Mazda 2 mzr1.5 Engine Workshop Manual 2010 PDF

1993-1U-10E(INDEX).
fm 1 ページ２０１０年５月１２日　水曜日　午後２時１４分
Engine CONTENTS
Workshop Title Section
Manual GENERAL INFORMATION 00
MZR 1.5 ENGINE 01
FOREWORD © 2010 Mazda Motor Corporation

PRINTED IN U.S.A., MAY 2010
This manual explains the service points for Form No. 1993–1U–10E
the above-indicated automotive system. Part No. 9999–95–MZR–11
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
WARNING(US).fm 1 ページ２０１０年３月１１日　木曜日　午後１時２８分
WARNING
Servicing a vehicle can be dangerous. If you have not received
service-related training, the risks of injury, property damage, and
failure of servicing increase. The recommended servicing procedures
for the vehicle in this workshop manual were developed with
Mazda-trained technicians in mind. This manual may be useful to
non-Mazda trained technicians, but a technician with our
service-related training and experience will be at less risk when
performing service operations. However, all users of this manual are
expected to at least know general safety procedures.
This manual contains "Warnings" and "Cautions" applicable to risks

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

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

the latest available at the time of printing, and Mazda Motor Corporation
reserves the right to change the vehicle designs and alter the contents
of this manual without notice and without incurring obligation.
Parts should be replaced with genuine Mazda replacement parts or

with parts which match the quality of genuine Mazda replacement
parts. Persons using replacement parts of lesser quality than that of
genuine Mazda replacement parts must satisfy themselves thoroughly
that neither personal safety nor safety of the vehicle will be
jeopardized.
Mazda Motor Corporation is not responsible for any problems which

may arise from the use of this manual. The cause of such problems
includes but is not limited to insufficient service-related training, use of
improper tools, use of replacement parts of lesser quality than that of
genuine Mazda replacement parts, or not being aware of any revision
of this manual.
1993-1U-10F.book 1 ページ２０１０年４月１６日　金曜日　午後１時５７分
GENERAL INFORMATION 00SECTION

00-00
Toc of SCT INFORMATION . . . . 00-00

GENERAL
Toc of SCT
00-00 GENERAL INFORMATION
UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-00–1 Preparation of Tools and
Conversion to SI Units Measuring Equipment . . . . . . . . . . . . 00-00–6
(Système International d'Unités) . . . . . 00-00–2 Special Service Tools . . . . . . . . . . . . . . 00-00–6
Rounding Off . . . . . . . . . . . . . . . . . . . . . 00-00–2 Disassembly . . . . . . . . . . . . . . . . . . . . . 00-00–7
Upper and Lower Limits . . . . . . . . . . . . 00-00–2 Inspection During Removal,
HOW TO USE THIS MANUAL . . . . . . . . . 00-00–2 Disassembly . . . . . . . . . . . . . . . . . . . . 00-00–7
Range of Topics . . . . . . . . . . . . . . . . . . 00-00–2 Arrangement of Parts . . . . . . . . . . . . . . 00-00–7
Service Procedure . . . . . . . . . . . . . . . . 00-00–2 Cleaning of Parts . . . . . . . . . . . . . . . . . 00-00–7
Symbols . . . . . . . . . . . . . . . . . . . . . . . . 00-00–3 Reassembly . . . . . . . . . . . . . . . . . . . . . 00-00–8
Advisory Messages. . . . . . . . . . . . . . . . 00-00–4 Adjustment . . . . . . . . . . . . . . . . . . . . . . 00-00–8
ELECTRICAL SYSTEM . . . . . . . . . . . . . . 00-00–5 Rubber Parts and Tubing . . . . . . . . . . . 00-00–8
Connectors . . . . . . . . . . . . . . . . . . . . . . 00-00–5 Hose Clamps . . . . . . . . . . . . . . . . . . . . 00-00–9
ABBREVIATIONS. . . . . . . . . . . . . . . . . . . 00-00–6 Torque Formulas . . . . . . . . . . . . . . . . . 00-00–9
FUNDAMENTAL PROCEDURES. . . . . . . 00-00–6 Vise . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-00–9
NEW STANDARDS . . . . . . . . . . . . . . . . . 00-00–9
End of Toc
NG: GENERAL INFORMATION
00-00–1
GENERAL INFORMATION
UNITS
id000000100400
Electric current A (ampere)

Electric power W (watt)
Electric resistance ohm
Electric voltage V (volt)
mm (millimeter)
Length
in (inch)
kPa (kilo pascal)
Negative pressure mmHg (millimeters of mercury)
inHg (inches of mercury)
kPa (kilo pascal)
Positive pressure kgf/cm2 (kilogram force per square

centimeter)
psi (pounds per square inch)
Number of
rpm (revolutions per minute)
revolutions
N·m (Newton meter)
kgf·m (kilogram force meter)
Torque kgf·cm (kilogram force centimeter)
ft·lbf (foot pound force)
in·lbf (inch pound force)
L (liter)
US qt (U.S. quart)
Imp qt (Imperial quart)
Volume ml (milliliter)
cc (cubic centimeter)
cu in (cubic inch)
fl oz (fluid ounce)
g (gram)
Weight
oz (ounce)
Conversion to SI Units (Système International d"Unités)

• All numerical values in this manual are based on SI units. Numbers shown in conventional units are converted
from these values.
Rounding Off
• Converted values are rounded off to the same number of places as the SI unit value. For example, if the SI unit
value is 17.2 and the value after conversion is 37.84, the converted value will be rounded off to 37.8.
Upper and Lower Limits

• When the data indicates upper and lower limits, the converted values are rounded down if the SI unit value is
an upper limit and rounded up if the SI unit value is a lower limit. Therefore, converted values for the same SI
unit value may differ after conversion. For example, consider 2.7 kgf/cm2 in the following specifications:
210—260 kPa {2.1—2.7 kgf/cm2, 30—38 psi}

270—310 kPa {2.7—3.2 kgf/cm2, 39—45 psi}
• The actual converted values for 2.7 kgf/cm2 are 264 kPa and 38.4 psi. In the first specification, 2.7 is used as
an upper limit, so the converted values are rounded down to 260 and 38. In the second specification, 2.7 is
used as a lower limit, so the converted values are rounded up to 270 and 39.
End Of Sie
WM: GENERAL INFORMATION
00-00–2
GENERAL INFORMATION
HOW TO USE THIS MANUAL
id000000000100
Range of Topics
• This manual contains procedures for performing all required service operations. The procedures are divided
into the following five basic operations:
— Removal/Installation 00-00
— 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
00-00–3
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
00-00–4
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
00-00–5
GENERAL INFORMATION
ELECTRICAL SYSTEM
id000000000500
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
00-00–6
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.
Caution
• To prevent damage to the terminal, wrap
a thin wire around the tester probe before
inserting into terminal.
CHU0000W011
End Of Sie
GOOD NO GOOD
CHU0000W012
ABBREVIATIONS
id000000010100
ATX Automatic Transaxle

CMP Camshaft Position
EX Exhaust
IN Intake
MTX Manual Transaxle
OCV Oil Control Valve
OS Over Size
SST Special Service Tool
STD Standard
TDC Top Dead Center
End Of Sie
GAIHAN: -
00-00–7
GENERAL INFORMATION
FUNDAMENTAL PROCEDURES
id000000750100
Preparation of Tools and Measuring Equipment
• Be sure that all necessary tools and measuring
equipment are available before starting any work.
CHU0014W003
Special Service Tools

• Use special service tools or equivalent when they
are required.
49 SE01 310
WGIWXX0024E
Disassembly
• If the disassembly procedure is complex,
requiring many parts to be disassembled, all parts
should be marked in a place that will not affect
their performance or external appearance and
identified so that reassembly can be performed
easily and efficiently.
WGIWXX0027E
Inspection During Removal, Disassembly

• When removed, each part should be carefully
inspected for malfunction, deformation, damage
and other problems.
WGIWXX0028E
00-00–8
GENERAL INFORMATION
Arrangement of Parts
• All disassembled parts should be carefully
arranged for reassembly.
• Be sure to separate or otherwise identify the parts
to be replaced from those that will be reused.
00-00
WGIWXX0029E
Cleaning of Parts
• All parts to be reused should be carefully and
thoroughly cleaned in the appropriate method.
Warning
• Using compressed air can cause dirt and
other particles to fly out causing injury to
the eyes. Wear protective eye wear
whenever using compressed air.
WGIWXX0030E
Reassembly
• Standard values, such as torques and certain
adjustments, must be strictly observed in the
reassembly of all parts.
• If removed, the following parts should be replaced
with new ones:
— Oil seals
— Gaskets
— O-rings
— Lockwashers
— Cotter pins
— Nylon nuts
WGIWXX0031E
• Depending on location:
— Sealant and gaskets, or both, should be
applied to specified locations. When sealant
is applied, parts should be installed before
sealant hardens to prevent leakage.
— Oil should be applied to the moving
components of parts.
— Specified oil or grease should be applied at
the prescribed locations (such as oil seals)
before reassembly.
CHU0014W006
00-00–9
GENERAL INFORMATION
Adjustment
• Use suitable gauges and testers when making
adjustments.
CHU0014W005
Rubber Parts and Tubing

• Prevent gasoline or oil from getting on rubber
parts or tubing.
WGIWXX0034E
Hose Clamps
• When reinstalling, position the hose clamp in the
original location on the hose and squeeze the
clamp lightly with large pliers to ensure a good fit.
WGIWXX0035E
Torque Formulas
• When using a torque wrench-SST or equivalent
combination, the written torque must be SST
3
recalculated due to the extra length that the SST

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.
00-00–10
GENERAL INFORMATION
Vise
• When using a vise, put protective plates in the
jaws of the vise to prevent damage to parts.
End Of Sie
EN: GENERAL INFORMATION
00-00
PROTECTIVE PLATES
CHU0014W010
NEW STANDARDS
id000000157100
• Following is a comparison of the previous standard and the new standard.
New Standard Previous Standard
Remark
Abbrevi-ation Name Abbrevi-ation Name
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
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 solenoid Fuel Shut Off Solenoid FCV Fuel Cut Valve #6
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
00-00–11
GENERAL INFORMATION
New Standard Previous Standard
Remark
Abbrevi-ation Name Abbrevi-ation Name
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 Thermo-sensor
Temperature Sensor
TR Transmission (Transaxle) Range — Inhibitor Position
TC Turbocharger — Turbocharger
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
00-00–12
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ENGINE 01SECTION
01-10
Toc of SCT
MECHANICAL. . . . . . . . . . . . . . 01-10 SERVICE TOOLS . . . . . . . . . . . 01-60
TECHNICAL DATA . . . . . . . . . . 01-50
Toc of SCT
01-10 MECHANICAL
ENGINE OVERHAUL OIL CONTROL VALVE (OCV)
SERVICE WARNING . . . . . . . . . . . . . . . 01-10–1 INSPECTION . . . . . . . . . . . . . . . . . . . . . 01-10–19
ENGINE Coil Resistance Inspection . . . . . . . . . . 01-10–19
MOUNTING/DISMOUNTING . . . . . . . . . 01-10–2 Spool Valve Operation Inspection . . . . 01-10–19
Mounting . . . . . . . . . . . . . . . . . . . . . . . . 01-10–2 CAMSHAFT INSPECTION . . . . . . . . . . . 01-10–20
Dismounting . . . . . . . . . . . . . . . . . . . . . 01-10–3 CYLINDER BLOCK INSPECTION . . . . . 01-10–21
TIMING CHAIN DISASSEMBLY. . . . . . . . 01-10–3 OIL JET VALVE INSPECTION . . . . . . . . 01-10–21
Crankshaft Pulley Installation Bolt PISTON, PISTON RING, PISTON PIN
Disassembly Note . . . . . . . . . . . . . . . . 01-10–4 INSPECTION . . . . . . . . . . . . . . . . . . . . . 01-10–22
Engine Front Cover CONNECTING ROD INSPECTION . . . . . 01-10–23
Disassembly Note . . . . . . . . . . . . . . . . 01-10–4 CRANKSHAFT INSPECTION . . . . . . . . . 01-10–24
Timing Chain Tensioner BOLT INSPECTION . . . . . . . . . . . . . . . . . 01-10–26
Disassembly Note . . . . . . . . . . . . . . . . 01-10–4 OIL PUMP INSPECTION . . . . . . . . . . . . . 01-10–26
CYLINDER HEAD DISASSEMBLY (I) . . . 01-10–5 VALVE CLEARANCE INSPECTION . . . . 01-10–27
Camshaft Sprocket, Variable Valve VALVE CLEARANCE
Timing Actuator Disassembly Note . . . 01-10–6 ADJUSTMENT. . . . . . . . . . . . . . . . . . . . 01-10–27
Camshaft Cap Disassembly Note . . . . . 01-10–6 CYLINDER BLOCK ASSEMBLY (I) . . . . 01-10–31
Tappet Disassembly Note . . . . . . . . . . . 01-10–6 Main Bearing Assembly Note . . . . . . . . 01-10–32
Cylinder Head Disassembly Note . . . . . 01-10–6 Lower Cylinder Block
CYLINDER HEAD Assembly Note . . . . . . . . . . . . . . . . . . 01-10–33
DISASSEMBLY (II) . . . . . . . . . . . . . . . . . 01-10–7 Piston Pin Assembly Note . . . . . . . . . . 01-10–34
Valve Keeper Disassembly Note . . . . . . 01-10–8 Piston Ring Assembly Note . . . . . . . . . 01-10–36
Valve Seal Disassembly Note . . . . . . . . 01-10–8 Piston, Connecting Rod Component
CYLINDER BLOCK Assembly Note . . . . . . . . . . . . . . . . . . 01-10–36
DISASSEMBLY (I) . . . . . . . . . . . . . . . . . 01-10–8 Connecting Rod Bearing
Knock Sensor Disassembly Note . . . . . 01-10–10 Assembly Note . . . . . . . . . . . . . . . . . . 01-10–36
Drive Plate (ATX), Flywheel (MTX) Connecting Rod Cap
Disassembly Note . . . . . . . . . . . . . . . . 01-10–10 Assembly Note . . . . . . . . . . . . . . . . . . 01-10–37
Oil Filter Disassembly Note . . . . . . . . . . 01-10–10 CYLINDER BLOCK ASSEMBLY (II) . . . . 01-10–37
Oil Pan Disassembly Note. . . . . . . . . . . 01-10–10 Inner Rotor, Outer Rotor
CYLINDER BLOCK Assembly Note . . . . . . . . . . . . . . . . . . 01-10–39
DISASSEMBLY (II) . . . . . . . . . . . . . . . . . 01-10–10 Oil Pan Assembly Note. . . . . . . . . . . . . 01-10–39
Connecting Rod Cap Oil Filter Assembly Note. . . . . . . . . . . . 01-10–39
Disassembly Note . . . . . . . . . . . . . . . . 01-10–11 Rear Oil Seal Assembly Note. . . . . . . . 01-10–39
Piston Pin Disassembly Note . . . . . . . . 01-10–12 Drive Plate (ATX), Flywheel (MTX)
Lower Cylinder Block Assembly Note . . . . . . . . . . . . . . . . . . 01-10–40
Disassembly Note . . . . . . . . . . . . . . . . 01-10–13 Oil Pump Assembly Note . . . . . . . . . . . 01-10–40
CYLINDER HEAD INSPECTION . . . . . . . 01-10–14 Knock Sensor Assembly Note . . . . . . . 01-10–41
VALVE SEAT INSPECTION/REPAIR . . . . 01-10–15 CYLINDER HEAD ASSEMBLY (I). . . . . . 01-10–41
VALVE, VALVE GUIDE INSPECTION . . . 01-10–15 Valve Seal Assembly Note . . . . . . . . . . 01-10–41
VALVE GUIDE REPLACEMENT . . . . . . . 01-10–17 Valve Keeper Assembly Note . . . . . . . . 01-10–42
Removal . . . . . . . . . . . . . . . . . . . . . . . . 01-10–17 CYLINDER HEAD ASSEMBLY (II) . . . . . 01-10–42
Installation . . . . . . . . . . . . . . . . . . . . . . . 01-10–17 Cylinder Head Assembly Note . . . . . . . 01-10–43
VALVE SPRING INSPECTION . . . . . . . . . 01-10–18 Camshaft Assembly Note. . . . . . . . . . . 01-10–44
TAPPET INSPECTION . . . . . . . . . . . . . . . 01-10–18 Camshaft Sprocket, Variable Valve
VARIABLE VALVE TIMING ACTUATOR Timing Actuator Assembly Note . . . . . 01-10–44
INSPECTION . . . . . . . . . . . . . . . . . . . . . 01-10–19 TIMING CHAIN ASSEMBLY . . . . . . . . . . 01-10–44
Timing Chain Assembly Note . . . . . . . . 01-10–46
01-10–1
MECHANICAL
Engine Front Cover Assembly Note . . . 01-10–46 Cylinder Head Cover
Crankshaft Pulley Installation Bolt Assembly Note . . . . . . . . . . . . . . . . . . 01-10–48
Assembly Note . . . . . . . . . . . . . . . . . . 01-10–48
End of Toc
ENGINE OVERHAUL SERVICE WARNING
EN: ENGINE COMPLETE
id011000503900
Warning
x Continuous exposure to USED engine oil has caused skin cancer in laboratory mice. Protect your
skin by washing with soap and water immediately after this work.
End Of Sie
ENGINE MOUNTING/DISMOUNTING
id011000507000
Mounting
1. Install the SSTs (arms) to the specified position
as shown, and hand-tighten the SST bolts.
49 L010 102 49 L010 106
bezuue00000001
2. Assemble the SSTs (bolts, nuts, and plate) to the

specified position as shown.
3. Assemble the SSTs (arms and bolts) in Step 1 to
the SSTs (bolts, nuts, and plate) in Step 2.
49 L010 101
49 L010 104
49 L010 105
bezuue00000002
01-10–2
MECHANICAL
4. Adjust the bolts so that approx. 20 mm {0.79 in}
of thread is exposed from the side of the plate.
5. Adjust the bolts and nuts so that the plate and
arms are parallel.
49 L010 106 PARALLEL
6. Mount the engine on the SST. 49 L010 101
Warning 49 L010 102
x The self-locking brake system of the 49 L010 105 01-10
engine stand may not be effective when
the engine is held in an unbalanced ENGINE
position. This could lead to sudden, rapid
movement of the engine and the
mounting stand handle causing serious
injury. Never keep the engine in an 49 L010 104 49 L010 103 APPROX. 20 mm {0.79 in}
unbalanced position, and always hold the
rotating handle firmly when turning the
engine.
bezuue00000003
7. Remove the oil drain plug and drain the engine
oil.
8. Install the drain plug and a new washer.
Tightening torque
30—41 N·m {3.1—4.1 kgf·m, 23—30 ft·lbf}
Dismounting
1. Dismount in the reverse order of mounting.
End Of Sie
01-10–3
MECHANICAL
TIMING CHAIN DISASSEMBLY
id011000505500
1. Disassemble in the order indicated in the table.
4
1 3
2
R
10
R R
6 R
8 R
SST R
9
5
11
R
12
16
15
13 14
bezuue00000004
1 Spark plug 10 Engine front cover

2 Camshaft position (CMP) sensor (See 01-10-4 Engine Front Cover Disassembly Note)
3 Cylinder head cover 11 Timing chain tensioner
(See 01-10-4 Timing Chain Tensioner Disassembly
4 Drive belt auto tensioner Note)
5 Oil level gauge pipe 12 Timing chain tensioner arm
6 Oil control valve (OCV) 13 Timing chain guide
7 Idler pulley 14 Timing chain
8 OCV oil filter, plug 15 Crankshaft sprocket
9 Crankshaft pulley 16 Key
(See 01-10-4 Crankshaft Pulley Installation Bolt
Disassembly Note)
01-10–4
MECHANICAL
Crankshaft Pulley Installation Bolt Disassembly Note
1. Lock the drive plate (ATX) or flywheel (MTX)
against rotation using the SST.
2. Remove the crankshaft pulley installation bolt.
49 E011 1A0
01-10
bezuue00000005
Engine Front Cover Disassembly Note

1. Remove the oil seal using a flathead screwdriver.
bezuue00000006
Timing Chain Tensioner Disassembly Note

1. Push down the link plate of the timing chain
tensioner using a thin flathead screwdriver
(precision screwdriver) and release the plunger
lock.
PLUNGER
LINK PLATE
bezuue00000007
2. Push back the plunger slowly in the direction

shown in the figure with the link plate still pushed
down.
3. Free the link plate with the plunger still pushed.
4. Move the plunger back and forth 2—3 mm
{0.08—0.11 in} and insert an approx. 1.5 mm
{0.059 in} wire or paper clip where the link plate
hole and the tensioner body hole overlap to fix the
link plate and lock the plunger.
LINK PLATE
bezuue00000008
01-10–5
MECHANICAL
End Of Sie
WIRE OR
PAPER CLIP
bezuue00000009
CYLINDER HEAD DISASSEMBLY (I)

id011000500400
3
4
2
6
7 R
B3E0110E025
01-10–6
MECHANICAL
1 Water outlet 4 Camshaft
2 Camshaft sprocket, variable valve timing actuator 5 Tappet
(See 01-10-6 Camshaft Sprocket, Variable Valve (See 01-10-6 Tappet Disassembly Note)
Timing Actuator Disassembly Note) 6 Cylinder head
3 Camshaft cap (See 01-10-6 Cylinder Head Disassembly Note)
(See 01-10-6 Camshaft Cap Disassembly Note) 7 Cylinder head gasket
01-10
Camshaft Sprocket, Variable Valve Timing Actuator Disassembly Note
1. Hold the camshaft using a suitable wrench on the
cast hexagon as shown in the figure.
2. Loosen the camshaft sprocket installation bolt.
ADJ2224E077
Camshaft Cap Disassembly Note

1. Inspect the camshaft end play. (See 01-10-20 CAMSHAFT INSPECTION)
2. Loosen the camshaft cap installation bolts in two 14 16 6 8
to three passes in the order shown in the figure, 10 12 18 20
and then remove the camshaft caps. 2
3
1
4
2
4
3
8
5
1
9 11 19 17 15 13 7 5
B3E2224E008
Tappet Disassembly Note
Note
x The tappets are numbered to make sure they are assembled in their original positions. When removed,
keep the tappets with the cylinder head from where they were removed. Do not mix the tappets.
01-10–7
MECHANICAL
Cylinder Head Disassembly Note
1. Loosen the camshaft cap installation bolts in two to three passes in the order shown in the figure, and remove
them.
End Of Sie
3 7 10 6 2
4 8 9 5 1
B3E0110E024
CYLINDER HEAD DISASSEMBLY (II)

id011000500500
1 SST
2
3
SST R 5
B3E0110E026
1 Valve keeper 4 Valve

(See 01-10-8 Valve Keeper Disassembly Note) 5 Valve seal
2 Upper valve spring seat (See 01-10-8 Valve Seal Disassembly Note)
3 Valve spring
01-10–8
MECHANICAL
Valve Keeper Disassembly Note
1. Remove the valve keeper using the SSTs.
49 0636 100B
01-10
49 B012 0A2
b3e0110e124
Valve Seal Disassembly Note

1. Remove the valve seal using the SST.
End Of Sie
49 S120 170
VALVE SEAL
VALVE GUIDE
B3E0110E061
01-10–9
MECHANICAL
CYLINDER BLOCK DISASSEMBLY (I)
id011000500600
R
8 7 SST
12
14
13
18
MTX
17
15 16 7
R
SST
4
5 R 3 SST
11
2
R
9 SST R
1
6 10
bezuue00000102
.
1 Thermostat cover 9 Oil filter

2 Thermostat (See 01-10-10 Oil Filter Disassembly Note)
3 Knock sensor 10 Oil pan
(See 01-10-10 Knock Sensor Disassembly Note) (See 01-10-10 Oil Pan Disassembly Note)
4 Oil separator 11 Oil strainer
5 Water pump 12 Oil pump cover
6 Oil pump 13 Inner rotor
7 Drive plate (ATX), flywheel (MTX) 14 Outer rotor
(See 01-10-10 Drive Plate (ATX), Flywheel (MTX) 15 Plunger plug
Disassembly Note) 16 Plunger spring
8 End plate 17 Control plunger
18 Oil pump body
01-10–10
MECHANICAL
Knock Sensor Disassembly Note
1. Remove the knock sensor using the SST.
49 H018 001
01-10
bezuue00000103
Drive Plate (ATX), Flywheel (MTX) Disassembly Note

2. Remove the drive plate or flywheel installation
49 E011 1A0
bolts.
bez0je00000006
Oil Filter Disassembly Note

1. Remove the oil filter using the SST or
commercially available, cup-type oil filter wrench
(67 mm {2.6 in} diameter, 14 sided). 49 G014 001
OR COMMERCIALLY
AVAILABLE CUP-TYPE
OIL FILTER WRENCH
bezuue00000104
Oil Pan Disassembly Note

1. Remove the oil pan using a separator tool.
End Of Sie
bezuue00000105
01-10–11
MECHANICAL
CYLINDER BLOCK DISASSEMBLY (II)
id011000500700
15
4
10 R
R 13
14
12
6 SST
8
11
3
2
1
9
bezuue00000096
1 Connecting rod cap 8 Connecting rod

(See 01-10-11 Connecting Rod Cap Disassembly 9 Lower cylinder block
Note) (See 01-10-13 Lower Cylinder Block Disassembly
2 Lower connecting rod bearing Note)
3 Upper connecting rod bearing 10 Rear oil seal
4 Connecting rod, piston assembly 11 Lower main bearing
5 Piston ring 12 Crankshaft
6 Piston pin 13 Upper main bearing, thrust bearing
(See 01-10-12 Piston Pin Disassembly Note) 14 Oil jet valve
7 Piston 15 Upper cylinder block
01-10–12
MECHANICAL
Connecting Rod Cap Disassembly Note
Caution
x When removing the connecting rod bearings and reusing them, put a paint mark showing the front
end and the journal number before the removal.
1. Inspect the connecting rod side clearance. (See

01-10-23 CONNECTING ROD INSPECTION.) 01-10
b3e0110e087
Piston Pin Disassembly Note

1. Before extracting the piston pin, inspect the following.
(1) Check the oscillation torque as shown. Verify
that the large end drops under its own weight
with no resistance.
x If the piston shakes heavily or unsmoothly,
replace the piston and the piston pin.
bezuue00000097
49 L011 006A
49 E011 001A 49 E011 002A
bezuue00000098
01-10–13
MECHANICAL
3. Insert the SST through the piston pin as shown in
the figure and assemble.
49 E011 002A
49 E011 001A 49 L011 006A
bezuue00000099
4. Set the piston with the SSTs assembled and the

connecting rod component as shown in the figure.
5. Press out the piston pin.
49 D011 002B
49 L011 001
bezuue00000100
01-10–14
MECHANICAL
Lower Cylinder Block Disassembly Note
Caution
x When removing the main bearing and reusing them, put a paint mark showing the front end and
the journal number before the removal.
1. Inspect the crankshaft end play. (See 01-10-24 CRANKSHAFT INSPECTION.)

2. Loosen the lower cylinder block installation bolts 01-10
in the order shown in the figure.
End Of Sie
2 12 11 1
16 15
5
6
10 20 19
9
17 18
7
8
3 4
13 14
bezuue00000101
CYLINDER HEAD INSPECTION

id011000507100
1. Carry out the color contrast penetrate examination on the cylinder head surface.
x If there is a crack, replace the cylinder head.
2. Measure the combustion chamber side of the
cylinder head for distortion in six directions as
shown in the figure using a straight edge and
feeler gauge.
x If it exceeds the maximum specification,
replace the cylinder head.
Cylinder head maximum distortion, head

gasket side
0.10 mm {0.0039 in}
b3e0110e008
3. Measure the contact surface of the exhaust

manifold and the intake manifold as shown in the
figure for distortion using a straight edge and
feeler gauge.
x If it exceeds the maximum specification, grind
the surface or replace the cylinder head.
Cylinder head maximum distortion, manifold

side
0.05 mm {0.002 in}
Cylinder head maximum grinding, manifold

bezuue00000010
side
0.20 mm {0.0079 in}
End Of Sie
01-10–15
MECHANICAL
VALVE SEAT INSPECTION/REPAIR
id011000501300
1. Measure the contact width of the valve face and
the valve seat using the valve lapping compound
(red lead).
Valve seat standard contact width

SEAT CONTACT
0.8—1.4 mm {0.04—0.05 in} WIDTH
bezuue00000014
x If not within the specification, resurface the

valve seat using the 45q valve seat cutter or
resurface the valve face, or the both.
+0 ':
2. Verify that the valve seating position is at the
center of the valve face.
x If the seating position is too high, correct the
‫ޕ‬

‫ޕ‬
valve seat using a 70q (IN) 70q (EX) valve seat
cutter, and a 45q valve seat cutter. ‫ޕ‬ ‫ޕ‬

x If the seating position is too low, correct the
valve seat using a 35q (IN) 30q (EX) valve seat
‫ޕ‬

‫ޕ‬
cutter, and a 45q valve seat cutter.
bezuue00000015
Valve seat angle
45q
3. Check the valve seat for sinking. Measure the

protruding length (dimension L) of the valve stem
using a valve of standard length.
x If it exceeds the specification, replace the
cylinder head.
Valve seat standard sinkage amount

(Dimension L) L
39.25 mm {1.545 in}
End Of Sie
bezuue00000016
VALVE, VALVE GUIDE INSPECTION

id011000506200
1. Measure the valve head margin thickness using a
vernier caliper.
x If not within the specification, replace the
IN : 27.8 mm {1.09 in}
valve. EX : 24.7 mm {0.972 in}
Valve head standard margin thickness

1.6—2.0 mm {0.063—0.078 in}
MARGIN THICKNESS
bezuue00000017
01-10–16
MECHANICAL
2. Measure the length of each valve using the
vernier caliper.
x If it is less than the minimum specification,
replace the valve.
Valve length (Dimension L)

Standard
IN: 96.80—97.40 mm {3.812—3.834 in} L 01-10
EX: 96.30—96.90 mm {3.792—3.814 in}
Minimum
IN: 96.58 mm {3.802 in}
EX: 96.08 mm {3.783 in}
b3e0110e068
3. Measure the stem diameter of each valve using

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

Standard
IN: 5.470—5.485 mm {0.2154—0.2159 in} C
EX: 5.465—5.480 mm {0.2152—0.2157 in}
Minimum
bezuue00000018
IN: 5.424 mm {0.2136 in}
EX: 5.419 mm {0.2134 in}
4. Measure the inner diameter of each valve guide

using the caliper gauge. Measurement positions X
total six and they are in the X and Y directions at Y
the three points (A, B, and C) as shown in the
figure. A
valve guide. (See 01-10-17 VALVE GUIDE
REPLACEMENT.) B
Valve guide standard inner diameter

C
5.510—5.530 mm {0.2170—0.2177 in}
bezuue00000019
5. Calculate the clearance between the valve stem

and the valve guide by subtracting the inner
diameter of the valve guide from the outer
VALVE STEM
diameter of the corresponding valve stem.
replace the valve or the valve guide, or both. VALVE GUIDE
(See 01-10-17 VALVE GUIDE
REPLACEMENT.) CLEARANCE
Clearance between valve stem and guide

Standard
IN: 0.025—0.060 mm {0.0010—0.0023 in}
EX: 0.030—0.065 mm {0.0012—0.0025 in}
Maximum bezuue00000020
0.1 mm {0.004 in}
01-10–17
MECHANICAL
6. Measure the projection height (dimension A) of
each valve guide using the vernier caliper. VALVE GUIDE
x If not within the specification, replace the A
valve guide. (See 01-10-17 VALVE GUIDE
REPLACEMENT.)
Valve guide standard projection height

12.2—12.8 mm {0.481—0.503 in}
End Of Sie CYLINDER HEAD
bezuue00000021
VALVE GUIDE REPLACEMENT

id011000501200
Removal
1. Remove the valve guide from the combustion
chamber side using the SST. 49 B012 015
VALVE GUIDE
bezuue00000022
Installation
1. Assemble the SSTs so that depth L is as
specified.
Depth L 49 L012 004A

L
12.2—12.8 mm {0.481—0.503 in}
49 L012 003A
49 L012 002A
b3e0110e071
2. Tap the valve guide in from the camshaft side

using the SSTs set in Step 1. 49 L012 003A
49 L012 004A
End Of Sie
49 L012 002A
VALVE GUIDE
bezuue00000023
01-10–18
MECHANICAL
VALVE SPRING INSPECTION
id011000501400
1. Measure the spring height using a spring tester.
valve spring.
Valve spring standard height

27.5 mm {1.08 in} (pressing force 262.8 N
{26.80 kgf, 59.08 lbf} 01-10
2. Measure the amount of off-square on the valve

spring using a square.
(1) Rotate the valve spring one full turn and
measure “A” at the point where the gap is the
bezuue00000024
largest.
replace the valve spring.
Maximum valve spring off-square A

2.0q (3.45 mm {0.136 in})
UPPER
End Of Sie
LOWER
bezuue00000025
TAPPET INSPECTION
id011000505800
1. Measure the diameter of each tappet bore using
the caliper gauge. Measurement points are the
inner diameter in the X and Y directions, at the X
points (A and B) as shown in the figure.
Y
Standard tappet bore diameter
30.0—30.025 mm {1.1812—1.1820 in}
A
B
bezuue00000026
2. Measure the tappet body outer diameter of each

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

29.959—29.975 mm {1.1795—1.1801 in}
3. Calculate the clearance between the tappet and

the related bore by subtracting the inner diameter
of the tappet bore from the outer diameter of the
corresponding tappet.
bezuue00000027
replace the tappet or the cylinder head.
Clearance between tappet and tappet bore

Standard
0.025—0.066 mm {0.0010—0.0025 in}
Maximum
0.18 mm {0.0071 in}
01-10–19
MECHANICAL
End Of Sie
VARIABLE VALVE TIMING ACTUATOR INSPECTION

id011000506000
Caution
x Variable valve timing actuator cannot be disassembled because it is a precision unit.
1. Verify that the camshaft knock pin hole of the

rotor and the T-mark on the cover of the variable
valve timing actuator are aligned and placed at
the same position by rotating them by hand.
T-MARK
Caution COVER
x If the camshaft knock pin hole and the T-
mark are not aligned, rotate the rotor (the CAMSHAFT
KNOCK-PIN
camshaft installing part) until a click is HOLE
heard, and verify that they are fixed in
place.
x If the rotor is not secured even though their

camshaft knock pin hole and the T-mark are ROTOR
aligned, replace the variable valve timing
actuator.
End Of Sie
ada2226e005
OIL CONTROL VALVE (OCV) INSPECTION

id011000506100
Coil Resistance Inspection
1. Measure the coil resistance between terminals A
and B using the tester.
x If not within the specification, replace the oil
control valve (OCV).
B A
OCV coil resistance

6.9—7.9 ohms [20qC {68qF}]
bezuue00000028
Spool Valve Operation Inspection

1. Verify that the spool valve in the oil control valve
(OCV) is in the maximum valve timing retard
position as shown in the figure.
x If it cannot be verified as shown, replace the
oil control valve (OCV).
2. Apply battery positive voltage between the oil
control valve (OCV) terminals A and B, and verify
that the spool valve operates and moves to the
maximum valve timing advance position. SPOOL VALVE
x If it cannot be verified as shown in the figure, (MAXIMUM VALVE TIMING RETARD POSITION
replace the oil control valve (OCV).
b3e0110e090
Note
x When applying battery positive voltage
between the oil control valve (OCV) terminals, the connection of the positive and negative battery cable
can be with either of the oil control valve (OCV) terminals.
01-10–20
MECHANICAL
3. Stop applying battery positive voltage and verify
that the spool valve returns to the maximum valve
VALVE TIMING VALVE TIMING
timing retard position.
ADVANCE RETARD
x If it cannot be verified as shown in the figure,
replace the oil control valve (OCV).
End Of Sie
01-10
SPOOL VALVE
(MAXIMUM VALVE TIMING ADVANCE POSITION)
b3e0110e091
CAMSHAFT INSPECTION
id011000501500
1. Set the No.1 and No.5 journals of the camshaft on
V-blocks.
2. Measure the camshaft runout using a dial gauge.
replace the camshaft.
Camshaft maximum runout

0.03 mm {0.001 in}
b3e0110e074
3. Measure the cam lobe height as shown using the

micrometer.
Cam lobe height

Standard
IN: 41.373 mm {1.6289 in}
EX: 40.597 mm {1.5983 in}
Minimum
IN: 41.30 mm {1.626 in}
EX: 40.53 mm {1.596 in}
b3e0110e076
4. Measure the camshaft journal diameter using the

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

Standard Y
25.950—25.975 mm {1.0217—1.0226 in} X
Minimum
24.910 mm {0.98071 in}
bezuue00000029
01-10–21
MECHANICAL
5. Measure the camshaft journal oil clearance using
a plastigauge with the tappet removed.
Note
x Clean the camshaft journal and the journal
receptacle part.
x Cut the plastigauge to the same length as
the journal width and position it in parallel to PLASTIGAUGE
the camshaft.

replace the cylinder head.
bezuue00000030
Camshaft journal oil clearance

Standard
0.025—0.071 mm {0.0010—0.0027 in}
Maximum
0.090 mm {0.0035 in}
6. Measure the camshaft end play using a dial

gauge.
replace the cylinder head or the camshaft.
Camshaft end play

Standard
0.07—0.19 mm {0.003—0.007 in}
Maximum
0.20 mm {0.0079 in}
End Of Sie bezuue00000031
CYLINDER BLOCK INSPECTION

id011000507200
1. Measure the distortion in six directions as shown
in the figure using a square and feeler gauge.
replace the cylinder block.
Cylinder block maximum distortion, head

gasket side
0.10 mm {0.0039 in}
bezuue00000032
2. Measure the cylinder bore using a cylinder bore

X
gauge. Measurement positions are in the X and Y
directions at 35.0 mm {1.38 in} below the top
surface of the cylinder. Y
x If it is not within the specification, replace the
cylinder block.
Standard cylinder bore diameter 35.0 mm {1.38 in}

78.000—78.013 mm {3.0709—3.0713 in}
End Of Sie
bezuue00000033
01-10–22
MECHANICAL
OIL JET VALVE INSPECTION
id011000505900
1. Apply 230 kPa {2.35 kgf/cm2, 33.4 psi} or more of compressed air to oil jet valve A and verify that air passes
through oil jet valve B.
x If air does not flow, replace the oil jet valve.
End Of Sie
$
01-10
#
bezuue00000107
PISTON, PISTON RING, PISTON PIN INSPECTION

id011000506600
1. Measure the piston outer diameter using a
micrometer. The measurement position is 12.5
mm {0.492 in} from the lower end of the piston,
and in the thrust direction.
Piston outer diameter

77.970—77.980 mm {3.0697—3.0700 in}
2. Calculate the piston-to-cylinder clearance from

the cylinder bore inner diameter and the piston 12.5 mm {0.492 in}
outer diameter.
bezuue00000034
replace the piston or the cylinder block.
Clearance between piston and cylinder

Standard
0.020—0.043 mm {0.0008—0.0016 in}
Maximum
0.070 mm {0.0028 in}
3. Measure the piston ring-to-ring groove clearance

around the entire circumference using a feeler
gauge.
replace the piston ring.
Clearance between piston ring and ring

groove
Standard
Top: 0.035—0.065 mm {0.0014—0.0025 in}
Second: 0.030—0.070 mm {0.0012—0.0027
in}
b3e0110e081
Oil: 0.040—0.120 mm {0.0016—0.0047 in}
Maximum
Top, Second: 0.150 mm {0.0059 in}
Oil: 0.20 mm {0.0079 in}
01-10–23
MECHANICAL
4. Measure the piston ring end gap using a feeler
gauge.
x If if exceeds the maximum specification,
replace the piston ring.
Piston ring end gap

Standard
Top: 0.14—0.24 mm {0.0056—0.0094 in} PISTON RING
Second: 0.24—0.37 mm {0.010—0.014 in}
Oil: 0.10—0.35 mm {0.004—0.013 in}
Maximum
1.0 mm {0.039 in}
bezuue00000035
5. Measure the piston pin hole diameter.

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

18.988—19.000 mm {0.74756—0.74803 in} #
$
:
%
&
;
adj2224e253
6. Measure the piston pin outer diameter using a X

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

18.974—18.980 mm {0.74701—0.74724 in} A
B
7. Calculate the clearance between the piston pin
hole diameter and the piston pin outer diameter.
C
D
piston or the piston pin.
adj2224e255
Standard clearance between piston pin hole

and piston pin
0.008—0.026 mm {0.0004—0.0010 in}
End Of Sie
CONNECTING ROD INSPECTION
id011000502800
1. Install the connecting rod cap. (See 01-10-31 CYLINDER BLOCK ASSEMBLY (I).)
2. Measure the side clearance at the large end of
the connecting rod using a feeler gauge.
replace the connecting rod or the crankshaft.
Side clearance at the large end of the

connecting rod
Standard
0.110—0.292 mm {0.0044—0.0114 in}
Maximum
0.435 mm {0.0171 in}
b3e0110e087
01-10–24
MECHANICAL
3. Measure the oil clearance at the large end of the
connecting rod using a plastigauge. PLASTIGAUGE
replace the bearing or grind the crank pin, and
use oversize bearings so that the specified
clearance is obtained.
Note 01-10
x Cut the plastigauge as wide as the
connecting rod bearing width, place it
parallel to the crankshaft, keeping away from
the oil hole.
bezuue00000036
Bearing oil clearance at the large end of

connecting rod
Standard
0.016—0.037 mm {0.0007—0.0014 in}
Maximum
0.10 mm {0.0039 in}
Connecting rod bearing thickness (Center thickness)

STD: 1.509—1.524 mm {0.0594—0.0599 in}
OS 0.25: 1.629—1.637 mm {0.0642—0.0644 in}
OS 0.50: 1.729—1.737 mm {0.0681—0.0683 in}
4. Measure the inner diameter at the small end of

X
the connecting rod using a caliper gauge.
Standard connecting rod small end inner

diameter Y
18.943—18.961 mm {0.74579—0.74649 in}
5. Calculate the clearance between the connecting

rod small end inner diameter and the piston pin
outer diameter.
connecting rod or the piston pin.
adj2224e254
Standard clearance between connecting rod

small end and piston pin
–0.037— –0.013 mm {–0.0014— –0.0006 in}
6. Inspect the connecting rod for bending and

distortion using a connecting rod aligner.
replace the connecting rod.
Connecting rod maximum bending

0.050 mm {0.0020 in} [Per 50 mm {2.0 in}]
Connecting rod maximum distortion

0.075 mm {0.0030 in} [Per 50 mm {2.0 in}]
Connecting rod center-to-center distance

amj2224e255
140.60—140.70 mm {5.536—5.539 in}
End Of Sie
01-10–25
MECHANICAL
CRANKSHAFT INSPECTION
id011000502500
1. Measure the crankshaft end play using a dial
gauge.
replace the crankshaft or grind the crankshaft
thrust side, and install the oversize bearing so
that the specified end play is obtained.
Thrust bearing thickness

STD: 2.500—2.550 mm {0.0985—0.1003 in}
OS 0.25: 2.625—2.675 mm {0.1034—0.1053
in}
OS 0.50: 2.750—2.800 mm {0.1083—0.1102
b3e0110e083
in}
OS 0.75: 2.875—2.925 mm {0.1132—0.1151
in}
Crankshaft end play

Standard
0.080—0.282 mm {0.0032—0.0111 in}
Maximum
0.30 mm {0.012 in}
2. Measure the crankshaft main journal runout on V-

blocks using a dial gauge.
replace the crankshaft.
Crankshaft main journal maximum runout

0.10 mm {0.0039 in}
bezuue00000037
3. Inspect the main journal diameter and crank pin

diameter. Measurement positions total four and
A B
they are in the X and Y directions, at two points (A
and B) as shown in the figure. X
x If not within the specification or exceeds the
maximum off-round, replace the crankshaft or
grind the journal to fit the oversize bearing. Y
Crankshaft main journal diameter

STD: 49.938—49.956 mm {1.9661—1.9667 in}
OS 0.25: 49.688—49.706 mm {1.9563—
1.9569 in}
b3e0110e085
OS 0.50: 49.438—49.456 mm {1.9464—
1.9470 in}
Crankshaft main journal maximum off-round

0.050 mm {0.0020 in}
Crank pin journal diameter

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

0.10 mm {0.0039 in}
01-10–26
MECHANICAL
4. Inspect the main journal oil clearance using the
following procedure.
(1) Install the upper main bearing and crankshaft.
(2) Position a plastigauge on the journals.
(3) Install the lower main bearing and the lower
cylinder block.
(See 01-10-31 CYLINDER BLOCK
ASSEMBLY (I).) 01-10
(4) Remove the lower cylinder block.
(See 01-10-10 CYLINDER BLOCK
DISASSEMBLY (II).)
(5) Measure the main journal oil clearance.
b3e0110e086
replace the main bearing or grind the
main bearing journal part and install the oversize bearing.
Crankshaft main journal oil clearance

Standard
0.019—0.038 mm {0.0008—0.0014 in}
Maximum
0.084 mm {0.0033 in}
Main bearing thickness

STD: 2.508—2.529 mm {0.09875—0.09956 in}
OS 0.25: 2.625—2.635 mm {0.1034—0.1037 in}
OS 0.50: 2.750—2.760 mm {0.1083—0.1086 in}
End Of Sie
BOLT INSPECTION
id011000503300
1. Measure the length of each bolt.
replace the bolt.
Cylinder head bolt length

Standard: 128.9—129.5 mm {5.075 —5.098
in}
Maximum: 130.2 mm {5.126 in} L
Connecting rod bolt length

Standard: 46.7—47.3 mm {1.84—1.86 in}
Maximum: 48.0 mm {1.89 in}
bezuue00000038
End Of Sie
OIL PUMP INSPECTION
id011000505300
1. Measure the clearance between the inner rotor
and the outer rotor using a feeler gauge.
replace the inner rotor or outer rotor, or both.
Tip clearance between inner rotor and outer

rotor
Standard: 0.02—0.18 mm {0.0008—0.0070
in}
Maximum: 0.20 mm {0.0079 in}
bezuue00000039
01-10–27
MECHANICAL
2. Measure the clearance between the outer rotor
and the oil pump body using a feeler gauge.
replace the outer rotor or oil pump, or both.
Body clearance between outer rotor and oil

pump body
Standard: 0.090—0.175 mm {0.0036—0.0068
in}
Maximum: 0.20 mm {0.0079 in}
bezuue00000040
3. Measure the side clearance using a straight edge

and feeler gauge.
inner rotor, outer rotor, oil pump, or all of
them.
Oil pump side clearance

Standard: 0.03—0.07 mm {0.0012—0.0027
in}
Maximum: 0.090 mm {0.0035 in}
bezuue00000041
4. Measure the weight at which the plunger spring

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

compressed to 35.42 mm {1.394 in}
62.5—68.9 N {6.38—7.02 kgf, 14.1—15.4 lbf}
End Of Sie
bezuue00000024
VALVE CLEARANCE INSPECTION

id011000503500
1. Turn the crankshaft clockwise so that the No.1 piston is at TDC of the compression stroke.
2. Measure the valve clearance at A shown in the A B A B
figure.
tappet and adjust the valve to the median
value. (See 01-10-27 VALVE CLEARANCE EX
ADJUSTMENT.)
NO.1 NO.2 NO.3 NO.4
Standard valve clearance [Engine cold] IN

0.27—0.33 mm {0.011—0.012 in}
Note A A B B
x Make sure to note the measured values for
adj2224e103
choosing the suitable replacement tappets.
3. Rotate the crankshaft clockwise 360q so that the No.4 piston is at TDC of the compression stroke.
01-10–28
MECHANICAL
4. Measure the valve clearance at B shown in the A B A B
figure.
tappet and adjust the valve to the median
value. (See 01-10-27 VALVE CLEARANCE EX
ADJUSTMENT)
NO.1 NO.2 NO.3 NO.4
Standard valve clearance [Engine cold] IN 01-10

0.27—0.33 mm {0.011—0.012 in}
Note A A B B
x Make sure to note the measured values for
adj2224e103
choosing the suitable replacement tappets.
End Of Sie
VALVE CLEARANCE ADJUSTMENT
id011000503600
1. Remove the engine front cover blind plug shown
in the figure.
BLIND PLUG R
am3zzw0000629
2. Insert a M6 bolt (45—80 mm {1.8—3.1 in} length

bolt with threads to the end) into the service hole
(right side) by hand as shown in the figure. Pull BOLT
back the inserted bolt approx. 2 mm {0.08 in} from
where it contacts the tensioner arm, and set the
bolt in a position slightly outward of the tensioner
arm.
3. Release tension on the timing chain.
FRONT COVER
TENSIONER ARM
bezuue00000043
01-10–29
MECHANICAL
(1) Press down the link plate of the chain
tensioner from the service hole on the left
side using a thin flathead screwdriver
(precision screwdriver) as shown in the figure.
Then rotate the crank pulley backwards
(counterclockwise) with the plunger lock
released.
Note
x When the crankshaft pulley is turned
counterclockwise, the timing chain loosens
because the tensioner arm is pressed by the
timing chain and the plunger of the chain
tensioner is pressed in.
bezuue00000044
PLUNGER
LINK PLATE
bezuue00000045
(2) Insert the M6 bolt installed to the engine front

cover to the position where it catches the RIB
RIB
inside of the rib on the tensioner arm.
Note
x When the timing chain loosens, the
tensioner arm moves to the position shown
in the figure and presses the M6 bolt to
secure the tensioner arm.
bezuue00000046
TENSIONER ARM
RIB
SERVICE HOLE
bezuue00000047
01-10–30
MECHANICAL
4. Fix the camshaft using a wrench on the cast
hexagon.
5. Remove the camshaft sprocket installation bolt.
01-10
bezuue00000048
6. Remove the timing sprocket on the exhaust side

with the timing chain positioned out of the way.
bezuue00000049
7. Loosen the camshaft cap installation bolts in two 12 18 14 16 6 8

10 20
to three passes in the order shown in the figure,
and remove the camshaft caps. 2
8. Remove the intake and exhaust side camshafts.
3
1
4
2
9. Remove the tappets.

10. Select a proper tappet according to the result of
4
the valve clearance inspection and install it.
Tappet to be selected: thickness of the 3
removed tappet + measured valve
8
5
clearance - standard valve clearance 1

9 11 19 17 15 13 7 5
Standard valve clearance [Engine cold]
bezuue00000050
0.27—0.33 mm {0.011—0.012 in}
11. Align the timing marks on the crank pulley and the TIMING MARK
engine front cover, and then align the No.1 TDC
cylinder to the TDC.
12. Install the intake and exhaust camshafts with the
No.1 cylinder so that it is near TDC of the
compression stroke.
bezuue00000051
01-10–31
MECHANICAL
13. Install the camshaft cap to the position shown in 3 1 5 15 13
11 9 7
the figure, and temporarily tighten the No.2 and
No.7 camshaft installation bolts. 19
14. Tighten the camshaft installation bolts in two to
3
1
4
2
three passes uniformly in the order shown in the
figure. 17
Tightening torque 18
12—14 N·m {123—142 kgf·cm, 107—123
8
5
7
in·lbf} 20
12 10 2 4 6 8 14 16
bezuue00000052
15. Install the exhaust camshaft sprocket and the

timing chain at the same time.
bezuue00000049
x Align the sprocket timing marks on the intake TIMING MARK CYLINDER HEAD
and exhaust camshafts so that they form a UPPER SURFACE
straight line in alignment with the upper
horizontal surface of the cylinder head.
bezuue00000053
16. Hold the exhaust camshaft using a wrench on the

cast hexagon.
17. Tighten the camshaft sprocket installation bolt.
Tightening torque
50—60 N·m {5.1—6.1 kgf·m, 37—44 ft·lbf}
18. Remove the M6 bolt holding the tensioner arm.

19. Verify that there is no slack in the timing chain,
and then verify that the marks on the camshaft
sprocket and the crank pulley are aligned.
20. Inspect the valve timing by rotating the crankshaft
am3zzw0000032
clockwise twice.
21. Install the new engine front cover blind plug.
Tightening torque
3.0—6.0 N·m {31—61 kgf·cm, 27—53 in·lbf}
End Of Sie
BLIND PLUG R
am3zzw0000629
01-10–32
MECHANICAL
CYLINDER BLOCK ASSEMBLY (I)
id011000504000
1. Assemble in the order indicated in the table.
11 01-10
10 OIL
R OIL
3
8 OIL 4
2
8—10 N·m
SST {82—101 kgf·cm,
71—88 in·lbf}
9 OIL
OIL 5 OIL
12 OIL
13
6 SEALANT
14
23—26 {2.4—2.6, 17—19}

+82.5˚— 97.5˚
OIL
24—26 {2.5—2.6, 18—19}
+42.5˚— 47.5˚
19—25 {2.0—2.5, 15—18}
bezuue00000054
1 Upper cylinder block 9 Piston pin

2 Oil jet valve (See 01-10-34 Piston Pin Assembly Note)
3 Upper main bearing, thrust bearing 10 Piston ring
(See 01-10-32 Main Bearing Assembly Note) (See 01-10-36 Piston Ring Assembly Note)
4 Crankshaft 11 Piston, connecting rod component
(See 01-10-36 Piston, Connecting Rod Component
5 Lower main bearing Assembly Note)
(See 01-10-32 Main Bearing Assembly Note)
12 Upper connecting rod bearing
6 Lower cylinder block (See 01-10-36 Connecting Rod Bearing Assembly
(See 01-10-33 Lower Cylinder Block Assembly Note)
Note)
7 Connecting rod
8 Piston
01-10–33
MECHANICAL
13 Lower connecting rod bearing
(See 01-10-36 Connecting Rod Bearing Assembly
Note)
14 Connecting rod cap
(See 01-10-37 Connecting Rod Cap Assembly
Note)
Main Bearing Assembly Note
Caution
x If a main bearing is reused, mistaking the position and direction of the bearing could result in
engine damage due to seizure or burning of the bearing. Using the identifier paint marks employed
during removal, assemble the main bearings at the positions numbered when the journal was
removed, and so that the painted areas are on the front sides.
1. Assemble the upper and lower main bearing as specified shown in the figure.
Caution
x If the lower main bearing is not assembled according to the specification it could result in engine
damage from seizure or burning of the bearing. Measure the bearing using a vernier caliper and
assemble it within the specification.
Upper main bearing
MEASUREMENT
AREA
5 {0.2}
5 {0.2}
0.70—1.1 1.9—2.3 1.9—2.3

{0.028— {0.075— {0.075—
0.043} 0.090} 0.090}
1.8—2.2 1.9—2.3
{0.071—0.086} {0.075—0.090} mm {in}
bezuue00000070
Lower main bearing
MEASUREMENT
AREA
5 {0.2}
5 {0.2}
1.9—2.3 1.9—2.3
{0.075— {0.075—
0.090} 0.090}
2.45—2.85 1.9—2.3
{0.097—0.112} {0.075—0.090}
1.8—2.2 {0.071—0.086} mm {in}
bezuue00000056
01-10–34
MECHANICAL
Lower Cylinder Block Assembly Note
Caution
x Install the lower cylinder block before the applied silicone sealant starts to harden.
1. Apply silicone sealant to the lower cylinder block

attachment side as shown in the figure.
2. Apply clean engine oil to the lower cylinder block 01-10
installation bolts A.
SEALANT
SEALANT
2.0—6.0 mm
{0.08—0.23 in}
bezuue00000057
3. Tighten the lower cylinder block installation bolts 10 A

9A
A in two steps in the order shown in the figure.
(1)Tightening torque
24—26 N·m {2.5—2.6 kgf·m, 18—19 ft·lbf} 5A 6A
(2)Tightening angle
42.5q—47.5q
1 A 2A
4A 3A
8A 7A
bezuue00000058
4. Tighten the lower cylinder block installation bolts

B in the order shown in the figure. B 9 10 B
Tightening torque
19—25 N·m {2.0—2.5 kgf·m, 15—18 ft·lbf} 6B
B 5
B 1
2B
B 4
3B
B 8 7 B
bezuue00000059
01-10–35
MECHANICAL
5. Loosen bolts A and tighten the lower cylinder 10 A
9A
block installation bolts in two steps in the order
shown a second time.
(1)Tightening torque 5A 6A
24—26 N·m {2.5—2.6 kgf·m, 18—19 ft·lbf}
(2)Tightening angle
42.5q—47.5q 1 A 2A
4A 3A
8A 7A
bezuue00000058
Piston Pin Assembly Note

PISTON PIN
49 L011 006A
49 E011 001A 49 E011 002A
bezuue00000063
2. Adjust the SSTs (stopper bolt) to the L length.

49 D011 002B
Standard L length L
60.85 mm {2.396 in}
49 L011 001
49 L011 005
bezuue00000064
3. Point the end mark on the connecting rod and F-

mark on the piston in the same direction as
shown in the figure.
F-MARK
ALIGNMENT MARK
bezuue00000065
01-10–36
MECHANICAL
4. Insert the assembled piston pin and the SSTs into
the piston and the connecting rod.
49 L011 006A
PISTON PIN
01-10
49 E011 001A
bezuue00000066
5. Set the SSTs as shown in the figure.

6. Press the piston pin into the piston and 49 L011 006A
connecting rod until the SST (guide) contacts the PISTON PIN
SST (stopper bolt) using the hydraulic press. If it PISTON
is less than the specification, replace the piston
CONNECTING ROD
pin or the connecting rod.
Pressure force
2940—14700 N {300—1498 kg, 660—3297 49 E011 001A
49 L011 005
lbf}
49 L011 001
bezuue00000067
Piston Ring Assembly Note

1. Assemble the oil ring.
2. Install the second ring with the notch facing
downward.
3. Install the top ring with scraper face side upward.
bezuue00000068
Piston, Connecting Rod Component Assembly Note
Note
x After a piston with identification (F) on its
upper end is installed, perform the PCM PISTON UPPER VIEW
reprogramming, referring to the Workshop
Manual, to prevent damage to the engine. FRONT MARK
ENGINE
FRONT SIDE PISTON
IDENTIFICATION
MARK
bezuue00000060
01-10–37
MECHANICAL
1. Position the end gap of each oil ring as shown in
the figure. 30° 30°
PISTON PIN AXIS
UPPER OIL RING RAIL LOWER OIL RING RAIL

OIL RING SPACER
bezuue00000061
2. Insert the piston into the cylinder with the mark on PISTON FRONT MARK
top of the piston facing the front of the engine.
ENGINE FRONT
bezuue00000062
Connecting Rod Bearing Assembly Note
Caution
x If a connecting rod bearing is reused, mistaking the position and direction of the bearing could
result in engine damage due to seizure or burning of the bearing.
Using the identifier paint marks employed during removal, assemble the main bearings at the
positions numbered when the journal was removed, and so that the painted areas are on the front
sides.
1. Install the connecting rod bearing to the

connecting rod and the connecting rod cap as ENGINE FRONT ENGINE FRONT
specified shown in the figure.
Caution
x If the connecting rod bearing is not ROD SIDE CAP SIDE
assembled according to the specification
it could result in engine damage from
seizure or burning of the bearing.
Measure the bearing using a vernier 2.40—2.80 mm 2.40—2.80 mm
{0.095—0.110 in} {0.095—0.110 in}
caliper and install it within the
specification.
bezuue00000069
Connecting Rod Cap Assembly Note

1. Install the connecting rod cap with the knock pins and the alignment marks aligned.
2. Tighten the connecting rod cap installation bolt in two steps.
23—26 N·m {2.4—2.6 kgf·m, 17—19 ft·lbf}
(2)Tightening angle
82.5q—97.5q
End Of Sie
01-10–38
MECHANICAL
CYLINDER BLOCK ASSEMBLY (II)
id011000504100
SST 97—103 R
{9.9—10, 72—75}
5
OIL
11 12 13
6 5.9—8.8 N·m
{61—89 kgf·cm,
SST
53—77 in·lbf} R 01-10
7
1
OIL
MTX
2
4 3
27—39
13
{2.8—3.9, R SST
20—28}
16
R 8—10 N·m
19—25 15
{2.0—2.5, {82—101 kgf·cm,
15—18} 71—88 in·lbf}
17 SST
20—34
{2.1—3.4, 15—25}
8
R
19—25
18 {2.0—2.5,
15—18}
14 19
19—25
OIL
{2.0—2.5,
15—18}
10 SST R
12—15 N·m
{123—152 kgf·cm, 107—132 in·lbf}
SEALANT
9 8—10 N·m
{82—101 kgf·cm, 71—88 in·lbf} N·m {kgf·m, ft·lbf}
bezuue00000071
1 Oil pump body 11 Rear oil seal

2 Control plunger (See 01-10-39 Rear Oil Seal Assembly Note)
3 Plunger spring 12 End plate
4 Plunger plug 13 Drive plate (ATX), flywheel (MTX)
(See 01-10-40 Drive Plate (ATX), Flywheel (MTX)
5 Outer rotor Assembly Note)
(See 01-10-39 Inner Rotor, Outer Rotor Assembly
Note) 14 Oil pump
(See 01-10-40 Oil Pump Assembly Note)
6 Inner rotor
(See 01-10-39 Inner Rotor, Outer Rotor Assembly 15 Water pump
Note) 16 Oil separator
7 Oil pump cover 17 Knock sensor
8 Oil strainer (See 01-10-41 Knock Sensor Assembly Note)
9 Oil pan 18 Thermostat
(See 01-10-39 Oil Pan Assembly Note) 19 Thermostat cover
10 Oil filter
(See 01-10-39 Oil Filter Assembly Note)
01-10–39
MECHANICAL
Inner Rotor, Outer Rotor Assembly Note
1. Assemble the inner rotor and the outer rotor with
the punch marks aligned. PUNCH MARK
bezuue00000072
Oil Pan Assembly Note
Caution
x Install the oil pan before the applied silicone sealant starts to harden.
1. Apply silicone sealant as shown in the figure.

SEALANT
Diameter
2.0—6.0 mm {0.08—0.23 in}
bezuue00000073
2. Tighten the oil pan installation bolts in the order 11 8 4 1 5 9

8—10 N·m {82—101 kgf·cm, 71—88 in·lbf} 16
13
14
15
7 3 2 6 10
bezuue00000074
Oil Filter Assembly Note

1. Install the oil filter according to the instruction on
the package or side of the oil filter.
49 G014 001
Note OR COMMERCIALLY
Tightening torque AVAILABLE CUP-TYPE
12—15 N·m {123—152 kgf·cm, 107—132 in·lbf} OIL FILTER WRENCH
Angle tightening
When the O-ring contacts the oil filter installation
surface, turn the filter another one rotation.
bezuue00000104
01-10–40
MECHANICAL
Rear Oil Seal Assembly Note
1. Apply clean engine oil to a new rear oil seal.
2. Insert the rear oil seal to the cylinder block by hand.
3. Install the rear oil seal using the SST.
01-10
49 E033 101
bezuue00000076
CYLINDER BLOCK
0—0.50 mm
{0—0.019 in}
REAR OIL SEAL
bezuue00000077
Drive Plate (ATX), Flywheel (MTX) Assembly Note

2. Tighten the flywheel installation bolts in two to
49 E011 1A0
three passes in the order shown in the figure.
1
6 4
3
5
2
bezuue00000078
Oil Pump Assembly Note

1. Install the gasket to the oil pump.
2. Install the oil pump and gasket as a single unit.
bezuue00000079
01-10–41
MECHANICAL
Knock Sensor Assembly Note
1. Install the knock sensor using the SST.
End Of Sie
49 H018 001
bezuue00000080
CYLINDER HEAD ASSEMBLY (I)

id011000504300
5 SST
4
3
SST R 1
B3E0110E029
.
1 Valve seal 4 Upper valve spring seat

(See 01-10-41 Valve Seal Assembly Note) 5 Valve keeper
2 Valve (See 01-10-42 Valve Keeper Assembly Note)
3 Valve spring
01-10–42
MECHANICAL
Valve Seal Assembly Note
1. Press in the valve seal to the valve guide by hand.
2. Tap the SST shown in the figure using a plastic
hammer. 49 T032 302
VALVE
SEAL 01-10
B3E0110E123
Valve Keeper Assembly Note

1. Install the valve keeper using the SST.
End Of Sie
49 0636 100B
49 B012 0A2
b3e0110e124
01-10–43
MECHANICAL
CYLINDER HEAD ASSEMBLY (II)
id011000504400
12—14 N·m
{123—142 kgf·cm, 107—123 in·lbf}
OIL
5 4
19—25
R {2.0—2.5,
15—18}
3
6
50—60
{5.1—6.1, 2
37—44}
18—22 {1.9—2.2, 14—16} 1 R

+85˚—95˚
+85°—95°

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1 Cylinder head gasket 5 Camshaft cap

2 Cylinder head (See 01-10-44 Camshaft Assembly Note)
(See 01-10-43 Cylinder Head Assembly Note) 6 Camshaft sprocket, variable valve timing actuator
3 Tappet (See 01-10-44 Camshaft Sprocket, Variable Valve
Timing Actuator Assembly Note)
4 Camshaft
(See 01-10-44 Camshaft Assembly Note) 7 Water outlet
01-10–44
MECHANICAL
Cylinder Head Assembly Note
1. Tighten the cylinder head installation bolts in 8 4 1 5 9
three steps in the order shown in the figure.
18—22 N·m {1.9—2.2 kgf·m, 14—16 ft·lbf}
(2)Tightening angle
85q—95q 01-10
(3) Tightening angle
85q—95q
7 3 2 6 10
bezuue00000082
Camshaft Assembly Note
Note
x Install the camshaft with the No.1 camshaft positioned at TDC of the compression stroke.
1. Install the camshaft cap to the position shown in 3 1 5 15 13

11 9 7
the figure, and temporarily tighten the No.2 and
No.7 camshaft installation bolts. 19
2. Tighten the camshaft cap installation bolts in two
3
1
4
2
to three passes uniformly in the order shown in
the figure. 17
12—14 N·m {123—142 kgf·cm, 107—123
8
5
7
in·lbf} 20
12 10 2 4 6 8 14 16
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Camshaft Sprocket, Variable Valve Timing Actuator Assembly Note

1. Fix the camshaft using a suitable wrench on the
cast hexagon as shown in the figure.
2. Tighten the camshaft sprockets and variable valve
timing actuator installation bolts.
Tightening torque
50—60 N·m {5.1—6.1 kgf·m, 37—44 ft·lbf}
End Of Sie
bezuue00000084
01-10–45
MECHANICAL
TIMING CHAIN ASSEMBLY
id011000505600
7—10 N·m
8—10 N·m 15—22
13 {82—101 kgf·cm,
{72—101 kgf·cm,
{1.6—2.2, 12—16} 62—88 in·lbf}
71—88 in·lbf}
19—25
16 14
{2.0—2.5, 15—18} 15
R
7 SEALANT
R
R
8—10 N·m
{82—101 kgf·cm, 11
71—88 in·lbf}
R
R
9
32—47
{3.3—4.7, 38—51
24—34} {3.9—5.2,
38—51 29—37}
{3.9—5.2,
29—37} 10
R SST SEALANT
38—51 8—10 N·m 8—10 N·m

OIL
{3.9—5.2, {82—101 kgf·cm, {82—101 kgf·cm,
29—37} 71—88 in·lbf} 71—88 in·lbf}
8 19—25
{2.0—2.5, 15—18} 12
SST 157—167
{16.1—17, 116—123}
6 R
19—25
{2.0—2.5, 15—18}
5
1
19—25
{2.0—2.5, 15—18}
2
4 3
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1 Key 9 OCV oil filter, plug

2 Crankshaft sprocket 10 Idler pulley
3 Timing chain 11 OCV
(See 01-10-46 Timing Chain Assembly Note) 12 Oil level gauge pipe
4 Timing chain guide 13 Drive belt auto tensioner
5 Timing chain tensioner arm 14 Cylinder head cover
6 Timing chain tensioner (See 01-10-48 Cylinder Head Cover Assembly Note)
7 Engine front cover 15 CMP sensor
(See 01-10-46 Engine Front Cover Assembly Note) 16 Spark plug
8 Crankshaft pulley
(See 01-10-48 Crankshaft Pulley Installation Bolt
Assembly Note)
01-10–46
MECHANICAL
Timing Chain Assembly Note
1. Align the key groove of the crankshaft sprocket to
the timing mark, and then position the No.1 TIMING MARK
cylinder to TDC. KEY GROOVE
01-10
bezuue00000086
2. Align the timing marks on the camshaft sprockets TIMING MARK CYLINDER HEAD
so that they form a straight line in alignment with UPPER SURFACE
the upper horizontal surface of the cylinder head.
3. Install the timing chain.
4. Install the timing chain guide and timing chain
tensioner arm.
bezuue00000087
5. Install the chain adjuster and then remove the

wire or paper clip used for fixing. (Remove the
installed stopper when installing the new chain
tensioner.)
6. Verify that there is no slack on the timing chain
and then verify that each sprocket is positioned in STOPPER
the proper place again.
7. Inspect the valve timing by rotating the crankshaft
clockwise twice. LINK PLATE
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Engine Front Cover Assembly Note
Caution
x Install the engine front cover before the applied silicone sealant starts to harden.
1. Apply silicone sealant to the engine front cover as

Diameter
2—4 mm {0.08—0.15 in}
SEALANT
bezuue00000089
01-10–47
MECHANICAL
2. Tighten the engine front cover installation bolts in
the order shown in the figure.
x Install bolt (1) using a new seal washer.
Position Tightening torque 2 1 7
6
8—10 N·m {82—101 kgf·cm,
9
71—88 in·lbf}
19—25 N·m {2.0—2.5 kgf·m,
1—6, 8, 10, 12—15, 17, 18
15—18 ft·lbf} 11
12
38—51 N·m {3.9—5.2 kgf·m,
7, 11, 16 15 16
29—37 ft·lbf}
8 3
9
13 18
17 14
5 4
10
bezuue00000090
3. Install the oil seal using the SST.
FRONT OIL SEAL
49 H010 401
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ENGINE FRONT
COVER
0—0.50 mm
HAMMER {0—0.019 in}
FRONT OIL
49 H010 401 SEAL
bezuue00000092
01-10–48
MECHANICAL
4. Install the oil filter to the plug and insert it in the
front cover as shown in the figure.
Tightening torque
32—47 N·m {3.3—4.7 kgf·m, 24—34 ft·lbf} PLUG
FILTER FRONT COVER
01-10
ALUMINUM WASHER
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Crankshaft Pulley Installation Bolt Assembly Note

2. Tighten the crankshaft pulley installation bolt.
49 E011 1A0
Tightening torque
157—167 N·m {16.1—17 kgf·m, 116—123
ft·lbf}
bez0je00000066
Cylinder Head Cover Assembly Note
Caution
x Install the cylinder head cover before the applied silicone sealant starts to harden.
1. Apply silicone sealant as shown in the figure. SEALANT
Diameter 2.0— 6.0 mm

2—6 mm {0.1—0.2 in} {0.1—0.2 in}
SEALANT
Length
6—26 mm {0.3—1.0 in} 6 —26 mm
{0.3—1.0 in}
FRONT COVER
MATING FACES
bezuue00000095
01-10–49
MECHANICAL
2. Tighten the cylinder head cover installation bolts
in the order shown in the figure. 2 9 8
Tightening torque 3
7—10 N·m {72—101 kgf·cm, 62—88 in·lbf}
7
End Of Sie 4
1 5 10 6
bezuue00000106
01-10–50
TECHNICAL DATA
01-50 TECHNICAL DATA
ENGINE TECHNICAL DATA . . . . . . . . . . 01-50–1
End of Toc
ENGINE TECHNICAL DATA
WM: ENGINE
id015000800100
01-50
Item Specification
Cylinder head maximum distortion, head gasket side 0.10 mm {0.0039 in}
Cylinder head maximum distortion, manifold side 0.05 mm {0.002 in}
Cylinder head maximum grinding, manifold side 0.20 mm {0.0079 in}
Valve seat standard contact width 0.8—1.4 mm {0.04—0.05 in}
Valve seat angle 45°
Valve seat standard sinkage amount (Dimension L) 39.25 mm {1.545 in}
Valve head standard margin thickness 1.6—2.0 mm {0.063—0.078 in}
Standard
IN: 96.80—97.40 mm {3.812—3.834 in}
EX: 96.30—96.90 mm {3.792—3.814 in}
Valve length (Dimension L)
Minimum
IN: 96.58 mm {3.802 in}
EX: 96.08 mm {3.783 in}
Standard
IN: 5.470—5.485 mm {0.2154—0.2159 in}
EX: 5.465—5.480 mm {0.2152—0.2157 in}
Valve stem diameter
Minimum
IN: 5.424 mm {0.2136 in}
EX: 5.419 mm {0.2134 in}
Valve guide standard inner diameter 5.510—5.530 mm {0.2170—0.2177 in}
Standard
IN: 0.025—0.060 mm {0.0010—0.0023 in}
Clearance between valve stem and guide EX: 0.030—0.065 mm {0.0012—0.0025 in}
Maximum
0.1 mm {0.004 in}
Valve guide standard projection height 12.2—12.8 mm {0.481—0.503 in}
Valve spring standard height 27.5 mm {1.08 in} (pressing force 262.8 N {26.80 kgf, 59.08 lbf}
Maximum valve spring off-square 2.0° (3.45 mm {0.136 in})
Standard tappet bore diameter 30.0—30.025 mm {1.1812—1.1820 in}
Standard tappet body outer diameter 29.959—29.975 mm {1.1795—1.1801 in}
Standard
0.025—0.066 mm {0.0010—0.0025 in}
Clearance between tappet and tappet bore
Maximum
0.18 mm {0.0071 in}
OCV coil resistance 6.9—7.9 ohms [20°C {68°F}]
Camshaft maximum runout 0.03 mm {0.001 in}
Standard
IN: 41.373 mm {1.6289 in}
EX: 40.597 mm {1.5983 in}
Cam lobe height
Minimum
IN: 41.30 mm {1.626 in}
EX: 40.53 mm {1.596 in}
Standard
25.950—25.975 mm {1.0217—1.0226 in}
Camshaft journal diameter
Minimum
24.910 mm {0.98071 in}
Standard
0.025—0.071 mm {0.0010—0.0027 in}
Camshaft journal oil clearance
Maximum
0.090 mm {0.0035 in}
Standard
0.07—0.19 mm {0.003—0.007 in}
Camshaft end play
Maximum
0.20 mm {0.0079 in}
01-50–1
TECHNICAL DATA
Item Specification
Cylinder block maximum distortion, head gasket side 0.10 mm {0.0039 in}
Standard cylinder bore diameter 78.000—78.013 mm {3.0709—3.0713 in}
Piston outer diameter 77.970—77.980 mm {3.0697—3.0700 in}
Standard
0.020—0.043 mm {0.0008—0.0016 in}
Clearance between piston and cylinder
Maximum
0.070 mm {0.0028 in}
Standard
Top: 0.035—0.065 mm {0.0014—0.0025 in}
Second: 0.030—0.070 mm {0.0012—0.0027 in}
Clearance between piston ring and ring groove Oil: 0.040—0.120 mm {0.0016—0.0047 in}
Maximum
Top, Second: 0.150 mm {0.0059 in}
Oil: 0.20 mm {0.0079 in}
Standard
Top: 0.14—0.24 mm {0.0056—0.0094 in}
Second: 0.24—0.37 mm {0.010—0.014 in}
Piston ring end gap
Oil: 0.10—0.35 mm {0.004—0.013 in}
Maximum
1.0 mm {0.039 in}
Standard piston pin hole diameter 18.988—19.000 mm {0.74756—0.74803 in}
Standard piston pin outer diameter 18.974—18.980 mm {0.74701—0.74724 in}
Standard clearance between piston pin hole and
0.008—0.026 mm {0.0004—0.0010 in}
piston pin
Standard
0.110—0.292 mm {0.0044—0.0114 in}
Side clearance at the large end of the connecting rod
Maximum
0.435 mm {0.0171 in}
Standard
Bearing oil clearance at the large end of connecting 0.016—0.037 mm {0.0007—0.0014 in}
rod Maximum
0.10 mm {0.0039 in}
STD: 1.509—1.524 mm {0.0594—0.0599 in}
Connecting rod bearing thickness (Center thickness) OS 0.25: 1.629—1.637 mm {0.0642—0.0644 in}
OS 0.50: 1.729—1.737 mm {0.0681—0.0683 in}
Standard connecting rod small end inner diameter 18.943—18.961 mm {0.74579—0.74649 in}
Standard clearance between connecting rod small end
–0.037—–0.013 mm {–0.0014—–0.0006 in}
and piston pin
Connecting rod maximum bending 0.050 mm {0.0020 in}[Per 50 mm {2.0 in}]
Connecting rod maximum distortion 0.075 mm {0.0030 in}[Per 50 mm {2.0 in}]
Connecting rod center-to-center distance 140.60—140.70 mm {5.536—5.539 in}
STD: 2.500—2.550 mm {0.0985—0.1003 in}
OS 0.25: 2.625—2.675 mm {0.1034—0.1053 in}
Thrust bearing thickness
OS 0.50: 2.750—2.800 mm {0.1083—0.1102 in}
OS 0.75: 2.875—2.925 mm {0.1132—0.1151 in}
Standard
0.080—0.282 mm {0.0032—0.0111 in}
Crankshaft end play
Maximum
0.30 mm {0.012 in}
Crankshaft main journal maximum runout 0.10 mm {0.0039 in}
STD: 49.938—49.956 mm {1.9661—1.9667 in}
Crankshaft main journal diameter OS 0.25: 49.688—49.706 mm {1.9563—1.9569 in}
OS 0.50: 49.438—49.456 mm {1.9464—1.9470 in}
Crankshaft main journal maximum off-round 0.050 mm {0.0020 in}
STD: 47.940—47.956 mm {1.8875—1.8880 in}
Crank pin journal diameter OS 0.25: 47.690—47.706 mm {1.8776—1.8781 in}
OS 0.50: 47.440—47.456 mm {1.8678—1.8683 in}
Crank pin journal maximum off-round 0.10 mm {0.0039 in}
Standard
0.019—0.038 mm {0.0008—0.0014 in}
Crankshaft main journal oil clearance
Maximum
0.084 mm {0.0033 in}
01-50–2
TECHNICAL DATA
Item Specification
STD: 2.508—2.529 mm {0.09875—0.09956 in}
Main bearing thickness OS 0.25: 2.625—2.635 mm {0.1034—0.1037 in}
OS 0.50: 2.750—2.760 mm {0.1083—0.1086 in}
Standard: 128.9—129.5 mm {5.075 —5.098 in}
Cylinder head bolt length
Maximum: 130.2 mm {5.126 in}
Standard: 46.7—47.3 mm {1.84—1.86 in}
Connecting rod bolt length
Maximum: 48.0 mm {1.89 in} 01-50
Standard: 0.02—0.18 mm {0.0008—0.0070 in}
Tip clearance between inner rotor and outer rotor
Maximum: 0.20 mm {0.0079 in}
Body clearance between outer rotor and oil pump Standard: 0.090—0.175 mm {0.0036—0.0068 in}
body Maximum: 0.20 mm {0.0079 in}
Standard: 0.03—0.07 mm {0.0012—0.0027 in}
Oil pump side clearance
Maximum: 0.090 mm {0.0035 in}
Weight at which the plunger spring height is
62.5—68.9 N {6.38—7.02 kgf, 14.1—15.4 lbf}
compressed to 35.42 mm {1.394 in}
Standard valve clearance [Engine cold] 0.27—0.33 mm {0.011—0.012 in}
End Of Sie
01-50–3
1993-1U-10E(01-60).fm 1 ページ２０１０年５月１２日　水曜日　午後２時６分
SERVICE TOOLS
01-60 SERVICE TOOLS
ENGINE SST . . . . . . . . . . . . . . . . . . . . . . 01-60–1
End of Toc
ENGINE SST
SOKYU_WM: ENGINE
id016000119200
1: Mazda SST number 01-60
2: Global SST number
Example
1: 49 0107
680A
2: —
Engine stand
1: 49 0107 1: 49 L010 1A0 1: 49 E011 1A0

680A 2: — 2: —
2: —
Engine hanger Ring gear brake
Engine stand set set
1: 49 0636 1: 49 B012 0A2 1: 49 S120 170

100B 2: — 2: —
2: —
Pivot Valve seal
Valve spring remover
lifter arm
1: 49 H018 001 1: 49 G014 001 1: 49 L011

2: — 2: — 0A0C
2: —
Knock sensor Oil filter wrench
wrench Piston pin
setting set
1: 49 E011 1: 49 E011 1: 49 B012 015

001A 002A 2: —
2: — 2: —
Valve guide
Piston pin guide Screw installer
1: 49 L012 1: 49 E033 101 1: 49 T032 302

0A0B 2: — 2: —
2: —
Dust cover Bearing installer
Valve seal and installer
valve guide
installer set
01-60–1
1993-1U-10E(01-60).fm 2 ページ２０１０年５月１２日　水曜日　午後２時６分
SERVICE TOOLS
1: 49 H010 401
2: —
Oil seal installer

— —
End Of Sie
01-60–2

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1993-1U-10E(INDEX).

Manual GENERAL INFORMATION 00

MZR 1.5 ENGINE 01

FOREWORD © 2010 Mazda Motor Corporation

In order to do these procedures safely,

All the contents of this manual, including

Mazda Motor Corporation reserves the right

All rights reserved. No part of this book may

Mazda Motor Corporation

This manual contains "Warnings" and "Cautions" applicable to risks

The procedures recommended and described in this manual are

The contents of this manual, including drawings and specifications, are

Parts should be replaced with genuine Mazda replacement parts or

Mazda Motor Corporation is not responsible for any problems which

GENERAL INFORMATION 00SECTION

Toc of SCT INFORMATION . . . . 00-00

Electric current A (ampere)

Positive pressure kgf/cm2 (kilogram force per square

Conversion to SI Units (Système International d"Unités)

Upper and Lower Limits

210—260 kPa {2.1—2.7 kgf/cm2, 30—38 psi}

49 H002 671 SHOWS TIGHTENING

INSTALL THE PARTS BY SHOWS APPLICATION

Apply petroleum Appropriate

Upper and lower limits

• Connectors can be disconnected by pressing or

ATX Automatic Transaxle

Special Service Tools

Inspection During Removal, Disassembly

Rubber Parts and Tubing

recalculated due to the extra length that the SST

or equivalent adds to the torque wrench.

Recalculate the torque by using the following

formulas. Choose the formula that applies to you.

Torque Unit Formula

in·lbf in·lbf × [L/(L+A)]

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

#1: Diagnostic trouble codes depend on the diagnostic test mode

49 L010 102 49 L010 106

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

1 Spark plug 10 Engine front cover

Engine Front Cover Disassembly Note

Timing Chain Tensioner Disassembly Note

2. Push back the plunger slowly in the direction

CYLINDER HEAD DISASSEMBLY (I)

Camshaft Cap Disassembly Note

Tappet Disassembly Note

CYLINDER HEAD DISASSEMBLY (II)

1 Valve keeper 4 Valve

Valve Seal Disassembly Note

1 Thermostat cover 9 Oil filter

Drive Plate (ATX), Flywheel (MTX) Disassembly Note

Oil Filter Disassembly Note

Oil Pan Disassembly Note

1 Connecting rod cap 8 Connecting rod

1. Inspect the connecting rod side clearance. (See

Piston Pin Disassembly Note

2. Assemble the SSTs as shown in the figure.

49 E011 001A 49 E011 002A

49 E011 001A 49 L011 006A

4. Set the piston with the SSTs assembled and the

1. Inspect the crankshaft end play. (See 01-10-24 CRANKSHAFT INSPECTION.)

CYLINDER HEAD INSPECTION