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Mazda 5. Manual - part 8

01–10–18

MECHANICAL

Maximum cylinder block distortion

0.10 mm {0.004 in}

2. Measure the cylinder bores in X and Y directions

at 42 mm {1.65 in} below the top surface.

• If not within the specification, replace the

cylinder block.

Standard diameter limit

L8: 83.000—83.030 mm {3.2677—3.2689 in}
Except L8: 87.500—87.530 mm {3.4449—

3.4460 in}

Minimum / maximum bore diameter limit

L8: 82.940—83.090 mm {3.2653—3.2712 in}
Except L8: 87.440—87.590 mm {3.4425—

3.4484 in}

End Of Sie

OIL JET VALVE INSPECTION

B3E011010730201

1. Apply compressed air to oil jet valve A and verify that air passes through oil jet valve B.

• If air does not flow, replace the oil jet valve.

Air pressure

216—274 kPa {2.2—2.7 kgf·cm

31.4—39.7

psi}

End Of Sie

PISTON INSPECTION

B3E011011010201

Caution

• The piston, piston ring and connecting rod cannot be disassembled.

• When replacing the piston, piston pin, piston ring and connecting rod, replace them together as a

single unit.

1. Measure the outer diameter of each piston at right angle 90

° to the piston pin, 10.0 mm {0.40 in} above the

under of the piston.

• If not within the specification, replace the piston, piston pin, piston ring and connecting rod as a single unit.

Piston diameter

L8: 82.965—82.995 mm {3.2664—3.2675 in}
Except L8: 87.465—87.495 mm {3.4435—

3.4446 in}

2. Measure the piston-to-cylinder clearance.

• If not within the specification, replace the

piston, piston pin, piston ring and connecting
rod as a single unit.

Standard clearance

0.022—0.047 mm {0.0009—0.0018 in}

ADJ2224E089

42 mm {1.65 in}

D6E110ZE1009

B3E0110E079

B3E0110E080

MECHANICAL

01–10–19

Maximum clearance

0.11 mm {0.0043 in}

3. Measure the piston ring-to-ring groove clearance around the entire circumference.

• If it exceeds the specification, replace the piston, piston pin, piston ring and connecting rod as a single unit.

Standard clearance

Top: 0.04—0.08 mm {0.0016—0.0031 in}
Second: 0.03—0.07 mm {0.0012—0.0027 in}
Oil: 0.06—0.15 mm {0.0024—0.0059 in}

Maximum clearance

Top: 0.17 mm {0.0067 in}
Second, Oil: 0.15 mm {0.0059 in}

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 ring end gap with a feeler

gauge.

• If it exceeds the specification, replace the

piston, piston pin, piston ring and connecting
rod as a single unit.

Standard end gap

Top: 0.16—0.26 mm {0.0063—0.010 in}
Second: 0.33—0.48 mm {0.0130—0.0189 in}
Oil (rail): 0.20—0.70 mm {0.0079—0.0275 in}

Maximum end gap

1.0 mm {0.0393 in}

End Of Sie

CRANKSHAFT INSPECTION

B3E011011301201

1. Install the main bearing cap. (See 01–10–28 Main Bearing Cap Assembly Note.)
2. Measure the crankshaft end play.

• If it exceeds the specification, replace the thrust bearing or crankshaft so that the specified end play is

obtained.

Standard end play

0.22—0.45 mm {0.0087—0.0177 in}

Maximum end play

0.55 mm {0.022 in}

3. Remove the main bearing cap. (See 01–10–6

Camshaft Cap Disassembly Note.)

4. Measure the crankshaft runout.

• If it exceeds the specification, replace the

crankshaft.

B3E0110E081

PISTON RING

B3E0110E082

B3E0110E083

01–10–20

MECHANICAL

Maximum runout

0.05 mm {0.0019 in}

5. Measure the journal diameter in X and Y

directions at the two points (A and B) as indicated
in the figure.

• If it exceeds the specification, replace the

crankshaft or grind the journal and install the
undersize bearing.

Main journal diameter

STD
51.980—52.000 mm {2.0465—2.0472 in}
US0.25
51.730—51.750 mm {2.0367—2.0374 in}

Maximum Main journal off-round

0.05 mm {0.0019 in}

Crank pin diameter

L8
STD: 46.980—47.000 mm {1.8497—1.8503

in}

US0.25: 46.730—46.750 mm {1.8398—1.8405 in}
LF
STD: 46.980—47.000 mm {1.8497—1.8503 in}
US0.25: 46.730—46.750 mm {1.8398—1.8405 in}
LF (With variable valve timing mechanism)
STD: 46.980—47.000 mm {1.8497—1.8503 in}
US0.25: 46.730—46.750 mm {1.8398—1.8405 in}
L3
STD: 49.980—50.000 mm {1.9677—1.9685 in}
US0.25: 49.730—49.750 mm {1.9579—1.9586 in}
L3 (With variable valve timing mechanism)
STD: 49.980—50.000 mm {1.9677—1.9685 in}
US0.25: 49.730—49.750 mm {1.9579—1.9586 in}

Maximum Crank pin off-round

0.05 mm {0.0019 in}

6. Install the main bearing caps and crankshaft.
7. Position a plastigauge atop the journals in the axial direction.
8. Install the main bearing caps and cylinder block. (See 01–10–28 Main Bearing Cap Assembly Note.)
9. Remove the main bearing caps. (See 01–10–6 Camshaft Cap Disassembly Note.)

10. Measure the main journal oil clearance.

• If it exceeds the specification, replace the main bearing using the main bearing selection table or grind the

main journal and install the oversize bearings so that the specified oil clearance is obtained.

Standard clearance

0.019—0.035 mm {0.0007—0.0013 in}

Maximum clearance

0.10 mm {0.0039 in}

Main bearing size

STD: 2.506—2.509
OS0.25: 2.506—2.509

End Of Sie

B3E0110E084

B3E0110E085

B3E0110E086

MECHANICAL

01–10–21

CONNECTING ROD INSPECTION

B3E011011211201

Caution

• The piston, piston ring and connecting rod cannot be disassembled.

• When replacing the piston, piston pin, piston ring and connecting rod, replace them together as a

single unit.

1. Install the connecting rod cap. (See 01–10–30 Connecting Rod Cap Assembly Note.)
2. Measure the connecting rod large end side clearance.

• If it exceeds the specification, replace the piston, piston pin, piston ring and connecting rod as a single unit.

Standard clearance

0.14—0.36 mm {0.0056—0.0141 in}

Maximum clearance

0.435 mm {0.0172 in}

3. Remove the connecting rod cap.
4. Position plastigauge atop the journals in the axial

direction.

5. Install the connecting rod bearing and connecting

rod cap. (See 01–10–30 Connecting Rod Cap
Assembly Note.)

6. Remove the connecting rod cap.
7. Measure the connecting rod oil clearance.

• If it exceeds the specification, replace the connecting rod bearing or grind the crank pin and use oversize

bearings so that the specified clearance is obtained.

Standard clearance

0.026—0.052 mm {0.0011—0.0020 in}

Maximum clearance

0.1 mm {0.0039 in}

Connecting rod bearing size

L8
STD: 1.498—1.504 mm {0.0589—0.0592 in}
OS0.25: 1.623—1.629 mm {0.0639—0.0641

in}

LF
STD: 1.498—1.504 mm {0.0589—0.0592 in}
OS0.25: 1.623—1.629 mm {0.0639—0.0641 in}
LF (With variable valve timing mechanism)
STD: 1.498—1.504 mm {0.0589—0.0592 in}
OS0.25: 1.623—1.629 mm {0.0639—0.0641 in}
L3
STD: 1.496—1.502 mm {0.0589—0.0591 in}
OS0.25: 1.621—1.627 mm {0.0639—0.0640 in}
L3 (With variable valve timing mechanism)
STD: 1.496—1.502 mm {0.0589—0.0591 in}
OS0.25: 1.621—1.627 mm {0.0639—0.0640 in}

End Of Sie

BOLT INSPECTION

B3E011010135201

1. Measure the length of each bolt.

• If it exceeds the specification, replace the bolt.

B3E0110E087

B3E0110W128

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