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Mazda 5. Manual - part 3

GENERAL INFORMATION

00–00–9

End Of Sie

NEW STANDARDS

B3E000000003201

• Following is a comparison of the previous standard and the new standard.

GOOD

NO GOOD

CHU0000W012

New Standard

Previous Standard

Remark

Abbrevi-

ation

Name

Abbrevi-
ation

Name

Accelerator Pedal

—

Accelerator Pedal

ACL

Air Cleaner

—

Air Cleaner

A/C

Air Conditioning

—

Air Conditioning

BARO

Barometric Pressure

—

Atmospheric Pressure

B+

Battery Positive Voltage

Battery Voltage

—

Brake Switch

—

Stoplight Switch

—

Calibration Resistor

—

Corrected Resistance

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

CKP sensor Crankshaft Position Sensor

—

Crank Angle Sensor 2

DLC

Data Link Connector

—

Diagnosis Connector

DTM

Diagnostic Test Mode

—

Test Mode

DTC

Diagnostic Trouble Code(s)

—

Service Code(s)

Distributor Ignition

—

Spark Ignition

DLI

Distributorless Ignition

—

Direct Ignition

Electronic Ignition

—

Electronic Spark Ignition

ECT

Engine Coolant Temperature

—

Water Thermo

Engine Modification

—

Engine Modification

—

Engine Speed Input Signal

—

Engine RPM Signal

EVAP

Evaporative Emission

—

Evaporative Emission

EGR

Exhaust Gas Recirculation

—

Exhaust Gas Recirculation

Fan Control

—

Fan Control

Flexible Fuel

—

Flexible Fuel

4GR

Fourth Gear

—

Overdrive

—

Fuel Pump Relay

—

Circuit Opening Relay

FSO

solenoid

Fuel Shut Off Solenoid

FCV

Fuel Cut Valve

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

—

Incorrect Gear Ratio

—

Injection Pump

FIP

Fuel Injection Pump

00–00–10

GENERAL INFORMATION

#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

—

Input/Turbine Speed Sensor

—

Pulse Generator

IAT

Intake Air Temperature

—

Intake Air Thermo

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

Open Loop

—

Open Loop

—

Output Speed Sensor

—

Vehicle Speed Sensor 1

Oxidation Catalytic Converter

—

Catalytic Converter

O2S

Oxygen Sensor

—

Oxygen Sensor

PNP

Park/Neutral Position

—

Park/Neutral Range

—

PCM Control Relay

—

Main Relay

PSP

Power Steering Pressure

—

Power Steering Pressure

PCM

Powertrain Control Module

ECU

Engine Control Unit

—

Pressure Control Solenoid

—

Line Pressure Solenoid Valve

PAIR

Pulsed Secondary Air Injection

—

Secondary Air Injection System

Pulsed
injection

—

Pump Speed Sensor

—

NE Sensor

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

Throttle Body

—

Throttle Body

TP sensor

Throttle Position Sensor

—

Throttle Sensor

TCV

Timer Control Valve

TCV

Timing Control Valve

TCC

Torque Converter Clutch

—

Lockup Position

TCM

Transmission (Transaxle) Control
Module

—

EC-AT Control Unit

—

Transmission (Transaxle) Fluid
Temperature Sensor

—

ATF Thermosensor

Transmission (Transaxle) Range

—

Inhibitor Position

Turbocharger

—

Turbocharger

VSS

Vehicle Speed Sensor

—

Vehicle Speed Sensor

Voltage Regulator

—

IC Regulator

VAF sensor Volume Air Flow Sensor

—

Air flow Sensor

WUTWC

Warm Up Three Way Catalytic
Converter

—

Catalytic Converter

WOT

Wide Open Throttle

—

Fully Open

New Standard

Previous Standard

Remark

Abbrevi-

ation

Name

Abbrevi-
ation

Name

GENERAL INFORMATION

00–00–11

#6 : Part name of diesel engine

End Of Sie

ABBREVIATIONS

B3E000000011201

End Of Sie

ATDC

After Top Dead Center

ATX

Automatic Transaxle

EGR

Exhaust Gas Recirculation

Exhaust

Intake

MTX

Manual Transaxle

OCV

Oil Control Valve

TDC

Top Dead Center

SST

Special Service Tool

01–10–1

ENGINE

SECTION

Toc of SCT

MECHANICAL . . . . . . . . . . . . . 01-10
TECHNICAL DATA. . . . . . . . . . 01-50

SERVICE TOOLS . . . . . . . . . . . 01-60

Toc of SCT

01–10

MECHANICAL

ENGINE OVERHAUL

SERVICE WARNING . . . . . . . . . . . . . . . 01–10–1

ENGINE MOUNTING/DISMOUNTING  . .  01–10–1
TIMING CHAIN DISASSEMBLY . . . . . . .  01–10–3
CYLINDER HEAD (I) DISASSEMBLY. . .  01–10–5
CYLINDER HEAD (II) DISASSEMBLY . .  01–10–7
CYLINDER BLOCK (I) DISASSEMBLY  .  01–10–9
CYLINDER BLOCK (II) DISASSEMBLY . 01–10–10
CYLINDER HEAD INSPECTION. . . . . . .  01–10–11
VALVE, VALVE GUIDE INSPECTION . . .  01–10–12
VALVE GUIDE REPLACEMENT . . . . . . .  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  . . . . . 01–10–21
BOLT INSPECTION . . . . . . . . . . . . . . . . . 01–10–21
VARIABLE VALVE TIMING ACTUATOR

INSPECTION . . . . . . . . . . . . . . . . . . . . . 01–10–22

OIL CONTROL VALVE (OCV)

INSPECTION . . . . . . . . . . . . . . . . . . . . . 01–10–22

VALVE CLEARANCE INSPECTION  . . . . 01–10–23
VALVE CLEARANCE ADJUSTMENT  . . . 01–10–24
CYLINDER BLOCK (I) ASSEMBLY . . . . . 01–10–27
CYLINDER BLOCK (II) ASSEMBLY  . . . . 01–10–33
CYLINDER HEAD (I) ASSEMBLY . . . . . . 01–10–36
CYLINDER HEAD (II) ASSEMBLY. . . . . . 01–10–37
TIMING CHAIN ASSEMBLY. . . . . . . . . . . 01–10–40

End of Toc

ENGINE OVERHAUL SERVICE WARNING

B3E011002000201

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

ENGINE MOUNTING/DISMOUNTING

B3E011002000202

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).

49 L010 102

B3E0110W127

49 L010 101

49 L010 104

49 L010 105

ADJ2224E013

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