2006 2008 Engine Overhaul

2007 Mazda MX-5 Miata Sport
2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata
2006-08 ENGINE
Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata
ENGINE IDENTIFICATION
Engine can be identified by engine model and number
ENGINE IDENTIFICATION CODE

Engine Code
2.0L 4-Cylinder LF
2.3L 4-Cylinder L3
MECHANICAL
ENGINE OVERHAUL SERVICE WARNING
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.
ENGINE MOUNTING/DISMOUNTING
1. Install the SSTs (arms) to the cylinder block holes as shown, and hand-tighten the bolts (part No.:
9YA20-1003) or M10 x 1.5T length 90 mm {3.55 in}.
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Thursday, July 09, 2009 2:43:30
2:43:24 PM Page 1 © 2005 Mitchell Repair Information Company, LLC.
Fig. 1: Installing SST (Arms) To Cylinder Block Holes

Courtesy of MAZDA MOTORS CORP.
2. Assemble the SSTs (bolts, nuts and plate) to the specified positions.
3. Adjust the SSTs (bolts) so that less than 20 mm {0.79 in} of thread is exposed.
4. Make the SSTs (arms and plate) parallel by adjusting the SSTs (bolts and nuts).
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Thursday, July 09, 2009 2:43:25 PM Page 2 © 2005 Mitchell Repair Information Company, LLC.
Fig. 2: Assembling SSTs (Bolts, Nuts And Plate) To Positions

5. Tighten the SSTs (bolts and nuts) to affix the SSTs firmly.
Fig. 3: Identifying SST Bolts, Nuts & Parallel Plates
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WARNING:  Self-locking brake system of the engine stand may not be

effective when the engine is held in an unbalanced position.
This could lead to sudden, rapid movement of the engine and
mounting stand handle and cause serious injury. Never keep
the engine in an unbalanced position, and always hold the
rotating handle firmly when turning the engine.
6. Mount the engine on the SST (engine stand).

7. Drain the engine oil into a container.
8. Install the oil pan drain plug.
 With washer
1. Install the oil pan drain plug with a new washer.
Tightening torque
30-41 N.m {3.1-4.1 kgf.m, 23-30 ft.lbf}
 Without washer
1. Inspect the seal rubber of the oil pan drain plug and make sure there are no cracks or damage.
- If necessary, replace the oil pan drain plug.
2. Clean the flange surface (seal rubber) on the oil pan drain plug, then install the oil pan drain
plug.
Tightening torque
22-30 N.m {2.2-3.1 kgf.m, 16-22 ft.lbf}
DISMOUNTING
 Dismount in the reverse order of mounting.
TIMING CHAIN DISASSEMBLY
1. Disassemble in the order indicated in the table.
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Fig. 4: Exploded View Of Timing Chain Components

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

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

Chain Tensioner Disassembly Note
1. Unlock the chain tensioner ratchet using a suitable screw driver or equivalent tool.
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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Fig. 7: Disassembling Chain Tensioner

Oil Pump Sprocket Disassembly Note
1. Hold the oil pump sprocket using the SST .
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Fig. 8: Holding Oil Pump Sprocket Using SST

CYLINDER HEAD (I) DISASSEMBLY
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Fig. 9: Exploded View Of Cylinder Head (I) Disassembly

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
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installation bolt or variable valve timing actuator installation bolt (With variable valve timing
mechanism).
Without variable valve timing mechanism
Fig. 10: Using Wrench On Cast Hexagon

With variable valve timing mechanism
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Fig. 11: Using Wrench On Cast Hexagon

Camshaft Cap Disassembly Note
1. Before removing the camshaft caps, inspect the following:

 Camshaft end play and camshaft journal oil clearance (See CAMSHAFT INSPECTION).
NOTE:  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 steps in the order shown in the figure.
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Fig. 12: Identifying Loosening Sequence Of Camshaft Cap Bolts

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 steps in the order shown in the figure.
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Fig. 13: Loosening Cylinder Head Bolts

CYLINDER HEAD (II) DISASSEMBLY
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Fig. 14: Exploded View Of Cylinder Head (II) Disassembly

Valve Keeper Disassembly Note
1. Remove the valve keeper using the SSTs .
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Fig. 15: Removing Valve Keeper

Valve Seal Disassembly Note
1. Remove the valve seal using the SST.
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Fig. 16: Removing Valve Seal

CYLINDER BLOCK (I) DISASSEMBLY
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Fig. 17: Exploded View Of Cylinder Block (I) Disassembly

Drive Plate (ATX), Flywheel (MTX) Disassembly Note
1. Hold the crankshaft using the SST.

2. Remove the bolts in several passes.
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Fig. 18: Removal Sequence Of Drive Plate Or Flywheel Bolts

CYLINDER BLOCK (II) DISASSEMBLY
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Fig. 19: Exploded View Of Cylinder Block (II) Disassembly

Connecting Rod Cap Disassembly Note
1. Before removing connecting rod inspect the connecting rod side clearance. (See CONNECTING ROD
INSPECTION).
2. Remove the connecting rod bolt from the connecting rod cap by tapping the bolt with a plastic hammer.
NOTE:  The tappets are numbered to make sure they are assembled in their
original positions. When removed, keep the tappets with the cylinder
head they were removed from. Do not mix the tappets.
Main Bearing Cap Disassembly Note
1. Before removing main bearing cap inspect the crankshaft end play. (See CRANKSHAFT
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INSPECTION).
2. Loosen the main bearing cap bolts in two or three steps in the order shown in the figure.
Fig. 20: Loosening Main Bearing Cap Bolts

CYLINDER HEAD INSPECTION
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.
Cylinder head gasket contact surface distortion (Maximum)
0.10 mm {0.004 in}
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Fig. 21: Measuring Cylinder Head For Distortion

4. Measure the manifold contact surface distortion as shown in the figure.
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Fig. 22: Measuring Manifold Contact Surface Distortion

 If it exceeds the maximum specification, grind the surface or replace the cylinder head.
Manifold contact surfaces distortion (Maximum)
0.10 mm {0.004 in}
Manifold contact surfaces distortion (Maximum grinding)
0.15 mm {0.006 in}
VALVE, VALVE GUIDE INSPECTION
1. Measure the valve head margin thickness of each valve.

 If it is less than the specification, replace the valve.
Valve head margin thickness (Minimum)
IN: 1.62 mm {0.0637 in}
EX: 1.82 mm {0.0716 in}
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Fig. 23: Measuring Valve Head Margin Thickness Of Each Valve

2. Measure the length of each valve. Replace the valve if necessary.

 If it is less than the specification, replace the valve.
Valve length (Standard)
IN: 102.99-103.79 mm {4.055-4.086 in}
EX: 104.25-105.05 mm {4.105-4.135 in}
Valve length (Minimum)
IN: 102.99 mm {4.055 in}
EX: 104.25 mm {4.104 in}
Fig. 24: Measuring Length Of Each Valve

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.
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Valve stem diameter (Standard)
IN: 5.470-5.485 mm {0.2154-0.2159 in}
EX: 5.465-5.480 mm {0.2152-0.2157 in}
Valve stem diameter (Minimum)
IN: 5.440 mm {0.2142 in}
EX: 5.435 mm {0.2140 in}
Fig. 25: Measuring Stem Diameter

4. Measure the inner diameter of each valve guide in X and Y directions at the three points (A, B, and C) as
indicated in the figure.
 If not as specified, replace the valve guide.
Valve guide inner diameter (Standard)
5.509-5.539 mm {0.2169-0.2180 in}
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Fig. 26: Measuring Valve Guise Inner Diameter

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 to guide clearance (Standard)
IN: 0.024-0.069 mm {0.0009-0.0027 in}
EX: 0.029-0.074 mm {0.0012-0.0029 in}
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Fig. 27: Calculating Valve Stem To Guide Clearance

Valve stem to guide clearance (Maximum) 0.10 mm {0.004 in}
6. Measure the protrusion height (dimension A) of each valve guide without lower valve spring seat.
 If not within the specified, replace the valve guide.
Valve guide protrusion height (standard) 12.2-12.8 mm {0.481-0.503 in}
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Fig. 28: Measuring Protrusion Height (Dimension A) Of Each Valve Guide

VALVE GUIDE REPLACEMENT
Valve Guide Removal
1. Remove the valve guide from the combustion chamber side using the SST .
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Fig. 29: Removing Valve Guide From Combustion Chamber Side

Valve Guide Installation
1. Assemble the SSTs so that depth L is as specified.
Valve guide protrusion height (standard)
12.2-12.8 mm {0.481-0.503 in}
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Fig. 30: Measuring Valve Guide Protrusion Height

2. Tap the valve guide in from the top of the cylinder head until the SSTs contacts the cylinder head.
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Fig. 31: Installing Valve Guide

3. Verify that the valve guide protrusion height (dimension A) is within the specification.
Valve guide protrusion height (standard)
12.2-12.8 mm {0.481-0.503 in}
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Fig. 32: Verifying Valve Guide Height

VALVE SEAT INSPECTION/REPAIR
1. Measure the seat contact width.

 If not within the specification, resurface the valve seat using a 45° valve seat cutter and/or resurface
the valve face.
Valve seat contact width (Standard)
1.2-1.6 mm {0.048-0.062 in}
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Fig. 33: Measuring Seat Contact Width

2. Verify that the valve seating position is at the center of the valve face.
1. If the seating position is too out side, correct the valve seat using a 70° (IN) or 65° (EX) cutter, and
a 45° cutter.
2. If the seating position is too inner side, correct the valve seat using a 35° (IN) cutter, and a 30°
(EX) cutter, and a 45° cutter.
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Fig. 34: Positioning Center Of Valve Face

3. Inspect the sinking of the valve seat. Measure the protruding length (dimension L) of the valve stem.
 If not specified, replace the cylinder head.
Valve protrusion height (Standard)
IN: 40.64-42.24 mm {1.600-1.662 in}
EX: 40.50-42.10 mm {1.595-1.657 in}
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Fig. 35: Measuring Protruding Length (Dimension L) Of Valve Stem

VALVE SPRING INSPECTION
1. Apply pressing force to the pressure spring and inspect the spring height.
 If it is less than the specification, replace the valve spring.
Valve spring pressing force
390 N {39.76 kgf, 87.67 lbf}
Valve spring standard height H
28.68 mm {1.129 in}
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Fig. 36: Performing Valve Spring Inspection

2. Measure the out-of-square of the valve spring, using a square, as shown in the figure.
1. Rotate the valve spring one full turn and measure "A" at the point where the gap is the largest.
 If it exceeds the specification, replace the valve spring.
Valve spring out-of-square (Maximum)
1.95 mm {0.0767 in}
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Fig. 37: Measuring Valve Spring Out-Of-Square

CAMSHAFT INSPECTION
1. Set the No. 1 and No.5 journals on V-blocks.

2. Measure the camshaft runout.
 If it exceeds the specification, replace the camshaft.
Maximum runout (Maximum)
0.03 mm {0.0012 in}
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Fig. 38: Measuring Camshaft Runout

3. Measure the cam lobe height at the two points as shown in the figure.
 If it is less than the specification, replace the camshaft.
Camshaft standard height (mm {in})
IN: 42.44 {1.671}
EX: 41.18 {1.621}
IN: 42.12 {1.659}
EX: 41.08 {1.618}
Camshaft minimum height (mm {in})
IN: 42.33 {1.666}

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EX: 41.06 {1.616}
IN: 42.01 {1.653}
EX: 40.96 {1.612}
Fig. 39: Measuring Cam Lobe Height At Two Points

4. Measure the journal diameters in X and Y directions at the two points (A and B) as indicated in the
figure.
 If it is less than the specification, replace the camshaft.
Camshaft journal diameter (Standard)
24.96-24.98 mm {0.9827-0.9834 in}
Camshaft journal diameter (Minimum)
24.95 mm {0.982 in}
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Fig. 40: Measuring Journal Diameters In X And Y Directions At Two Points (A And B)
5. Remove the tappet.

6. Position a plastigage atop the journals in the axial direction.
7. Install the camshaft cap. (See CAMSHAFT ASSEMBLY NOTE).
8. Remove the camshaft cap. (See CAMSHAFT CAP DISASSEMBLY NOTE).
9. Measure the oil clearance.
 If it exceeds the specification, replace the cylinder head.
Camshaft journal oil clearance (Standard)
0.035-0.080 mm {0.0014-0.0031 in}
Camshaft journal oil clearance (Maximum)
0.09 mm {0.0035 in}
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Fig. 41: Measuring Oil Clearance Using Plastigauge

10. Install the camshaft cap. (See CAMSHAFT ASSEMBLY NOTE).

11. Measure the camshaft end play.
 If it exceeds the specification, replace the cylinder head or camshaft.
Camshaft end play (Standard)
0.09-0.24 mm {0.0035-0.0094 in}
Camshaft end play (Maximum)
0.25 mm {0.0098 in}
12. Remove the camshaft cap. (See CAMSHAFT CAP DISASSEMBLY NOTE).
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Fig. 42: Measuring Camshaft End Play

TAPPET INSPECTION
1. Measure the tappet hole inner diameter in X and Y directions at the two points (A and B) shown in the
figure.
Tappet bore diameter (Standard)
31.000-31.030 mm {1.2205-1.2216 in}
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Fig. 43: Measuring Tappet Hole Inner Diameter

2. Measure the tappet body outer diameter in X and Y directions at the two points (A and B) shown in the
figure.
Tappet diameter (Standard)
30.970-30.980 mm {1.2193-1.2196 in}
3. Subtract the tappet body outer diameter from the tappet hole inner diameter.
 If it exceeds the specification, replace the tappet or cylinder head.
Tappet-to-Tappet bore oil clearance (Standard)
0.02-0.06 mm {0.0008-0.0023 in}
Tappet-to-Tappet bore oil clearance (Maximum)
0.15 mm {0.006 in}
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Fig. 44: Measuring Tappet Body Outer Diameter In X And Y Directions At Two Points (A And B)
CYLINDER BLOCK INSPECTION
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.
Cylinder head gasket contact surfaces distortion (Maximum)
0.10 mm {0.004 in}
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Fig. 45: Measuring Distortion Of Cylinder Block Top Surface In Six Directions
2. Measure the cylinder bores in X and Y directions at 42 mm {1.65 in} below the top surface.
 If not within the specification, replace the cylinder block.
Cylinder bore diameter (Standard)
87.500-87.530 mm {3.4449-3.4460 in}
Minimum / maximum bore diameter limit
87.440-87.590 mm {3.4425-3.4484 in}
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Fig. 46: Measuring Cylinder Bores In X And Y Directions At Below Top Surface
OIL JET VALVE INSPECTION
1. Apply compressed air to oil jet valve A and verify that air passes through oil jet valve B.
 If air does not flow, replace the oil jet valve.
Oil jet valve air pressure
216-274 kPa {2.2-2.7 kgf.cm2 31.4-39.7 psi}
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Fig. 47: Inspecting Oil Jet Valve

PISTON INSPECTION
CAUTION:  The piston and connecting rod cannot be disassembled.

 When replacing the piston, piston pin, piston ring and connecting
rod, replace them together as a single unit.
1. Measure the outer diameter of each piston at right angle 90° to the piston pin, 10.0 mm {0.40 in} above
the under of the piston.
 If not within the specification, replace the piston, piston pin, piston ring and connecting rod as a
single unit.
Piston diameter (Standard)
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87.465-87.495 mm {3.4435-3.4446 in}
2. Measure the piston-to-cylinder clearance.

 If not within the specification, replace the piston, piston pin, piston ring and connecting rod as a
single unit.
Fig. 48: Measuring Piston-To-Cylinder Clearance

Piston-to-cylinder clearance (Standard)
0.025-0.045 mm {0.0010-0.0017 in}
Piston-to-cylinder clearance (Maximum)
0.11 mm {0.0043 in}
3. Measure the piston ring-to-ring groove clearance around the entire circumference.
 If it exceeds the specification, replace the piston, piston pin, piston ring and connecting rod as a
single unit.
Piston ring-to-ring groove clearance (Standard)

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Top: 0.03-0.08 mm {0.0012-0.0031 in}
Second: 0.03-0.07 mm {0.0012-0.0027 in}
Oil: 0.03-0.07 mm {0.0012-0.0027 in}
Piston ring-to-ring groove clearance (Maximum)
Top: 0.17 mm {0.0067 in}
Second, Oil: 0.15 mm {0.0059 in}
Fig. 49: Measuring Piston Ring-To-Ring Groove Clearance

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.
single unit.
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Piston end gap (Standard)
Top: 0.16-0.31 mm {0.0063-0.0122 in}
Second: 0.33-0.48 mm {0.0130-0.0189 in}
Oil (rail): 0.20-0.70 mm {0.0079-0.0275 in}
Piston end gap (Maximum)
1.0 mm {0.0393 in}
Fig. 50: Measuring Each Piston Ring End Gap With Feeler Gauge
CRANKSHAFT INSPECTION
1. Install the main bearing cap. (See MAIN BEARING CAP ASSEMBLY NOTE).
2. Measure the crankshaft end play.
 If it exceeds the specification, replace the thrust bearing or crankshaft so that the specified end play
is obtained.
Crankshaft end play (Standard)
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0.22-0.45 mm {0.0087-0.0177 in}
Crankshaft end play (Maximum)
0.55 mm {0.0216 in}
Fig. 51: Measuring Crankshaft End Play

3. Remove the main bearing cap. (See MAIN BEARING CAP DISASSEMBLY NOTE).
4. Measure the crankshaft runout.
 If it exceeds the specification, replace the crankshaft.
Crankshaft runout (Maximum)
0.05 mm {0.0019 in}
5. Measure the journal diameter in X and Y directions at the two points (A and B) as indicated in the figure.
 If it exceeds the specification, replace the crankshaft or grind the journal and install the undersize
bearing.
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Fig. 52: Measuring Crankshaft Runout

Main journal bearing size
STD: 51.980-52.000 mm {2.0464-2.0472 in}
US0.25: 51.730-51.750 mm {2.0366-2.0373 in}
Main journal out of round (Maximum)
0.05 mm {0.0019 in}
Crank pin journal diameter [LF]
STD: 46.980-47.000 mm {1.8497-1.8503 in}
US0.25: 46.730-46.750 mm {1.8398-1.8405 in}
Crank pin journal diameter [L3]
STD: 49.980-50.000 mm {1.9677-1.9685 in}
US0.25: 49.730-49.750 mm {1.9579-1.9586 in}
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Crank pin out of round (Maximum)
0.05 mm {0.0019 in}
Fig. 53: Measuring Journal Diameter In X And Y Directions At Two Points (A And B)
6. Install the main bearing caps and crankshaft.

7. Position a plastigage atop the journals in the axial direction.
8. Install the main bearing caps and cylinder block. (See MAIN BEARING CAP ASSEMBLY NOTE).
9. Remove the main bearing caps. (See MAIN BEARING CAP DISASSEMBLY NOTE).
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 oil clearance (Standard)
0.019-0.035 mm {0.0007-0.0013 in}
Main journal oil clearance (Maximum)
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0.10 mm {0.0039 in}
Main bearing size
STD: 2.506-2.509 mm {0.0987-0.0988 in}
OS0.25: 2.628-2.634 mm {0.1034-0.1037 in}
Fig. 54: Measuring Main Journal Oil Clearance

CONNECTING ROD INSPECTION
CAUTION:  The piston and connecting rod cannot be disassembled.

 When replacing the piston, piston pin, piston ring and connecting
rod, replace them together as a single unit.
1. Install the connecting rod cap. (See CONNECTING ROD CAP ASSEMBLY NOTE).
2. Measure the connecting rod large end side clearance.
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single unit.
Connecting rod side clearance (Standard)
0.14-0.36 mm {0.0056-0.0141 in}
Connecting rod side clearance (Maximum)
0.435 mm {0.0172 in}
Fig. 55: Measuring Connecting Rod Large End Side Clearance

3. Remove the connecting rod cap.

4. Position plastigage atop the journals in the axial direction.
5. Install the connecting rod bearing and connecting rod cap. (See CONNECTING ROD CAP
ASSEMBLY NOTE).
6. Remove the connecting rod cap.
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.
Connecting rod bearing oil clearance (Standard)
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0.026-0.052 mm {0.0011-0.0020 in}
Connecting rod bearing oil clearance (Maximum)
0.1 mm {0.0039 in}
Connecting rod bearing size [LF]
STD: 1.498-1.504 mm {0.0589-0.0592 in}
OS0.25: 1.623-1.629 mm {0.0639-0.0641 in}
Connecting rod bearing size [L3]
STD: 1.496-1.502 mm {0.0589-0.0591 in}
OS0.25: 1.621-1.627 mm {0.0639-0.0641 in}
Fig. 56: Measuring Connecting Rod Oil Clearance

BOLT INSPECTION
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1. Measure the length of each bolt.

 If it exceeds the specification, replace the bolt.
Bolt length (mm {in})
Cylinder head bolt (With washer)
Standard: 149.2-149.8 {5.87-5.90}
Maximum: 150.5 {5.91}
Cylinder head bolt (Without washer)
Standard: 145.2-145.8 {5.72-5.74}
Maximum: 146.5 {5.77}
Connecting rod bolt
Standard: 44.7-45.3 {1.75-1.78}
Maximum: 46.0 {1.81}
Main bearing cap bolt (Plastic region tightening bolt only)
Standard: 110.0-110.6 {4.33-4.35}
Maximum: 111.3 {4.38}
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Fig. 57: Measuring Length Of Each Bolt

VARIABLE VALVE TIMING ACTUATOR INSPECTION [WITH VARIABLE VALVE TIMING

MECHANISM]
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 bump 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.
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Fig. 58: Aligning Actuator Rotor Groove & Notch

OIL CONTROL VALVE (OCV) INSPECTION [WITH VARIABLE VALVE TIMING MECHANISM]
Coil Resistance Inspection
1. Disconnect the negative battery cable.

2. Disconnect the oil control valve (OCV) connector.
3. Measure the resistance between terminals A and B using an ohmmeter.
 If not as specified, replace the oil control valve (OCV).
Specification
6.9-7.9 ohms [20 °C {68 °F}]
4. Connect the oil control valve (OCV) connector.
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Fig. 59: Identifying Coil Control Valve Connector Terminals

Spool Valve Operation Inspection
1. Disconnect the negative battery cable.

2. Remove the oil control valve (OCV).
3. Verify that the spool valve in the oil control valve (OCV) is in the maximum valve timing retard position
as indicated in the figure.
 If it exceeds the specification, replace the oil control valve (OCV).
4. Verify that the battery is fully charged.

 If it is less than specification, recharge the battery.
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Fig. 60: Identifying Spool Valve

5. Apply battery positive voltage between the oil control valve (OCV) terminals and verify that the spool
valve operates and moves to the maximum valve timing advance position.
 If it exceeds the specification, replace the oil control valve (OCV).
NOTE:  When applying battery positive voltage between the oil control valve
(OCV) terminals, the connection can be either of the following:
 Positive battery cable to terminal A, negative battery cable to
terminal B
 Positive battery cable to terminal B, negative battery cable to
terminal A
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Fig. 61: Positioning Spool Valve Operates And Moves To Maximum Valve Timing Advance
6. Stop applying battery positive voltage and verify that the spool valve returns to the maximum valve
timing retard position.
 If it exceed the specification, replace the oil control valve (OCV).
VALVE CLEARANCE INSPECTION
1. Measure the valve clearance as follows.

1. Turn the crankshaft clockwise so that the No. 1 piston is at TDC of the compression stroke.
2. Measure the valve clearance at A in the figure.
 If the valve clearance exceeds the standard, replace the tappet. (See VALVE CLEARANCE
ADJUSTMENT).
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Fig. 62: Measuring Valve Clearance At Point A

NOTE:  Make sure to note the measured values for choosing the
suitable replacement tappets.
Valve clearance [Engine cold]
IN: 0.22-0.28 mm {0.0087-0.0110 in}
EX: 0.27-0.33 mm {0.0106-0.0130 in}
3. Turn the crankshaft 360° clockwise so that the No.4 piston is at TDC of the compression stroke.
4. Measure the valve clearance at B in the figure.
 If the valve clearance exceeds the standard, replace the tappet. (See VALVE CLEARANCE
ADJUSTMENT).
NOTE:  Make sure to note the measured values for choosing the suitable
replacement tappets.
IN: 0.22-0.28 mm {0.0087-0.0110 in}
Microsoft
EX: 0.27-0.33 mm {0.0106-0.0130 in}
VALVE CLEARANCE ADJUSTMENT
1. Remove the engine front cover lower blind plug.

2. Remove the engine front cover upper blind plug.
3. Remove the cylinder block lower blind plug.
4. Install the SST as shown in the figure.
Fig. 63: Locating Engine Front Cover Upper & Lower Blind Plug
CAUTION:  Removal of this SST is extremely important. If you crank the

engine with this SST installed, the cylinder block will be
damaged.
5. Turn the crankshaft clockwise so that the crankshaft is in the No. 1 cylinder TDC position.
Microsoft
Fig. 64: Locating Cylinder Block SST

6. Loosen the timing chain.

1. Using a suitable screwdriver or equivalent tool, unlock the chain tensioner ratchet.
2. Turn the exhaust camshaft clockwise using a suitable wrench on the cast hexagon and loosen the
timing chain.
3. Placing the suitable bolt (M6 x 1.0 Length 25-35 mm {0.9-1.3 in}) at the engine front cover upper
blind plug, secure the chain guide at the position where the tension is released.
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Fig. 65: Loosening Timing Chain

7. Hold the exhaust camshaft using a suitable wrench on the cast hexagon as shown in the figure.
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Fig. 66: Holding Camshaft Using Suitable Wrench On Cast Hexagon

8. Remove the exhaust camshaft sprocket.
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Fig. 67: Removing Exhaust Camshaft Sprocket

9. Loosen the camshaft cap bolts in several passes in the order shown in the figure.
NOTE:  The cylinder head and the camshaft caps are numbered to make sure
they are reassembled in their original position. When removed, keep
the caps with the cylinder head they were removed from. Do not mix
the caps.
Microsoft
Fig. 68: Identifying Loosening Sequence Of Camshaft Cap Bolts

10. Remove the camshaft.

11. Remove the tappet.
12. Select proper adjustment shim.
New adjustment shim
= Removed shim thickness + Measured valve clearance - Standard valve clearance (IN: 0.25 mm
{0.0098 in}, EX: 0.30 mm {0.0118 in})
IN: 0.22-0.28 mm {0.0087-0.0110 in}
EX: 0.27-0.33 mm {0.0106-0.0130 in}
13. Install the camshaft with No. 1 cylinder aligned with the TDC position.
14. Tighten the camshaft cap bolt using the following two steps.
Tightening torque
1. 5.0-9.0 N.m
Microsoft
{51.0-91.7 kgf.cm, 44.3-79.5 in.lbf}
2. 14.0-17.0 N.m
{1.43-1.73 kgf.m, 10.4-12.5 ft.lbf}
Fig. 69: Camshaft Cap Bolt Tightening Sequence

15. Install a new washer (except for Mazda6).
Microsoft
Fig. 70: Camshaft Sprocket Washer

16. Install the exhaust camshaft sprocket.
NOTE:  Do not tighten the bolt for the camshaft sprocket during this step.
First confirm the valve timing, then tighten the bolt.
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Fig. 71: Exhaust Camshaft Sprocket

17. Install the SST to the camshaft as shown in the figure.

18. Remove the M6 x 1.0 bolt from the engine front cover to apply tension to the timing chain.
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Fig. 72: Installing SST To Camshaft

20. Hold the exhaust camshaft using a suitable wrench on the cast hexagon as shown in the figure.
21. Tighten the exhaust camshaft sprocket lock bolt.
Tightening torque
69-75 N.m {7.1-7.6 kgf.m, 50.9-55.3 ft.lbf}
22. Remove the SST from the camshaft.

23. Remove the SST from the block lower blind plug.
24. Rotate the crankshaft clockwise two turns until the TDC position.
 If not aligned, loosen the camshaft sprocket lock bolt and repeat from Step 17.
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25. Install the new engine front cover upper blind plug.
Tightening torque
8.0-11.5 N.m {82-117 kgf.cm, 71-101 in.lbf}
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Fig. 74: Installing Engine Front Cover Upper Blind Plug

26. 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}
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Fig. 75: Installing Cylinder Block Lower Blind Plug

27. Install the new engine front cover lower blind plug.
Tightening torque
10-14 N.m {102-142 kgf.cm, 89-123 in.lbf}
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Fig. 76: Identifying Engine Front Cover Lower Blind Plug

CYLINDER BLOCK (I) ASSEMBLY
1. Assemble in the order indicated in the table.
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Fig. 77: Exploded View Of Cylinder Block (I) Assembly & Torque Specification
Main Bearing Cap Assembly Note
1. Install the main bearing caps in the order indicated in the figure.
2. Tighten the main bearing cap bolts using the SST (49 D032 316).
Tightening torque
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Plastic region tightening bolt (Bolt stem length 110 mm)
1. 44-46 N.m {4.5-4.6 kgf.m, 32.5-33.9 ft.lbf}

2. 175°-185°
Elastic region tightening bolt (Bolt stem length 104 mm)
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.lbt}
4. 38-42 N.m {3.9-4.2 kgf.m, 28.1-30.9 ft.lbt}
5. Loosen all the bolts. (no remaining torque).
6. 3-7 N.m {30.6-71.3 kgf.cm, 26.6-61.9 in.lbt}
7. 18-22 N.m {1.9-2.2 kgf.m, 13.3-16.2 ft.lbt}
8. 87.5°-92.5°
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Fig. 78: Tightening Sequence Of Main Bearing Cap Bolts

Piston Ring Assembly Note
1. Install the two oil control ring segments and spacer.

2. Verify that the second ring is installed with scraper face side downward.
3. Verify that the top ring is installed with scraper face side inner of upper.
Fig. 79: Identifying Piston Rings

Piston Assembly Note
1. Position the end gap of each ring as indicated in the figure.
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Fig. 80: Positioning End Gap Of Each Ring

2. Insert the piston and connecting rod into the cylinder with the arrow mark to front of the engine.
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Fig. 81: Inserting Piston And Connecting Rod Into Cylinder Bore
Connecting Rod Bearing Assembly Note
1. Install the connecting rod bearing to the connecting rod and connecting rod caps, as shown in the figure.
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Fig. 82: Installing Connecting Rod Bearing

Connecting Rod Cap Assembly Note
CAUTION:  When assembling the connecting rod caps, align the broken, rough
faces of the connecting rods and connecting rod caps.
1. Tighten the connecting rod bolts in two steps using the SST (49 D032 316).
Tightening torque
1. 26-32 N.m
{2.7-3.2 kgf.m, 19.2-23.6 ft.lbf}
2. 80°-100°
Balancer Unit Assembly Note
Microsoft
1. Confirm by visual inspection that there is no damage to the balancer unit gear and verify that the shaft
turns smoothly.
 If there is any damage or malfunction, replace the balancer unit.
CAUTION:  Due to the precision interior construction of the balancer unit, it

cannot be disassembled.
Fig. 83: Attaching SST To Balancer

3. Turn the crankshaft clockwise the crankshaft is in the No. 1 cylinder TDC position (until the balance
weight is attached to the SST ).
4. Install the adjustment shim to the seat face of the balancer unit.
5. With the balancer unit marks at the exact top center, assemble the unit to the cylinder block.
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Fig. 84: Identifying Marks At Exact Top Center

6. Set the SST as shown, then measure the gear backlash using a dial gauge.
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Fig. 85: Measuring Gear Backlash Using Dial Gauge

NOTE:  For an accurate measurement of gear backlash, insert a screwdriver into

the crankshaft No. 1 balance weight area and set both the rotation and the
thrust direction with the screwdriver, using a prying action, as shown in
the figure.
Microsoft
Fig. 86: Measuring Gear Backlash

 If the backlash exceeds the specified range, remeasure the backlash and,
using the adjustment shim selection table, select the proper shim,
according to the following procedure.
CAUTION:  When measuring the backlash, rotate the crankshaft one full rotation
and verify that it is within the specified range at all of the following
six positions: 10°, 30°, 100°, 190°, 210°, 280° ATDC.
Value range
0.005-0.101 mm {0.00019-0.0039 in}
1. Using master adjustment shim (No.50), assemble the balancer unit to the cylinder block, then measure the
backlash.
2. Select the proper adjustment shim according to the measured value.
3. Install the selected adjustment shim to the balancer unit, then assemble the balancer unit to the cylinder
block.
Adjustment shim selection table

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ADJUSTMENT SHIM SELECTION CHART

Selection Shim thickness Selection Shim thickness
Backlash mm {in} Backlash mm {in}
shim (No). mm {in} shim (No). mm {in}
0.267-0.273
0.127-0.133
{0.01051- 15 1.15 {0.0452} 35 1.35 {0.0531}
{0.00500-0.00523}
0.01074}
0.260-0.266
0.120-0.126
{0.01023- 16 1.16 {0.0456} 36 1.36 {0.0535}
{0.00472-0.00496}
0.01047}
0.253-0.259
0.113-0.119
{0.00996- 17 1.17 {0.0460} 37 1.37 {0.0539}
{0.00444-0.00468}
0.01019}
0.246-0.252
0.106-0.112
{0.00968- 18 1.18 {0.0464} 38 1.38{0.0543}
{0.00417-0.00440}
0.00992}
0.239-0.245
0.099-0.105
{0.00940- 19 1.19 {0.0468} 39 1.39 {0.0547}
{0.00389-0.00413}
0.00964}
0.232-0.238
0.092-0.098 .087
{0.00913- 20 1.20 {0.0472} 40 1.40 {0.0551}
{0.00362-0.00385}
0.00937}
0.225-0.231
0.085-0.091
{0.00885- 21 1.21 {0.0476} 41 1.41 {0.0555}
{0.00334-0.00358}
0.00909}
0.218-0.224
0.078-0.084
{0.00858- 22 1.22 {0.0480} 42 1.42 {0.0559}
{0.00307-0.00330}
0.00881}
0.211-0.217
0.071-0.077
{0.00830- 23 1.23 {0.0484} 43 1.43 {0.0562}
{0.00279-0.00303}
0.00854}
0.204-0.210
0.064-0.070
{0.00803- 24 1.24 {0.0488} 44 1.44 {0.0566}
{0.00251-0.00275}
0.00826}
0.197-0.203
0.057-0.063
{0.00775- 25 1.25 {0.492} 45 1.45 {0.0570}
{0.00224-0.00248}
0.00799}
0.190-0.196
0.050-0.056
{0.00748- 26 1.26 {0.496} 46 1.46 {0.0574}
{0.00196-0.00220}
0.00771}
0.183-0.189
0.043-0.049
{0.00720- 27 1.27 {0.499} 47 1.47 {0.0578}
{0.00169-0.00192}
0.00744}
0.176-0.182
0.036-0.042
{0.00692- 28 1.28 {0.503} 48 1.48 {0.0582}
{0.00141-0.00165}
0.00716}
Microsoft
0.169-0.175
0.029-0.035
{0.00665- 29 1.29 {0.507} 49 1.49 {0.0586}
{0.00114-0.00137}
0.00688}
0.162-0.168
0.022-0.028
{0.00637- 30 1.30 {0.511} 50 (master) 1.50 {0.0590}
{0.000866-0.00110}
0.00661}
0.155-0.161
0.015-0.021
{0.00610- 31 1.31 {0.515} 51 1.51 {0.0594}
{0.00059-0.000826}
0.00633}
0.148-0.154
0.008-0.014
{0.00582- 32 1.32 {0.519} 52 1.52 {0.0598}
{0.000314-0.000551}
0.00606}
0.141-0.147
0.001-0.007
{0.00555- 33 1.33 {0.523} 53 1.53 {0.0602}
{0.00003-0.000275}
0.00578}
0.134-0.140
0.000-0.000 {0.000-
{0.00527- 34 1.34 {0.527} 54 1.54 {0.0606}
0.000}
0.00551}
CYLINDER BLOCK (II) ASSEMBLY
Microsoft
Fig. 87: Exploded View Of Cylinder Block (II) Assembly & Torque Specification
Rear Oil Seal Assembly Note
1. Apply clean engine oil to the new oil seal lip.

2. Install the rear oil seal using the SST as shown in the figure.
Microsoft
Fig. 88: Installing Rear Oil Seal Using SST

3. Tighten the rear oil seal bolts in the order as shown in the figure.
Tightening torque
8.0-11.5 N.m
{81.6-117.2 kgf.cm, 70.9-101.7 in.lbf}
Microsoft
Fig. 89: Rear Oil Seal Bolt Tightening Sequence

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
{4.70-5.50 kgf.m, 34.0-39.8 ft.lbf
2. 76-84 N.m
{7.75-8.56 kgf.m, 56.1-61.9 ft.lbf
3. 108-116 N.m
{11.1-11.8 kgf.m, 79.7-85.5 ft.lbf

Microsoft
Fig. 90: Tightening Sequence Of Drive Plate Or Flywheel Bolts (Performed In 3 Steps)
Oil pan Assembly Note
1. Apply a continuous bead of silicone sealant to the oil pan as indicated in the figure.
CAUTION:  Install the oil pan within 10min of applying the silicone sealant
 Make sure that there is no oil or dust on the seal side of oil pan.
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Fig. 91: Installing Silicone Sealant To Oil Pan

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2. Use a square ruler to unite the oil pan and the cylinder block junction side on the engine front cover side.
Fig. 92: Using Square Ruler To Align Oil Pan & Cylinder Block
3. Tighten the rear oil pan bolts in the order as shown in the figure.
Tightening torque
17-23 N.m
{1.8-2.3 kgf.m, 12.6-16.9 ft.lbf}
Microsoft
Fig. 93: Rear Oil Pan Bolts Tightening Sequence

CYLINDER HEAD (I) ASSEMBLY
Microsoft
Fig. 94: Exploded View Of Cylinder Head (I) Assembly & Torque Specification
Valve Seal Assembly Note
1. Press the valve seal onto the valve guide by hand.

2. Lightly tap the SST using a plastic hammer.
Microsoft
Fig. 95: Pressing Valve Seal

Valve Keeper Assembly Note
1. Install the valve keeper using the SSTs .
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Fig. 96: Installing Valve Keeper

CYLINDER HEAD (II) ASSEMBLY
Microsoft
Fig. 97: Exploded View Of Cylinder Head (II) Assembly & Torque Specification
Cylinder Head Bolt Assembly Note
1. Tighten the cylinder head bolts in the order indicated in the figure in 5 steps using the SST (49 D032
316).
Microsoft
Tightening torque
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. 98: Cylinder Head Bolt Tightening Sequence

Camshaft Assembly Note

Microsoft
1. Set the cam position of No. 1 cylinder at the top dead center (TDC) and install the camshaft.
2. Temporarily tighten the camshaft bearing caps evenly in 2-3 steps.
3. Tighten the camshaft cap bolt in the order shown two steps.
Tightening torque
1. 5.0-9.0 N.m
{51.0-91.7 kgf.cm, 44.3-79.5 in.lbf}
2. 14-17 N.m
{1.43-1.73 kgf.m, 10.4-12.5 ft.lbf}
Fig. 99: Camshaft Cap Bolt Tightening Sequence

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
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installation.
TIMING CHAIN ASSEMBLY
Microsoft
Fig. 100: Exploded View Of Timing Chain Assembly & Torque Specification
Oil Pump Sprocket Assembly Note
1. Hold the oil pump sprocket using the SST .
Fig. 101: Assembling Oil Pump Sprocket

Timing Chain Assembly Note
1. Install the SST to the camshaft, then align the No. 1 camshaft position with the TDC.
Microsoft

2. Remove the cylinder block lower blind plug.

Microsoft
Fig. 103: Installing SST In Place Of Cylinder Block Lower Blind Plug
5. Install the timing chain.
6. Install the chain tensioner and remove the retaining wire.
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Fig. 104: Chain Tensioner Retaining Wire

Camshaft Sprocket, Variable Valve Timing Actuator Assembly Note
1. Hold the camshaft using a suitable wrench on the cast hexagon as shown in the figure.
2. Tighten the camshaft sprocket lock bolt.
Tightening torque
69-75 N.m {7.1-7.6 kgf.m, 50.9-55.3 ft.lbf}
Microsoft

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.
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Fig. 106: Installing Front Oil Seal

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Fig. 107: Using SST And Hammer

Engine Front Cover Assembly Note
1. Apply silicone sealant to the engine front cover as shown in the figure.
CAUTION:  Install the cylinder head cover within 10 min of applying the
silicone sealant.
 Silicone sealant is not need in area C as indicated below due to
an existing. (With variable valve timing mechanism)
 Make sure that there is no oil or dust on the seal side of oil pan.
Thickness
A: 2.2-3.2 mm {0.087-0.125 in}
B: 1.5-2.5 mm {0.059-0.098 in}
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Fig. 108: Applying Silicone Sealant To Engine Front Cover

2. Install the cylinder head cover bolts in the order as shown in the figure.
CYLINDER HEAD COVER BOLTS SPECIFICATION

Bolt No. Tightening torque N.m {kgf.m, ft.lbf}
Microsoft
8.0-11.5 N.m
1-18
{81.6-117.2 kgf.cm, 70.9-101.7 in.lbf}
19-22 40-55 {4.1-5.6, 29.6-40.5}
Fig. 109: Engine Front Cover Bolt Tightening Sequence
Microsoft
Crankshaft Pulley Lock Bolt Assembly Note
1. Install the SST to the camshaft as shown in the figure.

2. Install the M6 x 1.0 bolt in by hand.

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Fig. 111: Installing M6 X 1.0 Bolt On Crankshaft Pulley

4. Hold the crankshaft pulley using the SST .

5. Tighten the crankshaft pulley lock bolt in the order shown following two steps using the SST (49 D032
316).
Tightening torque
1. 96-104 N.m
{9.8-10.6 kgf.m, 70.9-76.7 ft.lbf}
2. 87°-93°
6. Remove the M6 x 1.0 bolt.
7. Remove the SST from the camshaft.
8. Remove the SST from the block lower blind plug.
9. Rotate the crankshaft clockwise two turns until the TDC position.
 If not aligned, loosen the crankshaft pulley lock bolt and repeat from Step 1.
10. Install the cylinder block lower blind plug.
Tightening torque
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18-22 N.m {1.9-2.2 kgf.m, 13.3-16.2 ft.lbf}
Fig. 112: Locking Flywheel Using SST

Cylinder Head Cover Assembly Note
1. Apply silicone sealant to the mating faces as shown in the figure.
CAUTION:  Install the cylinder head cover within 10 min of applying the
silicone sealant.
Dot diameter
4.0-6.0 mm {0.16-0.23 in}
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Fig. 113: Applying Silicone Sealant To Mating Faces

2. Install the cylinder head cover with a new gasket.

3. Tighten the bolts in the order shown in the figure.
Tightening torque
8.0-10.5 N.m
{81.6-107.1 kgf.cm, 70.9-92.9 in.lbf}
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Fig. 114: Cylinder Head Cover Bolt Tightening Sequence

01-50 TECHNICAL DATA

ENGINE TECHNICAL DATA
ENGINE TECHNICAL DATA SPECIFICATION

Item Specification
Cylinder head gasket contact surface distortion
0.10 mm {0.004 in}
(Maximum)
Manifold contact surfaces distortion (Maximum) 0.10 mm {0.004 in}
Manifold contact surfaces distortion (Maximum
0.15 mm {0.006 in}
grinding)
IN: 1.62 mm {0.0637 in}
Valve head margin thickness (Minimum)
EX: 1.82 mm {0.0716 in}
IN: 102.99-103.79 mm {4.055-4.086 in}
Valve length (Standard)
EX: 104.25-105.05 mm {4.105-4.135 in}
IN: 102.99 mm {4.055 in}
Valve length (Minimum)
EX: 104.25 mm {4.104 in}
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IN: 5.470-5.485 mm {0.2154-0.2159 in}

Valve stem diameter (Standard)
EX: 5.465-5.480 mm {0.2152-0.2157 in}
IN: 5.440 mm {0.2142 in}
Valve stem diameter (Minimum)
EX: 5.435 mm {0.2140 in}
Valve guide inner diameter (Standard) 5.509-5.539 mm {0.2169-0.2180 in}
IN: 0.024-0.069 mm {0.0009-0.0027 in}
Valve stem to guide clearance (Standard)
EX: 0.029-0.074 mm {0.0012-0.0029 in}
Valve stem to guide clearance (Maximum) 0.10 mm {0.004 in}
Valve guide protrusion height (standard) 12.2-12.8 mm {0.481-0.503 in}
Valve seat contact width (Standard) 1.2-1.6 mm {0.048-0.062 in}
IN: 40.64-42.24 mm {1.600-1.662 in}
Valve protrusion height (Standard)
EX: 40.50-42.10 mm {1.595-1.657 in}
Valve spring pressing force 390 N {39.76 kgf, 87.67 lbf}
Valve spring standard height H 28.68 mm {1.129 in}
Valve spring out-of-square (Maximum) 1.95 mm {0.0767 in}
Maximum runout (Maximum) 0.03 mm {0.0012 in}
IN: 42.44 {1.671}
EX: 41.18 {1.621}
Camshaft standard height (mm {in})
IN: 42.12 {1.659}
EX: 41.08 {1.618}
IN: 42.33 {1.666}
EX: 41.06 {1.616}
Camshaft minimum height (mm {in})
IN: 42.01 {1.653}
EX: 40.96 {1.612}
Camshaft journal diameter (Standard) 24.96-24.98 mm {0.9827-0.9834 in}
Camshaft journal diameter (Minimum) 24.95 mm {0.982 in}
Camshaft journal oil clearance (Standard) 0.035-0.080 mm {0.0014-0.0031 in}
Camshaft journal oil clearance (Maximum) 0.09 mm {0.0035 in}
Camshaft end play (Standard) 0.09-0.24 mm {0.0035-0.0094 in}
Camshaft end play (Maximum) 0.25 mm {0.0098 in}
Tappet bore diameter (Standard) 31.000-31.030 mm {1.2205-1.2216 in}
Tappet diameter (Standard) 30.970-30.980 mm {1.2193-1.2196 in}
Tappet-to-Tappet bore oil clearance (Standard) 0.02-0.06 mm {0.0008-0.0023 in}
Tappet-to-Tappet bore oil clearance (Maximum) 0.15 mm {0.006 in}
Cylinder head gasket contact surfaces distortion
0.10 mm {0.004 in}
(Maximum)
Cylinder bore diameter (Standard) 87.500-87.530 mm {3.4449-3.4460 in}
Minimum / maximum bore diameter limit 87.440-87.590 mm {3.4425-3.4484 in}
Oil jet valve air pressure 216-274 kPa {2.2-2.7 kgf.cm2 31.4-39.7 psi}
Microsoft
Piston diameter (Standard) 87.465-87.495 mm {3.4435-3.4446 in}

Piston-to-cylinder clearance (Standard) 0.025-0.045 mm {0.0010-0.0017 in}
Piston-to-cylinder clearance (Maximum) 0.11 mm {0.0043 in}
Top: 0.03-0.08 mm {0.0012-0.0031 in}
Piston ring-to-ring groove clearance (Standard) Second: 0.03-0.07 mm {0.0012-0.0027 in}
Oil: 0.03-0.07 mm {0.0012-0.0027 in}
Top: 0.17 mm {0.0067 in}
Piston ring-to-ring groove clearance (Maximum)
Second, Oil: 0.15 mm {0.0059 in}
Top: 0.16-0.31 mm {0.0063-0.0122 in}
Piston end gap (Standard) Second: 0.33-0.48 mm {0.0130-0.0189 in}
Oil (rail): 0.20-0.70 mm {0.0079-0.0275 in}
Piston end gap (Maximum) 1.0 mm {0.0393 in}
Crankshaft end play (Standard) 0.22-0.45 mm {0.0087-0.0177 in}
Crankshaft end play (Maximum) 0.55 mm {0.0216 in}
Crankshaft runout (Maximum) 0.05 mm {0.0019 in}
STD: 51.980-52.000 mm {2.0464-2.0472 in}
Main journal bearing size
US0.25: 51.730-51.750 mm {2.0366-2.0373 in}
Main journal out of round (Maximum) 0.05 mm {0.0019 in}
STD: 46.980-47.000 mm {1.8497-1.8503 in}
Crank pin journal diameter [LF]
US0.25: 46.730-46.750 mm {1.8398-1.8405 in}
STD: 49.980-50.000 mm {1.9677-1.9685 in}
Crank pin journal diameter [L3]
US0.25: 49.730-49.750 mm {1.9579-1.9586 in}
Crank pin out of round (Maximum) 0.05 mm {0.0019 in}
Main journal oil clearance (Standard) 0.019-0.035 mm {0.0007-0.0013 in}
Main journal oil clearance (Maximum) 0.10 mm {0.0039 in}
STD: 2.506-2.509 mm {0.0987-0.0988 in}
Main bearing size
OS0.25: 2.628-2.634 mm {0.1034-0.1037 in}
Connecting rod side clearance (Standard) 0.14-0.36 mm {0.0056-0.0141 in}
Connecting rod side clearance (Maximum) 0.435 mm {0.0172 in}
Connecting rod bearing oil clearance (Standard) 0.026-0.052 mm {0.0011-0.0020 in}
Connecting rod bearing oil clearance (Maximum) 0.1 mm {0.0039 in}
STD: 1.498-1.504 mm {0.0589-0.0592 in}
Connecting rod bearing size [LF]
OS0.25: 1.623-1.629 mm {0.0639-0.0641 in}
STD: 1.496-1.502 mm {0.0589-0.0591 in}
Connecting rod bearing size [L3]
OS0.25: 1.621-1.627 mm {0.0639-0.0641 in}
Cylinder head bolt (With washer)

Standard: 149.2-149.8 {5.87-5.90}
Maximum: 150.5 {5.91}
Bolt length (mm {in}) Cylinder head bolt (Without washer)
Standard: 145.2-145.8 {5.72-5.74}
Maximum: 146.5 {5.77}
Connecting rod bolt
Standard: 44.7-45.3 {1.75-1.78}
Microsoft
Maximum: 46.0 {1.81}

Main bearing cap bolt (Plastic region tightening
bolt only)
Standard: 110.0-110.6 {4.33-4.35}
Maximum: 111.3 {4.38}
IN: 0.22-0.28 mm {0.0087-0.0110 in}
EX: 0.27-0.33 mm {0.0106-0.0130 in}
Value range 0.005-0.101 mm {0.00019-0.0039 in}
01-60 SERVICE TOOLS

ENGINE SST
1. Mazda SST number

2. Global SST number
Example
1. 49 UN20 5072
2. 205-072
Holder
Microsoft
Fig. 115: Identifying Engine SST Holder

ENGINE SERVICE TOOLS SPECIFICATION
1: 49 UN30
1: 49 E011
1: - 3465
1A0
2: 303-507 2: 303-465
2:-
Crankshaft TDC Camshaft
Ring gear
setting peg Alignment
brake set
timing Tool
1: 49 B012
015 1: 49 0636 100B
1: 49 G032 354
2:- 2:-
2:-
Valve Valve spring
Adjusting wrench
guide lifter arm
installer
1: 49 L010
Microsoft
1A0
2:-
1: 49 B012 0A2 Engine 1: 49 H010 401
2:- hanger set 2:-
Pivot Oil seal installer
1: 49 T032
1: 49 S120 170
1: 49 0107 680A 302
2:-
2:- 2:-
Valve seal
Engine stand Bearing
remover
installer
1: 49
1: 49 L012 0A0B UN30
2:- 3328 1: 49 D032 316
Valve seal and 2: 303-328 2:-
valve guide Rear oil Protractor
installer set seal
replacer
1: 49 G011 201
2:- - -
Attachment
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2006 2008 Engine Overhaul

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2007 Mazda MX-5 Miata Sport

ENGINE IDENTIFICATION CODE

Fig. 1: Installing SST (Arms) To Cylinder Block Holes

Fig. 2: Assembling SSTs (Bolts, Nuts And Plate) To Positions

Fig. 3: Identifying SST Bolts, Nuts & Parallel Plates

Courtesy of MAZDA MOTORS CORP.

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

6. Mount the engine on the SST (engine stand).

1. Install the oil pan drain plug with a new washer.

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

22-30 N.m {2.2-3.1 kgf.m, 16-22 ft.lbf}

 Dismount in the reverse order of mounting.

TIMING CHAIN DISASSEMBLY

1. Disassemble in the order indicated in the table.

Fig. 4: Exploded View Of Timing Chain Components

Crankshaft Pulley Lock Bolt Disassembly Note

Fig. 5: Installing SST Ring Gear To Lock Crankshaft Against Rotation

Front Oil Seal Disassembly Note

1. Remove the oil seal using a screwdriver.

Fig. 6: Removing Oil Seal

Chain Tensioner Disassembly Note

Fig. 7: Disassembling Chain Tensioner

Oil Pump Sprocket Disassembly Note

1. Hold the oil pump sprocket using the SST .

Fig. 8: Holding Oil Pump Sprocket Using SST

CYLINDER HEAD (I) DISASSEMBLY

1. Disassemble in the order indicated in the table.

Fig. 9: Exploded View Of Cylinder Head (I) Disassembly

Without variable valve timing mechanism

Fig. 10: Using Wrench On Cast Hexagon

With variable valve timing mechanism

Fig. 11: Using Wrench On Cast Hexagon

Camshaft Cap Disassembly Note

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

Fig. 12: Identifying Loosening Sequence Of Camshaft Cap Bolts

Tappet Disassembly Note

Cylinder Head Bolt Disassembly Note

Fig. 13: Loosening Cylinder Head Bolts

CYLINDER HEAD (II) DISASSEMBLY

1. Disassemble in the order indicated in the table.

Fig. 14: Exploded View Of Cylinder Head (II) Disassembly

Valve Keeper Disassembly Note

1. Remove the valve keeper using the SSTs .

Fig. 15: Removing Valve Keeper

Valve Seal Disassembly Note

1. Remove the valve seal using the SST.

Fig. 16: Removing Valve Seal

CYLINDER BLOCK (I) DISASSEMBLY

1. Disassemble in the order indicated in the table.

Fig. 17: Exploded View Of Cylinder Block (I) Disassembly

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

1. Hold the crankshaft using the SST.

Fig. 18: Removal Sequence Of Drive Plate Or Flywheel Bolts

CYLINDER BLOCK (II) DISASSEMBLY

1. Disassemble in the order indicated in the table.

Fig. 19: Exploded View Of Cylinder Block (II) Disassembly

Connecting Rod Cap Disassembly Note

Main Bearing Cap Disassembly Note

Fig. 20: Loosening Main Bearing Cap Bolts