2.3L V6: Other Mazda Millenia I facelift

FUEL PRESSURE RELEASE

1. Remove cruise control actuator. Start engine. Remove fuel pump relay located in engine compartment, behind left front strut tower. Allow engine to idle until it stalls. Crank engine several times to eliminate remainder of fuel pressure. Turn ignition off. Install fuel pump relay.
2. Before disconnecting any fuel line connections, cover connection with shop towel to absorb any residual gasoline that may remain in fuel line. Carefully loosen fuel line connection, allowing residual gasoline to be released.

COOLING SYSTEM BLEEDING

Fill radiator and coolant reservoir. Start engine and allow to idle until engine is at normal operating temperature. Accelerate engine to 2200-2800 RPM for 5 minutes. Shut engine off and allow engine to cool. Remove filler cap. Verify coolant level is near filler neck. If coolant level is not near filler neck, top off coolant and repeat procedure. Fill coolant reservoir to FULL level.

ENGINE

Note. Remove engine and transaxle as an assembly.

EXHAUST MANIFOLD

Note. Exhaust manifolds are also identified as warm-up three-way catalytic converters.

TIMING BELT

Camshaft

1. Visually inspect camshaft gears. If helical gear is defective, replace camshaft. If friction gear is defective, replace friction gear. Ensure matching marks are aligned. Tighten lock nut to specification. See «TORQUE SPECIFICATIONS»(ref-3917-S38585952592000052500000) . Inspect remaining components for damage. Measure camshaft journal diameter, lobe height and runout. Replace camshaft if not within specification. See «CAMSHAFT»(ref-3917-S08737516682000052500000) table under ENGINE SPECIFICATIONS.
2. With tappet and shim removed from cylinder head, install one camshaft in cylinder head, without camshaft bearing caps. Check camshaft end play. Install Plastigage on camshaft journals. Install bearing caps and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-3917-S38585952592000052500000) .
3. Remove bearing caps and measure bearing oil clearance. Repeat procedure on remaining camshaft. Replace camshaft and/or cylinder head if end play or oil clearance is not within specification. See «CAMSHAFT»(ref-3917-S08737516682000052500000) table under ENGINE SPECIFICATIONS.

Tappet Bore

Measure tappet bore in 2 directions. Ensure bore is within specification. See TAPPET BORE in CYLINDER HEAD table under ENGINE SPECIFICATIONS.

Valve Springs

Ensure valve spring free length, pressure and out-of-square are within specification. See VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS.

Valve Stem Oil Seals

1. Lubricate valve stem oil seal with engine oil. Assemble Valve Stem Oil Seal Installer Set (49-L012-001, 49-L012-005 and 49-L012-002).
2. Adjust valve stem oil seal installer so depth is set at specified distance for proper valve stem oil seal application. (Scheme 35) Adjust depth to.591" (15.00 mm) for intake valve stem oil seal or.531" (13.50 mm) for exhaust valve stem oil seal. NOTE: Intake and exhaust valve seals are different. Exhaust valve seal has 2 ridges on top and intake valve seal has one or none. Ensure proper valve stem oil seal is used.
3. Insert valve stem oil seal into installer. Press valve stem oil seal on valve guide until fully seated. Remove valve stem oil seal installer.

Scheme 35

Scheme 36

1. Ensure valve guide inside diameter and installed height are within specification. See «CYLINDER HEAD»(ref-3917-S31334376842000052500000) table under ENGINE SPECIFICATIONS. Replace valve guide if inside diameter exceeds specification or valve guide installed height is not within specification. NOTE: Measure valve guide installed height from top of valve guide to cylinder head surface.
2. To replace valve guide, using hammer and Valve Guide Remover (49-B012-005), drive valve guide toward camshaft side of cylinder head. To install, assemble Valve Guide Installer Set (49-L012-004, 49-L012-003 and 49-L012-002).
3. Adjust valve guide installer so depth is set at specified distance for proper valve guide application. (Scheme 36) Adjust depth to.528-.551" (13.40-14.00 mm) for intake valve guide, or.469-.492" (11.90-12.50 mm) for exhaust valve guides.
4. Using hammer and valve guide installer, drive valve guide in from camshaft side of cylinder head until valve guide installer contacts cylinder head.
5. Ensure valve guide installed height is within specification. See «CYLINDER HEAD»(ref-3917-S31334376842000052500000) table under ENGINE SPECIFICATIONS. If valve guide installed height is not within specification, readjust depth on valve guide installer and adjust valve guide installed height.

Valve Seat

Ensure valve seat angle and seat width are within specification. See CYLINDER HEAD table under ENGINE SPECIFICATIONS. Valve seat replacement information is not available from manufacturer.

Valve Seat Correction Angles

Use a 70- degree stone to lower exhaust valve seat and a 75-degree stone to lower intake valve seat contact area. Use 25-degree stone to raise exhaust valve seat, and a 35-degree stone to raise intake valve seat contact area.

Valves

1. Ensure valve length, stem diameter, head diameter and valve margin are within specification. See «VALVES & VALVE SPRINGS»(ref-3917-S38777880632000052500000) table under ENGINE SPECIFICATIONS.
2. To check valve installed height, ensure valve is within minimum refinish length. See «VALVES & VALVE SPRINGS»(ref-3917-S38777880632000052500000) table under ENGINE SPECIFICATIONS.
3. Install valve in cylinder head. Using caliper, measure valve protrusion from top of valve stem to spring seat on cylinder head. (Scheme 37) If valve stem protrusion is 1.709-1.728" (43.40-43.90 mm), valve and cylinder head can be used. If valve stem protrusion exceeds 1.732" (44.00 mm) replace cylinder head.

Scheme 37

TAPPET

Measure tappet outside diameter in 2 directions. Calculate oil clearance between tappet housing bore and tappet. Ensure tappet oil clearance is within specification. See TAPPET table under ENGINE SPECIFICATIONS. If oil clearance is not within specification, replace tappet or cylinder head as necessary.

Fitting Pistons

1. Measure piston skirt at 90-degree angle to piston pin 1.12" (28.5 mm) below lowest piston ring groove. Measure cylinder bore diameter just below top of bore, at middle of cylinder bore and just above bottom of cylinder bore and record measurements.
2. If cylinder taper and out-of-round are NOT within specification, bore cylinder to next oversize. If cylinder taper and out of round are within specification, subtract piston diameter measurement from cylinder bore measurement to determine piston-to-cylinder clearance. See «PISTONS, PINS & RINGS»(ref-3917-S30775479782000052500000) table under ENGINE SPECIFICATIONS. If piston-to-cylinder clearance is excessive, replace piston or bore cylinder to next oversize.

Piston Rings

Ensure piston ring end gap and side clearance are within specification. See PISTONS, PINS & RINGS table under ENGINE SPECIFICATIONS. Position piston ring gaps in proper areas. (Scheme 38)

Scheme 38

Rod Bearings

1. Ensure connecting rod and connecting rod cap are marked with matching cylinder number for reassembly reference. Install piston so front mark ("R" or "L") on top of piston is toward timing belt end of engine.
2. Measure connecting rod cap bolt length. Measurement is taken from contact surface of bolt head to tip of bolt shank. Replace bolt if measurement exceeds 1.889" (48.00 mm). Coat connecting rod bolt threads with engine oil before tightening to specification. Ensure bearing oil clearance and connecting rod side play are within specification. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(ref-3917-S18194710892000052500000) table under ENGINE SPECIFICATIONS.

Scheme 39

Scheme 40

Scheme 41

Scheme 42

Scheme 43

1. Before removing crankshaft, measure and record crankshaft end play. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(ref-3917-S18194710892000052500000) table under ENGINE SPECIFICATIONS. If end play exceeds maximum, grind crankshaft thrust width to 1.214-1.215" (30.82-30.87 mm) or 1.224-1.225" (31.07-31.12 mm) and install.010" (.25 mm) or.020" (.50 mm) oversize thrust bearing. Note that cylinder block contains a lower cylinder block section. (Scheme 39) Loosen lower cylinder block bolts in sequence using several steps. (Scheme 40) CAUTION: Do not pry on cylinder block except where indicated. (Scheme 41) Note location and length of lower cylinder block bolts for reassembly reference. Bolts must be installed in proper location. (Scheme 43)
2. Remove lower cylinder block retaining bolts. To loosen lower cylinder block, tap on lower cylinder block while prying with a screwdriver at rear of cylinder block. (Scheme 41) Separate lower cylinder block from cylinder block.
3. Measure lower cylinder block bolt length at specified areas on retaining bolts "A", "B" and "C". (Scheme 42) Replace bolts if not within specification. See «LOWER CYLINDER BLOCK BOLT SPECIFICATIONS»(ref-3917-S01524264232000052500000) table. NOTE: Lower cylinder block bolts "A" have a No. 4 stamped on top of bolt head and bolts "B" are stamped with an "I". Bolts "C" are the shortest bolts. Bolts "D" are outer bolts. LOWER CYLINDER BLOCK BOLT SPECIFICATIONS Application In. (mm) Bolt "A" Length Standard 5.34-5.37 (135.7-136.3) Maximum 5.45 (138.5) Bolt "B" Length Standard 5.34-5.37 (135.7-136.3) Maximum 5.45 (138.5) Bolt "C" Length Standard 4.71-4.74 (119.7-120.3) Maximum 4.76 (121.0)
4. Ensure crankshaft journal diameter, taper and out-of-round are with within specification. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(ref-3917-S18194710892000052500000) table under ENGINE SPECIFICATIONS. CAUTION: DO NOT remove fillet roll on crankshaft journals when grinding journals for undersize bearings.
5. Crankshaft journals can be ground for.010" (.25 mm) undersize bearings if diameter is not within specification. Grind crankshaft rod journals to 2.0745-2.0749" (52.690-52.705 mm). Grind main bearing journals to 2.4287-2.4293" (61.688-61.705 mm) for undersize bearings.
6. To check oil clearance, install upper main and thrust bearings in cylinder block. Rear (No. 4) main bearing is wider than all other main bearings. Install lower main and thrust bearings, and lower cylinder block.
7. Coat lower cylinder block bolt threads and bolt-to-lower cylinder block surface with engine oil. Install bolts "A", "B" and "C" in proper location on cylinder block. (Scheme 43) NOTE: Manufacturer does not require lower cylinder block bolts "D" to be installed when checking oil clearance.
8. Tighten bolts to specification in sequence using several steps. Perform STEPS 1 and 2 of illustration. (Scheme 43) Measure inside diameter of main bearings on front and rear main bearings. Subtract crankshaft main journal diameter from main bearing inside diameter to determine oil clearance.
9. Ensure crankshaft main bearing oil clearance is within specification. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(ref-3917-S18194710892000052500000) table under ENGINE SPECIFICATIONS.
10. Crankshaft main journals can be ground for.010" (.25 mm) undersize bearings if oil clearance is not within specification. CAUTION: DO NOT remove fillet roll on crankshaft journals when grinding journals for undersize bearings.
11. When performing final installation of crankshaft, ensure oil jet is installed in cylinder block. See «OIL JET»(ref-3917-S12588133252000052500000) under ENGINE OILING. Install main and thrust bearings in cylinder block and in lower cylinder block. Rear (No. 4) main bearing is wider than all other main bearings. CAUTION: Ensure thrust bearing is installed on rear (No. 4) main bearing with oil groove facing inward.
12. Coat all bearings and crankshaft journals with engine oil. Install crankshaft. Ensure lower cylinder block and cylinder block sealing surfaces are clean. Apply sealant on cylinder block in specified areas. (Scheme 44) DO NOT allow sealant to enter bolt holes.
13. Install lower cylinder block. Coat lower cylinder block bolt threads with engine oil. Install bolts in proper location on cylinder block. Tighten bolts to specification in sequence using several steps. (Scheme 43) Ensure crankshaft end play is within specification. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(ref-3917-S18194710892000052500000) table under ENGINE SPECIFICATIONS. Replace thrust bearing if end play is not within specification.

Scheme 44

Thrust Bearing

Install thrust bearing on rear (No. 4) main bearing, with grooves facing toward crankshaft (away from cylinder block). Replace thrust bearing if crankshaft end play is not within specification. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS.

Cylinder Block

1. Inspect cylinder block deck surface warpage. Replace cylinder block if deck warpage exceeds specification. See «CYLINDER BLOCK»(ref-3917-S41835479622000052500000) table under ENGINE SPECIFICATIONS.
2. Measure cylinder bore diameter just below top of bore, at middle of cylinder bore and just above bottom of cylinder bore. Ensure cylinder bore diameter, taper and out-of-round are within specification. If cylinder bore diameter, taper or out-of-round exceeds specification, bore cylinder to nearest oversize. Cylinder block can be bored for .010" (.25 mm) or .020" (.50 mm) oversize pistons.

Oil Pressure

Inspect oil pressure at gallery above oil filter. With engine at normal operating temperature, oil pressure should be 44-66 psi (3.1-4.7 kg/cm 2 ) at 3000 RPM.