Installing the cylinder head (Mazda Capella GD)

Insert the cylinder head gasket, but ensure that the valves and openings in the block are not covered by the gasket. Ensure that proper sealing has been applied. You should always replace the seal, even if the old one still looks good. The installation of the cylinder head and further assembly should now be carried out in accordance with the required engine type.

2.4.5.1. Gasoline engine (except DOHC engine)

Install the cylinder head and, using figure 28, insert bolts 9 and 10 first. Tighten the bolts by hand to secure the head. After this, insert the remaining bolts and now gradually tighten them in the reverse order of the sequence shown in the figure (10 becomes 1, 9 becomes 2, etc.). Tightening of the cylinder head bolts is carried out in the following order:

• tighten the bolts in the specified sequence with a torque of 30 Nm;
• tighten the bolts in the specified sequence with a torque of 50 Nm;
• tighten the bolts in the specified sequence to a final torque of 80-86 Nm.

Thoroughly clean the camshaft bearing surfaces in the cylinder head and lubricate with engine oil. Place the camshaft into the holes and turn until the dowel pin is at the top.

The engine has 12 valves

• Lubricate the cams and bearing numbers well and install the camshaft bearing caps with the arrows facing forward in accordance with their numbers. Cover No. 3 has a hole for supplying oil, which should come out on the left side from the end side.
• Place the rocker arm mechanism on the camshaft, rear shaft and cylinder head. Make sure that the rocker arm or gaskets are not pinched between the axle and the camshaft bearing cap.
• Rocker arm axle stand bolts in reverse order figure 27, tighten to a torque of 18-27 Nm.
• Lubricate the outer side and the working edge of the new sealing ring for the front housing with engine oil and insert the sealing ring into the front of the housing.
• Place a new dry seal on the end surface of the cylinder head and install the front cover onto the head. Tighten the bolts to 19-25 Nm (figure 63).

The engine has 8 valves

• Install the cylinder head using Figure 28. Insert bolts 9 and 10 first. Tighten the bolts by hand to align the cylinder head. After this, insert the remaining bolts and gradually tighten them in the reverse order shown in the figure (10 becomes 1. 9 becomes 2, etc.). Tightening of the cylinder head bolts is carried out in the same manner as described for the 12-valve engine. Thoroughly clean the camshaft bearing surfaces in the cylinder head and lubricate with engine oil. Place the camshaft into the hole and turn it until the locating pin is at the top.
• Insert the bolts into the rocker arm axle posts, lubricate the holes for the camshaft bearings.
• Apply a thin layer of sealant to the surface of the cylinder head where the front and rear bearing caps are located and install the rocker arm assembly onto the camshaft and cylinder head. Tighten the rocker arm axle support bolts in the reverse order shown in Figure 27 to 18-26 Nm.
• Lubricate the outer side and the working edge of the new sealing ring for the front housing with engine oil and insert it into the front of the housing.
• Place a new dry seal on the end surface of the cylinder head and install the front cover onto the head. Tighten the bolts to 19-26 Nm (figure 63).

• For all versions, install the rear housing with a new seal and tighten the bolts to 19-25 Nm.
• If the crankshaft drive gear is removed, drive a woodruff key into the end of the crankshaft and rotate the shaft until the key is aligned with the control mark on the oil pump housing, as shown in the figure 64. Place the crankshaft gear on the shaft and insert the bolts. Tighten them to 157-167 Nm. The engine must be held in a comfortable position.

• Place the camshaft drive gear onto the camshaft so that the locating pin engages with the engagement pins. Make sure that the camshaft gear has two signs.
• If an engine with the letter designations F6 or F8 is assembled, then the hole with number 3 comes into contact with the woodruff key; if an engine with the letter designation FE is assembled, then the hole with number 2 comes into contact.
• Screw the bolts into the drive gear, insert a metal rod through the gear hole (insert against the cylinder head) and tighten the bolts to a torque of 48-66 Nm.
• Rotate the camshaft gear until it reaches the position shown in the figure 65, meaning markings 2 and 3.
• Install the timing belt drive roller and tighten the bolts to 37-52 Nm.
• Install the outer belt device and tensioner spring. Temporarily tighten the device with the spring fully extended.
• Put on the belt. If the same belt was used as before, it must be threaded through both drive gears, the tensioner and the water pump. Make sure that the direction arrow points in the direction of engine rotation. If installing a new belt, check the outside edge of the belt to determine which direction the arrow is pointing. There should be no oil or grease on the belt.

Now the tensioner is installed in the following order:

• loosen the tensioner mounting bolts and allow the tensioner to push the belt inward;
• rotate the engine twice in the normal direction of rotation and again, as described above, point the indicator sign;
• move the engine to the position shown in the figure 66, and tighten the belt tensioner bolts to a tightening torque of 37-63 Nm;
• if an old belt is used, measure the belt tension between both drive gears at the location shown in the figure 67. To do this, hang a spring scale on the belt and pull it outward with a force of 10 kg. The belt should move 5.5-6.5 mm for an FE engine, and 4.0-5.0 mm for an F6 or F8 engine.

• Place the guide shield onto the end of the crankshaft.
• Check again that the bolts of both driven wheels are tightened and the lower belt guard cover is screwed on with a new seal. Tighten the bolts to a tightening torque of 7-10 Nm.
• Install the upper protective cover with a new seal and tighten the bolts to the same tightening torque.
• Place the pulley on the crankshaft and tighten the bolts to 8-12 Nm.
• For a petrol engine, install with two new seals and an intermediate flange. The seals and flange must be free of oil or grease. Lubricate the end of the pump lever with a small amount of fat.
• Set the valve clearance as described in the relevant chapter.
• All other work should be carried out in the reverse order of removal.

2.4.5.2. Gasoline engine - DOHC engine

• Install the cylinder head as described in the next chapter. Tightening torques are the same. Figure 35 shows the bolt release diagram. Tightening occurs in the reverse order.
• Thoroughly clean the bearing surfaces in the cylinder head and lubricate with engine oil. Place the camshafts into the holes and rotate until the dowel pin is on the top side of the shafts.
• Lubricate the camshaft oil seal ring and camshaft journal well and carefully press the seal ring onto the shaft and cylinder head.
• Lubricate the cams and bearing journals thoroughly and install the camshaft bearing caps onto the camshaft in accordance with the markings. Lubricate the surfaces of the front cover in front of the nozzle with sealant.
• Bolts in accordance with the tightening sequence on figure 56 tighten to a torque of 18-26 Nm. Rotate both shafts several times to check for clamping.
• Screw the front shield to the cylinder head and tighten to 8-12 Nm.
• Shown in the picture Lubricate 68 places with sealant and install the cylinder head cover. Tighten the bolts to 4-6 Nm.

• If the crankshaft drive gear is removed, drive a woodruff key into the end of the crankshaft and rotate the shaft until the key is in line with the control marks on the oil pump housing, as shown in the figure 64. Place the crankshaft wheel on the crankshaft and insert the bolts. Tighten them to 157-167 Nm. The engine must be supported accordingly.
• Place the camshaft drive gear onto the shaft so that the locating pin engages. Make sure that the camshaft gear is marked with the letter I (intake shaft) или E (exhaust shaft). Mount the drive gear in the appropriate manner.
• Screw the bolts into the drive gear and insert a metal rod through the hole (insert against the cylinder head) and tighten the bolts to a torque of 48-65 Nm. Tighten both bolts in the same manner.
• Turn the camshaft gear until they are in the position shown in the figure 69 position, i.e. the corresponding positions should be occupied by the letters I and E.

• Mount the drive roller on the toothed belt and tighten the bolts to 37-52 Nm.
• Install the belt tensioner and tensioner spring. Temporarily tighten the device with the spring fully extended. To do this, press the tensioner outward until the bolts are tightly tightened.
• Apply the timing belt. If a used belt is used, it must be fitted through both drive gears and the belt tensioner. Make sure that the direction arrows point in the direction of engine rotation. If installing a new belt, check the outside edge of the belt to determine which direction the arrow is pointing. There should be no oil or grease on the belt.

Now the tensioner is installed in the following order:

• loosen the tensioner mounting bolts and allow the tensioner to push the belt inward;
• rotate the engine twice in the normal direction of rotation and again, as described above, point the indicator sign;
• turn the crankshaft until the marking on the right camshaft pulley is in line with the marking on the rear panel;
• measure the belt tension between both drive gears at the location shown in the figure 70. To do this, hang the spring scale on the belt and pull it outward with a force of 10 kg. The belt should move 7.5-8.5 mm. If not, repeat the above installation.

• Place the guide shield onto the end of the crankshaft.
• Check again that all driven wheel bolts are tightened and the lower belt guard is screwed on with a new seal. Tighten the bolts to a tightening torque of 7-10 Nm.
• Install the upper protective cover with a new seal and tighten the bolts to the same tightening torque.
• Place the pulley on the crankshaft and tighten the bolts to 12-17 Nm.
• Set the valve clearance as described in the relevant chapter.
• All other work should be carried out in the reverse order of engine removal.

2.4.5.3. Diesel engine

• Turn the crankshaft until the drive gear reaches the position shown on the figure 35. If the drive gear is not yet installed, it can be installed temporarily.
• Apply the cylinder head gasket.
• Remove the cylinder head bolts and measure their length one by one. The measurement is taken from the lower edge of the support washer to the end of the thread. If the bolts are longer than 114.5 mm, they must be replaced because they have stretched. Lubricate the threads of high-quality bolts with motor oil.
• Guided by the drawing 71, tighten the bolts in the specified sequence with a tightening torque of 30 Nm.

• Mark all bolt support washers with colored dots (quick-drying paint) or in some other noticeable way.
• Only with the help of interchangeable heads, extensions and ratchets (without a torque wrench) tighten the bolts in the specified tightening sequence by the next 90° (quarter turn).
• Tighten all bolts again in the specified sequence by another 90°. It is imperative to follow the correct sequence.
• Thoroughly clean the bearing surfaces of the camshaft in the bearing head and lubricate with engine oil. Place the camshafts into the holes and turn them until the keyway is on the top side.
• Apply a thin layer of sealant to the surface of the cylinder head where the front and rear covers are mounted.
• Insert the camshaft caps according to their numbers and hit with a hammer. The arrows should point upwards. Tighten the nuts and caps slightly.
• Lightly oil the new O-rings and use your thumb to push them onto the camshaft and bores until the outer edges are trimmed.
• Tighten the camshaft cover nuts in several steps, working from the middle to the edges, to a tightening torque of 20-26 Nm.
• Install glow plugs (15-20 Nm) and connect the wires.
• Install the injectors and oil drain line. It is necessary to use new shaft discs and copper washers, however in the picture 72 indicates what the arrangement of the parts should be. The side shown in the circle is marked with paint and should be facing up. The injectors need to be tightened to 60-70 Nm, the oil drain line to 31-45 Nm.

• Screw the front and rear engine clamps (37-52 Nm front, 19-26 Nm rear).
• Install the thermostat housing with a new seal (16-23 Nm), install the thermostats on the upper side using a pin and insert a new seal (side to the body). Screw on the cover and tighten to 7-10 Nm.
• Install the water pump with a new seal. The painted side of the seal is located opposite the water pump. Tighten the three large bolts to 31-45 Nm, the small bolts to 8-11 Nm.
• Install the water pipe, oil pressure switch and oil level indicator pipe with dipstick in this order.
• Install the high-pressure fuel pump together with the console and tighten the fasteners to 37-52 Nm. If the pump is not separated from the console, the valve train must be installed.
• Screw on the high pressure line and tighten the union nuts to 25-30 Nm.
• Install the large cover on the drive side, first checking that the sealing rubber fits perfectly. Tighten the bolts to 8-12 Nm.
• Install the timing belt pulley on the rear side of the camshaft, hold the shaft on a plane in the middle and tighten the bolts with washers to 55-65 Nm.
• If the crankshaft drive gear is installed, insert the disc springs into the ends of the crankshaft and tighten the bolts firmly while turning the engine. Tighten the bolts to 157-167 Nm. Hold the engine in a comfortable position.
• Place the camshaft drive gear onto the shaft so that the key engages.
• Screw the bolts into the drive gear, hold the shaft in the middle with a wrench and tighten the bolts with a tightening torque of 55-65 Nm.
• Turn the camshaft gear until the marking on the drive gear is aligned with the marking on the sealing area.
• Using a key, place the drive gear of the high-pressure fuel pump on the shaft and turn the gear until the markings on the gear and the sealing area are in line. Screw the bolts used during dismantling back into the gear and tighten the drive gear bolts to 60-70 Nm.
• Install the belt tensioner and tensioner spring. Temporarily set the tensioner to the outward position.
• Turn the crankshaft back until the mark on the drive gear is in line with the mark on the oil pump.
• Using the drawing 73, check that all markings are positioned as shown before installing the timing belt.

• Put on the toothed belt. If the old belt is used, it should be put on in the following sequence: through the crankshaft gear, the high-pressure pump gear, the camshaft gear, the water pump and the tension roller. The arrows indicate the direction of engine rotation. If a new belt is being installed, the outer edge of the belt must be checked to determine which way the arrow is pointing. The belt must be absolutely free of oil and grease.
• Install the timing belt drive roller on the top side and tighten the bolts to 37-52 Nm. Figure 74 shows the location of the drive roller.

The tensioner is now installed in the following sequence:

• loosen the tensioner mounting bolts and allow the tensioner to push the belt inward;
• rotate the engine twice in the normal direction of rotation and check the markings on the gears again as described (see figure 73);
• tighten the tensioner bolts to a tightening torque of 37-53 Nm;
• measure the belt tension between both drive wheels as shown in the figure 75th place. To do this, hang a spring scale on the belt and pull the belt outward with a force of 10 kg. The belt should advance between 9.0 and 11.5 mm. If not, repeat the above installation.

• Check again that the bolts of all drive wheels are tightened and that the left and right belt drive protective covers are screwed on. Tighten the bolts to 7-10 Nm.
• Place the timing belt pulley on the crankshaft and tighten the bolts to 23-32 Nm.
• Set the valve clearance as described in the relevant chapter.
• All remaining work should be carried out in the reverse order of dismantling.