3.0L V6: Other Mazda MPV I

FUEL PRESSURE RELEASE

Start engine and disconnect airflow meter connector. Operate engine until it stalls. Turn ignition off and reconnect airflow meter connector.

COOLING SYSTEM BLEEDING

1. Fill radiator and coolant reservoir with coolant. Install radiator cap. Start engine and allow to idle until engine reaches normal operating temperature. Accelerate engine to 2200-2800 RPM for 5 seconds several times. NOTE: If engine coolant temperature exceeds normal operating temperature, air exists in cooling system. Repeat step 1).
2. Allow engine to idle. Shut engine off and allow engine to cool. Remove radiator cap. Verify coolant level is near filler neck. If coolant level is not near filler neck, repeat steps 1) and 2). Fill coolant reservoir to FULL level.

ENGINE

Note. Manufacturer lists procedure with transmission being removed prior to engine removal.

CRANKSHAFT FRONT SEAL

Note. Manufacturer lists procedure with oil pump removed.

CAMSHAFT

Note. Manufacturer lists procedure with engine removed.

CYLINDER HEAD

1. Inspect cylinder head warpage at cylinder block and manifold areas. Resurface or replace cylinder head if warpage exceeds specification. See «CYLINDER HEAD SPECIFICATIONS»(ref-49061-S05741225042001011500000) table under ENGINE SPECIFICATIONS. CAUTION: Ensure cylinder head height is within specification after resurfacing cylinder head. See «CYLINDER HEAD SPECIFICATIONS»(ref-49061-S05741225042001011500000) table under ENGINE SPECIFICATIONS.
2. Ensure valve stem installed height is within specification. See «VALVES & VALVE SPRINGS SPECIFICATIONS»(ref-49061-S42696374642001011500000) table. Ensure camshaft bore diameter and camshaft oil clearance is within specification. See «CAMSHAFT SPECIFICATIONS»(ref-49061-S31073454452001011500000) table under ENGINE SPECIFICATIONS.

VALVE SPRINGS

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

VALVE STEM OIL SEALS

1. Lubricate valve stem oil seal with engine oil. Assemble Valve Stem Oil Seal Installer components (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 28) Adjust depth to.701-.732" (17.80-18.60 mm) for intake valve stem oil seal, or.952-.984" (24.20-25.00 mm) for exhaust valve stem oil seal.
3. Install valve stem oil seal on valve stem oil seal installer. Press valve stem oil seal on valve stem until valve stem oil seal installer contacts cylinder head. Remove valve stem oil seal installer.

Scheme 28

Scheme 29

1. Ensure valve guide inside diameter and installed height is within specification. See «CYLINDER HEAD SPECIFICATIONS»(ref-49061-S05741225042001011500000) table under ENGINE SPECIFICATIONS. Replace valve guide if inside diameter exceeds specification or valve guide installed height is not within specification. NOTE: Valve guide installed height is measured from top of valve guide to cylinder head surface.
2. To replace valve guide, use hammer and Valve Guide Remover (49-0249-01A) to drive valve guide toward camshaft side of cylinder head. To install, assemble Valve Guide Installer components (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 29) Adjust depth to.520-.543" (13.20-13.80 mm) for intake valve guide, or.772-.795" (19.60-20.20 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 SPECIFICATIONS»(ref-49061-S05741225042001011500000) table under ENGINE SPECIFICATIONS.
6. If valve guide installed height is not within specification, readjust depth on valve guide installer and adjust valve guide installed height. Regrind valve seat after installing valve guide.

Note. Although intake and exhaust valve guides are shaped differently, use exhaust valve guide for replacement of either valve guide.

VALVE SEAT

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

VALVES

1. Ensure minimum refinish length, stem diameter, head diameter and valve margin are within specification. See «VALVES & VALVE SPRINGS SPECIFICATIONS»(ref-49061-S42696374642001011500000) table under ENGINE SPECIFICATIONS. NOTE: Valve stem installed height may also be referred to as valve seat sinkage.
2. To check valve stem installed height, ensure valve is within minimum refinish length. See «VALVES & VALVE SPRINGS SPECIFICATIONS»(ref-49061-S42696374642001011500000) table under ENGINE SPECIFICATIONS.
3. Install valve in cylinder head. Using caliper, measure valve stem installed height from top of valve stem to cylinder head surface.
4. Using valve stem installed height, determine if valve spring shim is required to bring valve stem installed height to standard dimension. See «VALVE STEM INSTALLED HEIGHT SPECIFICATIONS»(ref-49061-S27415737722001011500000) table. Install valve spring shim (if required) on cylinder head before installing valve springs.

VALVE STEM INSTALLED HEIGHT SPECIFICATIONS

VALVE SEAT CORRECTION ANGLES

Use 65-degree stone to lower valve seat contact area. Use 35-degree (intake) or 15-degree (exhaust) stone to raise valve seat contact area.

VALVE LASH ADJUSTERS

1. Inspect face of valve lash adjuster for wear and damage. Replace valve lash adjuster if damaged. If valve lash adjuster is removed from rocker arm, install NEW "O" ring on valve lash adjuster.
2. Pour engine oil into oil reservoir in rocker arm. Apply engine oil on valve lash adjuster, and carefully install into rocker arm.

FITTING PISTONS

1. To determine if piston-to-cylinder clearance is within specification, measure piston skirt diameter at.866" (22.00 mm) below bottom of oil ring groove, at 90-degree angle to piston pin.
2. Different diameter pistons are used. Piston identification size mark is located on top of piston. see scheme 13 Ensure piston diameter is within specification. See «PISTONS, PINS & RINGS SPECIFICATIONS»(ref-49061-S42589533662001011500000) table under ENGINE SPECIFICATIONS.
3. Measure cylinder bore diameter just below top of bore, at middle of cylinder bore and just above bottom of cylinder bore. Different standard diameter cylinder bores may be used. Cylinder bore diameter is determined by size mark ("A", "B" or "C") stamped on lower edge of cylinder block. (Scheme 30)
4. Ensure cylinder bore diameter is within specification. See «CYLINDER BLOCK SPECIFICATIONS»(ref-49061-S09779471942001011500000) table under ENGINE SPECIFICATIONS. Determine piston clearance.
5. Replace piston or bore cylinder block if clearance is not within specification. See «PISTONS, PINS & RINGS SPECIFICATIONS»(ref-49061-S42589533662001011500000) table under ENGINE SPECIFICATIONS. Cylinder block can be bored for.010" (.25 mm) or.020" (.50 mm) oversize pistons.
6. If replacing standard piston, proper size mark piston must be installed in accordance with cylinder bore size mark on cylinder block. See «PISTON APPLICATIONS»(ref-49061-S38276910882001011500000) table. Ensure piston clearance is within specification. See «PISTONS, PINS & RINGS SPECIFICATIONS»(ref-49061-S42589533662001011500000) table under ENGINE SPECIFICATIONS.

PISTON APPLICATIONS

Scheme 30

PISTON RINGS

Ensure piston ring end gap and side clearance are within specification. See PISTONS, PINS & RINGS SPECIFICATIONS table under ENGINE SPECIFICATIONS. Position piston ring gaps in proper areas, with identification mark "R" on ring toward top of piston. (Scheme 31)

Scheme 31

ROD BEARINGS

1. Ensure connecting rod and connecting rod cap are marked with matching cylinder number for reassembly reference. Piston must be installed so front mark ("R" or "L") is toward timing belt end of engine. see scheme 13 NOTE: Piston must be installed in cylinder block with front mark ("R" or "L") facing toward timing belt end of engine. Piston with front mark "R" goes on right side of cylinder block and piston with front mark "L" goes on left side. References to right and left side assumes view from rear of engine.
2. Coat connecting rod bolt threads and nut-to-connecting rod cap surface with engine oil. Ensure matching marks on connecting rod and rod cap are aligned. Tighten connecting rod nuts to specification when checking oil clearance. See «TORQUE SPECIFICATIONS»(ref-49061-S19566747542001011500000).
3. Ensure bearing oil clearance and connecting rod side play are within specification. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS SPECS»(ref-49061-S29210309392001011500000) and «CONNECTING RODS SPECIFICATIONS»(ref-49061-S17725803522001011500000) tables under ENGINE SPECIFICATIONS.
4. Grind crankshaft to 2.0744-2.0750" (52.690-52.705 mm) for.010" (.25 mm) undersize rod bearings if oil clearance exceeds specification. Replace connecting rod if side play exceeds specification.

CRANKSHAFT & MAIN BEARINGS

1. Note direction of main bearing cap installation. Main bearing caps are numbered for location on top of bearing cap with No. 1 at timing belt end. Arrow on main bearing cap should point toward timing belt end.
2. Remove main bearing caps and crankshaft. Ensure crankshaft runout, main bearing journal diameter, taper, and out-of-round are within specification. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS SPECS»(ref-49061-S29210309392001011500000) table under ENGINE SPECIFICATIONS.
3. Install main bearings and crankshaft. Ensure thrust bearing is installed on No. 4 main bearing with grooves facing toward crankshaft (away from bearing cap or cylinder block).
4. Install main bearing caps. Ensure main bearing caps are installed with No. 1 at timing belt end and arrow on main bearing cap pointing toward timing belt end of engine.
5. Coat main bearing cap bolt threads and seat area of bolt with engine oil. Alternately tighten main bearing cap bolts to specification in sequence using several steps. (Scheme 32) See «TORQUE SPECIFICATIONS»(ref-49061-S19566747542001011500000).
6. Ensure crankshaft end play and main bearing oil clearance are within specification. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS SPECS»(ref-49061-S29210309392001011500000) table under ENGINE SPECIFICATIONS. Replace thrust bearing if crankshaft end play is not within specification.

Scheme 32

THRUST BEARING

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

CYLINDER BLOCK

1. Inspect cylinder block deck warpage. Resurface cylinder block if deck warpage exceeds specification. See «CYLINDER BLOCK SPECIFICATIONS»(ref-49061-S09779471942001011500000) table under ENGINE SPECIFICATIONS. CAUTION: Cylinder block deck height must be within specification if cylinder block is resurfaced. Cylinder block deck surface is measured from crankshaft center line to cylinder block deck surface. See «CYLINDER BLOCK SPECIFICATIONS»(ref-49061-S09779471942001011500000) table under ENGINE SPECIFICATIONS.
2. Measure cylinder bore diameter just below top of bore, middle of cylinder bore and just above bottom of cylinder bore. Different standard diameter cylinder bores may be used. Cylinder bore diameter is determined by size mark ("A", "B" or "C") stamped on lower edge of cylinder block. (Scheme 30)
3. Ensure cylinder bore diameter is within specification. See «CYLINDER BLOCK SPECIFICATIONS»(ref-49061-S09779471942001011500000) table under ENGINE SPECIFICATIONS. Bore cylinder block if cylinder bore diameter is not within specification. Cylinder block can be bored for.010" (.25 mm) or.020" (.50 mm) oversize pistons.

Oil Pressure

With engine at normal operating temperature, oil pressure should be 13-35 psi (0.9-2.5 kg/cm 2 ) at 1000 RPM, and 53-75 psi (3.7-5.3 kg/cm 2 ) at 3000 RPM.

OIL PUMP

Note. Manufacturer lists procedure with engine removed for servicing oil pump.

CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS SPECS

CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS SPECS