RENESIS Rotary Engine Workshop Manual PDF

1773-1U-03C(INDEX).
pdf 10/8/2008 10:00:06 AM
2008 Mazda Motor Corporation

PRINTED IN U.S.A., OCTOBER 2008
Part No. 9999-95-E13B-MSP09
up to October, 2008. Any changes that occur

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MY
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Engine Workshop Manual 13B-MSP (Multi Side Port) (1773–1U–03C)
GENERAL INFORMATION 00 SECTION

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

GENERAL
Toc of SCT
00–00 GENERAL INFORMATION
HOW TO USE THIS MANUAL . . . . . . . . . 00–00–1 Inspection During Removal,
Range of Topics . . . . . . . . . . . . . . . . . . 00–00–1 Disassembly . . . . . . . . . . . . . . . . . . . . 00–00–6
Service Procedure . . . . . . . . . . . . . . . . 00–00–2 Arrangement of Parts . . . . . . . . . . . . . . 00–00–7
Symbols . . . . . . . . . . . . . . . . . . . . . . . . 00–00–4 Cleaning of Parts . . . . . . . . . . . . . . . . . 00–00–7
Advisory Messages. . . . . . . . . . . . . . . . 00–00–4 Reassembly . . . . . . . . . . . . . . . . . . . . . 00–00–7
UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–00–5 Adjustment . . . . . . . . . . . . . . . . . . . . . . 00–00–8
Conversion to SI Units Rubber Parts and Tubing . . . . . . . . . . . 00–00–8
(Système International d'Unités) . . . . . 00–00–5 Hose Clamps . . . . . . . . . . . . . . . . . . . . 00–00–8
Rounding Off . . . . . . . . . . . . . . . . . . . . . 00–00–5 Torque Formulas . . . . . . . . . . . . . . . . . 00–00–8
Upper and Lower Limits . . . . . . . . . . . . 00–00–5 Vise . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–00–9
FUNDAMENTAL PROCEDURES. . . . . . . 00–00–6 ELECTRICAL SYSTEM. . . . . . . . . . . . . . 00–00–9
Preparation of Tools and Measuring Connectors . . . . . . . . . . . . . . . . . . . . . . 00–00–9
Equipment . . . . . . . . . . . . . . . . . . . . . . 00–00–6 SAE STANDARDS. . . . . . . . . . . . . . . . . . 00–00–11
Special Service Tools . . . . . . . . . . . . . . 00–00–6 ABBREVIATIONS . . . . . . . . . . . . . . . . . . 00–00–11
Disassembly . . . . . . . . . . . . . . . . . . . . . 00–00–6 IDENTIFYING SPECIFICATION . . . . . . . 00–00–12
End of Toc
HOW TO USE THIS MANUAL
CHU000000001E01
Range of Topics
• This manual contains procedures for performing all required service operations. The procedures are divided
into the following five basic operations:
— Removal/Installation
— Disassembly/Assembly
— Replacement
— Inspection
— Adjustment
• Simple operations which can be performed easily just by looking at the vehicle (i.e., removal/installation of
parts, jacking, vehicle lifting, cleaning of parts, and visual inspection) have been omitted.
Revised 6/2008 (Ref. No. R108/08) 00–00–1

GENERAL INFORMATION
Service Procedure
Inspection, adjustment
• Inspection and adjustment procedures are
divided into steps. Important points regarding the SHOWS PROCEDURE ORDER
location and contents of the procedures are FOR SERVICE
explained in detail and shown in the illustrations.
Fluid Pressure Inspection
1. Assemble the SSTs as shown in the figure.
Tightening torque
39—49 N·m {4.0—5.0 kgf·m, 29—36 ft·lbf}
49 1232 670A
49 H002 671 SHOWS TIGHTENING

TORQUE
49 H032 322 SPECIFICATIONS
Caution
Connect the gauge set from under
the vehicle to prevent contact with
the drive belt and the cooling fan.
WGIWXX0009E
00–00–2
GENERAL INFORMATION
Repair procedure
1. Most repair operations begin with an overview illustration. It identifies the components, shows how the parts fit
together, and describes visual part inspection. However, only removal/installation procedures that need to be
performed methodically have written instructions.
2. Expendable parts, tightening torques, and symbols for oil, grease, and sealant are shown in the overview
illustration. In addition, symbols indicating parts requiring the use of special service tools or equivalent are also 00–00
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.
YLU000WA0
00–00–3
GENERAL INFORMATION
Symbols
• There are eight symbols indicating oil, grease, fluids, sealant, and the use of SST or equivalent. These symbols
show application points or use of these materials during service.
Symbol Meaning Kind
New appropriate
OIL Apply oil engine oil or gear
oil
New appropriate
BRAKE Apply brake fluid
FLUID brake fluid
New appropriate
Apply automatic
automatic
transaxle/
ATF
transaxle/
transmission fluid
transmission fluid
Appropriate
Apply grease
GREASE
grease
Appropriate
SEALANT Apply sealant
sealant
Apply petroleum Appropriate

P jelly petroleum jelly
O-ring, gasket,
R Replace part
etc.
Use SST or
SST equivalent
Appropriate tools
Advisory Messages
• You will find several Warnings, Cautions, Notes, Specifications and Upper and Lower Limits in this
manual.
Warning
• A Warning indicates a situation in which serious injury or death could result if the warning is ignored.
Caution
• A Caution indicates a situation in which damage to the vehicle or parts could result if the caution is ignored.
Note
• A Note provides added information that will help you to complete a particular procedure.
Specification
• The values indicate the allowable range when performing inspections or adjustments.
Upper and lower limits

• The values indicate the upper and lower limits that must not be exceeded when performing inspections or
adjustments.
End Of Sie
00–00–4
GENERAL INFORMATION
UNITS
CHU000000002E01
Electric current A (ampere)

Electric power W (watt)
Electric resistance ohm
00–00
Electric voltage V (volt)
mm (millimeter)
Length
in (inch)
kPa (kilo pascal)
Negative pressure mmHg (millimeters of mercury)
inHg (inches of mercury)
kPa (kilo pascal)
Positive pressure kgf/cm2 (kilogram force per square

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

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

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

270—310 kPa {2.7—3.2 kgf/cm2, 39—45 psi}
• The actual converted values for 2.7 kgf/cm2 are 264 kPa and 38.4 psi. In the first specification, 2.7 is used as
an upper limit, so the converted values are rounded down to 260 and 38. In the second specification, 2.7 is
used as a lower limit, so the converted values are rounded up to 270 and 39.
End Of Sie
00–00–5
GENERAL INFORMATION
FUNDAMENTAL PROCEDURES
CHU000000004E01
Preparation of Tools and Measuring Equipment
• Be sure that all necessary tools and measuring
equipment are available before starting any work.
CHU0014W003
Special Service Tools

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

• When removed, each part should be carefully
inspected for malfunction, deformation, damage
and other problems.
WGIWXX0028E
00–00–6
GENERAL INFORMATION
Arrangement of Parts
• All disassembled parts should be carefully
arranged for reassembly.
• Be sure to separate or otherwise identify the parts
to be replaced from those that will be reused.
00–00
WGIWXX0029E
Cleaning of Parts
• All parts to be reused should be carefully and
thoroughly cleaned in the appropriate method.
Warning
• Using compressed air can cause dirt and
other particles to fly out causing injury to
the eyes. Wear protective eye wear
whenever using compressed air.
WGIWXX0030E
Reassembly
• Standard values, such as torques and certain
adjustments, must be strictly observed in the
reassembly of all parts.
• If removed, the following parts should be replaced
with new ones:
— Oil seals
— Gaskets
— O-rings
— Lock washers
— Cotter pins
— Nylon nuts
WGIWXX0031E
• Depending on location:
— Sealant and gaskets, or both, should be
applied to specified locations. When sealant
is applied, parts should be installed before
sealant hardens to prevent leakage.
— Oil should be applied to the moving
components of parts.
— Specified oil or grease should be applied at
the prescribed locations (such as oil seals)
before reassembly.
CHU0014W006
00–00–7
GENERAL INFORMATION
Adjustment
• Use suitable gauges and testers when making
adjustments.
CHU0014W005
Rubber Parts and Tubing

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

2
or equivalent adds to the torque wrench.

1 0
Recalculate the torque by using the following

1
formulas. Choose the formula that applies to you.

2
3
Torque Unit Formula

N·m N·m × [L/(L+A)]
kgf·m kgf·m × [L/(L+A)]
A L
kgf·cm kgf·cm × [L/(L+A)]
ft·lbf ft·lbf × [L/(L+A)] WGIWXX0036E
in·lbf in·lbf × [L/(L+A)]
A : The length of the SST past the torque wrench drive.

L : The length of the torque wrench.
00–00–8
GENERAL INFORMATION
Vise
• When using a vise, put protective plates in the
jaws of the vise to prevent damage to parts.
End Of Sie
00–00
PROTECTIVE PLATES
CHU0014W010
ELECTRICAL SYSTEM
CHU000000006E01
Connectors
Disconnecting connectors
• When disconnecting connector, grasp the
connectors, not the wires. GOOD NO GOOD
CHU0000W014
• Connectors can be disconnected by pressing or

pulling the lock lever as shown.
WGIWXX0042E
Locking connector
• When locking connectors, listen for a click
indicating they are securely locked.
WGIWXX0043E
00–00–9
GENERAL INFORMATION
Inspection
• When a tester is used to inspect for continuity or
measuring voltage, insert the tester probe from GOOD NO GOOD
the wiring harness side.
• Inspect the terminals of waterproof connectors
from the connector side since they cannot be
accessed from the wiring harness side.
Caution
• To prevent damage to the terminal, wrap
a thin wire around the tester probe before
inserting into terminal.
CHU0000W011
End Of Sie
GOOD NO GOOD
CHU0000W012
00–00–10
GENERAL INFORMATION
SAE STANDARDS
CHU000000003E02
• In accordance with new regulations, SAE (Society of Automotive Engineers) standard names and abbreviations
are now used in this manual. The table below lists the names and abbreviations that have been used in Mazda
manuals up to now and their SAE equivalents.
SAE Standard SAE Standard 00–00
Remark Remark
Abbreviation Name Abbreviation Name
AP Accelerator Pedal MAP Manifold Absolute Pressure
APP Accelerator Pedal Position MAF Mass Air Flow
ACL Air Cleaner MAF sensor Mass Air Flow Sensor
A/C Air Conditioning MFL Multiport Fuel Injection
A/F Air Fuel Ratio OBD On-board Diagnostic System
BARO Barometric Pressure OL Open Loop
B+ Battery Positive Voltage OC Oxidation Catalytic Converter
CMP sensor Camshaft Position Sensor O2S Oxygen Sensor
LOAD Calculated Load Value PNP Park/Neutral Position
CAC Charge Air Cooler PID Parameter Identification
CLS Closed Loop System PSP Power Steering Pressure
CTP Closed Throttle Position PCM Powertrain Control Module #3
CPP Clutch Pedal Position Pulsed
PAIR Pulsed Secondary Air Injection
CIS Continuous Fuel Injection System injection
CKP sensor Crankshaft Position Sensor Injection
DLC Data Link Connector AIR Secondary Air Injection with air
DTM Diagnostic Test Mode #1 pump
DTC Diagnostic Test Code(s) SAPV Secondary Air Pulse Valve
DI Distributor Ignition Sequential Multiport Fuel
SFI
DLI Distributorless Ignition Injection
EI Electronic Ignition #2 3GR Third Gear
ECT Engine Coolant Temperature TWC Three Way Catalytic Converter
EM Engine Modification TB Throttle Body
EVAP Evaporative Emission TP Throttle Position
EGR Exhaust Gas Recirculation TP sensor Throttle Position Sensor
FC Fan Control TCC Torque Converter Clutch
FF Flexible Fuel Transmission (Transaxle) Control
TCM
4GR Fourth Gear Module
GEN Generator TR Transmission (Transaxle) Range
GND Ground TC Turbocharger
With VSS Vehicle Speed Sensor
HO2S Heated Oxygen Sensor
heater VR Voltage Regulator
IAC Idle Air Control VAF sensor Volume Air Flow Sensor
IAT Intake Air Temperature Warm Up Three Way Catalytic
WU-TWC #4
KS Knock Sensor Converter
MIL Malfunction Indicator Lamp WOP Wide Open Throttle
#1 : Diagnostic trouble codes depend on the diagnostic test mode.

#2 : Controlled by the PCM
#3 : Device that controls engine and powertrain
#4 : Directly connected to exhaust manifold
End Of Sie
ABBREVIATIONS
CHU000000011E01
AT Automatic Transmission
MT Manual Transmission
SST Special Service Tool
End Of Sie
00–00–11
GENERAL INFORMATION
IDENTIFYING SPECIFICATION
CHU000000000E01
• Because the engine construction varies depending on the vehicle’s period of manufacture, determine the
service specification by referring to the following identification.
Identifying Specification
Applicable VIN
Type A Except below
JM1 FE172*9# 400001—
JM1 FE174*9# 400001—
Type B
JM1 FE17M*9# 400001—
JM1 FE17P*9# 400001—
End Of Sie
00–00–12 Added 6/2008 (Ref. No. R108/08)

MECHANICAL
Toc of SCT
MECHANICAL . . . . . . . . . . . . . 01-10 SERVICE TOOLS . . . . . . . . . . . 01-60
TECHNICAL DATA. . . . . . . . . . 01-50
Toc of SCT
01–10 MECHANICAL
01–10
ENGINE OVERHAUL SERVICE PILOT BEARING
WARNING . . . . . . . . . . . . . . . . . . . . . . . 01–10–2 INSPECTION/REPLACEMENT [MT] . . . 01–10–24
ENGINE MOUNTING/DISMOUNTING . . 01–10–2 Inspection . . . . . . . . . . . . . . . . . . . . . . . 01–10–24
Mounting . . . . . . . . . . . . . . . . . . . . . . . 01–10–2 Replacement . . . . . . . . . . . . . . . . . . . . . 01–10–24
Dismounting . . . . . . . . . . . . . . . . . . . . . 01–10–3 ECCENTRIC SHAFT BYPASS
HOUSING DISASSEMBLY I . . . . . . . . . . 01–10–4 VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . 01–10–25
Oil Pan Disassembly Note . . . . . . . . . . 01–10–5 ECCENTRIC SHAFT POSITION PLATE
Oil Pan Upper Block INSPECTION . . . . . . . . . . . . . . . . . . . . . 01–10–25
Disassembly Note . . . . . . . . . . . . . . . 01–10–5 MAIN BEARING OIL CLEARANCE
HOUSING DISASSEMBLY II. . . . . . . . . . 01–10–6 INSPECTION . . . . . . . . . . . . . . . . . . . . . 01–10–25
Pulley Lockbolt Disassembly Note . . . . 01–10–7 MAIN BEARING REPLACEMENT . . . . . . 01–10–26
Front Cover Disassembly Note . . . . . . 01–10–7 Removal . . . . . . . . . . . . . . . . . . . . . . . . 01–10–26
Oil Pump Sprocket Installation . . . . . . . . . . . . . . . . . . . . . . . 01–10–27
Disassembly Note . . . . . . . . . . . . . . . 01–10–7 OIL PUMP INSPECTION . . . . . . . . . . . . . 01–10–29
HOUSING DISASSEMBLY III . . . . . . . . . 01–10–8 Type A . . . . . . . . . . . . . . . . . . . . . . . . . . 01–10–29
Flywheel (MT), Counterweight (AT) Type B . . . . . . . . . . . . . . . . . . . . . . . . . . 01–10–29
Disassembly Note . . . . . . . . . . . . . . . 01–10–9 ROTOR ASSEMBLY . . . . . . . . . . . . . . . . . 01–10–30
Tension Bolt Disassembly Note . . . . . . 01–10–10 Oil Seal Spring Assembly Note . . . . . . . 01–10–30
Rear Housing Disassembly Note . . . . . 01–10–10 O-Ring Assembly Note . . . . . . . . . . . . . 01–10–31
Stationary Gear Disassembly Note . . . 01–10–10 Oil Seal Assembly Note . . . . . . . . . . . . 01–10–32
Tubular Dowel Disassembly Note. . . . . 01–10–10 Cut-Off Seal Spring Assembly Note . . . 01–10–32
Rotor Housing Disassembly Note . . . . 01–10–11 Cut-Off Seal Assembly Note . . . . . . . . . 01–10–33
Rotor Disassembly Note . . . . . . . . . . . 01–10–11 HOUSING ASSEMBLY I . . . . . . . . . . . . . . 01–10–34
Intermediate Housing Thrust Plate Assembly Note . . . . . . . . . 01–10–35
Disassembly Note . . . . . . . . . . . . . . . 01–10–12 Rotor Assembly Note . . . . . . . . . . . . . . 01–10–35
ROTOR DISASSEMBLY . . . . . . . . . . . . . 01–10–12 Oil Jet Plug Assembly Note. . . . . . . . . . 01–10–36
Oil Seal Disassembly Note. . . . . . . . . . 01–10–13 Rotor Housing Assembly Note . . . . . . . 01–10–37
Oil Seal Spring Disassembly Note . . . . 01–10–13 Intermediate Housing
SIDE HOUSING (FRONT, INTERMEDIATE, Assembly Note . . . . . . . . . . . . . . . . . . 01–10–38
REAR) INSPECTION. . . . . . . . . . . . . . . 01–10–13 Rear Oil Seal Assembly Note . . . . . . . . 01–10–39
ROTOR HOUSING INSPECTION . . . . . . 01–10–14 Rear Housing Assembly Note . . . . . . . . 01–10–40
ROTOR INSPECTION . . . . . . . . . . . . . . . 01–10–15 Tension Bolt Assembly Note . . . . . . . . . 01–10–40
APEX SEAL INSPECTION . . . . . . . . . . . 01–10–16 Flywheel (MT), Counterweight (AT)
SIDE SEAL INSPECTION . . . . . . . . . . . . 01–10–17 Assembly Note . . . . . . . . . . . . . . . . . . 01–10–41
CUT-OFF SEAL INSPECTION . . . . . . . . 01–10–18 HOUSING ASSEMBLY II . . . . . . . . . . . . . 01–10–42
OIL SEAL INSPECTION . . . . . . . . . . . . . 01–10–18 Spacer Assembly Note . . . . . . . . . . . . . 01–10–43
SPRING INSPECTION . . . . . . . . . . . . . . 01–10–18 Oil Pump Drive Gear
Oil Seal Spring . . . . . . . . . . . . . . . . . . . 01–10–18 Assembly Note . . . . . . . . . . . . . . . . . . 01–10–43
Cut-off Seal Spring. . . . . . . . . . . . . . . . 01–10–19 Oil Pump Sprocket Wheel
Side Seal Spring . . . . . . . . . . . . . . . . . 01–10–19 Assembly Note . . . . . . . . . . . . . . . . . . 01–10–43
Corner Seal Spring . . . . . . . . . . . . . . . 01–10–19 Front Oil Seal Assembly Note . . . . . . . . 01–10–43
Apex Seal Spring . . . . . . . . . . . . . . . . . 01–10–19 Front Cover Assembly Note . . . . . . . . . 01–10–44
ROTOR BEARING OIL CLEARANCE Pulley Lockbolt Assembly Note . . . . . . . 01–10–44
INSPECTION . . . . . . . . . . . . . . . . . . . . . 01–10–20 HOUSING ASSEMBLY III . . . . . . . . . . . . . 01–10–45
ROTOR BEARING REPLACEMENT. . . . 01–10–21 Oil Pan Upper Block
Removal . . . . . . . . . . . . . . . . . . . . . . . . 01–10–21 Assembly Note . . . . . . . . . . . . . . . . . . 01–10–47
Installation . . . . . . . . . . . . . . . . . . . . . . 01–10–21 Oil Pan Assembly Note . . . . . . . . . . . . . 01–10–47
ECCENTRIC SHAFT INSPECTION . . . . 01–10–22
ECCENTRIC SHAFT END PLAY
INSPECTION . . . . . . . . . . . . . . . . . . . . . 01–10–22
End of Toc
Revised 6/2008 (Ref. No. R108/08) 01–10–1

MECHANICAL
ENGINE OVERHAUL SERVICE WARNING
CHU011002000E01
Warning
• Continuous exposure to USED engine oil has caused skin cancer in laboratory mice. Protect your
skin by washing with soap and water immediately after this work.
End Of Sie
ENGINE MOUNTING/DISMOUNTING
CHU011002000E12
Caution
• The oil pan could be damaged or dented if the engine's own weight is subjected to an impact
against a level surface. Always set two pieces of wood in the positions shown in the figure to
prevent the oil pan from being dented. If the oil pan is dented, the amount of intake oil and the fluid
pressure will decrease. (Type B)
OIL PAN
PIECE OF WOOD
ENGINE FRONT SIDE
ENGINE FRONT SIDE
GHE0110E001
Mounting
Using 49 L010 1A0
1. Remove the stud bolt.
STUD BOLT
T T
L L
CHU0110E048
2. Install the SSTs (arms) to the specified three 99784 0890 OR M8x1.25
position as shown in the figure, and temporarily LENGTH 90 mm {3.55 in} BOLT
tighten with the SSTs (bolts) and 99784 0890 or
M8×1.25 length 90 mm {3.55 in} bolt. 49 L010 102
T T
L L
49 L010 107
CHU0110E049
01–10–2 Revised 6/2008 (Ref. No. R108/08)

MECHANICAL
3. Install the SSTs (bolt, nut) to the three specified
positions as shown in the figure.
4. Install the SSTs (bolts, nuts, hook, plate) in Step 3 49 L010 101
to the SST (arms, bolts) set in Step 2. 49 L010 104
5. Adjust the bolt threads by turning them so that
they project approx. 20 mm {0.79 in} from the
plate end.
6. Adjust the bolts and nuts so that the plate and 49 L010 105 01–10
arms are parallel.
BHJ0110E003
7. Mount the engine to the SST (engine stand).

8. Remove the oil pan drain plug and drain the 49 L010 107 PARALLEL
engine oil. 99784 0890 OR M8x1.25 49 L010 101
LENGTH 90 mm {0.55 in}
9. Replace with a new washer and install the oil pan BOLT
drain plug.
49 L010 102 49 L010 105
Tightening torque ENGINE
Type A : 29.4—39.2 N·m {3.00—3.99 kgf·m,
21.7—28.9 ft·lbf}
Type B : 29.4—41.2 N·m {3.00—4.20 kgf·m, 49 L010 104
49 L010 103 49 L010 104 APPROX. 20 mm {0.79in}
21.7—30.3 ft·lbf}
CHU0110E050
Using 49 J010 3A0A

1. Install the SSTs to the position shown in the WHEN USING 49 J010 3A0A
figure.
49 J010 301A
A M8×1.25 length 25 mm {1.28 in} bolt
99940 1201 (left side engine mount installation nut) 49 J010 302A
B T T
or M12×1.5 nut
99756 1230 (left side engine mount installation nut) L L
C
+ washer
2. Mount the engine to the SST (engine stand).

3. Remove the oil pan drain plug and drain the
engine oil.
4. Install the oil pan drain plug with a new washer. ONLY WHEN USING 49 J010 301A
49 J010 301A
Tightening torque A
Type A : 29.4—39.2 N·m {3.00—3.99 kgf·m,
21.7—28.9 ft·lbf}
T T
Type B : 29.4—41.2 N·m {3.00—4.20 kgf·m,
21.7—30.3 ft·lbf} B L L
CHU0110E058
Dismounting
1. Dismount in the reverse order of mounting.
2. Tighten the stud bolt. (Only when using 49 L010 101.)
Tightening torque
14.7—34.3 N·m {1.50—3.49 kgf·m, 10.9—25.2 ft·lbf}
End Of Sie
Revised 6/2008 (Ref. No. R108/08) 01–10–3

MECHANICAL
HOUSING DISASSEMBLY I
CHU011002000E04
1. Disassemble in the order indicated in the table.
Type A
6 2
1
R
3 R
4
R
11
10
8 R
BHJ0110E006
1 Oil filter component 7 Oil pan

2 Engine hanger (engine rear side) (See 01–10–5 Oil Pan Disassembly Note.)
3 Engine coolant temperature sensor 8 Clip
4 Engine hanger (engine front side) 9 Oil baffle plate
5 Water pump body 10 Oil-level sensor
6 Thermostat component 11 Oil strainer
01–10–4 Revised 6/2008 (Ref. No. R108/08)

MECHANICAL
01–10-4 MECHANICAL
CHU011002000E04
Type B
5 1
R
2
R
01–10
3 4
R
12
10
11
9 R
BHJ0110F002
1 Engine hanger (engine rear side) 7 Oil pan upper block

2 Engine coolant temperature sensor (See 01–10–5 Oil Pan Upper Block Disassembly
Note.)
3 Engine hanger (engine front side)
8 Baffle plate
4 Water pump body
9 Clip
5 Thermostat component
10 Oil level switch
6 Oil pan
(See 01–10–5 Oil Pan Disassembly Note.) 11 Baffle plate
12 Oil strainer
End Of Sie
Revised 6/2008 (Ref. No. R108/08) 01–10-4–1

MECHANICAL
THIS PAGE INTENTIONALLY

LEFT BLANK
01–10-4–2
MECHANICAL
Oil Pan Disassembly Note
1. Remove the oil pan using the separator tool.
01–10
BHJ0111W014
Oil Pan Upper Block Disassembly Note

1. Remove the oil pan upper block using the
separator tool.
End Of Sie
BHJ0111E014
Revised 6/2008 (Ref. No. R108/08) 01–10–5

MECHANICAL
HOUSING DISASSEMBLY II
CHU011002000E05
Type A
R 4
3
15
1 SST 17 18
16
12
13
10
14
11 SST
R 20 R
23
6 R
R 25
19
5
9 21
24 22
8
BHJ0110E008
1 Pulley lockbolt 13 Oil pump drive gear

(See 01–10–7 Pulley Lockbolt Disassembly Note.) 14 Oil pump component
2 Pulley component 15 Balance weight
3 Eccentric shaft bypass valve 16 Thrust plate
4 Spring 17 Needle bearing
5 Front cover 18 Spacer
(See 01–10–7 Front Cover Disassembly Note.)
19 Rear outer rotor
6 Front oil seal
20 Rear inner rotor
7 Plug
21 Middle plate
8 Control valve spring
22 Front outer rotor
9 Control valve
23 Front inner rotor
10 Metering oil pump drive gear
24 Shaft
11 Oil pump sprocket wheel
(See 01–10–7 Oil Pump Sprocket Disassembly 25 Oil pump body
Note.)
12 Oil pump chain
01–10–6 Revised 6/2008 (Ref. No. R108/08)

MECHANICAL
CHU011002000E04
Type B
2
1 SST 3 4
R 8 01–10
R
9
15 18 19 20 21
10 R
R R
5
11 16
17
R
14 SST
13
6 R
12
BHJ0110F003
1 Pulley lockbolt 12 Oil filter joint

(See 01–10–7 Pulley Lockbolt Disassembly Note.) 13 Plug
2 Pulley component 14 Oil pump sprocket wheel
3 Eccentric shaft bypass valve (See 01–10–7 Oil Pump Sprocket Disassembly
4 Spring Note.)
5 Front cover 15 Oil pump chain
(See 01–10–7 Front Cover Disassembly Note.) 16 Oil pump drive gear
6 Front oil seal 17 Oil pump component
7 OCV 18 Balance weight
8 Oil pipe 19 Thrust plate
9 OCV case 20 Needle bearing
10 Plug 21 Spacer
11 OCV oil filter
End Of Sie
Revised 6/2008 (Ref. No. R108/08) 01–10-6–1

MECHANICAL

LEFT BLANK
01–10-6–2
MECHANICAL
Pulley Lockbolt Disassembly Note
1. Lock the flywheel (MT) or counterweight (AT) MT AT
against rotation using the SST.
01–10
49 F011 101 49 1881 055A
BHJ0110E007
Front Cover Disassembly Note

1. Loosen the engine front cover installation bolts in
the order shown in the figure. 1
5
7
4
3 2
BHJ0110E009
Oil Pump Sprocket Disassembly Note

2. Unlock the crimped part of the lock washer and
remove the locknut and lock washer.
49 F011 101 49 1881 055A
BHJ0110E007
3. Remove the oil pump drive gear and oil pump

sprocket wheel with the oil pump chain engaged.
End Of Sie
BHJ0110E104
01–10–7
MECHANICAL
HOUSING DISASSEMBLY III
CHU011002000E06
22
21 SST
19
18
12
10 SST
20
11
R R
9
R
16
15
14
13 R
17
8
I
H
F
E G
7 SST C D
A B
1
R R
2
R 4 R
R SST
AT 1
R 5 SST SST
3
6
BHJ0110E010
1 Flywheel (MT), counterweight (AT) Tension bolt

2
(See 01–10–9 Flywheel (MT), Counterweight (AT) (See 01–10–10 Tension Bolt Disassembly Note.)
Disassembly Note.)
01–10–8
MECHANICAL
3 Rear housing 10 Tubular dowel (front rotor housing side)
(See 01–10–10 Rear Housing Disassembly Note.) (See 01–10–10 Tubular Dowel Disassembly Note.)
4 Rear oil seal 11 Intermediate housing
5 Rear stationary gear (See 01–10–12 Intermediate Housing Disassembly
(See 01–10–10 Stationary Gear Disassembly Note.) Note.)
6 Pressure regulator (Type A) 12 Front rotor housing
(See 01–10–11 Rotor Housing Disassembly Note.)
7 Tubular dowel (rear rotor housing side)
(See 01–10–10 Tubular Dowel Disassembly Note.) 13 Eccentric shaft 01–10
8 Rear rotor housing 14 Oil jet plug
(See 01–10–11 Rotor Housing Disassembly Note.) 15 Spring
9 Rear rotor 16 Steel ball
A: Side seal 17 Front rotor
B: Side seal spring (See 01–10–11 Rotor Disassembly Note.)
C: Corner seal
D: Corner seal plug 18 Plate
E: Corner Seal Spring 19 Needle bearing
F: Side piece 20 Thrust plate
G: Apex seal 21 Front stationary gear
H: Apex seal spring (short) (See 01–10–10 Stationary Gear Disassembly Note.)
I: Apex seal spring (long)
(See 01–10–11 Rotor Disassembly Note.) 22 Front housing
Flywheel (MT), Counterweight (AT) Disassembly Note

49 F011 101 49 1881 055A
BHJ0110E007
2. Remove the locknut using the SST.

MT 49 0820 035 AT
BHJ0110E011
3. Remove the flywheel (MT) or counterweight (AT),

MT 49 0839 305A AT
using the SST.
BHJ0110E012
Revised 6/2008 (Ref. No. R108/08) 01–10–9

MECHANICAL
Tension Bolt Disassembly Note
1. Loosen the tension bolts in 2⎯3 passes in the
3 6
order shown in the figure and remove them. 7 10
11
15
14
18
17
16
12
13
2 8 1
4 5 9
BHJ0110E013
Rear Housing Disassembly Note

1. Move the rear housing to the left and right to cut the oil film.
2. Remove the rear housing.
Caution SEAL
• If a seal adheres to the rear housing, put
it back in its original position in the rotor.
CHU0110E039
Stationary Gear Disassembly Note

1. Remove the stationary gear using the SST.
49 0813 235
BHJ0110E016
Tubular Dowel Disassembly Note

1. Remove the tubular dowel using the SST.
49 0813 215A
BHJ0110E017
01–10–10
MECHANICAL
Rotor Housing Disassembly Note
1. Remove the rotor housing being careful not to
drop the apex seal.
01–10
BHJ0110E020
Rotor Disassembly Note
Note
• Pair each seal and spring according to the INTERNAL GEAR SIDE OPPOSITE INTERNAL GEAR SIDE
numbers shown in the figure, and place
them in the SST according to the numbers 1 2
ROTATION LOCK TAB TAB
shown on the SST.
5
6
3 4
CHU0110E056
1. Remove the side piece, apex seal, corner seal,

side seal, and spring on the engine rear side, and 49 0813 250
place them in the SST while keeping them in
order.
BHJ0110E019
2. Move the rotor to the left and right to cut the oil
film.
3. Remove the rotor.
Caution
• If a seal adheres to the side housing, put
it back in its original position in the rotor.
• Place the removed rotor upright on soft
material such as a rubber sheet or cloth.
Do not allow the oil seal to directly
contact metal are similar hard surface.
BHJ0110E021
01–10–11
MECHANICAL
4. Remove the corner seal, side seal, and spring on
the engine front side, and place them in the SST
while keeping them in order.
49 0813 250
BHJ0110E022
Intermediate Housing Disassembly Note

1. Lift the intermediate housing up while another
person pushes the eccentric shaft upward
approx. 3 cm {1.18 in}.
2. Rotate and remove the intermediate housing at
the point where the eccentric shaft does not
catch.
Caution
• If a seal adheres to the intermediate
housing, put it back in its original
position in the rotor.
BHJ0110E023
End Of Sie
ROTOR DISASSEMBLY
CHU011002000E07
6 SST
4 R
7 R
3 SST
BHJ0110E024
1 Cut-off seal 3 Outer oil seal

2 Cut-off seal spring (See 01–10–13 Oil Seal Disassembly Note.)
4 Outer O-ring (large radius)
01–10–12
MECHANICAL
5 Outer oil seal spring 7 Inner O-ring (small radius)
(See 01–10–13 Oil Seal Spring Disassembly Note.) 8 Inner oil seal spring
6 Inner oil seal (See 01–10–13 Oil Seal Spring Disassembly Note.)
(See 01–10–13 Oil Seal Disassembly Note.)
Oil Seal Disassembly Note

1. Remove the oil seal using the SST. 01–10
Caution 49 0813 225A

• Be sure to keep the removed oil seals
separated according to their removal
position.
BHJ0110E025
Oil Seal Spring Disassembly Note
Caution
• Be sure to keep the removed oil seal springs separated according to their removal positions.
End Of Sie
SIDE HOUSING (FRONT, INTERMEDIATE, REAR) INSPECTION
CHU011010D00E01
1. Inspect the intermediate housing for clogging in the intake and exhaust port.
Caution
• Carefully inspect the anti-wet port of the INTERMEDIATE HOUSING
intermediate housing since it is an
essential port.
ANTI-WET PORT
• If there is any malfunction, replace the

corresponding side housing.
CHU0110E001
2. Inspect the side housing for distortion in four

positions as shown in the figure using a straight 1 2
edge and a feeler gauge.
• If the distortion exceeds the maximum,
replace the corresponding side housing. 3
Maximum distortion
0.04 mm {0.0016 in}
4
3. Inspect the following three items related to wear
in the areas where the rotor contacts the side
housing using a dial gauge.
• If any one of the items exceeds the maximum,
BHJ0110E026
replace the corresponding side housing.
01–10–13
MECHANICAL
(1) Vertical wear
WEAR AREA
Maximum wear
0.10 mm {0.0039 in}
CHU0110E002
(2) Convex oval OIL SEAL PATH

B A
Maximum wear
Oil seal inner path (A): 0.01 mm {0.0004 in}
Oil seal outer path (B): 0.10 mm {0.0039 in}
CHU0110E003
(3) Oil seal stepped path wear WEAR AREA
Maximum wear
0.02 mm {0.0008 in}
End Of Sie
CHU0110E004
ROTOR HOUSING INSPECTION

CHU011010B08E01
1. Measure the width of the rotor housing at four
points (A, B, C, and D) as shown in the figure
using a micrometer.
2. Compute the width variation.
• If it exceeds the maximum, replace the rotor
housing.
Width difference = (width A) – (the smallest

of widths B, C, or D)
Maximum width difference

0.06 mm {0.0024 in}
TENSION BOLT HOLE
SEAL RUBBER GROOVE
End Of Sie
A
20 mm {0.79 in}
B
C
D
MEASUREMENT POINT SHEET METAL
CHU0110E005
01–10–14
MECHANICAL
ROTOR INSPECTION
CHU011011B10E01
1. Inspect the rotor and side housing clearance according to the following procedure:
• If it is less than the minimum specification, replace the rotor.
(1) Measure the width of the rotor housing in the
position shown in the figure using a SHEET METAL
micrometer.
Caution 01–10
• Move the sheet metal piece out of the
way when measuring.
MEASUREMENT POINT
CHU0110E040
(2) Measure the rotor width at various positions

around the rotor round periphery using a
micrometer.
BHJ0110E032
(3) Compute the rotor and side housing

clearance using the measurements from (1)
and (2).
Rotor and side housing clearance = (rotor

housing width) – (maximum rotor width)
Standard clearance
0.05—0.19 mm {0.0020—0.0074 in}
Minimum clearance
0.05 mm {0.002 in}
2. Measure the protrusion of the rotor round using a

CHU0110E006
straight edge and a feeler gauge.
Caution
• Measure the the protrusion of the rotor round in the three apexes of the rotor on both the front and
rear sides.
• Because the rotor round has two levels, be careful not to measure the level difference of the
middle level.
• If it is less than the minimum specification,

replace the rotor.
Standard projection
0.12—0.18 mm {0.0048—0.0070 in}
Minimum projection
0.1 mm {0.0039 in}
CHU0110E007
01–10–15
MECHANICAL
3. Inspect the corner seal groove of the rotor by
inserting the SST. 49 0839 165
• If 1/2 or more of either end of the SST can be
inserted into the seal groove, replace the
corner seal.
• If 1/2 or more of both ends of the SST can be
inserted into the corner seal groove, replace
the rotor.
Caution
• Do not push the SST in with force.
• Keep the SST perpendicular to the seal
BHJ0110E035
groove.
• When replacing the corner seal, replace
with one that matches the S or L inscription on the rotor.
4. Measure the clearance between the apex seal

groove and the apex seal using a feeler gauge.
• If it exceeds the maximum specification,
replace the apex seal.
• If the clearance is still not within the standard
after replacing the apex seal, replace the
rotor.
Standard clearance
0.042—0.101 mm {0.0017—0.0039 in}
Maximum clearance
0.15 mm {0.0059 in}
CHU0110E008
End Of Sie
APEX SEAL INSPECTION
CHU011011B10E02
1. Measure the height in the positions shown in the
figure.
replace the apex seal.
• Replace the apex seal spring also whenever
replacing the apex seal.
Standard Height
5.3 mm {0.20 in}
Minimum height
4.3 mm {0.17 in}
BHJ0110E037
End Of Sie
01–10–16
MECHANICAL
SIDE SEAL INSPECTION
CHU011011B10E04
Replacing with a new side seal.
If replacing the side seal, select the appropriate side seal from the side seal groove length rank marked on the
1.
rotor.
Note
• If a new side seal is inserted, measuring the clearance is not recommended to maintain an appropriate
side seal clearance value.
01–10
Side seal selection table
Side seal groove length
Part number of side seal
rank stamp INTERNAL GEAR SIDE OPPOSITE INTERNAL GEAR SIDE
F
TWO-DIMENSION
G BAR CODE
N3Z1 11 C10*
H
s* sB *
I B F F
J
K
N3Z2 11 C10*
L
F
M
N * *
s
s
s
* *
F
O
F
N3Z3 11 C10*
P
Q
SIDE SEAL GROOVE LENGTH RANK STAMP
R (A RANK MARK IS STAMPED FOR EACH SIDE SEAL GROOVE)
S
N3Z4 11 C10*
T
*: IDENTIFICATION NUMBER (1 OR 2) USED ONLY FOR
U LINE ASSEMBLY
V
W CHU110ZEC001
N3Z5 11 C10*
X
Y
* : Revision indication (alphabetical order)

Reusing the side seal
1. Measure the side seal and corner seal clearance and verify that it doesn’t exceed the maximum.
(1) Assemble the corner seal.
(2) Insert a 0.15 mm {0.0059 in} feeler gauge into the tapered surface side of the side seal as shown in the
figure, and fix the side seal by pressing uniformly so that it contacts the inner side of the groove (straight
surface).
Caution
• Press the feeler gauge firmly on both ends of the side seal.
(3) Measure the clearance between both ends of the side seal and the corner seal using a feeler gauge.
FEELER GAUGE
(INSERT INTO BOTH ENDS)
SEC. A-A
FEELER GAUGE
A
0.15 mm {0.0059 in}
A
SIDE SEAL
SIDE SEAL
ROTOR
CORNER SEAL
CHU110ZEC002
Revised 9/2008 (Ref. No. R174/08) 01–10–17

MECHANICAL
(4) If the sum of the clearances on both ends exceeds the maximum, replace with a new side seal by selecting
one from the side seal selection table.
Maximum clearance
0.4 mm {0.016 in}
END OF SIE
CUT-OFF SEAL INSPECTION

CHU011011B10E05
1. Measure the cut-off seal height using a vernier
caliper.
replace the cut-off seal.
Caution
• Measure the cut-off seal height around
the complete perimeter.
Standard height
3.95 mm {0.1555 in}
Minimum height BHJ0110E042
3.8 mm {0.15 in}
End Of Sie
OIL SEAL INSPECTION
CHU011011B10E06
1. Measure the following two items using a vernier caliper.
• If either of the items exceeds the maximum specification, replace the oil seal.
(1) Width of area that contacts the oil seal lip.
Caution
• Measure the contact width around the
complete perimeter.
Maximum contact width A A

0.5 mm {0.02 in}
SEC. A-A
BHJ0110E043
(2) Circumferential width of any damage along
the lip.
LIP
Maximum circumferential width of the oil seal

lip NICK
2.5 mm {0.098 in} or 10 nicks or more
2.5 mm {0.098 in}
End Of Sie
CHU0110E012
SPRING INSPECTION
CHU011011B10E07
Oil Seal Spring
1. Assemble the oil seal springs into the rotor.
2. Assemble the O-rings into the oil seals.
3. Assemble the oil seals into the rotor.
4. Measure the oil seal projection using a vernier
caliper.
replace the oil seal spring.
Minimum projection
0.5 mm {0.02 in}
OIL SEAL
OIL SEAL SPRING
CHU0110E013
01–10–18
MECHANICAL
Cut-off Seal Spring
1. Assemble the cut-off seal spring into the rotor.
2. Referring to the cut-off seal inspection procedure, verify that the height of the cut-off seal is at the minimum
specification or more. (See 01–10–18 CUT-OFF SEAL INSPECTION.)
3. Assemble the cut-off seal into the rotor.
4. Measure the cut-off seal projection using a
vernier caliper.
• If it is less than the minimum specification, CUT-OFF SEAL 01–10
replace the cut-off seal spring. CUT-OFF SEAL SPRING
Minimum projection
0.5 mm {0.02 in}
CHU0110E041
Side Seal Spring

1. Assemble the side seal spring into the rotor.
2. Assemble the side seal into the rotor.
3. Measure the side seal projection using a vernier
caliper.
SIDE SEAL
replace the side seal spring. SIDE SEAL SPRING
Minimum projection
0.5 mm {0.02 in}
CHU0110E015
Corner Seal Spring

1. Assemble the corner seal spring into the rotor.
2. Assemble the corner seal into the rotor.
3. Measure the corner seal projection using a
vernier caliper. CORNER SEAL
replace the corner seal spring. CORNER SEAL SPRING
Minimum projection
0.5 mm {0.02 in}
CHU0110E016
Apex Seal Spring
Note
• Inspect the long apex seal spring.
Revised 6/2008 (Ref. No. R108/08) 01–10–19

MECHANICAL
1. Measure the height of the apex seal spring using
a vernier caliper with the spring placed on a
surface plate.
replace the apex seal spring.
APEX SEAL SPRING (LONG)
Standard height
5.4 mm {0.213 in}
Minimum height
3.5 mm {0.148 in}
CHU0110E064
End Of Sie
ROTOR BEARING OIL CLEARANCE INSPECTION
CHU011011B10E08
1. Measure the outer diameter of the rotor journal ROTOR JOURNAL (SIDE VIEW)
using a micrometer.
Caution MEASUREMENT
• Measure the rotor journal at a point LOCATION
slightly off-center since the center
section is raised. Do not measure at the
center because it does not contact the
NOT MEASURED
rotor bearing.
CHU0110E071
2. Measure the inner diameter of the rotor bearing

using a cylinder gauge.
BHJ0110E062
3. Calculate the rotor bearing oil clearance from the

rotor journal outer diameter and the rotor bearing
inner diameter.
ROTOR
Rotor bearing oil clearance = (rotor bearing ROTOR BEARING
inner diameter) – (rotor journal outer
diameter) ECCENTRIC SHAFT
• If it exceeds the minimum specification,

replace the rotor bearing. (See 01–10–21
ROTOR BEARING REPLACEMENT.)
• If not within the specification, even with the
CHU0110E017
rotor bearing replaced, replace the eccentric
shaft.
Standard rotor bearing oil clearance

0.06—0.08 mm {0.0024—0.0030 in}
Maximum rotor bearing oil clearance
0.1 mm {0.0039 in}
End Of Sie
01–10–20
MECHANICAL
ROTOR BEARING REPLACEMENT
CHU011011B10E09
Removal
1. Set the rotor with the internal gear at the bottom.
2. Remove the adapter ring and the securing screw
from the SST.
49 0813 240
01–10
ADAPTER RING
SECURING SCREW
BHJ0110F004
3. Remove the rotor bearing using the SST.
49 0813 240
BHJ0110E063
Installation
1. Remove the SST handle.
49 0813 240
BHJ0110E064
2. Temporarily assemble so that the rotor bearing

tab and the rotor notch are aligned after pressing ALIGN TAB AND NOTCH
in the rotor bearing and rotor.
3. Set the temporarily assembled rotor bearing and
rotor on a hydraulic press.
CHU0110E018
4. Press in the rotor bearing using the SST.

End Of Sie
49 0813 240
BHJ0110E066
Revised 6/2008 (Ref. No. R108/08) 01–10–21

MECHANICAL
ECCENTRIC SHAFT INSPECTION
CHU011011D01E01
1. Inspect for clogging in the oil passage.
• If there is any clogging, remove it with a
needle or similar device and clean with
compressed air.
BHJ0110E050
2. After setting the eccentric shaft main journal on V-

blocks and a surface plate, measure the runout at
the end of the eccentric shaft using a dial gauge.
replace the eccentric shaft.
Standard runout
0.02 mm {0.0008 in}
Maximum runout
0.06 mm {0.0024 in}
End Of Sie BHJ0110E051
ECCENTRIC SHAFT END PLAY INSPECTION

CHU011011D01E02
2. Assemble the parts in the following order:
(1) Spacer
(2) Needle bearing
(3) Thrust plate
(4) Balance weight
(5) Oil pump drive gear
(6) Metering oil pump drive gear (Type A)
49 F011 101 49 1881 055A
BHJ0110E007
Caution
• When assembling the spacer, do not
allow the spacer to be caught in the
needle bearing in the plate.
BHJ0110E052
01–10–22 Revised 6/2008 (Ref. No. R108/08)

MECHANICAL
SPACER NEEDLE BEARING
3. Assemble the eccentric shaft pulley, eccentric
PLATE
shaft position plate, pulley boss component apply
engine oil to the pulley lockbolt threads, and then
tighten.
Tightening torque
300—340 N·m {30.6—34.6 kgf·m, 222—250 01–10
ft·lbf} THRUST PLATE
4. Remove the SST. GOOD NO GOOD

CHU0110E019
5. Measure the end play of the eccentric shaft using

a dial gauge.
• If not within the specification, replace the
spacer with one that is thicker than the
currently assembled one. If it exceeds the
specification, replace with a thinner spacer.
Standard end play

0.04—0.09 mm {0.0016—0.0035 in}
BHJ0110E054
Spacer types
(mm {in})
Marking Dimension
A 7.985 {0.3144}
B 8.005 {0.3152}
C 8.025 {0.3159}
D 8.045 {0.3167}
E 8.065 {0.3175}
Note
• If the end play is not within the specification even after replacing with an A-marked spacer, adjust by
grinding it and reuse.
End Of Sie
Revised 6/2008 (Ref. No. R108/08) 01–10–23

MECHANICAL
PILOT BEARING INSPECTION/REPLACEMENT [MT]
CHU011011D01E03
Inspection
Caution
• Inspect the pilot bearing when it is installed to the eccentric shaft.
1. Before removing the pilot bearing, inspect it for damage, wear, and proper rotation.
• If there is any malfunction, replace the pilot bearing.
Replacement
Removal
1. Fix the eccentric shaft on a vice.
2. Remove the pilot bearing and the oil seal together
using the SST.
49 1285 071
BHJ0110E070
Installation
1. Install a new pilot bearing using the SSTs.
PILOT BEARING
2. Apply grease to the pilot bearing.
49 F011 1A1
49 G030 797
GREASE
11.5—12.25 mm {0.4528—0.4822 in}

CHU0110E020
3. Install a new oil seal using the SSTs.

End Of Sie OIL SEAL 49 F011 1A1
49 G030 797
5.5—6.3 mm {0.217—0.248 in}
CHU0110E021
01–10–24
MECHANICAL
ECCENTRIC SHAFT BYPASS VALVE
CHU011011D01E04
Warning
• Engine oil temperature will increase during the inspection and become very dangerous. Be careful
not to burn yourself during the inspection.
1. Put the eccentric shaft bypass valve in a

VERNIER CALIPER
container filled with engine oil. 01–10
2. Heat the container and verify that the projection
protrudes more than the minimum specification
when the engine oil temperature is 60 °C {140
°F}.
• If it is less than the minimum specification, PROJECTION PART
replace the eccentric shaft bypass valve.
Minimum projection
6 mm {0.24 in}
CHU0110E057
End Of Sie
ECCENTRIC SHAFT POSITION PLATE INSPECTION
CHU011011D01E05
1. Visually inspect the eccentric shaft position plate
ECCENTRIC SHAFT
for damage and erosion. POSITION PLATE
• If there is any malfunction, replace the
eccentric shaft position plate.
Eccentric shaft pulley tightening torque

14.2—17.2 N·m {1.45—1.75 kgf·m, 10.5—12.6
ft·lbf}
End Of Sie
BHJ0110E106
MAIN BEARING OIL CLEARANCE INSPECTION

CHU011010E00E01
1. Using a micrometer, measure the outer diameters
of the inside main journal.
INSIDE INSIDE
OUTSIDE OUTSIDE
CHU0110E022
2. Using a cylinder bore gauge, measure the inner

diameter of the stationary gear main bearing.
BHJ0110E056
Revised 6/2008 (Ref. No. R108/08) 01–10–25

MECHANICAL
3. Calculate the main bearing oil clearance from the
main journal outer diameter and the main bearing
inner diameter. MAIN BEARING STATIONARY GEAR
Main bearing oil clearance = (main bearing

inner diameter) – (main journal outer
diameter)

replace the main bearing. (See 01–10–26
MAIN BEARING REPLACEMENT.) ECCENTRIC SHAFT
— If the clearance is not within the
CHU0110E023
specification after replacing the main
bearing, replace the eccentric shaft.
Standard main bearing oil clearance

Without stopper screw: 0.045—0.085 mm {0.0018—0.0033 in}
With stopper screw: 0.055—0.075 mm {0.0022—0.0029 in}
Maximum main bearing oil clearance

Without stopper screw: 0.1 mm {0.0039 in}
With stopper screw: 0.1 mm {0.0039 in}
End Of Sie
MAIN BEARING REPLACEMENT
CHU011010E00E02
Removal
1. Remove the stopper screw. (With stopper screw)
STOPPER SCREW
CHU0110E042
2. Remove the adapter ring and the securing screw

from the SST.
3. Set the stationary gear to the hydraulic press so 49 0813 235
that the gear faces upward.
ADAPTER RING
SECURING SCREW
BHJ0110F005
4. Remove the main bearing using the SST.
49 0813 235
BHJ0110E057
01–10–26 Revised 6/2008 (Ref. No. R108/08)

MECHANICAL
Installation
Without stopper screw
1. Temporarily assemble the stationary gear and the
main bearing so that the main bearing tab and ALIGN TAB AND NOTCH
notch are aligned after pressing in the main
bearing and stationary gear.
01–10
CHU0110E043
49 0813 235
BHJ0110E059
3. Position the gear of the stationary gear

downward, and install the main bearing by
pressing it with the SST.
Caution
• Press the main bearing in so that the top
of the main bearing is flush with the top
of the stationary gear flange. 49 0813 235
BHJ0110E060
With stopper screw

1. Temporarily assemble the stationary gear and the
main bearing so that the main bearing screw hole
and the stationary gear screw hole are aligned OIL HOLE
after pressing in the main bearing and rotor.
STOPPER SCREW HOLE
CHU0110E044
Revised 6/2008 (Ref. No. R108/08) 01–10–27

MECHANICAL
49 0813 235
BHJ0110E059
3. Position the gear of the stationary gear

downward, and install the main bearing using the
SST.
Caution
• Press the main bearing in so that the top
of the main bearing is flush with the top
of the stationary gear flange. 49 0813 235
BHJ0110E060
4. Apply thread-locking compound to the stopper

screw and install.
Tightening torque
3.2—4.7 N·m STOPPER SCREW
{33—47 kgf·cm, 29—41 in·lbf}
End Of Sie
CHU0110E042
01–10–28
MECHANICAL
OIL PUMP INSPECTION
CHU011014100E01
Type A
1. Measure the body clearance between the outer
rotor and the body using a feeler gauge.
replace the oil pump.
Standard body clearance 01–10

0.20—0.25 mm {0.0079—0.0098 in}
Maximum body clearance
0.3 mm {0.0118 in}
BHJ0110E067
2. Measure the tip clearance between the inner rotor

and the outer rotor using a feeler gauge.
Standard tip clearance

0.03—0.12 mm {0.0012—0.0047 in}
Maximum tip clearance
0.15 mm {0.0059 in}
BHJ0110E068
3. Measure the side clearance between the rotor

and the side housing using a straight edge and a
feeler gauge.
Standard side clearance

0.03—0.125 mm {0.0012—0.0049 in}
Maximum side clearance
0.15 mm {0.0059 in}
BHJ0110E069
Type B
Note
• The oil pump cannot be disassembled because it is a precision unit. If a malfunction occurs, replace the
oil pump component as a single unit.
1. Visually inspect the oil pump gasket.

• Replace the oil pump component if the condition corresponds to any one of the following:
— The lip is damaged.
— The lip and the metallic outer ring are at SHAPE OF NEW GASKET LIP
the same level. SHAPE OF DETERIORATED
End Of Sie GASKET LIP (LEVEL WITH
METALLIC OUTER RING)
METALLIC OUTER RING
GHE0110E002
Revised 6/2008 (Ref. No. R108/08) 01–10–29

MECHANICAL
ROTOR ASSEMBLY
CHU011002000E08
1. Assemble in the order indicated in the table.
5 R P
2 R P
BHJ0110E074
1 Inner oil seal spring 5 Outer O-ring (large radius)

(See 01–10–30 Oil Seal Spring Assembly Note.) (See 01–10–31 O-Ring Assembly Note.)
2 Inner O-ring (small radius) 6 Outer oil seal
(See 01–10–31 O-Ring Assembly Note.) (See 01–10–32 Oil Seal Assembly Note.)
3 Inner oil seal 7 Cut-off seal spring
(See 01–10–32 Oil Seal Assembly Note.) (See 01–10–32 Cut-Off Seal Spring Assembly
4 Outer oil seal spring Note.)
(See 01–10–30 Oil Seal Spring Assembly Note.) 8 Cut-off seal
(See 01–10–33 Cut-Off Seal Assembly Note.)
Oil Seal Spring Assembly Note

1. Assemble the oil seal spring with the identification color upward.
Spring Identification Color
Front rotor Rear rotor
Rotor Engine Engine Engine Engine
front side rear side front side rear side
Inner White Blue White Blue
White + White +
Outer Blue + pink Blue + pink
pink pink
01–10–30
MECHANICAL
Caution
• It is possible that the identification color
may not be visible when reusing the oil
spring. In that case, assemble the
ENGINE FRONT SIDE AND REAR SIDE
rounded end towards the rotor side and
the squared end upward.
• Be careful when assembling the oil seal
spring of the front and rear rotor since SQUARED END
ROTOR 01–10
each spring of the engine front side and ROTATION ROTOR
engine rear side are the same. DIRECTION ROTATION
DIRECTION
Note
• Either one of the two rotation lock slots on
the oil seal can be used as a reference.
ROUNDED END
CHU0110E024
• Assemble the rounded end within 0—15 mm

{0—0.59 in} away from the oil seal spring
rotation lock. 0—15 mm {0—0.59 in} ROTATION LOCK
IDENTIFICATION COLOR
ROTOR ROTATION DIRECTION
CHU0110E025
O-Ring Assembly Note

1. Apply petroleum jelly to a new O-ring.
2. Assemble the O-ring to the oil seal.
Note
• Assemble the thicker O-ring to the inner oil
seal (small radius), and the thinner O-ring to
the outer oil seal (large radius).
BHJ0110E077
01–10–31
MECHANICAL
Oil Seal Assembly Note
1. Temporarily install the oil seal with the squared
end of the oil seal spring fit into the slot of the oil OIL SEAL SLOT
seal.
SQUARED END
CHU0110E026
2. Push in the oil seal using an old oil seal.

3. Verify that the stroke of the oil seal is smooth and
0.5—0.6 mm
there is no catching by pushing the oil seal with
{0.020—0.023 in}
your hand.
OLD OIL SEAL
ROTOR
CHU0110E027
Cut-Off Seal Spring Assembly Note

1. Assemble the cut-off seal spring with the spring
end turned upward.
ROTATION LOCK PIN
Note PINK PAINT

• When replacing a cut-off seal with a new
one, assemble the seal with the pink surface
facing upward.
ROTOR
CHU0110E028
01–10–32
MECHANICAL
Cut-Off Seal Assembly Note
1. Assemble the cut-off seal so that it does not run
over the rotation lock pin. CUT-OFF SEAL ROTATION LOCK PIN
End Of Sie
GOOD
ROTOR 01–10
CUT-OFF SEAL SPRING
NO GOOD
NO GOOD
CHU0110E029
01–10–33
MECHANICAL
HOUSING ASSEMBLY I
CHU011002000E09
1 OIL
OIL
12 OIL
11
R
4 OIL 2
5
R
6
3
OIL 7 SEALANT
15.7—22.5 8
{1.61—2.29, 11.6—16.5}
9 R P
10 OIL
3.9—11.7
14
{40—119 kgf·cm,
35—103 in·lbf}
I H 16 OIL
15
F
G R
D E OIL
C
A B
P
P
OIL
R OIL
OIL
R P
SEALANT 22
31.4—39.2 SEALANT
{3.21—3.99, 23.2—28.9}
R P
21
OIL
SST
13
392—490
R 18 {39.8—49.9, 290—361}
R P
OIL
19 R SEALANT
SST AT
20
15.7—22.5
{1.61—2.29, 11.6—16.5}
R OIL
SST
22
OIL
17 N·m {kgf·m, ft·lbf}

68.6—78.4 {6.70—7.99, 50.6—57.8}
CHU0110E052
1 Front housing 3 Thrust plate

2 Front stationary gear (See 01–10–35 Thrust Plate Assembly Note.)
4 Needle bearing
01–10–34
MECHANICAL
5 Plate 13 Intermediate housing
6 Front rotor (See 01–10–38 Intermediate Housing Assembly
A: Side seal Note.)
B: Side seal spring 14 Rear rotor
C: Corner seal (See 01–10–35 Rotor Assembly Note.)
D: Corner seal plug 15 Rear rotor housing
E: Corner seal spring (See 01–10–37 Rotor Housing Assembly Note.)
F: Side piece
G: Apex seal 16 Tubular dowel (rear rotor housing side) 01–10
H: Apex seal spring (short) 17 Pressure regulator (Type A)
I: Apex seal spring (long) 18 Rear stationary gear
(See 01–10–35 Rotor Assembly Note.) 19 Rear oil seal
7 Steel ball (See 01–10–39 Rear Oil Seal Assembly Note.)
8 Spring 20 Rear housing
9 Oil jet plug (See 01–10–40 Rear Housing Assembly Note.)
(See 01–10–36 Oil Jet Plug Assembly Note.) Tension bolt
21
10 Eccentric shaft (See 01–10–40 Tension Bolt Assembly Note.)
11 Front rotor housing 22 Flywheel (MT), counterweight (AT)
(See 01–10–37 Rotor Housing Assembly Note.) (See 01–10–41 Flywheel (MT), Counterweight (AT)
12 Tubular dowel (front rotor housing side) Assembly Note.)
Thrust Plate Assembly Note

1. Place the chamfer side facing the stationary gear.
CHAMFER SIDE
STATIONARY GEAR SIDE
CHU0110E045
Rotor Assembly Note
Caution
• Assemble only the side seal and corner seal on the engine front side while the rotor is not
assembled.
1. Assemble the side seal spring in the direction

shown in the figure.
SIDE SEAL SIDE
ROTOR SIDE
CHU0110E046
Revised 6/2008 (Ref. No. R108/08) 01–10–35

MECHANICAL
2. Assemble the side seal spring in the direction SIDE SEAL
shown in the figure.
3. Apply petroleum jelly between the side seal and
side seal groove.
ROTOR
SIDE SEAL SPRING

CHU0110E047
4. Assemble the corner seal plug to the corner seal.
CORNER SEAL
CORNER SEAL PLUG
CORNER SEAL SPRING
CHU0110E030
Note
• When replacing a corner seal with new one,
assemble the corner seal with the painting
surface facing upward. S:PINK
L:WHITE
5. Assemble the corner seal and corner seal spring
with the notch aligned with the apex seal groove.
6. Apply petroleum jelly between the corner seal and
corner seal groove.
7. Place the rotor in the housing.
CHU0110E051
8. Insert the SST into the apex seal groove of the

rotor and verify that the apex seal groove of the GOOD
corner seal is aligned with the apex seal groove of
the rotor.
9. Assemble the side seal and corner seal for the
engine rear side in the same way as the engine NO GOOD
front side.
49 0813 225A
CHU0110E070
Oil Jet Plug Assembly Note

1. Apply thread locking compound to the seating face of the oil jet plug.
2. Install the oil jet plug.
Tightening torque
3.9—11.7 N·m
{40—119 kgf·cm, 35—103 in·lbf}
01–10–36 Revised 6/2008 (Ref. No. R108/08)

MECHANICAL
Rotor Housing Assembly Note
Caution
• Assemble the seal rubber without any torsion.
• Do not get oil or grease on the seal rubber.
1. Apply petroleum jelly to a new seal rubber.

2. Assemble the outer seal rubber to the housing 01–10
with the white paint in the direction shown in the
figure.
WHITE PAINT
HOUSING
CHU0110E061
3. Assemble the inner seal rubber to the housing

with the seal rubber joint placed between A—B.
CHU0110E062
4. Apply the silicone sealant to the position indicated

in the figure. 8—12 mm
{0.32—0.47 in}
SEAL RUBBER
Bead thickness
GROOVE
2.5—6.5 mm {0.099—0.255 in}
SEALANT
CHU0110E033
5. Apply thread locking compound to the attaching

surface of the apex seal and the side piece and
affix them. ATTACHING SURFACE
Caution
• After adhesion, make sure that there is
no gap between the apex seal and side
piece.
CHU0110E059
Revised 6/2008 (Ref. No. R108/08) 01–10–37

MECHANICAL
• If adhesive protrudes, remove with a ADHESIVE
razor.
Note
• When using a new apex seal, the procedure
above is not needed.
RAZOR
CHU0110E069
6. Assemble the apex seal and apex seal spring

(short) together with the side piece to the engine
APEX SEAL SPRING(SHORT)
rear side.
CHU0110E063
7. Assemble the apex seal spring (long) while

pressing the apex seal spring (short). APEX SEAL SPRING (SHORT)
Caution SPRING STOPPER

• Assemble the apex seal spring until it APEX SEAL SPRING (LONG)
catches the spring stopper of the side
piece.
ROTOR HOUSING ROTOR
CHU0110E034
Intermediate Housing Assembly Note

1. Assemble the intermediate housing with the
support of an assistant pushing the eccentric
shaft up approx. 3 cm {1.18 in}.
BHJ0110E023
01–10–38 Revised 6/2008 (Ref. No. R108/08)

MECHANICAL
Caution
• Do not allow the side piece to be caught
between the rotor housing and
intermediate housing.
GOOD 01–10
NO GOOD
CHU0110E060
Rear Oil Seal Assembly Note

1. Assemble the oil seal using the SST.
Caution
• Insert the rear oil seal until it is reaches 49 J027 001
to the seating face.
OIL SEAL
STATIONARY GEAR
CHU0110E035
01–10–39
MECHANICAL
Rear Housing Assembly Note
1. Assemble the rear housing with the rear stationary gear and the internal gear of the rotor engaged.
Caution
• Do not allow the side piece to be caught between the rotor housing and rear housing.
GOOD
NO GOOD
CHU0110E060
Tension Bolt Assembly Note

1. Apply engine oil to the tension bolt threads and
assemble to the housing with a new seal washer. INDENTED BOLT
HEAD
Caution
• Assemble a tension bolt which has a seal
washer with the rubber projection facing
the housing side.
WITHOUT SEAL
WASHER
CHU0110E036
2. Tighten the tension bolts in the order indicated in

15 11
 3 passes.
the figure in 2 13 7
9
Tightening torque
5
31.4—39.2 N·m
{3.21—3.99 kgf·m, 23.2—28.9 ft·lbf} 3
1
2
4
8
14 6
17 12 18
16 10
BHJ0110E094
01–10–40
MECHANICAL
Flywheel (MT), Counterweight (AT) Assembly Note
against rotation using the SSTs.
01–10
49 F011 101 49 1881 055A
BHJ0110E007
2. Tighten the locknut using the SST.

MT 49 0820 035 AT
Tightening torque
392—490 N·m
{40.0—49.9 kgf·m, 290—361 ft·lbf}
End Of Sie
BHJ0110E011
01–10–41
MECHANICAL
HOUSING ASSEMBLY II
CHU011002000E10
Type A
SEALANT
OIL
SST 24
254—294
{25.9—29.9, 188—216} 22
R 23
11
8
10 9
OIL
14
13
16
25 SEALANT
SST
12
R
15 SST
6.9—9.8
0.98—2.94 {0.10—0.29, 0.73—2.16}
{0.8—0.9, 5.1—7.2}
31.4—46.1 3
{3.21—4.70, 23.2—34.0}
R
OIL
20 R
SST
6 7
21 R
17 5
2 4 OIL
18
18.6—25.5 {1.90—2.60, 13.8—18.8} OIL
1
19
39.2—49.0 {4.00—4.99, 29.0—36.1} N·m {kgf·m, ft·lbf}
BHE0110E001
1 Oil pump body 14 Oil pump chain

2 Shaft 15 Oil pump sprocket wheel
3 Front inner rotor (See 01–10–43 Oil Pump Sprocket Wheel Assembly
Note.)
4 Front outer rotor
16 Metering oil pump drive gear
5 Middle plate
17 Control valve
6 Rear inner rotor
18 Control valve spring
7 Rear outer rotor
19 Plug
8 Spacer
(See 01–10–43 Spacer Assembly Note.) 20 Front oil seal
(See 01–10–43 Front Oil Seal Assembly Note.)
9 Needle bearing
21 Front cover
10 Thrust plate (See 01–10–44 Front Cover Assembly Note.)
11 Balance weight 22 Spring
12 Oil pump component 23 Eccentric shaft bypass valve
13 Oil pump drive gear 24 Pulley component
(See 01–10–43 Oil Pump Drive Gear Assembly
Note.) 25 Pulley lockbolt
(See 01–10–44 Pulley Lockbolt Assembly Note.)
01–10–42 Revised 6/2008 (Ref. No. R108/08)

MECHANICAL
CHU011002000E04
Type B
SEALANT 7.8—10.8 {80—110 kgf·cm,
OIL 20 69.0—95.5 in·lbf}
SST
254—294
19 18
{25.9—29.9, 188—216}
21 7.8—10.8 {80—110 kgf·cm,
14 69.0—95.5 in·lbf} 01–10
7.8—10.8 {80—110 kgf·cm, R
69.0—95.5 in·lbf}
13
R
7.8—10.8 {80—110 kgf·cm,

15 69.0—95.5 in·lbf}
31.4—47.0 {3.21—4.79, 23.2—34.6}
7 4 3 2 1
12
R
17 R
R 6
11
R
7.8—10.8 {80—110 kgf·cm, 69.0—95.5 in·lbf}
8 SST
9 31.4—46.1 {3.21—4.70, 23.2—34.0}
R 13.5—19.3 {1.38—1.96, 9.96—14.2}

16 OIL
SST
10
18.6—25.5 {1.90—2.60, 13.8—18.8}
29.4—40.2 {2.30—4.09, 21.7—29.6} N·m {kgf·m, ft·lbf}
GHE0110E003
1 Spacer 11 OCV oil filter

(See 01–10–43 Spacer Assembly Note.) 12 Plug
2 Needle bearing 13 OCV case
3 Thrust plate 14 Oil pipe
4 Balance weight 15 OCV
5 Oil pump component 16 Front oil seal
6 Oil pump drive gear (See 01–10–43 Front Oil Seal Assembly Note.)
(See 01–10–43 Oil Pump Drive Gear Assembly 17 Front cover
Note.) (See 01–10–44 Front Cover Assembly Note.)
7 Oil pump chain 18 Spring
8 Oil pump sprocket wheel 19 Eccentric shaft bypass valve
(See 01–10–43 Oil Pump Sprocket Wheel Assembly
Note.) 20 Pulley component
9 Plug 21 Pulley lockbolt
(See 01–10–44 Pulley Lockbolt Assembly Note.)
10 Oil filter joint
End Of Sie
Revised 6/2008 (Ref. No. R108/08) 01–10-42–1

MECHANICAL

LEFT BLANK
01–10-42–2
MECHANICAL
Spacer Assembly Note
Caution
• When assembling the spacer, do not allow the spacer to be caught in the needle bearing of the
plate.
SPACER NEEDLE BEARING
Note
PLATE
• Perform eccentric shaft end play inspection. 01–10
(See01–10–22 ECCENTRIC SHAFT END
PLAY INSPECTION.)
THRUST PLATE
GOOD NO GOOD
CHU0110E019
Oil Pump Drive Gear Assembly Note

1. Assemble the oil pump drive gear or oil pump
sprocket wheel with the oil pump chain engaged.
BHJ0110E101
Oil Pump Sprocket Wheel Assembly Note

1. Lock the flywheel (MT) and counterweight (AT) MT AT
2. Assemble the oil pump shaft with a new lock
washer and locknut, and tighten.
Tightening torque
31.4—46.1 N·m
{3.21—4.70 kgf·m, 23.2—34.0 ft·lbf}
3. Bend the lock washer and crimp. 49 F011 101 49 1881 055A
BHJ0110E007
Front Oil Seal Assembly Note

1. Press the oil seal in using the SST.
FRONT COVER
OIL SEAL
49 F010 401A 1.5—2.5 mm {0.06—0.09 in}
CHU0110E037
01–10–43
MECHANICAL
Front Cover Assembly Note
1. Before installing the front cover, install the pulley
boss to the eccentric shaft and measure the PULLEY BOSS
height between the eccentric shaft top and the
pulley boss.
• If not within the specification, verify that the 10.34—11.14 mm
spacer is not caught in the needle bearing. {0.4071—0.4385 in}
Standard
10.34—11.14 mm {0.4071—0.4385 in}
ECCENTRIC SHAFT
CHU0110E038
2. Tighten the engine front cover installation bolts in

the order shown in the figure. 7
3
Tightening torque
18.6—25.5 N·m 2
{1.90—2.60 kgf·m, 13.8—18.8 ft·lbf}
1
4
5 6
BHJ0110E098
Pulley Lockbolt Assembly Note

49 F011 101 49 1881 055A
BHJ0110E007
2. Apply engine oil to the pulley lockbolt threads.

3. Assemble a new O-ring. ENGINE OIL
4. Apply silicone sealant to the seating face.
O-RING
5. Tighten the pulley lockbolt.
Tightening torque
300—340 N·m
{30.6—34.6 kgf·m, 222—250 ft·lbf}
End Of Sie
SEALANT
CHU0110E066
01–10–44
MECHANICAL
HOUSING ASSEMBLY III
CHU011002000E11
Type A
10
6
18.6—25.5 31.4—46.1 11
{1.90—2.60, 13.8—18.8} {3.21—4.70, 23.2—34.0}
15.7—23.5 01–10
R {1.61—2.39, 11.6—16.5} 18.6—25.5
9 {1.9—2.6, 13.8—18.8}
R
R
18.6—25.5 {1.90—2.60, 13.8—18.8}
8
7
14.2—17.2 {1.45—1.75, 10.5—12.6}

R
18.6—25.5 {1.90—2.60, 13.8—18.8}
1
7.8—10.8 {80—110 kgf·cm, 69.0—95.5 in·lbf}
7.8—10.8 {80—110 kgf·cm, 69.0—95.5 in·lbf}
3
7.8—10.8 {80—110 kgf·cm, 69.0—95.5 in·lbf}
SEALANT
8.8—11.8 4 R
{90—120 kgf·cm, 78—104 in·lbf}
N·m {kgf·m, ft·lbf}
CHU0110E054
1 Oil strainer 6 Thermostat component

2 Oil-level sensor 7 Water pump body
3 Oil baffle plate 8 Engine hanger (engine front side)
4 Clip 9 Engine coolant temperature sensor
5 Oil pan 10 Engine hanger (engine rear side)
(See 01–10–47 Oil Pan Assembly Note.) 11 Oil filter component
Revised 6/2008 (Ref. No. R108/08) 01–10–45

MECHANICAL
Type B
31.4—46.1
18.6—25.5 {1.90—2.60, 8 {3.21—4.70, 23.2—34.0} 12
13.8—18.8} R
15.7—23.5
{1.61—2.39, 11.6—16.5}
11
R
18.6—25.5 {1.90—2.60,
13.8—18.8}
R
18.6—25.5 {1.90—2.60,
13.8—18.8} 10 9
R
1
7.8—10.8 {80—110 kgf·cm,
69.0—95.5 in·lbf}
7.8—10.8 {80—110 kgf·cm, 5

69.0—95.5 in·lbf} 7.8—10.8 {80—110 kgf·cm,
69.0—95.5 in·lbf}
2
SEALANT
4 R
SEALANT
18.6—25.5 {1.90—2.60, 13.8—18.8} 7.8—10.8 {80—110 kgf·cm,

69.0—95.5 in·lbf}
N·m {kgf·m, ft·lbf}
GHE0110E004
1 Oil strainer 7 Oil pan

2 Baffle plate (See 01–10–47 Oil Pan Assembly Note.)
3 Oil level switch 8 Thermostat component
4 Clip 9 Water pump body
5 Baffle plate 10 Engine hanger (engine front side)
6 Oil pan upper block 11 ECT sensor
(See 01–10–47 Oil Pan Upper Block Assembly 12 Engine hanger (engine rear side)
Note.)
01–10–46 Revised 6/2008 (Ref. No. R108/08)

MECHANICAL
Oil Pan Upper Block Assembly Note
Caution
• Apply the silicon sealant in a single, unbroken line around the whole perimeter.
• Install the oil pan upper block within 5 min after applying the silicone sealant.
• Using bolts with the old seal adhering
could cause cracks in the housing.
DAMAGE 01–10
1. Completely clean and remove any oil, dirt, sealant
or other foreign material that may be adhering to
the oil pan upper block and housing.
2. When reusing the oil pan upper block installation
bolts, clean any old sealant from the bolts.
OLD SEALANT
CHU0111W004
3. Apply silicone sealant to the areas as shown in

the figure.
Caution A
• Apply silicone sealant to the outer
circumference of the bolt hole at
locations A shown in the figure.
SEALANT
Thickness
2.5—6.5 mm {0.10—0.26 in}
4. Install the oil pan upper block to the housing.

5. Tighten the oil pan upper block installation bolts.
Tightening torque
18.6—25.5 N·m {1.9—2.6 kgf·m, 13.8—18.8
ft·lbf}
BHJ0110F010
Oil Pan Assembly Note

Type A
Caution
• Using bolts with the oil sealant still
adhering could cause cracks in the
housing. Clean all sealant off all oil pan DAMAGE
bolts before assembly.
• Apply the silicon sealant in a single,
unbroken line around the whole
perimeter.
• Install the engine front cover within 5 min
after applying the silicone sealant. OLD SEALANT
1. Completely clean and remove any oil, dirt, sealant

CHU0111W004
the housing and oil pan.
2. When reusing oil pan installation bolts, clean any old sealant from the bolts.
3. Apply silicone sealant to the areas shown in the
figure.
SEALANT
Bead thickness
2.5—6.5 mm {0.1—0.2 in}
4. Tighten the oil pan installation bolts.
Tightening torque
8.8—11.8 N·m
{90—120 kgf·cm, 78—104 in·lbf} BHJ0110E100
Revised 6/2008 (Ref. No. R108/08) 01–10–47

MECHANICAL
Type B
Caution
• Apply the silicon sealant in a single, unbroken line around the whole perimeter.
• Install the oil pan within 5 min after applying the silicone sealant.
• Using bolts with the old seal adhering
could cause cracks in the housing.
1. Completely clean and remove any oil, dirt, sealant DAMAGE

the oil pan upper block and oil pan.
2. When reusing the oil pan installation bolts, clean
any old sealant from the bolts.
OLD SEALANT
CHU0111W004
3. Apply silicone sealant to the areas as shown in

the figure. SEALANT
Thickness
2.5—6.5 mm {0.10—0.26 in}
4. Install the oil pan to the oil pan upper block.

5. Tighten the oil pan installation bolts.
Tightening torque
7.8—10.8 N·m {80—110 kgf·cm, 69.0—95.5
in·lbf}
AR8WZW000007
End Of Sie
01–10–48 Revised 6/2008 (Ref. No. R108/08)

TECHNICAL DATA
01–50 TECHNICAL DATA
ENGINE TECHNICAL DATA . . . . . . . . . . 01–50–1
End of Toc
ENGINE TECHNICAL DATA
CHU015001001E02
ENGINE TYPE 01–50

ITEMS 13B-MSP
STANDARD POWER HIGH POWER
SIDE HOUSING (FRONT, INTERMEDIATE, REAR) INSPECTION
Maximum distortion (mm {in}) 0.04 {0.0016}
Maximum wear
(mm {in}) 0.10 {0.0039}
(Vertical wear)
Maximum wear Oil seal inner path 0.01 {0.0004}
(mm {in})
(Convex oval) Oil seal outer path 0.10 {0.0039}
Maximum wear
(mm {in}) 0.02 {0.0008}
(Oil seal stepped path wear)
ROTOR HOUSING
Maximum width difference (mm {in}) 0.06 {0.0024}
ROTOR
Standard 0.05—0.19 {0.0020—0.0074}
Rotor and side housing clearance (mm {in})
Maximum 0.05 {0.002}
Standard 0.12—0.18 {0.0048—0.0070}
Protrusion of the rotor round (mm {in})
Minimum 0.1 {0.0039}
Standard 0.042—0.077 {0.0017—0.0030}
Apex seal groove and the apex seal clearance (mm {in})
Maximum 0.15 {0.0059}
APEX SEAL, APEX SEAL SPRING
Standard 5.3 {0.20}
Apex seal height (mm {in})
Minimum 4.3 {0.17}
Standard 5.4 {0.213}
Apex seal spring height (mm {in})
Minimum 3.5 {0.148}
CORNER SEAL, CORNER SEAL SPRING
Minimum projection of the corner seal (mm {in}) 0.5 {0.02}
SIDE SEAL, SIDE SEAL SPRING
Corner seal and side seal clearance (mm {in}) Maximum 0.4 {0.016}
Minimum projection of the side seal (mm {in}) 0.5 {0.02}
CUT-OFF SEAL, CUT OFF SEAL SPRING
Standard 3.95 {0.1555}
Cut-off seal height (mm {in})
Minimum 3.8 {0.15}
Minimum projection of the cut off seal (mm {in}) 0.5 {0.02}
OIL SEAL, OIL SEAL SPRING
Maximum contact width (mm {in}) 0.5 {0.02}
Maximum circumferential width (mm {in}) 2.5 {0.098} (or 10 nicks or more)
Minimum projection of the oil seal (mm {in}) 0.5 {0.02}
ECCENTRIC SHAFT
Without stopper screw: 0.045—0.085 {0.0022—
Standard 0.0029}
Main bearing oil clearance (mm {in}) With stopper screw: 0.055—0.075 {0.0018—0.0033}
Maximum 0.1 {0.0039 in}
Standard 0.06—0.08 {0.0024—0.0030}
Rotor bearing oil clearance (mm {in})
Maximum 0.1 {0.0039}
Standard 0.02 {0.0008}
Runout (mm {in})
Maximum 0.06 {0.0024}
End play (mm {in}) Standard 0.04—0.09 {0.0016—0.0035}
ECCENTRIC SHAFT BYPASS VALVE
Minimum projection (mm {in}) 6 {0.24}
Revised 6/2008 (Ref. No. R108/09) 01–50–1
TECHNICAL DATA
ENGINE TYPE
ITEMS 13B-MSP
STANDARD POWER HIGH POWER
OIL PUMP
Standard 0.20—0.25 {0.0079—0.0098}
Body clearance (Type A) (mm {in})
Maximum 0.3 {0.0118}
Standard 0.03—0.12 {0.0012—0.0047}
Tip clearance (Type A) (mm {in})
Maximum 0.15 {0.0059}
Standard 0.03—0.125 {0.0012—0.0049}
Side clearance (Type A) (mm {in})
Maximum 0.15 {0.0059}
End Of Sie
01–50–2 Revised 6/2008 (Ref. No. R108/08)

SERVICE TOOLS
01–60 SERVICE TOOLS
ENGINE SST . . . . . . . . . . . . . . . . . . . . . . 01–60–1
End of Toc
ENGINE SST
CHU016001001E02
49 0107 680A 49 L010 1A0 49 J010 3A0A

01–60
Engine stand Engine hanger Hanger, Engine

set stand
49 1881 055A 49 0820 035 49 0839 305A
Stopper counter Flywheel box Counterweight

weight (AT) wrench puller
49 F011 101 49 0813 250 49 0813 215A
Ring gear brake Seal case Dowel puller

(MT) and oil pump
puller
49 0813 225A 49 0813 235 49 0813 240
Oil seal remover Main bearing Rotor bush

puller and puller and
installer installer
49 0839 165 49 F011 1A1 49 1285 071
Corner seal Bearing installer Needle bearing

gauge set (MT) puller (MT)
49 G030 797 49 F010 401A 49 J027 001
Handle (MT) Installer Bearing installer
End Of Sie
01–60–1

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1773-1U-03C(INDEX).

pdf 10/8/2008 10:00:06 AM

2008 Mazda Motor Corporation

Part No. 9999-95-E13B-MSP09

up to October, 2008. Any changes that occur

GENERAL INFORMATION 00 SECTION

Toc of SCT INFORMATION . . . . 00-00

Revised 6/2008 (Ref. No. R108/08) 00–00–1

49 H002 671 SHOWS TIGHTENING

Apply petroleum Appropriate

Upper and lower limits

Electric current A (ampere)

Positive pressure kgf/cm2 (kilogram force per square

Conversion to SI Units (Système International d'Unités)

Upper and Lower Limits

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

Special Service Tools

Inspection During Removal, Disassembly

Rubber Parts and Tubing

recalculated due to the extra length that the SST

or equivalent adds to the torque wrench.

Recalculate the torque by using the following

formulas. Choose the formula that applies to you.

Torque Unit Formula

in·lbf in·lbf × [L/(L+A)]

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

• Connectors can be disconnected by pressing or

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

00–00–12 Added 6/2008 (Ref. No. R108/08)

Revised 6/2008 (Ref. No. R108/08) 01–10–1

ENGINE FRONT SIDE

ENGINE FRONT SIDE

01–10–2 Revised 6/2008 (Ref. No. R108/08)

7. Mount the engine to the SST (engine stand).

Using 49 J010 3A0A

2. Mount the engine to the SST (engine stand).

Revised 6/2008 (Ref. No. R108/08) 01–10–3

1 Oil filter component 7 Oil pan

01–10–4 Revised 6/2008 (Ref. No. R108/08)

1 Engine hanger (engine rear side) 7 Oil pan upper block

Revised 6/2008 (Ref. No. R108/08) 01–10-4–1

THIS PAGE INTENTIONALLY

Oil Pan Upper Block Disassembly Note

Revised 6/2008 (Ref. No. R108/08) 01–10–5

1 Pulley lockbolt 13 Oil pump drive gear

01–10–6 Revised 6/2008 (Ref. No. R108/08)

1 Pulley lockbolt 12 Oil filter joint

Revised 6/2008 (Ref. No. R108/08) 01–10-6–1

THIS PAGE INTENTIONALLY

49 F011 101 49 1881 055A

Front Cover Disassembly Note

Oil Pump Sprocket Disassembly Note

49 F011 101 49 1881 055A

3. Remove the oil pump drive gear and oil pump

1 Flywheel (MT), counterweight (AT) Tension bolt