

49 L010 106

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MECHANICAL

01-10–4

TIMING CHAIN DISASSEMBLYid011000505500

1. Disassemble in the order indicated in the table.

.

2

R

SST

R

R

R

R

R

R

R

15

16

1413

11

12

9

7

8

1

10

6

5

3

4

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1 Spark plug2 Camshaft position (CMP) sensor3 Cylinder head cover4 Drive belt auto tensioner5 Oil level gauge pipe6 Oil control valve (OCV)7 Idler pulley8 OCV oil filter, plug9 Crankshaft pulley

(See 01-10-4 Crankshaft Pulley Installation Bolt Disassembly Note)

10 Engine front cover(See 01-10-4 Engine Front Cover Disassembly Note)

11 Timing chain tensioner(See 01-10-4 Timing Chain Tensioner Disassembly Note)

12 Timing chain tensioner arm13 Timing chain guide14 Timing chain15 Crankshaft sprocket16 Key

MECHANICAL

01-10–5

01-10

Crankshaft Pulley Installation Bolt Disassembly Note1. Lock the drive plate (ATX) or flywheel (MTX)

against rotation using the SST.2. Remove the crankshaft pulley installation bolt.

Engine Front Cover Disassembly Note1. Remove the oil seal using a flathead screwdriver.

Timing Chain Tensioner Disassembly Note1. Push down the link plate of the timing chain

tensioner using a thin flathead screwdriver (precision screwdriver) and release the plunger lock.

2. Push back the plunger slowly in the direction shown in the figure with the link plate still pushed down.

3. Free the link plate with the plunger still pushed.4. Move the plunger back and forth 2—3 mm

{0.08—0.11 in} and insert an approx. 1.5 mm {0.059 in} wire or paper clip where the link plate hole and the tensioner body hole overlap to fix the link plate and lock the plunger.

49 E011 1A0

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PLUNGER

LINK PLATE

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LINK PLATE

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MECHANICAL

01-10–6

End Of Sie

CYLINDER HEAD DISASSEMBLY (I)id011000500400


.

WIRE OR PAPER CLIP

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7

5

43

6

1

2

R

R

B3E0110E025

MECHANICAL

01-10–7

01-10Camshaft Sprocket, Variable Valve Timing Actuator Disassembly Note1. Hold the camshaft using a suitable wrench on the

cast hexagon as shown in the figure.2. Loosen the camshaft sprocket installation bolt.

Camshaft Cap Disassembly Note1. Inspect the camshaft end play. (See 01-10-20 CAMSHAFT INSPECTION)2. Loosen the camshaft cap installation bolts in two

to three passes in the order shown in the figure, and then remove the camshaft caps.

Tappet Disassembly Note

NoteThe tappets are numbered to make sure they are assembled in their original positions. When removed, keep the tappets with the cylinder head from where they were removed. Do not mix the tappets.

1 Water outlet2 Camshaft sprocket, variable valve timing actuator

(See 01-10-6 Camshaft Sprocket, Variable Valve Timing Actuator Disassembly Note)

3 Camshaft cap(See 01-10-6 Camshaft Cap Disassembly Note)

4 Camshaft5 Tappet

(See 01-10-6 Tappet Disassembly Note)6 Cylinder head

(See 01-10-6 Cylinder Head Disassembly Note)7 Cylinder head gasket

ADJ2224E077

1 2 3 4

5 7 86

9

8

7 5

4

3

10 6

1

2

19

18

17 15

1614

1311

12 20

B3E2224E008

MECHANICAL

01-10–8

Cylinder Head Disassembly Note1. Loosen the camshaft cap installation bolts in two to three passes in the order shown in the figure, and remove

them.End Of Sie

CYLINDER HEAD DISASSEMBLY (II)id011000500500


.

9

6

58

3

4 1

2107

B3E0110E024

SST R

SST

5

4

3

1

2

B3E0110E026

1 Valve keeper(See 01-10-8 Valve Keeper Disassembly Note)

2 Upper valve spring seat3 Valve spring

4 Valve5 Valve seal

(See 01-10-8 Valve Seal Disassembly Note)

MECHANICAL

01-10–9

01-10

Valve Keeper Disassembly Note1. Remove the valve keeper using the SSTs.

Valve Seal Disassembly Note1. Remove the valve seal using the SST.

End Of Sie

49 B012 0A2

49 0636 100B

b3e0110e124

49 S120 170

VALVE SEALVALVE GUIDE

B3E0110E061

MECHANICAL

01-10–10

CYLINDER BLOCK DISASSEMBLY (I)id011000500600


.

R

18

1716

14

15

13

128 7

5

4

3

9

10

11

6

2

R

R

R7

SST

SST

SST

SST

MTX

1

R

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1 Thermostat cover2 Thermostat3 Knock sensor

(See 01-10-10 Knock Sensor Disassembly Note)4 Oil separator5 Water pump6 Oil pump7 Drive plate (ATX), flywheel (MTX)

(See 01-10-10 Drive Plate (ATX), Flywheel (MTX) Disassembly Note)

8 End plate

9 Oil filter(See 01-10-10 Oil Filter Disassembly Note)

10 Oil pan(See 01-10-10 Oil Pan Disassembly Note)

11 Oil strainer12 Oil pump cover13 Inner rotor14 Outer rotor15 Plunger plug16 Plunger spring17 Control plunger18 Oil pump body

MECHANICAL

01-10–11

01-10

Knock Sensor Disassembly Note1. Remove the knock sensor using the SST.

Drive Plate (ATX), Flywheel (MTX) Disassembly Note1. Lock the drive plate (ATX) or flywheel (MTX)

against rotation using the SST.2. Remove the drive plate or flywheel installation

bolts.

Oil Filter Disassembly Note1. Remove the oil filter using the SST or

commercially available, cup-type oil filter wrench (67 mm {2.6 in} diameter, 14 sided).

Oil Pan Disassembly Note1. Remove the oil pan using a separator tool.

End Of Sie

49 H018 001

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49 E011 1A0

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49 G014 001OR COMMERCIALLY AVAILABLE CUP-TYPE OIL FILTER WRENCH

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MECHANICAL

01-10–12

CYLINDER BLOCK DISASSEMBLY (II)id011000500700


.

7

6

4

3

10

9

8

2

1

5

R

14

13

11

12

SST

R

15

bezuue00000096

1 Connecting rod cap(See 01-10-11 Connecting Rod Cap Disassembly Note)

2 Lower connecting rod bearing3 Upper connecting rod bearing4 Connecting rod, piston assembly5 Piston ring6 Piston pin

(See 01-10-12 Piston Pin Disassembly Note)7 Piston

8 Connecting rod9 Lower cylinder block

(See 01-10-13 Lower Cylinder Block Disassembly Note)

10 Rear oil seal11 Lower main bearing12 Crankshaft13 Upper main bearing, thrust bearing14 Oil jet valve15 Upper cylinder block

MECHANICAL

01-10–13

01-10

Connecting Rod Cap Disassembly Note

CautionWhen removing the connecting rod bearings and reusing them, put a paint mark showing the front end and the journal number before the removal.

1. Inspect the connecting rod side clearance. (See 01-10-23 CONNECTING ROD INSPECTION.)

Piston Pin Disassembly Note1. Before extracting the piston pin, inspect the following.

(1) Check the oscillation torque as shown. Verify that the large end drops under its own weight with no resistance.

If the piston shakes heavily or unsmoothly, replace the piston and the piston pin.

2. Assemble the SSTs as shown in the figure.

b3e0110e087

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49 L011 006A

49 E011 001A 49 E011 002A

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MECHANICAL

01-10–14

3. Insert the SST through the piston pin as shown in the figure and assemble.

4. Set the piston with the SSTs assembled and the connecting rod component as shown in the figure.

5. Press out the piston pin.

49 E011 002A

49 L011 006A49 E011 001A

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49 L011 001

49 D011 002B

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MECHANICAL

01-10–15

01-10

Lower Cylinder Block Disassembly Note

CautionWhen removing the main bearing and reusing them, put a paint mark showing the front end and the journal number before the removal.

1. Inspect the crankshaft end play. (See 01-10-24 CRANKSHAFT INSPECTION.)2. Loosen the lower cylinder block installation bolts

in the order shown in the figure.End Of Sie

CYLINDER HEAD INSPECTIONid011000507100

1. Carry out the color contrast penetrate examination on the cylinder head surface.If there is a crack, replace the cylinder head.

2. Measure the combustion chamber side of the cylinder head for distortion in six directions as shown in the figure using a straight edge and feeler gauge.

If it exceeds the maximum specification, replace the cylinder head.

Cylinder head maximum distortion, head gasket side

0.10 mm {0.0039 in}

3. Measure the contact surface of the exhaust manifold and the intake manifold as shown in the figure for distortion using a straight edge and feeler gauge.

If it exceeds the maximum specification, grind the surface or replace the cylinder head.

Cylinder head maximum distortion, manifold side

0.05 mm {0.002 in}

Cylinder head maximum grinding, manifold side

0.20 mm {0.0079 in}

End Of Sie

9

87

5

43

10 19

1817

1516

1413

1112

20

6

12

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b3e0110e008

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MECHANICAL

01-10–16

VALVE SEAT INSPECTION/REPAIRid011000501300

1. Measure the contact width of the valve face and the valve seat using the valve lapping compound (red lead).

Valve seat standard contact width0.8—1.4 mm {0.04—0.05 in}

If not within the specification, resurface the valve seat using the 45 valve seat cutter or resurface the valve face, or the both.

2. Verify that the valve seating position is at the center of the valve face.

If the seating position is too high, correct the valve seat using a 70 (IN) 70 (EX) valve seat cutter, and a 45 valve seat cutter.If the seating position is too low, correct the valve seat using a 35 (IN) 30 (EX) valve seat cutter, and a 45 valve seat cutter.

Valve seat angle45

3. Check the valve seat for sinking. Measure the protruding length (dimension L) of the valve stem using a valve of standard length.

If it exceeds the specification, replace the cylinder head.

Valve seat standard sinkage amount (Dimension L)

39.25 mm {1.545 in}

End Of Sie

VALVE, VALVE GUIDE INSPECTIONid011000506200

1. Measure the valve head margin thickness using a vernier caliper.

If not within the specification, replace the valve.

Valve head standard margin thickness1.6—2.0 mm {0.063—0.078 in}

SEAT CONTACT WIDTH

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L

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MARGIN THICKNESS

IN : 27.8 mm {1.09 in}EX : 24.7 mm {0.972 in}

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MECHANICAL

01-10–17

01-10

2. Measure the length of each valve using the vernier caliper.

If it is less than the minimum specification, replace the valve.

Valve length (Dimension L)StandardIN: 96.80—97.40 mm {3.812—3.834 in}EX: 96.30—96.90 mm {3.792—3.814 in}MinimumIN: 96.58 mm {3.802 in}EX: 96.08 mm {3.783 in}

3. Measure the stem diameter of each valve using the micrometer. Measurement positions total six and they are in the X and Y directions at the three points (A, B, and C) as shown in the figure.

If it is less than the minimum specification, replace the valve.

Valve stem diameterStandardIN: 5.470—5.485 mm {0.2154—0.2159 in}EX: 5.465—5.480 mm {0.2152—0.2157 in}MinimumIN: 5.424 mm {0.2136 in}EX: 5.419 mm {0.2134 in}

4. Measure the inner diameter of each valve guide using the caliper gauge. Measurement positions total six and they are in the X and Y directions at the three points (A, B, and C) as shown in the figure.

If not within the specification, replace the valve guide. (See 01-10-17 VALVE GUIDE REPLACEMENT.)

Valve guide standard inner diameter5.510—5.530 mm {0.2170—0.2177 in}

5. Calculate the clearance between the valve stem and the valve guide by subtracting the inner diameter of the valve guide from the outer diameter of the corresponding valve stem.

If it exceeds the maximum specification, replace the valve or the valve guide, or both. (See 01-10-17 VALVE GUIDE REPLACEMENT.)

Clearance between valve stem and guideStandardIN: 0.025—0.060 mm {0.0010—0.0023 in}EX: 0.030—0.065 mm {0.0012—0.0025 in}Maximum0.1 mm {0.004 in}

L

b3e0110e068

X

Y

A

B

C

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X

Y

A

B

C

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VALVE STEM

VALVE GUIDE

CLEARANCE

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MECHANICAL

01-10–18

6. Measure the projection height (dimension A) of each valve guide using the vernier caliper.

If not within the specification, replace the valve guide. (See 01-10-17 VALVE GUIDE REPLACEMENT.)

Valve guide standard projection height12.2—12.8 mm {0.481—0.503 in}

End Of Sie

VALVE GUIDE REPLACEMENTid011000501200

Removal1. Remove the valve guide from the combustion

chamber side using the SST.

Installation1. Assemble the SSTs so that depth L is as

specified.

Depth L12.2—12.8 mm {0.481—0.503 in}

2. Tap the valve guide in from the camshaft side using the SSTs set in Step 1.

End Of Sie

A

VALVE GUIDE

CYLINDER HEAD

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VALVE GUIDE

49 B012 015

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L49 L012 004A

49 L012 003A

49 L012 002A

b3e0110e071

49 L012 004A49 L012 003A

49 L012 002A

VALVE GUIDE

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MECHANICAL

01-10–19

01-10

VALVE SPRING INSPECTIONid011000501400

1. Measure the spring height using a spring tester.If it exceeds the specification, replace the valve spring.

Valve spring standard height27.5 mm {1.08 in} (pressing force 262.8 N

{26.80 kgf, 59.08 lbf}

2. Measure the amount of off-square on the valve spring using a square.(1) Rotate the valve spring one full turn and

measure “A” at the point where the gap is the largest.

If it exceeds the maximum specification, replace the valve spring.

Maximum valve spring off-square2.0 (3.45 mm {0.136 in})

End Of Sie

TAPPET INSPECTIONid011000505800

1. Measure the diameter of each tappet bore using the caliper gauge. Measurement points are the inner diameter in the X and Y directions, at the points (A and B) as shown in the figure.

Standard tappet bore diameter30.0—30.025 mm {1.1812—1.1820 in}

2. Measure the tappet body outer diameter of each valve using the micrometer. Measure the outer diameter in the X and Y directions, at the four points (A and B) as shown in the figure.

Standard tappet body outer diameter29.959—29.975 mm {1.1795—1.1801 in}

3. Calculate the clearance between the tappet and the related bore by subtracting the inner diameter of the tappet bore from the outer diameter of the corresponding tappet.

If it exceeds the maximum specification, replace the tappet or the cylinder head.

Clearance between tappet and tappet boreStandard0.025—0.066 mm {0.0010—0.0025 in}Maximum0.18 mm {0.0071 in}

bezuue00000024

A

UPPER

LOWER

bezuue00000025

X

Y

A

B

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A

BY

X

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MECHANICAL

01-10–20

End Of Sie

VARIABLE VALVE TIMING ACTUATOR INSPECTIONid011000506000

CautionVariable valve timing actuator cannot be disassembled because it is a precision unit.

1. Verify that the camshaft knock pin hole of the rotor and the T-mark on the cover of the variable valve timing actuator are aligned and placed at the same position by rotating them by hand.

CautionIf the camshaft knock pin hole and the T- mark are not aligned, rotate the rotor (the camshaft installing part) until a click is heard, and verify that they are fixed in place.

If the rotor is not secured even though their camshaft knock pin hole and the T-mark are aligned, replace the variable valve timing actuator.

End Of Sie

OIL CONTROL VALVE (OCV) INSPECTIONid011000506100

Coil Resistance Inspection1. Measure the coil resistance between terminals A

and B using the tester.If not within the specification, replace the oil control valve (OCV).

OCV coil resistance6.9—7.9 ohms [20 C {68 F}]

Spool Valve Operation Inspection1. Verify that the spool valve in the oil control valve

(OCV) is in the maximum valve timing retard position as shown in the figure.

If it cannot be verified as shown, replace the oil control valve (OCV).

2. Apply battery positive voltage between the oil control valve (OCV) terminals A and B, and verify that the spool valve operates and moves to the maximum valve timing advance position.

If it cannot be verified as shown in the figure, replace the oil control valve (OCV).

NoteWhen applying battery positive voltage between the oil control valve (OCV) terminals, the connection of the positive and negative battery cable can be with either of the oil control valve (OCV) terminals.

COVER

ROTOR

T-MARK

CAMSHAFTKNOCK-PINHOLE

ada2226e005

AB

bezuue00000028

SPOOL VALVE(MAXIMUM VALVE TIMING RETARD POSITION

b3e0110e090

MECHANICAL

01-10–21

01-10

3. Stop applying battery positive voltage and verify that the spool valve returns to the maximum valve timing retard position.

If it cannot be verified as shown in the figure, replace the oil control valve (OCV).

End Of Sie

CAMSHAFT INSPECTIONid011000501500

1. Set the No.1 and No.5 journals of the camshaft on V-blocks.

2. Measure the camshaft runout using a dial gauge.If it exceeds the maximum specification, replace the camshaft.

Camshaft maximum runout0.03 mm {0.001 in}

3. Measure the cam lobe height as shown using the micrometer.

If it is less than the minimum specification, replace the camshaft.

Cam lobe heightStandardIN: 41.373 mm {1.6289 in}EX: 40.597 mm {1.5983 in}MinimumIN: 41.30 mm {1.626 in}EX: 40.53 mm {1.596 in}

4. Measure the camshaft journal diameter using the micrometer. Measurement positions total four, and they are in the X and Y directions, at the two points (A and B) as shown in the figure.

If it is less than the minimum specification, replace the camshaft.

Camshaft journal diameterStandard25.950—25.975 mm {1.0217—1.0226 in}Minimum24.910 mm {0.98071 in}

VALVE TIMING ADVANCE

VALVE TIMING RETARD

SPOOL VALVE(MAXIMUM VALVE TIMING ADVANCE POSITION)

b3e0110e091

b3e0110e074

b3e0110e076

AB

XY

bezuue00000029

MECHANICAL

01-10–22

5. Measure the camshaft journal oil clearance using a plastigauge with the tappet removed.

NoteClean the camshaft journal and the journal receptacle part.Cut the plastigauge to the same length as the journal width and position it in parallel to the camshaft.

If it exceeds the maximum specification, replace the cylinder head.

Camshaft journal oil clearanceStandard0.025—0.071 mm {0.0010—0.0027 in}Maximum0.090 mm {0.0035 in}

6. Measure the camshaft end play using a dial gauge.

If it exceeds the maximum specification, replace the cylinder head or the camshaft.

Camshaft end playStandard0.07—0.19 mm {0.003—0.007 in}Maximum0.20 mm {0.0079 in}

End Of Sie

CYLINDER BLOCK INSPECTIONid011000507200

1. Measure the distortion in six directions as shown in the figure using a square and feeler gauge.

If it exceeds the maximum specification, replace the cylinder block.

Cylinder block maximum distortion, head gasket side

0.10 mm {0.0039 in}

2. Measure the cylinder bore using a cylinder bore gauge. Measurement positions are in the X and Y directions at 35.0 mm {1.38 in} below the top surface of the cylinder.

If it is not within the specification, replace the cylinder block.

Standard cylinder bore diameter78.000—78.013 mm {3.0709—3.0713 in}

End Of Sie

PLASTIGAUGE

bezuue00000030

bezuue00000031

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35.0 mm {1.38 in}

X

Y

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MECHANICAL

01-10–23

01-10

OIL JET VALVE INSPECTIONid011000505900

1. Apply 230 kPa {2.35 kgf/cm2, 33.4 psi} or more of compressed air to oil jet valve A and verify that air passes through oil jet valve B.

If air does not flow, replace the oil jet valve.End Of Sie

PISTON, PISTON RING, PISTON PIN INSPECTIONid011000506600

1. Measure the piston outer diameter using a micrometer. The measurement position is 12.5 mm {0.492 in} from the lower end of the piston, and in the thrust direction.

Piston outer diameter77.970—77.980 mm {3.0697—3.0700 in}

2. Calculate the piston-to-cylinder clearance from the cylinder bore inner diameter and the piston outer diameter.

If it exceeds the maximum specification, replace the piston or the cylinder block.

Clearance between piston and cylinderStandard0.020—0.043 mm {0.0008—0.0016 in}Maximum0.070 mm {0.0028 in}

3. Measure the piston ring-to-ring groove clearance around the entire circumference using a feeler gauge.

If it exceeds the maximum specification, replace the piston ring.

Clearance between piston ring and ring groove

StandardTop: 0.035—0.065 mm {0.0014—0.0025 in}Second: 0.030—0.070 mm {0.0012—0.0027

in}Oil: 0.040—0.120 mm {0.0016—0.0047 in}MaximumTop, Second: 0.150 mm {0.0059 in}Oil: 0.20 mm {0.0079 in}

bezuue00000107

12.5 mm {0.492 in}

bezuue00000034

b3e0110e081

MECHANICAL

01-10–24

4. Measure the piston ring end gap using a feeler gauge.

If if exceeds the maximum specification, replace the piston ring.

Piston ring end gapStandardTop: 0.14—0.24 mm {0.0056—0.0094 in}Second: 0.24—0.37 mm {0.010—0.014 in}Oil: 0.10—0.35 mm {0.004—0.013 in}Maximum1.0 mm {0.039 in}

5. Measure the piston pin hole diameter. Measurement positions total eight and they are in the X and Y directions at four points (A, B, C, and D) as shown in the figure.

Standard piston pin hole diameter18.988—19.000 mm {0.74756—0.74803 in}

6. Measure the piston pin outer diameter using a micrometer. Measurement positions total eight and they are in the X and Y directions at the four points (A, B, C, and D) as shown in the figure.

Standard piston pin outer diameter18.974—18.980 mm {0.74701—0.74724 in}

7. Calculate the clearance between the piston pin hole diameter and the piston pin outer diameter.

If not within the specification, replace the piston or the piston pin.

Standard clearance between piston pin hole and piston pin

0.008—0.026 mm {0.0004—0.0010 in}

End Of SieCONNECTING ROD INSPECTION

id011000502800

1. Install the connecting rod cap. (See 01-10-31 CYLINDER BLOCK ASSEMBLY (I).)2. Measure the side clearance at the large end of

the connecting rod using a feeler gauge.If it exceeds the maximum specification, replace the connecting rod or the crankshaft.

Side clearance at the large end of the connecting rod

Standard0.110—0.292 mm {0.0044—0.0114 in}Maximum0.435 mm {0.0171 in}

PISTON RING

bezuue00000035

adj2224e253

AB

C

D

X

Y

adj2224e255

b3e0110e087

MECHANICAL

01-10–25

01-10

3. Measure the oil clearance at the large end of the connecting rod using a plastigauge.

If it exceeds the maximum specification, replace the bearing or grind the crank pin, and use oversize bearings so that the specified clearance is obtained.

NoteCut the plastigauge as wide as the connecting rod bearing width, place it parallel to the crankshaft, keeping away from the oil hole.

Bearing oil clearance at the large end of connecting rod

Standard0.016—0.037 mm {0.0007—0.0014 in}Maximum0.10 mm {0.0039 in}

Connecting rod bearing thickness (Center thickness)STD: 1.509—1.524 mm {0.0594—0.0599 in}OS 0.25: 1.629—1.637 mm {0.0642—0.0644 in}OS 0.50: 1.729—1.737 mm {0.0681—0.0683 in}

4. Measure the inner diameter at the small end of the connecting rod using a caliper gauge.

Standard connecting rod small end inner diameter

18.943—18.961 mm {0.74579—0.74649 in}

5. Calculate the clearance between the connecting rod small end inner diameter and the piston pin outer diameter.

If not within the specification, replace the connecting rod or the piston pin.

Standard clearance between connecting rod small end and piston pin

–0.037— –0.013 mm {–0.0014— –0.0006 in}

6. Inspect the connecting rod for bending and distortion using a connecting rod aligner.

If it exceeds the maximum specification, replace the connecting rod.

Connecting rod maximum bending0.050 mm {0.0020 in} [Per 50 mm {2.0 in}]

Connecting rod maximum distortion0.075 mm {0.0030 in} [Per 50 mm {2.0 in}]

Connecting rod center-to-center distance140.60—140.70 mm {5.536—5.539 in}

End Of Sie

PLASTIGAUGE

bezuue00000036

X

Y

adj2224e254

amj2224e255

MECHANICAL

01-10–26

CRANKSHAFT INSPECTIONid011000502500

1. Measure the crankshaft end play using a dial gauge.

If it exceeds the maximum specification, replace the crankshaft or grind the crankshaft thrust side, and install the oversize bearing so that the specified end play is obtained.

Thrust bearing thicknessSTD: 2.500—2.550 mm {0.0985—0.1003 in}OS 0.25: 2.625—2.675 mm {0.1034—0.1053

in}OS 0.50: 2.750—2.800 mm {0.1083—0.1102

in}OS 0.75: 2.875—2.925 mm {0.1132—0.1151

in}

Crankshaft end playStandard0.080—0.282 mm {0.0032—0.0111 in}Maximum0.30 mm {0.012 in}

2. Measure the crankshaft main journal runout on V-blocks using a dial gauge.

If it exceeds the maximum specification, replace the crankshaft.

Crankshaft main journal maximum runout0.10 mm {0.0039 in}

3. Inspect the main journal diameter and crank pin diameter. Measurement positions total four and they are in the X and Y directions, at two points (A and B) as shown in the figure.

If not within the specification or exceeds the maximum off-round, replace the crankshaft or grind the journal to fit the oversize bearing.

Crankshaft main journal diameterSTD: 49.938—49.956 mm {1.9661—1.9667 in}OS 0.25: 49.688—49.706 mm {1.9563—

1.9569 in}OS 0.50: 49.438—49.456 mm {1.9464—

1.9470 in}

Crankshaft main journal maximum off-round0.050 mm {0.0020 in}

Crank pin journal diameterSTD: 47.940—47.956 mm {1.8875—1.8880 in}OS 0.25: 47.690—47.706 mm {1.8776—1.8781 in}OS 0.50: 47.440—47.456 mm {1.8678—1.8683 in}

Crank pin journal maximum off-round0.10 mm {0.0039 in}

b3e0110e083

bezuue00000037

A B

X

Y

b3e0110e085

MECHANICAL

01-10–27

01-10

4. Inspect the main journal oil clearance using the following procedure.(1) Install the upper main bearing and crankshaft.(2) Position a plastigauge on the journals.(3) Install the lower main bearing and the lower

cylinder block. (See 01-10-31 CYLINDER BLOCK ASSEMBLY (I).)

(4) Remove the lower cylinder block.(See 01-10-10 CYLINDER BLOCK DISASSEMBLY (II).)

(5) Measure the main journal oil clearance.If it exceeds the maximum specification, replace the main bearing or grind the main bearing journal part and install the oversize bearing.

Crankshaft main journal oil clearanceStandard0.019—0.038 mm {0.0008—0.0014 in}Maximum 0.084 mm {0.0033 in}

Main bearing thicknessSTD: 2.508—2.529 mm {0.09875—0.09956 in}OS 0.25: 2.625—2.635 mm {0.1034—0.1037 in}OS 0.50: 2.750—2.760 mm {0.1083—0.1086 in}

End Of SieBOLT INSPECTION

id011000503300

1. Measure the length of each bolt.If it exceeds the maximum specification, replace the bolt.

Cylinder head bolt lengthStandard: 128.9—129.5 mm {5.075 —5.098

in}Maximum: 130.2 mm {5.126 in}

Connecting rod bolt lengthStandard: 46.7—47.3 mm {1.84—1.86 in}Maximum: 48.0 mm {1.89 in}

End Of SieOIL PUMP INSPECTION

id011000505300

1. Measure the clearance between the inner rotor and the outer rotor using a feeler gauge.

If it exceeds the maximum specification, replace the inner rotor or outer rotor, or both.

Tip clearance between inner rotor and outer rotor

Standard: 0.02—0.18 mm {0.0008—0.0070 in}

Maximum: 0.20 mm {0.0079 in}

b3e0110e086

L

bezuue00000038

bezuue00000039

MECHANICAL

01-10–28

2. Measure the clearance between the outer rotor and the oil pump body using a feeler gauge.

If it exceeds the maximum specification, replace the outer rotor or oil pump, or both.

Body clearance between outer rotor and oil pump body

Standard: 0.090—0.175 mm {0.0036—0.0068 in}

Maximum: 0.20 mm {0.0079 in}

3. Measure the side clearance using a straight edge and feeler gauge.

If it exceeds the specification, replace the inner rotor, outer rotor, oil pump, or all of them.

Oil pump side clearanceStandard: 0.03—0.07 mm {0.0012—0.0027

in}Maximum: 0.090 mm {0.0035 in}

4. Measure the weight at which the plunger spring height is compressed to 35.42 mm {1.394 in} using a spring tester.

If it exceeds the specification, replace the plunger spring.

Weight at which the plunger spring height is compressed to 35.42 mm {1.394 in}

62.5—68.9 N {6.38—7.02 kgf, 14.1—15.4 lbf}

End Of Sie

VALVE CLEARANCE INSPECTIONid011000503500

1. Turn the crankshaft clockwise so that the No.1 piston is at TDC of the compression stroke.2. Measure the valve clearance at A shown in the

figure.If not within the specification, replace the tappet and adjust the valve to the median value. (See 01-10-27 VALVE CLEARANCE ADJUSTMENT.)

Standard valve clearance [Engine cold]0.27—0.33 mm {0.011—0.012 in}

NoteMake sure to note the measured values for choosing the suitable replacement tappets.

3. Rotate the crankshaft clockwise 360 so that the No.4 piston is at TDC of the compression stroke.

bezuue00000040

bezuue00000041

bezuue00000024

A

EX

IN

A

NO.1 NO.2 NO.3 NO.4

A

B A B

B B

adj2224e103

MECHANICAL

01-10–29

01-10

4. Measure the valve clearance at B shown in the figure.

If not within the specification, replace the tappet and adjust the valve to the median value. (See 01-10-27 VALVE CLEARANCE ADJUSTMENT)


NoteMake sure to note the measured values for choosing the suitable replacement tappets.

End Of SieVALVE CLEARANCE ADJUSTMENT

id011000503600

1. Remove the engine front cover blind plug shown in the figure.

2. Insert a M6 bolt (45—80 mm {1.8—3.1 in} length bolt with threads to the end) into the service hole (right side) by hand as shown in the figure. Pull back the inserted bolt approx. 2 mm {0.08 in} from where it contacts the tensioner arm, and set the bolt in a position slightly outward of the tensioner arm.

3. Release tension on the timing chain.

A

EX

IN

A

NO.1 NO.2 NO.3 NO.4

A

B A B

B B

adj2224e103

BLIND PLUG R

am3zzw0000629

BOLT

FRONT COVER

TENSIONER ARM

bezuue00000043

MECHANICAL

01-10–30

(1) Press down the link plate of the chain tensioner from the service hole on the left side using a thin flathead screwdriver (precision screwdriver) as shown in the figure. Then rotate the crank pulley backwards (counterclockwise) with the plunger lock released.

NoteWhen the crankshaft pulley is turned counterclockwise, the timing chain loosens because the tensioner arm is pressed by the timing chain and the plunger of the chain tensioner is pressed in.

(2) Insert the M6 bolt installed to the engine front cover to the position where it catches the inside of the rib on the tensioner arm.

NoteWhen the timing chain loosens, the tensioner arm moves to the position shown in the figure and presses the M6 bolt to secure the tensioner arm.

bezuue00000044

PLUNGER

LINK PLATE

bezuue00000045

RIBRIB

bezuue00000046

RIB

TENSIONER ARM

SERVICE HOLE

bezuue00000047

MECHANICAL

01-10–31

01-10

4. Fix the camshaft using a wrench on the cast hexagon.

5. Remove the camshaft sprocket installation bolt.

6. Remove the timing sprocket on the exhaust side with the timing chain positioned out of the way.

7. Loosen the camshaft cap installation bolts in two to three passes in the order shown in the figure, and remove the camshaft caps.

8. Remove the intake and exhaust side camshafts.9. Remove the tappets.

10. Select a proper tappet according to the result of the valve clearance inspection and install it.Tappet to be selected: thickness of the

removed tappet + measured valve clearance - standard valve clearance


11. Align the timing marks on the crank pulley and the engine front cover, and then align the No.1 cylinder to the TDC.

12. Install the intake and exhaust camshafts with the No.1 cylinder so that it is near TDC of the compression stroke.

bezuue00000048

bezuue00000049

1 2 3 4

5 7 86

9

8

7 5

4

3

10 6

1

2

19

18

17 15

1614

1311

12 20

bezuue00000050

TIMING MARK

TDC

bezuue00000051

MECHANICAL

01-10–32

13. Install the camshaft cap to the position shown in the figure, and temporarily tighten the No.2 and No.7 camshaft installation bolts.

14. Tighten the camshaft installation bolts in two to three passes uniformly in the order shown in the figure.

Tightening torque12—14 N·m {123—142 kgf·cm, 107—123

in·lbf}

15. Install the exhaust camshaft sprocket and the timing chain at the same time.

Align the sprocket timing marks on the intake and exhaust camshafts so that they form a straight line in alignment with the upper horizontal surface of the cylinder head.

16. Hold the exhaust camshaft using a wrench on the cast hexagon.

17. Tighten the camshaft sprocket installation bolt.


18. Remove the M6 bolt holding the tensioner arm.19. Verify that there is no slack in the timing chain,

and then verify that the marks on the camshaft sprocket and the crank pulley are aligned.

20. Inspect the valve timing by rotating the crankshaft clockwise twice.

21. Install the new engine front cover blind plug.

Tightening torque3.0—6.0 N·m {31—61 kgf·cm, 27—53 in·lbf}

End Of Sie

1 2 3 4

5 7 86

9

8

7 5

4

3

10 6

1

2

19

18

17

15

1614

1311

12

20

bezuue00000052

bezuue00000049

TIMING MARK CYLINDER HEAD UPPER SURFACE

bezuue00000053

am3zzw0000032

BLIND PLUG R

am3zzw0000629

MECHANICAL

01-10–33

01-10

CYLINDER BLOCK ASSEMBLY (I)id011000504000

1. Assemble in the order indicated in the table.

.

7

6

4

310

9

82

1

5

14

13

11

12

23—26 {2.4—2.6, 17—19}+82.5˚— 97.5˚

8—10 N·m{82—101 kgf·cm,71—88 in·lbf}

19—25 {2.0—2.5, 15—18}

24—26 {2.5—2.6, 18—19}+42.5˚— 47.5˚

SST

OILOIL

OILOIL

OILOIL

OILOIL

OILOIL

OILOIL

OILOIL

R

SEALANTSEALANT


OILOIL

bezuue00000054

1 Upper cylinder block2 Oil jet valve3 Upper main bearing, thrust bearing

(See 01-10-32 Main Bearing Assembly Note)4 Crankshaft5 Lower main bearing

(See 01-10-32 Main Bearing Assembly Note) 6 Lower cylinder block

(See 01-10-33 Lower Cylinder Block Assembly Note)

7 Connecting rod8 Piston

9 Piston pin(See 01-10-34 Piston Pin Assembly Note)

10 Piston ring(See 01-10-36 Piston Ring Assembly Note)

11 Piston, connecting rod component(See 01-10-36 Piston, Connecting Rod Component Assembly Note)

12 Upper connecting rod bearing (See 01-10-36 Connecting Rod Bearing Assembly Note)

MECHANICAL

01-10–34

Main Bearing Assembly Note

CautionIf a main bearing is reused, mistaking the position and direction of the bearing could result in engine damage due to seizure or burning of the bearing. Using the identifier paint marks employed during removal, assemble the main bearings at the positions numbered when the journal was removed, and so that the painted areas are on the front sides.

1. Assemble the upper and lower main bearing as specified shown in the figure.

CautionIf the lower main bearing is not assembled according to the specification it could result in engine damage from seizure or burning of the bearing. Measure the bearing using a vernier caliper and assemble it within the specification.

Upper main bearing

Lower main bearing

13 Lower connecting rod bearing(See 01-10-36 Connecting Rod Bearing Assembly Note)

14 Connecting rod cap(See 01-10-37 Connecting Rod Cap Assembly Note)

MEASUREMENTAREA

5 {0

.2}

5 {0.2}

0.70—1.1{0.028—0.043}

mm {in}1.9—2.3{0.075—0.090}

1.9—2.3{0.075—0.090}

1.9—2.3{0.075—0.090}

1.8—2.2{0.071—0.086}

bezuue00000070

5 {0.2}

5 {0

.2}

MEASUREMENTAREA

1.8—2.2 {0.071—0.086}

2.45—2.85{0.097—0.112}

1.9—2.3{0.075—0.090}

1.9—2.3{0.075—0.090}

1.9—2.3{0.075—0.090}

mm {in}bezuue00000056

MECHANICAL

01-10–35

01-10

Lower Cylinder Block Assembly Note

CautionInstall the lower cylinder block before the applied silicone sealant starts to harden.

1. Apply silicone sealant to the lower cylinder block attachment side as shown in the figure.

2. Apply clean engine oil to the lower cylinder block installation bolts A.

3. Tighten the lower cylinder block installation bolts A in two steps in the order shown in the figure.

(1)Tightening torque24—26 N·m {2.5—2.6 kgf·m, 18—19 ft·lbf}

(2)Tightening angle42.5 —47.5

4. Tighten the lower cylinder block installation bolts B in the order shown in the figure.


2.0—6.0 mm {0.08—0.23 in}

SEALANTSEALANT

SEALANTSEALANT

bezuue00000057

9

8 7

5

4 3

10

6

1 2

A

A

A

A

A

A

A

A

A

A

bezuue00000058

B

9

8 7

5

43

10

6

1

2

B

B

B

B B

B

B

BB

bezuue00000059

MECHANICAL

01-10–36

5. Loosen bolts A and tighten the lower cylinder block installation bolts in two steps in the order shown a second time.


(2)Tightening angle42.5 —47.5

Piston Pin Assembly Note1. Assemble the SSTs as shown in the figure.

2. Adjust the SSTs (stopper bolt) to the L length.

Standard L length60.85 mm {2.396 in}

3. Point the end mark on the connecting rod and F- mark on the piston in the same direction as shown in the figure.

9

8 7

5

4 3

10

6

1 2

A

A

A

A

A

A

A

A

A

A

bezuue00000058

49 L011 006A

49 E011 001A 49 E011 002A

PISTON PIN

bezuue00000063

L

49 L011 001

49 L011 005

49 D011 002B

bezuue00000064

F-MARK

ALIGNMENT MARK

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MECHANICAL

01-10–37

01-10

4. Insert the assembled piston pin and the SSTs into the piston and the connecting rod.

5. Set the SSTs as shown in the figure.6. Press the piston pin into the piston and

connecting rod until the SST (guide) contacts the SST (stopper bolt) using the hydraulic press. If it is less than the specification, replace the piston pin or the connecting rod.

Pressure force2940—14700 N {300—1498 kg, 660—3297

lbf}

Piston Ring Assembly Note1. Assemble the oil ring.2. Install the second ring with the notch facing

downward.3. Install the top ring with scraper face side upward.

Piston, Connecting Rod Component Assembly Note

NoteAfter a piston with identification (F) on its upper end is installed, perform the PCM reprogramming, referring to the Workshop Manual, to prevent damage to the engine.

PISTON PIN

49 L011 006A

49 E011 001A

bezuue00000066

PISTON PIN

PISTON

CONNECTING ROD

49 E011 001A

49 L011 006A

49 L011 005

49 L011 001

bezuue00000067

bezuue00000068

PISTON UPPER VIEW

FRONT MARK

PISTON IDENTIFICATION MARK

ENGINEFRONT SIDE

bezuue00000060

MECHANICAL

01-10–38

1. Position the end gap of each oil ring as shown in the figure.

2. Insert the piston into the cylinder with the mark on top of the piston facing the front of the engine.

Connecting Rod Bearing Assembly Note

CautionIf a connecting rod bearing is reused, mistaking the position and direction of the bearing could result in engine damage due to seizure or burning of the bearing.Using the identifier paint marks employed during removal, assemble the main bearings at the positions numbered when the journal was removed, and so that the painted areas are on the front sides.

1. Install the connecting rod bearing to the connecting rod and the connecting rod cap as specified shown in the figure.

CautionIf the connecting rod bearing is not assembled according to the specification it could result in engine damage from seizure or burning of the bearing. Measure the bearing using a vernier caliper and install it within the specification.

Connecting Rod Cap Assembly Note1. Install the connecting rod cap with the knock pins and the alignment marks aligned.2. Tighten the connecting rod cap installation bolt in two steps.

(1)Tightening torque 23—26 N·m {2.4—2.6 kgf·m, 17—19 ft·lbf}

(2)Tightening angle 82.5 —97.5

End Of Sie

30° 30°PISTON PIN AXIS

LOWER OIL RING RAILUPPER OIL RING RAILOIL RING SPACER

bezuue00000061

ENGINE FRONT

PISTON FRONT MARK

bezuue00000062

2.40—2.80 mm{0.095—0.110 in}

ENGINE FRONT ENGINE FRONT

ROD SIDE CAP SIDE

2.40—2.80 mm{0.095—0.110 in}

bezuue00000069

MECHANICAL

01-10–39

01-10

CYLINDER BLOCK ASSEMBLY (II)id011000504100


.

MTX

9

8

5

4

10

11

2

R

R

R

1

16

14

15

1312

17

6

20—34{2.1—3.4, 15—25}

97—103{9.9—10, 72—75}

5.9—8.8 N·m{61—89 kgf·cm,53—77 in·lbf}

27—39{2.8—3.9, 20—28}

SST

SST

OILOIL

OILOIL

OILOIL

SST

SST

SST13

R

SEALANTSEALANT

N·m {kgf·m, ft·lbf}8—10 N·m{82—101 kgf·cm, 71—88 in·lbf}

R

R

19—25{2.0—2.5, 15—18}

12—15 N·m{123—152 kgf·cm, 107—132 in·lbf}

19—25{2.0—2.5, 15—18}

19—25{2.0—2.5, 15—18}

8—10 N·m{82—101 kgf·cm,71—88 in·lbf}

3

7

19

18

bezuue00000071

1 Oil pump body2 Control plunger3 Plunger spring4 Plunger plug5 Outer rotor

(See 01-10-39 Inner Rotor, Outer Rotor Assembly Note)

6 Inner rotor(See 01-10-39 Inner Rotor, Outer Rotor Assembly Note)

7 Oil pump cover8 Oil strainer9 Oil pan

(See 01-10-39 Oil Pan Assembly Note)10 Oil filter

(See 01-10-39 Oil Filter Assembly Note)

11 Rear oil seal(See 01-10-39 Rear Oil Seal Assembly Note)

12 End plate13 Drive plate (ATX), flywheel (MTX)

(See 01-10-40 Drive Plate (ATX), Flywheel (MTX) Assembly Note)

14 Oil pump(See 01-10-40 Oil Pump Assembly Note)

15 Water pump16 Oil separator17 Knock sensor

(See 01-10-41 Knock Sensor Assembly Note)18 Thermostat19 Thermostat cover

MECHANICAL

01-10–40

Inner Rotor, Outer Rotor Assembly Note1. Assemble the inner rotor and the outer rotor with

the punch marks aligned.

Oil Pan Assembly Note

CautionInstall the oil pan before the applied silicone sealant starts to harden.

1. Apply silicone sealant as shown in the figure.

Diameter2.0—6.0 mm {0.08—0.23 in}

2. Tighten the oil pan installation bolts in the order shown in the figure.

Tightening torque8—10 N·m {82—101 kgf·cm, 71—88 in·lbf}

Oil Filter Assembly Note1. Install the oil filter according to the instruction on

the package or side of the oil filter.

NoteTightening torque12—15 N·m {123—152 kgf·cm, 107—132 in·lbf}Angle tighteningWhen the O-ring contacts the oil filter installation

surface, turn the filter another one rotation.

PUNCH MARK

bezuue00000072

SEALANTSEALANT

bezuue00000073

98

7

54

3 106

1

2

15

16

14

13

11

12

bezuue00000074

49 G014 001OR COMMERCIALLY AVAILABLE CUP-TYPE OIL FILTER WRENCH

bezuue00000104

MECHANICAL

01-10–41

01-10

Rear Oil Seal Assembly Note1. Apply clean engine oil to a new rear oil seal.2. Insert the rear oil seal to the cylinder block by hand.3. Install the rear oil seal using the SST.

Drive Plate (ATX), Flywheel (MTX) Assembly Note1. Lock the drive plate (ATX) or flywheel (MTX)

against rotation using the SST.2. Tighten the flywheel installation bolts in two to

three passes in the order shown in the figure.

Oil Pump Assembly Note1. Install the gasket to the oil pump.2. Install the oil pump and gasket as a single unit.

49 E033 101

bezuue00000076

REAR OIL SEAL

0—0.50 mm {0—0.019 in}

CYLINDER BLOCK

bezuue00000077

49 E011 1A0

5

4

3

61

2

bezuue00000078

bezuue00000079

MECHANICAL

01-10–42

Knock Sensor Assembly Note1. Install the knock sensor using the SST.

End Of Sie

CYLINDER HEAD ASSEMBLY (I)id011000504300


.

49 H018 001

bezuue00000080

SST R

SST5

4

3

1

2

B3E0110E029

1 Valve seal(See 01-10-41 Valve Seal Assembly Note)

2 Valve3 Valve spring

4 Upper valve spring seat5 Valve keeper

(See 01-10-42 Valve Keeper Assembly Note)

MECHANICAL

01-10–43

01-10

Valve Seal Assembly Note1. Press in the valve seal to the valve guide by hand.2. Tap the SST shown in the figure using a plastic

hammer.

Valve Keeper Assembly Note1. Install the valve keeper using the SST.

End Of Sie

VALVE SEAL

49 T032 302

B3E0110E123

49 B012 0A2

49 0636 100B

b3e0110e124

MECHANICAL

01-10–44

CYLINDER HEAD ASSEMBLY (II)id011000504400


.

7

5 4

3

6

1

2

R

R


19—25{2.0—2.5,15—18}

50—60{5.1—6.1, 37—44}

18—22 {1.9—2.2, 14—16}+85˚—95˚

+85°—95°

OILOIL

12—14 N·m{123—142 kgf·cm, 107—123 in·lbf}

bezuue00000081

1 Cylinder head gasket2 Cylinder head

(See 01-10-43 Cylinder Head Assembly Note)3 Tappet4 Camshaft

(See 01-10-44 Camshaft Assembly Note)

5 Camshaft cap(See 01-10-44 Camshaft Assembly Note)

6 Camshaft sprocket, variable valve timing actuator(See 01-10-44 Camshaft Sprocket, Variable Valve Timing Actuator Assembly Note)

7 Water outlet

MECHANICAL

01-10–45

01-10

Cylinder Head Assembly Note1. Tighten the cylinder head installation bolts in

three steps in the order shown in the figure.


(2)Tightening angle85 —95

(3) Tightening angle85 —95

Camshaft Assembly Note

NoteInstall the camshaft with the No.1 camshaft positioned at TDC of the compression stroke.

1. Install the camshaft cap to the position shown in the figure, and temporarily tighten the No.2 and No.7 camshaft installation bolts.

2. Tighten the camshaft cap installation bolts in two to three passes uniformly in the order shown in the figure.

Tightening torque12—14 N·m {123—142 kgf·cm, 107—123

in·lbf}

Camshaft Sprocket, Variable Valve Timing Actuator Assembly Note1. Fix the camshaft using a suitable wrench on the

cast hexagon as shown in the figure.2. Tighten the camshaft sprockets and variable valve

timing actuator installation bolts.


End Of Sie

98

7

54

3

1

2 106bezuue00000082

1 2 3 4

5 7 86

9

8

7 5

4

3

10 6

1

2

19

18

17

15

1614

1311

12

20

bezuue00000083

bezuue00000084

MECHANICAL

01-10–46

TIMING CHAIN ASSEMBLYid011000505600


.

2

R

R

R

8—10 N·m{82—101 kgf·cm, 71—88 in·lbf}

15—22{1.6—2.2, 12—16}

7—10 N·m{72—101 kgf·cm, 62—88 in·lbf}

32—47{3.3—4.7, 24—34}

38—51{3.9—5.2, 29—37}

157—167{16.1—17, 116—123}

R

38—51{3.9—5.2,29—37}

SST

SST

SEALANTSEALANT

OILOIL

R

19—25{2.0—2.5, 15—18}

R

SEALANTSEALANT


12

R

1

6

34

8

10

9

11

7

13

1516 14

5

8—10 N·m{82—101 kgf·cm, 71—88 in·lbf}

8—10 N·m{82—101 kgf·cm, 71—88 in·lbf}

38—51{3.9—5.2, 29—37}

8—10 N·m{82—101 kgf·cm, 71—88 in·lbf}

19—25{2.0—2.5, 15—18}

19—25{2.0—2.5, 15—18}

19—25{2.0—2.5, 15—18}

bezuue00000085

1 Key2 Crankshaft sprocket3 Timing chain

(See 01-10-46 Timing Chain Assembly Note)4 Timing chain guide5 Timing chain tensioner arm6 Timing chain tensioner7 Engine front cover

(See 01-10-46 Engine Front Cover Assembly Note)8 Crankshaft pulley

(See 01-10-48 Crankshaft Pulley Installation Bolt Assembly Note)

9 OCV oil filter, plug10 Idler pulley11 OCV12 Oil level gauge pipe13 Drive belt auto tensioner14 Cylinder head cover

(See 01-10-48 Cylinder Head Cover Assembly Note)15 CMP sensor16 Spark plug

MECHANICAL

01-10–47

01-10

Timing Chain Assembly Note1. Align the key groove of the crankshaft sprocket to

the timing mark, and then position the No.1 cylinder to TDC.

2. Align the timing marks on the camshaft sprockets so that they form a straight line in alignment with the upper horizontal surface of the cylinder head.

3. Install the timing chain.4. Install the timing chain guide and timing chain

tensioner arm.

5. Install the chain adjuster and then remove the wire or paper clip used for fixing. (Remove the installed stopper when installing the new chain tensioner.)

6. Verify that there is no slack on the timing chain and then verify that each sprocket is positioned in the proper place again.

7. Inspect the valve timing by rotating the crankshaft clockwise twice.

Engine Front Cover Assembly Note

CautionInstall the engine front cover before the applied silicone sealant starts to harden.

1. Apply silicone sealant to the engine front cover as shown in the figure.

Diameter2—4 mm {0.08—0.15 in}

TIMING MARK

KEY GROOVE

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TIMING MARK CYLINDER HEAD UPPER SURFACE

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LINK PLATE

STOPPER

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SEALANT

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MECHANICAL

01-10–48

2. Tighten the engine front cover installation bolts in the order shown in the figure.

Install bolt (1) using a new seal washer.

3. Install the oil seal using the SST.

Position Tightening torque

9 8—10 N·m {82—101 kgf·cm, 71—88 in·lbf}

1—6, 8, 10, 12—15, 17, 18 19—25 N·m {2.0—2.5 kgf·m, 15—18 ft·lbf}

7, 11, 16 38—51 N·m {3.9—5.2 kgf·m, 29—37 ft·lbf}

98

7

5 4

3

12

10

18

17

15 16

14

13

1112

6

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FRONT OIL SEAL

49 H010 401

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HAMMER

FRONT OILSEAL

ENGINE FRONT COVER

49 H010 401

0—0.50 mm {0—0.019 in}

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MECHANICAL

01-10–49

01-10

4. Install the oil filter to the plug and insert it in the front cover as shown in the figure.


Crankshaft Pulley Installation Bolt Assembly Note1. Lock the drive plate (ATX) or flywheel (MTX)

against rotation using the SST.2. Tighten the crankshaft pulley installation bolt.

Tightening torque157—167 N·m {16.1—17 kgf·m, 116—123

ft·lbf}

Cylinder Head Cover Assembly Note

CautionInstall the cylinder head cover before the applied silicone sealant starts to harden.

1. Apply silicone sealant as shown in the figure.

Diameter2—6 mm {0.1—0.2 in}

Length6—26 mm {0.3—1.0 in}

PLUGFILTER FRONT COVER

ALUMINUM WASHER

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49 E011 1A0

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SEALANTSEALANT

SEALANTSEALANT

2.0— 6.0 mm{0.1—0.2 in}

6 —26 mm{0.3—1.0 in}

FRONT COVER MATING FACES

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MECHANICAL

01-10–50

2. Tighten the cylinder head cover installation bolts in the order shown in the figure.

Tightening torque 7—10 N·m {72—101 kgf·cm, 62—88 in·lbf}

End Of Sie

9 8

7

5

4

3

1

2

10 6bezuue00000106

TECHNICAL DATA

01-50–1

01-50

01-50 TECHNICAL DATAENGINE TECHNICAL DATA . . . . . . . . . . 01-50–1

End of TocWM: ENGINEENGINE TECHNICAL DATA

id015000800100

Item SpecificationCylinder head maximum distortion, head gasket side 0.10 mm {0.0039 in}Cylinder head maximum distortion, manifold side 0.05 mm {0.002 in}Cylinder head maximum grinding, manifold side 0.20 mm {0.0079 in}Valve seat standard contact width 0.8—1.4 mm {0.04—0.05 in}Valve seat angle 45°Valve seat standard sinkage amount (Dimension L) 39.25 mm {1.545 in}Valve head standard margin thickness 1.6—2.0 mm {0.063—0.078 in}

Valve length (Dimension L)

StandardIN: 96.80—97.40 mm {3.812—3.834 in}EX: 96.30—96.90 mm {3.792—3.814 in}

MinimumIN: 96.58 mm {3.802 in}EX: 96.08 mm {3.783 in}

Valve stem diameter



Valve guide standard inner diameter 5.510—5.530 mm {0.2170—0.2177 in}

Clearance between valve stem and guide


Maximum0.1 mm {0.004 in}

Valve guide standard projection height 12.2—12.8 mm {0.481—0.503 in}Valve spring standard height 27.5 mm {1.08 in} (pressing force 262.8 N {26.80 kgf, 59.08 lbf}Maximum valve spring off-square 2.0° (3.45 mm {0.136 in})Standard tappet bore diameter 30.0—30.025 mm {1.1812—1.1820 in}Standard tappet body outer diameter 29.959—29.975 mm {1.1795—1.1801 in}

Clearance between tappet and tappet bore

Standard0.025—0.066 mm {0.0010—0.0025 in}


OCV coil resistance 6.9—7.9 ohms [20°C {68°F}]Camshaft maximum runout 0.03 mm {0.001 in}

Cam lobe height

StandardIN: 41.373 mm {1.6289 in}EX: 40.597 mm {1.5983 in}


Camshaft journal diameter

Standard25.950—25.975 mm {1.0217—1.0226 in}

Minimum24.910 mm {0.98071 in}

Camshaft journal oil clearance

Standard0.025—0.071 mm {0.0010—0.0027 in}


Camshaft end play

Standard0.07—0.19 mm {0.003—0.007 in}



TECHNICAL DATA

01-50–2

Cylinder block maximum distortion, head gasket side 0.10 mm {0.0039 in}Standard cylinder bore diameter 78.000—78.013 mm {3.0709—3.0713 in}Piston outer diameter 77.970—77.980 mm {3.0697—3.0700 in}

Clearance between piston and cylinder

Standard0.020—0.043 mm {0.0008—0.0016 in}


Clearance between piston ring and ring groove

StandardTop: 0.035—0.065 mm {0.0014—0.0025 in}

Second: 0.030—0.070 mm {0.0012—0.0027 in}Oil: 0.040—0.120 mm {0.0016—0.0047 in}

MaximumTop, Second: 0.150 mm {0.0059 in}

Oil: 0.20 mm {0.0079 in}

Piston ring end gap

StandardTop: 0.14—0.24 mm {0.0056—0.0094 in}

Second: 0.24—0.37 mm {0.010—0.014 in}Oil: 0.10—0.35 mm {0.004—0.013 in}


Standard piston pin hole diameter 18.988—19.000 mm {0.74756—0.74803 in}Standard piston pin outer diameter 18.974—18.980 mm {0.74701—0.74724 in}Standard clearance between piston pin hole and piston pin 0.008—0.026 mm {0.0004—0.0010 in}

Side clearance at the large end of the connecting rod

Standard0.110—0.292 mm {0.0044—0.0114 in}


Bearing oil clearance at the large end of connecting rod

Standard0.016—0.037 mm {0.0007—0.0014 in}


Connecting rod bearing thickness (Center thickness)STD: 1.509—1.524 mm {0.0594—0.0599 in}

OS 0.25: 1.629—1.637 mm {0.0642—0.0644 in}OS 0.50: 1.729—1.737 mm {0.0681—0.0683 in}

Standard connecting rod small end inner diameter 18.943—18.961 mm {0.74579—0.74649 in}Standard clearance between connecting rod small end and piston pin –0.037—–0.013 mm {–0.0014—–0.0006 in}

Connecting rod maximum bending 0.050 mm {0.0020 in}[Per 50 mm {2.0 in}]Connecting rod maximum distortion 0.075 mm {0.0030 in}[Per 50 mm {2.0 in}]Connecting rod center-to-center distance 140.60—140.70 mm {5.536—5.539 in}

Thrust bearing thickness

STD: 2.500—2.550 mm {0.0985—0.1003 in}OS 0.25: 2.625—2.675 mm {0.1034—0.1053 in}OS 0.50: 2.750—2.800 mm {0.1083—0.1102 in}OS 0.75: 2.875—2.925 mm {0.1132—0.1151 in}

Crankshaft end play

Standard0.080—0.282 mm {0.0032—0.0111 in}


Crankshaft main journal maximum runout 0.10 mm {0.0039 in}

Crankshaft main journal diameterSTD: 49.938—49.956 mm {1.9661—1.9667 in}

OS 0.25: 49.688—49.706 mm {1.9563—1.9569 in}OS 0.50: 49.438—49.456 mm {1.9464—1.9470 in}

Crankshaft main journal maximum off-round 0.050 mm {0.0020 in}

Crank pin journal diameterSTD: 47.940—47.956 mm {1.8875—1.8880 in}

OS 0.25: 47.690—47.706 mm {1.8776—1.8781 in}OS 0.50: 47.440—47.456 mm {1.8678—1.8683 in}

Crank pin journal maximum off-round 0.10 mm {0.0039 in}

Crankshaft main journal oil clearance

Standard0.019—0.038 mm {0.0008—0.0014 in}

Maximum 0.084 mm {0.0033 in}

Item Specification


TECHNICAL DATA

01-50–3

01-50

End Of Sie

Main bearing thicknessSTD: 2.508—2.529 mm {0.09875—0.09956 in}

OS 0.25: 2.625—2.635 mm {0.1034—0.1037 in}OS 0.50: 2.750—2.760 mm {0.1083—0.1086 in}

Cylinder head bolt length Standard: 128.9—129.5 mm {5.075 —5.098 in}Maximum: 130.2 mm {5.126 in}

Connecting rod bolt length Standard: 46.7—47.3 mm {1.84—1.86 in}Maximum: 48.0 mm {1.89 in}

Tip clearance between inner rotor and outer rotor Standard: 0.02—0.18 mm {0.0008—0.0070 in}Maximum: 0.20 mm {0.0079 in}

Body clearance between outer rotor and oil pump body

Standard: 0.090—0.175 mm {0.0036—0.0068 in}Maximum: 0.20 mm {0.0079 in}

Oil pump side clearance Standard: 0.03—0.07 mm {0.0012—0.0027 in}Maximum: 0.090 mm {0.0035 in}

Weight at which the plunger spring height is compressed to 35.42 mm {1.394 in} 62.5—68.9 N {6.38—7.02 kgf, 14.1—15.4 lbf}

Standard valve clearance [Engine cold] 0.27—0.33 mm {0.011—0.012 in}

Item Specification



SERVICE TOOLS

01-60–1

01-60

01-60 SERVICE TOOLSENGINE SST . . . . . . . . . . . . . . . . . . . . . . 01-60–1

End of TocSOKYU_WM: ENGINEENGINE SST

id016000119200

1: Mazda SST number2: Global SST numberExample1: 49 0107 680A2: —

Engine stand

1: 49 0107 680A2: —

Engine stand

1: 49 L010 1A02: —

Engine hanger set

1: 49 E011 1A02: —

Ring gear brake set

1: 49 0636 100B2: —

Valve spring lifter arm

1: 49 B012 0A22: —

Pivot

1: 49 S120 1702: —

Valve seal remover

1: 49 H018 0012: —

Knock sensor wrench

1: 49 G014 0012: —

Oil filter wrench

1: 49 L011 0A0C2: —

Piston pin setting set

1: 49 E011 001A2: —

Piston pin guide

1: 49 E011 002A2: —

Screw

1: 49 B012 0152: —

Valve guide installer

1: 49 L012 0A0B2: —

Valve seal and valve guide installer set

1: 49 E033 1012: —

Dust cover installer

1: 49 T032 3022: —

Bearing installer

1993-1U-10E(01-60).fm 1 ページ２０１０年５月１２日　水曜日　午後２時６分

SERVICE TOOLS

01-60–2

End Of Sie

1: 49 H010 4012: —

Oil seal installer— —

1993-1U-10E(01-60).fm 2 ページ２０１０年５月１２日　水曜日　午後２時６分

1993-1U-10E

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