1. business and industrial
2. energy
3. oil

1993-1U-10E(INDEX).fm 1 ページ
２０１０年５月１２日　水曜日　午後２時１４分
Engine
Workshop
Manual
MZR 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 Corporation
HIROSHIMA, JAPAN
CONTENTS
Title
Section
GENERAL INFORMATION
00
ENGINE
01
© 2010 Mazda Motor Corporation
PRINTED IN U.S.A., MAY 2010
Form No. 1993–1U–10E
Part No. 9999–95–MZR–11
WARNING(US).fm
1 ページ
２０１０年３月１１日　木曜日　午後１時２８分
WARNING
Servicing 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.
1993-1U-10F.book
1 ページ
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GENERAL INFORMATION
00
SECTION
Toc
of SCT INFORMATION . . . . 00-00
GENERAL
Toc of SCT
00-00
GENERAL INFORMATION
UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-00–1
Conversion to SI Units
(Système International d'Unités) . . . . . 00-00–2
Rounding Off . . . . . . . . . . . . . . . . . . . . . 00-00–2
Upper and Lower Limits . . . . . . . . . . . . 00-00–2
HOW TO USE THIS MANUAL . . . . . . . . . 00-00–2
Range of Topics . . . . . . . . . . . . . . . . . . 00-00–2
Service Procedure . . . . . . . . . . . . . . . . 00-00–2
Symbols . . . . . . . . . . . . . . . . . . . . . . . . 00-00–3
Advisory Messages. . . . . . . . . . . . . . . . 00-00–4
ELECTRICAL SYSTEM . . . . . . . . . . . . . . 00-00–5
Connectors . . . . . . . . . . . . . . . . . . . . . . 00-00–5
ABBREVIATIONS. . . . . . . . . . . . . . . . . . . 00-00–6
FUNDAMENTAL PROCEDURES. . . . . . . 00-00–6
Preparation of Tools and
Measuring Equipment . . . . . . . . . . . .
Special Service Tools . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . .
Inspection During Removal,
Disassembly . . . . . . . . . . . . . . . . . . . .
Arrangement of Parts . . . . . . . . . . . . . .
Cleaning of Parts . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . .
Adjustment . . . . . . . . . . . . . . . . . . . . . .
Rubber Parts and Tubing . . . . . . . . . . .
Hose Clamps . . . . . . . . . . . . . . . . . . . .
Torque Formulas . . . . . . . . . . . . . . . . .
Vise . . . . . . . . . . . . . . . . . . . . . . . . . . .
NEW STANDARDS . . . . . . . . . . . . . . . . .
00-00–6
00-00–6
00-00–7
00-00–7
00-00–7
00-00–7
00-00–8
00-00–8
00-00–8
00-00–9
00-00–9
00-00–9
00-00–9
End of Toc
NG: GENERAL INFORMATION
00-00–1
00-00
1993-1U-10F.book
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GENERAL INFORMATION
UNITS
Electric current
Electric power
Electric resistance
Electric voltage
Length
Negative pressure
Positive pressure
Number of
revolutions
Torque
Volume
Weight
id000000100400
A (ampere)
W (watt)
ohm
V (volt)
mm (millimeter)
in (inch)
kPa (kilo pascal)
mmHg (millimeters of mercury)
inHg (inches of mercury)
kPa (kilo pascal)
kgf/cm2 (kilogram force per square
centimeter)
psi (pounds per square inch)
rpm (revolutions per minute)
N·m (Newton meter)
kgf·m (kilogram force meter)
kgf·cm (kilogram force centimeter)
ft·lbf (foot pound force)
in·lbf (inch pound force)
L (liter)
US qt (U.S. quart)
Imp qt (Imperial quart)
ml (milliliter)
cc (cubic centimeter)
cu in (cubic inch)
fl oz (fluid ounce)
g (gram)
oz (ounce)
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 Sie
WM: GENERAL INFORMATION
00-00–2
1993-1U-10F.book
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GENERAL INFORMATION
HOW TO USE THIS MANUAL
id000000000100
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 Procedure
Inspection, 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.
SHOWS PROCEDURE ORDER
FOR SERVICE
Fluid Pressure Inspection
1. Assemble the SSTs as shown in the figure.
Tightening torque
39—49 N·m {4.0—5.0 kgf·m, 29—36 ft·lbf}
49 1232 670A
49 H002 671
49 H032 322
SHOWS TIGHTENING
TORQUE
SPECIFICATIONS
Caution
Connect the gauge set from under
the vehicle to prevent contact with
the drive belt and the cooling fan.
WGIWXX0009E
00-00–3
00-00
1993-1U-10F.book
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GENERAL INFORMATION
Repair procedure
1. 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.
SHOWS SERVICE
ITEM (S)
Procedure
1
"Removal/Installation"
Portion
"Inspection After
Installation" Portion
2
INDICATES ANY RELEVANT
REFERENCES WHICH NEED
TO BE FOLLOWED DURING
INSTALLATION
LOWER TRAILING LINK, UPPER TRAILING LINK REMOVAL/INSTALLATION
1. 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.
11
INSTALL THE PARTS BY
PERFORMING STEPS
— IN REVERSE ORDER
1—3
12 SST
8
10
7
44—60 {4.4—6.2, 32—44}
R
GREASE
SHOWS PROCEDURE ORDER
FOR SERVICE
SHOWS SPECIAL
SERVICE TOOL (SST)
FOR SERVICE OPERATION
SST
9
43—56 {4.3—5.8, 32—41}
SHOWS APPLICATION
POINTS OF GREASE, ETC.
R
SHOWS TIGHTENING
TORQUE
SPECIFICATIONS
SHOWS NON-REUSEABLE PARTS
SST
3
5
SHOWS DETAILS
6
SST
94—116 {9.5—11.9, 69—86}
GREASE
4
R
2
SHOWS THERE
ARE REFERRAL
NOTES FOR SERVICE
1
2
3
4
5
6
1
118—156 {12.0—16.0, 87—115}
R
SHOWS TIGHTENING
TORQUE UNITS
N·m {kgf·m, ft·lbf}
Split pin
Nut
Lower trailing link ball joint
(See 02-14-5 Lower Trailing Link Ball Joint Removal Note)
Bolt
Lower trailing link
Dust boot (lower trailing link)
Lower Trailing Link Ball Joint, Upper Trailing Link
Ball Joint Removal Note
Remove the ball joint using the SSTs.
7
8
9
10
11
12
Split pin
Nut
Upper trailing link ball joint
(See 02-14-5 Upper Trailing Link Ball Joint Removal Note)
Nut
Upper trailing link
Dust boot (upper trailing link)
49 T028 304
49 T028 305
UPPER TRAILING LINK
LOWER TRAILING LINK
SHOWS SPECIAL
SERVICE TOOL (SST)
NO.
KNUCKLE
49 T028 303
SHOWS REFERRAL
NOTES FOR
SERVICE
BHE0000W104
00-00–4
1993-1U-10F.book
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GENERAL INFORMATION
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.
Symbol
Meaning
Kind
Apply oil
New 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
P
Apply petroleum
jelly
Appropriate
petroleum jelly
R
Replace part
O-ring, gasket,
etc.
SST
Use SST or
equivalent
Appropriate tools
OIL
BRAKE
FLUID
ATF
GREASE
SEALANT
00-00
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
00-00–5
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GENERAL INFORMATION
ELECTRICAL SYSTEM
Connectors
Disconnecting connectors
• When disconnecting connector, grasp the
connectors, not the wires.
id000000000500
GOOD
NO GOOD
CHU0000W014
• Connectors can be disconnected by pressing or
pulling the lock lever as shown.
WGIWXX0042E
Locking connector
• When locking connectors, listen for a click
indicating they are securely locked.
WGIWXX0043E
00-00–6
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GENERAL INFORMATION
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.
GOOD
NO GOOD
00-00
Caution
• To prevent damage to the terminal, wrap
a thin wire around the tester probe before
inserting into terminal.
CHU0000W011
End Of Sie
GOOD
NO GOOD
CHU0000W012
ABBREVIATIONS
ATX
CMP
EX
IN
MTX
OCV
OS
SST
STD
TDC
id000000010100
Automatic Transaxle
Camshaft Position
Exhaust
Intake
Manual Transaxle
Oil Control Valve
Over Size
Special Service Tool
Standard
Top Dead Center
End Of Sie
GAIHAN: -
00-00–7
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GENERAL INFORMATION
FUNDAMENTAL PROCEDURES
id000000750100
Preparation of Tools and Measuring Equipment
• Be sure that all necessary tools and measuring
equipment are available before starting any work.
CHU0014W003
Special Service Tools
• Use special service tools or equivalent when they
are required.
49 SE01 310
WGIWXX0024E
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.
WGIWXX0027E
Inspection During Removal, Disassembly
• When removed, each part should be carefully
inspected for malfunction, deformation, damage
and other problems.
WGIWXX0028E
00-00–8
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GENERAL INFORMATION
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.
00-00
WGIWXX0029E
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.
WGIWXX0030E
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
WGIWXX0031E
• 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.
CHU0014W006
00-00–9
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GENERAL INFORMATION
Adjustment
• Use suitable gauges and testers when making
adjustments.
CHU0014W005
Rubber Parts and Tubing
• Prevent gasoline or oil from getting on rubber
parts or tubing.
WGIWXX0034E
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.
WGIWXX0035E
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.
SST
3
2
1
0
1
2
3
Torque Unit
N·m
kgf·m
kgf·cm
ft·lbf
in·lbf
Formula
N·m × [L/(L+A)]
kgf·m × [L/(L+A)]
kgf·cm × [L/(L+A)]
ft·lbf × [L/(L+A)]
in·lbf × [L/(L+A)]
A : The length of the SST past the torque wrench drive.
L : The length of the torque wrench.
00-00–10
A
L
WGIWXX0036E
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GENERAL INFORMATION
Vise
• When using a vise, put protective plates in the
jaws of the vise to prevent damage to parts.
End Of Sie
EN: GENERAL INFORMATION
00-00
PROTECTIVE PLATES
CHU0014W010
NEW STANDARDS
id000000157100
• Following is a comparison of the previous standard and the new standard.
Abbrevi-ation
AP
ACL
A/C
BARO
B+
—
—
CMP sensor
CAC
CLS
CTP
CPP
CIS
CS sensor
CKP sensor
DLC
DTM
DTC
DI
DLI
EI
ECT
EM
—
EVAP
EGR
FC
FF
4GR
—
FSO solenoid
GEN
GND
HO2S
IAC
—
—
—
—
New Standard
Name
Accelerator Pedal
Air Cleaner
Air Conditioning
Barometric Pressure
Battery Positive Voltage
Brake Switch
Calibration Resistor
Camshaft Position Sensor
Charge Air Cooler
Closed Loop System
Closed Throttle Position
Clutch Pedal Position
Continuous Fuel Injection System
Control Sleeve Sensor
Crankshaft Position Sensor
Data Link Connector
Diagnostic Test Mode
Diagnostic Trouble Code(s)
Distributor Ignition
Distributorless Ignition
Electronic Ignition
Engine Coolant Temperature
Engine Modification
Engine Speed Input Signal
Evaporative Emission
Exhaust Gas Recirculation
Fan Control
Flexible Fuel
Fourth Gear
Fuel Pump Relay
Fuel Shut Off Solenoid
Generator
Ground
Heated Oxygen Sensor
Idle Air control
IDM Relay
Incorrect Gear Ratio
Injection Pump
Input/Turbine Speed Sensor
Abbrevi-ation
—
—
—
—
Vb
—
—
—
—
—
—
—
—
CSP sensor
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
FCV
—
—
—
—
—
—
FIP
—
Previous Standard
Name
Accelerator Pedal
Air Cleaner
Air Conditioning
Atmospheric Pressure
Battery Voltage
Stoplight Switch
Corrected Resistance
Crank Angle Sensor
Intercooler
Feedback System
Fully Closed
Idle Switch
Clutch Position
Control Sleeve Position Sensor
Crank Angle Sensor 2
Diagnosis Connector
Test Mode
Service Code(s)
Spark Ignition
Direct Ignition
Electronic Spark Ignition
Water Thermo
Engine Modification
Engine RPM Signal
Evaporative Emission
Exhaust Gas Recirculation
Fan Control
Flexible Fuel
Overdrive
Circuit Opening Relay
Fuel Cut Valve
Alternator
Ground/Earth
Oxygen Sensor
Idle Speed Control
Spill Valve Relay
—
Fuel Injection Pump
Pulse Generator
Remark
#6
#6
#1
#2
#3
#6
With heater
#6
#6
00-00–11
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GENERAL INFORMATION
Abbrevi-ation
IAT
KS
MIL
MAP
MAF sensor
MFL
OBD
OL
—
OC
O2S
PNP
—
PSP
PCM
—
PAIR
—
AIR
SAPV
SFI
New Standard
Name
Intake Air Temperature
Knock Sensor
Malfunction Indicator Lamp
Manifold Absolute Pressure
Mass Air Flow Sensor
Multiport Fuel Injection
On-Board Diagnostic
Open Loop
Output Speed Sensor
Oxidation Catalytic Converter
Oxygen Sensor
Park/Neutral Position
PCM Control Relay
Power Steering Pressure
Powertrain Control Module
Pressure Control Solenoid
—
Secondary Air Injection System
Pump Speed Sensor
—
NE Sensor
Secondary Air Injection
—
Secondary Air Injection System
Secondary Air Pulse Valve
Sequential Multipoint Fuel Injection
Shift Solenoid A
—
Shift Solenoid B
TCM
—
TR
TC
VSS
VR
VAF sensor
WUTWC
WOT
Previous Standard
Name
Intake Air Thermo
Knock Sensor
Malfunction Indicator Light
Intake Air Pressure
Airflow Sensor
Multiport Fuel Injection
Diagnosis/Self-Diagnosis
Open Loop
Vehicle Speed Sensor 1
Catalytic Converter
Oxygen Sensor
Park/Neutral Range
Main Relay
Power Steering Pressure
Engine Control Unit
Line Pressure Solenoid Valve
Pulsed Secondary Air Injection
—
—
3GR
TWC
TB
TP sensor
TCV
TCC
Abbrevi-ation
—
—
—
—
—
—
—
—
—
—
—
—
—
—
ECU
—
Shift Solenoid C
Third Gear
Three Way Catalytic Converter
Throttle Body
Throttle Position Sensor
Timer Control Valve
Torque Converter Clutch
Transmission (Transaxle) Control
Module
Transmission (Transaxle) Fluid
Temperature Sensor
Transmission (Transaxle) Range
Turbocharger
Vehicle Speed Sensor
Voltage Regulator
Volume Air Flow Sensor
Warm Up Three Way Catalytic
Converter
Wide Open Throttle
—
—
—
—
—
—
—
—
—
—
—
TCV
—
Reed Valve
Sequential Fuel Injection
12 Shift Solenoid Valve
Shift A Solenoid Valve
23 Shift Solenoid Valve
Shift B Solenoid Valve
34 Shift Solenoid Valve
3rd Gear
Catalytic Converter
Throttle Body
Throttle Sensor
Timing Control Valve
Lockup Position
—
EC-AT Control Unit
—
ATF Thermo-sensor
—
—
—
—
—
Inhibitor Position
Turbocharger
Vehicle Speed Sensor
IC Regulator
Air flow Sensor
—
Catalytic Converter
—
Fully Open
Remark
#6
#4
Pulsed
injection
#6
Injection
with air
pump
#6
#5
#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 engine
End Of Sie
00-00–12
7(DQQMࡍ࡯ࠫ㧞㧜㧝㧜ᐕ㧠᦬㧝㧢ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧡㧣ಽ
ENGINE
01
SECTION
01-10
Toc
of SCT
MECHANICAL.
. . . . . . . . . . . . . 01-10
SERVICE TOOLS . . . . . . . . . . . 01-60
TECHNICAL DATA . . . . . . . . . . 01-50
Toc of SCT
01-10
MECHANICAL
ENGINE OVERHAUL
SERVICE WARNING . . . . . . . . . . . . . . . 01-10–1
ENGINE
MOUNTING/DISMOUNTING . . . . . . . . . 01-10–2
Mounting . . . . . . . . . . . . . . . . . . . . . . . . 01-10–2
Dismounting . . . . . . . . . . . . . . . . . . . . . 01-10–3
TIMING CHAIN DISASSEMBLY. . . . . . . . 01-10–3
Crankshaft Pulley Installation Bolt
Disassembly Note . . . . . . . . . . . . . . . . 01-10–4
Engine Front Cover
Disassembly Note . . . . . . . . . . . . . . . . 01-10–4
Timing Chain Tensioner
Disassembly Note . . . . . . . . . . . . . . . . 01-10–4
CYLINDER HEAD DISASSEMBLY (I) . . . 01-10–5
Camshaft Sprocket, Variable Valve
Timing Actuator Disassembly Note . . . 01-10–6
Camshaft Cap Disassembly Note . . . . . 01-10–6
Tappet Disassembly Note . . . . . . . . . . . 01-10–6
Cylinder Head Disassembly Note . . . . . 01-10–6
CYLINDER HEAD
DISASSEMBLY (II) . . . . . . . . . . . . . . . . . 01-10–7
Valve Keeper Disassembly Note . . . . . . 01-10–8
Valve Seal Disassembly Note . . . . . . . . 01-10–8
CYLINDER BLOCK
DISASSEMBLY (I) . . . . . . . . . . . . . . . . . 01-10–8
Knock Sensor Disassembly Note . . . . . 01-10–10
Drive Plate (ATX), Flywheel (MTX)
Disassembly Note . . . . . . . . . . . . . . . . 01-10–10
Oil Filter Disassembly Note . . . . . . . . . . 01-10–10
Oil 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 . . . . . . . . 01-10–12
Lower Cylinder Block
Disassembly Note . . . . . . . . . . . . . . . . 01-10–13
CYLINDER HEAD INSPECTION . . . . . . . 01-10–14
VALVE SEAT INSPECTION/REPAIR . . . . 01-10–15
VALVE, VALVE GUIDE INSPECTION . . . 01-10–15
VALVE GUIDE REPLACEMENT . . . . . . . 01-10–17
Removal . . . . . . . . . . . . . . . . . . . . . . . . 01-10–17
Installation . . . . . . . . . . . . . . . . . . . . . . . 01-10–17
VALVE SPRING INSPECTION . . . . . . . . . 01-10–18
TAPPET INSPECTION . . . . . . . . . . . . . . . 01-10–18
VARIABLE VALVE TIMING ACTUATOR
INSPECTION . . . . . . . . . . . . . . . . . . . . . 01-10–19
OIL CONTROL VALVE (OCV)
INSPECTION . . . . . . . . . . . . . . . . . . . . .
Coil Resistance Inspection . . . . . . . . . .
Spool Valve Operation Inspection . . . .
CAMSHAFT INSPECTION . . . . . . . . . . .
CYLINDER BLOCK INSPECTION . . . . .
OIL JET VALVE INSPECTION . . . . . . . .
PISTON, PISTON RING, PISTON PIN
INSPECTION . . . . . . . . . . . . . . . . . . . . .
CONNECTING ROD INSPECTION . . . . .
CRANKSHAFT INSPECTION . . . . . . . . .
BOLT INSPECTION . . . . . . . . . . . . . . . . .
OIL PUMP INSPECTION . . . . . . . . . . . . .
VALVE CLEARANCE INSPECTION . . . .
VALVE CLEARANCE
ADJUSTMENT. . . . . . . . . . . . . . . . . . . .
CYLINDER BLOCK ASSEMBLY (I) . . . .
Main Bearing Assembly Note . . . . . . . .
Lower Cylinder Block
Assembly Note . . . . . . . . . . . . . . . . . .
Piston Pin Assembly Note . . . . . . . . . .
Piston Ring Assembly Note . . . . . . . . .
Piston, Connecting Rod Component
Assembly Note . . . . . . . . . . . . . . . . . .
Connecting Rod Bearing
Assembly Note . . . . . . . . . . . . . . . . . .
Connecting Rod Cap
Assembly Note . . . . . . . . . . . . . . . . . .
CYLINDER BLOCK ASSEMBLY (II) . . . .
Inner Rotor, Outer Rotor
Assembly Note . . . . . . . . . . . . . . . . . .
Oil Pan Assembly Note. . . . . . . . . . . . .
Oil Filter Assembly Note. . . . . . . . . . . .
Rear Oil Seal Assembly Note. . . . . . . .
Drive Plate (ATX), Flywheel (MTX)
Assembly Note . . . . . . . . . . . . . . . . . .
Oil Pump Assembly Note . . . . . . . . . . .
Knock Sensor Assembly Note . . . . . . .
CYLINDER HEAD ASSEMBLY (I). . . . . .
Valve Seal Assembly Note . . . . . . . . . .
Valve Keeper Assembly Note . . . . . . . .
CYLINDER HEAD ASSEMBLY (II) . . . . .
Cylinder Head Assembly Note . . . . . . .
Camshaft Assembly Note. . . . . . . . . . .
Camshaft Sprocket, Variable Valve
Timing Actuator Assembly Note . . . . .
TIMING CHAIN ASSEMBLY . . . . . . . . . .
Timing Chain Assembly Note . . . . . . . .
01-10–19
01-10–19
01-10–19
01-10–20
01-10–21
01-10–21
01-10–22
01-10–23
01-10–24
01-10–26
01-10–26
01-10–27
01-10–27
01-10–31
01-10–32
01-10–33
01-10–34
01-10–36
01-10–36
01-10–36
01-10–37
01-10–37
01-10–39
01-10–39
01-10–39
01-10–39
01-10–40
01-10–40
01-10–41
01-10–41
01-10–41
01-10–42
01-10–42
01-10–43
01-10–44
01-10–44
01-10–44
01-10–46
01-10–1
7(DQQMࡍ࡯ࠫ㧞㧜㧝㧜ᐕ㧠᦬㧝㧢ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧡㧣ಽ
MECHANICAL
Engine Front Cover Assembly Note . . . 01-10–46
Crankshaft Pulley Installation Bolt
Assembly Note . . . . . . . . . . . . . . . . . . 01-10–48
Cylinder Head Cover
Assembly Note . . . . . . . . . . . . . . . . . . 01-10–48
End of Toc
ENGINE OVERHAUL SERVICE WARNING
EN: ENGINE COMPLETE
id011000503900
Warning
x Continuous 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 Sie
ENGINE MOUNTING/DISMOUNTING
id011000507000
Mounting
1. Install the SSTs (arms) to the specified position
as shown, and hand-tighten the SST bolts.
49 L010 102
49 L010 106
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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 101
49 L010 104
49 L010 105
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01-10–2
7(DQQMࡍ࡯ࠫ㧞㧜㧝㧜ᐕ㧠᦬㧝㧢ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧡㧣ಽ
MECHANICAL
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.
Warning
x The 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.
49 L010 106
PARALLEL
49 L010 101
49 L010 102
49 L010 105
ENGINE
49 L010 104
49 L010 103 APPROX. 20 mm {0.79 in}
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Tightening torque
30—41 N·m {3.1—4.1 kgf·m, 23—30 ft·lbf}
Dismounting
1. Dismount in the reverse order of mounting.
End Of Sie
01-10–3
01-10
7(DQQMࡍ࡯ࠫ㧞㧜㧝㧜ᐕ㧠᦬㧝㧢ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧡㧣ಽ
MECHANICAL
TIMING CHAIN DISASSEMBLY
id011000505500
1. Disassemble in the order indicated in the table.
4
1
2
R
10
R
6
3
R
R
R
R
8
7
R
SST
9
5
11
R
12
16
15
13
14
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.
1
2
3
4
5
6
7
8
9
Spark plug
Camshaft position (CMP) sensor
Cylinder head cover
Drive belt auto tensioner
Oil level gauge pipe
Oil control valve (OCV)
Idler pulley
OCV oil filter, plug
Crankshaft pulley
(See 01-10-4 Crankshaft Pulley Installation Bolt
Disassembly Note)
01-10–4
10
11
12
13
14
15
16
Engine front cover
(See 01-10-4 Engine Front Cover Disassembly Note)
Timing chain tensioner
(See 01-10-4 Timing Chain Tensioner Disassembly
Note)
Timing chain tensioner arm
Timing chain guide
Timing chain
Crankshaft sprocket
Key
7(DQQMࡍ࡯ࠫ㧞㧜㧝㧜ᐕ㧠᦬㧝㧢ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧡㧣ಽ
MECHANICAL
Crankshaft Pulley Installation Bolt Disassembly Note
1. Lock the drive plate (ATX) or flywheel (MTX)
against rotation using the SST.
2. Remove the crankshaft pulley installation bolt.
49 E011 1A0
01-10
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Engine Front Cover Disassembly Note
1. Remove the oil seal using a flathead screwdriver.
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Timing Chain Tensioner Disassembly Note
1. Push down the link plate of the timing chain
tensioner using a thin flathead screwdriver
(precision screwdriver) and release the plunger
lock.
PLUNGER
LINK PLATE
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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.
LINK PLATE
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01-10–5
7(DQQMࡍ࡯ࠫ㧞㧜㧝㧜ᐕ㧠᦬㧝㧢ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧡㧣ಽ
MECHANICAL
End Of Sie
WIRE OR
PAPER CLIP
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CYLINDER HEAD DISASSEMBLY (I)
id011000500400
1. Disassemble in the order indicated in the table.
3
4
1
R
5
2
6
7 R
B3E0110E025
.
01-10–6
7(DQQMࡍ࡯ࠫ㧞㧜㧝㧜ᐕ㧠᦬㧝㧢ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧡㧣ಽ
MECHANICAL
1
2
3
Water outlet
Camshaft sprocket, variable valve timing actuator
(See 01-10-6 Camshaft Sprocket, Variable Valve
Timing Actuator Disassembly Note)
Camshaft cap
(See 01-10-6 Camshaft Cap Disassembly Note)
4
5
6
7
Camshaft
Tappet
(See 01-10-6 Tappet Disassembly Note)
Cylinder head
(See 01-10-6 Cylinder Head Disassembly Note)
Cylinder head gasket
01-10
Camshaft Sprocket, Variable Valve Timing Actuator Disassembly Note
1. Hold the camshaft using a suitable wrench on the
cast hexagon as shown in the figure.
2. Loosen the camshaft sprocket installation bolt.
ADJ2224E077
14
20
16
6
8
4
2
1
18
3
Camshaft Cap Disassembly Note
1. Inspect the camshaft end play. (See 01-10-20 CAMSHAFT INSPECTION)
2. Loosen the camshaft cap installation bolts in two
10 12
to three passes in the order shown in the figure,
2
and then remove the camshaft caps.
8
7
6
5
4
3
1
9
11
19
17
15
13
7
5
B3E2224E008
Tappet Disassembly Note
Note
x The 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.
01-10–7
7(DQQMࡍ࡯ࠫ㧞㧜㧝㧜ᐕ㧠᦬㧝㧢ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧡㧣ಽ
MECHANICAL
Cylinder Head Disassembly Note
1. Loosen the camshaft cap installation bolts in two to three passes in the order shown in the figure, and remove
them.
End Of Sie
3
4
7
8
6
10
9
5
2
1
B3E0110E024
CYLINDER HEAD DISASSEMBLY (II)
id011000500500
1. Disassemble in the order indicated in the table.
1 SST
2
3
SST
R
5
4
B3E0110E026
.
1
2
3
Valve keeper
(See 01-10-8 Valve Keeper Disassembly Note)
Upper valve spring seat
Valve spring
01-10–8
4
5
Valve
Valve seal
(See 01-10-8 Valve Seal Disassembly Note)
7(DQQMࡍ࡯ࠫ㧞㧜㧝㧜ᐕ㧠᦬㧝㧢ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧡㧣ಽ
MECHANICAL
Valve Keeper Disassembly Note
1. Remove the valve keeper using the SSTs.
49 0636 100B
01-10
49 B012 0A2
b3e0110e124
Valve Seal Disassembly Note
1. Remove the valve seal using the SST.
End Of Sie
49 S120 170
VALVE SEAL
VALVE GUIDE
B3E0110E061
01-10–9
7(DQQMࡍ࡯ࠫ㧞㧜㧝㧜ᐕ㧠᦬㧝㧢ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧡㧣ಽ
MECHANICAL
CYLINDER BLOCK DISASSEMBLY (I)
id011000500600
1. Disassemble in the order indicated in the table.
7 SST
8
12
R
14
13
18
MTX
17
16
15
7
R
SST
4
5
R
3 SST
11
2
R
9 SST
R
1
6
10
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.
1
2
3
4
5
6
7
8
Thermostat cover
Thermostat
Knock sensor
(See 01-10-10 Knock Sensor Disassembly Note)
Oil separator
Water pump
Oil pump
Drive plate (ATX), flywheel (MTX)
(See 01-10-10 Drive Plate (ATX), Flywheel (MTX)
Disassembly Note)
End plate
01-10–10
9
10
11
12
13
14
15
16
17
18
Oil filter
(See 01-10-10 Oil Filter Disassembly Note)
Oil pan
(See 01-10-10 Oil Pan Disassembly Note)
Oil strainer
Oil pump cover
Inner rotor
Outer rotor
Plunger plug
Plunger spring
Control plunger
Oil pump body
7(DQQMࡍ࡯ࠫ㧞㧜㧝㧜ᐕ㧠᦬㧝㧢ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧡㧣ಽ
MECHANICAL
Knock Sensor Disassembly Note
1. Remove the knock sensor using the SST.
49 H018 001
01-10
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Drive Plate (ATX), Flywheel (MTX) Disassembly Note
1. Lock the drive plate (ATX) or flywheel (MTX)
against rotation using the SST.
2. Remove the drive plate or flywheel installation
bolts.
49 E011 1A0
bez0je00000006
Oil Filter Disassembly Note
1. Remove the oil filter using the SST or
commercially available, cup-type oil filter wrench
(67 mm {2.6 in} diameter, 14 sided).
49 G014 001
OR COMMERCIALLY
AVAILABLE CUP-TYPE
OIL FILTER WRENCH
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Oil Pan Disassembly Note
1. Remove the oil pan using a separator tool.
End Of Sie
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01-10–11
7(DQQMࡍ࡯ࠫ㧞㧜㧝㧜ᐕ㧠᦬㧝㧢ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧡㧣ಽ
MECHANICAL
CYLINDER BLOCK DISASSEMBLY (II)
id011000500700
1. Disassemble in the order indicated in the table.
15
4
10 R
5
R
13
7
14
12
6 SST
8
11
3
2
1
9
bezuue00000096
.
1
2
3
4
5
6
7
Connecting rod cap
(See 01-10-11 Connecting Rod Cap Disassembly
Note)
Lower connecting rod bearing
Upper connecting rod bearing
Connecting rod, piston assembly
Piston ring
Piston pin
(See 01-10-12 Piston Pin Disassembly Note)
Piston
01-10–12
8
9
10
11
12
13
14
15
Connecting rod
Lower cylinder block
(See 01-10-13 Lower Cylinder Block Disassembly
Note)
Rear oil seal
Lower main bearing
Crankshaft
Upper main bearing, thrust bearing
Oil jet valve
Upper cylinder block
7(DQQMࡍ࡯ࠫ㧞㧜㧝㧜ᐕ㧠᦬㧝㧢ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧡㧣ಽ
MECHANICAL
Connecting Rod Cap Disassembly Note
Caution
x When 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.)
01-10
b3e0110e087
Piston Pin Disassembly Note
1. 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.
x If the piston shakes heavily or unsmoothly,
replace the piston and the piston pin.
bezuue00000097
2. Assemble the SSTs as shown in the figure.
49 L011 006A
49 E011 001A
49 E011 002A
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01-10–13
7(DQQMࡍ࡯ࠫ㧞㧜㧝㧜ᐕ㧠᦬㧝㧢ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧡㧣ಽ
MECHANICAL
3. Insert the SST through the piston pin as shown in
the figure and assemble.
49 E011 002A
49 E011 001A
49 L011 006A
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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 D011 002B
49 L011 001
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01-10–14
7(DQQMࡍ࡯ࠫ㧞㧜㧝㧜ᐕ㧠᦬㧝㧢ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧡㧣ಽ
MECHANICAL
Lower Cylinder Block Disassembly Note
Caution
x When 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.
01-10
End Of Sie
2
12
11
16
15
20
19
1
5
6
10
9
17
18
7
8
3
4
13
14
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CYLINDER HEAD INSPECTION
id011000507100
1. Carry out the color contrast penetrate examination on the cylinder head surface.
x 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.
x If it exceeds the maximum specification,
replace the cylinder head.
Cylinder head maximum distortion, head
gasket side
0.10 mm {0.0039 in}
b3e0110e008
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.
x 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}
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End Of Sie
01-10–15
7(DQQMࡍ࡯ࠫ㧞㧜㧝㧜ᐕ㧠᦬㧝㧢ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧡㧣ಽ
MECHANICAL
VALVE SEAT INSPECTION/REPAIR
id011000501300
1. Measure the contact width of the valve face and
the valve seat using the valve lapping compound
(red lead).
Valve seat standard contact width
0.8—1.4 mm {0.04—0.05 in}
SEAT CONTACT
WIDTH
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x If not within the specification, resurface the
valve seat using the 45q 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.
x If the seating position is too high, correct the
valve seat using a 70q (IN) 70q (EX) valve seat
cutter, and a 45q valve seat cutter.
x If the seating position is too low, correct the
valve seat using a 35q (IN) 30q (EX) valve seat
cutter, and a 45q valve seat cutter.
':
+0
‫ޕ‬
‫ޕ‬
‫ޕ‬
‫ޕ‬
‫ޕ‬
‫ޕ‬
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Valve seat angle
45q
3. Check the valve seat for sinking. Measure the
protruding length (dimension L) of the valve stem
using a valve of standard length.
x If it exceeds the specification, replace the
cylinder head.
Valve seat standard sinkage amount
(Dimension L)
39.25 mm {1.545 in}
L
End Of Sie
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VALVE, VALVE GUIDE INSPECTION
1. Measure the valve head margin thickness using a
vernier caliper.
x If not within the specification, replace the
valve.
id011000506200
IN : 27.8 mm {1.09 in}
EX : 24.7 mm {0.972 in}
Valve head standard margin thickness
1.6—2.0 mm {0.063—0.078 in}
MARGIN THICKNESS
bezuue00000017
01-10–16
7(DQQMࡍ࡯ࠫ㧞㧜㧝㧜ᐕ㧠᦬㧝㧢ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧡㧣ಽ
MECHANICAL
2. Measure the length of each valve using the
vernier caliper.
x If it is less than the minimum specification,
replace the valve.
Valve length (Dimension L)
Standard
IN: 96.80—97.40 mm {3.812—3.834 in}
EX: 96.30—96.90 mm {3.792—3.814 in}
Minimum
IN: 96.58 mm {3.802 in}
EX: 96.08 mm {3.783 in}
01-10
L
b3e0110e068
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.
x If it is less than the minimum specification,
replace the valve.
X
Y
A
Valve stem diameter
Standard
IN: 5.470—5.485 mm {0.2154—0.2159 in}
EX: 5.465—5.480 mm {0.2152—0.2157 in}
Minimum
IN: 5.424 mm {0.2136 in}
EX: 5.419 mm {0.2134 in}
B
C
bezuue00000018
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.
x If not within the specification, replace the
valve guide. (See 01-10-17 VALVE GUIDE
REPLACEMENT.)
X
Y
A
B
Valve guide standard inner diameter
5.510—5.530 mm {0.2170—0.2177 in}
C
bezuue00000019
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.
x 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 guide
Standard
IN: 0.025—0.060 mm {0.0010—0.0023 in}
EX: 0.030—0.065 mm {0.0012—0.0025 in}
Maximum
0.1 mm {0.004 in}
VALVE STEM
VALVE GUIDE
CLEARANCE
bezuue00000020
01-10–17
7(DQQMࡍ࡯ࠫ㧞㧜㧝㧜ᐕ㧠᦬㧝㧢ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧡㧣ಽ
MECHANICAL
6. Measure the projection height (dimension A) of
each valve guide using the vernier caliper.
x If not within the specification, replace the
valve guide. (See 01-10-17 VALVE GUIDE
REPLACEMENT.)
VALVE GUIDE
A
Valve guide standard projection height
12.2—12.8 mm {0.481—0.503 in}
End Of Sie
CYLINDER HEAD
bezuue00000021
VALVE GUIDE REPLACEMENT
id011000501200
Removal
1. Remove the valve guide from the combustion
chamber side using the SST.
49 B012 015
VALVE GUIDE
bezuue00000022
Installation
1. Assemble the SSTs so that depth L is as
specified.
Depth L
12.2—12.8 mm {0.481—0.503 in}
49 L012 004A
L
49 L012 003A
49 L012 002A
b3e0110e071
2. Tap the valve guide in from the camshaft side
using the SSTs set in Step 1.
49 L012 003A
End Of Sie
49 L012 004A
49 L012 002A
VALVE GUIDE
bezuue00000023
01-10–18
7(DQQMࡍ࡯ࠫ㧞㧜㧝㧜ᐕ㧠᦬㧝㧢ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧡㧣ಽ
MECHANICAL
VALVE SPRING INSPECTION
id011000501400
1. Measure the spring height using a spring tester.
x If it exceeds the specification, replace the
valve spring.
Valve spring standard height
27.5 mm {1.08 in} (pressing force 262.8 N
{26.80 kgf, 59.08 lbf}
01-10
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.
x If it exceeds the maximum specification,
replace the valve spring.
bezuue00000024
A
Maximum valve spring off-square
2.0q (3.45 mm {0.136 in})
UPPER
End Of Sie
LOWER
bezuue00000025
TAPPET INSPECTION
id011000505800
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.
X
Y
Standard tappet bore diameter
30.0—30.025 mm {1.1812—1.1820 in}
A
B
bezuue00000026
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 diameter
29.959—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.
x If it exceeds the maximum specification,
replace the tappet or the cylinder head.
A
Y
B
X
bezuue00000027
Clearance between tappet and tappet bore
Standard
0.025—0.066 mm {0.0010—0.0025 in}
Maximum
0.18 mm {0.0071 in}
01-10–19
7(DQQMࡍ࡯ࠫ㧞㧜㧝㧜ᐕ㧠᦬㧝㧢ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧡㧣ಽ
MECHANICAL
End Of Sie
VARIABLE VALVE TIMING ACTUATOR INSPECTION
id011000506000
Caution
x Variable 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.
Caution
x If the camshaft knock pin hole and the Tmark are not aligned, rotate the rotor (the
camshaft installing part) until a click is
heard, and verify that they are fixed in
place.
x 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.
T-MARK
COVER
CAMSHAFT
KNOCK-PIN
HOLE
ROTOR
End Of Sie
ada2226e005
OIL CONTROL VALVE (OCV) INSPECTION
id011000506100
Coil Resistance Inspection
1. Measure the coil resistance between terminals A
and B using the tester.
x If not within the specification, replace the oil
control valve (OCV).
B
A
OCV coil resistance
6.9—7.9 ohms [20qC {68qF}]
bezuue00000028
Spool Valve Operation Inspection
1. Verify that the spool valve in the oil control valve
(OCV) is in the maximum valve timing retard
position as shown in the figure.
x 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.
x If it cannot be verified as shown in the figure,
replace the oil control valve (OCV).
SPOOL VALVE
(MAXIMUM VALVE TIMING RETARD POSITION
b3e0110e090
Note
x When 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.
01-10–20
7(DQQMࡍ࡯ࠫ㧞㧜㧝㧜ᐕ㧠᦬㧝㧢ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧡㧣ಽ
MECHANICAL
3. Stop applying battery positive voltage and verify
that the spool valve returns to the maximum valve
timing retard position.
x If it cannot be verified as shown in the figure,
replace the oil control valve (OCV).
VALVE TIMING
ADVANCE
VALVE TIMING
RETARD
End Of Sie
01-10
SPOOL VALVE
(MAXIMUM VALVE TIMING ADVANCE POSITION)
b3e0110e091
CAMSHAFT INSPECTION
id011000501500
1. Set the No.1 and No.5 journals of the camshaft on
V-blocks.
2. Measure the camshaft runout using a dial gauge.
x If it exceeds the maximum specification,
replace the camshaft.
Camshaft maximum runout
0.03 mm {0.001 in}
b3e0110e074
3. Measure the cam lobe height as shown using the
micrometer.
x If it is less than the minimum specification,
replace the camshaft.
Cam lobe height
Standard
IN: 41.373 mm {1.6289 in}
EX: 40.597 mm {1.5983 in}
Minimum
IN: 41.30 mm {1.626 in}
EX: 40.53 mm {1.596 in}
b3e0110e076
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.
x If it is less than the minimum specification,
replace the camshaft.
Camshaft journal diameter
Standard
25.950—25.975 mm {1.0217—1.0226 in}
Minimum
24.910 mm {0.98071 in}
B
A
Y
X
bezuue00000029
01-10–21
7(DQQMࡍ࡯ࠫ㧞㧜㧝㧜ᐕ㧠᦬㧝㧢ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧡㧣ಽ
MECHANICAL
5. Measure the camshaft journal oil clearance using
a plastigauge with the tappet removed.
Note
x Clean the camshaft journal and the journal
receptacle part.
x Cut the plastigauge to the same length as
the journal width and position it in parallel to
the camshaft.
PLASTIGAUGE
x If it exceeds the maximum specification,
replace the cylinder head.
bezuue00000030
Camshaft journal oil clearance
Standard
0.025—0.071 mm {0.0010—0.0027 in}
Maximum
0.090 mm {0.0035 in}
6. Measure the camshaft end play using a dial
gauge.
x If it exceeds the maximum specification,
replace the cylinder head or the camshaft.
Camshaft end play
Standard
0.07—0.19 mm {0.003—0.007 in}
Maximum
0.20 mm {0.0079 in}
End Of Sie
bezuue00000031
CYLINDER BLOCK INSPECTION
id011000507200
1. Measure the distortion in six directions as shown
in the figure using a square and feeler gauge.
x If it exceeds the maximum specification,
replace the cylinder block.
Cylinder block maximum distortion, head
gasket side
0.10 mm {0.0039 in}
bezuue00000032
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.
x If it is not within the specification, replace the
cylinder block.
Standard cylinder bore diameter
78.000—78.013 mm {3.0709—3.0713 in}
X
Y
35.0 mm {1.38 in}
End Of Sie
bezuue00000033
01-10–22
7(DQQMࡍ࡯ࠫ㧞㧜㧝㧜ᐕ㧠᦬㧝㧢ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧡㧣ಽ
MECHANICAL
OIL JET VALVE INSPECTION
id011000505900
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.
x If air does not flow, replace the oil jet valve.
End Of Sie
$
01-10
#
bezuue00000107
PISTON, PISTON RING, PISTON PIN INSPECTION
id011000506600
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 diameter
77.970—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.
x If it exceeds the maximum specification,
replace the piston or the cylinder block.
12.5 mm {0.492 in}
bezuue00000034
Clearance between piston and cylinder
Standard
0.020—0.043 mm {0.0008—0.0016 in}
Maximum
0.070 mm {0.0028 in}
3. Measure the piston ring-to-ring groove clearance
around the entire circumference using a feeler
gauge.
x If it exceeds the maximum specification,
replace the piston ring.
Clearance between piston ring and ring
groove
Standard
Top: 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}
Maximum
Top, Second: 0.150 mm {0.0059 in}
Oil: 0.20 mm {0.0079 in}
b3e0110e081
01-10–23
7(DQQMࡍ࡯ࠫ㧞㧜㧝㧜ᐕ㧠᦬㧝㧢ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧡㧣ಽ
MECHANICAL
4. Measure the piston ring end gap using a feeler
gauge.
x If if exceeds the maximum specification,
replace the piston ring.
Piston ring end gap
Standard
Top: 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}
Maximum
1.0 mm {0.039 in}
PISTON RING
bezuue00000035
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 diameter
18.988—19.000 mm {0.74756—0.74803 in}
#
$
%
&
:
;
adj2224e253
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 diameter
18.974—18.980 mm {0.74701—0.74724 in}
7. Calculate the clearance between the piston pin
hole diameter and the piston pin outer diameter.
x If not within the specification, replace the
piston or the piston pin.
X
Y
A
B
C
D
adj2224e255
Standard clearance between piston pin hole
and piston pin
0.008—0.026 mm {0.0004—0.0010 in}
End Of Sie
CONNECTING 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.
x If it exceeds the maximum specification,
replace the connecting rod or the crankshaft.
Side clearance at the large end of the
connecting rod
Standard
0.110—0.292 mm {0.0044—0.0114 in}
Maximum
0.435 mm {0.0171 in}
b3e0110e087
01-10–24
7(DQQMࡍ࡯ࠫ㧞㧜㧝㧜ᐕ㧠᦬㧝㧢ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧡㧣ಽ
MECHANICAL
3. Measure the oil clearance at the large end of the
connecting rod using a plastigauge.
x 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.
Note
x Cut the plastigauge as wide as the
connecting rod bearing width, place it
parallel to the crankshaft, keeping away from
the oil hole.
PLASTIGAUGE
01-10
bezuue00000036
Bearing oil clearance at the large end of
connecting rod
Standard
0.016—0.037 mm {0.0007—0.0014 in}
Maximum
0.10 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.
x If not within the specification, replace the
connecting rod or the piston pin.
X
Y
adj2224e254
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.
x If it exceeds the maximum specification,
replace the connecting rod.
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}
amj2224e255
End Of Sie
01-10–25
7(DQQMࡍ࡯ࠫ㧞㧜㧝㧜ᐕ㧠᦬㧝㧢ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧡㧣ಽ
MECHANICAL
CRANKSHAFT INSPECTION
id011000502500
1. Measure the crankshaft end play using a dial
gauge.
x 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 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}
b3e0110e083
Crankshaft end play
Standard
0.080—0.282 mm {0.0032—0.0111 in}
Maximum
0.30 mm {0.012 in}
2. Measure the crankshaft main journal runout on Vblocks using a dial gauge.
x If it exceeds the maximum specification,
replace the crankshaft.
Crankshaft main journal maximum runout
0.10 mm {0.0039 in}
bezuue00000037
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.
x 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 diameter
STD: 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 diameter
STD: 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}
01-10–26
A
B
X
Y
b3e0110e085
7(DQQMࡍ࡯ࠫ㧞㧜㧝㧜ᐕ㧠᦬㧝㧢ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧡㧣ಽ
MECHANICAL
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.
x If it exceeds the maximum specification,
replace the main bearing or grind the
main bearing journal part and install the oversize bearing.
01-10
b3e0110e086
Crankshaft main journal oil clearance
Standard
0.019—0.038 mm {0.0008—0.0014 in}
Maximum
0.084 mm {0.0033 in}
Main bearing thickness
STD: 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 Sie
BOLT INSPECTION
id011000503300
1. Measure the length of each bolt.
x If it exceeds the maximum specification,
replace the bolt.
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}
L
bezuue00000038
End Of Sie
OIL PUMP INSPECTION
id011000505300
1. Measure the clearance between the inner rotor
and the outer rotor using a feeler gauge.
x 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}
bezuue00000039
01-10–27
7(DQQMࡍ࡯ࠫ㧞㧜㧝㧜ᐕ㧠᦬㧝㧢ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧡㧣ಽ
MECHANICAL
2. Measure the clearance between the outer rotor
and the oil pump body using a feeler gauge.
x 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}
bezuue00000040
3. Measure the side clearance using a straight edge
and feeler gauge.
x If it exceeds the specification, replace the
inner rotor, outer rotor, oil pump, or all of
them.
Oil pump side clearance
Standard: 0.03—0.07 mm {0.0012—0.0027
in}
Maximum: 0.090 mm {0.0035 in}
bezuue00000041
4. Measure the weight at which the plunger spring
height is compressed to 35.42 mm {1.394 in}
using a spring tester.
x 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
bezuue00000024
VALVE CLEARANCE INSPECTION
id011000503500
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
A
B
A
figure.
x If not within the specification, replace the
tappet and adjust the valve to the median
EX
value. (See 01-10-27 VALVE CLEARANCE
ADJUSTMENT.)
Standard valve clearance [Engine cold]
0.27—0.33 mm {0.011—0.012 in}
Note
x Make sure to note the measured values for
choosing the suitable replacement tappets.
B
NO.1
NO.2
NO.3
NO.4
A
A
B
B
IN
3. Rotate the crankshaft clockwise 360q so that the No.4 piston is at TDC of the compression stroke.
01-10–28
adj2224e103
7(DQQMࡍ࡯ࠫ㧞㧜㧝㧜ᐕ㧠᦬㧝㧢ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧡㧣ಽ
MECHANICAL
4. Measure the valve clearance at B shown in the
figure.
x 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}
A
B
A
B
NO.1
NO.2
NO.3
NO.4
EX
IN
Note
x Make sure to note the measured values for
choosing the suitable replacement tappets.
01-10
A
A
B
B
adj2224e103
End Of Sie
VALVE CLEARANCE ADJUSTMENT
id011000503600
1. Remove the engine front cover blind plug shown
in the figure.
BLIND PLUG R
am3zzw0000629
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.
BOLT
FRONT COVER
TENSIONER ARM
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01-10–29
7(DQQMࡍ࡯ࠫ㧞㧜㧝㧜ᐕ㧠᦬㧝㧢ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧡㧣ಽ
MECHANICAL
(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.
Note
x When 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.
bezuue00000044
PLUNGER
LINK PLATE
bezuue00000045
(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.
RIB
RIB
Note
x When 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.
bezuue00000046
TENSIONER ARM
RIB
SERVICE HOLE
bezuue00000047
01-10–30
7(DQQMࡍ࡯ࠫ㧞㧜㧝㧜ᐕ㧠᦬㧝㧢ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧡㧣ಽ
MECHANICAL
4. Fix the camshaft using a wrench on the cast
hexagon.
5. Remove the camshaft sprocket installation bolt.
01-10
bezuue00000048
6. Remove the timing sprocket on the exhaust side
with the timing chain positioned out of the way.
bezuue00000049
Standard valve clearance [Engine cold]
0.27—0.33 mm {0.011—0.012 in}
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.
12
10
18
14
20
16
6
8
4
3
2
1
2
7
6
8
4
3
5
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
1
9
11
19
17
15
13
7
5
bezuue00000050
TIMING MARK
TDC
bezuue00000051
01-10–31
7(DQQMࡍ࡯ࠫ㧞㧜㧝㧜ᐕ㧠᦬㧝㧢ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧡㧣ಽ
MECHANICAL
1
7
5
15
13
4
3
2
1
19
17
7
8
18
6
Tightening torque
12—14 N·m {123—142 kgf·cm, 107—123
in·lbf}
3
9
11
5
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.
20
12
10
2
4
6
8
14
16
bezuue00000052
15. Install the exhaust camshaft sprocket and the
timing chain at the same time.
bezuue00000049
x 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.
TIMING MARK
CYLINDER HEAD
UPPER SURFACE
bezuue00000053
16. Hold the exhaust camshaft using a wrench on the
cast hexagon.
17. Tighten the camshaft sprocket installation bolt.
Tightening torque
50—60 N·m {5.1—6.1 kgf·m, 37—44 ft·lbf}
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.
am3zzw0000032
Tightening torque
3.0—6.0 N·m {31—61 kgf·cm, 27—53 in·lbf}
End Of Sie
BLIND PLUG R
am3zzw0000629
01-10–32
7(DQQMࡍ࡯ࠫ㧞㧜㧝㧜ᐕ㧠᦬㧝㧢ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧡㧣ಽ
MECHANICAL
CYLINDER BLOCK ASSEMBLY (I)
id011000504000
1. Assemble in the order indicated in the table.
1
01-10
11
10
8
OIL
R
OIL
SST
9
3
OIL
4
2
8—10 N·m
{82—101 kgf·cm,
71—88 in·lbf}
OIL
7
OIL
5
12
OIL
OIL
13
6
14
SEALANT
23—26 {2.4—2.6, 17—19}
+82.5˚— 97.5˚
OIL
24—26 {2.5—2.6, 18—19}
+42.5˚— 47.5˚
19—25 {2.0—2.5, 15—18}
N·m {kgf·m, ft·lbf}
bezuue00000054
.
1
2
3
4
5
6
7
8
Upper cylinder block
Oil jet valve
Upper main bearing, thrust bearing
(See 01-10-32 Main Bearing Assembly Note)
Crankshaft
Lower main bearing
(See 01-10-32 Main Bearing Assembly Note)
Lower cylinder block
(See 01-10-33 Lower Cylinder Block Assembly
Note)
Connecting rod
Piston
9
10
11
12
Piston pin
(See 01-10-34 Piston Pin Assembly Note)
Piston ring
(See 01-10-36 Piston Ring Assembly Note)
Piston, connecting rod component
(See 01-10-36 Piston, Connecting Rod Component
Assembly Note)
Upper connecting rod bearing
(See 01-10-36 Connecting Rod Bearing Assembly
Note)
01-10–33
7(DQQMࡍ࡯ࠫ㧞㧜㧝㧜ᐕ㧠᦬㧝㧢ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧡㧣ಽ
MECHANICAL
13
14
Lower connecting rod bearing
(See 01-10-36 Connecting Rod Bearing Assembly
Note)
Connecting rod cap
(See 01-10-37 Connecting Rod Cap Assembly
Note)
Main Bearing Assembly Note
Caution
x If 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.
Caution
x If 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
5 {0.2}
MEASUREMENT
AREA
5 {0.2}
0.70—1.1
{0.028—
0.043}
1.8—2.2
{0.071—0.086}
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}
bezuue00000070
Lower main bearing
5 {0.2}
MEASUREMENT
AREA
5 {0.2}
1.9—2.3
{0.075—
0.090}
2.45—2.85
{0.097—0.112}
1.8—2.2 {0.071—0.086}
1.9—2.3
{0.075—
0.090}
1.9—2.3
{0.075—0.090}
mm {in}
bezuue00000056
01-10–34
7(DQQMࡍ࡯ࠫ㧞㧜㧝㧜ᐕ㧠᦬㧝㧢ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧡㧣ಽ
MECHANICAL
Lower Cylinder Block Assembly Note
Caution
x Install 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.
01-10
SEALANT
SEALANT
2.0—6.0 mm
{0.08—0.23 in}
bezuue00000057
3. Tighten the lower cylinder block installation bolts
A in two steps in the order shown in the figure.
9A
(1)Tightening torque
24—26 N·m {2.5—2.6 kgf·m, 18—19 ft·lbf}
(2)Tightening angle
42.5q—47.5q
10 A
5A
6A
1 A
2A
4A
3A
8A
7A
bezuue00000058
4. Tighten the lower cylinder block installation bolts
B in the order shown in the figure.
B
Tightening torque
19—25 N·m {2.0—2.5 kgf·m, 15—18 ft·lbf}
B
5
B
1
9
10 B
6B
2B
B
4
3B
B
8
7 B
bezuue00000059
01-10–35
7(DQQMࡍ࡯ࠫ㧞㧜㧝㧜ᐕ㧠᦬㧝㧢ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧡㧣ಽ
MECHANICAL
5. Loosen bolts A and tighten the lower cylinder
block installation bolts in two steps in the order
shown a second time.
9A
(1)Tightening torque
24—26 N·m {2.5—2.6 kgf·m, 18—19 ft·lbf}
(2)Tightening angle
42.5q—47.5q
10 A
5A
6A
1 A
2A
4A
3A
8A
7A
bezuue00000058
Piston Pin Assembly Note
1. Assemble the SSTs as shown in the figure.
PISTON PIN
49 E011 001A
49 L011 006A
49 E011 002A
bezuue00000063
2. Adjust the SSTs (stopper bolt) to the L length.
Standard L length
60.85 mm {2.396 in}
49 D011 002B
L
49 L011 001
49 L011 005
bezuue00000064
3. Point the end mark on the connecting rod and Fmark on the piston in the same direction as
shown in the figure.
F-MARK
ALIGNMENT MARK
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01-10–36
7(DQQMࡍ࡯ࠫ㧞㧜㧝㧜ᐕ㧠᦬㧝㧢ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧡㧣ಽ
MECHANICAL
4. Insert the assembled piston pin and the SSTs into
the piston and the connecting rod.
49 L011 006A
PISTON PIN
01-10
49 E011 001A
bezuue00000066
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 force
2940—14700 N {300—1498 kg, 660—3297
lbf}
49 L011 006A
PISTON PIN
PISTON
CONNECTING ROD
49 E011 001A
49 L011 005
49 L011 001
bezuue00000067
Piston Ring Assembly Note
1. Assemble the oil ring.
2. Install the second ring with the notch facing
downward.
3. Install the top ring with scraper face side upward.
bezuue00000068
Piston, Connecting Rod Component Assembly Note
Note
x After 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 UPPER VIEW
FRONT MARK
ENGINE
FRONT SIDE
PISTON
IDENTIFICATION
MARK
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01-10–37
7(DQQMࡍ࡯ࠫ㧞㧜㧝㧜ᐕ㧠᦬㧝㧢ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧡㧣ಽ
MECHANICAL
1. Position the end gap of each oil ring as shown in
the figure.
30°
30°
PISTON PIN AXIS
LOWER OIL RING RAIL
UPPER OIL RING RAIL
OIL RING SPACER
bezuue00000061
2. Insert the piston into the cylinder with the mark on
top of the piston facing the front of the engine.
PISTON FRONT MARK
ENGINE FRONT
bezuue00000062
Connecting Rod Bearing Assembly Note
Caution
x If 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.
Caution
x If 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.
ENGINE FRONT
ROD SIDE
CAP SIDE
2.40—2.80 mm
{0.095—0.110 in}
2.40—2.80 mm
{0.095—0.110 in}
Connecting Rod Cap Assembly Note
1. 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
82.5q—97.5q
End Of Sie
01-10–38
ENGINE FRONT
bezuue00000069
7(DQQMࡍ࡯ࠫ㧞㧜㧝㧜ᐕ㧠᦬㧝㧢ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧡㧣ಽ
MECHANICAL
CYLINDER BLOCK ASSEMBLY (II)
id011000504100
1. Assemble in the order indicated in the table.
SST
6
OIL
5
5.9—8.8 N·m
{61—89 kgf·cm,
53—77 in·lbf}
11
12
13
97—103 R
{9.9—10, 72—75}
SST
R
01-10
7
1
OIL
MTX
2
3
4
13
27—39
{2.8—3.9,
20—28}
19—25
{2.0—2.5,
15—18}
15
SST
R
16
R
8—10 N·m
{82—101 kgf·cm,
71—88 in·lbf}
17 SST
20—34
{2.1—3.4, 15—25}
8
R
19—25
{2.0—2.5,
15—18}
18
19
14
19—25
{2.0—2.5,
15—18}
10 SST
SEALANT
9
OIL
R
12—15 N·m
{123—152 kgf·cm, 107—132 in·lbf}
8—10 N·m
{82—101 kgf·cm, 71—88 in·lbf}
N·m {kgf·m, ft·lbf}
bezuue00000071
.
1
2
3
4
5
6
7
8
9
10
Oil pump body
Control plunger
Plunger spring
Plunger plug
Outer rotor
(See 01-10-39 Inner Rotor, Outer Rotor Assembly
Note)
Inner rotor
(See 01-10-39 Inner Rotor, Outer Rotor Assembly
Note)
Oil pump cover
Oil strainer
Oil pan
(See 01-10-39 Oil Pan Assembly Note)
Oil filter
(See 01-10-39 Oil Filter Assembly Note)
11
12
13
14
15
16
17
18
19
Rear oil seal
(See 01-10-39 Rear Oil Seal Assembly Note)
End plate
Drive plate (ATX), flywheel (MTX)
(See 01-10-40 Drive Plate (ATX), Flywheel (MTX)
Assembly Note)
Oil pump
(See 01-10-40 Oil Pump Assembly Note)
Water pump
Oil separator
Knock sensor
(See 01-10-41 Knock Sensor Assembly Note)
Thermostat
Thermostat cover
01-10–39
7(DQQMࡍ࡯ࠫ㧞㧜㧝㧜ᐕ㧠᦬㧝㧢ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧡㧣ಽ
MECHANICAL
Inner Rotor, Outer Rotor Assembly Note
1. Assemble the inner rotor and the outer rotor with
the punch marks aligned.
PUNCH MARK
bezuue00000072
Oil Pan Assembly Note
Caution
x Install the oil pan before the applied silicone sealant starts to harden.
1. Apply silicone sealant as shown in the figure.
SEALANT
Diameter
2.0—6.0 mm {0.08—0.23 in}
bezuue00000073
2. Tighten the oil pan installation bolts in the order
shown in the figure.
Tightening torque
8—10 N·m {82—101 kgf·cm, 71—88 in·lbf}
8
11
4
5
1
9
12
16
13
14
15
7
3
2
6
10
bezuue00000074
Oil Filter Assembly Note
1. Install the oil filter according to the instruction on
the package or side of the oil filter.
Note
Tightening torque
12—15 N·m {123—152 kgf·cm, 107—132 in·lbf}
Angle tightening
When the O-ring contacts the oil filter installation
surface, turn the filter another one rotation.
49 G014 001
OR COMMERCIALLY
AVAILABLE CUP-TYPE
OIL FILTER WRENCH
bezuue00000104
01-10–40
7(DQQMࡍ࡯ࠫ㧞㧜㧝㧜ᐕ㧠᦬㧝㧢ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧡㧣ಽ
MECHANICAL
Rear Oil Seal Assembly Note
1. 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.
01-10
49 E033 101
bezuue00000076
CYLINDER BLOCK
0—0.50 mm
{0—0.019 in}
REAR OIL SEAL
bezuue00000077
Drive Plate (ATX), Flywheel (MTX) Assembly Note
1. 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.
49 E011 1A0
1
6
4
3
5
2
bezuue00000078
Oil Pump Assembly Note
1. Install the gasket to the oil pump.
2. Install the oil pump and gasket as a single unit.
bezuue00000079
01-10–41
7(DQQMࡍ࡯ࠫ㧞㧜㧝㧜ᐕ㧠᦬㧝㧢ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧡㧣ಽ
MECHANICAL
Knock Sensor Assembly Note
1. Install the knock sensor using the SST.
End Of Sie
49 H018 001
bezuue00000080
CYLINDER HEAD ASSEMBLY (I)
id011000504300
1. Assemble in the order indicated in the table.
5 SST
4
3
SST
R
1
2
B3E0110E029
.
1
2
3
Valve seal
(See 01-10-41 Valve Seal Assembly Note)
Valve
Valve spring
01-10–42
4
5
Upper valve spring seat
Valve keeper
(See 01-10-42 Valve Keeper Assembly Note)
7(DQQMࡍ࡯ࠫ㧞㧜㧝㧜ᐕ㧠᦬㧝㧢ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧡㧣ಽ
MECHANICAL
Valve Seal Assembly Note
1. Press in the valve seal to the valve guide by hand.
2. Tap the SST shown in the figure using a plastic
hammer.
49 T032 302
VALVE
SEAL
01-10
B3E0110E123
Valve Keeper Assembly Note
1. Install the valve keeper using the SST.
End Of Sie
49 0636 100B
49 B012 0A2
b3e0110e124
01-10–43
7(DQQMࡍ࡯ࠫ㧞㧜㧝㧜ᐕ㧠᦬㧝㧢ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧡㧣ಽ
MECHANICAL
CYLINDER HEAD ASSEMBLY (II)
id011000504400
1. Assemble in the order indicated in the table.
12—14 N·m
{123—142 kgf·cm, 107—123 in·lbf}
OIL
5
4
7
19—25
{2.0—2.5,
15—18}
R
3
6
50—60
{5.1—6.1,
37—44}
2
1 R
18—22 {1.9—2.2, 14—16}
+85˚—95˚
+85°—95°
N·m {kgf·m, ft·lbf}
bezuue00000081
.
1
2
3
4
Cylinder head gasket
Cylinder head
(See 01-10-43 Cylinder Head Assembly Note)
Tappet
Camshaft
(See 01-10-44 Camshaft Assembly Note)
01-10–44
5
6
7
Camshaft cap
(See 01-10-44 Camshaft Assembly Note)
Camshaft sprocket, variable valve timing actuator
(See 01-10-44 Camshaft Sprocket, Variable Valve
Timing Actuator Assembly Note)
Water outlet
7(DQQMࡍ࡯ࠫ㧞㧜㧝㧜ᐕ㧠᦬㧝㧢ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧡㧣ಽ
MECHANICAL
Cylinder Head Assembly Note
1. Tighten the cylinder head installation bolts in
three steps in the order shown in the figure.
8
4
5
1
9
(1)Tightening torque
18—22 N·m {1.9—2.2 kgf·m, 14—16 ft·lbf}
(2)Tightening angle
85q—95q
(3) Tightening angle
85q—95q
01-10
2
3
7
6
10
bezuue00000082
Camshaft Assembly Note
Note
x Install the camshaft with the No.1 camshaft positioned at TDC of the compression stroke.
1
7
5
15
13
4
3
2
1
19
17
7
8
18
6
Tightening torque
12—14 N·m {123—142 kgf·cm, 107—123
in·lbf}
3
9
11
5
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.
20
12
10
2
4
6
8
14
16
bezuue00000083
Camshaft Sprocket, Variable Valve Timing Actuator Assembly Note
1. 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.
Tightening torque
50—60 N·m {5.1—6.1 kgf·m, 37—44 ft·lbf}
End Of Sie
bezuue00000084
01-10–45
7(DQQMࡍ࡯ࠫ㧞㧜㧝㧜ᐕ㧠᦬㧝㧢ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧡㧣ಽ
MECHANICAL
TIMING CHAIN ASSEMBLY
id011000505600
1. Assemble in the order indicated in the table.
13
8—10 N·m
{82—101 kgf·cm,
71—88 in·lbf}
19—25
{2.0—2.5, 15—18}
7—10 N·m
{72—101 kgf·cm,
62—88 in·lbf}
15—22
{1.6—2.2, 12—16}
16
14
15
R
7
SEALANT
R
R
8—10 N·m
{82—101 kgf·cm,
71—88 in·lbf}
11
9
R
R
32—47
{3.3—4.7,
24—34}
38—51
{3.9—5.2,
29—37}
38—51
{3.9—5.2,
29—37}
10
R SST
38—51
{3.9—5.2,
29—37}
OIL
8
SST
SEALANT
8—10 N·m
{82—101 kgf·cm,
71—88 in·lbf}
8—10 N·m
{82—101 kgf·cm,
71—88 in·lbf}
19—25
{2.0—2.5, 15—18}
12
157—167
{16.1—17, 116—123}
R
6
19—25
{2.0—2.5, 15—18}
5
1
19—25
{2.0—2.5, 15—18}
2
4
3
N·m {kgf·m, ft·lbf}
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.
1
2
3
4
5
6
7
8
Key
Crankshaft sprocket
Timing chain
(See 01-10-46 Timing Chain Assembly Note)
Timing chain guide
Timing chain tensioner arm
Timing chain tensioner
Engine front cover
(See 01-10-46 Engine Front Cover Assembly Note)
Crankshaft pulley
(See 01-10-48 Crankshaft Pulley Installation Bolt
Assembly Note)
01-10–46
9
10
11
12
13
14
15
16
OCV oil filter, plug
Idler pulley
OCV
Oil level gauge pipe
Drive belt auto tensioner
Cylinder head cover
(See 01-10-48 Cylinder Head Cover Assembly Note)
CMP sensor
Spark plug
7(DQQMࡍ࡯ࠫ㧞㧜㧝㧜ᐕ㧠᦬㧝㧢ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧡㧣ಽ
MECHANICAL
Timing Chain Assembly Note
1. Align the key groove of the crankshaft sprocket to
the timing mark, and then position the No.1
cylinder to TDC.
TIMING MARK
KEY GROOVE
01-10
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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.
TIMING MARK
CYLINDER HEAD
UPPER SURFACE
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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.
STOPPER
LINK PLATE
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Engine Front Cover Assembly Note
Caution
x Install 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.
Diameter
2—4 mm {0.08—0.15 in}
SEALANT
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01-10–47
7(DQQMࡍ࡯ࠫ㧞㧜㧝㧜ᐕ㧠᦬㧝㧢ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧡㧣ಽ
MECHANICAL
2. Tighten the engine front cover installation bolts in
the order shown in the figure.
x Install bolt (1) using a new seal washer.
Position
9
1—6, 8, 10, 12—15, 17, 18
7, 11, 16
Tightening torque
8—10 N·m {82—101 kgf·cm,
71—88 in·lbf}
19—25 N·m {2.0—2.5 kgf·m,
15—18 ft·lbf}
38—51 N·m {3.9—5.2 kgf·m,
29—37 ft·lbf}
6
1
2
7
11
12
8
16
3
9
13
18
15
17
14
5
4
10
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3. Install the oil seal using the SST.
FRONT OIL SEAL
49 H010 401
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ENGINE FRONT
COVER
0—0.50 mm
{0—0.019 in}
HAMMER
49 H010 401
FRONT OIL
SEAL
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01-10–48
7(DQQMࡍ࡯ࠫ㧞㧜㧝㧜ᐕ㧠᦬㧝㧢ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧡㧣ಽ
MECHANICAL
4. Install the oil filter to the plug and insert it in the
front cover as shown in the figure.
Tightening torque
32—47 N·m {3.3—4.7 kgf·m, 24—34 ft·lbf}
PLUG
FILTER
FRONT COVER
01-10
ALUMINUM WASHER
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Crankshaft Pulley Installation Bolt Assembly Note
1. Lock the drive plate (ATX) or flywheel (MTX)
against rotation using the SST.
2. Tighten the crankshaft pulley installation bolt.
49 E011 1A0
Tightening torque
157—167 N·m {16.1—17 kgf·m, 116—123
ft·lbf}
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Cylinder Head Cover Assembly Note
Caution
x Install the cylinder head cover before the applied silicone sealant starts to harden.
1. Apply silicone sealant as shown in the figure.
SEALANT
Diameter
2—6 mm {0.1—0.2 in}
2.0— 6.0 mm
{0.1—0.2 in}
SEALANT
Length
6—26 mm {0.3—1.0 in}
6 —26 mm
{0.3—1.0 in}
FRONT COVER
MATING FACES
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01-10–49
7(DQQMࡍ࡯ࠫ㧞㧜㧝㧜ᐕ㧠᦬㧝㧢ᣣ‫ޓ‬㊄ᦐᣣ‫ޓ‬ඦᓟ㧝ᤨ㧡㧣ಽ
MECHANICAL
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}
2
9
8
3
7
End Of Sie
4
1
5
10
6
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01-10–50
1993-1U-10F.book
1 ページ
２０１０年４月１６日　金曜日　午後１時５７分
TECHNICAL DATA
01-50
TECHNICAL DATA
ENGINE TECHNICAL DATA . . . . . . . . . . 01-50–1
End of Toc
ENGINE TECHNICAL DATA
WM: ENGINE
Item
Cylinder head maximum distortion, head gasket side
Cylinder head maximum distortion, manifold side
Cylinder head maximum grinding, manifold side
Valve seat standard contact width
Valve seat angle
Valve seat standard sinkage amount (Dimension L)
Valve head standard margin thickness
Valve length (Dimension L)
Valve stem diameter
Valve guide standard inner diameter
Clearance between valve stem and guide
Valve guide standard projection height
Valve spring standard height
Maximum valve spring off-square
Standard tappet bore diameter
Standard tappet body outer diameter
Clearance between tappet and tappet bore
OCV coil resistance
Camshaft maximum runout
Cam lobe height
Camshaft journal diameter
Camshaft journal oil clearance
Camshaft end play
id015000800100
Specification
0.10 mm {0.0039 in}
0.05 mm {0.002 in}
0.20 mm {0.0079 in}
0.8—1.4 mm {0.04—0.05 in}
45°
39.25 mm {1.545 in}
1.6—2.0 mm {0.063—0.078 in}
Standard
IN: 96.80—97.40 mm {3.812—3.834 in}
EX: 96.30—96.90 mm {3.792—3.814 in}
Minimum
IN: 96.58 mm {3.802 in}
EX: 96.08 mm {3.783 in}
Standard
IN: 5.470—5.485 mm {0.2154—0.2159 in}
EX: 5.465—5.480 mm {0.2152—0.2157 in}
Minimum
IN: 5.424 mm {0.2136 in}
EX: 5.419 mm {0.2134 in}
5.510—5.530 mm {0.2170—0.2177 in}
Standard
IN: 0.025—0.060 mm {0.0010—0.0023 in}
EX: 0.030—0.065 mm {0.0012—0.0025 in}
Maximum
0.1 mm {0.004 in}
12.2—12.8 mm {0.481—0.503 in}
27.5 mm {1.08 in} (pressing force 262.8 N {26.80 kgf, 59.08 lbf}
2.0° (3.45 mm {0.136 in})
30.0—30.025 mm {1.1812—1.1820 in}
29.959—29.975 mm {1.1795—1.1801 in}
Standard
0.025—0.066 mm {0.0010—0.0025 in}
Maximum
0.18 mm {0.0071 in}
6.9—7.9 ohms [20°C {68°F}]
0.03 mm {0.001 in}
Standard
IN: 41.373 mm {1.6289 in}
EX: 40.597 mm {1.5983 in}
Minimum
IN: 41.30 mm {1.626 in}
EX: 40.53 mm {1.596 in}
Standard
25.950—25.975 mm {1.0217—1.0226 in}
Minimum
24.910 mm {0.98071 in}
Standard
0.025—0.071 mm {0.0010—0.0027 in}
Maximum
0.090 mm {0.0035 in}
Standard
0.07—0.19 mm {0.003—0.007 in}
Maximum
0.20 mm {0.0079 in}
01-50–1
01-50
1993-1U-10F.book
2 ページ
２０１０年４月１６日　金曜日　午後１時５７分
TECHNICAL DATA
Item
Cylinder block maximum distortion, head gasket side
Standard cylinder bore diameter
Piston outer diameter
Clearance between piston and cylinder
Clearance between piston ring and ring groove
Piston ring end gap
Standard piston pin hole diameter
Standard piston pin outer diameter
Standard clearance between piston pin hole and
piston pin
Side clearance at the large end of the connecting rod
Bearing oil clearance at the large end of connecting
rod
Connecting rod bearing thickness (Center thickness)
Standard connecting rod small end inner diameter
Standard clearance between connecting rod small end
and piston pin
Connecting rod maximum bending
Connecting rod maximum distortion
Connecting rod center-to-center distance
Thrust bearing thickness
Crankshaft end play
Crankshaft main journal maximum runout
Crankshaft main journal diameter
Crankshaft main journal maximum off-round
Crank pin journal diameter
Crank pin journal maximum off-round
Crankshaft main journal oil clearance
01-50–2
Specification
0.10 mm {0.0039 in}
78.000—78.013 mm {3.0709—3.0713 in}
77.970—77.980 mm {3.0697—3.0700 in}
Standard
0.020—0.043 mm {0.0008—0.0016 in}
Maximum
0.070 mm {0.0028 in}
Standard
Top: 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}
Maximum
Top, Second: 0.150 mm {0.0059 in}
Oil: 0.20 mm {0.0079 in}
Standard
Top: 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}
Maximum
1.0 mm {0.039 in}
18.988—19.000 mm {0.74756—0.74803 in}
18.974—18.980 mm {0.74701—0.74724 in}
0.008—0.026 mm {0.0004—0.0010 in}
Standard
0.110—0.292 mm {0.0044—0.0114 in}
Maximum
0.435 mm {0.0171 in}
Standard
0.016—0.037 mm {0.0007—0.0014 in}
Maximum
0.10 mm {0.0039 in}
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}
18.943—18.961 mm {0.74579—0.74649 in}
–0.037—–0.013 mm {–0.0014—–0.0006 in}
0.050 mm {0.0020 in}[Per 50 mm {2.0 in}]
0.075 mm {0.0030 in}[Per 50 mm {2.0 in}]
140.60—140.70 mm {5.536—5.539 in}
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}
Standard
0.080—0.282 mm {0.0032—0.0111 in}
Maximum
0.30 mm {0.012 in}
0.10 mm {0.0039 in}
STD: 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}
0.050 mm {0.0020 in}
STD: 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}
0.10 mm {0.0039 in}
Standard
0.019—0.038 mm {0.0008—0.0014 in}
Maximum
0.084 mm {0.0033 in}
1993-1U-10F.book
3 ページ
２０１０年４月１６日　金曜日　午後１時５７分
TECHNICAL DATA
Item
Main bearing thickness
Cylinder head bolt length
Connecting rod bolt length
Tip clearance between inner rotor and outer rotor
Body clearance between outer rotor and oil pump
body
Oil pump side clearance
Weight at which the plunger spring height is
compressed to 35.42 mm {1.394 in}
Standard valve clearance [Engine cold]
Specification
STD: 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}
Standard: 128.9—129.5 mm {5.075 —5.098 in}
Maximum: 130.2 mm {5.126 in}
Standard: 46.7—47.3 mm {1.84—1.86 in}
Maximum: 48.0 mm {1.89 in}
Standard: 0.02—0.18 mm {0.0008—0.0070 in}
Maximum: 0.20 mm {0.0079 in}
Standard: 0.090—0.175 mm {0.0036—0.0068 in}
Maximum: 0.20 mm {0.0079 in}
Standard: 0.03—0.07 mm {0.0012—0.0027 in}
Maximum: 0.090 mm {0.0035 in}
62.5—68.9 N {6.38—7.02 kgf, 14.1—15.4 lbf}
0.27—0.33 mm {0.011—0.012 in}
End Of Sie
01-50–3
01-50
1993-1U-10F.book
4 ページ
２０１０年４月１６日　金曜日　午後１時５７分
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
SERVICE TOOLS
ENGINE SST . . . . . . . . . . . . . . . . . . . . . . 01-60–1
End of Toc
ENGINE SST
SOKYU_WM: ENGINE
id016000119200
1: Mazda SST number
2: Global SST number
Example
1: 49 0107
680A
2: —
Engine stand
1: 49 L010 1A0
2: —
1: 49 E011 1A0
2: —
Engine hanger
set
Ring gear brake
set
1: 49 B012 0A2
2: —
1: 49 S120 170
2: —
Pivot
Valve seal
remover
1: 49 H018 001
2: —
1: 49 G014 001
2: —
1: 49 L011
0A0C
2: —
Knock sensor
wrench
Oil filter wrench
1: 49 E011
001A
2: —
1: 49 E011
002A
2: —
Piston pin guide
Screw
Valve guide
installer
1: 49 L012
0A0B
2: —
1: 49 E033 101
2: —
1: 49 T032 302
2: —
Dust cover
installer
Bearing installer
1: 49 0107
680A
2: —
Engine stand
1: 49 0636
100B
2: —
Valve spring
lifter arm
Valve seal and
valve guide
installer set
Piston pin
setting set
1: 49 B012 015
2: —
01-60–1
01-60
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
SERVICE TOOLS
1: 49 H010 401
2: —
Oil seal installer
End Of Sie
01-60–2
—
—