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Title Section

GENERAL INFORMATION 00

ENGINE

CONTENTS

Engine

Workshop

Manual

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.

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

PRINTED IN U.S.A., AUGUST 2005

Form No. 1866–1U–05H

Part No. 9999–95–LFL3–05

Summary of content (60 pages)

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Engine Workshop Manual LF L3 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.
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GENERAL INFORMATION 00 SECTION Toc of SCT INFORMATION . . . . 00-00 GENERAL Toc of SCT 00–00 GENERAL INFORMATION HOW TO USE THIS MANUAL . . . . . . . . . 00–00–2 Range of Topics . . . . . . . . . . . . . . . . . . 00–00–2 Service Procedure . . . . . . . . . . . . . . . . 00–00–2 Symbols . . . . . . . . . . . . . . . . . . . . . . . . 00–00–4 Advisory Messages. . . . . . . . . . . . . . . . 00–00–4 UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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GENERAL INFORMATION HOW TO USE THIS MANUAL E5U000000000E01 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.
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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.
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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.
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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 E5U000000000E02 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) 00–00 kgf/cm2 (kilogram force per square centimeter) psi (pounds per square inch) rpm (revolutions per minute) N·m (Newton meter) kgf·m (kilogram force met
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GENERAL INFORMATION FUNDAMENTAL PROCEDURES E5U000000000E03 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.
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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.
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GENERAL INFORMATION 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.
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GENERAL INFORMATION ELECTRICAL SYSTEM Connectors Disconnecting connectors • When disconnecting connector, grasp the connectors, not the wires. E5U000000000E04 GOOD NO GOOD 00–00 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.
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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. GOOD NO GOOD CHU0000W011 • Inspect the terminals of waterproof connectors from the connector side since they cannot be accessed from the wiring harness side. GOOD NO GOOD Caution • To prevent damage to the terminal, wrap a thin wire around the tester probe before inserting into terminal.
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GENERAL INFORMATION NEW STANDARDS E5U000000000E05 • Following is a comparison of the previous standard and the new standard.
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GENERAL INFORMATION New Standard Abbreviation PNP — PSP PCM — PAIR — AIR SAPV SFI Name Park/Neutral Position PCM Control Relay Power Steering Pressure Powertrain Control Module Pressure Control Solenoid Previous Standard Abbreviation — — — ECU — Name Park/Neutral Range Main Relay Power Steering Pressure Engine Control Unit Line Pressure Solenoid Valve Pulsed Secondary Air Injection — Secondary Air Injection System Pump Speed Sensor — NE Sensor Secondary Air Injection — Secondary Air Injection Sy
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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. . . . . . . . . . . . . . . . . . . . . . . . 01–10–2 ENGINE MOUNTING/DISMOUNTING . . . . . . . . . 01–10–3 DISMOUNTING. . . . . . . . . . . . . . . . . . . 01–10–3 TIMING CHAIN DISASSEMBLY. . . . . . . . 01–10–4 Crankshaft Pulley Lock Bolt Disassembly Note . . . . . . . . . . . .
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MECHANICAL Front Oil Seal Assembly Note . . . . . . . . 01–10–40 Engine Front Cover Assembly Note . . . 01–10–41 Crankshaft Pulley Lock Bolt Assembly Note . . . . . . . . . . . . . . . . . . 01–10–41 Cylinder Head Cover Assembly Note . . . . . . . . . . . . . . . . . . 01–10–42 End of Toc ENGINE OVERHAUL SERVICE WARNING E5U011002000E01 Warning • Continuous exposure with USED engine oil has caused skin cancer in laboratory mice.
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MECHANICAL ENGINE MOUNTING/DISMOUNTING 1. Install the SSTs (arms) to the cylinder block holes as shown, and hand-tighten the bolts (part No.: 9YA20-1003) or M10 × 1.5T length 90 mm {3.55 in}. E5U011002000E02 49 L010 102 01–10 B3E0110W127 2. Assemble the SSTs (bolts, nuts and plate) to the specified positions. 3. Adjust the SSTs (bolts) so that less than 20 mm {0.79 in} of thread is exposed. 4. Make the SSTs (arms and plate) parallel by adjusting the SSTs (bolts and nuts).
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MECHANICAL TIMING CHAIN DISASSEMBLY E5U011002000E03 1. Disassemble in the order indicated in the table. . 1 8 3 R 2 14 7 R 9 5 R 6 4 SST R WITHOUT A/C 10 WITH VARIABLE VALVE TIMING MECHANISM 13 19 11 12 18 16 15 SST 17 E5U110ZE7S01 1 2 3 4 5 6 7 8 9 Oil level gauge (if equipped) Spark plug Cylinder head cover Crankshaft pulley lock bolt (See 01–10–5 Crankshaft Pulley Lock Bolt Disassembly Note.
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Engine Workshop Manual LF L3 (1866–1U–05H) MECHANICAL Crankshaft Pulley Lock Bolt Disassembly Note 1. Install the SST to the ring gear to lock the crankshaft against rotation. 49 E011 1A0 01–10 D3U110ZE4003 Front Oil Seal Disassembly Note 1. Remove the oil seal using a screwdriver. E6U110ZWB044 Chain Tensioner Disassembly Note 1. Unlock the chain tensioner ratchet using a suitable screw driver or equivalent tool. 2. Slowly press the tensioner piston. 3. Hold the chain tensioner piston with a 1.
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Engine Workshop Manual LF L3 (1866–1U–05H) MECHANICAL CYLINDER HEAD (I) DISASSEMBLY E5U011002000E04 1. Disassemble in the order indicated in the table. . WITH VARIABLE VALVE TIMING MECHANISM 4 3 2 * 5 R 7 4 2 6 8 R * R * 1 9 R *: IF WASHER IS NOT INSTALLED TO THE ENGINE, INSTALL A NEW WASHER.
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MECHANICAL Camshaft Sprocket Lock Bolt, Variable Valve Timing Actuator Lock Bolt Disassembly Note 1. Hold the camshaft by using a wrench on the cast hexagon as shown, and loosen the camshaft sprocket installation bolt or variable valve timing actuator installation bolt (With variable valve timing mechanism). Without variable valve timing mechanism 01–10 B3E0110E056 With variable valve timing mechanism B3E0110E058 Camshaft Cap Disassembly Note 1.
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MECHANICAL Cylinder Head Bolt Disassembly Note 1. Loosen the cylinder head bolts in 2—3 steps in the order shown in the figure. 3 7 10 6 2 End Of Sie 4 8 9 5 1 B3E0110E059 CYLINDER HEAD (II) DISASSEMBLY E5U011002000E05 1. Disassemble in the order indicated in the table. . 2 SST 3 1 8 4 R 6 SST R 7 1 5 B3E0110E060 1 2 3 4 Engine hanger Valve keeper (See 01–10–8 Valve Keeper Disassembly Note.
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MECHANICAL Valve Seal Disassembly Note 1. Remove the valve seal using the SST. End Of Sie 49 S120 170 VALVE SEAL VALVE GUIDE B3E0110E061 CYLINDER BLOCK (I) DISASSEMBLY E5U011002000E06 1. Disassemble in the order indicated in the table. .
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MECHANICAL Drive Plate (ATX), Flywheel (MTX) Disassembly Note 1. Hold the crankshaft using the SST. 2. Remove the bolts in several passes. End Of Sie 49 E011 1A0 1 3 6 5 4 2 B3E0110E051 CYLINDER BLOCK (II) DISASSEMBLY E5U011002000E07 1. Disassemble in the order indicated in the table. . 5 6 L3 11 12 10 7 10 4 L3 9 3 2 8 1 E5U110ZE7S07 1 2 3 4 5 6 Balancer unit Adjustment shim Connecting rod cap (See 01–10–11 Connecting Rod Cap Disassembly Note.
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MECHANICAL Connecting Rod Cap Disassembly Note 1. Before removing connecting rod inspect the connecting rod side clearance. (See 01–10–20 CONNECTING ROD INSPECTION.) 2. Remove the connecting rod bolt from the connecting rod cap by tapping the bolt with a plastic hammer. Note • The tappets are numbered to make sure they are assembled in their original positions. When removed, keep the tappets with the cylinder head they were removed from. Do not mix the tappets. Main Bearing Cap Disassembly Note 1.
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MECHANICAL End Of Sie VALVE, VALVE GUIDE INSPECTION E5U011012111E01 1. Measure the valve head margin thickness of each valve. • If it is less than the specification, replace the valve. Valve head margin thickness (Minimum) IN: 1.62 mm {0.0637 in} EX: 1.82 mm {0.0716 in} IN : 33.5 mm {1.31 in} EX : 28.3 mm {1.14 in} MARGIN THICKNESS C3U0110E051 2. Measure the length of each valve. Replace the valve if necessary. • If it is less than the specification, replace the valve. Valve length (Standard) IN: 102.
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MECHANICAL 5. Calculate the valve stem to guide clearance by subtracting the outer diameter of the valve stem from the inner diameter of the corresponding valve guide. • If it exceeds the specification, replace the valve and/or the valve guide. VALVE STEM VALVE GUIDE CLEARANCE Valve stem to guide clearance (Standard) IN: 0.024—0.069 mm {0.0009—0.0027 in} EX: 0.029—0.074 mm {0.0012—0.0029 in} 01–10 Valve stem to guide clearance (Maximum) 0.10 mm {0.004 in} 6.
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MECHANICAL 2. Tap the valve guide in from the top of the cylinder head until the SSTs contacts the cylinder head. 49 L012 003A 49 L012 004A 49 L012 002A VALVE GUIDE B3E0110E072 3. Verify that the valve guide protrusion height (dimension A) is within the specification. VALVE GUIDE A Valve guide protrusion height (standard) 12.2—12.8 mm {0.481—0.503 in} End Of Sie CYLINDER HEAD C3U0110E004 VALVE SEAT INSPECTION/REPAIR E5U011010102E01 1. Measure the seat contact width.
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MECHANICAL End Of Sie VALVE SPRING INSPECTION E5U011012125E01 1. Apply pressing force to the pressure spring and inspect the spring height. • If it is less than the specification, replace the valve spring. Valve spring pressing force 390 N {39.76 kgf, 87.67 lbf} 01–10 Valve spring standard height H 28.68 mm {1.129 in} ADJ2224E028 2. Measure the out-of-square of the valve spring, using a square, as shown in the figure.
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MECHANICAL 4. Measure the journal diameters in X and Y directions at the two points (A and B) as indicated in the figure. • If it is less than the specification, replace the camshaft. B A Camshaft journal diameter (Standard) 24.96—24.98 mm {0.9827—0.9834 in} Y Camshaft journal diameter (Minimum) 24.95 mm {0.982 in} X 5. Remove the tappet. 6. Position a plastigage atop the journals in the axial direction. 7. Install the camshaft cap. (See 01–10–37 Camshaft Assembly Note.) 8. Remove the camshaft cap.
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MECHANICAL TAPPET INSPECTION E5U011012431E01 1. Measure the tappet hole inner diameter in X and Y directions at the two points (A and B) shown in the figure. X Tappet bore diameter (Standard) 31.000—31.030 mm {1.2205—1.2216 in} Y 01–10 A B ADJ2224E023 2. Measure the tappet body outer diameter in X and Y directions at the two points (A and B) shown in the figure. A Y Tappet diameter (Standard) 30.970—30.980 mm {1.2193—1.2196 in} B X 3.
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MECHANICAL OIL JET VALVE INSPECTION 1. Apply compressed air to oil jet valve A and verify that air passes through oil jet valve B. • If air does not flow, replace the oil jet valve. E5U011010730E01 B Oil jet valve air pressure 216—274 kPa {2.2—2.7 kgf·cm2 31.4—39.7 psi} End Of Sie A B3E0110E079 PISTON INSPECTION E5U011011010E01 Caution • The piston and connecting rod cannot be disassembled.
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MECHANICAL 4. Insert the piston ring into the cylinder by hand and use the piston to push it to the bottom of the ring travel. 5. Measure each piston ring end gap with a feeler gauge. • If it exceeds the specification, replace the piston, piston pin, piston ring and connecting rod as a single unit. PISTON RING 01–10 Piston end gap (Standard) Top: 0.16—0.31 mm {0.0063—0.0122 in} Second: 0.33—0.48 mm {0.0130—0.0189 in} Oil (rail): 0.20—0.70 mm {0.0079—0.0275 in} B3E0110E082 Piston end gap (Maximum) 1.
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MECHANICAL 6. 7. 8. 9. 10. Install the main bearing caps and crankshaft. Position a plastigage atop the journals in the axial direction. Install the main bearing caps and cylinder block. (See 01–10–28 Main Bearing Cap Assembly Note.) Remove the main bearing caps. (See 01–10–11 Main Bearing Cap Disassembly Note.) Measure the main journal oil clearance.
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MECHANICAL End Of Sie BOLT INSPECTION E5U011010135E01 1. Measure the length of each bolt. • If it exceeds the specification, replace the bolt. Bolt length (mm {in}) Cylinder head bolt (With washer) Standard: 149.2—149.8 {5.87—5.90} Maximum: 150.5 {5.91} Cylinder head bolt (Without washer) Standard: 145.2—145.8 {5.72—5.74} Maximum: 146.5 {5.77} Connecting rod bolt Standard: 44.7—45.3 {1.75—1.78} Maximum: 46.0 {1.81} Main bearing cap bolt (Plastic region tightening bolt only) Standard: 110.0—110.6 {4.33—4.
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MECHANICAL Spool Valve Operation Inspection 1. Disconnect the negative battery cable. 2. Remove the oil control valve (OCV). 3. Verify that the spool valve in the oil control valve (OCV) is in the maximum valve timing retard position as indicated in the figure. • If it exceeds the specification, replace the oil control valve (OCV). 4. Verify that the battery is fully charged. • If it is less than specification, recharge the battery. SPOOL VALVE (MAXIMUM VALVE TIMING RETARD POSITION B3E0110E090 5.
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MECHANICAL End Of Sie VALVE CLEARANCE ADJUSTMENT E5U011012111E04 1. Remove the engine front cover lower blind plug. 2. Remove the engine front cover upper blind plug. 3. Remove the cylinder block lower blind plug. 01–10 UPPER BLIND PLUG LOWER BLIND PLUG B3E0110E093 4. Install the SST as shown in the figure. Caution • Removal of this SST is extremely important. If you crank the engine with this SST installed, the cylinder block will be damaged. 303-507 5.
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MECHANICAL 7. Hold the exhaust camshaft using a suitable wrench on the cast hexagon as shown in the figure. B3E0110E095 8. Remove the exhaust camshaft sprocket. EXHAUST CAMSHAFT SPROCKET B3E0110E097 9. Loosen the camshaft cap bolts in several passes in the order shown in the figure. Note • The cylinder head and the camshaft caps are numbered to make sure they are reassembled in their original position. When removed, keep the caps with the cylinder head they were removed from. Do not mix the caps.
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Engine Workshop Manual LF L3 (1866–1U–05H) MECHANICAL 15. Install a new washer. R 01–10 D3U110ZE4012 16. Install the exhaust camshaft sprocket. Note • Do not tighten the bolt for the camshaft sprocket during this step. First confirm the valve timing, then tighten the bolt. EXHAUST CAMSHAFT SPROCKET B3E0110E097 17. Install the SST to the camshaft as shown in the figure. 18. Remove the M6 × 1.0 bolt from the engine front cover to apply tension to the timing chain. 19.
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Engine Workshop Manual LF L3 (1866–1U–05H) MECHANICAL 25. Install the new engine front cover upper blind plug. Tightening torque 8.0—11.5 N·m {82—117 kgf·cm, 71—101 in·lbf} BLIND PLUG B3E0110E101 26. 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} BLIND PLUG B3E0110E102 27. Install the new engine front cover lower blind plug.
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MECHANICAL CYLINDER BLOCK (I) ASSEMBLY E5U011002000E08 1. Assemble in the order indicated in the table. . 01–10 8 6 OIL 2.9—4.9 N·m {30—40 kgf·cm, 25.67—43.4 in·lbf} 2 1 L3 OIL OIL OIL 3 7 L3 9 3 OIL 10 4 11 5 26—32 {2.7—3.2, 19.2—23.6}+80°—100° SST 12 25+44—46 {2.6+4.5—4.7, 18.4+32.5—33.9} SST PLASTIC REGION TIGHTENING BOLT (BOLT STEM LENGTH 110 mm) 44—46 {4.5—4.6, 32.5—33.9} +175°—185° SST ELASTIC REGION TIGHTENING BOLT (BOLT STEM LENGTH 104 mm) 3—7 N·m {30.6—71.3 kgf·cm,26.
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MECHANICAL Main Bearing Cap Assembly Note 1. Install the main bearing caps in the order indicated in the figure. 2. Tighten the main bearing cap bolts using the SST (49 D032 316). Tightening torque Plastic region tightening bolt (Bolt stem length 110 mm) (1) 44—46 N·m {4.5—4.6 kgf·m, 32.5—33.9 ft·lbf} (2) 175°—185° 9 5 1 3 7 10 6 2 4 8 B3E0110E105 Elastic region tightening bolt (Bolt stem length 104 mm) (1) Apply engine oil to all bolts. (2) 3—7 N·m {30.6—71.3 kgf·cm, 26.6—61.
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MECHANICAL 2. Insert the piston and connecting rod into the cylinder with the arrow mark to front of the engine. 01–10 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.
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MECHANICAL 5. With the balancer unit marks at the exact top center, assemble the unit to the cylinder block. MARK B3E0110E111 6. Set the SST as shown, then measure the gear backlash using a dial gauge. 49 G011 201 DIAL GAUGE 41.4 mm {1.629 in} DRIVEN GEAR SHAFT CENTER B3E0110E112 Note • For an accurate measurement of gear backlash, insert a screwdriver into the crankshaft No.
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MECHANICAL Adjustment shim selection table Backlash mm {in} 0.267—0.273 {0.01051— 0.01074} 0.260—0.266 {0.01023— 0.01047} 0.253—0.259 {0.00996— 0.01019} 0.246—0.252 {0.00968— 0.00992} 0.239—0.245 {0.00940— 0.00964} 0.232—0.238 {0.00913— 0.00937} 0.225—0.231 {0.00885— 0.00909} 0.218—0.224 {0.00858— 0.00881} 0.211—0.217 {0.00830— 0.00854} 0.204—0.210 {0.00803— 0.00826} 0.197—0.203 {0.00775— 0.00799} 0.190—0.196 {0.00748— 0.00771} 0.183—0.189 {0.00720— 0.00744} 0.176—0.182 {0.00692— 0.00716} 0.169—0.175 {0.
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MECHANICAL CYLINDER BLOCK (II) ASSEMBLY E5U011002000E09 1. Assemble in the order indicated in the table. SST R 1 OIL 46—54 {4.70—5.50, 34.0—39.8}+76—84 {7.75—8.56, 56.1—61.9}+108—116 {11.1—11.8, 79.7—85.5} A SST R 13 MTX R 4 A 7 16.2—23.8 {1.66—2.42, 12.0—17.5} R A 6 WITHOUT OIL COOLER R SPIN-ON TYPE CARTRIDGE TYPE 2 R IF EQUIPPED R 5 3 8.0—12 N·m {81.6—122.3 kgf·cm, 70.9—106.2in·lbf} +20°—25° SEALANT A B R 8 WITH OIL COOLER A 10 30—39 {3.1—3.9, 22.2—28.7} 15—20 {1.6—2.
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MECHANICAL Rear Oil Seal Assembly Note 1. Apply clean engine oil to the new oil seal lip. 2. Install the rear oil seal using the SST as shown in the figure. 01–10 303-328 (49 UN30 3328) CUE110BW2005 3. Tighten the rear oil seal bolts in the order as 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 6 2 4 B3E0110E116 Drive Plate (ATX), Flywheel (MTX) Assembly Note 1. Hold the crankshaft using the SST. 2. Tighten the bolts in the 3 steps in the figure.
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MECHANICAL Oil pan Assembly Note 1. Apply a continuous bead of silicone sealant to the oil pan as indicated in the figure. ENGINE FRONT SIDE 2.2—3.2 mm{0.087—0.126 in} Caution • Install the oil pan within 10min of applying the silicone sealant • Make sure that there is no oil or dust on the seal side of oil pan. REAR OIL SEAL C3U0110E061 2. Use a square ruler to unite the oil pan and the cylinder block junction side on the engine front cover side. CYLINDER BLOCK OIL PAN -0.05—0.05 mm {-0.0020—0.
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Engine Workshop Manual LF L3 (1866–1U–05H) MECHANICAL CYLINDER HEAD (I) ASSEMBLY E5U011002000E10 1. Assemble in the order indicated in the table. . 42—48 {4.3—4.8, 31.0—35.4} 8 1 SST 7 8.0—11.5 N·m {81.6—117.2 kgf·cm, 70.9—101.7 in·lbf} 6 5 R 01–10 3 SST R 2 8 56—60 {5.8—6.1, 41.3—44.2} 4 42—48 {4.3—4.8, 31.0—35.
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Engine Workshop Manual LF L3 (1866–1U–05H) MECHANICAL CYLINDER HEAD (II) ASSEMBLY E5U011002000E11 1. Assemble in the order indicated in the table. 5.0—9.0 N·m {51.0—91.7 kgf·cm, 44.3—79.5 in·lbf}+ 14—17 {1.43—1.73, 10.4—12.5} WITH VARIABLE VALVE TIMING MECHANISM 5.0—9.0 N·m {51.0—91.7 kgf·cm, 44.3—79.5 in·lbf}+ 14—17 {1.43—1.73, 10.4—12.5} 8.0—11.5 N·m {81.5—117 kgf·cm 70.8—101in·lbf} 8 6 5 7 R * 3 3—11 {30.6—112 kgf·cm, 26.6—97.3 in·lbf}+ 13—17 {1.4—1.7, 9.6—12.5}+ 43—47 {4.4—4.7, 31.8—34.
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MECHANICAL Cylinder Head Bolt Assembly Note 1. Tighten the cylinder head bolts in the order indicated in the figure in 5 steps using the SST (49 D032 316). 8 Tightening torque (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° (5) 88°—92° 1 4 9 5 01–10 7 2 3 6 10 C3U0110E054 Camshaft Assembly Note 1. Set the cam position of No.1 cylinder at the top dead center (TDC) and install the camshaft.
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MECHANICAL TIMING CHAIN ASSEMBLY E5U011002000E12 1. Assemble in the order indicated in the table. . 8.0—11.5 N·m {81.6—117.2 kgf·cm, 70.9—101.7 in·lbf} 40—55 {4.1—5.6, 29.6—40.5} SEALANT 20 19 12 A 18 R 6 14 OIL 20—30 {2.1—3.0, 14.8—22.1} R SST R 13 16 SEALANT 15 17 SST R 96—104 {9.8—10.6, 70.9—76.7}+ 87°—93° WITHOUT A/C 20—30 {2.1—3.0, 14.8—22.1} SEALANT 10 40—55 {4.1—5.6, 29.6—40.5} 11 69—75 {7.1—7.6, 50.9—55.3} SST WITH VARIABLE VALVE TIMING MECHANISM 7 A A A : 8.0—10.
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MECHANICAL Oil Pump Sprocket Assembly Note 1. Hold the oil pump sprocket using the SST. 01–10 49 G032 354 B3E0110E125 Timing Chain Assembly Note 1. Install the SST to the camshaft, then align the No. 1 camshaft position with the TDC. 2. Remove the cylinder block lower blind plug. 303-465 (49 UN30 3465) C3U0110E052 3. Install the SST as shown in the figure. 4. Turn the crankshaft clockwise so that the crankshaft is in the No.1 cylinder TDC position. 5. Install the timing chain.
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MECHANICAL Camshaft Sprocket, Variable Valve Timing Actuator Assembly Note 1. Hold the camshaft using a suitable wrench on the cast hexagon as shown in the figure. 2. Tighten the camshaft sprocket lock bolt. Tightening torque 69—75 N·m {7.1—7.6 kgf·m, 50.9—55.3 ft·lbf} B3E0110E095 Front Oil Seal Assembly Note 1. Apply clean engine oil to the oil seal. 2. Push the oil seal slightly in by hand. 3. Compress the oil seal using the SST and a hammer. 49 H010 401 B3E0110E127 HAMMER ENGINE FRONT COVER 0—0.
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MECHANICAL Engine Front Cover Assembly Note 1. Apply silicone sealant to the engine front cover as shown in the figure. B Caution • Install the cylinder head cover within 10 min of applying the silicone sealant. • Silicone sealant is not need in area C as indicated below due to an existing. (With variable valve timing mechanism) • Make sure that there is no oil or dust on the seal side of oil pan. 01–10 A B C Thickness A: 2.2—3.2 mm {0.087—0.125 in} B: 1.5—2.5 mm {0.059—0.098 in} B3E0110E129 2.
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MECHANICAL 2. Install the M6 × 1.0 bolt in by hand. 3. Turn the crankshaft clockwise so that the crankshaft is in the No.1 cylinder TDC position. BOLT B3E0110E063 4. Hold the crankshaft pulley using the SST. 5. Tighten the crankshaft pulley lock bolt in the order shown following two steps using the SST (49 D032 316). 49 E011 1A0 Tightening torque (1) 96—104 N·m {9.8—10.6 kgf·m, 70.9—76.7 ft·lbf} (2) 87°—93° Remove the M6 × 1.0 bolt. Remove the SST from the camshaft.
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TECHNICAL DATA 01–50 TECHNICAL DATA ENGINE TECHNICAL DATA . . . . . . . . . .
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TECHNICAL DATA Item Minimum / maximum bore diameter limit Oil jet valve air pressure Piston diameter (Standard) Piston-to-cylinder clearance (Standard) Piston-to-cylinder clearance (Maximum) Piston ring-to-ring groove clearance (Standard) Piston ring-to-ring groove clearance (Maximum) Piston end gap (Standard) Piston end gap (Maximum) Crankshaft end play (Standard) Crankshaft end play (Maximum) Crankshaft runout (Maximum) Main journal bearing size Main journal out of round (Maximum) Crank pin journal diamet
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SERVICE TOOLS 01–60 SERVICE TOOLS ENGINE SST . . . . . . . . . . . . . . . . . . . . . .
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SERVICE TOOLS 1:49 G011 201 2: – Attachment End Of Sie 01–60–2 — —