2.6l 4-cyl Mazda MPV V

ENGINE IDENTIFICATION

Engine number is stamped on a flat spot on upper left front of cylinder block deck.

ENGINE IDENTIFICATION CODES

ENGINE

Removal

1. Release fuel pressure by starting engine and disconnecting fuel pump connector at fuel tank. After engine dies, turn ignition off and reconnect fuel pump connector.
2. Remove hood. Disconnect negative battery cable. Remove starter and transmission. Drain engine oil and coolant. Remove engine undercover.
3. Remove solenoid valve assembly. Remove cooling fan and fan shroud. Remove drive belts and radiator hoses. Remove transmission cooling lines (if equipped). Remove radiator.
4. Remove accelerator cable, air cleaner and resonance chamber. Remove PRC solenoid valve. Mark and remove vacuum hoses from engine. Remove heater and fuel hoses. Cover fuel hose connections with shop towel to stop spray from any residual pressure. Plug fuel hoses to prevent fuel leakage.
5. Mark and disconnect connectors and wires from engine. Remove shroud upper panel from right side of firewall. Remove A/C pipe bracket. Remove power steering pump pulley. Remove power steering pump and A/C compressor with hoses attached. Secure power steering pump and A/C compressor out of way.
6. Remove exhaust pipe and bracket. Remove upper and lower grilles and upper radiator support plate. Remove condenser fan. Remove left and right upper engine mount nuts (2). Do not remove lower engine mount nuts. Install engine lift chain to engine hooks and lift engine from vehicle.

Scheme 1

Scheme 2

Installation

To install, reverse removal procedure. Tighten bolts and nuts to specifications. See TORQUE SPECIFICATIONS . Adjust all control cables. Check all fluid levels.

CYLINDER HEAD & MANIFOLDS

Scheme 3

1. (Scheme 1) Start engine and disconnect fuel pump connector at fuel tank. After engine dies, turn ignition off and reconnect fuel pump relay or connector.
2. Remove accelerator cable, air intake pipe and resonance chamber. Remove A/C drive belt and idler pulley. Remove spark plug wires and spark plugs. Drain radiator and remove upper radiator hose. Remove brake vacuum hose.
3. Remove coolant hose from oil cooler. Remove canister hose. Cover fuel hose connections with shop towel to stop spray from any residual pressure. Disconnect fuel hoses. Plug fuel hoses to prevent fuel leakage.
4. Disconnect oxygen sensor connector. Mark and disconnect all vacuum and electrical connectors. Remove valve cover. Rotate crankshaft and position No. 1 piston at TDC of compression stroke. Mark and remove distributor.
5. Remove distributor drive gear from camshaft. Remove service cover on timing chain cover. Push chain adjuster sleeve to left and insert pin to hold in place. (Scheme 3)
6. Wire timing chain to camshaft sprocket to retain valve timing. Remove camshaft pulley from camshaft dowel. Remove intake manifold bracket. Remove exhaust pipe and bracket. Remove cylinder head bolts "A". (Scheme 4) Remove remaining bolts in 2 or 3 steps, in sequence shown. Remove cylinder head and gasket.

Note. Cylinder head bolts must be loosened in proper sequence to prevent cylinder head warpage or cracking.

Scheme 4

Inspection

Check cylinder head height and warpage. Resurface head if warpage exceeds specification. See CYLINDER HEAD SPECIFICATIONS table. Replace cylinder head if not within specification after resurfacing.

CYLINDER HEAD SPECIFICATIONS

1. Apply silicone sealant to parting line between timing cover and cylinder block. Install head gasket and cylinder head. Apply oil to head bolt threads and seating surface.
2. Using proper sequence, tighten bolts to specification using 2 or 3 steps. (Scheme 5) See «TORQUE SPECIFICATIONS»(/mazda/mpv/v-1986-1991/remont/mechanical/#26l-4-cyl__torque-specifications). Install timing chain sprocket and chain. Remove pin from chain adjuster to tension chain. To install remaining components, reverse removal procedure. Tighten bolts to specification.

Scheme 5

COUNTERBALANCE DRIVE & TIMING CHAINS

Note. Inspect counterbalance drive chain and timing chain before removal. If counterbalance chain adjuster can be pushed to bottom of slot, replace counterbalance chain. If 13 or more notches are visible on timing chain adjuster, replace timing chain.

1. Disconnect negative battery cable. Drain engine oil and coolant. Remove cooling fan and fan shroud. Remove drive belts and radiator hoses.
2. Remove cylinder head and manifolds as shown in «CYLINDER HEAD & MANIFOLDS»(/mazda/mpv/v-1986-1991/remont/mechanical/#26l-4-cyl__cylinder-head-manifolds) . Raise vehicle. Remove engine undercover. Remove oil pan gusset plates and oil pan. Lower vehicle.
3. Remove water pump pulley. Remove alternator, power steering pump, A/C compressor and brackets. Remove water pump and coolant by-pass pipe. Remove crankshaft pulley and chain cover.
4. Remove counterbalance shaft idler sprocket lock bolt. Remove counterbalance shaft chain guides and idler sprocket. Remove spacer from front of crankshaft and crankshaft sprocket. Remove counterbalance shaft chain.
5. Remove timing chain adjuster and camshaft pulley. Remove timing chain and crankshaft sprocket. Remove timing chain lever and chain guide.

Scheme 6

Scheme 7

1. Install timing chain guide and chain lever. Insert pin in chain adjuster lever hole to hold adjusting sleeve. (Scheme 3) Install chain adjuster onto cylinder block.
2. Align camshaft and crankshaft sprocket timing marks. (Scheme 6) Secure timing chain to camshaft pulley with wire and let pulley rest on chain between chain lever and guide.
3. Install counterbalance crankshaft sprocket with flange facing inward. Install counterbalance chain and idler sprocket. Ensure that all 5 alignment marks align. (Scheme 7)
4. Install counterbalance chain guides. To adjust counterbalance chain, loosen adjusting bolt and push upper guide downward with a pressure of 11 lbs. (5 kg.). Pull back on guide.13-.14" (3.2-3.8 mm) and tighten bolt. There should be about.12" (3 mm) slack between counterbalance chain and upper guide.
5. Install cylinder head and manifolds as shown in «CYLINDER HEAD & MANIFOLDS»(/mazda/mpv/v-1986-1991/remont/mechanical/#26l-4-cyl__cylinder-head-manifolds). To install remaining components, reverse removal procedure. Tighten bolts to specification.

Removal & Installation

Remove counterbalance drive and timing chains. See COUNTERBALANCE DRIVE & TIMING CHAINS . Remove thrust plate bolts retaining counterbalance shafts in cylinder block. Mark counterbalance shafts for reassembly. To install remaining components, reverse removal procedure. Tighten bolts to specification.

1. Rotate crankshaft and position No. 1 piston at TDC of compression stroke. Mark and remove distributor. Remove cylinder head cover, gasket and end seals. Remove distributor drive gear from camshaft.
2. Wire timing chain to camshaft sprocket to retain valve timing. Remove camshaft pulley from camshaft dowel. Loosen rocker arm bolts gradually. Remove camshaft bearing cap bolts, rocker arms and rocker shafts as an assembly. Remove camshaft.

1. Inspect camshaft lobes for scoring or wear. Measure camshaft bearing journals, runout and lobe height.
2. Measure camshaft bearing-to-journal oil clearance. Replace components if not within specification. See «CAMSHAFT SPECIFICATIONS»(/mazda/mpv/v-1986-1991/remont/mechanical/#26l-4-cyl) table.

1. Apply engine oil to camshaft journals and bearings. Install camshaft with dowel pin facing upward.
2. Install new "O" ring on distributor. Coat "O" ring and distributor drive gear or blade with engine oil prior to installation. Apply sealant to end seals prior to installation.
3. To install remaining components, reverse removal procedure using new gaskets. Tighten bolts to specification.

VALVE ARRANGEMENT

Right Side: All intake.

Left Side: All exhaust.

Remove valve cover and gasket. Loosen rocker arm bolts gradually. Remove camshaft bearing cap bolts, rocker arms and rocker shafts as an assembly. DO NOT allow components to separate during removal. Mark component location for reassembly reference.

Disassembly & Inspection

Disassemble rocker arm and shaft assemblies. Mark components for location. Inspect rocker arm and shaft for damage or flaking. Measure rocker arm I.D. and rocker arm shaft O.D. Determine oil clearance. Replace components if not within specification. See ROCKER ARM & SHAFT SPECIFICATIONS table.

ROCKER ARM & SHAFT SPECIFICATIONS

Reassembly & Installation

1. If hydraulic lash adjuster was removed from rocker arm, fill reservoir of rocker arm with oil. Coat hydraulic lash adjuster with oil and install in rocker arm. Reassemble rocker arms and shafts.
2. To install, reverse removal procedure. Ensure No. 4 bearing cap contains the oil passage from cylinder head. Tighten bolts, in 2 or 3 steps, in sequence. (Scheme 8)

Scheme 8

VALVE CLEARANCE ADJUSTMENTS

Note. Valve clearance is not adjustable, though some valve noise may occur if engine has not been operated for an extended period of time. The noise should disappear after the engine reaches normal operating temperature. If noise persists, check oil pressure, level and condition.

Remove valve cover. Check movement of Hydraulic Lash Adjuster (HLA) by pushing down each rocker by hand. If the rocker moves down, replace HLA.

Note. Do not remove HLA unless necessary. "O" ring can be damaged during removal.

Remove valve cover and rocker arm shaft assembly. HLA can be removed by hand or, if this is difficult, with pliers.

Install new "O" ring on HLA. Coat rocker arm oil reservoir and HLA with engine oil. Install HLA into rocker arm, ensuring "O" ring is not damaged.

VALVE SPRINGS

Measure free length of valve springs. Replace springs if not within specification. See VALVE SPRINGS table. Check valve spring for squareness. Replace spring if out-of-square exceeds .069" (1.75 mm).

Measure valve guide bore, height and valve stem clearance. Replace guide if not within specification. See VALVE GUIDE SPECIFICATIONS table.

VALVE GUIDE SPECIFICATIONS

Note. Although design of intake and exhaust valve guides are different, use exhaust valve guides on both sides for replacement.

1. To remove valve guide, use Valve Guide Remover/Installer (49 0249 010A) and drive valve guide from combustion chamber side of cylinder head. Note length of valve guides.
2. To install, install clip on valve guide. Using valve guide remover/installer, drive guide into head from side opposite combustion chamber. Drive valve guide in until clip contacts cylinder head. Ensure stem-to-guide clearance and installed height are within specification. See «VALVE GUIDE SPECIFICATIONS»(/mazda/mpv/v-1986-1991/remont/mechanical/#26l-4-cyl) table.

1. Valve seat sinkage should be checked after valve and valve seat have been reconditioned and lightly lapped. With valve installed, measure distance between end of valve stem and cylinder head.
2. Standard installed height is 1.929" (49.00 mm). Acceptable installed height is 1.929-1.949" (49.00-49.50 mm).
3. Spacer plate (shim) must be installed between spring seat and cylinder head to adjust if height is 1.949-1.988" (49.50-50.50 mm). Replace cylinder head if height exceeds 1.988" (50.50 mm).

1. Remove cylinder head. See «CYLINDER HEAD & MANIFOLDS»(/mazda/mpv/v-1986-1991/remont/mechanical/#26l-4-cyl__cylinder-head-manifolds). Remove oil pan, oil pump strainer and stiffener tray. Ensure cylinder ridge is removed. Mark connecting rod and cap for cylinder identification.
2. Note direction of "F" (Front) mark on piston located near piston pin area. (Scheme 9) This mark is positioned toward timing belt side of engine. Remove rod cap. Remove piston assembly.

1. Ensure piston ring end gap and side clearance are within specification. Install rings on piston with ring code identification marks toward top of piston. Lubricate piston, rings and cylinder bore with engine oil.
2. Properly space ring end gaps on piston. (Scheme 9) Install piston and rod into cylinder bore. Ensure piston is installed with "F" mark toward front (timing chain end) of engine. (Scheme 9)
3. Check bearing clearance using Plastigage method. Tighten rod cap nuts to specification. See «TORQUE SPECIFICATIONS»(/mazda/mpv/v-1986-1991/remont/mechanical/#26l-4-cyl__torque-specifications). Ensure rod moves freely on crankshaft. Check connecting rod side play. Repair or replace connecting rod if not within specification. See «CRANKSHAFT MAIN & CONNECTING ROD BEARINGS»(/mazda/mpv/v-1986-1991/remont/mechanical/#26l-4-cyl) table.

Scheme 9

FITTING PISTONS & RINGS

Measure cylinder bore and piston skirt diameter. Piston skirt diameter should be measured at 90 degree angle to piston pin approximately .71" (18.0 mm) below oil ring groove. Clearance between piston and cylinder bore must be within specification. Check piston rings for side clearance and end gap. See PISTONS , PINS & RINGS table.

Note connecting rod identification mark and "F" (Front) mark on piston. (Scheme 10) Using press and Piston Pin Remover/Installer (49 L011 0A0), remove pin.

Scheme 10

1. Inspect piston for cracks or damage in ring areas. Check ring side clearance. Replace piston if not within specification. See «PISTONS»(/mazda/mpv/v-1986-1991/remont/mechanical/#26l-4-cyl) , PINS & RINGS table.
2. Check connecting rod for bend or twist and center-to-center length. Replace components if not within specification. See CONNECTING ROD SPECIFICATIONS table.
3. Measure piston pin outer diameter. Outer diameter should be .9050-.9055" (22.974-23.000 mm). Replace if not within specification.

CONNECTING ROD SPECIFICATIONS

1. Ensure connecting rod identification mark is positioned correctly. (Scheme 11) Apply engine oil to piston pin and to connecting rod bore.
2. Insert piston pin from piston side marked "F". Force required to install pin should be 1100-3300 lbs. (500-1500 kg). Replace components if force required is not within specification. Ensure connecting moves smoothly.

1. Remove flywheel or drive plate. Remove engine end plate and rear seal case. Remove timing chain cover and oil pump assembly. Remove oil pan, oil pump strainer and stiffener tray. Ensure connecting rods and main bearing cap are marked for location.
2. Remove connecting rod caps and bearings. Note direction of arrow on main bearing caps. Remove main bearing caps. Ensure all components are placed in correct order. Remove crankshaft. Remove main bearings from cylinder block. Mark bearings for location.

Inspect crankshaft for cracks, damaged gear or threads. Check crankshaft for runout, out-of-round and taper. Replace or repair crankshaft if not within specification. See CRANKSHAFT MAIN & CONNECTING ROD BEARINGS table.

Scheme 11

1. Install upper main bearings in cylinder block. Ensure oil hole is aligned and bearing is properly seated. Lubricate bearings with engine oil.
2. Install crankshaft in block. Install main bearing caps in original location with arrow toward front of engine. CAUTION: Main bearing cap must be installed in original location with arrow facing toward front of engine.
3. Check oil clearance using Plastigage method. Tighten bolts in sequence to specification. (Scheme 11) Remove main bearing cap. Clearance must be within specification. If oil clearance exceeds specification, replace bearings or crankshaft.
4. Ensure crankshaft rotates freely with main bearing caps installed. Check crankshaft end play. See «CRANKSHAFT END PLAY»(/mazda/mpv/v-1986-1991/remont/mechanical/#26l-4-cyl__crankshaft-end-play).
5. Install connecting rod caps and bearings. Ensure components are installed in original location. Check bearing clearance using Plastigage method. Tighten rod nuts to specification. Ensure connecting rods move freely on crankshaft.
6. To install remaining components, reverse removal procedure. Clean sealant from flywheel or drive plate bolts. Apply sealant on flywheel or drive plate bolts and install. Tighten bolts to specification.

1. Mark bearing cap and connecting rod for location. Remove connecting rod cap and bearing.
2. Install replacement bearing. Ensure reference marks on rod cap and connecting rod are aligned. Check bearing clearance using Plastigage method. Tighten nuts to specification.
3. Ensure connecting rod moves freely on crankshaft. Check connecting rod side clearance. Clearance must be within specification. See «CRANKSHAFT MAIN & CONNECTING ROD BEARINGS»(/mazda/mpv/v-1986-1991/remont/mechanical/#26l-4-cyl) table.

CRANKSHAFT END PLAY

End play must be within specification. See CRANKSHAFT MAIN & CONNECTING ROD BEARINGS table. If not within specification, crankshaft must be ground and undersized main bearing installed.

Disconnect negative battery cable. Drain engine oil. Remove cooling fan and fan shroud. Remove drive belts and water pump pulley. Remove crankshaft pulley. Pry out front seal.

Apply engine oil to new oil seal lip. Tap seal into timing chain cover using suitable pipe or tool. Install oil seal flush with surface of timing chain cover. To install remaining components, reverse removal procedure. Tighten bolts to specification.

1. Disconnect negative battery cable. Drain engine oil. Remove transmission. Remove flywheel or drive plate. Pry seal from seal case.
2. To install, coat seal lip with oil. Press seal in seal case. Install flywheel or drive plate. To install remaining components, reverse removal procedure. Tighten bolts to specification.

ENGINE OILING SYSTEM

Oil pressure is provided by a rotor-type pump driven by the front of the crankshaft. Pressure relief valve is located in the oil pump body. An oil cooler is mounted between oil filter and cylinder block.

Scheme 12

CRANKCASE CAPACITY

Oil capacity is 5.8 qts. (5.5L) with filter replacement.

OIL PRESSURE

Oil pressure is 16-30 psi (1.1-2.1 kg/cm 2 ) at idle and 44-58 psi (3.1-4.1 kg/cm 2 ) at 3000 RPM.

PRESSURE RELIEF VALVE

Pressure relief valve is nonadjustable and is located in oil pump cover. Oil pressure is limited to 57-71 psi (4.0-5.0 kg/cm 2 ).

1. Disconnect negative battery cable. Drain engine oil and coolant. Remove cooling fan and fan shroud. Remove drive belts and radiator hoses.
2. Raise vehicle. Remove engine undercover. Remove oil pan gusset plates and oil pan.

Apply sealant around entire gasket surface of oil pan. Apply locking agent to oil pan bolts. To install remaining components, reverse removal procedure. Tighten bolts to specification.

1. Disconnect negative battery cable. Drain engine oil and coolant. Remove cooling fan and fan shroud. Remove drive belts and radiator hoses.
2. Remove cylinder head and manifolds as shown in «CYLINDER HEAD & MANIFOLDS»(/mazda/mpv/v-1986-1991/remont/mechanical/#26l-4-cyl__cylinder-head-manifolds) section. Raise vehicle. Remove engine undercover. Remove oil pan gusset plates and oil pan. Lower vehicle.
3. Remove water pump pulley. Remove alternator, power steering pump, A/C compressor and brackets. Remove water pump and coolant by-pass pipe. Remove crankshaft pulley and chain cover with oil pump.

1. Disassemble pump. With rotors in pump body, check clearance between outer rotor and pump body. Place straightedge across pump body to check rotor side clearance.
2. Check clearance between straightedge and both rotors. Check clearance between tip of both rotors. Replace gear set or pump assembly if not within specification. See OIL PUMP SPECIFICATIONS table. Ensure relief valve slides freely in pump body bore. Inspect relief valve spring for damage. Measure free length of relief spring. Spring should measure 1.827" (46.40 mm)

OIL PUMP SPECIFICATIONS (1)

1. Coat all components with oil. Install rotors with alignment marks aligned and positioned toward pump cover. Apply Loctite to oil pump cover bolts and tighten.
2. To install, reverse removal procedure. Apply engine oil to new oil seal and install. Apply sealant to pump sealing surfaces and install. Ensure sealant does not enter oil passage.

Drain cooling system. Disconnect hoses at oil cooler. Remove oil filter. Remove oil cooler retaining nut. Remove oil cooler. To install, reverse removal procedure. Tighten nut to specification.

COOLING SPECIFICATIONS

COOLANT SYSTEM CAPACITY

BELT TENSION

PRESSURE CAP

Remove cooling fan belt, cooling fan and fan shroud. Remove water pump pulley and water pump.

Inspect water pump body for cracks and damage to gasket surface. Inspect impeller for damage.

Install using new gasket. To install remaining components, reverse removal procedure. Tighten bolts to specification.

Note. For further information on cooling systems, see appropriate ENGINE COOLING article.

GENERAL ENGINE SPECIFICATIONS

GENERAL ENGINE SPECIFICATIONS

CRANKSHAFT MAIN & CONNECTING ROD BEARINGS SPECS

CRANKSHAFT MAIN & CONNECTING ROD BEARINGS SPECS

CONNECTING ROD SPECIFICATIONS

CONNECTING ROD SPECIFICATIONS

PISTONS, PINS & RINGS SPECIFICATIONS

PISTONS, PINS & RINGS SPECIFICATIONS

VALVE SPECIFICATIONS

VALVE SPECIFICATIONS

CYLINDER HEAD SPECIFICATIONS

CYLINDER HEAD SPECIFICATIONS

CAMSHAFT SPECIFICATIONS

CAMSHAFT SPECIFICATIONS

CYLINDER BLOCK SPECIFICATIONS

CYLINDER BLOCK SPECIFICATIONS

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• TORQUE SPECIFICATIONS
• CYLINDER HEAD & MANIFOLDS
• COUNTERBALANCE DRIVE & TIMING CHAINS
• CAMSHAFT SPECIFICATIONS
• CRANKSHAFT END PLAY