CX 7 2009 2.3L

2009 Mazda CX-7 Grand Touring
2007-09 ENGINE Mechanical - Overhaul - 2.3L (L3 With TC) - CX-7, Mazda 3 (2007-08) Mazda6 (2007)
2007-09 ENGINE
Mechanical - Overhaul - 2.3L (L3 With TC) - CX-7, Mazda 3 (2007-08) Mazda6 (2007)
MECHANICAL
ENGINE OVERHAUL SERVICE WARNING
WARNING: l Continuous exposure to USED engine oil has been shown to cause
skin cancer in laboratory mice. Protect your skin by washing with
soap and water immediately after performing work.
ENGINE MOUNTING/DISMOUNTING
Installation
1. Install the SST (arms) to the four positions as shown in the figure and temporarily tighten the bolts (Part
No.: 9YA20-1003) or M10 x 1.5T length 90 mm {3.55 in}.
Fig. 1: Positions For Installing SST (Arms)

Courtesy of MAZDA MOTORS CORP.
viernes, 19 de marzo de 2021 08:32:19

08:32:14 a. m. Page 1 © 2011 Mitchell Repair Information Company, LLC.
2. Install the SSTs (bolts, nuts, hook, and plate) to the four positions as shown in the figure.
3. Install the SST (bolts, nuts, hook, and plate) set in Step 2 to the SST (arms and bolts) set in Step 1.
4. Adjust the bolts so that approx. 20 mm {0.79 in} of thread is exposed from the side of the plate.
5. Adjust the bolts and nuts so that the plate and arms are parallel.
Fig. 2: Positions For Installing SSTs

6. Install the engine to the SST (engine stand).

7. Remove the oil drain plug and drain the engine oil.
8. Replace the gasket with a new one and install the oil pan drain plug.
Tightening torque
30-41 N.m {3.1-4.1 kgf.m, 23-30 ft.lbf}
viernes, 19 de marzo de 2021 08:32:14 a. m. Page 2 © 2011 Mitchell Repair Information Company, LLC.
Fig. 3: Installing Engine To SST (Engine Stand)

Removal
1. Remove in the reverse order of installation.
TIMING CHAIN DISASSEMBLY
1. Disassemble in the order indicated in the table.
Fig. 4: Disassembling View Of Timing Chain

Crankshaft Pulley Lock Bolt Disassembly Note
1. Install the SST to the ring gear to lock the crankshaft against rotation.
Fig. 5: Installing SST To Ring Gear

Front Oil Seal Disassembly Note
1. Remove the oil seal using a flathead screwdriver.
Fig. 6: Removing Oil Seal Using Flathead Screwdriver

Timing Chain Tensioner Disassembly Note
1. Press the timing chain tensioner ratchet to the left using a thin flathead screwdriver (precision
screwdriver) to unlock the plunger.
Fig. 7: Pressing Timing Chain Tensioner Ratchet To Left

2. Slowly press the plunger back in the direction shown in the figure while pressing the ratchet.
Fig. 8: Pressing Plunger Back

3. Release the ratchet with the plunger still pressed down.
Fig. 9: Releasing Ratchet

4. Press-in the plunger until the ratchet position is as indicated in the figure, and then insert the wire to lock
the plunger.
Fig. 10: Identifying Ratchet Position For Pressing In Plunger

Oil Pump Driven Sprocket Disassembly Note
1. Install the SST on the oil pump driven sprocket to lock the oil pump against rotation.
Fig. 11: Holding Oil Pump Sprocket Using SST

CYLINDER HEAD (I) DISASSEMBLY
Fig. 12: Disassembling View Of Cylinder Head (I)

Camshaft Sprocket, Variable Valve Timing Actuator Disassembly Note
1. Before removing the camshaft, hold the camshaft using a wrench on the cast hexagon and loosen the
camshaft sprocket installation bolt.
Fig. 13: Loosening Camshaft Sprocket Bolt

Camshaft Cap Disassembly Note
1. Before removing the camshaft cap, Inspect the camshaft end play. (See CAMSHAFT INSPECTION).
NOTE: l Determine the position of each removed camshaft cap.
2. Loosen the camshaft cap bolts in two to three passes in the order shown in the figure and remove the
camshaft caps.
Fig. 14: Camshaft Cap Bolts Loosening Sequence

Tappet Disassembly Note
NOTE: l Determine the position of each removed tappet.
Cylinder Head Disassembly Note
1. Loosen the cylinder head installation bolts in two to three passes in the order shown in the figure and
remove them.
Fig. 15: Cylinder Head Installation Bolts Loosening Sequence

CYLINDER HEAD (II) DISASSEMBLY
Fig. 16: Disassembling View Of Cylinder Head (II)

Valve Keeper Disassembly Note
1. Remove the valve keeper using the SSTs .
Fig. 17: Removing Valve Keeper Using SSTs

Valve Seal Disassembly Note
1. Remove the valve seal using the SST.
Fig. 18: Removing Valve Seal Using SST

CYLINDER BLOCK (I) DISASSEMBLY
Fig. 19: Disassembling View Of Cylinder Block (I)

Oil Pan Disassembly Note
1. Remove the oil pan using a oil pan seal cutter.
Fig. 20: Removing Oil Pan Using Oil Pan Seal Cutter
Flywheel Disassembly Note
1. Use the SST to lock the crankshaft against rotation.
Fig. 21: Locking Crankshaft Using SST

CYLINDER BLOCK (II) DISASSEMBLY
Fig. 22: Disassembling View Of Cylinder Block (II)

Pilot Bearing Disassembly Note
NOTE: l The pilot bearing does not need to be removed unless you are replacing it.
1. Use the SST to remove the pilot bearing.
Fig. 23: Removing Pilot Bearing Using SST

Connecting Rod Cap Disassembly Note
1. Before removing the connecting rod cap, inspect the connecting rod side clearance. (See CONNECTING
ROD CLEARANCE INSPECTION).
NOTE: l Determine the position of each removed connecting rod cap.
Fig. 24: Inspecting Connecting Rod Side Clearance

Connecting Rod, Piston Disassembly Note
1. Before removing the connecting rod and piston, remove the carbon in the cylinder.
2. Before removing the connecting rod piston, inspect the oil clearance at the large end of the connecting
rod. (See CONNECTING ROD CLEARANCE INSPECTION).
Piston Pin Disassembly Note
1. Before removing the piston pin, weigh the connecting rod. (See PISTON, CONNECTING ROD
INSPECTION).
2. Remove the piston pin using the SST .
Fig. 25: Removing Piston Pin Using SST

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 to three passes in the order shown in the figure and remove
them.
Fig. 26: Main Bearing Cap Bolts Loosening Order

CYLINDER HEAD INSPECTION
1. Inspect the cylinder head surface for cracks and other damage using a red dye penetrant.
l If there is a malfunction, replace the cylinder head.
2. Measure the combustion chamber side of the cylinder head for distortion in six directions as shown in the
figure using a straight edge and feeler gauge.
l If the distortion exceeds the maximum specification, replace the cylinder head.
Maximum distortion, head gasket side 0.10 mm {0.004 in}
Fig. 27: Identifying Direction For Measuring Distortion

3. Inspect the contact surface of the exhaust manifold and the intake manifold for distortion by measuring as
shown in the figure using a straight edge and feeler gauge.
l If the distortion exceeds the maximum specification, grind the surface or replace the cylinder head.
Maximum distortion, manifold side 0.10 mm {0.004 in}
Maximum cutting length, manifold side 0.15 mm {0.006 in}
Fig. 28: Inspecting Contact Surface Of Exhaust Manifold And Intake Manifold For 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
IN: 0.7-1.3mm {0.0276-0.0511 in}
EX: 0.7-1.3mm {0.0276-0.0511 in}
Fig. 29: Identifying Valve Contact Width

2. Verify that the area where the valve seat contacts the valve face is centered.
l If the seating position is too high, resurface the valve seat using a 70° (IN) 65° (EX) valve seat
cutter and a 45° valve seat cutter.
l If the seating position is too low, resurface the valve seat using a 35° (IN) 30° (EX) valve seat
cutter and a 45° valve seat cutter.
Valve seat angle
IN: 45°
EX: 45°
Fig. 30: Resurfacing Valve Seat

3. Inspect the valve seat for sinkage. Measure the protruding length (dimension L) of the valve stem using a
valve of standard length.
l If it is not within the specification, replace the cylinder head.
Standard valve seat sinkage amount (Dimension L)
IN: 40.64-42.24 mm {1.600-1.662 in}
EX: 40.50-42.10 mm {1.595-1.657 in}
Fig. 31: Identifying Valve Seat Sinkage Amount (Dimension L)

VALVE, VALVE GUIDE INSPECTION
1. Measure the valve head margin thickness using a vernier caliper.

l If it is less than the minimum specification, replace the valve.
Minimum valve head margin thickness
IN: 1.62 mm {0.0637 in}
EX: 1.82 mm {0.0716 in}
Fig. 32: Identifying Valve Head Margin Thickness

2. Measure the length of the each valve using a vernier caliper.

l If it is not within the specification, replace the valve.
Standard valve length (Dimension L)
IN: 102.99-103.79 mm {4.055-4.086 in}
EX: 104.25-105.05 mm {4.105-4.135 in}
Fig. 33: Identifying Valve Length (Dimension L)

3. Measure the stem diameter of each valve using the micrometer. Measurement positions total six and are
in the X and Y directions, at three points (A, B, and C) as shown in the figure.
l If it is less than the minimum specification, replace the valve.
Valve stem diameter
Standard
IN: 5.970-5.985 mm {0.2351-0.2356 in}
EX: 5.965-5.980 mm {0.2349-0.2354 in}
Minimum
IN: 5.940 mm {0.2339 in}
EX: 5.935 mm {0.2336 in}
Fig. 34: Measuring Stem Diameter Of Valve Using Micrometer

4. Measure the inner diameter of each valve guide using the caliper gauge. Measurement positions total six
and are in the X and Y directions, at three points (A, B, and C) as shown in the figure.
l If it is not within the specification, replace the valve guide.
Standard valve guide inner diameter
IN: 6.009-6.039 mm {0.2366-0.2377 in}
EX: 6.009-6.039 mm {0.2366-0.2377 in}
Fig. 35: Measuring Inner Diameter Of Valve Guide Using Caliper Gauge
5. Calculate the clearance between the valve stem and the valve guide by subtracting the inner diameter of
the valve guide from the outer diameter of the corresponding valve stem.
l If it exceeds the maximum specification, replace the valve or valve guide.
Clearance between valve stem and guide Standard
IN: 0.024-0.069 mm {0.0009-0.0027 in}
EX: 0.029-0.074 mm {0.0012-0.0029 in}
Maximum
0.10 mm {0.004 in}
Fig. 36: Identifying Clearance Between Valve Stem And Valve Guide
6. Measure the projection height (dimension A) of each valve guide using the vernier caliper.
l If it is not within the specification, replace the valve guide.
Standard valve guide projection height
IN: 12.2-12.8 mm {0.481-0.503 in}
EX: 12.2-12.8 mm {0.481-0.503 in}
Fig. 37: Identifying Projection Height (Dimension A)

VALVE GUIDE REPLACEMENT
Removal
1. Tap the valve guide out from combustion chamber side using the SST.
Fig. 38: Taping Valve Guide Out From Combustion Chamber Side Using SST
Installation
1. Assemble the SSTs so that dimension L is as specified.
IN: 12.2-12.8 mm {0.481-0.503 in}
EX: 12.2-12.8 mm {0.481-0.503 in}
Fig. 39: Assembling SSTs

2. Tap the valve guide in from the cam side using the SSTs assembled in Step 1.
Fig. 40: Identifying Valve Guide

Fig. 41: Tapping Valve Guide In From Cam Side Using SSTs
VALVE SPRING INSPECTION
1. Measure the valve spring height using the spring tester.

l If it is not within the specification, replace the valve spring.
Valve spring installation height
37.90 mm {1.492 in} (171.5 N {17.49 kgf, 38.55 lbf})
Fig. 42: Measuring Valve Spring Height Using Spring Tester

2. Measure the amount of off-square on the valve spring using a 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 maximum specification, replace the valve spring.
Maximum valve spring off-square 2.55 mm {0.100 in}
Fig. 43: Measuring Amount Of Off-Square On Valve Spring Using Square

TAPPET INSPECTION
1. Measure the diameter of each tappet bore using the caliper gauge. Measurement positions total four and
are in the X and Y directions, at two points (A and B) as shown in the figure.
Standard tappet bore diameter
31.000-31.030 mm {1.2205-1.2216 in}
Fig. 44: Measuring Diameter Of Tappet Bore Using Caliper Gauge

2. Measure the tappet body outer diameter of each valve using the micrometer. Measurement positions total
four and are in the X and Y directions, at two points (A and B) as shown in the figure.
Standard tappet body outer diameter
30.970-30.980 mm {1.2193-1.2196 in}
Fig. 45: Measuring Tappet Body Outer Diameter

3. Calculate the clearance between the tappet and the related tappet bore by subtracting the outer diameter of
the tappet from the inner diameter of the tappet bore.
l If it exceeds the maximum specification, replace the tappet or cylinder head.
Clearance between tappet and tappet bore
Standard
0.02-0.06 mm {0.0008-0.0023 in}
Maximum
0.15 mm {0.006 in}
VARIABLE VALVE TIMING ACTUATOR INSPECTION
1. Rotate the variable valve timing actuator by hand and verify that the groove of the rotor and notch of the
cover on the variable valve timing actuator are aligned and fitted.
CAUTION: l If the groove and notch are not aligned, rotate the rotor toward the
valve timing retard position until a locking sound is heard and verify
that they are set in place.
l If the rotor and cover are not secured even though their notch and groove are aligned, replace the variable
valve timing actuator.
CAUTION: l Due to the precision interior construction of the variable valve timing
actuator, it cannot be disassembled.
Fig. 46: Identifying Rotor And Cover

OIL CONTROL VALVE (OCV) INSPECTION
Coil Resistance Inspection
1. Measure the coil resistance between terminals A and B using a tester.
l If it is not within the specification, replace the oil control valve.
Oil control valve coil resistance
6.9-7.9 ohms [20°C {68°F}]
Fig. 47: Identifying Oil Control Valve (OCV) Terminals

Spool Valve Operation Inspection
1. Verify that the spool valve inside the oil control valve is at the maximum valve timing retard position as
shown in the figure.
l If there is any malfunction, replace the oil control valve.
Fig. 48: Identifying Spool Valve (Maximum Valve Timing Retard Position)
2. Apply battery positive voltage between the oil control valve terminals A and B and verify that the spool
valve operates and move to the maximum valve timing retard position.
NOTE: l When applying battery positive voltage between the oil control valve
terminals, the connection of the positive and negative cables can be
either terminal A or B.
3. Stop applying battery positive voltage and verify that the spool valve returns to the maximum valve
timing retard position.
Fig. 49: Identifying Spool Valve (Maximum Valve Timing Advanced Position)
CAMSHAFT INSPECTION
1. Set the No. 1 and No.5 journals of the camshaft on V-blocks.

2. Measure the camshaft runout using the dial gauge.
l If it is not within the specification, replace the camshaft.
Maximum camshaft runout
0.03 mm {0.0012 in}
Fig. 50: Measuring Camshaft Runout

3. Measure the cam height using the micrometer as shown in the figure.
l If it is less than the minimum specification, replace the camshaft.
Cam height
Standard
IN: 42.44 mm {1.671 in}
EX: 41.18 mm {1.622 in}
Minimum
IN: 42.34 mm {1.667 in}
EX: 41.08 mm {1.618 in}
Fig. 51: Measuring Cam Height Using Micrometer

4. Measure the journal diameter using the micrometer. Measurement positions total four and are in the X
and Y directions, at two points (A and B) as shown in the figure.
l If it is less than the minimum specification, replace the camshaft.
Camshaft journal diameter
Standard
24.96-24.98 mm {0.9827-0.9834 in}
Minimum
24.95 mm {0.982 in}
Fig. 52: Journal Diameter Measurement Positions

5. Measure the camshaft journal oil clearance using the plastigage with the tappet removed.
l If it exceeds the maximum specification, replace the cylinder head.
NOTE: l Clean the camshaft journal and the journal receptacle part.
l Cut the plastigage to the same length as the journal width and
position it parallel to the camshaft.
Camshaft journal oil clearance
Standard
0.04-0.08 mm {0.002-0.003 in}
Maximum
0.09 mm {0.0035 in}
Fig. 53: Measuring Camshaft Journal Oil Clearance Using Plastigage

6. Measure the camshaft end play using a dial gauge.

l If it exceeds the maximum specification, replace the cylinder head or camshaft.
Camshaft end play
Standard
0.09-0.24 mm {0.0035-0.0094 in}
Maximum
0.25 mm {0.0099 in}
Fig. 54: Measuring Camshaft End Play Using Dial Gauge

CYLINDER BLOCK INSPECTION
1. Measure the cylinder block for distortion in six directions as shown in the figure using a straight edge and
feeler gauge.
l If it exceeds the maximum specification, replace the cylinder block.
Fig. 55: Measuring Cylinder Block Distortion In Six Directions

2. Measure the cylinder bore diameter using the cylinder gauge. The measurement position is in the X and Y
directions at a point 42 mm below the top surface of the cylinder as shown in the figure.
l If it exceeds the maximum specification, replace the cylinder block.
Maximum bore inner diameter 87.500-87.530 mm {3.4449-3.4460 in}
Fig. 56: Cylinder Bore Diameter Measurement Position

OIL JET VALVE INSPECTION
1. Apply 0.17-0.23 MPa or more of compressed air to oil jet valve A and verify that air passes through oil
jet valve B. If this cannot be verified, replace the oil jet valve.
Fig. 57: Identifying Oil Jet Valve A And B

PISTON INSPECTION
1. Measure the piston outer diameter using the micrometer.
The measurement position is 10.0 mm {0.40 in} from the lower end of the piston and in the thrust
direction.
l If it is not within the specification, replace the piston.
Standard piston outer diameter 87.465-87.495 mm {3.4435-3.4446 in}
2. Calculate the cylinder-to-piston clearance from the cylinder bore diameter and the piston outer diameter.
l If the clearance is at the maximum specification or more, replace the piston or cylinder block.
Fig. 58: Measuring Piston Outer Diameter Using Micrometer

Clearance between piston and cylinder
Standard
0.025-0.045 mm {0.0010-0.0017 in}
Maximum
0.11 mm {0.0043 in}
3. Measure the piston-to-ring groove clearance along the perimeter using a feeler gauge.
l If the clearance is at the maximum specification or more, replace the piston or piston ring.
Clearance between piston ring and ring groove
Standard
Top: 0.005-0.08 mm {0.0020-0.0031 in}
Second: 0.03-0.07 mm {0.0012-0.0027in}
Oil: 0.02-0.06 mm {0.0008-0.0023 in}
Maximum
Top: 0.17 mm {0.0067 in}
Second, Oil: 0.15 mm {0.0059 in}
Fig. 59: Measuring Piston-To-Ring Groove Clearance

4. Measure the piston ring end gap using a feeler gauge.

l If it is at the maximum specification or more, replace the piston ring.
Piston ring end gap
Standard
Top: 0.14-0.24 mm {0.0056-0.0094 in}
Second: 0.34-0.44 mm {0.0134-0.0173 in}
Oil (rail): 0.15-0.40 mm {0.0060-0.0157 in}
Maximum
1.0 mm {0.0393 in}
Fig. 60: Measuring Piston Ring End Gap Using Feeler Gauge
PISTON PIN INSPECTION
1. Measure the piston pin hole diameter using the caliper gauge. Measurement positions total eight and are
in the X and Y directions, at four points (A, B, C, and D) as shown in the figure.
Standard piston pin hole diameter 22.504-22.508 mm {0.8860-0.8861 in}
Fig. 61: Measuring Piston Pin Hole Diameter

2. Measure the inner diameter on the small end of the connecting rod using the caliper gauge. Measurement
positions total eight and are in the X and Y directions, at four points (A, B, C, and D) as shown in the
figure.
Standard connecting rod small end inner diameter
22.510-22.521 mm {0.8863-0.8866 in}
Fig. 62: Measuring Inner Diameter On Small End Of Connecting Rod Using Caliper Gauge
3. Measure the piston pin outer diameter using the micrometer. Measurement positions total eight and are in
the X and Y directions, at four points (A, B, C, and D) as shown in the figure.
Standard piston pin outer diameter
22.495-22.500 mm {0.8857-0.8858 in}
Fig. 63: Measuring Piston Pin Outer Diameter Using Micrometer

4. Calculate the clearance between the piston pin hole diameter and the piston pin outer diameter.
l If it is not within the specification, replace the piston or the piston pin.
Standard clearance between piston pin hole diameter and piston outer diameter
0.004-0.013 mm {0.0002-0.0005 in}
5. Calculate the clearance between the inner diameter on the small end of the connecting rod and the piston
pin outer diameter.
l If it is not within the specification, replace the connecting rod or the piston pin.
Standard clearance between connecting rod small end inner diameter and piston pin outer diameter
0.010-0.026 mm {0.0004-0.0010 in}
CONNECTING ROD CLEARANCE INSPECTION
1. Measure the side clearance at the large end of the connecting rod using a feeler gauge.
l If it is at the maximum specification or more, replace the connecting rod or crankshaft.
Connecting rod large end side clearance
Standard
0.14-0.36 mm {0.0056-0.0141 in}
Maximum
0.435 mm {0.0172 in}
Fig. 64: Measuring Connecting Rod Side Clearance

2. Using a plastigage, measure the oil clearance at the large end of the connecting rod.
l If it is at the maximum specification or more, replace the bearing or grind the crank pin and use
oversize bearings so that the specified clearance is obtained.
NOTE: l Cut the plastigage as wide as the connecting rod bearing width, place
it parallel to the crankshaft, keeping away from the oil hole.
Bearing oil clearance at the large end of connecting rod
Standard
0.027-0.051 mm {0.0011-0.0020 in}
Maximum
0.1 mm {0.0039 in}
Fig. 65: Measuring Oil Clearance Using Plastigage

Connecting rod bearing size
STD
1.495-1.519 mm {0.0589-0.0598 in}
OS0.25
1.614-1.626 mm {0.0636-0.0640 in}
OS0.50
1.739-1.751 mm {0.0685-0.0689 in}
PISTON, 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. If the piston shakes heavily or unsmoothly, replace the connecting rod and piston pin.
Fig. 66: Checking Oscillation Torque

CONNECTING ROD INSPECTION
1. Inspect the connecting rod for bending and distortion using the connecting rod aligner. If it is at the
maximum specification or more, replace the connecting rod.
Maximum connecting rod bending [per 50 mm {1.968 in}]
0.070 mm {0.0019 in}
Fig. 67: Inspecting Connecting Rod For Bending And Distortion Using Connecting Rod Aligner
Maximum connecting rod distortion [per 50 mm {1.968 in}]
0.060 mm {0.0027 in}
Connecting rod center-to-center distance
150.65-150.75 mm {5.9311-5.9350 in}
CRANKSHAFT INSPECTION
1. Measure the crankshaft end play using a dial gauge.

l If it exceeds the maximum specification, replace the thrust bearing or crankshaft so that the
specified end play is obtained.
Crankshaft end play
Standard
0.22-0.45 mm {0.0087-0.0177 in}
Maximum
0.55 mm {0.021 in}
Fig. 68: Measuring Crankshaft End Play Using Dial Gauge

2. Measure the runout of the main journal using a V-block and dial gauge.
l If it is at the maximum specification or more, replace the crankshaft.
Maximum main journal runout 0.05 mm {0.0019 in}
Fig. 69: Measuring Runout Of Main Journal

3. Inspect the main journal diameter and crank pin diameter. Measurement positions total four and are in the
X and Y directions, at two points (A and B) as shown in the figure.
l If it is not within the specification or if it exceeds the maximum off-round, grind the journal with an
oversized bearing.
Main journal diameter
STD
51.980-52.000 mm {2.0465-2.0472 in}
OS0.25
51.730-51.750 mm {2.0367-2.0374 in}
Maximum main journal off-round 0.05 mm {0.0019 in}
Fig. 70: Main Journal And Crank Pin Diameter Measurement Positions
Crank pin diameter
STD
51.980-52.000 mm {2.0465-2.0472 in}
OS0.25
51.730-51.750 mm {2.0367-2.0374 in}
Maximum crank pin off-round 0.05 mm {0.0019 in}
4. Inspect the main journal oil clearance using the following procedure.
1. Install the upper main bearing and crankshaft.

2. Position a plastigage on the journals.
3. Install the lower main bearing and main bearing cap and tighten the bolts in the order shown in the figure.
Tightening procedure
1. Apply engine oil to all bolts.

2. 3-7 N.m {30.6-71.3 kgf.cm, 26.6-61.9 in.lbf}
3. 23-27 N.m {2.4-2.7 kgf.m, 17-19.9 ft.lbf}
4. 38-42 N.m {3.9-4.2 kgf.m, 28.1-30.9 ft.lbf}
5. Loosen all the bolts (until bolts are torque-free).
6. 3-7 N.m {30.6-71.3 kgf.cm, 26.6-61.9 in.lbf}
7. 18-22 N.m {1.9-2.2 kgf.m, 13.3-16.2 ft.lbf}
8. 87.5°-92.5°
Fig. 71: Main Bearing Cap Bolts Tightening Order

4. Loosen the bolts in the reverse order of tightening.

5. Measure the main journal oil clearance.
l If it is not within the specification, replace the main bearing, or grind the main journal and use oversized
bearings so that the specified oil clearance is obtained.
Main journal oil clearance
Standard
0.016-0.039 mm {0.0007-0.0015 in}
Maximum
0.10 mm {0.0039 in}
Fig. 72: Measuring Main Journal Oil Clearance

Main bearing size (UPPER)
STD
2.501-2.522 mm {0.0985-0.0992 in}
OS0.25
2.623-2.629 mm {0.1033-0.1035 in}
OS0.50
2.748-2.754 mm {0.1082-0.1084 in}
Main bearing size (LOWER)
STD
2.501-2.529 mm {0.0985-0.0995 in}
OS0.25
2.624-2.630 mm {0.1034-0.1035 in}
OS0.50
2.749-2.755 mm {0.1083-0.1084 in}
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. 73: Inspecting Pilot Bearing

BOLT INSPECTION
1. Measure the length of the each bolt.

l If it exceeds the maximum specification, replace the bolt.
Cylinder head bolt length
Standard
144.7-145.3 mm {5.696-5.720 in}
Maximum
146 mm {5.748 in}
Connecting rod bolt length
Standard
43.7-44.3 mm {1.720-1.744 in}
Maximum
46 mm {1.811 in}
Fig. 74: Identifying Bolt Length

VALVE CLEARANCE INSPECTION/ADJUSTMENT
VALVE CLEARANCE INSPECTION
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 it is not within the specification, replace the tappet and adjust the valve clearance to the standard
clearance. (See VALVE CLEARANCE ADJUSTMENT).
Standard valve clearance [when cold]
IN: 0.22-0.28 mm {0.0087-0.0110 in}
EX: 0.27-0.33 mm {0.0106-0.0130 in}
NOTE: l When replacing the tappet, select the tappet according to the
measured value and note down the measured value.
3. Rotate the crankshaft clockwise 360° so that the No. 4 piston is at the TDC of the compression stroke.
4. Measure the valve clearance at B in the figure.
l If it is not within the specification, replace the tappet and adjust the valve clearance to the standard
clearance. (See VALVE CLEARANCE ADJUSTMENT).
Fig. 75: Positions For Measuring Valve Clearance

IN: 0.22-0.28 mm {0.0087-0.0110 in}
EX: 0.27-0.33 mm {0.0106-0.0130 in}
NOTE: l When replacing the tappet, select the tappet according to the
measured value and note down the measured value.
VALVE CLEARANCE ADJUSTMENT
1. Remove the engine front cover lower blind plug.

2. Remove the engine front cover upper blind plug.
Fig. 76: Identifying Lower And Upper Blind Plug

3. Remove the cylinder block lower blind plug and install the SST .
4. Rotate the crankshaft clockwise so that the No. 1 piston is at TDC of the compression stroke. (The
position crank weight contacts the SST ).
Fig. 77: Installing SST

5. Loosen the timing chain.

1. Using a suitable screwdriver or equivalent tool, unlock the timing chain tensioner ratchet.
2. Rotate the exhaust camshaft clockwise using a suitable wrench on the cast hexagon and loosen the
timing chain tensioner.
Fig. 78: Loosening Timing Chain

3. Using a suitable bolt (M6 X 1.0 length 25-35 mm {0.99-1.37 in}) at the engine front cover upper
blind plug, secure the tensioner arm at the position where the tension is released.
Fig. 79: Securing Tensioner Arm Using Suitable Bolt

6. Secure the exhaust camshaft using a wrench on the cast hexagon and loosen the camshaft sprocket
installation bolt.
Fig. 80: Holding Camshaft Using Suitable Wrench On Cast Hexagon

7. Remove the installation bolt and exhaust camshaft sprocket.
Fig. 81: Removing/Installing Exhaust Camshaft Sprocket

8. Loosen the camshaft cap bolts in two or three passes in the order shown in the figure, and remove the
camshaft bearing caps.
NOTE: l The camshaft caps are to be kept ordered for correct reassembly in
their original positions. Do not mix the caps.
Fig. 82: Camshaft Cap Bolts Loosening Sequence

9. Remove the camshafts for intake and exhaust sides.

10. Remove the tappet.
11. Select and install the suitable tappet according to the result of valve clearance inspection.
Selected tappet = Removed tappet thickness + Measured valve clearance - Standard valve clearance
IN: 0.22-0.28 mm {0.0087-0.0110 in}
EX: 0.27-0.33 mm {0.0106-0.0130 in}
12. Install the camshaft with the No. 1 cylinder cam aligned at TDC of the compression stroke.
13. Install the camshaft bearing cap and tighten the camshaft bearing cap bolts in two passes in the order
shown in the figure.
1. 5.0-9.0 N.m {51.0-91.7 kgf.cm, 44.3-79.6 in.lbf}

2. 14.0-17.0 N.m {1.5-1.7 kgf.m, 10.4-12.5 ft.lbf}
Fig. 83: Camshaft Cap Bolts Tightening Sequence

14. Install a new washer.
Fig. 84: Installing Washer

15. Install the exhaust camshaft sprocket.
CAUTION: l Do not tighten the camshaft sprocket installation bolt during

this step.
Fig. 85: Removing/Installing Exhaust Camshaft Sprocket

16. Install the SST on the camshaft as shown in the figure.

17. Remove the bolt (M6 X 1.0 length 25-35 mm {0.99-1.37 in}) from the engine front cover upper blind
plug and apply tension to the timing chain.
18. Rotate the crankshaft clockwise and verify that the No. 1 piston is at TDC of the compression stroke.
Fig. 86: Installing SST On Camshaft

19. Secure the exhaust camshaft using a wrench on the cast hexagon and tighten the sprocket installation bolt.
Tightening torque
69-75 N.m {7.1-7.6 kgf.m, 50.9-55.3 ft.lbf}
Fig. 87: Securing Exhaust Camshaft Using Wrench

20. Remove the SST from the camshaft.

21. Remove the SST installed in the cylinder block lower blind plug hole.
22. Rotate the crankshaft clockwise two turns and inspect the valve timing.
23. Apply silicone sealant and install the engine front cover upper blind plug.
Tightening torque
8.0-11.5 N.m {81.6-117.2 kgf.cm, 70.9-101.7 in.lbf}
24. Install the cylinder block lower blind plug.
Tightening torque
18-22 N.m {1.9-2.2 kgf.m, 13.3-16.2 ft.lbf}
25. Install a new engine front cover lower blind plug.
Tightening torque
10.0-14.0 N.m {102.0-142.7 kgf.cm, 88.6-123.9 in.lbf}
CYLINDER BLOCK (I) ASSEMBLY
1. Assemble in the order indicated in the table.
Fig. 88: Assembling Cylinder Block (I) & Torque Specification

Main Bearing Cap Assembly Note
1. Tighten the crank bearing caps in the order shown in the figure.
1. Apply engine oil to all bolts.

2. 3-7 N.m {30.6-71.3 kgf.cm, 26.6-61.9 in.lbf}
3. 23-27 N.m {2.4-2.7 kgf.m, 17-19.9 ft.lbf}
4. 38-42 N.m {3.9-4.2 kgf.m, 28.1-30.9 ft.lbf}
5. Loosen all the bolts (until bolts are torque-free).
6. 3-7 N.m {30.6-71.3 kgf.cm, 26.6-61.9 in.lbf}
7. 18-22 N.m {1.9-2.2 kgf.m, 13.3-16.2 ft.lbf}
8. 87.5°-92.5°
Fig. 89: Crank Bearing Caps Tightening Order

Piston Pin Assembly Note
1. Assemble the piston pin using the SST.
Fig. 90: Assembling Piston Pin Using SST

Piston Ring Assembly Note
1. Assemble the oil ring.

2. Assemble the second ring with the notch facing downward.
3. Assemble the top ring with scraper face side upward.
Fig. 91: Assembling Piston Ring

Piston Assembly Note
1. Position the end gap of each ring so they are not aligned as shown in the figure.
Fig. 92: Positioning Ring End Gap

2. Insert the piston into the cylinder with the arrow on top of the piston facing the front of the engine.
Fig. 93: Inserting Piston Into Cylinder

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. 94: Installing Connecting Rod Bearing

Connecting Rod Cap Assembly Note
CAUTION: l When assembling the connecting rod caps, align the broken, rough
faces of the connecting rods and connecting rod caps.
1. Tighten the connecting rod installation bolts using the following procedure.
1. 26-31 N.m {2.7-3.1 kgf.m, 19.2-22.8 ft.lbf}

2. 80°-100°
Balancer Unit Assembly Note
1. Confirm by visual inspection that there is no damage to the balancer unit gear and verify that the shaft
rotates smoothly.
l If there is any malfunction, replace the balancer unit.
CAUTION: l Due to the precision interior construction of the balancer unit, it

cannot be disassembled.
2. Remove the cylinder block lower blind plug and install the SST.
position crank weight contacts the SST. )
4. Install the adjustment shim to the seating face of the balancer unit.

5. With the balancer unit marks at the exact top center, assemble the balancer unit to the cylinder block.
Fig. 96: Identifying Balancer Unit Marks

6. Set the SST as shown in the figure and measure the gear backlash using a dial gauge.
NOTE: l To measure the backlash precisely, insert a flathead screwdriver into the
crankshaft No. 1 crank weight area and set both the rotation and the thrust
direction with the flathead screwdriver, using a prying action, as shown in
the figure.
Fig. 97: Measuring Gear Backlash Using Dial Gauge

l If it exceeds the maximum specification, remeasure the backlash and,

using the adjustment shim selection table, select the proper shim,
according to the following procedure.
CAUTION: l When measuring the backlash, rotate the crankshaft one full rotation
and verify that it is within the specified range at all of the following
six positions: 10, 30, 100, 190, 210, 280 ATDC.
Maximum gear backlash
0.005-0.101 mm {0.00019-0.0039 in}
Fig. 98: Checking Crankshaft No. 1 Backlush

1. Using master shim (No.50), assemble the balancer unit to the cylinder block and measure the backlash.
2. Select the proper adjustment shim according to the measured value.
3. Install the selected adjustment shim to the balancer unit and assemble the balancer unit to the cylinder
block.
Adjustment shim selection table
ADJUSTMENT SHIM SELECTION REFERENCE

Backlash mm Selection shim Shim thickness Backlash mm Selection shim Shim thickness
{in} (No). mm {in} {in} (No). 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- {0.00417-
18 1.18 {0.0464} 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 .087
{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} {0.00307- 42 1.42 {0.0559}
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) 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- {0.00003-
33 1.33 {0.523} 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}
Pilot Bearing Assembly Note
1. Use the SSTs to install the pilot bearing.
Fig. 99: Installing Pilot Bearing Using SSTs

Fig. 100: Positions For Installing Pilot Bearing

CYLINDER BLOCK (II) ASSEMBLY
Fig. 101: Assembling Cylinder Block (II) & Torque Specification

Rear Oil Seal Assembly Note
1. Apply clean engine oil to a new rear oil seal.

2. Install the rear oil seal using a SST .
Fig. 102: Installing Rear Oil Seal Using SST

3. Tighten the installation bolts in the order shown in the figure.
Tightening torque
8.0-11.5 N.m {81.6-117.2 kgf.cm, 70.9-101.7 in.lbf}
Fig. 103: Rear Oil Seal Bolt Tightening Sequence

Flywheel Assembly Note
1. Secure the crankshaft using the SST .

2. Tighten the installation bolts in two or three passes in the order shown in the figure.
Tightening torque
151.3-161.1 N.m {15.43-16.42 kgf.m, 111.6-118.8 ft.lbf}
Fig. 104: Flywheel Installation Bolts & Tightening Sequnce

Oil Pan Assembly Note
1. Apply silicone sealant to the areas shown in the figure.

2. Assemble the oil pan.
Fig. 105: Applying Silicone Sealant

3. Use a straight edge to align the junction of the oil pan and the cylinder block on the engine front cover
side.
Fig. 106: Aligning Junction Of Oil Pan And Cylinder Block Using Straight Edge
4. Tighten the bolts in the order shown in the figure.
Tightening torque
17-23 N.m {1.8-2.3 kgf.m, 12.6-16.9 ft.lbf}
Fig. 107: Bolts Tightening Order

CYLINDER HEAD (I) ASSEMBLY
Fig. 108: Assembling Cylinder Head (I) & Torque Specification

Water Outlet Case Assembly Note
1. Tighten the bolts in the order shown in the figure.
Fig. 109: Water Outlet Case Bolts Tightening Order

Valve Seal Assembly Note
1. Press in the valve seal to the valve guide by hand.

2. Set the SST and tap it using a plastic hammer.
Fig. 110: Installing Valve Seal

Valve Keeper Assembly Note
1. Assemble the valve keeper using the SST .
Fig. 111: Assembling Valve Keeper Using SST

CYLINDER HEAD (II) ASSEMBLY
Fig. 112: Assembling Cylinder Head (II) & Torque Specification

Cylinder Head Assembly Note
1. Tighten the cylinder head installation bolts in five passes in the order shown in the figure.
1. 3-11 N.m {30.6-112 kgf.cm, 26.6-97.3 in.lbf}

2. 13-17 N.m {1.4-1.7 kgf.m, 9.6-12.5 ft.lbf}
3. 43-47 N.m {4.4-4.7 kgf.m, 31.8-34.6 ft.lbf}
4. 88°-92°
5. 88°-92°
Fig. 113: Cylinder Head Installation Bolts Tightening Order

Camshaft Assembly Note
NOTE: l Install the camshaft with the No. 1 cylinder cam aligned at TDC of the
compression stroke.
1. Carefully apply adhesive agent to the area indicated in the figure so that it does not leak into the sliding
part.
Thickness
1.0 mm {0.039 in}
Fig. 114: Applying Adhesive Agent

2. Install the camshaft caps and hand-tighten the camshaft cap bolts evenly in two or three passes, and then
tighten the camshaft cap bolts in two passes, in the order shown in the figure.
1. 5.0-9.0 N.m {51.0-91.7 kgf.cm, 44.3-79.5 in.lbf}

2. 14.0-17.0 N.m {1.5-1.7 kgf.m, 10.4-12.5 ft.lbf}
Fig. 115: Camshaft Cap Bolts Tightening Order

Camshaft Sprocket, Variable Valve Timing Actuator Assembly Note
1. Leave the camshaft sprocket installation bolt temporarily tightened until the timing chain is installed.
After the timing chain is installed, tighten it to the specified torque.
TIMING CHAIN ASSEMBLY
Fig. 116: Timing Chain Components & Torque Specification

Drive Sprocket Assembly Note
1. The oil pump drive sprocket has the assembly direction as shown in the figure.
Fig. 117: Assembling Oil Pump Drive Sprocket

Oil Pump Driven Sprocket Assembly Note
1. Install the SST on the oil pump driven sprocket to lock the oil pump against rotation.
Fig. 118: Installing SST On Oil Pump Driven Sprocket

Timing Chain Assembly Note
1. Install the SST on the camshaft and align the No. 1 camshaft position at TDC of the compression stroke.
Fig. 119: Installing SST On Camshaft

2. Remove the cylinder block lower blind plug from the cylinder block and install the SST .
position crank weight contacts the SST ).
4. Install the timing chain.

5. After the chain adjuster is installed, remove the paper clip (stopper).
Fig. 121: Removing Paper Clip (Stopper)

Camshaft Sprocket Lock Bolt Assembly Note
1. Lock the camshaft against rotation using a wrench on the cast hexagon.
2. Tighten the camshaft sprocket installation bolt.
Tightening torque
69-75 N.m {7.1-7.6 kgf.m, 50.9-55.3 ft.lbf}
Fig. 122: Holding Camshaft Using Suitable Wrench On Cast Hexagon

Fig. 123: Tightening Camshaft Sprocket Installation Bolt

Engine Front Cover Assembly Note
1. Apply silicone sealant to the engine front cover.
CAUTION: l Install the engine front cover within 10 minutes of applying the
silicone sealant.
l Silicone sealant is not need in area C as indicated below due to
an existing.
NOTE: l Install the engine front cover within 10 min after applying the silicone
sealant.
Thickness
A: 2.2-3.2 mm {0.087-0.125 in}
B: 1.5-2.5 mm {0.059-0.098 in}
Fig. 124: Applying Silicone Sealant To Engine Front Cover

2. Tighten the engine front cover installation bolts in the order shown in the figure.
ENGINE FRONT COVER INSTALLATION BOLTS TIGHTENING SPECIFICATIONS

Installation position
Tightening torque N.m
{kgf.m, ft.lbf}
8.0-11.5 N.m {81.6-117.2
1-18
kgf.cm, 70.9-101.7 in.lbf}
19-22 40-55 {4.1-5.6, 29.7-40.5}
Fig. 125: Engine Front Cover Bolts Tightening Order

3. Install the oil seal using the SST .
Front oil seal press-in amount
0-0.5 mm {0-0.019 in}
Fig. 126: Installing Front Oil Seal

Fig. 127: Identifying Front Oil Seal Installation Recess Value

Crankshaft Pulley Lock Bolt Assembly Note
1. Install the crankshaft pulley to the front cover using a bolt (M6 X 1.0) . Temporarily tighten the bolt.
Fig. 128: Installing M6 X 1.0 Bolt

2. Use the SST to lock the crankshaft against rotation.
Fig. 129: Locking Crankshaft Using SST

3. Tighten the pulley lock bolt.
1. 96-104 N.m {9.8-10.6 kgf.m, 70.9-76.7 ft.lbf}

2. 87°-93°
4. Remove the SST from the camshaft, and remove the bolt from the crankshaft pulley.
5. Remove the SST from the cylinder block lower blind plug, and install the cylinder block lower blind
plug.
Fig. 130: Tightening Crankshaft Bolt

Cylinder Head Cover Assembly Note
1. Apply silicone sealant to the areas shown in the figure.
Thickness
5.0 mm {0.196 in}
Fig. 131: Identifying Areas For Applying Silicone Sealant (1 Of 2)

Fig. 132: Identifying Areas For Applying Silicone Sealant (2 Of 2)

2. Install the cylinder head cover installation bolts in the order shown in the figure.
Tightening torque
8.0-10.5 N.m {81.6-107 kgf.cm, 70.9-92.9 in.lbf}
Fig. 133: Cylinder Head Cover Bolt Tightening Sequence

01-50 TECHNICAL DATA

ENGINE TECHNICAL DATA
ENGINE TECHNICAL DATA

Item Specification
Maximum distortion, manifold side 0.10 mm {0.004 in}
Maximum cutting length, manifold side 0.15 mm {0.006 in}
IN: 0.7-1.3mm {0.0276-0.0511 in}
Standard valve seat contact width
EX: 0.7-1.3mm {0.0276-0.0511 in}
IN: 45°
Valve seat angle
EX: 45°
IN: 40.64-42.24 mm {1.600-1.662 in}
Standard valve seat sinkage amount (Dimension L)
EX: 40.50-42.10 mm {1.595-1.657 in}
IN: 1.62 mm {0.0637 in}
Minimum valve head margin thickness
EX: 1.82 mm {0.0716 in}
IN: 102.99-103.79 mm {4.055-4.086

in}
Standard valve length (Dimension L)
EX: 104.25-105.05 mm {4.105-4.135
in}
Standard
IN: 5.970-5.985 mm {0.2351-0.2356
in}
EX: 5.965-5.980 mm {0.2349-0.2354
Valve stem diameter
in}
Minimum
IN: 5.940 mm {0.2339 in}
EX: 5.935 mm {0.2336 in}
IN: 6.009-6.039 mm {0.2366-0.2377
in}
Standard valve guide inner diameter
EX: 6.009-6.039 mm {0.2366-0.2377
in}
Standard
IN: 0.024-0.069 mm {0.0009-0.0027
in}
Clearance between valve stem and guide EX: 0.029-0.074 mm {0.0012-0.0029
in}
Maximum
0.10 mm {0.004 in}
IN: 12.2-12.8 mm {0.481-0.503 in}
EX: 12.2-12.8 mm {0.481-0.503 in}
37.90 mm {1.492 in} (171.5 N {17.49
Valve spring installation height
kgf, 38.55 lbf})
Maximum valve spring off-square 2.55 mm {0.100 in}
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
0.02-0.06 mm {0.0008-0.0023 in}
Clearance between tappet and tappet bore
Maximum
0.15 mm {0.006 in}
Oil control valve coil resistance 6.9-7.9 ohms [20°C {68°F}]
Maximum camshaft runout 0.03 mm {0.0012 in}
Standard
IN: 42.44 mm {1.671 in}
EX: 41.18 mm {1.622 in}
Cam height
Minimum
IN: 42.34 mm {1.667 in}
EX: 41.08 mm {1.618 in}
Standard
24.96-24.98 mm {0.9827-0.9834 in}
Camshaft journal diameter
Minimum
24.95 mm {0.982 in}
Standard
0.04-0.08 mm {0.002-0.003 in}
Camshaft journal oil clearance
Maximum
0.09 mm {0.0035 in}
Standard
0.09-0.24 mm {0.0035-0.0094 in}
Camshaft end play
Maximum
0.25 mm {0.0099 in}
Maximum bore inner diameter 87.500-87.530 mm {3.4449-3.4460 in}
Standard piston outer diameter 87.465-87.495 mm {3.4435-3.4446 in}
Standard
0.025-0.045 mm {0.0010-0.0017 in}
Clearance between piston and cylinder
Maximum
0.11 mm {0.0043 in}
Standard
Top: 0.005-0.08 mm {0.0020-0.0031
in}
Second: 0.03-0.07 mm {0.0012-
Clearance between piston ring and ring groove 0.0027in}
Oil: 0.02-0.06 mm {0.0008-0.0023 in}
Maximum
Top: 0.17 mm {0.0067 in}
Second, Oil: 0.15 mm {0.0059 in}
Standard
Top: 0.14-0.24 mm {0.0056-0.0094
in}
Second: 0.34-0.44 mm {0.0134-0.0173
Piston ring end gap in}
Oil (rail): 0.15-0.40 mm {0.0060-
0.0157 in}
Maximum
1.0 mm {0.0393 in}
Standard piston pin hole diameter 22.504-22.508 mm {0.8860-0.8861 in}
Standard connecting rod small end inner diameter 22.510-22.521 mm {0.8863-0.8866 in}
Standard piston pin outer diameter 22.495-22.500 mm {0.8857-0.8858 in}
Standard clearance between piston pin hole diameter and piston
0.004-0.013 mm {0.0002-0.0005 in}
outer diameter
Standard clearance between connecting rod small end inner
0.010-0.026 mm {0.0004-0.0010 in}
diameter and piston pin outer diameter
Standard
0.14-0.36 mm {0.0056-0.0141 in}
Connecting rod large end side clearance
Maximum
0.435 mm {0.0172 in}
Standard
0.027-0.051 mm {0.0011-0.0020 in}
Maximum
Bearing oil clearance at the large end of connecting rod
0.1 mm {0.0039 in}
STD
1.495-1.519 mm {0.0589-0.0598 in}
OS0.25
Connecting rod bearing size
1.614-1.626 mm {0.0636-0.0640 in}
OS0.50
1.739-1.751 mm {0.0685-0.0689 in}
Maximum connecting rod bending [per 50 mm] 0.070 mm {0.0019 in}
Maximum connecting rod distortion [per 50 mm] 0.060 mm {0.0027 in}
Connecting rod center-to-center distance 150.65-150.75 mm {5.9311-5.9350 in}
Standard
0.22-0.45 mm {0.0087-0.0177 in}
Crankshaft end play
Maximum
0.55 mm {0.021 in}
Maximum main journal runout 0.05 mm {0.0019 in}
STD
51.980-52.000 mm {2.0465-2.0472 in}
Main journal diameter
OS0.25
51.730-51.750 mm {2.0367-2.0374 in}
Maximum main journal off-round 0.05 mm {0.0019 in}
STD
51.980-52.000 mm {2.0465-2.0472 in}
Crank pin diameter
OS0.25
51.730-51.750 mm {2.0367-2.0374 in}
Maximum crank pin off-round 0.05 mm {0.0019 in}
Standard
0.016-0.039 mm {0.0007-0.0015 in}
Main journal oil clearance
Maximum
0.10 mm {0.0039 in}
STD
2.501-2.522 mm {0.0985-0.0992 in}
OS0.25
Main bearing size (UPPER)
2.623-2.629 mm {0.1033-0.1035 in}
OS0.50
2.748-2.754 mm {0.1082-0.1084 in}
STD
2.501-2.529 mm {0.0985-0.0995 in}
OS0.25
Main bearing size (LOWER)
2.624-2.630 mm {0.1034-0.1035 in}
OS0.50
2.749-2.755 mm {0.1083-0.1084 in}
Standard
144.7-145.3 mm {5.696-5.720 in}
Cylinder head bolt length
Maximum
146 mm {5.748 in}
Standard
43.7-44.3 mm {1.720-1.744 in}
Connecting rod bolt length
Maximum
46 mm {1.811 in}
IN: 0.22-0.28 mm {0.0087-0.0110 in}
EX: 0.27-0.33 mm {0.0106-0.0130 in}
Maximum gear backlash 0.005-0.101 mm {0.00019-0.0039 in}
Front oil seal press-in amount 0-0.5 mm {0-0.019 in}
01-60 SERVICE TOOLS

ENGINE SST [L3 WITH T/C]
1. Mazda SST number

2. Global SST number
Example
SST EXAMPLE
1: 49 UN30
310610
2: 303-1061
Camshaft alignment timing tool
SST DESCRIPTION
1:-2: 303-507 1:-2: 205-072-02 1: 49 G032 354
Crankshaft TDC Crankshaft 2:-
timing peg holding tool pins Adjusting wrench
1: 49 E011 1A0 1: 49 0636 100B 1: 49 B012 0A2

2:- 2:- 2:-
Ring gear brake Valve spring Pivot
set lifter arm
1: 49 B012 015 1: 49 H010 401 1: 49 0107 680A
2:- 2:- 2:-
Valve guide Oil seal installer Engine stand
installer
1: 49 L010 1A0 1: 49 S120 170 1: 49 L012 0A0B

2:- 2:- 2:-
Engine hanger Valve seal Valve seal and
set remover valve guide
installer set
1: 49 T032 302 1: 49 UN30 Camshaft 1: 49 G011 201
2:- 310610 alignment 2:-
Bearing installer 2: 303-1061 timing tool Attachment
1: 49 UN20 5153 1: 49 1285 071 1: 49 UN30 3328

2: 205-153 2:- 2: 303-328
Handle Bearing puller Rear oil seal
replacer
1: 49 T011 001 1: 49 UN30 8157 Pilot bearing -
2:- 2: 308-157 installer
Piston pin
installer

CX 7 2009 2.3L

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2009 Mazda CX-7 Grand Touring

Fig. 1: Positions For Installing SST (Arms)

viernes, 19 de marzo de 2021 08:32:19

Fig. 2: Positions For Installing SSTs

6. Install the engine to the SST (engine stand).

30-41 N.m {3.1-4.1 kgf.m, 23-30 ft.lbf}

Fig. 3: Installing Engine To SST (Engine Stand)

1. Remove in the reverse order of installation.

TIMING CHAIN DISASSEMBLY

1. Disassemble in the order indicated in the table.

Fig. 4: Disassembling View Of Timing Chain

Crankshaft Pulley Lock Bolt Disassembly Note

Fig. 5: Installing SST To Ring Gear

Front Oil Seal Disassembly Note

1. Remove the oil seal using a flathead screwdriver.

Fig. 6: Removing Oil Seal Using Flathead Screwdriver

Timing Chain Tensioner Disassembly Note

Fig. 7: Pressing Timing Chain Tensioner Ratchet To Left

Fig. 8: Pressing Plunger Back

3. Release the ratchet with the plunger still pressed down.

Fig. 9: Releasing Ratchet

Fig. 10: Identifying Ratchet Position For Pressing In Plunger

Oil Pump Driven Sprocket Disassembly Note

Fig. 11: Holding Oil Pump Sprocket Using SST

CYLINDER HEAD (I) DISASSEMBLY

1. Disassemble in the order indicated in the table.

Fig. 12: Disassembling View Of Cylinder Head (I)

Camshaft Sprocket, Variable Valve Timing Actuator Disassembly Note

Fig. 13: Loosening Camshaft Sprocket Bolt

Camshaft Cap Disassembly Note

NOTE: l Determine the position of each removed camshaft cap.

Fig. 14: Camshaft Cap Bolts Loosening Sequence

Tappet Disassembly Note

NOTE: l Determine the position of each removed tappet.

Cylinder Head Disassembly Note

Fig. 15: Cylinder Head Installation Bolts Loosening Sequence

CYLINDER HEAD (II) DISASSEMBLY

1. Disassemble in the order indicated in the table.

Fig. 16: Disassembling View Of Cylinder Head (II)

Valve Keeper Disassembly Note

1. Remove the valve keeper using the SSTs .

Fig. 17: Removing Valve Keeper Using SSTs

Valve Seal Disassembly Note

1. Remove the valve seal using the SST.

Fig. 18: Removing Valve Seal Using SST

CYLINDER BLOCK (I) DISASSEMBLY

1. Disassemble in the order indicated in the table.

Fig. 19: Disassembling View Of Cylinder Block (I)

Oil Pan Disassembly Note

1. Remove the oil pan using a oil pan seal cutter.

Flywheel Disassembly Note

1. Use the SST to lock the crankshaft against rotation.

Fig. 21: Locking Crankshaft Using SST

CYLINDER BLOCK (II) DISASSEMBLY

1. Disassemble in the order indicated in the table.

Fig. 22: Disassembling View Of Cylinder Block (II)

Pilot Bearing Disassembly Note

1. Use the SST to remove the pilot bearing.

Fig. 23: Removing Pilot Bearing Using SST