timing MAZDA 626 1987 Owner's Guide

1 A ASSEMBLY (TIMING BELT)
TIMING BELT
Torque Specifications
6—B N<m (60—80 cm-kg, 52—69 In-lb)
(1.25—1.75 m-kg, 109—152 in-lb)

1
A—82
69G01B-160

ASSEMBLY (TIMING BELT) 1 A
Camshaft Pulley
1. Install the camshaft pulley on the camshaft with the
dowel pin fit into the hole at the 2 mark (FE) or 3
mark (F8, F6).
76G01A-083
2. Tighten the camshaft pulley lock bolt.
Tightening torque:
47—65 N-m (4.8—6.6 m-kg, 35—48 ft-lb)
76G01A-141
3. Align the mating mark on the pulley with the align-
ment mark on the front housing.
Note
For FE engine, align "2" mark.
For F8, F6 engine, align "3" mark.
76G01A-084
Timing Belt Pulley
1. Reverse the direction of the SST (ring gear brake).
2. Install the crankshaft key.
3. Install the timing belt pulley on the crankshaft.
Tightening torque: 157—167 N-m
(16.0—17.0 m-kg, 116—123 ft-lb)
4. Release the ring gear brake.
5. Align the timing belt pulley and the pump body
alignment marks.
86U01X-160

1
A—83

1A ASSEMBLY (TIMING BELT)
Tensioner lock bolt
69G01B-165
76G01A-085
79G01C-097
Timing Belt Idler Pulley
Install the timing belt idler pulley.
Tightening torque:
37—52 Nm (3.8—5.3 m-kg, 27—38 ft-lb)
Timing Belt Tensioner
1. Install the timing belt tensioner and tensioner
spring.
2. Tentatively secure the tensioner with the spring fully
extended.
Timing Belt
1. Install the timing belt, (keep the tension side of belt
as tight as possible.)
Caution
a) If the timing belt is being reused, it must be
reinstalled to rotate in the original direction.
b) Check that there is no oil, grease, or dirt on
the timing belt.
2. Loosen the tensioner lock bolt.
3. Turn the crankshaft twice in the direction of rotation.
4. Check that the mating marks are correctly aligned.
If not aligned, remove the timing belt and tension-
er, and repeat the above-mentioned procedure.
5. Tighten the timing belt tensioner lock bolt.
Tightening torque:
37—52 Nm (3.8—5.3 m-kg, 27—38 ft-lb)
4BGQ1A-186
1A—84

ASSEMBLY (TIMING BELT) 1A
6. Check the timing belt deflection. If the deflection
is not correct, loosen the tensioner lock bolt and
repeat steps 3—5 above. Replace the tensioner
spring if necessary.
Belt deflection:
FE: 5.5—6.5 mm (0.22—0.26 in)
F8, F6: 4.0—5.0 mm (0.16—0.20 in)
/98 N (10kg, 22 lb)
76G01A-086
Baffle Plate
Position the baffle plate on the timing belt pulley.
Timing Belt Cover
Install the lower timing belt cover, upper timing belt
cover, and new gaskets.
Tightening torque:
7—10 Nm (70—100 cm-kg, 61—87 in-lb)
86U01X-163
Crankshaft Pulley
Install the crankshaft pulley.
Tightening torque: 12—17 N-m
(1.25—1.75 m-kg, 109—152 in-lb)
69G01B-170
76G01A-142
Valve Clearance (8-valve)
Adjust the valve clearance. (Refer to page
1
A—10.)
Cylinder Head Cover
1. Apply silicon sealant to the shaded areas shown
in the figure.
2. Install the cylinder head cover.
Tightening torque:
6—8 N-m (60—80 cm-kg, 52—69 in-lb)
1A—85

1
ENGINE
(DOHC)
OUTLINE 1B— 2
STRUCTURAL VIEW 1B— 2
SPECIFICATIONS 1B— 3
TROUBLESHOOTING GUIDE 1B— 3
TUNE-UP PROCEDURE IB— 5
ON-VEHICLE INSPECTION 1B—10
COMPRESSION 1B—10
ON-VEHICLE MAINTENANCE 1B—11
TIMING BELT 1B—11
CYLINDER HEAD 1B—16
REMOVAL 1B—22
DISASSEMBLY 1B—24
AUXILIARY PARTS 1B—24
TIMING BELT 1B—26
CYLINDER HEAD 1B—28
CYLINDER BLOCK 1B—30
INSPECTION AND REPAIR 1B—34
ASSEMBLY 1B—48
CYLINDER BLOCK 1B—48
CYLINDER HEAD 1B—59
TIMING BELT 1B—64
AUXILIARY PARTS 1B—68
INSTALLATION 1B—73
TRANSAXLE ASSEMBLY 1B—73
ENGINE INSTALLATION 1B—74
76G01B-001

TROUBLESHOOTING GUIDE 1 B
SPECIFICATIONS
Engine model FE DOHC
Item Leaded fuel Unleaded fuel
Type Gasoline, 4 cycle
Cylinder arrangement and number In line, 4 cylinders
Combustion chamber Pentroof
Valve system OHC, belt driven
Displacement cc (cu in) 1,998 (121.9)
Bore and stroke mm (in) 86.0 x 86.0 (3.39 x 3.39)
Compression ratio 10.0 : 1 9.2 : 1
Compression pressure Standard 1,422 (14.5, 206)—290 1,373 (14.0, 199)—310
kPa (kg/cm2, psi)-rpm Minimum 996 (10.2, 144)—290 961 (9.8, 139)—310
IN Open BTDC 10° 10°
Valve timing
IN Close ABDC 60° 55° Valve timing
EX Open BBDC 60° 55° EX Close ATDC 10° 10°
Valve clearance mm (in) IN 0; Maintenance-free Valve clearance mm (in) EX 0; Maintenance-free
Idle speed rpm 750 ± 50
Ignition timing BTDC 12° ± 1°
Firing order 1—3--4-2
76G01B-002
TROUBLESHOOTING GUIDE
Problem Possible Cause Remedy Page
Difficult starting Malfunction of engine-related components
Burned valve
Worn piston, piston ring, or cylinder
Failed cylinder head gasket
Replace
Replace or repair Replace
1B—35 1B—43 1B—16
Malfunction of fuel system Refer to Section 4C
Malfunction of electrical system Refer to Section 5
Poor Idling Malfunction of engine-related components Malfunction of HLA
Poor valve to valve seat contact
Failed cylinder head gasket
Replace
Repair or replace
Replace
1B—60 1B—37 1B—16
Malfunction of fuel system Refer to Section 4C
Excessive oil
consumption Oil working up Worn piston ring groove or sticking piston ring Worn piston or cylinder
Replace
Replace or repair
1B-43 1B-43
Oil working down
Worn valve seal
Worn valve stem or guide
Replace
Replace 1B-35
Oil leakage Refer to Section 2A
76G01B-003
1B—3

TROUBLESHOOTING GUIDE 1 B
Problem Possible Cause Remedy Page
Insufficient power Insufficient compression Malfunction of HLA Compression leakage from valve seat Seized valve stem Weak or broken valve spring Failed cylinder head gasket Cracked or distorted cylinder head Sticking, damaged, or worn piston ring Cracked or worn piston
Replace Repair
Replace
Replace Replace Replace Replace Replace
1B—60 1B—37 1B—35 1B—38 1B-16 1B—34 1B—43 1B—43
Malfunction of fuel system Refer to Section 4C
Others Slipping clutch Dragging brakes Wrong size tires
Refer to Section 6 Refer to Section 11 Refer to Section 12
Abnormal combustion Malfunction of engine-related components Malfunction of HLA Sticking or burned valve
Weak or broken valve spring Carbon accumulation in combustion chamber
Replace Replace Replace
Eliminate carbon
1B-60
1B-35
1B—38
Malfunction of fuel system Refer to Section 4C
Engine noise Crankshaft or bearing related parts
Excessive main bearing oil clearance Main bearing seized or heat-damaged Excessive crankshaft end play Excessive connecting rod bearing oil clearance Connecting rod bearing seized or heat-damaged
Replace or repair Replace
Replace or repair Replace or repair Replace
1B-51 1B—51 1B—52 1B—53 1B—53
Piston related parts
Worn cylinder Worn piston or piston pin Seized piston Damaged piston ring Bent connecting rod
Replace or repair
Replace
Replace Replace Replace
1B—41 1B-44 1B—43 1B—43 1B-44
Valves or timing related parts Malfunction of HLA* Broken valve spring Excessive valve guide clearance Malfunction of timing belt tensioner
Replace Replace Replace Replace
1B-60 1B—38 1B—35 1B—47
Malfunction of cooling system Refer to Section 3A
Malfunction of fuel system Refer to Section 4C
Others Malfunction of water pump bearing Improper drive belt tension Malfunction of alternator bearing Exhaust gas leakage
Replace Adjust Replace Repair
1B— 6
1B—34
* Tappet noise may occur if the engine is not operated for an extended period of time. The noise should stop after the engine has reached normal operating temperature. 76G01B-004
1B—4

TUNE-UP PROCEDURE 1 B
High-Tension Lead
Check the following points. Clean or replace if
necessary.
1. Damaged lead
2. Carbon deposits
86U01X-014
i^rrr ' /
49 0187 280
76G01B-011
76G01B-012
Hydraulic Lash Adjuster (HLA)
Note
Tappet noise may occur if the engine is not
operated for an extended period of time. The
noise should stop after the engine has
reached normal operating temperature.
1. Check for tappet noise. If noise exists, check the
following points.
(1) Engine oil condition and level
(2) Engine oil pressure (Refer to Section 2A)
2. If the noise does not stop, check for movement of
each HLA by pushing it during disassembly.
3. If the HLA moves, replace the HLA. (Refer to page
1B—60.)
Ignition Timing
1. Warm up the engine and run it at idle.
2. Turn all electric loads OFF.
3. Connect a timing light tester.
4. Disconnect the vacuum hose from the vacuum
control, and plug the hose.
5. Check that the ignition timing mark (yellow) on the
crankshaft pulley and the timing mark on the tim-
ing belt cover are aligned.
Ignition timing: 12° ± 1° BTDC
(at idle speed)

76G01B-008

1B—8

TUNE-UP PROCEDURE 1 B
76G01B-015
6. If necessary, adjust the ignition timing by turning
the distributor.
Idle Speed
1. Ground the test connector to the vehicle with a
jumper wire.
2. Connect a tachometer to the engine.
3. Check the idle speed.
Idle speed: 750 ± 50 rpm
4. If necessary, remove the blind cap from the throt-
tle body and adjust by turning the air adjust screw.
5. Install the blind cap and disconnect the jumper wire
from the test connector.
Idle Mixture
1. Connect an exhaust gas analyzer to the vehicle.
2. Measure the CO and HC concentration.
CO concentration: 1.5 ± 0.5%
HC concentration: Less than 1,000 ppm
3. If necessary, remove the blind cap from the air flow
meter and adjust by turning the bypass air adjust
screw with SST.
4. Install the blind cap to the air flow meter and dis-
connect the jumper wire from the test connector.
76G01B-016
1B—9

ON-VEHICLE MAINTENANCE (TIMING BELT) 1 B
ON-VEHICLE MAINTENANCE
TIMING BELT
Removal
1. Disconnect the negative battery cable.
2. Remove in the sequence shown in the figure referring to the removal note for specially marked parts.
76G01A-108
76G01B-020
1. Center cover
2. High-tension lead and spark plug
3. Engine side cover
4. Drive belt
5. Crankshaft pulley
6. Engine mount bracket
7. Upper timing belt cover
8. Lower timing belt cover
9. Baffle plate
10. Timing belt tensioner
11. Timing belt tensioner spring
12. Timing belt
1B—11