timing belt MAZDA 626 1987 Workshop Manual

0 PRE-DELIVERY INSPECTION
PRE-DELIVERY INSPECTION TABLE
EXTERIOR
INSPECT and ADJUST, if necessary, the following items
to the specifications:
• Glass, exterior bright metal and paint for damage
• Wheel lug nuts
88—118 N m (9—12 m-kg, 65—87 ft-lb)
• Tire pressures (Refer to section 12)
• All weatherstrips for damage or detachment
• Operation of bonnet release and lock
• Operation of fuel lid and trunk lid (Back door) opener
• Door operation and alignment
• Headlight aiming
INSTALL following parts:
• Wheel caps or rings (if equipped)
• Outside rear view mirror(s)
UNDER BONNET—ENGINE OFF
INSPECT and ADJUST, if necessary, the following items
to the specifications:
• Fuel, coolant and hydraulic lines, fittings, connections and
components for leaks
• Engine oil level
• Power steering fluid level (if equipped)
• Brake and clutch master cylinder fluid level (if equipped)
• Windshield washer reservoir fluid level
• Radiator coolant level and specific gravity
Protection °C (°F) Specific gravity at 20°C (68°F)
-4 (25) 1.028
-16(3) 1.054
-26 (-15) 1.066 -40 (-40) 1.078
• Tightness of water hose clamps (including heater hoses)
• Tightness of battery terminals
• Manual transaxle oil level
• Drive belt tensions (Refer to section 1)
• Accelerator cable and its linkage for free movement
• Headlight cleaner fluid level (if equipped)
CLEAN spark plugs
INTERIOR
INSTALL the following parts:
• Rubber stopper for inside rear view mirror
• Fuse for accessories
CHECK the operations of the following items:
• Seat controls (sliding and reclining) and head rest
• Door locks including childproof door locks (if equipped)
• Seat belts and warning system
• Ignition switch and steering lock
• Inhibitor switch (ATX only)
• All lights including warning and indicator lights
• Sound warning system
• Headlight cleaner (if equipped)
• Horn, wipers and washers (front and rear, if equipped)
• Radio and antenna (if equipped)
• Cigarette lighter and clock
• Remote control outside rear view mirrors (if equipped)
• Power windows (if equipped)
• Heater, defroster and air conditioner at various mode
selection (if equipped)
• Sunroof (if equipped)
ADJUST antenna trimmer on radio (if equipped)
CHECK the following items:
• Presence of spare fuse
• Upholstery and interior finish
CHECK and ADJUST, if necessary, the following items:
• Operation and fit of windows
• Pedal height and free play of brake and clutch pedal
Pedal height mm (in) free play mm (in)
Clutch pedal 216.5-221.5 (8.52-8.72) 5-13 (0.2-0.51)
Brake pedal 222-227 (8.74-8.94) 4-7 (0.16-0.28)
• Parking brake
5-7 noches/98 N (10 kg, 22lb)
UNDER BONNET—ENGINE RUNNING AT
OPERATING TEMPERATURE
CHECK the following items:
• Operation of idle-up system for air conditioner or power
steering (if equipped)
• Automatic transaxle fluid level
• Operation of dash pot
• Initial ignition timing
• Idle speed
ON HOIST
CHECK the following items:
• Underside fuel, coolant and hydraulic lines, fittings, con-
nections and components for leaks
• Tires for cuts or bruises
• Steering linkage, suspension, exhaust system and all un-
derside hardware for looseness or damage
REMOVE protective cover from brake discs
ROAD TEST"
CHECK the following items:
• Brake operation
• Clutch operation
• Steering control
• Operation of meters and gauge
• Squeaks, rattles or unusual noise
• Engine general performance (including turbo)
• Emergency locking retractors
• Cruise control system (if equipped)
AFTER ROAD TEST
REMOVE seat and floor mat protective covers
CHECK for necessary owner information materials, tools and
spare tire in vehicle
-76G00X-002
0-2

For ECE Leaded gasoline
Chart symbols:
I
A
R
T
O
X
Inspect: Visual examination or functional measurement of a system's operation (performance)
Adjust : Examination resulting in adjustment or replacement
Replace or change
Tighten
Applicable
Not applicable
F8 engine with carbretor, MTX, ATX
FE engine with carbretor, MTX, ATX
FE DOHC engine with fuel injection, 4WS, MTX
RF-CX, RF-N engine with MTX
REMARKS:
Major service interval at 12 months/20,000 km (12,000 Miles), Lubrication service based on distance only 10,000 km (6,000 Miles) not time
After 80,000 km (48,000 Miles) or 48 months, continue to follow the described maintenance items and intervals periodically.
As for * marked items in this maintenance chart, please pay attention to the following points.
*1 Replacement of the timing belt is required at every 100,000 km (60,000 Miles). Failure to repace the timing belt may result in damage to the engine.
*2 If the vehicle is operatie under the following conditions, it is suggested that the engine oil and oil filter be changed more often than at usual recommended intervals.
a) Driving in dusty conditions.
b) Extended periods of idling or low speed operation.
c) Driving for a prolonged period in cold temperatures or driving only short distances regulary.
*3. If the vehicle is operated in very dusty or sandy areas, inspect and, if necessary, replace more often than at usual recommended intervals.
*4. This is a full function check of all electrical systems, i.e., all lights, washers (including condition of blades) electrical windows, sunroof, horn, etc....
*5. Replace every two years.
If there has been continuous hard driving, mountain driving, or if the brakes are used extensively or the vehicle is operated in extremely humid climates, the
brake fluid should be changed annually.
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Emission Control and Related Systems
The ignition and fuel systems are vitally important to the proper operation of the emissions control and related systems, as well as for efficient engine operation.
It is strongly recommended that all servicing related to these systems be done by your Authorized Mazda Dealer.
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Interval
Procedure & item
Number of Months or km, whichever corns first
©1 ©2 ©3 ©4 Service data and inspection point Page
Interval
Procedure & item
Months — 6 12 18 24 30 36 42 48 ©1 ©2 ©3 ©4 Service data and inspection point Page
Interval
Procedure & item

x 1000 Km
1 10 20 30 40 50 60 70 80 ©1 ©2 ©3 ©4 Service data and inspection point Page
Interval
Procedure & item
Miles x
1000 0.6 6 12 18 24 30 36 42 48
©1 ©2 ©3 ©4 Service data and inspection point Page
Battery electrolyte level and specific gravity A A A A O o O O • Electroyte level • Specific gravity 5-8
Drive belts A A A A A O 0 o O • Cracks or damage • Tension

1
A—7
1B—6
1C-7
Engine timing belts Replace every 100,000 Km o o o o — 1A—14 1B—11 1C—11
Engine valve clearance A A A A A o X X o
• Valve clearance: F8 (Hot engine) IN: 0.30 mm (0.012 in) EX: 0.30 mm (0.012 in) FE-12-valve, FE (DOHC) IN: 0; Maintenance free EX: 0; Maintenance free RF-CX, RF-N (Cold engine) IN: 0.25 mm (0.010 in) EX: 0.35 mm (0.014 in)
1A-10
1C—85
Intake and exhaust manifold nuts and
bolts T T T o o X X
• Retighten the intake and exhaust manifold nuts
N-m (m-kg, ft-lb)

1
A—86 1B—68 1C—89
Intake and exhaust manifold nuts and
bolts T T T o o X X IN EX
1
A—86 1B—68 1C—89
Intake and exhaust manifold nuts and
bolts T T T o o X X F8, FE 19-30 (1.9-3.1,
14-22)
22-28 (22—2.9, 16-21)

1
A—86 1B—68 1C—89
Intake and exhaust manifold nuts and
bolts T T T o o X X
RF-CX RF-N 16-23 (1.6-2,3,
12-17)
22-26 (2.2-2.7,
16-20)

1
A—86 1B—68 1C—89
Engine oil *2 R R R R R R R R R o o 0 o
• Oil pan capacity F8, FE: 3.6 liters (3.8 US qt, 3.2 Imp qt) RF-CX, RF-N:
5.0 liters (5.3 US qt, 4.4 Imp qt)
2A—6
2B-6
Oil filter *2 R R R R R R R R o o o o
• Oil filter capacity F8, FE 12-valve
0.3 liters (0.32 US qt, 0.26 Imp qt) FE (DOHC)
0.2 liters (0.21 US qt, 0.18 Imp qt) RF-CX, RF-N
0.4 liters (0.42 US qt, 0.35 Imp qt)
2A—6
2B-6
Fuel filter (R) for carbretor model (R) R (R) R o 0 o o — 4A—37

r
For ECE Unleaded gasoline
Chart symbols:
I
A
R
T
O
X
Inspect: Visual examination or functional measurement of a system's operation (performance)
Adjust: Examination resulting in adjustment or replacement
Replace or change
Tighten
Applicable
Not applicable
FE engine with fuel injection, MTX, ATX
FE DOHC engine with fuel injection, 4WS, MTX
FE engine with carburetor, MTX, ATX
RF-CX, RF-N engine with MTX
REMARKS:
Major service interval at 12 months/20,000 km (12,000 Miles), Lubrication service based on distance only 10,000 km (6,000 Miles) not time
After 80,000 km (48,000 Miles) or 48 months, continue to follow the described maintenance items and intervals periodically.
As for * marked items in this maintenance chart, please pay attention to the following points.
*1 Replacement of the timing belt is required at every 100,000 km (60,000 Miles). Failure to repace the timing belt may result in damage to the engine.
*2 If the vehicle is operated under the following conditions, it is suggested that the engine oil and oil filter be changed more often than at usual recommended
intervals.
a) Driving in dusty conditions.
b) Extended periods of idling or low speed operation.
c) Driving for a prolonged period in cold temperatures or driving only short distances regulary.
*3. If the vehicle is operated in very dusty or sandy areas, inspect and, if necessary, replace more often than at usual recommended intervals.
*4. This is a full function check of all electrical systems, i.e., all lights, washers (including condition of blades) electrical windows, sunroof, horn, etc....
*5. Replace every two years.
If there has been continuous hard driving, mountain driving, or if the brakes are used extensively or the vehicle is operated in extremely humid climates, the brake fluid
should be changed annually.
Emission Control and Related Systems
The ignition and fuel systems are vitally important to the proper operation of the emissions control and related systems, as well as for efficient engine operation. It is
strongly recommended that all servicing related to these systems be done by your Authorized Mazda Dealer.
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Interval
Procedure & item
Number of Months or km, whichever corns first
Months

x
1000
Km
Miles x 1000
0.6
6
10
12
20
12
18
30
18
24
40
24
30
50
30
36
60
36
42
70
42
48
80
48
®3 ©4 Service data and inspection point Page
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c 3 a to Qt (0 O
A
Battery electrolyte level and specific gravity O o o o Electroyte level Specific gravity 5-8
Drive belts O O o o Cracks or damage Tension

1
A—7
1B-6
1C-7
Engine timing belts Replace Severy 100,000 Km O O o o
Engine valve clearance
Intake and exhaust manifold nuts and bolts
O
O
o o
Valve clearance: FE-8-valve (Hot engine) IN: 0.30 mm (0.012 in) EX: 0.30 mm (0.012 in) FE (DOHC)
IN: 0; Maintenance free EX: 0; Maintenance free RF-CX, RF-N (Cold engine) IN: 0.25 mm (0.010 in) EX: 0.35 mm (0.014 in)
O IN EX
FE FE DOHC 19-30(1.9-3.1,
14-22)
22-28 (2.2-2.9
16-21)
1A—14 1B—11 1C-11

1
A—10
1C-85
Retighten the intake and exhaust manifold nuts
N-m (m-kg, ft-lb)
1A—86
1B—68 CO 0 1 m o
m a
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Engine oil O
Oil filter O
O o o
Oil pan capacity FE: 3.6 liters
(3.8 US qt, 3.17 Imp qt) RF-CX, RF-N: 5.0 liters (5.3 US qt, 4.4 Imp qt)
O o o
Oil filter capacity FE 8-valve
0.3 liters (0.32 US qt, 0.26 Imp qt) FE (DOHC)
0.2 liters (0.21 US qt, 0.18 Imp qt) RF-CX, RF-N
0.4 liters (0.42 US qt, 0.35 Imp qt)
2A-6
2B-6
2A-6
2B-6

For General
Chart symbols:
I : Inspect: Visual examination and/or functional measurement of a system's operation or performance.
A : Adjust: Examination resuiting in adjustment or replacement.
R : Replace or change
T : Tighten
O : Applicable
X : Not applicable
© 1 : F6, F8 engine with carburetor, MTX, ATX
© 2 : FE engine with carbretor, MTX, ATX
©3 : FE DOHC engine with fuel injection, MTX
® 4 : RF-N engine with MTX
NOTE:
As the result of visual examination or functional measurement of a system's operation(performance), correct, clean or replace as required.
REMARKS:
After 80,000 km (48,000 Miles) or 48 months, continue to follow the described maintenance items and intervals periodically.
As for * marked items in this maintenance chart, please pay attention to the following points.
*1. If the vehicle is operated under the following conditions, it is suggested that the engine oil and oil filter be changed more often than at usual recommended
intervals.
a) Driving in dusty conditions.
b) Extended periods of idling or low speed operation.
c) Driving for a prolonged period in cold temperatures or driving only short distances regularly.
"2. Replacement of the timing belt is required at every 100,000 km (60,000 Miles). Failure to repace the timing belt may result in damage to the engine.
*3 If the vehicle is operated in very dusty or sandy areas, inspect and, if necessary, replace more often than at usual recommended intervals.
*4 Adjust or inspect alternator and water pump drive belt, and power steering and air conditioner drive belt, vacuum pump belt, super charger belt if equipped.
*5 Replace every two years.
If there has been continuous hard driving, mountain driving, or if the brakes are used extensively or the vehicle is operated in extremely humid climates, the
brake fluid should be changed annually.
*6. Only F6 carbretor for Singapore (MTX Model)
Emission Control and Related Systems
The ignition and fuel systems are vitally important to the proper operation of the emissions control and related systems, as well as for efficient engine operation. It i
strongly recommended that all servicing related to these systems be done by your Authorized Mazda Dealer.
o CJ1

Interval
Procedure & item
Number of Months or km, whichever corns first
©1 ©2 ©3 ©4 Service data and inspection point Page
Interval
Procedure & item
Months — 6 12 18 24 30 36 42 48 ©1 ©2 ©3 ©4 Service data and inspection point Page
Interval
Procedure & item

x
1000
Km
1 10 20 30 40 50 60 70 80 ©1 ©2 ©3 ©4 Service data and inspection point Page
Interval
Procedure & item
Miles x
1000 0.6 6 12 18 24 30 36 42 48
©1 ©2 ©3 ©4 Service data and inspection point Page
Choke system I I I I O O X X
• Carburetor linkage • Choke diaphragm • Choke valve clearance • Unloader system
4A—26
4A-34
4A-34
4A—33
Cooling system I I I I O O o o • Hoses for cracks or wear 3A-5 3B—4
Engine coolant (with reservoir) Reprace every 24 months O O o o • Coolant level 3 A—5 3B—4
Battery electrolyte level and specific gravity I I I I O o o o • Electrolyte level • Specific gravity 5—8
Engine timing belts *2 Replace every 100,000 km O o o o —
1A—14 1B—11 1C—11
Drive belts *4 A I I I I I I I I O o o o • Cracks or damage • Tension
1A—7
1
B—6 1C—7
Engine valve clearance
(1) For Gasoline engine (I) I (I) I (I) I (I) I
T
O o X o
• Valve clearance F6, F8, FE-8-valve (Hot engine) IN: 0.30 mm (0.012 in) EX: 0.30 mm (0.012 in) FE-12-valve, FE (DOHC) IN: 0; Maintenance free EX: 0; Maintenance free RF-N (Cold engine) IN: 0.25 mm (0.01 in) EX: 0.35 mm (0.014 in)
1A—10
1C—85
Exhaust manifold nuts and bolts T T
I
T o o X X
• Retighten the intake and exhaust manifold nuts
N-m (m-kg, ft-lb) 1A—86 1B—68 1C—89 Exhaust manifold nuts and bolts T T
I
T o o X X IN EX 1A—86 1B—68 1C—89 Exhaust manifold nuts and bolts T T
I
T o o X X
F6, F8, FE 19-30 (1.9-3.1, 14-22) 22-28 (2.2-2.9, 16-21)
1A—86 1B—68 1C—89 Exhaust manifold nuts and bolts T T
I
T o o X X
RF-N 16-23 (1.6-2.3,
12-17) 22-26 (2.2-2 7,
16-20)
1A—86 1B—68 1C—89
Engine oil *1 Replace every 5000 km or 6 months X X o o
• Oil pan capacity FE DOHC: 3.6 liters
(3.8 US qt, 3.2 Imp qt) RF-N: 5.0 liters
(5.3 US pt, 4.4 Imp qt)
2A-6
2B—6
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ENGINE
(SOHC)
OUTLINE 1A— 2
STRUCTURAL VIEW 1A— 2
SPECIFICATIONS 1A— 4
TROUBLESHOOTING GUIDE 1A— 4
TUNE-UP PROCEDURE 1A— 6
ON-VEHICLE INSPECTION 1A-13
COMPRESSION 1A—13
ON-VEHICLE MAINTENANCE 1A—14
TIMING BELT 1A—14
CYLINDER HEAD 1A—20
VALVE SEAL 1A—26
REMOVAL 1A—34
DISASSEMBLY 1A—36
AUXILIARY PARTS 1A—36
TIMING BELT 1A—38
CYLINDER HEAD 1A—40
CYLINDER BLOCK 1A—44
INSPECTION AND REPAIR 1A—48
ASSEMBLY 1A—62
CYLINDER BLOCK 1A—62
CYLINDER HEAD 1A—73
TIMING BELT 1A—82
AUXILIARY PARTS 1A—86
INSTALLATION 1A—91
TRANSAXLE ASSEMBLY 1A—91
ENGINE INSTALLATION 1A—92
76G01A-001

1A TROUBLESHOOTING GUIDE
SPECIFICATIONS
——Engine model
Item ^ FE 12 -valve FE 8-valve F8 F6 ——Engine model
Item ^ FE 12 -valve ECE Except ECE ECE General F6
Type Gasoline, 4 cycle
Cylinder arrangement and number In line, 4 cylinders
Combustion chamber Pentroof Multispherical
Valve system OHC, belt driven
Displacement cc (cu in) 1,998 (121.9) 1,789 (109.1) 1,587 (96.8)
Bore and stroke mm (in) 86.0 x 86.0 (3.39 x 3.39) 86.0 x 77.0 (3.39 x 3.03) 81.0 x 77.0 (3.19 x 3.03)
Compression ratio 9.5 : 1 8.6 : 1 9.0 : 1
Compression pressure kPa (kg/cm2, psi)—rpm
Standard 1,422 (14.5,
206)—280 1,275 (13.0, 185)—270 1,128 (11.5, 164)—270 Compression pressure kPa (kg/cm2, psi)—rpm Minimum 996 (10.2,
144)—280 893 (9.1, 129)—270 790 (8.1, 114)—270
Valve timing
IN Open BTDC 14° 16° 20° 20° 17° 17°
Valve timing
IN Close ABDC 56° 54° 65° 65° 56° 56° Valve timing
EX Open BBDC 69° 54° 65° 65° 64° 64° Valve timing
EX Close ATDC 13° 16° 20° 20° 15° 15°
Valve clearance mm (in)
IN 0; Mainte-nance-free 0.30 (0.012)
Valve clearance mm (in)
EX 0; Mainte-nance-free 0.30 (0.012)
Idle speed rpm
MTX 800 _+5S ... carb., 850 ± 50 ... Fl
Idle speed rpm ATX 900 _+5g ... carb., 850 ± 50 ... Fl 950 _+5§ carb. 850 ±
50
.Fl
Ignition timing BTDC 6° ± 1°
Firing order
1
-3-4-2
76G01A-003
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
1A-49
1A-57

1
A—20
Malfunction of fuel system Refer to Section 4
Malfunction of electrical system Refer to Section 5
Poor idling Malfunction of engine-related components Malfunction of HLA Improper valve clearance Poor valve to valve seat contact Failed cylinder head gasket
Replace Adjust Repair or replace Replace

1
A—75 1A-10 1 A—51
1
A—20
Malfunction of fuel system Refer to Section 4
Excessive oil
consumption
Oil working up Worn piston ring groove or sticking piston ring Worn piston or cylinder Replace Replace or repair

1
A—57 1A—57
Oil working down
Worn valve seal
Worn valve stem or guide Replace
Replace
1A—26
1A—49
Oil leakage Refer to Section 2A
76G01A-004
1A—4

TROUBLESHOOTING GUIDE 1 A
Problem Possible Cause Remedy Page
Insufficient power Insufficient compression Malfunction of HLA Improper valve clearance 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
Adjust
Repair
Replace Replace Replace Replace Replace Replace
1A—75 1A—10
1
A—51 1A—49 1A—53
1
A—20 1A—48 1A—57
1
A—57
Malfunction of fuel system Refer to Section 4
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
Improper valve clearance Sticking or burned valve
Weak or broken valve spring Carbon accumulation in combustion chamber
Replace Adjust Replace Replace
Eliminate carbon

1
A—75 1A—10 1A—49 1A—53
Malfunction of fuel system Refer to Section 4
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
1A—65
1
A—65 1A—66 1A—67
1
A—67
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
1A—55
1
A—57
1
A—57
1
A—57 1A—59
Valves or timing related parts Malfunction of HLA* Improper valve clearance Broken valve spring Excessive valve guide clearance Malfunction of timing belt tensioner
Replace Adjust
Replace Replace Replace
1A—75 1A—10 1A—53 1A—49 1A—61
Malfunction of cooling system Refer to Section 3A
Malfunction of fuel system Refer to Section 4
Others Malfunction of water pump bearing Improper drive belt tension Malfunction of alternator bearing Exhaust gas leakage
Replace Adjust Replace Repair
1 A— 7

1
A—48
* 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.
76G01A-005
1A—5