Mazda LF Wartungshandbuch

CONTENTSEngineWorkshopManualL8LFL3FOREWORDThis manual explains the disassembly, inspection, repair, and reassembly procedures for the above-indicated

GI–8FUNDAMENTAL PROCEDURES • Depending on location:— Sealant and gaskets, or both, should be applied to specified locations. When sealant is applied,

FUNDAMENTAL PROCEDURES GI–9GITORQUE FORMULASA6E201400004E15• When using a torque wrench-SST or equivalent combination, the written torque must be reca

GI–10ELECTRICAL SYSTEM ELECTRICAL PARTSA6E201700006E01Battery cable• Before disconnecting connectors or removing electrical parts, disconnect the nega

ELECTRICAL SYSTEM GI–11GI• Connectors can be disconnected by pressing or pulling the lock lever as shown.Locking connector• When locking connectors, l

GI–12ELECTRICAL SYSTEM TerminalsInspection• Pull lightly on individual wires to verify that they are secured in the terminal.Wiring HarnessWiring colo

NEW STANDARDS GI–13GINEW STANDARDSA6E202800020E01• Following is a comparison of the previous standard and the new standard.NEW STANDARDSNew Standard P

GI–14NEW STANDARDS #1 : Diagnostic trouble codes depend on the diagnostic test mode#2 : Controlled by the PCM#3 : In some models, there is a fuel pump

ABBREVIATIONS GI–15GIABBREVIATIONSA6E203000011E01End Of SieABBREVIATIONSMTX Manual transaxleATX Automatic transaxleATDC After top dead centerTDC Top d

B–1BBENGINEENGINE...B-2ENGINE OVERHAUL SERVICE WARNING ...B-2ENGINE MOUNTING/DISMOU

B–2ENGINE ENGINE OVERHAUL SERVICE WARNINGA6E242402000E01Warning••••Continuous exposure with USED engine oil has caused skin cancer in laboratory mice.

WARNINGServicing a vehicle can be dangerous. If you have not received service-related training, the risks of injury, property damage, and failure of s

ENGINE B–3BTIMING CHAIN DISASSEMBLYA6E242402000E041. Disassemble in the order indicated in the table..AME2224E3371 Spark plug2 Cylinder head cover 3 C

B–4ENGINE Crankshaft Pulley Lock Bolt Disassembly Note1. Hold the crankshaft using the SST.2. Remove the crankshaft pulley lock bolt.Front Oil Seal Di

ENGINE B–5BCYLINDER HEAD (I) DISASSEMBLYA6E242402000E051. Disassemble in the order indicated in the table.2..AME2224E0011 Camshaft sprocket lock bolt,

B–6ENGINE Camshaft Sprocket Lock Bolt, Variable Valve Timing Actuator Lock Bolt (L3 (with variable valve timing mechanism)) Disassembly Note1. Hold th

ENGINE B–7BTappet Disassembly NoteNote• The tappets are numbered to make sure they are assembled in their original positions. When removed, keep the t

B–8ENGINE Valve Keeper Disassembly Note1. Remove the valve keeper using the SSTs.Valve Seal Disassembly Note1. Remove the valve seal using the SST.End

ENGINE B–9BCYLINDER BLOCK (I) DISASSEMBLYA6E242402000E071. Disassemble in the order indicated in the table.2..AME2224E0111 Oil pan2 Oil filter cover 3

B–10ENGINE Drive Plate (ATX), Flywheel (MTX) Disassembly Note1. Hold the crankshaft using the SST.2. Remove the bolts in several passes.End Of SieCYLI

ENGINE B–11B.Connecting Rod Cap Disassembly Note1. Inspect the connecting rod side clearance. (See B–22 CONNECTING ROD INSPECTION .)2. Remove the conn

B–12ENGINE CYLINDER HEAD INSPECTIONA6E242410100E011. Carry out color contrast penetrate examination on the cylinder head surface. • Replace the cylind

GI–1GIGIGENERAL INFORMATIONHOW TO USE THIS MANUAL... GI-2RANGE OF TOPICS... GI-2SERVI

ENGINE B–13B3. Measure the stem diameter of each valve in X and Y directions at the three points (A, B, and C) as indicated in the figure. • If not as

B–14ENGINE VALVE GUIDE REPLACEMENTA6E242412111E04Valve Guide Removal1. Remove the valve guide from the combustion chamber side using the SST.Valve Gui

ENGINE B–15BVALVE SEAT INSPECTION/REPAIRA6E242410102E011. Measure the seat contact width.• If necessary, resurface the valve seat using a 45° valve s

B–16ENGINE 2. Measure the out-of-square of the valve spring, using a square, as shown.(1) Rotate the valve spring one full turn and measure "A&qu

ENGINE B–17B4. Measure the journal diameters in X and Y directions at the two points (A and B) as indicated in the figure.• If not as specified, repla

B–18ENGINE TAPPET INSPECTIONA6E242412310E011. Measure the tappet hole inner diameter in X and Y directions at the two points (A and B) shown.Inner dia

ENGINE B–19BEnd Of SieOIL JET VALVE INSPECTIONA6E242410730E021. Apply compressed air to oil jet valve A and verify that air passes through oil jet val

B–20ENGINE 4. Insert the piston ring into the cylinder by hand and use the piston to push it to the bottom of the ring travel.5. Measure each piston r

ENGINE B–21B5. Measure the journal diameter in X and Y directions at the two points (A and B) as indicated in the figure. • If not as specified, repla

B–22ENGINE End Of SieCONNECTING ROD INSPECTIONA6E242411211E01Caution•••• The piston, piston ring and connecting rod cannot be disassembled.•••• When r

GI–2HOW TO USE THIS MANUAL RANGE OF TOPICSA6E201000001E01• This manual contains procedures for performing all required service operations. The procedu

ENGINE B–23BLength LEnd Of SieVARIABLE VALVE TIMING ACTUATOR INSPECTIONA6E242400142E02L3 (with variable valve timing mechanism) Caution•••• Variable v

B–24ENGINE Spool valve operation inspection1. Disconnect the negative battery cable.2. Remove the oil control valve (OCV).3. Verify that the spool val

ENGINE B–25BEnd Of SieVALVE CLEARANCE ADJUSTMENTA6E242412111E031. Remove the engine front cover lower blind plug.2. Remove the engine front cover uppe

B–26ENGINE 7. Hold the exhaust camshaft using a suitable wrench on the cast hexagon as shown.8. Remove the exhaust camshaft sprocket.9. Loosen the cam

ENGINE B–27B15. Install the exhaust camshaft sprocket.Note• Do not tighten the bolt for the camshaft sprocket during this step. First confirm the valv

B–28ENGINE 25. Install the engine front cover upper blind plug.Tightening torque: 10 N·m {1.0 kgf·m, 7.4 ft·lbf}26. Install the cylinder block lower b

ENGINE B–29BCYLINDER BLOCK (I) ASSEMBLYA6E242402000E091. Assemble in the order indicated in the table.2..AME2224E0391 Oil jet valve2 Upper main bearin

B–30ENGINE Main Bearing Caps Assembly Note1. Install the main bearing caps in the order indicated in the figure.Tightening torque: (1) 44—46 N·m {4.5

ENGINE B–31BConnecting Rod Bearing Assembly Note1. Install the connecting rod bearing to the connecting rod and connecting rod caps, as shown in the f

B–32ENGINE 6. Set the SST as shown, then measure the gear backlash using a dial gauge.• If the backlash exceeds the specified range, remeasure the bac

HOW TO USE THIS MANUAL GI–3GI4.End Of SieSYMBOLSA6E201000001E03• There are eight symbols indicating oil, grease, fluids, sealant, and SST or equivalen

ENGINE B–33BEnd Of Sie0.172—0.178 {0.00677—0.00700}27 1.27 {0.499}0.032—0.038 {0.00125—0.00149}47 1.47 {0.0578}0.165—0.171 {0.00649—0.00673}28 1.28 {0

B–34ENGINE CYLINDER BLOCK (II) ASSEMBLYA6E242402000E101. Assemble in the order indicated in the table.2..AME2224E0431731-1E-02C.book 34 ページ ２００２年４月２

ENGINE B–35BRear Oil Seal Assembly Note1. Apply silicone sealant to the mating faces as shown.Dot diameter: 4.0—6.0 mm {0.16—0.23 in}2. Apply clean en

B–36ENGINE Drive Plate (ATX), Flywheel (MTX) Assembly Note1. Hold the crankshaft using the SST.2. Tighten the bolts in the order indicated in the figu

ENGINE B–37B3. Tighten the rear oil pan bolts in the order as shown.Tightening torque:20—30 N·m {2.1—3.0 kgf·m, 15.2—21.6 in·lbf}End Of SieCYLINDER HE

B–38ENGINE Valve Seal Assembly Note1. Press the valve seal onto the valve guide by hand.2. Lightly tap the SST using a plastic hammer.Valve Keeper Ass

ENGINE B–39BCYLINDER HEAD (II) ASSEMBLYA6E242402000E121. Assemble in the order indicated in the table.2..AME2224E0461 Cylinder head gasket2 Cylinder h

B–40ENGINE Cylinder Head Bolt Assembly Note1. Tighten the cylinder head bolts in the order indicated in the figure in six steps.(1) Tighten to 5.0 N·m

ENGINE B–41BEnd Of SieTIMING CHAIN ASSEMBLYA6E242402000E131. Assemble in the order indicated in the table.2..AME2224E3271 Crankshaft sprocket2 Oil pum

B–42ENGINE Oil Pump Sprocket Assembly Note1. Hold the oil pump sprocket using the SST.Timing Chain Aassembly Note1. Install the SST to the camshaft, t

GI–4HOW TO USE THIS MANUAL End Of SieADVISORY MESSAGESA6E201000001E04• You'll find several Warnings, Cautions, Notes, Specifications and Upper an

ENGINE B–43B6. Install the chain tensioner and remove the retaining wire.Camshaft Sprocket, Variable Valve Timing Actuator (L3 (with variable valve ti

B–44ENGINE Front Oil Seal Aassembly Note1. Apply clean engine oil to the oil seal.2. Push the oil seal slightly in by hand.3. Compress the oil seal us

ENGINE B–45B2. Install the cylinder head cover bolts in the order as shown.Crankshaft Pulley Lock Bolt Aassembly Note1. Install the SST to the camshaf

B–46ENGINE 4. Hold the crankshaft pully using the SST.5. Tighten the crankshaft pulley lock bolt in the following two steps.(1) Tighten to 96—104 N·m

TD–1TDTDTECHNICAL DATATECHNICAL DATA ... TD-2ENGINE TECHNICAL DATA ... TD-21731-1E-

TD–2TECHNICAL DATA ENGINE TECHNICAL DATAA6E931001001E01TECHNICAL DATAItemEngineL8 LFL3, L3 (with variable valve timing mechanism)Cylinder headCylinder

TECHNICAL DATA TD–3TDCamshaftCamshaft runout (mm {in}) Maximum 0.03 {0.0012}Cam lobe height (mm {in})StandardIN 40.79 {1.606} 42.12{1.659}42.12 {1.659

TD–4TECHNICAL DATA *: With variable valve timing mechanismEnd Of SieConnecting rod and connecting rod bearingConnecting rod side clearance(mm {in})Sta

ST–1STSTSPECIAL TOOLSSPECIAL TOOLS...ST-2ENGINE SST ...

ST–2SPECIAL TOOLS ENGINE SSTA6E941001001E01Ford SST numbers are collated with Mazda SST numbers in the example below.Ford SSTs are marked with Ford SS

UNITS GI–5GIUNITSA6E201200002E01Conversion to SI Units (Système International d'Unités)• All numerical values in this manual are based on SI unit

SPECIAL TOOLS ST–3STEnd Of Sie1:49 JE01 054 (Europe) 49 UN30 3376(Except Europe)2: 303–376Plate1:49 G011 2012: –Attachment–1731-1E-02C.book 3 ページ ２０

GI–6FUNDAMENTAL PROCEDURES PREPARATION OF TOOLS AND MEASURING EQUIPMENTA6E201400004E02• Be sure that all necessary tools and measuring equipment are a

FUNDAMENTAL PROCEDURES GI–7GIINSPECTION DURING REMOVAL, DISASSEMBLYA6E201400004E08• When removed, each part should be carefully inspected for malfunct