Mazda B5 Engine Head/Block

Removing Cylinder Head from Mazda B5 Engine

     1.  Disconnect all cables and hoses that connected to cylinder head

     2.       Remove exhaust and intake manifolds

     3.       Take rocker cover off 

     4.       Remove timing belt cover

     5.       Mark direction and position of the belt at #1 cylinder TDC

6.       

    6. Carefully pull the belt off the cam sprockets

    7.   Holding cam with size 24 spanner, remove the cam shaft sprocket screw on each cam (note I-for intake and E- for exhaust markings on sprockets)

    8.  Take the metal timing belt protecting cover off   

    9.   Loosen the head bolts in order:

             Intake Side      

              1 7  9  6 4

              3 5 10 8 2

            Exhaust Side

  

     

      10.   Carefully lift the Engine Head, do not use screw driver or similar, because it is really easy to damage the machined surface of Head and Block.

Disassembling Engine Head

1.      

    1.  Loosen the cam shaft holding bolts

    2.  Keep cam shaft holders in order (note, arrow imprinted on cam holders indicates towards the crankshaft pulley, Letter “I” – stands for Intake side and “E”- stands for Exhaust side, numbers on each holder represents the position of the holder starting from “1”- from crank pulley)

    3.  Mark each valve’s position (eg. E1, E2….E8) (Tip: cardboard box can be used to keep valves in order. Simply pop the valve through the cardboard and write the position of the valve on the box)

      4.  Using correct size valve spring compressor remove the valves (Tip: magnet or magnetic screwdriver can be used to remove the valve keepers)

5.       Note that some of the valve springs have top and bottom sides

Inspecting Cylinder Head

1.       Visual check of all components for any damage

2.       With metal ruler and filler gauge check the warp across, along and diagonal of the head surface. In my case it seems like head has been machined and it is 0mm warp in every direction.

3.       Make sure that valve guides are not damaged, visually check every valve guide. They all in OK condition (no cracks, no rust, no carbon built ups)

Valve Stem Measurement

Three measurements need to be taken per valve. Top (A), Middle (B) and Bottom (C) of the stem.

	Cylinder 1		Cylinder 2		Cylinder 3		Cylinder 4
A on Valve 1	5.975mm	5.98mm	5.98mm	5.98mm	5.98mm	5.975mm	5.98mm	5.975mm
A on Valve 2	5.975mm	5.975mm	5.975mm	5.975mm	5.98mm	5.97mm	5.975mm	5.97mm
B on Valve 1	5.975mm	5.975mm	5.975mm	5.975mm	5.98mm	5.97mm	5.98mm	5.975mm
B on Valve 2	5.975mm	5.975mm	5.975mm	5.97mm	5.975mm	5.97mm	5.975mm	5.975mm
C on Valve 1	5.975mm	5.97mm	5.975mm	5.97mm	5.975mm	5.97mm	5.975mm	5.975mm
C on Valve 2	5.975mm	5.97mm	5.975mm	5.975mm	5.975mm	5.975mm	5.975mm	5.97mm
	In	Ex	In	Ex	In	Ex	In	Ex
Average Reading 1	5.975mm	5.975mm	5.976mm	5.975mm	5.978mm	5.972mm	5.978mm	5.975mm
Average Reading 2	5.975mm	5.973mm	5.975mm	5.973mm	5.977mm	5.972mm	5.975mm	5.972mm

Unable to measure valve guides, therefore cannot calculate Valve Stem to Guide clearance. Specified clearance is 0.03mm – 0.04mm for Intake side, 0.04mm – 0.05mm for exhaust side.

Valves Condition

Examine all valves for any damage

Cylinder 1

Cylinder 2

Cylinder 3

Cylinder 4

Ex1

Ex2

In1

In2

Ex1

Ex2

In1

In2

Ex1

Ex2

In1

In2

Ex1

Ex2

In1

In2

Damage to the tip

V

V

V

V

V

V

V

V

V

V

V

V

V

V

V

V

Damage or wear in collet grooves

V

V

V

V

V

V

V

V

V

V

V

V

V

V

V

V

Pitting or erosion of valve stem

V

V

V

V

V

V

V

V

V

V

V

V

V

V

V

V

Marks on stem that have sharp edges

V

V

V

V

V

V

V

V

V

V

V

V

V

V

V

V

Signs of scuffing or seizure

V

V

V

V

V

V

V

V

V

V

V

V

V

V

V

V

Cracks or erosion in fillet area

V

V

V

V

V

V

V

V

V

V

V

V

V

V

V

V

Stretching of the stem

V

V

V

V

V

V

V

V

V

V

V

V

V

V

V

V

Straightness of the stem

V

V

V

V

V

V

V

V

V

V

V

V

V

V

V

V

Mechanical damage to the head, erosion or cupping

V

V

V

V

V

V

V

V

V

V

V

V

V

V

V

V

Valve Margin

1.5

1.2

1.0

1.0

1.6

1.5

0.8

0.8

1.2

1.2

0.9

0.9

1.2

1.5

0.5

0.5

Since minimum Valve margin is 1mm then 6 Valves need to be serviced/replaced.

Visually check the Valve seats for seat width, angle, thickness of remaining material and any sort of damage (cracks, erosion..)

Inspecting Valve Springs

Put a spring upright on flat surface and place a combination square next to it. Rotate the spring and measure the distance between a combination square and top of the spring with feeler gauge. It should not be more than 1/16 inch (1.59mm). The spring that is not square would cause uneven wear on Valve stem and Guide.

Cylinder #				Ok	Fail
1	In	1mm	1mm	V
	Ex	1mm	1mm	V
2	In	1mm	1mm	V
	Ex	0mm	1mm	V
3	In	0mm	1mm	V
	Ex	1mm	1mm	V
4	In	1mm	1mm	V
	Ex	1mm	1mm	V

Check the free length of the Valve Spring

Note all springs must be within 1.5mm of each other

Cylinder #				Ok	Fail
1	In	47mm	47mm	V
	Ex	47mm	47mm	V
2	In	47mm	47mm	V
	Ex	47mm	47mm	V
3	In	47mm	47mm	V
	Ex	47mm	47mm	V
4	In	47mm	47mm	V
	Ex	47mm	47mm	V

Valve Spring Tension

Valve Spring Pleasure tester is required. Place the spring in to the tester and compress the spring to 40mm and record the result. All springs should be within 5kg range.

Cylinder #				Ok	Fail
1	In	16.7kg	16.6kg	V
	Ex	17.2kg	17.5kg	V
2	In	17.1kg	17kg	V
	Ex	17.6kg	17.2kg	V
3	In	16.5kg	16.9kg	V
	Ex	17.1kg	16.9kg	V
4	In	17.5kg	17.1kg	V
	Ex	17kg	17.2kg	V

Inspecting camshaft for wear and general condition

Using micrometer measure camshaft lobes

Tightening sequence is....

intake side
8 6 2 4 10
9 3 1 5 7
exhaust side
 

Testing 2N3055 Transistor

Here is the diagram of 2N3055 transistor taken from http://www.datasheetoo.com

the multimeter should be set up on diode test to check the transistor

V1-tab = 0.635 V

Vtab-1= OL

V1-2 = 0.637

V2-1 = OL

Vtab-2 = OL

V2-tab = OL

test showed that it has common connector that shows the voltage, which is 1. so connector 1 is Base.
0.637 V > 0.635 V. That means that connector 2 is Emitter and TAB is Collector.

Transistors

Different types of transistors

P - P type (holes)

N - N type (electrons)

transistors have tree (or more) connectors:

B - Base

E - Emitter

C - Collector

       Tip: E>C always!

transistors that used as switches normally act as two diodes connected together anode and anode or cathode to cathode.

two anodes connected called NPN

and acts as two cathodes connected together

Tip: how to tell which transistor is on the diagram:

Look at arrow

NPN - Not Point iN

PNP - Point iN Please

Relays

4 pin relay

Relay base layout:

connectors:

85 - coil negative

86 - coil positive

30,87 - Switch terminals (in 4pin relay 30 to 87 is NO( normally open))

5 pin Relay

Base Layout:

connectors:

85 - coil negative

86 - coil positive

30,87 - Switch terminals (NO( normally open))

30, 87A - Switch terminals (NC (normally closed))

using relays create a circuit which output two independent positive from one alarm negative

ver1

Ver2 suggested by Carl

relay in circuit powering Light Bulb.

relay in hi/low beam switching

Set of 4pin relays powering the window motor

another version suggested by Kit using two 5 pin relays

  

to prevent circuit components from back emf produced by inductor (relay coil) the diode is installed.

some automotive relays already come with built in diode.

2003 Audy A4 Servicing

Oxygen sensor

provided:

      Resistors:      R2, R3, R4 – 1K ohm 0.25W               (brown, black, red)

                           R5 – 390R ohm 0.25W                       (orange, white, brown)

                           R6 – 10K ohm 0.25W                        (brown, black, orange)

                           R7 – 270R ohm 0.25W                       (red, violet, brown)

                           R8 – 470R ohm 0.25W                       (yellow, violet, brown)

     

       Diodes:         D2, D3, D4 – 1N4001 - 50V 3A

      Zener Diode: D1 – 9.1V 0.5W

     Capacitors:  C1, C2 – 0.1uF 50V

      LEDs:         LED1- RED, LED5- Yellow, LED6- Green

      IC:               IC - LM324 with IC socket 

     Wires:         Green, Black and Red (about 0.5-0.75 meters each) with crocodile clips

     box.

here is the diagram taken from Unitec O2 components installation guide 

PCB After installing all components

Put the cables through the whole in the box

now it's testing time:

make sure that the power supply set to independent. set one side to about 12 V and the other at 0V. connect two negative wires from power supply together. connect O2 sensor to 12V side red to "+" and black to "-". connect green wire from O2 Sensor to other side of the power supply with 0V. green LED should illuminate, which indicates that mixture is lean.

rise the voltage from 0V to about 0.4V. Yellow LED should light up and Red should turn off. this indicates that the mixture is optimal.

go higher and at around 0.7V the red LED should come up and yellow should be off. this indicates that the mixture is rich.

after successfully tested sensor can be connected to the car to check if your O2 sensor is working. also can be used in everyday driving to monitor the mixture.  

Battery Testing

There are number of tests that can be performed to check the condition of the battery. Today I am going to check my battery EXIDE X56C with 550 CCA. It is maintenance free type of the batteries.

First is visual test.
 Check the battery for leaks, cracks, and signs of swelling, check that terminals are clean. Check that electrolyte in all cells is at recommended level (if not, add distil water)

OCV test 
Open Circuit Voltage requires voltmeter. Get voltage readings from the battery terminals (doors should be closed, IGN key is out and all interior/exterior lights should be turned off).  Surface Charge must be removed by turning on headlights for about one minute.

Readings:

12.6 V – 12.7 V = 100% of Charge

12.45 V – 12.5 V = 75% of Charge

12.3 V – 12.4 V = 50 % of Charge

12.15 V – 12.2 V = 25 % of Charge

the Voltage is 12.77V. PASS

If Voltage is less than 12.3 V then Battery should be charged overnight. 13.8 V-14.9 V power supply can be used with current of 2A-8A to charge the battery (lower Current and longer charging time is better). Connect “+” on power supply with “+” battery and “-“  power supply with “-“ battery terminal.

Hydrometer Test.
 Hydrometer, Safety Glasses and source of water nearby are required. Open cell caps in all cells. Place hydrometer in the cell and squeeze the rubber top on hydrometer. Let some electrolyte in (not too much, just enough to make the tube inside hydrometer to float).  Eye level should be in height with fluid inside the hydrometer in order to get correct readings.

1.240 – 1.260 = 100% Charged

1.210 – 1.240 = 75% Charged

1.180 – 1.210 = 50 % Charged

 1.150 – 1.180 = 25 % Charged

In my case battery is sealed. unable to perform this Test.

High rate discharge test

for this test we need load tester. we would need to apply a half of battery's CCA (550/2=275A) for 15-20 seconds. During this test battery's voltage should not drop below 9.6 Volts. connect load tester cables to battery's terminals, positive to positive and negative to negative. Rotate the knob on load tester until you reach 275 Amps. Keep an eye on build in Volt Meter (or you can use separate one) the voltage should not go below 9.6V mark during 15-20 seconds. voltage reading: 10.2V. PASS 

alternatively, car's starter can be used instead of load tester. make sure you disconnect the IGN coil (to prevent car from starting). connect your voltmeter to the battery and get someone to crank the engine while you taking Voltage readings.


Amp Draw


This test determines how much current drains from the battery when the car is off, all doors are closed and IGN key is out. For this test we need working Amp meter. DO NOT START THE CAR as you can damage your Amp meter (if it's unfused). Make sure you connect Amp meter in series with battery (so the current will flow through the Amp meter). Connect Battery Negative to Amp meter Negative and car's negative terminal to Amp meter positive. Accepted range is 0.03-0.05 Amps. 

it's 0.025 A. PASS

Digital Battery Test

This is the most common test that used by battery dealers nowadays. since the tester powered by the Battery being tested, make sure the voltage of the battery is not below 7 Volts. connect tester to battery's terminals, positive to positive and negative to negative. Once connected, the tester should display the voltage of the battery. using "arrow up" and "arrow down" buttons choose the right CCA for your battery, in my case it's 550 CCA. once selected correct CCA press "test" button. The Tester might show the following "CH"- charge the battery to continue the test, "PASS" - no faults found and battery is in good order, "FAIL" - fault was detected during the test.

I got "PASS".

Battery Report:

The Battery has passed all tests and it is in good condition and does not require any further testing/maintenance. Battery is ready to use.