AUX MAZDA 626 1987 User Guide

DISASSEMBLY (AUXILIARY PARTS) 1 B
1. Oil level gauge
2. P/S oil pump bracket
3. EGR pipe(Unleaded fuel)
4. Exhaust manifold insulator
5. Exhaust manifold assembly
6. Coolant inlet pipe and bypass pipe
7. Engine hanger
8. Alternator
9. Alternator strap and bracket
10. Engine mount bracket
11. Center cover
12. Distributor and high-tension lead
13. Spark plug
14. Thermostat and thermostat cover
15. Intake manifold bracket
16. Intake manifold assembly
17. Oil filter
18. Oil cooler
19. Oil pressure switch
76G01B-039
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49 G030 D05A
76G01A-120
Disassembly Note
Engine hanger
Remove the exhaust manifold; then connect the SST
to the engine.
69G01X-000
1B—25

DISASSEMBLY
(AUXILIARY PARTS) 1 B
AUXILIARY PARTS
Torque Specifications
37—63 N-m (3.8—6.4 m-kg, 27—46 ft-lb) 19—30 N-m (1.9—3.1 m-kg, 14—22 ft-lb)
85—117 N-m (8.7—11.9 m 63—86 ft-lb)
19—30 N-m (1.9—3.1 m-kg 14—22 ft-lb)
19—25 N-m (1.9—2.6 m-kg, 14—19 ft-lb)
37—63 N-m (3.8—6.4 m-kg, 27—46 ft-lb)
34—49 N-m (3.5—5.0 m-kg, 25-36 ft-lb)
19—30 N-m (1.9—3.1 m-kg, 14-22 ft-lb)
37—52 N-m '(If (3.8—5.3 m-kg, | / 27—38 ft-lb)
19—30 N-m (1.9—3.1 m-kg, 14—22 ft-lb)
19—30 N-m (1.9—3.1 m-kg, 14—22 ft-lb)
34—44 N-m (3.5—4.5 m-kg, 25—33 ft-lb)
19—30 N-m (1.9—3.1 m-kg, 14—2 Z ft-lb)
86U01X-164
1B—68

ASSEMBLY (AUXILIARY PARTS) 1 B
Oil Pressure Switch
Install the oil pressure switch.
Tightening torque: 12—18 N-m
(1.2—1.8 m-kg, 104—156 in-lb)
76G01A-087
Oil Cooler
Install the oil cooler.
Tightening torque:
29—39 N-m (3.0—4.0 m-kg, 22—29 ft-lb)
Oil Filter
1. Apply a small amount of engine oil to the rubber
seal of the new filter.
2. Install the oil filter and tighten it by hand until the
rubber seal contacts the base.
3. Then tighten the filter
1
and 1/6 turn with a wrench.
76G01B-099
Intake Manifold Assembly
1. Place the new gasket in position.
2. Install the intake manifold assembly.
3. Tighten the nuts in two or three steps.
Tightening torque:
19—30 N-m (1.9—3.1 m-kg, 14—22 ft-lb)
86U01X-167
Intake Manifold Bracket
Install the intake manifold bracket.
Tightening torque:
19—30 N-m (1.9—3.1 m-kg, 14—22 ft-lb)
86U01X-168
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1B-69

1 B ASSEMBLY (AUXILIARY PARTS)
Thermostat and Thermostat Cover
1. Install the thermostat into the cylinder head with
the jiggle pin at the top.
2. Position a new gasket with the printed side facing
the cylinder head.
3. Install the thermostat cover.
Tightening torque:
19—30 Nm (1.9—3.1 m-kg, 14—22 ft-lb)
86U01X-169
Spark Plug
1. Apply anti-seize compound or molybdenum-based
lubricant to the spark plug threads.
2. Install the spark plugs.
Tightening torque:
15—23
N
m (1.5—2.3 m-kg, 11—17 ft-lb)
86U01X-219
1B—70
Distributor
1. Apply engine oil to the O-ring, and position it on
the distributor.
2. Apply engine oil to the blade.
3. Install the distributor.
4. Loosely tighten the distributor mounting bolt.
High-Tension Lead
Install the high-tension leads.
Center Cover
Install the center cover.
Tightening torque:
8—12 Nm (80—120 cm-kg, 69—104 in-lb)
Engine Mount Bracket
1. Install the engine mount bracket.
Tightening torque:
85—117
N m
(8.7—11.9 m-kg, 63—86 ft-lb)
2. Install the stay to the engine mount bracket.
Tightening torque:
37—52
N
m (3.8—5.3 m-kg, 27—38 ft-lb)

ASSEMBLY (AUXILIARY PARTS) 1 B
Alternator
1. Install the alternator strap and bracket.
Tightening torque:
37—63 Nm (3.8—6.4 m-kg, 27—46 ft-lb)
86U01X-171
Install the alternator.
Tightening torque
(g): 31—46 N-m
(3.2—4.7 m-kg, 23—34 ft-lb)
(§): 37—52 N-m
(3.8—5.3 m-kg, 27—38 ft-lb)
Install the alternator drive belt, and adjust the belt
deflection. (Refer to page 1B—6.)
76G01B-102
Coolant Inlet Pipe and Bypass Pipe
1. Install the coolant inlet pipe.
Tightening torque:
19—25 N-m (1.9—2.6 m-kg, 14—19 ft-lb)
2. Apply vegetable oil to the O-ring.
3. Install the coolant bypass pipe.
Tightening torque:
37—63 N-m (3.8—6.4 m-kg, 27—46 ft-lb)
Engine Hanger
Install the front and rear engine hangers.
Tightening torque:
19—30 N-m (1.9—3.1 m-kg, 14—22 ft-lb)
76G01A-092
1B—71

1 B ASSEMBLY (AUXILIARY PARTS)
Exhaust Manifold Assembly
1. Place the new gaskets in position with the ridge
facing the cylinder head.
2. Install the exhaust manifold assembly.
3. Tighten the nuts in two or three steps.
Tightening torque:
34—49
N
m (3.5—5.0 m-kg, 25—36 ft-lb)
76G01B-105
Exhaust Manifold Insulator
Install the exhaust manifold insulator.
Tightening torque:
19—30 Nm (1.9—3.1 m-kg, 14—22 ft-lb)
EGR Pipe (Unleaded fuel)
Install the EGR pipe.
Tightening torque:
34—44 N-m (3.5—4.5 m-kg, 25—33 ft-lb)
76G01B-106
P/S Oil Pump Bracket
Install the P/S oil pump bracket.
Tightening torque:
37—63 N-m (3.8—6.4 m-kg, 27—46 ft-lb)
86U01X-178
1B—72

ENGINE
(DIESEL)
OUTLINE 1C— 2
STRUCTURAL VIEW 1C— 2
SPECIFICATIONS 1C— 3
TROUBLESHOOTING GUIDE 1C— 3
TUNE-UP PROCEDURE 1C— 5
ON-VEHICLE INSPECTION 1C—10
COMPRESSION 1C—10
ON-VEHICLE MAINTENANCE 1C—11
TIMING BELT 1C—11
CYLINDER HEAD 1C—16
VALVE SEAL 1C—24
REMOVAL 1C—31
DISASSEMBLY 1C—34
AUXILIARY PARTS 1C—34
TIMING BELT 1C—36
INJECTION PUMP 1C—39
CYLINDER HEAD 1C—40
CYLINDER BLOCK 1C—43
INSPECTION AND REPAIR 1C—47
ASSEMBLY 1C—62
CYLINDER BLOCK 1C—62
CYLINDER HEAD 1C—73
INJECTION PUMP 1C—78
TIMING BELT 1C—81
AUXILIARY PARTS 1C—87
INSTALLATION 1C—91
TRANSAXLE ASSEMBLY 1C—91
ENGINE INSTALLATION 1C—92 76G01C-001

1 C DISASSEMBLY (AUXILIARY PARTS)
DISASSEMBLY
1. Remove in the sequence shown in the figure referring to the disassembly note for specially marked
parts.
2. Code all identical parts (such as pistons, piston rings, connecting rods, and valve springs) so that
they can be reinstalled in the cylinder from which they were removed.
3. Clean the parts with steam, blow off any remaining water with compressed air.
Note
Care should be taken during the disassembly of any part or system to study its order of
assembly. Any deformation, wear, or damage should also be noted.
AUXILIARY PARTS
1C-34

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

AUXILIARY PARTS
Torque Specifications
ASSEMBLY (AUXILIARY PARTS) 1 C
RF-N
19—26 N m (1.9—2.6 m-kg, 14—19 ft-lb)

22—26 N
(2.2-2.7 16—20 ft-lb)
8—11 N m (80—110 cm-kg, '-g 69—95 in-lb)
0—110 cm-kg, 169—95 in-lb)
. 22—26 N m (2.2—2.7 m-kg, 16—20 ft-lb)
37—52 N m (3.8—5.3 m-kg, 27—38 ft-lb) I
8—11 N-m (80—110 cm-kg, 69—95 In-lb)
37—52 N-m (3,8—5.3 m-kg, 27-38 ft-lb)
86U01X-164
Alternator Bracket and Exhaust Pipe Bracket
Install the alternator bracket and exhaust pipe stay.
Tightening torque:
37—52
N
m (3.8—5.3 m-kg, 27—38 ft-lb)
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76G01C-212

1C—87