Documente Academic
Documente Profesional
Documente Cultură
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CAUTION DESCRIPTION
Disconnect the battery cables before doing any disas-
sembly and repair to the engine or parts of the elec- The Mazda engine is a four cylinder engine that has a
trical system. displacement of 1489 cm3 (90.8 in3). The firing order is
The diodes and resistors in the electrical system can 1–3–4–2. It is available with either a gasoline or an LPG
be damaged if the following cautions are not fol- fuel system. The number one cylinder is toward the end
lowed: of the engine with the cooling fan.
1 1
1. SPARK PLUG
2. EXHAUST MANIFOLD
3. DIPSTICK
4. ALTERNATOR
1
The overhead camshaft is driven by a chain. The cam- ing.
shaft operates the rocker arms that actuate the valves.
The pistons are aluminum alloy and have three piston
rings. Each of the two compression rings have a special
The crankshaft has five main bearings. The main bear- shape designed for its position on the piston. The third
ing in the center of the crankshaft is also the thrust bear- piston ring is the oil control ring.
REPAIRS
CYLINDER HEAD, CAMSHAFT AND 9. Remove the cylinder head capscrew that is below the
VALVE MECHANISM front of the camshaft as shown in FIGURE 3. Loosen
the remaining capscrews for the cylinder head in the se-
quence shown in FIGURE 4. Remove the capscrews.
Removal
1 5 9 8 4
3
1. SPACER
2. GEAR
2 3. SEAL
1
2
c. Remove the sprockets and chain for the oil pump.
1. CAMSHAFT Remove the timing chain and crankshaft sprock-
SPROCKET 2
2. TIMING CHAIN
et.
3. CRANKSHAFT d. Remove the guides for the timing chain. Remove
SPROCKET
the timing chain tensioner. See FIGURE 17.
Cleaning
1
WARNING
Cleaning solvents can be flammable and toxic and
3 can cause skin irritation. When using cleaning sol-
vents, always follow the solvent manufacturer’s rec-
ommended safety procedures.
Clean all of the parts in solvent. Make sure that all oil
passages are clean. Make sure all machined surfaces are
smooth.
FIGURE 5. TIMING CHAIN AND SPROCKETS Check the bottom surface of the cylinder head for distor-
tion. Use a straight edge and a thickness gauge. Do the
measurements at the positions shown in FIGURE 7. The
11. Lift the cylinder head from the block. maximum amount of distortion is 0.15 mm (0.0059 in).
When grinding the cylinder head, the maximum amount
12. Use a valve spring compressor and remove the valve of correction is 0.2 mm (0.008 in).
retainers, springs and valves from the head. See
FIGURE 6.
3
shafts. Clean the oil passages in the rocker shafts and
rocker arms. Check the clearance between the rocker A
arms and the rocker shafts. The maximum clearance is B
0.10 mm (0.004 in). The correct dimension for the inside C
diameter of a rocker arm is 19.000 to 19.033 mm (0.748 D
to 0.749 in). The correct dimension for the outside diam- 3
1
eter of a rocker shaft is 18.959 to 18.980 mm (0.746 to
0.747 in). If the parts do not meet specification, replace
the rocker arm(s) or the rocker shaft(s).
2
CAMSHAFT
1. FRONT JOURNAL
2. CENTER JOURNAL
3. REAR JOURNAL
Check the camshaft for cracks or damage.
FIGURE 9. CAMSHAFT INSPECTION
Measure the camshaft journals at four points A–D as
Check the movement of the camshaft in the cylinder
shown in FIGURE 9. The minimum dimensions for the
head. Install the supports for the rocker shafts. Install the
journals are as follows:
camshaft and thrust plate. Tighten the nut for the cam-
Front and Rear Journals – 41.949 to 41.965 mm
shaft to 69 to 79 N.m (51 to 58 lbf ft).Use a dial indicator
(1.651 to 1.652 in)
on the end of the camshaft as shown in FIGURE 8. The
Center Journal – 41.919 to 41.935 mm (1.650 to
maximum movement is 0.20 mm (0.008 in). Install a
1.651 in)
new thrust plate if the measurement is not correct.
Check the camshaft for being straight. Put the front and
rear journals in V blocks and rotate the camshaft one
complete turn. See FIGURE 10. The maximum amount
that the dial indicator can indicate is 0.05 mm (0.002 in).
4
any of the clearances are greater than 0.15 mm (0.0059 If replacement is necessary, use a tool to remove the
in), replace the cylinder head assembly. valve guide(s). Remove the seal from the valve guide,
then remove the valve guide.
Install a new camshaft when there is any damage or
when it does not meet specifications. To install a valve guide, install the retaining ring on the
valve guide. Use the tool and install the valve guide until
TIMING CHAIN AND SPROCKETS the retaining ring contacts the cylinder head. See
FIGURE 12. Install the seals on the valve guides.
Check the timing chain for loose or broken links. Check
the sprockets and chain guides for wear or damage. Use NOTE: The intake and exhaust valve guides are not the
new parts as necessary. same. Make sure the valve guides are installed correctly.
VALVE SEATS
EXHAUST
75°
FIGURE 11. MEASURE THE CLEARANCE FOR
THE CAMSHAFT
1.4 mm
VALVE GUIDES (0.055 in)
45°
Measure the clearance between the valve stems and the 45°
valve guides. Normal clearance is 0.018 to 0.055 mm
(0.0007 to 0.002 in). Replace the valve or valve guide
INTAKE
when the clearance is more than 0.20 mm (0.008 in).
75°
3
2 1.4 mm
1 (0.055 in)
15°
45°
5
valve seat is too deep and the cylinder head must be re- 2. Inspect the valves for cracks, burned faces and distor-
placed. tion. Inspect the seat face of the valves for wear and
damage. Measure the thickness of the valve head. See
The minimum thickness for an intake valve is 0.5 mm
(0.020 in). The minimum thickness for an exhaust valve
is 1.0 mm (0.040 in).
VALVES
1. DIAMETER
2. THICKNESS,
VALVE HEAD
Installation
1
1. Clean the surface of the cylinder head and the surface
of the block.
FIGURE 15. INSPECT THE VALVES a. Install the guides for the timing chain on the cylin-
der block. See FIGURE 17.
6
nut on the oil pump shaft to 30 to 34 N.m (22 to 25
1 lbf ft). Bend the lock washer on the nut.
1. CYLINDER BLOCK 1
2. GASKET
3. FRONT COVER
4. OIL SEAL 2
1. CHAIN GUIDE
1. TIMING MARK 1
2. POLISHED LINK
7
1. CAMSHAFT
2. TIMING CHAIN
3. TENSIONER 18
4. NUT 15
5. DRIVE GEAR 19
6. SPACER
7. SPROCKET
8. INTAKE VALVE 16
18
17
16 1
20
13 15
12
11
11
10
9 10
9 14
8
8. Install the spacer and distributor drive gear. Hold the 4. Remove the sprockets and chain for the oil pump. Re-
capscrew on the crankshaft pulley and tighten the nut for move the timing chain and crankshaft sprocket.
the camshaft to 69 to 79 N.m (51 to 58 lbf ft).
5. Remove the oil pump and strainer as an assembly.
9. Adjust the timing chain as follows:
6. Remove the caps for the connecting rods. Put a mark
a. See FIGURE 23. Remove the two access plugs. of identification on each cap so that they will be installed
Loosen the capscrew for the timing chain guide. to the same location.
b. Use a screwdriver and push on the chain guide 7. Before removing the crankshaft, measure the clear-
with a force of approximately 1 kg (2.2 lb) and ance between the crankshaft and the flange of the rear
tighten the capscrew. main bearing. See FIGURE 24. Push the crankshaft
fully forward before making the measurement. Normal
c. Install the access plugs. clearance is 0.08 to 0.242 mm (0.003 to 0.0095 in). The
maximum clearance is 0.30 mm (0.012 in). If the clear-
ance is greater than the specification, replace the thrust
bearing.
3 1
10. Adjust the valve clearance. 8. Put marks for identification on the bearing caps.
Loosen the capscrews for the main bearing caps in steps,
11. Use a silicone sealant on the half round seals in the
then remove the capscrews and the caps. Remove the
cylinder head. Install the seal in the cylinder head.
crankshaft. Remove the oil seal from the crankshaft. Re-
Install the gasket and the valve cover. Tighten the cap-
move the main bearings from the engine.
screws for the valve cover to 19 to 30 N.m (14 to 22 lbf
ft). Inspection And Repair
12. Install the distributor. CRANKSHAFT
CRANKSHAFT AND MAIN BEARINGS 1. Visually inspect the crankshaft for wear, cracks or
other damage. Replace the crankshaft if it has cracks.
Removal 2. Use a micrometer to measure the diameter of the jour-
nals for the crankshaft. See FIGURE 25. Make the
1. Remove the cylinder head. measurement at several locations for each journal. If the
2. Remove the crankshaft pulley. Remove the oil pan. measurements are less than specifications, grind the
crankshaft and install undersize bearings. The correct
3. Remove the front cover from the cylinder block. dimensions for the journals are as follows:
9
Main Journal Diameter – 49.938 to 49.956 mm 4. Check the passages for oil in the crankshaft. Make
(1.966 to 1.983 in) sure the passages are clean, with no restrictions.
2
1 4
10
the cylinder block. Tighten the capscrews for the front
cover to 19 to 26 N.m (14 to 19 lbf ft).
1
8. Use a silicone sealant on the oil pan and install the oil
pan. Tighten the capscrews to 7 to 9 N.m (5 to 7 lbf ft).
5. Install the key and sprocket for the timing chain on the WARNING
crankshaft. Install the timing chain on the sprocket so Cleaning solvents can be flammable and toxic and
that the polished link is aligned with the mark on the can cause skin irritation. When using cleaning sol-
sprocket. Install the camshaft sprocket in the timing vents, always follow the solvent manufacturer’s rec-
chain. Use a piece of wire or a tie strap to hold the ommended safety procedures.
sprocket in position on the timing chain. Make sure the
polished chain link is aligned with the timing mark on Clean all of the parts in solvent. Make sure that all oil
the sprocket. passages and grooves are clean. Make sure all machined
surfaces are smooth.
6. Install the key on the oil pump shaft. Install the chain
and sprockets for the oil pump. Tighten the nut on the oil Inspection And Repair
pump shaft to 30 to 34 N.m (22 to 25 lbf ft). Bend the
lock washer on the nut. PISTONS
7. Install the oil seal in the front cover. Install the baffle 1. Inspect the pistons for wear and cracks. Replace a pis-
on the crankshaft. Install the front cover and gaskets on ton that has damage.
11
Top Piston Ring – 0.20–0.40 mm (0.008–0.016 in)
FIGURE 28. MEASURING THE PISTON 2nd Piston Ring – 0.030–0.065 mm (0.0012–0.0026 in)
1
2
12
Assembly And Installation
1
1. “F” MARK
1. “F” MARK
2. OIL PORT
13
CYLINDER BLOCK Ring Gear
Repairs WARNING
Wear eye protection for this operation to prevent eye
injury from metal chips. You will be using a hammer
1. After the cylinder block is cleaned, check its surface and chisel to break the ring gear.
for distortion. See FIGURE 34. If the amount of distor-
tion is greater than 0.15 mm (0.0059 in), grind the sur- Before the ring gear is removed, check the position of
face of the cylinder block. the chamfer on the teeth.
1. Remove the capscrews for the flywheel, then remove 2. Install the flywheel on the crankshaft. Apply a thread
the flywheel and the drive plate. locking adhesive on the threads of the capscrews. then
install the capscrews and lock washers. Tighten the cap-
2. If necessary, remove the adapter plate. screws to 71 N.m (52 lbf ft).
14
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