Beruflich Dokumente
Kultur Dokumente
SECTION
00
Toc of SCT
GENERAL INFORMATION . . . . .00-00
Toc of SCT
0000 GENERAL INFORMATION
HOW TO USE THIS MANUAL. . . . . . . . . 00001 ELECTRICAL SYSTEM . . . . . . . . . . . . . . 00008
UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . 00003 NEW STANDARDS. . . . . . . . . . . . . . . . . . 00009
FUNDAMENTAL PROCEDURES . . . . . . 00004 ABBREVIATIONS. . . . . . . . . . . . . . . . . . . 000011
End of Toc
HOW TO USE THIS MANUAL
B3E000000001201
Range of Topics
This manual contains procedures for performing all required service operations. The procedures are divided
into the following five basic operations:
Removal/Installation
Disassembly/Assembly
Replacement
Inspection
Adjustment
Simple operations which can be performed easily just by looking at the vehicle (i.e., removal/installation of
parts, jacking, vehicle lifting, cleaning of parts, and visual inspection) have been omitted.
Service Procedure
Inspection, adjustment
Inspection and adjustment procedures are
divided into steps. Important points regarding the SHOWS PROCEDURE ORDER
location and contents of the procedures are FOR SERVICE
explained in detail and shown in the illustrations.
Fluid Pressure Inspection
1. Assemble the SSTs as shown in the figure.
Tightening torque
3949 Nm {4.05.0 kgfm, 2936 ftlbf}
49 1232 670A
WGIWXX0009E
Repair procedure
1. Most repair operations begin with an overview illustration. It identifies the components, shows how the parts fit
together, and describes visual part inspection. However, only removal/installation procedures that need to be
performed methodically have written instructions.
2. Expendable parts, tightening torques, and symbols for oil, grease, and sealant are shown in the overview
illustration. In addition, symbols indicating parts requiring the use of special service tools or equivalent are also
shown.
00001
GENERAL INFORMATION
3. Procedure steps are numbered and the part that is the main point of that procedure is shown in the illustration
with the corresponding number. Occasionally, there are important points or additional information concerning a
procedure. Refer to this information when servicing the related part.
SHOWS SERVICE
Procedure ITEM (S)
INDICATES ANY RELEVANT
1
LOWER TRAILING LINK, UPPER TRAILING LINK REMOVAL/INSTALLATION REFERENCES WHICH NEED
1. Jack up the rear of the vehicle and support it with safety stands. TO BE FOLLOWED DURING
"Removal/Installation" 2. Remove the undercover. (See 01-10-4 Undercover Removal)
Portion 3. Remove in the order indicated in the table. INSTALLATION
4. Install in the reverse order of removal.
2 5. Inspect the rear wheel alignment and adjust it if necessary.
"Inspection After SHOWS SPECIAL
Installation" Portion 11 SERVICE TOOL (SST)
9 SST
SHOWS PROCEDURE ORDER FOR SERVICE OPERATION
GREASE
FOR SERVICE 12 SST R
SHOWS TIGHTENING
TORQUE
SPECIFICATIONS SHOWS NON-REUSEABLE PARTS
SST
3
5
6 SHOWS DETAILS
SST
GREASE
4 R
94116 {9.511.9, 6986}
2 118156 {12.016.0, 87115} SHOWS TIGHTENING
SHOWS THERE 1 R TORQUE UNITS
ARE REFERRAL
Nm {kgfm, ftlbf}
NOTES FOR SERVICE
1 Split pin 7 Split pin
2 Nut 8 Nut
3 Lower trailing link ball joint 9 Upper trailing link ball joint
(See 02-14-5 Lower Trailing Link Ball Joint Removal Note) (See 02-14-5 Upper Trailing Link Ball Joint Removal Note)
4 Bolt 10 Nut
5 Lower trailing link 11 Upper trailing link
6 Dust boot (lower trailing link) 12 Dust boot (upper trailing link)
Lower Trailing Link Ball Joint, Upper Trailing Link 49 T028 304 UPPER TRAILING LINK
Ball Joint Removal Note 49 T028 305 LOWER TRAILING LINK
Remove the ball joint using the SSTs.
SHOWS SPECIAL
SERVICE TOOL (SST)
NO. KNUCKLE
49 T028 303
SHOWS REFERRAL
NOTES FOR
SERVICE
BHE0000W104
Symbols
There are eight symbols indicating oil, grease, fluids, sealant, and the use of SST or equivalent. These symbols
show application points or use of these materials during service.
Symbol Meaning Kind
New appropriate
OIL Apply oil engine oil or gear
oil
00002
GENERAL INFORMATION
Symbol Meaning Kind
00
New appropriate
BRAKE Apply brake fluid
FLUID brake fluid
New appropriate
Apply automatic
automatic
transaxle/
ATF
transaxle/
transmission fluid
transmission fluid
Appropriate
Apply grease
GREASE
grease
Appropriate
SEALANT Apply sealant
sealant
O-ring, gasket,
R Replace part
etc.
Use SST or
SST equivalent
Appropriate tools
Advisory Messages
You will find several Warnings, Cautions, Notes, Specifications and Upper and Lower Limits in this
manual.
Warning
A Warning indicates a situation in which serious injury or death could result if the warning is ignored.
Caution
A Caution indicates a situation in which damage to the vehicle or parts could result if the caution is ignored.
Note
A Note provides added information that will help you to complete a particular procedure.
Specification
The values indicate the allowable range when performing inspections or adjustments.
00003
GENERAL INFORMATION
kPa (kilo pascal)
Rounding Off
Converted values are rounded off to the same number of places as the SI unit value. For example, if the SI unit
value is 17.2 and the value after conversion is 37.84, the converted value will be rounded off to 37.8.
The actual converted values for 2.7 kgf/cm2 are 264 kPa and 38.4 psi. In the first specification, 2.7 is used as
an upper limit, so the converted values are rounded down to 260 and 38. In the second specification, 2.7 is
used as a lower limit, so the converted values are rounded up to 270 and 39.
End Of Sie
FUNDAMENTAL PROCEDURES
B3E000000004201
Preparation of Tools and Measuring Equipment
Be sure that all necessary tools and measuring
equipment are available before starting any work.
CHU0014W003
00004
GENERAL INFORMATION
Special Service Tools
Use special service tools or equivalent when they
are required. 00
49 SE01 310
WGIWXX0024E
Disassembly
If the disassembly procedure is complex,
requiring many parts to be disassembled, all parts
should be marked in a place that will not affect
their performance or external appearance and
identified so that reassembly can be performed
easily and efficiently.
WGIWXX0027E
WGIWXX0028E
Arrangement of Parts
All disassembled parts should be carefully
arranged for reassembly.
Be sure to separate or otherwise identify the parts
to be replaced from those that will be reused.
WGIWXX0029E
00005
GENERAL INFORMATION
Cleaning of Parts
All parts to be reused should be carefully and
thoroughly cleaned in the appropriate method.
Warning
Using compressed air can cause dirt and
other particles to fly out causing injury to
the eyes. Wear protective eye wear
whenever using compressed air.
WGIWXX0030E
Reassembly
Standard values, such as torques and certain
adjustments, must be strictly observed in the
reassembly of all parts.
If removed, the following parts should be replaced
with new ones:
Oil seals
Gaskets
O-rings
Lockwashers
Cotter pins
Nylon nuts
WGIWXX0031E
Depending on location:
Sealant and gaskets, or both, should be
applied to specified locations. When sealant
is applied, parts should be installed before
sealant hardens to prevent leakage.
Oil should be applied to the moving
components of parts.
Specified oil or grease should be applied at
the prescribed locations (such as oil seals)
before reassembly.
CHU0014W006
Adjustment
Use suitable gauges and testers when making
adjustments.
CHU0014W005
00006
GENERAL INFORMATION
Rubber Parts and Tubing
Prevent gasoline or oil from getting on rubber
parts or tubing. 00
WGIWXX0034E
Hose Clamps
When reinstalling, position the hose clamp in the
original location on the hose and squeeze the
clamp lightly with large pliers to ensure a good fit.
WGIWXX0035E
Torque Formulas
When using a torque wrench-SST or equivalent
combination, the written torque must be SST
3
recalculated due to the extra length that the SST
2
or equivalent adds to the torque wrench.
1 0
Recalculate the torque by using the following
1
formulas. Choose the formula that applies to you. 3
2
Vise
When using a vise, put protective plates in the
jaws of the vise to prevent damage to parts.
End Of Sie
PROTECTIVE PLATES
CHU0014W010
00007
GENERAL INFORMATION
ELECTRICAL SYSTEM
B3E000000006201
Connectors
Disconnecting connectors
When disconnecting connector, grasp the
connectors, not the wires. GOOD NO GOOD
CHU0000W014
WGIWXX0042E
Locking connector
When locking connectors, listen for a click
indicating they are securely locked.
WGIWXX0043E
Inspection
When a tester is used to inspect for continuity or
measuring voltage, insert the tester probe from GOOD NO GOOD
the wiring harness side.
Inspect the terminals of waterproof connectors
from the connector side since they cannot be
accessed from the wiring harness side.
Caution
To prevent damage to the terminal, wrap
a thin wire around the tester probe before
inserting into terminal.
CHU0000W011
00008
GENERAL INFORMATION
End Of Sie
GOOD NO GOOD 00
CHU0000W012
NEW STANDARDS
B3E000000003201
Following is a comparison of the previous standard and the new standard.
New Standard Previous Standard
Abbrevi- Abbrevi- Remark
Name Name
ation ation
AP Accelerator Pedal Accelerator Pedal
ACL Air Cleaner Air Cleaner
A/C Air Conditioning Air Conditioning
BARO Barometric Pressure Atmospheric Pressure
B+ Battery Positive Voltage Vb Battery Voltage
Brake Switch Stoplight Switch
Calibration Resistor Corrected Resistance #6
CMP sensor Camshaft Position Sensor Crank Angle Sensor
CAC Charge Air Cooler Intercooler
CLS Closed Loop System Feedback System
CTP Closed Throttle Position Fully Closed
CPP Clutch Pedal Position Idle Switch
CIS Continuous Fuel Injection System Clutch Position
CS sensor Control Sleeve Sensor CSP sensor Control Sleeve Position Sensor #6
CKP sensor Crankshaft Position Sensor Crank Angle Sensor 2
DLC Data Link Connector Diagnosis Connector
DTM Diagnostic Test Mode Test Mode #1
DTC Diagnostic Trouble Code(s) Service Code(s)
DI Distributor Ignition Spark Ignition
DLI Distributorless Ignition Direct Ignition
EI Electronic Ignition Electronic Spark Ignition #2
ECT Engine Coolant Temperature Water Thermo
EM Engine Modification Engine Modification
Engine Speed Input Signal Engine RPM Signal
EVAP Evaporative Emission Evaporative Emission
EGR Exhaust Gas Recirculation Exhaust Gas Recirculation
FC Fan Control Fan Control
FF Flexible Fuel Flexible Fuel
4GR Fourth Gear Overdrive
Fuel Pump Relay Circuit Opening Relay #3
FSO
Fuel Shut Off Solenoid FCV Fuel Cut Valve #6
solenoid
GEN Generator Alternator
GND Ground Ground/Earth
HO2S Heated Oxygen Sensor Oxygen Sensor With heater
IAC Idle Air control Idle Speed Control
IDM Relay Spill Valve Relay #6
Incorrect Gear Ratio
Injection Pump FIP Fuel Injection Pump #6
00009
GENERAL INFORMATION
New Standard Previous Standard
Abbrevi- Abbrevi- Remark
Name Name
ation ation
Input/Turbine Speed Sensor Pulse Generator
IAT Intake Air Temperature Intake Air Thermo
KS Knock Sensor Knock Sensor
MIL Malfunction Indicator Lamp Malfunction Indicator Light
MAP Manifold Absolute Pressure Intake Air Pressure
MAF sensor Mass Air Flow Sensor Airflow Sensor
MFL Multiport Fuel Injection Multiport Fuel Injection
OBD On-Board Diagnostic Diagnosis/Self-Diagnosis
OL Open Loop Open Loop
Output Speed Sensor Vehicle Speed Sensor 1
OC Oxidation Catalytic Converter Catalytic Converter
O2S Oxygen Sensor Oxygen Sensor
PNP Park/Neutral Position Park/Neutral Range
PCM Control Relay Main Relay #6
PSP Power Steering Pressure Power Steering Pressure
PCM Powertrain Control Module ECU Engine Control Unit #4
Pressure Control Solenoid Line Pressure Solenoid Valve
Pulsed
PAIR Pulsed Secondary Air Injection Secondary Air Injection System
injection
Pump Speed Sensor NE Sensor #6
Injection
AIR Secondary Air Injection Secondary Air Injection System with air
pump
SAPV Secondary Air Pulse Valve Reed Valve
SFI Sequential Multipoint Fuel Injection Sequential Fuel Injection
12 Shift Solenoid Valve
Shift Solenoid A
Shift A Solenoid Valve
23 Shift Solenoid Valve
Shift Solenoid B
Shift B Solenoid Valve
Shift Solenoid C 34 Shift Solenoid Valve
3GR Third Gear 3rd Gear
TWC Three Way Catalytic Converter Catalytic Converter
TB Throttle Body Throttle Body
TP sensor Throttle Position Sensor Throttle Sensor
TCV Timer Control Valve TCV Timing Control Valve #6
TCC Torque Converter Clutch Lockup Position
Transmission (Transaxle) Control
TCM EC-AT Control Unit
Module
Transmission (Transaxle) Fluid
ATF Thermosensor
Temperature Sensor
TR Transmission (Transaxle) Range Inhibitor Position
TC Turbocharger Turbocharger
VSS Vehicle Speed Sensor Vehicle Speed Sensor
VR Voltage Regulator IC Regulator
VAF sensor Volume Air Flow Sensor Air flow Sensor
Warm Up Three Way Catalytic
WUTWC Catalytic Converter #5
Converter
WOT Wide Open Throttle Fully Open
000010
GENERAL INFORMATION
#6 : Part name of diesel engine
00
End Of Sie
ABBREVIATIONS
B3E000000011201
End Of Sie
000011
ENGINE 01SECTION
Toc of SCT
MECHANICAL . . . . . . . . . . . . . 01-10 SERVICE TOOLS . . . . . . . . . . . 01-60
TECHNICAL DATA. . . . . . . . . . 01-50
Toc of SCT
0110 MECHANICAL
ENGINE OVERHAUL OIL JET VALVE INSPECTION . . . . . . . . . 011018
01
SERVICE WARNING . . . . . . . . . . . . . . . 01101 PISTON INSPECTION . . . . . . . . . . . . . . . 011018
ENGINE MOUNTING/DISMOUNTING . . 01101 CRANKSHAFT INSPECTION . . . . . . . . . 011019
TIMING CHAIN DISASSEMBLY . . . . . . . 01103 CONNECTING ROD INSPECTION . . . . . 011021
CYLINDER HEAD (I) DISASSEMBLY. . . 01105 BOLT INSPECTION . . . . . . . . . . . . . . . . . 011021
CYLINDER HEAD (II) DISASSEMBLY . . 01107 VARIABLE VALVE TIMING ACTUATOR
CYLINDER BLOCK (I) DISASSEMBLY . 01109 INSPECTION . . . . . . . . . . . . . . . . . . . . . 011022
CYLINDER BLOCK (II) DISASSEMBLY . 011010 OIL CONTROL VALVE (OCV)
CYLINDER HEAD INSPECTION. . . . . . . 011011 INSPECTION . . . . . . . . . . . . . . . . . . . . . 011022
VALVE, VALVE GUIDE INSPECTION . . . 011012 VALVE CLEARANCE INSPECTION . . . . 011023
VALVE GUIDE REPLACEMENT . . . . . . . 011013 VALVE CLEARANCE ADJUSTMENT . . . 011024
VALVE SEAT INSPECTION/REPAIR . . . 011014 CYLINDER BLOCK (I) ASSEMBLY . . . . . 011027
VALVE SPRING INSPECTION . . . . . . . . 011015 CYLINDER BLOCK (II) ASSEMBLY . . . . 011033
CAMSHAFT INSPECTION . . . . . . . . . . . 011015 CYLINDER HEAD (I) ASSEMBLY . . . . . . 011036
TAPPET INSPECTION . . . . . . . . . . . . . . 011017 CYLINDER HEAD (II) ASSEMBLY. . . . . . 011037
CYLINDER BLOCK INSPECTION . . . . . 011017 TIMING CHAIN ASSEMBLY. . . . . . . . . . . 011040
End of Toc
ENGINE OVERHAUL SERVICE WARNING
B3E011002000201
Warning
Continuous exposure with USED engine oil has caused skin cancer in laboratory mice. Protect
your skin by washing with soap and water immediately after this work.
End Of Sie
ENGINE MOUNTING/DISMOUNTING
B3E011002000202
1. Install the SSTs (arms) to the cylinder block holes
as shown, and hand-tighten the bolts (part No.:
9YA20-1003) or M10 1.5T length 90 mm {3.55 49 L010 102
in}.
B3E0110W127
49 L010 105
ADJ2224E013
01101
MECHANICAL
5. Tighten the SSTs (bolts and nuts) to affix the
SSTs firmly. PARALLEL
49 L010 101
Warning 49 L010 102
Self-locking brake system of the engine
49 L010 105
stand may not be effective when the
engine is held in an unbalanced position. ENGINE
This could lead to sudden, rapid
movement of the engine and mounting
stand handle and cause serious injury.
49 L010 104 49 L010 103 APPROX. 20 mm {0.79 in}
Never keep the engine in an unbalanced
position, and always hold the rotating
D6E110ZE1010
handle firmly when turning the engine.
Tightening torque
3041 Nm {3.14.1 kgfm, 2330 ftlbf}
Without washer
1. Inspect the seal rubber of the oil pan drain plug and make sure there are no cracks or damage.
If necessary, replace the oil pan drain plug.
2. Clean the flange surface (seal rubber) on the oil pan drain plug, then install the oil pan drain plug.
Tightening torque
2230 Nm {2.23.1 kgfm, 1622 ftlbf}
DISMOUNTING
Dismount in the reverse order of mounting.
End Of Sie
01102
MECHANICAL
TIMING CHAIN DISASSEMBLY
B3E011002000203
1. Disassemble in the order indicated in the table. .
1
3
2
R 01
14
7
R 9
5
6
4 SST R
10
19
11
17
12 15 SST
16
18
D6E110ZE1001
01103
MECHANICAL
Crankshaft Pulley Lock Bolt Disassembly Note
1. Install the SST to the ring gear to lock the
crankshaft against rotation.
49 E011 1A0
E6U110ZEB033
B3E0110E053
B3E0110E052
49 G032 354
B3E0110E054
01104
MECHANICAL
CYLINDER HEAD (I) DISASSEMBLY
B3E011002000204
1. Disassemble in the order indicated in the table.
4
3
01
5
2 R
7
4
2
6
8
R R
9 R
10
D6E110ZE1013
01105
MECHANICAL
7 Cylinder head bolt
(See 01107 Cylinder Head Bolt Disassembly
Note.)
8 Cylinder head
9 Cylinder head gasket
10 Cylinder block
Camshaft Sprocket Lock Bolt, Variable Valve Timing Actuator Lock Bolt (With variable valve timing
mechanism) Disassembly Note
1. Hold the camshaft by using a wrench on the cast hexagon as shown, and loosen the camshaft sprocket
installation bolt or variable valve timing actuator installation bolt (With variable valve timing mechanism).
Without variavcble valve timing mechanism.
B3E0110E056
With variable valve timing mechanism
B3E0110E058
Note
The camshaft caps are numbered to make sure they are assembled in their original positions. When
removed, keep the caps with the cylinder head they were removed from. Do not mix the caps.
2
12
11
15 16 19 20 17 18 13 14
B3E0110E057
Note
The tappets are numbered to make sure they are assembled in their original positions. When removed,
01106
MECHANICAL
keep the tappets with the cylinder head they were removed from. Do not mix the tappets.
01
4 8 9 5 1
B3E0110E059
2 SST 1
3 8
4
R 6
SST
R
B3E0110E060
01107
MECHANICAL
When using the SSTs (49 0636 100B, 49 B012 0A2)
49 0636 100B
49 B012 0A2
B3E0110E124
When using the SST (49 JE02 0A2) (Europe only)
49 JE02 0A2
CUE110ZER01
49 S120 170
VALVE SEAL
VALVE GUIDE
B3E0110E061
01108
MECHANICAL
CYLINDER BLOCK (I) DISASSEMBLY
B3E011002000206
1. Disassemble in the order indicated in the table.
.
R
R 14
SST
12
MTX
13
R
01
9
6
R
MODEL WITH GASKET
7 WITHOUT OIL COOLER
CARTRIDGE SPIN-ON
11 TYPE TYPE
R R
8 R 4
10
OIL
R
3
OIL
R
2
1
WITH OIL COOLER
MODEL WITHOUT GASKET CARTRIDGE
TYPE
R
R
SPIN-ON
4 TYPE
OIL
3
OIL R
2 R
D6E110ZE1006
01109
MECHANICAL
13 End plate (MTX)
14 Rear oil seal
B3E0110E051
Note
The internal parts of the cylinder block will not be available for the TRIBUTE (L.H.D.) Face-lifted model
(Refer to TRIBUTE Workshop Manual for identifying Face-lifted model.)
12
6
11 10
4 9
3
2 8
13
7
D6E110ZE1007
1 Balancer unit (L3, L3 (with variable valve timing 2 Connecting rod cap
mechanism)) (See 011011 Connecting Rod Cap Disassembly
Note.)
011010
MECHANICAL
3 Lower connecting rod bearing
4 Upper connecting rod bearing
5 Connecting rod, Piston component
6 Piston ring
7 Main bearing cap
(See 011011 Main Bearing Cap Disassembly
Note.)
8 Lower main bearing, thrust bearing
9 Crankshaft
10 Upper main bearing, thrust bearing
11 Oil jet valve 01
12 Cylinder block
13 Adjustment shim
Note
Determine the position of each removed connecting rod cap.
1 5 9 7 3
B3E0110E067
Maximum distortion:
0.10 mm {0.004 in}
B3E0110E008
011011
MECHANICAL
Maximum distortion:
0.10 mm {0.004 in} IN
Maximum grinding:
0.15 mm {0.006 in}
End Of Sie
EX
B3E0110E132
Margin thickness
IN: 1.62 mm {0.0637 in} L8 IN : 31.0 mm {1.22 in}
EX: 1.82 mm {0.0716 in} EX : 26.3 mm {1.03 in}
IN : 33.5 mm {1.31 in}
EXCEPT L8
2. Measure the length of each valve. Replace the EX : 28.3 mm {1.14 in}
valve if necessary.
If it is less than the specification, replace the
valve.
MARGIN THICKNESS
D6E110ZE1008
Standard length L
IN: 102.99103.79 mm {4.0554.086 in}
EX: 104.25105.05 mm {4.1054.135 in}
Minimum length L
IN: 102.99 mm {4.055 in}
EX: 104.25 mm {4.105 in} L
valve.
Standard diameter X
IN: 5.4705.485 mm {0.21540.2159 in}
EX: 5.4655.480 mm {0.21520.2157 in} Y
Minimum diameter A
IN: 5.470 mm {0.2154 in}
EX: 5.465 mm {0.2152 in} B
011012
MECHANICAL
Standard Inner diameter
X
5.5095.539 mm {0.21690.2180 in}
Y
5. Calculate the valve stem to guide clearance by
subtracting the outer diameter of the valve stem A
from the inner diameter of the corresponding
valve guide.
If it exceeds the specification, replace the B
valve and/or the valve guide.
C
ADJ2224E026
01
Standard clearance:
IN: 0.0240.069 mm {0.00090.0027 in} VALVE STEM
EX: 0.0290.074 mm {0.00120.0029 in}
VALVE GUIDE
Maximum clearance:
0.10 mm {0.004 in} CLEARANCE
End Of Sie
CYLINDER HEAD
B3E0110E069
VALVE GUIDE
B3E0110E070
011013
MECHANICAL
Valve Guide Installation
1. Assemble the SSTs so that depth L is as
specified.
49 L012 003A
49 L012 002A
B3E0110E071
2. Tap the valve guide in from the cam side using the
SSTs assembled in Step 1. 49 L012 003A
49 L012 004A
49 L012 002A
VALVE GUIDE
B3E0110E072
A
Standard height:
12.212.8 mm {0.4810.503 in}
End Of Sie
CYLINDER HEAD
B3E0110E069
Standard width:
1.21.6 mm {0.0480.062 in}
ADA2224E019
011014
MECHANICAL
(2) If the seating position is too inner side, correct
the valve seat using a 35 (IN) cutter, and a
30 (EX) cutter, and a 45 cutter.
IN EX
3. Inspect the sinking of the valve seat. Measure the
protruding length (dimension L) of the valve stem.
If not specified, replace the cylinder head. 70 65
45 45
35 30
B3E0110E133
01
Standard dimension L:
IN: 40.6442.24 mm {1.6001.662 in}
EX: 40.5042.10 mm {1.5951.657 in}
End Of Sie
ADJ2224E079
Pressing force
390 N {39.76 kgf, 87.67 lbf}
Standard height
28.68 mm {1.129 in}
End Of Sie
UPPER
LOWER
B3E0110E073
CAMSHAFT INSPECTION
B3E011012420201
1. Set the No.1 and No.5 journals on V-blocks.
2. Measure the camshaft runout.
If it exceeds the specification, replace the camshaft.
011015
MECHANICAL
Maximum runout
0.03 mm {0.0012 in}
B3E0110E074
4. Measure the journal diameters in X and Y directions at the two points (A and B) as indicated in the figure.
If it is less than the specification, replace the camshaft.
Standard diameter
24.9624.98 mm {0.98270.9834 in} B
A
Minimum diameter
24.95 mm {0.982 in}
B3E0110E075
Standard clearance
0.040.08 mm {0.0020.003 in}
B3E0110E077
011016
MECHANICAL
Maximum clearance
0.09 mm {0.0035 in}
10. Install the camshaft cap. (See 011039 Camshaft Assembly Note.)
11. Measure the camshaft end play.
If it exceeds the specification, replace the cylinder head or camshaft.
B3E0110E078
TAPPET INSPECTION
B3E011012310201
1. Measure the tappet hole inner diameter in X and
Y directions at the two points (A and B) shown in
the figure. X
Inner diameter Y
31.00031.030 mm {1.22051.2216 in}
A
B
ADJ2224E023
Maximum clearance
0.15 mm {0.006 in}
End Of Sie
CYLINDER BLOCK INSPECTION
B3E011010300201
1. Measure the distortion of the cylinder block top surface in six directions as indicated in the figure.
If it exceeds the maximum, replace the cylinder block.
011017
MECHANICAL
ADJ2224E089
X
Standard diameter limit
L8: 83.00083.030 mm {3.26773.2689 in}
Except L8: 87.50087.530 mm {3.4449 Y
3.4460 in}
Minimum / maximum bore diameter limit
L8: 82.94083.090 mm {3.26533.2712 in}
Except L8: 87.44087.590 mm {3.4425 42 mm {1.65 in}
3.4484 in}
End Of Sie
D6E110ZE1009
Air pressure
216274 kPa {2.22.7 kgfcm2 31.439.7 B
psi}
End Of Sie
B3E0110E079
PISTON INSPECTION
B3E011011010201
Caution
The piston, piston ring and connecting rod cannot be disassembled.
When replacing the piston, piston pin, piston ring and connecting rod, replace them together as a
single unit.
1. Measure the outer diameter of each piston at right angle 90 to the piston pin, 10.0 mm {0.40 in} above the
under of the piston.
If not within the specification, replace the piston, piston pin, piston ring and connecting rod as a single unit.
Piston diameter
L8: 82.96582.995 mm {3.26643.2675 in}
Except L8: 87.46587.495 mm {3.4435
3.4446 in}
Standard clearance
B3E0110E080
0.0220.047 mm {0.00090.0018 in}
011018
MECHANICAL
Maximum clearance
0.11 mm {0.0043 in}
3. Measure the piston ring-to-ring groove clearance around the entire circumference.
If it exceeds the specification, replace the piston, piston pin, piston ring and connecting rod as a single unit.
Standard clearance
Top: 0.040.08 mm {0.00160.0031 in}
Second: 0.030.07 mm {0.00120.0027 in}
Oil: 0.060.15 mm {0.00240.0059 in}
Maximum clearance 01
Top: 0.17 mm {0.0067 in}
Second, Oil: 0.15 mm {0.0059 in}
B3E0110E081
End Of Sie
CRANKSHAFT INSPECTION
B3E011011301201
1. Install the main bearing cap. (See 011028 Main Bearing Cap Assembly Note.)
2. Measure the crankshaft end play.
If it exceeds the specification, replace the thrust bearing or crankshaft so that the specified end play is
obtained.
011019
MECHANICAL
Maximum runout
0.05 mm {0.0019 in}
B3E0110E084
Standard clearance
0.0190.035 mm {0.00070.0013 in}
Maximum clearance
0.10 mm {0.0039 in}
011020
MECHANICAL
CONNECTING ROD INSPECTION
B3E011011211201
Caution
The piston, piston ring and connecting rod cannot be disassembled.
When replacing the piston, piston pin, piston ring and connecting rod, replace them together as a
single unit.
1. Install the connecting rod cap. (See 011030 Connecting Rod Cap Assembly Note.)
2. Measure the connecting rod large end side clearance.
If it exceeds the specification, replace the piston, piston pin, piston ring and connecting rod as a single unit.
Standard clearance 01
0.140.36 mm {0.00560.0141 in}
Maximum clearance
0.435 mm {0.0172 in}
Standard clearance
0.0260.052 mm {0.00110.0020 in}
Maximum clearance
0.1 mm {0.0039 in}
End Of Sie
BOLT INSPECTION
B3E011010135201
1. Measure the length of each bolt.
If it exceeds the specification, replace the bolt.
011021
MECHANICAL
End Of Sie
VARIABLE VALVE TIMING ACTUATOR INSPECTION
B3E011000142201
Caution
Variable valve timing actuator cannot be disassembled because it is a precision unit.
1. Confirm that the groove of the rotor and notch of the cover at the variable valve timing actuator are aligned and
fixed.
If the notch and the bump are not aligned, rotate the rotor toward the valve timing retard position by hand
until they are in place.
If the rotor and cover are not fixed even though their notch and groove are aligned, replace the variable
valve timing actuator.
End Of Sie
COVER
NOTCH
ROTOR
B3E0110E089
Specification
6.97.9 ohms [20 C {68 F}]
OIL CONTROL VALVE (OCV)
4. Connect the oil control valve (OCV) connector.
A B
B3E2226W002
SPOOL VALVE
(MAXIMUM VALVE TIMING ADVANCE POSITION)
B3E0110E091
Note
Make sure to note the measured values for choosing the suitable replacement tappets.
A B A B
Standard [Engine cold]
IN: 0.220.28 mm {0.00870.0110 in} EX
EX: 0.270.33 mm {0.01060.0130 in}
Note
Make sure to note the measured values for choosing the suitable replacement tappets.
011023
MECHANICAL
End Of Sie
VALVE CLEARANCE ADJUSTMENT
B3E011012111204
1. Remove the engine front cover lower blind plug.
2. Remove the engine front cover upper blind plug.
3. Remove the cylinder block lower blind plug.
UPPER
BLIND
PLUG
LOWER BLIND
PLUG
B3E0110E093
B3E0110E094
B3E0110E096
011024
MECHANICAL
7. Hold the exhaust camshaft using a suitable
wrench on the cast hexagon as shown in the
figure.
B3E0110E095
01
8. Remove the exhaust camshaft sprocket.
EXHAUST
CAMSHAFT
SPROCKET
B3E0110E097
Note
The cylinder head and the camshaft caps 2
are numbered to make sure they are 12
reassembled in their original position. When
removed, keep the caps with the cylinder
head they were removed from. Do not mix
the caps.
11
15 16 19 20 17 18 13 14
10. Remove the camshaft.
B3E0110E057
11. Remove the tappet.
12. Select proper adjustment shim.
13. Install the camshaft with No.1 cylinder aligned with the TDC position.
14. Tighten the camshaft cap bolt using the following
5 6 1 2 3 4 7 8
two steps. 9
Tightening torque
(1) 5.09.0 Nm 10
{51.091.7 kgfcm, 44.379.5 inlbf} 20
(2)14.017.0 Nm
{1.431.73 kgfm, 10.412.5 ftlbf}
19
15 16 11 12 13 14 17 18
B3E0110E098
011025
MECHANICAL
15. Install a new washer.
E6U110ZWB020
Note
Do not tighten the bolt for the camshaft
sprocket during this step. First confirm the
valve timing, then tighten the bolt.
B3E0110E097
Europe
49 JE01 054
B3E0110E099
Except Europe
18. Remove the M6 1.0 bolt from the engine front 303-376
cover to apply tension to the timing chain. (49 UN30 3376)
19. Turn the crankshaft clockwise so that the
crankshaft is in the No.1 cylinder TDC position.
B3E0110E100
Nm {kgfm, ftlbf}
Bolt type Tightening torque
Bolt and washer 6975 {7.17.6, 50.955.3}
assembly
Washer based bolt 8995 {9.19.6, 65.770.0}
B3E0110E095
011026
MECHANICAL
Bolt type Tightening torque
Washer based bolt
for variable valve 6975 {7.17.6, 50.955.3}
timing mechanism
BLIND
PLUG
B3E0110E101
Tightening torque
20 Nm {2.0 kgfm, 14.8 ftlbf}
BLIND
PLUG
B3E0110E102
28. Install the new engine front cover lower blind plug.
BLIND PLUG
Tightening torque
12 Nm {1.2 kgfm, 8.9 ftlbf}
End Of Sie
B3E0110E103
Note
The internal parts of the cylinder block will not be available for the TRIBUTE (L.H.D.) Face-lifted model
(Refer to TRIBUTE Workshop Manual for identifying Face-lifted model.)
011027
MECHANICAL
1. Assemble in the order indicated in the table. .
6 2.94.9 Nm
{3040 kgfcm,
OIL
25.6743.4 inlbf}
3
3
OIL 8
L3, L3 (with variable valve
9 timing mechanism) OIL
OIL
10 4
12
5
2632 {2.73.2, Plastic region tightening bolt
2023}+80100 (Bolt stem length 110 mm)
4446 {4.54.6, 32.533.9}
+175185
Elastic region tightening bolt
(Bolt stem length 104 mm)
37 Nm {30.671.3 kgfcm,26.661.9 inlbf}
11 +2327 {2.42.7, 1719.9}
25+4446 SST OIL +3842 {3.94.2, 28.130.9}
{2.6+4.54.7, Loosen all the bolts
1.84+32.533.9} +37 Nm {30.671.3 kgfcm,26.661.9 inlbf}
+1822 {1.92.2, 13.316.2}
+87.592.5
Nm {kgfm, ftlbf}
D6E110ZE1002
Tightening torque
Plastic region tightening bolt (Bolt stem length 110 mm)
(1) 4446 Nm {4.54.6 kgfm, 32.533.9 ftlbf}
(2) 175185
011028
MECHANICAL
Elastic region tightening bolt (Bolt stem length 104 mm)
(1) Apply engine oil to all bolts.
(2) 37 Nm {30.671.3 kgfcm, 26.661.9 inlbf}
(3) 2327 Nm {2.42.7 kgfm, 1719.9 ftlbt}
(4) 3842 Nm {3.94.2 kgfm, 28.130.9 ftlbt}
(5) Loosen all the bolts. (no remaining torque.)
(6) 37 Nm {30.671.3 kgfcm, 26.661.9 inlbt}
(7) 1822 Nm {1.92.2 kgfm, 13.316.2 ftlbt}
(8) 87.592.5
01
9 5 1 3 7
10 6 2 4 8
B3E0110E105
D6E110ZE1K014
011029
MECHANICAL
2. Insert the piston and connecting rod into the
cylinder with the arrow mark to front of the engine.
B3E0110E108
B3E0110E109
Caution
When assembling the connecting rod caps, align the broken, rough faces of the connecting rods
and connecting rod caps.
1. Tighten the connecting rod bolts in two steps using the SST (49 D032 316).
Tightening torque
(1) 2632 Nm
{2.73.2 kgfm, 19.223.6 ftlbf}
(2) 80100
Caution
Due to the precision interior construction of the balancer unit, it cannot be disassembled.
B3E0110E110
011030
MECHANICAL
5. With the balancer unit marks at the exact top
center, assemble the unit to the cylinder block.
MARK
B3E0110E111
01
6. Set the SST as shown, then measure the gear
49 G011 201 DIAL GAUGE
backlash using a dial gauge.
Note 41.4 mm
{1.629 in}
B3E0110E112
Caution
When measuring the backlash, rotate the crankshaft one full rotation and verify that it is within the
specified range at all of the following six positions: 10, 30, 100, 190, 210, 280 ATDC.
Value range
0.0050.101 mm {0.000190.0039 in}
(1) Using master adjustment shim (No.50), assemble the balancer unit to the cylinder block, then measure the
backlash.
(2) Select the proper adjustment shim according to the measured value.
(3) Install the selected adjustment shim to the balancer unit, then assemble the balancer unit to the cylinder
block.
011031
MECHANICAL
Adjustment shim selection table
Backlash Selection shim Shim thickness Backlash Selection shim Shim thickness
mm {in} (No.) mm {in} mm {in} (No.) mm {in}
0.2670.273 0.1270.133
{0.01051 15 1.15 {0.0452} {0.00500 35 1.35 {0.0531}
0.01074} 0.00523}
0.2600.266 0.1200.126
{0.01023 16 1.16 {0.0456} {0.00472 36 1.36 {0.0535}
0.01047} 0.00496}
0.2530.259 0.1130.119
{0.00996 17 1.17 {0.0460} {0.00444 37 1.37 {0.0539}
0.01019} 0.00468}
0.2460.252 0.1060.112
{0.00968 18 1.18 {0.0464} {0.00417 38 1.38{0.0543}
0.00992} 0.00440}
0.2390.245 0.0990.105
{0.00940 19 1.19 {0.0468} {0.00389 39 1.39 {0.0547}
0.00964} 0.00413}
0.2320.238 0.0920.098
{0.00913 20 1.20 {0.0472} .087 {0.00362 40 1.40 {0.0551}
0.00937} 0.00385}
0.2250.231 0.0850.091
{0.00885 21 1.21 {0.0476} {0.00334 41 1.41 {0.0555}
0.00909} 0.00358}
0.2180.224
0.0780.084
{0.00858 22 1.22 {0.0480} 42 1.42 {0.0559}
{0.00307
0.00881}
0.00330}
0.2110.217 0.0710.077
{0.00830 23 1.23 {0.0484} {0.00279 43 1.43 {0.0562}
0.00854} 0.00303}
0.2040.210 0.0640.070
{0.00803 24 1.24 {0.0488} {0.00251 44 1.44 {0.0566}
0.00826} 0.00275}
0.1970.203 0.0570.063
{0.00775 25 1.25 {0.492} {0.00224 45 1.45 {0.0570}
0.00799} 0.00248}
0.1900.196 0.0500.056
{0.00748 26 1.26 {0.496} {0.00196 46 1.46 {0.0574}
0.00771} 0.00220}
0.1830.189 0.0430.049
{0.00720 27 1.27 {0.499} {0.00169 47 1.47 {0.0578}
0.00744} 0.00192}
0.1760.182 0.0360.042
{0.00692 28 1.28 {0.503} {0.00141 48 1.48 {0.0582}
0.00716} 0.00165}
0.1690.175 0.0290.035
{0.00665 29 1.29 {0.507} {0.00114 49 1.49 {0.0586}
0.00688} 0.00137}
0.1620.168 0.0220.028
{0.00637 30 1.30 {0.511} {0.000866 50 (master) 1.50 {0.0590}
0.00661} 0.00110}
0.1550.161 0.0150.021
{0.00610 31 1.31 {0.515} {0.00059 51 1.51 {0.0594}
0.00633} 0.000826}
0.1480.154 0.0080.014
{0.00582 32 1.32 {0.519} {0.000314 52 1.52 {0.0598}
0.00606} 0.000551}
0.1410.147 0.0010.007
{0.00555 33 1.33 {0.523} {0.00003 53 1.53 {0.0602}
0.00578} 0.000275}
0.1340.140
0.0000.000
{0.00527 34 1.34 {0.527} 54 1.54 {0.0606}
{0.0000.000}
0.00551}
011032
MECHANICAL
End Of Sie
CYLINDER BLOCK (II) ASSEMBLY
B3E011002000221
1. Assemble in the order indicated in the table.
108116
A {11.111.8,
OIL
79.785.5}
SST R 1 SST
R
3
MTX
2
01
R
6
9
R 16.223.8 {1.662.42,
A MODEL WITH GASKET 12.017.5}
8
CARTRIDGE SPIN-ON
4 TYPE TYPE
R R
B
7 A R 11
R
5
A 12
8.012 Nm {81.6122.3
kgfcm, 70.9106.2
R
inlbf}+2025 3035 1520
2030 {3.13.5, 13 {1.62.0,
2030 14 {2.13.0, 22.225.8} 1114}
{2.13.0, 14.822.1}
14.822.1} WITH OIL COOLER
MODEL WITHOUT GASKET CARTRIDGE
TYPE
3039
{3.13.9,
22.228.7}
10
R
R SPIN-ON
A : 8.011.5 Nm TYPE
B
{81.6117.2 kgfcm, 11
70.9101.7 inlbf}
2030
{2.13.0, 12
14.822.1}
R
3035 R 1520 Nm {kgfm, ftlbf}
{3.13.5, 13 {1.62.0,
22.225.8} 1114}
B3E0110W126
011033
MECHANICAL
9 Knock sensor
10 Oil cooler
11 Oil filter adapter
12 Oil filter
13 Oil filter cover (cartridge type)
14 Oil pan
(See 011035 Oil pan Assembly Note)
Thickness
4.06.0 mm {0.160.23 in}
SEALANT
B3E0110E114
303-328
(49 UN30 3328)
CUE110BW2005
Tightening torque
8.011.5 Nm
{81.6117.2 kgfcm, 70.9101.7 inlbf}
AME2224E002
011034
MECHANICAL
2. Tighten the bolts in the 3 steps in the figure.
Tightening torque
(1) 4654 Nm
{4.705.50 kgfm, 34.039.8 ftlbf
(2) 7684 Nm
{7.758.56 kgfm, 56.161.9 ftlbf
(3) 108116 Nm
{11.111.8 kgfm, 79.785.5 ftlbf
AME2224E102
01
B3E0110E120
End Of Sie
13 8 4 1 5 9
10
11
12 7 3 2 6
B3E0110E122
011035
MECHANICAL
CYLINDER HEAD (I) ASSEMBLY
B3E011002000222
1. Assemble in the order indicated in the table. .
4248 {4.34.8,
31.035.4} 8 1
SST 7
8.011.5 Nm {81.6117.2
6 kgfcm, 70.9101.7 inlbf}
5
R 3
SST
R
5660 {5.86.1,
8 41.344.2}
4
4248 {4.34.8, 31.035.4}
Nm { kgfm, ftlbf}
B3E0110E130
VALVE
SEAL
B3E0110E123
011036
MECHANICAL
When using the SSTs (49 0636 100B, 49 B012 0A2)
49 0636 100B
49 B012 0A2
01
B3E0110E124
When using the SST (49 JE02 0A2) (Europe only)
End Of Sie
49 JE02 0A2
CUE110ZER01
011037
MECHANICAL
5.09.0 Nm
{51.091.7 kgfcm,
44.379.5 inlbf}+
1417
{1.431.73,
10.412.5}
With variable valve timing mechanism
5.09.0 Nm
8.011.5 Nm {51.091.7 kgfcm, 6
{81.5117 kgfcm 44.379.5 inlbf}+
70.8101inlbf} 1417
{1.431.73, 5
8 10.412.5} 311
{0.41.1 kgfm, 27.697.3 inlbf}+
1317 {1.41.7, 9.612.5}+
4347 {4.44.7, 31.834.8}+
7 8892+
R * 8892
3
6 SST
4
5 2
R R *
1 R
*:If washer is not installed to the engine, install a new washer Nm {kgfm, ftlbf}
D6E110ZE1011
011038
MECHANICAL
Cylinder Head Bolt Assembly Note
1. Tighten the cylinder head bolts in the order
indicated in the figure in 5 steps using the SST
(49 D032 316).
Tightening torque
(1) 311 Nm
{0.41.1 kgfm, 27.697.3 inlbf}
(2) 1317 Nm
{1.41.7 kgfm, 9.5912.5 ftlbf}
(3) 4347 Nm
{4.44.7 kgfm, 31.834.6 ftlbf} 01
(4) 8892
AME2224E047
(5) 8892
Tightening torque
(1) 5.09.0 Nm
{51.091.7 kgfcm, 44.379.6 inlbf}
(2) 14.017.0 Nm
{1.51.7 kgfm, 10.412.5 ftlbf}
AME2224E048
Camshaft Sprocket, Variable Valve Timing Actuator (With variable valve timing mechanism) Assembly Note
1. Temporarily tighten the camshaft sprocket or variable valve timing actuator (With variable valve timing
mechanism) installation bolts by hand until the timing chain is installed.
2. Fully tighten the camshaft sprocket or variable valve timing actuator (With variable valve timing mechanism)
installation bolts after timing chain installation.
End Of Sie
011039
MECHANICAL
TIMING CHAIN ASSEMBLY
B3E011002000224
1. Assemble in the order indicated in the table.
20
A
18
8.011.5 Nm 19
{81.6117.2 kgfcm,
70.9101.7 inlbf}
4055
{4.15.6, 13
29.640.5}
R
6
14
R
OIL
R
2030 SST
{2.13.0,
14.822.1} 12
SEALANT
16
15
*
11
SEALANT
17 SST R 2030
96104 {2.13.0, 10
{9.810.6,
70.976.7}+
14.822.1} 11 *
8793 With variable valve timing mechanism
7
A SEALANT
A
1
A : 8.011.5 Nm 9
{81.6117.2 kgfcm,
70.9101.7 inlbf}
SEALANT
*:BOLT AND WASHER ASSEMBLY 3
6975 {7.17.6, 50.955.3} 8 5 SST *
WASHER BASED BOLT 4 2030 11
8995 {9.19.6, 65.770.0} 2 {2.13.0,
14.822.1} Nm {kgfm, ftlbf}
D6E110ZE1012
1 Crankshaft sprocket
2 Oil pump chain
3 Oil pump sprocket
(See 011041 Oil Pump Sprocket Assembly Note.)
4 Oil pump chain guide
5 Oil pump chain tensioner
6 Seal (With variable valve timing mechanism)
7 Timing chain
(See 011041 Timing Chain Assembly Note.)
8 Chain guide
9 Tensioner arm
10 Chain tensioner
11 Camshaft sprocket, variable valve timing actuator
(With variable valve timing mechanism)
(See 011042 Camshaft Sprocket, Variable Valve
Timing Actuator (With variable valve timing
mechanism) Assembly Note.)
011040
MECHANICAL
12 Front oil seal
(See 011042 Front Oil Seal Assembly Note.)
13 Engine front cover
(See 011043 Engine Front Cover Assembly
Note.)
14 Drive belt idler pulley (Without stretch-type A/C drive
belt)
15 Water pump pulley
16 Crankshaft pulley
17 Crankshaft pulley lock bolt
(See 011044 Crankshaft Pulley Lock Bolt
Assembly Note.) 01
18 Cylinder head cover
(See 011045 Cylinder Head Cover Assembly
Note)
19 Spark plug
20 Oil level gauge (If equipped)
49 G032 354
B3E0110E125
B3E0110E099
Except Europe
2. Remove the cylinder block lower blind plug. 303-376
(49 UN30 3376)
B3E0110E100
011041
MECHANICAL
3. Install the SST as shown in the figure.
4. Turn the crankshaft clockwise so that the
crankshaft is in the No.1 cylinder TDC position.
5. Install the timing chain. 303-507
(49 JE01 061)
B3E0110E110
B3E0110E126
Camshaft Sprocket, Variable Valve Timing Actuator (With variable valve timing mechanism) Assembly Note
1. Hold the camshaft using a suitable wrench on the cast hexagon as shown in the figure.
2. Tighten the camshaft sprocket lock bolt.
Nm {kgfm, ftlbf}
Engine Camshaft
Bolt type Tightening torque
type sprocket
8995
B
{9.19.6, 65.770.0}
L8 IN side
6975
LF C
{7.17.6, 50.955.3}
L3
6975
EX side A, C
{7.17.6, 50.955.3}
A Can not use B3E0110E095
1 IN side 6975
L3* B, C
{7.17.6, 50.955.3}
LF*1
6975
EX side A, C
{7.17.6, 50.955.3}
011042
MECHANICAL
3. Compress the oil seal using the SST and a
hammer.
49 H010 401
B3E0110E127
01
49 B014 001
FRONT OIL SEAL
B3E0110E134
Caution
Install the cylinder head cover within 10 min of applying the silicone sealant.
Silicone sealant is not need in area C as indicated below due to an existing. (With variable valve
timing mechanism)
Thickness B
A: 2.03.0 mm {0.0790.118 in}
B: 1.52.5 mm {0.0590.098 in}
C B
B3E0110E129
011043
MECHANICAL
2. Install the cylinder head cover bolts in the order
as shown in the figure. 20 21 22
Bolt No. Tightening torque Nm {kgfm, ftlbf} 18
118 8.011.5 Nm
{81.6117.2 kgfcm, 70.9101.7 inlbf} 17
1922 4055 {4.15.6, 29.740.5} 11
10
7 8
4
3 1
5
2
19
6
9 12
13
16
15 14
B3E0110E062
B3E0110E099
Except Europe
303-376
(49 UN30 3376)
B3E0110E100
011044
MECHANICAL
2. Install the M6 1.0 bolt in by hand.
3. Turn the crankshaft clockwise so that the
crankshaft is in the No.1 cylinder TDC position.
BOLT
B3E0110E063
01
4. Hold the crankshaft pulley using the SST.
5. Tighten the crankshaft pulley lock bolt in the order 49 B011 105
shown following two steps using the SST (49
D032 316).
Tightening torque
(1) 96104 Nm
{9.810.6 kgfm, 70.976.7 ftlbf}
(2) 8793
205-072
(49 UN20 5072)
6. Remove the M6 1.0 bolt.
7. Remove the SST from the camshaft.
B3E0110W107
8. Remove the SST from the block lower blind plug.
9. Rotate the crankshaft clockwise two turns until
the TDC position.
If not aligned, loosen the crankshaft pulley lock bolt and repeat from Step 1.
10. Install the cylinder block lower blind plug.
Tightening torque
20 Nm {2.0 kgfm, 14.8 ftlbf}
Caution
Install the cylinder head cover within 10 min of applying the silicone sealant.
Dot diameter
4.06.0 mm {0.160.23 in}
SEALANT
SEALANT
B3E0110E064
011045
MECHANICAL
3. Tighten the bolts in the order shown in the figure.
6 3 7 12
11
Tightening torque
8.0 12 Nm 10 2 1
{81.6122.3 kgfcm, 70.9106.2 inlbf}
End Of Sie 13
14
9
5 4 8
B3E0110W050
011046
TECHNICAL DATA
End of Toc
ENGINE TECHNICAL DATA
B3E015002000201
Engine
Item
L8 LF L3 01
Cylinder head
Cylinder head gasket
(mm {in}) Maximum 0.10 {0.004}
contact surfaces distortion
Manifold contact surfaces Maximum 0.10 {0.004}
(mm {in})
distortion Maximum grinding 0.15 {0.006}
IN 0.220.28 {0.00870.0110}
Valve clearance [Engine cold] (mm {in})
EX 0.270.33 {0.01060.0130}
Valve and valve guide
IN 5.4705.485 {0.21540.2159}
Standard
EX 5.4655.480 {0.21520.2157}
Valve stem diameter (mm {in})
IN 5.470 {0.2154}
Minimum
EX 5.465 {0.2152}
IN 0.0240.069 {0.00090.0027}
Standard
Valve stem to guide EX 0.0290.074 {0.00120.0029}
(mm {in})
clearance IN 0.10 {0.004}
Maximum
EX 0.10 {0.004}
IN 102.99103.79 {4.0554.086}
Standard
EX 104.25105.05 {4.1054.135}
Valve length (mm {in})
IN 102.99 {4.055}
Minimum
EX 104.25 {4.104}
IN 5.5095.539 {0.21690.2180}
Valve guide inner diameter (mm {in}) Standard
EX 5.5095.539 {0.21690.2180}
Valve guide protrusion IN 12.212.8 {0.4810.503}
(mm {in}) Standard
height EX 12.212.8 {0.4810.503}
IN 1.62 {0.0637}
Valve head margin thickness (mm {in}) Minimum
EX 1.82 {0.0716}
Valve seat
IN 1.21.6 {0.0480.062}
Valve seat contact width (mm {in}) Standard
EX 1.21.6 {0.0480.062}
IN 45
Valve seat angle ()
EX 45
Valve seat sinking IN 40.6442.24 {1.6001.662}
(mm {in}) Standard
(Valve protrusion height) EX 40.5042.10 {1.5951.657}
Valve spring
Out-of-square (mm {in}) Maximum 1.95 {0.0767}
Pressing force (N {kgf, lbf}) [mm {in}] Standard height H 390 {39.76, 87.67} [28.68 {1.129}]
Camshaft
Camshaft runout (mm {in}) Maximum 0.03 {0.0012}
IN 40.79 {1.606} 42.12 {1.659} 42.44 {1.671}
Standard
EX 41.08 {1.618} 41.08 {1.618} 41.18 {1.622}
Cam lobe height (mm {in})
IN 40.67 {1.601} 42.01 {1.653} 42.33 {1.666}
Minimum
EX 40.96 {1.612} 40.96 {1.612} 41.06 {1.616}
Standard 24.9624.98 {0.98270.9834}
Journal diameter (mm {in})
Minimum 24.95 {0.982}
Standard 0.040.08 {0.0020.003}
Journal oil clearance (mm {in})
Maximum 0.09 {0.0035}
01501
TECHNICAL DATA
Engine
Item
L8 LF L3
Standard 0.090.24 {0.00350.0099}
End play (mm {in})
Maximum 0.25 {0.009}
Tappet
Tappet bore diameter (mm {in}) Standard 31.00031.030 {1.22051.2216}
Tappet diameter (mm {in}) Standard 30.97030.980 {1.21931.2196}
Tappet-to-Tappet bore oil Standard 0.020.06 {0.00080.0023}
(mm {in})
clearance Maximum 0.15 {0.006}
Cylinder block
Cylinder head gasket
(mm {in}) Maximum 0.10 {0.004}
contact surfaces distortion
Cylinder bore diameter
[Measure the cylinder bore
83.00083.030
at 42 mm (mm {in}) Standard 87.50087.530 {3.44493.4460}
{3.26773.2689}
{1.65 in} below the top
surface]
Minimum / maximum bore 82.94083.090
(mm {in}) 87.44087.590 {3.44253.4484}
diameter Limit {3.26533.2712}
Piston
82.96582.995
Piston diameter (mm {in}) Standard 87.46587.495 {3.44353.4446}
{3.26643.2675}
Standard 0.0220.047 {0.00090.0018}
Piston-to-cylinder clearance (mm {in})
Maximum 0.11 {0.0043}
Piston ring
Top 0.040.08 {0.00160.0031}
Standard
Second 0.030.07 {0.00120.0027}
Piston ring-to-ring groove (mm {in}) Oil (rail) 0.060.15 {0.00240.0059}
clearance Top 0.17 {0.0067}
Maximum Second 0.15 {0.0059}
Oil (rail) 0.15 {0.0059}
Top 0.160.26 {0.00630.010}
Standard Second 0.330.48 {0.01300.0189}
End gap Oil (rail) 0.200.70 {0.00790.0275}
(mm {in})
(measured in cylinder) Top 1.0 {0.0393}
Maximum Second 1.0 {0.0393}
Oil (rail) 1.0 {0.0393}
Connecting rod and connecting rod bearing
Connecting rod side Standard 0.140.36 {0.00560.0141}
(mm {in})
clearance Maximum 0.435 {0.0172}
1.4961.502
Standard 1.4981.504 {0.05890.0592}
{0.05890.0591}
1.6211.627
Connecting rod bearing size (mm {in}) 0.25 {0.01} Oversize 1.6231.629 {0.06390.0641}
{0.06390.0641}
1.7461.752
0.50 {0.02} Oversize 1.7481.754 {0.06880.0690}
{0.06880.0690}
Connecting rod bearing oil Standard 0.0260.052 {0.00110.0020}
(mm {in})
clearance Maximum 0.10 {0.0039}
Crankshaft
Crankshaft runout (mm {in}) Maximum 0.05 {0.0019}
Standard 51.98052.000 {2.04642.0472}
Main journal diameter (mm {in}) 0.25 {0.01}
51.73051.750 {2.03662.0373}
undersize
Standard 0.0190.035 {0.00070.0013}
Main journal oil clearance (mm {in})
Maximum 0.10 {0.0039}
Main journal out of round (mm {in}) Maximum 0.05 {0.0019}
01502
TECHNICAL DATA
Engine
Item
L8 LF L3
Standard 2.5062.509 {0.09870.0988}
Main bearing size (mm {in}) 0.25 {0.01} Oversize 2.6282.634 {0.10340.1037}
0.50 {0.02} Oversize 2.7532.759 {0.10840.1086}
49.98050.000
Standard 46.98047.000 {1.84971.8503}
{1.96771.9685}
Crank pin journal diameter (mm {in})
0.25 {0.01} 49.73049.750
46.73046.750 {1.83981.8405}
undersize {1.95791.9586}
Crank pin out of round (mm {in}) Maximum 0.05 {0.022}
Standard 0.220.45 {0.00870.0177} 01
Crankshaft end play (mm {in})
Maximum 0.55 {0.0216}
Front oil seal
Pushing distance of the front oil seal
(mm {in}) 00.5 {00.019}
[from the edge of the engine front cover]
Bolt
Standard 145.2145.8 {5.725.74}
Cylinder head bolt length
Maximum 146.5 {5.77}
Standard 44.745.3 {1.751.78}
Connecting rod bolt length
Maximum 46.0 {1.81}
Standard 110.0110.6 {4.334.35}
Main bearing cap bolt length
Maximum 111.3 {4.38}
Balance shaft
0.005-0.101
Gear backlash (mm {in}) Maximum {0.00019
0.0039}
Engine
Item LF (With variable valve timing mechanism)
L3 (With variable valve timing mechanism)
Cylinder head
Cylinder head gasket
(mm {in}) Maximum 0.10 {0.004}
contact surfaces distortion
Manifold contact surfaces Maximum 0.10 {0.004}
(mm {in})
distortion Maximum grinding 0.15 {0.006}
IN 0.220.28 {0.00870.0110}
Valve clearance [Engine cold] (mm {in})
EX 0.270.33 {0.01060.0130}
Valve and valve guide
IN 5.4705.485 {0.21540.2159}
Standard
EX 5.4655.480 {0.21520.2157}
Valve stem diameter (mm {in})
IN 5.470 {0.2154}
Minimum
EX 5.465 {0.2152}
IN 0.0240.069 {0.00090.0027}
Standard
Valve stem to guide EX 0.0290.074 {0.00120.0029}
(mm {in})
clearance IN 0.10 {0.004}
Maximum
EX 0.10 {0.004}
IN 102.99103.79 {4.0554.086}
Standard
EX 104.25105.05 {4.1054.135}
Valve length (mm {in})
IN 102.99 {4.055}
Minimum
EX 104.25 {4.104}
IN 5.5095.539 {0.21690.2180}
Valve guide inner diameter (mm {in}) Standard
EX 5.5095.539 {0.21690.2180}
Valve guide protrusion IN 12.212.8 {0.4810.503}
(mm {in}) Standard
height EX 12.212.8 {0.4810.503}
IN 1.62 {0.0637}
Valve head margin thickness (mm {in}) Minimum
EX 1.82 {0.0716}
Valve seat
01503
TECHNICAL DATA
Engine
Item LF (With variable valve timing mechanism)
L3 (With variable valve timing mechanism)
IN 1.21.6 {0.0480.062}
Valve seat contact width (mm {in}) Standard
EX 1.21.6 {0.0480.062}
IN 45
Valve seat angle ()
EX 45
Valve seat sinking IN 40.6442.24 {1.6001.662}
(mm {in}) Standard
(Valve protrusion height) EX 40.5042.10 {1.5951.657}
Valve spring
Out-of-square (mm {in}) Maximum 1.95 {0.0767}
Pressing force (N {kgf, lbf}) [mm {in}] Standard height H 390 {39.76, 87.67} [28.68 {1.129}]
OCV (Oil control valve)
Coil resistance [20 C {68F}] (ohm) Standard 6.97.9
Camshaft
Camshaft runout (mm {in}) Maximum 0.03 {0.0012}
IN 42.44 {1.671}
Standard
EX 41.18 {1.622}
Cam lobe height (mm {in})
IN 42.33 {1.666}
Minimum
EX 41.06 {1.616}
Standard 24.9624.98 {0.98270.9834}
Journal diameter (mm {in})
Minimum 24.95 {0.982}
Standard 0.040.08 {0.0020.003}
Journal oil clearance (mm {in})
Maximum 0.09 {0.0035}
Standard 0.090.24 {0.00350.0099}
End play (mm {in})
Maximum 0.25 {0.009}
Tappet
Tappet bore diameter (mm {in}) Standard 31.00031.030 {1.22051.2216}
Tappet diameter (mm {in}) Standard 30.97030.980 {1.21931.2196}
Tappet-to-Tappet bore oil Standard 0.020.06 {0.00080.0023}
(mm {in})
clearance Maximum 0.15 {0.006}
Cylinder block
Cylinder head gasket
(mm {in}) Maximum 0.10 {0.004}
contact surfaces distortion
Cylinder bore diameter
[Measure the cylinder bore
at 42 mm (mm {in}) Standard 87.50087.530 {3.44493.4460}
{1.65 in} below the top
surface]
Minimum / maximum bore
(mm {in}) 87.44087.590 {3.44253.4484}
diameter Limit
Piston
Piston diameter (mm {in}) Standard 87.46587.495 {3.44353.4446}
Standard 0.0220.047 {0.00090.0018}
Piston-to-cylinder clearance (mm {in})
Maximum 0.11 {0.0043}
Piston ring
Top 0.040.08 {0.00160.0031}
Standard
Second 0.030.07 {0.00120.0027}
Piston ring-to-ring groove (mm {in}) Oil (rail) 0.060.15 {0.00240.0059}
clearance Top 0.17 {0.0067}
Maximum Second 0.15 {0.0059}
Oil (rail) 0.15 {0.0059}
01504
TECHNICAL DATA
Engine
Item LF (With variable valve timing mechanism)
L3 (With variable valve timing mechanism)
Top 0.160.26 {0.00630.010}
Standard Second 0.330.48 {0.01300.0189}
End gap Oil (rail) 0.200.70 {0.00790.0275}
(mm {in})
(measured in cylinder) Top 1.0 {0.0393}
Maximum Second 1.0 {0.0393}
Oil (rail) 1.0 {0.0393}
Connecting rod and connecting rod bearing
01
Connecting rod side Standard 0.140.36 {0.00560.0141}
(mm {in})
clearance Maximum 0.435 {0.0172}
Standard 1.4961.502 {0.05890.0591}
Connecting rod bearing size (mm {in}) 0.25 Oversize 1.6211.627 {0.06390.0641}
0.50 Oversize 1.7461.752 {0.06880.0690}
Connecting rod bearing oil Standard 0.0260.052 {0.00110.0020}
(mm {in})
clearance Maximum 0.10 {0.0039}
Crankshaft
Crankshaft runout (mm {in}) Maximum 0.05 {0.0019}
Standard 51.98052.000 {2.04642.0472}
Main journal diameter (mm {in}) 0.25 {0.01}
51.73051.750 {2.03662.0373}
undersize
Standard 0.0190.035 {0.00070.0013}
Main journal oil clearance (mm {in})
Maximum 0.10 {0.0039}
Main journal out of round (mm {in}) Maximum 0.05 {0.0019}
Standard 2.5062.509 {0.09870.0988}
Main bearing size (mm {in}) 0.25 {0.01} Oversize 2.6282.634 {0.10340.1037}
0.50 {0.02} Oversize 2.7532.759 {0.10840.1086}
Standard 49.98050.000 {1.96771.9685}
Crank pin journal diameter (mm {in}) 0.25 {0.01}
49.73049.750 {1.95791.9586}
undersize
Crank pin out of round (mm {in}) Maximum 0.05 {0.022}
Standard 0.220.45 {0.00870.0177}
Crankshaft end play (mm {in})
Maximum 0.55 {0.0216}
Front oil seal
Pushing distance of the front oil seal
(mm {in}) 00.5 {00.019}
[from the edge of the engine front cover]
Bolt
Standard 145.2145.8 {5.725.74}
Cylinder head bolt length
Maximum 146.5 {5.77}
Standard 44.745.3 {1.751.78}
Connecting rod bolt length
Maximum 46.0 {1.81}
Standard 110.0110.6 {4.334.35}
Main bearing cap bolt length
Maximum 111.3 {4.38}
Balance shaft
Gear backlash (mm {in}) Maximum L3: 0.005-0.101 {0.000190.0039}
Engine
Item
L3
Cylinder Block
Cylinder bore diameter (mm {in}) 87.587.53 {3.4443.445}
Cylinder bore maximum out-of-round (mm {in}) 0.008 {0.0003}
Main bearing bore diameter (mm {in}) 57.02057.038 {2.2442.245}
01505
TECHNICAL DATA
Engine
Item
L3
0.1 mm/general
0.05 mm/200 x 200
Head gasket surface flatness
{0.0003 in./general}
{0.0019 in./7.87 x 7.87}
Piston
Diameter (1) (mm {in}) 87.587.51 {3.4443.445}
Diameter (2) (mm {in}) 87.5187.52 {3.44523.4456}
Diameter (3) (mm {in}) 87.5287.53 {3.4443.446}
Piston-to-bore clearance (mm {in}) 0.0250.045 {0.00090.0017}
Ring groove width top (mm {in}) 1.2031.205 {0.04730.0474}
Ring groove width 2nd (mm {in}) 1.171.19 {0.04600.0468}
Ring groove width oil (mm {in}) 2.5012.503 {0.09840.0985}
Piston skirt coating thickness (mm {in}) 0.0080.020 {0.00030.0007}
Piston Pin
Diameter (mm {in}) 20.99521.0 {0.82660.8268}
Length (mm {in}) 59.660.4 {2.3462.377}
Piston-to-pin clearance (mm {in}) 0.0080.016 {0.00030.0006}
Pin-to-rod clearance Press fit
Cylinder Head
Valve lift at zero lash (exhaust) (mm {in}) 7.4 {0.2913}
Valve lift at zero lash (intake) (mm {in}) 7.9 {0.311}
Valve guide diameter (mm {in}) 5.5095.539 {0.2160.218}
Valve seat width intake/exhaust (mm {in}) 0.991.84 {0.0380.072}
Valve seat angle () 45
Valve seat runout (mm {in}) 0.075 {0.0029}
Valve lash adjuster bore diameter (mm {in}) 31.0031.03 {1.2201.221}
Cam bore diameter (mm {in}) 25.01525.040 {0.9840.985}
Valve
Valve head diameter intake (mm {in}) 34.8535.15 {1.3721.383}
Valve head diameter exhaust (mm {in}) 29.8530.15 {1.1751.187}
Valve stem diameter intake (mm {in}) 5.4705.485 {0.21530.2159}
Valve stem diameter exhaust (mm {in}) 5.4655.480 {0.21510.2157}
Valve stem-to-guide clearance intake (mm {in}) 0.0027 {0.0009}
Valve stem-to-guide clearance exhaust (mm {in}) 0.0029 {0.0011}
Valve face runout (mm {in}) 0.05 {0.001 in}
Valve face angle () 45
Valve Spring Compression Pressure
Intake and exhaust (installed) (N {kgf, lbs}) 172.4 {17.576, 38.667}
Intake (valve open) 8.9 mm (0.35 in) of lift (N {kgf, lbs}) 432.5 {44.105, 97.032}
Exhaust (valve open) 7.4 mm of lift (N {kgf, lbs}) 416.1 {42.426, 93.338}
Free length (mm {in}) 44.92 {1.768}
Assembled height (mm {in}) 37.9 {1.492}
Crankshaft
Main bearing journal diameter (mm {in}) 51.98052.000 {2.0462.047}
Production repair (mm {in}) 51.73051.750 {2.0362.037}
Main bearing clearance (mm {in}) 0.0190.035 {0.00070.0013}
Connecting rod journal diameter (mm {in}) 49.98050.000 {1.9671.968}
Production repair (mm {in}) 49.73049.750 {1.9571.958}
End play (mm {in}) 0.220.43 {0.0080.016}
Rings
Width top (mm {in}) 1.171.185 {0.04600.0466}
Width 2nd (mm {in}) 1.1971.199 {0.04710.0472}
Width oil (mm {in}) 2.382.45 {0.0930.096}
Ring gap (in bore) top (mm {in}) 0.160.31 {0.0060.012}
01506
TECHNICAL DATA
Engine
Item
L3
Ring gap (in bore) 2nd (mm {in}) 0.330.48 {0.0120.018}
Ring gap (in bore) oil (mm {in}) 0.20.7 {0.0070.027}
Valve Tappet
Diameter (mm {in}) 30.9730.98 {1.21921.2196}
Tappet-to-valve clearance intake (mm {in}) 0.22 0.28 {0.0080.011}
Tappet-to-valve clearance exhaust (mm {in}) 0.270.33 {0.0100.013}
Tappet-to-bore clearance (mm {in}) 0.020.06 {0.00070.0023}
Camshaft 01
Lobe lift intake (mm {in}) 8.24999 {0.32}
Lobe lift exhaust (mm {in}) 7.80007 {0.307 }
Runout (1) No. 3 Journal Supported by No. 1 and No. 5 0.03 {0.001}
(mm {in})
journals.
Thrust clearance (mm {in}) 0.090.24 {0.0030.009}
Journal diameter (mm {in}) 24.9624.98 {0.9820.983}
Journal-to-bore clearance (mm {in}) 0.0350.080 {0.0010.003}
Connecting Rod
Bearing clearance (mm {in}) 0.0270.052 {0.0010.002}
Bearing thickness (mm {in}) 1.4961.520 {0.0580.059}
Crank bore diameter (mm {in}) 53.02553.045 {2.0872.088}
Pin bore diameter (mm {in}) 20.96520.985 {0.8250.826}
Length (center-to-center) (mm {in}) 154.8 {6.094}
Side clearance (mm {in}) 1.953.05 {0.0760.120}
Axial clearance (mm {in}) 0.140.36 {0.0050.014}
End Of Sie
01507
SERVICE TOOLS
End of Toc
ENGINE SST
B3E016002000201
1: Mazda SST number
2: Global SST number
Example
1:49 JE01 061
2:303-507 01
Crankshaft TDC
Setting Pin
01601
SERVICE TOOLS
1:49 JE01 054 49 UN30 3465 1:49 G011 201
Camshaft 2: 303465 2:
Alignment Camshaft
timing Tool Alignment Attachment
(Europe) timing Tool
(Except Europe)
End Of Sie
01602