service repair manual

1. SERVICE REPAIR
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9. 1
INTRODUCTION
DANGER
Some gaskets used in this engine can contain asbes-
tos or other fibers. Breathing asbestos dust is a can-
cer or lung disease hazard. Do not create dust! Use
vacuum equipment for asbestos or follow the clean-
ing procedure described below.
• Make sure the gasket material is wet with
water or oil to prevent particles in the air.
• Use a hand scraper to remove old gasket mate-
rial. Do not use a power tool or compressedair.
• Discard all asbestos material in a closed con-
tainer while it is still wet.
Put an “ASBESTOS” warning label on the con-
tainer. Discard asbestos material safely.
CAUTION
Disconnectthebatterycablesbeforedoinganydisas-
sembly and repair to the engine or parts of the elec-
trical system.
The diodes and resistors in the electrical system can
be damaged if the following cautions are not fol-
lowed:
• Do not disconnect the battery when the engine
is running. The voltage surge can damage the
diodes and resistors.
• Do not disconnect an electric wire before the
engine is stopped and the key switch is “OFF”.
• Do not cause a short circuit by connection of
the electric wires to the wrong terminals.
Make sure a correct identification is made of
the wire before it is connected.
• Make sure a battery is the correct voltage and
polarity before it is connected.
• Do not check for current flow by making a
spark because the transistors can be damaged.
DESCRIPTION
The Mazda engine is a four cylinder engine that has a
displacement of 1489 cm3 (90.8 in3). The firing order is
1–3–4–2. It is available with either a gasoline or an LPG
fuel system. The number one cylinder is toward the end
of the engine with the cooling fan.
FIGURE 1. M4–1.5G ENGINE
1. SPARK PLUG
2. EXHAUST MANIFOLD
3. DIPSTICK
4. ALTERNATOR
1
2
3
4
1

10. 2
The overhead camshaft is driven by a chain. The cam-
shaft operates the rocker arms that actuate the valves.
The crankshaft has five main bearings. The main bear-
ing in the center of the crankshaft is also the thrust bear-
ing.
The pistons are aluminum alloy and have three piston
rings. Each of the two compression rings have a special
shape designed for its position on the piston. The third
piston ring is the oil control ring.
REPAIRS
CYLINDER HEAD, CAMSHAFT AND
VALVE MECHANISM
Removal
1. Disconnect the connections at the battery.
2. Drain the cooling system.
3. Remove the air cleaner, the carburetor linkage, the in-
take and exhaust manifolds.
4. Remove the coolant hoses.
5. Remove the bracket for the cooling fan.
6. Disconnect the wires at the distributor. Remove the
capscrew for the distributor mount and pull the distribu-
tor from the cylinder head.
FIGURE 2. REMOVE THE CAMSHAFT GEAR
1. SPACER
2. GEAR
3. SEAL
1
2
3
7. Remove the valve cover. Remove the half round seals
from the cylinder head. See FIGURE 2.
8. Hold the bolt on the crankshaft pulley and remove the
nut on the camshaft. Remove the drive gear for the dis-
tributor and the spacer. See FIGURE 2.
9. Remove the cylinder head capscrew that is below the
front of the camshaft as shown in FIGURE 3. Loosen
the remaining capscrews for the cylinder head in the se-
quence shown in FIGURE 4. Remove the capscrews.
FIGURE 3. CYLINDER HEAD CAPSCREW
10. Remove the rocker shaftassembly. See FIGURE 21.
Remove the camshaft, leaving the sprocket and chain in
the engine. Use a piece of wire or a tie strap to hold the
sprocket in position on the timing chain. Make sure the
polished chain link is aligned with the timing mark on
the sprocket. See FIGURE 5. and FIGURE 18.
FIGURE 4. SEQUENCE FOR REMOVAL OF THE
CYLINDER HEAD
1 5 9 8 4
10 7 3
6
2

11. 3
FIGURE 5. TIMING CHAIN AND SPROCKETS
1. CAMSHAFT
SPROCKET
2. TIMING CHAIN
3. CRANKSHAFT
SPROCKET
1
2
3
11. Lift the cylinder head from the block.
12. Use a valve spring compressor and remove the valve
retainers, springs and valves from the head. See
FIGURE 6.
FIGURE 6. REMOVE THE VALVES
13. Remove the timing chain as follows:
a. Remove the crankshaft pulley. Remove the oil
pan.
b. Remove the front cover from the cylinder block.
c. Remove the sprockets and chain for the oil pump.
Remove the timing chain and crankshaft sprock-
et.
d. Remove the guides for the timing chain. Remove
the timing chain tensioner. See FIGURE 17.
Cleaning
WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning sol-
vents, always follow the solvent manufacturer’s rec-
ommended safety procedures.
Clean all of the parts in solvent. Make sure that all oil
passages are clean. Make sure all machined surfaces are
smooth.
Inspection And Repairs
CYLINDER HEAD
Checkthebottomsurfaceofthecylinderheadfordistor-
tion. Use a straight edge and a thickness gauge. Do the
measurements at the positions shown in FIGURE 7. The
maximum amount of distortion is 0.15 mm (0.0059 in).
When grinding the cylinder head, the maximum amount
of correction is 0.2 mm (0.008 in).
FIGURE 7. CYLINDER HEAD INSPECTION
ROCKER SHAFT ASSEMBLY (See FIGURE 21.)
Disassembletherockershaftassembly.Putmarksonthe
rocker arms so that they can be installed on the same

12. 4
shafts. Clean the oil passages in the rocker shafts and
rocker arms. Check the clearance between the rocker
arms and the rocker shafts. The maximum clearance is
0.10mm(0.004in).Thecorrectdimensionfortheinside
diameter of a rocker arm is 19.000 to 19.033 mm (0.748
to 0.749 in). The correctdimensionfortheoutsidediam-
eter of a rocker shaft is 18.959 to 18.980 mm (0.746 to
0.747 in). If the parts do not meet specification, replace
the rocker arm(s) or the rocker shaft(s).
CAMSHAFT
Check the camshaft for cracks or damage.
Check the movement of the camshaft in the cylinder
head.Installthesupportsfortherockershafts.Installthe
camshaft and thrust plate. Tighten the nut for the cam-
shaft to 69 to 79 N.m (51 to 58 lbf ft).Use a dial indicator
on the end of the camshaft as shown in FIGURE 8. The
maximum movement is 0.20 mm (0.008 in). Install a
new thrust plate if the measurement is not correct.
FIGURE 8. CHECK THE CAMSHAFT
Measure the height of the camshaft lobes. See
FIGURE 9. The minimum height of the intake and ex-
haust lobes are 43.912 mm (1.729 in).
FIGURE 9. CAMSHAFT INSPECTION
1. FRONT JOURNAL
2. CENTER JOURNAL
3. REAR JOURNAL
A
D
B
C
1
2
3
Measure the camshaft journals at four points A–D as
shown in FIGURE 9. The minimum dimensions for the
journals are as follows:
Front and Rear Journals – 41.949 to 41.965 mm
(1.651 to 1.652 in)
Center Journal – 41.919 to 41.935 mm (1.650 to
1.651 in)
Check the camshaft for being straight. Put the front and
rear journals in V blocks and rotate the camshaft one
complete turn. See FIGURE 10. The maximum amount
that the dial indicator can indicate is 0.05 mm (0.002 in).
FIGURE 10. CHECK THE CAMSHAFT
Measure the clearance between the camshaft and the
bore in the cylinder head. Use a plastic gauge material as
shown in FIGURE 11. Tighten the capscrews for the
caps to 76 to 81 N.m (56 to 60 lbf ft). The correct clear-
ance for the front and rear journals is 0.035 to 0.076 mm
(0.0014 to 0.003 in). The correct clearance for the center
journal is 0.065 to 0.106 mm (0.0026 to 0.0041 in). If

13. 5
any of the clearances are greater than 0.15 mm (0.0059
in), replace the cylinder head assembly.
Install a new camshaft when there is any damage or
when it does not meet specifications.
TIMING CHAIN AND SPROCKETS
Check the timing chain for loose or broken links. Check
the sprockets and chain guides for wear or damage. Use
new parts as necessary.
FIGURE 11. MEASURE THE CLEARANCE FOR
THE CAMSHAFT
VALVE GUIDES
Measure the clearance between the valve stems and the
valve guides. Normal clearance is 0.018 to 0.055 mm
(0.0007 to 0.002 in). Replace the valve or valve guide
when the clearance is more than 0.20 mm (0.008 in).
FIGURE 12. VALVE GUIDE
2
1. CYLINDER HEAD
2. RETAINING RING
3. VALVE GUIDE
1
3
If replacement is necessary, use a tool to remove the
valve guide(s). Remove the seal from the valve guide,
then remove the valve guide.
To install a valve guide, install the retaining ring on the
valve guide. Use the tool and install the valve guide until
the retaining ring contacts the cylinder head. See
FIGURE 12. Install the seals on the valve guides.
NOTE: The intake and exhaust valve guides are not the
same. Make sure the valve guides are installed correctly.
VALVE SEATS
Inspect the condition of the valve seats. If the valve seats
have cracks, the cylinder head must be replaced. If the
condition of the valve seats is good, check the contact
pattern of the valve and the valve seat. Use a valve seat
grinder to make sure the valve seats are with the specifi-
cations shown in FIGURE 13. Use a valve compound to
make sure the valves fit the seats.
FIGURE 13. VALVE SEAT SPECIFICATIONS
75°
75°
45°
15°
45°
1.4 mm
(0.055 in)
EXHAUST
INTAKE
1.4 mm
(0.055 in)
45°
Check the depth of the valve seats by measuring the
length of the valve stem as shown in FIGURE 14. The
standard dimension from the valve spring seat to the end
of the valve stem is 39.5 mm (1.55 in). When the mea-
surement is 0.5 to 1.5 mm (0.02 to 0.06 in) more than
standard, use a spacer under the valve spring seat. When
the measurement is more than 41.0 mm (1.61 in), the

14. 6
valve seat is too deep and the cylinder head must be re-
placed.
FIGURE 14. VALVE GUIDE
1. VALVE STEM
1
VALVES
1. See FIGURE 15. Inspect the stem of each valve for
wear. Use a micrometer to measure the outside diameter
ofthestem.Theminimumdimensionforanintakevalve
is 7.980 mm (0.3142 in). The minimum dimension for
an exhaust valve is 7.975 mm (0.3140 in).
FIGURE 15. INSPECT THE VALVES
1. DIAMETER
2. THICKNESS,
VALVE HEAD
1
2
2. Inspect the valves for cracks, burned faces and distor-
tion. Inspect the seat face of the valves for wear and
damage. Measure the thickness of the valve head. See
The minimum thickness for an intake valve is 0.5 mm
(0.020 in). The minimum thickness for an exhaust valve
is 1.0 mm (0.040 in).
3. If the valves need grinding the correct surface angle is
45° for both intake and exhaust valves.
VALVE SPRINGS
Check the valve springs for damage. See FIGURE 16.
Measure the free length of the valve springs. The mini-
mum length is 42.0 mm (1.65 in). Check the valve
springs for being square. See FIGURE 16. If the mea-
surement is more than 1.52 mm (0.059 in), replace the
valve spring(s).
FIGURE 16. INSPECT THE VALVE SPRINGS
MEASURE
HERE
Installation
1. Clean the surface of the cylinder head and the surface
of the block.
2. Install the valves and valve springs.
3. If the timing chain was removed, do the following:
a. Install the guides for the timing chain on the cylin-
der block. See FIGURE 17.

15. 7
FIGURE 17. CHAIN GUIDES FOR TIMING
CHAIN
1
1. CHAIN GUIDE
b. Install the key and sprocket for the timing chain on
the crankshaft. Install the timing chain on the
sprocket so that the polished link is aligned with
the mark on the sprocket. Install the camshaft
sprocket in the timing chain. Use a piece of wire
oratiestraptoholdthesprocketinpositiononthe
timing chain. See FIGURE 18. Make sure the
polished chain link is aligned with the timing
mark on the sprocket.
FIGURE 18. TIMING CHAIN
1. TIMING MARK
2. POLISHED LINK
1
2
1
2
c. Install the tensioner for the timing chain.
d. Install the key on the oil pump shaft. Install the
chain and sprockets for the oil pump. Tighten the
nut on the oil pump shaft to 30 to 34 N.m (22 to 25
lbf ft). Bend the lock washer on the nut.
e. Install the oil seal in the front cover. Install the
baffle on the crankshaft. Install the front cover
and gaskets on the cylinder block. See
FIGURE 19. Tighten the capscrews for the front
cover to 19 to 26 N.m (14 to 19 lbf ft).
1
FIGURE 19. FRONT COVER
2
1. CYLINDER BLOCK
2. GASKET
3. FRONT COVER
4. OIL SEAL
3
2
4
f. Use a silicone sealant on the oil pan and install the
oil pan. Tighten the capscrews to 7 to 9 N.m (5 to
7 lbf ft).
4. Use a gasket sealant at the joint between the cylinder
block and the front cover. See FIGURE 20. Install a new
cylinder head gasket to the block. Install the cylinder
head on the gasket.
FIGURE 20. INSTALL THE CYLINDER HEAD
1. APPLY SEALANT HERE
1

16. 8
FIGURE 21. ROCKER ARM AND CAMSHAFT ASSEMBLY
1. CAMSHAFT
2. TIMING CHAIN
3. TENSIONER
4. NUT
5. DRIVE GEAR
6. SPACER
7. SPROCKET
8. INTAKE VALVE
1
2
3
4
5
6
7
8
9 10
11
12
13
14
9. VALVE STEM SEAL
10. SPRING SEAT
11. VALVE SPRING
12. RETAINER
13. KEEPERS
14. EXHAUST VALVE
15. ROCKER SHAFT
16. SPRING
17. ROCKER ARM
18. SUPPORT
19. LOCK NUT
20. ADJUSTMENT SCREW
16
17
18
19
20
11
10
9
15
15
16
18
5. Install the camshaft as follows:
a. Install the key on the camshaft.
b. Remove the wire from the sprocket and chain.
Hold the sprocket so that the chain is tight.
c. Install the camshaft in the sprocket. Rotate the
crankshaft so that the dowel pin is at the top.
6. Assemble the rocker shaft assembly as shown in
FIGURE 21.
7. Lubricate the rocker shaft supports with oil, then
install the rocker shaft assembly on the cylinder head.
Install the capscrews and tighten in several steps to 85 to
91 N.m (63 to 67 lbf ft). Use the tightening sequence
shown in FIGURE 22. Install the capscrews that hold
the cylinder head to the front cover. Tighten the cap-
screws to 19 to 26 N.m (14 to 19 lbf ft).
FIGURE 22. CYLINDER HEAD TIGHTENING
SEQUENCE
1
5
9 8
4
10 7
3
6 2
FRONT OF ENGINE

17. 9
8. Install the spacer and distributor drive gear. Hold the
capscrewonthecrankshaftpulleyandtightenthenutfor
the camshaft to 69 to 79 N.m (51 to 58 lbf ft).
9. Adjust the timing chain as follows:
a. See FIGURE 23. Remove the two access plugs.
Loosen the capscrew for the timing chain guide.
b. Use a screwdriver and push on the chain guide
with a force of approximately 1 kg (2.2 lb) and
tighten the capscrew.
c. Install the access plugs.
FIGURE 23. ADJUST THE TIMING CHAIN
1. ACCESS HOLE FOR CHAIN GUIDE
CAPSCREW
2. ACCESS HOLE FOR CHAIN GUIDE
3. SCREWDRIVER
1
2
3
10. Adjust the valve clearance.
11. Use a silicone sealant on the half round seals in the
cylinder head. Install the seal in the cylinder head.
Install the gasket and the valve cover. Tighten the cap-
screws for the valve cover to 19 to 30 N.m (14 to 22 lbf
ft).
12. Install the distributor.
CRANKSHAFT AND MAIN BEARINGS
Removal
1. Remove the cylinder head.
2. Remove the crankshaft pulley. Remove the oil pan.
3. Remove the front cover from the cylinder block.
4. Remove the sprockets and chain for the oil pump. Re-
move the timing chain and crankshaft sprocket.
5. Remove the oil pump and strainer as an assembly.
6. Remove the caps for the connecting rods. Put a mark
ofidentificationoneachcapsothattheywillbeinstalled
to the same location.
7. Before removing the crankshaft, measure the clear-
ance between the crankshaft and the flange of the rear
main bearing. See FIGURE 24. Push the crankshaft
fully forward before making the measurement. Normal
clearance is 0.08 to 0.242 mm (0.003 to 0.0095 in). The
maximum clearance is 0.30 mm (0.012 in). If the clear-
ance is greater than the specification, replace the thrust
bearing.
FIGURE 24. MEASURE THE CRANKSHAFT
CLEARANCE
1. REAR MAIN BEARING
1
8. Put marks for identification on the bearing caps.
Loosen the capscrews for the main bearing caps in steps,
then remove the capscrews and the caps. Remove the
crankshaft. Remove the oil seal from the crankshaft.Re-
move the main bearings from the engine.
Inspection And Repair
CRANKSHAFT
1. Visually inspect the crankshaft for wear, cracks or
other damage. Replace the crankshaft if it has cracks.
2. Use a micrometer to measure the diameter of the jour-
nals for the crankshaft. See FIGURE 25. Make the
measurement at several locations for each journal. If the
measurements are less than specifications, grind the
crankshaft and install undersize bearings. The correct
dimensions for the journals are as follows:

18. 10
Main Journal Diameter – 49.938 to 49.956 mm
(1.966 to 1.983 in)
Connecting Rod Journals – 39.940 to 39.956 mm
(1.586 to 1.573 in)
3. Check the crankshaft for being straight. See
FIGURE 25. Put the front and rear journals in V blocks
and rotate the crankshaft one complete turn. The maxi-
mum amount that the dial indicator can indicate is 0.04
mm (0.0016 in).
FIGURE 25. CRANKSHAFT INSPECTION
1. REAR OIL SEAL SURFACE
2. CONNECTING ROD JOURNALS
3. MAIN BEARING JOURNALS
4. FRONT OIL SEAL SURFACE
2
1
3
4
4. Check the passages for oil in the crankshaft. Make
sure the passages are clean, with no restrictions.
MAIN BEARINGS
1. Visually inspect the main bearings for wear and dam-
age. Replace the bearings as necessary.
FIGURE 26. CHECK THE CLEARANCE FOR
THE MAIN BEARINGS
2. Measure the clearance between the main bearings and
the crankshaft. Use a plastic gauge material as shown in
FIGURE 26. Tighten the capscrews for the main bear-
ing caps to 65 to 69 N.m (48 to 51 lbf ft). The correct
clearance is 0.023 to 0.064 mm (0.0009 to 0.0025 in).
The maximum clearance is 0.08 mm (0.003 in).
Installation
1. Clean the main bearings and the areas at the block for
the main bearings. Install the main bearings and lubri-
cate them with oil.
2. Install the crankshaft on the bearings. Install the rear
seal on the crankshaft. Install the main bearings in the
caps and lubricate them with oil. Use the identification
marks and install the main bearing caps. Install the
thrust bearing at the rear main bearing cap. (The oil
grooves on the thrust bearing must contact the crank-
shaft.Tightenthecapscrewsforthemainbearingcapsto
65 to 69 N.m (48 to 51 lbf ft). Install the oil seals in the
grooves between the cylinder block and the cap for the
rear main bearing as shown in FIGURE 27.

19. 11
FIGURE 27. REAR OIL SEAL
1. REAR SEAL
2. CRANKSHAFT
3
2
1
3. MAIN BEARING CAP
4. SEAL
4
3. Install the pistons and the connecting rods.
4. Install the push rod for the fuel pump in the cylinder
block. Install the oil pump assembly. Make sure the
marksontherotorsintheoilpumparetowardtheengine
block. Install the oil strainer.
5. Install the key and sprocket for the timing chain on the
crankshaft. Install the timing chain on the sprocket so
that the polished link is aligned with the mark on the
sprocket. Install the camshaft sprocket in the timing
chain. Use a piece of wire or a tie strap to hold the
sprocket in position on the timing chain. Make sure the
polished chain link is aligned with the timing mark on
the sprocket.
6. Install the key on the oil pump shaft. Install the chain
and sprockets for the oil pump. Tighten the nut on the oil
pump shaft to 30 to 34 N.m (22 to 25 lbf ft). Bend the
lock washer on the nut.
7. Install the oil seal in the front cover. Install the baffle
on the crankshaft. Install the front cover and gaskets on
the cylinder block. Tighten the capscrews for the front
cover to 19 to 26 N.m (14 to 19 lbf ft).
8. Use a silicone sealant on the oil pan and install the oil
pan. Tighten the capscrews to 7 to 9 N.m (5 to 7 lbf ft).
9. Lubricate the oil seal, the install the pulley on the
crankshaft. Tighten the capscrew for the pulley to 156 to
165 N.m (115 to 122 lbf ft).
10.InstallthecylinderheadasdescribedinCYLINDER
HEAD, Installation.
PISTONS AND CONNECTING RODS
Removal And Disassembly
1. Remove the cylinder head.
2. Remove the oil pan and oil strainer.
3. Put a mark for identification on the top of each piston.
4. Clean the carbon from the top of each cylinder bore.
5. Remove the caps and bearings from each connecting
rod. Keep the caps and bearings with the correct piston
assemblies.
6. Push the connecting rod and piston from the block.
7. Carefully remove the piston rings from the pistons.
Use a tool to push the piston pin from the connecting
rod.
Cleaning
WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning sol-
vents, always follow the solvent manufacturer’s rec-
ommended safety procedures.
Clean all of the parts in solvent. Make sure that all oil
passages and grooves are clean. Make sure all machined
surfaces are smooth.
Inspection And Repair
PISTONS
1. Inspect the pistons for wear and cracks. Replace a pis-
ton that has damage.

20. 12
FIGURE 28. MEASURING THE PISTON
16.5 mm
(0.65 in)
2. Measure the outside diameter of the piston as shown
in FIGURE 28. The correct dimension is 76.954 to
76.974 mm (3.0297 to 3.0305 in). The maximum clear-
ance between the piston and the cylinder bore is 0.15
mm (0.0059 in).
PISTON RINGS
1. Measure the end clearance of each piston ring as
shown in FIGURE 29. Install the piston ring into the
cylinder bore where it will be used. Use a thickness
gauge to measure the amount of end clearance. The cor-
rect clearance is as follows:
FIGURE 29. MEASURING THE PISTON RINGS
1. PISTON RING END
CLEARANCE
2. PISTON RING
GROOVE
CLEARANCE
1
2
Top Piston Ring – 0.20–0.40 mm (0.008–0.016 in)
2nd Piston Ring – 0.20–0.40 mm (0.006–0.016 in)
Oil Ring – 0.30–0.90 mm (0.012–0.035 in)
Maximum clearance is 1.0 mm (0.039 in)
2. Measure the clearance between the piston ring and the
groove in the piston as shown in FIGURE 29. The cor-
rect dimensions are as follows:
Top Piston Ring – 0.030–0.065 mm (0.0012–0.0026 in)
2nd Piston Ring – 0.030–0.065 mm (0.0012–0.0026 in)
Maximum clearance is 0.15 mm (0.0059 in)
CONNECTING RODS AND BEARINGS
1. Use a special machine to check the connecting rods
for being straight. The maximum amount of distortion
per 100 mm (4.0 in) is 0.04 mm (0.0016 in). If the
amount of distortion is greater than the specification,
use a press to straighten the connecting rod.
2. Check the clearance between the rod bearings and the
journals of the crankshaft. Clean the rod bearings and
journals. Use a plastic gauge material as shown in
FIGURE 30. Tighten the nuts for the rod caps to 30 to 34
N.m (22 to 25 lbf ft). The correct clearance is 0.023 to
0.064 mm (0.0009 to 0.0025 in). The maximum clear-
ance is 0.10 mm (0.0039 in). If the clearance is greater
than the specifications, replace the bearings.
FIGURE 30. CHECK THE CLEARANCE OF THE
CONNECTING ROD BEARINGS
3. Check the clearance between the side of the connect-
ing rod and the crankshaft. The maximum clearance is
0.30 mm (0.012 in). Install a new connecting rod or
crankshaft if the clearance exceeds the limit.

21. 13
Assembly And Installation
PISTONS AND CONNECTING RODS
1. Align the oil port on the large end of the connecting
rod with the “F” mark on the piston. See FIGURE 31.
Lubricate the piston pin and bore in the piston with en-
gine oil. Install the piston pin from the side of the piston
with the “F” mark. Use a press to install the piston pin.
The force to push the pin into the piston must be 500 to
1500 kg (1100 to 3300 lb). If the force is not correct, re-
place the piston pin and/or connecting rod. Use the spe-
cial tool to make sure the piston pin is installed to the
correct depth. After installation, check that the piston
moves freely on the piston pin.
2. Install the piston rings on the pistons. During installa-
tion, the writing on each piston ring must be toward the
top of the piston. Check that the rings rotate freely, then
put the ends of the rings in the positions shown in
FIGURE 32. Make sure the ends of the upper and lower
oil control rings are each 30° from the piston pin. Also
make sure that the top and second rings are each 30°
from the piston pin. Lubricate the rings with engine oil.
FIGURE 31. CONNECTING ROD AND PISTON
1. “F” MARK
2. OIL PORT
1
2
3. Apply clean engine oil to the piston assembly. Install
the bearings for the connecting rods. Install the piston
into the correct cylinder making sure the “F” is toward
the front (timing belt end) of the engine.
FIGURE 32. PISTON RINGS
1. EXPANDER RING
2. OIL RING (UPPER)
3. OIL RING (LOWER)
° °
PISTON
PIN
° °
PISTON
PIN
1
2
3
OIL CONTROL
RING
TOP AND SECOND
RINGS
FIGURE 33. INSTALL THE PISTON
1. “F” MARK
1
4. Apply clean engine oil to the bearing then install the
cap to the correct connecting rod. During installation of
the caps, make sure to align the identification marks that
were made during disassembly. Tighten the nuts for the
rod caps to 30 to 34 N.m (22 to 25 lbf ft).

22. 14
CYLINDER BLOCK
Repairs
1. After the cylinder block is cleaned, check its surface
for distortion. See FIGURE 34. If the amount of distor-
tion is greater than 0.15 mm (0.0059 in), grind the sur-
face of the cylinder block.
FIGURE 34. INSPECT THE CYLINDER BLOCK
2. Check the cylinder bores for wear and damage. Meas-
ure each bore. The correct dimension is 77.000 to
77.019 mm (3.0315 to 3.0322 in). The wear limit above
this dimension is 0.15 mm (0.0059 in). Repair the cylin-
der block or use bigger pistons as necessary.
FLYWHEEL AND RING GEAR
Flywheel, Removal (See FIGURE 36.)
1. Remove the capscrews for the flywheel, then remove
the flywheel and the drive plate.
2. If necessary, remove the adapter plate.
Ring Gear
WARNING
Wear eye protection for this operation to prevent eye
injury from metal chips. You will be using a hammer
and chisel to break the ring gear.
Before the ring gear is removed, check the position of
the chamfer on the teeth.
1. See FIGURE 35. Use a hammer and chisel to break
the ring gear. Make sure that you do not damage the fly-
wheel.
FIGURE 35. RING GEAR REMOVAL
2. The ring gear must be heated before it can be installed
on the flywheel. Make sure that the ring gear is not
heated to more than 200°C (390°F).
WARNING
Hot parts. Wear protective clothing and gloves to
prevent burns.
3. Install the ring gear on the flywheel. Make sure that
the chamfer on the teeth is in the correct direction to-
ward the starter.
Flywheel, Installation (See FIGURE 36.)
1. If the adapter plate for the torque converter housing
was removed, install it on the engine. Tighten the cap-
screws to 41 N.m (30 lbf ft).
2. Install the flywheel on the crankshaft. Apply a thread
locking adhesive on the threads of the capscrews. then
install the capscrews and lock washers. Tighten the cap-
screws to 71 N.m (52 lbf ft).

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