belt MAZDA 626 1987 Owners Manual

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
TIMING BELT
Torque Specifications
69G01B-160
Seal Plate
1. Install the seal plate.
Tightening torque:
8—12 N
m
(0.8—1.2 m-kg, 69—104 in-lb)
2. Check that the seal plate sealing rubbers are in-
stalled in position.

76G01C-200

1C—81

1C ASSEMBLY (TIMING BELT)
Rear Camshaft Pulley
1. Install the rear camshaft pulley.
2. Hold the camshaft with a wrench (29 mm, 1.14 in)
and tighten to the specification.
Tightening torque:
55—65 Nm (5.6—6.6 m-kg, 41—48 ft-lb)
76G01C-189
Camshaft Pulley
1. Connect the camshaft pulley onto the camshaft with
the semicircular (woodruff) key.
4BG01B-200
2. Hold the camshaft with a wrench (29 mm, 1.14 in),
tighten the camshaft pulley lock bolt.
Tightening torque:
55—65 Nm (5.6—6.6 m-kg, 41—48 ft-lb)
3. Align the mark on the camshaft pulley with the mark
on the seal plate.
76G01C-190
Injection Pump Pulley
1. Install the injection pump pulley with the semicir-
cular (woodruff) key to the injection pump shaft.
2. Rotate the injection pump pulley until the timing
marks are aligned.
3. Affix the injection pump pulley to the bracket us-
ing two bolts (35—40 mm, 1.4—1.6 in).
4. Tighten the lock nut.
Tightening torque:
59—69 N-m (6.0—7.0 m-kg, 43—51 ft-lb)
1C-82

ASSEMBLY (TIMING BELT) 1 C
63G01D-431
76G01C-191
76G01C-192
Timing Belt Tensioner
1. Install the tensioner spring onto the tensioner.
2. Install the tensioner assembly.
3. Temporarily secure it so the tensioner is shifted
outward.
Timing Belt
1. Return the crankshaft about 45° to the timing mark
on the oil pump housing.
2. Check that the timing marks of the camshaft pul-
ley and the injection pump pulley align with the tim-
ing marks on the seal plate.
3. Install the timing belt in the sequence shown in the
figure.
Caution
The timing belt must be reinstalled in the same
direction of rotation for continued durability.

76G01C-200

1C—83

1C ASSEMBLY (TIMING BELT)
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76G01C-194
Timing marks
Timing marks
76G01C-195
76G01C-196
4. Install the idler pulley.
Tightening torque:
37—52 N
m
(3.8—5.3 m-kg, 27—38 ft-lb)
5. Remove the two affixing bolts from the injection
pump pulley.
6. Loosen the tensioner lock bolt.
7. Turn the crankshaft twice in the direction of rota-
tion (clockwise).
Caution
Do not rotate in reverse direction.
8. Check that each timing mark is correctly aligned.
If not aligned, remove the timing belt. Repeat step
2-9.
9. Tighten the timing belt tensioner lock bolt.
Tightening torque:
37—52
N m
(3.8—5.3 m-kg, 27—38 ft-lb)
10. Check the timing belt tension.
If the tension is not correct, loosen the tensioner
lock bolt and repeat step 6—9, or replace the ten-
sioner spring.
Standard deflection:
9.0—11.5 mm (0.35—0.45 in)
/98 N (10 kg, 22 lb)
Caution
Be sure not to apply tension other than that
of the tensioner spring.
76G01C-197
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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

1C ASSEMBLY (TIMING BELT)
Cam (intake)
Adjust disc
Valve clearance
0.30 mm (0.012 in) 4.00 mm (0.157 in)
76G01C-201
(5) Select an appropriate disc depending on the
valve clearance measured. And install it.
Example (intake valve):
Thickness of original adjusting disc + (measured
clearance — standard clearance) = thickness of
new adjusting disc.
4.00 + (0.30 - 0.25) = 4.05 mm
0.157 + (0.012 - 0.010) = 0.159 in
Note
a) The disc thickness is indicated by the num-
ber marked on the disc. For example, 3825
means 3.825 mm (0.1056 in).
b) Adjusting discs are available in 25 different
thicknesses within the 3.40—4.60 mm
(0.134—0.181 in) range, at intervals of 0.05
mm (0.002 in).
(6) Inspect the clearance again.
4. Set the No.4 cylinder to compression TDC.
5. Measure and adjust the valve clearance at No.3,
No.4 (intake), and No.2, No.4 (exhaust) in the same
way.
76G01C-202
Gasket
Head cover Apply sealant
^ 1 §
Cylinder Head Cover
1. Apply sealant to the shaded areas.
2. Install the cylinder head cover.
Tightening torque:
7—10 Nm (70—100 cm-kg, 61—89 in-lb)
3. Install the PVC hose.
76G01C-203
1C—86

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
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ASSEMBLY (AUXILIARY PARTS) 1 C
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76G01C-209
76G01C-210
76G01C-211
Intake Manifold
Install the intake manifold and gasket.
Tightening torque:
16—23 N-m (1.6—2.3 m-kg, 12—17 ft-lb)
Exhaust Manifold
1. Place the exhaust manifold gasket in position.
2. Install the exhaust manifold.
Tightening torque:
22—26 N-m (2.2—2.7 m-kg, 16—20 ft-lb)
Exhaust Manifold Insulator
Install the exhaust manifold insulator.
Tightening torque:
8—11 N-m (80—110 cm-kg, 69—95 in-lb)
Comprex Supercharger
1. Install the Comprex supercharger with new gasket.
Tightening torque:
22—26 N-m (2.2—2.7 m-kg, 16—20 ft-lb)
2. Install the Comprex supercharger drive belt, and
adjust the belt deflection. (Refer to page 1C—7)
76G01C-212
1C—89

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.
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.CSD water hose
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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