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Mazda Engine LF, L3. Manual - part 4

GENERAL INFORMATION

00–00–11

00–00

NEW STANDARDS

E5U000000000E05

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

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

—

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

GENERAL INFORMATION

00–00–12

#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
#6 : Part name of diesel engine

End Of Sie

ABBREVIATIONS

E5U000000000E06

End Of Sie

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

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

01–10

Toc of SCT

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

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

Toc of SCT

01–10

MECHANICAL

ENGINE OVERHAUL SERVICE

WARNING. . . . . . . . . . . . . . . . . . . . . . . . 01–10–2

ENGINE

MOUNTING/DISMOUNTING . . . . . . . . . 01–10–3

DISMOUNTING. . . . . . . . . . . . . . . . . . . 01–10–3

TIMING CHAIN DISASSEMBLY. . . . . . . . 01–10–4

Crankshaft Pulley Lock Bolt

Disassembly Note . . . . . . . . . . . . . . . . 01–10–5

Front Oil Seal Disassembly Note . . . . . 01–10–5
Chain Tensioner

Disassembly Note . . . . . . . . . . . . . . . . 01–10–5

Oil Pump Sprocket

Disassembly Note . . . . . . . . . . . . . . . . 01–10–5

CYLINDER HEAD (I)

DISASSEMBLY. . . . . . . . . . . . . . . . . . . . 01–10–6

Camshaft Sprocket Lock Bolt,

Variable Valve Timing Actuator
Lock Bolt Disassembly Note . . . . . . . . 01–10–7

Camshaft Cap Disassembly Note . . . . . 01–10–7
Tappet Disassembly Note . . . . . . . . . . . 01–10–7
Cylinder Head Bolt

Disassembly Note . . . . . . . . . . . . . . . . 01–10–8

CYLINDER HEAD (II)

DISASSEMBLY. . . . . . . . . . . . . . . . . . . . 01–10–8

Valve Keeper Disassembly Note . . . . . . 01–10–8
Valve Seal Disassembly Note . . . . . . . . 01–10–9

CYLINDER BLOCK (I)

DISASSEMBLY. . . . . . . . . . . . . . . . . . . . 01–10–9

Drive Plate (ATX), Flywheel (MTX)

Disassembly Note . . . . . . . . . . . . . . . . 01–10–10

CYLINDER BLOCK (II)

DISASSEMBLY. . . . . . . . . . . . . . . . . . . . 01–10–10

Connecting Rod Cap

Disassembly Note . . . . . . . . . . . . . . . . 01–10–11

Main Bearing Cap

Disassembly Note . . . . . . . . . . . . . . . . 01–10–11

CYLINDER HEAD INSPECTION . . . . . . . 01–10–11
VALVE, VALVE GUIDE

INSPECTION . . . . . . . . . . . . . . . . . . . . . 01–10–12

VALVE GUIDE REPLACEMENT . . . . . . . 01–10–13

Valve Guide Removal . . . . . . . . . . . . . . 01–10–13
Valve Guide Installation. . . . . . . . . . . . . 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 . . . . .  01–10–20
BOLT INSPECTION . . . . . . . . . . . . . . . . .  01–10–21
VARIABLE VALVE TIMING ACTUATOR

INSPECTION [With variable valve
timing mechanism]. . . . . . . . . . . . . . . . 01–10–21

OIL CONTROL VALVE (OCV)

INSPECTION [With variable valve
timing mechanism]. . . . . . . . . . . . . . . . 01–10–21

Coil Resistance Inspection . . . . . . . . . . 01–10–21
Spool Valve Operation Inspection . . . . 01–10–22

VALVE CLEARANCE

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

VALVE CLEARANCE

ADJUSTMENT. . . . . . . . . . . . . . . . . . . . 01–10–23

CYLINDER BLOCK (I) ASSEMBLY . . . . 01–10–27

Main Bearing Cap Assembly Note . . . .  01–10–28
Piston Ring Assembly Note . . . . . . . . .  01–10–28
Piston Assembly Note  . . . . . . . . . . . . .  01–10–28
Connecting Rod Bearing

Assembly Note . . . . . . . . . . . . . . . . . . 01–10–29

Connecting Rod Cap

Assembly Note . . . . . . . . . . . . . . . . . . 01–10–29

Balancer Unit Assembly Note. . . . . . . . 01–10–29

CYLINDER BLOCK (II)

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 01–10–32

Rear Oil Seal Assembly Note. . . . . . . . 01–10–33
Drive Plate (ATX), Flywheel (MTX)

Assembly Note . . . . . . . . . . . . . . . . . . 01–10–33

Oil pan Assembly Note. . . . . . . . . . . . . 01–10–34

CYLINDER HEAD (I) ASSEMBLY. . . . . . 01–10–35

Valve Seal Assembly Note . . . . . . . . . . 01–10–35
Valve Keeper Assembly Note . . . . . . . . 01–10–35

CYLINDER HEAD (II) ASSEMBLY . . . . . 01–10–36

Cylinder Head Bolt

Assembly Note . . . . . . . . . . . . . . . . . . 01–10–37

Camshaft Assembly Note. . . . . . . . . . . 01–10–37
Camshaft Sprocket, Variable Valve

Timing Actuator Assembly Note . . . . . 01–10–37

TIMING CHAIN ASSEMBLY . . . . . . . . . . 01–10–38

Oil Pump Sprocket Assembly Note . . . 01–10–39
Timing Chain Assembly Note . . . . . . . . 01–10–39
Camshaft Sprocket, Variable Valve

Timing Actuator Assembly Note . . . . . 01–10–40

MECHANICAL

01–10–2

Front Oil Seal Assembly Note . . . . . . . . 01–10–40
Engine Front Cover Assembly Note . . . 01–10–41

Crankshaft Pulley Lock Bolt

Assembly Note . . . . . . . . . . . . . . . . . . 01–10–41

Cylinder Head Cover

Assembly Note . . . . . . . . . . . . . . . . . . 01–10–42

End of Toc

ENGINE OVERHAUL SERVICE WARNING

E5U011002000E01

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

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