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Hello everyone!

I've had this little truck for a few years and its finally shit the bed completely. Multiple oil leaks, burns coolant, can't keep it running at all. WE SHALL REBUILD! Looking for recommendations on part suppliers for rebuild kits as it been years since I've done anything like this on a vehicle. Can someone point me towards a rebuild thread or parts list somewhere on the forum here? I'm new. thanks!
 

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Yes. Machine work and good rings haha. I just did a head gasket and top end on mine because of it pushing coolant out and wanting to over heat. And nasty smoke at start up. Tore head off straight edge it and looks great. Put back together and a have a little smoke still. Thinking it's the rings now... And actually still having some over heat issue. Gonna flush system and hope it's not the head...
 

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1992 Mazda, B2200 ext cab
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I think the OP is looking for the wonderful rebuild threads we used to have on Mazdatrucking. complete with pictures and guidance that you just cant get from the books.
Alas i really miss that fabulous site.
Bobmo
 

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If you're having a smoking issue, then it's you're rings.

Particularly, the oil control rings. And it is not really the ring's themselves, but the gunk in the piston ring grooves that keep the rings stuck to the pistons, and therefore not allowing them to "scrape" the oil from the cylinder walls as they are designed to do......once the engine heats up to operating temperature, the rings will expand and overcome the gunk in the ring grooves and start to do their job. When the engine cools down, the oil control rings are stuck once again.

Now, this is just my observations, but I have rebuilt more than a dozen of these Mazda engines.....and to some people, not the "correct" way! Very seldom do I have the cylinders bored out and order oversized pistons, I have only gone the "typical rebuild way" with 2 of the Mazda engines that I have rebuilt.......over the last 20 years or so.

If you pull a 100,000 mile or more Mazda FE, F2, or G6 engine apart, there is a good chance that when you clean the block up, you will still see the original cross hatch pattern from the factory honing process in the cylinders! What does that tell you? It tells you that the engine block cylinders are NOT worn very much!

Mazda used narrow, low tension rings when compared to domestic engines of the past.......and most manufactures do the same now.......but the engine metal in the Mazda engine blocks (in my opinion) seems to be much better (more nickel maybe?) and harder than the domestic engines of the past. I have rebuild SBC engines, Pontiac engines, and several V6 chevy engines......and I believe that the Mazda blocks are definitely "harder" to score and/or wear down. Again, my opinions.

But, after rebuilding more than a handful of these Mazda engines, and NOT using new pistons but rather cleaning them to look new again, and installing new standard size quality rings (Sealed Power, Mahle, NPR, etc.) I have never had an engine smoke (when it did beforehand) after I rebuilt it. I currently own a 1989 Mazda B2200 that I rebuilt the engine in, sold it twice, bought it back twice, and drive it currently almost daily, and it still doesn't smoke, and it is actually quite fast.......for a Mazda! I don't know the exact miles on the engine since it's rebuild, but it is definitely over 50,000 miles now......might be over 60,000.

The things you want to look for when tearing one of these Mazda engines down is,

Heavy or deep vertical scoring on the piston skirts, or the cylinder bores......if they are present (some light vertical scoring WILL be present) then you may want to have the engine cylinders bored, or replace the pistons, or both.....however, it's been my experience that light vertical scoring is all you may see.

Of course, rod & main bearing damage, crankshaft journal rotational scoring, thrust bearing surface conditions on the crankshaft, crankshaft keyway condition (usually only the B2000 & B2200 engines), etc.

And you want to measure everything and log it when pulling the engine apart.......so you'll need a decent Dial Caliper, 1", 2" & 3" Micrometers, Magnetic base Dial Indicator, and some telescoping or snap gauges, or a Dial Bore Gauge, and a good set of feeler gauges. Then also measure the new bearing oil clearances, ring end gaps, and crankshaft end play.......and record them also. This way you KNOW the exact condition of the engine at teardown AND at rebuild.
You can use Plasti-gage also, but I prefer to measure it all with tools.

Anyway, for parts and gaskets I usually buy quality name brand products from RockAuto.com......as well as Amazon sometimes, because I get free shipping most of the time with them. Find out the manufacturers part numbers, then search them on Amazon.

I will dig up some rebuild pictures of the past, and post them here in a day or two.......I gotta go work on a project or two now!
 

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I wanted to also say that most people you ask will mention changing the Valve Stem Seals if you're smoking on engine start up.......while this may be true on older domestic engines, it will not typically cure you're smoking condition with these Mazda engines......it is almost always the rings at fault on these engines. You will see the valve stem seals comment on Facebook and other social media sites.......a lot of keyboard certified Mechanics on there!! ;)
 

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I rebuilt the top end of my daily driver 1988 B2200 in 2011, used brand-new pistons and rings, new connecting rod bearings, and head remanufactured. By 2020 it had started smoking again, and using too much oil. I didn't have physical space or a hoist or help to install a remanufactured engine myself; I'm in Arizona, and rather than junk the truck I had a local engine remanufacturing company do its stuff, including the R&R. They found the bores to be out of round, and by then the bearings were bad. So they bored to first oversize.

So if you're doing the entire engine, I'd have a machine shop check the bores, crankshaft, etc.

With Covid and retirement, I just completed 9K miles on the new engine, and nearing the end of the 3-year warranty. I just re-sealed the Weber carb adapters and installed a new distributor last weekend, and it runs better.
 

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I still have my shirt also Cusser! I didn't even buy one......one of the MT members bought it for me and shipped it to me! If I'm not mistaken, it was Scotch!
I believe that I bought two (to help support the site); one is red, and one is blue, and still in great condition. I have well over 75 T-shirts from my decades at Dial soap, its softball teams and 10K races, my own softball teams, my daughter's softball teams, and then each season in the Prescott Senior Softball league we get another team shirt and hat. And the last two summers (5-month season) the team I was drafted on won the league, so we got nice lettered zip-front hoodies,

So I've bought very little clothes in the last decade, and Mrs. Cusser doesn't let me go outside naked !!!
 

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Here is a couple of teaser pics of the Oil Control Rings that are stuck in the piston ring grooves......and this engine was actually in decent shape, and was rebuilt by myself while reusing the original pistons with new rings installed......

Wood Metal Font Nickel Jewellery


Tire Automotive tire Wheel Font Bumper


Wood Body jewelry Jewellery Natural material Metal
 

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Please tell Mrs. Cusser "Thank You!" for me!!

:ROFLMAO:
Will do !!!

By the way, 1835cc VW engine I assembled back in 1986 and the 1600cc VW engine I built in 2016-2017 are still working fine. The B2200 continues to be my daily driver though; I drove it 25 miles away to play softball yesterday morning, then took Mrs. Cusser out in the B2200 for our 36th anniversary.
Tableware Table Smile Drinkware Dishware
 

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Will do !!!

By the way, 1835cc VW engine I assembled back in 1986 and the 1600cc VW engine I built in 2016-2017 are still working fine. The B2200 continues to be my daily driver though; I drove it 25 miles away to play softball yesterday morning, then took Mrs. Cusser out in the B2200 for our 36th anniversary.
View attachment 11087
Congratulations Cusser!
Have you ever noticed that a beautiful woman will get more beautiful as she ages, where as med get ......well more seasoned?
How is that?
Bobmo
 

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She's a keeper! Congratulations also!
Our 41st will be here very soon! We have reservations at a high dollar restaurant here in town.......very good steaks & such!

I guess I had better post some more engine pics to keep this thread on track! :)
 

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Here are some of the factory pistons that I clean up and reuse if they are not scored too bad......

Nickel Metal Auto part Composite material Titanium


Hand tool Wrench Tool Metalworking hand tool Bicycle part


One of these pistons had more scoring than I like to see/use, but I decided to use it anyway......and this engine is still going strong in my 1989 B2200 red regular cab truck.

Automotive tire Automotive design Bumper Gas Rim


Blue Automotive tire Hood Automotive design Rim


Gas Auto part Composite material Household hardware Metal


Auto part Metal Door Gas Aluminium


Gas Auto part Rim Household hardware Metal


Gas Cylinder Auto part Rim Machine


Crankset Tool Bicycle part Auto part Bicycle drivetrain part


Camera accessory Camera lens Gas Household hardware Cameras & optics
 
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