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1731-1E-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. Therefore, the contents of this manual may not exactly match the mechanism that you are currently serving.

Mazda Motor Corporation

HIROSHIMA, JAPAN

CONTENTS

General Information

Engine

Technical Data

Special Tools

Title

© 2002 Mazda Motor Corporation

PRINTED IN The Netherlands, MARCH 2002

1731–1E–02C

Section

GI

B

TD

ST

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. 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.

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

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 ................................................................ GI-5

FUNDAMENTAL PROCEDURES ........................ GI-6

PREPARATION OF TOOLS AND

MEASURING EQUIPMENT ............................ GI-6

SPECIAL SERVICE TOOLS .............................. GI-6

DISASSEMBLY.................................................. GI-6

INSPECTION DURING REMOVAL,

DISASSEMBLY............................................... GI-7

ARRANGEMENT OF PARTS ............................ GI-7

CLEANING OF PARTS...................................... GI-7

REASSEMBLY................................................... GI-7

ADJUSTMENT ................................................... GI-8

RUBBER PARTS AND TUBING ........................ GI-8

HOSE CLAMPS ................................................. GI-8

TORQUE FORMULAS....................................... GI-9

VISE ................................................................... GI-9

SST .................................................................... GI-9

ELECTRICAL SYSTEM...................................... GI-10

ELECTRICAL PARTS ...................................... GI-10

CONNECTORS................................................ GI-10

NEW STANDARDS ............................................ GI-13

NEW STANDARDS.......................................... GI-13

ABBREVIATIONS .............................................. GI-15

ABBREVIATIONS ............................................ GI-15

GI

GI–1

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., removal/installation of parts, jacking, vehicle lifting, cleaning of parts and visual inspection) have been omitted.

End Of Sie

SERVICE PROCEDURE

A6E201000001E02

Inspection, adjustment

Inspection and adjustment procedures are divided into steps. Important points regarding the location and contents of the procedures are explained in detail and shown in the illustrations.

XME2010001

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.

GI–2

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.

Symbol Meaning Kind

Apply oil

New appropriate engine oil or gear oil

Apply brake fluid

New appropriate brake fluid

GI–3

1731-1E-02C.book 4 ページ 2002年4月26日 金曜日 午前10時30分

Symbol

HOW TO USE THIS MANUAL

Meaning

Apply automatic transaxle/ transmission fluid

Kind

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.

Use SST or equivalent

Appropriate tools

End Of Sie

ADVISORY MESSAGES

A6E201000001E04

You'll 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

GI–4

1731-1E-02C.book 5 ページ 2002年4月26日 金曜日 午前10時30分

UNITS

UNITS

UNITS

Electrical current A (ampere)

Electric power W (watt)

Electric resistance ohm

Electric voltage V (volt)

Length mm (millimeter) in (inch)

Negative pressure

Positive pressure kPa (kilo pascal) mmHg (millimeters of mercury) inHg (inches of mercury) kPa (kilo pascal) kgf/cm

2

(kilogram force per square centimeter)

Torque

Volume

Weight psi (pounds per square inch)

N·m (Newton meter) kgf·m (kilogram force meter) kgf·cm (kilogram force centimeter) ft·lbf (foot pound force) in·lbf (inch pound force)

L (liter)

US qt (U.S. quart)

Imp qt (Imperial quart) ml (milliliter) cc (cubic centimeter) cu in (cubic inch) fl oz (fluid ounce) g (gram) oz (ounce)

A6E201200002E01

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/cm

2

in the following specifications:

210—260 kPa {2.1—2.7 kgf/cm

270—310 kPa {2.7—3.2 kgf/cm

2

2

, 30—38 psi}

, 39—45 psi}

The actual converted values for 2.7 kgf/cm

2

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

GI

GI–5

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

End Of Sie

SPECIAL SERVICE TOOLS

Use special service tools or equivalent when they are required.

X3U000WAH

A6E201400004E03

End Of Sie

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.

End Of Sie

X3U000WAJ

A6E201400004E07

X3U000WAL

GI–6

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

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.

X3U000WAM

A6E201400004E09

X3U000WAN

A6E201400004E10

End Of Sie

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.

End Of Sie

REASSEMBLY

Standard values, such as torques and certain adjustments, must be strictly observed in the reassembly of all parts.

If removed, these parts should be replaced with new ones:

— Oil seals

— Gaskets

— O-rings

— Lockwashers

— Cotter pins

— Nylon nuts

WGIWXX0030J

A6E201400004E11

WGIWXX0031J

GI–7

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.

End Of Sie

ADJUSTMENT

Use suitable gauges and/or testers when making adjustments.

WGIWXX0032J

A6E201400004E12

End Of Sie

RUBBER PARTS AND TUBING

Prevent gasoline or oil from getting on rubber parts or tubing.

X3U000WAS

A6E201400004E13

End Of Sie

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.

WGIWXX0034E

A6E201400004E14

WGIWXX0035J

End Of Sie

GI–8

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.

Torque Unit

N·m kgf·m kgf·cm ft·lbf in·lbf

Formula

N·m

×

[L/(L+A)] kgf·m

×

[L/(L+A)] kgf·cm

×

[L/(L+A)] ft·lbf × [L/(L+A)] in·lbf

×

[L/(L+A)]

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

L : The length of the torque wrench

End Of Sie

VISE

When using a vise, put protective plates in the jaws of the vise to prevent damage to parts.

A6E201400004E15

GI

WGIWXX0036E

A6E201400004E16

X3U000WAW

End Of Sie

SST

A6E201400004E18

Some Ford SST or equivalent are used as SSTs necessary for engine repair. Note that these SSTs are marked with Ford SST numbers.

Note that a Ford SST number is written together with a corresponding Mazda SST number as shown below.

Example (section ST)

XME2014002

Example (except section ST) End Of Sie

XME2014001

GI–9

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

Battery cable

Before disconnecting connectors or removing electrical parts, disconnect the negative battery cable.

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.

End Of Sie

CONNECTORS

Data link connector

Insert the probe into the terminal when connecting a jumper wire to the data link connector.

Caution

••••

Inserting a jumper wire probe into the data link connector terminal may damage the terminal.

Disconnecting connectors

When disconnecting connector, grasp the connectors, not the wires.

A6E201700006E01

WGIWXX0007E

X3U000WBU

A6E201700006E02

X3U000WAY

WGIWXX0041E

GI–10

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.

Locking connector

When locking connectors, listen for a click indicating they are securely locked.

Inspection

When a tester is used to inspect for continuity or measuring voltage, insert the tester probe from the wiring harness side.

Inspect the terminals of waterproof connectors from the connector side since they cannot be accessed from the wiring harness side.

Caution

••••

To prevent damage to the terminal, wrap a thin wire around the tester probe before inserting into terminal.

WGIWXX0042E

GI

X3U000WB1

X3U000WB2

WGIWXX0045E

GI–11

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.

CODE

B

BR

G

GY

L

LB

LG

COLOR

Black

Brown

Green

Gray

Blue

Light Blue

Light Green

CODE

O

P

R

V

W

Y

COLOR

Orange

Pink

Red

Violet

White

Yellow

End Of Sie

X3U000WB7

GI–12

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

NEW STANDARDS

Following is a comparison of the previous standard and the new standard.

New Standard

Abbreviation

AP

ACL

A/C

BARO

B+

Name

Accelerator Pedal

Air Cleaner

Air Conditioning

Barometric Pressure

Battery Positive Voltage

Brake Switch

— Calibration Resistor

CMP sensor Camshaft Position Sensor

CAC

CLS

Charge Air Cooler

Closed Loop System

CTP

CPP

CIS

Closed Throttle Position

Clutch Pedal Position

Continuous Fuel Injection System

CS sensor Control Sleeve Sensor

CKP sensor Crankshaft Position Sensor

DLC

DTM

DTC

Data Link Connector

Diagnostic Test Mode

Diagnostic Trouble Code(s)

DI

DLI

EI

ECT

Distributor Ignition

Distributorless Ignition

Electronic Ignition

Engine Coolant Temperature

EM

EVAP

EGR

FC

FF

4GR

Engine Modification

Engine Speed Input Signal

Evaporative Emission

Exhaust Gas Recirculation

Fan Control

Flexible Fuel

Fourth Gear

Fuel Pump Relay —

FSO solenoid

GEN

GND

HO2S

IAC

IAT

KS

Fuel Shut Off Solenoid

Generator

Ground

Heated Oxygen Sensor

Idle Air control

IDM Relay

Incorrect Gear Ratio

Injection Pump

Input/Turbine Speed Sensor

Intake Air Temperature

Knock Sensor

MIL

MAP

Malfunction Indicator Lamp

Manifold Absolute Pressure

MAF sensor Mass Air Flow Sensor

MFL Multiport Fuel Injection

OBD

OL

On-Board Diagnostic

Open Loop

FCV

FIP

Previous Standard

Abbreviation

Vb

Name

Accelerator Pedal

Air Cleaner

Air Conditioning

Atmospheric Pressure

Battery Voltage

Stoplight Switch

Corrected Resistance

Crank Angle Sensor

Intercooler

Feedback System

Fully Closed

Idle Switch

Clutch Position

CSP sensor Control Sleeve Position Sensor

— Crank Angle Sensor 2

Diagnosis Connector

Test Mode

Service Code(s)

Spark Ignition

Direct Ignition

Electronic Spark Ignition

Water Thermo

Engine Modification

Engine RPM Signal

Evaporative Emission

Exhaust Gas Recirculation

Fan Control

Flexible Fuel

Overdrive

Circuit Opening Relay

Fuel Cut Valve

Alternator

Ground/Earth

Oxygen Sensor

Idle Speed Control

Spill Valve Relay

Fuel Injection Pump

Pulse Generator

Intake Air Thermo

Knock Sensor

Malfunction Indicator Light

Intake Air Pressure

Airflow Sensor

Multiport Fuel Injection

Diagnosis/SelfDiagnosis

Open Loop

#6

#2

#6

#1

A6E202800020E01

GI

Remark

#3

#6

With heater

#6

#6

GI–13

1731-1E-02C.book 14 ページ 2002年4月26日 金曜日 午前10時30分

NEW STANDARDS

Abbreviation

OC

O2S

PNP

PSP

PCM

PAIR

New Standard

Name

Output Speed Sensor

Oxidation Catalytic Converter

Oxygen Sensor

Park/Neutral Position

PCM Control Relay

Power Steering Pressure

Powertrain Control Module

Pressure Control Solenoid

Pulsed Secondary Air Injection

Pump Speed Sensor

Abbreviation

ECU

Previous Standard

Name

Vehicle Speed Sensor 1

Catalytic Converter

Oxygen Sensor

Park/Neutral Range

Main Relay

Power Steering Pressure

Engine Control Unit

Line Pressure Solenoid Valve

Secondary Air Injection System

NE Sensor

#6

#4

Remark

AIR Secondary Air Injection — Secondary Air Injection System

Pulsed injection

#6

Injection with air pump

SAPV

SFI

Secondary Air Pulse Valve

Sequential Multipoint Fuel Injection

Shift Solenoid A

— Shift Solenoid B

3GR

TWC

TCM

Shift Solenoid C

Third Gear

Three Way Catalytic Converter

TB Throttle Body

TP sensor Throttle Position Sensor

TCV

TCC

Timer Control Valve

Torque Converter Clutch

Transmission (Transaxle) Control

Module

TR

TC

Transmission (Transaxle) Fluid

Temperature Sensor

Transmission (Transaxle) Range

Turbocharger

VSS

VR

Vehicle Speed Sensor

Voltage Regulator

VAF sensor Volume Air Flow Sensor

WUTWC

Warm Up Three Way Catalytic

Converter

WOT Wide Open Throttle

TCV

Reed Valve

Sequential Fuel Injection

1–2 Shift Solenoid Valve

Shift A Solenoid Valve

2–3 Shift Solenoid Valve

Shift B Solenoid Valve

3–4 Shift Solenoid Valve

3rd Gear

Catalytic Converter

Throttle Body

Throttle Sensor

Timing Control Valve

Lockup Position

ECAT Control Unit

ATF Thermosensor

Inhibitor Position

Turbocharger

Vehicle Speed Sensor

IC Regulator

Air flow Sensor

Catalytic Converter

Fully Open

#6

#5

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

#2 : Controlled by the PCM

#3 : In some models, there is a fuel pump relay that controls pump speed. That relay is now called the fuel pump relay (speed).

#4 : Device that controls engine and powertrain

#5 : Directly connected to exhaust manifold

#6 : Part name of diesel engine

End Of Sie

GI–14

1731-1E-02C.book 15 ページ 2002年4月26日 金曜日 午前10時30分

ABBREVIATIONS

MTX

ATX

ATDC

TDC

IN

EX

EGR

OCV

SST

Manual transaxle

Automatic transaxle

After top dead center

Top dead center

Intake

Exhaust

Exhaust gas recirculation

Oil control valve

Special service tool

End Of Sie

ABBREVIATIONS

ABBREVIATIONS

A6E203000011E01

GI

GI–15

1731-1E-02C.book 1 ページ 2002年4月26日 金曜日 午前10時30分

ENGINE

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 ............ B-10

CYLINDER HEAD INSPECTION ....................... B-11

VALVE, VALVE GUIDE INSPECTION............... B-12

VALVE GUIDE REPLACEMENT ....................... B-13

VALVE SEAT INSPECTION/REPAIR................ B-15

VALVE SPRING INSPECTION.......................... B-15

CAMSHAFT INSPECTION ................................ B-16

TAPPET INSPECTION ...................................... B-17

CYLINDER BLOCK INSPECTION..................... B-18

OIL JET VALVE INSPECTION .......................... B-19

PISTON INSPECTION....................................... B-19

CRANKSHAFT INSPECTION............................ B-20

CONNECTING ROD INSPECTION ................... B-22

BOLT INSPECTION........................................... B-22

VARIABLE VALVE TIMING ACTUATOR

INSPECTION .................................................. B-23

OIL CONTROL VALVE (OCV) INSPECTION .... B-23

VALVE CLEARANCE INSPECTION.................. B-24

VALVE CLEARANCE ADJUSTMENT ............... B-25

CYLINDER BLOCK (I) ASSEMBLY ................... B-29

CYLINDER BLOCK (II) ASSEMBLY .................. B-34

CYLINDER HEAD (I) ASSEMBLY ..................... B-37

CYLINDER HEAD (II) ASSEMBLY .................... B-39

TIMING CHAIN ASSEMBLY .............................. B-41

B

B–1

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

1. Install the SSTs (arms) to the cylinder block holes as shown, and hand-tighten the bolts (part No.:

9YA20-1003) or M10

××××

1.5T length 90 mm {3.55

in}.

A6E242402000E02

AME2224E065

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

3. Adjust the SSTs (bolts) so that less than 20 mm

{0.79 in} of thread is exposed.

4. Make the SSTs (arms and plate) parallel by adjusting the SSTs (bolts and nuts).

AME2224E300

5. Tighten the SSTs (bolts and nuts) to affix the

SSTs firmly.

Warning

••••

Self-locking brake system of the engine stand may not be effective when the engine is held in an unbalanced position.

This could lead to sudden, rapid movement of the engine and mounting stand handle and cause serious injury.

Never keep the engine in an unbalanced position, and always hold the rotating handle firmly when turning the engine.

6. Mount the engine on the SST (engine stand).

7. Drain the engine oil into a container.

8. Clean the flange surface (seal rubber) of the oil pan drain plug, then install the oil pan drain plug.

Tightening torque

20—30 N·m {2.1—3.0 kgf·m, 15—22 ft·lbf}

DISMOUNTING

Dismount in the reverse order of mounting.

End Of Sie

AME2224E301

B–2

1731-1E-02C.book 3 ページ 2002年4月26日 金曜日 午前10時30分

TIMING CHAIN DISASSEMBLY

1. Disassemble in the order indicated in the table.

.

ENGINE

A6E242402000E04

B

1 Spark plug

2 Cylinder head cover

3 Crankshaft pulley lock bolt

(See B–4 Crankshaft Pulley Lock Bolt Disassembly

Note )

4 Crankshaft pulley

5 Water pump pulley

6 Drive belt idler pulley

7 Engine front cover

8 Front oil seal

(See B–4 Front Oil Seal Disassembly Note )

AME2224E337

9 Chain tensioner

(See

B–4 Chain Tensioner Disassembly Note

)

10 Tensioner arm

11 Chain guide

12 Timing chain

13 Seal (L3 (with variable valve timing mechanism))

14 Oil pump chain tensioner

15 Oil pump chain guide

16 Oil pump sprocket

(See

B–4 Oil Pump Sprocket Disassembly Note )

17 Oil pump chain

18 Crankshaft sprocket

B–3

1731-1E-02C.book 4 ページ 2002年4月26日 金曜日 午前10時30分

Crankshaft Pulley Lock Bolt Disassembly Note

1. Hold the crankshaft using the SST.

2. Remove the crankshaft pulley lock bolt.

ENGINE

Front Oil Seal Disassembly Note

1. Remove the oil seal using a screwdriver.

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 1.5 mm

{0.06 in} wire or paper clip.

Oil Pump Sprocket Disassembly Note

1. Hold the oil pump sprocket using the SST.

End Of Sie

B–4

AME2224E339

AME2224E340

AME2224E106

AME2224E338

1731-1E-02C.book 5 ページ 2002年4月26日 金曜日 午前10時30分

CYLINDER HEAD (I) DISASSEMBLY

1. Disassemble in the order indicated in the table.

2.

ENGINE

A6E242402000E05

B

.

1 Camshaft sprocket lock bolt,Variable valve timing actuator lock bolt (L3 (with variable valve timing mechanism))

(See B–6 Camshaft Sprocket Lock Bolt, Variable

Valve Timing Actuator Lock Bolt (L3 (with variable valve timing mechanism)) Disassembly Note )

2 Camshaft sprocket,Variable valve timing actuator

(L3 (with variable valve timing mechanism))

3 Oil control valve (OCV) (L3 (with variable valve timing mechanism))

AME2224E001

4 Camshaft cap

(See

B–6 Camshaft Cap Disassembly Note )

5 Camshaft

6 Tappet

(See

B–7 Tappet Disassembly Note

)

7 Cylinder head bolt

(See

B–7 Cylinder Head Bolt Disassembly Note )

8 Cylinder head

9 Cylinder head gasket

10 Cylinder block

B–5

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. Before removing the camshaft caps, inspect the following.

— Camshaft end play and camshaft journal oil clearance (See B–16 CAMSHAFT INSPECTION .)

Note

The camshaft caps are numbered to make sure they are assembled in their original positions. When removed, keep the caps with the cylinder head they were removed from. Do not mix the caps.

2. Loosen the camshaft caps bolts in two or three steps in the order shown.

AME2224E006

B–6

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.

Cylinder Head Bolt Disassembly Note

1. Loosen the cylinder head bolts in two or three steps in the order shown.

B

End Of Sie

CYLINDER HEAD (II) DISASSEMBLY

1. Disassemble in the order indicated in the table.

2.

AME2224E005

A6E242402000E06

.

1 Engine hanger

2 Valve keeper

(See B–8 Valve Keeper Disassembly Note )

3 Upper valve spring seat

4 Valve spring

5 Valve

6 Valve seal

(See

B–8 Valve Seal Disassembly Note )

7 EGR pipe

8 Water outlet case

AME2224E008

B–7

1731-1E-02C.book 8 ページ 2002年4月26日 金曜日 午前10時30分

Valve Keeper Disassembly Note

1. Remove the valve keeper using the SSTs.

ENGINE

Valve Seal Disassembly Note

1. Remove the valve seal using the SST.

End Of Sie

AME2224E302

AME2224E303

B–8

1731-1E-02C.book 9 ページ 2002年4月26日 金曜日 午前10時30分

CYLINDER BLOCK (I) DISASSEMBLY

1. Disassemble in the order indicated in the table.

2.

ENGINE

A6E242402000E07

B

.

1 Oil pan

2 Oil filter cover

3 Oil filter

4 Oil filter adapter

5 Oil cooler

6 Knock sensor

7 Oil separator

8 Thermostat

9 Water pump

10 Oil strainer

AME2224E011

B–9

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 Oil pump

12 Flywheel (MTX ), Drive plate (ATX) (See

B–10 Drive

Plate (ATX), Flywheel (MTX) Disassembly Note

)

13 End plate (MTX)

14 Rear oil seal

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

1. Hold the crankshaft using the SST.

2. Remove the bolts in several passes.

End Of Sie

CYLINDER BLOCK (II) DISASSEMBLY

1. Disassemble in the order indicated in the table.

2.

AME2224E106

A6E242402000E08

B–10

AME2224E012

1731-1E-02C.book 11 ページ 2002年4月26日 金曜日 午前10時30分

ENGINE

.

1 Balancer unit (L3, L3 (with variable valve timing mechanism))

2 Connecting rod cap

(See B–11 Connecting Rod Cap Disassembly Note )

3 Lower connecting rod bearing

4 Upper connecting rod bearing

5 Connecting rod, Piston assembly

6 Piston ring

7 Main bearing cap

(See

B–11 Main Bearing Cap Disassembly Note )

8 Lower main bearing, thrust bearing

9 Crankshaft

10 Upper main bearing, thrust bearing

11 Oil jet valve

12 Cylinder block

13 Adjustment shim

B

Connecting Rod Cap Disassembly Note

1. Inspect the connecting rod side clearance. (See

B–22 CONNECTING ROD INSPECTION .)

2. Remove the connecting rod bolt from the connecting rod cap by tapping the bolt with a plastic hammer.

Note

The tappets are numbered to make sure they are assembled in their original positions. When removed, keep the tappets with the cylinder head they were removed from. Do not mix the tappets.

Main Bearing Cap Disassembly Note

1. Inspect the crankshaft end play. (See

B–20 CRANKSHAFT INSPECTION .)

2. Loosen the main bearing cap bolts in two or three steps in the order shown.

AME2224E341

End Of Sie

B–11

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

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.

Maximum distortion:

0.10 mm {0.004 in}

4. Measure the manifold contact surface distortion as shown.

If the distortion exceeds the maximum, grind the surface or replace the cylinder head.

Maximum distortion:

0.10 mm {0.004 in}

Maximum grinding:

0.15 mm {0.006 in}

End Of Sie

VALVE, VALVE GUIDE INSPECTION

1. Measure the valve head margin thickness of each valve.

If not specified, replace the valve.

Margin thickness:

IN: 1.62 mm {0.0637 in}

EX: 1.82 mm {0.0716 in}

2. Measure the length of each valve. Replace the valve if necessary.

If not specified, replace the valve.

Standard length L:

IN: 102.99—103.79 mm {4.055—4.086 in}

EX: 104.25—105.05 mm {4.105—4.135 in}

Minimum length L:

IN: 102.99 mm {4.055 in}

EX: 103.79 mm {4.086 in}

B–12

A6E242410100E01

AME2224E317

AME2224E318

A6E242412111E01

AME2224E070

AME2224E071

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.

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}

4. Measure the inner diameter of each valve guide 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 guide.

Standard Inner diameter:

IN: 5.509—5.539 mm {0.2169—0.2180 in}

EX: 5.509—5.539 mm {0.2169—0.2180 in}

5. Calculate the valve stem to guide clearance by subtracting the outer diameter of the valve stem from the inner diameter of the corresponding valve guide.

If not as specified, replace the valve and/or the valve guide.

Standard clearance:

IN: 0.024—0.069 mm {0.0009—0.0027 in}

EX: 0.029—0.074 mm {0.0012—0.0029 in}

Maximum clearance:

0.10 mm {0.004 in}

6. Measure the protrusion height (dimension A) of each valve guide without lower valve spring seat.

If not as specified, replace the valve guide.

Standard diameter:

IN: 12.2—12.8 mm {0.481—0.503 in}

EX: 12.2—12.8 mm {0.481—0.503 in}

End Of Sie

AME2224E313

B

AME2224E314

AME2224E315

AME2224E073

B–13

1731-1E-02C.book 14 ページ 2002年4月26日 金曜日 午前10時30分

VALVE GUIDE REPLACEMENT

Valve Guide Removal

1. Remove the valve guide from the combustion chamber side using the SST.

ENGINE

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}

2. Tap the valve guide in from the side opposite the camshaft side until the SSTs contacts the cylinder head.

3. Verify that the valve guide projection height

(dimension A ) is within the specification.

Standard height:

IN: 12.2—12.8 mm {0.481—0.501 in}

EX: 12.2—12.8 mm {0.481—0.501 in}

End Of Sie

B–14

A6E242412111E04

AME2224E312

AME2224E107

AME2224E018

AME2224E073

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

1. Measure the seat contact width.

If necessary, resurface the valve seat using a

45

°

valve seat cutter and/or resurface the valve face.

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.

(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.

(2) If the seating position is too inner side, correct the valve seat using a 30

°°°°

(IN) cutter, and a

0

°°°°

(EX) cutter, and a 45

°°°°

cutter.

3. Inspect the sinking of the valve seat. Measure the protruding length (dimension L) of the valve stem.

If not specified, replace the cylinder head.

Standard dimension L:

IN: 40.64—42.24 mm {1.600—1.662 in}

EX: 40.50—42.10 mm {1.595—1.657 in}

End Of Sie

VALVE SPRING INSPECTION

1. Apply pressing force to the pressure spring and inspect the spring height.

If not as specified, replace the valve spring.

Pressing force:

494.9 N {50.47 kgf, 111.2 lbf}

Standard height:

27.80 mm {1.094 in}

A6E242410102E01

B

AME2224E316

AME2224E020

AME2224E079

A6E242412125E01

AME2224E308

B–15

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})

End Of Sie

CAMSHAFT INSPECTION

1. Set the No.1 and No.5 journals on V-blocks.

2. Measure the camshaft runout.

If not as specified, replace the camshaft.

Maximum runout:

0.03 mm {0.0012 in}

3. Measure the cam lobe height at the two points as shown.

If not as specified, replace the camshaft.

Standard height (mm) {in}

Camshaft

INT

L8 LF, L3

L3 (with variable valve timing mechanism)

40.79 {1.606} 42.12 {1.659} 42.44 {1.671}

EXH 41.08 {1.618} 41.08 {1.618} 41.18 {1.622}

Minimum height (mm) {in}

Camshaft

INT

EXH

L8

40.692

{1.603}

40.982

{1.614}

LF, L3

42.022

{1.655}

40.982

{1.614}

L3 (with variable valve timing mechanism)

42.342

{1.667}

41.082

{1.618}

B–16

AME2224E309

A6E242412420E01

AME2224E082

AME2224E343

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.

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. (See

B–6 Camshaft Cap Disassembly Note .)

9. Measure the oil clearance.

If not as specified, replace the cylinder head.

Standard clearance:

0.04—0.08 mm {0.002—0.003 in}

Maximum clearance:

0.09 mm {0.0035 in}

10. Install the camshaft cap. (See B–40 Camshaft

Assembly Note )

11. Measure the camshaft end play.

If not as specified, replace the cylinder head or camshaft.

Standard end play:

0.09—0.24 mm {0.0035—0.0094 in}

Maximum end play:

0.25 mm {0.0099 in}

12. Remove the camshaft cap. (See

B–6 Camshaft

Cap Disassembly Note

.)

End Of Sie

AME2224E344

B

AME2224E307

AME2224E025

B–17

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

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}

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.

If not as specified, replace the tappet or cylinder head.

Clearance

Standard:

0.02—0.06 mm {0.0008—0.0023 in}

Maximum:

0.15 mm {0.006 in}

End Of Sie

CYLINDER BLOCK INSPECTION

1. Measure the distortion of the cylinder block top surface in the six directions as indicated in the figure.

If the distortion exceeds the maximum, replace the cylinder block.

Maximum cylinder block distortion:

0.10 mm {0.004 in}

2. Measure the cylinder bores in X and Y directions at 42 mm {1.65 in} below the top surface.

If the cylinder bore exceeds the wear limit, replace the cylinder block.

Standard diameter limit

L8:

83.000—83.030 mm {3.2677—3.2689 in}

LF, L3, L3 (with variable valve timing mechanism):

87.500—87.530 mm {3.4449—3.4460 in}

Minimum / maximum bore diameter limit

L8:

82.940—83.090 mm {3.2653—3.2712 in}

LF, L3, L3 (with variable valve timing mechanism):

87.440—87.590 mm {3.4425—3.4484 in}

B–18

A6E242412310E01

AME2224E319

AME2224E320

A6E242410300E01

AME2224E089

AME2224E090

1731-1E-02C.book 19 ページ 2002年4月26日 金曜日 午前10時30分

ENGINE

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.

Air pressure:

216—274 kPa {2.2—2.7kgf•cm

2

31.4—39.7 psi}

A6E242410730E02

B

AME2224E105

End Of Sie

PISTON INSPECTION

A6E242411010E01

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. Measure the outer diameter of each piston at right angle 90

°

to the piston pin, 10.0 mm {0.40 in} above the under of the piston.

If the piston diameter is below the standard diameter, replace the piston, piston pin, piston ring and connecting rod as a single unit.

Piston diameter

L8:

82.965—82.995 mm {3.2664—3.2675 in}

LF, L3, L3 (with variable valve timing mechanism):

87.465—87.495 mm {3.4435—3.4446 in}

AME2224E030

2. Measure the piston-to-cylinder clearance.

If not as specified, replace the piston, piston pin, piston ring and connecting rod as a single unit.

Standard clearance:

0.025—0.045 mm {0.0010—0.0017 in}

Maximum clearance:

0.11 mm {0.0043 in}

3. Measure the piston ring-to-ring groove clearance around the entire circumference.

If the piston ring-to-ring groove clearance exceeds the maximum clearance, replace the piston, piston pin, piston ring and connecting rod as a single unit.

Standard clearance:

Top: 0.03—0.08 mm {0.0012—0.0031 in}

Second: 0.03—0.07 mm {0.0012—0.0027in}

Oil: 0.03—0.07 mm {0.0012—0.0027 in}

Maximum clearance:

Top: 0.17 mm {0.0067 in}

Second, Oil: 0.15 mm {0.0059 in}

AME2224E029

B–19

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—0.0275 in}

Maximum end gap:

1.0 mm {0.0393 in}

End Of Sie

CRANKSHAFT INSPECTION

1. Install the main bearing cap. (See B–30 Main Bearing Caps Assembly Note

.)

2. Measure the crankshaft end play.

If not as specified, replace the thrust bearing or crankshaft so that the specified end play is obtained.

Standard end play:

0.22—0.45 mm {0.0087—0.0177 in}

Maximum end play:

0.55 mm {0.022 in}

3. Remove the main bearing cap. (See

B–11 Main

Bearing Cap Disassembly Note .)

4. Measure the crankshaft runout.

If the crankshaft runout exceeds the maximum runout, replace the crankshaft.

Maximum runout:

0.05 mm {0.0019 in}

L8, LF

AME2224E104

A6E242411301E01

AME2224E034

AME2224E035

L3, L3 (with variable valve timing mechanism)

AME2224E311

B–20

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.

Main journal

Bearing size

Standard

0.25 {0.01} undersize

Standard diameter mm {in}

51.980—52.000 {2.0464—2.0472}

51.730—51.750 {2.0366—2.0373}

Maximum out-of-round:

0.05 mm {0.0019 in}

Crank pin

Bearing size Standard diameter mm {in}

Standard 49.980—50.000 {1.9677—1.9685}

0.25 {0.01} undersize

49.730—49.750 {1.9579—1.9586}

Maximum out-of-round:

0.05 mm {0.0019 in}

6. Install the main bearing caps and crankshaft.

7. Position a plastigage atop the journals in the axial direction.

8. Install the main bearing caps and cylinder block. (See

B–30 Main Bearing Caps Assembly Note

.)

9. Remove the main bearing caps. (See B–11 Main Bearing Cap Disassembly Note .)

10. Measure the main journal oil clearance.

If the clearance exceeds the maximum, replace the main bearing using the main bearing selection table or grind the main journal and install the oversize bearings so that the specified oil clearance is obtained.

Standard clearance:

0.019—0.035 mm {0.0007—0.0013 in}

Maximum clearance:

0.10 mm {0.0039 in} mm {in}

Bearing size

Color Bearing thickness

Standard Green 2.506—2.509 {0.0987—0.0988}

0.25 {0.01} oversize

0.50 {0.02} oversize

2.628—2.634 {0.1034—0.1037}

2.753—2.759 {0.1084—0.1086}

AME2224E036

AME2224E038

B

B–21

1731-1E-02C.book 22 ページ 2002年4月26日 金曜日 午前10時30分

ENGINE

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.

If the connecting rod large end side clearance exceeds the maximum clearance, replace the piston, piston pin, piston ring and connecting rod as a single unit.

Standard clearance:

0.14—0.36 mm {0.0056—0.0141 in}

Maximum clearance:

0.435 mm {0.0172 in}

AME2224E059

3. Remove the connecting rod cap.

4. Position plastigage atop the journals in the axial direction.

5. Install the connecting rod bearing and connecting rod cap. (See B–31 Connecting Rod Cap Assembly Note .)

6. Remove the connecting rod cap.

7. Measure the connecting rod oil clearance.

If not as specified, replace the connecting rod bearing or grind the crank pin and use oversize bearings so that the specified clearance is obtained.

Standard clearance:

0.026—0.052 mm {0.0011—0.0020 in}

Maximum clearance:

0.1 mm {0.0039 in}

Bearing size

Standard

0.50 {0.02} oversize

0.25 {0.01} oversize

Color

Green mm {in}

Bearing thickness

1.496—1.502

{0.0589—0.0591}

1.748—1.754 {0.0688—0.0690}

1.623—1.629 {0.0639—0.0641}

AME2224E310

End Of Sie

BOLT INSPECTION

1. Measure the length of each bolt.

Replace any that exceeds maximum length.

A6E242410135E01

AME2224E050

B–22

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

{5.86—5.90}

150.5 {5.92}

44.7—45.3

{1.75—1.78}

46.0 {1.81}

110.0—110.6

{4.33—4.35}

111.3 {4.38}

End Of Sie

VARIABLE VALVE TIMING ACTUATOR INSPECTION

L3 (with variable valve timing mechanism)

Caution

••••

Variable valve timing actuator can not be disassembled it is a precision unit /

1. Confirm that notch of the rotor and bump of the cover at the variable valve timing actuator are aligned and fitted.

If the notch and the bump are not aligned, rotate the rotor toward the bulb timing retard position by hand until they are in place.

If the rotor and cover are not secured even though their notch and groove are aligned, replace the variable valve timing actuator.

End Of Sie

OIL CONTROL VALVE (OCV) INSPECTION

L3 (with variable valve timing mechanism)

Coil resistance inspection

1. Disconnect the negative battery cable.

2. Disconnect the oil control valve (OCV) connector.

3. Measure the resistance between terminals A and

B using an ohmmeter.

If not as specified, replace the oil control valve

(OCV).

Specification

6.9—7.9 ohms

4. Connect the oil control valve (OCV) connector.

A6E242400142E02

AME2224E342

A6E242414420E02

B

A6E2226W002

B–23

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. Apply battery positive voltage between the oil control valve (OCV) terminals and verify that the spool valve operates and moves to the maximum valve timing advance position.

If not as specified, replace the oil control valve

(OCV).

Note

When applying battery positive voltage between the oil control valve (OCV) terminals, the connection can be either of the following:

— Positive battery cable to terminal A, negative battery cable to terminal B

— Positive battery cable to terminal B, negative battery cable to terminal A

AME2226W004

6. Stop applying battery positive voltage and verify that the spool valve returns to the maximum valve timing retard position.

If not as specified, replace the oil control valve (OCV).

End Of Sie

VALVE CLEARANCE INSPECTION

A6E242412111E02

1. Measure the valve clearance as follows.

(1) Turn the crankshaft clockwise so that the

No.1 piston is at TDC of the compression stroke.

(2) Measure the valve clearance at A in the figure.

If the valve clearance exceeds the space the tappet. (See

B–25 VALVE

CLEARANCE ADJUSTMENT .)

Note

Make sure to note the measured values for choosing the suitable replacement tappets.

AME2212W001

Standard [Engine cold]

IN: 0.22—0.28 mm {0.0087—0.0110 in} (0.25

±±±±

0.03 mm {0.0098

±±±±

0.0011 in})

EX: 0.27—0.33 mm {0.0106—0.0130 in} (0.30

±±±±

0.03 mm {0.0118

±±±±

0.0011 in})

(3) Turn the crankshaft 360

°°°°

clockwise so that the No.4 piston is at TDC of the compression stroke.

(4) Measure the valve clearance at B in the figure.

If the valve clearance exceeds the standard, replace the tappet. (See

B–25 VALVE CLEARANCE

ADJUSTMENT .)

Note

Make sure to note the measured values for choosing the suitable replacement tappets.

Standard [Engine cold]

IN: 0.22—0.28 mm {0.0087—0.0110 in} (0.25

±±±±

0.03 mm {0.0098

±±±±

0.0011 in})

EX: 0.27—0.33 mm {0.0106—0.0130 in} (0.30

±±±±

0.03 mm {0.0118

±±±±

0.0011 in})

B–24

1731-1E-02C.book 25 ページ 2002年4月26日 金曜日 午前10時30分

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.

ENGINE

4. Install the SST as shown.

5. Turn the crankshaft clockwise the crankshaft is in the No.1 cylinder TDC position.

6. Loosen the timing chain.

(1) Using a suitable screwdriver or equivalent tool, unlock the chain tensioner ratchet.

(2) Turn the exhaust camshaft clockwise using a suitable wrench on the cast hexagon and loosened the timing chain.

(3) Placing the suitable bolt (M6 X 1.0 Length

25—35 mm {0.9—1.3 in}) at the engine front cover upper blind plug, secure the chain guide at the position where the tension is released.

A6E242412111E03

B

AMJ2212E004

AME2212W004

AME2212W005

B–25

1731-1E-02C.book 26 ページ 2002年4月26日 金曜日 午前10時30分

7. Hold the exhaust camshaft using a suitable wrench on the cast hexagon as shown.

ENGINE

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. Remove the camshaft.

11. Remove the tappet.

12. Select proper adjustment shim.

AME2212W008

New adjustment shim

= Removed shim thickness + Measured valve clearance - Standard valve clearance (IN: 0.25 mm

{0.0098 in}, EX: 0.30 mm {0.0118 in})

Standard [Engine cold]

IN: 0.22—0.28 mm {0.0087—0.0110 in} (0.25

±±±±

0.03 mm {0.0098

±±±±

0.0011 in})

EX: 0.27—0.33 mm {0.0106—0.0130 in} (0.30

±±±±

0.03 mm {0.0118

±±±±

0.0011 in})

13. Install the camshaft with No.1 cylinder aligned with the TDC position.

14. Tighten the camshaft cap bolt using the following two steps.

(1) Tighten to 5.0—9.0 N·m {51.0—91.7 kgf·cm,

44.3—79.5 in·lbf}.

(2) Tighten to 14.0—17.0 N·m {1.5—1.7 kgf·m,

10.4—12.5 ft·lbf}.

AME2212W009

B–26

1731-1E-02C.book 27 ページ 2002年4月26日 金曜日 午前10時30分

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.

16. Install the SST to the camshaft as shown.

ENGINE

Europe

AME2212W007

B

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.1 cylinder TDC position.

19. Hold the exhaust camshaft using a suitable wrench on the cast hexagon as shown.

20. Tighten the exhaust camshaft sprocket lock bolt

Tightening torque

69—75 N·m {7.10—7.6 kgf·m,

50.9—55.3 ft·lbf}

21. Remove the SST from the camshaft.

22. Remove the SST from the block lower blind plug.

23. Rotate the crankshaft clockwise two turns until the TDC position.

If not aligned, loosen the crankshaft pulley lock bolt and repeat from Step 14.

24. Apply silicone sealant to the engine front cover upper blind plug.

AME2212W006

B–27

1731-1E-02C.book 28 ページ 2002年4月26日 金曜日 午前10時30分

25. Install the engine front cover upper blind plug.

Tightening torque:

10 N·m {1.0 kgf·m, 7.4 ft·lbf}

ENGINE

26. Install the cylinder block lower blind plug.

Tightening torque:

20 N·m {2.0 kgf·m, 14.8 ft·lbf}

27. Install the new engine front cover lower blind plug.

Tightening torque:

12 N·m {1.2 kgf·m, 8.9 ft·lbf}

End Of Sie

AME2212W003

AME2212W012

AME2212W002

B–28

1731-1E-02C.book 29 ページ 2002年4月26日 金曜日 午前10時30分

CYLINDER BLOCK (I) ASSEMBLY

1. Assemble in the order indicated in the table.

2.

ENGINE

A6E242402000E09

B

.

1 Oil jet valve

2 Upper main bearing, thrust bearing

3 Crankshaft

4 Lower main bearing, thrust bearing

5 Main bearing cap

(See B–30 Main Bearing Caps Assembly Note

)

6

Piston ring

(See B–30 Piston Ring Assembly Note )

7 Connecting rod, Piston assembly

(See B–30 Piston Assembly Note )

AME2224E039

8 Upper connecting rod bearing

(See

B–31 Connecting Rod Bearing Assembly

Note

)

9 Lower connecting rod bearing

(See

B–31 Connecting Rod Bearing Assembly

Note

)

10 Connecting rod cap

(See

B–31 Connecting Rod Cap Assembly Note )

11 Engine balancer (L3 (with variable valve timing mechanism))

(See

B–31 Balancer Unit Assembly Note )

12 Adjustment shim

B–29

1731-1E-02C.book 30 ページ 2002年4月26日 金曜日 午前10時30分

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

°°°°

ENGINE

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.

Piston Assembly Note

1. Position the end gap of each ring as indicated in the figure.

2. Insert the piston and connecting rod into the cylinder with the arrow mark to front of the engine.

AME2224E052

AME2224E322

AME2224E323

AME2224E042

B–30

1731-1E-02C.book 31 ページ 2002年4月26日 金曜日 午前10時30分

Connecting Rod Bearing Assembly Note

1. Install the connecting rod bearing to the connecting rod and connecting rod caps, as shown in the figure.

ENGINE

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—23.6 ft·lbf}

(2) 80

°°°°

—100

°°°°

Balancer Unit Assembly Note

1. Confirm by visual inspection that there is no damage to the balancer unit gear and verify that the shaft turns smoothly.

If there is any damage or malfunction, replace the balancer unit.

Caution

••••

Due to the precision interior construction of the balancer unit, it cannot be disassembled.

2. Rotate the crankshaft clockwise and align the No. 1 cylinder to the TDC.

3. Install the adjustment shim to the seat face of the balancer unit.

4. With the balancer unit marks at the exact top center, assemble the unit to the cylinder block.

B

AME2224E061

5. Insert a screwdriver into the crankshaft No. 1 crankweight area and set both the rotation and the thrust direction with the screwdriver, using a prying action, as shown.

AME2224E080

B–31

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.

Caution

••••

When measuring the backlash, rotate the crankshaft one full rotation and verify that it is within the specified range at all of the following six positions: 10

°°°°

, 30

°°°°

,

100

°°°°

, 190

°°°°

, 210

°°°°

, 280

°°°°

ATDC.

Value range:

0.005—0.101 mm {0.00019—0.0039 in}

AME2224E060

(1) Using master adjustment shim (No.50), assemble the balancer unit to the cylinder block, then measure the backlash.

(2) Select the proper adjustment shim according to the measured value.

(3) Install the selected adjustment shim to the balancer unit, then assemble the balancer unit to the cylinder block.

Adjustment shim selection table

Backlash mm {in}

Selection shim

(No.)

Shim thickness mm {in}

Backlash mm {in}

Selection shim

(No.)

Shim thickness mm {in}

0.256—0.262

{0.0100—0.01031}

0.249—0.255

{0.0098—

0.010039}

0.242—0.248

{0.0096—0.00976}

0.235—0.241

{0.0093—0.0948}

0.228—0.234

{0.00897—

0.00921}

0.221—0.227

{0.00870—

0.00893}

0.214—0.220

{0.00842—

0.00874}

15

16

17

18

19

20

21

1.15 {0.0452}

1.16 {0.0456}

1.17 {0.0460}

1.18 {0.0464}

1.19 {0.0468}

1.20 {0.0472}

1.21 {0.0476}

0.116—0.122

{0.00456—

0.00480}

0.109—0.115

{0.00429—

0.00452}

0.102—0.108

{0.00401—

0.00425}

0.095—0.101

{0.00374—

0.00397}

0.088—0.094

{0.00346—

0.00370}

0.081—0.087

{0.00318—

0.00342}

0.074—0.080

{0.00291—

0.00314}

35

36

37

38

39

40

41

1.35 {0.0531}

1.36 {0.0535}

1.37 {0.0539}

1.38 {0.0543}

1.39 {0.0547}

1.40 {0.0551}

1.41 {0.0555}

0.207—0.213

{0.00814—

0.00838}

0.200—0.206

{0.00787—

0.00811}

0.193—0.199

{0.00759—

0.00783}

0.186—0.192

{0.00732—

0.00755}

0.179—0.185

{0.00704—

0.00728}

22

23

24

25

26

1.22 {0.0480}

1.23 {0.0484}

1.24 {0.0488}

1.25 {0.492}

1.26 {0.496}

0.067—0.073

{0.00263—

0.00287}

0.060—0.066

{0.00236—

0.00259}

0.053—0.059

{0.00208—

0.00232}

0.046—0.052

{0.00181—

0.00204}

0.039—0.045

{0.00153—

0.00177}

42

43

44

45

46

1.42 {0.0559}

1.43 {0.0562}

1.44 {0.0566}

1.45 {0.0570}

1.46 {0.0574}

B–32

1731-1E-02C.book 33 ページ 2002年4月26日 金曜日 午前10時30分

Backlash mm {in}

0.172—0.178

{0.00677—

0.00700}

0.165—0.171

{0.00649—

0.00673}

0.158—0.164

{0.00622—0.00645

0.151—0.157

{0.00594—

0.00618}

0.144—0.150

{0.0566—0.0590}

0.137—0.143

{0.00539—

0.00562}

0.130—0.136

{0.00511—

0.00535}

0.123—0.129

{0.00484—

0.00507}

End Of Sie

Selection shim

(No.)

27

28

29

30

31

32

33

34

ENGINE

Shim thickness mm {in}

1.27 {0.499}

1.28 {0.503}

1.29 {0.507}

1.30 {0.511}

1.31 {0.515}

1.32 {0.519}

Backlash mm {in}

0.032—0.038

{0.00125—

0.00149}

0.025—0.031

{0.000984—

0.00122}

0.018—0.024

{0.000708—

0.000944}

0.011—0.017

{0.000433—

0.000669}

0.004—0.010

{0.00015—

0.000393}

0.000—0.004

{0.000—0.000157}

1.33 {0.523}

1.34 {0.527}

0.000—0.000

{0.000—0.000}

0.000—0.000

{0.000—0.000}

Selection shim

(No.)

47

48

49

50 (master)

51

52

53

54

Shim thickness mm {in}

1.47 {0.0578}

1.48 {0.0582}

1.49 {0.0586}

1.50 {0.0590}

1.51 {0.0594}

1.52 {0.0598}

1.53 {0.0602}

1.54 {0.0606}

B

B–33

1731-1E-02C.book 34 ページ 2002年4月26日 金曜日 午前10時30分

CYLINDER BLOCK (II) ASSEMBLY

1. Assemble in the order indicated in the table.

2.

ENGINE

A6E242402000E10

.

B–34

AME2224E043

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 Rear oil seal

(See B–35 Rear Oil Seal Assembly Note )

2 End plate (MPV)

3

Flywheel (MTX), Drive plate (ATX) (See B–36 Drive

Plate (ATX), Flywheel (MTX) Assembly Note )

4 Oil pump

5 Oil strainer

6 Water pump

7 Thermostat

8 Oil separator

9 Knock sensor

10 Oil cooler

11 Oil filter adapter

12 Oil filter

13 Oil filter cover

14 Oil pan

(See

B–36 Oil pan Assembly Note )

15 MTX

Rear Oil Seal Assembly Note

1. Apply silicone sealant to the mating faces as shown.

Dot diameter:

4.0—6.0 mm {0.16—0.23 in}

2. Apply clean engine oil to the new oil seal lip.

3. Install the rear oil seal using the installer as shown.

AME2224E325

B

AME2224E326

4. Tighten the rear oil seal bolts in the order as shown.

Tightening torque:

8.0—11.5 N·m {81.6—117.2 kgf·m, 70.9—

101.7 in·lbf}

AME2224E002

B–35

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.

Oil pan Assembly Note

1. Apply a continuous bead of silicone sealant to the oil pan as indicated in the figure.

AME2224E102

2. Use a square ruler to unite the oil pan and the cylinder block junction side on the engine front cover side.

B–36

AME2224E555

AME2224E054

1731-1E-02C.book 37 ページ 2002年4月26日 金曜日 午前10時30分

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}

ENGINE

End Of Sie

CYLINDER HEAD (I) ASSEMBLY

1. Assemble in the order indicated in the table.

.

AME2224E056

A6E242402000E11

B

1 Water outlet case

2 EGR pipe

3 Valve seal

(See B–38 Valve Seal Assembly Note )

4 Valve

5 Valve spring

6 Upper valve spring seat

7 Valve keeper

(See

B–38 Valve Keeper Assembly Note )

8 Engine hanger

AME2224E044

B–37

1731-1E-02C.book 38 ページ 2002年4月26日 金曜日 午前10時30分

Valve Seal Assembly Note

1. Press the valve seal onto the valve guide by hand.

2. Lightly tap the SST using a plastic hammer.

ENGINE

Valve Keeper Assembly Note

1. Install the valve keeper using the SSTs.

End Of Sie

AME2224E321

AME2224E302

B–38

1731-1E-02C.book 39 ページ 2002年4月26日 金曜日 午前10時30分

CYLINDER HEAD (II) ASSEMBLY

1. Assemble in the order indicated in the table.

2.

ENGINE

A6E242402000E12

B

.

1 Cylinder head gasket

2 Cylinder head

3 Cylinder head bolt

(See B–40 Cylinder Head Bolt Assembly Note )

4 Tappet

5 Camshaft

(See B–40 Camshaft Assembly Note

)

AME2224E046

6 Camshaft cap

7 Camshaft sprocket, Variable valve timing actuator

(L3 (with variable valve timing mechanism))

(See

B–40 Camshaft Sprocket, Variable Valve

Timing Actuator (L3 (with variable valve timing mechanism)) Assembly Note

)

8 Oil control valve (OCV) (L3 (with variable valve timing mechanism))

B–39

1731-1E-02C.book 40 ページ 2002年4月26日 金曜日 午前10時30分

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

°°°°

.

ENGINE

Camshaft Assembly Note

1. Install the camshaft with No.1 cylinder aligned with TDC position.

2. Tighten the camshaft cap bolt using the following two steps.

(1) Tighten to 5.0—9.0 N·m {51.0—91.7 kgf·cm,

44.3—79.5 in·lbf}.

(2) Tighten to 14.0—17.0 N·m {1.5—1.7 kgf·m,

10.4—12.5 ft·lbf}.

AME2224E047

AME2224E048

Camshaft Sprocket, Variable Valve Timing Actuator (L3 (with variable valve timing mechanism)) Assembly

Note

1. Camshaft sprocket or variable valve timing actuator (L3 (with variable valve timing mechanism)) attachment bolt is changed into the state of a temporary bundle by hand until it attaches timing chain.

2. The attachment bolt of camshaft sprocket or variable valve timing actuator (L3 (with variable valve timing mechanism)) is bound tight for timing chain after attachment.

Tightening torque

69—75 N·m {7.10—7.60 kgf·m, 50.9—55.3 ft·lbf}

L8, LF, L3

AME2224E077

L3 (with variable valve timing mechanism)

AME2224E078

B–40

1731-1E-02C.book 41 ページ 2002年4月26日 金曜日 午前10時30分

1. Assemble in the order indicated in the table.

2.

ENGINE

A6E242402000E13

B

.

1 Crankshaft sprocket

2 Oil pump chain

3 Oil pump sprocket

(See B–42 Oil Pump Sprocket Assembly Note )

4 Oil pump chain guide

5 Oil pump chain tensioner

6 Seal (L3 (with variable valve timing mechanism))

7 Timing chain

(See B–42 Timing Chain Aassembly Note )

8 Chain guide

9 Tensioner arm

10 Chain tensioner

11 Camshaft sprocket, Variable Valve Timing Actuator

(L3 (with variable valve timing mechanism))

(See B–43 Camshaft Sprocket, Variable Valve

Timing Actuator (L3 (with variable valve timing mechanism)) Assembly Note )

AME2224E327

12 Front oil seal

(See

B–44 Front Oil Seal Aassembly Note )

13 Engine front cover

(See

B–44 Engine Front Cover Aassembly Note

)

14 Drive belt idler pulley

15 Water pump pulley

16 Crankshaft pulley

17 Crankshaft pulley lock bolt

(See

B–45 Crankshaft Pulley Lock Bolt Aassembly

Note

)

18 Cylinder head cover

(See

B–46 Cylinder Head Cover Aassembly Note )

19 Spark plug

B–41

1731-1E-02C.book 42 ページ 2002年4月26日 金曜日 午前10時30分

Oil Pump Sprocket Assembly Note

1. Hold the oil pump sprocket using the SST.

ENGINE

Timing Chain Aassembly Note

1. Install the SST to the camshaft, then align the No. 1 camshaft position with the TDC.

Europe

AME2224E340

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. Install the timing chain.

AMJ2224E666

B–42

1731-1E-02C.book 43 ページ 2002年4月26日 金曜日 午前10時30分

6. Install the chain tensioner and remove the retaining wire.

ENGINE

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

B

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—55.3 ft·lbf}

B–43

1731-1E-02C.book 44 ページ 2002年4月26日 金曜日 午前10時30分

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.

ENGINE

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.

••••

Silicone sealant is not need in area C as indicated below due to an existing. (L3

(with variable valve timing mechanism))

Thickness

A: 2.0—3.0 mm {0.079—0.118 in}

B: 1.5—2.5 mm {0.059—0.098 in}

AME2224E331

AME2224E332

AME2224E333

B–44

1731-1E-02C.book 45 ページ 2002年4月26日 金曜日 午前10時30分

2. Install the cylinder head cover bolts in the order as shown.

Bolt No.

1—18

Tigtining torque N·m {kgf·m, ft·lbf}

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}

ENGINE

Crankshaft Pulley Lock Bolt Aassembly Note

1. Install the SST to the camshaft as shown.

Europe

Except Europe

2. Install the M6 x 1.0 bolt in by hand.

3. Turn the crankshaft clockwise so that the crankshaft is in the No.1 cylinder TDC position.

AME2224E329

AME2224E328

AME2224E009

B–45

AME2224E334

B

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.

If not aligned, loosen the crankshaft pulley lock bolt and repeat from Step 1.

10. Install the cylinder block lower blind plug.

Tightening torque: 20 N·m {2.0 kgf·m, 14.8 ft·lbf}

Cylinder Head Cover Aassembly Note

1. Apply silicone sealant to the mating faces as shown.

Caution

••••

Install the cylinder head cover within 10 minutes of applying the silicone sealant.

Dot diameter: 4.0—6.0 mm {0.16—0.23 in}

2. Install the cylinder head cover with a new gasket.

3. Tighten the bolts in the order shown.

Tightening torque: 8.0 —12 N·m {81.6—122.3 kgf·cm, 70.9—106.2 in·lbf}

End Of Sie

AME2224E015

AME2224E335

AME2224E336

B–46

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

TECHNICAL DATA ............................................. TD-2

ENGINE TECHNICAL DATA ............................ TD-2

TD

TD–1

1731-1E-02C.book 2 ページ 2002年4月26日 金曜日 午前10時30分

ENGINE TECHNICAL DATA

Item

Cylinder head

Cylinder head gasket contact surfaces distortion

Manifold contact surfaces distortion

Valve clearance [Engine cold]

(mm {in}) Maximum

(mm {in})

Maximum

Maximum grinding

(mm {in})

IN

EX

Valve and valve guide

Valve stem diameter

Valve stem to guide clearance

Valve length

Valve guide inner diameter

Valve guide protrusion height

Valve head margin thickness

(mm {in})

(mm {in})

(mm {in})

Standard

Minimum

Standard

Maximum

Standard

Minimum

(mm {in}) Standard

IN

EX

IN

EX

IN

EX

IN

EX

IN

EX

IN

EX

IN

EX

(mm {in})

IN

EX

(mm {in}) Minimum

IN

EX

Valve seat

Valve seat contact width

Valve seat angle

(mm {in}) Standard

(

°

)

(mm {in}) Standard

IN

EX

IN

EX

IN

EX

Valve seat sinking

(Valve protrusion height)

Valve spring

Out-of-square

Pressing force at valve spring height H

OCV (Oil control valve)

Coil resistance [20

°

C{68

°

F}]

(mm {in}) Maximum

(N {kgf, lbf})

H: 27.8 mm

{1.094 in}

(ohm) Standard

TECHNICAL DATA

TECHNICAL DATA

L8

Engine

LF

A6E931001001E01

L3,

L3 (with variable valve timing mechanism)

0.10 {0.004}

0.10 {0.004}

0.15 {0.006}

0.22—0.28 {0.0087—0.0110}

0.27—0.33 {0.0106—0.0130}

5.470—5.485 {0.2154—0.2159}

5.465—5.480 {0.2152—0.2157}

5.440 {0.2142}

5.435 {0.2140}

0.024—0.069 {0.0009—0.0027}

0.029—0.074 {0.0012—0.0029}

0.10 {0.004}

0.10 {0.004}

102.99—103.79 {4.055—4.086}

104.25—105.05 {4.105—4.135}

102.99 {4.055}

103.79 {4.086}

5.509—5.539 {0.2169—0.2180}

5.509—5.539 {0.2169—0.2180}

12.2—12.8 {0.481—0.503}

12.2—12.8 {0.481—0.503}

1.62 {0.0637}

1.82 {0.0716}

1.2—1.6 {0.048—0.062}

1.2—1.6 {0.048—0.062}

45

45

40.64—42.24 {1.600—1.662}

40.50—42.10{1.595—1.657}

1% (2.10 {0.082})

494.9 {50.47,111.2}

– 6.9—7.9

*

TD–2

1731-1E-02C.book 3 ページ 2002年4月26日 金曜日 午前10時30分

Camshaft

Camshaft runout

Cam lobe height

Journal diameter

Journal oil clearance

End play

Tappet

Tappet bore diameter

Tappet diameter

Tappet-to-Tappet bore oil clearance

Cylinder block

Cylinder head gasket contact surfaces distortion

Cylinder bore diameter

[Measure the cylinder bore at 42 mm

{1.65 in} below the top surface]

Minimum / maximum bore diameter Limit

Piston

Piston diameter

Piston-to-cylinder clearance

Piston ring

Piston ring-to-ring groove clearance

End gap

(measured in cylinder)

Item

(mm {in}) Maximum

(mm {in})

Standard

IN

EX

IN

Minimum

EX

(mm {in})

Standard

(mm {in})

Minimum

Standard

Maximum

Standard

(mm {in})

Maximum

(mm {in}) Standard

(mm {in}) Standard

(mm {in})

Standard

Maximum

TECHNICAL DATA

Engine

L8 LF

L3,

L3 (with variable valve timing mechanism)

0.03 {0.0012}

40.79 {1.606} 42.12{1.659}

42.12 {1.659}

42.44{1.671}

*

41.08 {1.618}

41.08 {1.618} 41.08{1.618}

41.18 {1.622}

*

42.022{1.655}

40.692{1.603} 42.022{1.655}

42.342 {1.667}

*

40.982 {1.614}

40.982 {1.614} 40.982{1.614}

41.082 {1.618}

*

24.96—24.98 {0.9827—0.9834}

24.95 {0.982}

0.04—0.08 {0.002—0.003}

0.09 {0.0035}

0.09—0.24 {0.0035—0.0094}

0.25 {0.009}

31.000—31.030 {1.2205—1.2216}

30.970—30.980 {1.2193—1.2196}

0.02—0.06{0.0008—0.0023}

0.15 {0.006}

TD

(mm {in}) Maximum

(mm {in}) Standard

0.10 {0.004}

83.000—83.030

{3.2677—3.2689}

87.500—87.530 {3.4449—3.4460}

(mm {in})

82.940—83.090

{3.2653—3.2712}

87.440—87.590 {3.4425—3.4484}

(mm {in}) Standard

(mm {in})

Standard

Maximum

(mm {in})

(mm {in})

Standard

Maximum

Standard

Maximum

Top

Second

Oil (rail)

Top

Second

Oil (rail)

Top

Second

Oil (rail)

Top

Second

Oil (rail)

82.965—82.995

{3.2664—3.2675}

87.465—87.495 {3.4435—3.4446}

0.025—0.045 {0.0010—0.0017}

0.11 {0.0043}

0.03—0.08 {0.0012—0.0031}

0.03—0.07 {0.0012—0.0027}

0.03—0.07 {0.0012—0.0027}

0.17 {0.0067}

0.15 {0.0059}

0.15 {0.0059}

0.16—0.31 {0.0063—0.0122}

0.33—0.48 {0.0130—0.0189}

0.20—0.70 {0.0079—0.0275}

1.0 {0.0393}

1.0 {0.0393}

1.0 {0.0393}

TD–3

1731-1E-02C.book 4 ページ 2002年4月26日 金曜日 午前10時30分

Item

TECHNICAL DATA

Connecting rod and connecting rod bearing

Connecting rod side clearance

Connecting rod bearing size

(mm {in})

(mm {in})

Standard

Maximum

Standard

0.25 {0.01} Oversize

Connecting rod bearing oil clearance

(mm {in})

0.50 {0.02} Oversize

Standard

Maximum

Crankshaft

Crankshaft runout

Main journal diameter

Main journal oil clearance

Main journal out of round

Main bearing size

(mm {in}) Maximum

Standard

(mm {in}) 0.25 {0.01} undersize

(mm {in})

Standard

Maximum

(mm {in}) Maximum

Standard

(mm {in}) 0.25 {0.01} Oversize

Crank pin journal diameter

Connecting rod bolt length

Main bearing cap bolt length

(mm {in})

0.50 {0.02} Oversize

Standard

0.25 {0.01} undersize

Crank pin out of round

Crankshaft end play

(mm {in}) Maximum

Standard

(mm {in})

Maximum

Front oil seal

Pushing distance of the front oil seal

[from the edge of the engine front cover]

Bolt

Cylinder head bolt length

Standard

Maximum

Standard

Maximum

Standard

Maximum

(mm {in})

Balance shaft

Gear backlash (mm {in}) Maximum

L8

Engine

LF

L3,

L3 (with variable valve timing mechanism)

0.14—0.36 {0.0056—0.0141}

0.435 {0.0172}

1.496—1.502 {0.0589—0.0591}

1.623—1.629 {0.0639—0.0641}

1.748—1.754 {0.0688—0.0690}

0.026—0.052{0.0011—0.0020}

0.10{0.0039}

0.05 {0.0019}

51.980—52.000 {2.0464—2.0472}

51.730—51.750 {2.0366—2.0373}

0.019—0.035{0.0007—0.0013}

0.10 {0.0039}

0.05 {0.0019}

2.506—2.509 {0.0987—0.0988}

2.628—2.634 {0.1034—0.1037}

2.753—2.759 {0.1084—0.1086}

49.980—50.000 {1.9677—1.9685}

49.730—49.750 {1.9579—1.9586}

0.05 {0.022}

0.22—0.45{0.0087—0.0177}

0.55 {0.0216}

149.0—150.0 {5.86—5.90}

150.5 {5.92}

44.7—45.3 {1.75—1.78}

46.0 {1.81}

110.0—110.6 {4.33—4.35}

111.3 {4.38}

0—0.5 {0—0.019}

0.005-0.101

{0.00019—

0.0039}

*:

With variable valve timing mechanism

End Of Sie

TD–4

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

SPECIAL TOOLS .................................................ST-2

ENGINE SST .....................................................ST-2

ST

ST–1

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

Ford SST numbers are collated with Mazda SST numbers in the example below.

Ford SSTs are marked with Ford SST number.

Example

1:49 JE01 061

2:303-507

Peg

1: Mazda SST number

2: Ford SST number

1:49 JE01 061

2:303–507

Peg

1:49 G032 354

2: –

Adjusting wrench

1:49 B012 0A2

2: –

Pivot

1:49 0107 680A

2: –

Engine stand

1:49 L012 0A0B

2: –

Valve seal and valve guide installer set

1:49 UN20 5072

2:205–072

Holder

1:49 E011 1A0

2: –

Ring gear brake set

1:49 B012 015

2: –

Valve guide installer

1:49 L010 1A0

2: –

Engine hanger set

1:49 T032 302

2: –

Bearing installer

1:49 UN20

507202

2:205–072–02

Adapter

1:49 0636 100B

2: –

Valve spring lifter arm

1:49 H010 401

2: –

Oil seal installer

1:49 S120 170

2: –

Valve seal remover

1:49 D032 316

2: –

Protractor

A6E941001001E01

ST–2

1731-1E-02C.book 3 ページ 2002年4月26日 金曜日 午前10時30分

1:49 JE01 054

(Europe)

49 UN30 3376

(Except Europe)

2: 303–376

Plate

End Of Sie

SPECIAL TOOLS

1:49 G011 201

2: –

Attachment

ST

ST–3

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