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

TAPPET DISASSEMBLY NOTE

Note. The tappets are numbered to make sure they are assembled in their original positions. When removed, keep the tappets with the cylinder head they were removed from. Do not mix the tappets.

Scheme 54

1. Loosen the cylinder head bolts in 2-3 passes in the order shown in the figure.

Scheme 55

1. Disassemble in the order indicated in the figure.

Scheme 56

1. Remove the valve keeper using the SSTs .

Scheme 57

1. Remove the valve seal using the SST .

Scheme 58

1. Disassemble in the order indicated in the figure.

Scheme 59

1. Hold the crankshaft using the SST .
2. Remove the bolts in several passes.

Scheme 60

1. Disassemble in the order indicated in the figure.

CONNECTING ROD CAP DISASSEMBLY NOTE

1. Inspect the connecting rod side clearance. (See «CONNECTING ROD INSPECTION»(ref-345199-S25537868402009102000000) .)
2. Remove the connecting rod bolt from the connecting rod cap by tapping the bolt with a plastic hammer.

Scheme 61

1. Inspect the crankshaft end play. (See «CRANKSHAFT INSPECTION»(ref-345199-S38624264092009102000000) .)
2. Loosen the main bearing cap bolts in two or three steps in the order shown in the figure.

Scheme 62

Scheme 63

1. Perform color contrast penetrate examination on the cylinder head surface. Replace the cylinder head if necessary.
2. Inspect for the following and repair or replace if necessary. Sunken valve seats. Excessive camshaft oil clearance and end play.
3. Measure the cylinder head for distortion in six directions as shown in the figure. If it exceeds the maximum specification, replace the cylinder head. Maximum Distortion 0.10 mm {0.004 in}
4. Measure the manifold contact surface distortion as shown in the figure. If it exceeds the maximum specification, grind the surface or replace the cylinder head. Maximum Distortion 0.10 mm {0.004 in} Maximum Grinding 0.15 mm {0.006 in}

Scheme 64

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Scheme 69

1. Measure the valve head margin thickness of each valve. If it is less than the specification, replace the valve. Margin Thickness IN: 1.62 mm {0.0637 in} EX: 1.82 mm {0.0716 in}
2. Measure the length of each valve. Replace the valve if necessary. If it is less than the specification, replace the valve. Standard Length L IN: 102.99-103.79 mm {4.055-4.086 in} EX: 104.25-105.05 mm {4.105-4.135 in} Minimum Length L IN: 102.99 mm {4.055 in} EX: 104.25 mm {4.104 in}
3. Measure the stem diameter of each valve in X and Y directions at the three points (A, B, and C) as indicated in the figure. If it exceeds the specification, replace the valve. Standard Diameter IN: 5.470-5.485 mm {0.2154-0.2159 in} EX: 5.465-5.480 mm {0.2152-0.2157 in} Minimum Diameter IN: 5.440 mm {0.2142 in} EX: 5.435 mm {0.2140 in}
4. Measure the inner diameter of each valve guide in X and Y directions at the three points (A, B, and C) as indicated in the figure. If not as specified, replace the valve guide. Standard Inner Diameter 5.509-5.539 mm {0.2169-0.2180 in}
5. Calculate the valve stem to guide clearance by subtracting the outer diameter of the valve stem from the inner diameter of the corresponding valve guide. If it exceeds the specification, replace the valve and/or the valve guide. Standard Clearance IN: 0.024-0.069 mm {0.0009-0.0027 in} EX: 0.029-0.074 mm {0.0012-0.0029 in} Maximum Clearance 0.10 mm {0.004 in}
6. Measure the protrusion height (dimension A) of each valve guide without lower valve spring seat. If not within the specified, replace the valve guide. Standard Height 12.2-12.8 mm {0.481-0.503 in}

Scheme 70

1. Remove the valve guide from the combustion chamber side using the SST .

Scheme 71

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Scheme 73

1. Assemble the SSTs so that depth L is as specified. Depth L 12.2-12.8 mm {0.481-0.503 in}
2. Tap the valve guide in from the side opposite the camshaft side until the SSTs contacts the cylinder head.
3. Verify that the valve guide protrusion height (dimension A) is within the specification. Standard Height 12.2-12.8 mm {0.481-0.503 in}

Scheme 74

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Scheme 76

1. Measure the seat contact width. If not within the specification, resurface the valve seat using a 45° valve seat cutter and/or resurface the valve face. Standard Width 1.2-1.6 mm {0.048-0.062 in}
2. Verify that the valve seating position is at the center of the valve face. If the seating position is too out side, correct the valve seat using a 70° (IN) or 65° (EX) cutter, and a 45° cutter. If the seating position is too inner side, correct the valve seat using a 30° (IN) cutter, and a 0° (EX) cutter, and a 45° cutter.
3. Inspect the sinking of the valve seat. Measure the protruding length (dimension L) of the valve stem. If not specified, replace the cylinder head. Standard Dimension L IN: 40.64-42.24 mm {1.600-1.662 in} EX: 40.50-42.10 mm {1.595-1.657 in}

Scheme 77

Scheme 78

1. Apply pressing force to the pressure spring and inspect the spring height. If it is less than the specification, replace the valve spring. Pressing Force 390 N {39.76 kgf, 87.67 lbf} Standard Height 28.68 mm {1.129 in}
2. Measure the out-of-square of the valve spring, using a square, as shown in the figure. Rotate the valve spring one full turn and measure "A" at the point where the gap is the largest. If it exceeds the specification, replace the valve spring. Valve Spring Maximum Out-Of-Square 1% (2.23 mm {0.0877 in})

Scheme 79

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Scheme 83

1. Set the No.1 and No.5 journals on V-blocks.
2. Measure the camshaft runout. If it exceeds the specification, replace the camshaft. Maximum Runout 0.03 mm {0.0012 in}
3. Measure the cam lobe height at the two points as shown in the figure. If it is less than the specification, replace the camshaft. CAMSHAFT LOBE STANDARD HEIGHT SPECIFICATIONS Camshaft LF (mm {in}) L3 (mm {in}) IN 42.12 {1.659} 42.44 {1.671} EX 41.08 {1.618} 41.18 {1.622} CAMSHAFT LOBE MINIMUM HEIGHT SPECIFICATIONS Camshaft LF (mm {in}) L3 (mm {in}) IN 42.022 {1.655} 42.342 {1.667} EX 40.982 {1.614} 41.082 {1.618}
4. Measure the journal diameters in X and Y directions at the two points (A and B) as indicated in the figure. If it is less than the specification, replace the camshaft. Standard Diameter 24.96-24.98 mm {0.9827-0.9834 in} Minimum Diameter 24.95 mm {0.982 in}
5. Remove the tappet.
6. Position a plastigage atop the journals in the axial direction.
7. Install the camshaft cap. (See «CAMSHAFT ASSEMBLY NOTE»(ref-345199-S05210698742009102000000) .)
8. Remove the camshaft cap. (See «CAMSHAFT CAP DISASSEMBLY NOTE»(ref-345199-S41174420552009102000000) .)
9. Measure the oil clearance. If it exceeds the specification, replace the cylinder head. Standard Clearance 0.035-0.080 mm {0.0014-0.0031 in} Maximum Clearance 0.09 mm {0.0035 in}
10. Install the camshaft cap. (See «CAMSHAFT ASSEMBLY NOTE»(ref-345199-S05210698742009102000000) .)
11. Measure the camshaft end play. If it exceeds the specification, replace the cylinder head or camshaft. Standard End Play 0.09-0.24 mm {0.0035-0.0094 in} Maximum End Play 0.25 mm {0.0098 in}
12. Remove the camshaft cap. (See «CAMSHAFT CAP DISASSEMBLY NOTE»(ref-345199-S41174420552009102000000) .)

Scheme 84

Scheme 85

1. Measure the tappet hole inner diameter in X and Y directions at the two points (A and B) shown in the figure. Inner Diameter 31.000-31.030 mm {1.2205-1.2216 in}
2. Measure the tappet body outer diameter in X and Y directions at the two points (A and B) shown in the figure. Outer Diameter 30.970-30.980 mm {1.2193-1.2196 in}
3. Subtract the tappet body outer diameter from the tappet hole inner diameter. If it exceeds the specification, replace the tappet or cylinder head. Standard Clearance 0.02-0.06 mm {0.0008-0.0023 in} Maximum Clearance 0.15 mm {0.006 in}

Scheme 86

Scheme 87

1. Measure the distortion of the cylinder block top surface in six directions as indicated in the figure. If it exceeds the maximum, replace the cylinder block. Maximum Cylinder Block Distortion 0.10 mm {0.004 in}
2. Measure the cylinder bores in X and Y directions at 42 mm {1.65 in} below the top surface. If not within the specification, replace the cylinder block. Standard Diameter Limit 87.500-87.530 mm {3.4449-3.4460 in} Minimum/Maximum Bore Diameter Limit 87.440-87.590 mm {3.4425-3.4484 in}

Scheme 88

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. Air Pressure 216-274 kPa {2.2-2.7 kgf.cm 2 31.4-39.7 psi}

CONNECTING ROD CAP ASSEMBLY NOTE

1. Tighten the connecting rod bolts in two steps using the SST (49 D032 316) . Tightening Torque (1) 26-32 N.m {2.7-3.2 kgf.m, 19.2-23.6 ft.lbf} (2) 80°-100°

Scheme 89

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Scheme 91

Scheme 92

1. Confirm by visual inspection that there is no damage to the balancer unit gear see scheme 79 and verify that the shaft turns smoothly. If there is any damage or malfunction, replace the balancer unit. CAUTION: Due to the precision interior construction of the balancer unit, it cannot be disassembled.
2. Install the SST as shown in the figure.
3. Turn the crankshaft clockwise the crankshaft is in the No.1 cylinder TDC position (until the balance weight is attached to the SST ).
4. Install the adjustment shim to the seat face of the balancer unit.
5. With the balancer unit marks at the exact top center, assemble the unit to the cylinder block.
6. Set the SST as shown, then measure the gear backlash using a dial gauge. NOTE: For an accurate measurement of gear backlash, insert a screwdriver into the crankshaft No. 1 balance weight area and set both the rotation and the thrust direction with the screwdriver, using a prying action, as shown in the figure. If the backlash exceeds the specified range, remeasure the backlash and, using the adjustment shim selection table, select the proper shim, according to the following procedure. CAUTION: When measuring the backlash, rotate the crankshaft one full rotation and verify that it is within the specified range at all of the following six positions: 10°, 30°, 100°, 190°, 210°, 280° ATDC. Value Range 0.005-0.101 mm {0.00019-0.0039 in} Using master adjustment shim (No.50), assemble the balancer unit to the cylinder block, then measure the backlash. Select the proper adjustment shim according to the measured value. Install the selected adjustment shim to the balancer unit, then assemble the balancer unit to the cylinder block. See «TORQUE SPECIFICATIONS»(ref-345199-S40369068852009102000000) table.

Scheme 93

Scheme 94

1. Assemble in the order indicated in the figure.

Scheme 95

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Scheme 97

1. Apply silicone sealant to the mating faces as shown in the figure. Thickness 4.0-6.0 mm {0.16-0.23 in}
2. Apply clean engine oil to the new oil seal lip.
3. Install the rear oil seal using the jig as shown in the figure.
4. Tighten the rear oil seal bolts in the order as shown in the figure. Tightening Torque 8.0-11.5 N.m {81.6-117.2 kgf.cm, 70.9-101.7 in.lbf}

Scheme 98

1. Hold the crankshaft using the SST .
2. Tighten the bolts in the 3 steps in the figure. Tightening Torque (1) 46-54 N.m {4.70-5.50 kgf.m, 34.0-39.8 ft.lbf} (2) 76-84 N.m {7.75-8.56 kgf.m, 56.1-61.9 ft.lbf} (3) 108-116 N.m {11.1-11.8 kgf.m, 79.7-85.5 ft.lbf}

Scheme 99

Scheme 100

Scheme 101

1. Apply a continuous bead of silicone sealant to the oil pan as indicated in the figure. CAUTION: Install the oil pan within 10 min. of applying the silicone sealant. Make sure that there is no oil or dust on the seal side of oil pan.
2. Use a square ruler to unite the oil pan and the cylinder block junction side on the engine front cover side.
3. Tighten the rear oil pan bolts in the order as shown in the figure. Tightening Torque 17-23 N.m {1.8-2.3 kgf.m, 12.6-16.9 ft.lbf}

Scheme 102

1. Assemble in the order indicated in the figure.

Scheme 103

1. Press the valve seal onto the valve guide by hand.
2. Lightly tap the SST using a plastic hammer.

Scheme 104

1. Install the valve keeper using the SSTs .

Scheme 105

1. Assemble in the order indicated in the figure.

Scheme 106

1. Tighten the cylinder head bolts in the order indicated in the figure in 5 steps using the SST (49 D032 316) . Tightening Torque (1) 3-11 N.m {30.6-112 kgf.cm, 26.6-97.3 in.lbf} (2) 13-17 N.m {1.4-1.7 kgf.m, 9.6-12.5 ft.lbf} (3) 43-47 N.m {4.4-4.7 kgf.m, 31.8-34.6 ft.lbf} (4) 88°-92° (5) 88°-92°

Scheme 107

1. Set the cam position of No.1 cylinder at the Top Dead Center (TDC) and install the camshaft.
2. Temporarily tighten the camshaft bearing caps evenly in 2-3 passes.
3. Tighten the camshaft cap bolt in the order shown two steps. Tightening Torque (1) 5.0-8.0 N.m {51.0-81.5 kgf.cm, 44.3-70.8 in.lbf} (2) 14-17 N.m {1.43-1.73 kgf.m, 10.4-12.5 ft.lbf}

CAMSHAFT SPROCKET, VARIABLE VALVE TIMING ACTUATOR (L3) ASSEMBLY NOTE

1. Temporarily tighten the camshaft sprocket or variable valve timing actuator (L3) installation bolts by hand until the timing chain is installed.
2. Fully tighten the camshaft sprocket or variable valve timing actuator (L3) installation bolts after timing chain installation.

Scheme 108

1. Assemble in the order indicated in the figure.

Scheme 109

1. Hold the oil pump sprocket using the SST .

Scheme 110

Scheme 111

Scheme 112

1. Install the SST to the camshaft, then align the No. 1 camshaft position with the TDC.
2. Remove the cylinder block lower blind plug.
3. Install the SST as shown in the figure.
4. Turn the crankshaft clockwise so that the crankshaft is in the No.1 cylinder TDC position.
5. Install the timing chain.
6. Install the chain tensioner and remove the retaining wire.

Scheme 113

1. Hold the camshaft using a suitable wrench on the cast hexagon as shown in the figure.
2. Tighten the camshaft sprocket lock bolt. Tightening Torque 69-75 N.m {7.1-7.6 kgf.m, 50.9-55.3 ft.lbf}

Scheme 114

Scheme 115

1. Apply clean engine oil to the oil seal.
2. Push the oil seal slightly in by hand.
3. Compress the oil seal using the SST and a hammer.

Scheme 116

Scheme 117

1. Apply silicone sealant to the engine front cover as shown in the figure. CAUTION: Install the cylinder head cover within 10 min. of applying the silicone sealant. Silicone sealant is not need in area C as indicated below due to an existing. (L3) Make sure that there is no oil or dust on the seal side of oil pan. Thickness A: 2.2-3.2 mm {0.087-0.125 in} B: 1.5-2.5 mm {0.059-0.098 in}
2. Install the front cover bolts in the order as shown in the figure. FRONT COVER BOLT TORQUE SPECIFICATIONS Bolt No. Tightening Torque - N.m {kgf.m, ft.lbf} 1-18 8.0-11.5 {81.6-117.2 70.9-101.7} 19-22 40-55 {4.1-5.6, 29.7-40.5}

Scheme 118

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Scheme 120

Scheme 121

1. Install the SST to the camshaft as shown in the figure.
2. Install the M6 x 1.0 bolt in by hand.
3. Turn the crankshaft clockwise so that the crankshaft is in the No.1 cylinder TDC position.
4. Hold the crankshaft pulley using the SST .
5. Tighten the crankshaft pulley lock bolt in the order shown following two steps using the SST (49 D032 316) . Tightening Torque (1) 96-104 N.m {9.8-10.6 kgf.m, 70.9-76.7 ft.lbf} (2) 87°-93°
6. Remove the M6 x 1.0 bolt.
7. Remove the SST from the camshaft.
8. Remove the SST from the block lower blind plug.
9. Rotate the crankshaft clockwise two turns until the TDC position. If not aligned, loosen the crankshaft pulley lock bolt and repeat from step 1 .
10. Install the cylinder block lower blind plug. Tightening Torque 20 N.m {2.0 kgf.m, 14.8 ft.lbf}

Scheme 122

Scheme 123

1. Apply silicone sealant to the mating faces as shown in the figure. CAUTION: Install the cylinder head cover within 10 min. of applying the silicone sealant. Dot Diameter 4.0-6.0 mm {0.16-0.23 in}
2. Install the cylinder head cover with a new gasket.
3. Tighten the bolts in the order shown in the figure. Tightening Torque 8.0-10.5 N.m {81.6-107.1 kgf.cm, 70.9-92.9 in.lbf}