Mazda SKYACTIV-G 2.5 Workshop Manual

Page 1

Engine

CONTENTS

Workshop Manual SKYACTIV-G 2.5

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.

Title Section

GENERAL INFORMATION 00

ENGINE

PRINTED IN U.S.A., DECEMBER 2012 Form No. 1A36–1U–12L Part No. 9999–95–EWPY–14

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

Page 2

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WARNING

Servicing a vehicle can be dangerous. If you have not received service-related training, the risks of injury, property damage, and failure of servicing increase. The recommended servicing procedures for the vehicle in this workshop manual were developed with Mazda-trained technicians in mind. This manual may be useful to non-Mazda trained technicians, but a technician with our service-related training and experience will be at less risk when performing service operations. However, all users of this manual are expected to at least know general safety procedures.

This manual contains "Warnings" and "Cautions" applicable to risks not normally encountered in a general technician's experience. They should be followed to reduce the risk of injury and the risk that improper service or repair may damage the vehicle or render it unsafe. It is also important to understand that the "Warnings" and "Cautions" are not exhaustive. It is impossible to warn of all the hazardous consequences that might result from failure to follow the procedures.

The procedures recommended and described in this manual are effective methods of performing service and repair. Some require tools specifically designed for a specific purpose. Persons using procedures and tools which are not recommended by Mazda Motor Corporation must satisfy themselves thoroughly that neither personal safety nor safety of the vehicle will be jeopardized.

The contents of this manual, including drawings and specifications, are the latest available at the time of printing, and reserves the right to change the vehicle designs and alter the contents of this manual without notice and without incurring obligation.

Parts should be replaced with genuine Mazda replacement parts or with parts which match the quality of genuine Mazda replacement parts. Persons using replacement parts of lesser quality than that of genuine Mazda replacement parts must satisfy themselves thoroughly that neither personal safety nor safety of the vehicle will be jeopardized.

Mazda Motor Corporation is not responsible for any problems which may arise from the use of this manual. The cause of such problems includes but is not limited to insufficient service-related training, use of improper tools, use of replacement parts of lesser quality than that of genuine Mazda replacement parts, or not being aware of any revision of this manual.

Mazda Motor Corporation

Page 4

GENERAL INFORMATION

Toc of SC T

GENERAL INFORMATION . . . .00-00

Toc of SC T

00-00 GENERAL INFORMATION

SECTION

00-00

HOW TO USE THIS MANUAL . . . . . . . . . 00-00–1

Range of Topics . . . . . . . . . . . . . . . . . . 00-00–1

Service Procedure . . . . . . . . . . . . . . . . 00-00–2

Symbols . . . . . . . . . . . . . . . . . . . . . . . . 00-00–4

Advisory Messages. . . . . . . . . . . . . . . . 00-00–4

UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-00–5

Conversion From SI Units (Système

International d'Unités) . . . . . . . . . . . . . 00-00–5

Number Of Digits For

Converted Values . . . . . . . . . . . . . . . . 00-00–5

Converted Value Rounding Off And

Rounding Up/down . . . . . . . . . . . . . . . 00-00–5

ABBREVIATIONS. . . . . . . . . . . . . . . . . . . 00-00–6

FUNDAMENTAL PROCEDURES. . . . . . . 00-00–6

End of Toc

WM: GENERAL INFORMATION

HOW TO USE THIS MANUAL

Range of Topics

• This manual contains procedures for performing all required service operations. The procedures are divided into the following basic operations:

— Removal/Installation — Disassembly/Assembly — Replacement — Inspection — Adjustment

• Simple operations which can be performed easily just by looking at the actual unit (i.e., removal/installation of parts, cleaning of parts, and visual inspection) have been omitted.

Preparation of Tools and Measuring

Equipment . . . . . . . . . . . . . . . . . . . . . 00-00–6

Special Service Tools . . . . . . . . . . . . . . 00-00–6

Disassembly. . . . . . . . . . . . . . . . . . . . . 00-00–6

Inspection During Removal,

Disassembly. . . . . . . . . . . . . . . . . . . . 00-00–7

Arrangement of Parts . . . . . . . . . . . . . . 00-00–7

Cleaning of Parts . . . . . . . . . . . . . . . . . 00-00–7

Reassembly . . . . . . . . . . . . . . . . . . . . . 00-00–7

Adjustment . . . . . . . . . . . . . . . . . . . . . . 00-00–8

Rubber Parts and Tubing . . . . . . . . . . . 00-00–8

Torque Formulas . . . . . . . . . . . . . . . . . 00-00–8

Vise . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-00–9

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00-00–1

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GENERAL INFORMATION

Service Procedure Inspection, adjustment

• Inspection and adjustment procedures are divided into steps. Important points regarding the location and contents of the procedures are explained in detail and shown in the illustrations.

Fluid Pressure Inspection

1. Assemble the SSTs as shown in the figure.

49 1232 670A

SHOWS PROCEDURE ORDER FOR SERVICE

Tightening torque

39—49 N·m {4.0—5.0 kgf·m, 29—36 ft·lbf}

49 H002 671

Caution

49 H032 322

Connect the gauge set from under the vehicle to prevent contact with the drive belt and the cooling fan.

SHOWS TIGHTENING TORQUE SPECIFICATIONS

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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 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.

00-00–2

Page 6

GENERAL INFORMATION

GREASE

Procedure

"Removal/Installation" Portion

"Inspection After Installation" Portion

INSTALL THE PARTS BY PERFORMING STEPS

—

1—3 IN REVERSE ORDER

SHOWS THERE ARE REFERRAL NOTES FOR SERVICE

LOWER TRAILING LINK, UPPER TRAILING LINK REMOVAL/INSTALLATION

1. Jack up the rear of the vehicle and suppor t it with safety stands.

2. Remove the undercover. (See 01-10-4 Undercover Removal)

3. Remove in the order indicated in the table.

4. Install in the reverse order of removal.

5. Inspect the rear wheel alignment and adjust it if necessary.

SHOWS PROCEDURE ORDER FOR SERVICE

44—60 {4.4—6.2, 32—44}

SHOWS TIGHTENING TORQUE SPECIFICATIONS

SST

94—116 {9.5—11.9, 69—86}

Split pin

Nut

Lower trailing link ball joint

(See 02-14-5 Lower Trailing Link Ball Joint Removal Note) Bolt

Lower trailing link

Dust boot (lower trailing link)

GREASE

7 8 Nut 9 Upper trailing link ball joint

10 11 12

SHOWS SERVICE ITEM (S)

INDICATES ANY RELEVANT REFERENCES WHICH NEED TO BE FOLLOWED DURING INSTALLATION

SHOWS SPECIAL

SST

43—56 {4.3—5.8, 32—41}

SERVICE TOOL (SST) FOR SERVICE OPERATION

GREASE

SHOWS APPLICATION POINTS OF GREASE, ETC.

SHOWS NON-REUSEABLE PARTS

SHOWS DETAILS

118—156 {12.0—16.0, 87—115}

N·m {kgf·m, ft·lbf}

Split pin

(See 02-14-5 Upper Trailing Link Ball Joint Removal Note)

Nut Upper trailing link

Dust boot (upper trailing link)

00-00

SHOWS TIGHTENING TORQUE UNITS

Lower Trailing Link Ball Joint, Upper Trailing Link Ball Joint Removal Note

Remove the ball joint using the SSTs.

SHOWS REFERRAL NOTES FOR SERVICE

49 T028 304

49 T028 305

UPPER TRAILING LINK

LOWER TRAILING LINK

SHOWS SPECIAL SERVICE TOOL (SST) NO.

KNUCKLE

49 T028 303

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00-00–3

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GENERAL INFORMATION

OIL

BRAKE FLUID

ATF

GREASE

SEALANT

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

OIL

BRAKE FLUID

ATF

GREASE

SEALANT

Apply oil New appropriate engine oil or gear oil

Apply brake fluid New appropriate brake fluid

Apply automatic transaxle/ transmission fluid

New appropriate automatic transaxle/ transmission fluid

Apply grease Appropriate grease

Apply sealant

Apply petroleum jelly

Appropriate sealant

Appropriate petroleum jelly

Replace part O-ring, gasket, etc.

SST

Use SST or equivalent

Appropriate tools

Advisory Messages

• You will find several Warnings, Cautions, Notes, Specifications and Upper and Lower Limits in this

manual.

Warning

• A Warning indicates a situation in which serious injury or death could result if the warning is ignored.

Caution

• A Caution indicates a situation in which damage to the vehicle or parts could result if the caution is ignored.

Note

• A Note provides added information that will help you to complete a particular procedure.

Specification

• The values indicate the allowable range when performing inspections or adjustments.

Upper and lower limits

• The values indicate the upper and lower limits that must not be exceeded when performing inspections or adjustments.

End Of Sie

00-00–4

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GENERAL INFORMATION

UNITS

Electric current A (ampere) Electric power W (watt) Electric resistance ohm Electric voltage V (volt)

Length

Negative pressure

Positive pressure

Number of revolutions rpm (revolutions per minute)

To r qu e

Volum e

Weight

mm (millimeter) in (inch) kPa (kilo pascal) mmHg (millimeters of mercury) inHg (inches of mercury) kPa (kilo pascal)

kgf/cm psi (pounds per square inch)

N·m (Newton meter) kgf·m (kilogram force meter) 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) ml (milliliter) cc (cubic centimeter) cu in (cubic inch) fl oz (fluid ounce) g (gram) oz (ounce)

(kilogram force per square centimeter)

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00-00

Conversion From 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.

Number Of Digits For Converted Values

• The number digits for converted values is the same as the number of significant figures

of the SI unit.

• For the torque value, the number of significant figures is, in principle, is 2 digits, in consideration of market practicalities. However, if the number of decimal places at the upper and lower limits of the converted value differs, the one with least number of decimal places is used. In addition, if the integer part is 3 digits or more, the integer part becomes the significant number of figures.

*1 : The number of significant figures is the number of digits from the left-most non-zero digit to the right-most digit

including 0. (Example: 0.12 is 2 digits, 41.0 is 3 digits)

Converted Value Rounding Off And Rounding Up/down

• If there is no tolerance in the SI unit value, after conversion, rounding off is to within the number of significant digits.

• If there is tolerance in the SI unit value and the figure after conversion indicates the upper limit, the number of digits is rounded down to within the number of significant figures. If it indicates the lower limit, they are rounded up to within the number of significant figures.

• Even if the SI unit value is the same, the converted value may differ based on whether that value is the upper or lower limit.

End Of Sie

00-00–5

Page 9

GENERAL INFORMATION

ABBREVIATIONS

ATX Automatic Transaxle EX Exhaust HLA Hydraulic Lash Adjuster IN Intake MTX Manual Transaxle OCV Oil Control Valve TDC Top Dead Center SST Special Service Tool

End Of Sie

GAIHAN: -

FUNDAMENTAL PROCEDURES

Preparation of Tools and Measuring Equipment

• Be sure that all necessary tools and measuring equipment are available before starting any work.

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Special Service Tools

• Use special service tools or equivalent when they are required.

Disassembly

• If the disassembly procedure is complex, requiring many parts to be disassembled, all parts should be marked in a place that will not affect their performance or external appearance and identified so that reassembly can be performed easily and efficiently.

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49 SE01 310

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00-00–6

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Page 10

GENERAL INFORMATION

Inspection During Removal, Disassembly

• When removed, each part should be carefully inspected for malfunction, deformation, damage and other problems.

Arrangement of Parts

• All disassembled parts should be carefully arranged for reassembly.

• Be sure to separate or otherwise identify the parts to be replaced from those that will be reused.

00-00

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Cleaning of Parts

• All parts to be reused should be carefully and thoroughly cleaned in the appropriate method.

Warning

• Using compressed air can cause dirt and other particles to fly out causing injury to the eyes. Wear protective eye wear whenever using compressed air.

Reassembly

• Standard values, such as torques and certain adjustments, must be strictly observed in the reassembly of all parts.

• If removed, the following parts should be replaced with new ones:

— Oil seals — Gaskets — O-rings — Lockwashers — Cotter pins — Nylon nuts

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Page 11

• 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.

Adjustment

• Use suitable gauges and testers when making adjustments.

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Rubber Parts and Tubing

• Prevent gasoline or oil from getting on rubber parts or tubing.

Torque Formulas

• When using a torque wrench-SST or equivalent combination, the written torque must be recalculated due to the extra length that the SST or equivalent adds to the torque wrench. Recalculate the torque by using the following formulas. Choose the formula that applies to you.

Torque Unit Formula

N·m N·m × [L/(L+A)]

kgf·m kgf·m × [L/(L+A)]

kgf·cm kgf·cm × [L/(L+A)]

ft·lbf ft·lbf × [L/(L+A)]

in·lbf in·lbf × [L/(L+A)]

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SST

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

Page 12

GENERAL INFORMATION

Vise

• When using a vise, put protective plates in the jaws of the vise to prevent damage to parts.

End Of Sie

00-00

PROTECTIVE PLATES

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00-00–9

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Page 14

ENGINE

Toc of SC T

MECHANICAL. . . . . . . . . . . . . .01-10

TECHNICAL DATA . . . . . . . . . . 01-50

Toc of SC T

01-10 MECHANICAL

SECTION

01-10

SERVICE TOOLS . . . . . . . . . . . 01-60

ELECTRIC VARIABLE VALVE TIMING

MOTOR/DRIVER INSPECTION . . . . . . . 01-10–2

HYDRAULIC VARIABLE VALVE TIMING

ACTUATOR INSPECTION . . . . . . . . . . . 01-10–3

ELECTRIC VARIABLE VALVE TIMING

ACTUATOR INSPECTION . . . . . . . . . . . 01-10–3

OIL CONTROL VALVE (OCV)

INSPECTION . . . . . . . . . . . . . . . . . . . . . 01-10–4

Coil Resistance Inspection . . . . . . . . . . 01-10–4

Spool Valve Operation Inspection . . . . . 01-10–4

HYDRAULIC LASH ADJUSTER (HLA)

INSPECTION . . . . . . . . . . . . . . . . . . . . . 01-10–5

ROCKER ARM INSPECTION. . . . . . . . . . 01-10–5

ENGINE OVERHAUL SERVICE

WARNING. . . . . . . . . . . . . . . . . . . . . . . . 01-10–5

ENGINE MOUNTING/DISMOUNTING . . . 01-10–6

Mounting . . . . . . . . . . . . . . . . . . . . . . . . 01-10–6

Dismounting . . . . . . . . . . . . . . . . . . . . . 01-10–6

TIMING CHAIN DISASSEMBLY. . . . . . . . 01-10–7

Water Pump Pulley

Disassembly Note . . . . . . . . . . . . . . . . 01-10–9

Crankshaft Pulley Lock Bolt

Disassembly Note . . . . . . . . . . . . . . . . 01-10–10

Oil Pan Disassembly Note. . . . . . . . . . . 01-10–10

Engine Front Cover

Disassembly Note . . . . . . . . . . . . . . . . 01-10–10

Front Oil Seal Disassembly Note . . . . . 01-10–11

Chain Tensioner Disassembly Note . . . 01-10–11

Oil Pump Chain Disassembly Note. . . . 01-10–12

CYLINDER HEAD DISASSEMBLY (I) . . . 01-10–14

Electric Variable Valve Timing Actuator,

Hydraulic Variable Valve Timing

Actuator Disassembly Note. . . . . . . . . 01-10–16

Camshaft Cap Disassembly Note . . . . . 01-10–16

Rocker Arm Disassembly Note . . . . . . . 01-10–16

HLA Disassembly Note . . . . . . . . . . . . . 01-10–16

Cylinder Head Disassembly Note . . . . . 01-10–16

CYLINDER HEAD

DISASSEMBLY (II) . . . . . . . . . . . . . . . . . 01-10–17

Valve Keeper Disassembly Note . . . . . . 01-10–18

Valve Seal Disassembly Note . . . . . . . . 01-10–18

CYLINDER BLOCK

DISASSEMBLY (I) . . . . . . . . . . . . . . . . . 01-10–19

Dual-mass Flywheel (MTX)/ Drive

Plate (ATX) Installation Bolt

Disassembly Note . . . . . . . . . . . . . . . . 01-10–20

Dual-mass Flywheel

Disassembly Note (MTX) . . . . . . . . . . 01-10–21

Rear Oil Seal Disassembly Note . . . . . 01-10–21

CYLINDER BLOCK

DISASSEMBLY (II) . . . . . . . . . . . . . . . . 01-10–22

Pilot Bearing Disassembly Note. . . . . . 01-10–23

Connecting Rod Cap

Disassembly Note . . . . . . . . . . . . . . . 01-10–23

Connecting Rod Bearing

Disassembly Note . . . . . . . . . . . . . . . 01-10–23

Piston, Connecting Rod

Disassembly Note . . . . . . . . . . . . . . . 01-10–23

Snap Ring Disassembly Note. . . . . . . . 01-10–24

Lower Cylinder Block

Disassembly Note . . . . . . . . . . . . . . . 01-10–24

Thrust Bearing And Main Bearing

Disassembly Note . . . . . . . . . . . . . . . 01-10–25

Crankshaft Disassembly Note . . . . . . . 01-10–25

CYLINDER HEAD INSPECTION. . . . . . . 01-10–25

VALVE SEAT INSPECTION/REPAIR. . . . 01-10–26

VALVE, VALVE GUIDE

INSPECTION . . . . . . . . . . . . . . . . . . . . . 01-10–27

VALVE GUIDE REPLACEMENT . . . . . . . 01-10–29

Removal . . . . . . . . . . . . . . . . . . . . . . . . 01-10–29

Installation

VALVE SPRING INSPECTION . . . . . . . . 01-10–29

CAMSHAFT INSPECTION . . . . . . . . . . . 01-10–30

CYLINDER BLOCK INSPECTION . . . . . 01-10–32

OIL JET VALVE INSPECTION . . . . . . . . 01-10–32

PISTON INSPECTION . . . . . . . . . . . . . . . 01-10–32

PISTON RING INSPECTION . . . . . . . . . . 01-10–33

PISTON PIN INSPECTION . . . . . . . . . . . 01-10–34

PISTON AND CONNECTING ROD

INSPECTION . . . . . . . . . . . . . . . . . . . . . 01-10–35

CONNECTING ROD INSPECTION . . . . . 01-10–35

CONNECTING ROD CLEARANCE

INSPECTION . . . . . . . . . . . . . . . . . . . . . 01-10–35

CRANKSHAFT INSPECTION . . . . . . . . . 01-10–36

DUAL-MASS FLYWHEEL

INSPECTION . . . . . . . . . . . . . . . . . . . . . 01-10–37

Inspection Before Removal . . . . . . . . . 01-10–37

Inspection After Removal . . . . . . . . . . . 01-10–38

PILOT BEARING INSPECTION . . . . . . . 01-10–39

BOLT INSPECTION . . . . . . . . . . . . . . . . . 01-10–39

CYLINDER BLOCK ASSEMBLY (I) . . . . 01-10–40

Thrust Bearing And Main Bearing

Assembly Note . . . . . . . . . . . . . . . . . . 01-10–41

Plate Assembly Note . . . . . . . . . . . . . . 01-10–42

Lower Cylinder Block

Assembly Note . . . . . . . . . . . . . . . . . . 01-10–42

. . . . . . . . . . . . . . . . . . . . . . 01-10–29

01-10–1

Page 15

MECHANICAL

Piston Pin Assembly Note. . . . . . . . . . . 01-10–44

Snap Ring Assembly Note . . . . . . . . . . 01-10–44

Piston Ring Assembly Note. . . . . . . . . . 01-10–45

Connecting Rod Bearing

Assembly Note . . . . . . . . . . . . . . . . . . 01-10–46

Piston, Connecting Rod

Assembly Note . . . . . . . . . . . . . . . . . . 01-10–46

Connecting Rod Cap

Assembly Note . . . . . . . . . . . . . . . . . . 01-10–47

Pilot Bearing Assembly Note . . . . . . . . 01-10–47

CYLINDER BLOCK ASSEMBLY (II) . . . . 01-10–48

Balancer Unit Assembly Note . . . . . . . . 01-10–49

Oil Pump Assembly Note . . . . . . . . . . . 01-10–50

Water Pump Assembly Note . . . . . . . . . 01-10–51

Rear Oil Seal Assembly Note . . . . . . . . 01-10–52

End Plate Assembly Note . . . . . . . . . . . 01-10–53

Dual-mass Flywheel (MTX)/ Drive

Plate (ATX) Installation Bolt

Assembly Note . . . . . . . . . . . . . . . . . . 01-10–53

Knock Sensor (KS) Assembly Note . . . 01-10–54

CYLINDER HEAD ASSEMBLY (I) . . . . . . 01-10–55

Valve Seal Assembly Note . . . . . . . . . . 01-10–56

Valve Spring Assembly Note. . . . . . . . . 01-10–56

Valve Keeper Assembly Note . . . . . . . . 01-10–57

Thermostat Assembly Note . . . . . . . . . 01-10–58

CYLINDER HEAD ASSEMBLY (II) . . . . . 01-10–59

Cylinder Head Assembly Note . . . . . . . 01-10–61

Water Inlet Pipe Assembly Note. . . . . . 01-10–62

HLA Assembly Note . . . . . . . . . . . . . . . 01-10–63

Rocker Arm Assembly Note . . . . . . . . . 01-10–63

Camshaft Assembly Note. . . . . . . . . . . 01-10–64

Electric Variable Valve Timing Actuator,

Hydraulic Variable Valve Timing

Actuator Assembly Note. . . . . . . . . . . 01-10–66

TIMING CHAIN ASSEMBLY . . . . . . . . . . 01-10–67

Oil Pump Chain Assembly Note. . . . . . 01-10–69

Timing Chain Assembly Note. . . . . . . . 01-10–71

Engine Front Cover Assembly Note . . . 01-10–74

Oil Pan Assembly Note . . . . . . . . . . . . 01-10–77

Electric Variable Valve Timing Motor/

Driver Assembly Note. . . . . . . . . . . . . 01-10–79

Front Oil Seal Assembly Note . . . . . . . 01-10–80

Crankshaft Pulley Lock Bolt

Assembly Note . . . . . . . . . . . . . . . . . . 01-10–80

Water Pump Pulley Assembly Note . . . 01-10–81

Oil Shower Pipe Assembly Note . . . . . 01-10–81

Cylinder Head Cover

Assembly Note . . . . . . . . . . . . . . . . . . 01-10–82

Water Outlet Assembly Note. . . . . . . . . 01-10–57

End of Toc

WM: -

ELECTRIC VARIABLE VALVE TIMING MOTOR/DRIVER INSPECTION

id011000828100

Caution

• Do not disassemble the electric variable valve timing motor/driver because it is a precision unit.

• Do not apply excessive force when rotating the electric variable valve timing motor joint. If it is

rotated with excessive force, the electric variable valve timing motor could be damaged.

1. Rotate the electric variable valve timing motor joint to the left and right by your fingers and verify that it rotates

smoothly in 15° increments.

Note

• Rotate the joint area smoothly using only the tips of your fingers.

• The electric variable valve timing motor joint moves in 15° increments, and if the joint is moved 24 times, it

rotates one full rotation.

• If it does not rotate smoothly, replace the electric variable valve timing motor/driver.

End Of Sie

WM: VARIABLE VALVE TIMING ACTUATOR

JOINT

ELECTRIC VARIABLE VALVE TIMING MOTOR

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01-10–2

Page 16

MECHANICAL

HYDRAULIC VARIABLE VALVE TIMING ACTUATOR INSPECTION

Caution

• Do not disassemble the hydraulic variable valve timing actuator because it is a precision unit.

1. Verify that the notch of the rotor and projection of the cover on the hydraulic variable valve timing

PROJECTION

actuator are aligned and fitted.

• If the projection and notch are not aligned, rotate the rotor (camshaft installation) until a click is heard and verify that they are aligned

COVER

and fixed in place. — If the projection and notch are not aligned

or the rotor and cover are not secured even if their projection and notch are aligned, replace the hydraulic variable valve timing actuator.

End Of Sie

ELECTRIC VARIABLE VALVE TIMING ACTUATOR INSPECTION

Caution

• Do not disassemble the electric variable valve timing actuator because it is a precision unit.

1. Rotate the eccentric shaft of the electric variable valve timing actuator to the left and right by hand and verify that it rotates smoothly.

• If it does not rotate smoothly, replace the electric variable valve timing actuator.

JOINT GROOVE

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01-10

NOTCH

ROTOR

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id011000555500

Note

ECCENTRIC SHAFT

• Hook a finger onto the joint groove of the eccentric shaft to rotate the shaft easily.

• The eccentric shaft stops rotating at the maximum retard position when it is rotated counterclockwise as viewed from the front, and at the maximum advance position when rotated clockwise.

• The eccentric shaft rotates 15.8 turns from the maximum retard position to the maximum advance position.

End Of Sie

WM: OIL CONTROL VALVE (OCV)

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01-10–3

Page 17

MECHANICAL

OIL CONTROL VALVE (OCV) INSPECTION

Coil Resistance Inspection

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

OCV coil resistance

6.9—7.5 ohms [20°C {68°F}]

• If it is not within the specification, replace the OCV.

Spool Valve Operation Inspection

1. Verify that the spool valve in the OCV is in the maximum valve timing advance position as indicated in the figure.

• If there is any malfunction, replace the OCV.

Note

• When applying battery positive voltage between the OCV terminals, the connection can be either of the following: — Positive battery cable to terminal A,

negative battery cable to terminal B

— Positive battery cable to terminal B,

negative battery cable to terminal A

id011000801400

OIL CONTROL VALVE (OCV)

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SPOOL VALVE (MAXIMUM VALVE TIMING ADVANCE POSITION)

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2. Apply battery positive voltage between the OCV terminals and verify that the spool valve operates and moves to the maximum valve timing retard position.

• If there is any malfunction, replace the OCV.

3. Stop applying battery positive voltage and verify that the spool valve returns to the maximum valve timing advance position.

• If there is any malfunction, replace the OCV.

End Of Sie

WM: HYDRAULIC LASH ADJUSTER (HLA)

OIL CONTROL VALVE (OCV)

VALVE TIMING RETARD

SPOOL VALVE (MAXIMUM VALVE TIMING RETARD POSITION)

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VALVE TIMING ADVANCE

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01-10–4

Page 18

MECHANICAL

HYDRAULIC LASH ADJUSTER (HLA) INSPECTION

1. Visually inspect the HLA surface where it contacts the rocker arm for wear or damage.

• If there is any malfunction, replace the HLA.

End Of Sie

WM: ROCKER ARM

ROCKER ARM INSPECTION

1. Rotate the roller or the rocker arm by hand and verify that rotates smoothly.

• If it does not rotate smoothly, replace the rocker arm.

2. Visually inspect the rocker arm surface where it contacts the HLA and valve stem for wear or damage.

• If there is any malfunction, replace the rocker arm.

End Of Sie

EN: ENGINE COMPLETE

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ROCKER ARM CONTACT SURFACE

01-10

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id011000904800

ROLLER

ENGINE OVERHAUL SERVICE WARNING

Warning

• Continuous exposure to USED engine oil has been shown to cause skin cancer in laboratory mice. Protect your skin by washing with soap and water immediately after performing work.

End Of Sie

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id011000503900

01-10–5

Page 19

MECHANICAL

ENGINE MOUNTING/DISMOUNTING

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Mounting

1. Install the SST (arms) to the three positions as shown in the figure and temporarily tighten the bolts (Part No. 9YA20-1003 or M10 × 1.5 length 90 mm {3.55 in}).

SST INSTALLATION HOLE

ENGINE FRONT

SST INSTALLED

49 L010 102

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2. Install the SSTs (bolts and nuts) to the three positions of the SST (plate) as shown in the figure.

49 L010 101

49 L010 104

3. Install the SST (bolts, nuts and plate) set in Step 2 to the SST (arms) set in Step 1 using the SSTs (hook and nuts).

4. Adjust the bolts so that approx. 20 mm {0.79 in} of thread is exposed from the side of the plate.

5. Adjust the bolts and nuts so that the plate and arms are parallel.

6. Tighten the SSTs (bolts and nuts) to affix the SST firmly.

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

8. Remove the oil drain plug and drain the engine oil.

9. Replace the gasket with a new one and install the oil pan drain plug.

Tightening torque

30—41 N·m {3.1—4.1 kgf·m, 23—30 ft·lbf}

Dismounting

1. Dismount in the reverse order of mounting.

End Of Sie

49 L010 102

49 L010 104

ENGINE

PARALLEL

49 L010 103

49 L010 105

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49 L010 101

49 L010 104

49 L010 105

APPROX. 20 mm {0.79 in}

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01-10–6

Page 20

MECHANICAL

TIMING CHAIN DISASSEMBLY

Caution

• If the camshaft is rotated with the timing chain removed and the piston at the top dead center position, the valve may contact the piston and the engine could be damaged. When rotating the camshaft with the timing chain removed, rotate it after lowering the piston from the top dead center position.

• When rotating the camshaft using a wrench on the cast hexagon, the wrench may contact the rocker arm and damage

CAMSHAFT

WRENCH

CAST HEXAGON

the rocker arm. To prevent damage to the rocker arm when holding the camshaft on the cast hexagon, use a wrench on the rear side of the engine as shown in the figure to secure a clearance between the cam.

ROCKER ARM CONTACT

SECURE CLEARANCE

id011000505500

01-10

ENGINE REAR

Note

• Width at the cast hexagon of the camshaft is 22—24 mm {0.87—0.94 in}.

CAMSHAFT

DOES NOT CONTACT

CAST HEXAGON

22—24 mm {0.87

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—0.94 in}

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01-10–7

Page 21

MECHANICAL

1. Disassemble in the order indicated in the table.

SST

SST SST

1 Dipstick 2 Cylinder head cover 3 Oil shower pipe

01-10–8

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4 Spark plug 5 Water pump pulley

(See 01-10-9 Water Pump Pulley Disassembly Note.)

Page 22

MECHANICAL

6 Crankshaft pulley lock bolt

(See 01-10-10 Crankshaft Pulley Lock Bolt

Disassembly Note.) 7 Crankshaft pulley 8 Electric variable valve timing motor/driver 9Oil pan

(See 01-10-10 Oil Pan Disassembly Note.)

10 Engine front cover

(See 01-10-10 Engine Front Cover Disassembly

Note.)

11 Front oil seal

(See 01-10-11 Front Oil Seal Disassembly Note.)

12 Chain guide (No.1) 13 Chain tensioner

(See 01-10-11 Chain Tensioner Disassembly Note.)

14 Tensioner arm

15 Timing chain 16 Chain guide (No.2) 17 Crankshaft sprocket 18 Oil pump chain tensioner

(See 01-10-12 Oil Pump Chain Disassembly Note.)

19 Balancer shaft sprocket

(See 01-10-12 Oil Pump Chain Disassembly Note.)

20 Oil pump chain

(See 01-10-12 Oil Pump Chain Disassembly Note.)

21 Oil pump driven sprocket

(See 01-10-12 Oil Pump Chain Disassembly Note.) 22 Oil pump chain guide 23 Oil pump drive sprocket 24 Key

Water Pump Pulley Disassembly Note

Caution

• Be careful not to damage the belt groove and surface of the water pump pulley when using tools, otherwise it will cause wear, breakage, abnormal noise of the drive belt (stretch belt), damage to the pulley, and rust.

1. Align the water pump pulley hole with the water pump hole as shown in the figure.

WATER PUMP

HOLEHOLE

01-10

2. Insert an appropriate bolt (length approx. 70 mm {2.8 in}) into the water pump hole as shown in the

figure, and lock the water pump pulley against rotation.

3. Remove the water pump pulley.

4. Remove the bolt used for locking the water pump pulley against rotation.

WATER PUMP PULLEY

am3uuw00008841

WATER PUMP PULLEY

BOLT

am3uuw00008842

01-10–9

Page 23

MECHANICAL

Crankshaft Pulley Lock Bolt Disassembly Note

1. Hold the crankshaft using the SST.

2. Remove the crankshaft pulley lock bolt.

Oil Pan Disassembly Note

1. Remove the oil pan using a separator tool.

49 E011 1A0

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Engine Front Cover Disassembly Note

1. Remove the engine front cover installation bolts.

Using a screwdriver wrapped in a cloth, peel the sealant away a little at a time, and remove the engine front cover.

Caution

• Do not apply excessive force to the screwdriver. Otherwise, the engine front cover could be damaged.

• Be careful not to scratch or damage the seal surface. Otherwise, it could cause oil leakage.

CLOTH

adejjw00003946

CLOTH

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01-10–10

CLOTH

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Page 24

MECHANICAL

Front Oil Seal Disassembly Note

1. Remove the oil seal using a flathead screwdriver with the tip protected by a clean cloth.

Chain Tensioner Disassembly Note

1. While moving the exhaust camshaft back and forth in the direction of the arrow using a wrench on the cast hexagon, press down the link plate of the timing chain tensioner using a precision screwdriver and release the plunger lock.

CLOTH

01-10

FRONT OIL SEAL

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Note

• When moving the exhaust camshaft back and forth, the timing chain pushes the plunger in the chain tensioner making it easier to operate the link plate.

2. Push back the plunger slowly in the direction shown in the figure with the link plate still pushed down.

3. Remove the screwdriver from the link plate with the plunger still pushed down.

4. Release the force slightly from the plunger, and move it back and forth 2—3 mm {0.08—0.11 in}.

bp31je00000104

LINK PLATE

PLUNGER

am3uuw00008854

am3uuw00008855

01-10–11

Page 25

MECHANICAL

5. Insert a wire with an approx. diameter of 1.5 mm {0.059 in} or a paper clip where the link plate hole

and the tensioner body hole overlap to secure the link plate and lock the plunger.

6. Remove the chain tensioner.

WIRE OR PAPER CLIP

LINK PLATE

TENSIONER BODY HOLE

am3uuw00008856

Oil Pump Chain Disassembly Note

1. Hold the crankshaft using the SST.

2. Slightly loosen the balancer shaft sprocket and oil pump driven sprocket installation bolts.

Note

• At this stage, only loosen the installation bolts, do not remove them. Remove the bolts after removing the oil pump chain tensioner.

3. Set a cloth wrapped flathead screwdriver in the gap between the oil pump drive sprocket and the oil pump chain as shown in the figure.

OIL PUMP DRIVE SPROCKET

49 E011 1A0

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OIL PUMP CHAIN TENSIONER

01-10–12

OIL PUMP CHAIN

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Page 26

MECHANICAL

4. Move the screwdriver in the direction of the arrow and press the oil pump chain, and then press on the plunger of the oil pump chain tensioner.

OIL PUMP CHAIN

OIL PUMP DRIVE SPROCKET

OIL PUMP CHAIN TENSIONER

01-10

BEFORE PRESSING AFTER PRESSING

PLUNGER

OIL PUMP CHAIN TENSIONER

5. Insert a wire with an approx. diameter of 1.4 mm {0.055 in} or a paper clip into the body hole of the oil pump chain tensioner with the plunger pressed.

OIL PUMP CHAIN TENSIONER

bpe1ze00000065

Note

• The wire or paper clip secures the plunger, and the tension can be released.

6. Remove the oil pump chain tensioner.

7. Remove the oil pump chain and balancer shaft sprocket as a single unit.

8. Remove the oil pump driven sprocket.

End Of Sie

WIRE OR PAPER CLIP

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01-10–13

Page 27

MECHANICAL

CYLINDER HEAD DISASSEMBLY (I)

Caution

• When rotating the camshaft using a wrench on the cast hexagon, the wrench may contact the rocker arm and damage

CAMSHAFT

WRENCH

CAST HEXAGON

ROCKER ARM CONTACT

SECURE CLEARANCE

id011000500400

ENGINE REAR

Note

• Width at the cast hexagon of the camshaft is 22—24 mm {0.87—0.94 in}.

CAMSHAFT

DOES NOT CONTACT

CAST HEXAGON

22—24 mm {0.87

am3uuw00008837

—0.94 in}

am3uuw00009029

01-10–14

Page 28

MECHANICAL

1. Disassemble in the order indicated in the table.

01-10

WITHOUT OIL COOLER

WATER PUMP

WITH OIL COOLER

1 Electric variable valve timing actuator, hydraulic

variable valve timing actuator (See 01-10-16 Electric Variable Valve Timing Actuator, Hydraulic Variable Valve Timing Actuator

Disassembly Note.) 2OCV 3 Camshaft cap

(See 01-10-16 Camshaft Cap Disassembly Note.) 4 Camshaft

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5 OCV oil filter 6 Rocker arm

(See 01-10-16 Rocker Arm Disassembly Note.)

7HLA

(See 01-10-16 HLA Disassembly Note.) 8 Water inlet pipe 9 Cylinder head

(See 01-10-16 Cylinder Head Disassembly Note.)

10 Cylinder head gasket

01-10–15

Page 29

MECHANICAL

Electric Variable Valve Timing Actuator, Hydraulic Variable Valve Timing Actuator Disassembly Note

1. Hold the camshaft using a wrench on the cast hexagon and loosen the actuator installation bolt.

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Camshaft Cap Disassembly Note

1. Before removing the camshaft cap, Inspect the camshaft end play. (See 01-10-30 CAMSHAFT INSPECTION.)

2. Loosen the camshaft cap installation bolts in two or three passes in the order shown in the figure and remove the camshaft caps.

4 3

Rocker Arm Disassembly Note

1. Keep the rocker arms in the order of removal to enable reassembly in their original positions.

HLA Disassembly Note

1. Keep the HLAs in the order of removal to enable reassembly in their original positions.

Cylinder Head Disassembly Note

1. Loosen the cylinder head installation bolts in two or three passes in the order shown in the figure

and remove them.

End Of Sie

ENGINE FRONT

am3uuw00008985

159

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01-10–16

Page 30

MECHANICAL

CYLINDER HEAD DISASSEMBLY (II)

1. Disassemble in the order indicated in the table.

SST

id011000500500

01-10

1 Thermostat cover 2 Thermostat 3 Water outlet 4 Valve keeper

(See 01-10-18 Valve Keeper Disassembly Note.)

5 Upper valve spring seat

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6Valve spring 7Valve 8 Valve seal

(See 01-10-18 Valve Seal Disassembly Note.)

9 Lower valve spring seat

01-10–17

Page 31

Valve Keeper Disassembly Note

1. Remove the valve keeper using the SSTs.

MECHANICAL

49 B012 0A2A

49 0636 100B

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Valve Seal Disassembly Note

1. Remove the valve seal using the SST or pliers.

End Of Sie

49 S120 170

VALVE SEAL

VALVE GUIDE

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VALVE SEAL

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01-10–18

Page 32

MECHANICAL

CYLINDER BLOCK DISASSEMBLY (I)

Caution

• Do not disassemble the oil pump, water pump and balancer unit because it is a precision unit.

1. Disassemble in the order indicated in the table.

AT X

7 6

MTX

id011000500600

SST

01-10

1 Knock sensor (KS) 2 Oil separator 3 Dual-mass flywheel (MTX)/ drive plate (ATX)

installation bolt (See 01-10-20 Dual-mass Flywheel (MTX)/ Drive

Plate (ATX) Installation Bolt Disassembly Note.) 4 Backing plate (ATX) 5 Dual-mass flywheel (MTX), drive plate (ATX)

(See 01-10-21 Dual-mass Flywheel Disassembly

Note (MTX).)

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6 End plate 7 Rear oil seal

(See 01-10-21 Rear Oil Seal Disassembly Note.) 8 Water pump 9Oil strainer

10 Oil pump 11 Balancer unit

01-10–19

Page 33

MECHANICAL

Dual-mass Flywheel (MTX)/ Drive Plate (ATX) Installation Bolt Disassembly Note Dual-mass flywheel installation bolt (MTX)

1. Hold the crankshaft using the SST (49 E011 1A0).

2. Loosen the bolts uniformly and gradually in the order shown in the figure.

Note

• If the bolt installation holes are not positioned properly, perform the following procedure:

(1) Install the SST (49 S120 710) to the dual-

mass flywheel.

(2) Rotate the dual-mass flywheel (secondary

flywheel side) using the SST (49 S120 710).

(3) When the bolt installation holes are positioned

properly, hold the position and remove one of the bolts.

(4) After removing the bolt, set up the SST (49

G033 102) to lock the dual-mass flywheel (secondary flywheel side) against rotation.

49 E011 1A0

49 S120 710

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am6xuw00005540

Warning

• If all of the bolts are removed without locking the dual-mass flywheel (secondary flywheel side) against rotation, the dual-mass flywheel (primary or secondary flywheel side) may rotate, resulting in injury. Therefore, always set up the SST (49 G033 102).

• When the bolts are removed from the dual-mass flywheel, always cover the bolt holes using tape. If the SST (49 G033 102) is removed while the operator’s finger is inserted in the bolt hole, the dual-mass flywheel may rotate and the operator could be injured.

(5) Remove the remaining bolts.

Drive plate installation bolt (ATX)

1. Hold the crankshaft using the SST.

2. Loosen the bolts uniformly and gradually in the order shown in the figure.

49 G033 102

49 S120 710

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49 E011 1A0

01-10–20

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Page 34

MECHANICAL

Dual-mass Flywheel Disassembly Note (MTX)

Note

• When reusing the dual-mass flywheel, do not remove the SST (49 G033 102) locking the dual-mass

flywheel (secondary flywheel side) against rotation.

Rear Oil Seal Disassembly Note

1. Cut the oil seal lip using a utility knife.

2. Remove the oil seal using a flathead screwdriver with the tip protected by a clean cloth to prevent damage to the oil seal sliding part of the crankshaft.

End Of Sie

01-10

REAR OIL SEAL

CLOTH

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01-10–21

Page 35

MECHANICAL

CYLINDER BLOCK DISASSEMBLY (II)

1. Disassemble in the order indicated in the table.

id011000500700

SST

1 Pilot bearing (MTX)

(See 01-10-23 Pilot Bearing Disassembly Note.)

2 Connecting rod cap

(See 01-10-23 Connecting Rod Cap Disassembly Note.)

3 Lower connecting rod bearing

(See 01-10-23 Connecting Rod Bearing Disassembly Note.)

4 Piston, connecting rod

(See 01-10-23 Piston, Connecting Rod Disassembly Note.)

5 Upper connecting rod bearing

(See 01-10-23 Connecting Rod Bearing Disassembly Note.)

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6 Piston ring 7 Snap ring

(See 01-10-24 Snap Ring Disassembly Note.) 8 Piston pin 9Piston

10 Connecting rod 11 Lower cylinder block

(See 01-10-24 Lower Cylinder Block Disassembly

Note.)

12 Lower main bearing

(See 01-10-25 Thrust Bearing And Main Bearing

Disassembly Note.)

01-10–22

Page 36

MECHANICAL

13 Crankshaft

(See 01-10-25 Crankshaft Disassembly Note.) 14 Plate 15 Upper main bearing

(See 01-10-25 Thrust Bearing And Main Bearing

Disassembly Note.)

16 Thrust bearing

(See 01-10-25 Thrust Bearing And Main Bearing

Disassembly Note.) 17 Oil jet valve 18 Upper cylinder block

Pilot Bearing Disassembly Note

Note

• The pilot bearing does not need to be removed unless you are replacing it.

1. Use the SST to remove the pilot bearing.

49 1285 071

01-10

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Connecting Rod Cap Disassembly Note

1. Before removing the connecting rod cap, inspect the connecting rod side clearance. (See 01-10-35 CONNECTING ROD CLEARANCE INSPECTION.)

2. The removed connecting rod caps are to be kept so that they can be assembled to the same positions and in the direction as before removal.

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Connecting Rod Bearing Disassembly Note

1. The removed connecting rod bearings are to be kept so that they can be assembled to the same positions and in the direction as before removal.

Piston, Connecting Rod Disassembly Note

1. Before removing the piston and connecting rod, remove the carbon in the cylinder.

2. Before removing the piston and connecting rod, inspect the oil clearance at the large end of the connecting rod. (See 01-10-35 CONNECTING ROD CLEARANCE INSPECTION.)

01-10–23

Page 37

MECHANICAL

Snap Ring Disassembly Note

1. Before removing the snap ring, verify that the large end of connecting rod drops under its own weight with no resistance. (See 01-10-35 PISTON AND CONNECTING ROD INSPECTION.)

2. Remove the snap ring using a flathead screwdriver.

SNAP RING

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Lower Cylinder Block Disassembly Note

1. Before removing the lower cylinder block, inspect the crankshaft end play. (See 01-10-36 CRANKSHAFT INSPECTION.)

2. Loosen the lower cylinder block installation bolts B in two or three passes in the order shown in the figure and remove them.

BBBBB

3. Loosen the lower cylinder block installation bolts A in two or three passes in the order shown in the figure and remove them.

ENGINE FRONT

AAAA

BBBBB

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01-10–24

Page 38

MECHANICAL

4. Using a screwdriver wrapped in a cloth, peel the sealant away a little at a time, and remove the

LOWER CYLINDER BLOCK

lower cylinder block.

Caution

• Do not apply excessive force to the screwdriver. Otherwise, the lower cylinder block could be damaged.

• Be careful not to scratch or damage the seal surface. Otherwise, it could cause oil leakage.

CLOTH

bpe2ue00000025

Thrust Bearing And Main Bearing Disassembly Note

1. The removed thrust bearings and main bearings are to be kept so that they can be assembled to the same positions and in the direction as before removal.

Crankshaft Disassembly Note

Caution

• Placing the crankshaft on a disassembly bench will deform or damage it because the plate for the crankshaft position sensor signal detection installed to the crankshaft is larger than the counterweight. Therefore, set wood blocks or similar objects on the both sides of the crankshaft so that the plate does not contact the disassembly bench directly when placing the crankshaft on the bench.

01-10

CLOTH

End Of Sie

CYLINDER HEAD INSPECTION

1. Inspect the cylinder head surface for cracks and other damage using a red dye penetrant.

• If there is a malfunction, replace the cylinder head.

2. Measure the combustion chamber side of the cylinder head for distortion in six directions as shown in the figure using a straight edge and feeler gauge.

• If the distortion exceeds the maximum specification, replace the cylinder head. Do not attempt to repair the cylinder head by milling or grinding.

Maximum distortion, head gasket side of the

cylinder head

0.05 mm {0.002 in}

id011000507100

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01-10–25

Page 39

MECHANICAL

3. Inspect the contact surface of the exhaust manifold and the intake manifold for distortion by measuring as shown in the figure using a straight edge and feeler gauge.

• If the distortion on the intake manifold side exceeds the maximum specification, replace the cylinder head.

• If the distortion on the exhaust manifold side exceeds the maximum specification, grind the surface or replace the cylinder head.

Maximum distortion, manifold side

IN: 0.10 mm {0.0039 in} EX: 0.05 mm {0.002 in}

Maximum cutting length, manifold side

IN: Cutting not authorized EX: 0.20 mm {0.0079 in}

End Of Sie

VALVE SEAT INSPECTION/REPAIR

1. Measure the contact width of the valve face and the valve seat using the valve lapping compound.

• If it is not within the specification, resurface

the valve seat using the 45° valve seat cutter.

Standard valve seat contact width

1.37—1.84 mm {0.0540—0.0724 in}

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id011000501300

SEAT CONTACT WIDTH

Valve seat angle

45°

2. Verify that the area where the valve seat contacts the valve face is centered.

• If the seating position is too high, correct the

valve seat using a 70° (IN) 70° (EX) valve seat cutter and a 45° valve seat cutter.

• If the seating position is too low, correct as follows: — IN: Correct the valve seat using a 20°

valve seat cutter and then using a 45° valve cutter.

— EX: Correct the valve seat using a 45°

valve seat cutter.

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VALVE SEATVALVE SEAT

01-10–26

COMBUSTION CHAMBER

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Page 40

MECHANICAL

3. Inspect the valve seat for sinkage. Measure the protruding length (dimension L) of the valve stem using a valve of standard length.

• If it is not within the specification, replace the cylinder head.

Standard valve seat sinkage amount

(Dimension L)

IN: 48.93—50.17 mm {1.927—1.975 in} EX: 48.87—50.11 mm {1.925—1.972 in}

End Of Sie

VALVE, VALVE GUIDE INSPECTION

1. Measure the valve head margin thickness using a vernier caliper.

• If it is less than the standard specification, replace the valve.

Standard valve head margin thickness

IN: 1.75—1.95 mm {0.0689—0.0767 in} EX: 1.95—2.15 mm {0.0768—0.0846 in}

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

• If it is less than the minimum specification, replace the valve.

IN : 34.0 mm {1.34 in} EX : 29.0 mm {1.14 in}

MARGIN THICKNESS

01-10

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id011000506200

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Standard valve length

IN: 107.00—107.60 mm {4.2127—4.2362 in} EX: 117.09—117.69 mm {4.6099—4.6334 in}

Minimum valve length

IN: 106.78 mm {4.2039 in} EX: 116.87 mm {4.6012 in}.

3. Measure the valve stem diameter of each valve using the micrometer. Measurement positions total six and are in the X and Y directions, at three points (A, B, and C) as shown in the figure.

• If it is less than the minimum specification, replace the valve.

Standard valve stem diameter

IN: 5.470—5.485 mm {0.2154—0.2159 in} EX: 5.465—5.480 mm {0.2152—0.2157 in}

Minimum valve stem diameter

IN: 5.424 mm {0.2135 in} EX: 5.419 mm {0.2133 in}

bez0je00000017

bpe2ue00000084

01-10–27

Page 41

MECHANICAL

4. Measure the inner diameter of each valve guide using the caliper gauge. Measurement positions total six and are in the X and Y directions, at three points (A, B, and C) as shown in the figure.

• If it is not within the specification, replace the valve guide.

Standard valve guide inner diameter

IN: 5.510—5.530 mm {0.2170—0.2177 in} EX: 5.510—5.530 mm {0.2170—0.2177 in}

5. Calculate the clearance between the valve stem and the valve guide by subtracting the inner diameter of the valve guide from the outer diameter of the corresponding valve stem.

• If it exceeds the maximum specification, replace the valve or valve guide.

Standard clearance between valve stem and

guide

IN: 0.025—0.060 mm {0.0010—0.0023 in} EX: 0.030—0.065 mm {0.0012—0.0025 in}

Maximum clearance between valve stem and

guide

0.10 mm {0.0039 in}

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VALVE STEM

VALVE GUIDE

CLEARANCE

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6. Measure the projection height (dimension A) of each valve guide using the vernier caliper.

• If it is not within the specification, replace the valve guide.

Standard valve guide projection height

IN: 16.4—17.0 mm {0.646—0.669 in} EX: 16.4—17.0 mm {0.646—0.669 in}

End Of Sie

VALVE GUIDE

CYLINDER HEAD

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01-10–28

Page 42

MECHANICAL

VALVE GUIDE REPLACEMENT

Removal

1. Tap the valve guide out from combustion chamber

side using the SST.

Installation

1. Apply clean engine oil to the valve guide.

2. Tap the valve guide from the camshaft side using the SST so that the projection height (dimension A) is within the specification.

Standard valve guide projection height

IN: 16.4—17.0 mm {0.646—0.669 in} EX: 16.4—17.0 mm {0.646—0.669 in}

End Of Sie

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49 B012 015

01-10

VALVE GUIDE

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49 B012 015

VALVE GUIDE

VALVE SPRING INSPECTION

Caution

• The valve springs differ depending on the IN and EX sides.Therefore, verify the free length or identification paint beforehand and inspect the valve springs.

CYLINDER HEAD

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id011000501400

48.96 mm {1.928 in}

PURPLE PAINT

50.07 mm {1.971 in}

NOT PAINTED

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01-10–29

Page 43

MECHANICAL

1. Measure the valve spring height using the spring tester.

• If it is not within the specification, replace the valve spring.

Valve spring installation height

When pressurized with spring force of 228—

252 N {23.3—25.6 kgf, 51.3—56.6 lbf}, spring height is 38.0 mm {1.50 in}

2. Measure the amount of off-square on the valve spring using a square. (1) Rotate the valve spring one full turn and

measure A at the point where the gap is the largest.

• If it exceeds the maximum specification, replace the valve spring.

Maximum valve spring off-square

IN: 2.0 ° (1.7 mm {0.067 in}) EX: 2.0 ° (1.7 mm {0.067 in})

End Of Sie

CAMSHAFT INSPECTION

1. Set the No.1 and No.5 journals of the camshaft on V-blocks.

2. Measure the camshaft runout using the dial gauge.

• If it exceeds the maximum specification, replace the camshaft.

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UPPER

LOWER

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id011000501500

Maximum camshaft runout

0.030 mm {0.0012 in}

3. Measure the cam height using the micrometer as shown in the figure.

• If it is less than the minimum specification, replace the camshaft.

Standard cam height

IN: 42.34 mm {1.667 in} EX: 40.37 mm {1.589 in}

Minimum cam height

IN: 42.27 mm {1.664 in} EX: 40.30 mm {1.587 in}

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01-10–30

Page 44

4. Measure the journal diameter using the micrometer. Measurement positions total four and are in the X and Y directions, at two points (A and B) as shown in the figure.

• If it is less than the minimum specification, replace the camshaft.

MECHANICAL

A B

Standard camshaft journal diameter

24.96—24.98 mm {0.9827—0.9834 in}

Minimum camshaft journal diameter

24.93 mm {0.9815 in}

5. Measure the camshaft journal oil clearance using the following procedure: (1) Clean the camshaft journal and the journal receptacle part. (2) Put the camshaft on the cylinder head with the rocker arm detached. (3) Cut the plastigauge to the same length as the

journal width and position it parallel to the camshaft.

(4) Install the camshaft caps. (See 01-10-59

CYLINDER HEAD ASSEMBLY (II).)

(5) Remove the camshaft caps. (See 01-10-14

CYLINDER HEAD DISASSEMBLY (I).)

(6) Measure the camshaft journal oil clearance.

• If it exceeds the maximum specification, replace the cylinder head.

Standard camshaft journal oil clearance

0.035—0.080 mm {0.0014—0.0031 in}

Maximum camshaft journal oil clearance

0.090 mm {0.0035 in}

01-10

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PLASTIGAUGE

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

• If it exceeds the maximum specification, replace the cylinder head or camshaft.

Standard camshaft end play

0.07—0.22 mm {0.003—0.008 in}

Maximum camshaft end play

0.23 mm {0.0091 in}

End Of Sie

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Page 45

MECHANICAL

CYLINDER BLOCK INSPECTION

1. Measure the cylinder block for distortion in six directions as shown in the figure using a straight edge and feeler gauge.

• If it exceeds the maximum specification, replace the cylinder block.

Maximum distortion, head gasket side of the

cylinder block

0.10 mm {0.0039 in}

2. Measure the cylinder bore diameter using the cylinder gauge. The measurement position is in the X and Y directions at a point 43.9 mm {1.73 in} below the top surface of the cylinder as shown in the figure.

• If it is not within the specification, replace the cylinder block.

Standard cylinder bore diameter

89.000—89.030 mm {3.5040—3.5051 in}

End Of Sie

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.

• If there is air flow with air compressor of less

than 180 kPa {1.84 kgf/cm replace the oil jet valve.

, 26.1 psi},

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43.9 mm {1.73 in}

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id011000505900

Oil jet valve opening pressure

180—220 kPa {1.84—2.24 kgf/cm

, 26.2—

31.9 psi}

End Of Sie

PISTON INSPECTION

Caution

• If the piston is replaced, replace the piston, piston pin, and the snap ring as a single component.

1. Measure the piston outer diameter using the micrometer. The measurement position is 8.0 mm {0.31 in} from the lower end of the piston (area with no coating on the piston skirt) and in the thrust direction.

• If it is not within the specification, replace the piston.

Standard piston outer diameter

88.965—88.995 mm {3.5026—3.5037 in}

2. Measure the cylinder bore diameter. (See 01-1032 CYLINDER BLOCK INSPECTION.)

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01-10–32

Page 46

MECHANICAL

3. Calculate the cylinder-to-piston clearance from the cylinder bore diameter and the piston outer diameter.

• If the clearance exceeds the maximum specification, replace the piston or cylinder block.

Standard clearance between piston and cylinder

0.025—0.045 mm {0.0010—0.0017 in}

Maximum clearance between piston and cylinder

0.066 mm {0.0026 in}

4. Measure the piston-to-ring groove clearance along the perimeter using a feeler gauge. For the O-ring, measure the clearance with the O-ring assembled to the piston.

• If the clearance exceeds the maximum specification, replace the piston or piston ring.

Standard clearance between piston ring and

ring groove

Top: 0.04—0.08 mm {0.002—0.003 in} Second: 0.03—0.07 mm {0.0012—0.0027 in} Oil: 0.04—0.12 mm {0.002—0.004 in}

Maximum clearance between piston ring and

ring groove

Top: 0.12 mm {0.0047 in} Second: 0.10 mm {0.0039 in} Oil: 0.17 mm {0.0067 in}

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01-10

End Of Sie

PISTON RING INSPECTION

1. Using the piston, press the piston ring parallel into

the cylinder to 43.9 mm {1.73 in} from the upper end of the cylinder block.

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

• If it exceeds the maximum specification, replace the piston ring.

Standard piston ring end gap

Top: 0.13—0.18 mm {0.0052—0.0070 in} Second: 0.18—0.28 mm {0.008—0.011 in} Oil (Rail): 0.10—0.35 mm {0.004—0.013 in}

Maximum piston ring end gap

Top: 0.35 mm {0.014 in} Second: 0.45 mm {0.018 in} Oil (Rail): 0.52 mm {0.020 in}

43.9 mm {1.73 in}

id011000592300

PISTON

CYLINDER BLOCK

PISTON RING

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PISTON RING

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End Of Sie

01-10–33

Page 47

MECHANICAL

PISTON PIN INSPECTION

Caution

• If the piston or piston pin is replaced, replace the piston, piston pin and the snap ring as a single component.

1. Measure the piston pin outer diameter using the micrometer. Measurement positions total eight and are in the X and Y directions, at four points (A, B, C, and D) as shown in the figure.

Standard piston pin outer diameter

20.995—21.000 mm {0.82658—0.82677 in}

2. Measure the piston pin hole diameter using the caliper gauge. Measurement positions total eight and are in the X and Y directions, at four points

(A, B, C, and D) as shown in the figure.

Standard piston pin hole diameter

21.004—21.008 mm {0.82693—0.82708 in}

A B

3. Calculate the clearance between the piston pin hole diameter and the piston pin outer diameter.

• If it is not within the specification, replace the piston or the piston pin.

C D

Standard clearance between piston pin hole

diameter and piston pin outer diameter

0.004—0.013 mm {0.0002—0.0005 in}

id011000507500

A B

adj2224e255

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4. Measure the inner diameter on the small end of the connecting rod using the caliper gauge in the X and Y directions as shown in the figure.

Standard connecting rod small end inner

diameter

21.002—21.013 mm {0.82686—0.82728 in}

5. Calculate the clearance between the inner diameter on the small end of the connecting rod and the piston pin outer diameter.

• If it is not within the specification, replace the

CONNECTING ROD

connecting rod or the piston pin.

Standard clearance between connecting rod small end inner diameter and piston pin outer diameter

0.002—0.018 mm {0.00008—0.00070 in}

End Of Sie

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01-10–34

Page 48

MECHANICAL

PISTON AND CONNECTING ROD INSPECTION

1. Check the oscillation torque as shown in the figure. Verify that the large end drops under its own weight with no resistance.

• If the piston shakes heavily or unsmoothly, disassemble the piston and connecting rod, then inspect the following: (See 01-10-34 PISTON PIN INSPECTION.) — Clearance between piston pin outer

diameter and piston pin hole diameter.

— Clearance between piston pin outer

diameter and connecting rod small end inner diameter.

End Of Sie

CONNECTING ROD INSPECTION

1. Inspect the connecting rod for bending and distortion using the connecting rod aligner.

• If it exceeds the maximum specification, replace the connecting rod.

Maximum connecting rod bending

0.050 mm {0.0020 in}

Maximum connecting rod distortion

0.050 mm {0.0020 in}

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01-10

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Connecting rod center-to-center distance

154.8 mm {6.094 in}

End Of Sie

CONNECTING ROD CLEARANCE INSPECTION

1. Measure the side clearance at the large end of the connecting rod using a feeler gauge.

• If it exceeds the maximum specification, replace the connecting rod or crankshaft.

Standard side clearance at the large end of

connecting rod

0.14—0.36 mm {0.006—0.014 in}

Maximum side clearance at the large end of

connecting rod

0.465 mm {0.0183 in}

2. Measure the oil clearance at the large end of the connecting rod using the following procedure: (1) Cut the plastigauge as wide as the connecting

rod bearing width, place it parallel to the crankshaft, avoiding the oil hole.

(2) Install the lower connecting rod bearing and

connecting rod cap. (See 01-10-40 CYLINDER BLOCK ASSEMBLY (I).)

(3) Remove the connecting rod cap. (See 01-10-

22 CYLINDER BLOCK DISASSEMBLY (II).)

(4) Measure the oil clearance at the large end of

the connecting rod.

• If it exceeds the maximum specification, replace the bearing or grind the crank pin and use oversize bearings so that the specified clearance is obtained.

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id011000507600

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PLASTIGAUGE

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01-10–35

Page 49

MECHANICAL

Standard bearing oil clearance at the large end of the connecting rod

0.026—0.052 mm {0.0011—0.0020 in}

Maximum bearing oil clearance at the large end of the connecting rod

0.10 mm {0.0039 in}

Connecting rod bearing size

STD: 1.502—1.519 mm {0.05914—0.05980 in} OS 0.25: 1.628—1.631 mm {0.06410—0.06421 in} OS 0.50: 1.753—1.756 mm {0.06902—0.06913 in}

End Of Sie

CRANKSHAFT INSPECTION

1. Measure the crankshaft end play using a dial gauge.

• If it exceeds the maximum specification, replace the crankshaft or grind the thrust side of crankshaft and use the oversize thrust bearing so that the specified end play is obtained.

Standard crankshaft end play

0.08—0.29 mm {0.004—0.011 in}

id011000502500

Maximum crankshaft end play

0.30 mm {0.012 in}

Thrust bearing size

STD: 2.500—2.550 mm {0.0985—0.1003 in} OS 0.25: 2.625—2.675 mm {0.1034—0.1053

in}

2. Measure the runout of the main journal using a Vblock and dial gauge.

• If it exceeds the maximum specification, replace the crankshaft.

Maximum main journal runout

0.10 mm {0.0039 in}

3. Inspect the main journal diameter and crank pin diameter. Measurement positions total four and are in the X and Y directions, at two points (A and B) as shown in the figure.

• If it is not within the specification or if it exceeds the maximum off-round, grind the journal with an oversized bearing.

bp31je00000217

bpe2ue00000035

Standard main journal diameter

49.980—50.000 mm {1.9678—1.9685 in}

Maximum main journal off-round

0.005 mm {0.0002 in}

Standard crank pin diameter

49.980—50.000 mm {1.9678—1.9685 in}

Maximum crank pin off-round

0.005 mm {0.0002 in}

01-10–36

b3e0110e085

Page 50

MECHANICAL

4. Inspect the main journal oil clearance using the following procedure: (1) Install the thrust bearing, upper main bearing and crankshaft. (2) Position a plastigauge on the journals. (3) Install the lower main bearing and lower cylinder block. (See 01-10-40 CYLINDER BLOCK ASSEMBLY (I).) (4) Remove the lower cylinder block. (See 01-10-22 CYLINDER BLOCK DISASSEMBLY (II).) (5) Measure the main journal oil clearance.

• If it exceeds the maximum specification, replace the main bearing, or grind the main journal and use oversized bearings so that the specified oil clearance is obtained.

Standard main journal oil clearance

0.016—0.039 mm {0.0007—0.0015 in}

Maximum main journal oil clearance

0.084 mm {0.0033 in}

Main bearing size

STD: 2.489—2.510 mm {0.0980—0.0988 in} OS 0.25: 2.614—2.617 mm {0.10292—0.10303 in} OS 0.50: 2.739—2.742 mm {0.10784—0.10795 in}

End Of Sie

DUAL-MASS FLYWHEEL INSPECTION

bp31je00000152

id011000501900

01-10

Caution

• Do not rework the dual-mass flywheel if it is distorted.

• Do not clean the dual-mass flywheel with any kind of fluid. Clean the dual-mass flywheel with a dry

cloth only.

• Do not clean the gap between the primary and secondary mass. Only clean the bolt connection surface and the clutch surface.

Inspection Before Removal

1. Rotate the dual-mass flywheel or attempt to move it up and down, and left and right to verify that the center of the dual-mass flywheel does not move.

• If there is any movement as indicated by the arrows in the figure, replace the dual-mass flywheel.

2. Verify that the secondary mass does not rotate by 15 teeth or more.

• If it rotates by 15 teeth or more, replace the dual-mass flywheel.

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01-10–37

Page 51

MECHANICAL

3. Measure the amount of guide pin projection of the dual-mass flywheel.

• If it exceeds the maximum amount, replace the dual-mass flywheel.

Dual-mass flywheel guide pin projection

maximum amount

11.0—12.0 mm {0.434—0.472 in}

4. Using a dial indicator, measure the dual-mass flywheel runout.

• If it exceeds the maximum runout, replace the dual-mass flywheel.

Dual-mass flywheel maximum runout

1.5 mm {0.059 in}

ac5wzw00005674

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Inspection After Removal

1. Visually inspect the dual-mass flywheel for crack.

• If there is any crack, replace the dual-mass flywheel.

2. Visually inspect the ring gear on the dual-mass flywheel for damage.

• If there is any damage, replace the dual-mass flywheel.

3. Visually inspect the surface that contacts the clutch disc for scratches, nicks, and discoloration.

• If there is any malfunction, replace the dual-mass flywheel.

Note

• Correct slight scratches and discoloration using sandpaper.

4. Visually inspect for grease leakage between the primary mass and secondary mass.

• If there is grease leakage, replace the dualmass flywheel.

End Of Sie

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01-10–38

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Page 52

MECHANICAL

PILOT BEARING INSPECTION

1. Without removing the pilot bearing, turn the bearing while applying force in the axial direction.

• If there is any malfunction, replace the pilot bearing.

End Of Sie

BOLT INSPECTION

1. Measure the length of the each bolt.

• If it exceeds the maximum specification, replace the bolt.

Standard cylinder head bolt length

145.2—145.8 mm {5.717—5.740 in}

Maximum cylinder head bolt length

146.5 mm {5.768 in}

Standard connecting rod bolt length

43.7—44.3 mm {1.73—1.74 in}

Maximum connecting rod bolt length

45.0 mm {1.77 in}

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01-10

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End Of Sie

01-10–39

Page 53

MECHANICAL

OIL

SEALANT

OIL

CYLINDER BLOCK ASSEMBLY (I)

id011000504000

1. Assemble in the order indicated in the table.

OIL

8—11 N·m {82—112 kgf·cm, 71—97 in·lbf}

OIL

26—32 {2.7—3.2, 20—23} +80—100

1 Upper cylinder block

38—42 {3.9—4.2, 29—30} LOOSEN ALL THE BOLTS (UNTIL BOLTS ARE TORQUE-FREE)

OIL

+30—34 {3.1—3.4, 23—25} +57.5—62.5

2 Oil jet valve 3 Thrust bearing

(See 01-10-41 Thrust Bearing And Main Bearing Assembly Note.)

4 Upper main bearing

(See 01-10-41 Thrust Bearing And Main Bearing Assembly Note.)

5Plate

(See 01-10-42 Plate Assembly Note.)

6 Crankshaft

01-10–40

20—26 {2.1—2.6, 15—19}

OIL

19—25 {2.0—2.5, 15—18}

SEALANT

N·m {kgf·m, ft·lbf}

bpe5ue00000004

7 Lower main bearing

(See 01-10-41 Thrust Bearing And Main Bearing Assembly Note.)

8 Lower cylinder block

(See 01-10-42 Lower Cylinder Block Assembly Note.)

9 Connecting rod 10 Piston 11 Piston pin

(See 01-10-44 Piston Pin Assembly Note.)

12 Snap ring

(See 01-10-44 Snap Ring Assembly Note.)

Page 54

MECHANICAL

13 Piston ring

(See 01-10-45 Piston Ring Assembly Note.)

14 Upper connecting rod bearing

(See 01-10-46 Connecting Rod Bearing Assembly Note.)

15 Piston, connecting rod

(See 01-10-46 Piston, Connecting Rod Assembly Note.)

16 Lower connecting rod bearing

(See 01-10-46 Connecting Rod Bearing Assembly Note.)

17 Connecting rod cap

(See 01-10-47 Connecting Rod Cap Assembly Note.)

18 Pilot bearing (MTX)

(See 01-10-47 Pilot Bearing Assembly Note.)

Thrust Bearing And Main Bearing Assembly Note

Caution

• If the thrust bearings and main bearings are reused, assemble the bearings to the same positions and in the direction as before removal to prevent engine damage due to seizure or burning of the bearing.

• To prevent engine damage due to seizure or burning of the bearing, apply engine oil to the sliding part when assembling.

Thrust bearing

1. Apply clean engine oil to the thrust bearings.

2. Assemble the bearings with the oil groove of the thrust bearing pointed toward the sliding surface.

THRUST BEARING

01-10

Main bearing

1. Apply clean engine oil to the main bearings.

2. Align the positioning tab of the main bearing with the positioning groove of the lower and upper cylinder block, and assemble the bearings.

MAIN BEARING

AFTER INSTALLATION

OIL GROOVE

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GROOVE

TA B

CYLINDER BLOCK

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01-10–41

Page 55

MECHANICAL

Plate Assembly Note

Caution

1. Install the plate using the following procedure: (1) Install the groove of the plate tooth to the

position shown in the figure and temporarily

tighten bolt A. (2) Temporarily tighten the bolt B. (3) Install bolt C and tighten the bolts to the

specified tightening torque in the order of C,

B, and A.

Tightening torque

20—26 N·m {2.1—2.6 kgf·m, 15—19 ft·lbf}

Lower Cylinder Block Assembly Note

1. Completely clean and remove any oil, dirt, sealant or other foreign matter that may be adhering to the lower cylinder block and cylinder block.

2. When reusing the lower cylinder block installation bolts, clean any old sealant from the bolts.

PLATE

GROOVE

CRANKSHAFT

bpe2ue00000038

Caution

• Apply silicon sealant in a single, unbroken line.

• To prevent silicon sealant from hardening, adhere the engine front cover and the cylinder block

firmly within 10 min. after applying silicon sealant. After adhering them, tighten the installation bolts immediately.

• Using bolts with the old seal adhering could cause cracks in the cylinder block.

DAMAGE

OLD SEALANT

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01-10–42

Page 56

MECHANICAL

SEALANT

3. Apply silicon sealant to the lower cylinder block shown in the figure.

ENGINE FRONT

01-10

SEALANT

LESS THAN 4 mm {0.2 in}

SEALANT

LOWER CYLINDER BLOCK

SECTION A-A

0.5—1.5 mm {0.02—0.05 in}

SEALANT

Bead thickness

2—6 mm {0.1—0.2 in}

4. Install the lower cylinder block.

5. Tighten the lower cylinder block installation bolts using the following procedure: (1) Apply clean engine oil to the seating surface and thread of lower cylinder block installation bolts A.

LESS THAN 4 mm {0.2 in}

SEALANT

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01-10–43

Page 57

MECHANICAL

(2) Tighten lower cylinder block installation bolts

A in the order shown in the figure using the following procedure:

Tightening procedure

Step 1: 38—42 N·m {3.9—4.2 kgf·m, 29—30

ft·lbf}

Step 2: Loosen all the bolts (until bolts are

torque-free).

Step 3: 30—34 N·m {3.1—3.4 kgf·m, 23—25

ft·lbf}

Step 4: 57.5—62.5°

(3) Tighten the lower cylinder block installation

bolts B in the order shown in the figure.

Tightening torque

19—25 N·m {2.0—2.5 kgf·m, 15—18 ft·lbf}

6. After verifying that silicone sealant protrudes to the rear oil seal press-in part, wipe away the excess silicone sealant.

• If silicone sealant does not protrude to the rear oil seal press-in part, remove the lower cylinder block and apply silicone sealant again.

ENGINE FRONT

4 89 5

B BB B B

AA A

AA A A

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Piston Pin Assembly Note

1. Apply clean engine oil to the piston pin.

2. Insert the piston pin to the piston and connecting rod.

Note

• When assembling the piston to the connecting rod, each one can be assembled in either direction.

Snap Ring Assembly Note

Caution

• Do not compress the outer diameter of the snap ring more than necessary when assembling the snap ring (20.66 mm {0.8134 in} or less).

1. Insert a new snap ring using a thin plier.

B BB BB

89 5

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01-10–44

Page 58

MECHANICAL

Piston Ring Assembly Note

Note

• It is not required to position the end gap between the top ring and second ring.

1. Assemble the oil ring so that the end gap of each oil ring rail does not overlap as shown in the figure.

2. Assemble so that the identification paint marks on the top and second rings are visible to the right side of each end gap.

Note

• If there are no identification paint marks on the top and second rings, place the ring with the bigger inner circumference at the top as shown in the figure.

UPPER OIL RING RAIL

OIL RING SPACER

IDENTIFICATION PAINT MARK

END GAP

30° 30°

PISTON PIN AXIS

LOWER OIL RING RAIL

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TOP RING

SECOND RING

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TOP RING

NOTCH

01-10

SECOND RING

NOTCH

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01-10–45

Page 59

MECHANICAL

Connecting Rod Bearing Assembly Note

Caution

• If a connecting rod bearing is reused, assemble it to the same position and in the direction as before removal to prevent engine damage due to seizure or burning of the bearing.

• To prevent engine damage due to seizure or burning of the bearing, apply engine oil to the sliding part when assembling.

1. Apply engine oil to the connecting rod bearings.

2. Align the positioning tab of the connecting rod bearing with the positioning groove of the connecting rod and connecting rod cap, and assemble the bearings.

TA B

GROOVE

Piston, Connecting Rod Assembly Note

1. Insert the piston into the cylinder with the mark on top of the piston facing the intake side.

CONNECTING ROD BEARING

INSTALLED

ENGINE FRONT

CONNECTING ROD CAP

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6TN

01-10–46

MARKED

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Page 60

MECHANICAL

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.

• If the following condition is met, replace the connecting rod cap bolts. — Length exceeds maximum

specification

Standard connecting rod cap bolt length

43.7—44.3 mm {1.73—1.74 in}

01-10

Maximum connecting rod cap bolt length

45.0 mm {1.77 in}

1. Position so that the broken, rough faces of the connecting rods and connecting rod caps are aligned exactly, and assemble the connecting rod caps.

2. Tighten the connecting rod cap bolts in the following two steps.

Tightening procedure

Step 1: 26—32 N·m {2.7—3.2 kgf·m, 20—23 ft·lbf} Step 2: 80—100°

Pilot Bearing Assembly Note

1. Install new pilot bearing to the specified position using the following tools.

Tool

Snap-on brand millimeter size bushing

driver set (A160M) adapter A160M7 (20— 22 mm {0.79—0.86 in})

• Use the adapter with the 20 mm {0.79 in} side of the A160M7 (20—22 mm {0.79—

0.86 in}) facing the pilot bearing side.

Substitution tool

Outer diameter: 21 mm {0.83 in} Inner diameter: 19 mm {0.75 in}

adejjw00001214

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Standard pilot bearing position

Distance A of pilot bearing from crankshaft

end: 1.5—2.5 mm {0.060—0.098 in}

End Of Sie

CRANKSHAFT

PILOT BEARING

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01-10–47

Page 61

MECHANICAL

OIL

CYLINDER BLOCK ASSEMBLY (II)

1. Assemble in the order indicated in the table.

20—26 {2.1—2.6, 15—19}

id011000504100

OIL

SST

5 6

AT X

7 8

108—116 {11.1—11.8, 80—85}

SST

MTX

17—23 {1.8—2.3, 13—16}

152—160 {15.5—16.3, 113—118}

SST

20—26 {2.1—2.6, 15—19}

*1: 8—11 N·m {82—112 kgf·m, 71—97 ft·lbf}

1 Balancer unit

(See 01-10-49 Balancer Unit Assembly Note.)

2 Oil pump

(See 01-10-50 Oil Pump Assembly Note.) 3 Oil strainer 4 Water pump

(See 01-10-51 Water Pump Assembly Note.) 5 Rear oil seal

(See 01-10-52 Rear Oil Seal Assembly Note.) 6 End plate

(See 01-10-53 End Plate Assembly Note.)

16—22 {1.7—2.2, 12—16} +30—36 {3.1—3.6, 23—26}

20—26 {2.1—2.6, 15—19}

OIL

N·m {kgf·m, ft·lbf}

bpe5ue00000005

7 Dual-mass flywheel (MTX), drive plate (ATX) 8 Backing plate (ATX) 9 Dual-mass flywheel (MTX)/ drive plate (ATX)

installation bolt (See 01-10-53 Dual-mass Flywheel (MTX)/ Drive

Plate (ATX) Installation Bolt Assembly Note.) 10 Oil separator 11 Knock sensor (KS)

(See 01-10-54 Knock Sensor (KS) Assembly Note.)

01-10–48

Page 62

MECHANICAL

Balancer Unit Assembly Note

1. Assemble the balancer unit using the following procedure: (1) Tighten the bolts in the order shown in the

figure.

BALANCER UNIT

01-10

Tightening torque

Installation position Tightening torque

1—4 16—22 N·m {1.7—2.2 kgf·m, 12—16 ft·lbf}

5, 6 20—26 N·m {2.1—2.6 kgf·m, 15—19 ft·lbf}

(2) Retighten the bolts in the order of the

numbers indicated in the figure.

Tightening torque

30—36 N·m {3.1—3.6 kgf·m, 23—26 ft·lbf}

BALANCER UNIT

ENGINE FRONT

bpe1ze00000051

ENGINE FRONT

bpe1ze00000052

01-10–49

Page 63

MECHANICAL

Oil Pump Assembly Note

1. Install the oil pump using the following procedure:

(1) Temporarily tighten the three bolts shown in

the figure.

BOLT

OIL PUMP

(2) Tighten the two bolts shown in the figure to

the specified torque.

Note

• The tightening order for the two bolts is optional.

Tightening torque

20—26 N·m {2.1—2.6 kgf·m, 15—19 ft·lbf}

(3) Finally, tighten the bolt shown in the figure to

the specified torque.

BOLT

ENGINE FRONT

BOLT

OIL PUMP

BOLT

ENGINE FRONT

BOLT

bpe1ze00000053

bpe1ze00000054

Tightening torque

20—26 N·m {2.1—2.6 kgf·m, 15—19 ft·lbf}

01-10–50

OIL PUMP

BOLT

ENGINE FRONT

bpe1ze00000055

Page 64

MECHANICAL

Water Pump Assembly Note

Caution

• Assemble the water pump gasket to the correct direction shown in the figure. Otherwise, it could leak engine coolant and damage the engine.

WATER PUMP GASKET GROOVE WATER PUMP

1. Insert a new water pump gasket into the water pump groove.

2. Install the water pump.

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

Tightening torque

20—26 N·m {2.1—2.6 kgf·m, 15—19 ft·lbf}

WATER PUMP

01-10

bpe2ue00000053

bpe2ue00000054

01-10–51

Page 65

MECHANICAL

Rear Oil Seal Assembly Note

1. Apply clean engine oil to the inner surface of a new rear oil seal.

2. Insert the rear oil seal into the cylinder block by hand.

3. Tap the oil seal in evenly using the SST and a

hammer.

Rear oil seal press on amount

0—0.5 mm {0—0.019 in}

49 S033 101

VIEW FROM A

HAMMER

49 S033 101

REAR OIL SEAL

CYLINDER BLOCK

bpe1ze00000056

SECTION B-B

CYLINDER BLOCK

0—0.5 mm {0—0.019 in}

REAR OIL SEAL

bpe5ue00000006

01-10–52

Page 66

MECHANICAL

End Plate Assembly Note

1. After end plate assembly, crimp the parts A and B shown in the figure.

10 {0.39}

END PLATE

10 {0.39}

TUBULAR PIN

10 {0.39}

Crimp procedure

Crimp depth: 0.1—1.0 mm {0.004—0.039 in} Crimp width: 0.5—10.0 mm {0.02—0.39 in} Crimp locations: Part A is 1 or more on one-side within shaded area and part B is 2 or more within

shaded areas

2. After crimping, verify that there is no damage and removal of the end plate.

Dual-mass Flywheel (MTX)/ Drive Plate (ATX) Installation Bolt Assembly Note Dual-mass flywheel installation bolt (MTX)

1. Hold the crankshaft using the SST (49 E011 1A0).

2. Temporarily tighten the new bolts.

TUBULAR PIN

01-10

mm {in}

bpe2ue00000055

Note

• If the dual-mass flywheel (secondary flywheel side) is not positioned properly, perform the following procedure to install it:

(1) Temporarily tighten the new bolts to the

position as shown in the figure.

49 G033 102

49 E011 1A0

am6zzw00011777

01-10–53

Page 67

MECHANICAL

(2) Install the SST (49 S120 710) to the dual-

mass flywheel.

(3) Rotate the dual-mass flywheel (secondary

flywheel side) using the SST (49 S120 710), and then temporarily tighten the remaining new bolt after removing the SST (49 G033

102).

3. Tighten the new bolts in two or three passes in the order shown in the figure.

Tightening torque

152—160 N·m {15.5—16.3 kgf·m, 113—118

ft·lbf}

49 E011 1A0

49 G033 102

49 S120 710

am6xuw00005541

ac5wzw00005664

Drive plate installation bolt (ATX)

1. Hold the crankshaft using the SST.

2. Tighten the new bolts in two or three passes in the order shown in the figure.

Tightening torque

108—116 N·m {11.1—11.8 kgf·m, 80—85

ft·lbf}

Knock Sensor (KS) Assembly Note

• Verify that there is no foreign matter caught between the KS unit and cylinder block.

• The direction of the knock sensor connector must

be within the range shown in the figure.

End Of Sie

60º

49 E011 1A0

bpe1ze00000093

01-10–54

am6zzw00008568

Page 68

MECHANICAL

OIL

CYLINDER HEAD ASSEMBLY (I)

1. Assemble in the order indicated in the table.

SST

id011000504300

01-10

8—11 {82—112, 71—97}

OIL

1 Lower valve spring seat 2 Valve seal

(See 01-10-56 Valve Seal Assembly Note.) 3Valve 4 Valve spring

(See 01-10-56 Valve Spring Assembly Note.) 5 Upper valve spring seat

N·m {kgf·cm, in·lbf}

bpe1ze00000017

6 Valve keeper

(See 01-10-57 Valve Keeper Assembly Note.)

7 Water outlet

(See 01-10-57 Water Outlet Assembly Note.)

8 Thermostat

(See 01-10-58 Thermostat Assembly Note.)

9 Thermostat cover

01-10–55

Page 69

MECHANICAL

Valve Seal Assembly Note

1. Press on the valve seal to the valve guide using

the SST by hand.

Valve seal identification color

IN: GREEN EX: GRAY

Valve Spring Assembly Note

Caution

• The valve springs differ depending on IN and EX sides. Therefore, verify the free length or identification paint beforehand and assemble the valve springs correctly.

9.52 mm {0.375 in}

49 B012 016

3.5 mm {0.14 in}

VALVE SEAL

49 B012 016

VALVE SEAL

bpe1ze00000057

48.96 mm {1.928 in}

1. Assemble the valve spring with the small diameter side of the valve spring facing upward.

PURPLE PAINT

50.07 mm {1.971 in}

NOT PAINTE

bpe1ze00000094

01-10–56

Page 70

Valve Keeper Assembly Note

1. Install the valve keeper using the SST.

MECHANICAL

Water Outlet Assembly Note

1. Install the water outlet gasket with the bead of the gasket facing the direction shown in the figure.

2. Temporarily tighten the water outlet installation bolts.

49 0636 100B

49 B012 0A2A

01-10

bpe1ze00000020

SECTION B-B

CYLINDER HEAD WATER OUTLET

WATER OUTLET GASKET

BEAD

bpe1ze00000021

01-10–57

Page 71

MECHANICAL

3. Tighten bolt A of the 5 bolts shown in the figure to the specified torque first.

Tightening torque

8—11 N·m {82—112 kgf·cm, 71—97 in·lbf}

Note

• The tightening order for the remaining 3 bolts is optional.

Thermostat Assembly Note

1. Install the thermostat with the jiggle pin aligned with the notch of the water outlet.

End Of Sie

BOLT

WATER OUTLET

BOLT

bpe1ze00000022

NOTCH

JIGGLE-PIN

THERMOSTAT

bpe1ze00000023

01-10–58

Page 72

MECHANICAL

CYLINDER HEAD ASSEMBLY (II)

Caution

• When rotating the camshaft using a wrench on the cast hexagon, the wrench may contact the rocker arm and damage

CAMSHAFT

WRENCH

CAST HEXAGON

ROCKER ARM CONTACT

SECURE CLEARANCE

id011000504400

01-10

ENGINE REAR

Note

• Width at the cast hexagon of the camshaft is 22—24 mm {0.87—0.94 in}.

CAMSHAFT

DOES NOT CONTACT

CAST HEXAGON

22—24 mm {0.87

am3uuw00008968

—0.94 in}

am3uuw00009029

01-10–59

Page 73

1. Assemble in the order indicated in the table.

OIL

MECHANICAL

12—16 N·m {123—163 kgf·cm, 107—141 in·lbf}

20—26 {2.1—2.6, 15—19}

8—11 N·m {82—112 kgf·cm, 71—97 in·lbf}

75—85 {7.7—8.6, 56—62}

102—114 {10.5—11.6, 76—84}

WITHOUT OIL COOLER

3.0—6.0 N·m

{31—61 kgf·cm, 27—53 in·lbf} +8—11 N·m {82—112 kgf·cm, 71—97 in·lbf}

OIL

13—17 N·m {133—173 kgf·cm, 116—150 in·lbf} +43—47 {4.4—4.7, 32—34}

+85—95 +85—95°

OIL

WATER PUMP

1 Cylinder head gasket 2 Cylinder head

(See 01-10-61 Cylinder Head Assembly Note.)

3 Water inlet pipe

(See 01-10-62 Water Inlet Pipe Assembly Note.)

4HLA

(See 01-10-63 HLA Assembly Note.)

5 Rocker arm

(See 01-10-63 Rocker Arm Assembly Note.)

6 OCV oil filter

WITH OIL COOLER

N·m {kgf·m, ft·lbf}

bpe5ue00000007

7 Camshaft

(See 01-10-64 Camshaft Assembly Note.)

8 Camshaft cap

(See 01-10-64 Camshaft Assembly Note.)

9OCV

10 Electric variable valve timing actuator, hydraulic

variable valve timing actuator (See 01-10-66 Electric Variable Valve Timing Actuator, Hydraulic Variable Valve Timing Actuator Assembly Note.)

01-10–60

Page 74

MECHANICAL

Cylinder Head Assembly Note

Caution

• If the following condition is met, replace the cylinder head bolts. — Length exceeds maximum

specification

Standard cylinder head bolt length L

145.2—145.8 mm {5.717—5.740 in}

Maximum cylinder head bolt length L

146.5 mm {5.767 in}

1. When a cylinder head bolt is reused, apply engine oil to any part of the following:

• Bolt seating surface

• Cylinder head seating surface

2. Tighten the cylinder head bolts in the order shown in the following four steps.

Tightening procedure

Step 1: 13—17 N·m {133—173 kgf·cm, 116—

150 in·lbf}

Step 2: 43—47 N·m {4.4—4.7 kgf·m, 32—34

ft·lbf} Step 3: 85—95° Step 4: 85—95°

ENGINE FRONT

01-10

adejjw00001214

4 1 5 9

3 2 6

am3uuw00008818

01-10–61

Page 75

MECHANICAL

Water Inlet Pipe Assembly Note

Caution

• Do not apply oil (such as engine oil, ATF) to the O-ring of the water inlet pipe. Otherwise, the O-

ring could swell causing a seal malfunction.

1. Clean away the sealant adhering to the bolt hole on the cylinder block side of the water inlet pipe stay.

2. Apply engine coolant to the O-ring.

3. Install the O-ring to the water inlet pipe.

4. Insert the water inlet pipe into the water pump being careful not to damage the O-ring.

5. Install the water inlet pipe gasket with the gasket projection facing the direction shown in the figure.

PROJECTION

6. Tighten the bolts in the order shown in the figure.

12—16 N·m {123—163 kgf·cm, 107—141 in·lbf}

STAY

bpe2ue00000065

WATER INLET PIPEWATER OUTLET

20—26 {2.1—2.6, 15—19}

N·m {kgf·m, ft·lbf}

bpe5ue00000008

01-10–62

Page 76

MECHANICAL

OIL

HLA Assembly Note

1. Perform HLA air bleeding using the following procedure: (1) Put the HLA in a container filled with engine oil.

Caution

• Do not insert the round bar firmly because the check ball spring force is extremely weak.

(2) While lightly pressing the check ball using a

round bar (approx. 1.0 mm {0.039 in} diameter), bleed air by moving the plunger up and down.

(3) Press the end of the plunger in the oil and

verify that there is no rebounding feel.

• If rebounding feel cannot be eliminated, replace the HLA.

2. Install the HLAs to their original positions as before removal.

Rocker Arm Assembly Note

1. Apply engine oil to the HLAs and the end of the valve stems.

2. Install the rocker arms to their original positions as before removal.

CONTAINER FILLED WITH ENGINE OIL

PLUNGER

CHECK BALL

01-10

ROUND BAR

ROUND BAR (APPROX. 1.0

mm {0.039 in} DIAMETER)

bpe2ue00000067

OIL

VALVE STEM

HLA

VALV E

bpe2ue00000068

01-10–63

Page 77

MECHANICAL

OIL

Camshaft Assembly Note

1. As shown in the figure, apply gear oil (SAE No. 90 or equivalent) or engine oil to the center area of each journal of the cylinder head.

Caution

• Apply 0.05 ml {0.05 cc, 0.003 in

} or less of oil to journal No.6.

JOURNAL NO.6

OIL

2. Apply gear oil (SAE No. 90 or equivalent) or engine oil to the following locations of each camshaft.

• Thrust surface of front journal

3. As shown in the figure, align the cam position of cylinder No.1 around top dead center (TDC) and

EXHAUST CAMSHAFT

INTAKE CAMSHAFT

place the camshafts on the cylinder head.

CYLINDER HEAD

bpe2ue00000069

bpe2ue00000070

01-10–64

Page 78

MECHANICAL

OIL

4. As shown in the figure, apply gear oil (SAE No. 90 or equivalent) or engine oil to the center area of each journal of the camshaft.

OIL

01-10

5. Apply adhesive agent (Loctite 962T) around journal No.6 of the cylinder head or the exhaustside rear camshaft cap.

Caution

• Verify that there is no adhesive agent on the journal.

Adhesive agent bead width

0.5—1.5 mm {0.02—0.05 in}

6. Install the camshaft caps in the marked number order, and temporarily tighten the camshaft cap installation bolts in two or three passes evenly.

CYLINDER HEAD AROUND JOURNAL NO.6

EXHAUST-SIDE REAR CAMSHAFT CAP

GROOVE

bpe1ze00000011

ADHESIVE

bpe2ue00000071

01-10–65

Page 79

MECHANICAL

7. Tighten the camshaft cap installation bolts in two steps in the order shown in the figure.

MARKED NUMBER

am3uuw00008996

Tightening torque

Step 1: 3.0—6.0 N·m {31—61 kgf·cm, 27—53 in·lbf} Step 2: 8—11 N·m {82—112 kgf·cm, 71—97 in·lbf}

Electric Variable Valve Timing Actuator, Hydraulic Variable Valve Timing Actuator Assembly Note

1. Align the knock pin on the end of the camshaft with the notch on the actuator (intake side) or

ELECTRIC VARIABLE VALVE TIMING ACTUATOR

knock pin installation hole (exhaust side), then install the actuator to the camshaft.

INTAKE CAMSHAFT

NOTCH

HYDRAULIC VARIABLE VALVE TIMING ACTUATOR

KNOCK PIN INSTALLATION HOLE

KNOCK PIN

EXHAUST CAMSHAFT

KNOCK PIN

bpe2ue00000072

01-10–66

Page 80

MECHANICAL

2. Hold the camshaft using a wrench on the cast hexagon, and tighten the actuator installation bolt.

Tightening torque

Electric variable valve timing actuator

(intake side): 102—114 N·m {10.5—11.6 kgf·m, 76—84 ft·lbf}

Hydraulic variable valve timing actuator

(exhaust side): 75—85 N·m {7.7—8.6 kgf·m, 56—62 ft·lbf}

01-10

End Of Sie

TIMING CHAIN ASSEMBLY

Caution

• When rotating the camshaft using a wrench on the cast hexagon, the wrench may contact the rocker arm and damage the rocker arm. To prevent damage to the rocker arm when holding the camshaft on the cast hexagon, use a wrench on the rear side of the engine as shown in the figure to secure a clearance between the cam.

CAMSHAFT

ROCKER ARM CONTACT

SECURE CLEARANCE

WRENCH

CAST HEXAGON

bpe2ue00000073

id011000505600

ENGINE REAR

Note

• Width at the cast hexagon of the camshaft is 22—24 mm {0.87—0.94 in}.

CAMSHAFT

DOES NOT CONTACT

CAST HEXAGON

22—24 mm {0.87

01-10–67

am3uuw00008968

—0.94 in}

am3uuw00009029

Page 81

1. Assemble in the order indicated in the table.

SEALANT

OIL

SEALANT

MECHANICAL

SEALANT

20—26 {2.1—2.6, 15—19}

SST

90—110 {9.2—11, 67—81}

+55—65

4.5—7.0 N·m {46—71 kgf·m, 40—61 ft·lbf}

8.0—9.0 N·m

9—12 N·m {92—122 kgf·m, 80—106 ft·lbf}

{82—91 kgf·m, 71—79 ft·lbf}

SEALANT

15—20

{1.6—2.0, 12—14}

SST

OIL

SEALANT

*1: 8—11 N·m {82—112 kgf·m, 71—97 ft·lbf}

1Key

20—30 {2.1—3.0, 15—22}

2 Oil pump drive sprocket 3 Oil pump chain guide

SST SST

01-10–68

SEALANT

38—46 {3.9—4.6, 29—33}

4 Oil pump driven sprocket

(See 01-10-69 Oil Pump Chain Assembly Note.)

N·m {kgf·m, ft·lbf}

bpe1ze00000068

Page 82

MECHANICAL

5Oil pump chain

(See 01-10-69 Oil Pump Chain Assembly Note.)

6 Balancer shaft sprocket

(See 01-10-69 Oil Pump Chain Assembly Note.)

7 Oil pump chain tensioner

(See 01-10-69 Oil Pump Chain Assembly Note.) 8 Crankshaft sprocket 9 Chain guide (No.2)

10 Timing chain

(See 01-10-71 Timing Chain Assembly Note.)

11 Chain guide (No.1)

(See 01-10-71 Timing Chain Assembly Note.)

12 Tensioner arm

(See 01-10-71 Timing Chain Assembly Note.)

13 Chain tensioner

(See 01-10-71 Timing Chain Assembly Note.)

14 Engine front cover

(See 01-10-74 Engine Front Cover Assembly Note.)

Oil Pump Chain Assembly Note

1. Verify that the key and knock pin are aligned to the positions shown in the figure.

• If they are not in the positions shown in the figure, rotate the crankshaft and balancer shaft (No.1) to set cylinder No.1 to top dead center (TDC).

2. Temporarily assemble the oil pump driven sprocket.

3. Temporarily tighten the oil pump driven sprocket installation bolt.

15 Oil pan

(See 01-10-77 Oil Pan Assembly Note.)

16 Electric variable valve timing motor/driver

(See 01-10-79 Electric Variable Valve Timing Motor/ Driver Assembly Note.)

17 Front oil seal

(See 01-10-80 Front Oil Seal Assembly Note.) 18 Crankshaft pulley 19 Crankshaft pulley lock bolt

(See 01-10-80 Crankshaft Pulley Lock Bolt Assembly

Note.) 20 Water pump pulley

(See 01-10-81 Water Pump Pulley Assembly Note.) 21 Spark plug 22 Oil shower pipe

(See 01-10-81 Oil Shower Pipe Assembly Note.) 23 Cylinder head cover

(See 01-10-82 Cylinder Head Cover Assembly Note.) 24 Dipstick

KEY

01-10

4. Align the oil pump chain alignment mark with the balancer shaft sprocket alignment mark.

BALANCER SHAFT (NO.1)

KNOCK PIN

bpe1ze00000070

BALANCER SHAFT SPROCKET ALIGNMENT MARK

OIL PUMP CHAIN ALIGNMENT MARK (ORANGE)

bpe1ze00000071

01-10–69

Page 83

MECHANICAL

5. Install the oil pump chain and balancer shaft sprocket as a single unit while aligning the alignment marks on each sprocket and oil pump chain as shown in the figure.

OIL PUMP CHAIN ALIGNMENT MARK (YELLOW)

OIL PUMP DRIVE SPROCKET ALIGNMENT MARK

BALANCER SHAFT SPROCKET ALIGNMENT MARK

OIL PUMP CHAIN ALIGNMENT MARK (ORANGE)

KEY

6. Temporarily tighten the balancer shaft sprocket installation bolt.

7. Install the oil pump chain tensioner.

Caution

• At this stage, do not remove the wire or paper clip installed to the oil pump chain tensioner.

8. Hold the crankshaft using the SST.

9. Tighten the oil pump driven sprocket installation bolt.

Tightening torque

20—30 N·m {2.1—3.0 kgf·m, 15—22 ft·lbf}

10. Tighten the balancer shaft sprocket installation bolt.

Tightening torque

38—46 N·m {3.9—4.6 kgf·m, 29—33 ft·lbf}

11. Remove the wire or paper clip installed to the oil pump chain tensioner and apply tension to the oil pump chain.

• If a new oil pump chain tensioner is used, remove the installed stopper.

bpe1ze00000072

49 E011 1A0

bpe1ze00000096

01-10–70

Page 84

MECHANICAL

Timing Chain Assembly Note

1. Verify that the timing marks and the key are aligned to the position shown in the figure.

TIMING CHAIN ALIGNMENT MARK

CYLINDER HEAD UPPER SURFACE

01-10

TIMING MARK

KEY

bpe5ue00000009

Note

• The timing mark of SKYACTIV-G 2.5 is not completely parallel with the upper surface of the cylinder head.

• If they are not in the position shown in the figure, rotate the camshaft and crankshaft to set the cylinder No.1

top dead center (TDC).

01-10–71

Page 85

MECHANICAL

2. Install the timing chain while aligning the marks on each sprocket and the timing chain as shown in the figure.

TIMING CHAIN ALIGNMENT MARK (ORANGE)

CYLINDER HEAD UPPER SURFACE

HYDRAULIC VARIABLE VALVE TIMING ACTUATOR TIMING CHAIN ALIGNMENT MARK

CRANKSHAFT SPROCKET TIMING CHAIN ALIGNMENT MARK

TIMING MARK

TIMING CHAIN ALIGNMENT MARK (YELLOW)

bpe1ze00000075

3. Install the tensioner arm.

4. Install the chain tensioner.

5. After installing the chain tensioner, remove the installed wire or paper clip, and then apply tension to the timing chain.

• If a new chain tensioner is used, remove the installed stopper.

6. Install the chain guide (No.1).

7. Verify that there is no looseness in the timing chain, and re-verify that each sprocket is in the specified location.

01-10–72

STOPPER

LINK PLATE

am3uuw00008861

Page 86

MECHANICAL

8. Rotate the crankshaft clockwise two turns and inspect the valve timing.

CYLINDER HEAD UPPER SURFACE

01-10

TIMING MARK

KEY

bpe5ue00000010

Note

• The timing mark of SKYACTIV-G 2.5 is not completely parallel with the upper surface of the cylinder head.

01-10–73

Page 87

MECHANICAL

Engine Front Cover Assembly Note

Note

• For a new engine front cover, the positioning pins in the two locations shown in the figure project to the outside of the engine.

1. If the engine front cover is newly replaced, tap the positioning pins in the two locations to the seal surface side.

2. Completely clean and remove any oil, dirt, sealant or other foreign matter that may be adhering to the engine front cover, cylinder head, and cylinder block.

3. When reusing the engine front cover installation bolts, clean any old sealant from the bolts.

VIEW FROM A

ENGINE OUTSIDE

POSITIONING PIN

SEAL SIDE

POSITIONING PIN

bpe1ze00000006

Caution

• Apply the silicon sealant in a single, unbroken line.

• To prevent silicone sealant from hardening, adhere the engine front cover to the cylinder block within 10 min. after silicone sealant is applied. Tighten the installation bolts completely soon after adhering.

• Using bolts with the old seal adhering could cause cracks in the cylinder head and cylinder block.

POSITIONING PIN

WOOD SLAB

OLD SEALANT

ENGINE OUTSIDE

SEAL SIDE

POSITIONING PIN

0—1 mm

0.03 in}

{0—

bpe1ze00000007

DAMAGE

bpe1ze00000008

01-10–74

Page 88

MECHANICAL

SEALANT

4. Apply silicone sealant to the engine front cover as shown in the figure.

10 {0.39}

SEALANT

01-10

10 {0.39}

90°

10 {0.39}

Bead thickness

A: 2—6 mm {0.1—0.2 in} B: 4—6 mm {0.16—0.23 in} C: 4—8 mm {0.2—0.3 in}

SECTION D-D

0.5—1.5 mm {0.02

—0.05 in}

10 {0.39}

SEALANT

32.5 {1.28}

10 {0.39}

ENGINE FRONT COVER

mm {in}

bpe1ze00000078

01-10–75

Page 89

MECHANICAL

SEALANT

5. Apply silicone sealant to the areas shown in the figure.

Caution

• Apply the silicone sealant so that it goes into the cylinder head gasket.

6. Install the engine front cover to the engine.

Note

• Temporarily install an appropriate bolt to the drive belt auto tensioner installation bolt hole to prevent: — A silicone sealant adhesion malfunction

in the drive belt auto tensioner installation bolt hole.

— A bolt mis-installation due to silicone

sealant hardening.

7. Prepare an appropriate M8 X 1.25 bolt (length 40

mm {1.6 in}).

Caution

• For the number 10 bolt of the tightening order, install the bolts with new washer.

CYLINDER HEAD

SEALANT

CYLINDER BLOCK

DRIVE BELT AUTO TENSIONER INSTALLATION BOLT HOLE

VIEW FROM A

SEALANT

CYLINDER HEAD GASKET

am3uuw00008866

01-10–76

am3uuw00008867

Page 90

MECHANICAL

8. Tighten the engine front cover installation bolts in the order shown in the figure.

15 19 2016

M8 x 1.25, LENGTH

40 mm {1.6 in}

1822

5 2

WASHER

bpe1ze00000079

Tightening torque

20—26 N·m {2.1—2.6 kgf·cm, 15—19 in·lbf}

9. Remove the bolt installed to the drive belt auto tensioner installation bolt hole when installing the drive belt auto tensioner.

Oil Pan Assembly Note

1. Completely clean and remove any oil, dirt, sealant or other foreign matter that may be adhering to the cylinder block and oil pan.

2. When reusing the oil pan installation bolts, clean any old sealant from the bolts.

01-10

Caution

• Apply the silicon sealant in a single, unbroken line around the whole perimeter.

• To prevent silicone sealant from hardening, adhere the oil pan to the cylinder block within 10 min.

after silicone sealant is applied. Tighten the installation bolts completely soon after adhering.

• Using bolts with the old seal adhering could cause cracks in the cylinder block.

DAMAGE

OLD SEALANT

am6zzw00002304

01-10–77

Page 91

MECHANICAL

SEALANT

3. Apply silicone sealant to the oil pan along the inside of the bolt holes as shown in the figure.

A-A SECTIONAL VIEW

Thickness

3.0—7.0 mm {0.12—0.27 in}

4. Install the oil pan using the following procedure: (1) Install the oil pan to the cylinder block. (2) Temporarily tighten the two bolts shown in the

figure.

SEALANT

CYLINDER BLOCK

0.5—1.5 mm {0.02—0.05 in}

SEALANT

OIL PAN

bpe5ue00000011

(3) Tighten the bolts in the order shown in the

figure.

Tightening torque

8—11 N·m {82—112 kgf·cm, 71—97 in·lbf}

BOLT

16 12

1115

BOLT

bpe1ze00000081

10 14

bpe1ze00000082

01-10–78

Page 92

MECHANICAL

Electric Variable Valve Timing Motor/Driver Assembly Note

1. Install a new O-ring to the O-ring installation groove of the engine front cover.

Caution

• To prevent damage to the electric variable valve timing motor/driver, do not apply excessive force (force of 100 N {10.2 kgf, 22.5 lbf} or more) to the shaded areas shown in the figure.

2. Install the electric variable valve timing motor/ driver using the following procedures.

Note

• The eccentric shaft on the electric variable valve timing actuator side can be rotated to the left and right.

• The electric variable valve timing motor/ driver can be assembled with the joint groove of the eccentric shaft in any position, and it will not lead to vehicle damage or performance reduction.

01-10

bpe1ze00000009

JOINT GROOVE

ECCENTRIC SHAFT

(1) Before installation, rotate the joint on the end

of the electric variable valve timing motor so that it is aligned to the joint groove on the electric variable valve timing actuator side.

(2) Engage the joint on the end of the electric

variable valve timing motor with the joint groove on the electric variable valve timing

actuator side. (3) Attach the seal surface. (4) Tighten the electric variable valve timing

motor/driver installation bolts.

Tightening torque

20—26 N·m {2.1—2.6 kgf·m, 15—19 ft·lbf}

ELECTRIC VALIABLE VALVE TIMING ACTUATOR

JOINT

ELECTRIC VARIABLE VALVE TIMING MOTOR/DRIVER

ELECTRIC VARIABLE VALVE TIMING ACTUATOR

am3uuw00009042

JOINT GROOVE

am3uuw00009043

01-10–79

Page 93

MECHANICAL

Front Oil Seal Assembly Note

1. Apply clean engine oil to the inner surface of a new front oil seal.

2. Insert the front oil seal into the engine front cover by hand.

3. Tap the oil seal in evenly using the SST and a

hammer.

Front oil seal press on amount

0—0.5 mm {0—0.019 in}

49 G028 205

VIEW FROM A

HAMMER

49 G028 205

FRONT OIL SEAL

ENGINE FRONT COVER

am3uuw00008830

Crankshaft Pulley Lock Bolt Assembly Note

1. Hold the crankshaft using the SST.

2. Tighten the crankshaft pulley lock bolt in the order shown in the following two steps.

Tightening procedure

Step 1: 90—110 N·m {9.2—11 kgf·m, 67—81

ft·lbf}

Step 2: 55—65°

SECTION B-B

ENGINE FRONT COVER

0—0.5 mm {0—0.019 in}

FRONT OIL SEAL

am3uuw00008831

49 E011 1A0

bpe1ze00000069

01-10–80

Page 94

MECHANICAL

Water Pump Pulley Assembly Note

Caution

1. Install the water pump pulley to the water pump and temporarily tighten the bolt.

2. Align the water pump pulley hole with the water pump hole as shown in the figure.

WATER PUMP

HOLEHOLE

WATER PUMP PULLEY

3. Insert an appropriate bolt (length 70 mm {2.8 in}) into the water pump hole shown in the figure and

WATER PUMP PULLEY

lock the water pump pulley against rotation.

4. Completely tighten the water pump pulley bolt to the specified torque.

Tightening torque

8—11 N·m {82—112 kgf·cm, 71—97 in·lbf}

01-10

bpe2ue00000081

5. Remove the bolt used for locking the water pump pulley against rotation.

Oil Shower Pipe Assembly Note

1. Install the oil shower pipe in the order shown in the figure.

BOLT

am3uuw00008874

2 3

OIL SHOWER PIPE

am3zzw00012759

01-10–81

Page 95

MECHANICAL

Tightening torque

Installation position Tightening torque

1 9—12 N·m {92—122 kgf·cm, 80—106 in·lbf}

2, 3 8.0—9.0 N·m {82—91 kgf·cm, 71—79 in·lbf}

Cylinder Head Cover Assembly Note

Caution

• To assure the sealing performance of the cylinder head cover, be careful of the following: — Verify that the cylinder head cover gasket is inserted into the cylinder head cover groove and

install the cylinder head cover.

— Completely clean and remove any oil, dirt, sealant or other foreign matter from the seal

surface.

• To prevent silicone sealant from hardening, adhere the cylinder head cover and the cylinder head within 10 min. after silicone sealant is applied. Tighten the installation bolts completely soon after adhering.

1. Insert a new cylinder head cover gasket into the cylinder head cover groove.

01-10–82

Page 96

MECHANICAL

SEALANT

2. Apply silicone sealant to the areas shown in the figure.

ENGINE FRONT SIDE

SEALANT

2—6 mm {0.1—0.2 in}

ENGINE FRONT COVER

4—5 mm {0.16—0.19 in}

CYLINDER HEAD

VIEW FROM A

3—13 mm {0.2—0.5 in}

01-10

3—13 mm {0.2—0.5 in}

SEALANT

2—6 mm {0.1—0.2 in}

ENGINE REAR SIDE

4—5 mm {0.16—0.19 in}

SEALANT

ENGINE FRONT

CYLINDER HEAD

COVER

ENGINE FRONT COVER MATCHING SURFACE

EXHAUST-SIDE REAR CAMSHAFT CAP

VIEW FROM B

2—6 mm {0.1—0.2 in}

EXHAUST-SIDE REAR CAMSHAFT CAP

2—6 mm {0.1—0.2 in}

3. Tighten the cylinder head cover bolts in the order shown in the figure.

Tightening torque

4.5—7.0 N·m {46—71 kgf·cm, 40—61 in·lbf}

End Of Sie

CYLINDER HEAD

bpe2ue00000082

38 7 4

6 2 51

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01-10–83

Page 97

Page 98

TECHNICAL DATA

01-50 TECHNICAL DATA

ENGINE TECHNICAL DATA . . . . . . . . . . 01-50–1

End of Toc

WM: ENGINE

ENGINE TECHNICAL DATA

Item Specification

OCV coil resistance 6.9—7.5 ohms [20°C {68°F}] Maximum distortion, head gasket side of the cylinder

head

Maximum distortion, manifold side

Maximum cutting length, manifold side

Standard valve seat contact width 1.37—1.84 mm {0.0540—0.0724 in} Valve seat angle 45°

Standard valve seat sinkage amount (Dimension L)

Standard valve head margin thickness

Standard valve length

Minimum valve length

Standard valve stem diameter

Minimum valve stem diameter

Standard valve guide inner diameter

Standard clearance between valve stem and guide

Maximum clearance between valve stem and guide 0.10 mm {0.0039 in}

Standard valve guide projection height

Valve spring installation height

Maximum valve spring off-square

Maximum camshaft runout 0.030 mm {0.0012 in}

Standard cam height

Minimum cam height

Standard camshaft journal diameter 24.96—24.98 mm {0.9827—0.9834 in} Minimum camshaft journal diameter 24.93 mm {0.9815 in} Standard camshaft journal oil clearance 0.035—0.080 mm {0.0014—0.0031 in} Maximum camshaft journal oil clearance 0.090 mm {0.0035 in} Standard camshaft end play 0.07—0.22 mm {0.003—0.008 in} Maximum camshaft end play 0.23 mm {0.0091 in} Maximum distortion, head gasket side of the cylinder

block Standard cylinder bore diameter 89.000—89.030 mm {3.5040—3.5051 in}

Oil jet valve opening pressure Standard piston outer diameter 88.965—88.995 mm {3.5026—3.5037 in}

Standard clearance between piston and cylinder 0.025—0.045 mm {0.0010—0.0017 in} Maximum clearance between piston and cylinder 0.066 mm {0.0026 in}

When pressurized with spring force of 228—252 N {23.3—25.6 kgf,

IN: 48.93—50.17 mm {1.927—1.975 in}

EX: 48.87—50.11 mm {1.925—1.972 in}

IN: 1.75—1.95 mm {0.0689—0.0767 in}

EX: 1.95—2.15 mm {0.0768—0.0846 in}

IN: 107.00—107.60 mm {4.2127—4.2362 in}

EX: 117.09—117.69 mm {4.6099—4.6334 in}

IN: 5.470—5.485 mm {0.2154—0.2159 in}

EX: 5.465—5.480 mm {0.2152—0.2157 in}

IN: 5.510—5.530 mm {0.2170—0.2177 in}

EX: 5.510—5.530 mm {0.2170—0.2177 in}

IN: 0.025—0.060 mm {0.0010—0.0023 in}

EX: 0.030—0.065 mm {0.0012—0.0025 in}

IN: 16.4—17.0 mm {0.646—0.669 in}

EX: 16.4—17.0 mm {0.646—0.669 in}

51.3—56.6 lbf}, spring height is 38.0 mm {1.50 in}

180—220 kPa {1.84—2.24 kgf/cm

0.05 mm {0.002 in}

IN: 0.10 mm {0.0039 in}

EX: 0.05 mm {0.002 in}

IN: Cutting not authorized

EX: 0.20 mm {0.0079 in}

IN: 106.78 mm {4.2039 in}

EX: 116.87 mm {4.6012 in}.

IN: 5.424 mm {0.2135 in}

EX: 5.419 mm {0.2133 in}

IN: 2.0 ° (1.7 mm {0.067 in})

EX: 2.0 ° (1.7 mm {0.067 in})

IN: 42.34 mm {1.667 in}

EX: 40.37 mm {1.589 in}

IN: 42.27 mm {1.664 in}

EX: 40.30 mm {1.587 in}

0.10 mm {0.0039 in}

, 26.2—31.9 psi}

id015000800100

01-50

01-50–1

Page 99

TECHNICAL DATA

Item Specification

Standard clearance between piston ring and ring groove

Maximum clearance between piston ring and ring groove

Standard piston ring end gap

Maximum piston ring end gap

Standard piston pin outer diameter 20.995—21.000 mm {0.82658—0.82677 in} Standard piston pin hole diameter 21.004—21.008 mm {0.82693—0.82708 in} Standard clearance between piston pin hole diameter

and piston pin outer diameter Standard connecting rod small end inner diameter 21.002—21.013 mm {0.82686—0.82728 in} Standard clearance between connecting rod small end

inner diameter and piston pin outer diameter Maximum connecting rod bending 0.050 mm {0.0020 in} Maximum connecting rod distortion 0.050 mm {0.0020 in} Connecting rod center-to-center distance 154.8 mm {6.094 in} Standard side clearance at the large end of

connecting rod Maximum side clearance at the large end of

connecting rod Standard bearing oil clearance at the large end of the

connecting rod Maximum bearing oil clearance at the large end of the

connecting rod

Connecting rod bearing size

Standard crankshaft end play 0.08—0.29 mm {0.004—0.011 in} Maximum crankshaft end play 0.30 mm {0.012 in}

Thrust bearing size

Maximum main journal runout 0.10 mm {0.0039 in} Standard main journal diameter 49.980—50.000 mm {1.9678—1.9685 in} Maximum main journal off-round 0.005 mm {0.0002 in} Standard crank pin diameter 49.980—50.000 mm {1.9678—1.9685 in} Maximum crank pin off-round 0.005 mm {0.0002 in} Standard main journal oil clearance 0.016—0.039 mm {0.0007—0.0015 in} Maximum main journal oil clearance 0.084 mm {0.0033 in}

Main bearing size

Dual-mass flywheel guide pin projection maximum amount

Dual-mass flywheel maximum runout 1.5 mm {0.059 in} Standard cylinder head bolt length 145.2—145.8 mm {5.717—5.740 in} Maximum cylinder head bolt length 146.5 mm {5.768 in} Standard connecting rod bolt length 43.7—44.3 mm {1.73—1.74 in} Maximum connecting rod bolt length 45.0 mm {1.77 in} Rear oil seal press on amount 0—0.5 mm {0—0.019 in} Front oil seal press on amount 0—0.5 mm {0—0.019 in}

Top: 0.04—0.08 mm {0.002—0.003 in}

Second: 0.03—0.07 mm {0.0012—0.0027 in}

Oil: 0.04—0.12 mm {0.002—0.004 in}

Top: 0.12 mm {0.0047 in}

Second: 0.10 mm {0.0039 in}

Oil: 0.17 mm {0.0067 in}

Top: 0.13—0.18 mm {0.0052—0.0070 in}

Second: 0.18—0.28 mm {0.008—0.011 in}

Oil (Rail): 0.10—0.35 mm {0.004—0.013 in}

Top: 0.35 mm {0.014 in}

Second: 0.45 mm {0.018 in}

Oil (Rail): 0.52 mm {0.020 in}

0.004—0.013 mm {0.0002—0.0005 in}

0.002—0.018 mm {0.00008—0.00070 in}

0.14—0.36 mm {0.006—0.014 in}

0.465 mm {0.0183 in}

0.026—0.052 mm {0.0011—0.0020 in}

0.10 mm {0.0039 in}

STD: 1.502—1.519 mm {0.05914—0.05980 in} OS 0.25: 1.628—1.631 mm {0.06410—0.06421 in} OS 0.50: 1.753—1.756 mm {0.06902—0.06913 in}

STD: 2.500—2.550 mm {0.0985—0.1003 in}

OS 0.25: 2.625—2.675 mm {0.1034—0.1053 in}

STD: 2.489—2.510 mm {0.0980—0.0988 in} OS 0.25: 2.614—2.617 mm {0.10292—0.10303 in} OS 0.50: 2.739—2.742 mm {0.10784—0.10795 in}

11.0—12.0 mm {0.434—0.472 in}

End Of Sie

01-50–2

Page 100

SERVICE TOOLS

01-60 SERVICE TOOLS

ENGINE SST . . . . . . . . . . . . . . . . . . . . . . 01-60–1

End of Toc

SOKYU_WM: ENGINE

ENGINE SST

1: Mazda SST number 2: Global SST number

Example

1: 49 E011 1A0 2: –

Ring gear brake set

id016000119200

01-60

1: 49 L010 1A0 2: –

Engine hanger set

1: 49 0636 100B 2: –

Valve spring lifter arm

1: 49 S120 710 2: –

Coupling flange holder

1: 49 B012 015 2: –

Valve guide installer

1: 49 G028 205 2: –

Oil seal installer

1: 49 0107 680A 2: –

Engine stand

1: 49 B012 0A2A 2: –

Pivot

1: 49 G033 102 2: –

Handle

1: 49 S033 101 2: –

Dust cover installer

1: 49 E011 1A0 2: –

Ring gear brake set

1: 49 S120 170 2: –

Valve seal remover

1: 49 1285 071 2: –

Bearing puller

1: 49 B012 016 2: –

Attachment

——

End Of Sie

01-60–1

Mazda SKYACTIV-G 2.5 Workshop Manual

Specifications and Main Features

Frequently Asked Questions

User Manual