Mazda 2006-2008 RX7 Engine Instruction manual

Title Section
GENERAL INFORMATION 00
ENGINE 01
CONTENTS
Engine
Workshop
Manual
LF
L3
FOREWORD
This manual explains the service points for
the above-indicated automotive system.
This manual covers all models with the
above-indicated automotive system, not any
one specific model.
In order to do these procedures safely,
quickly, and correctly, you must first read
this manual and any other relevant service
materials carefully.
All the contents of this manual, including
drawings and specifications, are the latest
available at the time of printing.
As modifications affecting repair or
maintenance occur, relevant information
supplementary to this volume will be made
available at Mazda dealers. This manual
should be kept up-to-date.
Mazda Motor Corporation reserves the right
to alter the specifications and contents of
this manual without obligation or advance
notice.
All rights reserved. No part of this book may
be reproduced or used in any form or by any
means, electronic or mechanical—including
photocopying and recording and the use of
any kind of information storage and retrieval
system—without permission in writing.
Mazda Motor Corporation
HIROSHIMA, JAPAN
©2005 Mazda Motor Corporation
PRINTED IN U.S.A., AUGUST 2005
Form No. 1866–1U–05H
Part No. 9999–95–LFL3–05

00
GENERAL INFORMATION
00–00–1
SECTION
00–00
To c o f S C T
GENERAL INFORMATION . . . . 00-00
To c o f S C T
00–00 GENERAL INFORMATION
HOW TO USE THIS MANUAL . . . . . . . . . 00–00–2
Range of Topics . . . . . . . . . . . . . . . . . . 00–00–2
Service Procedure . . . . . . . . . . . . . . . . 00–00–2
Symbols . . . . . . . . . . . . . . . . . . . . . . . . 00–00–4
Advisory Messages. . . . . . . . . . . . . . . . 00–00–4
UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–00–5
Conversion to SI Units (Système
International d'Unités) . . . . . . . . . . . . . 00–00–5
Rounding Off . . . . . . . . . . . . . . . . . . . . . 00–00–5
Upper and Lower Limits . . . . . . . . . . . . 00–00–5
FUNDAMENTAL PROCEDURES. . . . . . . 00–00–6
Preparation of Tools and Measuring
Equipment. . . . . . . . . . . . . . . . . . . . . . 00–00–6
Special Service Tools . . . . . . . . . . . . . . 00–00–6
Disassembly . . . . . . . . . . . . . . . . . . . . . 00–00–6
Inspection During Removal,
Disassembly . . . . . . . . . . . . . . . . . . . . 00–00–6
Arrangement of Parts . . . . . . . . . . . . . . 00–00–7
Cleaning of Parts . . . . . . . . . . . . . . . . . 00–00–7
Reassembly . . . . . . . . . . . . . . . . . . . . . 00–00–7
Adjustment . . . . . . . . . . . . . . . . . . . . . . 00–00–7
Rubber Parts and Tubing . . . . . . . . . . . 00–00–8
Hose Clamps . . . . . . . . . . . . . . . . . . . . 00–00–8
Torque Formulas . . . . . . . . . . . . . . . . . 00–00–8
Vise . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–00–8
ELECTRICAL SYSTEM. . . . . . . . . . . . . . 00–00–9
Connectors. . . . . . . . . . . . . . . . . . . . . . 00–00–9
NEW STANDARDS . . . . . . . . . . . . . . . . . 00–00–11
ABBREVIATIONS . . . . . . . . . . . . . . . . . . 00–00–12
End of Toc

GENERAL INFORMATION
00–00–2
HOW TO USE THIS MANUAL
E5U000000000E01
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
location and contents of the procedures are
explained in detail and shown in the illustrations.
49 H002 671
49 H032 322
49 1232 670A
SHOWS PROCEDURE ORDER
FOR SERVICE
Fluid Pressure Inspection
1. Assemble the SSTs as shown in the figure.
Tightening torque
SHOWS TIGHTENING
TORQUE
SPECIFICATIONS
Caution
Connect the gauge set from under
the vehicle to prevent contact with
the drive belt and the cooling fan.
39—49 N·m {4.0—5.0 kgf·m, 29—36 ft·lbf}
WGIWXX0009E

GENERAL INFORMATION
00–00–3
00–00
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.
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.
GREASE
GREASE
GREASE
GREASE
SHOWS NON-REUSEABLE PARTS
SHOWS DETAILS
KNUCKLE
UPPER TRAILING LINK
LOWER TRAILING LINK
SST
SST
SST
SST
R
R
R
R
9
2
1
4
5
3
6
1
2
8
7
12
10
11
N·m {kgf·m, ft·lbf}
118—156 {12.0—16.0, 87—115}
94—116 {9.5—11.9, 69—86}
43—56 {4.3—5.8, 32—41}
49 T028 304
49 T028 305
49 T028 303
Procedure
LOWER TRAILING LINK, UPPER TRAILING LINK REMOVAL/INSTALLATION
1. Jack up the rear of the vehicle and support it with safety stands.
2. Remove the undercover. (See 01-10-4 Undercover Removal)
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.
5. Inspect the rear wheel alignment and adjust it if necessary.
1Split pin
2Nut
3Lower trailing link ball joint
4
(See 02-14-5 Lower Trailing Link Ball Joint Removal Note)
Bolt
5Lower trailing link
6Dust boot (lower trailing link)
7Split pin
8 Nut
9 Upper trailing link ball joint
(See 02-14-5 Upper Trailing Link Ball Joint Removal Note)
10 Nut
11 Upper trailing link
12 Dust boot (upper trailing link)
Lower Trailing Link Ball Joint, Upper Trailing Link
Ball Joint Removal Note
Remove the ball joint using the SSTs.
—44—60 {4.4—6.2, 32—44}
"Removal/Installation"
Portion
"Inspection After
Installation" Portion
INSTALL THE PARTS BY
PERFORMING STEPS
1—3 IN REVERSE ORDER
SHOWS PROCEDURE ORDER
FOR SERVICE
SHOWS TIGHTENING
TORQUE
SPECIFICATIONS
SHOWS SERVICE
ITEM (S)
INDICATES ANY RELEVANT
REFERENCES WHICH NEED
TO BE FOLLOWED DURING
INSTALLATION
SHOWS SPECIAL
SERVICE TOOL (SST)
FOR SERVICE OPERATION
SHOWS APPLICATION
POINTS OF GREASE, ETC.
SHOWS TIGHTENING
TORQUE UNITS
SHOWS SPECIAL
SERVICE TOOL (SST)
NO.
SHOWS REFERRAL
NOTES FOR
SERVICE
SHOWS THERE
ARE REFERRAL
NOTES FOR SERVICE
BHE0000W104

GENERAL INFORMATION
00–00–4
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.
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.
Upper and lower limits
•The values indicate the upper and lower limits that must not be exceeded when performing inspections or
adjustments.
End Of Sie
Symbol Meaning Kind
Apply oil
New appropriate
engine oil or gear
oil
Apply brake fluid New appropriate
brake fluid
Apply automatic
transaxle/
transmission fluid
New appropriate
automatic
transaxle/
transmission fluid
Apply grease Appropriate
grease
Apply sealant Appropriate
sealant
Apply petroleum
jelly
Appropriate
petroleum jelly
Replace part O-ring, gasket,
etc.
Use SST or
equivalent Appropriate tools
OIL
BRAKE
FLUID
A
A
TF
TF
GREASE
GREASE
SEALANT
P
R
SST

GENERAL INFORMATION
00–00–5
00–00
UNITS
E5U000000000E02
Conversion to SI Units (Système International d'Unités)
•All numerical values in this manual are based on SI units. Numbers shown in conventional units are converted
from these values.
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.
Upper and Lower Limits
•When the data indicates upper and lower limits, the converted values are rounded down if the SI unit value is
an upper limit and rounded up if the SI unit value is a lower limit. Therefore, converted values for the same SI
unit value may differ after conversion. For example, consider 2.7 kgf/cm
2
in the following specifications:
210—260 kPa {2.1—2.7 kgf/cm
2
, 30—38 psi}
270—310 kPa {2.7—3.2 kgf/cm
2
, 39—45 psi}
•The actual converted values for 2.7 kgf/cm
2
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
Electric current A (ampere)
Electric power W (watt)
Electric resistance ohm
Electric voltage V (volt)
Length mm (millimeter)
in (inch)
Negative pressure
kPa (kilo pascal)
mmHg (millimeters of mercury)
inHg (inches of mercury)
Positive pressure
kPa (kilo pascal)
kgf/cm
2(kilogram force per square
centimeter)
psi (pounds per square inch)
Number of
revolutions rpm (revolutions per minute)
To r q u e
N·m (Newton meter)
kgf·m (kilogram force meter)
kgf·cm (kilogram force centimeter)
ft·lbf (foot pound force)
in·lbf (inch pound force)
Volume
L (liter)
US qt (U.S. quart)
Imp qt (Imperial quart)
ml (milliliter)
cc (cubic centimeter)
cu in (cubic inch)
fl oz (fluid ounce)
Weight g (gram)
oz (ounce)

GENERAL INFORMATION
00–00–6
FUNDAMENTAL PROCEDURES
E5U000000000E03
Preparation of Tools and Measuring Equipment
•Be sure that all necessary tools and measuring
equipment are available before starting any work.
Special Service Tools
•Use special service tools or equivalent when they
are required.
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.
Inspection During Removal, Disassembly
•When removed, each part should be carefully
inspected for malfunction, deformation, damage
and other problems.
CHU0014W003
49 SE01 310
WGIWXX0024E
WGIWXX0027E
WGIWXX0028E

GENERAL INFORMATION
00–00–7
00–00
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.
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.
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
•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.
Adjustment
•Use suitable gauges and testers when making
adjustments.
WGIWXX0029E
C5U0000W001
WGIWXX0031E
CHU0014W006
CHU0014W005

GENERAL INFORMATION
00–00–8
Rubber Parts and Tubing
•Prevent gasoline or oil from getting on rubber
parts or tubing.
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.
Torque Formulas
•When using a torque wrench-SST or equivalent
combination, the written torque must be
recalculated due to the extra length that the SST
or equivalent adds to the torque wrench.
Recalculate the torque by using the following
formulas. Choose the formula that applies to you.
A : The length of the SST past the torque wrench drive.
L : The length of the torque wrench.
Vise
•When using a vise, put protective plates in the
jaws of the vise to prevent damage to parts.
End Of Sie
WGIWXX0034E
WGIWXX0035E
Torque Unit Formula
N·m N·m ×[L/(L+A)]
kgf·m kgf·m ×[L/(L+A)]
kgf·cm kgf·cm ×[L/(L+A)]
ft·lbf ft·lbf ×[L/(L+A)]
in·lbf in·lbf ×[L/(L+A)]
0
1
1
2
2
3
3
SST
AL
WGIWXX0036E
PROTECTIVE PLATES
CHU0014W010

GENERAL INFORMATION
00–00–9
00–00
ELECTRICAL SYSTEM
E5U000000000E04
Connectors
Disconnecting connectors
•When disconnecting connector, grasp the
connectors, not the wires.
•Connectors can be disconnected by pressing or
pulling the lock lever as shown.
Locking connector
•When locking connectors, listen for a click
indicating they are securely locked.
GOOD NO GOOD
CHU0000W014
WGIWXX0042E
WGIWXX0043E

GENERAL INFORMATION
00–00–10
Inspection
•When a tester is used to inspect for continuity or
measuring voltage, insert the tester probe from
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.
End Of Sie
GOOD NO GOOD
CHU0000W011
GOOD NO GOOD
CHU0000W012

GENERAL INFORMATION
00–00–11
00–00
NEW STANDARDS
E5U000000000E05
•Following is a comparison of the previous standard and the new standard.
New Standard Previous Standard
Remark
Abbrevi-
ation Name Abbrevi-
ation Name
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
solenoid Fuel Shut Off Solenoid FCV Fuel Cut Valve #6
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
— 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

GENERAL INFORMATION
00–00–12
#1 : Diagnostic trouble codes depend on the diagnostic test mode
#2 : Controlled by the PCM
#3 : In some models, there is a fuel pump relay that controls pump speed. That relay is now called the fuel pump
relay (speed).
#4 : Device that controls engine and powertrain
#5 : Directly connected to exhaust manifold
#6 : Part name of diesel engine
End Of Sie
ABBREVIATIONS
E5U000000000E06
End Of Sie
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
PAIR Pulsed Secondary Air Injection — Secondary Air Injection System Pulsed
injection
— Pump Speed Sensor — NE Sensor #6
AIR Secondary Air Injection — Secondary Air Injection System
Injection
with air
pump
SAPV Secondary Air Pulse Valve — Reed Valve
SFI Sequential Multipoint Fuel Injection — Sequential Fuel Injection
— Shift Solenoid A — 12 Shift Solenoid Valve
— Shift A Solenoid Valve
— Shift Solenoid B — 23 Shift Solenoid Valve
— 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
TCM Transmission (Transaxle) Control
Module — EC-AT Control Unit
—Transmission (Transaxle) Fluid
Temperature Sensor — ATF Thermosensor
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
WUTWC Warm Up Three Way Catalytic
Converter — Catalytic Converter #5
WOT Wide Open Throttle — Fully Open
New Standard Previous Standard
Remark
Abbrevi-
ation Name Abbrevi- ation Name
ATDC After Top Dead Center
ATX Automatic Transaxle
EGR Exhaust Gas Recirculation
EX Exhaust
IN Intake
MTX Manual Transaxle
OCV Oil Control Valve
TDC Top Dead Center
SST Special Service Tool

01–10–1
01
ENGINE
SECTION
01–10
To c o f S C T
MECHANICAL. . . . . . . . . . . . . . 01-10
TECHNICAL DATA . . . . . . . . . .01-50
SERVICE TOOLS . . . . . . . . . . . 01-60
To c o f S C T
01–10 MECHANICAL
ENGINE OVERHAUL SERVICE
WARNING. . . . . . . . . . . . . . . . . . . . . . . . 01–10–2
ENGINE
MOUNTING/DISMOUNTING . . . . . . . . . 01–10–3
DISMOUNTING. . . . . . . . . . . . . . . . . . . 01–10–3
TIMING CHAIN DISASSEMBLY. . . . . . . . 01–10–4
Crankshaft Pulley Lock Bolt
Disassembly Note . . . . . . . . . . . . . . . . 01–10–5
Front Oil Seal Disassembly Note . . . . . 01–10–5
Chain Tensioner
Disassembly Note . . . . . . . . . . . . . . . . 01–10–5
Oil Pump Sprocket
Disassembly Note . . . . . . . . . . . . . . . . 01–10–5
CYLINDER HEAD (I)
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . 01–10–6
Camshaft Sprocket Lock Bolt,
Variable Valve Timing Actuator
Lock Bolt Disassembly Note . . . . . . . . 01–10–7
Camshaft Cap Disassembly Note . . . . . 01–10–7
Tappet Disassembly Note . . . . . . . . . . . 01–10–7
Cylinder Head Bolt
Disassembly Note . . . . . . . . . . . . . . . . 01–10–8
CYLINDER HEAD (II)
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . 01–10–8
Valve Keeper Disassembly Note . . . . . . 01–10–8
Valve Seal Disassembly Note . . . . . . . . 01–10–9
CYLINDER BLOCK (I)
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . 01–10–9
Drive Plate (ATX), Flywheel (MTX)
Disassembly Note . . . . . . . . . . . . . . . . 01–10–10
CYLINDER BLOCK (II)
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . 01–10–10
Connecting Rod Cap
Disassembly Note . . . . . . . . . . . . . . . . 01–10–11
Main Bearing Cap
Disassembly Note . . . . . . . . . . . . . . . . 01–10–11
CYLINDER HEAD INSPECTION . . . . . . . 01–10–11
VALVE, VALVE GUIDE
INSPECTION . . . . . . . . . . . . . . . . . . . . . 01–10–12
VALVE GUIDE REPLACEMENT . . . . . . . 01–10–13
Valve Guide Removal . . . . . . . . . . . . . . 01–10–13
Valve Guide Installation. . . . . . . . . . . . . 01–10–13
VALVE SEAT
INSPECTION/REPAIR . . . . . . . . . . . . . . 01–10–14
VALVE SPRING INSPECTION . . . . . . . . . 01–10–15
CAMSHAFT INSPECTION . . . . . . . . . . . . 01–10–15
TAPPET INSPECTION . . . . . . . . . . . . . . . 01–10–17
CYLINDER BLOCK
INSPECTION . . . . . . . . . . . . . . . . . . . . . 01–10–17
OIL JET VALVE INSPECTION . . . . . . . . 01–10–18
PISTON INSPECTION . . . . . . . . . . . . . . . 01–10–18
CRANKSHAFT INSPECTION . . . . . . . . . 01–10–19
CONNECTING ROD INSPECTION . . . . . 01–10–20
BOLT INSPECTION . . . . . . . . . . . . . . . . . 01–10–21
VARIABLE VALVE TIMING ACTUATOR
INSPECTION [With variable valve
timing mechanism]. . . . . . . . . . . . . . . . 01–10–21
OIL CONTROL VALVE (OCV)
INSPECTION [With variable valve
timing mechanism]. . . . . . . . . . . . . . . . 01–10–21
Coil Resistance Inspection . . . . . . . . . . 01–10–21
Spool Valve Operation Inspection . . . . 01–10–22
VALVE CLEARANCE
INSPECTION . . . . . . . . . . . . . . . . . . . . . 01–10–22
VALVE CLEARANCE
ADJUSTMENT. . . . . . . . . . . . . . . . . . . . 01–10–23
CYLINDER BLOCK (I) ASSEMBLY . . . . 01–10–27
Main Bearing Cap Assembly Note . . . . 01–10–28
Piston Ring Assembly Note . . . . . . . . . 01–10–28
Piston Assembly Note . . . . . . . . . . . . . 01–10–28
Connecting Rod Bearing
Assembly Note . . . . . . . . . . . . . . . . . . 01–10–29
Connecting Rod Cap
Assembly Note . . . . . . . . . . . . . . . . . . 01–10–29
Balancer Unit Assembly Note. . . . . . . . 01–10–29
CYLINDER BLOCK (II)
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 01–10–32
Rear Oil Seal Assembly Note. . . . . . . . 01–10–33
Drive Plate (ATX), Flywheel (MTX)
Assembly Note . . . . . . . . . . . . . . . . . . 01–10–33
Oil pan Assembly Note. . . . . . . . . . . . . 01–10–34
CYLINDER HEAD (I) ASSEMBLY. . . . . . 01–10–35
Valve Seal Assembly Note . . . . . . . . . . 01–10–35
Valve Keeper Assembly Note . . . . . . . . 01–10–35
CYLINDER HEAD (II) ASSEMBLY . . . . . 01–10–36
Cylinder Head Bolt
Assembly Note . . . . . . . . . . . . . . . . . . 01–10–37
Camshaft Assembly Note. . . . . . . . . . . 01–10–37
Camshaft Sprocket, Variable Valve
Timing Actuator Assembly Note. . . . . 01–10–37
TIMING CHAIN ASSEMBLY . . . . . . . . . . 01–10–38
Oil Pump Sprocket Assembly Note . . . 01–10–39
Timing Chain Assembly Note . . . . . . . . 01–10–39
Camshaft Sprocket, Variable Valve
Timing Actuator Assembly Note. . . . . 01–10–40

MECHANICAL
01–10–2
Front Oil Seal Assembly Note . . . . . . . . 01–10–40
Engine Front Cover Assembly Note . . . 01–10–41
Crankshaft Pulley Lock Bolt
Assembly Note . . . . . . . . . . . . . . . . . . 01–10–41
Cylinder Head Cover
Assembly Note . . . . . . . . . . . . . . . . . . 01–10–42
End of Toc
ENGINE OVERHAUL SERVICE WARNING
E5U011002000E01
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

MECHANICAL
01–10–3
01–10
ENGINE MOUNTING/DISMOUNTING
E5U011002000E02
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
in}.
2. Assemble the SSTs (bolts, nuts and plate) to the
specified positions.
3. Adjust the SSTs (bolts) so that less than 20 mm
{0.79 in} of thread is exposed.
4. Make the SSTs (arms and plate) parallel by
adjusting the SSTs (bolts and nuts).
5. Tighten the SSTs (bolts and nuts) to affix the
SSTs firmly.
Warning
•Self-locking brake system of the engine
stand may not be effective when the
engine is held in an unbalanced position.
This could lead to sudden, rapid
movement of the engine and mounting
stand handle and cause serious injury.
Never keep the engine in an unbalanced
position, and always hold the rotating
handle firmly when turning the engine.
6. Mount the engine on the SST (engine stand).
7. Drain the engine oil into a container.
8. Install the oil pan drain plug.
•With washer
1. Install the oil pan drain plug with a new washer.
Tightening torque
30—41 N·m {3.1—4.1 kgf·m, 23—30 ft·lbf}
•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
22—30 N·m {2.2—3.1 kgf·m, 16—22 ft·lbf}
DISMOUNTING
•Dismount in the reverse order of mounting.
End Of Sie
49 L010 102
B3E0110W127
49 L010 101
49 L010 104
49 L010 105
C3U0110E001
49 L010 101
49 L010 102
49 L010 104 49 L010 103
49 L010 105
PARALLEL
APPROX. 20 mm {0.79 in}
ENGINE
BOLT
E5U110ZW8S01

MECHANICAL
01–10–4
TIMING CHAIN DISASSEMBLY
E5U011002000E03
1. Disassemble in the order indicated in the table. .
SST
SST
R
R
R
R
WITH VARIABLE VALVE TIMING
MECHANISM
9
8
7
4
1
2
6
18
17
15
16
12
5
13
11
3
14
19
10
WITHOUT A/C
E5U110ZE7S01
1 Oil level gauge (if equipped)
2 Spark plug
3 Cylinder head cover
4 Crankshaft pulley lock bolt
(See 01–10–5 Crankshaft Pulley Lock Bolt
Disassembly Note.)
5 Crankshaft pulley
6 Water pump pulley
7 Drive belt idler pulley (Without stretch-type A/C drive
belt)
8 Engine front cover
9 Front oil seal
(See 01–10–5 Front Oil Seal Disassembly Note.)
10 Chain tensioner
(See 01–10–5 Chain Tensioner Disassembly Note.)
11 Tensioner arm
12 Chain guide
13 Timing chain
14 Seal (With variable valve timing mechanism)
15 Oil pump chain tensioner
16 Oil pump chain guide
17 Oil pump sprocket
(See 01–10–5 Oil Pump Sprocket Disassembly
Note.)
18 Oil pump chain
19 Crankshaft sprocket

MECHANICAL
01–10–5
01–10
Engine Workshop Manual LF L3 (1866–1U–05H)
Crankshaft Pulley Lock Bolt Disassembly Note
1. Install the SST to the ring gear to lock the
crankshaft against rotation.
Front Oil Seal Disassembly Note
1. Remove the oil seal using a screwdriver.
Chain Tensioner Disassembly Note
1. Unlock the chain tensioner ratchet using a
suitable screw driver or equivalent tool.
2. Slowly press the tensioner piston.
3. Hold the chain tensioner piston with a 1.5 mm
{0.06 in} wire or paper clip.
Oil Pump Sprocket Disassembly Note
1. Hold the oil pump sprocket using the SST.
End Of Sie
49 E011 1A0
D3U110ZE4003
E6U110ZWB044
TENSIONER PISTON
RATCHET
RACK
C3U0110W098
49 G032 354
B3E0110E054

MECHANICAL
01–10–6
Engine Workshop Manual LF L3 (1866–1U–05H)
Revised 12/2005 (Ref. No. R145/05)
CYLINDER HEAD (I) DISASSEMBLY E5U011002000E04
1. Disassemble in the order indicated in the table..
9
8
7
5
4
4
3
1
2
2
R
6
R
R
R
WITH VARIABLE VALVE TIMING MECHANISM
**
*
*: IF WASHER IS NOT INSTALLED TO THE ENGINE, INSTALL A NEW WASHER.
E5U110ZECL01
1 Camshaft sprocket lock bolt, variable valve timing
actuator lock bolt (With variable valve timing
mechanism)
(See 01–10–7 Camshaft Sprocket Lock Bolt,
Variable Valve Timing Actuator Lock Bolt
Disassembly Note .)
2 Camshaft sprocket, variable valve timing actuator
(With variable valve timing mechanism)
3 Oil control valve (OCV) (with variable valve timing
mechanism)
4 Camshaft cap
(See 01–10–7 Camshaft Cap Disassembly Note.)
5 Camshaft
6 Tappet
(See 01–10–7 Tappet Disassembly Note.)
7 Cylinder head bolt
(See 01–10–8 Cylinder Head Bolt Disassembly
Note.)
8 Cylinder head
9 Cylinder head gasket