Engine Mechanical - General - Engine Overhaul: Other Mazda Tribute I facelift

ACCESSORY DRIVE

Note. For 3.0L, see ACCESSORY DRIVE

Scheme 1

Scheme 2

Scheme 3

1. Verify the customer's concern by operating the engine to duplicate the condition.
2. Inspect to determine if any of the following mechanical concerns apply: NOTE: Minor cracks in the V-grooved portion of the drive belt are considered normal and acceptable. If the drive belt has chunks missing from the ribs, a new drive belt should be installed. Install a new drive belt if any of the following conditions exist: rib chunk-out, severe glazing, frayed cords or other concerns.
3. Inspect for drive belt cracking/chunking/wear. V-Ribbed Serpentine Drive Belt With Cracks Across Ribs V-Ribbed Serpentine Drive Belt With Chunks of Rib Missing
4. If the concerns remain after inspection, determine the symptoms and go to the Symptom Chart.

Belt Tensioner - Mechanical

The only mechanical check that needs to be made is a check for tensioner stick, grab or bind.

1. Remove the belt in the area of the tensioner.
2. Rotate the tensioner from its relaxed position through its full stroke and back to the relaxed position to make sure there is no stick, grab or bind and to make sure that there is tension on the belt tensioner spring.
3. If the tensioner meets the above criteria, proceed to test the tensioner dynamically. If the tensioner does not meet the above criteria, install a new tensioner. Refer to ACCESSORY DRIVE BELT TENSIONER - 2.0L ZETEC .

Belt Tensioner - Dynamic

The belt tensioner can be checked dynamically as follows

1. With the engine running, observe the belt tensioner movement. The belt tensioner should move (respond) when the A/C clutch cycles (if equipped), or when the engine is accelerated rapidly. If the belt tensioner movement is constant without A/C clutch cycling or acceleration, a pulley or shaft is probably bent or a pulley is out of round. In rare cases, excessive drive belt rideout (uneven depth of grooves in drive belt ) can cause excessive drive belt tensioner movement. This condition can be checked by installing a new drive belt, and repeating the observation.
2. With the engine off, check routing of the drive belt. Refer to ACCESSORY DRIVE .
3. Inspect the belt tensioner wear indicator to confirm the drive belt is within operating range. Install a new drive belt if necessary. Refer to ACCESSORY DRIVE BELT TENSIONER - 2.0L ZETEC .

VALVE - SPRING FREE LENGTH

1. Measure the free length of each valve spring. Refer to SPECIFICATIONS . If out of specification, install new components as necessary.

VALVE - SPRING STRENGTH

1. Use a Valve/Clutch Spring Tester to check the valve spring for correct strength at the specified valve spring length. Refer to SPECIFICATIONS . If out of specification, install new components as necessary.

VALVE - SPRING SQUARENESS

1. Measure the out-of-square on each valve spring. Turn the valve spring and observe the space between the top of the valve spring and the square. Install a new valve spring if out of square.

VALVE - STEM DIAMETER

1. Measure the diameter of each intake and exhaust valve stem at the points shown. Verify the diameter is within specification. Refer to SPECIFICATIONS . If out of specification, install new components as necessary.

VALVE - GUIDE INNER DIAMETER

1. Measure the inner diameter of the valve guides in two directions where indicated. Refer to SPECIFICATIONS .
2. If the valve guide is not within specifications, ream the valve guide and install a valve with an oversize stem or remove the valve guide and install a new valve guide.

Valve and Seat Refacing Measurements

1. Check the valve head and seat. Check valve angles. Check margin width. Be sure margin width is within specification. Refer to SPECIFICATIONS .
2. Inspect for abnormalities on the valve face and seat.

VALVE - SEAT WIDTH

1. Measure the valve seat width. If necessary, grind the valve seat to specification. Refer to SPECIFICATIONS . Measure the intake valve seat width. Measure the exhaust valve seat width. Recheck the valve spring installed length after the seats have been ground, and shim the valve springs as necessary to achieve the correct installed spring length.

VALVE - SEAT RUNOUT

1. Use the Valve Seat Runout Gauge to check valve seat runout. Refer to SPECIFICATIONS .

VALVE - SPRING INSTALLED LENGTH

1. Measure the installed length of each valve spring. Refer to SPECIFICATIONS . If out of specification, install new components.

VALVE - STEM TO VALVE GUIDE CLEARANCE

Note. The valve springs must be removed before checking valve stem to valve guide clearance.

Note. Valve stem diameter must be within specifications before checking valve stem to valve guide clearance.

Note. If necessary, use a magnetic base.

1. Install a Valve Stem Clearance Tool on the valve stem and install a Dial Indicator with Bracketry. Lower the valve until the Valve Stem Clearance Tool contacts the upper surface of the valve guide.
2. Move the Valve Stem Clearance Tool toward the indicator and zero the indicator. Move the Valve Stem Clearance Tool away from the indicator and note the reading. The reading will be DOUBLE the valve stem-to-valve guide clearance. Valves with oversize stems will need to be installed if out of specification. Refer to SPECIFICATIONS .

CONNECTING ROD - CLEANING

Note. If the connecting rod large end is mechanically split or cracked to produce a unique parting face, a locking joint is produced. Parts are not interchangeable.

1. Mark and separate the parts and clean with solvent. Clean the oil passages.

CONNECTING ROD - TWIST

1. Measure the connecting rod twist on a suitable alignment fixture. Follow the instructions of the fixture manufacturer. Verify the measurement is within specification. Refer to SPECIFICATIONS . If out of specification, install new components as necessary.

CONNECTING ROD - BEND

1. Measure the connecting rod bend on a suitable alignment fixture. Follow the instructions of the fixture manufacturer. Verify the bend measurement is within specification. Refer to SPECIFICATIONS . If out of specification, install new components as necessary.

CONNECTING ROD - LARGE END BORE

1. Tighten the bolts to specification, then measure the bore in two directions. The difference is the connecting rod bore out-of-round. Verify the out-of-round is within specification. Refer to SPECIFICATIONS . If out of specification, install new components as necessary.

CONNECTING ROD - BUSHING DIAMETER

1. Measure the inner diameter of the connecting rod bushing, if equipped. Verify the diameter is within specification. Refer to SPECIFICATIONS . If out of specification, install new components as necessary.

CONNECTING ROD - BEARING JOURNAL CLEARANCE

Note. The crankshaft connecting rod journals must be within specifications to check the connecting rod bearing journal clearance.

1. Remove the connecting rod bearing cap.
2. Position a piece of Plastigage across the bearing surface.
3. Install and tighten to specifications, then remove the connecting rod bearing cap.
4. Measure the Plastigage to get the connecting rod bearing journal clearance. The Plastigage should be smooth and flat. A changing width indicates a tapered or damaged connecting rod or connecting rod bearing. Refer to SPECIFICATIONS . If out of specification, install new components as necessary.

PISTON - SELECTION

Note. The cylinder bore must be within the specifications for taper and out-of-round before fitting a piston. Refer to SPECIFICATIONS .

1. Select a piston size based on the cylinder bore.
2. Choose the piston with the correct paint color.

PISTON - DIAMETER

1. Measure the piston dome and skirt diameter 90 degrees from the piston pin at the points indicated. Refer to SPECIFICATIONS . If it is out of specification, install new components as necessary.

PISTON - TO CYLINDER BORE CLEARANCE

1. Subtract the piston diameter from the cylinder bore diameter to find the piston-to-cylinder bore clearance. Refer to SPECIFICATIONS .

PISTON - RING END GAP

Note. Cylinder bore must be within specification for taper and out-of-round.

1. Use a piston without rings to push a piston ring in a cylinder to the bottom of ring travel.
2. Use a feeler gauge to measure the top piston ring end gap and the second piston ring end gap. Refer to SPECIFICATIONS .

PISTON - RING-TO-GROOVE CLEARANCE

1. Inspect for a step in the grooves.
2. Measure the piston ring-to-groove clearance. Refer to SPECIFICATIONS . If out of specification, install new components as necessary.

PISTON - PIN DIAMETER

1. Measure the piston pin diameter in two directions at the points shown. Verify the diameter is within specification. Refer to SPECIFICATIONS . If out of specification, install new components as necessary.

Scheme 4

Note. Piston and piston pins are a matched set and should not be interchanged.

Scheme 5

1. Measure the piston pin bore diameter in two directions on each side. Verify the diameter is within specification. Refer to SPECIFICATIONS . If it is out of specification, install new components as necessary.

CAMSHAFT - LOBE SURFACE

1. Inspect camshaft lobes for pitting or damage in the active area. Minor pitting is acceptable outside the active area. If excessive pitting or damage is present, install new components as necessary.

CAMSHAFT - LOBE LIFT

1. Use a Dial Indicator with Bracketry to measure camshaft intake/exhaust lobe lift. Rotate the camshaft and subtract the lowest indicator reading from the highest indicator reading to figure the camshaft lobe lift. Refer to SPECIFICATIONS . If out of specification, install new components as necessary.

CAMSHAFT JOURNAL - DIAMETER

1. Measure each camshaft journal diameter in two directions. Refer to SPECIFICATIONS . If it is out of specification, install new components as necessary.

CAMSHAFT - RUNOUT

Note. Camshaft journals must be within specifications before checking runout.

1. Use a Dial Indicator with Bracketry to measure the camshaft runout. Rotate the camshaft and subtract the lowest indicator reading from the highest indicator reading. Refer to SPECIFICATIONS . If it is out of specification, install new components as necessary.

CAMSHAFT JOURNAL - CLEARANCE, PLASTIGAGE METHOD

Note. The camshaft journals must meet specifications before checking camshaft journal clearance.

Scheme 6

1. Remove the camshaft bearing cap and lay Plastigage across the surface. NOTE: Do not turn the camshaft while carrying out this procedure.
2. Position the camshaft bearing cap and install the bolts.
3. Use Plastigage to verify the camshaft journal clearance. Refer to SPECIFICATIONS . If it is out of specification, install new components as necessary.

CAMSHAFT - END PLAY, OHC ENGINES

1. Remove the roller followers.
2. Use a Dial Indicator with Bracketry to measure camshaft end play.
3. Position the camshaft to the rear of the cylinder head.
4. Zero the indicator.
5. Move the camshaft to the front of the cylinder head. Note and record the camshaft end play. Refer to SPECIFICATIONS . If camshaft end play exceeds specifications, install new camshaft thrust bearing washers.

CRANKSHAFT - CONNECTING ROD JOURNAL TAPER, OUT OF ROUND

1. Measure the crankshaft connecting rod journal diameters in two directions perpendicular to one another at each end of the connecting rod journal. The difference in the measurements from one end to the other is the taper. Verify measurement is within the wear limit. Refer to SPECIFICATIONS . If it is out of specification, install new components as necessary.

CRANKSHAFT MAIN BEARING JOURNAL - TAPER

1. Measure each of the crankshaft main bearing journal diameters in at least two directions at each end of the main bearing journal. Refer to SPECIFICATIONS . If it out of specification, install new components as necessary.

CRANKSHAFT MAIN BEARING JOURNAL - DIAMETER

1. Measure each of the crankshaft main bearing journal diameters in at least two directions. Refer to SPECIFICATIONS . If it is out of specification, install new components as necessary.

Scheme 7

Note. Crankshaft main bearing journals must be within specifications before checking runout.

1. Use the Dial Indicator with Bracketry to measure the crankshaft runout. Rotate the crankshaft and subtract the lowest dial indicator reading from the highest dial indicator reading to figure the crankshaft runout. Refer to SPECIFICATIONS . If it is out of specification, install new components as necessary.

CRANKSHAFT MAIN BEARING JOURNAL - CLEARANCE

Note. Crankshaft main bearing journals must be within specifications before checking journal clearance.

1. Remove the crankshaft main bearing caps and crankshaft main bearing.
2. Lay a piece of Plastigage across the face of each crankshaft main bearing surface.
3. Install and remove the crankshaft main bearing cap.
4. Verify the crankshaft journal clearance. Refer to SPECIFICATIONS . If it is out of specification, install new components as necessary.

CRANKSHAFT - END PLAY

1. Measure the crankshaft end play. Use a Dial Indicator with Bracketry to measure crankshaft end play.
2. Position the crankshaft to the rear of the cylinder block.
3. Zero the indicator.
4. Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play. Refer to SPECIFICATIONS . If crankshaft end play exceeds specifications, install a new crankshaft thrust washer or crankshaft thrust main bearing.

CYLINDER BORE - CLEANING

1. Clean the cylinder bores with soap or detergent and water.
2. Thoroughly rinse with clean water and wipe dry with a clean, lint-free cloth.
3. Use a clean, lint-free cloth and lubricate the cylinder bores.

CYLINDER BORE - OUT-OF-ROUND

1. Measure the cylinder bore in two directions. The difference is the out-of-round. Refer to SPECIFICATIONS . Verify the out-of-round is within the wear limit and bore the cylinder to the next oversize limit.

CYLINDER BORE - TAPER

1. Measure the cylinder bore at the top and bottom. Verify the cylinder bore is within the wear limit. Refer to SPECIFICATIONS . The difference indicates the cylinder bore taper. Bore the cylinder to the next oversize.