f2 mitchell

2.2L 4-CYL & 2.2L 4-CYL TURBO

1988 ENGINES Mazda - 2.2L & 2.2L Turbo 4-Cylinder

ENGINE CODING

ENGINE IDENTIFICATION

Engine can be identified by engine code number stamped on pad located in front of exhaust manifold.

ENGINE IDENTIFICATION CODES

REMOVAL & INSTALLATION

ENGINE

Removal (B2200)

1. Remove hood. Drain engine oil and coolant. Disconnect negative battery cable. Remove air cleanerassembly and dipstick. Disconnect all coolant hoses. Remove cooling fan, radiator shroud and radiator.Disconnect accelerator and cruise control cables. Disconnect fuel hoses.

2. Disconnect all vacuum hoses and electrical connections. Remove 3-way solenoid valve, vacuum sensorassembly, duty solenoid valve assembly and vacuum switch.

3. Remove secondary air pipe assembly. Disconnect exhaust pipe from manifold. Remove A/C compressorand power steering pump with hoses attached.

4. Remove starter motor. Remove gusset plates near engine mounts. Remove rear cover. Supporttransmission. Remove transmission-to-engine bolts and engine mount bolts. Remove engine.

Installation (All Models)

To install, reverse removal procedure. Adjust all control cables. Adjust all fluid levels.

Removal (MX-6 & 626)

1. Engine and transaxle are removed as an assembly. Fuel pressure must be released. Start engine anddisconnect circuit opening relay. Relay is located near clutch pedal area. See Fig. 1. Operate engine untilit stalls. With ignition off, reinstall circuit opening relay.

Application Engine CodeB2200, MX-6 & 626: 2.2L 4-Cylinder & 2.2L 4-Cylinder Turbo F2

CAUTION: Fuel pressure must be released prior to removing fuel lines.

1988 Mazda 6262.2L 4-CYL & 2.2L 4-CYL TURBO 1988 ENGINES Mazda - 2.2L & 2.2L Turbo 4-Cylinder


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Fig. 1: Circuit Opening Relay LocationCourtesy of MAZDA MOTORS CORP.

2. Remove hood. Drain engine oil, transaxle fluid and coolant. Disconnect negative battery cable. Removebattery and battery carrier. Remove air cleaner and intake hoses.

3. Disconnect all coolant, vacuum and fuel hoses, and electrical connections. Cover fuel lines with shoptowel prior to removal as lines may retain pressure. Remove all control cables. Remove radiator andcooling fan. On turbo models, disconnect intercooler hoses.

4. Disconnect speedometer cable, clutch release cylinder and shift rods (M/T), or control cable (A/T) andelectrical connectors at transaxle. Remove A/C compressor and power steering pump with hoses attached.

5. Remove front wheels, splash shields and stabilizer bar. Remove drive axles. See appropriate article inDRIVE AXLES section. Disconnect exhaust pipe from manifold. Remove engine and transaxle mountingnuts. Remove engine and transaxle as an assembly.

Installation (All Models)

To install, reverse removal procedure. Adjust all control cables. Adjust all fluid levels.

CYLINDER HEAD & MANIFOLDS

Removal (B2200)

1. Disconnect negative battery cable. Drain cooling system. Rotate crankshaft and position No. 1 piston atTDC of compression stroke. Remove air cleaner, cooling fan and radiator shroud. Disconnect accelerator


domingo, 04 de octubre de 2015 10:10:01 a.m. © 2011 Mitchell Repair Information Company, LLC.

cable.

2. Disconnect fuel hoses and remove fuel pump (M/T). Disconnect all coolant, vacuum and fuel hoses, andelectrical connections. Remove 3-way solenoid valves and vacuum sensor assembly.

3. Remove duty solenoid valve assembly. Remove spark plug wires, spark plugs and distributor. Removesecondary air pipe assembly. Remove intake manifold and carburetor as an assembly. Remove exhaustmanifold heat shield and manifold. Remove timing belt. See TIMING BELT.

4. Remove valve cover and gasket. Gradually remove cylinder head bolts in proper sequence. See Fig. 2.Remove cylinder head and gasket.

CAUTION: Cylinder head bolts must be loosened in proper sequence to preventcylinder head warpage or cracking.



Fig. 2: Cylinder Head Bolt Removal & Installation SequenceCourtesy of MAZDA MOTORS CORP.

Inspection

Check cylinder head height and warpage. Resurface head if warpage exceeds specification. See CYLINDERHEAD SPECIFICATIONS table. Replace cylinder head if not within specification after resurfacing.

CYLINDER HEAD SPECIFICATIONS

Installation

1. Ensure proper gasket application. See Fig. 3. Install cylinder head. Apply oil to head bolt threads andseating surface. Using proper sequence, tighten bolts to specification using 2 steps. See Fig. 2. SeeTORQUE SPECIFICATIONS.

2. Apply silicone sealant to designated area prior to valve cover installation. See Fig. 4. Coat distributor "O"ring with oil and install on distributor. Coat distributor blade or drive gear with oil prior to installation.

3. Install timing belt. To install remaining components, reverse removal procedure. Tighten bolts tospecification.

CYLINDER HEAD & MANIFOLDS

Removal (MX-6 & 626)

1. Engine and transaxle are removed as an assembly. Fuel pressure must be released. Start engine anddisconnect circuit opening relay. Relay is located near clutch pedal area. See Fig. 1. Operate engine untilit stalls. With ignition off, reinstall circuit opening relay.

2. Disconnect negative battery cable. Drain cooling system. Remove air intake pipe. Disconnect all lines forturbo (if equipped). Disconnect all coolant, vacuum and fuel hoses, and electrical connections. Cover fuellines with shop towel prior to removal as lines may retain pressure. Remove all control cables at throttlebody.

3. Remove 3-way solenoid valves, EGR solenoid assembly and EGR pipe. Remove insulator from exhaustmanifold. Disconnect exhaust pipe at manifold. Remove exhaust manifold and turbo (if equipped).Remove distributor. Remove rear housing.

4. Remove intake manifold. Remove timing belt. See TIMING BELT. Remove valve cover and gasket.Gradually remove cylinder head bolts in proper sequence. See Fig. 2. Remove cylinder head and gasket.

Application In. (mm)Height 3.620-3.624 (91.95-92.05)Maximum Grind Limit .008 (.20)Maximum Warpage .006 (.20)

CAUTION: Fuel pressure must be released prior to removing fuel lines.

CAUTION: Cylinder head bolts must be loosened in proper sequence to prevent



Inspection

Check cylinder head height and warpage. Resurface head if warpage exceeds specification. See CYLINDERHEAD SPECIFICATIONS table. Replace cylinder head if not within specification after resurfacing.

CYLINDER HEAD SPECIFICATIONS

Installation

1. Ensure proper gasket application. See Fig. 3. Install cylinder head. Apply oil to head bolt threads andseating surface. Using proper sequence, tighten bolts to specification using 2 steps. See Fig. 2. SeeTORQUE SPECIFICATIONS.

2. Apply silicone sealant to designated area prior to valve cover installation. See Fig. 4. Coat distributor "O"ring with oil and install on distributor. Coat distributor blade or drive gear with oil prior to installation.

3. Install timing belt. To install remaining components, reverse removal procedure. Tighten bolts tospecification.

Fig. 3: Head Gasket IdentificationCourtesy of MAZDA MOTORS CORP.

cylinder head warpage or cracking.

Application In. (mm)Height 3.620-3.624 (91.95-92.05)Maximum Grind Limit .008 (.20)Maximum Warpage .006 (.20)



Fig. 4: Applying Valve Cover SealantCourtesy of MAZDA MOTORS CORP.

TIMING BELT

Removal

1. Disconnect negative battery cable. On B2200 models, drain cooling system. Radiator removal may berequired. Remove cooling fan and shroud. Remove distributor from front housing. Remove cooling fanpulley and bracket. Remove secondary air pipe assembly.

2. On all models, remove all accessory drive belts. Remove crankshaft pulley. Remove timing belt covers.Remove baffle plate located in front of crankshaft sprocket. Note direction of baffle plate installation.

3. Rotate crankshaft to align crankshaft sprocket with timing mark. Ensure No. 1 mark on camshaft sprocketis aligned with timing mark on front housing. See Fig. 5.

4. If timing belt is to be reused, place arrow on belt to indicate belt rotation. Remove tensioner lock bolt,tensioner and spring. Remove timing belt.



Fig. 5: Aligning Timing MarksCourtesy of MAZDA MOTORS CORP.

5. If camshaft sprocket requires removal, remove retaining bolt and remove sprocket. Remove crankshaftsprocket if required.

Inspection

Inspect timing belt for wear on rounded edges of drive teeth. Inspect belt for signs of oil contamination. Replacebelt if damaged or contaminated. Inspect belt tensioner for smoothness or abnormal noise. Replace damagedcomponents.

Installation

1. Install sprockets with timing mark toward front of engine. Align camshaft and crankshaft sprocket timingmarks. See Fig. 5.

2. Install belt tensioner, lock bolt and tensioner spring. Position belt tensioner to limit of travel toward intakemanifold side and partially tighten lock bolt.

3. Install timing belt. If used belt is installed, ensure belt is installed in proper direction of rotation. Loosentensioner lock bolt to apply tension. Rotate crankshaft 2 revolutions in direction of rotation. Tightentensioner lock bolt. Ensure timing marks are properly aligned.

4. On MX-6 and 626 models, check for proper belt tension by measuring amount of deflection midwaybetween idler pulley and camshaft sprocket. Belt deflection should be .30-.33" (7.6-8.4 mm) when forceof 22 lbs. (10 kg) is applied. Repeat adjustment if deflection is not within specification.



5. To install remaining components, reverse removal procedure. Ensure baffle plate is installed with flat sideagainst crankshaft sprocket. Reverse removal procedure to complete installation.

6. On B2200 models, ensure distributor housing and drive gear marks are aligned. Rotate crankshaft untilNo. 1 piston is at TDC of compression stroke. Lubricate distributor gear with oil. Install distributor intohousing with marks facing upward.

CAMSHAFT & FRONT OIL SEAL

Removal

1. Remove timing belt and camshaft pulley. On B2200 models, remove fuel pump (M/T models), distributorand front housing. On MX-6 and 626 models, remove distributor and rear housing.

2. On all models, check camshaft end play. Replace camshaft or cylinder head if not within specification.See CAMSHAFT.

3. Remove rocker arm shaft assembly. See ROCKER ARM SHAFT ASSEMBLY. Remove camshaft. OnB2200 models, remove rear seal cap from cylinder head.

Inspection

1. Inspect camshaft lobes for scoring or wear. Measure camshaft bearing journals, runout and fuel pumpcam lobe height (B2200 models).

2. Measure camshaft bearing-to-journal oil clearance. Replace components if not within specification. SeeCAMSHAFT SPECIFICATIONS table.

Installation

1. Apply engine oil to camshaft journals and bearings. Install camshaft with dowel pin facing upward.Apply a thin coat of engine oil to camshaft oil seal and front housing. Press oil seal into housing.

2. Install new "O" ring on distributor. Coat "O" ring and distributor drive gear or blade with engine oil priorto installation. On B2200 models, apply sealant to seal cap prior to installation.

3. On all models, to install remaining components, reverse removal procedure using new gaskets. Tightenbolts to specification.

VALVE ARRANGEMENT

Intake Manifold Side: Intake Valves.

Exhaust Manifold Side: Exhaust Valves.

ROCKER ARM SHAFT ASSEMBLY

Removal

Remove valve cover and gasket. Loosen rocker arm bolts gradually in proper sequence. See Fig. 6. Remove

NOTE: Belt deflection specification not available on B2200 models.



camshaft bearing cap bolts, rocker arms and rocker shafts as an assembly. DO NOT allow components toseparate during removal. Mark component location for reassembly reference.



Fig. 6: Rocker Arm Bolt Removal & Installation SequenceCourtesy of MAZDA MOTORS CORP.

Disassembly & Inspection

Disassemble rocker arm and shaft assemblies. Mark components for location. Inspect rocker arm and shaft fordamage or flaking. Measure rocker arm I.D. and rocker arm shaft O.D. Determine oil clearance. Replacecomponents if not within specification. See ROCKER ARM & SHAFT SPECIFICATIONS table.

ROCKER ARM & SHAFT SPECIFICATIONS

Reassembly & Installation

1. If hydraulic lash adjuster was removed from rocker arm, fill reservoir of rocker arm with oil. Coathydraulic lash adjuster with oil and install in rocker arm. Reassemble rocker arms and shafts.

2. To install, reverse removal procedure. Prior to installing rocker shaft assembly, apply silicone sealant tofront and rear bearing cap-to-cylinder head contact areas.

3. On MX-6 and 626 models, ensure No. 3 bearing cap contains the oil passage from cylinder head. On allmodels, tighten bolts to specification in 2 steps using proper sequence. See Fig. 6.

VALVE SERVICE

CAUTION: Rocker arm component location must be marked for reassemblyreference.

Application In. (mm)Rocker Arm Bore

B2200 .6300-.6310 (16.000-16.027)All Others .748-.749 (19.00-19.03)

Shaft DiameterB2200 .6286-.6293 (15.966-15.984)All Others .746-.747 (18.95-18.97)

Rocker Arm-to-Shaft Clearance

B2200 (1) .0006-.0024 (.016-.061)

All Others (1) .0008-.0029 (.020-.074)

(1) Maximum clearance is .004" (.10 mm)

CAUTION: On B2200 models, intake rocker arm shaft is the long shaft. Ensureoil holes in center bearing cap face each other. On all other models,intake rocker arm shaft contains twice as many oil holes as exhaustside. The stepped ends of shaft must be installed at rear of cylinderhead. Ensure No. 3 bearing cap contains oil passage from cylinderhead.



Disassemble cylinder head. Measure valve stem diameter, valve margin and length. Replace valves not withinspecification. See VALVES.

VALVE GUIDE INSPECTION

Inspection

Measure valve guide bore, height and valve stem clearance. Replace guide if not within specification. SeeVALVE GUIDE SPECIFICATIONS table.

VALVE GUIDE SPECIFICATIONS

VALVE GUIDE

Removal & Installation (B2200)

1. To remove valve guide, use Valve Guide Remover/Installer (49 0221 251A) and drive valve guide fromcombustion chamber side of cylinder head. Note length of valve guides.

2. To install, install clip on valve guide. Using valve guide remover/installer, drive guide into head fromside opposite combustion chamber. Drive valve guide in until clip contacts cylinder head. Ensure stem-to-guide clearance and installed height are within specification. See VALVE GUIDE SPECIFICATIONStable.

VALVE GUIDE

Removal & Installation (MX-6, 626)

1. To remove valve guide, heat cylinder head to approximately 190°F (90°C). Using Valve GuideRemover/Installer (49 0221 251A), drive valve guide from combustion chamber side of cylinder head.Note length of valve guides.

Application In. (mm)Guide Bore

B2200 .3177-.3185 (8.070-8.090)All Others .2760-.2768 (7.010-7.030)

Guide Installed HeightB2200 .752-.772 (19.10-19.60)All Others .780-.799 (19.81-20.29)

Valve Stem-To-Guide Clearance

Exhaust (1) .0012-.0026 (.030-.066)

Intake (1) .0010-.0024 (.025-.061)

(1) Maximum clearance is .008" (.20 mm).

NOTE: Although design of intake and exhaust valve guides are different, use exhaustvalve guides on both sides for replacement.



2. To install, heat cylinder head to approximately 190°F (90°C). Using valve guide remover/installer, driveguide into head from side opposite combustion chamber. Install guide to proper installed height. SeeVALVE GUIDE SPECIFICATIONS table.

VALVE SEATS SERVICE

Inspection

1. Valve seat sinkage should be checked after valve and valve seat have been reconditioned and lightlylapped. With valve installed, measure distance between end of valve stem and cylinder head.

2. Standard installed height is 1.831" (46.50 mm) for B2200 models and 1.976" (50.19 mm) for all others. Ifinstalled height is within 1.831-1.850" (46.50-47.00 mm) for B2200 models and 1.976-2.008" (50.19-51.00 mm) for all other models, valve can be used as is.

3. Spacer plate must be installed between spring seat and cylinder head to adjust if height is 1.850-1.890" (47.00-48.00 mm) for B2200 models or 2.008-2.035" (51.00-51.70 mm) for all other models.Replace cylinder head if height exceeds 1.890" (48.00 mm) for B2200 models or 2.035" (51.69 mm) forall other models.

VALVE STEM OIL SEALS SERVICE

With valves removed, remove oil seals from cylinder head. Coat seals with oil. Using Valve Stem Oil SealInstaller (49 G030 222) for B2200 models or (49 H012 009) for all other models, install valve stem oil seal.

VALVE SPRINGS SERVICE

Measure free length of valve springs. Replace springs if not within specification. See VALVE SPRINGSPECIFICATIONS table. Check valve spring for squareness. Replace spring if out-of-squareexceeds .06" (1.5 mm) for inner springs or .07" (1.8 mm) for outer spring on B2200 models or .067" (1.7 mm)on all other models.

VALVE CLEARANCE ADJUSTMENT

No adjustment is required. Preload of hydraulic lifter is automatically adjusted.

CYLINDER BLOCK ASSEMBLY SERVICE

Inspection

1. Inspect cylinder block for cracks, warpage, cylinder bore taper and out-of-round. Replace or repaircylinder block if not within specification. See CYLINDER BLOCK SPECIFICATIONS table.

2. Measure cylinder bore and piston skirt diameter. Piston skirt diameter should be measured at 90 degreeangle to piston pin approximately .71" (18.0 mm) below oil ring groove. Clearance between piston andcylinder bore must be within specification. See PISTONS, PINS & RINGS SPECIFICATIONS table.

CAUTION: Large valve spring must be installed with closer pitch area toward cylinderhead.



CYLINDER BLOCK SPECIFICATIONS

OVERHAUL

OIL PAN

Removal

1. Disconnect negative battery cable. Drain engine oil. On B2200 models, remove engine splash shield andengine crossmember. Disconnect steering linkage at idler arm. Remove 2 gussets and flywheel inspectioncover.

2. On MX-6 and 626 models, remove front exhaust pipe. Remove clutch housing cover and gussets on M/Tmodels. Remove right sub-frame. On all models, remove oil pan. Oil strainer must be removed to removeoil baffle plate.

Installation

1. On B2200 models, apply sealant on one side of baffle plate and on oil pan in rear seal case and oil pumpjoining areas.

2. On MX-6 and 626 models, apply sealant on entire surface of oil baffle plate and oil pan. On all models,install baffle plate and oil strainer. Install oil pan.

PISTON & ROD ASSEMBLY

Removal

1. Remove cylinder head. See CYLINDER HEAD. Remove oil pan. Ensure cylinder ridge is removed.Mark connecting rod and cap for cylinder identification.

2. Note direction of "FRONT" mark on piston located near piston pin area. See Fig. 7. This mark ispositioned toward timing belt side of engine. Remove rod cap. Remove piston assembly.

Installation

1. Ensure piston ring end gap and side clearance are within specification. Install rings on piston with ringcode identification marks toward top of piston. Lubricate piston, rings and cylinder bore with engine oil.

2. Properly space ring end gaps on piston. See Fig. 7. Install piston and rod into cylinder bore. Ensure pistonis installed with "Front" mark toward timing belt side of engine. See Fig. 7.

3. Check bearing clearance using Plastigage method. Tighten rod cap nuts to specification. See TORQUESPECIFICATIONS. Ensure rod moves freely on crankshaft. Check connecting rod side play. Repair or

Application In. (mm)Bore Diameter: Standard 3.3859-3.3866 (86.000-86.019)Grinding Limit .008 (.20)Maximum Warpage .006 (.15)

Taper & Out-of-Round Limit (1) .0007 (.019)

(1) Specification not listed on B2200 models.



replace connecting rod if not within specification. See MAIN & ROD BEARINGS SPECIFICATIONStable.

Fig. 7: Piston & Ring Alignment

CAUTION: Piston and rod assembly must be installed with "Front" mark towardtiming belt side of engine.



Courtesy of MAZDA MOTORS CORP.

FITTING PISTONS

Measure cylinder bore and piston skirt diameter. Piston skirt diameter should be measured at 90 degree angle topiston pin approximately .71" (18.0 mm) below oil ring groove. Clearance between piston and cylinder boremust be within specification. See PISTONS, PINS & RINGS SPECIFICATIONS table.

PISTON PIN REPLACEMENT

Removal

Note connecting rod oil hole and "Front" mark on piston. See Fig. 7. Using press and Piston PinRemover/Installer (49 G030 042), remove pin.

Inspection

1. Inspect piston for cracks or damage in ring areas. Check ring side clearance. Replace piston if not withinspecification. See PISTONS, PINS & RINGS SPECIFICATIONS table.

2. Check connecting rod for bend or twist and center-to-center length. Replace components if not withinspecification See CONNECTING ROD SPECIFICATIONS table.

3. Measure piston pin outer diameter. Outer diameter should be .8651-.8654" (21.974-21.980 mm). Replaceif not within specification.

CONNECTING ROD SPECIFICATIONS

Installation

1. Ensure connecting rod oil hole is opposite "F" mark on piston. See Fig. 7. Apply engine oil to piston pinand to connecting rod bore.

2. Insert piston pin from piston side marked "F". Force required to install pin should be 1100-3300 lbs. (500-1500 kg). Replace components if force required is not within specification. Ensure connecting movessmoothly.

CRANKSHAFT & MAIN BEARINGS

Removal

1. Remove flywheel or drive plate. Remove rear seal case. Remove oil pump and oil pan. Ensure connectingrods and main bearing cap are marked for location.

2. Remove connecting rod caps and bearings. Note direction of arrow on main bearing caps. Remove mainbearing caps. Ensure all components are placed in correct order. Remove crankshaft. Remove mainbearings from cylinder block. Mark bearings for location.

Application In. (mm)Center-to-Center 6.238-6.242 (158.45-158.55)Maximum Twist or Bend .0024 (.060)



Inspection

Inspect crankshaft for cracks, damaged gear or threads. Check crankshaft for runout, out-of-round and taper.Replace or repair crankshaft if not within specification. See MAIN & ROD BEARINGS SPECIFICATIONStable.

Installation

1. Install upper main bearings in cylinder block. Ensure oil hole is aligned and bearing is properly seated.Lubricate bearings with engine oil.

2. Install crankshaft in block. Install main bearing caps in original location with arrow toward front ofengine.

3. Check oil clearance using Plastigage method. Tighten bolts to specification. Remove main bearing cap.Clearance must be within specification. If oil clearance exceeds specification, replace bearings orcrankshaft.

4. Ensure crankshaft rotates freely with main bearing caps installed. Check crankshaft end play. SeeCRANKSHAFT END PLAY.

5. Install connecting rod caps and bearings. Ensure components are installed in original location. Tightenrod nuts to specification. Ensure connecting rods move freely on crankshaft.

6. To install remaining components, reverse removal procedure. Clean sealant from flywheel or drive platebolts. Apply sealant on flywheel or drive plate bolts and install. Tighten bolts to specification.

CONNECTING ROD BEARINGS

Removal & Installation

1. Mark bearing cap and connecting rod for location. Remove connecting rod cap and bearing.

2. Install replacement bearing. Ensure reference marks on rod cap and connecting rod are aligned. Checkbearing clearance using Plastigage method. Tighten nuts to specification.

3. Ensure connecting rod moves freely on crankshaft. Check connecting rod side clearance. Clearance mustbe within specification. See MAIN & ROD BEARINGS SPECIFICATIONS table.

CRANKSHAFT END PLAY

End play must be within specification. See MAIN & ROD BEARINGS SPECIFICATIONS table. If notwithin specification, crankshaft must be ground and undersized main bearing installed.

REAR CRANKSHAFT OIL SEAL


1. Remove flywheel or drive plate. Remove rear oil seal case. Pry seal from seal case.

CAUTION: Main bearing cap must be installed in original location with arrowfacing toward front of engine.



2. To install, coat seal lip with oil. Press seal in seal case. Install seal case and gasket. Trim gasket even withoil pan mounting surface. Install flywheel or drive plate. Clean sealant from flywheel or drive plate bolts.Apply sealant on flywheel or drive plate bolts and install. Tighten bolts to specification.

ENGINE OILING SYSTEM

Oil pressure is provided by a rotor-type pump driven by the timing belt. Pressure relief valve is located in the oilpump body. Oil cooler, used on turbo models, is mounted between oil filter and cylinder block.

OIL PUMP & OIL SEAL

Removal

Disconnect negative battery cable. Drain engine oil. Remove timing belt and crankshaft sprocket. See TIMINGBELT. Remove oil pan, oil strainer and baffle plate. See OIL PAN. Remove oil pump.

Disassembly & Inspection

1. Disassemble pump. Note location of rotor alignment marks. With rotors in pump body, check clearancebetween outer rotor and pump body. Place straightedge across pump body to check rotor side clearance.

2. Check clearance between straightedge and both rotors. Check clearance between tip of both rotors.Replace gear set or pump assembly if not within specification. See OIL PUMP SPECIFICATIONS table.Ensure relief valve slides freely in pump body bore. Inspect relief valve spring for damage.

OIL PUMP SPECIFICATIONS

Reassembly & Installation

1. Coat all components with oil. To reassemble, reverse disassembly procedure. Install rotors with alignmentmarks aligned and positioned toward pump cover. Apply Loctite to oil pump cover bolts and tighten.

2. To install, reverse removal procedure. Apply a thin coat of grease to "O" ring and install on pump. Applyengine oil to new oil seal and install. Apply sealant to pump sealing surfaces and install. Ensure sealantdoes not enter oil passage.

OIL COOLER

Application In. (mm)Outer Rotor-to-Pump Body

Standard .0035-.0069 (.090-.176)Maximum .008 (.20)

Rotor Side ClearanceStandard .0012-.0035 (.030-.090)Maximum .004 (.10)

Rotor Tip ClearanceStandard .0017-.0033 (.044-.084)Maximum .007 (.18)




Drain cooling system. Disconnect hoses at oil cooler. Remove oil filter. Remove oil cooler retaining nut.Remove oil cooler. To install, reverse removal procedure. Tighten nut to specification.

WATER PUMP

Removal

1. Disconnect negative battery cable. Rotate crankshaft so No. 1 piston is at TDC of compresssion stroke.Drain coolant. On B2200 models, remove cooling fan, pulley and radiator shroud.

2. On all models, remove timing belt, idler pulley and belt tensioner. See TIMING BELT. On B2200models, remove coolant inlet pipe and gasket. On all models, remove water pump, "O" ring and rubberseals.

Installation

To install, reverse removal procedure using new "O" rings, rubber seals and gaskets. Coat "O" rings withpetroleum jelly prior to installation. Fill cooling system.

ENGINE SPECIFICATIONS

CRANKCASE CAPACITY

Crankcase capacity is 4.9 qts. (4.6L) with filter replacement.

NORMAL OIL PRESSURE

Oil pressure should be 43-57 psi (3-4 kg/cm2 ) at 3000 RPM.

GENERAL ENGINE SPECIFICATIONS

GENERAL ENGINE SPECIFICATIONS

NOTE: For further information on cooling systems, see appropriate article in theENGINE COOLING section.

Application In. (mm)B2200

DisplacementCubic Inches 133.2Liters 2.2

Fuel System 2-BblHP @ RPM 85 @ 4500Torque Ft. @ RPM 118 @ 2500Compression Ratio 8.6:1



VALVE SPECIFICATIONS

VALVE SPECIFICATIONS

Bore 3.39 (86.1)Stroke 3.70 (94.0)

MX-6 & 626 (Non-Turbo)Displacement

Cubic Inches 133.2Liters 2.2

Fuel System Fuel-InjectionHP @ RPM 110 @ 4700Torque Ft. @ RPM 130 @ 3000Compression Ratio 8.6:1Bore 3.39 (86.1)Stroke 3.70 (94.0)

MX-6 & 626 (Turbo)Displacement

Cubic Inches 133.2Liters 2.2

Fuel System Fuel-InjectionHP @ RPM 145 @ 4300Torque Ft. @ RPM 190 @ 3500Compression Ratio 7.8:1Bore 3.39 (86.1)Stroke 3.70 (94.0)

Application In. (mm)

B2200 (1)

IntakeHead Diameter 1.732 (43.99)Face Angle 45°Seat Angle 45°Seat Width .047-.063 (1.19-1.60)

Stem Diameter (2) .3161-.3167 (8.030-8.045)

Stem Clearance (3) .0010-.0024 (.025-.060)

Valve Lift n/aExhaust

Head Diameter 1.417 (35.99)Face Angle 45°Seat Angle 45°Seat Width .047-.063 (1.19-1.60)



PISTONS, PINS & RINGS SPECIFICATIONS

PISTONS, PINS & RINGS SPECIFICATIONS

Stem Diameter (4) .3159-.3165 (8.025-8.040)

Stem Clearance (3) .0012-.0026 (.030-.067)

Valve Lift n/a

MX-6 & 626 (1) (5)

IntakeHead Diameter 1.276-1.283 (32.41-32.59)Face Angle 45°Seat Angle 45°Seat Width .047-.063 (1.19-1.60)Stem Diameter .2744-.2750 (6.970-6.985)

Stem Clearance (3) .0010-.0024 (.025-.060)

Valve Lift n/aExhaust

Head Diameter 1.335-1.343 (33.91-34.12)Face Angle 45°Seat Angle 45°Seat Width .047-.063 (1.19-1.60)Stem Diameter .2742-.2748 (6.965-6.980)

Stem Clearance (3) .0012-.0026 (.030-.067)

Valve Lift n/a(1) Minimum valve margin on intake valves is .02" (.5 mm) and .04" (1.0 mm) on exhaust valves.

(2) Minimum diameter is .3142" (7.980 mm)

(3) Maximum clearance is .008" (.20 mm).

(4) Minimum diameter is .3140" (7.975 mm).

(5) Minimum valve length is 4.534" for (115.16 mm) for intake valves and 4.555" (115.70 mm) forexhaust valves.

Application In. (mm)

Pistons: Clearance (1) .0014-.0030 (.036-.075)

PinsPiston Fit (2)

Rod Fit PressRings

Ring No. 1End Gap .008-.014 (.20-.35)

Side Clearance (1) .0012-.0028 (.030-.070)



MAIN & ROD BEARINGS SPECIFICATIONS

MAIN & ROD BEARINGS SPECIFICATIONS

VALVE SPRING SPECIFICATIONS

VALVE SPRING SPECIFICATIONS

Ring No. 2End Gap .006-.012 (.15-.30)Side Clearance .0012-.0028 (.030-.070)

Oil Ring

End Gap (3) (4) .012-.035 (.30-.89)

Side Clearance n/a(1) Maximum clearance is .006" (.15 mm).

(2) Interference fit is .0005-.0015" (.013-.038 mm) on B2200 models and .0003-.0009" (.008-.023 mm)on all others.

(3) On turbo models clearance is .008-.028" (.020-.071 mm).

(4) Wear limit is .04" (1.0 mm).

Application In. (mm)Main Bearings

Journal Diameter (1) 2.3597-2.3604 (59.936-59.956)

Clearance (2) .0012-.0019 (.031-.049)

Thrust Bearing No. 3

Crankshaft End Play (3) .0031-.0071 (.079-.180)

Connecting Rod Bearings


Clearance (4) .0010-.0026 (.027-.067)

Side Play (5) .004-.010 (.10-.25)

(1) Maximum journal out-of-round and taper is .002" (.05 mm). Maximum crankshaft runoutis .0012" (.031 mm).

(2) On MX-6 and 626 models, all except No. 3 journal standard clearance is .0010-.0017" (.025-.043mm). No. 3 standard clearance is .0012-.0019" (.031-.049 mm). Maximum clearance on all modelsis .003" (.08 mm).

(3) Maximum end play is .012" (.30 mm).

(4) Wear limit is .004" (.10 mm).

(5) Maximum side play is .012" (.30 mm).



CAMSHAFT SPECIFICATIONS

CAMSHAFT SPECIFICATIONS (1) (2) (3)

Application In. (mm)B2200

Inner

Free Length (1) 1.73 (44.0)

Installed Height n/aPressure: Lbs. @ In. (Kg @ mm)

Valve Closed n/aValve Open n/a

Outer

Free Length (2) 2.05 (52.0)



MX-6 & 626Intake

Free Length (3) 1.95 (49.5)



Exhaust

Free Length (4) 1.98 (50.3)



(1) Limit is 1.68" (42.7 mm).

(2) Limit is 1.98" (50.4 mm).

(3) Limit is 1.90" (48.3 mm).

(4) Limit is 1.94" (49.3 mm).

Application In. (mm)Front & Rear




VALVE TIMING SPECIFICATIONS

VALVE TIMING SPECIFICATIONS

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Clearance (5) .0014-.0033 (.035-.085)

Lobe Lift n/aCenter


Clearance (2) .0026-.0045 (.066-.115)

Lobe Lift n/a(1) Maximum camshaft runout is .0012" (.031 mm).

(2) Standard end play is .003-.006" (.08-.15 mm) and limit is .008" (.20 mm).

(3) On B2200 models, fuel pump lobe height is 1.478-1.482"(37.54-37.64 mm) with wear limit of1.465" (37.21 mm).

(4) Maximum out-of-round is .002" (.05 mm).

(5) Maximum oil clearance is .006" (.15 mm).

Application SpecificationB2200

IntakeOpen (BTDC) 25°Close (ABDC) 59°

ExhaustOpen (BBDC) 64°Close (ATDC) 20°

MX-6 & 626Intake

Open (BTDC) 10°Close (ABDC) 49°

ExhaustOpen (BBDC) 55°Close (ATDC) 12°

Application Ft. Lbs. (N.m)Camshaft Pulley Bolt 35-48 (47-65)Connecting Rod Cap Nut 48-51 (65-69)Coolant Inlet Pipe Bolt 14-19 (19-26)



Cylinder Head Bolt (1) 59-64 (80-87)

Drive Plate Bolt (A/T) 71-76 (96-103)End Plate Bolt 14-19 (19-26)Exhaust Manifold Nut 16-21 (22-29)Flywheel Bolt (M/T) 71-76 (96-103)Front Housing Bolt 14-19 (19-26)Fuel Pump Bolt 14-19 (19-26)Intake Manifold Nut 14-19 (19-26)Main Bearing Cap Bolt 61-65 (83-88)Oil Cooler Nut 22-29 (30-39)Oil Pump Bolt

M8 14-19 (19-26)M10 27-38 (37-52)

Rear Housing Bolt 14-19 (19-26)

Rocker Arm Shaft Bolt (2) 13-20 (18-27)

Thermostat Cover Bolt 14-22 (19-30)Timing Belt Crankshaft Bolt 116-123 (157-167)Timing Belt Idler 27-38 (37-52)Timing Belt Tensioner Bolt 28-38 (38-52)Water Pump Bolt 14-19 (19-26)

INCH Lbs. (N.m)Crankshaft Pulley Bolt 109-152 (13-17)Oil Strainer Bolt 69-104 (8-12)Oil Pan Bolt 61-104 (7-12)Rear Seal Case Bolt 69-104 (8-12)Timing Belt Cover 61-87 (7-10)Valve Cover

B2200 26-35 (3-4)All Others 52-69 (6-8)

(1) Tighten in sequence. See Fig. 2.

(2) Tighten in sequence. See Fig. 6.



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