Engine Mechanical - Overhaul - 3.0L V6 (Aj Without Variable Valve Timing): Diagnosis Mazda MPV II рестайлинг

HYDRAULIC LASH ADJUSTER (HLA) INSPECTION

1. Measure the diameter of each HLA bore. Standard Diameter 16.018-16.057 mm {0.63063-0.63216 in}
2. Measure the diameter of each HLA. Standard Diameter 15.988-16.000 mm {0.62945-0.62992 in}
3. Calculate the clearance between the HLA and the related HLA bores. If the clearance exceeds the maximum clearance, replace the cylinder head or the HLA. Standard Clearance 0.018-0.069 mm {0.0008-0.0027 in} Maximum Clearance 0.16 mm {0. 0063 in}

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1. Measure the distortion of the cylinder block top surface in the six directions as indicated in the figure. If not as specified, replace the cylinder block. Cylinder Block Maximum Distortion 0.08 mm {0.0031 in}
2. Measure the cylinder bores in X and Y directions at 50 mm {2.0 in} below the top surface. If the difference between measurements A and C exceeds the maximum taper, replace the cylinder block. If the difference between measurements X and Y exceeds the maximum out-of-round, replace the cylinder block. Cylinder Bore 89.000-89.030 mm {3.5039-3.5051 in} Maximum Taper 0.020 mm {0.00079 in} Out-Of-Round 0.020 mm {0.00079 in}

PISTON CLEARANCE INSPECTION

1. Measure the piston-to-cylinder clearance. If not as specified, replace the piston or the cylinder block. If the piston is replaced, the piston rings must also be replaced. Standard Clearance 0.012-0.022 mm {0.0004-0.0008 in}

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1. Measure the piston ring-to-ring groove clearance around the entire circumference. If the piston ring-to-ring groove clearance exceeds the maximum clearance, replace the piston and piston ring. Standard Clearance Top: 0.040-0.075 mm {0.0016-0.0029 in} Second: 0.040-0.085 mm {0.0016-0.0033 in} Maximum Clearance 0.10 mm {0.0039 in}
2. Insert the piston ring into the cylinder by hand and use the piston to push it to the bottom of the ring travel.
3. Measure each piston ring end gap with a feeler gauge. If the piston ring end gap exceeds the maximum end gap, replace the piston ring. Standard End Gap Top: 0.10-0.25 mm {0.004-0.009 in} Second: 0.27-0.42 mm {0.011-0.016 in} Oil (Rail): 0.15-0.65 mm {0.006-0.025 in} Maximum End Gap Top: 0.50 mm {0.019 in} Second: 0.65 mm {0.025 in} Oil (Rail): 0.90 mm{0.035 in}

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1. Measure each piston pin bore diameter in X and Y directions at the four points (A, B, C, and D) as indicated in the figure. Standard Diameter 21.008-21.012 mm {0.82709-0.82724 in}
2. Measure each connecting rod small end inner diameter in X and Y directions as indicated in the figure. Standard Diameter 21.017-21.031 mm {0.82744-0.82799 in}
3. Measure each piston pin diameter in X and Y directions at the four points (A, B, C and D) as indicated in the figure. Standard Diameter 21.011-21.013 mm {0.82721-0.82728 in}
4. Calculate the piston pin-to-piston pin bore clearance. If not as specified, replace the piston and/or piston pin. Standard Clearance -0.005-0.001 mm {-0.00019-0.00003 in}
5. Calculate small end-to-piston pin clearance of the connecting rod. If small end-to-piston pin clearance of the connecting rod exceeds the maximum clearance, replace the connecting rod or piston pin. Standard Clearance 0.004-0.020 mm {0.00016-0.00078 in} Maximum Clearance 0.035 mm {0.0013 in}

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1. Measure the crankshaft runout. If the crankshaft runout exceeds the maximum runout, replace the crankshaft. Maximum Runout 0.05 mm {0.0019 in}
2. Measure the journal diameter in X and Y directions at the two points (A and B) as indicated in the figure. If not as specified, replace the crankshaft or grind the journal and install the undersize bearing.

MAIN JOURNAL BEARING SPECIFICATIONS

CRANK PIN

CRANKSHAFT OIL CLEARANCE INSPECTION/REPAIR

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1. Install the upper main bearing and crankshaft.
2. Position a plastigage atop the journals in the axial direction.
3. Install the lower main bearing and lower cylinder block, and tighten the bolts in the order indicated in the figure. Tightening Torque 37-43 N.m {3.7-4.4kgf.m, 27-31 ft.lbf}
4. Tighten the bolts by turning each 85° - 95° in the sequence as indicated in the figure.
5. Loosen the bolts in the reverse order of tightening.
6. Measure the main journal oil clearance. If the clearance exceeds the maximum, replace the main bearing using the main bearing selection table or grind the main journal and install the undersize bearings so that the specified oil clearance is obtained. Standard Clearance 0.025-0.045 mm {0.0010-0.0017 in} Maximum Clearance 0.050 mm {0.0019 in}

Main Bearing Selection Table

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Example Of Main Bearing Selection

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1. Measure the crankshaft end play. If not as specified, replace the thrust bearing and No.4 lower main bearing or crankshaft so that the specified end play is obtained. Standard End Play 0.110-0.232 mm {0.00434-0.00913 in}

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1. Measure each connecting rod for bending and distortion. If not as specified, replace the connecting rod. Bending 0.038 mm {0.0014 in}max./25 mm {0.98 in} Distortion 0.050 mm {0.0019 in}max./25 mm {0.98 in} Center-To-Center Distance 138.06-138.14 mm {5.4355-5.4385 in}

CONNECTING ROD OIL CLEARANCE INSPECTION/REPAIR

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1. Position plastigage atop the journals in the axial direction.
2. Install the connecting rod bearing and connecting rod cap. (See «CONNECTING ROD CAP ASSEMBLY NOTE»(ref-168954-S15990854282005070800000) .)
3. Remove the connecting rod cap.
4. Measure the connecting rod oil clearance. If not as specified, replace the connecting rod bearing or grind the crankpin and use undersize bearings so that the specified clearance is obtained. Standard Clearance 0.028-0.066 mm {0.0012-0.0025 in} CONNECTING ROD BEARING CLEARANCE Bearing Size (mm {in}) Bearing Thickness (mm {in}) Standard 1.500-1.506 {0.0591-0.0593} 0.02 (0.008} Undersize 1.510-1.518 {0.0595-0.0596} 0.05 {0.002} Undersize 1.525-1.531 {0.0601-0.0602} 0.25 {0.01} Undersize 1.625-1.631 {0.0640-0.0642}

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1. Measure the connecting rod large end side clearance. If the connecting rod side clearance exceeds the maximum clearance, replace the connecting rod and cap. Standard Clearance 0.10-0.30 mm {0.004-0.011 in} Maximum Clearance 0.35 mm {0.013 in}

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1. Assemble in the order indicated in the figure.

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1. Apply a continuous bead of silicone sealant to the upper cylinder block as indicated in the figure.
2. Install the lower cylinder block bolts in the order indicated in the figure. Tightening Torque 3.0-5.0 N.m {30-51 kgf.cm, 27-44 in.lbf}
3. Push crankshaft forward and then rearward to seat the crankshaft thrust washer.
4. Tighten the lower cylinder block bolts in the order indicated in the figure in four steps. Bolts 1-8: tighten to 22-28 N.m {2.2-2.9 kgf.m, 16-20 ft.lbf} . Bolts 9-16: tighten to 37-43 N.m {3.7-4.4 kgf.m, 27-31 ft.lbf} . Bolts 1-16: tighten 85°-95° . Bolts 17-22: tighten to 20-30 N.m {2.1-3.0 kgf.m, 15-22 ft.lbf} . Verify that the crankshaft rotates freely.
5. Assemble rear oil seal with part A of the SST (49 UN01 070) and the SST (49 UN30 3384) . Install the studs of the SST (49 UN30 3384) as indicated in the figure. Apply clean engine oil to the oil seal. Push the oil seal slightly in by hand. Install part A of the SST (49 UN01 070) and compress the oil seal with the nuts of the SST (49 UN30 3384) .

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1. Assemble the piston pin so that connecting rod's projection for discrimination faces opposite side of the arrow mark on the piston (rear side of the engine).
2. Apply clean engine oil to the piston pin.
3. Install the piston pin until the pin contacts the clip. If the pin cannot be installed easily, heat the piston.

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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. Install the top ring.

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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.