Mazda 5. Manual — part 9

01–10–22

MECHANICAL

Bolt length (mm {in})

Cylinder head bolt (With washer)
Standard: 149.2—145.8 {5.87—5.90}
Maximum: 150.5 {5.91}
Cylinder head bolt (Without washer)
Standard: 145.2—145.8 {5.72—5.74}
Maximum: 146.5 {5.77}
Connecting rod bolt
Standard: 44.7—45.3 {1.75—1.78}
Maximum: 46.0 {1.81}
Main bearing cap bolt (Plastic region

tightening bolt only)

Standard: 110.0—110.6 {4.33—4.35}
Maximum: 113.3{4.38}

End Of Sie

VARIABLE VALVE TIMING ACTUATOR INSPECTION

B3E011000142201

Caution

• Variable valve timing actuator cannot be disassembled because it is a precision unit.

1. Confirm that the groove of the rotor and notch of the cover at the variable valve timing actuator are aligned and

fixed.

• If the notch and the bump are not aligned, rotate the rotor toward the valve timing retard position by hand

until they are in place.

• If the rotor and cover are not fixed even though their notch and groove are aligned, replace the variable

valve timing actuator.

End Of Sie

OIL CONTROL VALVE (OCV) INSPECTION

B3E011014420201

Coil resistance inspection

1. Disconnect the negative battery cable.
2. Disconnect the oil control valve (OCV) connector.
3. Measure the resistance between terminals A and B using an ohmmeter.

• If not as specified, replace the oil control valve (OCV).

Specification

6.9—7.9 ohms [20

°C {68 °F}]

4. Connect the oil control valve (OCV) connector.

Spool valve operation inspection

1. Disconnect the negative battery cable.
2. Remove the oil control valve (OCV).
3. Verify that the spool valve in the oil control valve (OCV) is in the maximum valve timing retard position as

L

B3E0110E088

COVER

NOTCH

ROTOR

B3E0110E089

A

B

OIL CONTROL VALVE (OCV)

B3E2226W002

MECHANICAL

01–10–23

01

indicated in the figure.

• If it exceeds the specification, replace the oil control valve (OCV).

4. Verify that the battery is fully charged.

• If it is less than specification, recharge the

battery.

5. Apply battery positive voltage between the oil

control valve (OCV) terminals and verify that the
spool valve operates and moves to the maximum
valve timing advance position.

• If it exceeds the specification, replace the oil

control valve (OCV).

Note

• When applying battery positive voltage

between the oil control valve (OCV)
terminals, the connection can be either of
the following:

— Positive battery cable to terminal A, negative battery cable to terminal B

— Positive battery cable to terminal B, negative battery cable to terminal A

6. Stop applying battery positive voltage and verify

that the spool valve returns to the maximum valve
timing retard position.

• If it exceed the specification, replace the oil

control valve (OCV).

End Of Sie

VALVE CLEARANCE INSPECTION

B3E011012111203

1. Measure the valve clearance as follows.

(1) Turn the crankshaft clockwise so that the No.1 piston is at TDC of the compression stroke.
(2) Measure the valve clearance at A in the figure.

• If the valve clearance exceeds the standard, replace the tappet. (See 01–10–24 VALVE CLEARANCE

ADJUSTMENT.)

Note

• Make sure to note the measured values for choosing the suitable replacement tappets.

Standard [Engine cold]

IN: 0.22—0.28 mm {0.0087—0.0110 in}
EX: 0.27—0.33 mm {0.0106—0.0130 in}

(3) Turn the crankshaft 360

° clockwise so that the

No.4 piston is at TDC of the compression
stroke.

(4) Measure the valve clearance at B in the

figure.

• If the valve clearance exceeds the

standard, replace the tappet. (See 01–
10–24 VALVE CLEARANCE
ADJUSTMENT.)

Note

• Make sure to note the measured values for choosing the suitable replacement tappets.

Standard [Engine cold]

IN: 0.22—0.28 mm {0.0087—0.0110 in}
EX: 0.27—0.33 mm {0.0106—0.0130 in}

SPOOL VALVE
(MAXIMUM VALVE TIMING RETARD POSITION

B3E0110E090

VALVE TIMING
ADVANCE

VALVE TIMING
RETARD

SPOOL VALVE
(MAXIMUM VALVE TIMING ADVANCE POSITION)

B3E0110E091

A

A

A

A

B

B

B

B

EX

IN

B3E0110E092

01–10–24

MECHANICAL

End Of Sie

VALVE CLEARANCE ADJUSTMENT

B3E011012111204

1. Remove the engine front cover lower blind plug.
2. Remove the engine front cover upper blind plug.
3. Remove the cylinder block lower blind plug.

4. Install the SST as shown in the figure.
5. Turn the crankshaft clockwise so that the

crankshaft is in the No.1 cylinder TDC position.

6. Loosen the timing chain.

(1) Using a suitable screwdriver or equivalent

tool, unlock the chain tensioner ratchet.

(2) Turn the exhaust camshaft clockwise using a

suitable wrench on the cast hexagon and
loosen the timing chain.

(3) Placing the suitable bolt (M6

× 1.0 Length

25—35 mm {0.9—1.3 in}) at the engine front
cover upper blind plug hole, secure the chain
guide at the position where the tension is
released.

UPPER
BLIND
PLUG

LOWER BLIND
PLUG

B3E0110E093

303-507

(49 JE01 061)

B3E0110E094

3

1

2

BOLT (M6 x 1.0)

B3E0110E096

MECHANICAL

01–10–25

01

7. Hold the exhaust camshaft using a suitable

wrench on the cast hexagon as shown in the
figure.

8. Remove the exhaust camshaft sprocket.

9. Loosen the camshaft cap bolts in several passes

in the order shown in the figure.

Note

• The cylinder head and the camshaft caps

are numbered to make sure they are
reassembled in their original position. When
removed, keep the caps with the cylinder
head they were removed from. Do not mix
the caps.

10. Remove the camshaft.
11. Remove the tappet.
12. Select proper adjustment shim.

New adjustment shim

= Removed shim thickness + Measured valve clearance - Standard valve clearance (IN: 0.25 mm

{0.0098 in}, EX: 0.30 mm {0.0118 in})

Standard [Engine cold]

IN: 0.22—0.28 mm {0.0087—0.0110 in}
EX: 0.27—0.33 mm {0.0106—0.0130 in}

13. Install the camshaft with No.1 cylinder aligned with the TDC position.
14. Tighten the camshaft cap bolt using the following

two steps.

Tightening torque

(1) 5.0—9.0 N·m

{51.0—91.7 kgf·cm, 44.3—79.5 in·lbf}

(2)14.0—17.0 N·m

{1.43—1.73 kgf·m, 10.4—12.5 ft·lbf}

B3E0110E095

EXHAUST
CAMSHAFT
SPROCKET

B3E0110E097

9

8

7

5

4

3

1

2

10

19

18

17

15

16

14

13

11

12

20

6

B3E0110E057

9

8

7

5

4

3

1

2

10

19

18

17

15

16

14

13

11

12

20

6

B3E0110E098