engine MAZDA 626 1987 Workshop Manual

ASSEMBLY (CYLINDER
BLOCK)
1 C
6. Apply engine oil to the cylinder head bolts.
7. Tighten the cylinder head bolts.
(1) Tighten the bolts to the specified torque, in or-
der shown in the figure.
Tightening torque:
29 Nm (3.0 m-kg, 22 ft-lb)
4BG01B184
(2)Make paint marks on the bolt heads, as shown
in the figure.
(3)With the paint marks as a reference point, turn
the cylinder head bolts another 90°
(90°—105°) in the tightening direction. Tight-
en them in the order.
(4)Then tighten them once again 90°
(90°—105°) in the tightening order.
Caution
Be absolutely sure to tighten all bolts in the
order.
4BG01 B-185
Camshaft
1. Apply engine oil to the camshaft and journal part
of the cylinder head.
2. Set the seal cap.
3. Apply a coat of sealant (1016 77 739) to the area
shown in the figure.
4. Install the camshaft so that the key groove faces
directly upward.
4BG01 B-186
5. Install the camshaft caps according to the number

and
^
mark,
and loosely tighten the camshaft cap
nuts.
76G01C-172
1C—75

1 C ASSEMBLY (CYLINDER HEAD)
6. Apply a coat of engine oil to the new oil seal lip
and insert it.
76G01C-253
76G01C-173
Glow cord
Glow plug
76G01C-174
7. Tighten the camshaft cap nuts evenly in order
shown in the figure.
Tighten torque:
20—26
N m
(2.0—2.7 m-kg, 14—20 ft-lb)
Note
The adjustment of the valve clearance should
be made only after the camshaft pulley injec-
tion pump pulley and timing belt have been
installed.
Glow Plug and Glow Cord
1. Install the glow plugs.
Tightening torque:
15—20 Nm (1.5—2.0 m-kg, 11—15 ft-lb)
2. Install the glow cord.
Tightening torque:
0.8—1.5 Nm (8.0—15 cm-kg, 7—13 in-lb)
Injection Nozzle and Leak Pipe
1. Install the new corrugated washers and the new
copper gaskets in position.
2. Install the injection nozzles.
Tightening torque:
59—69 Nm (6.0—7.0 m-kg, 43—51 ft-lb)
Note
The corrugated washers and copper gaskets
must be replaced with new ones each time the
injection nozzles are removed.
3. Install the leak pipe.
Tightening torque:
31—44
N m
(3.2—4.5 m-kg, 23—33 ft-lb)
76G01C-175
1C—76

ASSEMBLY (CYLINDER HEAD) 1 C
76G01C-176
76G01C-177
Engine Hanger
Install the front and rear engine hanger.
Tightening torque:
Front: 37—52 Nm
(3.8—5.3 m-kg, 27—38 ft-lb)
Rear: 19—26 N-m
(1.9—2.6 m-kg, 14—19 ft-lb)
Thermostat Case
Install the thermostat case with gasket.
Tightening torque:
16—23 N-m (1.6—2.3 m-kg, 12—17 ft-lb)
Thermostat and Thermostat Cover
1. Install the thermostat into the thermostat case with
the jiggle pin at the top.
2. Position a new gasket with the printed side facing
the thermostat case.
3. Install the thermostat cover.
Tightening torque:
7—10 Nm (70—100 cm-kg, 61—87 in-lb)
76G01C-178
1C—77

1 C ASSEMBLY (INJECTION PUMP)
Injection Pump
1. Install the injection pump with the injection pump
brakcet.
Tightening torque:
37—52
N m
(3.8—5.3 m-kg, 27—38 ft-lb)
Note
If the injection pump bracket and the injection
pump are separated, injection timing adjust-
ment is necessary after installing the timing
belt.
2. Connect the CSD water hose and fuel hoses.
Injection Pipe
1. Check that no dirt or other foreign material is on
the pipe coupling.
2. Install the fuel injection pipes.
Tightening torque:
25—29 Nm (2.5—3.0 m-kg, 18—22 ft-lb)
76G01C-186
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No.3 Engine Mount and Idler
Install the No.3 engine mount and idler.
Tightening torque:
37—52
N
m (3.8—5.3 m-kg, 27—38 ft-lb)
76G01C-187
1C—80

ASSEMBLY (TIMING BELT) 1 C
76G01C-198
4BG01B-210
76G01C-199
Timing Belt Cover
Install the left and right timing belt covers.
Tightening torque:
7—10 Nm (70—100 cm-kg, 61—87 in-lb)
Crankshaft Pulley
Install the crankshaft pulley.
Tightening torque:
23—32 Nm (2.3—3.3 m-kg, 17—24 ft-lb)
Valve Clearance
1. Set the No.1 cylinder to compression TDC.
2. Measure the valve clearance at No.1, No.2 (intake),
and No.1, No.3 (exhaust).
Clearance (cold engine)
IN : 0.20—0.30 mm (0.008—0.012 in)
EX: 0.30—0.40 mm (0.012—0.016 in)
3. If the valve clearance is not within the specifica-
tion, adjust the valve clearance.
(1) Face the intake cam lobe straight upward.
(2) Move the tappet so that its notch is at the man-
ifold side.
(3) Press the tappet down until the adjusting disc
is accessible with the SST.
(4) Take out the adjusting disc.
76G01C-200
1C—85

1 C ASSEMBLY (AUXILIARY PARTS)
76G01C-205
76G01C-206
76G01C-207
o e-
Oil Cooler Assembly
1. Clean the contact surfaces of the cylinder block
and oil filter assembly.
2. Install new O-rings, and apply a coat of engine oil.
3. Install the oil cooler assembly.
Tightening torque:
Bolt A: 8—11 N-m
(80—110 cm-kg, 69—95 in-lb)
Bolt B: 37—52 N-m
(3.8—5.3 m-kg, 27—38 ft-lb)
4. Connect the water hose.
Oil Filter
1. Install the oil filter cover.
Tightening torque:
8—11 N-m (80—110 cm-kg, 69—95 in-lb)
2. Apply a coat of engine oil to the filter rubber seal.
3. Install the oil filter until the rubber seal contacts the
oil cooler by hand. Then tighten it a 7/6 turn fur-
ther with a band type wrench.
Alternator
1. Install the alternator.
Tightening torque:
Bolt A: 19—26 N m
(1.9—2.6 m-kg, 14—19 ft-lb)
Bolt B: 37—52 N-m
(3.8—5.3 m-kg, 27—38 ft-lb)
2. Install the alternator drive belt, and adjust the belt
deflection. (Refer to page 1C—7)
76G01C-208
1C—88
expert22 ajia http://rutracker.org

1 C ASSEMBLY (AUXILIARY PARTS)
76G01C-213
76G01C-214
Comprex Supercharger Insulator
Install the comprex supercharger insulator.
Tightening torque:
8—11 N-m (80—110 cm-kg, 69—95 in-lb)
Air Funnel Assembly
1. Install the air funnel assembly.
Tightening torque:
Bolt A: 19—26
N
m
(1.9—2.6 m-kg, 14—19 ft-lb)
Bolt B: 3—4
N
m
(35—45 cm-kg, 30—39 ft-lb)
2. Connect the actuator vacuum tube.
76G01C-215
Vacuum Pump
1. Install the vacuum pump with bracket.
Tightening torque:
37—52 N-m (3.8—5.3 m-kg, 27—38 ft-lb)
2. Connect the oil pipe and hose.
Tightening torque:
12—18 N-m (1.2—1.8 m-kg, 104—156 ft-lb)
3. Install the drive belt, and adjust the belt deflection.
(Refer to page 1C—7)
PCV Hose
Install the PCV hose.
I! Jfc)' j
.CSD water hose
ilJJM: !
76G01C-216
CSD Water Hose
1. Remove the engine from the engine hanger.
2. Tighten the oil pipe mounting bolts.
Bolt A: 8—11 N-m
(80—110 cm-kg, 69—95 in-lb)
Bolt B: 12—18 N-m
(1.2—1.8 m-kg, 104—156 ft-lb)
3. Install the CSD water hose.
Tightening torque:
37—52 N-m (3.8—5.3 m-kg, 27—38 ft-lb)
1C-90

INSTALLATION 1C
INSTALLATION
TRANSAXLE ASSEMBLY
Assemble the transaxle to the engine in the sequence shown in the figure referring to the installation note.
37—52 (3.8—5. 27—38
37-52 N m (3.8—5.3 m-kg, 27—38 ft-lb)
(80—110 cm-kg, 69—95 In-lb)
89—117 N-m (9.1—11.9 m-kg, 66—86 ft-lb)
7-52 N-m (3.8—5.3 m-kg, 27—38 ft-lb)
76G01C-217
1. Transaxle
2. Clutch under cover
3. Gusset plate
4. Water pipe
5. Starter
Installation Note
Clutch under cover
Before installation, fill the notches with silicon as
shown in the figure.

76G01C-219

1C—91

1C INSTALLATION
ENGINE INSTALLATION
Install the engine and transaxle assembly.
Warning: Be sure the vehicle is securely supported.
Torque Specifications
67-93 N-m {6.6—9.5 m-kg, 49—69 ft-Sb)
8—11 Nm (80—110 cm-kg,„ 69—95 in-lb)
85—117 N m (8.7—11.9 m-kg, 63—G6 ft-lb) S—11 N-m (80—110em-kg, 69—95 In-lb)
5—7 N-m (50—70 cm-kg, 43—61 in-lb)
67—93 N-m (6,8—9,5 m-kg, 49—69 ft-lb)
55—80 N-m (5.6—8.2 m-kg, 41—59 ft-lb)
8—11 N-m (80—110 cm-kg, 69—95 in-lb)
43—62 N-m (4.3—6.3 m-kg, 14—22 ft-lb)
7—10 N-m (70—100 cm-kg, 60—86 in-lb)
37—52 N-m (3.6—5.3 m-kg, 27—38 ft-lb)
34—49 N-m (3.5—5.0 m-kg, 25—36 ft-lb)
31—40 N-m 9 (3.2-4.1 m-kg, 23—30 ft-lb)
'8—11 N-m (80—110 cm-kg, 69—95 in-lb)
19—26 N-m (1.9—2.6 m-kg, 14—19 ft-lb)
29—44 N-m (3.0—4.5 m-kg, 22—33 ft-lb)
43—54 N-m (4.4—5.5 m-kg, 32—40 ft-lb)
-IS* 88—118 N-m ^-(9.0—12.0 m-kg, 65—87 ft-lb) 8—11 N-m (80—110 cm-kg, 69—95 In-lb)
86U01X-180
1C—92

INSTALLATION 1C
Engine Mount
Install the engine mount.
86U01X-181
Exhaust Pipe
1. Tighten exhaust pipe stay.
Tightening torque:
37—52 Nm (3.8—5.3 m-kg, 27—38 ft-lb)
2. Install the exhaust pipe.
Tightening torque:
19—26
N
m
(1.9—2.6 m-kg, 14—19 ft-lb)
(§): 34—49 N-m
(3.5—5.0 m-kg, 25—36 ft-lb)
76G01C-218
Extension Bar
Install the extension bar to the transaxle.
Tightening torque:
31—46 N-m (3.2—4.7 m-kg, 23—34 ft-lb)
Change Rod
Install the change rod to the transaxle.
Tightening torque:
16—22 N-m (1.6—2.3 m-kg, 12—17 ft-lb)
76G01C-219
1C—93