Engine CONTENTS

Workshop Title Section

Manual GENERAL INFORMATION 00

L3 WITH TC ENGINE 01

© 2005 Mazda Motor Corporation

FOREWORD PRINTED IN U.S.A., AUGUST 2005
Form No. 1833–1U–05H
This manual explains the service points for Part No. 9999–95–0L3T–06
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
 GENERAL INFORMATION 00
SECTION
00–00

Toc of SCT INFORMATION . . . . 00-00

GENERAL
Toc of SCT
00–00 GENERAL INFORMATION
HOW TO USE THIS MANUAL . . . . . . . . . 00–00–1 Inspection During Removal,
Range of Topics . . . . . . . . . . . . . . . . . . 00–00–1 Disassembly . . . . . . . . . . . . . . . . . . . . 00–00–5
Service Procedure . . . . . . . . . . . . . . . . 00–00–1 Arrangement of Parts . . . . . . . . . . . . . . 00–00–5
Symbols . . . . . . . . . . . . . . . . . . . . . . . . 00–00–3 Cleaning of Parts . . . . . . . . . . . . . . . . . 00–00–6
Advisory Messages. . . . . . . . . . . . . . . . 00–00–3 Reassembly . . . . . . . . . . . . . . . . . . . . . 00–00–6
UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–00–4 Adjustment . . . . . . . . . . . . . . . . . . . . . . 00–00–6
Conversion to SI Units Rubber Parts and Tubing . . . . . . . . . . . 00–00–7
(Système International d'Unités) . . . . . 00–00–4 Hose Clamps . . . . . . . . . . . . . . . . . . . . 00–00–7
Rounding Off . . . . . . . . . . . . . . . . . . . . . 00–00–4 Torque Formulas . . . . . . . . . . . . . . . . . 00–00–7
Upper and Lower Limits . . . . . . . . . . . . 00–00–4 Vise . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–00–7
FUNDAMENTAL PROCEDURES. . . . . . . 00–00–4 ELECTRICAL SYSTEM. . . . . . . . . . . . . . 00–00–8
Preparation of Tools and Connectors . . . . . . . . . . . . . . . . . . . . . . 00–00–8
Measuring Equipment . . . . . . . . . . . . . 00–00–4 SAE STANDARDS. . . . . . . . . . . . . . . . . . 00–00–9
Special Service Tools . . . . . . . . . . . . . . 00–00–5 ABBREVIATIONS . . . . . . . . . . . . . . . . . . 00–00–11
Disassembly . . . . . . . . . . . . . . . . . . . . . 00–00–5

End of Toc
HOW TO USE THIS MANUAL
E6U000000000E01
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 SHOWS PROCEDURE ORDER
location and contents of the procedures are FOR SERVICE
explained in detail and shown in the illustrations.
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 SHOWS TIGHTENING

TORQUE
49 H032 322 SPECIFICATIONS
Caution
Connect the gauge set from under
the vehicle to prevent contact with
the drive belt and the cooling fan.

WGIWXX0009E

00–00–1
 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
Procedure ITEM (S)
INDICATES ANY RELEVANT
1
LOWER TRAILING LINK, UPPER TRAILING LINK REMOVAL/INSTALLATION REFERENCES WHICH NEED
1. Jack up the rear of the vehicle and support it with safety stands. TO BE FOLLOWED DURING
"Removal/Installation" 2. Remove the undercover. (See 01-10-4 Undercover Removal)
Portion 3. Remove in the order indicated in the table. INSTALLATION
4. Install in the reverse order of removal.
2 5. Inspect the rear wheel alignment and adjust it if necessary.
"Inspection After SHOWS SPECIAL
Installation" Portion 11 SERVICE TOOL (SST)
9 SST
SHOWS PROCEDURE ORDER FOR SERVICE OPERATION

GREASE
FOR SERVICE 12 SST R

INSTALL THE PARTS BY SHOWS APPLICATION

PERFORMING STEPS 8 43—56 {4.3—5.8, 32—41}
POINTS OF GREASE, ETC.
10
— IN REVERSE ORDER
1—3 44—60 {4.4—6.2, 32—44} 7 R

SHOWS TIGHTENING
TORQUE
SPECIFICATIONS SHOWS NON-REUSEABLE PARTS

SST
3
5
6 SHOWS DETAILS
SST
GREASE

4 R
94—116 {9.5—11.9, 69—86}
2 118—156 {12.0—16.0, 87—115} SHOWS TIGHTENING
SHOWS THERE 1 R TORQUE UNITS
ARE REFERRAL
N·m {kgf·m, ft·lbf}
NOTES FOR SERVICE
1 Split pin 7 Split pin
2 Nut 8 Nut
3 Lower trailing link ball joint 9 Upper trailing link ball joint
(See 02-14-5 Lower Trailing Link Ball Joint Removal Note) (See 02-14-5 Upper Trailing Link Ball Joint Removal Note)
4 Bolt 10 Nut
5 Lower trailing link 11 Upper trailing link
6 Dust boot (lower trailing link) 12 Dust boot (upper trailing link)

Lower Trailing Link Ball Joint, Upper Trailing Link 49 T028 304 UPPER TRAILING LINK
Ball Joint Removal Note 49 T028 305 LOWER TRAILING LINK
Remove the ball joint using the SSTs.

SHOWS SPECIAL
SERVICE TOOL (SST)
NO. KNUCKLE

49 T028 303

SHOWS REFERRAL
NOTES FOR
SERVICE

BHE0000W104

00–00–2
 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
00–00
New appropriate
OIL Apply oil engine oil or gear
oil

New appropriate
BRAKE Apply brake fluid
FLUID brake fluid

New appropriate
Apply automatic
automatic
transaxle/
ATF
transaxle/
transmission fluid
transmission fluid

Appropriate
Apply grease
GREASE

grease

Appropriate
SEALANT Apply sealant
sealant

Apply petroleum Appropriate

P jelly petroleum jelly

O-ring, gasket,
R Replace part
etc.

Use SST or
SST equivalent
Appropriate tools

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

00–00–3
 GENERAL INFORMATION
UNITS
E6U000000000E02

Electric current A (ampere) N·m (Newton meter)

Electric power W (watt) kgf·m (kilogram force meter)
Electric resistance ohm Torque kgf·cm (kilogram force centimeter)
Electric voltage V (volt) ft·lbf (foot pound force)
mm (millimeter) in·lbf (inch pound force)
Length L (liter)
in (inch)
kPa (kilo pascal) US qt (U.S. quart)
Negative pressure mmHg (millimeters of mercury) Imp qt (Imperial quart)
inHg (inches of mercury) Volume ml (milliliter)
kPa (kilo pascal) cc (cubic centimeter)
kgf/cm2 (kilogram force per square cu in (cubic inch)
Positive pressure
centimeter) fl oz (fluid ounce)
psi (pounds per square inch) g (gram)
Weight
Number of oz (ounce)
rpm (revolutions per minute)
revolutions

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
FUNDAMENTAL PROCEDURES
E6U000000000E03
Preparation of Tools and Measuring Equipment
• Be sure that all necessary tools and measuring
equipment are available before starting any work.

CHU0014W003

00–00–4
 GENERAL INFORMATION
Special Service Tools
• Use special service tools or equivalent when they
are required.
49 SE01 310

00–00

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

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.

WGIWXX0029E

00–00–5
 GENERAL INFORMATION
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.

C5U0000W001

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

Adjustment
• Use suitable gauges and testers when making
adjustments.

CHU0014W005

00–00–6
 GENERAL INFORMATION
Rubber Parts and Tubing
• Prevent gasoline or oil from getting on rubber
parts or tubing.

00–00

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 SST
recalculated due to the extra length that the SST 3
2
or equivalent adds to the torque wrench. 1 0

Recalculate the torque by using the following

1

formulas. Choose the formula that applies to you.

2
3

Torque Unit Formula

N·m N·m × [L/(L+A)]
kgf·m kgf·m × [L/(L+A)]
A L
kgf·cm kgf·cm × [L/(L+A)]
ft·lbf ft·lbf × [L/(L+A)] WGIWXX0036E

in·lbf in·lbf × [L/(L+A)]

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

L : The length of the torque wrench.

Vise
• When using a vise, put protective plates in the
jaws of the vise to prevent damage to parts.
End Of Sie

PROTECTIVE PLATES
CHU0014W010

00–00–7
 GENERAL INFORMATION
ELECTRICAL SYSTEM
E6U000000000E04
Connectors
Disconnecting connectors
• When disconnecting connector, grasp the
connectors, not the wires. 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

00–00–8
 GENERAL INFORMATION
Inspection
• When a tester is used to inspect for continuity or
measuring voltage, insert the tester probe from GOOD NO GOOD
the wiring harness side.
• Inspect the terminals of waterproof connectors
from the connector side since they cannot be 00–00
accessed from the wiring harness side.

CHU0000W011

Caution
• To prevent damage to the terminal, wrap
a thin wire around the tester probe before GOOD NO GOOD
inserting into terminal.

CHU0000W012

End Of Sie
SAE STANDARDS
E6U000000000E05
• Following is a comparison of the previous standard and the new standard.
SAE Standard Previous Standard
Abbrevi- Abbrevi- Remark
Name Name
ation ation
AP Accelerator Pedal — Accelerator Pedal
ACL Air Cleaner — Air Cleaner
A/C Air Conditioning — Air Conditioning
BARO Barometric Pressure — Atmospheric Pressure
B+ Battery Positive Voltage Vb Battery Voltage
— Brake Switch — Stoplight Switch
— Calibration Resistor — Corrected Resistance #6
CMP sensor Camshaft Position Sensor — Crank Angle Sensor
CAC Charge Air Cooler — Intercooler
CLS Closed Loop System — Feedback System
CTP Closed Throttle Position — Fully Closed
CPP Clutch Pedal Position — Idle Switch
CIS Continuous Fuel Injection System — Clutch Position
CS sensor Control Sleeve Sensor CSP sensor Control Sleeve Position Sensor #6
CKP sensor Crankshaft Position Sensor — Crank Angle Sensor 2
DLC Data Link Connector — Diagnosis Connector
DTM Diagnostic Test Mode — Test Mode #1
DTC Diagnostic Trouble Code(s) — Service Code(s)
DI Distributor Ignition — Spark Ignition
DLI Distributorless Ignition — Direct Ignition
EI Electronic Ignition — Electronic Spark Ignition #2
ECT Engine Coolant Temperature — Water Thermo
EM Engine Modification — Engine Modification
— Engine Speed Input Signal — Engine RPM Signal
EVAP Evaporative Emission — Evaporative Emission

00–00–9
 GENERAL INFORMATION
SAE Standard Previous Standard
Abbrevi- Abbrevi- Remark
Name Name
ation ation
EGR Exhaust Gas Recirculation — Exhaust Gas Recirculation
FC Fan Control — Fan Control
FF Flexible Fuel — Flexible Fuel
4GR Fourth Gear — Overdrive
— Fuel Pump Relay — Circuit Opening Relay #3
FSO
Fuel Shut Off Solenoid FCV Fuel Cut Valve #6
solenoid
GEN Generator — Alternator
GND Ground — Ground/Earth
HO2S Heated Oxygen Sensor — Oxygen Sensor With heater
IAC 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
IAT Intake Air Temperature — Intake Air Thermo
KS Knock Sensor — Knock Sensor
MIL Malfunction Indicator Lamp — Malfunction Indicator Light
MAP Manifold Absolute Pressure — Intake Air Pressure
MAF sensor Mass Air Flow Sensor — Airflow Sensor
MFL Multiport Fuel Injection — Multiport Fuel Injection
OBD On-Board Diagnostic — Diagnosis/Self-Diagnosis
OL Open Loop — Open Loop
— Output Speed Sensor — Vehicle Speed Sensor 1
OC Oxidation Catalytic Converter — Catalytic Converter
O2S Oxygen Sensor — Oxygen Sensor
PNP Park/Neutral Position — Park/Neutral Range
— PCM Control Relay — Main Relay #6
PSP Power Steering Pressure — Power Steering Pressure
PCM Powertrain Control Module ECU Engine Control Unit #4
— Pressure Control Solenoid — Line Pressure Solenoid Valve
Pulsed
PAIR Pulsed Secondary Air Injection — Secondary Air Injection System
injection
— Pump Speed Sensor — NE Sensor #6
Injection
AIR Secondary Air Injection — Secondary Air Injection System with air
pump
SAPV Secondary Air Pulse Valve — Reed Valve
SFI Sequential Multipoint Fuel Injection — Sequential Fuel Injection
— 12 Shift Solenoid Valve
— Shift Solenoid A
— Shift A Solenoid Valve
— 23 Shift Solenoid Valve
— Shift Solenoid B
— Shift B Solenoid Valve
— Shift Solenoid C — 34 Shift Solenoid Valve
3GR Third Gear — 3rd Gear
TWC Three Way Catalytic Converter — Catalytic Converter
TB Throttle Body — Throttle Body
TP sensor Throttle Position Sensor — Throttle Sensor
TCV Timer Control Valve TCV Timing Control Valve #6
TCC Torque Converter Clutch — Lockup Position
Transmission (Transaxle) Control
TCM — EC-AT Control Unit
Module
Transmission (Transaxle) Fluid
— — ATF Thermosensor
Temperature Sensor

00–00–10
 GENERAL INFORMATION
SAE Standard Previous Standard
Abbrevi- Abbrevi- Remark
Name Name
ation ation
TR Transmission (Transaxle) Range — Inhibitor Position
TC Turbocharger — Turbocharger 00–00
VSS Vehicle Speed Sensor — Vehicle Speed Sensor
VR Voltage Regulator — IC Regulator
VAF sensor Volume Air Flow Sensor — Air flow Sensor
Warm Up Three Way Catalytic
WUTWC — Catalytic Converter #5
Converter
WOT Wide Open Throttle — Fully Open

#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
ABBREVIATIONS
E6U000000000E06

EGR Exhaust Gas Recirculation

EX Exhaust
IN Intake
MTX Manual Transaxle
OCV Oil Control Valve
TDC Top Dead Center
SST Special Service Tool

End Of Sie

00–00–11
 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 Spool Valve Operation Inspection . . . . 01–10–19
SERVICE WARNING . . . . . . . . . . . . . . . 01–10–2 CAMSHAFT INSPECTION . . . . . . . . . . . 01–10–20
ENGINE MOUNTING/DISMOUNTING . . . 01–10–2 CYLINDER BLOCK INSPECTION . . . . . 01–10–21
Installation . . . . . . . . . . . . . . . . . . . . . . . 01–10–2 OIL JET VALVE INSPECTION . . . . . . . . 01–10–22
Removal . . . . . . . . . . . . . . . . . . . . . . . . 01–10–2 PISTON INSPECTION . . . . . . . . . . . . . . . 01–10–22
TIMING CHAIN DISASSEMBLY. . . . . . . . 01–10–3 PISTON PIN INSPECTION . . . . . . . . . . . 01–10–23
Crankshaft Pulley Lock Bolt CONNECTING ROD CLEARANCE
Disassembly Note . . . . . . . . . . . . . . . . 01–10–4 INSPECTION . . . . . . . . . . . . . . . . . . . . . 01–10–24
Front Oil Seal Disassembly Note . . . . . 01–10–4 PISTON, CONNECTING ROD
Timing Chain Tensioner INSPECTION . . . . . . . . . . . . . . . . . . . . . 01–10–24
Disassembly Note . . . . . . . . . . . . . . . . 01–10–4 CONNECTING ROD INSPECTION . . . . . 01–10–25
Oil Pump Driven Sprocket CRANKSHAFT INSPECTION . . . . . . . . . 01–10–25
Disassembly Note . . . . . . . . . . . . . . . . 01–10–5 PILOT BEARING INSPECTION . . . . . . . 01–10–27
CYLINDER HEAD (I) DISASSEMBLY . . . 01–10–6 BOLT INSPECTION . . . . . . . . . . . . . . . . . 01–10–27
Camshaft Sprocket, Variable Valve VALVE CLEARANCE IN
Timing Actuator Disassembly Note . . . 01–10–7 SPECTION/ADJUSTMENT . . . . . . . . . . 01–10–28
Camshaft Cap Disassembly Note . . . . . 01–10–7 VALVE CLEARANCE INSPECTION . . 01–10–28
Tappet Disassembly Note . . . . . . . . . . . 01–10–7 VALVE CLEARANCE
Cylinder Head Disassembly Note . . . . . 01–10–7 ADJUSTMENT . . . . . . . . . . . . . . . . . . 01–10–28
CYLINDER HEAD (II) DISASSEMBLY. . . 01–10–8 CYLINDER BLOCK (I) ASSEMBLY . . . . 01–10–32
Valve Keeper Disassembly Note . . . . . . 01–10–8 Main Bearing Cap Assembly Note . . . . 01–10–33
Valve Seal Disassembly Note . . . . . . . . 01–10–8 Piston Pin Assembly Note . . . . . . . . . . 01–10–33
CYLINDER BLOCK (I) Piston Ring Assembly Note . . . . . . . . . 01–10–33
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . 01–10–9 Piston Assembly Note . . . . . . . . . . . . . 01–10–34
Oil Pan Disassembly Note. . . . . . . . . . . 01–10–10 Connecting Rod Bearing
Flywheel Disassembly Note . . . . . . . . . 01–10–10 Assembly Note . . . . . . . . . . . . . . . . . . 01–10–34
CYLINDER BLOCK (II) Connecting Rod Cap
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . 01–10–11 Assembly Note . . . . . . . . . . . . . . . . . . 01–10–34
Pilot Bearing Disassembly Note . . . . . . 01–10–12 Balancer Unit Assembly Note. . . . . . . . 01–10–35
Connecting Rod Cap Pilot Bearing Assembly Note . . . . . . . . 01–10–37
Disassembly Note . . . . . . . . . . . . . . . . 01–10–12 CYLINDER BLOCK (II) ASSEMBLY . . . . 01–10–38
Connecting Rod, Piston Rear Oil Seal Assembly Note. . . . . . . . 01–10–39
Disassembly Note . . . . . . . . . . . . . . . . 01–10–12 Flywheel Assembly Note . . . . . . . . . . . 01–10–39
Piston Pin Disassembly Note . . . . . . . . 01–10–12 Oil Pan Assembly Note. . . . . . . . . . . . . 01–10–39
Main Bearing Cap Disassembly Note . . 01–10–13 CYLINDER HEAD (I) ASSEMBLY. . . . . . 01–10–41
CYLINDER HEAD INSPECTION . . . . . . . 01–10–13 Water Outlet Case Assembly Note. . . . 01–10–41
VALVE SEAT INSPECTION/REPAIR . . . . 01–10–14 Valve Seal Assembly Note . . . . . . . . . . 01–10–42
VALVE, VALVE GUIDE INSPECTION . . . 01–10–14 Valve Keeper Assembly Note . . . . . . . . 01–10–42
VALVE GUIDE REPLACEMENT . . . . . . . 01–10–16 CYLINDER HEAD (II) ASSEMBLY . . . . . 01–10–43
Removal . . . . . . . . . . . . . . . . . . . . . . . . 01–10–16 Cylinder Head Assembly Note . . . . . . . 01–10–44
Installation . . . . . . . . . . . . . . . . . . . . . . . 01–10–16 Camshaft Assembly Note. . . . . . . . . . . 01–10–44
VALVE SPRING INSPECTION . . . . . . . . . 01–10–17 Camshaft Sprocket, Variable Valve
TAPPET INSPECTION . . . . . . . . . . . . . . . 01–10–18 Timing Actuator Assembly Note . . . . . 01–10–44
VARIABLE VALVE TIMING ACTUATOR TIMING CHAIN ASSEMBLY . . . . . . . . . . 01–10–45
INSPECTION . . . . . . . . . . . . . . . . . . . . . 01–10–18 Drive Sprocket Assembly Note. . . . . . . 01–10–46
OIL CONTROL VALVE (OCV) Oil Pump Driven Sprocket
INSPECTION . . . . . . . . . . . . . . . . . . . . . 01–10–19 Assembly Note . . . . . . . . . . . . . . . . . . 01–10–46
Coil Resistance Inspection . . . . . . . . . . 01–10–19 Timing Chain Assembly Note . . . . . . . . 01–10–46

01–10–1
 MECHANICAL
Camshaft Sprocket Lock Bolt Crankshaft Pulley Lock Bolt
Assembly Note . . . . . . . . . . . . . . . . . . 01–10–47 Assembly Note . . . . . . . . . . . . . . . . . . 01–10–49
Engine Front Cover Assembly Note . . . 01–10–48 Cylinder Head Cover Assembly Note . . 01–10–50

End of Toc
ENGINE OVERHAUL SERVICE WARNING
E6U011000000E02

Warning
• Continuous exposure to USED engine oil has been shown to cause skin cancer in laboratory mice.
Protect your skin by washing with soap and water immediately after performing work.

End Of Sie
ENGINE MOUNTING/DISMOUNTING
E6U011000000E01
Installation
1. Install the SST (arms) to the four positions as
shown in the figure and temporarily tighten the
bolts (Part No.: 9YA20-1003) or M10 × 1.5T 49 L010 102
length 90 mm {3.55 in}.

B3E0110W127

2. Install the SSTs (bolts, nuts, hook, and plate) to

the four positions as shown in the figure.
3. Install the SST (bolts, nuts, hook, and plate) set in 49 L010 101
Step 2 to the SST (arms and bolts) set in Step 1. 49 L010 104
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. 49 L010 105

C3U0110E001

6. Install the engine to the SST (engine stand).

7. Remove the oil drain plug and drain the engine PARALLEL
oil. 49 L010 101
8. Replace the gasket with a new one and install the 49 L010 102
oil pan drain plug.
49 L010 105
Tightening torque ENGINE
30—41 N·m {3.1—4.1 kgf·m, 23—30 ft·lbf}

49 L010 104 49 L010 103 APPROX. 20 mm {0.79 in}

E6U110ZEB040

Removal
1. Remove in the reverse order of installation.
End Of Sie

01–10–2
 MECHANICAL
TIMING CHAIN DISASSEMBLY
E6U011012201E04
1. Disassemble in the order indicated in the table.

7 01–10

6 13

R
R
8

3 SST
R 9

12

10

19 16 SST
14
18
15

11 17
E6U110ZEB011

.
1 Spark plug 10 Timing chain tensioner arm
2 Cylinder head cover 11 Timing chain guide
3 Crankshaft pulley lock bolt 12 Timing chain
(See 01–10–4 Crankshaft Pulley Lock Bolt 13 Oil jet
Disassembly Note.)
14 Oil pump chain tensioner
4 Crankshaft pulley
15 Oil pump chain guide
5 Water pump pulley
16 Oil pump driven sprocket
6 Drive belt idler pulley (See 01–10–5 Oil Pump Driven Sprocket
7 Engine front cover Disassembly Note.)
(See 01–10–4 Front Oil Seal Disassembly Note.) 17 Oil pump chain
8 Front oil seal 18 Crankshaft sprocket
9 Timing chain tensioner 19 Oil pump drive sprocket
(See 01–10–4 Timing Chain Tensioner Disassembly
Note.)

01–10–3
 MECHANICAL
Crankshaft Pulley Lock Bolt Disassembly Note
1. Install the SST to the ring gear to lock the
crankshaft against rotation.

49 E011 1A0

E6U110ZEB033

Front Oil Seal Disassembly Note

1. Remove the oil seal using a flathead screwdriver.

E6U110ZWB044

Timing Chain Tensioner Disassembly Note

1. Press the timing chain tensioner ratchet to the left
using a thin flathead screwdriver (precision
screwdriver) to unlock the plunger. RATCHET

PLUNGER

E6U110ZWB054

2. Slowly press the plunger back in the direction

shown in the figure while pressing the ratchet.

RATCHET

E6U110ZWB055

01–10–4
 MECHANICAL
3. Release the ratchet with the plunger still pressed
down.
RATCHET

01–10

E6U110ZWB056

4. Press-in the plunger until the ratchet position is as

indicated in the figure, and then insert the wire to RATCHET
lock the plunger.

WIRE INSERTION
HOLE

E6U110ZWB053

Oil Pump Driven Sprocket Disassembly Note

1. Install the SST on the oil pump driven sprocket to
lock the oil pump against rotation.
End Of Sie

49 G032 354

B3E0110E054

01–10–5
 MECHANICAL
CYLINDER HEAD (I) DISASSEMBLY
E6U011010100E01
1. Disassemble in the order indicated in the table.

1 4
R

6
5
7
R

8 R

E6U110ZEB024

1 Camshaft sprocket, Variable valve timing actuator 5 Tappet

(See 01–10–7 Camshaft Sprocket, Variable Valve (See 01–10–7 Tappet Disassembly Note.)
Timing Actuator Disassembly Note.) 6 Cylinder head bolt
2 OCV 7 Cylinder head
3 Camshaft cap (See 01–10–7 Cylinder Head Disassembly Note.)
(See 01–10–7 Camshaft Cap Disassembly Note.) 8 Cylinder head gasket
4 Camshaft

01–10–6
 MECHANICAL
Camshaft Sprocket, Variable Valve Timing Actuator Disassembly Note
1. Before removing the camshaft, hold the camshaft
using a wrench on the cast hexagon and loosen
the camshaft sprocket installation bolt.

01–10

B3E0110E058

Camshaft Cap Disassembly Note

1. Before removing the camshaft cap, Inspect the camshaft end play. (See 01–10–20 CAMSHAFT INSPECTION.)

Note
• Determine the position of each removed camshaft cap.

2. Loosen the camshaft cap bolts in two to three

1 3 5 4 2
passes in the order shown in the figure and
remove the camshaft caps.
EX

No.1 No.2 No.3 No.4

IN

2 4 6 5 3 1
E6U110ZEB001

Tappet Disassembly Note

Note
• Determine the position of each removed tappet.

Cylinder Head Disassembly Note

1. Loosen the cylinder head installation bolts in two
to three passes in the order shown in the figure 3 7 10 6 2
and remove them.
End Of Sie

4 8 9 5 1
B3E0110E059

01–10–7
 MECHANICAL
CYLINDER HEAD (II) DISASSEMBLY
E6U011010100E02
1. Disassemble in the order indicated in the table.

2 SST 1
3
4

R 6
SST 7
R

E6U110ZEB014

1 Engine hanger 5 Valve

2 Valve keeper 6 Valve seal
(See 01–10–8 Valve Keeper Disassembly Note.) (See 01–10–8 Valve Seal Disassembly Note.)
3 Upper valve spring seat 7 Water outlet case
4 Valve spring

Valve Keeper Disassembly Note

1. Remove the valve keeper using the SSTs.

49 0636 100B

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

01–10–8
 MECHANICAL
CYLINDER BLOCK (I) DISASSEMBLY
1. Disassemble in the order indicated in the table.
13 R
SST

R 14
12
01–10

R 6
9 R

R 4
7

R R
11
10 8
5
R

3 R

1 2

E6U110ZEB013

1 Oil pan 8 Thermostat

(See 01–10–10 Oil Pan Disassembly Note.) 9 Water pump
2 Oil filter cover 10 Oil strainer
3 Oil filter 11 Oil pump
4 Oil cooler 12 Flywheel
5 Oil filter adapter (See 01–10–10 Flywheel Disassembly Note.)
6 Knock sensor 13 End plate
7 Crankcase ventilation cover 14 Rear oil seal

01–10–9
 MECHANICAL
Oil Pan Disassembly Note
1. Remove the oil pan using a oil pan seal cutter.

1
E6U110ZEB022

Flywheel Disassembly Note

1. Use the SST to lock the crankshaft against
rotation.
End Of Sie
49 E011 1A0
1
3 6
5 4
2

B3E0110E051

01–10–10
 MECHANICAL
CYLINDER BLOCK (II) DISASSEMBLY
E6U011010300E02
1. Disassemble in the order indicated in the table.

01–10

7
10
9 SST
15
16
8 1 SST
11

14
6

3
4 13

12

E6U110ZEB015

1 Pilot bearing 9 Piston pin

(See 01–10–12 Pilot Bearing Disassembly Note.) (See01–10–12 Piston Pin Disassembly Note.)
2 Engine balancer 10 Piston
3 Connecting rod cap 11 Connecting rod
(See 01–10–12 Connecting Rod Cap Disassembly 12 Main bearing cap
Note.) (See 01–10–13 Main Bearing Cap Disassembly
4 Lower connecting rod bearing Note.)
5 Upper connecting rod bearing 13 Lower main bearing
6 Connecting rod piston 14 Crankshaft
(See 01–10–12 Connecting Rod, Piston 15 Upper main bearing, thrust bearing
Disassembly Note.) 16 Oil jet valve
7 Piston ring
8 Snap ring

01–10–11
 MECHANICAL
Pilot Bearing Disassembly Note

Note
• The pilot bearing does not need to be removed unless you are replacing it.

1. Use the SST to remove the pilot bearing.

49 1285 071

E6U110ZWB048

Connecting Rod Cap Disassembly Note

1. Before removing the connecting rod cap, inspect
the connecting rod side clearance. (See 01–10–
24 CONNECTING ROD CLEARANCE
INSPECTION.)

Note
• Determine the position of each removed
connecting rod cap.

B3E0110E087

Connecting Rod, Piston Disassembly Note

1. Before removing the connecting rod and piston, remove the carbon in the cylinder.
2. Before removing the connecting rod piston, inspect the oil clearance at the large end of the connecting rod.
(See 01–10–24 CONNECTING ROD CLEARANCE INSPECTION.)

Piston Pin Disassembly Note

1. Before removing the piston pin, weigh the connecting rod. (See 01–10–24 PISTON, CONNECTING ROD
INSPECTION.)
2. Remove the piston pin using the SST.

49 T011 001

E6U110ZEB034

01–10–12
 MECHANICAL
Main Bearing Cap Disassembly Note
1. Before removing the main bearing cap, inspect the crankshaft end play. (See 01–10–25 CRANKSHAFT
INSPECTION.)
2. Loosen the main bearing cap bolts in two to three
passes in the order shown in the figure and
remove them.
End Of Sie 2 6 10 8 4
01–10

1 5 9 7 3

B3E0110E067

CYLINDER HEAD INSPECTION

E6U011012201E02
1. Inspect the cylinder head surface for cracks and other damage using a red dye penetrant.
• If there is a malfunction, 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 the distortion exceeds the maximum
specification, replace the cylinder head.

Maximum distortion, head gasket side

0.10 mm {0.004 in}

B3E0110E008

3. Inspect the contact surface of the exhaust manifold and the intake manifold for distortion by measuring as
shown in the figure using a straight edge and feeler gauge.
• If the distortion exceeds the maximum
specification, grind the surface or replace the EX
cylinder head.

Maximum distortion, manifold side

0.10 mm {0.004 in}
IN
Maximum cutting length, manifold side
0.15 mm {0.006 in}

End Of Sie
C3U0110E003

01–10–13
 MECHANICAL
VALVE SEAT INSPECTION/REPAIR
E6U011010102E01
1. Measure the contact width of the valve face and the valve seat using the valve lapping compound.
• If it is not within the specification, resurface
the valve seat using the 45° valve seat cutter.

Standard valve seat contact width

IN: 0.7—1.3mm {0.0276—0.0511 in}
EX: 0.7—1.3mm {0.0276—0.0511 in} SEAT CONTACT
WIDTH

ADA2224E019

2. Verify that the area where the valve seat contacts the valve face is centered.
• If the seating position is too high, resurface the valve seat using a 70° (IN) 65° (EX) valve seat cutter and a
45° valve seat cutter.
• If the seating position is too low, resurface the
valve seat using a 35° (IN) 30° (EX) valve seat
cutter and a 45° valve seat cutter.
IN EX

Valve seat angle

IN: 45° 70° 65°
EX: 45°
45° 45°

35° 30°

B3E0110E133

3. Inspect the valve seat for sinkage. Measure the protruding length (dimension L) of the valve stem using a valve
of standard length.
• If it is not within the specification, replace the
cylinder head. L

Standard valve seat sinkage amount

(Dimension L)
IN: 40.64—42.24 mm {1.600—1.662 in}
EX: 40.50—42.10 mm {1.595—1.657 in}

End Of Sie

C3U0110E006

VALVE, VALVE GUIDE INSPECTION

E6U011010280E01
1. Measure the valve head margin thickness using a vernier caliper.
• If it is less than the minimum specification,
replace the valve.

Minimum valve head margin thickness

IN: 1.62 mm {0.0637 in} IN : 33.5 mm {1.31 in}
EX: 1.82 mm {0.0716 in} EX : 28.3 mm {1.14 in}

MARGIN THICKNESS

C3U0110E051

01–10–14
 MECHANICAL
2. Measure the length of the each valve using a vernier caliper.
• If it is not within the specification, replace the
valve.

Standard valve length (Dimension L)

IN: 102.99—103.79 mm {4.055—4.086 in}
EX: 104.25—105.05 mm {4.105—4.135 in}
01–10
L

B3E0110E068

3. Measure the stem diameter of each valve using the micrometer. Measurement positions total six and are in the
X and Y directions, at three points (A, B, and C) as shown in the figure.
• If it is less than the minimum specification,
replace the valve. X

Valve stem diameter Y

Standard
IN: 5.970—5.985 mm {0.2351—0.2356 in} A
EX: 5.965—5.980 mm {0.2349—0.2354 in}
Minimum B
IN: 5.940 mm {0.2339 in}
EX: 5.935 mm {0.2336 in} C

ADJ2224E024

4. Measure the inner diameter of each valve guide using the caliper gauge. Measurement positions total six and
are in the X and Y directions, at three points (A, B, and C) as shown in the figure.
• If it is not within the specification, replace the
X
valve guide.
Y
Standard valve guide inner diameter
IN: 6.009—6.039 mm {0.2366—0.2377 in} A
EX: 6.009—6.039 mm {0.2366—0.2377 in}
B

ADJ2224E026

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 valve guide.
VALVE STEM
Clearance between valve stem and guide
Standard VALVE GUIDE
IN: 0.024—0.069 mm {0.0009—0.0027 in}
EX: 0.029—0.074 mm {0.0012—0.0029 in} CLEARANCE
Maximum
0.10 mm {0.004 in}

ADA2224E027

01–10–15
 MECHANICAL
6. Measure the projection height (dimension A) of each valve guide using the vernier caliper.
• If it is not within the specification, replace the
valve guide. VALVE GUIDE

A
Standard valve guide projection height
IN: 12.2—12.8 mm {0.481—0.503 in}
EX: 12.2—12.8 mm {0.481—0.503 in}

End Of Sie

CYLINDER HEAD

C3U0110E004

VALVE GUIDE REPLACEMENT

E6U011010280E02
Removal
1. Tap the valve guide out from combustion chamber
side using the SST. 49 B012 015

VALVE GUIDE

C3U0110E005

Installation
1. Assemble the SSTs so that dimension L is as
specified.

Standard valve guide projection height 49 L012 004A

L
IN: 12.2—12.8 mm {0.481—0.503 in}
EX: 12.2—12.8 mm {0.481—0.503 in}
49 L012 003A

49 L012 002A
B3E0110E071

01–10–16
 MECHANICAL
2. Tap the valve guide in from the cam side using the
SSTs assembled in Step 1.

VALVE GUIDE

01–10

COMBUSTION CHAMBER SIDE

E6U110ZWB061

End Of Sie
49 L012 003A
49 L012 004A

49 L012 002A
VALVE GUIDE

B3E0110E072

VALVE SPRING INSPECTION

E6U011012125E01
1. Measure the valve spring height using the spring tester.
• If it is not within the specification, replace the
valve spring.

Valve spring installation height

37.90 mm {1.492 in} (171.5 N {17.49 kgf,
38.55 lbf})

ADJ2224E028

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. A

Maximum valve spring off-square

2.55 mm {0.100 in} UPPER

End Of Sie

LOWER

B3E0110E073

01–10–17
 MECHANICAL
TAPPET INSPECTION
E6U011012431E01
1. Measure the diameter of each tappet bore using
the caliper gauge. Measurement positions total
four and are in the X and Y directions, at two X
points (A and B) as shown in the figure.
Y
Standard tappet bore diameter
31.000—31.030 mm {1.2205—1.2216 in}
A
B

ADJ2224E023

2. Measure the tappet body outer diameter of each

valve using the micrometer. Measurement
positions total four and are in the X and Y A
directions, at two points (A and B) as shown in the Y
B
figure.
X
Standard tappet body outer diameter
30.970—30.980 mm {1.2193—1.2196 in}

3. Calculate the clearance between the tappet and

the related tappet bore by subtracting the outer
diameter of the tappet from the inner diameter of
ADJ2224E029
the tappet bore.
• If it exceeds the maximum specification, replace the tappet or cylinder head.

Clearance between tappet and tappet bore

Standard
0.02—0.06 mm {0.0008—0.0023 in}
Maximum
0.15 mm {0.006 in}

VARIABLE VALVE TIMING ACTUATOR INSPECTION

End Of Sie

E6U011012420E01
1. Rotate the variable valve timing actuator by hand and verify that the groove of the rotor and notch of the cover
on the variable valve timing actuator are aligned and fitted.

Caution
• If the groove and notch are not aligned, rotate the rotor toward the valve timing retard position
until a locking sound is heard and verify that they are set in place.

• If the rotor and cover are not secured even

though their notch and groove are aligned,
replace the variable valve timing actuator.
COVER
Caution
• Due to the precision interior construction
of the variable valve timing actuator, it
cannot be disassembled. NOTCH

End Of Sie ROTOR

B3E0110E089

01–10–18
 MECHANICAL
OIL CONTROL VALVE (OCV) INSPECTION
E6U011012420E02
Coil Resistance Inspection
1. Measure the coil resistance between terminals A and B using a tester.
• If it is not within the specification, replace the
oil control valve.

Oil control valve coil resistance OIL CONTROL VALVE (OCV)

6.9—7.9 ohms [20°C {68°F}] 01–10
A B

AME2226W002

Spool Valve Operation Inspection

1. Verify that the spool valve inside the oil control valve is at the maximum valve timing retard position as shown in
the figure.
• If there is any malfunction, replace the oil
control valve.

SPOOL VALVE
(MAXIMUM VALVE TIMING RETARD POSITION

B3E0110E090

2. Apply battery positive voltage between the oil control valve terminals A and B and verify that the spool valve
operates and move to the maximum valve timing advance position.
• If there is any malfunction, replace the oil
control valve.
VALVE TIMING VALVE TIMING
ADVANCE RETARD
Note
• When applying battery positive voltage
between the oil control valve terminals, the
connection of the positive and negative
cables can be either terminal A or B.
SPOOL VALVE
3. Stop applying battery positive voltage and verify (MAXIMUM VALVE TIMING ADVANCE POSITION)
that the spool valve returns to the maximum valve
timing retard position.
• If there is any malfunction, replace the oil
B3E0110E091

control valve.
End Of Sie

01–10–19
 MECHANICAL
CAMSHAFT INSPECTION
E6U011012420E03
1. Set the No.1 and No.5 journals of the camshaft on V-blocks.
2. Measure the camshaft runout using the dial gauge.
• If it is not within the specification, replace the
camshaft.

Maximum camshaft runout

0.03 mm {0.0012 in}

B3E0110E074

3. Measure the cam height using the micrometer as shown in the figure.
• If it is less than the minimum specification,
replace the camshaft.

Cam height
Standard
IN: 42.44 mm {1.671 in}
EX: 41.18 mm {1.622 in}
Minimum
IN: 42.34 mm {1.667 in}
EX: 41.08 mm {1.618 in}

B3E0110E076

4. Measure the journal diameter using the micrometer. Measurement positions total four and are in the X and Y
directions, at two points (A and B) as shown in the figure.
• If it is less than the minimum specification,
replace the camshaft.
B
Camshaft journal diameter A
Standard
24.96—24.98 mm {0.9827—0.9834 in}
Minimum
24.95 mm {0.982 in}
Y
X

B3E0110E075

01–10–20
 MECHANICAL
5. Measure the camshaft journal oil clearance using the plastigauge with the tappet removed.
• If it exceeds the maximum specification, replace the cylinder head.
Note
• Clean the camshaft journal and the journal receptacle part.
• Cut the plastigauge to the same length as
the journal width and position it parallel to
the camshaft.
01–10
Camshaft journal oil clearance
Standard
0.04—0.08 mm {0.002—0.003 in}
Maximum
0.09 mm {0.0035 in} PLASTIGAUGE

B3E0110E077

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

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

Camshaft end play

Standard
0.09—0.24 mm {0.0035—0.0094 in}
Maximum
0.25 mm {0.0099 in}

End Of Sie

B3E0110E078

CYLINDER BLOCK INSPECTION

E6U011010300E03
1. Measure the cylinder block 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 block.

Maximum distortion, head gasket side

0.10 mm {0.004 in}

ADJ2224E089

2. Measure the cylinder bore diameter using the cylinder gauge. The measurement position is in the X and Y
directions at a point 42 mm below the top surface of the cylinder as shown in the figure.
• If it exceeds the maximum specification,
X
replace the cylinder block.

Maximum bore inner diameter Y

87.500—87.530 mm {3.4449—3.4460 in}

End Of Sie
42 mm {1.65 in}

C3U0110E007

01–10–21
 MECHANICAL
OIL JET VALVE INSPECTION
E6U011011010E01
1. Apply 0.17—0.23 MPa or more of compressed air
to oil jet valve A and verify that air passes through
oil jet valve B. If this cannot be verified, replace
the oil jet valve.
End Of Sie

B
E6U110ZEB003

PISTON INSPECTION
E6U011011010E02
1. Measure the piston outer diameter using the micrometer.
The measurement position is 10.0 mm {0.40 in} from the lower end of the piston and in the thrust direction.

• If it is not within the specification, replace the

piston.

Standard piston outer diameter

87.465—87.495 mm {3.4435—3.4446 in}

2. Calculate the cylinder-to-piston clearance from

the cylinder bore diameter and the piston outer
diameter.
• If the clearance is at the maximum
specification or more, replace the piston or
cylinder block.
B3E0110E080

Clearance between piston and cylinder

Standard
0.025—0.045 mm {0.0010—0.0017 in}
Maximum
0.11 mm {0.0043 in}

3. Measure the piston-to-ring groove clearance along the perimeter using a feeler gauge.
• If the clearance is at the maximum
specification or more, replace the piston or
piston ring.

Clearance between piston ring and ring

groove
Standard
Top: 0.005—0.08 mm {0.0020—0.0031 in}
Second: 0.03—0.07 mm {0.0012—0.0027in}
Oil: 0.02—0.06 mm {0.0008—0.0023 in}
Maximum
Top: 0.17 mm {0.0067 in}
B3E0110E081
Second, Oil: 0.15 mm {0.0059 in}

01–10–22
 MECHANICAL
4. Measure the piston ring end gap using a feeler gauge.
• If it is at the maximum specification or more,
replace the piston ring.

Piston ring end gap

Standard
Top: 0.14—0.24 mm {0.0056—0.0094 in}
Second: 0.34—0.44 mm {0.0134—0.0173 in} 01–10
Oil (rail): 0.15—0.40 mm {0.0060—0.0157 in} PISTON RING
Maximum
1.0 mm {0.0393 in}

End Of Sie B3E0110E082

PISTON PIN INSPECTION

E6U011011010E03
1. Measure the piston pin hole diameter using the
caliper gauge. Measurement positions total eight
and 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

22.504—22.508 mm {0.8860—0.8861 in} A
B
X

C
D
Y
ADJ2224E253

2. Measure the inner diameter on the small end of

X
the connecting rod using the caliper gauge.
Measurement positions total eight and are in the
X and Y directions, at four points (A, B, C, and D)
as shown in the figure. Y

Standard connecting rod small end inner

diameter
22.510—22.521 mm {0.8863—0.8866 in}

ADJ2224E254

3. Measure the piston pin outer diameter using the X

micrometer. Measurement positions total eight
and are in the X and Y directions, at four points
(A, B, C, and D) as shown in the figure. Y

Standard piston pin outer diameter

22.495—22.500 mm {0.8857—0.8858 in} A
B
4. Calculate the clearance between the piston pin
hole diameter and the piston pin outer diameter.
C
• If it is not within the specification, replace the
D
piston or the piston pin.
ADJ2224E255

Standard clearance between piston pin hole

diameter and piston outer diameter
0.004—0.013 mm {0.0002—0.0005 in}

5. Calculate the clearance between the inner diameter on the small end of the connecting rod and the piston pin
outer diameter.
• If it is not within the specification, replace the connecting rod or the piston pin.

Standard clearance between connecting rod small end inner diameter and piston pin outer diameter
0.010—0.026 mm {0.0004—0.0010 in}

01–10–23
 MECHANICAL
CONNECTING ROD CLEARANCE INSPECTION
End Of Sie

E6U011011211E04
1. Measure the side clearance at the large end of the connecting rod using a feeler gauge.
• If it is at the maximum specification or more,
replace the connecting rod or crankshaft.

Connecting rod large end side clearance

Standard
0.14—0.36 mm {0.0056—0.0141 in}
Maximum
0.435 mm {0.0172 in}

B3E0110E087

2. Using a plastigauge, measure the oil clearance at the large end of the connecting rod.
• If it is at the maximum specification or more, replace the bearing or grind the crank pin and use oversize
bearings so that the specified clearance is obtained.

Note
• Cut the plastigauge as wide as the
PLASTIGAUGE
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
Standard
0.027—0.051 mm {0.0011—0.0020 in}
Maximum
0.1 mm {0.0039 in}
E6U110ZEB025
Connecting rod bearing size
STD
1.495—1.519 mm {0.0589—0.0598 in}
OS0.25
1.614—1.626 mm {0.0636—0.0640 in}
OS0.50
1.739—1.751 mm {0.0685—0.0689 in}

End Of Sie
PISTON, CONNECTING ROD INSPECTION
E6U011011211E02
1. Check the oscillation torque as shown in the
figure. Verify that the large end drops under its
own weight with no resistance. If the piston
shakes heavily or unsmoothly, replace the
connecting rod and piston pin.
End Of Sie

E6U110ZEB009

01–10–24
 MECHANICAL
CONNECTING ROD INSPECTION
E6U011011211E03
1. Inspect the connecting rod for bending and
distortion using the connecting rod aligner.
If it is at the maximum specification or more,
replace the connecting rod.

Maximum connecting rod bending [per 50 mm

{1.968 in}] 01–10
0.070 mm {0.0019 in}

Maximum connecting rod distortion

[per 50 mm {1.968 in}]
0.060 mm {0.0027 in}
AMJ2224E255

Connecting rod center-to-center distance

150.65—150.75 mm {5.9311—5.9350 in}

End Of Sie
CRANKSHAFT INSPECTION
E6U011011301E01
1. Measure the crankshaft end play using a dial gauge.
• If it exceeds the maximum specification,
replace the thrust bearing or crankshaft so
that the specified end play is obtained.

Crankshaft end play

Standard
0.22—0.45 mm {0.0087—0.0177 in}
Maximum
0.55 mm {0.021 in}

B3E0110E083

2. Measure the runout of the main journal using a V-block and dial gauge.
• If it is at the maximum specification or more,
replace the crankshaft.

Maximum main journal runout

0.05 mm {0.0019 in}

AME2224E311

01–10–25
 MECHANICAL
3. Inspect the main journal diameter and crank pin diameter. Measurement positions total four and are in the X
and Y directions, at two points (A and B) as shown in the figure.
• If it is not within the specification or if it
exceeds the maximum off-round, grind the
A B
journal with an oversized bearing.
X
Main journal diameter
STD
51.980—52.000 mm {2.0465—2.0472 in} Y
OS0.25
51.730—51.750 mm {2.0367—2.0374 in}

Maximum main journal off-round

0.05 mm {0.0019 in}
B3E0110E085

Crank pin diameter

STD
51.980—52.000 mm {2.0465—2.0472 in}
OS0.25
51.730—51.750 mm {2.0367—2.0374 in}

Maximum crank pin off-round

0.05 mm {0.0019 in}

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 main
bearing cap and tighten the bolts in the order
shown in the figure.
9 5 1 3 7
Tightening procedure
(1) Apply engine oil to all bolts.
(2) 3—7 N·m {30.6—71.3 kgf·cm, 26.6—61.9
in·lbf}
(3) 23—27 N·m {2.4—2.7 kgf·m, 17—19.9 10 6 2 4 8
ft·lbf}
(4) 38—42 N·m {3.9—4.2 kgf·m, 28.1—30.9
ft·lbf}
B3E0110E267
(5) Loosen all the bolts (until bolts are
torque-free).
(6) 3—7 N·m {30.6—71.3 kgf·cm, 26.6—61.9 in·lbf}
(7) 18—22 N·m {1.9—2.2 kgf·m, 13.3—16.2 ft·lbf}
(8) 87.5°—92.5°

(4) Loosen the bolts in the reverse order of tightening.

01–10–26
 MECHANICAL
(5) Measure the main journal oil clearance.
• If it is not within the specification, replace
the main bearing, or grind the main
journal and use oversized bearings so
that the specified oil clearance is
obtained.

Main journal oil clearance 01–10

Standard
0.016—0.039 mm {0.0007—0.0015 in}
Maximum
0.10 mm {0.0039 in}
B3E0110E086

Main bearing size (UPPER)

STD
2.501—2.522 mm {0.0985—0.0992 in}
OS0.25
2.623—2.629 mm {0.1033—0.1035 in}
OS0.50
2.748—2.754 mm {0.1082—0.1084 in}

Main bearing size (LOWER)

STD
2.501—2.529 mm {0.0985—0.0995 in}
OS0.25
2.624—2.630 mm {0.1034—0.1035 in}
OS0.50
2.749—2.755 mm {0.1083—0.1084 in}

End Of Sie
PILOT BEARING INSPECTION
E6U011011301E02
1. Without removing the pilot bearing, turn the bearing while applying force in the axial direction.
• If there is any malfunction, replace the pilot
bearing.
End Of Sie

ADJ4920W002

BOLT INSPECTION
E6U011010135E01
1. Measure the length of the each bolt.
• If it exceeds the maximum specification,
replace the bolt.

Cylinder head bolt length

Standard
144.7—145.3 mm {5.696—5.720 in}
Maximum
146 mm {5.748 in} L

Connecting rod bolt length

Standard
43.7—44.3 mm {1.720—1.744 in}
B3E0110E088
Maximum
46 mm {1.811 in}

End Of Sie

01–10–27
 MECHANICAL
VALVE CLEARANCE INSPECTION/ADJUSTMENT
E6U011012111E01
VALVE CLEARANCE INSPECTION
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 in the figure.
• If it is not within the specification, replace the tappet and adjust the valve clearance to the standard
clearance. (See 01–10–28 VALVE CLEARANCE ADJUSTMENT.)

Standard valve clearance [when cold]

IN: 0.22—0.28 mm {0.0087—0.0110 in}
EX: 0.27—0.33 mm {0.0106—0.0130 in}

Note
• When replacing the tappet, select the tappet
A B A B
according to the measured value and note
down the measured value.

3. Rotate the crankshaft clockwise 360° so that the EX

No.4 piston is at the TDC of the compression No.1 No.2 No.3 No.4
stroke.
4. Measure the valve clearance at B in the figure. IN
• If it is not within the specification, replace the
tappet and adjust the valve clearance to the
standard clearance. (See 01–10–28 VALVE A A B B
CLEARANCE ADJUSTMENT.)
E6U110ZEB002

Standard valve clearance [when cold]

IN: 0.22—0.28 mm {0.0087—0.0110 in}
EX: 0.27—0.33 mm {0.0106—0.0130 in}

Note
• When replacing the tappet, select the tappet according to the measured value and note down the
measured value.

VALVE CLEARANCE ADJUSTMENT

1. Remove the engine front cover lower blind plug.
2. Remove the engine front cover upper blind plug.

UPPER
BLIND
PLUG
LOWER BLIND
PLUG

B3E0110E093

3. Remove the cylinder block lower blind plug and

install the SST.
4. Rotate the crankshaft clockwise so that the No.1
piston is at TDC of the compression stroke. (The
position crank weight contacts the SST.)
303-507

E6U110ZWB050

01–10–28
 MECHANICAL
5. Loosen the timing chain.
(1) Using a suitable screwdriver or equivalent
tool, unlock the timing chain tensioner ratchet.
(2) Rotate the exhaust camshaft clockwise using 2
a suitable wrench on the cast hexagon and
loosen the timing chain tensioner.

01–10

BOLT(M6 x 1.0)
3

E6U110ZWB052

(3) Using a suitable bolt (M6 X 1.0 length 25—35

mm {0.99—1.37 in}) at the engine front cover
upper blind plug, secure the tensioner arm at RIB
the position where the tension is released. RIB

E6U110ZWB045

6. Secure the exhaust camshaft using a wrench on

the cast hexagon and loosen the camshaft
sprocket installation bolt.

B3E0110E095

7. Remove the installation bolt and exhaust

camshaft sprocket.

EXHAUST
CAMSHAFT
SPROCKET

E6U110ZWB008

01–10–29
 MECHANICAL
8. Loosen the camshaft cap bolts in two or three
1 3 5 4 2
passes in the order shown in the figure, and
remove the camshaft bearing caps.

Note EX
• The camshaft caps are to be kept ordered No.1 No.2 No.3 No.4
for correct reassembly in their original
positions. Do not mix the caps. IN

9. Remove the camshafts for intake and exhaust

sides. 2 1
4 6 5 3
10. Remove the tappet.
E6U110ZEB001
11. Select and install the suitable tappet according to
the result of valve clearance inspection.
Selected tappet = Removed tappet thickness + Measured valve clearance - Standard valve clearance

Standard valve clearance [when cold]

IN: 0.22—0.28 mm {0.0087—0.0110 in}
EX: 0.27—0.33 mm {0.0106—0.0130 in}

12. Install the camshaft with the No.1 cylinder cam aligned at TDC of the compression stroke.
13. Install the camshaft bearing cap and tighten the
5 3 1 2 4
camshaft bearing cap bolts in two passes in the
order shown in the figure.

Tightening procedure EX
(1) 5.0—9.0 N·m {51.0—91.7 kgf·cm,44.3— No.1 No.2 No.3 No.4
79.6 in·lbf}
(2) 14.0—17.0 N·m {1.5—1.7 kgf·m, 10.4— IN
12.5 ft·lbf}

5 3 1 2 4 6
E6U110ZEB012

14. Install a new washer.

E6U110ZWB020

15. Install the exhaust camshaft sprocket.

Caution
• Do not tighten the camshaft sprocket
installation bolt during this step.

EXHAUST
CAMSHAFT
SPROCKET

E6U110ZWB008

01–10–30
 MECHANICAL
16. Install the SST on the camshaft as shown in the
figure. 303-1061
17. Remove the bolt (M6 X 1.0 length 25—35 mm (49 UN30 310610)
{0.99—1.37 in}) from the engine front cover
upper blind plug and apply tension to the timing
chain.
18. Rotate the crankshaft clockwise and verify that
the No.1 piston is at TDC of the compression 01–10
stroke.

E6U110ZEB036

19. Secure the exhaust camshaft using a wrench on

the cast hexagon and tighten the sprocket
installation bolt.

Tightening torque
69—75 N·m {7.1—7.6 kgf·m, 50.9—55.3 ft·lbf}

20. Remove the SST from the camshaft.

21. Remove the SST installed in the cylinder block
lower blind plug hole.
22. Rotate the crankshaft clockwise two turns and
inspect the valve timing.
B3E0110E095
23. Apply silicone sealant and install the engine front
cover upper blind plug.

Tightening torque
8.0—11.5 N·m {81.6—117.2 kgf·cm, 70.9—101.7 in·lbf}

24. Install the cylinder block lower blind plug.

Tightening torque
18—22 N·m {1.9—2.2 kgf·m, 13.3—16.2 ft·lbf}

25. Install a new engine front cover lower blind plug.

Tightening torque
10.0—14.0 N·m {102.0—142.7 kgf·cm, 88.6—123.9 in·lbf}

End Of Sie

01–10–31
 MECHANICAL
CYLINDER BLOCK (I) ASSEMBLY
E6U011010300E04
1. Assemble in the order indicated in the table.

12

OIL

10

OIL
OIL

7 SST OIL
2
1
8 9 7.8—10.8 N·m
6 {80—110 kgf·cm,
16 SST
70—95 in·lbf}
3
OIL
11

14 OIL
OIL
13 4

5
26—31 {2.7—3.2,
20—23}+80°—100° 3—7 N·m {30.6—71.3
kgf·cm,26.6—61.9 in·lbf}
+23—27 {2.4—2.7, 17—19.9}
+38—42 {3.9—4.2, 28.1—30.9}
Loosen all the bolts (until
bolts are torque-free)
15 +3—7 N·m {30.6—71.3
OIL
25+44—46 kgf·cm,26.6—61.9 in·lbf}
{2.6+4.5—4.6, +18—22 {1.9—2.2, 13.3—16.2}
19+32.5—33.9} +87.5°—92.5°
N·m {kgf·m, ft·lbf}

E6U110ZEB016

1 Oil jet valve 12 Connecting rod, piston

(See 01–10–34 Piston Assembly Note.)
2 Upper main bearing, thrust bearing
13 Lower connecting rod bearing
3 Crankshaft
(See 01–10–34 Connecting Rod Bearing Assembly
4 Lower main bearing Note.)
5 Main bearing cap 14 Connecting rod cap
(See 01–10–33 Main Bearing Cap Assembly Note.) (See 01–10–34 Connecting Rod Cap Assembly
6 Connecting rod Note.)
7 Piston 15 Engine balancer
8 Piston pin (See 01–10–35 Balancer Unit Assembly Note.)
(See01–10–33 Piston Pin Assembly Note.) 16 Pilot bearing
9 Snap ring (See 01–10–37 Pilot Bearing Assembly Note.)
10 Piston ring
(See 01–10–33 Piston Ring Assembly Note.)
11 Upper connecting rod bearing
(See 01–10–34 Connecting Rod Bearing Assembly
Note.)

01–10–32
 MECHANICAL
Main Bearing Cap Assembly Note
1. Tighten the crank bearing caps in the order
shown in the figure.

Tightening procedure 9 5 1 3 7
(1) Apply engine oil to all bolts.
(2) 3—7 N·m {30.6—71.3 kgf·cm, 26.6—61.9
in·lbf} 01–10
(3) 23—27 N·m {2.4—2.7 kgf·m, 17—19.9
ft·lbf} 10 6 2 4 8
(4) 38—42 N·m {3.9—4.2 kgf·m, 28.1—30.9
ft·lbf}
(5) Loosen all the bolts (until bolts are
B3E0110E267
torque-free).
(6) 3—7 N·m {30.6—71.3 kgf·cm, 26.6—61.9
in·lbf}
(7) 18—22 N·m {1.9—2.2 kgf·m, 13.3—16.2 ft·lbf}
(8) 87.5°—92.5°

Piston Pin Assembly Note

1. Assemble the piston pin using the SST.

49 T011 001

E6U110ZEB034

Piston Ring Assembly Note

1. Assemble the oil ring.
2. Assemble the second ring with the notch facing downward.
3. Assemble the top ring with scraper face side
upward.

C3U0110E256

01–10–33
 MECHANICAL
Piston Assembly Note
1. Position the end gap of each ring so they are not UPPER OIL
aligned as shown in the figure. RING RAIL CAP

EXPANDER CAP
TOP RING
SECOND RING

PISTON PIN LOWER OIL

RING RAIL CAP
E6U110ZEB004

2. Insert the piston into the cylinder with the arrow

on top of the piston facing the front of the engine.

B3E0110E108

Connecting Rod Bearing Assembly Note

1. Install the connecting rod bearing to the
connecting rod and connecting rod caps as
shown in the figure. CONNECTING ROD
BEARING

2.3—2.7 mm {0.091—0.106 in}

B3E0110E109

Connecting Rod Cap Assembly Note

Caution
• When assembling the connecting rod caps, align the broken, rough faces of the connecting rods
and connecting rod caps.

1. Tighten the connecting rod installation bolts using the following procedure.

Tightening procedure
(1) 26—31 N·m {2.7—3.1 kgf·m, 19.2—22.8 ft·lbf}
(2) 80°—100°

01–10–34
 MECHANICAL
Balancer Unit Assembly Note
1. Confirm by visual inspection that there is no damage to the balancer unit gear and verify that the shaft rotates
smoothly.
• If there is any malfunction, replace the balancer unit.
Caution
• Due to the precision interior construction of the balancer unit, it cannot be disassembled.

2. Remove the cylinder block lower blind plug and 01–10

install the SST.
3. Rotate the crankshaft clockwise so that the No.1
piston is at TDC of the compression stroke. (The
position crank weight contacts the SST.)
4. Install the adjustment shim to the seating face of 303-507
the balancer unit.

E6U110ZWB050

5. With the balancer unit marks at the exact top

center, assemble the balancer unit to the cylinder
block.

MARK

B3E0110E111

6. Set the SST as shown in the figure and measure

49 G011 201 DIAL GAUGE
the gear backlash using a dial gauge.
Note
• To measure the backlash precisely, insert a 41.4 mm
{1.629 in}
flathead screwdriver into the crankshaft No.1
crank weight area and set both the rotation
and the thrust direction with the flathead
screwdriver, using a prying action, as shown
in the figure.
DRIVEN GEAR SHAFT CENTER

B3E0110E112

• If it exceeds the maximum specification,

remeasure the backlash and, using the
adjustment shim selection table, select the
proper shim, according to the following
procedure.
Caution
• When measuring the backlash, rotate the
crankshaft one full rotation and verify
that it is within the specified range at all
of the following six positions: 10, 30, 100,
190, 210, 280 ATDC.
B3E0110E113
Maximum gear backlash
0.005—0.101 mm {0.00019—0.0039 in}

(1) Using master shim (No.50), assemble the balancer unit to the cylinder block and measure the backlash.
(2) Select the proper adjustment shim according to the measured value.
(3) Install the selected adjustment shim to the balancer unit and assemble the balancer unit to the cylinder
block.
01–10–35
 MECHANICAL
Adjustment shim selection table
Backlash Selection shim Shim thickness Backlash Selection shim Shim thickness
mm {in} (No.) mm {in} mm {in} (No.) mm {in}
0.267—0.273 0.127—0.133
{0.01051— 15 1.15 {0.0452} {0.00500— 35 1.35 {0.0531}
0.01074} 0.00523}
0.260—0.266 0.120—0.126
{0.01023— 16 1.16 {0.0456} {0.00472— 36 1.36 {0.0535}
0.01047} 0.00496}
0.253—0.259 0.113—0.119
{0.00996— 17 1.17 {0.0460} {0.00444— 37 1.37 {0.0539}
0.01019} 0.00468}
0.246—0.252 0.106—0.112
{0.00968— 18 1.18 {0.0464} {0.00417— 38 1.38{0.0543}
0.00992} 0.00440}
0.239—0.245 0.099—0.105
{0.00940— 19 1.19 {0.0468} {0.00389— 39 1.39 {0.0547}
0.00964} 0.00413}
0.232—0.238 0.092—0.098
{0.00913— 20 1.20 {0.0472} .087 {0.00362— 40 1.40 {0.0551}
0.00937} 0.00385}
0.225—0.231 0.085—0.091
{0.00885— 21 1.21 {0.0476} {0.00334— 41 1.41 {0.0555}
0.00909} 0.00358}
0.218—0.224 0.078—0.084
{0.00858— 22 1.22 {0.0480} {0.00307— 42 1.42 {0.0559}
0.00881} 0.00330}
0.211—0.217 0.071—0.077
{0.00830— 23 1.23 {0.0484} {0.00279— 43 1.43 {0.0562}
0.00854} 0.00303}
0.204—0.210 0.064—0.070
{0.00803— 24 1.24 {0.0488} {0.00251— 44 1.44 {0.0566}
0.00826} 0.00275}
0.197—0.203 0.057—0.063
{0.00775— 25 1.25 {0.492} {0.00224— 45 1.45 {0.0570}
0.00799} 0.00248}
0.190—0.196 0.050—0.056
{0.00748— 26 1.26 {0.496} {0.00196— 46 1.46 {0.0574}
0.00771} 0.00220}
0.183—0.189 0.043—0.049
{0.00720— 27 1.27 {0.499} {0.00169— 47 1.47 {0.0578}
0.00744} 0.00192}
0.176—0.182 0.036—0.042
{0.00692— 28 1.28 {0.503} {0.00141— 48 1.48 {0.0582}
0.00716} 0.00165}
0.169—0.175 0.029—0.035
{0.00665— 29 1.29 {0.507} {0.00114— 49 1.49 {0.0586}
0.00688} 0.00137}
0.162—0.168 0.022—0.028
{0.00637— 30 1.30 {0.511} {0.000866— 50 (master) 1.50 {0.0590}
0.00661} 0.00110}
0.155—0.161 0.015—0.021
{0.00610— 31 1.31 {0.515} {0.00059— 51 1.51 {0.0594}
0.00633} 0.000826}
0.148—0.154 0.008—0.014
{0.00582— 32 1.32 {0.519} {0.000314— 52 1.52 {0.0598}
0.00606} 0.000551}
0.141—0.147 0.001—0.007
{0.00555— 33 1.33 {0.523} {0.00003— 53 1.53 {0.0602}
0.00578} 0.000275}
0.134—0.140
0.000—0.000
{0.00527— 34 1.34 {0.527} 54 1.54 {0.0606}
{0.000—0.000}
0.00551}

01–10–36
 MECHANICAL
Pilot Bearing Assembly Note
1. Use the SSTs to install the pilot bearing.
205-153
(49 UN20 5153)

308-157
(49 UN30 8157) 01–10

E6U110ZWB049

End Of Sie

PILOT BEARING

4.0—5.0 mm {0.16—0.19 in}

C3U0510W013

01–10–37
 MECHANICAL
CYLINDER BLOCK (II) ASSEMBLY
E6U011010300E05
1. Assemble in the order indicated in the table.

151.3—161.1
{15.43—16.42,
A 111.6— 118.8}
SST
OIL SST
R 1
R
3

A 16—24 {1.7—2.4,12— 17}

9 34—40 {3.5—4.0, 26—29}

R
6 R

R 11
8

R R
4
A 5 7 A
R 10
17—23 {1.8—2.3,
13—16 } A 20—30
{2.1—3.0,14.8— 22.1}
12 R

17—23 R
17—23 {1.8—2.3,12.6— 16.9}
{1.8—2.3,12.6— 16.9}
13
14 9.0—10.0 N·m
A 8.0—11.5 N·m SEALANT {91.8—101.9 kgf·cm,
{81.6—117.2 kgf·cm, 79.6—88.4in·lbf}
70.9—101.7in·lbf}

N·m {kgf·m, ft·lbf}

E6U110ZEB017

1 Rear oil seal 8 Crankcase ventilation cover

(See 01–10–39 Rear Oil Seal Assembly Note.) 9 Knock sensor
2 End plate 10 Oil filter adapter
3 Flywheel 11 Oil cooler
(See 01–10–39 Flywheel Assembly Note.) 12 Oil filter
4 Oil pump 13 Oil filter cover
5 Oil strainer 14 Oil pan
6 Water pump (See 01–10–39 Oil Pan Assembly Note.)
7 Thermostat

01–10–38
 MECHANICAL
Rear Oil Seal Assembly Note
1. Apply clean engine oil to a new rear oil seal.
2. Install the rear oil seal using a SST.

01–10
303-328
(49 UN30 3328)

CUE110BW2005

3. Tighten the installation bolts in the order shown in

the figure. 3
5
Tightening torque
8.0—11.5 N·m {81.6—117.2 kgf·cm, 70.9—
101.7 in·lbf}
1

2 4
B3E0110E116

Flywheel Assembly Note

1. Secure the crankshaft using the SST.
2. Tighten the installation bolts in two or three
passes in the order shown in the figure.

Tightening torque 49 E011 1A0

151.3—161.1 N·m {15.43—16.42 kgf·m, 1
111.6—118.8 ft·lbf} 3 6
5 4
2

B3E0110E119

Oil Pan Assembly Note

1. Apply silicone sealant to the areas shown in the
figure.
2. Assemble the oil pan.
2.2—3.2 mm
{0.087—0.126 in}

E6U111ZWB006

01–10–39
 MECHANICAL
3. Use a straight edge to align the junction of the oil
pan and the cylinder block on the engine front
cover side.
CYLINDER
BLOCK

OIL PAN

-0.05—0.05 mm {-0.0020—0.0020 in}

B3E0110E120

4. Tighten the bolts in the order shown in the figure.

13 8 4 1 5 9
Tightening torque 10
17—23 N·m {1.8—2.3 kgf·m, 12.6—16.9 ft·lbf}

End Of Sie

12 7 3 2 6 11
E6U110ZEB021

01–10–40
 MECHANICAL
CYLINDER HEAD (I) ASSEMBLY
E6U011010100E03
1. Disassemble in the order indicated in the table.
8.0—11.5 N·m
{81.6—117.2 kgf·cm,
42—48{4.3—4.8, 70.9—101.7 in·lbf}
31—35}

SST 6 7 01–10

1
R 2
SST R

OIL
3

42—48{4.3—4.8,
31—35}

N·m {kgf·m,ft·lbf}

E6U110ZEB018

1 Water outlet case 5 Upper valve spring seat

2 Valve seal 6 Valve keeper
(See 01–10–42 Valve Seal Assembly Note.) (See 01–10–42 Valve Keeper Assembly Note.)
3 Valve 7 Engine hanger
4 Valve spring

Water Outlet Case Assembly Note

1. Tighten the bolts in the order shown in the figure.
1 2

4
3

E6U110ZEB037

01–10–41
 MECHANICAL
Valve Seal Assembly Note
1. Press in the valve seal to the valve guide by hand.
2. Set the SST and tap it using a plastic hammer.
49 T032 302

VALVE
SEAL

B3E0110E123

Valve Keeper Assembly Note

1. Assemble the valve keeper using the SST.
End Of Sie
49 0636 100B

49 B012 0A2

B3E0110E124

01–10–42
 MECHANICAL
CYLINDER HEAD (II) ASSEMBLY
E6U011010100E04
1. Assemble in the order indicated in the table.
5.0—9.0 N·m {51.0—91.7
8.0—11.5 N·m kgf·cm, 44.3—79.5 in·lbf}+
{81.6—117.2 kgf·cm, 14—17 {1.5—1.7, 10.4—12.5}
70.9—101.7 in·lbf}

5
SEALANT
01–10
7

8.0—11.5 N·m 3 —11N·m {30.6—112

{81.6—117.2 kgf·cm, kgf·cm, 26.6—97.3 in·lbf}+
70.9—101.7 in·lbf} 13—17 {1.4—1.7, 9.6—12.5}+
43—47 {4.4—4.7, 31.8—34.6}+
OIL
4 88°—92°
+88°—92°
6
R

R 2

1 R

N·m {kgf·m, ft·lbf}

E6U110ZEB019

1 Cylinder head gasket 5 Camshaft cap

(See 01–10–44 Camshaft Assembly Note.)
2 Cylinder head
(See 01–10–44 Cylinder Head Assembly Note.) 6 Camshaft sprocket, variable valve timing actuator
(See 01–10–44 Camshaft Sprocket, Variable Valve
3 Tappet
Timing Actuator Assembly Note.)
4 Camshaft
7 OCV
(See 01–10–44 Camshaft Assembly Note.)

01–10–43
 MECHANICAL
Cylinder Head Assembly Note
1. Tighten the cylinder head installation bolts in five
passes in the order shown in the figure. 8 4 1 5 9

Tightening procedure
(1) 3— 11 N·m {30.6—112 kgf·cm, 26.6—97.3
in·lbf}
(2) 13— 17 N·m {1.4 —1.7 kgf·m, 9.6—12.5
ft·lbf}
(3) 43— 47 N·m {4.4 —4.7 kgf·m, 31.8—34.6
ft·lbf}
(4) 88°—92° 7 3 2 6 10
(5) 88°—92°
C3U0110E054

Camshaft Assembly Note

Note
• Install the camshaft with the No.1 cylinder cam aligned at TDC of the compression stroke.

1. Carefully apply adhesive agent to the area

indicated in the figure so that it does not leak into
the sliding part.

Thickness SEALANT

1.0 mm {0.039 in}

INTAKE REAR CAMSHAFT CAP

E6U110ZWB063

2. Install the camshaft caps and hand-tighten the

5 3 1 2 4
camshaft cap bolts evenly in two or three passes,
and then tighten the camshaft cap bolts in two
passes, in the order shown in the figure.
EX
Tightening procedure No.1 No.2 No.3 No.4
(1) 5.0—9.0 N·m {51.0—91.7 kgf·cm, 44.3—
79.5 in·lbf} IN
(2) 14.0—17.0 N·m {1.5—1.7 kgf·m, 10.4—
12.5 ft·lbf}
5 3 1 2 4 6
E6U110ZEB012

Camshaft Sprocket, Variable Valve Timing Actuator Assembly Note

1. Leave the camshaft sprocket installation bolt temporarily tightened until the timing chain is installed. After the
timing chain is installed, tighten it to the specified torque.
End Of Sie

01–10–44
 MECHANICAL
TIMING CHAIN ASSEMBLY
E6U011012201E03
1. Assemble in the order indicated in the table.
10.0—14.0 N·m
{1.1—1.5, 8.0—10.0 }
20 19
A
SEALANT
8.0—11.5 N·m
13 {81.6—117.2 kgf·cm,
70.9—101.7 in·lbf} 01–10
40—55{4.1—5.6,
29.7—40.5}
7
15

R R
OIL

20—30{2.1—3.0,
SST
14.8—22.1} 14
SEALANT

16

17 SEALANT

18 R SST 20—30{2.1—3.0,
14.8—22.1} 11
69—75{7.1—7.6,
12 50.9—55.3}

A
R
8
SST
10
A

SST 4
A 8.0—11.5 N·m
1 6
{81.6—117.2 kgf·cm,
2 5 20—30{2.1—3.0,
14.8—22.1}
70.9—101.7 in·lbf} N·m {kgf·m,ft·lbf}
A
9
3
E6U110ZEB020

1 Oil pump drive sprocket 12 Camshaft sprocket lock bolt

(See 01–10–46 Drive Sprocket Assembly Note.) (See 01–10–47 Camshaft Sprocket Lock Bolt
Assembly Note.)
2 Crankshaft sprocket
(See 01–10–46 Drive Sprocket Assembly Note.) 13 Front oil seal
3 Oil pump chain 14 Engine front cover
(See 01–10–48 Engine Front Cover Assembly Note.)
4 Oil pump driven sprocket
(See 01–10–46 Oil Pump Driven Sprocket Assembly 15 Drive belt idler pulley
Note.) 16 Water pump pulley
5 Oil pump chain guide 17 Crankshaft pulley
6 Oil pump chain tensioner 18 Crankshaft pulley lock bolt
7 Oil jet (See 01–10–49 Crankshaft Pulley Lock Bolt
Assembly Note.)
8 Timing chain
(See 01–10–46 Timing Chain Assembly Note.) 19 Cylinder head cover
(See 01–10–50 Cylinder Head Cover Assembly
9 Timing chain guide
Note.)
10 Timing chain tensioner arm
20 Spark plug
11 Timing chain tensioner

01–10–45
 MECHANICAL
Drive Sprocket Assembly Note
1. The oil pump drive sprocket has the assembly
direction as shown in the figure. OIL PUMP DRIVE SPROCKET

ENGINE FRONT

CRANKSHAFT SPROCKET

E6U110ZWB059

Oil Pump Driven Sprocket Assembly Note

1. Install the SST on the oil pump driven sprocket to
lock the oil pump against rotation.

49 G032 354

B3E0110E125

Timing Chain Assembly Note

1. Install the SST on the camshaft and align the
No.1 camshaft position at TDC of the 303-1061
compression stroke. (49 UN30 310610)

E6U110ZEB036

2. Remove the cylinder block lower blind plug from

the cylinder block and install the SST.
3. Rotate the crankshaft clockwise so that the No.1
piston is at TDC of the compression stroke. (The
position crank weight contacts the SST.)
4. Install the timing chain. 303-507

E6U110ZWB050

01–10–46
 MECHANICAL
5. After the chain adjuster is installed, remove the
paper clip (stopper).

STOPPER

01–10

E6U110ZWB057

Camshaft Sprocket Lock Bolt Assembly Note

1. Lock the camshaft against rotation using a wrench on the cast hexagon.
2. Tighten the camshaft sprocket installation bolt.

Tightening torque
69—75 N·m {7.1—7.6 kgf·m, 50.9—55.3 ft·lbf}

B3E0110E095

E6U110ZWB047

01–10–47
 MECHANICAL
Engine Front Cover Assembly Note
1. Apply silicone sealant to the engine front cover.

Caution
• Install the engine front cover within 10 minutes of applying the silicone sealant.
• Silicone sealant is not need in area C as
indicated below due to an existing. B

Note
• Install the engine front cover within 10 min
after applying the silicone sealant.

Thickness
A
A: 2.2—3.2 mm {0.087—0.125 in}
B: 1.5—2.5 mm {0.059—0.098 in} C B

B3E0110E129

2. Tighten the engine front cover installation bolts in the order shown in the figure.
Installation position Tightening torque N·m {kgf·m, ft·lbf}
1—18 8.011.5 N·m {81.6—117.2 kgf·cm, 70.9—101.7 in·lbf}
19—22 4055 {4.1—5.6, 29.7—40.5}

20 21 22
18

17
11
10

7 8
4
3 1
5
2
19
6

9 12

13
16
15 14
B3E0110E062

01–10–48
 MECHANICAL
3. Install the oil seal using the SST.

Front oil seal press-in amount

0—0.5 mm {0—0.019 in}

01–10

49 H010 401

B3E0110E127

HAMMER FRONT COVER BODY

0—0.5 mm
{0—0.019 in}

49 H010 401
FRONT OIL SEAL
C3U0110W057

Crankshaft Pulley Lock Bolt Assembly Note

1. Install the crankshaft pulley to the front cover
using a bolt (M6 X 1.0). Temporarily tighten the
bolt.

BOLT

B3E0110E063

2. Use the SST to lock the crankshaft against

rotation.

49 E011 1A0

E6U110ZEB039

01–10–49
 MECHANICAL
3. Tighten the pulley lock bolt.

Tightening procedure
(1) 96—104 N·m {9.8—10.6 kgf·m, 70.9—76.7
ft·lbf}
(2) 87°—93°

4. Remove the SST from the camshaft, and remove

the bolt from the crankshaft pulley.
5. Remove the SST from the cylinder block lower
blind plug, and install the cylinder block lower
blind plug.
E6U110ZEB038

Cylinder Head Cover Assembly Note

1. Apply silicone sealant to the areas shown in the
figure.
SEALANT

Thickness
5.0 mm {0.196 in}

SEALANT

E6U110ZWB058

SEALANT

SEALANT

E6U110ZWB007

2. Install the cylinder head cover installation bolts in

the order shown in the figure. 6 3 7 12
11
Tightening torque 10 2 1
8.0 —10.5 N·m {81.6—107 kgf·cm, 70.9—92.9
in·lbf}
13
End Of Sie 14

9
5 4 8
B3E0110W050

01–10–50
 TECHNICAL DATA
01–50 TECHNICAL DATA
ENGINE TECHNICAL DATA . . . . . . . . . . 01–50–1

End of Toc
ENGINE TECHNICAL DATA
E6U015000000E01

Item Specification
01–50
Maximum distortion, head gasket side 0.10 mm {0.004 in}
Maximum distortion, manifold side 0.10 mm {0.004 in}
Maximum cutting length, manifold side 0.15 mm {0.006 in}
IN: 0.7—1.3mm {0.0276—0.0511 in}
Standard valve seat contact width
EX: 0.7—1.3mm {0.0276—0.0511 in}
IN: 45°
Valve seat angle
EX: 45°
IN: 40.64—42.24 mm {1.600—1.662 in}
Standard valve seat sinkage amount (Dimension L)
EX: 40.50—42.10 mm {1.595—1.657 in}
IN: 1.62 mm {0.0637 in}
Minimum valve head margin thickness
EX: 1.82 mm {0.0716 in}
IN: 102.99—103.79 mm {4.055—4.086 in}
Standard valve length (Dimension L)
EX: 104.25—105.05 mm {4.105—4.135 in}
Standard
IN: 5.970—5.985 mm {0.2351—0.2356 in}
EX: 5.965—5.980 mm {0.2349—0.2354 in}
Valve stem diameter
Minimum
IN: 5.940 mm {0.2339 in}
EX: 5.935 mm {0.2336 in}
IN: 6.009—6.039 mm {0.2366—0.2377 in}
Standard valve guide inner diameter
EX: 6.009—6.039 mm {0.2366—0.2377 in}
Standard
IN: 0.024—0.069 mm {0.0009—0.0027 in}
Clearance between valve stem and guide EX: 0.029—0.074 mm {0.0012—0.0029 in}
Maximum
0.10 mm {0.004 in}
IN: 12.2—12.8 mm {0.481—0.503 in}
Standard valve guide projection height
EX: 12.2—12.8 mm {0.481—0.503 in}
Valve spring installation height 37.90 mm {1.492 in} (171.5 N {17.49 kgf, 38.55 lbf})
Maximum valve spring off-square 2.55 mm {0.100 in}
Standard tappet bore diameter 31.000—31.030 mm {1.2205—1.2216 in}
Standard tappet body outer diameter 30.970—30.980 mm {1.2193—1.2196 in}
Standard
0.02—0.06 mm {0.0008—0.0023 in}
Clearance between tappet and tappet bore
Maximum
0.15 mm {0.006 in}
Oil control valve coil resistance 6.9—7.9 ohms [20°C {68°F}]
Maximum camshaft runout 0.03 mm {0.0012 in}
Standard
IN: 42.44 mm {1.671 in}
EX: 41.18 mm {1.622 in}
Cam height
Minimum
IN: 42.34 mm {1.667 in}
EX: 41.08 mm {1.618 in}
Standard
24.96—24.98 mm {0.9827—0.9834 in}
Camshaft journal diameter
Minimum
24.95 mm {0.982 in}
Standard
0.04—0.08 mm {0.002—0.003 in}
Camshaft journal oil clearance
Maximum
0.09 mm {0.0035 in}

01–50–1
 TECHNICAL DATA
Item Specification
Standard
0.09—0.24 mm {0.0035—0.0094 in}
Camshaft end play
Maximum
0.25 mm {0.0099 in}
Maximum distortion, head gasket side 0.10 mm {0.004 in}
Maximum bore inner diameter 87.500—87.530 mm {3.4449—3.4460 in}
Standard piston outer diameter 87.465—87.495 mm {3.4435—3.4446 in}
Standard
0.025—0.045 mm {0.0010—0.0017 in}
Clearance between piston and cylinder
Maximum
0.11 mm {0.0043 in}
Standard
Top: 0.005—0.08 mm {0.0020—0.0031 in}
Second: 0.03—0.07 mm {0.0012—0.0027in}
Clearance between piston ring and ring groove Oil: 0.02—0.06 mm {0.0008—0.0023 in}
Maximum
Top: 0.17 mm {0.0067 in}
Second, Oil: 0.15 mm {0.0059 in}
Standard
Top: 0.14—0.24 mm {0.0056—0.0094 in}
Second: 0.34—0.44 mm {0.0134—0.0173 in}
Piston ring end gap
Oil (rail): 0.15—0.40 mm {0.0060—0.0157 in}
Maximum
1.0 mm {0.0393 in}
Standard piston pin hole diameter 22.504—22.508 mm {0.8860—0.8861 in}
Standard connecting rod small end inner diameter 22.510—22.521 mm {0.8863—0.8866 in}
Standard piston pin outer diameter 22.495—22.500 mm {0.8857—0.8858 in}
Standard clearance between piston pin hole diameter
0.004—0.013 mm {0.0002—0.0005 in}
and piston outer diameter
Standard clearance between connecting rod small end
0.010—0.026 mm {0.0004—0.0010 in}
inner diameter and piston pin outer diameter
Standard
0.14—0.36 mm {0.0056—0.0141 in}
Connecting rod large end side clearance
Maximum
0.435 mm {0.0172 in}
Standard
Bearing oil clearance at the large end of connecting 0.027—0.051 mm {0.0011—0.0020 in}
rod Maximum
0.1 mm {0.0039 in}
STD
1.495—1.519 mm {0.0589—0.0598 in}
OS0.25
Connecting rod bearing size
1.614—1.626 mm {0.0636—0.0640 in}
OS0.50
1.739—1.751 mm {0.0685—0.0689 in}
Maximum connecting rod bending [per 50 mm] 0.070 mm {0.0019 in}
Maximum connecting rod distortion [per 50 mm] 0.060 mm {0.0027 in}
Connecting rod center-to-center distance 150.65—150.75 mm {5.9311—5.9350 in}
Standard
0.22—0.45 mm {0.0087—0.0177 in}
Crankshaft end play
Maximum
0.55 mm {0.021 in}
Maximum main journal runout 0.05 mm {0.0019 in}
STD
51.980—52.000 mm {2.0465—2.0472 in}
Main journal diameter
OS0.25
51.730—51.750 mm {2.0367—2.0374 in}
Maximum main journal off-round 0.05 mm {0.0019 in}
STD
51.980—52.000 mm {2.0465—2.0472 in}
Crank pin diameter
OS0.25
51.730—51.750 mm {2.0367—2.0374 in}
Maximum crank pin off-round 0.05 mm {0.0019 in}

01–50–2
 TECHNICAL DATA
Item Specification
Standard
0.016—0.039 mm {0.0007—0.0015 in}
Main journal oil clearance
Maximum
0.10 mm {0.0039 in}
STD
2.501—2.522 mm {0.0985—0.0992 in}
OS0.25 01–50
Main bearing size (UPPER)
2.623—2.629 mm {0.1033—0.1035 in}
OS0.50
2.748—2.754 mm {0.1082—0.1084 in}
STD
2.501—2.529 mm {0.0985—0.0995 in}
OS0.25
Main bearing size (LOWER)
2.624—2.630 mm {0.1034—0.1035 in}
OS0.50
2.749—2.755 mm {0.1083—0.1084 in}
Standard
144.7—145.3 mm {5.696—5.720 in}
Cylinder head bolt length
Maximum
146 mm {5.748 in}
Standard
43.7—44.3 mm {1.720—1.744 in}
Connecting rod bolt length
Maximum
46 mm {1.811 in}
IN: 0.22—0.28 mm {0.0087—0.0110 in}
Standard valve clearance [when cold]
EX: 0.27—0.33 mm {0.0106—0.0130 in}
Maximum gear backlash 0.005—0.101 mm {0.00019—0.0039 in}
Front oil seal press-in amount 0—0.5 mm {0—0.019 in}

End Of Sie

01–50–3
 SERVICE TOOLS
01–60 SERVICE TOOLS
ENGINE SST [L3 WITH T/C]. . . . . . . . . . 01–60–1

End of Toc
ENGINE SST [L3 WITH T/C]
E6U016000000E02
1: Mazda SST number 01–60
2: Global SST number
Example
1:49 UN30
310610
2:303–1061

Camshaft
alignment
timing tool

1: – 1: – 1:49 G032 354

2:303–507 2:205–072–02 2: –

Crankshaft TDC Crankshaft Adjusting

timing peg holding tool pins wrench

1:49 E011 1A0 1:49 0636 100B 1:49 B012 0A2

2: – 2: – 2: –

Ring gear brake Valve spring Pivot

set lifter arm

1:49 B012 015 1:49 H010 401 1:49 0107 680A

2: – 2: – 2: –

Valve guide Oil seal installer Engine stand

installer

1:49 L010 1A0 1:49 S120 170 1:49 L012 0A0B

2: – 2: – 2: –

Engine hanger Valve seal Valve seal and

set remover valve guide
installer set

1:49 T032 302 1:49 UN30 1:49 G011 201

2: – 310610 2: –
2:303–1061
Bearing installer Attachment
Camshaft
alignment
timing tool

01–60–1
 SERVICE TOOLS
1:49 UN20 5153 1:49 1285 071 1:49 UN30 3328
2:205-153 2: – 2:303–328

Handle Bearing puller Rear oil seal

replacer

1: 49 T011 001 1:49 UN30 8157

2: – 2:308-157

Piston pin Pilot bearing

installer installer –

End Of Sie

01–60–2