engine MAZDA 626 1987 Workshop Manual

1 C ON-VEHICLE MEINTENANCE (VALVE SEAL)
3. Install the spring seat, valve springs and valve
keepers with the SST.
76G01C-059
Tappet and adjusting disc
1. Apply engine oil to the tappets.
2. Install the tappets in the hole.
3. Install the adjusting discs.
76G01C-060
Camshaft and camshaft cap
1. Move the No.1 piston to TDC, and then rotate
the crankshaft approximately 45°
76G01C-061
' Apply sealant
2. Apply engine oil to the camshaft and the journals.
3. Apply a coat of sealant to the shaded areas as
shown in the figure.
76G01C-062
1C-28

ON-VEHICLE MAINTENANCE (VALVE SEAL) 1 C
4. Set the camshaft and camshaft cap so that the key
groove faces directly upward.
And tighten the cap nuts loosely.
5. Apply a coat of engine oil to the new oil seal lip
and insert it.
76G01C-063
6. Tighten the camshaft cap nuts gradually and in the
order shown in the figure.
Tightening torque:
20—26 N-m (2.0—2.7 m-kg, 14—20 ft-lb)
76G01C-064
Camshaft pulley and rear camshaft pulley
Hold the camshaft with a wrench (29 mm, 1.14 in),
tighten the camshaft pulley and rear camshaft pul-
ley lock bolts.
Tightening torque:
55—65 N-m (5.6—6.6 m-kg, 41—48 ft-lb)
76G01C-066
1C—29

1 C ON-VEHICLE MAINTENANCE (VALVE SEAL)
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. (Refer to TIMING BELT of
ON-VEHICLE MAINTENANCE)
76G01C-067
Valve clearance
Measure the valve clearance, and adjust if necessary.
(Refer to page 1C—85).
76G01C-068
Gasket
Head cover App|y sealant
Cylinder head cover
1. Remove the rag pluged oil return hole.
2. Apply sealant to the shaded areas as shown in the
figure.
3. Install the cylinder head cover.
Tightening torque:
7—10 Nm (70—100 cm-kg, 61—87 in-lb)
4. Perform the necessary engine adjustments by
referring to TUNE-UP PROCEDURE section.
76G01C-069
1C-30

REMOVAL 1C
REMOVAL
1. Disconnect the negative battery cable.
2. Drain the engine oil and coolant.
3. Remove in the sequence shown in the figure referring to the removal note for specially marked parts.
76G01C-071
1. Battery and battery carrier
2. Accelerator cable
3. Air cleaner assembly
4. Radiator harness
5. Radiator hose
6. Radiator and cooling fan
7. Brake vacuum hose
8. Intercooler pipe and hose*
9. Fuel hose
10. Drive belt cover
Note
11. P/S pump
12. No.4 engine mount
13. Clutch release cylinder
14. Speedometer cable
15. Transaxle harness
16. A/C compressor
17. Engine harness
18. Heater hose
19. Front wheel
20. Engine side cover
21. Tie-rod end
22. Stabilizer control rod
23. Lower arm bushing
24. Driveshaft
25. Change rod
26. Extension bar
27. Exhaust pipe and stay
28. Engine mount
29. Engine and transaxle
30. Transaxle
marked parts are equipped only for RF-CX.
1C-31

REMOVAL 1C
Transaxle
Separate the transaxle from the engine in the sequence shown in the figure.
76G01C-073
1. Starter 4. Clutch under cover
2. Water pipe 5. Transaxle
3. Gusset plate
1C-33

DISASSEMBLY (AUXILIARY PARTS) 1 C
1. A/C compressor bracket 9. Alternator and drive belt
2. Vacuum pump and drive belt 10. Oil filter
3. Air funnel assembly 11. Oil filter cover
4. Comprex supercharger insulator 12. Oil cooler assembly
5. Comprex supercharger and drive belt 13. Exhaust pipe bracket
6. Exhaust manifold insulator 14. Alternator bracket
7. Exhaust manifold 15. Blow-by chamber
8. Intake manifold
Blow-by chamber
76G01C-074
Disassembly Note
Engine hanger
1. Remove the CSD hose.
2. Loosen the vacuum pump oil pipe bolts.
76G01C-075
3. Install the engine on the SST.
76G01C-076
1C—35

DISASSEMBLY (TIMING BELT) 1 C
76G01C-246
76G01C-078
76G01C-247
Disassembly Note
Crankshaft pulley
1. Set the SST against the flywheel.
2. Remove the crankshaft pulley.
Timing belt
1. Draw a direction arrow in the direction of engine
revolution on the timing belt, if the timing belt is to
be reused.
2. Loosen the timing belt tensioner bolt.
3. Shift the tensioner outward as far as possible and
temporarily tighten it.
4. Remove the timing belt, tensioner and spring.
Caution
Do not allow any oil or grease on the timing
belt.
5. Turn the crankshaft about 45° from the timing mark
which is marked on the oil pump housing.
76G01C-079
1C-37

DISASSEMBLY (INJECTION PUMP) 1 C
INJECTION PUMP
76G01C-082
1. No.3 engine mount and idler
2. Injection pipe
3. Injection pump
4. Oil level gauge and stay
5. Oil pipe
6. Fuel feed pipe
7. Oil pressure switch
8. Water pipe
9. Water pump
Disassembly Note
Injection pump
Remove the injection pump with its brackets.
If separate them, adjust the injection timing after in-
stalling the timing belt referring to Section 4D.
76G01C-083
1C-39

1 C DISASSEMBLY (CYLINDER HEAD)
CYLINDER HEAD
76G01C-079
1. Thermostat cover
2. Thermostat
3. Thermostat case
4. Front and rear engine
hanger
5. Fuel leak pipe
6. Injection nozzle
7. Glow cord
8. Glow plug
9. Camshaft cap
10. Oil seal
11. Camshaft
12. Cylinder head bolt
13. Cylinder head and gasket
14. Tappet and adjusting disc
15. Valve keepers
16. Upper spring seat
17. Valve spring
18. Valve
19. Lower spring seat
20. Valve seal
21. Valve guide and clip
1C-40

INSPECTION AND REPAIR 1C
Piston and Piston Pin
1. Measure the piston pin hole diameter in X and Y
directions at four points.
Diameter mm (in)
RF-CX 29.997-30.007 (1.1810-1.1814)
RF-N 24.997-25.007 (0.9841-0.9845)
76G01C-137
76G01C-139
2. Measure the piston pin diameter.
Diameter mm (in)
RF-CX 29.994-30.000 (1.1809-1.1811)
RF-N 24.994-25.000 (0.9840-0.9843)
3. Determine the piston pin to piston clearance by
subtracting the two figures.
Clearance-
-0.003—0.013 mm (0.0001—0.0005 in)
4. If the clearance exceeds the specification, replace
the piston and/or piston pin.
Connecting Rod
1. Measure the connecting rod small end bore.
Diameter mm (in)
RF-CX 30.014-30.030 (1.1817-1.1823)
RF-N 25.014-25.030 (0.9848-0.9854)
2. Check the clearance between the small end bore
and piston pin.
Clearance*
0.014—0.036 mm (0.0005—0.0015 in)
Maximum: 0.05 mm (0.002 in)
3. If the clearance exceeds the maximum, replace the
connecting rod bushing.
(1) Apply engine oil to the connecting rod and the
bushing.
(2) Align the oil holes of the connecting rod and
the bushing, and press the bushing in.
(3) Correct the bushing inner diameter, so that the
clearance is within the specification, by using
a spiral expansion reamer.

76G01C-144

1C-58