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The following technical bulletins were published by AERA.
 TIMING CHAIN INSTALLATION ON 79-85 MAZDA 2.0L
                  Timing Chain Installation On
                   1979-85 Mazda 2.0L Engines


Correct installation of the timing chain on 1979-85 Mazda 2.0L
engines is critical to achieve the proper valve timing.

Rather than aligning the camshaft and crankshaft gears with marks
on the cylinder head or block, this engine uses marked plates on
the timing chain to set valve timing.  
Start the timing process by rotating the crankshaft and camshaft
sprockets until the keyways are facing straight up (12 o'clock). 
This should face the camshaft sprocket timing mark at 3 o'clock
and the crankshaft sprocket timing mark at approximately 5
o'clock looking at the front of the engine.

Locate the three marked links on the timing chain.  Two links
should be positioned at the crankshaft sprocket so that the
timing mark is between the links (Figure 1).  Position the chain
and camshaft sprocket so that the mark is in the middle of the
other marked link (Figure 2).  There should be 20 unmarked plates
between the two positions.

Be careful, some timing chains do not use marked plates to
indicate the correct timing positions for the camshaft and
crankshaft.  Use the old chain as a guide to make your own marks
on the new chain. 
 
                                     The AERA Technical Committee


August 1991 - TB 796

##END##
 VALVE TRAIN NOISE ON MAZDA 2.0L ENGINES
                                                  Valve Train Noise On
                                             1993-94 Mazda 2.0L Engines

The AERA Technical Committee offers the following information regarding a valve train noise on 1993-94 Mazda 2.0L engines. This noise can be associated with the Hydraulic Lash Adjusters (HLA).

This noise appears after the engine has been run at idle for a long period of time. The noise appears because air is entering the oil gallery. To prevent this condition from happening, Mazda had redesigned the oil pump plunger as shown in Figure 1.  

HLA noise will appear at the top of the engine and is several times faster than that of the engine speed. Verify the complaint by running the engine at idle for a period of time not letting the vehicle overheat. If the HLA noise is present, replacement of the oil pump plunger is required. 

To replace the oil pump plunger, remove the snap ring at the bottom of the pump as shown in Figure 1. Remove spring seat, pressure spring and the plunger. Replace the old plunger with the new plunger, Part #JF01 14 115. Reassemble the bottom of the oil pump in the reverse procedure of disassembly

NOTE: Follow instructions in the service manual for disassembly and assembly of the engine to get access to the oil pump for replacement of the plunger.

                                                                        The AERA Technical Committee
 COOLANT IN THE OIL
                                          Coolant In The Oil On
                                     Mazda 1.5 & 1.6L Engines

AERA member machine shops should carefully inspect the cylinder head when resolving engine oil contamination complaints.

The cylinder head carries two cup type freeze plugs on the valve spring side of the cylinder head.  Leaking freeze plugs will accumulate a black residue during operations.  Pressure testing the cylinder head confirms that the plug or plugs were leaking.  

Successful repairs include replacement of the plug or peening the metal surrounding the plug over it.  Be sure to re-pressure test the cylinder head after repairs are completed.

                                                                              The AERA Technical Committee
 CYLINDER HEAD INTERCHANGE CAUTION
                                        Cylinder Head Interchange Caution For
                                           1995-96 Mazda 2.5L, KL Engines

The AERA Technical Committee offers the following information regarding cylinder head interchange for 1995-96 Mazda 2.5L, KL engines. The cylinder heads used in the 2.5L, KLD Millenia are not interchangeable between 1995 and 1996.

The 1995 model cylinder heads have two different sized Hydraulic Lash Adjusters (HLA), whereas the 1996 cylinder heads have only one size HLA. Use the following information when ordering a replacement cylinder head.

Right Head 1995                       Left Head 1995         VINS
    KL31-10-100B                        KL31-10-1AOB/C         S1100158-S1999999

Right Head 1996                       Left Head 1996         VINS
   KL01-10-100J                          KL01-10-1AOK              T1000001-

Supplying heads for these 1995-96 engines may lead to customer dissatisfaction if the incorrect head(s) are supplied.

                                                                              The AERA Technical Committee
 REVISED CYLINDER HEAD BOLT
                                                Revised Cylinder Bolt For
                                              1995 Mazda 2.5L, KL Engines

The AERA Technical Committee offers the following information on a revised cylinder head bolt for 1995 Mazda 2.5L KL engines. The cylinder head bolt length was reduced and the accompanying washer eliminated beginning with vehicle VIN Code 1YVGEDS5361783 and engine serial number KL556012. 

Using the short bolt with an additional washer may result in an improper clamping load.  The original design bolt (longer) may be used on engines produced after the serial number break ONLY if the washer is installed. The current head bolt (shorter) may be used on the engines produced before the serial number break ONLY if the washer is eliminated.

The torque values used to install the cylinder head bolts remains as previously published. Mazda allows reuse of bolts in good condition if their lengths do not exceed 5.315 (135mm) for the shorter bolts or 5.127 (132.5 mm) for longer bolts. Follow the steps listed below to tighten the cylinder head bolts for this engine.

	Step 1. Torque all bolts in sequence to 17-19 ft/lbs.
	Step 2. Paint on all bolts and head casting to help indicate their position.
	Step 3. Rotate all bolts in sequence an additional 85-95° (Figure 2 & 3).
	Step 4. Rotate all bolts in sequence an additional 85-95° (Figure 2 & 3).

                                                                              The AREA Technical Committee
 REVISED ROCKER ARM REDUCES NOISE
                                   Revised Rocker Arm Reduces Lifter Noise On
                                         1987-90 Mazda 2.2L (B2200) Engines

The AERA Technical Committee has recently become aware of a revised rocker arm that may reduce lifter noise on 1987-90 Mazda 2.2L engines. Generally this noise occurs only at engine startup, when the vehicle has not been used for a longer period. 

When the engine starts, an insufficient quantity of oil reaches the hydraulic lash adjuster (HLA) to refill it.  Therefore, the valve train may be noisy until the lash adjuster has been refilled.

The revised rocker arm features a larger oil passage to permit more oil to reach the lash adjuster.  The previous passage was .031 in diameter, which has been enlarged to .078 in the revised part.  Extended oil change intervals can lead to varnish and sludge buildup in the oil passage aggrevating the problem.

This engine uses a separate intake, Part #F240-12-131B, and exhaust, Part #F240-12-151B, rocker arm.  Engines manufactured after September 1, 1989 use the revised rocker arms. 

                                                                    The AERA Technical Committee
 FLYWHEEL SPECIFICATIONS
                     Flywheel Specifications


The following flywheel specifications may be used as reference
when surfacing flywheels.

                   Type of 
Manufacturer       flywh. Specs.          Comments

BMW                Step   .013 - .015
Datsun             Step   .003 - .005   No groove
                   Flat                   With groove
Datsun 240Z        Step   .010           With groove
Fiat Spider 1600   Step   .018
Ford Falcon        Cup    .018           6 Cylinder engines
Ford Courier       Cup    .285
                   Cup    .310
Ford Ranger        Cup    .003           V6 Cylinder engines
GM                 Cup    .125
GM - Buick         Cup    .125           V6 Cylinder engines
GM - Spirit        Cup    .195
Honda              Cup    .030           Small cup
                   Cup    .100 - .104   
                   Cup    .785           Long alignment pins
                   Cup    .900            Short alignment pins
Honda Accord       Cup    .615           
Mazda              Cup    .062           Rotary engines
Subaru             Cup    .785
Toyota             Step   .018 - .022   Large alignment pins
                   Cup    .055           Small cup
                   Cup    .965 - .970    Tercel, large cup
                   Step   .040           Tercel, step
                   Step   .020           Land Cruiser
VW                 Cup    .945           Air cooled, 6 Volt
                   Cup    .830           Scirocco
                   Cup    .835           Rabbit/Golf
                   Cup    .982           Air cooled bus engine
                   Cup    .830           Air cooled engine
                   Cup    .885           Air cooled engine

Specifications listed for Step type flywheels refer to the
height of the wear surface above the pressure plate mounting
surface.  Specifications for Cup type flywheels refer to the
height of the pressure plate mounting surface above the wear
surface.

                                     The AERA Technical Committee

February 1988 - SB 153


##END##
 CAMSHAFT INSTALLATION ON 1995-2002 MAZDA 2.3L KJ ENGINES
                                                   Camshaft Installation On
                                           1995-2002 Mazda 2.3L KJ Engines

The AERA Technical Committee offers the following information regarding camshaft installation on 1995-2003 Mazda 2.3L KJ engines.  If the camshafts are not installed correctly, engine damage may result. 

When reinstalling the camshafts during engine installation, the original timing marks may have been worn away over time. If this is the case, mark and install the intake and exhaust camshafts using the procedure described below. 

NOTE: The procedure for the left and right cylinder banks is different. Be sure to follow each procedure correctly. 

Right Bank Cylinder Head (Figure 1)

Intake Camshaft Indexing:   From the backside of the intake camshaft timing gear, locate the small stamped dot. Gear may need to be cleaned to locate the dot.  Start with the tooth with the dot and count clockwise 31 teeth. Mark the 31st tooth with a scribe mark. 

Exhaust Camshaft Indexing:   From the backside of the exhaust camshaft timing gear, locate the small stamped dot. Gear may need to be cleaned to locate the dot.  Start with the valley stamped with the dot and count clockwise 4 valleys. Mark the 4th valley with a scribe mark.

Installing Camshafts:   Align the marked intake gear tooth with the marked exhaust gear valley. Install the camshafts into the cylinder head. Verify the alignment of the scribed marks. 

Left Bank Cylinder Head (Figure 2)

Intake Camshaft Indexing:   From the backside of the intake camshaft timing gear, locate the small stamped dot. Gear may need to be cleaned to locate the dot.  Start with the tooth with the dot and count clockwise 1 tooth. Mark the 1st tooth with a scribe mark. 

Exhaust Camshaft Indexing:  From the backside of the exhaust camshaft timing gear, locate the small stamped dot. Gear may need to be cleaned to locate the dot.  Mark the valley with a scribe mark.

Installing Camshafts:  Align the marked intake gear tooth with the marked exhaust gear valley. Install the camshafts into the cylinder head. Verify the alignment of the scribed marks.

                                                                       The AERA Technical Committee
 LARGER CRANKSHAFT JOURNAL DIAMETER FOR 1.8L KIA ENGINES
                                         Larger Crankshaft Journal Diameter for
                                            1995-2002 Kia 1.8L VIN 5 Engines

The AERA Technical Committee offers the following information on a larger crankshaft journal for 1995-2002 Kia 1.8L VIN 5 engines. The main journal diameter for the crankshaft of this engine increased in diameter beginning with the 1998 model year. Mazda manufactured engines used prior to 1998 and Kia manufactured subsequent engines.

Caution should be used when ordering replacement parts including crankshafts and main bearing sets as aftermarket catalogs may not reflect two different part numbers for the different years. 

Application             Main Journal Diameter        Rod Journal Diameter     Stroke

1994-97                   1.9661-1.9668                        1.7693-1.7699                3.346  (49.939-49.957 mm)                                              (44.94-44.955 mm)        (85 mm)
                          Main set 0K2YA11SG0  

1998-02                  2.1629-2.1636                        1.7693-1.7699                 3.430
                              (54.938 - 54.956 mm)               (44.94-44.955 mm)         (87 mm)
                         Main set 0K2Y211SG0

Kia indicates connecting rod and main bearings are available in standard, .010 (.25 mm), .020 (.050 mm) & .030 (.75 mm) undersizes. Reference to the sizes listed in the Kia service manual should not be used for grinding, as they?re incorrect.  

                                                                         The AERA Technical Committee