Motor Ford Mazda 2013-2.5L

2013 Mazda 3 i Sport
2012 ENGINE Mechanical - Mazda 3, CX-7
2012 ENGINE
Mechanical - Mazda 3, CX-7
ENGINE OVERHAUL SERVICE WARNING
WARNING: l 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.
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 x 1.5T length 90 mm {3.55 in}.
Fig. 1: Identifying SST (49 L010 102) On Cylinder Block
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).
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Fig. 2: Identifying SST (Bolts, Nuts And Plate) Positions
5. Tighten the SSTs (bolts and nuts) to affix the SSTs firmly.
WARNING: l 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 (49 0107 680A).

7. Drain the engine oil into a container.
8. Install the oil pan drain plug.
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Fig. 3: Identifying SST Bolts And Nuts
1. Inspect the seal rubber of the oil pan drain plug and make sure there are no cracks or damage.
¡ If necessary, replace the oil pan drain plug.
2. Clean the flange surface (seal rubber) on the oil pan drain plug, then install the oil pan drain plug.
Tightening torque
25-30 N.m {2.6-3.0 kgf.m, 19-22 ft.lbf}
DISMOUNTING
l Dismount in the reverse order of mounting.
TIMING CHAIN DISASSEMBLY

1. Disassemble in the order indicated in the table.
Fig. 4: Identifying Timing Chain Disassemble Order
CRANKSHAFT PULLEY LOCK BOLT DISASSEMBLY NOTE
1. Install the SST to the ring gear to lock the crankshaft against rotation.
Fig. 5: Identifying SST (Crankshaft Pulley Lock)
FRONT OIL SEAL DISASSEMBLY NOTE
1. Remove the oil seal using a flat head screwdriver.
Fig. 6: Removing Oil Seal Using Flat Head 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.
Fig. 7: Holding Chain Tensioner Ratchet Lock Mechanism Away From Ratchet Stem With Thin
Screwdriver
OIL PUMP SPROCKET DISASSEMBLY NOTE
1. Temporarily install the crankshaft pulley and crankshaft pulley lock bolt to the crankshaft, and lock the
oil pump against rotation as shown in figure.
2. Remove the oil pump sprocket, and then remove the crankshaft pulley and crankshaft pulley lock bolt.
Fig. 8: Removing Crankshaft Pulley And Crankshaft Pulley Lock Bolt
CYLINDER HEAD DISASSEMBLY (I)

Fig. 9: Identifying Cylinder Head Disassemble Order
CAMSHAFT SPROCKET LOCK BOLT, VARIABLE VALVE TIMING ACTUATOR LOCK BOLT
DISASSEMBLY NOTE
1. Hold the camshaft by using a wrench on the cast hexagon as shown, and loosen the camshaft sprocket
installation bolt or variable valve timing actuator installation bolt.
Fig. 10: Loosening Camshaft Sprocket Installation Bolt Or Variable Valve Timing Actuator
Installation Bolt
CAMSHAFT CAP DISASSEMBLY NOTE
1. Before removing the camshaft caps, inspect the following:

¡ Camshaft end play and camshaft journal oil clearance (See CAMSHAFT INSPECTION.)
NOTE: l 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 2-3 passes in the order shown in the figure.
Fig. 11: Identifying Camshaft Caps Bolts Loosening Order
TAPPET DISASSEMBLY NOTE
NOTE: l 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 2-3 passes in the order shown in the figure.
Fig. 12: Identifying Cylinder Head Bolts Loosening Order
CYLINDER HEAD DISASSEMBLY (II)

Fig. 13: Identifying Cylinder Head Disassemble Order
VALVE KEEPER DISASSEMBLY NOTE
1. Remove the valve keeper using the SSTs.
Fig. 14: Removing Valve Keeper Using SSTs
VALVE SEAL DISASSEMBLY NOTE
1. Remove the valve seal using the SST.
Fig. 15: Removing Valve Seal Using SST
CYLINDER BLOCK DISASSEMBLY (I)

Fig. 16: Identifying Cylinder Block Disassemble Order
DRIVE PLATE (ATX), FLYWHEEL (MTX) DISASSEMBLY NOTE
1. Hold the crankshaft using the SST .

2. Remove the bolts in several passes.
Fig. 17: Identifying Flywheel Bolt Removal Sequence
CYLINDER BLOCK DISASSEMBLY (II)
CAUTION: l Placing the crankshaft on a disassembly bench will cause the drive
gear to contact the disassembly bench because the crankshaft drive
gear is larger than the counterweight. This could result in the drive
gear being scratched or damaged which could become a source of
noise. Therefore, set wood blocks or similar object on the both sides
of the crankshaft or place a thick clean rag under the drive gear so
that the drive gear does not contact the disassembly bench directly.
Fig. 18: Identifying Cylinder Block Disassemble Order
PILOT BEARING DISASSEMBLY NOTE
NOTE: l Only remove the pilot bearing if there is a malfunction in the pilot bearing
or when replacing the crankshaft.
1. Use the SST to remove the pilot bearing.
Fig. 19: Removing Pilot Bearing Using SST
CONNECTING ROD CAP DISASSEMBLY NOTE
NOTE: l Determine the position of each removed connecting rod cap.
1. Before removing the connecting rod cap, inspect the connecting rod side clearance. (See CONNECTING
ROD INSPECTION.)
2. Remove the connecting rod bolt from the connecting rod cap by tapping the bolt with a plastic hammer.
MAIN BEARING CAP DISASSEMBLY NOTE
1. Before removing the main bearing cap, inspect the crankshaft end play. (See CRANKSHAFT
INSPECTION.)
2. Loosen the main bearing cap bolts in two or three steps in the order shown in the figure.
Fig. 20: Identifying Main Bearing Cap Bolts Loosening Sequence
CYLINDER HEAD INSPECTION

1. Perform color contrast penetrate examination on the cylinder head surface.
lReplace 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 six directions as shown in the figure.
l If it exceeds the maximum specification, replace the cylinder head.
Maximum distortion, head gasket side
0.10 mm {0.004 in}
Fig. 21: Measuring Cylinder Head For Distortion In Six Directions
4. Measure the manifold contact surface distortion as shown in the figure.

l If it exceeds the maximum specification, grind the surface or replace the cylinder head.
Maximum distortion, manifold side
0.10 mm {0.0039 in}
Maximum cutting length, manifold side
0.15 mm {0.0059 in}
Fig. 22: Measuring Manifold Contact Surface Distortion
VALVE SEAT INSPECTION/REPAIR

1. Measure the contact width of the valve face and the valve seat using the valve lapping compound.
l If it is not within the specification, resurface the valve seat using the 45° valve seat cutter.
Standard valve seat contact width
0.99-1.84 mm {0.039-0.072 in}
2. Verify that the valve seating position is at the center of the valve face.
1. If the seating position is too inner side, correct the valve seat using a 70° (IN) or 65° (EX) cutter,
and a 45° cutter.
Fig. 23: Checking Valve Seat Contact Width
2. If the seating position is too out side, correct the valve seat using a 30° (IN) or 0° (EX) cutter, and a
45° cutter.
Valve seat angle
45°
Fig. 24: Checking Valve Seat Angle
3. Inspect the sinking of the valve seat. Measure the protruding length (dimension L) of the valve stem.
l If not specified, replace the valve.
¡ If not as specified, replace the cylinder head.
Standard valve seat sinkage amount
(Dimension L)
IN: 40.64-42.24 mm {1.601-1.662 in}
EX: 40.50-41.30 mm {1.60-1.65 in}
Fig. 25: Measuring Protruding Length (Dimension L) Of Valve Stem
VALVE, VALVE GUIDE INSPECTION

1. Measure the valve head margin thickness using a vernier caliper.
l If it is less than the specification, replace the valve.
Minimum valve head margin thickness
IN: 1.65 mm {0.0650 in}
EX: 1.85 mm {0.0728 in}
2. Measure the length of each valve. Replace the valve if necessary.

l If it is less than the specification, replace the valve.
Fig. 26: Checking Valve Head Margin Thickness
Standard valve length (Dimension L)
IN: 102.99-103.79 mm {4.0548-4.0862 in}
EX: 104.25-105.05 mm {4.1044-4.1358 in}
Minimum valve length (Dimension L)
IN: 102.99 mm {4.0548 in}
EX: 104.25 mm {4.1044 in}
Fig. 27: Measuring Valve Length (Dimension L)
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.

l If it exceeds the specification, replace the valve.
Standard valve stem diameter
IN: 5.470-5.485 mm {0.2154-0.2159 in}
EX: 5.465-5.480 mm {0.2152-0.2157 in}
Minimum valve stem diameter
IN: 5.470 mm {0.2154 in}
EX: 5.465 mm {0.2152 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.
Fig. 28: Measuring Stem Diameter Of Each Valve In X And Y Directions At Three Points (A, B,
And C)
l If not as specified, replace the valve guide.
Standard valve guide inner diameter
5.509-5.539 mm {0.2169-0.2180 in}
Fig. 29: Measuring Inner Diameter Of Each Valve Guide In X And Y Directions At Three Points
(A, B, And C)
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.
l If it exceeds the specification, replace the valve and/or the valve guide.
Standard clearance between valve stem and guide
IN: 0.024-0.069 mm {0.0010-0.0027 in}
EX: 0.029-0.074 mm {0.0012-0.0029 in}
Maximum clearance between valve stem and guide
0.10 mm {0.004 in}
Fig. 30: Inspecting Clearance Between Valve Stem And Guide
6. Measure the protrusion height (dimension A) of each valve guide without lower valve spring seat using
the vernier caliper.
l If not within the specification, replace the valve guide.
Standard valve guide projection height
12.2-12.8 mm {0.481-0.503 in}
Fig. 31: Measuring Protrusion Height (Dimension A) Of Valve Guide Without Lower Valve Spring
Seat
VALVE GUIDE REPLACEMENT

VALVE GUIDE REMOVAL
1. Remove the valve guide from the combustion chamber side using the SST .
Fig. 32: Removing Valve Guide From Combustion Chamber Side Using SST
VALVE GUIDE INSTALLATION
1. Assemble the SSTs so that depth L is as specified.
12.2-12.8 mm {0.481-0.503 in}
Fig. 33: Measuring Valve Guide Projection Height
2. Tap the valve guide in from the cam side using the SSTs assembled in Step 1.
Fig. 34: Tapping Valve Guide In From Cam Side Using SSTs
3. Verify that the valve guide protrusion height (dimension A) is within the specification using the vernier
caliper.
12.2-12.8 mm {0.481-0.503 in}
Fig. 35: Measuring Valve Guide Projection Height
VALVE SPRING INSPECTION

1. Apply pressing force to the pressure spring and inspect the spring height.
l If it is less than the specification, replace the valve spring.
Valve spring installation height
28.68 mm {1.129 in} (390 N {39.8 kgf, 87.7 lbf})
2. Measure the out-of-square of the valve spring, using a square, as shown in the figure.
Fig. 36: Measuring Out-Of-Square Of Valve Spring Using Square
1. Rotate the valve spring one full turn and measure "A" at the point where the gap is the largest.
l If it exceeds the specification, replace the valve spring.
Maximum valve spring off-square
3.41 mm {0.134} (2°)
Fig. 37: Measuring Valve Spring Off-Square
TAPPET INSPECTION
1. Measure the tappet hole inner diameter in X and Y directions at the two points (A and B) shown in the
figure.
Standard tappet bore diameter
31.000-31.030 mm {1.2205-1.2216 in}
Fig. 38: Measuring Tappet Hole Inner Diameter In X And Y Directions At Two Points (A And B)
2. Measure the tappet body outer diameter in X and Y directions at the two points (A and B) shown in the
figure.
Standard tappet body 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.
l If it exceeds the specification, replace the tappet or cylinder head.
Standard clearance between tappet and tappet bore
0.02-0.06 mm {0.001-0.002 in}
Maximum clearance between tappet and tappet bore
0.15 mm {0.0059 in}
Fig. 39: Measuring Tappet Body Outer Diameter In X And Y Directions At Two Points (A And B)
VARIABLE VALVE TIMING ACTUATOR INSPECTION
CAUTION: l Variable valve timing actuator cannot be disassembled because it is

a precision unit.
1. Confirm that the groove of the rotor and notch of the cover at the variable valve timing actuator are
aligned and fixed.
l If the notch and the groove are not aligned, rotate the rotor toward the valve timing retard position
by hand until they are in place.
l If the rotor and cover are not fixed even though their notch and groove are aligned, replace the
variable valve timing actuator.
Fig. 40: Inspecting Variable Valve Timing Actuator
OIL CONTROL VALVE (OCV) INSPECTION

COIL RESISTANCE INSPECTION
1. Measure the resistance between terminals A and B using an ohmmeter.

l If not as specified, replace the OCV.
OCV coil resistance
6.9-7.9 ohms [20 °C {68 °F}]
2. Connect the OCV connector.
Fig. 41: Identifying OCV Connector Terminals
SPOOL VALVE OPERATION INSPECTION
1. Verify that the spool valve in the OCV is in the maximum valve timing retard position as indicated in the
figure.
l If it exceeds the specification, replace the OCV.
2. Verify that the battery is fully charged.

l If it is less than specification, recharge the battery.
3. Apply battery positive voltage between the OCV terminals and verify that the spool valve operates and
moves to the maximum valve timing advance position.
l If it exceeds the specification, replace the OCV.
Fig. 42: Inspecting Spool Valve In OCV Is In Maximum Valve Timing Retard Position
NOTE: l When applying battery positive voltage between the 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
4. Stop applying battery positive voltage and verify that the spool valve returns to the maximum valve
timing retard position.
l If it exceed the specification, replace the OCV.
Fig. 43: Inspecting Spool Valve Returns To Maximum Valve Timing Retard Position
CAMSHAFT INSPECTION
1. Set the No.1 and No.5 journals on V-blocks.
2. Measure the camshaft runout.
l If it exceeds the specification, replace the camshaft.
Maximum camshaft runout
0.03 mm {0.0012 in}
3. Measure the cam lobe height at the two points as shown in the figure.
l If it is less than the specification, replace the camshaft.
Fig. 44: Measuring Camshaft Runout
Camshaft standard height
IN: 42.44 mm {1.671 in}
EX: 41.18 mm {1.621 in}
Camshaft minimum height
IN: 42.33 mm {1.666 in}
EX: 41.06 mm {1.616 in}
4. Measure the journal diameters in X and Y directions at the two points (A and B) as indicated in the
figure.
l If it is less than the specification, replace the camshaft.
Fig. 45: Measuring Cam Lobe Height At Two Points
Camshaft journal standard diameter
24.96-24.98 mm {0.9827-0.9834 in}
Camshaft journal minimum diameter
24.95 mm {0.9822 in}
5. Remove the tappet.
Fig. 46: Measuring Journal Diameters In X And Y Directions At Two Points (A And B)
6. Position a plastigauge atop the journals in the axial direction.

7. Install the camshaft cap. (See CYLINDER HEAD ASSEMBLY (II).)
8. Remove the camshaft cap. (See CYLINDER HEAD DISASSEMBLY (I).)
9. Measure the oil clearance.
l If it exceeds the specification, replace the cylinder head.
Fig. 47: Positioning Plastigauge Atop Journals In Axial Direction
Camshaft journal standard oil clearance
0.04-0.08 mm {0.002-0.003 in}
Camshaft journal maximum oil clearance
0.09 mm {0.003 in}
10. Install the camshaft cap. (See CYLINDER HEAD ASSEMBLY (II).)
11. Measure the camshaft end play.
l If it exceeds the specification, replace the cylinder head or camshaft.
Camshaft standard end play
0.09-0.24 mm {0.004-0.009 in}
Camshaft maximum end play
0.25 mm {0.0098 in}
12. Remove the camshaft cap. (See CYLINDER HEAD DISASSEMBLY (I).)
Fig. 48: Measuring Camshaft End Play
CYLINDER BLOCK INSPECTION

1. Measure the distortion of the cylinder block top surface in six directions as indicated in the figure.
l If it exceeds the maximum, replace the cylinder block.
Maximum distortion, head gasket side
0.10 mm {0.0039 in}
Fig. 49: Measuring Distortion Of Cylinder Block Top Surface In Six Directions
2. Measure the cylinder bores in X and Y directions at 42 mm {1.65 in} below the top surface.
l If not within the specification, replace the cylinder block.
Maximum bore inner diameter
89.000-89.030 mm {3.5040-3.5051 in}
Fig. 50: Measuring Cylinder Bores In X And Y Directions At 42 mm (1.65 in) Below Top Surface
OIL JET VALVE INSPECTION

1. Apply compressed air to oil jet valve A and verify that air passes through oil jet valve B.
l If air does not flow, replace the oil jet valve.
Air pressure
280 kPa {2.86 kgf/cm2 , 40.7 psi} or more
Fig. 51: Inspecting Oil Jet Valve
PISTON INSPECTION
1. Measure the outer diameter of each piston at right angle 90° to the piston pin, 10.0 mm {0.40 in} above
the bottom of the piston.
l If not within the specification, replace the piston, piston pin and snap ring as a single unit.
Standard piston outer diameter
88.965-88.995 mm {3.5026-3.5037 in}
2. Measure the piston-to-cylinder clearance.

l If not within the specification, replace the piston, piston pin and snap ring as a single unit.
Standard clearance between piston and cylinder
0.025-0.045 mm {0.0010-0.0017 in}
Fig. 52: Measuring Outer Diameter Of Each Piston At Right Angle 90° To Piston Pin, 10.0 mm
(0.40 in) Above Bottom Of Piston
Maximum clearance between piston and cylinder
0.11 mm {0.0043 in}
3. Measure the piston ring-to-ring groove clearance around the entire circumference.
l If it exceeds the specification, replace the piston ring.
Standard clearance between piston ring and ring groove
Top: 0.04-0.08 mm {0.002-0.003 in}
Second: 0.03-0.07 mm {0.0012-0.0027 in}
Oil: 0.06-0.15 mm {0.003-0.005 in}
Maximum clearance between piston ring and ring groove
Top: 0.17 mm {0.0066 in}
Second, Oil: 0.15 mm {0.0059 in}
Fig. 53: Measuring Piston Ring-To-Ring Groove Clearance Around Entire Circumference
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.
l If it exceeds the specification, replace the piston ring.
Standard piston ring end gap
Top: 0.16-0.26 mm {0.0063-0.010 in}
Second: 0.31-0.46 mm {0.013-0.018 in}
Oil (rail): 0.15-0.40 mm {0.006-0.015 in}
Fig. 54: Measuring Piston Ring End Gap
Maximum piston ring end gap
1.0 mm {0.039 in}
PISTON AND CONNECTING ROD INSPECTION

1. Check the oscillation torque as shown in the figure. Verify that the large end drops under its own weight
with no resistance.
l If the piston shakes heavily or unsmoothly, disassemble the piston and connecting rod, replace the
piston and snap ring, piston pin, then inspect the inner diameter of the connecting rod at the small
end. (See CONNECTING ROD INSPECTION.)
Fig. 55: Inspecting Piston And Connecting Rod
CONNECTING ROD INSPECTION

1. Install the connecting rod cap. (See CYLINDER BLOCK ASSEMBLY (I).)
2. Measure the connecting rod large end side clearance.
l If it exceeds the specification, replace the piston, piston pin, snap ring and connecting rod.
Connecting rod large end standard side clearance
0.14-0.36 mm {0.006-0.014 in}
Connecting rod large end maximum side clearance
0.435 mm {0.0171 in}
Fig. 56: Measuring Connecting Rod Large End Side Clearance
3. Remove the connecting rod cap.

4. Position plastigauge atop the journals in the axial direction.
5. Install the connecting rod bearing and connecting rod cap. (See CYLINDER BLOCK ASSEMBLY (I).)
6. Remove the connecting rod cap.
7. Measure the connecting rod oil clearance.
l If it exceeds the specification, replace the connecting rod bearing or grind the crank pin and use
oversize bearings so that the specified clearance is obtained.
Standard bearing oil clearance at the large end of connecting rod
0.026-0.052 mm {0.0011-0.0020 in}
Maximum bearing oil clearance at the large end of connecting rod
0.1 mm {0.003 in}
Connecting rod bearing size
STD: 1.497-1.521 mm {0.05894-0.05988 in}
OS 0.25: 1.622-1.628 mm {0.06386-0.06409 in}
OS 0.50: 1.747-1.753 mm {0.06878-0.06901 in}
Fig. 57: Measuring Connecting Rod Oil Clearance
8. Measure the connecting rod small end using a caliper gauge.

l If not exceeds the specification, replace the connecting rod.
Standard connecting rod small end inner diameter
20.010-20.021 mm {0.78780-0.78822 in}
9. Calculate the clearance between the connecting rod small end inner diameter and the new piston pin outer
diameter.
l If not exceeds the specification, replace the connecting rod.
Fig. 58: Measuring Connecting Rod Small End Using Caliper Gauge
Standard clearance between connecting rod small end inner diameter and piston pin outer
diameter
0.010-0.026 mm {0.0004-0.0010 in}
CRANKSHAFT INSPECTION
1. Install the main bearing cap. (See CYLINDER BLOCK ASSEMBLY (I).)
2. Measure the crankshaft end play.
l If it exceeds the specification, replace the thrust bearing or crankshaft so that the specified end play
is obtained.
Crankshaft standard end play
0.22-0.45 mm {0.009-0.017 in}
Crankshaft maximum end play
0.55 mm {0.022 in}
3. Remove the main bearing cap. (See CYLINDER BLOCK DISASSEMBLY (II).)
Fig. 59: Measuring Crankshaft End Play
4. Measure the crankshaft runout.

l If it exceeds the specification, replace the crankshaft.
Maximum main journal runout
0.05 mm {0.001 in}
5. Measure the journal diameter in X and Y directions at the two points (A and B) as indicated in the figure.
l If it exceeds the specification, replace the crankshaft or grind the journal and install the undersize
bearing.
Fig. 60: Measuring Crankshaft Runout
Main journal diameter
STD: 51.980-52.000 mm {2.0465-2.0472 in}
US 0.25: 51.730-51.750 mm {2.0367-2.0374 in}
Maximum main journal off-round
0.005 mm {0.0001 in}
Crank pin diameter
STD: 51.980-52.000 mm {2.0465-2.0472 in}
US 0.25: 51.730-51.750 mm {2.0367-2.0374 in}
Fig. 61: Measuring Journal Diameter In X And Y Directions At Two Points (A And B)
Maximum crank pin off-round
0.005 mm {0.0001 in}
6. Install the main bearing caps and crankshaft. (See CYLINDER BLOCK ASSEMBLY (I).)
7. Position a plastigauge atop the journals in the axial direction.
8. Install the main bearing caps and cylinder block. (See CYLINDER BLOCK ASSEMBLY (I).)
9. Remove the main bearing caps. (See CYLINDER BLOCK DISASSEMBLY (II).)
10. Measure the main journal oil clearance.
l If it exceeds the specification, 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.
Main journal standard oil clearance
0.016-0.046 mm {0.0007-0.0018 in}
Main journal maximum oil clearance
0.10 mm {0.0039 in}
Main bearing size
STD: 2.501-2.529 mm {0.09847-0.09956 in}
OS0.25: 2.623-2.630 mm {0.1033-0.1035 in}
Fig. 62: Measuring Main Journal Oil Clearance
PILOT BEARING INSPECTION

1. Without removing the pilot bearing, turn the bearing while applying force in the axial direction.
l If there is any malfunction, replace the pilot bearing.
Fig. 63: Inspecting Pilot Bearing
BOLT INSPECTION
1. Measure the length of each bolt.
l If it exceeds the specification, replace the bolt.
Cylinder head bolt length
Standard: 145.2-145.8 mm {5.717-5.740 in}
Maximum: 146.5 mm {5.768 in}
Connecting rod bolt length
Standard: 43.7-44.3 mm {1.73-1.74 in}
Maximum: 45.0 mm {1.77 in}
Main bearing cap bolt length
Standard: 104.0-104.6 mm {4.095-4.118 in}
Fig. 64: Measuring Length Of Bolt
VALVE CLEARANCE INSPECTION

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.
l If the valve clearance exceeds the standard, replace the tappet. (See VALVE CLEARANCE
ADJUSTMENT.)
NOTE: l Make sure to note the measured values for choosing the
suitable replacement tappets.
Standard valve clearance [when cold]
IN: 0.22-0.28 mm {0.009-0.011 in}
EX: 0.27-0.33 mm {0.011-0.012 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.
l If the valve clearance exceeds the standard, replace the tappet. (See VALVE CLEARANCE
ADJUSTMENT.)
Fig. 65: Identifying Valve Clearance Measuring Locations (A And B)
NOTE: l Make sure to note the measured values for choosing the
suitable replacement tappets.
Standard valve clearance [when cold]
IN: 0.22-0.28 mm {0.009-0.011 in}
EX: 0.27-0.33 mm {0.011-0.012 in}
VALVE CLEARANCE ADJUSTMENT

1. Remove the engine front cover lower blind plug.
Fig. 66: Identifying Engine Front Cover Lower Blind Plug
2. Remove the engine front cover upper blind plug.
Fig. 67: Identifying Engine Front Cover Upper Blind Plug
3. Remove the cylinder block lower blind plug, and install the SST .
4. Rotate the crankshaft in the direction of the engine rotation so that the No.1 piston is at TDC of the
compression stroke. (Until the counterweight contacts SST and stops.)
5. Loosen the timing chain using the following procedure:
Fig. 68: Identifying SST (303-507)
1. Insert a suitable bolt (M6 X 1.0, length 25-35 mm {0.99-1.3 in}) into the engine front cover upper
blind plug and tighten it until it contacts the chain tensioner arm, and then rotate it back one turn.
(Set the bolt slightly away from the chain tensioner arm so that it does not contact it.)
Fig. 69: Inserting Suitable Bolt (M6 X 1.0, Length 25-35 mm [0.99-1.3 in]) Into Engine Front
Cover Upper Blind Plug
2. Using the cast hexagon on the exhaust camshaft, apply force counterclockwise to facilitate
unlocking the chain tensioner ratchet.
3. Using a Hex bit socket (2.5 mm {0.098 in}) or T15 Torx bit socket, unlock the chain tensioner
ratchet so that it can be lifted up.
Fig. 70: Applying Force Counterclockwise To Facilitate Unlocking Chain Tensioner Ratchet
Fig. 71: Unlocking Chain Tensioner Ratchet
4. Using the cast hexagon on the exhaust camshaft, apply force in the direction of the engine rotation
to increase tension on the chain.
Fig. 72: Applying Force In Direction Of Engine Rotation To Increase Tension On Chain
NOTE: l The chain tensioner rack is compressed using the chain tension
generated by applying force to the exhaust camshaft in the
direction of the engine rotation.
NOTE: l The racket has not been unlocked if the bolt cannot be pressed
in approx. 5 mm {0.2 in}.
5. Screw in the bolt set in Step 1 approx. 5 mm {0.2 in} and secure the tensioner arm with the rack
compressed.
Fig. 73: Applying Force To Exhaust Camshaft In Direction Of Engine Rotation
Fig. 74: Securing Tensioner Arm With Rack Compressed
l If the tensioner arm cannot be secured, return the bolt to its original position and repeat the
procedure from Step 3.
6. Fix the exhaust camshaft using a wrench on the cast hexagon, and loosen the camshaft sprocket
installation bolt.
CAUTION: l Perform the work carefully so that the washer does not drop
out.
Fig. 75: Holding Camshaft Sprocket On Cast Hexagon
7. Remove the exhaust camshaft sprocket installation bolt, exhaust camshaft sprocket, and washer as a
single unit.
Fig. 76: Removing Exhaust Camshaft Sprocket Installation Bolt, Exhaust Camshaft Sprocket, And
Washer
8. Remove the OCV.
NOTE: l The camshaft caps are to be kept ordered for correct reassembly in
their original positions. Do not mix the caps.
Fig. 77: Identifying OCV
9. Loosen the camshaft cap bolts in two or three steps in the order shown in the figure and remove the
camshaft cap.
Fig. 78: Identifying Camshaft Cap Bolt Loosening Order
10. Remove the camshafts for the intake and exhaust sides.
11. Remove the tappet.
12. Install an appropriate tappet based on the results of the valve clearance inspection.
Selected tappet = Removed tappet thickness + Measured valve clearance - Standard valve clearance
Standard valve clearance [Engine cold]
IN: 0.22-0.28 mm {0.009-0.011 in}
EX: 0.27-0.33 mm {0.011-0.012 in}
13. Verify that No.1 cylinder is at TDC of the compression stroke. (Position counterweight contacts SST .)
14. Apply the gear oil (SAE No.90 or equivalent) to each journal of the cylinder head as shown in the figure.
Fig. 79: Applying Gear Oil (SAE No.90 Or Equivalent) To Each Journal Of Cylinder Head
15. Install the camshaft with No.1 cylinder aligned with the TDC position.
16. Apply the gear oil (SAE No.90 or equivalent) to each journal of the camshaft as shown in the figure.
17. Temporarily tighten the camshaft cap bolts evenly in 2-3 steps.
Fig. 80: Applying Gear Oil (SAE No.90 Or Equivalent) To Each Journal Of Camshaft
18. Tighten the camshaft cap bolts in the order shown in the following two steps.
Tightening procedure
1. 5.0-9.0 N.m {51-91 kgf.cm, 45-79 in.lbf}

2. 14-17 N.m {1.5-1.7 kgf.m, 11-12 ft.lbf}
Fig. 81: Identifying Camshaft Cap Bolt Tightening Order
19. Install the OCV.
Tightening torque
8-11 N.m {82-112 kgf.cm, 71-97 in.lbf}
CAUTION: l Install a washer to the fourth or fifth thread of the exhaust

camshaft sprocket bolt being careful not to drop the washer.
l Do not tighten the camshaft sprocket installation bolt at this
stage. Verify the valve timing before performing the bolt
tightening.
Fig. 82: Identifying OCV
20. Install the exhaust camshaft sprocket installation bolt, exhaust camshaft sprocket, and a new washer as a
single unit.
Fig. 83: Identifying Exhaust Camshaft Sprocket Installation Bolt, Exhaust Camshaft Sprocket, And
Washer
21. Install the SST on the camshaft as shown in the figure.
22. Remove the installation bolt for the engine front cover upper blind plug (M6 X 1.0 length 25-35mm
{1.0-1.3 in}) , and apply tension to the timing chain.
23. Fix the exhaust camshaft using a wrench on the cast hexagon, and tighten the sprocket installation bolt.
24. Remove the SST from the camshaft.
25. Remove the SST installed in the cylinder block lower blind plug hole.
Fig. 84: Installing SST (303-465) On Camshaft
26. Rotate the crankshaft clockwise two turns and inspect the valve timing.
l If not aligned, repeat the procedure from 21.
27. Install the cylinder block lower blind plug.
Tightening torque
18-22 N.m {1.9-2.2 kgf.m, 14-16 ft.lbf}
Fig. 85: Identifying Cylinder Block Lower Blind Plug
28. Apply the silicone sealant and install the engine front cover upper blind plug.
Tightening torque
8.0-11.5 N.m {82-117 kgf.cm, 71-101 in.lbf}
Fig. 86: Identifying Engine Front Cover Upper Blind Plug
29. Install a new engine front cover lower blind plug.
Tightening torque
10-14 N.m {102-142 kgf.cm, 89-123 in.lbf}
Fig. 87: Identifying Engine Front Cover Lower Blind Plug
CYLINDER BLOCK ASSEMBLY (I)

1. Assemble in the order indicated in the table.
Fig. 88: Identifying Cylinder Block Assembling Order
MAIN BEARING CAP ASSEMBLY NOTE
1. Install the main bearing caps in the order indicated in the figure, using the SST (49 D032 316) .
Tightening torque
1. 8-12 N.m {82-122 kgf.cm, 71-106 in.lbf}

2. 28-32 N.m {2.9-3.2 kgf.m, 21-23 ft.lbf}
3. 87.5-92.5°
Fig. 89: Identifying Main Bearing Caps Installing Order
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 chamfered face side inner of upper.
Fig. 90: Identifying Piston Ring Assembly
4. Position the end gap of each ring as indicated in the figure.
Fig. 91: Identifying Piston Rings End Gap Position
CONNECTING ROD BEARING ASSEMBLY NOTE
1. Install the connecting rod bearing to the connecting rod and connecting rod caps, as shown in the figure.
Fig. 92: Installing Connecting Rod Bearing To Connecting Rod And Connecting Rod Caps
PISTON ASSEMBLY NOTE
1. Insert the piston and connecting rod into the cylinder with the arrow mark to front of the engine.
Fig. 93: Inserting Piston And Connecting Rod Into Cylinder With Arrow Mark To Front Of Engine
CONNECTING ROD CAP ASSEMBLY NOTE
1. Tighten the connecting rod bolts in two steps using the SST (49 D032 316).
Tightening torque
1. 26-32 N.m {2.7-3.2 kgf.m, 20-23 ft.lbf}

2. 80-100°
BALANCER UNIT ASSEMBLY NOTE
CAUTION: l The balancer unit cannot be disassembled due to the precision

interior construction of the balancer unit.
1. Visually inspect the balancer unit gear for damage and verify that the shaft rotates smoothly.
l If there is any malfunction, replace the balancer unit.
2. Remove the cylinder block lower blind plug and install the SST.
3. Rotate the crankshaft in the direction of engine rotation so that the No. 1 cylinder is at top dead center
(TDC). (Until the counterweight contacts the SST and stops.)
NOTE: l If the cylinder block, crankshaft, crankshaft main bearing, and

balancer unit are not replaced, use the adjustment shim as it is. In
this case, go to Step 12.
4. Assemble the master shims (No. 50) to the shim seating face of the balancer unit at the angles shown in
the figure.
CAUTION: l Engage the gears slowly and place the balancer unit on the
cylinder block while being careful not to contact the balancer
unit gear strongly with the crankshaft drive gear and damage it.
Fig. 95: Assembling Master Shims (No. 50) To Shim Seating Face Of Balancer Unit At Angles
5. With the balancer unit marks at the exact top center positions, assemble the balancer unit to the cylinder
block and tighten the bolts in a crisscross pattern in two steps.
Tightening torque
1. 25 N.m {2.5 kgf.m, 18 ft.lbf}

2. 39-45 N.m {4.0-4.5 kgf.m, 29-33 ft.lbf}
6. Remove the SST installed in Step 2.
7. Measure the gear backlash using the following procedure.
Fig. 96: Identifying Balancer Unit Marks At Exact Top Center Positions
1. Place the ATDC marks 10 °, 30 °, 100 °, 190 °, 210 °, 280 ° on the rear side of the crankshaft to
indicate the angles.
2. Insert a flathead screwdriver into the crankshaft No.1 counterweight area and set both the rotation
and the thrust direction with the flathead screwdriver, using a prying action, as shown in the figure
for accurate measurement of the backlash.
Fig. 97: Inserting Flathead Screwdriver Into Crankshaft No.1 Counterweight Area
3. Set the SST and a dial gauge as shown in the figure.

4. Rotate the driven gear to the left and right so that the crankshaft drive gear and balancer unit gear
contact each other lightly.
5. When measuring the backlash, rotate the crankshaft one full rotation and measure the backlash at 6
locations (A to F) as shown in the figure.
Fig. 98: Setting SST (49 G011 201) And Dial Gauge
Fig. 99: Identifying Crankshaft Backlash Measuring Locations (A To F)
8. Select the adjustment shim from the selection table based on the measured minimum value of the
backlash.
ADJUSTMENT SHIM SELECTION

Measured backlash mm {in} Selection shim (No.) Shim thickness mm {in}
0.267-0.273 {0.01051- 0.01074} 15 1.15 {0.0452}
0.260-0.266 {0.01023- 0.01047} 16 1.16 {0.0456}
0.253-0.259 {0.00996- 0.01019} 17 1.17 {0.0460}
0.246-0.252 {0.00968- 0.00992} 18 1.18 {0.0464}
0.239-0.245 {0.00940- 0.00964} 19 1.19 {0.0468}
0.232-0.238 {0.00913- 0.00937} 20 1.20 {0.0472}
0.225-0.231 {0.00885- 0.00909} 21 1.21 {0.0476}
0.218-0.224 {0.00858- 0.00881} 22 1.22 {0.0480}
0.211-0.217 {0.00830- 0.00854} 23 1.23 {0.0484}
0.204-0.210 {0.00803- 0.00826} 24 1.24 {0.0488}
0.197-0.203 {0.00775- 0.00799} 25 1.25 {0.492}
0.190-0.196 {0.00748- 0.00771} 26 1.26 {0.496}
0.183-0.189 {0.00720- 0.00744} 27 1.27 {0.499}
0.176-0.182 {0.00692- 0.00716} 28 1.28 {0.503}
0.169-0.175 {0.00665- 0.00688} 29 1.29 {0.507}

0.162-0.168 {0.00637- 0.00661} 30 1.30 {0.511}
0.155-0.161 {0.00610- 0.00633} 31 1.31 {0.515}
0.148-0.154 {0.00582- 0.00606} 32 1.32 {0.519}
0.141-0.147 {0.00555- 0.00578} 33 1.33 {0.523}
0.134-0.140 {0.00527- 0.00551} 34 1.34 {0.527}
0.127-0.133 {0.00500- 0.00523} 35 1.35 {0.0531}
0.120-0.126 {0.00472- 0.00496} 36 1.36 {0.0535}
0.113-0.119 {0.00444- 0.00468} 37 1.37 {0.0539}
0.106-0.112 {0.00417- 0.00440} 38 1.38{0.0543}
0.099-0.105 {0.00389- 0.00413} 39 1.39 {0.0547}
0.092-0.098 {0.00362- 0.00385} 40 1.40 {0.0551}
0.085-0.091 {0.00334- 0.00358} 41 1.41 {0.0555}
0.078-0.084 {0.00307- 0.00330} 42 1.42 {0.0559}
0.071-0.077 {0.00279- 0.00303} 43 1.43 {0.0562}
0.064-0.070 {0.00251- 0.00275} 44 1.44 {0.0566}
0.057-0.063 {0.00224- 0.00248} 45 1.45 {0.0570}
0.050-0.056 {0.00196- 0.00220} 46 1.46 {0.0574}
0.043-0.049 {0.00169- 0.00192} 47 1.47 {0.0578}
0.036-0.042 {0.00141- 0.00165} 48 1.48 {0.0582}
0.029-0.035 {0.00114- 0.00137} 49 1.49 {0.0586}
0.022-0.028 {0.000866- 0.00110} 50 (master shim) 1.50 {0.0590}
0.015-0.021 {0.00059- 0.000826} 51 1.51 {0.0594}
0.008-0.014 {0.000314- 0.000551} 52 1.52 {0.0598}
0.001-0.007 {0.00003- 0.000275} 53 1.53 {0.0602}
0.000-0.000 {0.000-0.000} 54 1.54 {0.0606}
9. Verify that the No. 1 cylinder is at TDC.

l If not aligned, perform Steps 2-3.
10. Remove the master shim from the balancer unit and assemble the selected adjustment shim at the angles
shown in the figure.
11. Perform Steps 5-7.
12. Verify that the measured backlash is within the specified range.
l If the backlash exceeds the maximum specification, replace the adjustment shim and repeat Steps
4-12.
Measured backlash maximum
0.01-0.10 mm {0.001-0.003 In}
Fig. 100: Assembling Selected Adjustment Shim At Angles
PILOT BEARING ASSEMBLY NOTE
1. Assemble the pilot bearing using the corresponding 20 mm {0.79 in} side of a Snap-on brand millimeter
size bushing driver set A160M adapter A160M7 (20-22 mm {0.79-0.86 in}).
Substitution
A160M7 (20 mm {0.79 in})
Outer diameter: 21 mm {0.83 in}
Inner diameter: 19 mm {0.75 in}
Fig. 101: Assembling Pilot Bearing
Fig. 102: Identifying Pilot Bearing Installation Dimensions
CYLINDER BLOCK ASSEMBLY (II)

Fig. 103: Identifying Cylinder Block Assemble Order
REAR OIL SEAL ASSEMBLY NOTE
1. Apply clean engine oil to the new oil seal lip.

2. Install the SST to the non-woven fabric side of the rear oil seal.
Fig. 104: Installing SST (303-328) To Non-Woven Fabric Side Of Rear Oil Seal
3. From the back side of the rear oil seal, verify that there is no damage or separation in the lip area of the
rear oil seal.
4. Install the rear oil seal to the engine.
Fig. 105: Inspecting Lip Area Of Rear Oil Seal
5. Tighten the rear oil seal bolts in the order as shown in the figure. (Except TRIBUTE (L.H.D.) Face-lifted
model.)
Tightening torque
8-11 N.m {82-112 kgf.cm, 71-97 in.lbf}
Fig. 106: Identifying Rear Oil Seal Bolt Tightening Order
DRIVE PLATE (ATX), FLYWHEEL (MTX) ASSEMBLY NOTE
1. Hold the crankshaft using the SST .

2. Tighten the bolts in the 3 steps in the figure.
Tightening torque
1. 46-54 N.m {4.7-5.5 kgf.m, 34-39 ft.lbf}

2. 76-84 N.m {7.8-8.5 kgf.m, 57-61 ft.lbf}
3. 108-116 N.m {11.1-11.8 kgf.m, 80-85 ft.lbf}
Fig. 107: Identifying Flywheel Bolts Tightening Sequence
OIL PAN ASSEMBLY NOTE
1. Apply a continuous bead of silicone sealant to the oil pan as indicated in the figure.
Fig. 108: Applying Continuous Bead Of Silicone Sealant To Oil Pan
2. Use a square ruler to unite the oil pan and the cylinder block junction side on the engine front cover side.
Fig. 109: Assemblying Oil Pan And Cylinder Block Junction Side On Engine Front Cover Side
Using Square Ruler
3. Tighten the rear oil pan bolts in the order as shown in the figure.
Tightening torque
17-23 N.m {1.8-2.3 kgf.m, 13-16 ft.lbf}
Fig. 110: Identifying Rear Oil Pan Bolt Tightening Order
CYLINDER HEAD ASSEMBLY (I)

Fig. 111: Identifying Cylinder Head Assemblying Order
VALVE SEAL ASSEMBLY NOTE
1. Press the valve seal onto the valve guide by hand.
2. Lightly tap the SST using a plastic hammer.
Fig. 112: Tapping SST Using Plastic Hammer
VALVE KEEPER ASSEMBLY NOTE
1. Install the valve keeper using the SSTs .
Fig. 113: Installing Valve Keeper Using SSTs
CYLINDER HEAD ASSEMBLY (II)

Fig. 114: Identifying Cylinder Head Assemblying Order
CYLINDER HEAD BOLT ASSEMBLY NOTE
1. Tighten the cylinder head bolts in the order indicated in the figure in 5 steps. However, use the SST (49
D32 316) in Steps 4 and 5.
Tightening torque
1. 3-11 N.m {31-112 kgf.cm, 27-97 in.lbf}

2. 13-17 N.m {133-173 kgf.cm, 116-150 in.lbf}
3. 43-47 N.m {4.4-4.7 kgf.m, 32-34 ft.lbf}
4. 88-92°
5. 88-92°
Fig. 115: Identifying Cylinder Head Bolt Tightening Order
CAMSHAFT ASSEMBLY NOTE
1. Apply the gear oil (SAE No.90 or equivalent) to each journal of the cylinder head as shown in the figure.
2. Set the cam position of No.1 cylinder at the top dead center (TDC) and install the camshaft.
Fig. 116: Applying Gear Oil (SAE No.90 Or Equivalent) To Each Journal Of Cylinder Head
3. Apply the gear oil (SAE No.90 or equivalent) to each journal of the camshaft as shown in the figure.
4. Temporarily tighten the camshaft cap bolts evenly in 2-3 steps.
5. Tighten the camshaft cap bolts in the order shown with the following two steps.
Fig. 117: Applying Gear Oil (SAE No.90 Or Equivalent) To Each Journal Of Camshaft
Tighten torque
1. 5.0-9.0 N.m {51-91 kgf.cm, 45-79 in.lbf}

2. 14-17 N.m {1.5-1.7 kgf.m, 11-12 ft.lbf}
Fig. 118: Identifying Camshaft Cap Bolt Tightening Order
CAMSHAFT SPROCKET, VARIABLE VALVE TIMING ACTUATOR ASSEMBLY NOTE
1. Temporarily tighten the camshaft sprocket or variable valve timing actuator installation bolts by hand
until the timing chain is installed.
2. Fully tighten the camshaft sprocket or variable valve timing actuator installation bolts after timing chain
installation.
TIMING CHAIN ASSEMBLY

Fig. 119: Identifying Timing Chain Assembling Order
OIL PUMP SPROCKET ASSEMBLY NOTE
1. Temporarily install the crankshaft pulley and crankshaft pulley lock bolt to the crankshaft, and lock the
oil pump against rotation as shown in figure.
2. Install the oil pump sprocket, and then remove the crankshaft pulley and crankshaft pulley lock bolt.
Tightening torque
20-30 N.m {2.1-3.0 kgf.m, 15-22 ft.lbf}
Fig. 120: Tightening Crankshaft Pulley Lock Bolt
TIMING CHAIN ASSEMBLY NOTE
1. Install the SST to the camshaft, then align the No. 1 camshaft position with the TDC.
2. Remove the cylinder block lower blind plug.
Fig. 121: Installing SST To Camshaft
3. Install the SST as shown in the figure.

4. Turn the crankshaft clockwise so that the crankshaft is in the No.1 cylinder TDC position.
5. Install the timing chain.
6. Install the chain tensioner and remove the retaining wire.
Fig. 123: Identifying Chain Tensioner And Retaining Wire
CAMSHAFT SPROCKET, VARIABLE VALVE TIMING ACTUATOR ASSEMBLY NOTE
1. Hold the camshaft using a suitable wrench on the cast hexagon as shown in the figure.
2. Tighten the camshaft sprocket lock bolt.
Tightening torque
69-75 N.m {7.1-7.6 kgf.m, 51-55 ft.lbf}
Fig. 124: Tightening Camshaft Sprocket Lock Bolt
FRONT OIL SEAL ASSEMBLY 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.
Fig. 125: Compressing Oil Seal Using SST (49 H010 401)
Front oil seal press-in amount
0-0.5 mm {0-0.019 in}
Fig. 126: Identifying Front Oil Seal Press-In Amount
ENGINE FRONT COVER ASSEMBLY NOTE
CAUTION: l Install the engine front cover within 10 minutes of applying the
silicone sealant.
1. Apply silicone sealant to the engine front cover as shown.
Fig. 127: Applying Silicone Sealant To Engine Front Cover
Thickness
A. 2.2-3.2 mm {0.09-0.12 in}

B. 1.5-2.5 mm {0.06-0.098 in}
C. 2.2-4.3 mm {0.09-0.16 in}
D. 3.3-4.3 mm {0.13-0.16 in}
2. Install the cylinder head cover bolts in the order as shown in the figure.
No. Tightening torque

1-18 8.0-11.5 N.m {81.6-117.2 kgf.cm, 70.9- 101.7 in.lbf}
19-22 40-55 N.m {4.1-5.6 kgf.m, 30-40 ft.lbf}
Fig. 128: Identifying Cylinder Head Cover Bolts Installation Order
CRANKSHAFT PULLEY LOCK BOLT ASSEMBLY NOTE
1. Install the SST to the camshaft as shown in the figure.

2. Verify that No.1 cylinder is at TDC of the compression stroke. (Position counterweight contacts SST .)
Fig. 129: Installing SST To Camshaft
3. To position the crankshaft pulley, temporarily tighten it and, using a suitable bolt (M6 X 1.0) , fix the
crankshaft pulley to the engine front cover.
Fig. 130: Identifying SST (303-507) And Bolt (M6 X 1.0)
4. Install the SST to the ring gear to lock the crankshaft against rotation.
5. Tighten the crankshaft pulley lock bolt in the order shown in the following two steps using the SST (49
D032 316).
Tightening procedure
1. 96-104 N.m {9.8-10 kgf.m, 71-76 ft.lbf}

2. 87-93°
Fig. 131: Identifying SST On Ring Gear To Lock Crankshaft Against Rotation
6. Remove the bolt (M6 X 1.0) installed to the crankshaft pulley.

7. Remove the SST from the camshaft.
8. Remove the SST from the cylinder block lower blind plug hole.
9. Remove the SST from the ring gear.
10. Rotate the crankshaft clockwise two turns and inspect the valve timing.
l If not aligned, loosen the crankshaft pulley lock bolt and repeat from Step 1.
11. Install the cylinder block lower blind plug.
Tightening torque
18-22 N.m {1.9-2.2 kgf.m, 14-16 ft.lbf}
Fig. 132: Identifying Cylinder Block Lower Blind Plug
CYLINDER HEAD COVER ASSEMBLY NOTE
CAUTION: l Install the cylinder head cover within 10 min of applying the silicone
sealant.
1. Apply silicone sealant to the mating faces as shown in the figure.
Thickness
4.0-6.0 mm {0.16-0.23 in}
2. Install the cylinder head cover with a new gasket.
Fig. 133: Applying Silicone Sealant To Mating Faces Of Cylinder Head Cover
3. Tighten the bolts in the order shown in the figure.
Tightening torque
8.0 -9.5 N.m {82-96 kgf.cm, 71-84 in.lbf}
Fig. 134: Identifying Cylinder Head Cover Bolt Tightening Order

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2013 Mazda 3 i Sport

2012 ENGINE Mechanical - Mazda 3, CX-7

Mechanical - Mazda 3, CX-7

ENGINE OVERHAUL SERVICE WARNING

Fig. 1: Identifying SST (49 L010 102) On Cylinder Block

jueves, 18 de marzo de 2021 11:36:45

Fig. 2: Identifying SST (Bolts, Nuts And Plate) Positions

WARNING: l Self-locking brake system of the engine stand may not be

6. Mount the engine on the SST (49 0107 680A).

Fig. 3: Identifying SST Bolts And Nuts

25-30 N.m {2.6-3.0 kgf.m, 19-22 ft.lbf}

l Dismount in the reverse order of mounting.

TIMING CHAIN DISASSEMBLY

Fig. 4: Identifying Timing Chain Disassemble Order

CRANKSHAFT PULLEY LOCK BOLT DISASSEMBLY NOTE

Fig. 5: Identifying SST (Crankshaft Pulley Lock)

FRONT OIL SEAL DISASSEMBLY NOTE

1. Remove the oil seal using a flat head screwdriver.

Fig. 6: Removing Oil Seal Using Flat Head Screwdriver

CHAIN TENSIONER DISASSEMBLY NOTE

OIL PUMP SPROCKET DISASSEMBLY NOTE

Fig. 8: Removing Crankshaft Pulley And Crankshaft Pulley Lock Bolt

CYLINDER HEAD DISASSEMBLY (I)

Fig. 9: Identifying Cylinder Head Disassemble Order

CAMSHAFT CAP DISASSEMBLY NOTE

1. Before removing the camshaft caps, inspect the following:

Fig. 11: Identifying Camshaft Caps Bolts Loosening Order

TAPPET DISASSEMBLY NOTE

CYLINDER HEAD BOLT DISASSEMBLY NOTE

Fig. 12: Identifying Cylinder Head Bolts Loosening Order

CYLINDER HEAD DISASSEMBLY (II)

Fig. 13: Identifying Cylinder Head Disassemble Order

VALVE KEEPER DISASSEMBLY NOTE

1. Remove the valve keeper using the SSTs.

Fig. 14: Removing Valve Keeper Using SSTs

VALVE SEAL DISASSEMBLY NOTE

1. Remove the valve seal using the SST.

Fig. 15: Removing Valve Seal Using SST

CYLINDER BLOCK DISASSEMBLY (I)

Fig. 16: Identifying Cylinder Block Disassemble Order

DRIVE PLATE (ATX), FLYWHEEL (MTX) DISASSEMBLY NOTE

1. Hold the crankshaft using the SST .

Fig. 17: Identifying Flywheel Bolt Removal Sequence

CYLINDER BLOCK DISASSEMBLY (II)

1. Disassemble in the order indicated in the table.

Fig. 18: Identifying Cylinder Block Disassemble Order

PILOT BEARING DISASSEMBLY NOTE

1. Use the SST to remove the pilot bearing.

Fig. 19: Removing Pilot Bearing Using SST

CONNECTING ROD CAP DISASSEMBLY NOTE

NOTE: l Determine the position of each removed connecting rod cap.

MAIN BEARING CAP DISASSEMBLY NOTE

Fig. 20: Identifying Main Bearing Cap Bolts Loosening Sequence

CYLINDER HEAD INSPECTION

lReplace the cylinder head if necessary.

Maximum distortion, head gasket side

0.10 mm {0.004 in}

Fig. 21: Measuring Cylinder Head For Distortion In Six Directions