Technical data

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CONTENTS

Engine

Workshop

Manual

FOREWORD

This manual explains the disassembly,

inspection, repair, and reassembly

procedures for the above-indicated engine.

In order to do these procedures safety,

quickly, and correctly, you must first read

this manual and any other relevant service

materials carefully.

The information in this manual is current

up to March, 2002. Any changes that occur

after that time will not be reflected in

this particular manual. Therefore, the contents

of this manual may not exactly match

the mechanism that you are currently

serving.

Mazda Motor Corporation

HIROSHIMA, JAPAN

PRINTED IN The Netherlands, MARCH 2002

1731–1E–02C

Title Section

General Information GI

Engine B

Technical Data TD

Special Tools ST

1731-1E-02C(INDEX).fm 1 ページ２００２年３月１３日水曜日午後５時８分

Summary of content (70 pages)

PAGE 1
731-1E-02C(INDEX).fm 1 ページ２００２年３月１３日水曜日午後５時８分 Engine Workshop Manual L8 LF L3 FOREWORD This manual explains the disassembly, inspection, repair, and reassembly procedures for the above-indicated engine. In order to do these procedures safety, quickly, and correctly, you must first read this manual and any other relevant service materials carefully. The information in this manual is current up to March, 2002. Any changes that occur after that time will not be reflected in this particular manual.
PAGE 2
1731-1E-02C(WARNING).fm 1 ページ２００２年３月１３日水曜日午後５時９分 WARNING Servicing a vehicle can be dangerous. If you have not received service-related training, the risks of injury, property damage, and failure of servicing increase. The recommended servicing procedures for the vehicle in this workshop manual were developed with Mazda-trained technicians in mind.
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1731-1E-02C.book 1 ページ２００２年４月２６日金曜日午前１０時３０分 GENERAL INFORMATION GI GI HOW TO USE THIS MANUAL ............................. GI-2 RANGE OF TOPICS .......................................... GI-2 SERVICE PROCEDURE ................................... GI-2 SYMBOLS.......................................................... GI-3 ADVISORY MESSAGES ................................... GI-4 UNITS ................................................................... GI-5 UNITS ...................................
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1731-1E-02C.book 2 ページ２００２年４月２６日金曜日午前１０時３０分 HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL RANGE OF TOPICS A6E201000001E01 • 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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1731-1E-02C.book 3 ページ２００２年４月２６日金曜日午前１０時３０分 HOW TO USE THIS MANUAL 4. GI XME2010010 End Of Sie SYMBOLS A6E201000001E03 • There are eight symbols indicating oil, grease, fluids, sealant, and SST or equivalent use. These symbols show application points or use of these materials during service.
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1731-1E-02C.book 4 ページ２００２年４月２６日金曜日午前１０時３０分 HOW TO USE THIS MANUAL Symbol Meaning Kind Apply automatic transaxle/ transmission fluid New appropriate automatic transaxle/ transmission fluid Apply grease Appropriate grease Apply sealant Appropriate sealant Apply petroleum jelly Appropriate petroleum jelly Replace part O-ring, gasket, etc.
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1731-1E-02C.
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1731-1E-02C.book 6 ページ２００２年４月２６日金曜日午前１０時３０分 FUNDAMENTAL PROCEDURES FUNDAMENTAL PROCEDURES PREPARATION OF TOOLS AND MEASURING EQUIPMENT • Be sure that all necessary tools and measuring equipment are available before starting any work. A6E201400004E02 X3U000WAH End Of Sie SPECIAL SERVICE TOOLS • Use special service tools or equivalent when they are required.
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1731-1E-02C.book 7 ページ２００２年４月２６日金曜日午前１０時３０分 FUNDAMENTAL PROCEDURES INSPECTION DURING REMOVAL, DISASSEMBLY • When removed, each part should be carefully inspected for malfunction, deformation, damage, and other problems. A6E201400004E08 GI X3U000WAM End Of Sie 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.
PAGE 10
1731-1E-02C.book 8 ページ２００２年４月２６日金曜日午前１０時３０分 FUNDAMENTAL PROCEDURES • 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.
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1731-1E-02C.book 9 ページ２００２年４月２６日金曜日午前１０時３０分 FUNDAMENTAL PROCEDURES TORQUE FORMULAS • When using a torque wrench-SST or equivalent combination, the written torque must be recalculated due to the extra length that the SST or equivalent adds to the torque wrench. Recalculate the torque using the following formulas. Choose the formula that applies to you.
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1731-1E-02C.book 10 ページ２００２年４月２６日金曜日午前１０時３０分 ELECTRICAL SYSTEM ELECTRICAL SYSTEM ELECTRICAL PARTS A6E201700006E01 Battery cable • Before disconnecting connectors or removing electrical parts, disconnect the negative battery cable. WGIWXX0007E Wiring Harness • To remove the wiring harness from the clip in the engine room, pry up the hook of the clip using a flathead screwdriver.
PAGE 13
1731-1E-02C.book 11 ページ２００２年４月２６日金曜日午前１０時３０分 ELECTRICAL SYSTEM • Connectors can be disconnected by pressing or pulling the lock lever as shown. GI WGIWXX0042E Locking connector • When locking connectors, listen for a click indicating they are securely locked. X3U000WB1 Inspection • When a tester is used to inspect for continuity or measuring voltage, insert the tester probe from the wiring harness side.
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1731-1E-02C.book 12 ページ２００２年４月２６日金曜日午前１０時３０分 ELECTRICAL SYSTEM Terminals Inspection • Pull lightly on individual wires to verify that they are secured in the terminal. X3U000WB4 Wiring Harness Wiring color codes • Two-color wires are indicated by a two-color code symbol. • The first letter indicates the base color of the wire and the second the color of the stripe.
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1731-1E-02C.book 13 ページ２００２年４月２６日金曜日午前１０時３０分 NEW STANDARDS NEW STANDARDS GI NEW STANDARDS A6E202800020E01 • Following is a comparison of the previous standard and the new standard.
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1731-1E-02C.
PAGE 17
31-1E-02C.
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1731-1E-02C.book 1 ページ２００２年４月２６日金曜日午前１０時３０分 ENGINE B B ENGINE .................................................................. B-2 ENGINE OVERHAUL SERVICE WARNING ....... B-2 ENGINE MOUNTING/DISMOUNTING ................ B-2 TIMING CHAIN DISASSEMBLY .......................... B-3 CYLINDER HEAD (I) DISASSEMBLY ................. B-5 CYLINDER HEAD (II) DISASSEMBLY ................ B-7 CYLINDER BLOCK (I) DISASSEMBLY ............... B-9 CYLINDER BLOCK (II) DISASSEMBLY ............
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1731-1E-02C.book 2 ページ２００２年４月２６日金曜日午前１０時３０分 ENGINE ENGINE ENGINE OVERHAUL SERVICE WARNING A6E242402000E01 Warning • Continuous exposure with USED engine oil has caused skin cancer in laboratory mice. Protect your skin by washing with soap and water immediately after this work. End Of Sie ENGINE MOUNTING/DISMOUNTING A6E242402000E02 1. Install the SSTs (arms) to the cylinder block holes as shown, and hand-tighten the bolts (part No.: ×1.5T length 90 mm {3.55 9YA20-1003) or M10× in}.
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1731-1E-02C.book 3 ページ２００２年４月２６日金曜日午前１０時３０分 ENGINE TIMING CHAIN DISASSEMBLY A6E242402000E04 1. Disassemble in the order indicated in the table. .
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1731-1E-02C.book 4 ページ２００２年４月２６日金曜日午前１０時３０分 ENGINE Crankshaft Pulley Lock Bolt Disassembly Note 1. Hold the crankshaft using the SST. 2. Remove the crankshaft pulley lock bolt. AME2224E106 Front Oil Seal Disassembly Note 1. Remove the oil seal using a screwdriver. AME2224E338 Chain Tensioner Disassembly Note 1. Hold the chain tensioner ratchet lock mechanism away from the ratchet stem with a thin screwdriver. 2. Slowly press the tensioner piston. 3. Hold the chain tensioner piston with a 1.
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1731-1E-02C.book 5 ページ２００２年４月２６日金曜日午前１０時３０分 ENGINE CYLINDER HEAD (I) DISASSEMBLY A6E242402000E05 1. Disassemble in the order indicated in the table. 2. B AME2224E001 .
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1731-1E-02C.book 6 ページ２００２年４月２６日金曜日午前１０時３０分 ENGINE Camshaft Sprocket Lock Bolt, Variable Valve Timing Actuator Lock Bolt (L3 (with variable valve timing mechanism)) Disassembly Note 1. Hold the camshaft by using a wrench on the cast hexagon as shown, and loosen the camshaft sprocket lock bolt or variable valve timing actuator lock bolt (L3 (with variable valve timing mechanism)). L8, LF, L3 AME2224E077 L3 (with variable valve timing mechanism) AME2224E078 Camshaft Cap Disassembly Note 1.
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1731-1E-02C.book 7 ページ２００２年４月２６日金曜日午前１０時３０分 ENGINE Tappet Disassembly Note 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. B Cylinder Head Bolt Disassembly Note 1. Loosen the cylinder head bolts in two or three steps in the order shown. AME2224E005 End Of Sie CYLINDER HEAD (II) DISASSEMBLY A6E242402000E06 1.
PAGE 25
1731-1E-02C.book 8 ページ２００２年４月２６日金曜日午前１０時３０分 ENGINE Valve Keeper Disassembly Note 1. Remove the valve keeper using the SSTs. AME2224E302 Valve Seal Disassembly Note 1. Remove the valve seal using the SST.
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1731-1E-02C.book 9 ページ２００２年４月２６日金曜日午前１０時３０分 ENGINE CYLINDER BLOCK (I) DISASSEMBLY A6E242402000E07 1. Disassemble in the order indicated in the table. 2. B AME2224E011 .
PAGE 27
1731-1E-02C.book 10 ページ２００２年４月２６日金曜日午前１０時３０分 ENGINE 11 12 13 14 Oil pump Flywheel (MTX ), Drive plate (ATX) (See B–10 Drive Plate (ATX), Flywheel (MTX) Disassembly Note) End plate (MTX) Rear oil seal Drive Plate (ATX), Flywheel (MTX) Disassembly Note 1. Hold the crankshaft using the SST. 2. Remove the bolts in several passes. AME2224E106 End Of Sie CYLINDER BLOCK (II) DISASSEMBLY A6E242402000E08 1. Disassemble in the order indicated in the table. 2.
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1731-1E-02C.book 11 ページ２００２年４月２６日金曜日午前１０時３０分 ENGINE .
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1731-1E-02C.book 12 ページ２００２年４月２６日金曜日午前１０時３０分 ENGINE CYLINDER HEAD INSPECTION A6E242410100E01 1. Carry out color contrast penetrate examination on the cylinder head surface. • Replace the cylinder head if necessary. 2. Inspect for the following and repair or replace if necessary. (1) Sunken valve seats (2) Excessive camshaft oil clearance and end play 3. Measure the cylinder head for distortion in the six directions as shown. • If the distortion exceeds the maximum, replace the cylinder head.
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1731-1E-02C.book 13 ページ２００２年４月２６日金曜日午前１０時３０分 ENGINE 3. Measure the stem diameter of each valve in X and Y directions at the three points (A, B, and C) as indicated in the figure. • If not as specified, replace the valve. B Standard diameter: IN: 5.470—5.485 mm {0.2154—0.2159 in} EX: 5.465—5.480 mm {0.2152—0.2157 in} Maximum diameter: IN: 5.440 mm {0.2142 in} EX: 5.435 mm {0.2140 in} AME2224E313 4.
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1731-1E-02C.book 14 ページ２００２年４月２６日金曜日午前１０時３０分 ENGINE VALVE GUIDE REPLACEMENT A6E242412111E04 Valve Guide Removal 1. Remove the valve guide from the combustion chamber side using the SST. AME2224E312 Valve Guide Installation 1. Assemble the SSTs so that depth L is as specified. Depth L: IN: 12.2—12.8 mm {0.481—0.501 in} EX: 12.2—12.8 mm {0.481—0.501 in} AME2224E107 2. Tap the valve guide in from the side opposite the camshaft side until the SSTs contacts the cylinder head. AME2224E018 3.
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1731-1E-02C.book 15 ページ２００２年４月２６日金曜日午前１０時３０分 ENGINE VALVE SEAT INSPECTION/REPAIR A6E242410102E01 1. Measure the seat contact width. • If necessary, resurface the valve seat using a 45° valve seat cutter and/or resurface the valve face. B Standard width: 1.2—1.6 mm {0.048—0.062 in} 2. Verify that the valve seating position is at the center of the valve face. AME2224E316 (1) If the seating position is too out side, correct the valve seat using a 70°° (IN) or 65°° (EX) cutter, and a 45°° cutter.
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1731-1E-02C.book 16 ページ２００２年４月２６日金曜日午前１０時３０分 ENGINE 2. Measure the out-of-square of the valve spring, using a square, as shown. (1) Rotate the valve spring one full turn and measure "A" at the point where the gap is the largest. • If not as specified, replace the valve spring. Valve spring maximum out-of-square: 1% (2.10 mm {0.0826 in}) AME2224E309 End Of Sie CAMSHAFT INSPECTION A6E242412420E01 1. Set the No.1 and No.5 journals on V-blocks. 2. Measure the camshaft runout.
PAGE 34
1731-1E-02C.book 17 ページ２００２年４月２６日金曜日午前１０時３０分 ENGINE 4. Measure the journal diameters in X and Y directions at the two points (A and B) as indicated in the figure. • If not as specified, replace the camshaft. B Standard diameter: 24.96—24.98 mm {0.9827—0.9834 in} Minimum diameter: 24.95 mm {0.982 in} 5. Remove the tappet. 6. Position plasticgage atop the journals in the axial direction. 7. IInstall the camshaft cap. (See B–40 Camshaft Assembly Note.) 8. Remove the camshaft cap.
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1731-1E-02C.book 18 ページ２００２年４月２６日金曜日午前１０時３０分 ENGINE TAPPET INSPECTION A6E242412310E01 1. Measure the tappet hole inner diameter in X and Y directions at the two points (A and B) shown. Inner diameter: 31.000—31.030 mm {1.2205—1.2216 in} AME2224E319 2. Measure the tappet body outer diameter in X and Y directions at the two points (A and B) shown. Outer diameter: 30.970—30.980 mm {1.2193—1.2196 in} 3. Subtract the tappet body outer diameter from the tappet hole inner diameter.
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1731-1E-02C.book 19 ページ２００２年４月２６日金曜日午前１０時３０分 ENGINE End Of Sie OIL JET VALVE INSPECTION A6E242410730E02 1. Apply compressed air to oil jet valve A and verify that air passes through oil jet valve B. • If not ventilation,replace the oil jet valve. B Air pressure: 216—274 kPa {2.2—2.7kgf•cm2 31.4—39.7 psi} AME2224E105 End Of Sie PISTON INSPECTION A6E242411010E01 Caution • The piston, piston ring and connecting rod cannot be disassembled.
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1731-1E-02C.book 20 ページ２００２年４月２６日金曜日午前１０時３０分 ENGINE 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 the piston ring end gap exceeds the maximum end gap, replace the piston, piston pin, piston ring and connecting rod as a single unit. Standard end gap: Top: 0.16—0.31 mm {0.0063—0.012 in} Second: 0.33—0.48 mm {0.0130—0.0189 in} Oil (rail): 0.20—0.70 mm {0.0079—0.
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1731-1E-02C.book 21 ページ２００２年４月２６日金曜日午前１０時３０分 ENGINE 5. Measure the journal diameter in X and Y directions at the two points (A and B) as indicated in the figure. • If not as specified, replace the crankshaft or grind the journal and install the undersize bearing. B Main journal mm {in} Bearing size Standard 0.25 {0.01} undersize Standard diameter 51.980—52.000 {2.0464—2.0472} 51.730—51.750 {2.0366—2.0373} AME2224E036 Maximum out-of-round: 0.05 mm {0.
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1731-1E-02C.book 22 ページ２００２年４月２６日金曜日午前１０時３０分 ENGINE End Of Sie CONNECTING ROD INSPECTION A6E242411211E01 Caution • The piston, piston ring and connecting rod cannot be disassembled. • When replacing the piston, piston pin, piston ring and connecting rod, replace them together as a single unit. 1. Install the connecting rod cap. (See B–31 Connecting Rod Cap Assembly Note.) 2. Measure the connecting rod large end side clearance.
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1731-1E-02C.book 23 ページ２００２年４月２６日金曜日午前１０時３０分 ENGINE Length L bolt Cylinder head bolt Connecting rod bolt Main bearing cap bolt Standard (mm) {in} Maximum (mm) {in} 149.0—150 150.5 {5.92} {5.86—5.90} 44.7—45.3 46.0 {1.81} {1.75—1.78} 110.0—110.6 111.3 {4.38} {4.33—4.35} B End Of Sie VARIABLE VALVE TIMING ACTUATOR INSPECTION A6E242400142E02 L3 (with variable valve timing mechanism) Caution • Variable valve timing actuator can not be disassembled it is a precision unit / 1.
PAGE 41
1731-1E-02C.book 24 ページ２００２年４月２６日金曜日午前１０時３０分 ENGINE 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 not as specified, replace the oil control valve (OCV). 4. Verify that the battery is fully charged. • If not as specified, recharge the battery. AME2226W003 5.
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1731-1E-02C.book 25 ページ２００２年４月２６日金曜日午前１０時３０分 ENGINE End Of CLEARANCE Sie VALVE ADJUSTMENT A6E242412111E03 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. B AMJ2212E004 4. Install the SST as shown. 5. Turn the crankshaft clockwise the crankshaft is in the No.1 cylinder TDC position. AME2212W004 6. Loosen the timing chain.
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1731-1E-02C.book 26 ページ２００２年４月２６日金曜日午前１０時３０分 ENGINE 7. Hold the exhaust camshaft using a suitable wrench on the cast hexagon as shown. AME2212W006 8. Remove the exhaust camshaft sprocket. AME2212W007 9. Loosen the camshaft cap bolts in several passes in the order shown. 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. 10.
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1731-1E-02C.book 27 ページ２００２年４月２６日金曜日午前１０時３０分 ENGINE 15. 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. B 16. Install the SST to the camshaft as shown. AME2212W007 Europe AME2212W010 Except Europe AME2212W011 17. Remove the M6 x 1.0 bolt from the engine front cover to apply tension to the timing chain. 18. Turn the crankshaft clockwise the crankshaft is in the No.
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1731-1E-02C.book 28 ページ２００２年４月２６日金曜日午前１０時３０分 ENGINE 25. Install the engine front cover upper blind plug. Tightening torque: 10 N·m {1.0 kgf·m, 7.4 ft·lbf} AME2212W003 26. Install the cylinder block lower blind plug. Tightening torque: 20 N·m {2.0 kgf·m, 14.8 ft·lbf} AME2212W012 27. Install the new engine front cover lower blind plug. Tightening torque: 12 N·m {1.2 kgf·m, 8.
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1731-1E-02C.book 29 ページ２００２年４月２６日金曜日午前１０時３０分 ENGINE CYLINDER BLOCK (I) ASSEMBLY A6E242402000E09 1. Assemble in the order indicated in the table. 2. B AME2224E039 .
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1731-1E-02C.book 30 ページ２００２年４月２６日金曜日午前１０時３０分 ENGINE Main Bearing Caps Assembly Note 1. Install the main bearing caps in the order indicated in the figure. Tightening torque: (1) 44—46 N·m {4.5—4.6 kgf·m, 32.5—33.9 ft·lbf} (2) 175°°—185°° AME2224E052 Piston Ring Assembly Note 1. Install the two oil control ring segments and spacer. 2. Verify that the second ring is installed with scraper face side downward. 3. Verify that the top ring is installed with scraper face side inner of upper.
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1731-1E-02C.book 31 ページ２００２年４月２６日金曜日午前１０時３０分 ENGINE Connecting Rod Bearing Assembly Note 1. Install the connecting rod bearing to the connecting rod and connecting rod caps, as shown in the figure. B AME2224E053 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 bolts in two steps. Tightening torque: (1) 26—32 N·m {2.7—3.2 kgf·m, 19.2—23.
PAGE 49
1731-1E-02C.book 32 ページ２００２年４月２６日金曜日午前１０時３０分 ENGINE 6. Set the SST as shown, then measure the gear backlash using a dial gauge. • If the backlash exceeds the specified range, remeasure the backlash and, using the adjustment shim selection table, select the proper shim, according to the following procedure.
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1731-1E-02C.book 33 ページ２００２年４月２６日金曜日午前１０時３０分 ENGINE Backlash mm {in} 0.172—0.178 {0.00677— 0.00700} 0.165—0.171 {0.00649— 0.00673} Selection shim (No.) Shim thickness mm {in} 27 1.27 {0.499} 28 1.28 {0.503} 0.158—0.164 {0.00622—0.00645 29 1.29 {0.507} 0.151—0.157 {0.00594— 0.00618} 30 1.30 {0.511} 0.144—0.150 {0.0566—0.0590} 31 1.31 {0.515} 32 1.32 {0.519} 33 34 0.137—0.143 {0.00539— 0.00562} 0.130—0.136 {0.00511— 0.00535} 0.123—0.129 {0.00484— 0.00507} Backlash mm {in} 0.032—0.
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1731-1E-02C.book 34 ページ２００２年４月２６日金曜日午前１０時３０分 ENGINE CYLINDER BLOCK (II) ASSEMBLY A6E242402000E10 1. Assemble in the order indicated in the table. 2. AME2224E043 .
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1731-1E-02C.book 35 ページ２００２年４月２６日金曜日午前１０時３０分 ENGINE 1 2 3 4 5 6 7 Rear oil seal (See B–35 Rear Oil Seal Assembly Note) End plate (MPV) Flywheel (MTX), Drive plate (ATX) (See B–36 Drive Plate (ATX), Flywheel (MTX) Assembly Note) Oil pump Oil strainer Water pump Thermostat 8 9 10 11 12 13 14 15 Oil separator Knock sensor Oil cooler Oil filter adapter Oil filter Oil filter cover Oil pan (See B–36 Oil pan Assembly Note) MTX B Rear Oil Seal Assembly Note 1.
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1731-1E-02C.book 36 ページ２００２年４月２６日金曜日午前１０時３０分 ENGINE Drive Plate (ATX), Flywheel (MTX) Assembly Note 1. Hold the crankshaft using the SST. 2. Tighten the bolts in the order indicated in the figure in several passes. AME2224E102 Oil pan Assembly Note 1. Apply a continuous bead of silicone sealant to the oil pan as indicated in the figure. AME2224E555 2. Use a square ruler to unite the oil pan and the cylinder block junction side on the engine front cover side.
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1731-1E-02C.book 37 ページ２００２年４月２６日金曜日午前１０時３０分 ENGINE 3. Tighten the rear oil pan bolts in the order as shown. Tightening torque: 20—30 N·m {2.1—3.0 kgf·m, 15.2—21.6 in·lbf} B AME2224E056 End Of Sie CYLINDER HEAD (I) ASSEMBLY A6E242402000E11 1. Assemble in the order indicated in the table. .
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1731-1E-02C.book 38 ページ２００２年４月２６日金曜日午前１０時３０分 ENGINE Valve Seal Assembly Note 1. Press the valve seal onto the valve guide by hand. 2. Lightly tap the SST using a plastic hammer. AME2224E321 Valve Keeper Assembly Note 1. Install the valve keeper using the SSTs.
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1731-1E-02C.book 39 ページ２００２年４月２６日金曜日午前１０時３０分 ENGINE CYLINDER HEAD (II) ASSEMBLY A6E242402000E12 1. Assemble in the order indicated in the table. 2. B AME2224E046 .
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1731-1E-02C.book 40 ページ２００２年４月２６日金曜日午前１０時３０分 ENGINE Cylinder Head Bolt Assembly Note 1. Tighten the cylinder head bolts in the order indicated in the figure in six steps. (1) Tighten to 5.0 N·m {51 kgf·cm, 44.3 in·lbf}. (2) Tighten to 13— 17 N·m {1.4 —1.7 kgf·m, 9.6—12.5 ft·lbf}. (3) Tighten to 44— 46 N·m {4.5 —4.6 kgf·m, 32.5—33.9 ft·lbf}. (4) Tighten 88°°—92°°. (5) Tighten 88°°—92°°. AME2224E047 Camshaft Assembly Note 1. Install the camshaft with No.1 cylinder aligned with TDC position. 2.
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1731-1E-02C.book 41 ページ２００２年４月２６日金曜日午前１０時３０分 ENGINE End Of Sie TIMING CHAIN ASSEMBLY A6E242402000E13 1. Assemble in the order indicated in the table. 2. B AME2224E327 .
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1731-1E-02C.book 42 ページ２００２年４月２６日金曜日午前１０時３０分 ENGINE Oil Pump Sprocket Assembly Note 1. Hold the oil pump sprocket using the SST. AME2224E340 Timing Chain Aassembly Note 1. Install the SST to the camshaft, then align the No. 1 camshaft position with the TDC. Europe AME2224E329 Except Europe AME2224E328 2. Remove the cylinder block lower blind plug. 3. Install the SST as shown. 4. Turn the crankshaft clockwise so that the crankshaft is in the No.1 cylinder TDC position. 5.
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1731-1E-02C.book 43 ページ２００２年４月２６日金曜日午前１０時３０分 ENGINE 6. Install the chain tensioner and remove the retaining wire. B AME2224E330 Camshaft Sprocket, Variable Valve Timing Actuator (L3 (with variable valve timing mechanism)) Assembly Note 1. Hold the camshaft using a suitable wrench on the cast hexagon as shown. L8, LF, L3 AME2224E077 L3 (with variable valve timing mechanism) AME2224E078 2. Tighten the camshaft sprocket lock bolt. Tightening torque: 69—75 N·m {7.10—7.6 kgf·m, 50.9—55.
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1731-1E-02C.book 44 ページ２００２年４月２６日金曜日午前１０時３０分 ENGINE Front Oil Seal Aassembly 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. AME2224E331 AME2224E332 Engine Front Cover Aassembly Note 1. Apply silicone sealant to the engine front cover as shown. Caution • Install the cylinder head cover within 10 minutes of applying the silicone sealant.
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1731-1E-02C.book 45 ページ２００２年４月２６日金曜日午前１０時３０分 ENGINE 2. Install the cylinder head cover bolts in the order as shown. Bolt No. Tigtining 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} B AME2224E334 Crankshaft Pulley Lock Bolt Aassembly Note 1. Install the SST to the camshaft as shown. Europe AME2224E329 Except Europe AME2224E328 2. Install the M6 x 1.0 bolt in by hand. 3.
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1731-1E-02C.book 46 ページ２００２年４月２６日金曜日午前１０時３０分 ENGINE 4. Hold the crankshaft pully using the SST. 5. Tighten the crankshaft pulley lock bolt in the following two steps. (1) Tighten to 96—104 N·m {9.8—10.6 kgf·m, 70.9—76.7 ft·lbf} (2) Tighten 87°°—93°° . 6. Remove the M6 x 1.0 bolt. 7. Remove the SST from the camshaft. 8. Remove the SST from the block lower blind plug. 9. Rotate the crankshaft clockwise two turns until the TDC position.
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1731-1E-02C.book 1 ページ２００２年４月２６日金曜日午前１０時３０分 TECHNICAL DATA TD TECHNICAL DATA ............................................. TD-2 ENGINE TECHNICAL DATA ............................
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1731-1E-02C.book 2 ページ２００２年４月２６日金曜日午前１０時３０分 TECHNICAL DATA TECHNICAL DATA ENGINE TECHNICAL DATA A6E931001001E01 Engine Item Cylinder head Cylinder head gasket contact surfaces distortion Manifold contact surfaces distortion L8 LF (mm {in}) Maximum (mm {in}) Valve clearance [Engine cold] L3, L3 (with variable valve timing mechanism) 0.10 {0.004} Maximum Maximum grinding IN (mm {in}) EX 0.10 {0.004} 0.15 {0.006} 0.22—0.28 {0.0087—0.0110} 0.27—0.33 {0.0106—0.
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1731-1E-02C.book 3 ページ２００２年４月２６日金曜日午前１０時３０分 TECHNICAL DATA Engine Item Camshaft Camshaft runout L8 LF (mm {in}) Maximum 0.03 {0.0012} IN 40.79 {1.606} 42.12{1.659} EX 41.08 {1.618} 41.08{1.618} IN 40.692{1.603} 42.022{1.655} EX 40.982 {1.614} 40.982{1.
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1731-1E-02C.book 4 ページ２００２年４月２６日金曜日午前１０時３０分 TECHNICAL DATA Engine Item Connecting rod and connecting rod bearing Standard Connecting rod side (mm {in}) clearance Maximum Standard Connecting rod bearing size (mm {in}) 0.25 {0.01} Oversize 0.50 {0.02} Oversize Standard Connecting rod bearing oil (mm {in}) clearance Maximum Crankshaft Crankshaft runout (mm {in}) Maximum Standard Main journal diameter (mm {in}) 0.25 {0.
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1731-1E-02C.book 1 ページ２００２年４月２６日金曜日午前１０時３０分 SPECIAL TOOLS ST SPECIAL TOOLS .................................................ST-2 ENGINE SST .....................................................
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1731-1E-02C.book 2 ページ２００２年４月２６日金曜日午前１０時３０分 SPECIAL TOOLS SPECIAL TOOLS ENGINE SST A6E941001001E01 Ford SST numbers are collated with Mazda SST numbers in the example below. Ford SSTs are marked with Ford SST number.
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1731-1E-02C.