Download PDF: Service Reference Manual for UTILEV Mazda Engine 2.2L

Service Reference Manual MAZDA ENGINE 2.2L UT15P, UT18P [A261, A266]; UT20P, UT25P, UT30P, UT35P [A281, A285]; UT20C, UT25C, UT30C, UT32C [A273, A279]

P/N 76001980

The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the product. Updated technical service information may be available from your local authorized UTILEV® distributor. Service Manuals provide general guidelines for maintenance and service and are intended for use by trained and experienced technicians. Failure to properly maintain equipment or to follow instructions contained in the Service Manual could result in damage to the products, personal injury, property damage or death.

SAFETY PRECAUTIONS MAINTENANCE AND REPAIR  When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the weight of the load. 

Do not lift heavy parts by hand, use a lifting mechanism.



Wear safety glasses.

 DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.  Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section. 

Keep the unit clean and the working area clean and orderly.



Use the correct tools for the job.



Keep the tools clean and in good condition.

 Always use UTILEV APPROVED parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer. 

Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to remove parts.



Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit needs repairs.



Be sure to follow the WARNING and CAUTION notes in the instructions.

 Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable. Be sure to follow the necessary safety precautions when handling these fuels and when working on these fuel systems.  Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this manual:

WARNING Symbol indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION Symbol indicates a hazardous situation which, if not avoided, could result in minor or moderate injury and property damage.

On the lift truck, the WARNING symbol and word are on orange back- ground. The CAUTION symbol and word are on yellow background.

TABLE OF CONTENTS Section 1: General…………………………………………………………………………………………………………….. 2 Serial Number……………………………………………….…………………………………………………...… 2 Section 2: Engine Removal and Installation............................................................................................................................. 3 Cylinder Head, Camshaft, and Valve Mechanism…………………………………………………………………. 3 Section 3: Crankshaft and Main Bearings Repair…………………………………………………………………………….. 15 Section 4: Cylinder Block Repair............................................................................................................................................. 20 Section 5: Oil Pump Repair...................................................................................................................................................... 21 Section 6 Flywheel and Ring Gear Repair……………………………………………………………………………………. 27 Section 7: Compression Pressure Check................................................................................................................................... 29 Engine Specifications............................................................................................................................................... 30 Engine Data.............................................................................................................................................................. 30 Engine Speeds.......................................................................................................................................................... 30 2007, and Later, Emission Compliant Engines........................................................................................................ 30 All Engines Except 2007, and Later, Emission Compliant Engines........................................................................ 30 Thermostat................................................................................................................................................................ 31 Cylinder Head........................................................................................................................................................... 31 Valve Mechanism..................................................................................................................................................... 31 Camshaft................................................................................................................................................................... 32 Crankshaft…............................................................................................................................................................. 33 Connecting Rods....................................................................................................................................................... 33 Cylinder Block.......................................................................................................................................................... 33 Pistons....................................................................................................................................................................... 33 Oil Pump................................................................................................................................................................... 33 Torque Specifications............................................................................................................................................... 33

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This

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General This section has the instructions for removal, disassembly, repair, assembly, installation, checks, and adjustments for the Mazda and 2.2L engines. The engine specifications are given at the end of the section.

Additional information on the Mazda 2.2L 2012 emissions compliant engine components can be found in 2012 Emission Certified LPG Fuel System 2.2L Mazda Engine Parts & Service Manual or 2012 Emission Certified Gas Fuel System 2.2L Mazda Engine Parts & Service Manual

SERIAL NUMBER The engine serial number is located on the top left hand side of the cylinder head cover. See Figure 1.

Figure 1. Engine Serial Number Location

2

Engine Removal and Installation

REMOVAL OF ENGINE CAUTION •

Only use the engine coolant specified. Other engine coolants may affect warranty coverage, cause an internal buildup of rust and scale and or shorten engine life.

•

Prevent dirt and debris from contaminating engine coolant.

Carefully clean the radiator cap and the surrounding area before you remove the cap.

•

1.

Disconnect the battery cables at the battery.

2. Disconnect the throttle cable and vehicle electrical harness from the engine 3. Drain the engine coolant. Disconnect the radiator hoses from the engine.

4.

Drain the engine oil..

5. Disconnect the exhaust system from the exhaust manifold.

6. Remove the engine from the vehicle. Fix the engine on a horizontal base.

NEVER mix different types of engine coolants. This may adversely affect the properties of the engine coolant.

A CAUTION Be sure to fix the engine securely to prevent injury or damage to parts due to falling during the work.

A WARNING SHOCK HAZARD! • Turn off the battery switch (if equipped) or disconnect the negative battery cable before servicing the electrical system.

7. Clean the engine by washing with solvent, air or steam cleaning. Carefully operate so as to prevent any foreign matter from entering the engine.

• Check the electrical harnesses for cracks, abrasions, and damaged or corroded connectors. ALWAYS keep the connectors and terminals clean.

• Failure to comply could result in death or serious injury.

Cylinder Head, Camshaft, and Valve Mechanism Repair REMOVE

4.

Remove coolant hoses.

1.

Disconnect connections at battery.

5.

Remove the V belt.

2.

Drain cooling system.

6.

Remove the cooling fan.

7.

Remove bracket for cooling fan.

3. Remove air cleaner, throttle cable (if equipped), intake manifold, and exhaust manifold.

3

8. Remove the six capscrews retaining the crankshaft pulley to the timing pulley and remove the crankshaft pulley.

9.

Remove the spark plugs from the cylinder head.

10. Remove upper and lower timing belt covers. See Figure 2.

Figure 3. Timing Belt 13. Remove the CAM angle sensor 14. Remove camshaft pulley. Keep pulley from rotating and loosen capscrew. Remove capscrew and pulley. See Figure 4

1. LOWER TIMING BELT COVER 2. UPPER TIMING BELT COVER 3. TIMING BELT TENSIONER Figure 2. Timing Belt Covers 11. Loosen capscrews for timing belt tensioner and remove spring. Remove capscrews and timing belt tensioner.

12. Use chalk to mark direction of timing belt rotation. See Figure 3. Remove timing belt.

4

Figure 4. Camshaft Gear Removal

15. Remove nuts and capscrews for front housing.

Then remove housing. See Figure 5.

18. Remove capscrews for cylinder head in proper sequence. See Figure 8.

Figure 8. Cylinder Head Removal Sequence

1. FRONT HOUSING 2. GASKET 3. OIL SEAL Figure 5. Front Housing

29. Lift cylinder head from the block.

20. Use valve spring compressor to remove valve retainers, springs, and valves from head. See Figure 9 16. Remove valve cover.

17. Loosen capscrews for rocker shaft supports in proper sequence. See Figure 6. Remove rocker shaft assembly and camshaft

Figure 9. Valve Removal

Figure 6. Rocker Assembly Removal Sequence

5

CAM ANGLE SENSOR, GAS AND LPG ENGINES Remove WARNING Always disconnect the battery ground cable before making repairs to prevent possible damage and injury. Install a tag on the battery terminal so that no one connects the cable on the terminal.

1.

Install NOTE: Coat the new O-ring and the gear on the distributor with clean engine oil.

1. Install a new O-ring onto the CAM angle sensor. See Figure 1 0 .

A. LUBRICATE O-RING AND GEAR WITH CLEAN ENGINE OIL

Disconnect the negative battery cable.

2. Rotate crankshaft until No. 1 piston is at TDC on compression stroke.

3. Disconnect the electrical connector from the side of the CAM angle sensor. See Figure 10.

4. Make alignment marks on the engine and the CAM angle sensor housing to aid in the correct installation of the CAM angle sensor.

5. Remove the mounting bolt from the CAM angle sensor housing. See Figure 10.

CAUTION If the engine crankshaft has been moved since the CAM angle sensor was removed, see the repair procedures for the engine to correctly install the CAM angle sensor. DO NOT do Step 2.

2. Verify that the CAM angle sensor matching marks on the CAM angle sensor housing and the CAM angle sensor gear are properly aligned. See Figure 11. Install the CAM angle sensor into the engine without turning the CAM angle sensor housing. Install the mounting bolt and tighten to 19 to 25 N•m (14 to 18 lb. ft.). See Figure 10.

6. Remove the CAM angle sensor from the engine without turning the CAM angle sensor housing. See Figure 10.

3. Connect the electrical connector to the side of the CAM angle sensor. See Figure 11.

7.

4.

Remove and discard the O-ring.

Re-time the engine. Refer to Ignition System.

1. MATCHING MARKS 2. CAM ANGLE SENSOR GEAR 3. CAM ANGLE SENSOR HOUSING Figure 11. CAM Angle Sensor Matching Marks 1.

2.

3.

4.

6

O-RING MOUNTING BOLT CAM ANGLE SENSOR ELECTRICAL CONNECTOR Figure 10. CAM Angle Sensor Removal

CAM Angle Sensor Voltage Check

5. Tag and disconnect all the ignition coil electrical connectors.

6.

Turn the ignition ON.

WARNING Turning the ignition switch to the ON position with the fuel injector connector still connected will actuate the fuel injector. Make sure that the fuel injector connector has been disconnected from the ignition coils before turning the ignition switch to the ON position when performing the following voltage check.

1.

Verify that the ignition is OFF.

2.

Disconnect the fuel injector connector.

3. Remove the CAM angle sensor. See the section Remove above.

4.

7. Measure the voltage between terminal A and terminal D. See Figure 12.

8. Rotate the CAM angle sensor drive by hand and verify the output signal. If not as specified, inspect the related wiring harnesses for open or short. If wiring harnesses are okay, replace the CAM angle sensor.

Specification: 1 pulse (5 V)/rev.

9. Install the CAM angle sensor and set engine timing. See the section Install above.

10. Connect all the ignition coil electrical connectors as tagged.

11. Connect the fuel injector connector.

Connect the CAM angle sensor 4-pin connector.

1. CAM ANGLE SENSOR 2. CAM ANGLE SENSOR CONNECTOR (ON CAM ANGLE SENSOR) 3. 4-PIN ELECTRICAL CONNECTOR Figure 12. CAM Angle Sensor Voltage Check

7

CLEAN

WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s recommended safety procedures.

CAUTION DO NOT damage machined surfaces when cleaning.

Clean all parts in solvent. Make sure all oil passages are clean and all machined surfaces are smooth.

INSPECT AND REPAIR Cylinder Head 1. Use straight edge and thickness gauge to check bottom surface of cylinder head for distortion. Do the measurements at the positions shown in Figure 13.

Maximum amount of distortion is 0.15 mm (0.0059 in.). If grinding of cylinder head is necessary, maximum amount of correction is 0.2 mm (0.008 in.).

Figure 13. Cylinder Head Inspection

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2. For the intake and exhaust manifold mounting surfaces, use the same inspection procedures and correct if there are any faults.

Maximum amount of distortion is 0.15 mm (0.0059 in.). If grinding of cylinder head is necessary, maximum amount of correction is 0.2 mm (0.008 in.).

Rocker Shaft Assembly 1. Disassemble rocker shaft assembly. Put marks on rocker arms so they can be installed on correct shafts.

2. Clean oil passages in rocker shafts and rocker arms.

3. Check clearance between rocker arms and rocker shafts. Maximum clearance is 0.10 mm (0.004 in.).

Correct dimension for inside diameter of rocker arms 16.000 to 16.027 mm (0.6299 to 0.6311 in.).

Correct dimension for outside diameter of rocker shaft is 15.966 to 15.984 mm (0.6286 to 0.6293 in.).

If components do not meet specifications, replace rocker arm(s) or rocker shaft(s) as necessary.

Camshaft 1. Check camshaft for cracks or damage.

2. Use dial indicator on end of camshaft to check movement of camshaft in cylinder head. See Figure 14. Maximum movement is 0.20 mm (0.008 in.).

1.

2.

3.

4.

FRONT OIL SEAL SURFACE FRONT JOURNAL (NO. 1) CENTER JOURNALS (NOS. 2, 3, AND 4) REAR JOURNAL (NO. 5) Figure 15. Camshaft Inspection

Figure 14. Camshaft Check 3. Measure height of camshaft lobes. See Figure 15. Minimum height of intake and exhaust lobes is 37.170 mm (1.4634 in.).

4. Measure camshaft journals at four points (A-D) as shown in Figure 15. Minimum journals are as follows: • Front and Rear Journals (Nos. 1 and 5) -31.940 to 31.965 mm (1.2575 to 1.2585 in.)

• Center Journals (Nos. 2, 3 and 4) - 31.910 to 31.935 mm (1.2563 to 1.2573 in.)

• Front Oil Seal Surface - 33.961 to 34.000 mm (1.3371 to 1.3386 in.)

5. Check camshaft for straightness. Put front and rear journals in V blocks and rotate camshaft one complete turn. See Figure 16. Maximum amount that the dial indicator should indicate is 0.03 mm (0.0012 in.).

1. PLASTIC GAUGE 2. SCALE Figure 17. Camshaft Clearance Measurement

Figure 16. Camshaft Check 6. Measure clearance between camshaft and bore in cylinder head as follows: a. Install camshaft in cylinder head. b. Put plastic gauge material between each camshaft journal and cap. Do not allow camshaft to rotate. c. Tighten capscrews for caps to 18 to 27 N•m (13 to 20 lb. ft.).

Correct clearance for journals No. 1 and 5 is 0.035 to 0.085 mm (0.0014 to 0.0033 in.). Correct clearance for journals No. 2, 3, and 4 is 0.065 to 0.115 mm (0.0026 to 0.0045 in.). If any clearances are greater than 0.15 mm (0.0059 in.), replace cylinder head assembly. Figure 17.

7. Replace camshaft if there is any damage or if it does not meet specifications.

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Valve Guides 1. Measure clearance between valve stems and valve guides.

Normal clearance for intake valve guides is 0.025 to 0.060 mm (0.001 to 0.002 in.).

Normal clearance for exhaust valve guides is 0.030 to 0.065 mm (0.0012 to 0.0026 in.).

If clearance is more than 0.10 mm (0.004 in.), replace valve or valve guide.

2. If replacement is necessary, remove seal from valve guide(s). Then use tool to remove valve guide(s) from the combustion chamber side.

3. To install valve guide, install retaining ring on valve guide. Use valve guide installation tool to install valve guide so that retaining ring contacts cylinder head. See Figure 18.

Correct height of valve guide above valve spring seat is 19.1 to 19.6 mm (0.75 to 0.77 in.).

A. EXHAUST B. INTAKE 1. VALVE SEAT WIDTH 2. EXHAUST VALVE SEAT 3. INTAKE VALVE SEAT Figure 19. Valve Seat Specifications Valves 1. Measure length of each valve.

Minimum length for intake valve is 111.19 mm (4.378 in.).

Minimum length for exhaust valve is 110.99 mm (4.370 in.).

2. Inspect stem of each valve for wear. Use micrometer to measure outside diameter of stem at different points (A - E). See Figure 20.

Minimum dimension for intake valve is 7.980 mm (0.3142 in.). Minimum dimension for exhaust valve is 7.975 mm (0.3140 in.).

1. CYLINDER HEAD 2. RETAINING RING 3. VALVE GUIDE Figure 18. Valve Guide Inspection Valve Seats 1. Inspect condition of valve seats. If valve seats have cracks, cylinder head must be replaced.

2. If valve seats are in good condition, check contact pattern of valve and valve seat. Use valve seat grinder to make sure valve seats are within specifications shown in Figure 19. Use valve compound to make sure valves fit seats.

1. VALVE STEM 2. THICKNESS, VALVE HEAD Figure 20. Valve Inspection

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3. Inspect valves for cracks, burned faces, and distortion.

Inspect seat face of valves for wear and damage.

4. Measure thickness of valve head. Minimum thickness for intake valve is 0.5 mm (0.020 in.).

Minimum thickness for exhaust valve is 1.0 mm (0.040 in.).

If valves need grinding, correct surface angle is 30° for both intake and exhaust valves Valve Springs 1. Check valve springs for damage.

2. Measure free length of valve springs. See Figure 17.

Minimum length of inner valve spring is 46.3mm (1.823 in.). Minimum length of outer valve spring is 50.6 mm (1.992 in.).

3. Check valve springs for squareness. See Figure 21. Correct squareness of inner valve spring is 1.66 mm (0.065 in.).

Correct squareness of outer valve spring is 1.82 mm (0.072 in.).

If measurement is more than specification, replace valve spring(s).

2. Using the appropriate seal installer tool, insert valve seals into valve guides. See Figure 22.

1.

2.

3.

4.

TOOL CYLINDER HEAD VALVE GUIDE VALVE SEAL Figure 22. Valve Seal Installation

3. Use valve spring compressor to install valve retainers, springs, and valves into head. See Figure 23.

Figure 23. Valve Installation

A. MEASURE HERE Figure 21. Valve Springs Inspection

4. Install new gasket and cylinder head on engine block.

5. Install capscrews and washers for cylinder head.

Tighten capscrews to 82 to 88 N•m (60 to 65 lb. ft.) in proper sequence. See Figure 24.

INSTALL 1. Clean surface of cylinder head and surface of engine block.

Figure 24. Cylinder Head Installation

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6. Apply gasket sealer to areas shown by arrows.

Lubricate camshaft with clean engine oil. Then install camshaft. Make sure dowel pin is at top of camshaft.

See Figure 25.

8. Tighten capscrews for rocker shaft supports to 18 to 27 N•m (13 to 20 lb. ft.) in proper sequence. See Figure 26.

Figure 26. Rocker Shaft Assembly Installation 9. If necessary, install oil seal in front housing. See Figure 27. Use new gasket and install front housing on cylinder head. Tighten capscrews for front housing to 19 to 26 N•m (168 to 230 lb. in).

1. DOWEL PIN 2. APPLY SEALANT HERE Figure 25. Camshaft Installation

7. Assemble rocker shaft assembly. See Figure 25.

Lubricate rocker arms and shafts with engine oil. Put capscrews in rocker shaft supports. Then install assembly on cylinder head

1. FRONT HOUSING 2. GASKET 3. OIL SEAL Figure 27. Front Housing 10. With dowel pin at top of camshaft, install camshaft pulley.

Check that number 1 on pulley is positioned approximately 2.5° in the retard direction A. NO. 1 AND NO. 3 ARE THE SAME B. NO. 2 AND NO. 4 ARE THE SAME Figure 25. Rocker Shaft Assembly

12

11. Install capscrew and washer for camshaft pulley.

See Figure 28. Keep pulley from turning and tighten capscrew to 48 to 66 N•m (35 to 49 lb. ft.).

14. Clean any oil or grease from pulleys. Install timing belt so that it goes in same direction as mark made during removal 15. Loosen lock bolt and apply spring tension on belt. Rotate crankshaft pulley clockwise two complete turns and check timing marks.

If timing marks are correct, tighten lock bolt for tensioner to 20 to 35 N•m (15 to 26 lb. ft.). Be sure tensioner does not move together with lock bolt rotation. Check movement on tension side of timing belt. See Figure 30.

If tension is correct, belt will move 9 to 10 mm (0.36 to 0.39 in.) with 10 kg (22 lb.) of force.

1. TIMING MARKS 2. CAMSHAFT PULLEY Figure 28. Camshaft Pulley Installation

12. Align timing marks for crankshaft timing pulley.

See Figure 29.

1. TENSIONER 3. LOCK BOLT 2. SPRING 4. TENSION SIDE Figure 30. Timing Belt Installation 16. Install lower timing belt cover and new gasket.

Tighten capscrews to 7 to 8 N•m (5 to 6 lb. ft.).

Install upper timing belt cover and new gasket.

Tighten capscrews to 8 to 12 N•m (6 to 9 lb. ft.). See Figure 31.

1. CRANKSHAFT TIMING PULLEY 2. TIMING MARK

17. Install crankshaft pulley and six capscrews to retain pulley. Tighten pulley to 12 to 17 N•m (9 to 13 lb. ft.

Figure 29. Timing Belt Installation 13. Install timing belt tensioner and spring. Move tensioner fully toward intake side of engine and temporarily tighten lock bolt. .

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22. Install bracket for cooling fan.

23. Install coolant hoses.

24. Install air cleaner, throttle linkage (if equipped), intake manifold, and exhaust manifold.

CAUTION Additives may damage the cooling system. Before using additives, contact your local dealer 25. Fill cooling system.

26. Connect connections at battery.

1. LOWER TIMING BELT COVER 2. UPPER TIMING BELT COVER 3. TIMING BELT TENSIONER Figure 31. Timing Belt Covers

18. Apply gasket sealer to the areas shown in Figure 32. Install new gasket and valve cover.

Figure 32. Valve Cover Installation 19. Install valve cover capscrews and tighten to 6 to 8 N•m (52 to 70 lb. in).

20. Install spark plugs in cylinder head. Tighten spark plugs to 15 to 23 N•m (11 to 16 lb. ft.).

21. Install the CAM angle sensor. See section CAM

ANGLE SENSOR, ENGINES

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GAS

AND

LPG

Crankshaft and Main Bearings Repair REMOVE 1.

Remove the V belt.

2.

Remove the cooling fan.

3.

Remove bracket for cooling fan.

4. Remove six capscrews that hold crankshaft pulley to timing pulley.

5.

9. Before removing crankshaft, measure clearance between crankshaft and flange of center main bearing. See Figure 34. Push crankshaft fully forward before making measurement.

Maximum clearance is 0.30 mm (0.012 in.). If clearance is greater than specification, replace center main bearing or grind crankshaft and install new main bearing.

Remove capscrew from crankshaft timing pulley.

Install special tool with spacer on crankshaft to remove timing pulley. Rotate tool until it touches front of crankshaft. Hit tool with hammer to loosen timing pulley. Remove pulley, dowel pin, tapered ring, and spacer. Remove tool. See Figure 33.

1. CENTER MAIN BEARING 1. SPACER 2. TOOL Figure 33. Crankshaft Timing Pulley Removal 6.

Remove oil pan and oil strainer.

Figure 34. Crankshaft Clearance Measurement 10. Put identification marks on bearing caps. Loosen capscrews for main bearing caps in steps. Then remove capscrews, caps, and crankshaft.

7. Remove rear cover. Remove front cover with oil pump.

8. Remove caps for connecting rods. Put identification mark on each cap so they will be installed in correct location.

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Crankshaft

3. Check crankshaft for straightness. See Figure 35.

Put front and rear journals in V blocks and rotate crankshaft one complete turn. Maximum amount that dial indicator should indicate is 0.03 mm (0.0012 in.).

1. Inspect crankshaft for wear, cracks, or other damage. Replace crankshaft if it has cracks.

4. Check oil passages crankshaft. Make sure passages are clean and have no restrictions.

INSPECT AND REPAIR

2. Use micrometer to measure diameter of journals for crankshaft. See Figure 35. Make measurement at several locations for each journal. Correct dimensions for journals are as follows: Main Journal Diameter - 59.937 to 59.995 mm (2.3597 to 2.3620 in.)

Connecting Rod Journals - 50.940 to 50.955 mm (2.0055 to 2.0061 in.)

Rear Oil Seal Surface - 89.946 to 90.000 mm (3.5412 to 3.5433 in.)

Front Oil Seal Surface - 33.961 to 34.000 mm (1.3371 to 1.3386 in.)

If measurements are less than specifications, grind crankshaft and install oversize bearings. Refer to the Parts Manual for the different bearing sizes.

Main Bearings NOTE: Inspect main bearings for damage. If any main bearing is damaged, all main bearings must be replaced.

1. To inspect main bearings for wear, measure clearance between main bearings and crankshaft using plastic gauge. See Figure 36. a.

Reinstall crankshaft in cylinder block.

b. Put plastic gauge material on journals and install main bearing caps. Tighten capscrews for bearing caps to 84 to 90 N•m (62 to 66 lb. ft.). c. Remove bearing caps. Plastic gauge material will adhere to journals or bearing caps. d. Use graduations on scale to measure width of plastic gauge material at its widest point.

Correct clearance for journals No.1, 2, 4, and 5 is 0.025 to 0.043 mm (0.00099 to 0.00169 in.).

Correct clearance for journal No. 3 is 0.031 to 0.049 mm (0.00123 to 0.00192 in.).

If any clearance is greater than specification, replace all main bearings.

1.

2.

3.

4.

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REAR OIL SEAL SURFACE CONNECTING ROD JOURNALS MAIN BEARING JOURNALS FRONT OIL SEAL SURFACE Figure 35. Crankshaft Inspection

1. PLASTIC GAUGE MATERIAL 2. SCALE Figure 36. Main Bearings Clearance Check

INSTALL 1. Clean areas of cylinder block around main bearings. Carefully install bottom half of new main bearings if necessary. Lubricate bearings with clean engine oil.

2.

7. Install new gasket and rear cover. See Figure 37.

Make sure dowel pin is installed. Tighten cap- screws to 8 to 12 N•m (70 to 106 lb. in). Cut off part of gasket that extends past bottom of cylinder block.

8. Install oil strainer. Tighten capscrews to 8 to 12 N•m (70 to 106 lb. in).

Install crankshaft.

3. Install top half of main bearings in caps and lubricate with oil. Use identification marks to install main bearing caps in correct locations. Tighten capscrews for main bearing caps to 84 to 90 N•m (62 to 66 lb. ft.).

9. Apply adhesive sealant to a new oil pan gasket and install new gasket and oil pan. Tighten capscrews to 8 to 12 N•m (71 to 106 lb. in).

4. Install pistons and connecting rods as described in Pistons and Connecting Rods Repair.

5. Make sure O-ring is in oil pump housing.

Lubricate oil seal with engine oil. Use adhesive sealant to install housing to cylinder block. Make sure there is no sealant in oil port. Tighten M10 capscrews to 38 to 53 N•m (28 to 39 lb. ft.). Tighten M8 capscrews to 19 to 26 N•m (14 to 19 lb. ft.).

6. Lubricate surfaces of oil seal with engine oil.

Use press to install oil seal in rear cover. Install alignment pin in cylinder block.

1. REAR COVER 2. OIL SEAL 3. CRANKSHAFT Figure 37. Rear Cover

Pistons and Connecting Rods Repair REMOVE AND DISASSEMBLE 1. Remove cylinder head as described in Cylinder Head, Camshaft, and Valve Mechanism Repair.

2.

NOTE: Measure and record the pin depth in the piston for correct reassembly.

6. Push connecting rod and piston from cylinder block.

Remove oil pan and oil strainer.

7. Carefully remove piston rings from pistons. Use tool to push piston pin from connecting rod.

CAUTION DO NOT damage top of piston when placing identification mark. DO NOT place a deep identification mark in top of piston.

CLEAN

3.

Put identification mark on top of each piston.

4.

Clean carbon from top of each cylinder bore.

Cleaning solvents can be flammable and toxic and can cause skin irritation.

When using cleaning solvents, always follow solvent manufacturer’s recommended safety procedures.

5. Remove caps and bearings from each connecting rod. Keep caps and bearings with correct piston assemblies.

WARNING

Clean all parts in solvent. Make sure all oil passages and grooves are clean. Make sure all machined surfaces are smooth.

17

INSPECT AND REPAIR Pistons 1. Inspect pistons for wear and cracks. Replace any piston that is damaged.

2. Measure outside diameter of piston. See Figure 38. Correct dimension is 85.943 to 85.965 mm (3.3836 to 3.3844 in.). Maximum clearance between piston and cylinder bore is 0.15 mm (0.0059 in.).

Maximum amount of distortion per 50 mm (1.97 in.) is 0.18 mm (0.007 in.).

Maximum amount of bending per 50 mm (1.97 in.) is 0.075 mm (0.003 in.).

If amount of distortion is greater than specification, install new connecting rod.

Figure 38. Piston Measurement

Piston Rings 1. Install piston ring into cylinder bore where it will be used. Use thickness gauge to measure amount of end clearance of each piston ring. See Figure 39.

Correct dimensions are as follows: Top Piston Ring - 0.20 to 0.35 mm (0.008 to 0.014 in.)

2nd Piston Ring - 0.15 to 0.30 mm (0.006 to 0.012 in.)

Oil Ring - 0.20 to 0.70 mm (0.008 to 0.027 in.)

Maximum clearance is 1.0 mm (0.039 in.)

2. Measure clearance between piston ring and groove in piston. See Figure 39. Correct dimensions are as follows: Top Piston Ring - 0.03 to 0.07 mm (0.0012 to 0.0028 in.)

2nd Piston Ring - 0.03 to 0.07 mm (0.0012 to 0.0028 in.)

Maximum clearance is 0.15 mm (0.0059 in.)

Connecting Rods and Bearings 1. Use alignment tool to check connecting rods for straightness. Contact your local machine shop.

18

1. PISTON RING END CLEARANCE 2. PISTON RING GROOVE CLEARANCE Figure 39. Piston Rings Measurement 2. Clean rod bearings and crankshaft journals. To check bearings for wear, measure clearance between rod bearings and journals. See Figure 40. a. Put plastic gauge material on crankshaft journals and install rod caps. Tighten capscrews for rod caps to 51 to 56 N•m (48 to 51 lb. ft.). Do not rotate connecting rod. b. Remove rod caps. Plastic gauge material will adhere to journals or rod caps. c. Use graduations on scale to measure width of plastic gauge material at its widest point.

Correct clearance is 0.027 to 0.067 mm (0.0011 to 0.0026 in.). If any clearance is greater than specification, replace all rod bearings.

1. PLASTIC GAUGE 2. SCALE Figure 40. Connecting Rod Bearings Clearance Check

ASSEMBLE AND INSTALL 1. Align oil port on large end of connecting rod with F mark on piston. See Figure 41. Lubricate piston pin and bore in piston with engine oil.

A. Oil Control Ring B. Top and Second Rings 1. Expander Ring 4. Top Ring 2. Oil Ring (Upper) 5 Second Ring 3. Oil Ring (Lower) Figure 42. Piston Rings 4. Apply clean engine oil to piston assembly. Install bearings for connecting rods. Install piston into correct cylinder, making sure F is toward front (timing belt end) of engine. See Figure 43.

1. F MARK 2. OIL PORT Figure 41. Connecting Rod and Piston 2. Use press to install piston pin. Amount of force required to push pin into piston must be 500 to 1500 kg (1102 to 3306 lb.). If force is not correct, replace piston pin and/or connecting rod.

Make sure piston pin is installed to correct depth, recorded earlier. After installation, check that piston moves freely on piston pin.

3. Install piston rings on pistons. During installation, writing on each piston ring must be toward top of piston. Check that rings rotate freely.

Then put ends of rings in positions shown in Figure 42. Make sure ends of upper and lower oil control rings are each 30° from piston pin. Also make sure that top and second rings are each 30° from piston pin. Lubricate rings with engine oil.

1. F Mark Figure 43. Piston Installation 5. Apply clean engine oil to bearing. Then install each cap to correct connecting rod. During installation of caps, make sure to align identification marks that were made during disassembly. Tighten nuts for caps to 51 to 56 N•m (38 to 41 lb. ft.).

19

Cylinder Block Repair 1. After cylinder block is cleaned, check surface for distortion. See Figure 44.

If amount of distortion is greater than 0.15 mm (0.0059 in.), grind surface of cylinder block.

Maximum amount of correction permitted is 0.20 mm (0.008 in.).

2. Check cylinder bores for wear and damage.

Measure each bore. Correct dimension is 86.00 to 86.019 mm (3.3858 to 3.3866 in.). Wear limit above this dimension is 0.15 mm (0.0059 in.).

Repair cylinder block or use bigger pistons as necessary.

Reference 2012 Emission Certified LPG Fuel System 2.2L Mazda Engine Parts & Service Manual and 2012 Emission Certified Bi-Fuel System 2.2L Mazda Engine Parts & Service Manual.

Figure 44. Cylinder Block Inspection

20

Oil Pump Repair Before removing oil pump, replace sending unit with pressure gauge and check oil pressure. Minimum oil pressure at governed rpm is approximately 275 kPa (40 psi). If pressure is less than specification, oil pump or engine bearings need repair.

7. Loosen capscrews for timing belt tensioner and remove spring. Remove capscrews and timing belt tensioner.

8. Use chalk to mark direction of rotation of timing belt. See Figure 46. Remove timing belt.

REMOVE 1.

Remove the V belt.

2.

Remove the cooling fan.

3.

Remove bracket for cooling fan.

4. Remove six capscrews that hold crankshaft shaft pulley to timing pulley.

5. Remove upper and lower timing belt covers. See Figure 45.

6.

Align engine timing marks.

Figure 46. Timing Belt 9. Remove capscrew from crankshaft timing pulley.

Install special tool with spacer on crankshaft to remove timing pulley. Rotate tool until it touches front of crankshaft. Hit tool with hammer to loosen timing pulley. Remove pulley, dowel pin, tapered ring, and spacer. Remove tool. See Figure 47.

1. LOWER TIMING BELT COVER 2. UPPER TIMING BELT COVER 3. TIMING BELT TENSIONER

1. SPACER

2. TOOL

Figure 47. Crankshaft Timing Pulley Removal

Figure 45. Timing Belt Covers

21

CLEAN 10. Remove capscrews that hold oil pan to cylinder block. Remove oil pan.

11. Remove the capscrew retaining the oil strainer assembly and remove the oil strainer assembly.

12. Remove capscrews that hold front cover (pump housing) to cylinder block. Remove front cover and oil pump assembly.

WARNING Cleaning solvents can be flammable and toxic and can cause skin irritation. When using cleaning solvents, always follow the solvent manufacturer’s recommended safety procedures.

DISASSEMBLE 1.

Remove screws and pump cover. See Figure 48.

CAUTION DO NOT damage cleaning.

machined

surface

when

Clean all parts in solvent. Make sure all machined surfaces are smooth.

INSPECT 1. Check front cover (pump housing) and pump cover for wear or damage. Check plunger spring for damage.

2.

1. SCREW 2. COVER 3. OUTER GEAR 4. INNER GEAR 5. FRONT COVER (HOUSING) 6. OIL SEAL 7. PLUNGER 8. SNAP RING Figure 48. Oil Pump 2. Remove outer gear and inner gear from pump body.

3. Remove snap ring and plunger assembly from housing.

22

Measure parts of oil pump. See Figure 46.

a. Measure clearance between inner rotor tip and outer rotor. Maximum clearance is 0.18 mm (0.007 in.). If clearance is more than 0.18 mm (0.007 in.), repair as necessary. b. Measure clearance between housing and outer rotor. Correct clearance is 0.090 to 0.176 mm (0.0035 to 0.0069 in.). If clearance is more than 0.20 mm (0.008 in.), repair as necessary. c. Use straight edge to measure side clearance of rotors. Correct clearance is 0.03 to 0.09 mm (0.0012 to 0.0035 in.). If clearance is more than 0.10 mm (0.004 in.), repair as necessary.

1. CLEARANCE BETWEEN INNER ROTOR TOOTH TIP AND OUTER ROTOR 2. CLEARANCE BETWEEN HOUSING AND OUTER ROTOR 3. SIDE CLEARANCE OF ROTORS IN HOUSING Figure 49. Oil Pump Measurement

ASSEMBLE 1. Install oil seal in oil pump housing. Make sure front edge of oil seal is even with outer edge of housing. See Figure 48.

2. Lubricate gears with clean engine oil. Install gears in housing.

3. Install pump cover. Apply thread-locking compound on screws for pump cover. Then install screws.

4.

Install plunger assembly and snap ring.

INSTALL

1. O-RING

1. Install O-ring on oil pump housing. Use grease to hold O-ring in position. Lubricate oil seal with engine oil. See Figure 50.

3. Install new gasket for strainer and install strainer assembly. Tighten capscrews to 8 to 12 N•m (70 to 106 lb. in). See Figure 48

2. Use adhesive sealant to install oil pump housing on cylinder block. Make sure there is no sealant in oil port. Tighten M10 capscrews to 38 to 53 N•m (28 to 39 lb. ft.). Tighten M8 capscrews to 19 to 26 N•m (14 to 19 lb. ft.).

Figure 50. Oil Pump

4. Apply adhesive sealant to a new oil pan gasket and install new gasket and oil pan. Tighten capscrews to 8 to 12 N•m (70 to 106 lb. in). See Figure 51.

23

1. CAPSCREW 2. OIL STRAINER 3. CAPSCREW 4. OIL PAN

5. GASKET 6. CAPSCREW 7. GASKET 8. OIL PUMP Figure 51. Oil Strainer and Oil Pan

24

Cooling System Repair THERMOSTAT Replace 1.

FAN ASSEMBLY Remove and Disassemble

Drain cooling system to level of thermostat.

2. Disconnect hose and remove thermostat housing.

Remove thermostat. See Figure 52.

1.

Loosen alternator and remove fan belt.

2. Remove capscrews for fan. Remove fan and pulley from hub.

3. Remove capscrews that hold fan bracket to engine. Remove fan bracket.

4. Use press to remove fan hub from shaft. Remove snap ring, push bearing, and shaft from bracket. See Figure 53.

1.

2.

3.

4.

CYLINDER BLOCK GASKET THERMOSTAT HOUSING

Figure 52. Thermostat 3. Test operation of thermostat Thermostat must begin to open at 82 ±1.5°C (180 ±3°F). Thermostat must be completely open at 95°C (203°F).

4. Install thermostat and new gasket. Make sure print side of gasket is toward thermostat.

5. Install thermostat housing and tighten capscrews to 19 to 26 N•m (14 to 19 lb. ft.).

1. FAN 4. SNAP RING 2. PULLEY 5. SHAFT 3. HUB 6. BRACKET Figure 53. Fan Assembly

Assemble and Install CAUTION Additives may damage the cooling system. Before using additives, contact your dealer.

6. Connect hose and fill cooling system. Start engine and check for leaks.

1. Use press to install shaft and bearing in bracket.

See Figure 50. Push bearing in until it touches bracket. Install snap ring. Install hub on shaft.

2. Install bracket assembly on cylinder block.

Tighten M10 and M12 capscrews to 38 to 64 N•m (28 to 47 lb. ft.).

3. to

Install pulley and fan on hub. Tighten capscrews 27 N•m (20 lb. ft.).

25

4. Install fan belt. Adjust tension of the fan belt.

Check movement of fan belt between fan and alternator.

NOTE: Tension for belt is correct when it moves 17 to 19 mm (0.67 to 0.75 in.) with 10 kg (22 lb.) of force. Tighten alternator when tension is correct.

WATER PUMP Remove 1.

Drain cooling system.

2.

Loosen alternator and remove fan belt.

3. Remove capscrews for the fan. Remove fan and pulley from the hub.

4. Remove capscrews that hold fan bracket to engine. Remove fan bracket.

5. Remove six capscrews that hold crankshaft shaft pulley to timing pulley.

6. Remove upper and lower timing belt covers. See Figure 54.

7.

1. LOWER TIMING BELT COVER 2. UPPER TIMING BELT COVER 3. TIMING BELT TENSIONER Figure 54. Timing Belt Covers

Align engine timing marks.

8. Loosen capscrews for timing belt tensioner and remove spring. Remove capscrews and timing belt tensioner.

CAUTION DO NOT rotate the camshaft gear or the crankshaft gear while the timing belt is removed.

If either of the gears is moved, it will be necessary to align the timing marks.

9. Use chalk to mark direction of rotation of timing belt. See Figure 55. Then remove timing belt.

10. Disconnect hose at water pump. Remove capscrews for water pump. Then remove water pump from cylinder block.

26

Figure 55. Timing Belt

Install

6. Install coolant hoses. Fill cooling system with coolant.

1. Install water pump with a new gasket. Tighten capscrews to 19 to 26 N•m (14 to 19 lb. ft.).

7.

2. Clean any oil or grease from pulleys. Install timing belt so that it goes in same direction as mark made during removal.

WARNING

3. Loosen lock bolt and apply spring tension on belt. Rotate crankshaft pulley clockwise two complete turns and check timing marks.

If timing marks are correct, tighten lock bolt for tensioner to 38 to 53 N•m (28 to 39 lb. ft.). Check movement on tension side of timing belt. See Figure 56.

Start engine and check cooling system for leaks.

DO NOT remove the radiator cap from the radiator when the engine is hot. When the radiator cap is removed, the pressure is released from the system. If the system is hot, the steam and boiling coolant can cause burns. DO NOT remove the cover for the radiator when the engine is running.

8.

After engine has been operated, stop engine. If

If tension is correct, belt will move 9 to 10 mm (0.36 to 0.39 in.) with 10 kg (22 lb.) of force.

4. Install lower timing belt cover and gasket.

Tighten capscrews to 7 to 10 N•m (62 to 89 lb. in).

Install upper timing belt cover and gasket. Tighten capscrews to 7 to 10 N•m (62 to 89 lb. in). See Figure 54.

5. Install fan assembly as described in the procedure for Fan Assembly, Assemble and Install.

CAUTION Additives may damage the cooling system. Before using additives, contact your dealer.

coolant is hot, give engine time to cool. Check coolant level and add coolant if necessary.

1. TENSIONER 3. LOCK BOLT 2. SPRING 4. TENSION SIDE Figure 56. Timing Belt Installation

Flywheel and Ring Gear Repair REMOVE 1. Remove capscrews for flywheel. Then remove flywheel and adapter plate. See Figure 57.

2.

If necessary, remove flywheel housing.

INSTALL

2. Install adapter plate on crankshaft. Install the flywheel.

3. Apply Loctite® 222 or equivalent on threads of capscrews. Then install capscrews for flywheel.

Tighten capscrews to 96 to 103 N•m (71 to 76 lb. ft.) in proper sequence. See Figure 57.

1. If flywheel housing was removed, install it on engine. Tighten M14 capscrews to 114 to 136 N•m (84 to 100 lb. ft.). Tighten M10 Capscrews to 38 N•m (28 lb. ft.).

27

Legend for Figure 57 A. TIGHTENING SEQUENCE 1. FLYWHEEL HOUSING 2. WASHER 3. CAPSCREW 4. ADAPTER PLATE 5. CAPSCREW 6. WASHER 7. FLYWHEEL 8. PIN 9. CAPSCREW 10. CAPSCREW Figure 57. Flywheel Arrangement

Valve Adjustment 1. Rotate crankshaft until No. 1 piston is at TDC on compression stroke (intake and exhaust valves closed).

2. Adjust clearance of intake valves for No. 1 and No. 2 cylinders and exhaust valves for the No. 1 and No. 3 cylinders. See Figure 58. Correct clearance for intake valves when engine is cold is 0.15±0.05 mm (0.0059 ±0.002 in.). Correct clearance for exhaust valves when engine is cold is 0.35±0.05 mm (0.0138 ±0.002 in.).

To adjust clearance, loosen lock nut and turn adjustment screw. Tighten lock nut to 16 to 21 N•m (12 to 15 lb. ft.).

NOTE: During adjustment of valves, check position of balls in ends of rocker arms. Flat surface of ball must be in contact with stem of valve.

3. Rotate crankshaft clockwise one complete turn.

Adjust remaining valves.

Legend for Figure 58 A. INTAKE VALVES B. EXHAUST VALVES C. INTAKE (ENGINE COLD): 0.15 mm (0.0059 in.), EXHAUST (ENGINE COLD): 0.35 mm (0.0138 in.)

1. CAMSHAFT 2. ROCKER ARM 3. BALL 4. VALVESTEM

28

Figure 58. Valve Adjustment

Compression Pressure Check CAUTION When removing or installing the spark plugs from the aluminum cylinder head, it is important that you use care because of the dissimilar metals.

Penetrating oil may need to be used when removing the spark plugs. Apply a couple of drops of engine oil to the spark plugs before installation.

1. Remove spark plugs from cylinder head.

Disconnect high tension wire at ignition coil.

2. Install compression gauge in No. 1 cylinder.

Make sure gauge has minimum range of 1725 kPa (250 psi). See Figure 59.

3. Use starter to crank engine at least six revolutions. Check pressure reading and release pressure. Repeat test again and make note of highest pressure. Do this test for each cylinder.

The standard and minimum pressure specifications are shown in Table 1.

• If pressure reading does not increase, low pressure was caused by worn valves, valve seats, or valve guides.

• If low pressure readings are in two cylinders next to each other, cylinder head may be leaking.

Table 1. Pressure Specifications Pressure

Gasoline

Standard Pressure

1130 kPa (164 psi) @ 270 rpm 793 kPa (115 psi) @ 270 rpm

Minimum Pressure Maximum Difference Between Cylinders

LPG 1130 kPa (164 psi) @ 270 rpm 793 kPa (115 psi) @ 270 rpm

196 kPa (28 psi)

4. If the readings are lower than minimum reading, there is a problem with the valves, piston rings, or cylinder head gasket. Do the following tests to find the problem: a. Add approximately 30 ml (1.0 oz.) of engine oil to each cylinder at spark plug hole. b. Crank engine approximately 10 revolutions to distribute oil. c. Install compression gauge and do same tests as described in Step 3.

• If pressure reading increases to normal reading, low pressure was caused by worn or damaged piston rings. Cylinder bore may also be damaged.

1. ADAPTER Figure 59. Compression Pressure Check

29

Engine Timing Adjustment The base ignition timing is adjustable by rotating the cam angle sensor housing. To check or set the timing, perform the following procedures: 1.

Warm up the engine to normal operating temperature.

2.

Make sure all accessories are OFF.

3.

Verify t h e engine speed is between 500 to 900 rpm.

4.

Install a jumper wire a c r o s s the engine control unit (ECU) timing test port connector terminals

Engine Specifications ENGINE DATA Engine Type Bore × Stroke (2.2L) Displacement (2.2L) Firing Order Valve Clearance (Exhaust, Engine cold) Valve Clearance (Intake, Engine Cold) Compression Ratio Gasoline Compression Ratio LPG (2.2L) Compression Pressure Gasoline Compression Pressure LPG Maximum Difference Between Cylinders Engine Timing (No. 1 Cylinder): Gasoline LPG Oil Pressure @ 2400 rpm

In-line, Four Cylinders 86 mm (3.39 in.) ×94 mm (3.70 in.)

2184 cm 3 (133.2 in. 3) 1-3-4-2 0.35 ±0.05 mm (0.0138 ±0.002 in.)

0.15 ±0.05 mm (0.0059±0.002 in.)

8.6:1 10.1:1 1130 kPa (164 psi) @ 270 rpm 1130 kPa (164 psi) @ 270 rpm 196 kPa (28 psi) 6° BTDC (Orange Mark) 6° BTDC (Orange Mark) 226 to 362 kPa (33 to 53 psi)

2012 and Later, Emission Compliant Engines Engine Speed, 1.5 to 2 Ton Lift Trucks, 2.2L: Idle Speed Governed Speed Engine Speed, 2.0 to 3.5 Ton Lift Trucks, 2.2L: Idle Speed Governed Speed Stall Speed (New 2.2L Engine): Gasoline LPG Stall Speed (2.2L Engine with 30 Hours or More): Gasoline LPG

720 ±25 rpm 2400 ±25 rpm 720 ±25 rpm 2700 ±25 rpm 1990 ±100 rpm 2010 ±100 rpm 2010 ±100 rpm 2050 ±100 rpm

THERMOSTAT Starts to Open Fully Open

30

82 ±1.5°C (180 ±35°F) 95 ±1.5°C (203 ±35°F)

CYLINDER HEAD Height Distortion Limit Grinding Limit

91.95 to 92.05 mm (3.620 to 3.624 in.)

0.15 mm (0.006 in.)

0.20 mm (0.008 in.)

VALVE MECHANISM Inside Diameter of Valve Guide Clearance in Guide (Exhaust) Clearance in Guide (Intake) Service Limit (Intake and Exhaust) Valve Length (Intake) Service Limit Valve Length (Exhaust) Service Limit Diameter of Valve Stem (Intake) Service Limit Diameter of Valve Stem (Exhaust) Service Limit Valve Head Thickness (Intake) Valve Head Thickness (Exhaust) Valve Face Angle (Intake and Exhaust) Spring Free Length Outer Service Limit Spring Free Length Inner Service Limit Spring Out of Square Outer Spring Out of Square Inner Rocker Arm Shaft Diameter Rocker Arm Bore Diameter Clearance between Rocker Arm and Shaft Service Limit

8.07 to 8.09 mm (0.3177 to 0.3185 in.)

0.030 to 0.065 mm (0.0012 to0.0026 in.)

0.025 to 0.060 mm (0.001 to 0.0024 in.)

0.10 mm (0.004 in.)

111.49 to 112.29 mm (4.390 to 4.420 in.)

111.19 mm (4.378 in.)

111.29 to 112.09 mm (4.382 to 4.412 in.)

110.99 mm (4.370 in.)

8.03 to 8.045 mm (0.3161 to 0.3167 in.)

7.980 mm (0.3142 in.)

8.025 to 8.045 mm (0.3159 to 0.3167 in.)

7.975 mm (0.3140 in.)

0.5 mm (0.020 in.)

1.0 mm (0.040 in.)

30° 52.2 mm (2.055 in.)

50.6 mm (1.992 in.)

47.7 mm (1.878 in.)

46.3 mm (1.823 in.)

More than 1.82 mm (0.072 in.)

More than 1.66 mm (0.065 in.)

15.966 to 15.984 mm (0.6286 to 0.6293 in.)

16.000 to 16.027 mm (0.6299 to 0.6311 in.)

0.016 to 0.061 mm (0.0006 to 0.0024 in.)

0.10 mm (0.004 in.)

CAMSHAFT Runout Cam Lobes to Production Limit Cam Lobes to Service Limit Bearing Journals (Nos. 1 and 5) Bearing Journals (Nos. 2, 3, and 4) Bearing Journal Wear Limit Clearance between Journals and Bore (Nos. 1 and 5) Clearance between Journals and Bore (Nos. 2, 3, and 4) Service Limit End Clearance Service Limit

Less than 0.03 mm (0.0012 in.)

37.370 mm (1.4713 in.)

37.170 mm (1.4634 in.)

31.940 to 31.965 mm (1.2575 to 1.2585 in.)

31.910 to 31.935 mm (1.2563 to 1.2573 in.)

0.03 mm (0.0012 in.)

0.035 to 0.085 mm (0.0014 to 0.0033 in.)

0.065 to 0.115 mm (0.0026 to 0.0045 in.)

0.15 mm (0.006 in.)

0.08 to 0.16 mm (0.003 to 0.006 in.)

0.20 mm (0.008 in.)

31

CRANKSHAFT Runout Main Bearing Journal Diameter, Standard Service Limit 0.25 mm (0.01 in.) Undersize (Nos. 1, 2, 4, and 5) 0.25 mm (0.01 in.) Undersize (No. 3) 0.50 mm (0.02 in.) Undersize (Nos. 1, 2, 4, and 5) 0.50 mm (0.02 in.) Undersize (No. 3) 0.75 mm (0.03 in.) Undersize (Nos. 1, 2, 4, and 5) 0.75 mm (0.03 in.) Undersize (No. 3 Grinding Limit Clearance between Journals and Main Bearings (Nos. 1, 2, 4, and 5) Clearance between Journals and Main Bearings (No. 3) Service Limit

0.031 to 0.049 mm (0.0012 to 0.0019 in.)

0.08 mm (0.003 in.)

Connecting Rod Journal Diameter, Standard 0.25 mm (0.01 in.) Undersize 0.50 mm (0.02 in.) Undersize 0.75 mm (0.03 in.) Undersize 0.25 mm (0.01 in.) Undersize (Nos. 1, 2, 4, and 5) Service Limit Grinding Limit

50.940 to 50.955 mm (2.0055 to 2.0061 in.)

50.690 to 50.705 mm (1.9957 to 1.9962 in.)

50.440 to 50.455 mm (1.9859 to 1.9864 in.)

50.190 to 50.205 mm (1.9760 to 1.9765 in.)

59.679 to 59.736 mm (2.3496 to 2.3518 in.)

0.05 mm (0.002 in.)

0.75 mm (0.030 in.)

Thrust Bearing Thickness, Standard 0.25 mm (0.01 in.) Undersize 0.50 mm (0.02 in.) Undersize 0.75 mm (0.03 in.) Undersize

27.94 to 27.99 mm (1.1000 to 1.1019 in.)

28.04 to 28.09 mm (1.1040 to 1.1060 in.)

28.12 to 28.17 mm (1.1071 to 1.1090 in.)

28.20 to 28.25 mm (1.1103 to 1.1122 in.)

Thrust Bearing Clearance Service Limit

0.08 to 0.18 mm (0.003 to 0.007 in.)

0.30 mm (0.012 in.)

less than 0.03 mm (0.0012 in.)

59.937 to59.955 mm (2.3597 to 2.3604 in.)

0.05 mm (0.002 in.)

59.679 to 59.736 mm (2.3496 to 2.3518 in.)

59.673 to 59.730 mm (2.3494 to 2.3515 in.)

59.429 to 59.486 mm (2.3398 to 2.3419 in.)

59.423 to 59.480 mm (2.3395 to 2.3417 in.)

59.179 to 59.236 mm (2.3299 to 2.3321 in.)

59.173 to 59.230 mm (2.3297 to 2.3318 in.)

0.75 mm (0.030 in.)

0.025 to 0.043 mm (0.000099 to 0.00169 in.)

CONNECTING RODS Distortion Limit 0.18 mm (0.007 in.) per 50 mm (1.97 in.)

Bending Limit 0.075 mm (0.003 in.) per 50 mm (1.97 in.)

21.943 to 21.961 mm (0.8639 to 0.8646 in.)

Small End Bore 0.037 to 0.013 mm (0.0014 to 0.0006 in.)

Interference between Piston Pin and Bore Clearance Between Crankshaft Journals 0.027 to 0.067 mm (0.0011 to 0.0026 in.) and Rod Bearings Service Limit ............... 0.10 mm (0.004 in.)

32

CYLINDER BLOCK Distortion at Top Surface Grinding Limit Bore Diameter Wear Limit

0.15 mm (0.0059 in.)

0.20 mm (0.008 in.)

86.00 to 86.019 mm (3.3858 to 3.3866 in.)

0.15 mm (0.0059 in.)

PISTONS Diameter, Standard

85.945 to 85.965 mm (3.3836 to 3.3844 in.)

0.25 mm (0.01 in.) Oversize 0.50 mm (0.02 in.) Oversize

86.193 to 86.215 mm (3.394 to 3.3943 in.)

86.44. to 86.465 mm (3.4033 to 3.4041 in.)

Clearance between Piston and Bore Service Limit

0.035 to 0.076 mm (0.0014 to 0.0030 in.)

21.988 to 21.998 mm (0.8657 to 0.8660 in.)

Groove Width for Piston Rings Nos. 1 and 2

1.520 to 1.540 mm (0.0598 to 0.0606 in.)

Groove Width for Oil Ring

4.020 to 4.040 mm (0.1583 to 0.1591 in.)

Piston Ring Clearance in Groove (Nos. 1 and 2) Service Limit Piston Ring End Clearance: Top Ring Second Ring Oil Control Ring Service Limit (All Rings)

0.03 to 0.07 mm (0.0012 to 0.0028 in.)

0.15 mm (0.0059 in.)

0.20 to 0.35 mm (0.008 to 0.014 in.)

0.15 to 0.30 mm (0.006 to 0.012 in.)

0.20 to 0.70 mm (0.008 to 0.027 in.)

1.0 mm (0.039 in.)

OIL PUMP Clearance between Inner Rotor Tip and Outer Rotor Service Limit 0.18 mm (0.007 in.)

Clearance between Housing and Outer Rotor Service Limit

0.090 to 0.176 mm (0.0036 to 0.0069 in.)

0.20 mm (0.008 in.)

Side Clearance between Rotors and Housing Service Limit

0.03 to 0.09 mm (0.0012 to 0.0035 in.)

0.10 mm (0.004 in.)

Torque Specifications Camshaft Pulley Lock Bolt

48 to 66 N•m (35 to 49 lb. ft.)

Camshaft Cap

18 to 27 N•m (13 to 20 lb. ft.)

Cooling Fan

27 N•m (20 lb. ft.)

Connecting Rod Cap

66 to 70 N•m (49 to 52 lb. ft.)

Crankshaft Pulley

12 to 17 N•m (9 to 13 lb. ft.)

33

34

Cylinder Head

81 to 88 N•m (60 to 65 lb. ft.)

Engine Mount to Engine

55 N•m (41 lb. ft.)

Engine Mount Capscrew

150 N•m (111 lb. ft.)

Exhaust Manifold

22 to 29 N•m (16 to 21 lb. ft.)

Flywheel

96 to 103 N•m (71 to 76 lb. ft.)

Flywheel Housing Front Housing

M10 Capscrews 38 N•m (28 lb. ft.)

M14 Capscrews 114 to 136 N•m (84 to 100 lb. ft.)

19 to 26 N•m (14 to 19 lb. ft.)

Heat Gauge Unit

11.8 to 17.6 N•m (105 to 156 lb. in)

Intake Manifold

19 to 31 N•m (14 to 23 lb. ft.)

Main Bearing Cap

84 to 90 N•m (62 to 66 lb. ft.)

Oil Pan

8 to 12 N•m (71 to 106 lb. in)

Oil Pressure Switch

12 to 17 N•m (9 to 13 lb. ft.)

Oil Pan Drain Plug

30 to 41 N•m (22 to 30 lb. ft.)

Oil Pump

M8 Capscrews 19 to 26 N•m (14 to 19 lb. ft.)

M10 Capscrews 38 to 53 N•m (28 to 39 lb. ft.)

Oil Strainer

8 to 12 N•m (71 to 106 lb. in)

Rocker Cover

6 to 8 N•m (52 to 70 lb. in)

Rear Cover

8 to 12 N•m (70 to 106 lb. in)

Rocker Shaft Assembly

18 to 27 N•m (13 to 20 lb. ft.)

Spark Plugs

15 to 23 N•m (11 to 16 lb. ft.)

Starter

38 N•m (28 lb. ft.)

Thermostat Housing Capscrews

19 to 26 N•m (14 to 19 lb. ft.)

Timing Belt Cover Capscrews

7 to 10 N•m (62 to 89 lb. in)

Timing Belt Tension Lock Bolt

38 to 53 N•m (28 to 39 lb. ft.)

Timing Pulley Lock Bolt

157 to 167 N•m (116 to 123 lb. ft.)

Water Pump

19 to 26 N•m (14 to 19 lb. in)

NOTES

Utilev TECHNICAL PUBLICATIONS 3/12 (7/11)(5/10)(12/09)(8/09)(12/06)(8/05)(5/05)(12/04) Printed in U.S.A.

35