DONS engine (two camshafts) (Mazda Capella GD)

Cylinder head

Cylinder head height	133.95-134.05 mm
Permissible warpage of the cylinder head surface	0.15 mm
Permissible warping of the nozzle surface	0.10 mm
Permissible additional processing of the cylinder head surface	0.20 mm
Max clearance between hydraulic tappets and cylinder head surface	0.025-0.066 mm
— max distance	0.18 mm
Valve seat angle	45°

Valve disc diameter:
— intake valves	33.4-33.8 mm
- exhaust valves	28.8-29.0 mm
Valve length:
— intake valves	103.18 mm (min. 102.68 mm)
- exhaust valves	103.94 mm (min. 103.44 mm)
Valve stem diameter:
— intake valves	5.970-5.985 mm
- exhaust valves	5.965-5.980 mm
Operating clearance of valve stems in guides:
— intake valves	0.025-0.060 mm
- exhaust valves	0.030-0.065 mm
— max working clearance of valve stems in guides	0.20 mm
Valve plate rib thickness:
— intake valves	11-17 mm
- exhaust valves	11-17 mm
Wear limit	1.0 mm

Inner diameter	6.01-6.03 mm
Cylinder head installation temperature	80—100°C
Play in the guides	11.4-11.9 mm

Free length:
- external springs	39.1 mm (minimum length 38.7 mm)
- internal springs	38.0 mm (minimum length 37.7 mm)
Permissible warping of the upper side:
- outer springs	1.4 mm
- internal springs	1.3 mm
Installation length:
- external springs	31.5 mm at 8.0 kg
- internal springs	33.0 mm at 12.5–27.7 kg

Valve seat angle	45°
Valve seat width	1.2-1.6 mm
Valve seat depth	measure the protruding length of the valve stems

Axial clearance of the camshaft	0.08-0.10 mm
— max axial clearance	0.20 mm
Max camshaft bend	0.03 mm
Clearance in camshaft bearings	0.035-0.085 mm
— wear limit, all bearings	0.15 mm
Bearing journal diameter	29.940-29.965 mm
- wear limit	less than 0.05 mm
Height of protrusions - for leaded gasoline:
— intake valves	44.855 mm, wear limit
- exhaust valves	44.855 mm, wear limit
Height of protrusions - for unleaded gasoline:
— inlet and outlet valves	44.852 mm, wear limit

Valve timing	For gasoline containing lead	For unleaded gasoline
Opening the intake valves	10° before top dead center	10° before top dead center
Closing the intake valves	60° after bottom dead center	55° after bottom dead center
Opening the exhaust valves	60° before bottom dead center	55° before bottom dead center
Closing the exhaust valves	10° after top dead center	10° after top dead center

Piston rings	2 piston rings. 1 three-piece oil scraper piston ring
Piston pins	with safety rings
Piston diameter	85.944-85.964 mm
— permissible deviations	0.25 and 0.50 mm
Piston clearance:
— nominal size	0.036-0.075 mm
- wear limit	0.15 mm
Piston ring stem clearance:
- upper ring	0.20-0.35 mm
- more harmful ring	0.15-0.30 mm
- oil scraper piston ring	0.20-0.70 mm
- wear limit	100 mm
Maximum ring clearance in the piston groove:
- upper ring	0.030-0.070 mm
- middle ring	0.030-0.070 mm
- wear limit	0.15 mm
Piston ring thickness:
- upper rings	1.47-1.49 mm
- the second ring	1.47-1.49 mm
Permissible deviations of piston rings	as for pistons

Diameter	21,987-21,993 mm
Working clearance in connecting rods	0.010-0.027 mm
Working clearance in pistons	from 0.005 to 0.011 mm

Length, center to center	149.95-150.05 mm
The hole in the connecting rod heads	22.003-22.014 mm
Allowable twisting or bending	0.06 mm per 100 mm of length
Axial clearance on the crankshaft journals	0.11-0.26 mm
- wear limit	0.30 mm
Working clearance of connecting rod bearings	0.027-0.067 mm
- wear limit	0.10 mm
Permissible deviations of bearing liners	0,25; 0.50 and 0.75 mm

Number of main bearings	5
Perception of axial pressure	through the flange bearing shell on the middle bearing
Main/connecting rod bearing design	thin-walled bearing shells
Crankshaft axial clearance	0.03-0.18 mm
- wear limit	0.30 mm
Radial (working) clearance of the main bearing:
— nominal clearance, except for bearing No. 3	0.25-0.043 mm
— nominal clearance, bearing No. 3	0.031-0.049 mm
- wear limit	0.08 mm
Radial (working) clearance of the connecting rod bearing:
— nominal clearance	0.027-0.068 mm
- wear limit	0.10 mm
Main bearing journal diameter:
— nominal diameter	59.937-59.955 mm
- wear limit	0.05 mm
— finishing boundary	0.75 mm
Max, constriction or quality	0.05 mm
Max crankshaft bending	0.03 mm
Permissible deviations of bearing liners	0,25; 0.50 and 0.75 mm
Crankshaft journal diameter:
— nominal diameter	50.940-50.955 mm
- wear limit	0.05 mm
— finishing boundary	0.75 mm
Max, constriction or quality	0.05 mm
Permissible deviation of bearing shells	0,25; 0.50 and 0.75 mm
Max flywheel surface runout	0.10 mm

Cylinder block height	289.0 mm
Max. sealing surface warpage	0.15 mm
Cylinder bore	86,000-86,019 mm
Hole deviations	0.25 and 0.50 mm
Max bore wear	0.15 mm
Max, tapering or ovality	0.02 mm
Piston working clearance	0,036-0,075
Place of measurement of piston diameter	18.0 mm below the ring groove in the right corner relative to the piston pins