Cylinder head assembly (Mazda Capella GD)

All cylinder head parts must be thoroughly cleaned and carefully laid out on the workbench in such an order that assembly can be carried out correctly. It is necessary to use the corresponding assembly drawings of the individual cylinder head components.

2.4.4.1. Gasoline engine

• Insert the valves into the guide bushings one by one. The rods must be well lubricated. If the same valves are used again, they must be inserted into the corresponding guide bushings.
• Place the valve stem sealing rings on the stems and guide bushings and press them firmly as described and shown in the figure 48. For DONS engines, there is no need to hammer in the sealing rings, just press them in.
• Install the valve spring seats and valve springs onto the cylinder head (on the corresponding valves if the same springs are used). If expansion washers were used to compensate for the length of the valves, they must fit into the valve spring seats. The springs have less winding at one end. This side enters the cylinder head. Figure 60 shows the valve spring. The DOHC engine has two springs for each valve.

• Insert the upper valve spring plates and install the valve lifter in accordance with the drawing 30 to compress the springs. If the ends of the rods protrude from the upper spring plates, you need to insert both valve crackers into the rod groove and slowly remove the puller.
• Use a plastic hammer to strike the top side of the valve stem. In this case, poorly inserted crackers will fall out. For safety, cover the edges of the springs with a cloth to prevent parts from falling out.
• In a standard engine, all rocker arm shaft parts should be well lubricated and the shafts should be assembled. The axes of the intake (front) and exhaust (rear) valves cannot be confused. To find the difference, you need to count the grease holes. The intake valve axis has twice as many holes as the exhaust valve axis. It is also necessary to ensure that rocker arms No. 1 and No. 3, as well as No. 2 and No. 4, are identical, but must be installed in their original positions if old parts were used. The rocker arm axles must be assembled in accordance with the drawing 61. The end of each axis is secured. This end goes into the opposite side. The drawing shows which rocker arms are the same.

• If hydraulic adjustment parts are installed (12 valves) and they have been replaced, the oil pockets need to be filled with oil and the regulator carefully pressed into the rocker arm so as not to damage the O-ring.
• For a DOHC engine, lubricate the hydraulic lifters on the outside with oil and insert them into the original holes if they have not been replaced.
• Check the cleanliness of the cylinder head surfaces and be sure to remove all remaining seals. If the cylinder block has been washed, there should be no residue of detergents in the threads of the cylinder head bolts.
• Reinstall all parts removed from the cylinder head.

2.4.4.2. Diesel engine

• Insert the valves into the guide bushings one by one. The rods must be well lubricated. If previously used valves are reinstalled, they must be inserted into the corresponding guide bushings. The above instructions apply to valves that have already been ground.
• Place the valve stem sealing rings on the stems and guide bushings and press them firmly as described and shown in the figure 48.
• Install the valve spring seats and valve springs onto the cylinder head (on the corresponding valves if the same springs are used). If expansion washers were used to compensate for the length of the valves, they must fit into the valve spring seats.
• Insert the upper valve spring plates and install the valve lifter in accordance with the drawing 30 to compress the springs. If the ends of the rods are released from the upper spring plates, both valve crackers must be inserted into the rod opening and the puller must be slowly removed.
• Use a plastic hammer to strike the top side of the valve stem. In this case, poorly inserted crackers will fall out. For safety, cover the edges of the spring with a cloth to prevent parts from falling out.
• Lubricate the tappets and their adjusting washers with engine oil and insert them into the original holes. The adjusting washers are included in the tappets (figure 62).

• Check the cleanliness of the cylinder head surfaces and be sure to remove all remaining seals. If the cylinder block has been washed, there should be no residue of detergents in the threads of the cylinder head bolts.
• Reinstall all parts removed from the cylinder head.

(The text of the article is taken from the website: «mazbook»)