Documente Academic
Documente Profesional
Documente Cultură
fm 1
Engine
Workshop
Manual
MZR 1.5
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.
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 mechanicalincluding
photocopying and recording and the use of
any kind of information storage and retrieval
systemwithout permission in writing.
Mazda Motor Corporation
HIROSHIMA, JAPAN
CONTENTS
Title
Section
GENERAL INFORMATION
00
ENGINE
01
WARNING(US).fm
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 Mazda Motor Corporation
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.
1993-1U-10F.book
GENERAL INFORMATION
00
SECTION
Toc
of SCT INFORMATION . . . . 00-00
GENERAL
Toc of SCT
00-00
GENERAL INFORMATION
UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-001
Conversion to SI Units
(Systme International d'Units) . . . . . 00-002
Rounding Off . . . . . . . . . . . . . . . . . . . . . 00-002
Upper and Lower Limits . . . . . . . . . . . . 00-002
HOW TO USE THIS MANUAL . . . . . . . . . 00-002
Range of Topics . . . . . . . . . . . . . . . . . . 00-002
Service Procedure . . . . . . . . . . . . . . . . 00-002
Symbols . . . . . . . . . . . . . . . . . . . . . . . . 00-003
Advisory Messages. . . . . . . . . . . . . . . . 00-004
ELECTRICAL SYSTEM . . . . . . . . . . . . . . 00-005
Connectors . . . . . . . . . . . . . . . . . . . . . . 00-005
ABBREVIATIONS. . . . . . . . . . . . . . . . . . . 00-006
FUNDAMENTAL PROCEDURES. . . . . . . 00-006
00-006
00-006
00-007
00-007
00-007
00-007
00-008
00-008
00-008
00-009
00-009
00-009
00-009
End of Toc
NG: GENERAL INFORMATION
00-001
00-00
1993-1U-10F.book
GENERAL INFORMATION
UNITS
Electric current
Electric power
Electric resistance
Electric voltage
Length
Negative pressure
Positive pressure
Number of
revolutions
Torque
Volume
Weight
id000000100400
A (ampere)
W (watt)
ohm
V (volt)
mm (millimeter)
in (inch)
kPa (kilo pascal)
mmHg (millimeters of mercury)
inHg (inches of mercury)
kPa (kilo pascal)
kgf/cm2 (kilogram force per square
centimeter)
psi (pounds per square inch)
rpm (revolutions per minute)
Nm (Newton meter)
kgfm (kilogram force meter)
kgfcm (kilogram force centimeter)
ftlbf (foot pound force)
inlbf (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)
End Of Sie
WM: GENERAL INFORMATION
00-002
1993-1U-10F.book
GENERAL INFORMATION
HOW TO USE THIS MANUAL
id000000000100
Range of Topics
This manual contains procedures for performing all required service operations. The procedures are divided
into the following five basic operations:
Removal/Installation
Disassembly/Assembly
Replacement
Inspection
Adjustment
Simple operations which can be performed easily just by looking at the vehicle (i.e., removal/installation of
parts, jacking, vehicle lifting, cleaning of parts, and visual inspection) have been omitted.
Service Procedure
Inspection, adjustment
Inspection and adjustment procedures are
divided into steps. Important points regarding the
location and contents of the procedures are
explained in detail and shown in the illustrations.
49 1232 670A
49 H002 671
49 H032 322
SHOWS TIGHTENING
TORQUE
SPECIFICATIONS
Caution
Connect the gauge set from under
the vehicle to prevent contact with
the drive belt and the cooling fan.
WGIWXX0009E
00-003
00-00
1993-1U-10F.book
GENERAL INFORMATION
Repair procedure
1. Most repair operations begin with an overview illustration. It identifies the components, shows how the parts fit
together, and describes visual part inspection. However, only removal/installation procedures that need to be
performed methodically have written instructions.
2. Expendable parts, tightening torques, and symbols for oil, grease, and sealant are shown in the overview
illustration. In addition, symbols indicating parts requiring the use of special service tools or equivalent are also
shown.
3. Procedure steps are numbered and the part that is the main point of that procedure is shown in the illustration
with the corresponding number. Occasionally, there are important points or additional information concerning a
procedure. Refer to this information when servicing the related part.
SHOWS SERVICE
ITEM (S)
Procedure
1
"Removal/Installation"
Portion
"Inspection After
Installation" Portion
12 SST
10
GREASE
SHOWS SPECIAL
SERVICE TOOL (SST)
FOR SERVICE OPERATION
SST
SHOWS APPLICATION
POINTS OF GREASE, ETC.
SHOWS TIGHTENING
TORQUE
SPECIFICATIONS
SST
SHOWS DETAILS
6
SST
94116 {9.511.9, 6986}
GREASE
SHOWS THERE
ARE REFERRAL
NOTES FOR SERVICE
1
2
3
4
5
6
SHOWS TIGHTENING
TORQUE UNITS
Nm {kgfm, ftlbf}
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)
7
8
9
10
11
12
Split pin
Nut
Upper trailing link ball joint
(See 02-14-5 Upper Trailing Link Ball Joint Removal Note)
Nut
Upper trailing link
Dust boot (upper trailing link)
49 T028 304
49 T028 305
SHOWS SPECIAL
SERVICE TOOL (SST)
NO.
KNUCKLE
49 T028 303
SHOWS REFERRAL
NOTES FOR
SERVICE
BHE0000W104
00-004
1993-1U-10F.book
GENERAL INFORMATION
Symbols
There are eight symbols indicating oil, grease, fluids, sealant, and the use of SST or equivalent. These symbols
show application points or use of these materials during service.
Symbol
Meaning
Kind
Apply oil
New appropriate
engine oil or gear
oil
New appropriate
brake fluid
Apply automatic
transaxle/
transmission fluid
New appropriate
automatic
transaxle/
transmission fluid
Apply grease
Appropriate
grease
Apply sealant
Appropriate
sealant
Apply petroleum
jelly
Appropriate
petroleum jelly
Replace part
O-ring, gasket,
etc.
SST
Use SST or
equivalent
Appropriate tools
OIL
BRAKE
FLUID
ATF
GREASE
SEALANT
00-00
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
00-005
1993-1U-10F.book
GENERAL INFORMATION
ELECTRICAL SYSTEM
Connectors
Disconnecting connectors
When disconnecting connector, grasp the
connectors, not the wires.
id000000000500
GOOD
NO GOOD
CHU0000W014
WGIWXX0042E
Locking connector
When locking connectors, listen for a click
indicating they are securely locked.
WGIWXX0043E
00-006
1993-1U-10F.book
GENERAL INFORMATION
Inspection
When a tester is used to inspect for continuity or
measuring voltage, insert the tester probe from
the wiring harness side.
Inspect the terminals of waterproof connectors
from the connector side since they cannot be
accessed from the wiring harness side.
GOOD
NO GOOD
00-00
Caution
To prevent damage to the terminal, wrap
a thin wire around the tester probe before
inserting into terminal.
CHU0000W011
End Of Sie
GOOD
NO GOOD
CHU0000W012
ABBREVIATIONS
ATX
CMP
EX
IN
MTX
OCV
OS
SST
STD
TDC
id000000010100
Automatic Transaxle
Camshaft Position
Exhaust
Intake
Manual Transaxle
Oil Control Valve
Over Size
Special Service Tool
Standard
Top Dead Center
End Of Sie
GAIHAN: -
00-007
1993-1U-10F.book
GENERAL INFORMATION
FUNDAMENTAL PROCEDURES
id000000750100
CHU0014W003
WGIWXX0024E
Disassembly
If the disassembly procedure is complex,
requiring many parts to be disassembled, all parts
should be marked in a place that will not affect
their performance or external appearance and
identified so that reassembly can be performed
easily and efficiently.
WGIWXX0027E
WGIWXX0028E
00-008
1993-1U-10F.book
GENERAL INFORMATION
Arrangement of Parts
All disassembled parts should be carefully
arranged for reassembly.
Be sure to separate or otherwise identify the parts
to be replaced from those that will be reused.
00-00
WGIWXX0029E
Cleaning of Parts
All parts to be reused should be carefully and
thoroughly cleaned in the appropriate method.
Warning
Using compressed air can cause dirt and
other particles to fly out causing injury to
the eyes. Wear protective eye wear
whenever using compressed air.
WGIWXX0030E
Reassembly
Standard values, such as torques and certain
adjustments, must be strictly observed in the
reassembly of all parts.
If removed, the following parts should be replaced
with new ones:
Oil seals
Gaskets
O-rings
Lockwashers
Cotter pins
Nylon nuts
WGIWXX0031E
Depending on location:
Sealant and gaskets, or both, should be
applied to specified locations. When sealant
is applied, parts should be installed before
sealant hardens to prevent leakage.
Oil should be applied to the moving
components of parts.
Specified oil or grease should be applied at
the prescribed locations (such as oil seals)
before reassembly.
CHU0014W006
00-009
1993-1U-10F.book
10
GENERAL INFORMATION
Adjustment
Use suitable gauges and testers when making
adjustments.
CHU0014W005
WGIWXX0034E
Hose Clamps
When reinstalling, position the hose clamp in the
original location on the hose and squeeze the
clamp lightly with large pliers to ensure a good fit.
WGIWXX0035E
Torque Formulas
When using a torque wrench-SST or equivalent
combination, the written torque must be
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.
SST
3
1
0
2
3
Torque Unit
Nm
kgfm
kgfcm
ftlbf
inlbf
Formula
Nm [L/(L+A)]
kgfm [L/(L+A)]
kgfcm [L/(L+A)]
ftlbf [L/(L+A)]
inlbf [L/(L+A)]
00-0010
L
WGIWXX0036E
1993-1U-10F.book
11
GENERAL INFORMATION
Vise
When using a vise, put protective plates in the
jaws of the vise to prevent damage to parts.
End Of Sie
EN: GENERAL INFORMATION
00-00
PROTECTIVE PLATES
CHU0014W010
NEW STANDARDS
id000000157100
CMP sensor
CAC
CLS
CTP
CPP
CIS
CS sensor
CKP sensor
DLC
DTM
DTC
DI
DLI
EI
ECT
EM
EVAP
EGR
FC
FF
4GR
FSO solenoid
GEN
GND
HO2S
IAC
New Standard
Name
Accelerator Pedal
Air Cleaner
Air Conditioning
Barometric Pressure
Battery Positive Voltage
Brake Switch
Calibration Resistor
Camshaft Position Sensor
Charge Air Cooler
Closed Loop System
Closed Throttle Position
Clutch Pedal Position
Continuous Fuel Injection System
Control Sleeve Sensor
Crankshaft Position Sensor
Data Link Connector
Diagnostic Test Mode
Diagnostic Trouble Code(s)
Distributor Ignition
Distributorless Ignition
Electronic Ignition
Engine Coolant Temperature
Engine Modification
Engine Speed Input Signal
Evaporative Emission
Exhaust Gas Recirculation
Fan Control
Flexible Fuel
Fourth Gear
Fuel Pump Relay
Fuel Shut Off Solenoid
Generator
Ground
Heated Oxygen Sensor
Idle Air control
IDM Relay
Incorrect Gear Ratio
Injection Pump
Input/Turbine Speed Sensor
Abbrevi-ation
Vb
CSP sensor
FCV
FIP
Previous Standard
Name
Accelerator Pedal
Air Cleaner
Air Conditioning
Atmospheric Pressure
Battery Voltage
Stoplight Switch
Corrected Resistance
Crank Angle Sensor
Intercooler
Feedback System
Fully Closed
Idle Switch
Clutch Position
Control Sleeve Position Sensor
Crank Angle Sensor 2
Diagnosis Connector
Test Mode
Service Code(s)
Spark Ignition
Direct Ignition
Electronic Spark Ignition
Water Thermo
Engine Modification
Engine RPM Signal
Evaporative Emission
Exhaust Gas Recirculation
Fan Control
Flexible Fuel
Overdrive
Circuit Opening Relay
Fuel Cut Valve
Alternator
Ground/Earth
Oxygen Sensor
Idle Speed Control
Spill Valve Relay
Remark
#6
#6
#1
#2
#3
#6
With heater
#6
#6
00-0011
1993-1U-10F.book
12
GENERAL INFORMATION
Abbrevi-ation
IAT
KS
MIL
MAP
MAF sensor
MFL
OBD
OL
OC
O2S
PNP
PSP
PCM
PAIR
AIR
SAPV
SFI
New Standard
Name
Intake Air Temperature
Knock Sensor
Malfunction Indicator Lamp
Manifold Absolute Pressure
Mass Air Flow Sensor
Multiport Fuel Injection
On-Board Diagnostic
Open Loop
Output Speed Sensor
Oxidation Catalytic Converter
Oxygen Sensor
Park/Neutral Position
PCM Control Relay
Power Steering Pressure
Powertrain Control Module
Pressure Control Solenoid
NE Sensor
Shift Solenoid B
TCM
TR
TC
VSS
VR
VAF sensor
WUTWC
WOT
Previous Standard
Name
Intake Air Thermo
Knock Sensor
Malfunction Indicator Light
Intake Air Pressure
Airflow Sensor
Multiport Fuel Injection
Diagnosis/Self-Diagnosis
Open Loop
Vehicle Speed Sensor 1
Catalytic Converter
Oxygen Sensor
Park/Neutral Range
Main Relay
Power Steering Pressure
Engine Control Unit
Line Pressure Solenoid Valve
3GR
TWC
TB
TP sensor
TCV
TCC
Abbrevi-ation
ECU
Shift Solenoid C
Third Gear
Three Way Catalytic Converter
Throttle Body
Throttle Position Sensor
Timer Control Valve
Torque Converter Clutch
Transmission (Transaxle) Control
Module
Transmission (Transaxle) Fluid
Temperature Sensor
Transmission (Transaxle) Range
Turbocharger
Vehicle Speed Sensor
Voltage Regulator
Volume Air Flow Sensor
Warm Up Three Way Catalytic
Converter
Wide Open Throttle
TCV
Reed Valve
Sequential Fuel Injection
12 Shift Solenoid Valve
Shift A Solenoid Valve
23 Shift Solenoid Valve
Shift B Solenoid Valve
34 Shift Solenoid Valve
3rd Gear
Catalytic Converter
Throttle Body
Throttle Sensor
Timing Control Valve
Lockup Position
ATF Thermo-sensor
Inhibitor Position
Turbocharger
Vehicle Speed Sensor
IC Regulator
Air flow Sensor
Catalytic Converter
Fully Open
Remark
#6
#4
Pulsed
injection
#6
Injection
with air
pump
#6
#5
00-0012
7(DQQM
ENGINE
01
SECTION
01-10
Toc
of SCT
MECHANICAL.
. . . . . . . . . . . . . 01-10
01-10
MECHANICAL
ENGINE OVERHAUL
SERVICE WARNING . . . . . . . . . . . . . . . 01-101
ENGINE
MOUNTING/DISMOUNTING . . . . . . . . . 01-102
Mounting . . . . . . . . . . . . . . . . . . . . . . . . 01-102
Dismounting . . . . . . . . . . . . . . . . . . . . . 01-103
TIMING CHAIN DISASSEMBLY. . . . . . . . 01-103
Crankshaft Pulley Installation Bolt
Disassembly Note . . . . . . . . . . . . . . . . 01-104
Engine Front Cover
Disassembly Note . . . . . . . . . . . . . . . . 01-104
Timing Chain Tensioner
Disassembly Note . . . . . . . . . . . . . . . . 01-104
CYLINDER HEAD DISASSEMBLY (I) . . . 01-105
Camshaft Sprocket, Variable Valve
Timing Actuator Disassembly Note . . . 01-106
Camshaft Cap Disassembly Note . . . . . 01-106
Tappet Disassembly Note . . . . . . . . . . . 01-106
Cylinder Head Disassembly Note . . . . . 01-106
CYLINDER HEAD
DISASSEMBLY (II) . . . . . . . . . . . . . . . . . 01-107
Valve Keeper Disassembly Note . . . . . . 01-108
Valve Seal Disassembly Note . . . . . . . . 01-108
CYLINDER BLOCK
DISASSEMBLY (I) . . . . . . . . . . . . . . . . . 01-108
Knock Sensor Disassembly Note . . . . . 01-1010
Drive Plate (ATX), Flywheel (MTX)
Disassembly Note . . . . . . . . . . . . . . . . 01-1010
Oil Filter Disassembly Note . . . . . . . . . . 01-1010
Oil Pan Disassembly Note. . . . . . . . . . . 01-1010
CYLINDER BLOCK
DISASSEMBLY (II) . . . . . . . . . . . . . . . . . 01-1010
Connecting Rod Cap
Disassembly Note . . . . . . . . . . . . . . . . 01-1011
Piston Pin Disassembly Note . . . . . . . . 01-1012
Lower Cylinder Block
Disassembly Note . . . . . . . . . . . . . . . . 01-1013
CYLINDER HEAD INSPECTION . . . . . . . 01-1014
VALVE SEAT INSPECTION/REPAIR . . . . 01-1015
VALVE, VALVE GUIDE INSPECTION . . . 01-1015
VALVE GUIDE REPLACEMENT . . . . . . . 01-1017
Removal . . . . . . . . . . . . . . . . . . . . . . . . 01-1017
Installation . . . . . . . . . . . . . . . . . . . . . . . 01-1017
VALVE SPRING INSPECTION . . . . . . . . . 01-1018
TAPPET INSPECTION . . . . . . . . . . . . . . . 01-1018
VARIABLE VALVE TIMING ACTUATOR
INSPECTION . . . . . . . . . . . . . . . . . . . . . 01-1019
01-1019
01-1019
01-1019
01-1020
01-1021
01-1021
01-1022
01-1023
01-1024
01-1026
01-1026
01-1027
01-1027
01-1031
01-1032
01-1033
01-1034
01-1036
01-1036
01-1036
01-1037
01-1037
01-1039
01-1039
01-1039
01-1039
01-1040
01-1040
01-1041
01-1041
01-1041
01-1042
01-1042
01-1043
01-1044
01-1044
01-1044
01-1046
01-101
7(DQQM
MECHANICAL
Engine Front Cover Assembly Note . . . 01-1046
Crankshaft Pulley Installation Bolt
Assembly Note . . . . . . . . . . . . . . . . . . 01-1048
End of Toc
ENGINE OVERHAUL SERVICE WARNING
EN: ENGINE COMPLETE
id011000503900
Warning
x Continuous exposure to USED engine oil has caused skin cancer in laboratory mice. Protect your
skin by washing with soap and water immediately after this work.
End Of Sie
ENGINE MOUNTING/DISMOUNTING
id011000507000
Mounting
1. Install the SSTs (arms) to the specified position
as shown, and hand-tighten the SST bolts.
49 L010 102
49 L010 106
bezuue00000001
49 L010 105
bezuue00000002
01-102
7(DQQM
MECHANICAL
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. Mount the engine on the SST.
Warning
x The self-locking brake system of the
engine stand may not be effective when
the engine is held in an unbalanced
position. This could lead to sudden, rapid
movement of the engine and the
mounting stand handle causing serious
injury. Never keep the engine in an
unbalanced position, and always hold the
rotating handle firmly when turning the
engine.
7. Remove the oil drain plug and drain the engine
oil.
8. Install the drain plug and a new washer.
49 L010 106
PARALLEL
49 L010 101
49 L010 102
49 L010 105
ENGINE
49 L010 104
bezuue00000003
Tightening torque
3041 Nm {3.14.1 kgfm, 2330 ftlbf}
Dismounting
1. Dismount in the reverse order of mounting.
End Of Sie
01-103
01-10
7(DQQM
MECHANICAL
TIMING CHAIN DISASSEMBLY
id011000505500
10
R
R
R
8
7
SST
9
5
11
R
12
16
15
13
14
bezuue00000004
1
2
3
4
5
6
7
8
9
Spark plug
Camshaft position (CMP) sensor
Cylinder head cover
Drive belt auto tensioner
Oil level gauge pipe
Oil control valve (OCV)
Idler pulley
OCV oil filter, plug
Crankshaft pulley
(See 01-10-4 Crankshaft Pulley Installation Bolt
Disassembly Note)
01-104
10
11
12
13
14
15
16
7(DQQM
MECHANICAL
Crankshaft Pulley Installation Bolt Disassembly Note
1. Lock the drive plate (ATX) or flywheel (MTX)
against rotation using the SST.
2. Remove the crankshaft pulley installation bolt.
49 E011 1A0
01-10
bezuue00000005
bezuue00000006
PLUNGER
LINK PLATE
bezuue00000007
01-105
7(DQQM
MECHANICAL
End Of Sie
WIRE OR
PAPER CLIP
bezuue00000009
id011000500400
1
R
2
6
7 R
B3E0110E025
.
01-106
7(DQQM
MECHANICAL
1
2
Water outlet
Camshaft sprocket, variable valve timing actuator
(See 01-10-6 Camshaft Sprocket, Variable Valve
Timing Actuator Disassembly Note)
Camshaft cap
(See 01-10-6 Camshaft Cap Disassembly Note)
4
5
6
7
Camshaft
Tappet
(See 01-10-6 Tappet Disassembly Note)
Cylinder head
(See 01-10-6 Cylinder Head Disassembly Note)
Cylinder head gasket
01-10
Camshaft Sprocket, Variable Valve Timing Actuator Disassembly Note
1. Hold the camshaft using a suitable wrench on the
cast hexagon as shown in the figure.
2. Loosen the camshaft sprocket installation bolt.
ADJ2224E077
14
20
16
18
4
3
1
9
11
19
17
15
13
5
B3E2224E008
01-107
7(DQQM
MECHANICAL
Cylinder Head Disassembly Note
1. Loosen the camshaft cap installation bolts in two to three passes in the order shown in the figure, and remove
them.
End Of Sie
10
B3E0110E024
id011000500500
SST
B3E0110E026
.
1
2
3
Valve keeper
(See 01-10-8 Valve Keeper Disassembly Note)
Upper valve spring seat
Valve spring
01-108
4
5
Valve
Valve seal
(See 01-10-8 Valve Seal Disassembly Note)
7(DQQM
MECHANICAL
Valve Keeper Disassembly Note
1. Remove the valve keeper using the SSTs.
49 0636 100B
01-10
49 B012 0A2
b3e0110e124
End Of Sie
49 S120 170
VALVE SEAL
VALVE GUIDE
B3E0110E061
01-109
7(DQQM
MECHANICAL
CYLINDER BLOCK DISASSEMBLY (I)
id011000500600
7 SST
12
14
13
18
MTX
17
16
15
SST
3 SST
11
9 SST
1
6
10
bezuue00000102
.
1
2
3
4
5
6
7
Thermostat cover
Thermostat
Knock sensor
(See 01-10-10 Knock Sensor Disassembly Note)
Oil separator
Water pump
Oil pump
Drive plate (ATX), flywheel (MTX)
(See 01-10-10 Drive Plate (ATX), Flywheel (MTX)
Disassembly Note)
End plate
01-1010
9
10
11
12
13
14
15
16
17
18
Oil filter
(See 01-10-10 Oil Filter Disassembly Note)
Oil pan
(See 01-10-10 Oil Pan Disassembly Note)
Oil strainer
Oil pump cover
Inner rotor
Outer rotor
Plunger plug
Plunger spring
Control plunger
Oil pump body
7(DQQM
MECHANICAL
Knock Sensor Disassembly Note
1. Remove the knock sensor using the SST.
49 H018 001
01-10
bezuue00000103
49 E011 1A0
bez0je00000006
49 G014 001
OR COMMERCIALLY
AVAILABLE CUP-TYPE
OIL FILTER WRENCH
bezuue00000104
End Of Sie
bezuue00000105
01-1011
7(DQQM
MECHANICAL
CYLINDER BLOCK DISASSEMBLY (II)
id011000500700
4
10 R
5
R
13
14
12
6 SST
8
11
3
1
9
bezuue00000096
.
2
3
4
5
6
7
01-1012
8
9
10
11
12
13
14
15
Connecting rod
Lower cylinder block
(See 01-10-13 Lower Cylinder Block Disassembly
Note)
Rear oil seal
Lower main bearing
Crankshaft
Upper main bearing, thrust bearing
Oil jet valve
Upper cylinder block
7(DQQM
MECHANICAL
Connecting Rod Cap Disassembly Note
Caution
x When removing the connecting rod bearings and reusing them, put a paint mark showing the front
end and the journal number before the removal.
1. Inspect the connecting rod side clearance. (See
01-10-23 CONNECTING ROD INSPECTION.)
01-10
b3e0110e087
bezuue00000097
49 L011 006A
49 E011 001A
49 E011 002A
bezuue00000098
01-1013
7(DQQM
MECHANICAL
3. Insert the SST through the piston pin as shown in
the figure and assemble.
49 E011 002A
49 E011 001A
49 L011 006A
bezuue00000099
49 D011 002B
49 L011 001
bezuue00000100
01-1014
7(DQQM
MECHANICAL
Lower Cylinder Block Disassembly Note
Caution
x When removing the main bearing and reusing them, put a paint mark showing the front end and
the journal number before the removal.
1. Inspect the crankshaft end play. (See 01-10-24 CRANKSHAFT INSPECTION.)
2. Loosen the lower cylinder block installation bolts
in the order shown in the figure.
01-10
End Of Sie
2
12
11
16
15
20
19
6
10
9
17
18
8
3
4
13
14
bezuue00000101
1. Carry out the color contrast penetrate examination on the cylinder head surface.
x If there is a crack, 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.
x If it exceeds the maximum specification,
replace the cylinder head.
Cylinder head maximum distortion, head
gasket side
0.10 mm {0.0039 in}
b3e0110e008
bezuue00000010
End Of Sie
01-1015
7(DQQM
MECHANICAL
VALVE SEAT INSPECTION/REPAIR
id011000501300
SEAT CONTACT
WIDTH
bezuue00000014
':
+0
bezuue00000015
End Of Sie
bezuue00000016
id011000506200
MARGIN THICKNESS
bezuue00000017
01-1016
7(DQQM
MECHANICAL
2. Measure the length of each valve using the
vernier caliper.
x If it is less than the minimum specification,
replace the valve.
Valve length (Dimension L)
Standard
IN: 96.8097.40 mm {3.8123.834 in}
EX: 96.3096.90 mm {3.7923.814 in}
Minimum
IN: 96.58 mm {3.802 in}
EX: 96.08 mm {3.783 in}
01-10
b3e0110e068
X
Y
A
B
C
bezuue00000018
X
Y
A
C
bezuue00000019
VALVE STEM
VALVE GUIDE
CLEARANCE
bezuue00000020
01-1017
7(DQQM
MECHANICAL
6. Measure the projection height (dimension A) of
each valve guide using the vernier caliper.
x If not within the specification, replace the
valve guide. (See 01-10-17 VALVE GUIDE
REPLACEMENT.)
VALVE GUIDE
A
End Of Sie
CYLINDER HEAD
bezuue00000021
id011000501200
Removal
1. Remove the valve guide from the combustion
chamber side using the SST.
49 B012 015
VALVE GUIDE
bezuue00000022
Installation
1. Assemble the SSTs so that depth L is as
specified.
Depth L
12.212.8 mm {0.4810.503 in}
49 L012 004A
L
49 L012 003A
49 L012 002A
b3e0110e071
49 L012 003A
End Of Sie
49 L012 004A
49 L012 002A
VALVE GUIDE
bezuue00000023
01-1018
7(DQQM
MECHANICAL
VALVE SPRING INSPECTION
id011000501400
01-10
bezuue00000024
End Of Sie
LOWER
bezuue00000025
TAPPET INSPECTION
id011000505800
X
Y
bezuue00000026
B
X
bezuue00000027
01-1019
7(DQQM
MECHANICAL
End Of Sie
id011000506000
Caution
x Variable valve timing actuator cannot be disassembled because it is a precision unit.
1. Verify that the camshaft knock pin hole of the
rotor and the T-mark on the cover of the variable
valve timing actuator are aligned and placed at
the same position by rotating them by hand.
Caution
x If the camshaft knock pin hole and the Tmark are not aligned, rotate the rotor (the
camshaft installing part) until a click is
heard, and verify that they are fixed in
place.
x If the rotor is not secured even though their
camshaft knock pin hole and the T-mark are
aligned, replace the variable valve timing
actuator.
T-MARK
COVER
CAMSHAFT
KNOCK-PIN
HOLE
ROTOR
End Of Sie
ada2226e005
bezuue00000028
SPOOL VALVE
(MAXIMUM VALVE TIMING RETARD POSITION
b3e0110e090
Note
x When applying battery positive voltage
between the oil control valve (OCV) terminals, the connection of the positive and negative battery cable
can be with either of the oil control valve (OCV) terminals.
01-1020
7(DQQM
MECHANICAL
3. Stop applying battery positive voltage and verify
that the spool valve returns to the maximum valve
timing retard position.
x If it cannot be verified as shown in the figure,
replace the oil control valve (OCV).
VALVE TIMING
ADVANCE
VALVE TIMING
RETARD
End Of Sie
01-10
SPOOL VALVE
(MAXIMUM VALVE TIMING ADVANCE POSITION)
b3e0110e091
CAMSHAFT INSPECTION
id011000501500
b3e0110e074
b3e0110e076
B
A
Y
X
bezuue00000029
01-1021
7(DQQM
MECHANICAL
5. Measure the camshaft journal oil clearance using
a plastigauge with the tappet removed.
Note
x Clean the camshaft journal and the journal
receptacle part.
x Cut the plastigauge to the same length as
the journal width and position it in parallel to
the camshaft.
PLASTIGAUGE
bezuue00000030
End Of Sie
bezuue00000031
bezuue00000032
X
Y
End Of Sie
bezuue00000033
01-1022
7(DQQM
MECHANICAL
OIL JET VALVE INSPECTION
id011000505900
1. Apply 230 kPa {2.35 kgf/cm2, 33.4 psi} or more of compressed air to oil jet valve A and verify that air passes
through oil jet valve B.
x If air does not flow, replace the oil jet valve.
End Of Sie
$
01-10
#
bezuue00000107
bezuue00000034
b3e0110e081
01-1023
7(DQQM
MECHANICAL
4. Measure the piston ring end gap using a feeler
gauge.
x If if exceeds the maximum specification,
replace the piston ring.
Piston ring end gap
Standard
Top: 0.140.24 mm {0.00560.0094 in}
Second: 0.240.37 mm {0.0100.014 in}
Oil: 0.100.35 mm {0.0040.013 in}
Maximum
1.0 mm {0.039 in}
PISTON RING
bezuue00000035
#
$
%
&
;
adj2224e253
A
B
C
D
adj2224e255
End Of Sie
CONNECTING ROD INSPECTION
id011000502800
1. Install the connecting rod cap. (See 01-10-31 CYLINDER BLOCK ASSEMBLY (I).)
2. Measure the side clearance at the large end of
the connecting rod using a feeler gauge.
x If it exceeds the maximum specification,
replace the connecting rod or the crankshaft.
Side clearance at the large end of the
connecting rod
Standard
0.1100.292 mm {0.00440.0114 in}
Maximum
0.435 mm {0.0171 in}
b3e0110e087
01-1024
7(DQQM
MECHANICAL
3. Measure the oil clearance at the large end of the
connecting rod using a plastigauge.
x 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.
Note
x Cut the plastigauge as wide as the
connecting rod bearing width, place it
parallel to the crankshaft, keeping away from
the oil hole.
PLASTIGAUGE
01-10
bezuue00000036
adj2224e254
amj2224e255
End Of Sie
01-1025
7(DQQM
MECHANICAL
CRANKSHAFT INSPECTION
id011000502500
b3e0110e083
bezuue00000037
01-1026
B
X
b3e0110e085
7(DQQM
MECHANICAL
4. Inspect the main journal oil clearance using the
following procedure.
(1) Install the upper main bearing and crankshaft.
(2) Position a plastigauge on the journals.
(3) Install the lower main bearing and the lower
cylinder block.
(See 01-10-31 CYLINDER BLOCK
ASSEMBLY (I).)
(4) Remove the lower cylinder block.
(See 01-10-10 CYLINDER BLOCK
DISASSEMBLY (II).)
(5) Measure the main journal oil clearance.
x If it exceeds the maximum specification,
replace the main bearing or grind the
main bearing journal part and install the oversize bearing.
01-10
b3e0110e086
End Of Sie
BOLT INSPECTION
id011000503300
bezuue00000038
End Of Sie
OIL PUMP INSPECTION
id011000505300
01-1027
7(DQQM
MECHANICAL
2. Measure the clearance between the outer rotor
and the oil pump body using a feeler gauge.
x If it exceeds the maximum specification,
replace the outer rotor or oil pump, or both.
Body clearance between outer rotor and oil
pump body
Standard: 0.0900.175 mm {0.00360.0068
in}
Maximum: 0.20 mm {0.0079 in}
bezuue00000040
End Of Sie
bezuue00000024
id011000503500
1. Turn the crankshaft clockwise so that the No.1 piston is at TDC of the compression stroke.
2. Measure the valve clearance at A shown in the
A
B
A
figure.
x If not within the specification, replace the
tappet and adjust the valve to the median
EX
value. (See 01-10-27 VALVE CLEARANCE
ADJUSTMENT.)
Standard valve clearance [Engine cold]
0.270.33 mm {0.0110.012 in}
Note
x Make sure to note the measured values for
choosing the suitable replacement tappets.
NO.1
NO.2
NO.3
NO.4
IN
3. Rotate the crankshaft clockwise 360q so that the No.4 piston is at TDC of the compression stroke.
01-1028
adj2224e103
7(DQQM
MECHANICAL
4. Measure the valve clearance at B shown in the
figure.
x If not within the specification, replace the
tappet and adjust the valve to the median
value. (See 01-10-27 VALVE CLEARANCE
ADJUSTMENT)
Standard valve clearance [Engine cold]
0.270.33 mm {0.0110.012 in}
NO.1
NO.2
NO.3
NO.4
EX
IN
Note
x Make sure to note the measured values for
choosing the suitable replacement tappets.
01-10
B
adj2224e103
End Of Sie
VALVE CLEARANCE ADJUSTMENT
id011000503600
BLIND PLUG R
am3zzw0000629
BOLT
FRONT COVER
TENSIONER ARM
bezuue00000043
01-1029
7(DQQM
MECHANICAL
(1) Press down the link plate of the chain
tensioner from the service hole on the left
side using a thin flathead screwdriver
(precision screwdriver) as shown in the figure.
Then rotate the crank pulley backwards
(counterclockwise) with the plunger lock
released.
Note
x When the crankshaft pulley is turned
counterclockwise, the timing chain loosens
because the tensioner arm is pressed by the
timing chain and the plunger of the chain
tensioner is pressed in.
bezuue00000044
PLUNGER
LINK PLATE
bezuue00000045
RIB
RIB
Note
x When the timing chain loosens, the
tensioner arm moves to the position shown
in the figure and presses the M6 bolt to
secure the tensioner arm.
bezuue00000046
TENSIONER ARM
RIB
SERVICE HOLE
bezuue00000047
01-1030
7(DQQM
MECHANICAL
4. Fix the camshaft using a wrench on the cast
hexagon.
5. Remove the camshaft sprocket installation bolt.
01-10
bezuue00000048
bezuue00000049
12
10
18
14
20
16
4
3
5
1
9
11
19
17
15
13
5
bezuue00000050
TIMING MARK
TDC
bezuue00000051
01-1031
7(DQQM
MECHANICAL
1
15
13
19
17
7
18
6
Tightening torque
1214 Nm {123142 kgfcm, 107123
inlbf}
11
20
12
10
14
16
bezuue00000052
bezuue00000049
TIMING MARK
CYLINDER HEAD
UPPER SURFACE
bezuue00000053
am3zzw0000032
Tightening torque
3.06.0 Nm {3161 kgfcm, 2753 inlbf}
End Of Sie
BLIND PLUG R
am3zzw0000629
01-1032
7(DQQM
MECHANICAL
CYLINDER BLOCK ASSEMBLY (I)
id011000504000
01-10
11
10
OIL
OIL
SST
OIL
2
810 Nm
{82101 kgfcm,
7188 inlbf}
OIL
OIL
12
OIL
OIL
13
6
14
SEALANT
OIL
1
2
3
4
5
6
7
8
9
10
11
12
Piston pin
(See 01-10-34 Piston Pin Assembly Note)
Piston ring
(See 01-10-36 Piston Ring Assembly Note)
Piston, connecting rod component
(See 01-10-36 Piston, Connecting Rod Component
Assembly Note)
Upper connecting rod bearing
(See 01-10-36 Connecting Rod Bearing Assembly
Note)
01-1033
7(DQQM
MECHANICAL
13
14
5 {0.2}
MEASUREMENT
AREA
5 {0.2}
0.701.1
{0.028
0.043}
1.82.2
{0.0710.086}
1.92.3
{0.075
0.090}
1.92.3
{0.0750.090}
1.92.3
{0.075
0.090}
mm {in}
bezuue00000070
5 {0.2}
MEASUREMENT
AREA
5 {0.2}
1.92.3
{0.075
0.090}
2.452.85
{0.0970.112}
1.82.2 {0.0710.086}
1.92.3
{0.075
0.090}
1.92.3
{0.0750.090}
mm {in}
bezuue00000056
01-1034
7(DQQM
MECHANICAL
Lower Cylinder Block Assembly Note
Caution
x Install the lower cylinder block before the applied silicone sealant starts to harden.
1. Apply silicone sealant to the lower cylinder block
attachment side as shown in the figure.
2. Apply clean engine oil to the lower cylinder block
installation bolts A.
01-10
SEALANT
SEALANT
2.06.0 mm
{0.080.23 in}
bezuue00000057
9A
(1)Tightening torque
2426 Nm {2.52.6 kgfm, 1819 ftlbf}
(2)Tightening angle
42.5q47.5q
10 A
5A
6A
1 A
2A
4A
3A
8A
7A
bezuue00000058
Tightening torque
1925 Nm {2.02.5 kgfm, 1518 ftlbf}
B
10 B
6B
2B
4
3B
7 B
bezuue00000059
01-1035
7(DQQM
MECHANICAL
5. Loosen bolts A and tighten the lower cylinder
block installation bolts in two steps in the order
shown a second time.
9A
(1)Tightening torque
2426 Nm {2.52.6 kgfm, 1819 ftlbf}
(2)Tightening angle
42.5q47.5q
10 A
5A
6A
1 A
2A
4A
3A
8A
7A
bezuue00000058
49 E011 001A
49 L011 006A
49 E011 002A
bezuue00000063
49 D011 002B
L
49 L011 001
49 L011 005
bezuue00000064
3. Point the end mark on the connecting rod and Fmark on the piston in the same direction as
shown in the figure.
F-MARK
ALIGNMENT MARK
bezuue00000065
01-1036
7(DQQM
MECHANICAL
4. Insert the assembled piston pin and the SSTs into
the piston and the connecting rod.
49 L011 006A
PISTON PIN
01-10
49 E011 001A
bezuue00000066
49 L011 006A
PISTON PIN
PISTON
CONNECTING ROD
49 E011 001A
49 L011 005
49 L011 001
bezuue00000067
bezuue00000068
ENGINE
FRONT SIDE
PISTON
IDENTIFICATION
MARK
bezuue00000060
01-1037
7(DQQM
MECHANICAL
1. Position the end gap of each oil ring as shown in
the figure.
30
30
PISTON PIN AXIS
ENGINE FRONT
bezuue00000062
ENGINE FRONT
ROD SIDE
CAP SIDE
2.402.80 mm
{0.0950.110 in}
2.402.80 mm
{0.0950.110 in}
End Of Sie
01-1038
ENGINE FRONT
bezuue00000069
7(DQQM
MECHANICAL
CYLINDER BLOCK ASSEMBLY (II)
id011000504100
OIL
5.98.8 Nm
{6189 kgfcm,
5377 inlbf}
11
12
13
97103 R
{9.910, 7275}
SST
R
01-10
1
OIL
MTX
2
3
13
2739
{2.83.9,
2028}
1925
{2.02.5,
1518}
15
SST
16
R
810 Nm
{82101 kgfcm,
7188 inlbf}
17 SST
2034
{2.13.4, 1525}
8
R
1925
{2.02.5,
1518}
18
19
14
1925
{2.02.5,
1518}
10 SST
SEALANT
OIL
1215 Nm
{123152 kgfcm, 107132 inlbf}
810 Nm
{82101 kgfcm, 7188 inlbf}
Nm {kgfm, ftlbf}
bezuue00000071
1
2
3
4
5
7
8
9
10
11
12
13
14
15
16
17
18
19
01-1039
7(DQQM
MECHANICAL
Inner Rotor, Outer Rotor Assembly Note
1. Assemble the inner rotor and the outer rotor with
the punch marks aligned.
PUNCH MARK
bezuue00000072
Diameter
2.06.0 mm {0.080.23 in}
bezuue00000073
11
9
12
16
13
14
15
10
bezuue00000074
49 G014 001
OR COMMERCIALLY
AVAILABLE CUP-TYPE
OIL FILTER WRENCH
bezuue00000104
01-1040
7(DQQM
MECHANICAL
Rear Oil Seal Assembly Note
1. Apply clean engine oil to a new rear oil seal.
2. Insert the rear oil seal to the cylinder block by hand.
3. Install the rear oil seal using the SST.
01-10
49 E033 101
bezuue00000076
CYLINDER BLOCK
00.50 mm
{00.019 in}
49 E011 1A0
1
6
bezuue00000078
bezuue00000079
01-1041
7(DQQM
MECHANICAL
Knock Sensor Assembly Note
1. Install the knock sensor using the SST.
End Of Sie
49 H018 001
bezuue00000080
id011000504300
5 SST
4
3
SST
B3E0110E029
.
1
2
3
Valve seal
(See 01-10-41 Valve Seal Assembly Note)
Valve
Valve spring
01-1042
4
5
7(DQQM
MECHANICAL
Valve Seal Assembly Note
1. Press in the valve seal to the valve guide by hand.
2. Tap the SST shown in the figure using a plastic
hammer.
49 T032 302
VALVE
SEAL
01-10
B3E0110E123
End Of Sie
49 0636 100B
49 B012 0A2
b3e0110e124
01-1043
7(DQQM
MECHANICAL
CYLINDER HEAD ASSEMBLY (II)
id011000504400
OIL
7
1925
{2.02.5,
1518}
3
6
5060
{5.16.1,
3744}
1 R
Nm {kgfm, ftlbf}
bezuue00000081
.
1
2
3
4
01-1044
5
6
Camshaft cap
(See 01-10-44 Camshaft Assembly Note)
Camshaft sprocket, variable valve timing actuator
(See 01-10-44 Camshaft Sprocket, Variable Valve
Timing Actuator Assembly Note)
Water outlet
7(DQQM
MECHANICAL
Cylinder Head Assembly Note
1. Tighten the cylinder head installation bolts in
three steps in the order shown in the figure.
(1)Tightening torque
1822 Nm {1.92.2 kgfm, 1416 ftlbf}
(2)Tightening angle
85q95q
(3) Tightening angle
85q95q
01-10
10
bezuue00000082
15
13
19
17
7
18
6
Tightening torque
1214 Nm {123142 kgfcm, 107123
inlbf}
11
20
12
10
14
16
bezuue00000083
End Of Sie
bezuue00000084
01-1045
7(DQQM
MECHANICAL
TIMING CHAIN ASSEMBLY
id011000505600
810 Nm
{82101 kgfcm,
7188 inlbf}
1925
{2.02.5, 1518}
710 Nm
{72101 kgfcm,
6288 inlbf}
1522
{1.62.2, 1216}
16
14
15
R
SEALANT
R
R
810 Nm
{82101 kgfcm,
7188 inlbf}
11
3247
{3.34.7,
2434}
3851
{3.95.2,
2937}
3851
{3.95.2,
2937}
10
R SST
3851
{3.95.2,
2937}
OIL
8
SST
SEALANT
810 Nm
{82101 kgfcm,
7188 inlbf}
810 Nm
{82101 kgfcm,
7188 inlbf}
1925
{2.02.5, 1518}
12
157167
{16.117, 116123}
6
1925
{2.02.5, 1518}
5
1
1925
{2.02.5, 1518}
3
Nm {kgfm, ftlbf}
bezuue00000085
1
2
3
4
5
6
7
8
Key
Crankshaft sprocket
Timing chain
(See 01-10-46 Timing Chain Assembly Note)
Timing chain guide
Timing chain tensioner arm
Timing chain tensioner
Engine front cover
(See 01-10-46 Engine Front Cover Assembly Note)
Crankshaft pulley
(See 01-10-48 Crankshaft Pulley Installation Bolt
Assembly Note)
01-1046
9
10
11
12
13
14
15
16
7(DQQM
MECHANICAL
Timing Chain Assembly Note
1. Align the key groove of the crankshaft sprocket to
the timing mark, and then position the No.1
cylinder to TDC.
TIMING MARK
KEY GROOVE
01-10
bezuue00000086
TIMING MARK
CYLINDER HEAD
UPPER SURFACE
bezuue00000087
STOPPER
LINK PLATE
bezuue00000088
bezuue00000089
01-1047
7(DQQM
MECHANICAL
2. Tighten the engine front cover installation bolts in
the order shown in the figure.
x Install bolt (1) using a new seal washer.
Position
9
16, 8, 10, 1215, 17, 18
7, 11, 16
Tightening torque
810 Nm {82101 kgfcm,
7188 inlbf}
1925 Nm {2.02.5 kgfm,
1518 ftlbf}
3851 Nm {3.95.2 kgfm,
2937 ftlbf}
11
12
8
16
3
9
13
18
15
17
14
4
10
bezuue00000090
49 H010 401
bezuue00000091
ENGINE FRONT
COVER
00.50 mm
{00.019 in}
HAMMER
49 H010 401
FRONT OIL
SEAL
bezuue00000092
01-1048
7(DQQM
MECHANICAL
4. Install the oil filter to the plug and insert it in the
front cover as shown in the figure.
Tightening torque
3247 Nm {3.34.7 kgfm, 2434 ftlbf}
PLUG
FILTER
FRONT COVER
01-10
ALUMINUM WASHER
bezuue00000093
49 E011 1A0
Tightening torque
157167 Nm {16.117 kgfm, 116123
ftlbf}
bez0je00000066
SEALANT
Diameter
26 mm {0.10.2 in}
2.0 6.0 mm
{0.10.2 in}
SEALANT
Length
626 mm {0.31.0 in}
6 26 mm
{0.31.0 in}
FRONT COVER
MATING FACES
bezuue00000095
01-1049
7(DQQM
MECHANICAL
2. Tighten the cylinder head cover installation bolts
in the order shown in the figure.
Tightening torque
710 Nm {72101 kgfcm, 6288 inlbf}
3
7
End Of Sie
10
6
bezuue00000106
01-1050
1993-1U-10F.book
TECHNICAL DATA
01-50
TECHNICAL DATA
End of Toc
ENGINE TECHNICAL DATA
WM: ENGINE
Item
Cylinder head maximum distortion, head gasket side
Cylinder head maximum distortion, manifold side
Cylinder head maximum grinding, manifold side
Valve seat standard contact width
Valve seat angle
Valve seat standard sinkage amount (Dimension L)
Valve head standard margin thickness
id015000800100
Specification
0.10 mm {0.0039 in}
0.05 mm {0.002 in}
0.20 mm {0.0079 in}
0.81.4 mm {0.040.05 in}
45
39.25 mm {1.545 in}
1.62.0 mm {0.0630.078 in}
Standard
IN: 96.8097.40 mm {3.8123.834 in}
EX: 96.3096.90 mm {3.7923.814 in}
Minimum
IN: 96.58 mm {3.802 in}
EX: 96.08 mm {3.783 in}
Standard
IN: 5.4705.485 mm {0.21540.2159 in}
EX: 5.4655.480 mm {0.21520.2157 in}
Minimum
IN: 5.424 mm {0.2136 in}
EX: 5.419 mm {0.2134 in}
5.5105.530 mm {0.21700.2177 in}
Standard
IN: 0.0250.060 mm {0.00100.0023 in}
EX: 0.0300.065 mm {0.00120.0025 in}
Maximum
0.1 mm {0.004 in}
12.212.8 mm {0.4810.503 in}
27.5 mm {1.08 in} (pressing force 262.8 N {26.80 kgf, 59.08 lbf}
2.0 (3.45 mm {0.136 in})
30.030.025 mm {1.18121.1820 in}
29.95929.975 mm {1.17951.1801 in}
Standard
0.0250.066 mm {0.00100.0025 in}
Maximum
0.18 mm {0.0071 in}
6.97.9 ohms [20C {68F}]
0.03 mm {0.001 in}
Standard
IN: 41.373 mm {1.6289 in}
EX: 40.597 mm {1.5983 in}
Minimum
IN: 41.30 mm {1.626 in}
EX: 40.53 mm {1.596 in}
Standard
25.95025.975 mm {1.02171.0226 in}
Minimum
24.910 mm {0.98071 in}
Standard
0.0250.071 mm {0.00100.0027 in}
Maximum
0.090 mm {0.0035 in}
Standard
0.070.19 mm {0.0030.007 in}
Maximum
0.20 mm {0.0079 in}
01-501
01-50
1993-1U-10F.book
TECHNICAL DATA
Item
Cylinder block maximum distortion, head gasket side
Standard cylinder bore diameter
Piston outer diameter
Clearance between piston and cylinder
01-502
Specification
0.10 mm {0.0039 in}
78.00078.013 mm {3.07093.0713 in}
77.97077.980 mm {3.06973.0700 in}
Standard
0.0200.043 mm {0.00080.0016 in}
Maximum
0.070 mm {0.0028 in}
Standard
Top: 0.0350.065 mm {0.00140.0025 in}
Second: 0.0300.070 mm {0.00120.0027 in}
Oil: 0.0400.120 mm {0.00160.0047 in}
Maximum
Top, Second: 0.150 mm {0.0059 in}
Oil: 0.20 mm {0.0079 in}
Standard
Top: 0.140.24 mm {0.00560.0094 in}
Second: 0.240.37 mm {0.0100.014 in}
Oil: 0.100.35 mm {0.0040.013 in}
Maximum
1.0 mm {0.039 in}
18.98819.000 mm {0.747560.74803 in}
18.97418.980 mm {0.747010.74724 in}
0.0080.026 mm {0.00040.0010 in}
Standard
0.1100.292 mm {0.00440.0114 in}
Maximum
0.435 mm {0.0171 in}
Standard
0.0160.037 mm {0.00070.0014 in}
Maximum
0.10 mm {0.0039 in}
STD: 1.5091.524 mm {0.05940.0599 in}
OS 0.25: 1.6291.637 mm {0.06420.0644 in}
OS 0.50: 1.7291.737 mm {0.06810.0683 in}
18.94318.961 mm {0.745790.74649 in}
0.0370.013 mm {0.00140.0006 in}
0.050 mm {0.0020 in}[Per 50 mm {2.0 in}]
0.075 mm {0.0030 in}[Per 50 mm {2.0 in}]
140.60140.70 mm {5.5365.539 in}
STD: 2.5002.550 mm {0.09850.1003 in}
OS 0.25: 2.6252.675 mm {0.10340.1053 in}
OS 0.50: 2.7502.800 mm {0.10830.1102 in}
OS 0.75: 2.8752.925 mm {0.11320.1151 in}
Standard
0.0800.282 mm {0.00320.0111 in}
Maximum
0.30 mm {0.012 in}
0.10 mm {0.0039 in}
STD: 49.93849.956 mm {1.96611.9667 in}
OS 0.25: 49.68849.706 mm {1.95631.9569 in}
OS 0.50: 49.43849.456 mm {1.94641.9470 in}
0.050 mm {0.0020 in}
STD: 47.94047.956 mm {1.88751.8880 in}
OS 0.25: 47.69047.706 mm {1.87761.8781 in}
OS 0.50: 47.44047.456 mm {1.86781.8683 in}
0.10 mm {0.0039 in}
Standard
0.0190.038 mm {0.00080.0014 in}
Maximum
0.084 mm {0.0033 in}
1993-1U-10F.book
TECHNICAL DATA
Item
Main bearing thickness
Cylinder head bolt length
Connecting rod bolt length
Tip clearance between inner rotor and outer rotor
Body clearance between outer rotor and oil pump
body
Oil pump side clearance
Weight at which the plunger spring height is
compressed to 35.42 mm {1.394 in}
Standard valve clearance [Engine cold]
Specification
STD: 2.5082.529 mm {0.098750.09956 in}
OS 0.25: 2.6252.635 mm {0.10340.1037 in}
OS 0.50: 2.7502.760 mm {0.10830.1086 in}
Standard: 128.9129.5 mm {5.075 5.098 in}
Maximum: 130.2 mm {5.126 in}
Standard: 46.747.3 mm {1.841.86 in}
Maximum: 48.0 mm {1.89 in}
Standard: 0.020.18 mm {0.00080.0070 in}
Maximum: 0.20 mm {0.0079 in}
Standard: 0.0900.175 mm {0.00360.0068 in}
Maximum: 0.20 mm {0.0079 in}
Standard: 0.030.07 mm {0.00120.0027 in}
Maximum: 0.090 mm {0.0035 in}
62.568.9 N {6.387.02 kgf, 14.115.4 lbf}
0.270.33 mm {0.0110.012 in}
End Of Sie
01-503
01-50
1993-1U-10F.book
1993-1U-10E(01-60).fm 1
SERVICE TOOLS
01-60
SERVICE TOOLS
End of Toc
ENGINE SST
SOKYU_WM: ENGINE
id016000119200
1: 49 L010 1A0
2:
1: 49 E011 1A0
2:
Engine hanger
set
1: 49 B012 0A2
2:
1: 49 S120 170
2:
Pivot
Valve seal
remover
1: 49 H018 001
2:
1: 49 G014 001
2:
1: 49 L011
0A0C
2:
Knock sensor
wrench
1: 49 E011
001A
2:
1: 49 E011
002A
2:
Screw
Valve guide
installer
1: 49 L012
0A0B
2:
1: 49 E033 101
2:
1: 49 T032 302
2:
Dust cover
installer
Bearing installer
1: 49 0107
680A
2:
Engine stand
1: 49 0636
100B
2:
Valve spring
lifter arm
Piston pin
setting set
1: 49 B012 015
2:
01-601
01-60
1993-1U-10E(01-60).fm 2
SERVICE TOOLS
1: 49 H010 401
2:
Oil seal installer
End Of Sie
01-602