My October 2011 B2200 Engine Rebuild

Last Updated: Feb 24, 2015


My October 2011 B2200 Engine Rebuild, salvaged from my MazdaTrucking.com thread. At 182,900 miles, my 1988 B2200 Cab Plus was smoking too much and burning/using oil, time to "go in" and be environmental. Oh yeah - need to add that I purchased new NPR pistons, rings, and bearings from online retailer. I bought a few exhaust gaskets locally, and the Mazda bypass hoses locally as well. The original two heater hoses were replaced with Gates hoses from Rock Auto, and I used Fel-Pro head gasket set from them as well. Rock Auto also provided the flexible lower clutch line, which I replaced when my slave cylinder (local lifetime warranty) started leaking in the middle of all this. Cylinder head was machined locally ($260), used my existing lifters. Hone and ring compressor were loaners from AutoZone.

Out of pocket cost was about $700. It took me 1.5 days to dismantle and get the cylinder heads and the connecting rods/pistons to the machine shop, who also hung those. It took me 2.5 days to put together, but that also includes fussin' with the vacuum leak under the Weber carb, I had tried to re-use those gaskets once too many times.


Before starting, I got my calculator and camera phone ready.

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Before starting.
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Pan and baffle off; looked pretty clean, and no junk in the oil pan at all:
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My old broken fan shroud:
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New (parts yard) top and old fan shroud bottom:
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"New" fan shroud overlaid on the Murray 2-row radiator. Red arrows show Murray shroud mounting holes. Blue arrows show where I drilled my own 1/4 inch holes, so I can use 6.0mm x 1.0mm bolts/nuts.
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My engine set to TDC for #1
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My Weber/adapters/intake manifold taken off as a unit (those 12mm gear wrenches are great). The two arrows point to the small 8mm i.d. bypass hoses that I need to buy new.
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Fan bracket removed and timing belt off camshaft pulley.
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Underside of valve cover after baffle removed. I'll need to get a new PCV grommet.
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Rocker arms and under valve cover.
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Cylinder head off.
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Second view of engine block
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Underside of cylinder head. I don't see any cracks (good).
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Oil rings stuck in piston groove, source of oil getting into and/or staying in cylinder
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Also, I could still see the original honing marks on the cylinders, and there was no ridge.
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Bearings looked in great shape for 183K miles !!!
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Crankshaft journals also looked real good, not getting this reground or doing new main bearings
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Refurbished cylinder head back from the shop
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I had to remove the rocker arms to add sealant and assembly lube
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Cylinder head front piece added with camshaft seal and
camshaft gear
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Intake manifold and Weber 32/36 DGEV carburetor back on
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Weber 32/36 DGEV carburetor with EGR block-off plate
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New piston and rings v. old piston. Again note that oil control ring is not out any further than the piston on the old
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Engine block before light honing with electric drill
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After honing with electric drill, hone marks visible
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Using wooden dowels to keep head gasket aligned and to
aid cylinder head alignment
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Cylinder head, valve cover, timing belt installed
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Finished view of engine compartment: The B2200 runs good, NO SMOKE, and no leaks so far.
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Had big-time stalling issue after starting up, traced to vacuum leak under carburetor, as I had re-used (too many times) the carburetor base gasket. New gaskets are available only from California or NY, so I bought this rubberized gasket material and made my own
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The garage space where I did all this.
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Workbench after completion, before cleaning up. Note oil spill of

Credits

Created By: Cusser