Contents: Checking the technical condition ⇓ Assembly ⇓
Checking the technical condition
Clean all parts thoroughly. Wash the mating surfaces of the parts with solvent. Never clean the mating surfaces with sharp objects or abrasive materials.
Make sure there are no signs of wear, scratches or burrs on the mating surfaces.
Measure the dimensions of the cylinders, crankshaft, pistons and other parts (see nominal and repair dimensions in the subsection "Detailed technical specifications").
Check the condition of the pistons and connecting rods.
Remove the piston rings.
Separate the piston and connecting rod. To do this, remove one of the retaining rings from the piston pin and press out the pin.
Check the condition of the main and connecting rod bearing shells. No adjustment operations should be performed on the shells. If there are any scuffs, scratches or peeling, replace the shells with new ones.
Check the markings on the pistons and connecting rods.
Replace the connecting rod bolts and small end bushing if necessary.
Assembly
Replace seals and rings, lock washers and nuts each time the engine is reassembled.
As you assemble the engine, lubricate the rubbing surfaces of the parts with engine oil.
When assembling the engine, install the parts in accordance with the factory marks and those applied during disassembly, install unnoticed parts in their original places (liners, piston rings, pistons, etc.).
Turn the cylinder block over and place it on the stand.
On the B6 EGI engine, install piston oil sprayers.
Lubricate the main bearing shells with engine oil and install them into the cylinder block seats and into the main bearing caps, ensuring that the lubrication holes are correctly positioned.
Place the crankshaft in the main bearings and insert the thrust half rings into the 4th main bearing sockets. Install the main bearing caps and tighten their mounting bolts.
Check the axial play of the crankshaft using an indicator, the leg of which should rest against into the crankshaft flange.
Press the rear crankshaft oil seal into the holder, having previously lubricated its edges with engine oil, and install the holder with a new gasket.
Connect the pistons to the connecting rods so that the mark on the lower head of the connecting rod is opposite the "F" mark (see photo) on the piston, which should be directed towards the camshaft drive.
Install the bearing shells in the connecting rods and connecting rod caps, lubricated with engine oil. Install the connecting rods and caps on the crankshaft journals, tighten the connecting rod bolts. The connecting rod caps must be installed so that the marks on the cap and on the lower connecting rod head are opposite each other.
Lubricate the cylinder walls with engine oil.
Using a piston ring compressor, insert the pistons with connecting rods into the cylinders so that the "F" marks on the pistons are directed towards the camshaft drive.
Install the front cover assembly with the oil pump onto the crankshaft and put the oil pump receiver in place.
Press the new front crankshaft oil seal into the front cover.
Install the oil pan.
Install the water pump with a new gasket.
Install the thermostat, new gasket and thermostat housing with the steam outlet facing up.
Install the flywheel on the crankshaft, lock the flywheel with the Mazda 49E 301 060 locking device and tighten the mounting bolts.
Install the crankshaft timing pulley.
Install the cylinder head.
Install the camshaft drive belt.