Mazda 2.5L (L5) Engine Workshop Manual (2009-2013)

1924-1U-08F(INDEX).
fm 1 ページ２００８年５月２３日金曜日午後１時４３分
Engine CONTENTS
Workshop Title Section
Manual GENERAL INFORMATION 00

L5 ENGINE 01
FOREWORD
© 2008 Mazda Motor Corporation
This manual explains the service points for PRINTED IN U.S.A., JUNE 2008
the above-indicated automotive system. Form No. 1924–1U–08F
This manual covers all models with the Part No. 9999–95–00L5–09
above-indicated automotive system, not any
one specific model.
In order to do these procedures safely,

quickly, and correctly, you must first read
this manual and any other relevant service
materials carefully.
All the contents of this manual, including

drawings and specifications, are the latest
available at the time of printing.
As modifications affecting repair or
maintenance occur, relevant information
supplementary to this volume will be made
available at Mazda dealers. This manual
should be kept up-to-date.
Mazda Motor Corporation reserves the right

to alter the specifications and contents of
this manual without obligation or advance
notice.
All rights reserved. No part of this book may

be reproduced or used in any form or by any
means, electronic or mechanical—including
photocopying and recording and the use of
any kind of information storage and retrieval
system—without permission in writing.
Mazda Motor Corporation

HIROSHIMA, JAPAN
1929-1U-08F(05-60).backup.fm 2 ページ２００８年５月２６日月曜日午前９時４３分
End Of Sie
1924-1U-08F.book 1 ページ２００８年５月２２日木曜日午前１１時４８分
GENERAL INFORMATION 00SECTION

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 NEW STANDARDS . . . . . . . . . . . . . . . . . 00-00–10
Special Service Tools . . . . . . . . . . . . . . 00-00–6 ABBREVIATIONS . . . . . . . . . . . . . . . . . . 00-00–12
Disassembly . . . . . . . . . . . . . . . . . . . . . 00-00–6
End of Toc
HOW TO USE THIS MANUAL
EN: GENERAL INFORMATION
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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.
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.
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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.
SHOWS SERVICE
Procedure ITEM (S)
INDICATES ANY RELEVANT
1
LOWER TRAILING LINK, UPPER TRAILING LINK REMOVAL/INSTALLATION REFERENCES WHICH NEED
1. Jack up the rear of the vehicle and support it with safety stands. TO BE FOLLOWED DURING
"Removal/Installation" 2. Remove the undercover. (See 01-10-4 Undercover Removal)
Portion 3. Remove in the order indicated in the table. INSTALLATION
4. Install in the reverse order of removal.
2 5. Inspect the rear wheel alignment and adjust it if necessary.
"Inspection After SHOWS SPECIAL
Installation" Portion 11 SERVICE TOOL (SST)
9 SST
SHOWS PROCEDURE ORDER FOR SERVICE OPERATION
GREASE
FOR SERVICE 12 SST R
INSTALL THE PARTS BY SHOWS APPLICATION

PERFORMING STEPS 8 43—56 {4.3—5.8, 32—41}
POINTS OF GREASE, ETC.
10
— IN REVERSE ORDER
1—3 44—60 {4.4—6.2, 32—44} 7 R
SHOWS TIGHTENING
TORQUE
SPECIFICATIONS SHOWS NON-REUSEABLE PARTS
SST
3
5
6 SHOWS DETAILS
SST
GREASE
4 R
94—116 {9.5—11.9, 69—86}
2 118—156 {12.0—16.0, 87—115} SHOWS TIGHTENING
SHOWS THERE 1 R TORQUE UNITS
ARE REFERRAL
N·m {kgf·m, ft·lbf}
NOTES FOR SERVICE
1 Split pin 7 Split pin
2 Nut 8 Nut
3 Lower trailing link ball joint 9 Upper trailing link ball joint
(See 02-14-5 Lower Trailing Link Ball Joint Removal Note) (See 02-14-5 Upper Trailing Link Ball Joint Removal Note)
4 Bolt 10 Nut
5 Lower trailing link 11 Upper trailing link
6 Dust boot (lower trailing link) 12 Dust boot (upper trailing link)
Lower Trailing Link Ball Joint, Upper Trailing Link 49 T028 304 UPPER TRAILING LINK
Ball Joint Removal Note 49 T028 305 LOWER TRAILING LINK
Remove the ball joint using the SSTs.
SHOWS SPECIAL
SERVICE TOOL (SST)
NO. KNUCKLE
49 T028 303
SHOWS REFERRAL
NOTES FOR
SERVICE
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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
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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
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Preparation of Tools and Measuring Equipment
• Be sure that all necessary tools and measuring
equipment are available before starting any work.
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Special Service Tools

• Use special service tools or equivalent when they
are required.
49 SE01 310
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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.
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Inspection During Removal, Disassembly

• When removed, each part should be carefully
inspected for malfunction, deformation, damage
and other problems.
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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
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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.
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Reassembly
• Standard values, such as torques and certain
adjustments, must be strictly observed in the
reassembly of all parts.
• If removed, the following parts should be replaced
with new ones:
— Oil seals
— Gaskets
— O-rings
— Lockwashers
— Cotter pins
— Nylon nuts
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• 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.
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00-00–7
GENERAL INFORMATION
Adjustment
• Use suitable gauges and testers when making
adjustments.
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Rubber Parts and Tubing

• Prevent gasoline or oil from getting on rubber
parts or tubing.
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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.
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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)] belbze00000022
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
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ELECTRICAL SYSTEM
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Connectors
Disconnecting connectors
• When disconnecting connector, grasp the
connectors, not the wires. GOOD NO GOOD
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• Connectors can be disconnected by pressing or

pulling the lock lever as shown.
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Locking connector
• When locking connectors, listen for a click
indicating they are securely locked.
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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.
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End Of Sie
GOOD NO GOOD
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NEW STANDARDS
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• Following is a comparison of the previous standard and the new standard.
New Standard Previous Standard
Abbrevi- Abbrevi- Remark
Name Name
ation ation
AP Accelerator Pedal — Accelerator Pedal
ACL Air Cleaner — Air Cleaner
A/C Air Conditioning — Air Conditioning
BARO Barometric Pressure — Atmospheric Pressure
B+ Battery Positive Voltage Vb Battery Voltage
— Brake Switch — Stoplight Switch
— Calibration Resistor — Corrected Resistance #6
CMP sensor Camshaft Position Sensor — Crank Angle Sensor
CAC Charge Air Cooler — Intercooler
CLS Closed Loop System — Feedback System
CTP Closed Throttle Position — Fully Closed
CPP Clutch Pedal Position — Idle Switch
CIS Continuous Fuel Injection System — Clutch Position
CS sensor Control Sleeve Sensor CSP sensor Control Sleeve Position Sensor #6
CKP sensor Crankshaft Position Sensor — Crank Angle Sensor 2
DLC Data Link Connector — Diagnosis Connector
DTM Diagnostic Test Mode — Test Mode #1
DTC Diagnostic Trouble Code(s) — Service Code(s)
DI Distributor Ignition — Spark Ignition
DLI Distributorless Ignition — Direct Ignition
EI Electronic Ignition — Electronic Spark Ignition #2
ECT Engine Coolant Temperature — Water Thermo
EM Engine Modification — Engine Modification
— Engine Speed Input Signal — Engine RPM Signal
EVAP Evaporative Emission — Evaporative Emission
EGR Exhaust Gas Recirculation — Exhaust Gas Recirculation
FC Fan Control — Fan Control
00-00–10
GENERAL INFORMATION
Name Name
ation ation
FF Flexible Fuel — Flexible Fuel
4GR Fourth Gear — Overdrive 00-00
— Fuel Pump Relay — Circuit Opening Relay #3
FSO
Fuel Shut Off Solenoid FCV Fuel Cut Valve #6
solenoid
GEN Generator — Alternator
GND Ground — Ground/Earth
HO2S Heated Oxygen Sensor — Oxygen Sensor With heater
IAC Idle Air control — Idle Speed Control
— IDM Relay — Spill Valve Relay #6
— Incorrect Gear Ratio — —
— Injection Pump FIP Fuel Injection Pump #6
— Input/Turbine Speed Sensor — Pulse Generator
IAT Intake Air Temperature — Intake Air Thermo
KS Knock Sensor — Knock Sensor
MIL Malfunction Indicator Lamp — Malfunction Indicator Light
MAP Manifold Absolute Pressure — Intake Air Pressure
MAF sensor Mass Air Flow Sensor — Airflow Sensor
MFL Multiport Fuel Injection — Multiport Fuel Injection
OBD On-Board Diagnostic — Diagnosis/Self-Diagnosis
OL Open Loop — Open Loop
— Output Speed Sensor — Vehicle Speed Sensor 1
OC Oxidation Catalytic Converter — Catalytic Converter
O2S Oxygen Sensor — Oxygen Sensor
PNP Park/Neutral Position — Park/Neutral Range
— PCM Control Relay — Main Relay #6
PSP Power Steering Pressure — Power Steering Pressure
PCM Powertrain Control Module ECU Engine Control Unit #4
— Pressure Control Solenoid — Line Pressure Solenoid Valve
Pulsed
PAIR Pulsed Secondary Air Injection — Secondary Air Injection System
injection
— Pump Speed Sensor — NE Sensor #6
Injection
AIR Secondary Air Injection — Secondary Air Injection System with air
pump
SAPV Secondary Air Pulse Valve — Reed Valve
SFI Sequential Multipoint Fuel Injection — Sequential Fuel Injection
— 12 Shift Solenoid Valve
— Shift Solenoid A
— Shift A Solenoid Valve
— 23 Shift Solenoid Valve
— Shift Solenoid B
— Shift B Solenoid Valve
— Shift Solenoid C — 34 Shift Solenoid Valve
3GR Third Gear — 3rd Gear
TWC Three Way Catalytic Converter — Catalytic Converter
TB Throttle Body — Throttle Body
TP sensor Throttle Position Sensor — Throttle Sensor
TCV Timer Control Valve TCV Timing Control Valve #6
TCC Torque Converter Clutch — Lockup Position
Transmission (Transaxle) Control
TCM — EC-AT Control Unit
Module
Transmission (Transaxle) Fluid
— — ATF Thermosensor
Temperature Sensor
TR Transmission (Transaxle) Range — Inhibitor Position
TC Turbocharger — Turbocharger
00-00–11
GENERAL INFORMATION
Name Name
ation ation
VSS Vehicle Speed Sensor — Vehicle Speed Sensor
VR Voltage Regulator — IC Regulator
VAF sensor Volume Air Flow Sensor — Air flow Sensor
Warm Up Three Way Catalytic
WUTWC — Catalytic Converter #5
Converter
WOT Wide Open Throttle — Fully Open
#1 : Diagnostic trouble codes depend on the diagnostic test mode

#2 : Controlled by the PCM
#3 : In some models, there is a fuel pump relay that controls pump speed. That relay is now called the fuel pump
relay (speed).
#4 : Device that controls engine and powertrain
#5 : Directly connected to exhaust manifold
#6 : Part name of diesel engine
End Of Sie
ABBREVIATIONS
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ATX Automatic Transaxle

EX Exhaust
IN Intake
MTX Manual Transaxle
OCV Oil Control Valve
SST Special Service Tool
TDC Top Dead Center
End Of Sie
00-00–12
ENGINE 01SECTION
01-10
Toc of SCT
MECHANICAL. . . . . . . . . . . . . . 01-10 SERVICE TOOLS . . . . . . . . . . . 01-60
TECHNICAL DATA . . . . . . . . . . 01-50
Toc of SCT
01-10 MECHANICAL
ENGINE OVERHAUL OIL CONTROL VALVE (OCV)
SERVICE WARNING . . . . . . . . . . . . . . . 01-10–2 INSPECTION . . . . . . . . . . . . . . . . . . . . . 01-10–20
ENGINE MOUNTING/DISMOUNTING . . . 01-10–2 Coil resistance inspection. . . . . . . . . . . 01-10–20
DISMOUNTING. . . . . . . . . . . . . . . . . . . 01-10–3 Spool valve operation inspection . . . . . 01-10–20
TIMING CHAIN DISASSEMBLY. . . . . . . . 01-10–4 CAMSHAFT INSPECTION . . . . . . . . . . . 01-10–21
Crankshaft Pulley Lock Bolt CYLINDER BLOCK INSPECTION . . . . . 01-10–22
Disassembly Note . . . . . . . . . . . . . . . . 01-10–5 OIL JET VALVE INSPECTION . . . . . . . . 01-10–23
Front Oil Seal Disassembly Note . . . . . 01-10–5 PISTON INSPECTION . . . . . . . . . . . . . . . 01-10–23
Chain Tensioner PISTON AND CONNECTING ROD
Disassembly Note . . . . . . . . . . . . . . . . 01-10–5 INSPECTION . . . . . . . . . . . . . . . . . . . . . 01-10–24
Oil Pump Sprocket CONNECTING ROD INSPECTION . . . . . 01-10–24
Disassembly Note . . . . . . . . . . . . . . . . 01-10–5 CRANKSHAFT INSPECTION . . . . . . . . . 01-10–25
CYLINDER HEAD PILOT BEARING INSPECTION . . . . . . . 01-10–27
DISASSEMBLY(I) . . . . . . . . . . . . . . . . . . 01-10–6 BOLT INSPECTION . . . . . . . . . . . . . . . . . 01-10–27
Camshaft Sprocket Lock Bolt, VALVE CLEARANCE
Variable Valve Timing Actuator INSPECTION . . . . . . . . . . . . . . . . . . . . . 01-10–27
Lock Bolt Disassembly Note . . . . . . . . 01-10–7 VALVE CLEARANCE
Camshaft Cap Disassembly Note . . . . . 01-10–7 ADJUSTMENT. . . . . . . . . . . . . . . . . . . . 01-10–28
Tappet Disassembly Note . . . . . . . . . . . 01-10–7 CYLINDER BLOCK ASSEMBLY (I) . . . . 01-10–34
Cylinder Head Bolt Main Bearing Cap Assembly Note . . . . 01-10–35
Disassembly Note . . . . . . . . . . . . . . . . 01-10–7 Piston Ring Assembly Note . . . . . . . . . 01-10–35
CYLINDER HEAD Connecting Rod Bearing
DISASSEMBLY (II) . . . . . . . . . . . . . . . . . 01-10–8 Assembly Note . . . . . . . . . . . . . . . . . . 01-10–35
Valve Keeper Disassembly Note . . . . . . 01-10–8 Piston Assembly Note . . . . . . . . . . . . . 01-10–36
Valve Seal Disassembly Note . . . . . . . . 01-10–9 Connecting Rod Cap
CYLINDER BLOCK Assembly Note . . . . . . . . . . . . . . . . . . 01-10–36
DISASSEMBLY (I) . . . . . . . . . . . . . . . . . 01-10–10 Balancer Unit Assembly Note. . . . . . . . 01-10–36
Drive Plate (ATX), Flywheel (MTX) Pilot Bearing Assembly Note . . . . . . . . 01-10–39
Disassembly Note . . . . . . . . . . . . . . . . 01-10–11 CYLINDER BLOCK ASSEMBLY (II) . . . . 01-10–39
CYLINDER BLOCK Rear Oil Seal Assembly Note. . . . . . . . 01-10–41
DISASSEMBLY (II) . . . . . . . . . . . . . . . . . 01-10–12 Drive Plate (ATX), Flywheel (MTX)
Pilot Bearing Disassembly Note . . . . . . 01-10–13 Assembly Note . . . . . . . . . . . . . . . . . . 01-10–42
Connecting Rod Cap Oil pan Assembly Note. . . . . . . . . . . . . 01-10–42
Disassembly Note . . . . . . . . . . . . . . . . 01-10–13 CYLINDER HEAD ASSEMBLY (I). . . . . . 01-10–43
Main Bearing Cap Valve Seal Assembly Note . . . . . . . . . . 01-10–43
Disassembly Note . . . . . . . . . . . . . . . . 01-10–13 Valve Keeper Assembly Note . . . . . . . . 01-10–44
CYLINDER HEAD INSPECTION . . . . . . . 01-10–14 CYLINDER HEAD ASSEMBLY (II) . . . . . 01-10–44
VALVE SEAT INSPECTION/REPAIR . . . . 01-10–14 Cylinder Head Bolt
VALVE, VALVE GUIDE Assembly Note . . . . . . . . . . . . . . . . . . 01-10–45
INSPECTION . . . . . . . . . . . . . . . . . . . . . 01-10–15 Camshaft Assembly Note. . . . . . . . . . . 01-10–45
VALVE GUIDE REPLACEMENT . . . . . . . 01-10–17 Camshaft Sprocket, Variable Valve
Valve Guide Removal . . . . . . . . . . . . . . 01-10–17 Timing Actuator Assembly Note . . . . . 01-10–46
Valve Guide Installation. . . . . . . . . . . . . 01-10–17 TIMING CHAIN ASSEMBLY . . . . . . . . . . 01-10–47
VALVE SPRING INSPECTION . . . . . . . . . 01-10–18 Oil Pump Sprocket Assembly Note . . . 01-10–48
TAPPET INSPECTION . . . . . . . . . . . . . . . 01-10–19 Timing Chain Assembly Note . . . . . . . . 01-10–48
VARIABLE VALVE TIMING ACTUATOR Camshaft Sprocket, Variable Valve
INSPECTION . . . . . . . . . . . . . . . . . . . . . 01-10–19 Timing Actuator Assembly Note . . . . . 01-10–49
Front Oil Seal Assembly Note . . . . . . . 01-10–49
01-10–1
MECHANICAL
Engine Front Cover Assembly Note . . . 01-10–50 Cylinder Head Cover
Crankshaft Pulley Lock Bolt Assembly Note . . . . . . . . . . . . . . . . . . 01-10–52
Assembly Note . . . . . . . . . . . . . . . . . . 01-10–51
End of Toc
ENGINE OVERHAUL SERVICE WARNING
EN: ENGINE COMPLETE
id011000503900
Warning
• Continuous exposure with USED engine oil has caused skin cancer in laboratory mice. Protect
your skin by washing with soap and water immediately after this work.
End Of Sie
ENGINE MOUNTING/DISMOUNTING
id011000507000
1. Install the SSTs (arms) to the cylinder block holes
as shown, and hand-tighten the bolts (part No.:
9YA20-1003) or M10 × 1.5T length 90 mm {3.55 49 L010 102
in}.
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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).
49 L010 101 49 L010 104
49 L010 105
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01-10–2
MECHANICAL
5. Tighten the SSTs (bolts and nuts) to affix the
SSTs firmly.
Warning
• Self-locking brake system of the engine 49 L010 106 PARALLEL
49 L010 101
stand may not be effective when the
engine is held in an unbalanced position.
49 L010 102
This could lead to sudden, rapid 01-10
movement of the engine and mounting 49 L010 105
stand handle and cause serious injury. ENGINE
Never keep the engine in an unbalanced
position, and always hold the rotating
49 L010 104
handle firmly when turning the engine.
49 L010 103 APPROX. 20 mm {0.79 in}
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.
(1) Inspect the seal rubber of the oil pan drain beleue00000017
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
• Dismount in the reverse order of mounting.
End Of Sie
01-10–3
MECHANICAL
TIMING CHAIN DISASSEMBLY
id011000505500
1. Disassemble in the order indicated in the table. .
3
8
7
R
R
OIL
SST
9
SEALANT
5
6
4 R SST SEALANT
10
13 R
11 14
15
12 17
16
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1 Dipstick 10 Chain tensioner

2 Spark plug (See 01-10-5 Chain Tensioner Disassembly Note.)
3 Cylinder head cover 11 Tensioner arm
4 Crankshaft pulley lock bolt 12 Chain guide
(See 01-10-5 Crankshaft Pulley Lock Bolt 13 Timing chain
Disassembly Note.) 14 Oil pump chain tensioner
5 Crankshaft pulley 15 Oil pump sprocket
6 Water pump pulley (See 01-10-5 Oil Pump Sprocket Disassembly
7 Drive belt idler pulley Note.)
8 Engine front cover 16 Oil pump chain
9 Front oil seal 17 Crankshaft sprocket
(See 01-10-5 Front Oil Seal Disassembly Note.)
01-10–4
MECHANICAL
Crankshaft Pulley Lock Bolt Disassembly Note
1. Install the SST to the ring gear to lock the
crankshaft against rotation.
49 E011 1A0
01-10
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Front Oil Seal Disassembly Note

1. Remove the oil seal using a flat head screwdriver.
am8rrw00000656
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.
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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.
End Of Sie
CRANKSHAFT OIL PUMP

PULLEY SPROCKET
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01-10–5
MECHANICAL
CYLINDER HEAD DISASSEMBLY(I)
id011000500400
1. Disassemble in the order indicated in the table.
4
3
R 5
2
7
6
9 R
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1 Camshaft sprocket lock bolt, variable valve timing 6 Tappet

actuator lock bolt (See 01-10-7 Tappet Disassembly Note.)
(See 01-10-7 Camshaft Sprocket Lock Bolt, Variable 7 Cylinder head bolt
Valve Timing Actuator Lock Bolt Disassembly Note.) (See 01-10-7 Cylinder Head Bolt Disassembly
2 Camshaft sprocket, variable valve timing actuator Note.)
3 OCV 8 Cylinder head
4 Camshaft cap 9 Cylinder head gasket
(See 01-10-7 Camshaft Cap Disassembly Note.)
5 Camshaft
01-10–6
MECHANICAL
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.
01-10
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Camshaft Cap Disassembly Note

1. Before removing the camshaft caps, inspect the following:
— Camshaft end play and camshaft journal oil clearance (See 01-10-21 CAMSHAFT INSPECTION.)
Note
• The camshaft caps are numbered to make sure they are assembled in their original positions. When
removed, keep the caps with the cylinder head they were removed from. Do not mix the caps.
2. Loosen the camshaft caps bolts in 2—3 passes in

5 6 9 10 7 8 3 4
the order shown in the figure.
1
2
122
11
15 16 199 20 1 18
17 1 14
13
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Tappet Disassembly Note
Note
• The tappets are numbered to make sure they are assembled in their original positions. When removed,
keep the tappets with the cylinder head they were removed from. Do not mix the tappets.
Cylinder Head Bolt Disassembly Note

1. Loosen the cylinder head bolts in 2—3 passes in
the order shown in the figure. 3 7 10 6 2
End Of Sie
4 8 9 5 1
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01-10–7
MECHANICAL
CYLINDER HEAD DISASSEMBLY (II)
id011000500500
2 SST
1
3 8
4
R 6
SST
R
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1 Engine hanger 5 Valve

2 Valve keeper 6 Valve seal
(See 01-10-8 Valve Keeper Disassembly Note.) (See 01-10-9 Valve Seal Disassembly Note.)
3 Upper valve spring seat 7 EGR pipe
4 Valve spring 8 Water outlet case
Valve Keeper Disassembly Note

1. Remove the valve keeper using the SSTs.
49 0636 100B
49 B012 0A2
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01-10–8
MECHANICAL
Valve Seal Disassembly Note
1. Remove the valve seal using the SST.
End Of Sie
49 S120 170
01-10
VALVE SEAL
VALVE GUIDE
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01-10–9
MECHANICAL
CYLINDER BLOCK DISASSEMBLY (I)
id011000500600
R
R SST
13 12
MTX
R
9
6
R
7
A
11 R
8
R 10
CARTRIDGE TYPE OIL FILTER

WITH OIL COOLER
1
CARTRIDGE TYPE
OIL FILTER
WITHOUT OIL
SPIN-ON TYPE OIL FILTER 5 COOLER
WITH OIL COOLER
SPIN-ON TYPE R
OIL FILTER
WITHOUT OIL A
COOLER
4
5 R
4
3
A 3 R
R
4 R R
4
2
2
R
R
3 3
R R
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1 Oil pan 2 Oil filter cover
01-10–10
MECHANICAL
3 Oil filter 9 Water pump
4 Oil filter adapter 10 Oil strainer
5 Oil cooler (If equipped) 11 Oil pump
6 KS 12 Flywheel (MTX), Drive plate (ATX)
7 Oil separator (See 01-10-11 Drive Plate (ATX), Flywheel (MTX)
Disassembly Note)
8 Thermostat
13 Rear oil seal
01-10
Drive Plate (ATX), Flywheel (MTX) Disassembly Note

1. Hold the crankshaft using the SST.
2. Remove the bolts in several passes.
End Of Sie
1
3 6 49 E011 1A0
5 4
2
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01-10–11
MECHANICAL
CYLINDER BLOCK DISASSEMBLY (II)
id011000500700
Caution
• 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.
6
R
10
9
11
18
12
7 16
17
5
4 1
15
14
3
13
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1 Pilot bearing (MTX) 9 Snap ring

(See 01-10-13 Pilot Bearing Disassembly Note.) 10 Piston pin
2 Balancer unit 11 Piston
3 Adjustment shim 12 Connecting rod
4 Connecting rod cap 13 Main bearing cap
(See 01-10-13 Connecting Rod Cap Disassembly (See 01-10-13 Main Bearing Cap Disassembly
Note.) Note.)
5 Lower connecting rod bearing 14 Lower main bearing, thrust bearing
6 Connecting rod, piston component 15 Crankshaft
7 Upper connecting rod bearing 16 Upper main bearing, thrust bearing
8 Piston ring
01-10–12
MECHANICAL
17 Oil jet valve 18 Cylinder block
Pilot Bearing Disassembly Note
Note
• Only remove the pilot bearing if there is a malfunction in the pilot bearing or when replacing the
crankshaft. 01-10
1. Use the SST to remove the pilot bearing.
49 1285 071
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Connecting Rod Cap Disassembly Note
Note
• Determine the position of each removed connecting rod cap.
1. Before removing the connecting rod cap, inspect the connecting rod side clearance. (See 01-10-24
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 01-10-25 CRANKSHAFT
INSPECTION.)
2. Loosen the main bearing cap bolts in two or three
steps in the order shown in the figure.
End Of Sie
2 6 10 8 4
1 5 9 7 3
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01-10–13
MECHANICAL
CYLINDER HEAD INSPECTION
id011000507100
1. Perform color contrast penetrate examination on the cylinder head surface.
• Replace the cylinder head if necessary.
2. Inspect for the following and repair or replace if necessary.
(1) Sunken valve seats
(2) Excessive camshaft oil clearance and end play
3. Measure the cylinder head for distortion in six directions as shown in the figure.
• If it exceeds the maximum specification,
replace the cylinder head.
Maximum distortion, head gasket side

0.10 mm {0.004 in}
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4. Measure the manifold contact surface distortion

as shown in the figure.
• If it exceeds the maximum specification, grind
the surface or replace the cylinder head.
IN
Maximum distortion, manifold side
0.10 mm {0.0039 in}
Maximum cutting length, manifold side

0.15 mm {0.0059 in}
EX
End Of Sie
belbze00000097
VALVE SEAT INSPECTION/REPAIR

id011000501300
1. Measure the contact width of the valve face and the valve seat using the valve lapping compound.
• 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.
SEAT CONTACT
(1) If the seating position is too inner side, correct WIDTH
the valve seat using a 70° (IN) or 65° (EX)
cutter, and a 45° cutter.
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01-10–14
MECHANICAL
(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.
IN EX
Valve seat angle

45° 70° 65°
45° 45° 01-10
30°
b3e0110e133
3. Inspect the sinking of the valve seat. Measure the

protruding length (dimension L) of the valve stem.
• If not specified, replace the valve.
— If not as specified, replace the cylinder
head.
Standard valve seat sinkage amount

L
(Dimension L)
IN: 40.64—42.24 mm {1.601—1.662 in}
EX: 40.50—41.30 mm {1.60—1.65 in}
End Of Sie beleue00000074
VALVE, VALVE GUIDE INSPECTION

id011000506200
1. Measure the valve head margin thickness using a
vernier caliper.
• 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} IN : 33.5 mm {1.32 in}
EX : 28.3 mm {1.11 in}
2. Measure the length of each valve. Replace the
valve if necessary.
valve.
MARGIN THICKNESS
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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} L
belbze00000116
01-10–15
MECHANICAL
3. Measure the stem diameter of each valve in X and Y directions at the three points (A, B, and C) as indicated in
the figure.
• If 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}
X
Minimum valve stem diameter
IN: 5.470 mm {0.2154 in} Y
EX: 5.465 mm {0.2152 in}
A
4. Measure the inner diameter of each valve guide in
X and Y directions at the three points (A, B, and B
C) as indicated in the figure.
C
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• If not as specified, replace the valve guide.
Standard valve guide inner diameter

5.509—5.539 mm {0.2169—0.2180 in} X
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5. Calculate the valve stem to guide clearance by

subtracting the outer diameter of the valve stem
from the inner diameter of the corresponding
valve guide.
• If it exceeds the specification, replace the
valve and/or the valve guide. VALVE STEM
Standard clearance between valve stem and VALVE GUIDE

guide
IN: 0.024—0.069 mm {0.0010—0.0027 in} CLEARANCE
EX: 0.029—0.074 mm {0.0012—0.0029 in}
Maximum clearance between valve stem and

guide
0.10 mm {0.004 in}
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01-10–16
MECHANICAL
6. Measure the protrusion height (dimension A) of
each valve guide without lower valve spring seat
using the vernier caliper. A
• If not within the specification, replace the VALVE GUIDE
valve guide.
Standard valve guide projection height

12.2—12.8 mm {0.481—0.503 in} 01-10
End Of Sie CYLINDER HEAD
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VALVE GUIDE REPLACEMENT

id011000501200
Valve Guide Removal
1. Remove the valve guide from the combustion
chamber side using the SST.
49 B012 015
VALVE GUIDE
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Valve Guide Installation

1. Assemble the SSTs so that depth L is as
specified.

L
12.2—12.8 mm {0.481—0.503 in}
49 L012 004A
49 L012 003A
49 L012 002A
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2. Tap the valve guide in from the cam side using the
SSTs assembled in Step 1.
49 L012 003A
49 L012 004A
49 L012 002A
VALVE GUIDE
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01-10–17
MECHANICAL
3. Verify that the valve guide protrusion height
(dimension A) is within the specification using the
vernier caliper. A
VALVE GUIDE
12.2—12.8 mm {0.481—0.503 in}
End Of Sie
CYLINDER HEAD
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VALVE SPRING INSPECTION

id011000501400
1. Apply pressing force to the pressure spring and
inspect the spring height.
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.
belbze00000139
(1) Rotate the valve spring one full turn and

measure "A" at the point where the gap is the A
largest.
valve spring. UPPER
Maximum valve spring off-square

3.41 mm {0.134} (2°)
End Of Sie LOWER
belbze00000140
01-10–18
MECHANICAL
TAPPET INSPECTION
id011000505800
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} X
01-10
Y
A
B
belbze00000141
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} A
Y
B
3. Subtract the tappet body outer diameter from the
tappet hole inner diameter. X
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 belbze00000142
0.15 mm {0.0059 in}
End Of Sie
VARIABLE VALVE TIMING ACTUATOR INSPECTION
id011000506000
Caution
• 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.
• 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.
• If the rotor and cover are not fixed even though their notch and groove are aligned, replace the variable
valve timing actuator.
End Of Sie
COVER
NOTCH
ROTOR
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01-10–19
MECHANICAL
OIL CONTROL VALVE (OCV) INSPECTION
id011000506100
Coil resistance inspection
1. Measure the resistance between terminals A and
B using an ohmmeter.
• If not as specified, replace the OCV.
OCV coil resistance

6.9—7.9 ohms [20 °C {68 °F}] A B
2. Connect the OCV connector.
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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.
• If it exceeds the specification, replace the OCV.
2. Verify that the battery is fully charged.
• 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.
OCV. SPOOL VALVE
(MAXIMUM VALVE TIMING RETARD POSITION
Note
• When applying battery positive voltage
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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
VALVE TIMING VALVE TIMING
timing retard position.
ADVANCE RETARD
• If it exceed the specification, replace the OCV.
End Of Sie
SPOOL VALVE
(MAXIMUM VALVE TIMING ADVANCE POSITION)
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01-10–20
MECHANICAL
CAMSHAFT INSPECTION
id011000501500
1. Set the No.1 and No.5 journals on V-blocks.
2. Measure the camshaft runout.
camshaft.
Maximum camshaft runout

0.03 mm {0.0012 in} 01-10
3. Measure the cam lobe height at the two points as

shown in the figure.
camshaft.
belbze00000143
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.
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camshaft.
Camshaft journal standard diameter

24.96—24.98 mm {0.9827—0.9834 in} B
A
Camshaft journal minimum diameter
24.95 mm {0.9822 in}
5. Remove the tappet.

Y
X
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6. Position a plastigauge atop the journals in the

axial direction.
7. Install the camshaft cap. (See 01-10-44
CYLINDER HEAD ASSEMBLY (II).)
8. Remove the camshaft cap. (See 01-10-6
CYLINDER HEAD DISASSEMBLY(I).)
9. Measure the oil clearance.
• If it exceeds the specification, replace the PLASTIGAUGE
cylinder head.
Camshaft journal standard oil clearance

0.04—0.08 mm {0.002—0.003 in}
belbze00000146
Camshaft journal maximum oil clearance

0.09 mm {0.003 in}
10. Install the camshaft cap. (See 01-10-44 CYLINDER HEAD ASSEMBLY (II).)
01-10–21
MECHANICAL
11. Measure the camshaft end play.
• 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 01-10-6

CYLINDER HEAD DISASSEMBLY(I).)
End Of Sie
belbze00000147
CYLINDER BLOCK INSPECTION

id011000507200
1. Measure the distortion of the cylinder block top
surface in six directions as indicated in the figure.
• If it exceeds the maximum, replace the
cylinder block.
Maximum distortion, head gasket side

0.10 mm {0.0039 in}
belbze00000102
2. Measure the cylinder bores in X and Y directions

X
at 42 mm {1.65 in} below the top surface.
• If not within the specification, replace the
cylinder block. Y
Maximum bore inner diameter

89.000—89.030 mm {3.5040—3.5051 in}
42 mm {1.65 in}
End Of Sie
belbze00000103
01-10–22
MECHANICAL
OIL JET VALVE INSPECTION
id011000505900
1. Apply compressed air to oil jet valve A and verify that air passes through oil jet valve B.
• If air does not flow, replace the oil jet valve.
Air pressure
B
280 kPa {2.86 kgf/cm2, 40.7 psi} or more
01-10
End Of Sie
belbze00000104
PISTON INSPECTION
id011000502100
1. Measure the outer diameter of each piston at right angle 90° to the piston pin, 10.0 mm {0.40 in} above the
under of the piston.
• If 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.

• 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}
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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.
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

belbze00000106
ring groove
Top: 0.17 mm {0.0066 in}
Second, Oil: 0.15 mm {0.0059 in}
01-10–23
MECHANICAL
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.
piston ring.
Standard piston ring end gap

Top: 0.16—0.26 mm {0.0063—0.010 in} PISTON RING
Second: 0.31—0.46 mm {0.013—0.018 in}
Oil (rail): 0.15—0.40 mm {0.006—0.015 in}
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Maximum piston ring end gap

1.0 mm {0.039 in}
End Of Sie
PISTON AND CONNECTING ROD INSPECTION
id011000503100
1. Check the oscillation torque as shown in the figure. Verify that the large end drops under its own weight with no
resistance.
• 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 01-
10-24 CONNECTING ROD INSPECTION.)
End Of Sie
belbze00000171
CONNECTING ROD INSPECTION

id011000502800
1. Install the connecting rod cap. (See 01-10-34 CYLINDER BLOCK ASSEMBLY (I).)
2. Measure the connecting rod large end side
clearance.
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
belbze00000108
0.435 mm {0.0171 in}
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 01-10-34 CYLINDER BLOCK ASSEMBLY (I).)
6. Remove the connecting rod cap.
01-10–24
MECHANICAL
7. Measure the connecting rod oil clearance.
• 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}
01-10
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}
belbze00000109
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}
8. Measure the connecting rod small end using a

X
caliper gauge.
• If not exceeds the specification, replace the
connecting rod.
Y
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.
• If not exceeds the specification, replace the
adj2224e254
connecting rod.
Standard clearance between connecting rod small end inner diameter and piston pin outer diameter
0.010—0.026 mm {0.0004—0.0010 in}
End Of Sie
CRANKSHAFT INSPECTION
id011000502500
1. Install the main bearing cap. (See 01-10-34 CYLINDER BLOCK ASSEMBLY (I).)
2. Measure the crankshaft end play.
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 01-10-12

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CYLINDER BLOCK DISASSEMBLY (II).)
01-10–25
MECHANICAL
4. Measure the crankshaft runout.
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.
crankshaft or grind the journal and install the
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undersize bearing.
Main journal diameter

A B
STD: 51.980—52.000 mm {2.0465—2.0472 in}
US 0.25: 51.730—51.750 mm {2.0367—2.0374 X
in}
Maximum main journal off-round Y

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
belbze00000112
in}
Maximum crank pin off-round

0.005 mm {0.0001 in}
6. Install the main bearing caps and crankshaft. (See 01-10-34 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 01-10-34 CYLINDER BLOCK ASSEMBLY (I).)
9. Remove the main bearing caps. (See 01-10-12 CYLINDER BLOCK DISASSEMBLY (II).)
10. Measure the main journal oil clearance.
• 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}
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End Of Sie
01-10–26
MECHANICAL
PILOT BEARING INSPECTION
id011000505200
1. Without removing the pilot bearing, turn the bearing while applying force in the axial direction.
• If there is any malfunction, replace the pilot bearing.
End Of Sie
01-10
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BOLT INSPECTION
id011000503300
1. Measure the length of each bolt.
• 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}
L
Connecting rod bolt length
Standard: 43.7—44.3 mm {1.73—1.74 in}
Maximum: 45.0 mm {1.77 in}
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Main bearing cap bolt length
Standard: 104.0—104.6 mm {4.095—4.118
in}
End Of Sie
VALVE CLEARANCE INSPECTION
id011000503500
1. Measure the valve clearance as follows.
(1) Turn the crankshaft clockwise so that the No.1 piston is at TDC of the compression stroke.
(2) Measure the valve clearance at A in the figure.
• If the valve clearance exceeds the standard, replace the tappet. (See 01-10-28 VALVE CLEARANCE
ADJUSTMENT.)
Note
• Make sure to note the measured values for choosing the suitable replacement tappets.
A B A B
Standard valve clearance [when cold]
IN: 0.22—0.28 mm {0.009—0.011 in} EX
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. IN
(4) Measure the valve clearance at B in the
figure.
• If the valve clearance exceeds the
A B B
standard, replace the tappet. (See 01-10- A
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28 VALVE CLEARANCE ADJUSTMENT.)
Note
• Make sure to note the measured values for choosing the suitable replacement tappets.

IN: 0.22—0.28 mm {0.009—0.011 in}
EX: 0.27—0.33 mm {0.011—0.012 in}
01-10–27
MECHANICAL
End Of Sie
VALVE CLEARANCE ADJUSTMENT

id011000503600
1. Remove the engine front cover lower blind plug.
ENGINE FRONT R
COVER LOWER
BLIND PLUG
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2. Remove the engine front cover upper blind plug.
ENGINE FRONT
COVER UPPER
BLIND PLUG
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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:
303-507
(49 JE01 061)
abatjw00000791
(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.) BOLT (M6 x1.0,
LENGTH 25—35 mm
{0.99—1.3 in})
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01-10–28
MECHANICAL
(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.
01-10
am8rrw00002539
CHAIN TENSIONER
RATCHET
RACK
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(4) Using the cast hexagon on the exhaust

camshaft, apply force in the direction of the
engine rotation to increase tension on the
chain.
am8rrw00002541
01-10–29
MECHANICAL
Note
• The chain tensioner rack is compressed NOT COMPRESSED COMPRESSED
CHAIN
using the chain tension generated by TENSIONER
applying force to the exhaust camshaft in the
direction of the engine rotation.
Note
• The racket has not been unlocked if the bolt
cannot be pressed in approx. 5 mm {0.2 in}. TENSIONER
ARM
(5) Screw in the bolt set in Step 1 approx. 5 mm
{0.2 in} and secure the tensioner arm with the
rack compressed.
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NOT UNLOCK UNLOCK NOT UNLOCK UNLOCK
TENSIONER TENSIONER
ARM ARM
BOLT (M6 x1.0,

BOLT (M6 x1.0, LENGTH
LENGTH 25—35 mm
25—35 mm {0.99—1.3 in})
{0.99—1.3 in})
SECTIONAL VIEW
am6xuw0000205
• 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
• Perform the work carefully so that the
washer does not drop out.
am3zzw0000242
7. Remove the exhaust camshaft sprocket EXHAUST CAMSHAFT SPROCKET

installation bolt, exhaust camshaft sprocket, and
washer as a single unit.
EXHAUST CAMSHAFT
SPROCKET BOLT
WASHER R
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01-10–30
MECHANICAL
8. Remove the OCV.
Note
• The camshaft caps are to be kept ordered
for correct reassembly in their original
positions. Do not mix the caps.
01-10
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9. Loosen the camshaft cap bolts in two or three

5 6 9 10 7 8 3 4
steps in the order shown in the figure and remove
the camshaft cap. 1
10. Remove the camshafts for the intake and exhaust 2
sides.
11. Remove the tappet.
12. Install an appropriate tappet based on the results 122
of the valve clearance inspection.
Selected tappet = Removed tappet thickness + 11
Measured valve clearance - Standard valve
clearance
15 16 199 20 1 18
17 1 14
13
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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.
15. Install the camshaft with No.1 cylinder aligned
OIL
with the TDC position.
am6zzw0000218
01-10–31
MECHANICAL
each journal of the camshaft as shown in the
figure.
17. Temporarily tighten the camshaft cap bolts evenly
in 2—3 steps. OIL
am6zzw0000228
18. Tighten the camshaft cap bolts in the order shown

5 6 1 2 3 4 7 8
in the following two steps.
9
Tightening procedure 10
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}
20
19
155 16 11 12 13 14 1 18
17
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19. Install the OCV.
Tightening torque
8—11 N·m {82—112 kgf·cm, 71—97 in·lbf}
Caution
• Install a washer to the fourth or fifth
thread of the exhaust camshaft sprocket
bolt being careful not to drop the washer.
• Do not tighten the camshaft sprocket
installation bolt at this stage. Verify the
valve timing before performing the bolt
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tightening.
20. Install the exhaust camshaft sprocket installation

bolt, exhaust camshaft sprocket, and a new
washer as a single unit. EXHAUST CAMSHAFT
SPROCKET
WASHER R
EXHAUST CAMSHAFT
SPROCKET INSTALLATION
BOLT
am8rrw00002545
01-10–32
MECHANICAL
21. Install the SST on the camshaft as shown in the
303-465
figure.
(49 UN30 3465)
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 01-10
bolt.
24. Remove the SST from the camshaft.
25. Remove the SST installed in the cylinder block
lower blind plug hole.
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26. Rotate the crankshaft clockwise two turns and
inspect the valve timing.
• 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}
CYLINDER BLOCK
LOWER BLIND PLUG
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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}
ENGINE FRONT
COVER UPPER
BLIND PLUG
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29. Install a new engine front cover lower blind plug.
Tightening torque
10—14 N·m {102—142 kgf·cm, 89—123
in·lbf}
End Of Sie
ENGINE FRONT R
COVER LOWER
BLIND PLUG
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01-10–33
MECHANICAL
CYLINDER BLOCK ASSEMBLY (I)
id011000504000
1. Assemble in the order indicated in the table. .
OIL
10 12
8
9 OIL
7 R
OIL
11
3.0—4.9 N·m
13 OIL
{31—49 kgf·cm, OIL
27—43 in·lbf} 2
1
14
17
26—32 {2.7—3.2, 20—23}

+80—100°
3
OIL
4
15
5
8—12 N·m {82—122 kgf·cm, 71—106 in·lbf}
+28—32 {2.9—3.2, 21—23}
+87.5—92.5°
16 SST
25 {2.5, 18} OIL
+39—45 {4.0—4.5, 29—33}

SST
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1 Oil jet valve 12 Connecting rod, piston component

2 Upper main bearing, thrust bearing (See 01-10-36 Piston Assembly Note)
3 Crankshaft 13 Lower connecting rod bearing
(See 01-10-35 Connecting Rod Bearing Assembly
4 Lower main bearing, thrust bearing Note)
5 Main bearing cap 14 Connecting rod cap
(See 01-10-35 Main Bearing Cap Assembly Note) (See 01-10-36 Connecting Rod Cap Assembly
6 Connecting rod Note)
7 Piston 15 Adjustment shim
8 Piston pin (See 01-10-36 Balancer Unit Assembly Note)
9 Snap ring 16 Balancer unit
Piston ring (See 01-10-36 Balancer Unit Assembly Note)
10 17 Pilot bearing (MTX)
(See 01-10-35 Piston Ring Assembly Note)
11 Upper connecting rod bearing (See 01-10-39 Pilot Bearing Assembly Note.)
(See 01-10-35 Connecting Rod Bearing Assembly
Note)
01-10–34
MECHANICAL
Main Bearing Cap Assembly Note
1. Install the main bearing caps in the order
indicated in the figure, using the SST (49 D032
316).
9 5 1 3 7
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} 01-10
3. 87.5—92.5°
10 6 2 4 8
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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.
beleue00000006
4. Position the end gap of each ring as indicated in

the figure. TOP RING
30° 30°
UPPER OIL LOWER OIL

RING RAIL RING RAIL
OIL RING SPACER

AND SECOND RING
belbze00000058
Connecting Rod Bearing Assembly Note

1. Install the connecting rod bearing to the connecting rod and connecting rod caps, as shown in the figure.
CONNECTING ROD
BEARING
2.3—2.7 mm {0.10—0.106 in}
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01-10–35
MECHANICAL
Piston Assembly Note
1. Insert the piston and connecting rod into the
cylinder with the arrow mark to front of the engine.
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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
• 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.
• 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
• If the cylinder block, crankshaft, crankshaft
main bearing, and balancer unit are not 303-507
replaced, use the adjustment shim as it is. In (49 JE01 061)
this case, go to Step 12.
abatjw00000791
4. Assemble the master shims (No. 50) to the shim

seating face of the balancer unit at the angles 3 1
A
Caution
• Engage the gears slowly and place the
balancer unit on the cylinder block while 0˚—2.5˚ 0˚—2.5˚ 0˚—5˚
being careful not to contact the balancer
unit gear strongly with the crankshaft 4 2
drive gear and damage it.
3
0˚—2.5˚ 0˚—2.5˚ 0˚—5˚
1
4
2 VIEW A
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01-10–36
MECHANICAL
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 criss-
cross pattern in two steps.
Tightening torque
1. 25 N·m {2.5 kgf·m, 18 ft·lbt}
2. 39—45 N·m {4.0—4.5 kgf·m, 29—33 ft·lbf} 01-10
6. Remove the SST installed in Step 2. MARK
7. Measure the gear backlash using the following
procedure.
(1) Place the ATDC marks 10 °, 30 °, 100 °, 190
beleue00000050
°, 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.
belbze00000064
(3) Set the SST and a dial gauge as shown in the

DIAL GAUGE
figure.
(4) Rotate the driven gear to the left and right so 49 G011 201
that the crankshaft drive gear and balancer APPROX.
unit gear contact each other lightly. 40 mm {1.6 in}
(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.
DRIVEN GEAR SHAFT CENTER
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A B C D E F
(ATDC 10˚) (ATDC 30˚) (ATDC 100˚) (ATDC 190˚) (ATDC 210˚) (ATDC 280˚)
TDC
belbze00000188
8. Select the adjustment shim from the selection table based on the measured minimum value of the backlash.
01-10–37
MECHANICAL
Adjustment shim selection table
Measured Measured
Selection shim Shim thickness Selection shim Shim thickness
backlash backlash
(No.) mm {in} (No.) mm {in}
mm {in} mm {in}
0.267—0.273 0.127—0.133
{0.01051— 15 1.15 {0.0452} {0.00500— 35 1.35 {0.0531}
0.01074} 0.00523}
0.260—0.266 0.120—0.126
{0.01023— 16 1.16 {0.0456} {0.00472— 36 1.36 {0.0535}
0.01047} 0.00496}
0.253—0.259 0.113—0.119
{0.00996— 17 1.17 {0.0460} {0.00444— 37 1.37 {0.0539}
0.01019} 0.00468}
0.246—0.252 0.106—0.112
{0.00968— 18 1.18 {0.0464} {0.00417— 38 1.38{0.0543}
0.00992} 0.00440}
0.239—0.245 0.099—0.105
{0.00940— 19 1.19 {0.0468} {0.00389— 39 1.39 {0.0547}
0.00964} 0.00413}
0.232—0.238 0.092—0.098
{0.00913— 20 1.20 {0.0472} {0.00362— 40 1.40 {0.0551}
0.00937} 0.00385}
0.225—0.231 0.085—0.091
{0.00885— 21 1.21 {0.0476} {0.00334— 41 1.41 {0.0555}
0.00909} 0.00358}
0.218—0.224
0.078—0.084
{0.00858— 22 1.22 {0.0480} 42 1.42 {0.0559}
{0.00307—
0.00881}
0.00330}
0.211—0.217 0.071—0.077
{0.00830— 23 1.23 {0.0484} {0.00279— 43 1.43 {0.0562}
0.00854} 0.00303}
0.204—0.210 0.064—0.070
{0.00803— 24 1.24 {0.0488} {0.00251— 44 1.44 {0.0566}
0.00826} 0.00275}
0.197—0.203 0.057—0.063
{0.00775— 25 1.25 {0.492} {0.00224— 45 1.45 {0.0570}
0.00799} 0.00248}
0.190—0.196 0.050—0.056
{0.00748— 26 1.26 {0.496} {0.00196— 46 1.46 {0.0574}
0.00771} 0.00220}
0.183—0.189 0.043—0.049
{0.00720— 27 1.27 {0.499} {0.00169— 47 1.47 {0.0578}
0.00744} 0.00192}
0.176—0.182 0.036—0.042
{0.00692— 28 1.28 {0.503} {0.00141— 48 1.48 {0.0582}
0.00716} 0.00165}
0.169—0.175 0.029—0.035
{0.00665— 29 1.29 {0.507} {0.00114— 49 1.49 {0.0586}
0.00688} 0.00137}
0.162—0.168 0.022—0.028
{0.00637— 30 1.30 {0.511} {0.000866— 50 (master shim) 1.50 {0.0590}
0.00661} 0.00110}
0.155—0.161 0.015—0.021
{0.00610— 31 1.31 {0.515} {0.00059— 51 1.51 {0.0594}
0.00633} 0.000826}
0.148—0.154 0.008—0.014
{0.00582— 32 1.32 {0.519} {0.000314— 52 1.52 {0.0598}
0.00606} 0.000551}
0.141—0.147 0.001—0.007
{0.00555— 33 1.33 {0.523} {0.00003— 53 1.53 {0.0602}
0.00578} 0.000275}
0.134—0.140
0.000—0.000
{0.00527— 34 1.34 {0.527} 54 1.54 {0.0606}
{0.000—0.000}
0.00551}
01-10–38
Engine Workshop Manual L5 (1924–1U–08F)
MECHANICAL
9. Verify that the No. 1 cylinder is at TDC.
• If not aligned, perform Steps 2—3.
10. Remove the master shim from the balancer unit
and assemble the selected adjustment shim at 3 1
the angles shown in the figure.
A
11. Perform Steps 5—7.
12. Verify that the measured backlash is within the
specified range. 01-10
• If the backlash exceeds the maximum 0˚—2.5˚ 0˚—2.5˚ 0˚—5˚
specification, replace the adjustment shim
and repeat Steps 4—12. 4 2
Measured backlash maximum
0.01—0.10 mm {0.001—0.003 In}
3
0˚—2.5˚ 0˚—2.5˚ 0˚—5˚
1
4
2 VIEW A
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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}
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End Of Sie
PILOT BEARING
4.0—5.0 mm {0.16—0.19 in}
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CYLINDER BLOCK ASSEMBLY (II)

id011000504100
1. Assemble in the order indicated in the table.
01-10–39
Engine Workshop Manual L5 (1924–1U–08F)
MECHANICAL
46—54 {4.7—5.5, 34—39}

A +76—84 {7.8—8.5, 57—61}
OIL +108—116 {11.1—11.8, 80—85}
SST R 1
SST
R
2 MTX
R 8
A
7
16—24 {1.7—2.4,
12—17}
A
3 R
8—10 N·m
6 {82—101 kgf·cm, A : 8—11 N·m
R 4 71—88 in·lbf} {82—112 kgf·cm,
71—97 in·lbf}
OIL
8—12 N·m {82—122 kgf·cm,

71—106 in·lbf}
+17—23 {1.8—2.3, 13—16}
CARTRIDGE TYPE OIL FILTER
WITH OIL COOLER
34—40
17—23
17—23 {3.5—4.0,
{1.8—2.3,
{1.8—2.3, 26—29}
13—16}
13—16} 13 CARTRIDGE TYPE
OIL FILTER
WITHOUT OIL
SPIN-ON TYPE OIL FILTER
WITH OIL COOLER
9 COOLER
R
34—40
{3.5—4.0, A
26—29}
SPIN-ON TYPE 10
9 OIL FILTER R
WITHOUT OIL 10
A COOLER
20—30 11
{2.1—3.0, 11 R
10 15—22} R
R R
10
OIL 12
OIL
12
20—30 30—35 R
{2.1—3.0, OIL OIL 30—35 R {3.1—3.5,
15—22} {3.1—3.5, 23—25} OIL
OIL
11 R 11 R 23—25}
9—11 N·m
15—20 {1.6—2.0, 12—14} {92—112 kgf·cm, 80—97 in·lbf}
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01-10–40 Revised 9/2008 (Ref. No. R201/08)

MECHANICAL
1 Rear oil seal 7 Oil separator
(See 01-10-41 Rear Oil Seal Assembly Note) 8 KS
2 Flywheel (MTX), Drive plate (ATX) 9 Oil cooler
(See 01-10-42 Drive Plate (ATX), Flywheel (MTX)
Assembly Note) 10 Oil filter adapter
3 Oil pump 11 Oil filter
4 Oil strainer 12 Oil filter cover
5 Water pump 13 Oil pan 01-10
(See 01-10-42 Oil pan Assembly Note)
6 Thermostat
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. NON-WOVEN FABRIC
303-328
(49 UN30 3328)
beleue00000053
3. From the back side of the rear oil seal, verify that BACK SIDE OF REAR OIL SEAL
there is no damage or separation in the lip area of
the rear oil seal.
4. Install the rear oil seal to the engine.
LIP AREA
beleue00000054
5. Tighten the rear oil seal bolts in the order as

shown in the figure. (Except TRIBUTE (L.H.D.) 3
Face-lifted model.) 5
Tightening torque
8—11 N·m {82—112 kgf·cm, 71—97 in·lbf} 1
2
6
4
beleue00000055
01-10–41
MECHANICAL
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} 1
3. 108—116 N·m {11.1—11.8 kgf·m, 80—85 3 49 E011 1A0
6
ft·lbf}
5 4
2
beleue00000056
Oil pan Assembly Note

1. Apply a continuous bead of silicone sealant to the
oil pan as indicated in the figure.
2.2—3.2 mm
{0.09—0.12 in}
am6zzw0000230
2. Use a square ruler to unite the oil pan and the

cylinder block junction side on the engine front
cover side.
CYLINDER
BLOCK
OIL PAN
-0.05—0.05 mm {-0.002—0.002 in}
beleue00000057
3. Tighten the rear oil pan bolts in the order as

shown in the figure. 8
4 1 5 9
13
Tightening torque
17—23 N·m {1.8—2.3 kgf·m, 13—16 ft·lbf} 10
End Of Sie
11
12 7 3 2 6
beleue00000058
01-10–42
MECHANICAL
CYLINDER HEAD ASSEMBLY (I)
id011000504300
1. Assemble in the order indicated in the table. .
44—50 {4.5—5.0,
33—36} 8
8—11 N·m {82—112 kgf·cm,
SST 7 1 71—97 in·lbf}
6 01-10
5
R 3
SST
R
50—60 {5.1—6.1,
37—44}
8
44—50 {4.5—5.0, 33—36}

4
beleue00000059
1 Water outlet case 5 Valve spring

2 EGR pipe 6 Upper valve spring seat
3 Valve seal 7 Valve keeper
(See 01-10-43 Valve Seal Assembly Note) (See 01-10-44 Valve Keeper Assembly Note)
4 Valve 8 Engine hanger
Valve Seal Assembly Note

1. Press the valve seal onto the valve guide by hand.
2. Lightly tap the SST using a plastic hammer.
49 T032 302
VALVE
SEAL
beleue00000060
01-10–43
MECHANICAL
Valve Keeper Assembly Note
1. Install the valve keeper using the SSTs.
End Of Sie
49 0636 100B
49 B012 0A2
beleue00000061
CYLINDER HEAD ASSEMBLY (II)

id011000504400
8—11 N·m
{82—112 kgf·cm, 5.0—9.0 N·m {51—91 kgf·cm, 45—79 in·lbf}
71—97 in·lbf} + 14—17 {1.5—1.7, 11—12}
5 OIL
6
7
R
SST
3—11 N·m {31—112 kgf·cm, 27—97 in·lbf}
3 +13—17 N·m {133—173 kgf·cm, 116—150 in·lbf}
+43—47 {4.4—4.7, 32—34}
4 +88—92˚
R +88—92˚
1 R
beleue00000010
1 Cylinder head gasket 4 Tappet

2 Cylinder head 5 Camshaft
(See 01-10-45 Camshaft Assembly Note)
3 Cylinder head bolt
(See 01-10-45 Cylinder Head Bolt Assembly Note) 6 Camshaft cap
01-10–44
MECHANICAL
7 Camshaft sprocket, variable valve timing actuator 8 OCV
(See 01-10-46 Camshaft Sprocket, Variable Valve
Timing Actuator Assembly Note)
Cylinder Head Bolt Assembly Note

1. Tighten the cylinder head bolts in the order
indicated in the figure in 5 steps.However, use the 8 4 1 5 9 01-10
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° 7 3 2 6 10
beleue00000062
Camshaft Assembly Note

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. OIL
am5ezw0000118
01-10–45
MECHANICAL
each journal of the camshaft as shown in the
figure.
4. Temporarily tighten the camshaft cap bolts evenly
in 2—3 steps. OIL
5. Tighten the camshaft cap bolts in the order shown

with the following two steps.
am6zzw0000217
5 6 1 2 3 4 7 8
Tighten torque
1. 5.0—9.0 N·m {51—91 kgf·cm, 45—79 in·lbf} 9
2. 14—17 N·m {1.5—1.7 kgf·m, 11—12 ft·lbf} 10
20
19
155 16 11 12 13 14 1 18
17
beleue00000082
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.
End Of Sie
01-10–46
MECHANICAL
TIMING CHAIN ASSEMBLY
id011000505600
8.0—9.5 N·m {82—96

18 kgf·cm, 71—84 in·lbf}
10—14 N·m {102—142
kgf·cm, 89—123 in·lbf}
01-10
17
11
A
40—55 {4.1—5.6,
30—40} 16
12
R R
OIL
20—30 SST
{2.1—3.0,
15—22} 10
SEALANT
14
13 9
69—75
{7.1—7.6,
17—23 51—55} SEALANT
{1.8—2.3, 13—16}
15 R SST 9
69—75
96—104 {9.8—10,
{7.1—7.6,
71—76}
51—55}
+87—93°
8
A
5
R
A : 8—11 N·m {82—112 7 A 4

kgf·cm, 71—97 in·lbf} 20—30 3
6 1 {2.1—3.0,
15—22}
A
2
beleue00000012
1 Crankshaft sprocket 11 Engine front cover

(See 01-10-50 Engine Front Cover Assembly Note.)
2 Oil pump chain
12 Drive belt idler pulley
3 Oil pump sprocket
(See 01-10-48 Oil Pump Sprocket Assembly Note.) 13 Water pump pulley
4 Oil pump chain tensioner 14 Crankshaft pulley
5 Timing chain 15 Crankshaft pulley lock bolt
(See 01-10-48 Timing Chain Assembly Note.) (See 01-10-51 Crankshaft Pulley Lock Bolt
Assembly Note.)
6 Chain guide
16 Cylinder head cover
7 Tensioner arm
(See 01-10-52 Cylinder Head Cover Assembly
8 Chain tensioner Note)
9 Camshaft sprocket, variable valve timing actuator 17 Spark plug
(See 01-10-49 Camshaft Sprocket, Variable Valve
18 Oil level gauge
Timing Actuator Assembly Note.)
10 Front oil seal
(See 01-10-49 Front Oil Seal Assembly Note.)
01-10–47
MECHANICAL
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}
CRANKSHAFT OIL PUMP

PULLEY SPROCKET
beleue00000064
Timing Chain Assembly Note

1. Install the SST to the camshaft, then align the No.
303-465
1 camshaft position with the TDC.
(49 UN30 3465)
2. Remove the cylinder block lower blind plug.
beleue00000065
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.
303-507
5. Install the timing chain.
(49 JE01 061)
beleue00000011
6. Install the chain tensioner and remove the

retaining wire.
belbze00000086
01-10–48
MECHANICAL
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}
01-10
belbze00000189
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.
49 H010 401
beleue00000066
HAMMER OIL PUMP BODY

Front oil seal press-in amount
0—0.5 mm
0—0.5 mm {0—0.019 in} {0—0.019 in}
49 H010 401
FRONT OIL SEAL
beleue00000067
01-10–49
MECHANICAL
Engine Front Cover Assembly Note
Caution
• Install the engine front cover within 10 minutes of applying the silicone sealant.
1. Apply silicone sealant to the engine front cover as shown.

B
5 {0.2}
5 {0.2}
41 {1.6}
B
40 {1.6} C
C
5 {0.2}
D
D
5 {0.2}
C
C
mm {in}
am6xuw0000078
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. 20 21 22
No. Tightening torque
1—18 8.0—11.5 N·m {81.6—117.2 kgf·cm, 70.9— 18
101.7 in·lbf} 17
19—22 40—55 N·m {4.1—5.6 kgf·m, 30—40 ft·lbf} 11
10
8
7
1
4
3
2 5
6
19
9 12
16
13
15 14
beleue00000068
01-10–50
MECHANICAL
Crankshaft Pulley Lock Bolt Assembly Note
1. Install the SST to the camshaft as shown in the
303-465
figure.
(49 UN30 3465)
2. Verify that No.1 cylinder is at TDC of the
compression stroke. (Position counterweight
contacts SST.)
01-10
beleue00000065
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.
303-507
(49 JE01 061)
BOLT
beleue00000069
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).
49 E011 1A0
Tightening procedure
1. 96—104 N·m {9.8—10 kgf·m, 71—76 ft·lbf}
2. 87—93°
6. Remove the bolt (M6 X 1.0) installed to the

crankshaft pulley.
beleue00000070
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.
• 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}
CYLINDER BLOCK
LOWER BLIND PLUG
beleue00000071
01-10–51
MECHANICAL
Cylinder Head Cover Assembly Note
Caution
• Install the cylinder head cover within 10 min of applying the silicone sealant.
1. Apply silicone sealant to the mating faces as

Thickness SEALANT
4.0—6.0 mm {0.16—0.23 in}
2. Install the cylinder head cover with a new gasket.
SEALANT
am8rrw00000667
3. Tighten the bolts in the order shown in the figure.

6 2 3 7 12
Tightening torque
11
8.0 —9.5 N·m {82—96 kgf·cm, 71—84 in·lbf}
End Of Sie 10
13
14
9 5 4 8 1
am6xuw0000023
01-10–52
TECHNICAL DATA
01-50 TECHNICAL DATA
ENGINE TECHNICAL DATA . . . . . . . . . . 01-50–1
End of Toc
ENGINE TECHNICAL DATA
WM: ENGINE
id015000800100
01-50
Item Specification
Maximum distortion, head gasket side 0.10 mm {0.004 in}
Maximum distortion, manifold side 0.10 mm {0.0039 in}
Maximum cutting length, manifold side 0.15 mm {0.0059 in}
Standard valve seat contact width 0.99—1.84 mm {0.039—0.072 in}
Valve seat angle 45°
IN: 40.64—42.24 mm {1.601—1.662 in}
Standard valve seat sinkage amount (Dimension L)
EX: 40.50—41.30 mm {1.60—1.65 in}
IN: 1.65 mm {0.0650 in}
Minimum valve head margin thickness
EX: 1.85 mm {0.0728 in}
IN: 102.99—103.79 mm {4.0548—4.0862 in}
Standard valve length (Dimension L)
EX: 104.25—105.05 mm {4.1044—4.1358 in}
IN: 102.99 mm {4.0548 in}
Minimum valve length (Dimension L)
EX: 104.25 mm {4.1044 in}
IN: 5.470—5.485 mm {0.2154—0.2159 in}
Standard valve stem diameter
EX: 5.465—5.480 mm {0.2152—0.2157 in}
IN: 5.470 mm {0.2154 in}
Minimum valve stem diameter
EX: 5.465 mm {0.2152 in}
Standard valve guide inner diameter 5.509—5.539 mm {0.2169—0.2180 in}
IN: 0.024—0.069 mm {0.0010—0.0027 in}
Standard clearance between valve stem and guide
EX: 0.029—0.074 mm {0.0012—0.0029 in}
Maximum clearance between valve stem and guide 0.10 mm {0.004 in}
Standard valve guide projection height 12.2—12.8 mm {0.481—0.503 in}
Valve spring installation height 28.68 mm {1.129 in} (390 N {39.8 kgf, 87.7 lbf})
Maximum valve spring off-square 3.41 mm {0.134} (2°)
Standard tappet bore diameter 31.000—31.030 mm {1.2205—1.2216 in}
Standard tappet body outer diameter 30.970—30.980 mm {1.2193—1.2196 in}
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}
OCV coil resistance 6.9—7.9 ohms [20 °C {68 °F}]
Maximum camshaft runout 0.03 mm {0.0012 in}
IN: 42.44 mm {1.671 in}
Camshaft standard height
EX: 41.18 mm {1.621 in}
IN: 42.33 mm {1.666 in}
Camshaft minimum height
EX: 41.06 mm {1.616 in}
Camshaft journal standard diameter 24.96—24.98 mm {0.9827—0.9834 in}
Camshaft journal minimum diameter 24.95 mm {0.9822 in}
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}
Camshaft standard end play 0.09—0.24 mm {0.004—0.009 in}
Camshaft maximum end play 0.25 mm {0.0098 in}
Maximum distortion, head gasket side 0.10 mm {0.0039 in}
Maximum bore inner diameter 89.000—89.030 mm {3.5040—3.5051 in}
Standard piston outer diameter 88.965—88.995 mm {3.5026—3.5037 in}
Standard clearance between piston and cylinder 0.025—0.045 mm {0.0010—0.0017 in}
Maximum clearance between piston and cylinder 0.11 mm {0.0043 in}
Top: 0.04—0.08 mm {0.002—0.003 in}
Standard clearance between piston ring and ring
Second: 0.03—0.07 mm {0.0012—0.0027 in}
groove
Oil: 0.06—0.15 mm {0.003—0.005 in}
Maximum clearance between piston ring and ring Top: 0.17 mm {0.0066 in}
groove Second, Oil: 0.15 mm {0.0059 in}
01-50–1
TECHNICAL DATA
Item Specification
Top: 0.16—0.26 mm {0.0063—0.010 in}
Standard piston ring end gap Second: 0.31—0.46 mm {0.013—0.018 in}
Oil (rail): 0.15—0.40 mm {0.006—0.015 in}
Maximum piston ring end gap 1.0 mm {0.039 in}
Connecting rod large end maximum side clearance 0.435 mm {0.0171 in}
Standard bearing oil clearance at the large end of
0.026—0.052 mm {0.0011—0.0020 in}
connecting rod
Maximum bearing oil clearance at the large end of
0.1 mm {0.003 in}
connecting rod
STD: 1.497—1.521 mm {0.05894—0.05988 in}
Connecting rod bearing size 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}
Standard connecting rod small end inner diameter 20.010—20.021 mm {0.78780—0.78822 in}
Standard clearance between connecting rod small end
0.010—0.026 mm {0.0004—0.0010 in}
inner diameter and piston pin outer diameter
Crankshaft standard end play 0.22—0.45 mm {0.009—0.017 in}
Crankshaft maximum end play 0.55 mm {0.022 in}
Maximum main journal runout 0.05 mm {0.001 in}
STD: 51.980—52.000 mm {2.0465—2.0472 in}
Main journal diameter
US 0.25: 51.730—51.750 mm {2.0367—2.0374 in}
Maximum main journal off-round 0.005 mm {0.0001 in}
STD: 51.980—52.000 mm {2.0465—2.0472 in}
Crank pin diameter
US 0.25: 51.730—51.750 mm {2.0367—2.0374 in}
Maximum crank pin off-round 0.005 mm {0.0001 in}
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}
STD: 2.501—2.529 mm {0.09847—0.09956 in}
Main bearing size
OS0.25: 2.623—2.630 mm {0.1033—0.1035 in}
Standard: 145.2—145.8 mm {5.717—5.740 in}
Cylinder head bolt length
Maximum: 146.5 mm {5.768 in}
Standard: 43.7—44.3 mm {1.73—1.74 in}
Connecting rod bolt length
Maximum: 45.0 mm {1.77 in}
Main bearing cap bolt length Standard: 104.0—104.6 mm {4.095—4.118 in}
IN: 0.22—0.28 mm {0.009—0.011 in}
EX: 0.27—0.33 mm {0.011—0.012 in}
Front oil seal press-in amount 0—0.5 mm {0—0.019 in}
End Of Sie
01-50–2
SERVICE TOOLS
01-60 SERVICE TOOLS
ENGINE SST . . . . . . . . . . . . . . . . . . . . . . 01-60–1
End of Toc
ENGINE SST
SOKYU_WM: ENGINE
id016000119200
1: Mazda SST number 01-60
2: Global SST number
Example
1:49 JE01 061
2:303–507
Crankshaft TDC
setting pin
1:49 JE01 061 1:49 G011 201 1:49 1285 071

2:303–507 2:– 2: –
Crankshaft TDC Attachment Bearing puller

setting pin
1:49 UN30 3328 1:49 E011 1A0 1:49 0636 100B

2:303–328 2: – 2: –
Rear oil seal Ring gear brake Valve spring

replacer set lifter arm
1:49 B012 0A2 1:49 B012 015 1:49 H010 401

2: – 2: – 2: –
Pivot Valve guide Oil seal installer

installer
1:49 0107 680A 1:49 L010 1A0 1:49 S120 170

2: – 2: – 2: –
Engine stand Engine hanger Valve seal

set remover
1:49 L012 0A0B 1:49 T032 302 1:49 D032 316

2: – 2: – 2: –
Valve seal and Bearing installer Protractor

valve guide
installer set
01-60–1
SERVICE TOOLS
1:49 UN30 3465
2: 303–465
Camshaft — —
alignment
timing tool
End Of Sie
01-60–2

Mazda 2.5L (L5) Engine Workshop Manual (2009-2013)

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1924-1U-08F(INDEX).

fm 1 ページ ２００８年５月２３日 金曜日 午後１時４３分

Manual GENERAL INFORMATION 00

In order to do these procedures safely,

All the contents of this manual, including

Mazda Motor Corporation reserves the right

All rights reserved. No part of this book may

Mazda Motor Corporation

GENERAL INFORMATION 00SECTION

Toc of SCT INFORMATION . . . . 00-00

49 H002 671 SHOWS TIGHTENING

INSTALL THE PARTS BY SHOWS APPLICATION

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

ATX Automatic Transaxle

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

1 Dipstick 10 Chain tensioner

Front Oil Seal Disassembly Note

Chain Tensioner Disassembly Note

Oil Pump Sprocket Disassembly Note

CRANKSHAFT OIL PUMP

1 Camshaft sprocket lock bolt, variable valve timing 6 Tappet

Camshaft Cap Disassembly Note

2. Loosen the camshaft caps bolts in 2—3 passes in

Tappet Disassembly Note

Cylinder Head Bolt Disassembly Note

1 Engine hanger 5 Valve

Valve Keeper Disassembly Note

CARTRIDGE TYPE OIL FILTER

1 Oil pan 2 Oil filter cover

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

1. Disassemble in the order indicated in the table. .

1 Pilot bearing (MTX) 9 Snap ring

Pilot Bearing Disassembly Note

1. Use the SST to remove the pilot bearing.

Connecting Rod Cap Disassembly Note

Main Bearing Cap Disassembly Note

Maximum distortion, head gasket side

4. Measure the manifold contact surface distortion

Maximum cutting length, manifold side

VALVE SEAT INSPECTION/REPAIR

fm 1 ページ２００８年５月２３日金曜日午後１時４３分