Mazda MX-5 Miata Sport 2007 User manual

2006-08 ENGINE
Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata
ENGINE IDENTIFICATION
Engine can be identified by engine model and number
ENGINE IDENTIFICATION CODE
MECHANICAL
ENGINE OVERHAUL SERVICE WARNING
ENGINE MOUNTING/DISMOUNTING
1. Install the SSTs (arms) to the cylinder block holes as shown, and hand-tighten the bolts (part No.:
9YA20-1003) or M10 x 1.5T length 90 mm {3.55 in}.
Engine Code
2.0L 4-Cylinder LF
2.3L 4-Cylinder L3
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.
2007 Mazda MX-5 Miata Sport
2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata
2007 Mazda MX-5 Miata Sport
2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata
Microsoft
Thursday, July 09, 2009 2:43:24 PM Page 1 © 2005 Mitchell Repair Information Company, LLC.
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Fig. 1: Installing SST (Arms) To Cylinder Block Holes
Courtesy of MAZDA MOTORS CORP.
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).
2007 Mazda MX-5 Miata Sport
2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata
Microsoft
Thursday, July 09, 2009 2:43:25 PM Page 2 © 2005 Mitchell Repair Information Company, LLC.

Fig. 2: Assembling SSTs (Bolts, Nuts And Plate) To Positions
Courtesy of MAZDA MOTORS CORP.
5. Tighten the SSTs (bolts and nuts) to affix the SSTs firmly.
Fig. 3: Identifying SST Bolts, Nuts & Parallel Plates
2007 Mazda MX-5 Miata Sport
2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata
Microsoft
Thursday, July 09, 2009 2:43:25 PM Page 3 © 2005 Mitchell Repair Information Company, LLC.

Courtes
y
of MAZDA MOTORS CORP.
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.
TIMING CHAIN DISASSEMBLY
1. Disassemble in the order indicated in the table.
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.
2007 Mazda MX-5 Miata Sport
2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata
Microsoft
Thursday, July 09, 2009 2:43:25 PM Page 4 © 2005 Mitchell Repair Information Company, LLC.

Fig. 4: Exploded View Of Timing Chain Components
Courtesy of MAZDA MOTORS CORP.
Crankshaft Pulley Lock Bolt Disassembly Note
1. Install the SST to the rin
g
g
ear to lock the crankshaft a
g
ainst rotation.
2007 Mazda MX-5 Miata Sport
2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata
Microsoft
Thursday, July 09, 2009 2:43:25 PM Page 5 © 2005 Mitchell Repair Information Company, LLC.

Fig. 5: Installing SST Ring Gear To Lock Crankshaft Against Rotation
Courtesy of MAZDA MOTORS CORP.
Front Oil Seal Disassembly Note
1. Remove the oil seal usin
g
a screwdriver.
2007 Mazda MX-5 Miata Sport
2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata
Microsoft
Thursday, July 09, 2009 2:43:25 PM Page 6 © 2005 Mitchell Repair Information Company, LLC.

Fig. 6: Removing Oil Seal
Courtesy of MAZDA MOTORS CORP.
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.
2007 Mazda MX-5 Miata Sport
2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata
Microsoft
Thursday, July 09, 2009 2:43:25 PM Page 7 © 2005 Mitchell Repair Information Company, LLC.

Fig. 7: Disassembling Chain Tensioner
Courtesy of MAZDA MOTORS CORP.
Oil Pump Sprocket Disassembly Note
1. Hold the oil pump sprocket using the SST .
2007 Mazda MX-5 Miata Sport
2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata
Microsoft
Thursday, July 09, 2009 2:43:25 PM Page 8 © 2005 Mitchell Repair Information Company, LLC.

Fig. 8: Holding Oil Pump Sprocket Using SST
Courtesy of MAZDA MOTORS CORP.
CYLINDER HEAD (I) DISASSEMBLY
1. Disassemble in the order indicated in the table.
2007 Mazda MX-5 Miata Sport
2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata
Microsoft
Thursday, July 09, 2009 2:43:25 PM Page 9 © 2005 Mitchell Repair Information Company, LLC.

Fig. 9: Exploded View Of Cylinder Head (I) Disassembly
Courtesy of MAZDA MOTORS CORP.
Camshaft Sprocket Lock Bolt, Variable Valve Timing Actuator Lock Bolt Disassembly Note
1. Hold the camshaft by using a wrench on the cast hexagon as shown, and loosen the camshaft sprocket
2007 Mazda MX-5 Miata Sport
2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata
Microsoft
Thursday, July 09, 2009 2:43:25 PM Page 10 © 2005 Mitchell Repair Information Company, LLC.

installation bolt or variable valve timing actuator installation bolt (With variable valve timing
mechanism).
Without variable valve timing mechanism
Fig. 10: Using Wrench On Cast Hexagon
Courtesy of MAZDA MOTORS CORP.
With variable valve timing mechanism
2007 Mazda MX-5 Miata Sport
2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata
Microsoft
Thursday, July 09, 2009 2:43:25 PM Page 11 © 2005 Mitchell Repair Information Company, LLC.

Fig. 11: Using Wrench On Cast Hexagon
Courtesy of MAZDA MOTORS CORP.
Camshaft Cap Disassembly Note
1. Before removing the camshaft caps, inspect the following:
Camshaft end play and camshaft journal oil clearance (See CAMSHAFT INSPECTION).
2. Loosen the camshaft caps bolts in 2--3 steps in the order shown in the figure.
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.
2007 Mazda MX-5 Miata Sport
2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata
Microsoft
Thursday, July 09, 2009 2:43:25 PM Page 12 © 2005 Mitchell Repair Information Company, LLC.

Fig. 12: Identifying Loosening Sequence Of Camshaft Cap Bolts
Courtesy of MAZDA MOTORS CORP.
Tappet Disassembly Note
Cylinder Head Bolt Disassembly Note
1. Loosen the c
y
linder head bolts in 2-3 steps in the order shown in the fi
g
ure.
NOTE: The tappets are numbered to make sure they are assembled in their
original positions. When removed, keep the tappets with the cylinder head
they were removed from. Do not mix the tappets.
2007 Mazda MX-5 Miata Sport
2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata
Microsoft
Thursday, July 09, 2009 2:43:25 PM Page 13 © 2005 Mitchell Repair Information Company, LLC.

Fig. 13: Loosening Cylinder Head Bolts
Courtesy of MAZDA MOTORS CORP.
CYLINDER HEAD (II) DISASSEMBLY
1. Disassemble in the order indicated in the table.
2007 Mazda MX-5 Miata Sport
2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata
Microsoft
Thursday, July 09, 2009 2:43:25 PM Page 14 © 2005 Mitchell Repair Information Company, LLC.

Fig. 14: Exploded View Of Cylinder Head (II) Disassembly
Courtesy of MAZDA MOTORS CORP.
Valve Keeper Disassembly Note
1. Remove the valve keeper using the SSTs .
2007 Mazda MX-5 Miata Sport
2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata
Microsoft
Thursday, July 09, 2009 2:43:25 PM Page 15 © 2005 Mitchell Repair Information Company, LLC.

Fig. 15: Removing Valve Keeper
Courtesy of MAZDA MOTORS CORP.
Valve Seal Disassembly Note
1. Remove the valve seal using the SST.
2007 Mazda MX-5 Miata Sport
2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata
Microsoft
Thursday, July 09, 2009 2:43:25 PM Page 16 © 2005 Mitchell Repair Information Company, LLC.

Fig. 16: Removing Valve Seal
Courtesy of MAZDA MOTORS CORP.
CYLINDER BLOCK (I) DISASSEMBLY
1. Disassemble in the order indicated in the table.
2007 Mazda MX-5 Miata Sport
2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata
Microsoft
Thursday, July 09, 2009 2:43:25 PM Page 17 © 2005 Mitchell Repair Information Company, LLC.

Fig. 17: Exploded View Of Cylinder Block (I) Disassembly
Courtesy of MAZDA MOTORS CORP.
Drive Plate (ATX), Flywheel (MTX) Disassembly Note
1. Hold the crankshaft using the SST.
2. Remove the bolts in several passes.
2007 Mazda MX-5 Miata Sport
2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata
Microsoft
Thursday, July 09, 2009 2:43:25 PM Page 18 © 2005 Mitchell Repair Information Company, LLC.

Fig. 18: Removal Sequence Of Drive Plate Or Flywheel Bolts
Courtesy of MAZDA MOTORS CORP.
CYLINDER BLOCK (II) DISASSEMBLY
1. Disassemble in the order indicated in the table.
2007 Mazda MX-5 Miata Sport
2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata
Microsoft
Thursday, July 09, 2009 2:43:25 PM Page 19 © 2005 Mitchell Repair Information Company, LLC.

Fig. 19: Exploded View Of Cylinder Block (II) Disassembly
Courtesy of MAZDA MOTORS CORP.
Connecting Rod Cap Disassembly Note
1. Before removing connecting rod inspect the connecting rod side clearance. (See CONNECTING ROD
INSPECTION).
2. Remove the connecting rod bolt from the connecting rod cap by tapping the bolt with a plastic hammer.
Main Bearing Cap Disassembly Note
1. Before removin
g
main bearin
g
cap inspect the crankshaft end pla
y
. (See CRANKSHAFT
NOTE: The tappets are numbered to make sure they are assembled in their
original positions. When removed, keep the tappets with the cylinder
head they were removed from. Do not mix the tappets.
2007 Mazda MX-5 Miata Sport
2006-08 ENGINE Mechanical - Overhaul - 2.0L (LF) & 2.3L (L3) - Mazda6 & MX-5 Miata
Microsoft
Thursday, July 09, 2009 2:43:25 PM Page 20 © 2005 Mitchell Repair Information Company, LLC.