MAZDA 2,0 and 2,3 L3 LF Engines SM

Engine CONTENTS
Workshop Title Section
Manual GENERAL INFORMATION 00

LF ENGINE 01
L3 © 2005 Mazda Motor Corporation

PRINTED IN U.S.A., AUGUST 2005
Form No. 1866–1U–05H
Part No. 9999–95–LFL3–05
FOREWORD
This manual explains the service points for

the above-indicated automotive system.
This manual covers all models with the
above-indicated automotive system, not any
one specific model.
In order to do these procedures safely,

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

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

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

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

HIROSHIMA, JAPAN
GETtheMANUALS.org
GETtheMANUALS.org
GENERAL INFORMATION 00 SECTION
00–00
Toc of SCT INFORMATION . . . . 00-00

GENERAL
Toc of SCT
00–00 GENERAL INFORMATION
HOW TO USE THIS MANUAL . . . . . . . . . 00–00–2 Inspection During Removal,
Range of Topics . . . . . . . . . . . . . . . . . . 00–00–2 Disassembly . . . . . . . . . . . . . . . . . . . . 00–00–6
Service Procedure . . . . . . . . . . . . . . . . 00–00–2 Arrangement of Parts . . . . . . . . . . . . . . 00–00–7
Symbols . . . . . . . . . . . . . . . . . . . . . . . . 00–00–4 Cleaning of Parts . . . . . . . . . . . . . . . . . 00–00–7
Advisory Messages. . . . . . . . . . . . . . . . 00–00–4 Reassembly . . . . . . . . . . . . . . . . . . . . . 00–00–7
UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–00–5 Adjustment . . . . . . . . . . . . . . . . . . . . . . 00–00–7
Conversion to SI Units (Système Rubber Parts and Tubing . . . . . . . . . . . 00–00–8
International d'Unités) . . . . . . . . . . . . . 00–00–5 Hose Clamps . . . . . . . . . . . . . . . . . . . . 00–00–8
Rounding Off . . . . . . . . . . . . . . . . . . . . . 00–00–5 Torque Formulas . . . . . . . . . . . . . . . . . 00–00–8
Upper and Lower Limits . . . . . . . . . . . . 00–00–5 Vise . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–00–8
FUNDAMENTAL PROCEDURES. . . . . . . 00–00–6 ELECTRICAL SYSTEM. . . . . . . . . . . . . . 00–00–9
Preparation of Tools and Measuring Connectors . . . . . . . . . . . . . . . . . . . . . . 00–00–9
Equipment . . . . . . . . . . . . . . . . . . . . . . 00–00–6 NEW STANDARDS . . . . . . . . . . . . . . . . . 00–00–11
Special Service Tools . . . . . . . . . . . . . . 00–00–6 ABBREVIATIONS . . . . . . . . . . . . . . . . . . 00–00–12
Disassembly . . . . . . . . . . . . . . . . . . . . . 00–00–6
End of Toc
GETtheMANUALS.org 00–00–1
GENERAL INFORMATION
HOW TO USE THIS MANUAL
E5U000000000E01
Range of Topics
• This manual contains procedures for performing all required service operations. The procedures are divided
into the following five basic operations:
— Removal/Installation
— Disassembly/Assembly
— Replacement
— Inspection
— Adjustment
• Simple operations which can be performed easily just by looking at the vehicle (i.e., removal/installation of
parts, jacking, vehicle lifting, cleaning of parts, and visual inspection) have been omitted.
Service Procedure
Inspection, adjustment
• Inspection and adjustment procedures are
divided into steps. Important points regarding the SHOWS PROCEDURE ORDER
location and contents of the procedures are FOR SERVICE
explained in detail and shown in the illustrations.
Fluid Pressure Inspection
1. Assemble the SSTs as shown in the figure.
Tightening torque
39—49 N·m {4.0—5.0 kgf·m, 29—36 ft·lbf}
49 1232 670A
49 H002 671 SHOWS TIGHTENING

TORQUE
49 H032 322 SPECIFICATIONS
Caution
Connect the gauge set from under
the vehicle to prevent contact with
the drive belt and the cooling fan.
WGIWXX0009E
00–00–2 GETtheMANUALS.org
GENERAL INFORMATION
Repair procedure
1. Most repair operations begin with an overview illustration. It identifies the components, shows how the parts fit
together, and describes visual part inspection. However, only removal/installation procedures that need to be
performed methodically have written instructions.
2. Expendable parts, tightening torques, and symbols for oil, grease, and sealant are shown in the overview
illustration. In addition, symbols indicating parts requiring the use of special service tools or equivalent are also 00–00
shown.
3. Procedure steps are numbered and the part that is the main point of that procedure is shown in the illustration
with the corresponding number. Occasionally, there are important points or additional information concerning a
procedure. Refer to this information when servicing the related part.
SHOWS SERVICE
Procedure ITEM (S)
INDICATES ANY RELEVANT
1
LOWER TRAILING LINK, UPPER TRAILING LINK REMOVAL/INSTALLATION REFERENCES WHICH NEED
1. Jack up the rear of the vehicle and support it with safety stands. TO BE FOLLOWED DURING
"Removal/Installation" 2. Remove the undercover. (See 01-10-4 Undercover Removal)
Portion 3. Remove in the order indicated in the table. INSTALLATION
4. Install in the reverse order of removal.
2 5. Inspect the rear wheel alignment and adjust it if necessary.
"Inspection After SHOWS SPECIAL
Installation" Portion 11 SERVICE TOOL (SST)
9 SST
SHOWS PROCEDURE ORDER FOR SERVICE OPERATION
GREASE
FOR SERVICE 12 SST R
INSTALL THE PARTS BY SHOWS APPLICATION

PERFORMING STEPS 8 43—56 {4.3—5.8, 32—41}
POINTS OF GREASE, ETC.
10
— IN REVERSE ORDER
1—3 44—60 {4.4—6.2, 32—44} 7 R
SHOWS TIGHTENING
TORQUE
SPECIFICATIONS SHOWS NON-REUSEABLE PARTS
SST
3
5
6 SHOWS DETAILS
SST
GREASE
4 R
94—116 {9.5—11.9, 69—86}
2 118—156 {12.0—16.0, 87—115} SHOWS TIGHTENING
SHOWS THERE 1 R TORQUE UNITS
ARE REFERRAL
N·m {kgf·m, ft·lbf}
NOTES FOR SERVICE
1 Split pin 7 Split pin
2 Nut 8 Nut
3 Lower trailing link ball joint 9 Upper trailing link ball joint
(See 02-14-5 Lower Trailing Link Ball Joint Removal Note) (See 02-14-5 Upper Trailing Link Ball Joint Removal Note)
4 Bolt 10 Nut
5 Lower trailing link 11 Upper trailing link
6 Dust boot (lower trailing link) 12 Dust boot (upper trailing link)
Lower Trailing Link Ball Joint, Upper Trailing Link 49 T028 304 UPPER TRAILING LINK
Ball Joint Removal Note 49 T028 305 LOWER TRAILING LINK
Remove the ball joint using the SSTs.
SHOWS SPECIAL
SERVICE TOOL (SST)
NO. KNUCKLE
49 T028 303
SHOWS REFERRAL
NOTES FOR
SERVICE
BHE0000W104
GENERAL INFORMATION
Symbols
• There are eight symbols indicating oil, grease, fluids, sealant, and the use of SST or equivalent. These symbols
show application points or use of these materials during service.
Symbol Meaning Kind
New appropriate
OIL Apply oil engine oil or gear
oil
New appropriate
BRAKE Apply brake fluid
FLUID brake fluid
New appropriate
Apply automatic
automatic
transaxle/
ATF
transaxle/
transmission fluid
transmission fluid
Appropriate
Apply grease
GREASE
grease
Appropriate
SEALANT Apply sealant
sealant
Apply petroleum Appropriate

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

• The values indicate the upper and lower limits that must not be exceeded when performing inspections or
adjustments.
End Of Sie
GENERAL INFORMATION
UNITS
E5U000000000E02
Electric current A (ampere)

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

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

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

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

270—310 kPa {2.7—3.2 kgf/cm2, 39—45 psi}
• The actual converted values for 2.7 kgf/cm2 are 264 kPa and 38.4 psi. In the first specification, 2.7 is used as
an upper limit, so the converted values are rounded down to 260 and 38. In the second specification, 2.7 is
used as a lower limit, so the converted values are rounded up to 270 and 39.
End Of Sie
GENERAL INFORMATION
FUNDAMENTAL PROCEDURES
E5U000000000E03
Preparation of Tools and Measuring Equipment
• Be sure that all necessary tools and measuring
equipment are available before starting any work.
CHU0014W003
Special Service Tools

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

• When removed, each part should be carefully
inspected for malfunction, deformation, damage
and other problems.
WGIWXX0028E
GENERAL INFORMATION
Arrangement of Parts
• All disassembled parts should be carefully
arranged for reassembly.
• Be sure to separate or otherwise identify the parts
to be replaced from those that will be reused.
00–00
WGIWXX0029E
Cleaning of Parts
• All parts to be reused should be carefully and
thoroughly cleaned in the appropriate method.
Warning
• Using compressed air can cause dirt and
other particles to fly out causing injury to
the eyes. Wear protective eye wear
whenever using compressed air.
C5U0000W001
Reassembly
• Standard values, such as torques and certain
adjustments, must be strictly observed in the
reassembly of all parts.
• If removed, the following parts should be replaced
with new ones:
— Oil seals
— Gaskets
— O-rings
— Lockwashers
— Cotter pins
— Nylon nuts
WGIWXX0031E
• Depending on location:
— Sealant and gaskets, or both, should be
applied to specified locations. When sealant
is applied, parts should be installed before
sealant hardens to prevent leakage.
— Oil should be applied to the moving
components of parts.
— Specified oil or grease should be applied at
the prescribed locations (such as oil seals)
before reassembly.
CHU0014W006
Adjustment
• Use suitable gauges and testers when making
adjustments.
CHU0014W005
GENERAL INFORMATION
Rubber Parts and Tubing
• Prevent gasoline or oil from getting on rubber
parts or tubing.
WGIWXX0034E
Hose Clamps
• When reinstalling, position the hose clamp in the
original location on the hose and squeeze the
clamp lightly with large pliers to ensure a good fit.
WGIWXX0035E
Torque Formulas
• When using a torque wrench-SST or equivalent
combination, the written torque must be SST
3
recalculated due to the extra length that the SST 2
or equivalent adds to the torque wrench.

1 0
Recalculate the torque by using the following

1
formulas. Choose the formula that applies to you.

2
3
Torque Unit Formula

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

L : The length of the torque wrench.
Vise
• When using a vise, put protective plates in the
jaws of the vise to prevent damage to parts.
End Of Sie
PROTECTIVE PLATES
CHU0014W010
GENERAL INFORMATION
ELECTRICAL SYSTEM
E5U000000000E04
Connectors
Disconnecting connectors
• When disconnecting connector, grasp the
connectors, not the wires. GOOD NO GOOD
00–00
CHU0000W014
• Connectors can be disconnected by pressing or

pulling the lock lever as shown.
WGIWXX0042E
Locking connector
• When locking connectors, listen for a click
indicating they are securely locked.
WGIWXX0043E
GENERAL INFORMATION
Inspection
• When a tester is used to inspect for continuity or
measuring voltage, insert the tester probe from GOOD NO GOOD
the wiring harness side.
CHU0000W011
• Inspect the terminals of waterproof connectors

from the connector side since they cannot be GOOD NO GOOD
accessed from the wiring harness side.
Caution
• To prevent damage to the terminal, wrap
a thin wire around the tester probe before
inserting into terminal.
End Of Sie
CHU0000W012
GENERAL INFORMATION
NEW STANDARDS
E5U000000000E05
• Following is a comparison of the previous standard and the new standard.
New Standard Previous Standard
Abbrevi- Abbrevi- Remark
Name Name 00–00
ation ation
AP Accelerator Pedal — Accelerator Pedal
ACL Air Cleaner — Air Cleaner
A/C Air Conditioning — Air Conditioning
BARO Barometric Pressure — Atmospheric Pressure
B+ Battery Positive Voltage Vb Battery Voltage
— Brake Switch — Stoplight Switch
— Calibration Resistor — Corrected Resistance #6
CMP sensor Camshaft Position Sensor — Crank Angle Sensor
CAC Charge Air Cooler — Intercooler
CLS Closed Loop System — Feedback System
CTP Closed Throttle Position — Fully Closed
CPP Clutch Pedal Position — Idle Switch
CIS Continuous Fuel Injection System — Clutch Position
CS sensor Control Sleeve Sensor CSP sensor Control Sleeve Position Sensor #6
CKP sensor Crankshaft Position Sensor — Crank Angle Sensor 2
DLC Data Link Connector — Diagnosis Connector
DTM Diagnostic Test Mode — Test Mode #1
DTC Diagnostic Trouble Code(s) — Service Code(s)
DI Distributor Ignition — Spark Ignition
DLI Distributorless Ignition — Direct Ignition
EI Electronic Ignition — Electronic Spark Ignition #2
ECT Engine Coolant Temperature — Water Thermo
EM Engine Modification — Engine Modification
— Engine Speed Input Signal — Engine RPM Signal
EVAP Evaporative Emission — Evaporative Emission
EGR Exhaust Gas Recirculation — Exhaust Gas Recirculation
FC Fan Control — Fan Control
FF Flexible Fuel — Flexible Fuel
4GR Fourth Gear — Overdrive
— Fuel Pump Relay — Circuit Opening Relay #3
FSO
Fuel Shut Off Solenoid FCV Fuel Cut Valve #6
solenoid
GEN Generator — Alternator
GND Ground — Ground/Earth
HO2S Heated Oxygen Sensor — Oxygen Sensor With heater
IAC Idle Air control — Idle Speed Control
— IDM Relay — Spill Valve Relay #6
— Incorrect Gear Ratio — —
— Injection Pump FIP Fuel Injection Pump #6
— Input/Turbine Speed Sensor — Pulse Generator
IAT Intake Air Temperature — Intake Air Thermo
KS Knock Sensor — Knock Sensor
MIL Malfunction Indicator Lamp — Malfunction Indicator Light
MAP Manifold Absolute Pressure — Intake Air Pressure
MAF sensor Mass Air Flow Sensor — Airflow Sensor
MFL Multiport Fuel Injection — Multiport Fuel Injection
OBD On-Board Diagnostic — Diagnosis/Self-Diagnosis
OL Open Loop — Open Loop
— Output Speed Sensor — Vehicle Speed Sensor 1
OC Oxidation Catalytic Converter — Catalytic Converter
O2S Oxygen Sensor — Oxygen Sensor
GENERAL INFORMATION
New Standard Previous Standard
Abbrevi- Abbrevi- Remark
Name Name
ation ation
PNP Park/Neutral Position — Park/Neutral Range
— PCM Control Relay — Main Relay #6
PSP Power Steering Pressure — Power Steering Pressure
PCM Powertrain Control Module ECU Engine Control Unit #4
— Pressure Control Solenoid — Line Pressure Solenoid Valve
Pulsed
PAIR Pulsed Secondary Air Injection — Secondary Air Injection System
injection
— Pump Speed Sensor — NE Sensor #6
Injection
AIR Secondary Air Injection — Secondary Air Injection System with air
pump
SAPV Secondary Air Pulse Valve — Reed Valve
SFI Sequential Multipoint Fuel Injection — Sequential Fuel Injection
— 12 Shift Solenoid Valve
— Shift Solenoid A
— Shift A Solenoid Valve
— 23 Shift Solenoid Valve
— Shift Solenoid B
— Shift B Solenoid Valve
— Shift Solenoid C — 34 Shift Solenoid Valve
3GR Third Gear — 3rd Gear
TWC Three Way Catalytic Converter — Catalytic Converter
TB Throttle Body — Throttle Body
TP sensor
Throttle Position Sensor — Throttle Sensor
TCV Timer Control Valve TCV Timing Control Valve #6
TCC Torque Converter Clutch — Lockup Position
Transmission (Transaxle) Control
TCM — EC-AT Control Unit
Module
Transmission (Transaxle) Fluid
— — ATF Thermosensor
Temperature Sensor
TR Transmission (Transaxle) Range — Inhibitor Position
TC Turbocharger — Turbocharger
VSS Vehicle Speed Sensor — Vehicle Speed Sensor
VR Voltage Regulator — IC Regulator
VAF sensor Volume Air Flow Sensor — Air flow Sensor
Warm Up Three Way Catalytic
WUTWC — Catalytic Converter #5
Converter
WOT Wide Open Throttle — Fully Open
#1 : Diagnostic trouble codes depend on the diagnostic test mode

#2 : Controlled by the PCM
#3 : In some models, there is a fuel pump relay that controls pump speed. That relay is now called the fuel pump
relay (speed).
#4 : Device that controls engine and powertrain
#5 : Directly connected to exhaust manifold
#6 : Part name of diesel engine
End Of Sie
ABBREVIATIONS
E5U000000000E06
ATDC After Top Dead Center
ATX Automatic Transaxle
EGR Exhaust Gas Recirculation
EX Exhaust
IN Intake
MTX Manual Transaxle
OCV Oil Control Valve
TDC Top Dead Center
SST Special Service Tool
End Of Sie
ENGINE 01 SECTION
01–10
Toc of SCT
MECHANICAL. . . . . . . . . . . . . . 01-10 SERVICE TOOLS . . . . . . . . . . . 01-60
TECHNICAL DATA . . . . . . . . . . 01-50
Toc of SCT
01–10 MECHANICAL
ENGINE OVERHAUL SERVICE CYLINDER BLOCK
WARNING. . . . . . . . . . . . . . . . . . . . . . . . 01–10–2 INSPECTION . . . . . . . . . . . . . . . . . . . . . 01–10–17
ENGINE OIL JET VALVE INSPECTION . . . . . . . . 01–10–18
MOUNTING/DISMOUNTING . . . . . . . . . 01–10–3 PISTON INSPECTION . . . . . . . . . . . . . . . 01–10–18
DISMOUNTING. . . . . . . . . . . . . . . . . . . 01–10–3 CRANKSHAFT INSPECTION . . . . . . . . . 01–10–19
TIMING CHAIN DISASSEMBLY. . . . . . . . 01–10–4 CONNECTING ROD INSPECTION . . . . . 01–10–20
Crankshaft Pulley Lock Bolt BOLT INSPECTION . . . . . . . . . . . . . . . . . 01–10–21
Disassembly Note . . . . . . . . . . . . . . . . 01–10–5 VARIABLE VALVE TIMING ACTUATOR
Front Oil Seal Disassembly Note . . . . . 01–10–5 INSPECTION [With variable valve
Chain Tensioner timing mechanism]. . . . . . . . . . . . . . . . 01–10–21
Disassembly Note . . . . . . . . . . . . . . . . 01–10–5 OIL CONTROL VALVE (OCV)
Oil Pump Sprocket INSPECTION [With variable valve
Disassembly Note . . . . . . . . . . . . . . . . 01–10–5 timing mechanism]. . . . . . . . . . . . . . . . 01–10–21
CYLINDER HEAD (I) Coil Resistance Inspection . . . . . . . . . . 01–10–21
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . 01–10–6 Spool Valve Operation Inspection . . . . 01–10–22
Camshaft Sprocket Lock Bolt, VALVE CLEARANCE
Variable Valve Timing Actuator INSPECTION . . . . . . . . . . . . . . . . . . . . . 01–10–22
Lock Bolt Disassembly Note . . . . . . . . 01–10–7 VALVE CLEARANCE
Camshaft Cap Disassembly Note . . . . . 01–10–7 ADJUSTMENT. . . . . . . . . . . . . . . . . . . . 01–10–23
Tappet Disassembly Note . . . . . . . . . . . 01–10–7 CYLINDER BLOCK (I) ASSEMBLY . . . . 01–10–27
Cylinder Head Bolt Main Bearing Cap Assembly Note . . . . 01–10–28
Disassembly Note . . . . . . . . . . . . . . . . 01–10–8 Piston Ring Assembly Note . . . . . . . . . 01–10–28
CYLINDER HEAD (II) Piston Assembly Note . . . . . . . . . . . . . 01–10–28
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . 01–10–8 Connecting Rod Bearing
Valve Keeper Disassembly Note . . . . . . 01–10–8 Assembly Note . . . . . . . . . . . . . . . . . . 01–10–29
Valve Seal Disassembly Note . . . . . . . . 01–10–9 Connecting Rod Cap
CYLINDER BLOCK (I) Assembly Note . . . . . . . . . . . . . . . . . . 01–10–29
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . 01–10–9 Balancer Unit Assembly Note. . . . . . . . 01–10–29
Drive Plate (ATX), Flywheel (MTX) CYLINDER BLOCK (II)
Disassembly Note . . . . . . . . . . . . . . . . 01–10–10 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 01–10–32
CYLINDER BLOCK (II) Rear Oil Seal Assembly Note. . . . . . . . 01–10–33
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . 01–10–10 Drive Plate (ATX), Flywheel (MTX)
Connecting Rod Cap Assembly Note . . . . . . . . . . . . . . . . . . 01–10–33
Disassembly Note . . . . . . . . . . . . . . . . 01–10–11 Oil pan Assembly Note. . . . . . . . . . . . . 01–10–34
Main Bearing Cap CYLINDER HEAD (I) ASSEMBLY. . . . . . 01–10–35
Disassembly Note . . . . . . . . . . . . . . . . 01–10–11 Valve Seal Assembly Note . . . . . . . . . . 01–10–35
CYLINDER HEAD INSPECTION . . . . . . . 01–10–11 Valve Keeper Assembly Note . . . . . . . . 01–10–35
VALVE, VALVE GUIDE CYLINDER HEAD (II) ASSEMBLY . . . . . 01–10–36
INSPECTION . . . . . . . . . . . . . . . . . . . . . 01–10–12 Cylinder Head Bolt
VALVE GUIDE REPLACEMENT . . . . . . . 01–10–13 Assembly Note . . . . . . . . . . . . . . . . . . 01–10–37
Valve Guide Removal . . . . . . . . . . . . . . 01–10–13 Camshaft Assembly Note. . . . . . . . . . . 01–10–37
Valve Guide Installation. . . . . . . . . . . . . 01–10–13 Camshaft Sprocket, Variable Valve
VALVE SEAT Timing Actuator Assembly Note . . . . . 01–10–37
INSPECTION/REPAIR . . . . . . . . . . . . . . 01–10–14 TIMING CHAIN ASSEMBLY . . . . . . . . . . 01–10–38
VALVE SPRING INSPECTION . . . . . . . . . 01–10–15 Oil Pump Sprocket Assembly Note . . . 01–10–39
CAMSHAFT INSPECTION . . . . . . . . . . . . 01–10–15 Timing Chain Assembly Note . . . . . . . . 01–10–39
TAPPET INSPECTION . . . . . . . . . . . . . . . 01–10–17 Camshaft Sprocket, Variable Valve
Timing Actuator Assembly Note . . . . . 01–10–40
MECHANICAL
Front Oil Seal Assembly Note . . . . . . . . 01–10–40 Crankshaft Pulley Lock Bolt
Engine Front Cover Assembly Note . . . 01–10–41 Assembly Note . . . . . . . . . . . . . . . . . . 01–10–41
Cylinder Head Cover
Assembly Note . . . . . . . . . . . . . . . . . . 01–10–42
End of Toc
ENGINE OVERHAUL SERVICE WARNING
E5U011002000E01
Warning
• Continuous exposure with USED engine oil has caused skin cancer in laboratory mice. Protect
your skin by washing with soap and water immediately after this work.
End Of Sie
MECHANICAL
ENGINE MOUNTING/DISMOUNTING
E5U011002000E02
1. Install the SSTs (arms) to the cylinder block holes
as shown, and hand-tighten the bolts (part No.:
9YA20-1003) or M10 × 1.5T length 90 mm {3.55 49 L010 102
in}.
01–10
B3E0110W127
2. Assemble the SSTs (bolts, nuts and plate) to the

specified positions.
3. Adjust the SSTs (bolts) so that less than 20 mm 49 L010 101
{0.79 in} of thread is exposed. 49 L010 104
4. Make the SSTs (arms and plate) parallel by
adjusting the SSTs (bolts and nuts).
49 L010 105
C3U0110E001
5. Tighten the SSTs (bolts and nuts) to affix the

SSTs firmly. BOLT
PARALLEL
49 L010 101
Warning 49 L010 102
• Self-locking brake system of the engine
49 L010 105
stand may not be effective when the
engine is held in an unbalanced position. ENGINE
This could lead to sudden, rapid
movement of the engine and mounting
stand handle and cause serious injury.
49 L010 104 49 L010 103 APPROX. 20 mm {0.79 in}
Never keep the engine in an unbalanced
position, and always hold the rotating
E5U110ZW8S01
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.
End Of Sie
MECHANICAL
TIMING CHAIN DISASSEMBLY
E5U011002000E03
1. Disassemble in the order indicated in the table. .
8 1
3
R 2
14
7
R 9
5 R
6
4 SST R
WITHOUT A/C
10
WITH VARIABLE VALVE TIMING

13 MECHANISM
19
11
17
12 15 SST
16
18
E5U110ZE7S01
1 Oil level gauge (if equipped) 10 Chain tensioner

2 Spark plug (See 01–10–5 Chain Tensioner Disassembly Note.)
3 Cylinder head cover 11 Tensioner arm
4 Crankshaft pulley lock bolt 12 Chain guide
(See 01–10–5 Crankshaft Pulley Lock Bolt 13 Timing chain
Disassembly Note.) 14 Seal (With variable valve timing mechanism)
5 Crankshaft pulley 15 Oil pump chain tensioner
6 Water pump pulley 16 Oil pump chain guide
7 Drive belt idler pulley (Without stretch-type A/C drive 17 Oil pump sprocket
belt) (See 01–10–5 Oil Pump Sprocket Disassembly
8 Engine front cover Note.)
9 Front oil seal 18 Oil pump chain
(See 01–10–5 Front Oil Seal Disassembly Note.) 19 Crankshaft sprocket
Engine Workshop Manual LF L3 (1866–1U–05H)
MECHANICAL
Crankshaft Pulley Lock Bolt Disassembly Note
1. Install the SST to the ring gear to lock the
crankshaft against rotation.
49 E011 1A0
01–10
D3U110ZE4003
Front Oil Seal Disassembly Note

1. Remove the oil seal using a screwdriver.
E6U110ZWB044
Chain Tensioner Disassembly Note

1. Unlock the chain tensioner ratchet using a TENSIONER PISTON
RATCHET
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.
RACK
C3U0110W098
Oil Pump Sprocket Disassembly Note

1. Hold the oil pump sprocket using the SST.
End Of Sie
49 G032 354
B3E0110E054
MECHANICAL
CYLINDER HEAD (I) DISASSEMBLY
E5U011002000E04
WITH VARIABLE VALVE TIMING MECHANISM
4
3
5
2 *
R
7
4
2
6
8
R * R *
9 R
*: IF WASHER IS NOT INSTALLED TO THE ENGINE, INSTALL A NEW WASHER.

E5U110ZECL01
1 Camshaft sprocket lock bolt, variable valve timing 4 Camshaft cap

actuator lock bolt (With variable valve timing (See 01–10–7 Camshaft Cap Disassembly Note.)
mechanism) 5 Camshaft
(See 01–10–7 Camshaft Sprocket Lock Bolt,
Variable Valve Timing Actuator Lock Bolt 6 Tappet
Disassembly Note .) (See 01–10–7 Tappet Disassembly Note.)
2 Camshaft sprocket, variable valve timing actuator 7 Cylinder head bolt
(With variable valve timing mechanism) (See 01–10–8 Cylinder Head Bolt Disassembly
Note.)
3 Oil control valve (OCV) (with variable valve timing
mechanism) 8 Cylinder head
9 Cylinder head gasket
01–10–6 GETtheMANUALS.org Revised 12/2005 (Ref. No. R145/05)

MECHANICAL
Camshaft Sprocket Lock Bolt, Variable Valve Timing Actuator Lock Bolt Disassembly Note
1. Hold the camshaft by using a wrench on the cast hexagon as shown, and loosen the camshaft sprocket
installation bolt or variable valve timing actuator installation bolt (With variable valve timing mechanism).
Without variable valve timing mechanism
01–10
B3E0110E056
With variable valve timing mechanism
B3E0110E058
Camshaft Cap Disassembly Note

1. Before removing the camshaft caps, inspect the following:
— Camshaft end play and camshaft journal oil clearance (See 01–10–15 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

1 5 6 9 10 7 8 3 4
the order shown in the figure.
2
12
11
15 16 19 20 17 18 13 14
B3E0110E057
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.
MECHANICAL
Cylinder Head Bolt Disassembly Note
1. Loosen the cylinder head bolts in 2—3 steps in
the order shown in the figure. 3 7 10 6 2
End Of Sie
4 8 9 5 1
B3E0110E059
CYLINDER HEAD (II) DISASSEMBLY

E5U011002000E05
2 SST 1
3 8
4
R 6
SST
R
B3E0110E060
1 Engine hanger 5 Valve

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

1. Remove the valve keeper using the SSTs.
49 0636 100B
49 B012 0A2
B3E0110E124
MECHANICAL
Valve Seal Disassembly Note
1. Remove the valve seal using the SST.
End Of Sie
49 S120 170
VALVE SEAL 01–10

VALVE GUIDE
B3E0110E061
CYLINDER BLOCK (I) DISASSEMBLY

E5U011002000E06
R R
13
SST
1
MTX
R
10
7
R
12 8 WITHOUT OIL COOLER

R CARTRIDGE SPIN-ON
IF EQUIPPED TYPE TYPE
R
11
R 9 R 6
WITH OIL COOLER
OIL
4
OIL
5
3 R
R
2
E5U110ZE7S10
1 Flywheel (MTX), Drive plate (ATX) (See 01–10–10 7 Knock sensor

Drive Plate (ATX), Flywheel (MTX) Disassembly 8 Oil separator
Note)
9 Thermostat
2 Oil pan
10 Water pump
3 Oil filter cover (cartridge type)
11 Oil strainer
4 Oil filter
12 Oil pump
5 Oil cooler
13 Rear oil seal
6 Oil filter adapter
MECHANICAL
Drive Plate (ATX), Flywheel (MTX) Disassembly Note
1. Hold the crankshaft using the SST.
2. Remove the bolts in several passes.
End Of Sie
49 E011 1A0
1
3 6
5 4
2
B3E0110E051
CYLINDER BLOCK (II) DISASSEMBLY

E5U011002000E07
1. Disassemble in the order indicated in the table.
.
L3
12 11
10
7 10
4
L3
3 9
2
8
E5U110ZE7S07
1 Balancer unit 7 Upper connecting rod bearing

2 Adjustment shim 8 Main bearing cap
3 Connecting rod cap (See 01–10–11 Main Bearing Cap Disassembly
(See 01–10–11 Connecting Rod Cap Disassembly Note.)
Note.) 9 Lower main bearing, thrust bearing
4 Lower connecting rod bearing 10 Crankshaft
5 Connecting rod, Piston component 11 Upper main bearing, thrust bearing
6 Piston ring 12 Oil jet valve
MECHANICAL
Connecting Rod Cap Disassembly Note
1. Before removing connecting rod inspect the connecting rod side clearance. (See 01–10–20 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. 01–10
Main Bearing Cap Disassembly Note
1. Before removing main bearing cap inspect the crankshaft end play. (See 01–10–19 CRANKSHAFT
INSPECTION.)
2. Loosen the main bearing cap bolts in two or three
steps in the order shown in the figure.
End Of Sie
2 6 10 8 4
1 5 9 7 3
B3E0110E067
CYLINDER HEAD INSPECTION
E5U011010100E01
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}
B3E0110E008
4. Measure the manifold contact surface distortion

as shown in the figure. EX
IN
C3U0110E003
• 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}
MECHANICAL
End Of Sie
VALVE, VALVE GUIDE INSPECTION

E5U011012111E01
1. Measure the valve head margin thickness of each
valve.
• If it is less than the specification, replace the
valve.
IN : 33.5 mm {1.31 in}
Valve head margin thickness (Minimum) EX : 28.3 mm {1.14 in}
IN: 1.62 mm {0.0637 in}
EX: 1.82 mm {0.0716 in}
MARGIN THICKNESS
C3U0110E051
2. Measure the length of each valve. Replace the

valve if necessary.
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} L
Valve length (Minimum)

IN: 102.99 mm {4.055 in}
EX: 104.25 mm {4.104 in}
B3E0110E068
3. Measure the stem diameter of each valve in X

and Y directions at the three points (A, B, and C) X
as indicated in the figure.
• If it exceeds the specification, replace the Y
valve.
A
Valve stem diameter (Standard)
IN: 5.470—5.485 mm {0.2154—0.2159 in} B
EX: 5.465—5.480 mm {0.2152—0.2157 in}
C
Valve stem diameter (Minimum)
IN: 5.440 mm {0.2142 in}
ADJ2224E024
EX: 5.435 mm {0.2140 in}
4. Measure the inner diameter of each valve guide in

X
X and Y directions at the three points (A, B, and
C) as indicated in the figure. Y
• If not as specified, replace the valve guide.
A
Valve guide inner diameter (Standard)
5.509—5.539 mm {0.2169—0.2180 in}
B
ADJ2224E026
MECHANICAL
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 STEM
valve guide.
• If it exceeds the specification, replace the VALVE GUIDE
valve and/or the valve guide.
CLEARANCE
Valve stem to guide clearance (Standard) 01–10
IN: 0.024—0.069 mm {0.0009—0.0027 in}
EX: 0.029—0.074 mm {0.0012—0.0029 in}
Valve stem to guide clearance (Maximum)

ADA2224E027
0.10 mm {0.004 in}
6. Measure the protrusion height (dimension A) of

each valve guide without lower valve spring seat. VALVE GUIDE
• If not within the specified, replace the valve A
guide.
Valve guide protrusion height (standard)

12.2—12.8 mm {0.481—0.503 in}
CYLINDER HEAD
C3U0110E004
End Of Sie
VALVE GUIDE REPLACEMENT
E5U011012111E02
Valve Guide Removal
1. Remove the valve guide from the combustion
chamber side using the SST. 49 B012 015
VALVE GUIDE
C3U0110E005
Valve Guide Installation

1. Assemble the SSTs so that depth L is as
specified.
Valve guide protrusion height (standard) 49 L012 004A

L
12.2—12.8 mm {0.481—0.503 in}
49 L012 003A
49 L012 002A
B3E0110E071
MECHANICAL
2. Tap the valve guide in from the top of the cylinder
head until the SSTs contacts the cylinder head. 49 L012 003A
49 L012 004A
49 L012 002A
VALVE GUIDE
B3E0110E072
3. Verify that the valve guide protrusion height
(dimension A) is within the specification. VALVE GUIDE
A
Valve guide protrusion height (standard)
12.2—12.8 mm {0.481—0.503 in}
End Of Sie
CYLINDER HEAD
C3U0110E004
VALVE SEAT INSPECTION/REPAIR
E5U011010102E01
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) SEAT CONTACT

WIDTH
1.2—1.6 mm {0.048—0.062 in}
ADA2224E019
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
IN EX
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 70° 65°
the valve seat using a 35° (IN) cutter, and a
30° (EX) cutter, and a 45° cutter. 45° 45°
35° 30°
B3E0110E133
3. Inspect the sinking of the valve seat. Measure the
protruding length (dimension L) of the valve stem. L
• 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}
C3U0110E006
MECHANICAL
End Of Sie
VALVE SPRING INSPECTION

E5U011012125E01
1. Apply pressing force to the pressure spring and inspect the spring height.
valve spring.
Valve spring pressing force

390 N {39.76 kgf, 87.67 lbf}
01–10
Valve spring standard height H
28.68 mm {1.129 in}
ADJ2224E028
2. Measure the out-of-square of the valve spring,

using a square, as shown in the figure. A
(1) Rotate the valve spring one full turn and
measure "A" at the point where the gap is the
largest. UPPER
• If it exceeds the specification, replace the
valve spring.
Valve spring out-of-square (Maximum)

1.95 mm {0.0767 in} LOWER
End Of Sie B3E0110E073
CAMSHAFT INSPECTION
E5U011012420E01
1. Set the No.1 and No.5 journals on V-blocks.
2. Measure the camshaft runout.
camshaft.
Maximum runout (Maximum)

0.03 mm {0.0012 in}
B3E0110E074
3. Measure the cam lobe height at the two points as

shown in the figure.
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}
B3E0110E076
Camshaft minimum height (mm {in})

IN: 42.33 {1.666}
EX: 41.06 {1.616}
IN: 42.01 {1.653}
EX: 40.96 {1.612}
MECHANICAL
4. Measure the journal diameters in X and Y
directions at the two points (A and B) as indicated
in the figure. B
• If it is less than the specification, replace the A
camshaft.
Camshaft journal diameter (Standard)

24.96—24.98 mm {0.9827—0.9834 in}
Y
Camshaft journal diameter (Minimum) X
24.95 mm {0.982 in}
B3E0110E075
5. Remove the tappet.
6. Position a plastigage atop the journals in the axial
direction.
7. Install the camshaft cap. (See 01–10–37
Camshaft Assembly Note.)
8. Remove the camshaft cap. (See 01–10–7
Camshaft Cap Disassembly Note.)
9. Measure the oil clearance.
• If it exceeds the specification, replace the PLASTIGAUGE
cylinder head.
Camshaft journal oil clearance (Standard)

0.035—0.080 mm {0.0014—0.0031 in}
B3E0110E077
Camshaft journal oil clearance (Maximum)

0.09 mm {0.0035 in}
10. Install the camshaft cap. (See 01–10–37 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 01–10–7

Camshaft Cap Disassembly Note.)
End Of Sie
B3E0110E078
MECHANICAL
TAPPET INSPECTION
E5U011012431E01
1. Measure the tappet hole inner diameter in X and
Y directions at the two points (A and B) shown in
the figure. X
Tappet bore diameter (Standard) Y

31.000—31.030 mm {1.2205—1.2216 in}
01–10
A
B
ADJ2224E023
2. Measure the tappet body outer diameter in X and

Y directions at the two points (A and B) shown in
the figure. A
Y
B
Tappet diameter (Standard)
30.970—30.980 mm {1.2193—1.2196 in} X
3. Subtract the tappet body outer diameter from the

tappet hole inner diameter.
tappet or cylinder head.
ADJ2224E029
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}
End Of Sie
CYLINDER BLOCK INSPECTION
E5U011010300E01
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}
ADJ2224E089
2. Measure the cylinder bores in X and Y directions

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

87.500—87.530 mm {3.4449—3.4460 in}
42 mm {1.65 in}
Minimum / maximum bore diameter limit
87.440—87.590 mm {3.4425—3.4484 in}
End Of Sie C3U0110E007
MECHANICAL
OIL JET VALVE INSPECTION
E5U011010730E01
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. B
Oil jet valve air pressure

216—274 kPa {2.2—2.7 kgf·cm2 31.4—39.7
psi}
End Of Sie
A
B3E0110E079
PISTON INSPECTION
E5U011011010E01
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.
piston, piston pin, piston ring and connecting
rod as a single unit.
Piston diameter (Standard)

87.465—87.495 mm {3.4435—3.4446 in}
2. Measure the piston-to-cylinder clearance.

B3E0110E080
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)
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}
B3E0110E081
MECHANICAL
4. Insert the piston ring into the cylinder by hand and
use the piston to push it to the bottom of the ring
travel.
5. Measure each piston ring end gap with a feeler
gauge.
rod as a single unit. PISTON RING
01–10
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} B3E0110E082
Piston end gap (Maximum)

1.0 mm {0.0393 in}
End Of Sie
CRANKSHAFT INSPECTION
E5U011011301E01
1. Install the main bearing cap. (See 01–10–28 Main Bearing Cap Assembly Note.)
2. Measure the crankshaft end play.
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}
Crankshaft end play (Maximum)

0.55 mm {0.0216 in}
3. Remove the main bearing cap. (See 01–10–11

B3E0110E083
Main Bearing Cap Disassembly Note.)
4. Measure the crankshaft runout.
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.
crankshaft or grind the journal and install the
AME2224E311
undersize bearing.
Main journal bearing size
STD: 51.980—52.000 mm {2.0464—2.0472 A B
in}
X
US0.25: 51.730—51.750 mm {2.0366—2.0373
in}
Main journal out of round (Maximum) Y
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 B3E0110E085
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}
Crank pin out of round (Maximum)
0.05 mm {0.0019 in}
MECHANICAL
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 01–10–28 Main Bearing Cap Assembly Note.)
9. Remove the main bearing caps. (See 01–10–11 Main Bearing Cap Disassembly Note.)
10. Measure the main journal oil clearance.
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)
0.10 mm {0.0039 in}
Main bearing size B3E0110E086
STD: 2.506—2.509 mm {0.0987—0.0988 in}

OS0.25: 2.628—2.634 mm {0.1034—0.1037 in}
End Of Sie
CONNECTING ROD INSPECTION
E5U011011211E01
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 01–10–29 Connecting Rod Cap Assembly Note.)
2. Measure the connecting rod large end side
clearance.
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}
B3E0110E087
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 01–10–29 Connecting Rod Cap Assembly
Note.)
6. Remove the connecting rod cap.
7. Measure the connecting rod oil clearance.
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)
0.026—0.052 mm {0.0011—0.0020 in}
Connecting rod bearing oil clearance
(Maximum)
0.1 mm {0.0039 in}
B3E0110W128
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}
MECHANICAL
End Of Sie
BOLT INSPECTION
E5U011010135E01
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} 01–10
Cylinder head bolt (Without washer) L
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}
B3E0110E088
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}
End Of Sie
VARIABLE VALVE TIMING ACTUATOR INSPECTION [WITH VARIABLE VALVE TIMING MECHANISM]
E5U011012490E01
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, COVER
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, NOTCH
replace the variable valve timing actuator.
End Of Sie ROTOR
B3E0110E089
OIL CONTROL VALVE (OCV) INSPECTION [WITH VARIABLE VALVE TIMING MECHANISM]
E5U011014420E01
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.

A B
B3E0110W151
MECHANICAL
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.
SPOOL VALVE
(MAXIMUM VALVE TIMING RETARD POSITION
B3E0110E090
5. Apply battery positive voltage between the oil

control valve (OCV) terminals and verify that the
VALVE TIMING VALVE TIMING
spool valve operates and moves to the maximum
ADVANCE RETARD
valve timing advance position.
• If it exceeds the specification, replace the oil
control valve (OCV).
Note
• When applying battery positive voltage SPOOL VALVE
between the oil control valve (OCV) (MAXIMUM VALVE TIMING ADVANCE POSITION)
terminals, the connection can be either of
the following:
B3E0110E091
— Positive battery cable to terminal A,
negative battery cable to terminal B
— Positive battery cable to terminal B, negative battery cable to terminal A
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).
End Of Sie
VALVE CLEARANCE INSPECTION
E5U011012111E03
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 B
A B A
figure.
• If the valve clearance exceeds the EX
standard, replace the tappet. (See 01–
10–23 VALVE CLEARANCE
ADJUSTMENT.)
Note IN
• Make sure to note the measured values for
choosing the suitable replacement tappets.
A A B B
Valve clearance [Engine cold]
B3E0110E092
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 01–10–23 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}
EX: 0.27—0.33 mm {0.0106—0.0130 in}
MECHANICAL
End Of Sie
VALVE CLEARANCE ADJUSTMENT

E5U011012111E04
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.
UPPER 01–10
BLIND
PLUG
LOWER BLIND
PLUG
B3E0110E093
4. Install the SST as shown in the figure.
Caution
• Removal of this SST is extremely
important. If you crank the engine with
this SST installed, the cylinder block will 303-507
be damaged.
5. Turn the crankshaft clockwise so that the

crankshaft is in the No.1 cylinder TDC position.
D3U110ZE4006
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 2
suitable wrench on the cast hexagon and
loosen the timing chain.
(3) Placing the suitable bolt (M6 × 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.
BOLT (M6 x 1.0)

3
B3E0110E096
MECHANICAL
7. Hold the exhaust camshaft using a suitable
wrench on the cast hexagon as shown in the
figure.
B3E0110E095
8. Remove the exhaust camshaft sprocket.
EXHAUST
CAMSHAFT
SPROCKET
B3E0110E097
9. Loosen the camshaft cap bolts in several passes

1 5 6 9 10 7 8 3 4
in the order shown in the figure.
Note
• The cylinder head and the camshaft caps 2
are numbered to make sure they are 12
reassembled in their original position. When
removed, keep the caps with the cylinder
head they were removed from. Do not mix
the caps.
11
15 16 19 20 17 18 13 14
10. Remove the camshaft.
B3E0110E057
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
5 6 1 2 3 4 7 8
two steps. 9
Tightening torque
(1) 5.0—9.0 N·m 10
{51.0—91.7 kgf·cm, 44.3—79.5 in·lbf} 20
(2)14.0—17.0 N·m
{1.43—1.73 kgf·m, 10.4—12.5 ft·lbf}
19
15 16 11 12 13 14 17 18
B3E0110E098
MECHANICAL
15. Install a new washer.
01–10
D3U110ZE4012
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.
EXHAUST
CAMSHAFT
SPROCKET
B3E0110E097
17. Install the SST to the camshaft as shown in the

figure. 303-465
18. Remove the M6 × 1.0 bolt from the engine front (49 UN30 3465)
cover to apply tension to the timing chain.
C3U0110E066
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
B3E0110E095
lock bolt and repeat from Step 17.
Revised 12/2005 (Ref. No. R145/05) GETtheMANUALS.org 01–10–25

MECHANICAL
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}
BLIND
PLUG
B3E0110E101
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}
BLIND
PLUG
B3E0110E102
27. Install the new engine front cover lower blind plug.
ENGINE FRONT
Tightening torque COVER LOWER
10—14 N·m {102—142 kgf·cm, 89—123 BLIND PLUG
in·lbf}
End Of Sie
B3E0110W063
MECHANICAL
CYLINDER BLOCK (I) ASSEMBLY
E5U011002000E08
1. Assemble in the order indicated in the table. .
01–10
6 2.9—4.9 N·m
{30—40 kgf·cm,
OIL
25.67—43.4 in·lbf}
2 L3
1
OIL
3
OIL
7 3
9 L3 OIL
OIL
10 4
11
5
26—32 {2.7—3.2,
19.2—23.6}+80°—100°
ELASTIC REGION TIGHTENING BOLT
SST (BOLT STEM LENGTH 104 mm)
3—7 N·m {30.6—71.3 kgf·cm,26.6—61.9 in·lbf}
+23—27 {2.4—2.7, 17—19.9}
+38—42 {3.9—4.2, 28.1—30.9}
12 PLASTIC REGION TIGHTENING Loosen all the bolts
BOLT +3—7 N·m {30.6—71.3 kgf·cm,26.6—61.9 in·lbf}
25+44—46 SST (BOLT STEM LENGTH 110 mm) +18—22 {1.9—2.2, 13.3—16.2}
{2.6+4.5—4.7,
44—46 {4.5—4.6, 32.5—33.9} +87.5°—92.5° SST
18.4+32.5—33.9}
+175°—185° SST N·m {kgf·m, ft·lbf}
E5U110ZE7S03
1 Oil jet valve 8 Connecting rod, piston assembly

2 Upper main bearing, thrust bearing (See 01–10–28 Piston Assembly Note)
3 Crankshaft 9 Lower connecting rod bearing
(See 01–10–29 Connecting Rod Bearing Assembly
4 Lower main bearing, thrust bearing Note)
5 Main bearing cap 10 Connecting rod cap
(See 01–10–28 Main Bearing Cap Assembly Note) (See 01–10–29 Connecting Rod Cap Assembly
Piston ring Note)
6
(See 01–10–28 Piston Ring Assembly Note) 11 Adjustment shim
7 Upper connecting rod bearing 12 Balancer unit
(See 01–10–29 Connecting Rod Bearing Assembly (See 01–10–29 Balancer Unit Assembly Note)
Note)
MECHANICAL
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). 9 5 1 3 7
Tightening torque
Plastic region tightening bolt (Bolt stem
length 110 mm)
10 6 2 4 8
(1) 44—46 N·m {4.5—4.6 kgf·m, 32.5—33.9
ft·lbf}
(2) 175°—185°
B3E0110E105
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°
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. LF L3
C3U0110E056
Piston Assembly Note

1. Position the end gap of each ring as indicated in
the figure. TOP RING
30° 30°
UPPER OIL LOWER OIL

RING RAIL RING RAIL
OIL RING SPACER

AND SECOND RING
B3E0110E107
MECHANICAL
2. Insert the piston and connecting rod into the
cylinder with the arrow mark to front of the engine.
01–10
B3E0110E108
Connecting Rod Bearing Assembly Note

1. Install the connecting rod bearing to the
connecting rod and connecting rod caps, as
shown in the figure. CONNECTING ROD
BEARING
2.3—2.7 mm {0.091—0.106 in}
B3E0110E109
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

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.

3. Turn the crankshaft clockwise the crankshaft is in
the No.1 cylinder TDC position (until the balance
weight is attached to the SST).
303-507
4. Install the adjustment shim to the seat face of the
balancer unit.
D3U110ZE4007
MECHANICAL
5. With the balancer unit marks at the exact top
center, assemble the unit to the cylinder block.
MARK
B3E0110E111
6. Set the SST as shown, then measure the gear DIAL GAUGE
49 G011 201
backlash using a dial gauge.
41.4 mm
{1.629 in}
DRIVEN GEAR SHAFT CENTER
B3E0110E112
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.
B3E0110E113
• 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.
MECHANICAL
Adjustment shim selection table
Backlash Selection shim Shim thickness Backlash Selection shim Shim thickness
mm {in} (No.) mm {in} mm {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} 01–10
0.01047} 0.00496}
0.253—0.259 0.113—0.119
{0.00996— 17 1.17 {0.0460} {0.00444— 37 1.37 {0.0539}
0.01019} 0.00468}
0.246—0.252 0.106—0.112
{0.00968— 18 1.18 {0.0464} {0.00417— 38 1.38{0.0543}
0.00992} 0.00440}
0.239—0.245 0.099—0.105
{0.00940— 19 1.19 {0.0468} {0.00389— 39 1.39 {0.0547}
0.00964} 0.00413}
0.232—0.238 0.092—0.098
{0.00913— 20 1.20 {0.0472} .087 {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— 33 1.33 {0.523} {0.00003— 53 1.53 {0.0602}
0.00578} 0.000275}
0.134—0.140
0.000—0.000
{0.00527— 34 1.34 {0.527} 54 1.54 {0.0606}
{0.000—0.000}
0.00551}
End Of Sie
MECHANICAL
CYLINDER BLOCK (II) ASSEMBLY
E5U011002000E09
1. Assemble in the order indicated in the table.
46—54 {4.70—5.50,
34.0—39.8}+76—84
{7.75—8.56,
A 56.1—61.9}+108—116
OIL SST {11.1—11.8, 79.7—85.5}
R 1 SST
R
13
MTX
R
4
7
16.2—23.8 {1.66—2.42,
12.0—17.5}
R
A
6 WITHOUT OIL COOLER
2 CARTRIDGE SPIN-ON
TYPE TYPE
R R
IF EQUIPPED
R B
A R 8
3 5
8.0—12 N·m SEALANT
{81.6—122.3 kgf·cm, WITH OIL COOLER
70.9—106.2in·lbf} A
+20°—25°
10
30—39
{3.1—3.9, 15—20
22.2—28.7}
R
{1.6—2.0,
11—14}
9
R 11
30—35
20—30 {3.1—3.5,
17—23 12 8 {2.1—3.0, 22.2—25.8}
{1.8—2.3, 14.8—22.1}
12.6—16.9} 17—23
{1.8—2.3,
A : 8.0—11.5 N·m 12.6—16.9}
{81.6—117.2 kgf·cm,
70.9—101.7 in·lbf} N·m {kgf·m, ft·lbf}
E5U110ZE7S08
1 Rear oil seal 8 Oil filter adapter

(See 01–10–33 Rear Oil Seal Assembly Note) 9 Oil cooler
2 Oil pump 10 Oil filter
3 Oil strainer 11 Oil filter cover (cartridge type)
4 Water pump 12 Oil pan
5 Thermostat (See 01–10–34 Oil pan Assembly Note)
6 Oil separator 13 Flywheel (MTX), Drive plate (ATX) (See 01–10–33
7 Knock sensor Drive Plate (ATX), Flywheel (MTX) Assembly Note)
MECHANICAL
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.
01–10
303-328
(49 UN30 3328)
CUE110BW2005
3. Tighten the rear oil seal bolts in the order as

shown in the figure. 3
5
Tightening torque
8.0—11.5 N·m
{81.6—117.2 kgf·cm, 70.9—101.7 in·lbf}
1
2 4
B3E0110E116
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 49 E011 1A0
{4.70—5.50 kgf·m, 34.0—39.8 ft·lbf 1
(2) 76—84 N·m 3 6
{7.75—8.56 kgf·m, 56.1—61.9 ft·lbf
(3) 108—116 N·m 5 4
{11.1—11.8 kgf·m, 79.7—85.5 ft·lbf 2
B3E0110E119
MECHANICAL
Oil pan Assembly Note
1. Apply a continuous bead of silicone sealant to the
ENGINE FRONT SIDE
oil pan as indicated in the figure.
2.2—3.2 mm{0.087—0.126 in}
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.
REAR OIL SEAL

C3U0110E061
2. Use a square ruler to unite the oil pan and the

cylinder block junction side on the engine front
cover side.
CYLINDER
BLOCK
OIL PAN
-0.05—0.05 mm {-0.0020—0.0020 in}
B3E0110E120
3. Tighten the rear oil pan bolts in the order as

shown in the figure. 13 8 4 1 5 9
Tightening torque
17—23 N·m 10
{1.8—2.3 kgf·m, 12.6—16.9 ft·lbf}
End Of Sie
11
12 7 3 2 6
B3E0110E122
MECHANICAL
CYLINDER HEAD (I) ASSEMBLY
E5U011002000E10
42—48 {4.3—4.8,
31.0—35.4} 8 1
SST 7
8.0—11.5 N·m {81.6—117.2
6 kgf·cm, 70.9—101.7 in·lbf}
5
01–10
R 3
SST
R
56—60 {5.8—6.1,
8 41.3—44.2}
4
42—48 {4.3—4.8, 31.0—35.4}

B3E0110E130
1 Water outlet 5 Valve spring

2 EGR pipe 6 Upper valve spring seat
3 Valve seal 7 Valve keeper
(See 01–10–35 Valve Seal Assembly Note) (See 01–10–35 Valve Keeper Assembly Note)
4 Valve 8 Engine hanger
Valve Seal Assembly Note

1. Press the valve seal onto the valve guide by hand.
2. Lightly tap the SST using a plastic hammer.
49 T032 302
VALVE
SEAL
B3E0110E123
Valve Keeper Assembly Note

1. Install the valve keeper using the SSTs.
End Of Sie
49 0636 100B
49 B012 0A2
B3E0110E124
MECHANICAL
CYLINDER HEAD (II) ASSEMBLY
E5U011002000E11
1. Assemble in the order indicated in the table.
5.0—9.0 N·m
{51.0—91.7 kgf·cm,
44.3—79.5 in·lbf}+
14—17
{1.43—1.73,
10.4—12.5}
WITH VARIABLE VALVE TIMING MECHANISM
5.0—9.0 N·m
8.0—11.5 N·m {51.0—91.7 kgf·cm, 6
{81.5—117 kgf·cm 44.3—79.5 in·lbf}+
70.8—101in·lbf} 14—17
{1.43—1.73, 5 3—11
8 10.4—12.5} {30.6—112 kgf·cm,
26.6—97.3 in·lbf}+
13—17 {1.4—1.7, 9.6—12.5}+
43—47 {4.4—4.7, 31.8—34.6}+
7 88°—92°+
R * 88°—92°
3
6 SST
4
5 2
R * R *
1 R
*: IF WASHER IS NOT INSTALLED TO THE ENGINE, INSTALL A NEW WASHER.

E5U110ZECL02
.
1 Cylinder head gasket 6 Camshaft cap
2 Cylinder head 7 Camshaft sprocket, variable valve timing actuator
3 Cylinder head bolt (See 01–10–37 Camshaft Sprocket, Variable Valve
(See 01–10–37 Cylinder Head Bolt Assembly Note) Timing Actuator Assembly Note)
4 Tappet 8 Oil control valve (OCV) (With variable valve timing
mechanism)
5 Camshaft
(See 01–10–37 Camshaft Assembly Note)
01–10–36 GETtheMANUALS.org Revised 12/2005 (Ref. No. R145/05)

MECHANICAL
Cylinder Head Bolt Assembly Note
1. Tighten the cylinder head bolts in the order
indicated in the figure in 5 steps using the SST 8 4 1 5 9
(49 D032 316).
Tightening torque
(1) 3—11 N·m
{30.6—112 kgf·cm, 26.6—97.3 in·lbf} 01–10
(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} 7 3 2 6 10
(4) 88°—92°
C3U0110E054
(5) 88°—92°
Camshaft Assembly Note

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
5 6 1 2 3 4 7 8
two steps. 9
Tightening torque
(1) 5.0—9.0 N·m 10
{51.0—91.7 kgf·cm, 44.3—79.5 in·lbf} 20
(2) 14—17 N·m
{1.43—1.73 kgf·m, 10.4—12.5 ft·lbf}
19
15 16 11 12 13 14 17 18
B3E0110E098
Camshaft Sprocket, Variable Valve Timing Actuator Assembly Note

1. Temporarily tighten the camshaft sprocket or variable valve timing actuator installation bolts by hand until the
timing chain is installed.
2. Fully tighten the camshaft sprocket or variable valve timing actuator installation bolts after timing chain
installation.
End Of Sie
MECHANICAL
TIMING CHAIN ASSEMBLY
E5U011002000E12
8.0—11.5 N·m 20
{81.6—117.2 kgf·cm, A
70.9—101.7 in·lbf} 18
40—55 19
{4.1—5.6,
SEALANT
12
29.6—40.5} R
6
14
OIL
R
20—30 SST R
{2.1—3.0,
14.8—22.1} 13
16
SEALANT
15
WITHOUT
A/C
17 SST R 20—30
SEALANT
96—104 {2.1—3.0,
{9.8—10.6, 14.8—22.1}
70.9—76.7}+
87°—93° 40—55 10 11
{4.1—5.6, 69—75 {7.1—7.6, 50.9—55.3}
29.6—40.5} SST WITH VARIABLE VALVE TIMING
7 MECHANISM
A SEALANT
A
1
A : 8.0—10.5 N·m 9
{81.6—107.1 kgf·cm,
70.9—92.9 in·lbf}
3 SEALANT
8 5 SST
4 20—30 11 69—75 {7.1—7.6, 50.9—55.3}
2 {2.1—3.0,
14.8—22.1} N·m {kgf·m, ft·lbf}
E5U110ZE7S05
1 Crankshaft sprocket 12 Engine front cover

2 Oil pump chain (See 01–10–41 Engine Front Cover Assembly
Note.)
3 Oil pump sprocket
(See 01–10–39 Oil Pump Sprocket Assembly Note.) 13 Front oil seal
(See 01–10–40 Front Oil Seal Assembly Note.)
4 Oil pump chain guide
14 Drive belt idler pulley (Without stretch-type A/C drive
5 Oil pump chain tensioner belt)
6 Seal (With variable valve timing mechanism) 15 Water pump pulley
7 Timing chain 16 Crankshaft pulley
(See 01–10–39 Timing Chain Assembly Note.)
17 Crankshaft pulley lock bolt
8 Chain guide (See 01–10–41 Crankshaft Pulley Lock Bolt
9 Tensioner arm Assembly Note.)
10 Chain tensioner 18 Cylinder head cover
11 Camshaft sprocket, variable valve timing actuator (See 01–10–42 Cylinder Head Cover Assembly
(See 01–10–40 Camshaft Sprocket, Variable Valve Note)
Timing Actuator Assembly Note.) 19 Spark plug
20 Dipstick (if equipped)
MECHANICAL
Oil Pump Sprocket Assembly Note
1. Hold the oil pump sprocket using the SST.
01–10
49 G032 354
B3E0110E125
Timing Chain Assembly Note

1. Install the SST to the camshaft, then align the No.
1 camshaft position with the TDC. 303-465
2. Remove the cylinder block lower blind plug. (49 UN30 3465)
C3U0110E052

5. Install the timing chain.
303-507
D3U110ZE4007
6. Install the chain tensioner and remove the

retaining wire.
B3E0110E126
MECHANICAL
Camshaft Sprocket, Variable Valve Timing Actuator Assembly Note
1. Hold the camshaft using a suitable wrench on the cast hexagon as shown in the figure.
2. Tighten the camshaft sprocket lock bolt.
Tightening torque
69—75 N·m {7.1—7.6 kgf·m, 50.9—55.3
ft·lbf}
B3E0110E095
Front Oil Seal Assembly Note

1. Apply clean engine oil to the oil seal.
2. Push the oil seal slightly in by hand.
3. Compress the oil seal using the SST and a
hammer.
49 H010 401
B3E0110E127
HAMMER ENGINE FRONT COVER

0—0.5 mm
{0—0.019 in}
49 H010 401
FRONT OIL SEAL
E5U110ZE7S09
MECHANICAL
Engine Front Cover Assembly Note
1. Apply silicone sealant to the engine front cover as
shown in the figure. B
Caution
• Install the cylinder head cover within 10
min of applying the silicone sealant.
• Silicone sealant is not need in area C as 01–10
indicated below due to an existing. (With
A
variable valve timing mechanism)
• Make sure that there is no oil or dust on C B
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}
B3E0110E129
2. Install the cylinder head cover bolts in the order

as shown in the figure. 20 21 22
Bolt No. Tightening torque N·m {kgf·m, ft·lbf} 18
1—18 8.0—11.5 N·m
{81.6—117.2 kgf·cm, 70.9—101.7 in·lbf} 17
19—22 40—55 {4.1—5.6, 29.6—40.5} 11
10
7 8
4
3 1
5
2
19
6
9 12
13
16
15 14
B3E0110E062
Crankshaft Pulley Lock Bolt Assembly Note

1. Install the SST to the camshaft as shown in the
figure. 303-465
(49 UN30 3465)
C3U0110E066
MECHANICAL
2. Install the M6 × 1.0 bolt in by hand.
BOLT
B3E0110E063
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). 49 E011 1A0
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 × 1.0 bolt.

7. Remove the SST from the camshaft.
E5U110ZE7S11
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
18—22 N·m {1.9—2.2 kgf·m, 13.3—16.2 ft·lbf}
Cylinder Head Cover Assembly Note

1. Apply silicone sealant to the mating faces as
shown in the figure.
Caution SEALANT
• 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} SEALANT
2. Install the cylinder head cover with a new gasket.

B3E0110E064
3. Tighten the bolts in the order shown in the figure.

6 3 7 12
11
Tightening torque
8.0 —10.5 N·m 10 2 1
{81.6—107.1 kgf·cm, 70.9—92.9 in·lbf}
End Of Sie 13
14
9
5 4 8
B3E0110W050
TECHNICAL DATA
01–50 TECHNICAL DATA
ENGINE TECHNICAL DATA . . . . . . . . . . 01–50–1
End of Toc
ENGINE TECHNICAL DATA
E5U015000000E01
Item Specification
01–50
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}
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}
TECHNICAL DATA
Item Specification
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}
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}
Cylinder head bolt (Without washer)
Standard: 145.2—145.8 {5.72—5.74}
Maximum: 146.5 {5.77}
Bolt length (mm {in})
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}
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}
End Of Sie
SERVICE TOOLS
01–60 SERVICE TOOLS
ENGINE SST . . . . . . . . . . . . . . . . . . . . . . 01–60–1
End of Toc
ENGINE SST
E5U016002000E01
1: Mazda SST number 01–60
2: Global SST number
Example
1:49 UN20 5072
2:205–072
Holder
1: – 1:49 E011 1A0 1:49 UN30 3465

2:303–507 2: – 2: 303–465
Crankshaft TDC Ring gear brake Camshaft

setting peg set Alignment
timing Tool
1:49 G032 354 1:49 B012 015 1:49 0636 100B

2: – 2: – 2: –
Adjusting Valve guide Valve spring

wrench installer lifter arm
1:49 B012 0A2 1:49 L010 1A0 1:49 H010 401

2: – 2: – 2: –
Pivot Engine hanger Oil seal installer

set
1:49 0107 680A 1:49 T032 302 1:49 S120 170

2: – 2: – 2: –
Engine stand Bearing installer Valve seal

remover
1:49 L012 0A0B 1:49 UN30 3328 1:49 D032 316

2: – 2: 303-328 2: –
Valve seal and Rear oil seal Protractor

valve guide replacer
installer set
SERVICE TOOLS
1:49 G011 201
2: –
Attachment
— —
End Of Sie

MAZDA 2,0 and 2,3 L3 LF Engines SM

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Engine CONTENTS

Workshop Title Section

Manual GENERAL INFORMATION 00

L3 © 2005 Mazda Motor Corporation

This manual explains the service points for

In order to do these procedures safely,

All the contents of this manual, including

Mazda Motor Corporation reserves the right

All rights reserved. No part of this book may

Mazda Motor Corporation

Toc of SCT INFORMATION . . . . 00-00

49 H002 671 SHOWS TIGHTENING

INSTALL THE PARTS BY SHOWS APPLICATION

Apply petroleum Appropriate

Upper and lower limits

Electric current A (ampere)

Positive pressure kgf/cm2 (kilogram force per square

Conversion to SI Units (Système International d'Unités)

Upper and Lower Limits

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

Special Service Tools

Inspection During Removal, Disassembly

or equivalent adds to the torque wrench.

Recalculate the torque by using the following

formulas. Choose the formula that applies to you.

Torque Unit Formula

in·lbf in·lbf × [L/(L+A)]

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

• Connectors can be disconnected by pressing or

• Inspect the terminals of waterproof connectors

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

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

5. Tighten the SSTs (bolts and nuts) to affix the

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

WITH VARIABLE VALVE TIMING

1 Oil level gauge (if equipped) 10 Chain tensioner

Front Oil Seal Disassembly Note

Chain Tensioner Disassembly Note

Oil Pump Sprocket Disassembly Note

WITH VARIABLE VALVE TIMING MECHANISM

*: IF WASHER IS NOT INSTALLED TO THE ENGINE, INSTALL A NEW WASHER.

1 Camshaft sprocket lock bolt, variable valve timing 4 Camshaft cap

01–10–6 GETtheMANUALS.org Revised 12/2005 (Ref. No. R145/05)

Camshaft Cap Disassembly Note

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

Tappet Disassembly Note

CYLINDER HEAD (II) DISASSEMBLY

1 Engine hanger 5 Valve

Valve Keeper Disassembly Note

VALVE SEAL 01–10

CYLINDER BLOCK (I) DISASSEMBLY

12 8 WITHOUT OIL COOLER

1 Flywheel (MTX), Drive plate (ATX) (See 01–10–10 7 Knock sensor

CYLINDER BLOCK (II) DISASSEMBLY

1 Balancer unit 7 Upper connecting rod bearing

Cylinder head gasket contact surface

4. Measure the manifold contact surface distortion

Manifold contact surfaces distortion (Maximum)

Manifold contact surfaces distortion (Maximum grinding)