Engine Mechanical - Overhaul - 2.0L & 2.3L: Diagnosis Mazda 3 BL

TROUBLE SHOOTING

To trouble shoot engine mechanical components, see ENGINE MECHANICAL in BASIC TROUBLE SHOOTING article in GENERAL INFORMATION.

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1. Install the SSTs (arms) to the cylinder block holes as shown, and hand-tighten the bolts (part No.: 9YA20-1003) or M10 x 1.5T length 90 mm {3.55 in} .
2. Assemble the SSTs (bolts, nuts and plate) to the specified positions.
3. Adjust the SSTs (bolts) so that less than 20 mm {0.79 in} of thread is exposed.
4. Make the SSTs (arms and plate) parallel by adjusting the SSTs (bolts and nuts).
5. Tighten the SSTs (bolts and nuts) to affix the SSTs firmly. WARNING: Self-locking brake system of the engine stand may not be effective when the engine is held in an unbalanced position. This could lead to sudden, rapid movement of the engine and mounting stand handle and cause serious injury. Never keep the engine in an unbalanced position, and always hold the rotating handle firmly when turning the engine.
6. Mount the engine on the SST (engine stand).
7. Drain the engine oil into a container.
8. Install the oil pan drain plug. With washer. Install the oil pan drain plug with a new washer. Tightening Torque 30-41 N.m {3.1-4.1 kgf.m, 23-30 ft.lbf} Without washer. Inspect the seal rubber of the oil pan drain plug and make sure there are no cracks or damage. - If necessary, replace the oil pan drain plug. Clean the flange surface (seal rubber) on the oil pan drain plug, then install the oil pan drain plug. Tightening Torque 22-30 N.m {2.2-3.1 kgf.m, 16-22 ft.lbf}

PISTON INSPECTION

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1. Measure the outer diameter of each piston at right angle 90° to the piston pin, 10.0 mm {0.40 in} above the under of the piston. If not within the specification, replace the piston, piston pin, piston ring and connecting rod as a single unit. Piston Diameter 87.465-87.495 mm {3.4435-3.4446 in}
2. Measure the piston-to-cylinder clearance. If not within the specification, replace the piston, piston pin, piston ring and connecting rod as a single unit. Standard Clearance 0.025-0.045 mm {0.0010-0.0017 in} Maximum Clearance 0.11 mm {0.0043 in}
3. Measure the piston ring-to-ring groove clearance around the entire circumference. If it exceeds the specification, replace the piston, piston pin, piston ring and connecting rod as a single unit. Standard Clearance Top: 0.03-0.08 mm {0.0012-0.0031 in} Second: 0.03-0.07 mm {0.0012-0.0027 in} Oil: 0.03-0.07 mm {0.0012-0.0027 in} Maximum Clearance Top: 0.17 mm {0.0067 in} Second, Oil: 0.15 mm {0.0059 in}
4. Insert the piston ring into the cylinder by hand and use the piston to push it to the bottom of the ring travel.
5. Measure each piston ring end gap with a feeler gauge. If it exceeds the specification, replace the piston, piston pin, piston ring and connecting rod as a single unit. Standard End Gap Top: 0.16-0.31 mm {0.0063-0.0122 in} Second: 0.33-0.48 mm {0.0130-0.0189 in} Oil (Rail): 0.20-0.70 mm {0.0079-0.0275 in} Maximum End Gap 1.0 mm {0.0393 in}

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1. Install the main bearing cap. (See «MAIN BEARING CAP ASSEMBLY NOTE»(ref-345199-S00426364482009102000000) .)
2. Measure the crankshaft end play. If it exceeds the specification, replace the thrust bearing or crankshaft so that the specified end play is obtained. Standard End Play 0.22-0.45 mm {0.0087-0.0177 in} Maximum End Play 0.55 mm {0.0216 in}
3. Remove the main bearing cap. (See «MAIN BEARING CAP DISASSEMBLY NOTE»(ref-345199-S14297890592009102000000) .)
4. Measure the crankshaft runout. If it exceeds the specification, replace the crankshaft. Maximum Runout 0.05 mm {0.0019 in}
5. Measure the journal diameter in X and Y directions at the two points (A and B) as indicated in the figure. If it exceeds the specification, replace the crankshaft or grind the journal and install the undersize bearing. MAIN JOURNAL BEARING SPECIFICATION Bearing Size (mm {in}) Standard Diameter (mm {in}) Standard 51.980-52.000 {2.0464-2.0472} 0.25 {0.01} 51.730-51.750 {2.0366-2.0373} Maximum Out-Of-Round 0.05 mm {0.0019 in} CRANK PIN Type Bearing Size (mm {in}) Standard Diameter (mm {in}) LF Standard 46.980-47.000 {1.8497-1.8503} LF 0.25 {0.01} Undersize 46.730-46.750 {1.8398-1.8405} L3 Standard 49.980-50.000 {1.9677-1.9685} L3 0.25 {0.01} Undersize 49.730-49.750 {1.9579-1.9586} Maximum Out-Of-Round 0.05 mm {0.0019 in}
6. Install the main bearing caps and crankshaft.
7. Position a plastigage atop the journals in the axial direction.
8. Install the main bearing caps and cylinder block. (See «MAIN BEARING CAP ASSEMBLY NOTE»(ref-345199-S00426364482009102000000) .)
9. Remove the main bearing caps. (See «MAIN BEARING CAP DISASSEMBLY NOTE»(ref-345199-S14297890592009102000000) .)
10. Measure the main journal oil clearance. If it exceeds the specification, replace the main bearing using the main bearing selection table or grind the main journal and install the oversize bearings so that the specified oil clearance is obtained. Standard Clearance 0.019-0.035 mm {0.0007-0.0013 in} Maximum Clearance 0.10 mm {0.0039 in} MAIN BEARING SPECIFICATIONS Bearing Size (mm {in}) Bearing Thickness (mm {in}) Standard 2.506-2.509 {0.0987-0.0988} 0.25 {0.01} Oversize 2.628-2.634 {0.1034-0.1037} 0.50 {0.02} Oversize 2.753-2.759 {0.1084-0.1086}

CONNECTING ROD INSPECTION

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1. Install the connecting rod cap. (See «CONNECTING ROD CAP ASSEMBLY NOTE»(ref-345199-S19996417982009102000000) .)
2. Measure the connecting rod large end side clearance. If it exceeds the specification, replace the piston, piston pin, piston ring and connecting rod as a single unit. Standard Clearance 0.14-0.36 mm {0.0056-0.0141 in} Maximum Clearance 0.435 mm {0.0172 in}
3. Remove the connecting rod cap.
4. Position plastigage atop the journals in the axial direction.
5. Install the connecting rod bearing and connecting rod cap. (See «CONNECTING ROD CAP ASSEMBLY NOTE»(ref-345199-S19996417982009102000000) .)
6. Remove the connecting rod cap.
7. Measure the connecting rod oil clearance. If it exceeds the specification, replace the connecting rod bearing or grind the crank pin and use oversize bearings so that the specified clearance is obtained. Standard Clearance 0.026-0.052 mm {0.0011-0.0020 in} Maximum Clearance 0.10 mm {0.0039 in}

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1. Measure the length of each bolt. If it exceeds the specification, replace the bolt. Length L

VARIABLE VALVE TIMING ACTUATOR INSPECTION [L3]

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1. Confirm that the groove of the rotor and notch of the cover at the variable valve timing actuator are aligned and fixed. If the notch and the bump are not aligned, rotate the rotor toward the valve timing retard position by hand until they are in place. If the rotor and cover are not fixed even though their notch and groove are aligned, replace the variable valve timing actuator.

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1. Disconnect the negative battery cable.
2. Disconnect the Oil Control Valve (OCV) connector.
3. Measure the resistance between terminals A and B using an ohmmeter. If not as specified, replace the Oil Control Valve (OCV). Specification 6.9-7.9 ohms [20 °C {68 °F}]
4. Connect the Oil Control Valve (OCV) connector.

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1. Disconnect the negative battery cable.
2. Remove the Oil Control Valve (OCV).
3. Verify that the spool valve in the Oil Control Valve (OCV) is in the maximum valve timing retard position as indicated in the figure. If it exceeds the specification, replace the Oil Control Valve (OCV).
4. Verify that the battery is fully charged. If it is less than specification, recharge the battery.
5. Apply battery positive voltage between the Oil Control Valve (OCV) terminals and verify that the spool valve operates and moves to the maximum valve timing advance position. If it exceeds the specification, replace the Oil Control Valve (OCV). NOTE: When applying battery positive voltage between the Oil Control Valve (OCV) terminals, the connection can be either of the following: Positive battery cable to terminal A, negative battery cable to terminal B Positive battery cable to terminal B, negative battery cable to terminal A
6. Stop applying battery positive voltage and verify that the spool valve returns to the maximum valve timing retard position. If it exceed the specification, replace the Oil Control Valve (OCV).

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1. Measure the valve clearance as follows: Turn the crankshaft clockwise so that the No.1 piston is at TDC of the compression stroke. NOTE: Make sure to note the measured values for choosing the suitable replacement tappets. Measure the valve clearance at A in the figure. If the valve clearance exceeds the standard, replace the tappet. (See «VALVE CLEARANCE ADJUSTMENT»(ref-345199-S10664598992009102000000) .) Standard [Engine Cold] IN: 0.22-0.28 mm {0.0087-0.0110 in} EX: 0.27-0.33 mm {0.0106-0.0130 in}
2. Turn the crankshaft 360° clockwise so that the No.4 piston is at TDC of the compression stroke.
3. Measure the valve clearance at B in the figure. If the valve clearance exceeds the standard, replace the tappet. (See «VALVE CLEARANCE ADJUSTMENT»(ref-345199-S10664598992009102000000) .) Standard [Engine Cold] IN: 0.22-0.28 mm {0.0087-0.0110 in} EX: 0.27-0.33 mm {0.0106-0.0130 in}

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1. Remove the engine front cover lower blind plug.
2. Remove the engine front cover upper blind plug.
3. Remove the cylinder block lower blind plug.
4. Install the SST as shown in the figure.
5. Turn the crankshaft clockwise so that the crankshaft is in the No.1 cylinder TDC position.
6. Loosen the timing chain. Using a suitable screwdriver or equivalent tool, unlock the chain tensioner ratchet. Turn the exhaust camshaft clockwise using a suitable wrench on the cast hexagon and loosen the timing chain. Placing the suitable bolt (M6 x 1.0 Length 25-35 mm {0.9-1.3 in}) at the engine front cover upper blind plug, secure the chain guide at the position where the tension is released.
7. Hold the exhaust camshaft using a suitable wrench on the cast hexagon as shown in the figure.
8. Remove the exhaust camshaft sprocket.
9. Loosen the camshaft cap bolts in several passes in the order shown in the figure.
10. Remove the camshaft.
11. Remove the tappet.
12. Select proper adjustment shim. New Adjustment Shim = Removed Shim Thickness + Measured Valve Clearance - Standard Valve Clearance (IN: 0.25 mm {0.0098 in}, EX: 0.30 mm {0.0118 in}) Standard [Engine Cold] IN: 0.22-0.28 mm {0.0087-0.0110 in} EX: 0.27-0.33 mm {0.0106-0.0130 in}
13. Install the camshaft with No.1 cylinder aligned with the TDC position.
14. Tighten the camshaft cap bolt using the following two steps. Tightening Torque (1)5.0-9.0 N.m {51.0-91.7 kgf.cm, 44.3-79.5 in.lbf} (2)14.0-17.0 N.m {1.5-1.7 kgf.m, 10.4-12.5 ft.lbf}
15. Install the exhaust camshaft sprocket. NOTE: Do not tighten the bolt for the camshaft sprocket during this step. First confirm the valve timing, then tighten the bolt.
16. Install the SST to the camshaft as shown in the figure.
17. Remove the M6 x 1.0 bolt from the engine front cover to apply tension to the timing chain.
18. Turn the crankshaft clockwise so that the crankshaft is in the No.1 cylinder TDC position.
19. Hold the exhaust camshaft using a suitable wrench on the cast hexagon as shown in the figure.
20. Tighten the exhaust camshaft sprocket lock bolt. Tightening Torque 69-75 N.m {7.1-7.6 kgf.m, 50.9-55.3 ft.lbf}
21. Remove the SST from the camshaft.
22. Remove the SST from the block lower blind plug.
23. Rotate the crankshaft clockwise two turns until the TDC position. If not aligned, loosen the crankshaft pulley lock bolt and repeat from Step 14 .
24. Install the new engine front cover upper blind plug. Tightening Torque 8.0-11.5 N.m {81.6-117.2 kgf.cm, 70.9-101.7 in.lbf}
25. Install the cylinder block lower blind plug. Tightening Torque 18-22 N.m {1.9-2.2 kgf.m, 13.3-16.2 ft.lbf}
26. Install the new engine front cover lower blind plug. Tightening Torque 10-14 N.m {1.1-1.4 kgf.m, 7.4-10.3 ft.lbf}

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1. Assemble in the order indicated in the figure.

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1. Install the main bearing caps in the order indicated in the figure. Tightening Torque (1) 44-46 N.mn {4.5-4.6 kgf.m, 32.5-33.9 ft.lbf} (2) 175°-185°

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1. Install the two oil control ring segments and spacer.
2. Verify that the second ring is installed with scraper face side downward.
3. Verify that the top ring is installed with scraper face side inner of upper.

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1. Position the end gap of each ring as indicated in the figure.
2. Insert the piston and connecting rod into the cylinder with the arrow mark to front of the engine.

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1. Install the connecting rod bearing to the connecting rod and connecting rod caps, as shown in the figure.