2008 Mazda Motor Corporation
PRINTED IN U.S.A., OCTOBER 2008
up to October, 2008. Any changes that occur
Part No. 9999-95-E13B-MSP09
C
M
Y
CM
MY
CY
CMY
K
1773-1U-03C(INDEX).pdf 10/8/2008 10:00:06 AM
00
GENERAL INFORMATION
00–00–1
SECTION
00–00
Engine Workshop Manual 13B-MSP (Multi Side Port) (1773–1U–03C)
Revised 6/2008 (Ref. No. R108/08)
To c of SCT
GENERAL INFORMATION . . . . 00-00
To c of SCT
00–00 GENERAL INFORMATION
HOW TO USE THIS MANUAL . . . . . . . . . 00–00–1
Range of Topics . . . . . . . . . . . . . . . . . . 00–00–1
Service Procedure . . . . . . . . . . . . . . . . 00–00–2
Symbols . . . . . . . . . . . . . . . . . . . . . . . . 00–00–4
Advisory Messages. . . . . . . . . . . . . . . . 00–00–4
UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–00–5
Conversion to SI Units
(Système International d'Unités) . . . . . 00–00–5
Rounding Off. . . . . . . . . . . . . . . . . . . . . 00–00–5
Upper and Lower Limits . . . . . . . . . . . . 00–00–5
FUNDAMENTAL PROCEDURES. . . . . . . 00–00–6
Preparation of Tools and Measuring
Equipment. . . . . . . . . . . . . . . . . . . . . . 00–00–6
Special Service Tools . . . . . . . . . . . . . . 00–00–6
Disassembly . . . . . . . . . . . . . . . . . . . . . 00–00–6
Inspection During Removal,
Disassembly. . . . . . . . . . . . . . . . . . . . 00–00–6
Arrangement of Parts . . . . . . . . . . . . . . 00–00–7
Cleaning of Parts . . . . . . . . . . . . . . . . . 00–00–7
Reassembly . . . . . . . . . . . . . . . . . . . . . 00–00–7
Adjustment . . . . . . . . . . . . . . . . . . . . . . 00–00–8
Rubber Parts and Tubing . . . . . . . . . . . 00–00–8
Hose Clamps . . . . . . . . . . . . . . . . . . . . 00–00–8
Torque Formulas . . . . . . . . . . . . . . . . . 00–00–8
Vise . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–00–9
ELECTRICAL SYSTEM. . . . . . . . . . . . . . 00–00–9
Connectors. . . . . . . . . . . . . . . . . . . . . . 00–00–9
SAE STANDARDS. . . . . . . . . . . . . . . . . . 00–00–11
ABBREVIATIONS . . . . . . . . . . . . . . . . . . 00–00–11
IDENTIFYING SPECIFICATION . . . . . . . 00–00–12
End of Toc
HOW TO USE THIS MANUAL
CHU000000001E01
Range of Topics
• This manual contains procedures for performing all required service operations. The procedures are divided
into the following five basic operations:
— Removal/Installation
— Disassembly/Assembly
— Replacement
— Inspection
— Adjustment
• Simple operations which can be performed easily just by looking at the vehicle (i.e., removal/installation of
parts, jacking, vehicle lifting, cleaning of parts, and visual inspection) have been omitted.
GENERAL INFORMATION
00–00–2
Engine Workshop Manual 13B-MSP (Multi Side Port) (1773–1U–03C)
Service Procedure
Inspection, adjustment
• Inspection and adjustment procedures are
divided into steps. Important points regarding the
location and contents of the procedures are
explained in detail and shown in the illustrations.
49 H002 671
49 H032 322
49 1232 670A
SHOWS PROCEDURE ORDER
FOR SERVICE
Fluid Pressure Inspection
1. Assemble the SSTs as shown in the figure.
Tightening torque
SHOWS TIGHTENING
TORQUE
SPECIFICATIONS
Caution
Connect the gauge set from under
the vehicle to prevent contact with
the drive belt and the cooling fan.
39—49 N·m {4.0—5.0 kgf·m, 29—36 ft·lbf}
WGIWXX0009E
GENERAL INFORMATION
00–00–3
00–00
Repair procedure
1. Most repair operations begin with an overview illustration. It identifies the components, shows how the parts fit
together, and describes visual part inspection. However, only removal/installation procedures that need to be
performed methodically have written instructions.
2. Expendable parts, tightening torques, and symbols for oil, grease, and sealant are shown in the overview
illustration. In addition, symbols indicating parts requiring the use of special service tools or equivalent are also
shown.
3. Procedure steps are numbered and the part that is the main point of that procedure is shown in the illustration
with the corresponding number. Occasionally, there are important points or additional information concerning a
procedure. Refer to this information when servicing the related part.
YLU000WA0
GENERAL INFORMATION
00–00–4
Symbols
• There are eight symbols indicating oil, grease, fluids, sealant, and the use of SST or equivalent. These symbols
show application points or use of these materials during service.
Advisory Messages
• You will find several Warnings, Cautions, Notes, Specifications and Upper and Lower Limits in this
manual.
Warning
• A Warning indicates a situation in which serious injury or death could result if the warning is ignored.
Caution
• A Caution indicates a situation in which damage to the vehicle or parts could result if the caution is ignored.
Note
• A Note provides added information that will help you to complete a particular procedure.
Specification
• The values indicate the allowable range when performing inspections or adjustments.
Upper and lower limits
• The values indicate the upper and lower limits that must not be exceeded when performing inspections or
adjustments.
End Of Sie
Symbol Meaning Kind
Apply oil
New appropriate
engine oil or gear
oil
Apply brake fluid
New appropriate
brake fluid
Apply automatic
transaxle/
transmission fluid
New appropriate
automatic
transaxle/
transmission fluid
Apply grease
Appropriate
grease
Apply sealant
Appropriate
sealant
Apply petroleum
jelly
Appropriate
petroleum jelly
Replace part
O-ring, gasket,
etc.
Use SST or
equivalent
Appropriate tools
OIL
OIL
BRAKE
FLUID
A
A
TF
TF
GREASE
GREASE
SEALANT
P
R
SST
GENERAL INFORMATION
00–00–5
00–00
UNITS
CHU000000002E01
Conversion to SI Units (Système International d'Unités)
• All numerical values in this manual are based on SI units. Numbers shown in conventional units are converted
from these values.
Rounding Off
• Converted values are rounded off to the same number of places as the SI unit value. For example, if the SI unit
value is 17.2 and the value after conversion is 37.84, the converted value will be rounded off to 37.8.
Upper and Lower Limits
• When the data indicates upper and lower limits, the converted values are rounded down if the SI unit value is
an upper limit and rounded up if the SI unit value is a lower limit. Therefore, converted values for the same SI
unit value may differ after conversion. For example, consider 2.7 kgf/cm
2
in the following specifications:
210—260 kPa {2.1—2.7 kgf/cm
2
, 30—38 psi}
270—310 kPa {2.7—3.2 kgf/cm
2
, 39—45 psi}
• The actual converted values for 2.7 kgf/cm
2
are 264 kPa and 38.4 psi. In the first specification, 2.7 is used as
an upper limit, so the converted values are rounded down to 260 and 38. In the second specification, 2.7 is
used as a lower limit, so the converted values are rounded up to 270 and 39.
End Of Sie
Electric current A (ampere)
Electric power W (watt)
Electric resistance ohm
Electric voltage V (volt)
Length
mm (millimeter)
in (inch)
Negative pressure
kPa (kilo pascal)
mmHg (millimeters of mercury)
inHg (inches of mercury)
Positive pressure
kPa (kilo pascal)
kgf/cm
2
(kilogram force per square
centimeter)
psi (pounds per square inch)
Number of
revolutions
rpm (revolutions per minute)
Torque
N·m (Newton meter)
kgf·m (kilogram force meter)
kgf·cm (kilogram force centimeter)
ft·lbf (foot pound force)
in·lbf (inch pound force)
Volume
L (liter)
US qt (U.S. quart)
Imp qt (Imperial quart)
ml (milliliter)
cc (cubic centimeter)
cu in (cubic inch)
fl oz (fluid ounce)
Weight
g (gram)
oz (ounce)
GENERAL INFORMATION
00–00–6
FUNDAMENTAL PROCEDURES
CHU000000004E01
Preparation of Tools and Measuring Equipment
• Be sure that all necessary tools and measuring
equipment are available before starting any work.
Special Service Tools
• Use special service tools or equivalent when they
are required.
Disassembly
• If the disassembly procedure is complex,
requiring many parts to be disassembled, all parts
should be marked in a place that will not affect
their performance or external appearance and
identified so that reassembly can be performed
easily and efficiently.
Inspection During Removal, Disassembly
• When removed, each part should be carefully
inspected for malfunction, deformation, damage
and other problems.
CHU0014W003
49 SE01 310
WGIWXX0024E
WGIWXX0027E
WGIWXX0028E
GENERAL INFORMATION
00–00–7
00–00
Arrangement of Parts
• All disassembled parts should be carefully
arranged for reassembly.
• Be sure to separate or otherwise identify the parts
to be replaced from those that will be reused.
Cleaning of Parts
• All parts to be reused should be carefully and
thoroughly cleaned in the appropriate method.
Warning
•
••
• Using compressed air can cause dirt and
other particles to fly out causing injury to
the eyes. Wear protective eye wear
whenever using compressed air.
Reassembly
• Standard values, such as torques and certain
adjustments, must be strictly observed in the
reassembly of all parts.
• If removed, the following parts should be replaced
with new ones:
— Oil seals
— Gaskets
— O-rings
— Lock washers
— Cotter pins
— Nylon nuts
• Depending on location:
— Sealant and gaskets, or both, should be
applied to specified locations. When sealant
is applied, parts should be installed before
sealant hardens to prevent leakage.
— Oil should be applied to the moving
components of parts.
— Specified oil or grease should be applied at
the prescribed locations (such as oil seals)
before reassembly.
WGIWXX0029E
WGIWXX0030E
WGIWXX0031E
CHU0014W006
GENERAL INFORMATION
00–00–8
Adjustment
• Use suitable gauges and testers when making
adjustments.
Rubber Parts and Tubing
• Prevent gasoline or oil from getting on rubber
parts or tubing.
Hose Clamps
• When reinstalling, position the hose clamp in the
original location on the hose and squeeze the
clamp lightly with large pliers to ensure a good fit.
Torque Formulas
• When using a torque wrench-SST or equivalent
combination, the written torque must be
recalculated due to the extra length that the SST
or equivalent adds to the torque wrench.
Recalculate the torque by using the following
formulas. Choose the formula that applies to you.
A : The length of the SST past the torque wrench drive.
L : The length of the torque wrench.
CHU0014W005
WGIWXX0034E
WGIWXX0035E
Torque Unit Formula
N·mN·m
×
[L/(L+A)]
kgf·mkgf·m × [L/(L+A)]
kgf·cm kgf·cm × [L/(L+A)]
ft·lbf ft·lbf × [L/(L+A)]
in·lbf in·lbf × [L/(L+A)]
0
1
1
2
2
3
3
SST
A
L
WGIWXX0036E
GENERAL INFORMATION
00–00–9
00–00
Vise
• When using a vise, put protective plates in the
jaws of the vise to prevent damage to parts.
End Of Sie
ELECTRICAL SYSTEM
CHU000000006E01
Connectors
Disconnecting connectors
• When disconnecting connector, grasp the
connectors, not the wires.
• Connectors can be disconnected by pressing or
pulling the lock lever as shown.
Locking connector
• When locking connectors, listen for a click
indicating they are securely locked.
PROTECTIVE PLATES
CHU0014W010
GOOD
NO GOOD
CHU0000W014
WGIWXX0042E
WGIWXX0043E
GENERAL INFORMATION
00–00–10
Inspection
• When a tester is used to inspect for continuity or
measuring voltage, insert the tester probe from
the wiring harness side.
• Inspect the terminals of waterproof connectors
from the connector side since they cannot be
accessed from the wiring harness side.
Caution
•
••
• To prevent damage to the terminal, wrap
a thin wire around the tester probe before
inserting into terminal.
End Of Sie
GOOD
NO GOOD
CHU0000W011
GOOD NO GOOD
CHU0000W012
GENERAL INFORMATION
00–00–11
00–00
Engine Workshop Manual 13B-MSP (Multi Side Port) (1773–1U–03C)
SAE STANDARDS
CHU000000003E02
• In accordance with new regulations, SAE (Society of Automotive Engineers) standard names and abbreviations
are now used in this manual. The table below lists the names and abbreviations that have been used in Mazda
manuals up to now and their SAE equivalents.
#1 : Diagnostic trouble codes depend on the diagnostic test mode.
#2 : Controlled by the PCM
#3 : Device that controls engine and powertrain
#4 : Directly connected to exhaust manifold
End Of Sie
ABBREVIATIONS
CHU000000011E01
End Of Sie
SAE Standard
Remark
SAE Standard
Remark
Abbreviation Name Abbreviation Name
AP Accelerator Pedal MAP Manifold Absolute Pressure
APP Accelerator Pedal Position MAF Mass Air Flow
ACL Air Cleaner MAF sensor Mass Air Flow Sensor
A/C Air Conditioning MFL Multiport Fuel Injection
A/F Air Fuel Ratio OBD On-board Diagnostic System
BARO Barometric Pressure OL Open Loop
B+ Battery Positive Voltage OC Oxidation Catalytic Converter
CMP sensor Camshaft Position Sensor O2S Oxygen Sensor
LOAD Calculated Load Value PNP Park/Neutral Position
CAC Charge Air Cooler PID Parameter Identification
CLS Closed Loop System PSP Power Steering Pressure
CTP Closed Throttle Position PCM Powertrain Control Module #3
CPP Clutch Pedal Position
PAIR Pulsed Secondary Air Injection
Pulsed
injection
CIS Continuous Fuel Injection System
CKP sensor Crankshaft Position Sensor
AIR Secondary Air Injection
Injection
with air
pump
DLC Data Link Connector
DTM Diagnostic Test Mode #1
DTC Diagnostic Test Code(s) SAPV Secondary Air Pulse Valve
DI Distributor Ignition
SFI
Sequential Multiport Fuel
Injection
DLI Distributorless Ignition
EI Electronic Ignition #2 3GR Third Gear
ECT Engine Coolant Temperature TWC Three Way Catalytic Converter
EM Engine Modification TB Throttle Body
EVAP Evaporative Emission TP Throttle Position
EGR Exhaust Gas Recirculation TP sensor Throttle Position Sensor
FC Fan Control TCC Torque Converter Clutch
FF Flexible Fuel
TCM
Transmission (Transaxle) Control
Module
4GR Fourth Gear
GEN Generator TR Transmission (Transaxle) Range
GND Ground TC Turbocharger
HO2S Heated Oxygen Sensor
With
heater
VSS Vehicle Speed Sensor
VR Voltage Regulator
IAC Idle Air Control VAF sensor Volume Air Flow Sensor
IAT Intake Air Temperature
WU-TWC
Warm Up Three Way Catalytic
Converter
#4
KS Knock Sensor
MIL Malfunction Indicator Lamp WOP Wide Open Throttle
AT Automatic Transmission
MT Manual Transmission
SST Special Service Tool
GENERAL INFORMATION
00–00–12
Engine Workshop Manual 13B-MSP (Multi Side Port) (1773–1U–03C)
Added 6/2008 (Ref. No. R108/08)
IDENTIFYING SPECIFICATION
CHU000000000E01
• Because the engine construction varies depending on the vehicle’s period of manufacture, determine the
service specification by referring to the following identification.
Identifying Specification
End Of Sie
Applicable VIN
Type A Except below
Type B
JM1 FE172*9# 400001—
JM1 FE174*9# 400001—
JM1 FE17M*9# 400001—
JM1 FE17P*9# 400001—
MECHANICAL
01–10–1
01–10
Engine Workshop Manual 13B-MSP (Multi Side Port) (1773–1U–03C)
Revised 6/2008 (Ref. No. R108/08)
To c of SCT
MECHANICAL . . . . . . . . . . . . . 01-10
TECHNICAL DATA. . . . . . . . . . 01-50
SERVICE TOOLS . . . . . . . . . . . 01-60
To c of SCT
01–10 MECHANICAL
ENGINE OVERHAUL SERVICE
WARNING . . . . . . . . . . . . . . . . . . . . . . . 01–10–2
ENGINE MOUNTING/DISMOUNTING . . 01–10–2
Mounting . . . . . . . . . . . . . . . . . . . . . . . 01–10–2
Dismounting . . . . . . . . . . . . . . . . . . . . . 01–10–3
HOUSING DISASSEMBLY I . . . . . . . . . . 01–10–4
Oil Pan Disassembly Note . . . . . . . . . . 01–10–5
Oil Pan Upper Block
Disassembly Note . . . . . . . . . . . . . . . 01–10–5
HOUSING DISASSEMBLY II. . . . . . . . . . 01–10–6
Pulley Lockbolt Disassembly Note . . . . 01–10–7
Front Cover Disassembly Note . . . . . . 01–10–7
Oil Pump Sprocket
Disassembly Note . . . . . . . . . . . . . . . 01–10–7
HOUSING DISASSEMBLY III . . . . . . . . . 01–10–8
Flywheel (MT), Counterweight (AT)
Disassembly Note . . . . . . . . . . . . . . . 01–10–9
Tension Bolt Disassembly Note . . . . . . 01–10–10
Rear Housing Disassembly Note . . . . . 01–10–10
Stationary Gear Disassembly Note . . . 01–10–10
Tubular Dowel Disassembly Note. . . . . 01–10–10
Rotor Housing Disassembly Note . . . . 01–10–11
Rotor Disassembly Note . . . . . . . . . . . 01–10–11
Intermediate Housing
Disassembly Note . . . . . . . . . . . . . . . 01–10–12
ROTOR DISASSEMBLY . . . . . . . . . . . . . 01–10–12
Oil Seal Disassembly Note. . . . . . . . . . 01–10–13
Oil Seal Spring Disassembly Note . . . . 01–10–13
SIDE HOUSING (FRONT, INTERMEDIATE,
REAR) INSPECTION. . . . . . . . . . . . . . . 01–10–13
ROTOR HOUSING INSPECTION . . . . . . 01–10–14
ROTOR INSPECTION . . . . . . . . . . . . . . . 01–10–15
APEX SEAL INSPECTION . . . . . . . . . . . 01–10–16
SIDE SEAL INSPECTION . . . . . . . . . . . . 01–10–17
CUT-OFF SEAL INSPECTION . . . . . . . . 01–10–18
OIL SEAL INSPECTION . . . . . . . . . . . . . 01–10–18
SPRING INSPECTION . . . . . . . . . . . . . . 01–10–18
Oil Seal Spring . . . . . . . . . . . . . . . . . . . 01–10–18
Cut-off Seal Spring. . . . . . . . . . . . . . . . 01–10–19
Side Seal Spring . . . . . . . . . . . . . . . . . 01–10–19
Corner Seal Spring . . . . . . . . . . . . . . . 01–10–19
Apex Seal Spring . . . . . . . . . . . . . . . . . 01–10–19
ROTOR BEARING OIL CLEARANCE
INSPECTION . . . . . . . . . . . . . . . . . . . . . 01–10–20
ROTOR BEARING REPLACEMENT. . . . 01–10–21
Removal . . . . . . . . . . . . . . . . . . . . . . . . 01–10–21
Installation . . . . . . . . . . . . . . . . . . . . . . 01–10–21
ECCENTRIC SHAFT INSPECTION . . . . 01–10–22
ECCENTRIC SHAFT END PLAY
INSPECTION . . . . . . . . . . . . . . . . . . . . . 01–10–22
PILOT BEARING
INSPECTION/REPLACEMENT [MT] . . . 01–10–24
Inspection . . . . . . . . . . . . . . . . . . . . . . . 01–10–24
Replacement . . . . . . . . . . . . . . . . . . . . . 01–10–24
ECCENTRIC SHAFT BYPASS
VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . 01–10–25
ECCENTRIC SHAFT POSITION PLATE
INSPECTION . . . . . . . . . . . . . . . . . . . . . 01–10–25
MAIN BEARING OIL CLEARANCE
INSPECTION . . . . . . . . . . . . . . . . . . . . . 01–10–25
MAIN BEARING REPLACEMENT . . . . . . 01–10–26
Removal . . . . . . . . . . . . . . . . . . . . . . . . 01–10–26
Installation . . . . . . . . . . . . . . . . . . . . . . . 01–10–27
OIL PUMP INSPECTION . . . . . . . . . . . . . 01–10–29
Type A . . . . . . . . . . . . . . . . . . . . . . . . . . 01–10–29
Type B . . . . . . . . . . . . . . . . . . . . . . . . . . 01–10–29
ROTOR ASSEMBLY . . . . . . . . . . . . . . . . . 01–10–30
Oil Seal Spring Assembly Note . . . . . . . 01–10–30
O-Ring Assembly Note . . . . . . . . . . . . . 01–10–31
Oil Seal Assembly Note . . . . . . . . . . . . 01–10–32
Cut-Off Seal Spring Assembly Note . . . 01–10–32
Cut-Off Seal Assembly Note . . . . . . . . . 01–10–33
HOUSING ASSEMBLY I. . . . . . . . . . . . . . 01–10–34
Thrust Plate Assembly Note . . . . . . . . . 01–10–35
Rotor Assembly Note . . . . . . . . . . . . . . 01–10–35
Oil Jet Plug Assembly Note. . . . . . . . . . 01–10–36
Rotor Housing Assembly Note . . . . . . . 01–10–37
Intermediate Housing
Assembly Note . . . . . . . . . . . . . . . . . . 01–10–38
Rear Oil Seal Assembly Note . . . . . . . . 01–10–39
Rear Housing Assembly Note . . . . . . . . 01–10–40
Tension Bolt Assembly Note . . . . . . . . . 01–10–40
Flywheel (MT), Counterweight (AT)
Assembly Note . . . . . . . . . . . . . . . . . . 01–10–41
HOUSING ASSEMBLY II . . . . . . . . . . . . . 01–10–42
Spacer Assembly Note . . . . . . . . . . . . . 01–10–43
Oil Pump Drive Gear
Assembly Note . . . . . . . . . . . . . . . . . . 01–10–43
Oil Pump Sprocket Wheel
Assembly Note . . . . . . . . . . . . . . . . . . 01–10–43
Front Oil Seal Assembly Note . . . . . . . . 01–10–43
Front Cover Assembly Note . . . . . . . . . 01–10–44
Pulley Lockbolt Assembly Note . . . . . . . 01–10–44
HOUSING ASSEMBLY III . . . . . . . . . . . . . 01–10–45
Oil Pan Upper Block
Assembly Note . . . . . . . . . . . . . . . . . . 01–10–47
Oil Pan Assembly Note . . . . . . . . . . . . . 01–10–47
End of Toc
MECHANICAL
01–10–2
Engine Workshop Manual 13B-MSP (Multi Side Port) (1773–1U–03C)
Revised 6/2008 (Ref. No. R108/08)
ENGINE OVERHAUL SERVICE WARNING
CHU011002000E01
Warning
• Continuous exposure to 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
CHU011002000E12
Caution
• The oil pan could be damaged or dented if the engine's own weight is subjected to an impact
against a level surface. Always set two pieces of wood in the positions shown in the figure to
prevent the oil pan from being dented. If the oil pan is dented, the amount of intake oil and the fluid
pressure will decrease. (Type B)
Mounting
Using 49 L010 1A0
1. Remove the stud bolt.
2. Install the SSTs (arms) to the specified three
position as shown in the figure, and temporarily
tighten with the SSTs (bolts) and 99784 0890 or
M8×1.25 length 90 mm {3.55 in} bolt.
PIECE OF WOOD
OIL PAN
ENGINE FRONT SIDE
ENGINE FRONT SIDE
GHE0110E001
TT
LL
STUD BOLT
CHU0110E048
TT
LL
49 L010 102
49 L010 107
99784 0890 OR M8x1.25
LENGTH 90 mm {3.55 in} BOLT
CHU0110E049
MECHANICAL
01–10–3
01–10
Engine Workshop Manual 13B-MSP (Multi Side Port) (1773–1U–03C)
Revised 6/2008 (Ref. No. R108/08)
3. Install the SSTs (bolt, nut) to the three specified
positions as shown in the figure.
4. Install the SSTs (bolts, nuts, hook, plate) in Step 3
to the SST (arms, bolts) set in Step 2.
5. Adjust the bolt threads by turning them so that
they project approx. 20 mm {0.79 in} from the
plate end.
6. Adjust the bolts and nuts so that the plate and
arms are parallel.
7. Mount the engine to the SST (engine stand).
8. Remove the oil pan drain plug and drain the
engine oil.
9. Replace with a new washer and install the oil pan
drain plug.
Tightening torque
Type A : 29.4—39.2 N·m {3.00—3.99 kgf·m,
21.7—28.9 ft·lbf}
Type B : 29.4—41.2 N·m {3.00—4.20 kgf·m,
21.7—30.3 ft·lbf}
Using 49 J010 3A0A
1. Install the SSTs to the position shown in the
figure.
2. Mount the engine to the SST (engine stand).
3. Remove the oil pan drain plug and drain the
engine oil.
4. Install the oil pan drain plug with a new washer.
Tightening torque
Type A : 29.4—39.2 N·m {3.00—3.99 kgf·m,
21.7—28.9 ft·lbf}
Type B : 29.4—41.2 N·m {3.00—4.20 kgf·m,
21.7—30.3 ft·lbf}
Dismounting
1. Dismount in the reverse order of mounting.
2. Tighten the stud bolt. (Only when using 49 L010 101.)
Tightening torque
14.7—34.3 N·m {1.50—3.49 kgf·m, 10.9—25.2 ft·lbf}
End Of Sie
49 L010 101
49 L010 104
49 L010 105
BHJ0110E003
49 L010 101
49 L010 102
49 L010 105
PARALLEL
APPROX. 20 mm {0.79in}
ENGINE
49 L010 107
99784 0890 OR M8x1.25
LENGTH 90 mm {0.55 in}
BOLT
49 L010 104
49 L010 10449 L010 103
CHU0110E050
AM8×1.25 length 25 mm {1.28 in} bolt
B
99940 1201 (left side engine mount installation nut)
or M12×1.5 nut
C
99756 1230 (left side engine mount installation nut)
+ washer
TT
LL
TT
LL
49 J010 301A
A
B
C
ONLY WHEN USING 49 J010 301A
WHEN USING 49 J010 3A0A
49 J010 301A
49 J010 302A
CHU0110E058
MECHANICAL
01–10–4
Engine Workshop Manual 13B-MSP (Multi Side Port) (1773–1U–03C)
Revised 6/2008 (Ref. No. R108/08)
HOUSING DISASSEMBLY I
CHU011002000E04
1. Disassemble in the order indicated in the table.
Type A
.
9
8
7
5
4
1
2
10
11
6
R
R
R
3
R
R
BHJ0110E006
1 Oil filter component
2 Engine hanger (engine rear side)
3 Engine coolant temperature sensor
4 Engine hanger (engine front side)
5 Water pump body
6 Thermostat component
7Oil pan
(See 01–10–5 Oil Pan Disassembly Note.)
8 Clip
9 Oil baffle plate
10 Oil-level sensor
11 Oil strainer
MECHANICAL
01–10-4–1
01–10
Engine Workshop Manual 13B-MSP (Multi Side Port) (1773–1U–03C)
Revised 6/2008 (Ref. No. R108/08)
01–10-4 MECHANICAL
CHU011002000E04
Type B
.
End Of Sie
R
R
R
5
1
2
R
3
4
6
7
11
9
10
8
12
R
BHJ0110F002
1 Engine hanger (engine rear side)
2 Engine coolant temperature sensor
3 Engine hanger (engine front side)
4 Water pump body
5 Thermostat component
6 Oil pan
(See 01–10–5 Oil Pan Disassembly Note.)
7 Oil pan upper block
(See 01–10–5 Oil Pan Upper Block Disassembly
Note.)
8 Baffle plate
9 Clip
10 Oil level switch
11 Baffle plate
12 Oil strainer
MECHANICAL
01–10-4–2
Engine Workshop Manual 13B-MSP (Multi Side Port) (1773–1U–03C)
THIS PAGE INTENTIONALLY
LEFT BLANK
MECHANICAL
01–10–5
01–10
Engine Workshop Manual 13B-MSP (Multi Side Port) (1773–1U–03C)
Revised 6/2008 (Ref. No. R108/08)
Oil Pan Disassembly Note
1. Remove the oil pan using the separator tool.
Oil Pan Upper Block Disassembly Note
1. Remove the oil pan upper block using the
separator tool.
End Of Sie
BHJ0111W014
BHJ0111E014
MECHANICAL
01–10–6
Engine Workshop Manual 13B-MSP (Multi Side Port) (1773–1U–03C)
Revised 6/2008 (Ref. No. R108/08)
HOUSING DISASSEMBLY II
CHU011002000E05
1. Disassemble in the order indicated in the table.
Type A
.
9
8
7
5
4
3
1
2
10
19
18
17
15
16
14
13
11
12
20
6
R
R
21
22
23
24
R
R
R
SST
25
SST
BHJ0110E008
1 Pulley lockbolt
(See 01–10–7 Pulley Lockbolt Disassembly Note.)
2 Pulley component
3 Eccentric shaft bypass valve
4Spring
5 Front cover
(See 01–10–7 Front Cover Disassembly Note.)
6 Front oil seal
7Plug
8 Control valve spring
9 Control valve
10 Metering oil pump drive gear
11 Oil pump sprocket wheel
(See 01–10–7 Oil Pump Sprocket Disassembly
Note.)
12 Oil pump chain
13 Oil pump drive gear
14 Oil pump component
15 Balance weight
16 Thrust plate
17 Needle bearing
18 Spacer
19 Rear outer rotor
20 Rear inner rotor
21 Middle plate
22 Front outer rotor
23 Front inner rotor
24 Shaft
25 Oil pump body
MECHANICAL
01–10-6–1
01–10
Engine Workshop Manual 13B-MSP (Multi Side Port) (1773–1U–03C)
Revised 6/2008 (Ref. No. R108/08)
01–10-6 MECHANICAL
CHU011002000E04
Type B
.
End Of Sie
R
R
R
R
R
R
R
14
13
12
6
1
43
2
5
10
11
16
15 18 19
20
21
17
7
8
9
SST
SST
BHJ0110F003
1 Pulley lockbolt
(See 01–10–7 Pulley Lockbolt Disassembly Note.)
2 Pulley component
3 Eccentric shaft bypass valve
4Spring
5 Front cover
(See 01–10–7 Front Cover Disassembly Note.)
6 Front oil seal
7OCV
8 Oil pipe
9 OCV case
10 Plug
11 OCV oil filter
12 Oil filter joint
13 Plug
14 Oil pump sprocket wheel
(See 01–10–7 Oil Pump Sprocket Disassembly
Note.)
15 Oil pump chain
16 Oil pump drive gear
17 Oil pump component
18 Balance weight
19 Thrust plate
20 Needle bearing
21 Spacer
MECHANICAL
01–10-6–2
Engine Workshop Manual 13B-MSP (Multi Side Port) (1773–1U–03C)
THIS PAGE INTENTIONALLY
LEFT BLANK
MECHANICAL
01–10–7
01–10
Pulley Lockbolt Disassembly Note
1. Lock the flywheel (MT) or counterweight (AT)
against rotation using the SST.
Front Cover Disassembly Note
1. Loosen the engine front cover installation bolts in
the order shown in the figure.
Oil Pump Sprocket Disassembly Note
1. Lock the flywheel (MT) or counterweight (AT)
against rotation using the SST.
2. Unlock the crimped part of the lock washer and
remove the locknut and lock washer.
3. Remove the oil pump drive gear and oil pump
sprocket wheel with the oil pump chain engaged.
End Of Sie
MT
AT
49 1881 055A
49 F011 101
BHJ0110E007
7
5
4
3
1
2
6
BHJ0110E009
MT
AT
49 1881 055A
49 F011 101
BHJ0110E007
BHJ0110E104
MECHANICAL
01–10–8
HOUSING DISASSEMBLY III
CHU011002000E06
1. Disassemble in the order indicated in the table.
.
R
SST
R
R
R
R
R
R
R
R
9
8
7
5
4
3
10
19
18
17
15
16
14
13
11
12
6
1
R
R
2
SST
AT
1
A
B
C
D
E
G
F
H
I
20
21
22
SST
SST
SST
SST
BHJ0110E010
1 Flywheel (MT), counterweight (AT)
(See 01–10–9 Flywheel (MT), Counterweight (AT)
Disassembly Note.)
2
Tension bolt
(See 01–10–10 Tension Bolt Disassembly Note.)
MECHANICAL
01–10–9
01–10
Engine Workshop Manual 13B-MSP (Multi Side Port) (1773–1U–03C)
Revised 6/2008 (Ref. No. R108/08)
Flywheel (MT), Counterweight (AT) Disassembly Note
1. Lock the flywheel (MT) or counterweight (AT)
against rotation using the SST.
2. Remove the locknut using the SST.
3. Remove the flywheel (MT) or counterweight (AT),
using the SST.
3 Rear housing
(See 01–10–10 Rear Housing Disassembly Note.)
4 Rear oil seal
5 Rear stationary gear
(See 01–10–10 Stationary Gear Disassembly Note.)
6 Pressure regulator (Type A)
7 Tubular dowel (rear rotor housing side)
(See 01–10–10 Tubular Dowel Disassembly Note.)
8 Rear rotor housing
(See 01–10–11 Rotor Housing Disassembly Note.)
9 Rear rotor
A: Side seal
B: Side seal spring
C: Corner seal
D: Corner seal plug
E: Corner Seal Spring
F: Side piece
G: Apex seal
H: Apex seal spring (short)
I: Apex seal spring (long)
(See 01–10–11 Rotor Disassembly Note.)
10 Tubular dowel (front rotor housing side)
(See 01–10–10 Tubular Dowel Disassembly Note.)
11 Intermediate housing
(See 01–10–12 Intermediate Housing Disassembly
Note.)
12 Front rotor housing
(See 01–10–11 Rotor Housing Disassembly Note.)
13 Eccentric shaft
14 Oil jet plug
15 Spring
16 Steel ball
17 Front rotor
(See 01–10–11 Rotor Disassembly Note.)
18 Plate
19 Needle bearing
20 Thrust plate
21 Front stationary gear
(See 01–10–10 Stationary Gear Disassembly Note.)
22 Front housing
MT
AT
49 1881 055A
49 F011 101
BHJ0110E007
49 0820 035
MT
AT
BHJ0110E011
49 0839 305A
MT
AT
BHJ0110E012
MECHANICAL
01–10–10
Engine Workshop Manual 13B-MSP (Multi Side Port) (1773–1U–03C)
Tension Bolt Disassembly Note
1. Loosen the tension bolts in 2⎯3 passes in the
order shown in the figure and remove them.
Rear Housing Disassembly Note
1. Move the rear housing to the left and right to cut the oil film.
2. Remove the rear housing.
Caution
• If a seal adheres to the rear housing, put
it back in its original position in the rotor.
Stationary Gear Disassembly Note
1. Remove the stationary gear using the SST.
Tubular Dowel Disassembly Note
1. Remove the tubular dowel using the SST.
9
8
7
5
4
3
10
18
17
15
16
14
13
11
12
6
1
2
BHJ0110E013
SEAL
CHU0110E039
49 0813 235
BHJ0110E016
49 0813 215A
BHJ0110E017
MECHANICAL
01–10–11
01–10
Rotor Housing Disassembly Note
1. Remove the rotor housing being careful not to
drop the apex seal.
Rotor Disassembly Note
Note
• Pair each seal and spring according to the
numbers shown in the figure, and place
them in the SST according to the numbers
shown on the SST.
1. Remove the side piece, apex seal, corner seal,
side seal, and spring on the engine rear side, and
place them in the SST while keeping them in
order.
2. Move the rotor to the left and right to cut the oil
film.
3. Remove the rotor.
Caution
•
••
• If a seal adheres to the side housing, put
it back in its original position in the rotor.
•
••
• Place the removed rotor upright on soft
material such as a rubber sheet or cloth.
Do not allow the oil seal to directly
contact metal are similar hard surface.
BHJ0110E020
INTERNAL GEAR SIDE
OPPOSITE INTERNAL GEAR SIDE
TAB
ROTATION LOCK TAB
5
4
3
6
1
2
CHU0110E056
49 0813 250
BHJ0110E019
BHJ0110E021
MECHANICAL
01–10–12
4. Remove the corner seal, side seal, and spring on
the engine front side, and place them in the SST
while keeping them in order.
Intermediate Housing Disassembly Note
1. Lift the intermediate housing up while another
person pushes the eccentric shaft upward
approx. 3 cm {1.18 in}.
2. Rotate and remove the intermediate housing at
the point where the eccentric shaft does not
catch.
Caution
•
••
• If a seal adheres to the intermediate
housing, put it back in its original
position in the rotor.
End Of Sie
ROTOR DISASSEMBLY
CHU011002000E07
1. Disassemble in the order indicated in the table.
.
49 0813 250
BHJ0110E022
BHJ0110E023
8
7
5
4
3
6
1
2
R
R
SST
SST
BHJ0110E024
1Cut-off seal
2 Cut-off seal spring
3 Outer oil seal
(See 01–10–13 Oil Seal Disassembly Note.)
4 Outer O-ring (large radius)
MECHANICAL
01–10–13
01–10
Oil Seal Disassembly Note
1. Remove the oil seal using the SST.
Caution
•
••
• Be sure to keep the removed oil seals
separated according to their removal
position.
Oil Seal Spring Disassembly Note
Caution
•
••
• Be sure to keep the removed oil seal springs separated according to their removal positions.
End Of Sie
SIDE HOUSING (FRONT, INTERMEDIATE, REAR) INSPECTION
CHU011010D00E01
1. Inspect the intermediate housing for clogging in the intake and exhaust port.
Caution
•
••
• Carefully inspect the anti-wet port of the
intermediate housing since it is an
essential port.
• If there is any malfunction, replace the
corresponding side housing.
2. Inspect the side housing for distortion in four
positions as shown in the figure using a straight
edge and a feeler gauge.
• If the distortion exceeds the maximum,
replace the corresponding side housing.
Maximum distortion
0.04 mm {0.0016 in}
3. Inspect the following three items related to wear
in the areas where the rotor contacts the side
housing using a dial gauge.
• If any one of the items exceeds the maximum,
replace the corresponding side housing.
5 Outer oil seal spring
(See 01–10–13 Oil Seal Spring Disassembly Note.)
6 Inner oil seal
(See 01–10–13 Oil Seal Disassembly Note.)
7 Inner O-ring (small radius)
8 Inner oil seal spring
(See 01–10–13 Oil Seal Spring Disassembly Note.)
49 0813 225A
BHJ0110E025
ANTI-WET PORT
INTERMEDIATE HOUSING
CHU0110E001
4
3
1 2
BHJ0110E026
MECHANICAL
01–10–14
(1) Vertical wear
Maximum wear
0.10 mm {0.0039 in}
(2) Convex oval
Maximum wear
Oil seal inner path (A): 0.01 mm {0.0004 in}
Oil seal outer path (B): 0.10 mm {0.0039 in}
(3) Oil seal stepped path wear
Maximum wear
0.02 mm {0.0008 in}
End Of Sie
ROTOR HOUSING INSPECTION
CHU011010B08E01
1. Measure the width of the rotor housing at four
points (A, B, C, and D) as shown in the figure
using a micrometer.
2. Compute the width variation.
• If it exceeds the maximum, replace the rotor
housing.
Width difference = (width A) – (the smallest
of widths B, C, or D)
Maximum width difference
0.06 mm {0.0024 in}
End Of Sie
WEAR AREA
CHU0110E002
OIL SEAL PATH
B
A
CHU0110E003
WEAR AREA
CHU0110E004
A
B
C
D
20 mm {0.79 in}
MEASUREMENT POINT
TENSION BOLT HOLE
SEAL RUBBER GROOVE
SHEET METAL
CHU0110E005
MECHANICAL
01–10–15
01–10
ROTOR INSPECTION
CHU011011B10E01
1. Inspect the rotor and side housing clearance according to the following procedure:
• If it is less than the minimum specification, replace the rotor.
(1) Measure the width of the rotor housing in the
position shown in the figure using a
micrometer.
Caution
•
••
• Move the sheet metal piece out of the
way when measuring.
(2) Measure the rotor width at various positions
around the rotor round periphery using a
micrometer.
(3) Compute the rotor and side housing
clearance using the measurements from (1)
and (2).
Rotor and side housing clearance = (rotor
housing width) – (maximum rotor width)
Standard clearance
0.05—0.19 mm {0.0020—0.0074 in}
Minimum clearance
0.05 mm {0.002 in}
2. Measure the protrusion of the rotor round using a
straight edge and a feeler gauge.
Caution
•
••
• Measure the the protrusion of the rotor round in the three apexes of the rotor on both the front and
rear sides.
•
••
• Because the rotor round has two levels, be careful not to measure the level difference of the
middle level.
• If it is less than the minimum specification,
replace the rotor.
Standard projection
0.12—0.18 mm {0.0048—0.0070 in}
Minimum projection
0.1 mm {0.0039 in}
MEASUREMENT POINT
SHEET METAL
CHU0110E040
BHJ0110E032
CHU0110E006
CHU0110E007
MECHANICAL
01–10–16
3. Inspect the corner seal groove of the rotor by
inserting the SST.
• If 1/2 or more of either end of the SST can be
inserted into the seal groove, replace the
corner seal.
• If 1/2 or more of both ends of the SST can be
inserted into the corner seal groove, replace
the rotor.
Caution
•
••
• Do not push the SST in with force.
•
••
• Keep the SST perpendicular to the seal
groove.
•
••
• When replacing the corner seal, replace
with one that matches the S or L inscription on the rotor.
4. Measure the clearance between the apex seal
groove and the apex seal using a feeler gauge.
• If it exceeds the maximum specification,
replace the apex seal.
• If the clearance is still not within the standard
after replacing the apex seal, replace the
rotor.
Standard clearance
0.042—0.101 mm {0.0017—0.0039 in}
Maximum clearance
0.15 mm {0.0059 in}
End Of Sie
APEX SEAL INSPECTION
CHU011011B10E02
1. Measure the height in the positions shown in the
figure.
• If it is less than the minimum specification,
replace the apex seal.
• Replace the apex seal spring also whenever
replacing the apex seal.
Standard Height
5.3 mm {0.20 in}
Minimum height
4.3 mm {0.17 in}
End Of Sie
49 0839 165
BHJ0110E035
CHU0110E008
BHJ0110E037
MECHANICAL
01–10–17
01–10
Engine Workshop Manual 13B-MSP (Multi Side Port) (1773–1U–03C)
Revised 9/2008 (Ref. No. R174/08)
SIDE SEAL INSPECTION
CHU011011B10E04
Replacing with a new side seal.
1.
If replacing the side seal, select the appropriate side seal from the side seal groove length rank marked on the
rotor.
Note
• If a new side seal is inserted, measuring the clearance is not recommended to maintain an appropriate
side seal clearance value.
Side seal selection table
* : Revision indication (alphabetical order)
Reusing the side seal
1. Measure the side seal and corner seal clearance and verify that it doesn’t exceed the maximum.
(1) Assemble the corner seal.
(2) Insert a 0.15 mm {0.0059 in} feeler gauge into the tapered surface side of the side seal as shown in the
figure, and fix the side seal by pressing uniformly so that it contacts the inner side of the groove (straight
surface).
Caution
• Press the feeler gauge firmly on both ends of the side seal.
(3) Measure the clearance between both ends of the side seal and the corner seal using a feeler gauge.
Side seal groove length
rank stamp
Part number of side seal
F
N3Z1 11 C10
*
G
H
I
J
N3Z2 11 C10
*
K
L
M
N
N3Z3 11 C10
*
O
P
Q
R
N3Z4 11 C10
*
S
T
U
V
N3Z5 11 C10
*
W
X
Y
INTERNAL GEAR SIDE
OPPOSITE INTERNAL GEAR SIDE
s
F
s
s
F
F
s
s
s
B
F
TWO-DIMENSION
BAR CODE
F
F
B
*
*
SIDE SEAL GROOVE LENGTH RANK STAMP
(A RANK MARK IS STAMPED FOR EACH SIDE SEAL GROOVE)
*: IDENTIFICATION NUMBER (1 OR 2) USED ONLY FOR
LINE ASSEMBLY
*
*
*
*
CHU110ZEC001
A
A
SIDE SEAL
FEELER GA
UGE
(INSERT INTO BOTH ENDS)
CORNER SEAL
ROTOR
SIDE SEAL
FEELER GAUGE
0.15 mm {0.0059 in}
SEC. A-A
CHU110ZEC002
MECHANICAL
01–10–18
Engine Workshop Manual 13B-MSP (Multi Side Port) (1773–1U–03C)
(4) If the sum of the clearances on both ends exceeds the maximum, replace with a new side seal by selecting
one from the side seal selection table.
Maximum clearance
0.4 mm {0.016 in}
END OF SIE
CUT-OFF SEAL INSPECTION
CHU011011B10E05
1. Measure the cut-off seal height using a vernier
caliper.
• If it is less than the minimum specification,
replace the cut-off seal.
Caution
• Measure the cut-off seal height around
the complete perimeter.
Standard height
3.95 mm {0.1555 in}
Minimum height
3.8 mm {0.15 in}
End Of Sie
OIL SEAL INSPECTION
CHU011011B10E06
1. Measure the following two items using a vernier caliper.
• If either of the items exceeds the maximum specification, replace the oil seal.
(1) Width of area that contacts the oil seal lip.
Caution
• Measure the contact width around the
complete perimeter.
Maximum contact width
0.5 mm {0.02 in}
(2) Circumferential width of any damage along
the lip.
Maximum circumferential width of the oil seal
lip
2.5 mm {0.098 in} or 10 nicks or more
End Of Sie
SPRING INSPECTION
CHU011011B10E07
Oil Seal Spring
1. Assemble the oil seal springs into the rotor.
2. Assemble the O-rings into the oil seals.
3. Assemble the oil seals into the rotor.
4. Measure the oil seal projection using a vernier
caliper.
• If it is less than the minimum specification,
replace the oil seal spring.
Minimum projection
0.5 mm {0.02 in}
BHJ0110E042
A
A
SEC. A-A
BHJ0110E043
NICK
LIP
2.5 mm {0.098 in}
CHU0110E012
OIL SEAL
OIL SEAL SPRING
CHU0110E013
MECHANICAL
01–10–19
01–10
Engine Workshop Manual 13B-MSP (Multi Side Port) (1773–1U–03C)
Revised 6/2008 (Ref. No. R108/08)
Cut-off Seal Spring
1. Assemble the cut-off seal spring into the rotor.
2. Referring to the cut-off seal inspection procedure, verify that the height of the cut-off seal is at the minimum
specification or more. (See 01–10–18 CUT-OFF SEAL INSPECTION.)
3. Assemble the cut-off seal into the rotor.
4. Measure the cut-off seal projection using a
vernier caliper.
• If it is less than the minimum specification,
replace the cut-off seal spring.
Minimum projection
0.5 mm {0.02 in}
Side Seal Spring
1. Assemble the side seal spring into the rotor.
2. Assemble the side seal into the rotor.
3. Measure the side seal projection using a vernier
caliper.
• If it is less than the minimum specification,
replace the side seal spring.
Minimum projection
0.5 mm {0.02 in}
Corner Seal Spring
1. Assemble the corner seal spring into the rotor.
2. Assemble the corner seal into the rotor.
3. Measure the corner seal projection using a
vernier caliper.
• If it is less than the minimum specification,
replace the corner seal spring.
Minimum projection
0.5 mm {0.02 in}
Apex Seal Spring
Note
• Inspect the long apex seal spring.
CUT-OFF SEAL
CUT-OFF SEAL SPRING
CHU0110E041
SIDE SEAL
SIDE SEAL SPRING
CHU0110E015
CORNER SEAL
CORNER SEAL SPRING
CHU0110E016
MECHANICAL
01–10–20
Engine Workshop Manual 13B-MSP (Multi Side Port) (1773–1U–03C)
1. Measure the height of the apex seal spring using
a vernier caliper with the spring placed on a
surface plate.
• If it is less than the minimum specification,
replace the apex seal spring.
Standard height
5.4 mm {0.213 in}
Minimum height
3.5 mm {0.148 in}
End Of Sie
ROTOR BEARING OIL CLEARANCE INSPECTION
CHU011011B10E08
1. Measure the outer diameter of the rotor journal
using a micrometer.
Caution
• Measure the rotor journal at a point
slightly off-center since the center
section is raised. Do not measure at the
center because it does not contact the
rotor bearing.
2. Measure the inner diameter of the rotor bearing
using a cylinder gauge.
3. Calculate the rotor bearing oil clearance from the
rotor journal outer diameter and the rotor bearing
inner diameter.
Rotor bearing oil clearance = (rotor bearing
inner diameter) – (rotor journal outer
diameter)
• If it exceeds the minimum specification,
replace the rotor bearing. (See 01–10–21
ROTOR BEARING REPLACEMENT.)
• If not within the specification, even with the
rotor bearing replaced, replace the eccentric
shaft.
Standard rotor bearing oil clearance
0.06—0.08 mm {0.0024—0.0030 in}
Maximum rotor bearing oil clearance
0.1 mm {0.0039 in}
End Of Sie
APEX SEAL SPRING (LONG)
CHU0110E064
NOT MEASURED
MEASUREMENT
LOCATION
ROTOR JOURNAL (SIDE VIEW)
CHU0110E071
BHJ0110E062
ECCENTRIC SHAFT
ROTOR BEARING
ROTOR
CHU0110E017
MECHANICAL
01–10–21
01–10
Engine Workshop Manual 13B-MSP (Multi Side Port) (1773–1U–03C)
Revised 6/2008 (Ref. No. R108/08)
ROTOR BEARING REPLACEMENT
CHU011011B10E09
Removal
1. Set the rotor with the internal gear at the bottom.
2. Remove the adapter ring and the securing screw
from the SST.
3. Remove the rotor bearing using the SST.
Installation
1. Remove the SST handle.
2. Temporarily assemble so that the rotor bearing
tab and the rotor notch are aligned after pressing
in the rotor bearing and rotor.
3. Set the temporarily assembled rotor bearing and
rotor on a hydraulic press.
4. Press in the rotor bearing using the SST.
End Of Sie
49 0813 240
SECURING SCREW
ADAPTER RING
BHJ0110F004
49 0813 240
BHJ0110E063
49 0813 240
BHJ0110E064
ALIGN TAB AND NOTCH
CHU0110E018
49 0813 240
BHJ0110E066
MECHANICAL
01–10–22
Engine Workshop Manual 13B-MSP (Multi Side Port) (1773–1U–03C)
Revised 6/2008 (Ref. No. R108/08)
ECCENTRIC SHAFT INSPECTION
CHU011011D01E01
1. Inspect for clogging in the oil passage.
• If there is any clogging, remove it with a
needle or similar device and clean with
compressed air.
2. After setting the eccentric shaft main journal on V-
blocks and a surface plate, measure the runout at
the end of the eccentric shaft using a dial gauge.
• If it exceeds the maximum specification,
replace the eccentric shaft.
Standard runout
0.02 mm {0.0008 in}
Maximum runout
0.06 mm {0.0024 in}
End Of Sie
ECCENTRIC SHAFT END PLAY INSPECTION
CHU011011D01E02
1. Lock the flywheel (MT) or counterweight (AT)
against rotation using the SST.
2. Assemble the parts in the following order:
(1) Spacer
(2) Needle bearing
(3) Thrust plate
(4) Balance weight
(5) Oil pump drive gear
(6) Metering oil pump drive gear (Type A)
Caution
• When assembling the spacer, do not
allow the spacer to be caught in the
needle bearing in the plate.
BHJ0110E050
BHJ0110E051
MT
AT
49 1881 055A
49 F011 101
BHJ0110E007
BHJ0110E052
MECHANICAL
01–10–23
01–10
Engine Workshop Manual 13B-MSP (Multi Side Port) (1773–1U–03C)
Revised 6/2008 (Ref. No. R108/08)
3. Assemble the eccentric shaft pulley, eccentric
shaft position plate, pulley boss component apply
engine oil to the pulley lockbolt threads, and then
tighten.
Tightening torque
300—340 N·m {30.6—34.6 kgf·m, 222—250
ft·lbf}
4. Remove the SST.
5. Measure the end play of the eccentric shaft using
a dial gauge.
• If not within the specification, replace the
spacer with one that is thicker than the
currently assembled one. If it exceeds the
specification, replace with a thinner spacer.
Standard end play
0.04—0.09 mm {0.0016—0.0035 in}
Spacer types
(mm {in})
Note
• If the end play is not within the specification even after replacing with an A-marked spacer, adjust by
grinding it and reuse.
End Of Sie
PLATE
NEEDLE BEARING
THRUST PLATE
SPACER
NO GOOD
GOOD
CHU0110E019
BHJ0110E054
Marking Dimension
A 7.985 {0.3144}
B 8.005 {0.3152}
C 8.025 {0.3159}
D 8.045 {0.3167}
E 8.065 {0.3175}
MECHANICAL
01–10–24
Engine Workshop Manual 13B-MSP (Multi Side Port) (1773–1U–03C)
PILOT BEARING INSPECTION/REPLACEMENT [MT]
CHU011011D01E03
Inspection
Caution
• Inspect the pilot bearing when it is installed to the eccentric shaft.
1. Before removing the pilot bearing, inspect it for damage, wear, and proper rotation.
• If there is any malfunction, replace the pilot bearing.
Replacement
Removal
1. Fix the eccentric shaft on a vice.
2. Remove the pilot bearing and the oil seal together
using the SST.
Installation
1. Install a new pilot bearing using the SSTs.
2. Apply grease to the pilot bearing.
3. Install a new oil seal using the SSTs.
End Of Sie
49 1285 071
BHJ0110E070
49 G030 797
49 F011 1A1
PILOT BEARING
11.5—12.25 mm {0.4528—0.4822 in}
GREASE
CHU0110E020
49 G030 797
49 F011 1A1
OIL SEAL
5.5—6.3 mm {0.217—0.248 in}
CHU0110E021
MECHANICAL
01–10–25
01–10
Engine Workshop Manual 13B-MSP (Multi Side Port) (1773–1U–03C)
Revised 6/2008 (Ref. No. R108/08)
ECCENTRIC SHAFT BYPASS VALVE
CHU011011D01E04
Warning
• Engine oil temperature will increase during the inspection and become very dangerous. Be careful
not to burn yourself during the inspection.
1. Put the eccentric shaft bypass valve in a
container filled with engine oil.
2. Heat the container and verify that the projection
protrudes more than the minimum specification
when the engine oil temperature is 60 °C {140
°F}.
• If it is less than the minimum specification,
replace the eccentric shaft bypass valve.
Minimum projection
6 mm {0.24 in}
End Of Sie
ECCENTRIC SHAFT POSITION PLATE INSPECTION
CHU011011D01E05
1. Visually inspect the eccentric shaft position plate
for damage and erosion.
• If there is any malfunction, replace the
eccentric shaft position plate.
Eccentric shaft pulley tightening torque
14.2—17.2 N·m {1.45—1.75 kgf·m, 10.5—12.6
ft·lbf}
End Of Sie
MAIN BEARING OIL CLEARANCE INSPECTION
CHU011010E00E01
1. Using a micrometer, measure the outer diameters
of the inside main journal.
2. Using a cylinder bore gauge, measure the inner
diameter of the stationary gear main bearing.
PROJECTION PART
VERNIER CALIPER
CHU0110E057
ECCENTRIC SHAFT
POSITION PLATE
BHJ0110E106
INSIDE
INSIDE
OUTSIDE
OUTSIDE
CHU0110E022
BHJ0110E056
MECHANICAL
01–10–26
Engine Workshop Manual 13B-MSP (Multi Side Port) (1773–1U–03C)
Revised 6/2008 (Ref. No. R108/08)
3. Calculate the main bearing oil clearance from the
main journal outer diameter and the main bearing
inner diameter.
Main bearing oil clearance = (main bearing
inner diameter) – (main journal outer
diameter)
• If it exceeds the maximum specification,
replace the main bearing. (See 01–10–26
MAIN BEARING REPLACEMENT.)
— If the clearance is not within the
specification after replacing the main
bearing, replace the eccentric shaft.
Standard main bearing oil clearance
Without stopper screw: 0.045—0.085 mm {0.0018—0.0033 in}
With stopper screw: 0.055—0.075 mm {0.0022—0.0029 in}
Maximum main bearing oil clearance
Without stopper screw: 0.1 mm {0.0039 in}
With stopper screw: 0.1 mm {0.0039 in}
End Of Sie
MAIN BEARING REPLACEMENT
CHU011010E00E02
Removal
1. Remove the stopper screw. (With stopper screw)
2. Remove the adapter ring and the securing screw
from the SST.
3. Set the stationary gear to the hydraulic press so
that the gear faces upward.
4. Remove the main bearing using the SST.
ECCENTRIC SHAFT
STATIONARY GEAR
MAIN BEARING
CHU0110E023
STOPPER SCREW
CHU0110E042
49 0813 235
SECURING SCREW
ADAPTER RING
BHJ0110F005
49 0813 235
BHJ0110E057
MECHANICAL
01–10–27
01–10
Engine Workshop Manual 13B-MSP (Multi Side Port) (1773–1U–03C)
Revised 6/2008 (Ref. No. R108/08)
Installation
Without stopper screw
1. Temporarily assemble the stationary gear and the
main bearing so that the main bearing tab and
notch are aligned after pressing in the main
bearing and stationary gear.
2. Remove the SST handle.
3. Position the gear of the stationary gear
downward, and install the main bearing by
pressing it with the SST.
Caution
• Press the main bearing in so that the top
of the main bearing is flush with the top
of the stationary gear flange.
With stopper screw
1. Temporarily assemble the stationary gear and the
main bearing so that the main bearing screw hole
and the stationary gear screw hole are aligned
after pressing in the main bearing and rotor.
ALIGN TAB AND NOTCH
CHU0110E043
49 0813 235
BHJ0110E059
49 0813 235
BHJ0110E060
OIL HOLE
STOPPER SCREW HOLE
CHU0110E044
MECHANICAL
01–10–28
Engine Workshop Manual 13B-MSP (Multi Side Port) (1773–1U–03C)
2. Remove the SST handle.
3. Position the gear of the stationary gear
downward, and install the main bearing using the
SST.
Caution
• Press the main bearing in so that the top
of the main bearing is flush with the top
of the stationary gear flange.
4. Apply thread-locking compound to the stopper
screw and install.
Tightening torque
3.2—4.7 N·m
{33—47 kgf·cm, 29—41 in·lbf}
End Of Sie
49 0813 235
BHJ0110E059
49 0813 235
BHJ0110E060
STOPPER SCREW
CHU0110E042
MECHANICAL
01–10–29
01–10
Engine Workshop Manual 13B-MSP (Multi Side Port) (1773–1U–03C)
Revised 6/2008 (Ref. No. R108/08)
OIL PUMP INSPECTION
CHU011014100E01
Type A
1. Measure the body clearance between the outer
rotor and the body using a feeler gauge.
• If it exceeds the maximum specification,
replace the oil pump.
Standard body clearance
0.20—0.25 mm {0.0079—0.0098 in}
Maximum body clearance
0.3 mm {0.0118 in}
2. Measure the tip clearance between the inner rotor
and the outer rotor using a feeler gauge.
• If it exceeds the maximum specification,
replace the oil pump.
Standard tip clearance
0.03—0.12 mm {0.0012—0.0047 in}
Maximum tip clearance
0.15 mm {0.0059 in}
3. Measure the side clearance between the rotor
and the side housing using a straight edge and a
feeler gauge.
• If it exceeds the maximum specification,
replace the oil pump.
Standard side clearance
0.03—0.125 mm {0.0012—0.0049 in}
Maximum side clearance
0.15 mm {0.0059 in}
Type B
Note
• The oil pump cannot be disassembled because it is a precision unit. If a malfunction occurs, replace the
oil pump component as a single unit.
1. Visually inspect the oil pump gasket.
• Replace the oil pump component if the condition corresponds to any one of the following:
— The lip is damaged.
— The lip and the metallic outer ring are at
the same level.
End Of Sie
BHJ0110E067
BHJ0110E068
BHJ0110E069
METALLIC OUTER RING
SHAPE OF NEW GASKET LIP
SHAPE OF DETERIORATED
GASKET LIP (LEVEL WITH
METALLIC OUTER RING)
GHE0110E002
MECHANICAL
01–10–30
Engine Workshop Manual 13B-MSP (Multi Side Port) (1773–1U–03C)
ROTOR ASSEMBLY
CHU011002000E08
1. Assemble in the order indicated in the table.
.
Oil Seal Spring Assembly Note
1. Assemble the oil seal spring with the identification color upward.
Spring Identification Color
8
7
5
4
3
6
1
2
R
R
P
P
BHJ0110E074
1 Inner oil seal spring
(See 01–10–30 Oil Seal Spring Assembly Note.)
2 Inner O-ring (small radius)
(See 01–10–31 O-Ring Assembly Note.)
3 Inner oil seal
(See 01–10–32 Oil Seal Assembly Note.)
4 Outer oil seal spring
(See 01–10–30 Oil Seal Spring Assembly Note.)
5 Outer O-ring (large radius)
(See 01–10–31 O-Ring Assembly Note.)
6 Outer oil seal
(See 01–10–32 Oil Seal Assembly Note.)
7 Cut-off seal spring
(See 01–10–32 Cut-Off Seal Spring Assembly
Note.)
8 Cut-off seal
(See 01–10–33 Cut-Off Seal Assembly Note.)
Rotor
Front rotor Rear rotor
Engine
front side
Engine
rear side
Engine
front side
Engine
rear side
Inner White Blue White Blue
Outer
White +
pink
Blue + pink
White +
pink
Blue + pink
MECHANICAL
01–10–31
01–10
Caution
•
••
• It is possible that the identification color
may not be visible when reusing the oil
spring. In that case, assemble the
rounded end towards the rotor side and
the squared end upward.
•
••
• Be careful when assembling the oil seal
spring of the front and rear rotor since
each spring of the engine front side and
engine rear side are the same.
Note
• Either one of the two rotation lock slots on
the oil seal can be used as a reference.
• Assemble the rounded end within 0—15 mm
{0—0.59 in} away from the oil seal spring
rotation lock.
O-Ring Assembly Note
1. Apply petroleum jelly to a new O-ring.
2. Assemble the O-ring to the oil seal.
Note
• Assemble the thicker O-ring to the inner oil
seal (small radius), and the thinner O-ring to
the outer oil seal (large radius).
ROTOR
ROTATION
DIRECTION
ROTOR
ROTATION
DIRECTION
ENGINE FRONT SIDE AND REAR SIDE
SQUARED END
ROUNDED END
CHU0110E024
ROTOR ROTATION DIRECTION
IDENTIFICATION COLOR
0—15 mm {0—0.59 in}
ROTATION LOCK
CHU0110E025
BHJ0110E077
MECHANICAL
01–10–32
Oil Seal Assembly Note
1. Temporarily install the oil seal with the squared
end of the oil seal spring fit into the slot of the oil
seal.
2. Push in the oil seal using an old oil seal.
3. Verify that the stroke of the oil seal is smooth and
there is no catching by pushing the oil seal with
your hand.
Cut-Off Seal Spring Assembly Note
1. Assemble the cut-off seal spring with the spring
end turned upward.
Note
• When replacing a cut-off seal with a new
one, assemble the seal with the pink surface
facing upward.
OIL SEAL SLOT
SQUARED END
CHU0110E026
OLD OIL SEAL
ROTOR
0.5—0.6 mm
{0.020—0.023 in}
CHU0110E027
ROTOR
ROTATION LOCK PIN
PINK PAINT
CHU0110E028
MECHANICAL
01–10–33
01–10
Cut-Off Seal Assembly Note
1. Assemble the cut-off seal so that it does not run
over the rotation lock pin.
End Of Sie
ROTOR
ROTATION LOCK PIN
CUT-OFF SEAL
CUT-OFF SEAL SPRING
GOOD
NO GOOD
NO GOOD
CHU0110E029
MECHANICAL
01–10–34
HOUSING ASSEMBLY I
CHU011002000E09
1. Assemble in the order indicated in the table.
.
R
SEALANT
SEALANT
OIL
OIL
SST
R
R
R
R
SEALANT
SEALANT
SEALANT
SEALANT
SEALANT
SEALANT
OIL
OIL
OIL
OIL
OIL
OIL
OIL
OIL
OIL
OIL
OIL
OIL
OIL
OIL
OIL
OIL
OIL
OIL
R
R
R
R
OIL
OIL
OIL
OIL
OIL
OIL
9
8
7
5
4
3
10
19
18
17
15
16
14
13
11
12
6
1
2
R
R
OIL
OIL
AT
SST
A
B
C
D
E
G
F
H
I
P
P
P
P
N·m {kgf·m, ft·lbf}
68.6—78.4 {6.70—7.99, 50.6—57.8}
31.4—39.2
{3.21—3.99, 23.2—28.9}
392—490
{39.8—49.9, 290—361}
20
21
22
22
3.9—11.7
{40—119 kgf·cm,
35—103 in·lbf}
15.7—22.5
{1.61—2.29, 11.6—16.5}
15.7—22.5
{1.61—2.29, 11.6—16.5}
SST
OIL
OIL
P
P
CHU0110E052
1 Front housing
2 Front stationary gear
3 Thrust plate
(See 01–10–35 Thrust Plate Assembly Note.)
4 Needle bearing
MECHANICAL
01–10–35
01–10
Engine Workshop Manual 13B-MSP (Multi Side Port) (1773–1U–03C)
Revised 6/2008 (Ref. No. R108/08)
Thrust Plate Assembly Note
1. Place the chamfer side facing the stationary gear.
Rotor Assembly Note
Caution
• Assemble only the side seal and corner seal on the engine front side while the rotor is not
assembled.
1. Assemble the side seal spring in the direction
shown in the figure.
5Plate
6 Front rotor
A: Side seal
B: Side seal spring
C: Corner seal
D: Corner seal plug
E: Corner seal spring
F: Side piece
G: Apex seal
H: Apex seal spring (short)
I: Apex seal spring (long)
(See 01–10–35 Rotor Assembly Note.)
7 Steel ball
8Spring
9 Oil jet plug
(See 01–10–36 Oil Jet Plug Assembly Note.)
10 Eccentric shaft
11 Front rotor housing
(See 01–10–37 Rotor Housing Assembly Note.)
12 Tubular dowel (front rotor housing side)
13 Intermediate housing
(See 01–10–38 Intermediate Housing Assembly
Note.)
14 Rear rotor
(See 01–10–35 Rotor Assembly Note.)
15 Rear rotor housing
(See 01–10–37 Rotor Housing Assembly Note.)
16 Tubular dowel (rear rotor housing side)
17 Pressure regulator (Type A)
18 Rear stationary gear
19 Rear oil seal
(See 01–10–39 Rear Oil Seal Assembly Note.)
20 Rear housing
(See 01–10–40 Rear Housing Assembly Note.)
21
Tension bolt
(See 01–10–40 Tension Bolt Assembly Note.)
22 Flywheel (MT), counterweight (AT)
(See 01–10–41 Flywheel (MT), Counterweight (AT)
Assembly Note.)
CHAMFER SIDE
STATIONARY GEAR SIDE
CHU0110E045
SIDE SEAL SIDE
ROTOR SIDE
CHU0110E046
MECHANICAL
01–10–36
Engine Workshop Manual 13B-MSP (Multi Side Port) (1773–1U–03C)
Revised 6/2008 (Ref. No. R108/08)
2. Assemble the side seal spring in the direction
shown in the figure.
3. Apply petroleum jelly between the side seal and
side seal groove.
4. Assemble the corner seal plug to the corner seal.
Note
• When replacing a corner seal with new one,
assemble the corner seal with the painting
surface facing upward.
5. Assemble the corner seal and corner seal spring
with the notch aligned with the apex seal groove.
6. Apply petroleum jelly between the corner seal and
corner seal groove.
7. Place the rotor in the housing.
8. Insert the SST into the apex seal groove of the
rotor and verify that the apex seal groove of the
corner seal is aligned with the apex seal groove of
the rotor.
9. Assemble the side seal and corner seal for the
engine rear side in the same way as the engine
front side.
Oil Jet Plug Assembly Note
1. Apply thread locking compound to the seating face of the oil jet plug.
2. Install the oil jet plug.
Tightening torque
3.9—11.7 N·m
{40—119 kgf·cm, 35—103 in·lbf}
SIDE SEAL
ROTOR
SIDE SEAL SPRING
CHU0110E047
CHU0110E030
CORNER SEAL
CORNER SEAL PLUG
CORNER SEAL SPRING
S:PINK
L:WHITE
CHU0110E051
49 0813 225A
GOOD
NO GOOD
CHU0110E070
MECHANICAL
01–10–37
01–10
Engine Workshop Manual 13B-MSP (Multi Side Port) (1773–1U–03C)
Revised 6/2008 (Ref. No. R108/08)
Rotor Housing Assembly Note
Caution
• Assemble the seal rubber without any torsion.
• Do not get oil or grease on the seal rubber.
1. Apply petroleum jelly to a new seal rubber.
2. Assemble the outer seal rubber to the housing
with the white paint in the direction shown in the
figure.
3. Assemble the inner seal rubber to the housing
with the seal rubber joint placed between A—B.
4. Apply the silicone sealant to the position indicated
in the figure.
Bead thickness
2.5—6.5 mm {0.099—0.255 in}
5. Apply thread locking compound to the attaching
surface of the apex seal and the side piece and
affix them.
Caution
• After adhesion, make sure that there is
no gap between the apex seal and side
piece.
WHITE PAINT
HOUSING
CHU0110E061
B
A
CHU0110E062
SEALANT
8—12 mm
{0.32—0.47 in}
SEAL RUBBER
GROOVE
CHU0110E033
ATTACHING SURFACE
CHU0110E059
MECHANICAL
01–10–38
Engine Workshop Manual 13B-MSP (Multi Side Port) (1773–1U–03C)
Revised 6/2008 (Ref. No. R108/08)
• If adhesive protrudes, remove with a
razor.
Note
• When using a new apex seal, the procedure
above is not needed.
6. Assemble the apex seal and apex seal spring
(short) together with the side piece to the engine
rear side.
7. Assemble the apex seal spring (long) while
pressing the apex seal spring (short).
Caution
• Assemble the apex seal spring until it
catches the spring stopper of the side
piece.
Intermediate Housing Assembly Note
1. Assemble the intermediate housing with the
support of an assistant pushing the eccentric
shaft up approx. 3 cm {1.18 in}.
ADHESIVE
RAZOR
CHU0110E069
APEX SEAL SPRING(SHORT)
CHU0110E063
ROTOR HOUSING
ROTOR
APEX SEAL SPRING (LONG)
APEX SEAL SPRING (SHORT)
SPRING STOPPER
CHU0110E034
BHJ0110E023
MECHANICAL
01–10–39
01–10
Caution
•
••
• Do not allow the side piece to be caught
between the rotor housing and
intermediate housing.
Rear Oil Seal Assembly Note
1. Assemble the oil seal using the SST.
Caution
•
••
• Insert the rear oil seal until it is reaches
to the seating face.
GOOD
NO GOOD
CHU0110E060
49 J027 001
OIL SEAL
STATIONARY GEAR
CHU0110E035
MECHANICAL
01–10–40
Rear Housing Assembly Note
1. Assemble the rear housing with the rear stationary gear and the internal gear of the rotor engaged.
Caution
•
••
• Do not allow the side piece to be caught between the rotor housing and rear housing.
Tension Bolt Assembly Note
1. Apply engine oil to the tension bolt threads and
assemble to the housing with a new seal washer.
Caution
•
••
• Assemble a tension bolt which has a seal
washer with the rubber projection facing
the housing side.
2. Tighten the tension bolts in the order indicated in
the figure in 2
3 passes.
Tightening torque
31.4—39.2 N·m
{3.21—3.99 kgf·m, 23.2—28.9 ft·lbf}
GOOD
NO GOOD
CHU0110E060
WITHOUT SEAL
WASHER
INDENTED BOLT
HEAD
CHU0110E036
9
8
7
5
4
3
10
18
17
15
16
14
13
11
12
6
1
2
BHJ0110E094
MECHANICAL
01–10–41
01–10
Engine Workshop Manual 13B-MSP (Multi Side Port) (1773–1U–03C)
Flywheel (MT), Counterweight (AT) Assembly Note
1. Lock the flywheel (MT) or counterweight (AT)
against rotation using the SSTs.
2. Tighten the locknut using the SST.
Tightening torque
392—490 N·m
{40.0—49.9 kgf·m, 290—361 ft·lbf}
End Of Sie
MT
AT
49 1881 055A
49 F011 101
BHJ0110E007
49 0820 035
MT
AT
BHJ0110E011
MECHANICAL
01–10–42
Engine Workshop Manual 13B-MSP (Multi Side Port) (1773–1U–03C)
Revised 6/2008 (Ref. No. R108/08)
HOUSING ASSEMBLY II
CHU011002000E10
1. Assemble in the order indicated in the table.
Type A
.
9
8
7
5
4
3
1
2
10
19
18
17
15
16
14
13
11
12
20
6
24
23
21
22
R
R
R
R
R
N·m {kgf·m, ft·lbf}
18.6—25.5 {1.90—2.60, 13.8—18.8}
39.2—49.0 {4.00—4.99, 29.0—36.1}
31.4—46.1
{3.21—4.70, 23.2—34.0}
254—294
{25.9—29.9, 188—216}
6.9—9.8
{0.8—0.9, 5.1—7.2}
0.98—2.94 {0.10—0.29, 0.73—2.16}
SEALANT
SSTSST
SST
25
SST
OIL
OIL
OIL
OIL
SEALANT
SST
OIL
BHE0110E001
1 Oil pump body
2Shaft
3 Front inner rotor
4 Front outer rotor
5 Middle plate
6 Rear inner rotor
7 Rear outer rotor
8 Spacer
(See 01–10–43 Spacer Assembly Note.)
9 Needle bearing
10 Thrust plate
11 Balance weight
12 Oil pump component
13 Oil pump drive gear
(See 01–10–43 Oil Pump Drive Gear Assembly
Note.)
14 Oil pump chain
15 Oil pump sprocket wheel
(See 01–10–43 Oil Pump Sprocket Wheel Assembly
Note.)
16 Metering oil pump drive gear
17 Control valve
18 Control valve spring
19 Plug
20 Front oil seal
(See 01–10–43 Front Oil Seal Assembly Note.)
21 Front cover
(See 01–10–44 Front Cover Assembly Note.)
22 Spring
23 Eccentric shaft bypass valve
24 Pulley component
25 Pulley lockbolt
(See 01–10–44 Pulley Lockbolt Assembly Note.)
MECHANICAL
01–10-42–1
01–10
Engine Workshop Manual 13B-MSP (Multi Side Port) (1773–1U–03C)
Revised 6/2008 (Ref. No. R108/08)
01–10-42 MECHANICAL
CHU011002000E04
Type B
.
End Of Sie
R
R
R
R
R
R
R
6
5
10
12
11
16
15
18
4
19
3
20
2
21
1
17
7
8
14
9
13
SEALANT
SEALANT
SST
SST
OIL
OIL
SST
18.6—25.5 {1.90—2.60, 13.8—18.8}
13.5—19.3 {1.38—1.96, 9.96—14.2}
29.4—40.2 {2.30—4.09, 21.7—29.6}
31.4—47.0 {3.21—4.79, 23.2—34.6}
31.4—46.1 {3.21—4.70, 23.2—34.0}
OIL
OIL
N·m {kgf·m, ft·lbf}
7.8—10.8 {80—110 kgf·cm, 69.0—95.5 in·lbf}
7.8—10.8 {80—110 kgf
·cm,
69.0—95.5 in
·lbf}
7.8—10.8 {80—110 kgf
·cm,
69.0—95.5 in
·lbf}
7.8—10.8 {80—110 kgf
·cm,
69.0—95.5 in
·lbf}
7.8—10.8 {80—110 kgf
·cm,
69.0—95.5 in
·lbf}
254—294
{25.9—29.9, 188—216}
GHE0110E003
1 Spacer
(See 01–10–43 Spacer Assembly Note.)
2 Needle bearing
3 Thrust plate
4 Balance weight
5 Oil pump component
6 Oil pump drive gear
(See 01–10–43 Oil Pump Drive Gear Assembly
Note.)
7 Oil pump chain
8 Oil pump sprocket wheel
(See 01–10–43 Oil Pump Sprocket Wheel Assembly
Note.)
9 Plug
10 Oil filter joint
11 OCV oil filter
12 Plug
13 OCV case
14 Oil pipe
15 OCV
16 Front oil seal
(See 01–10–43 Front Oil Seal Assembly Note.)
17 Front cover
(See 01–10–44 Front Cover Assembly Note.)
18 Spring
19 Eccentric shaft bypass valve
20 Pulley component
21 Pulley lockbolt
(See 01–10–44 Pulley Lockbolt Assembly Note.)
MECHANICAL
01–10-42–2
Engine Workshop Manual 13B-MSP (Multi Side Port) (1773–1U–03C)
THIS PAGE INTENTIONALLY
LEFT BLANK
MECHANICAL
01–10–43
01–10
Spacer Assembly Note
Caution
•
••
• When assembling the spacer, do not allow the spacer to be caught in the needle bearing of the
plate.
Note
• Perform eccentric shaft end play inspection.
(See01–10–22 ECCENTRIC SHAFT END
PLAY INSPECTION.)
Oil Pump Drive Gear Assembly Note
1. Assemble the oil pump drive gear or oil pump
sprocket wheel with the oil pump chain engaged.
Oil Pump Sprocket Wheel Assembly Note
1. Lock the flywheel (MT) and counterweight (AT)
against rotation using the SSTs.
2. Assemble the oil pump shaft with a new lock
washer and locknut, and tighten.
Tightening torque
31.4—46.1 N·m
{3.21—4.70 kgf·m, 23.2—34.0 ft·lbf}
3. Bend the lock washer and crimp.
Front Oil Seal Assembly Note
1. Press the oil seal in using the SST.
PLATE
NEEDLE BEARING
THRUST PLATE
SPACER
NO GOOD
GOOD
CHU0110E019
BHJ0110E101
MT
AT
49 1881 055A
49 F011 101
BHJ0110E007
49 F010 401A
FRONT COVER
OIL SEAL
1.5—2.5 mm {0.06—0.09 in}
CHU0110E037
MECHANICAL
01–10–44
Front Cover Assembly Note
1. Before installing the front cover, install the pulley
boss to the eccentric shaft and measure the
height between the eccentric shaft top and the
pulley boss.
• If not within the specification, verify that the
spacer is not caught in the needle bearing.
Standard
10.34—11.14 mm {0.4071—0.4385 in}
2. Tighten the engine front cover installation bolts in
the order shown in the figure.
Tightening torque
18.6—25.5 N·m
{1.90—2.60 kgf·m, 13.8—18.8 ft·lbf}
Pulley Lockbolt Assembly Note
1. Lock the flywheel (MT) or counterweight (AT)
against rotation using the SSTs.
2. Apply engine oil to the pulley lockbolt threads.
3. Assemble a new O-ring.
4. Apply silicone sealant to the seating face.
5. Tighten the pulley lockbolt.
Tightening torque
300—340 N·m
{30.6—34.6 kgf·m, 222—250 ft·lbf}
End Of Sie
10.34—11.14 mm
{0.4071—0.4385 in}
PULLEY BOSS
ECCENTRIC SHAFT
CHU0110E038
7
5
4
3
1
2
6
BHJ0110E098
MT
AT
49 1881 055A
49 F011 101
BHJ0110E007
O-RING
ENGINE OIL
SEALANT
SEALANT
CHU0110E066
MECHANICAL
01–10–45
01–10
Engine Workshop Manual 13B-MSP (Multi Side Port) (1773–1U–03C)
Revised 6/2008 (Ref. No. R108/08)
HOUSING ASSEMBLY III
CHU011002000E11
1. Assemble in the order indicated in the table.
Type A
.
9
8
7
5
4
3
1
2
10
11
6
31.4—46.1
{3.21—4.70, 23.2—34.0}
18.6—25.5
{1.90—2.60, 13.8—18.8}
18.6—25.5 {1.90—2.60, 13.8—18.8}
18.6—25.5 {1.90—2.60, 13.8—18.8}
18.6—25.5
{1.9—2.6, 13.8—18.8}
7.8—10.8 {80—110 kgf
·cm, 69.0—95.5 in·lbf}
8.8—11.8
{90—120 kgf
·cm, 78—104 in·lbf}
N·m {kgf·m, ft·lbf}
R
R
R
R
14.2—17.2 {1.45—1.75, 10.5—12.6}
SEALANT
R
15.7—23.5
{1.61—2.39, 11.6—16.5}
7.8—10.8 {80—110 kgf·cm, 69.0—95.5 in·lbf}
7.8—10.8 {80—110 kgf
·cm, 69.0—95.5 in·lbf}
CHU0110E054
1 Oil strainer
2 Oil-level sensor
3 Oil baffle plate
4 Clip
5 Oil pan
(See 01–10–47 Oil Pan Assembly Note.)
6 Thermostat component
7 Water pump body
8 Engine hanger (engine front side)
9 Engine coolant temperature sensor
10 Engine hanger (engine rear side)
11 Oil filter component
MECHANICAL
01–10–46
Engine Workshop Manual 13B-MSP (Multi Side Port) (1773–1U–03C)
Revised 6/2008 (Ref. No. R108/08)
Type B
.
R
R
R
R
7
6
11
2
9
4
10
3
8
5
12
1
R
SEALANT
SEALANT
SEALANT
SEALANT
N·m {kgf·m, ft·lbf}
7.8—10.8 {80—110 kgf
·cm,
69.0—95.5 in
·lbf}
7.8—10.8 {80—110 kgf
·cm,
69.0—95.5 in
·lbf}
7.8—10.8 {80—110 kgf
·cm,
69.0—95.5 in
·lbf}
7.8—10.8 {80—110 kgf
·cm,
69.0—95.5 in
·lbf}
18.6—25.5 {1.90—2.60, 13.8—18.8}
18.6—25.5 {1.90—2.60,
13.8—18.8}
18.6—25.5 {1.90—2.60,
13.8—18.8}
18.6—25.5 {1.90—2.60,
13.8—18.8}
31.4—46.1
{3.21—4.70, 23.2—34.0}
15.7—23.5
{1.61—2.39, 11.6—16.5}
GHE0110E004
1 Oil strainer
2 Baffle plate
3 Oil level switch
4Clip
5 Baffle plate
6 Oil pan upper block
(See 01–10–47 Oil Pan Upper Block Assembly
Note.)
7Oil pan
(See 01–10–47 Oil Pan Assembly Note.)
8 Thermostat component
9 Water pump body
10 Engine hanger (engine front side)
11 ECT sensor
12 Engine hanger (engine rear side)
MECHANICAL
01–10–47
01–10
Engine Workshop Manual 13B-MSP (Multi Side Port) (1773–1U–03C)
Revised 6/2008 (Ref. No. R108/08)
Oil Pan Upper Block Assembly Note
Caution
• Apply the silicon sealant in a single, unbroken line around the whole perimeter.
• Install the oil pan upper block within 5 min after applying the silicone sealant.
• Using bolts with the old seal adhering
could cause cracks in the housing.
1. Completely clean and remove any oil, dirt, sealant
or other foreign material that may be adhering to
the oil pan upper block and housing.
2. When reusing the oil pan upper block installation
bolts, clean any old sealant from the bolts.
3. Apply silicone sealant to the areas as shown in
the figure.
Caution
• Apply silicone sealant to the outer
circumference of the bolt hole at
locations A shown in the figure.
Thickness
2.5—6.5 mm {0.10—0.26 in}
4. Install the oil pan upper block to the housing.
5. Tighten the oil pan upper block installation bolts.
Tightening torque
18.6—25.5 N·m {1.9—2.6 kgf·m, 13.8—18.8
ft·lbf}
Oil Pan Assembly Note
Type A
Caution
• Using bolts with the oil sealant still
adhering could cause cracks in the
housing. Clean all sealant off all oil pan
bolts before assembly.
• Apply the silicon sealant in a single,
unbroken line around the whole
perimeter.
• Install the engine front cover within 5 min
after applying the silicone sealant.
1. Completely clean and remove any oil, dirt, sealant
or other foreign material that may be adhering to
the housing and oil pan.
2. When reusing oil pan installation bolts, clean any old sealant from the bolts.
3. Apply silicone sealant to the areas shown in the
figure.
Bead thickness
2.5—6.5 mm {0.1—0.2 in}
4. Tighten the oil pan installation bolts.
Tightening torque
8.8—11.8 N·m
{90—120 kgf·cm, 78—104 in·lbf}
OLD SEALANT
DAMAGE
CHU0111W004
SEALANT
SEALANT
A
BHJ0110F010
OLD SEALANT
DAMAGE
CHU0111W004
SEALANT
SEALANT
BHJ0110E100
MECHANICAL
01–10–48
Engine Workshop Manual 13B-MSP (Multi Side Port) (1773–1U–03C)
Revised 6/2008 (Ref. No. R108/08)
Type B
Caution
• Apply the silicon sealant in a single, unbroken line around the whole perimeter.
• Install the oil pan within 5 min after applying the silicone sealant.
• Using bolts with the old seal adhering
could cause cracks in the housing.
1. Completely clean and remove any oil, dirt, sealant
or other foreign material that may be adhering to
the oil pan upper block and oil pan.
2. When reusing the oil pan installation bolts, clean
any old sealant from the bolts.
3. Apply silicone sealant to the areas as shown in
the figure.
Thickness
2.5—6.5 mm {0.10—0.26 in}
4. Install the oil pan to the oil pan upper block.
5. Tighten the oil pan installation bolts.
Tightening torque
7.8—10.8 N·m {80—110 kgf·cm, 69.0—95.5
in·lbf}
End Of Sie
OLD SEALANT
DAMAGE
CHU0111W004
SEALANT
SEALANT
AR8WZW000007
TECHNICAL DATA
01–50–1
01–50
Engine Workshop Manual 13B-MSP (Multi Side Port) (1773–1U–03C)
Revised 6/2008 (Ref. No. R108/09)
01–50 TECHNICAL DATA
ENGINE TECHNICAL DATA . . . . . . . . . . 01–50–1
End of Toc
ENGINE TECHNICAL DATA
CHU015001001E02
ITEMS
ENGINE TYPE
13B-MSP
STANDARD POWER HIGH POWER
SIDE HOUSING (FRONT, INTERMEDIATE, REAR) INSPECTION
Maximum distortion (mm {in}) 0.04 {0.0016}
Maximum wear
(Vertical wear)
(mm {in}) 0.10 {0.0039}
Maximum wear
(Convex oval)
(mm {in})
Oil seal inner path 0.01 {0.0004}
Oil seal outer path 0.10 {0.0039}
Maximum wear
(Oil seal stepped path wear)
(mm {in}) 0.02 {0.0008}
ROTOR HOUSING
Maximum width difference (mm {in}) 0.06 {0.0024}
ROTOR
Rotor and side housing clearance (mm {in})
Standard 0.05—0.19 {0.0020—0.0074}
Maximum 0.05 {0.002}
Protrusion of the rotor round (mm {in})
Standard 0.12—0.18 {0.0048—0.0070}
Minimum 0.1 {0.0039}
Apex seal groove and the apex seal clearance (mm {in})
Standard 0.042—0.077 {0.0017—0.0030}
Maximum 0.15 {0.0059}
APEX SEAL, APEX SEAL SPRING
Apex seal height (mm {in})
Standard 5.3 {0.20}
Minimum 4.3 {0.17}
Apex seal spring height (mm {in})
Standard 5.4 {0.213}
Minimum 3.5 {0.148}
CORNER SEAL, CORNER SEAL SPRING
Minimum projection of the corner seal (mm {in}) 0.5 {0.02}
SIDE SEAL, SIDE SEAL SPRING
Corner seal and side seal clearance (mm {in}) Maximum 0.4 {0.016}
Minimum projection of the side seal (mm {in}) 0.5 {0.02}
CUT-OFF SEAL, CUT OFF SEAL SPRING
Cut-off seal height (mm {in})
Standard 3.95 {0.1555}
Minimum 3.8 {0.15}
Minimum projection of the cut off seal (mm {in}) 0.5 {0.02}
OIL SEAL, OIL SEAL SPRING
Maximum contact width (mm {in}) 0.5 {0.02}
Maximum circumferential width (mm {in}) 2.5 {0.098} (or 10 nicks or more)
Minimum projection of the oil seal (mm {in}) 0.5 {0.02}
ECCENTRIC SHAFT
Main bearing oil clearance (mm {in})
Standard
Without stopper screw: 0.045—0.085 {0.0022—
0.0029}
With stopper screw: 0.055—0.075 {0.0018—0.0033}
Maximum 0.1 {0.0039 in}
Rotor bearing oil clearance (mm {in})
Standard 0.06—0.08 {0.0024—0.0030}
Maximum 0.1 {0.0039}
Runout (mm {in})
Standard 0.02 {0.0008}
Maximum 0.06 {0.0024}
End play (mm {in}) Standard 0.04—0.09 {0.0016—0.0035}
ECCENTRIC SHAFT BYPASS VALVE
Minimum projection (mm {in}) 6 {0.24}
TECHNICAL DATA
01–50–2
Engine Workshop Manual 13B-MSP (Multi Side Port) (1773–1U–03C)
Revised 6/2008 (Ref. No. R108/08)
End Of Sie
OIL PUMP
Body clearance (Type A) (mm {in})
Standard 0.20—0.25 {0.0079—0.0098}
Maximum 0.3 {0.0118}
Tip clearance (Type A) (mm {in})
Standard 0.03—0.12 {0.0012—0.0047}
Maximum 0.15 {0.0059}
Side clearance (Type A) (mm {in})
Standard 0.03—0.125 {0.0012—0.0049}
Maximum 0.15 {0.0059}
ITEMS
ENGINE TYPE
13B-MSP
STANDARD POWER HIGH POWER
SERVICE TOOLS
01–60–1
01–60
01–60 SERVICE TOOLS
ENGINE SST . . . . . . . . . . . . . . . . . . . . . . 01–60–1
End of Toc
ENGINE SST
CHU016001001E02
End Of Sie
49 0107 680A
Engine stand
49 L010 1A0
Engine hanger
set
49 J010 3A0A
Hanger, Engine
stand
49 1881 055A
Stopper counter
weight (AT)
49 0820 035
Flywheel box
wrench
49 0839 305A
Counterweight
puller
49 F011 101
Ring gear brake
(MT)
49 0813 250
Seal case
49 0813 215A
Dowel puller
and oil pump
puller
49 0813 225A
Oil seal remover
49 0813 235
Main bearing
puller and
installer
49 0813 240
Rotor bush
puller and
installer
49 0839 165
Corner seal
gauge
49 F011 1A1
Bearing installer
set (MT)
49 1285 071
Needle bearing
puller (MT)
49 G030 797
Handle (MT)
49 F010 401A
Installer
49 J027 001
Bearing installer
