Mazda engine MZR–CD. Manual - part 5

ABBREVIATIONS 

GI–15

GI

ABBREVIATIONS

AME203000011101

End Of Sie

ABBREVIATIONS

BDC

Bottom dead center

EX

Exhaust

IN

Intake

max

Maximum

min

Minimum

SST

Special service tool

TDC

Top dead center

B–1

B

B

ENGINE

ENGINE .................................................................. B-2

ENGINE OVERHAUL SERVICE WARNING ....... B-2
MOUNTING.......................................................... B-2
ENGINE DISMOUNTING..................................... B-3
TIMING BELT DISASSEMBLY ............................ B-3
CYLINDER HEAD (I) DISASSEMBLY ................. B-7
CYLINDER HEAD (II) DISASSEMBLY ................ B-8
CYLINDER BLOCK (I) DISASSEMBLY ............. B-10
CYLINDER BLOCK (II) DISASSEMBLY ............ B-13
CYLINDER HEAD INSPECTION ....................... B-14
VALVE, VALVE GUIDE INSPECTION............... B-15
VALVE GUIDE REPLACEMENT ....................... B-16
VALVE SEAT INSPECTION/REPAIR................ B-17
VALVE SPRING INSPECTION.......................... B-18
CAMSHAFT INSPECTION ................................ B-18
CAMSHAFT OIL CLEARANCE INSPECTION... B-19
CAMSHAFT END PLAY INSPECTION.............. B-19
CYLINDER BLOCK INSPECTION/REPAIR ...... B-20
OIL JET VALVE, NOZZLE INSPECTION .......... B-20
PISTON INSPECTION....................................... B-21
PISTON CLEARANCE INSPECTION/REPAIR . B-21
PISTON RING CLEARANCE INSPECTION...... B-21
PISTON PIN CLEARANCE INSPECTION......... B-22
CRANKSHAFT INSPECTION............................ B-22
CRANKSHAFT OIL CLEARANCE 
INSPECTION/REPAIR....................................... B-23
CRANKSHAFT END PLAY INSPECTION/

REPAIR........................................................... B-24

CONNECTING ROD INSPECTION ................... B-24
CONNECTING ROD OIL CLEARANCE 

INSPECTION/REPAIR.................................... B-24

CONNECTING ROD SIDE CLEARANCE 

INSPECTION .................................................. B-25

PISTON AND CONNECTING ROD 

INSPECTION .................................................. B-25

CYLINDER HEAD BOLT INSPECTION............. B-25
TIMING BELT AUTO TENSIONER 

INSPECTION .................................................. B-26

PILOT BEARING INSPECTION......................... B-26
OIL PUMP INSPECTION ................................... B-27
VALVE CLEARANCE INSPECTION.................. B-28
VALVE CLEARANCE ADJUSTMENT ............... B-28
CYLINDER BLOCK (I) ASSEMBLY ................... B-30
CYLINDER BLOCK (II) ASSEMBLY .................. B-32
CYLINDER HEAD (I) ASSEMBLY ..................... B-37
CYLINDER HEAD (II) ASSEMBLY .................... B-39
TIMING BELT ASSEMBLY ................................ B-43

B–2

ENGINE 

ENGINE OVERHAUL SERVICE WARNING

AME222402000101

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

MOUNTING

AME222402000102

1. Install the SST (arms) to the cylinder block holes 

as shown, and hand-tighten the SST (bolts).

2. Assemble the SSTs (bolts, nuts, and plate) to the 

specified positions.

3. Install the  SSTs (bolts, nuts, and plate) 

assembled in Step 2 to the  SSTs (arms) installed 
in Step 1.

4. Adjust the  SSTs (bolts) so that the thread is 

exposed less than 20 mm {0.79 in}.

5. Make the  SSTs (plate and arms) parallel by 

adjusting the  SSTs (bolts and nuts).

6. Tighten the  SSTs (bolts and nuts) to affix the 

SST firmly.

Warning

••••

The self-locking brake system of the 
engine stand may not be effective when 
the engine is held in an unbalanced 
position. This could lead to sudden, rapid 
movement of the engine and mounting 
stand handle and cause serious injury. 
Never keep the engine in an unbalanced 
position, and always hold the rotating 
handle firmly when turning the engine.

7. Mount the engine on the SST (engine stand).
8. Drain the engine oil into a container.
9. Install the drain plug and a new washer.

Tightening torque

30—41 N·m {3.0—42 kgf·m, 22—30 ft·Ibn}

ENGINE

AME2524E001

AME2524E002

AME2524E003

AME2524E004

ENGINE 

B–3

B

End Of Sie

ENGINE DISMOUNTING

AME222402000103

1. Dismount in the reverse order of mounting.

End Of Sie

TIMING BELT DISASSEMBLY

AME222402000112

1. Disassemble in the order indicated in the table.

2.

.

AME2516E001

1

Pulley cover

2

Crankshaft pulley
(See 

B–4 Crankshaft Pulley Disassembly Note

)

3

Timing belt cover

4

Guide plate

5

Crankshaft position sensor

6

Timing belt, timing belt auto tensioned
(See

B–4 Timing Belt, Timing Belt Auto Tensioner 

Disassembly Note

)

7

Idler

8

Injection pump pulley
(See 

B–5 Injection Pump Pulley Disassembly Note

)

9

Timing belt pulley
(See 

B–5 Timing Belt Pulley Disassembly Note

)

10

Gear cover

11

Drive gear
(See 

B–6 Drive Gear Disassembly Note

)

12

Gear case

13

Camshaft pulley
(See 

B–6 Camshaft Pulley Disassembly Note

)

14

Tensioner

15

Seal plate