1987 Mazda Truck B Series Truck L4-2000 1998cc Copyright © 2013, ALLDATA 10.

52SS Page 1

Cylinder Head Assembly: Service and Repair

CYLINDER HEAD
Removal and installation
1. Disconnect the negative cable from the battery.
2. Drain the engine coolant into a suitable container.
3. Remove each part in the numbered sequence shown in figure.
4. Install in the reverse order of removal.

1. Air cleaner assembly

2. Cooling fan & radiator cowling
3. Oil level gauge
4. Accelerator cable & cruise control cable
5. Fuel hoses
6. Heater hoses
7. Brake vacuum hose
8. 3-way solenoid valves & vacuum sensor assembly (Don't disconnect the vacuum tubes)
9. Duty solenoid valves assembly (Don't disconnect the vacuum tubes)
10. Vacuum switch (Don't disconnect the vacuum tube)
11. Canistor hoses
12. Engine harness coupler
13. High tension leads & spark plugs
14. Distributor
15. Secondary air pipes assembly & front engine hanger
16. Radiator hose, upper
17. Water bypass hoses & bracket
18. Intake manifold & carburetor assembly
19. Exhaust manifold insulator
20. Exhaust manifold
21. Timing belt cover, upper
22. Timing belt tensioner & spring
23. Timing bet
24. Camshaft pulley
25. Engine ground & rear engine hanger
1987 Mazda Truck B Series Truck L4-2000 1998cc Copyright © 2013, ALLDATA 10.52SS Page 2

26. Cylinder head cover

27. Cylinder head bolt
28. Cylinder head
29. Front cover and thermostat assembly

Camshaft pulley
1. Before removal of the camshaft pulley, turn the crankshaft to align the "A" mark of the camshaft pulley with the front housing timing mark.

2. As shown in the figure, the lock bolt of the camshaft pulley can be removed or installed by using a T-wrench on the front housing installation bot
to hold the camshaft pulley.

Fuel hoses (inlet and return)

After disconnecting the fuel hoses (inlet and return) plug them to avoid fuel leakage.

Cylinder head bolts

Fig. 2 Cylinder head bolt loosening sequence

Remove the cylinder head bolts in the numbered order shown in the figure. Loosen them gradually, in order.

Assembly
. Install the valve seals.
(1) Apply engine oil to the valve guides.
(2) Using the valve seal pusher (49 G030 160), install the valve seals.
1987 Mazda Truck B Series Truck L4-2000 1998cc Copyright © 2013, ALLDATA 10.52SS Page 3

Caution: Be sure to use the special tool for installation. If it is not installed correctly, oil might work down.

2. Install the valves into to the cylinder head.

(1) Install the lower spring seats.
(2) Insert the valves after applying engine oil to the valve stems.
(3) Install the valve springs and upper spring seats.
(4) Using the valve spring lifter arm (49 0636 1OOA) and pivot (49 G030 222), compress the valve springs. Install the spring retainers securely

3. Install the camshaft. Apply engine oil to the journals, then place the camshaft in position.

Caution: Be certain that the dowel pin of the camshaft faces straight up.

4. Apply a thin coat of sealant to the shaded areas as shown in the figure.

(1) Apply a liberal coat of engine oil to the cam-shaft journals.

(2) Install the rocker shaft assembly.

Caution: When the rocker shaft assembly is tightened, it must be done evenly and in the order shown in the figure.

(3) Tighten the rocker shaft assembly to the specified torque.

Rocker shaft assembly tightening torque:
18-26 N.m (1.8-2.7 m-kg, 13-2O ft-lb)

6. Install the auxiliary pants to the cylinder head.

(1) Fuel pump
(2) Front housing and thermostat (Apply engine oil to the camshaft oil seal)
1987 Mazda Truck B Series Truck L4-2000 1998cc Copyright © 2013, ALLDATA 10.52SS Page 4

Installation
1. Thoroughly remove all din and grease from the of the cylinder block with a rag.
2. Place the cylinder head gasket in position.

Caution:
a) Use a new cylinder head gasket.
b) Remove all dirt and grease from the t0p of the block and the cylinder head.

Fig. 18 Cylinder head bolt tightening sequence

3. Install the cylinder head, and tighten the cylinder head bolts to the specified torque.
Cylinder head tightening torque:
80-86 N-m (8.2-8.8 m-kg, 59-64 ft-lb

Caution:
a) Tighten the cylinder head bolts gradually and in the order shown in the figure.
b) Remember to use the new style surface treated plain washers.

4. Install the camshaft pulley onto the dowel pin a keyway with the "A" mark straight up, tighten 1 camshaft pulley bolt to the specified torque.
Camshaft pulley tightening torque:
47-65 N-m (4.8-6.6 m-kg, 35-48 ft-lb)

Caution: Be sure that the timing mark on the front housing and the "A" mark on the camshaft pull match.

5. Referring to the TIMING BELT section of 0N VEHICLE MAINTENANCE, install the timing belt.

6. Install the following parts.

1987 Mazda Truck B Series Truck L4-2000 1998cc Copyright © 2013, ALLDATA 10.52SS Page 5

(1) Engine ground and rear engine hanger

(2) Timing belt cover
Timing belt cover tightening torque:
7-1O N-m (O.7-1.O m-kg, 61-87 in-lb)

(3) Exhaust manifold

Exhaust manifold tightening torque:
21-28 N-m (2.2-2.9 m-kg, 16-21 ft-lb)

(4) Exhaust manifold insulator

(5) Water bypass hose and bracket
(6) Intake manifold and carburetor
Intake Manifold tightening torque:
19-25 N-m (1.9-2.6 m-kg, 14-19 ft-lb)

(7) Radiator hose

(8) Secondary air pipes assembly and front engine hanger
(9) Engine harness coupler
(10) Canister hoses
(11) Vacuum switch
(12) Duty solenoid valve assembly
(13) 3-way solenoid valve assembly

(14) Brake vacuum hose

(15) Heater hoses
(16) Fuel hoses
(17) Accelerator cable and cruise control cable (if equipped)

7. Install the distributor

(1) Lubricate the 0-ring and the drive gear with engine oil, and install it on the distributor.
(2) Match the distributor housing and drive gear mating marks, and install the distributor in the front housing with the marks facing straight up.
(3) Temporarily, loosely tighten the distributor installing bolt.
8. Install the spark plugs and connect the high Tension leads.
Spark plug tightening torque:
15-23 N-m (1.5-2.3 m-kg, 11-17 ft-lb)
1987 Mazda Truck B Series Truck L4-2000 1998cc Copyright © 2013, ALLDATA 10.52SS Page 6

9. adjust the valve clearance.

10. Install the cylinder head cover.

(1) Apply a coat of sealant to the shaded areas as shown in the figure.
(2) Install the cylinder head cover, and tighten it to the specified torque.
Cylinder head cover tightening torque:
3-4 N-m (O.3-O.4 m-kg, 24-34 in-lb)

11. Install the following parts:

(1) Radiator cowling
(2) Cooling fan
(3) Oil level gauge
(4) Air cleaner assembly
12. Fill the radiator with coolant.
13. Perform the necessary engine adjustments.