advertisement
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
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
MEASURING EQUIPMENT ............................ GI-6
SPECIAL SERVICE TOOLS .............................. GI-6
DISASSEMBLY.................................................. GI-6
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
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
)
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
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
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
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
.)
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
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.
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
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
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
)
9 Lower connecting rod bearing
(See
B–31 Connecting Rod Bearing Assembly
)
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
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
)
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
advertisement
* Your assessment is very important for improving the workof artificial intelligence, which forms the content of this project