lock MAZDA 626 1987 User Guide

1 A ON-VEHICLE MAINTENANCE (CYLINDER HEAD)
1. High-tension lead and spark plug
2. Accelerator cable
3. Throttle cable (ATX)
4. Air intake pipe (Fl)
5. Air cleaner assembly (carb.)
6. Fuel hose
7. Fuel pump (carb.)
8. Upper radiator hose
9. Heater hose
10. Brake vacuum hose
11. Canister hose (Fl, Middle East)
12. Three-way solenoid assembly
13. Engine harness connector and ground
14. Secondary air pipe assembly (except
General)
15. EGR pipe (Fl, Unleaded carb.)
16. Exhaust manifold insulator
17. Exhaust pipe
18. Exhaust manifold
19. Gusset plate (Fl)
20. Intake manifold bracket (Fl)
21. Intake manifold assembly
22. Distributor
23. A/C compressor and bracket
24. Upper timing belt cover
25. Timing belt tensioner spring
26. Timing belt
27. Cylinder head cover
28. Cylinder head and gasket 76G01A-031
Removal note
Fuel hose
Warning
a) Cover the hose with a rag because fuel will
spray out when disconnecting.
b) Keep sparks and open flame away from the
fuel area.
Plug the disconnected hoses to avoid fuel leakage.
Timing belt
1. Before removing the timing belt, turn the crankshaft
to align the mating mark of the camshaft pulley with
the front housing timing mark.
Note
For FE engine, align "2" mark.
For F8, F6 engine, align "3" mark.
2. Loosen the timing belt tensioner lock bolt.
3. Shift the tensioner outward as far as possible, then
temporarily tighten it.
1A—21

1 A ON-VEHICLE MAINTENANCE (CYLINDER HEAD)
Installation note
Cylinder head
1. Thoroughly remove all dirt and oil from the top of
the cylinder block with a rag.
2. Place a new cylinder head gasket in position.
86U01X-035
® (5)
CD
© (8)
3. Set the cylinder head in place.
4. Apply engine oil to the bolt threads and seat faces.
5. Tighten the cylinder head bolts in two or three steps
in the order shown in the figure.
Tightening torque:
80—86 N-m (8.2—8.8 m-kg, 59—64 ft-lb)
86U01X-036
Cylinder head cover
1. Apply silicon sealant to the shaded area shown in
the figure.
2. Install the cylinder head cover.
Tightening torque:
6—8
N
m (60—80 cm-kg, 52—69 in-lb)
86U01X-037
Timing belt
1. Align the mating mark of the camshaft pulley with
the front housing timing mark.
Note
For FE engine, align "2" mark.
For F8, F6 engine, align "3" mark.
2. Install the timing belt. (Refer to TIMING BELT of
ON-VEHICLE MAINTENANCE.)
76G01A-034
1A—24

ON-VEHICLE MAINTENANCE (VALVE SEAL) 1 A
76G01A-044
86U01X-212
76G01A-045
(8-valve)
Install the rocker arm and shaft assemblies on the cyl-
inder head and tighten them in three steps in the or-
der shown in the figure.
Tightening torque:
18—26 N-m (1.8—2.7 m-kg, 13—20 ft-lb)
Front housing
1. Replace the oil seal in the front housing.
2. Apply engine oil to the oil seal lip.
3. Install the front housing along with a new gasket.
Tightening torque:
19—25 N-m (1.9—2.6 m-kg, 14—19 ft-lb)
Rear housing
Install the rear housing along with a new gasket.
Tightening torque:
19—25 N-m (1.9—2.6 m-kg, 14—19 ft-lb)
Camshaft pulley
1. Install the camshaft pulley so that the mating mark
is aligned with the camshaft dowel pin straight up.
Note
For FE engine, align "2" mark.
For F8, F6 engine, align "3" mark.
2. Tighten the lock bolt.
Tightening torque:
47—65 N-m (4.8—6.6 m-kg, 35—48 ft-lb)
Timing belt
Install the timing belt. (Refer to TIMING BELT of ON-
VEHICLE MAINTENANCE.)

86U01X-052

1A—32

DISASSEMBLY (TIMING BELT) 1 A
Mark the
direction of
rotation
76G01A-121
76G01A-122
*
/ V \
T^pJl/1
Disassembly Note
Crankshaft pulley
1. Set the SST against the flywheel.
2. Remove the crankshaft pulley.
Timing belt
1. Loosen the tensioner lock bolt, and remove the ten-
sioner spring.
2. Mark the timing belt rotation for proper reinstalla-
tion if it is reused.
3. Remove the timing belt.
Caution
Be careful not to allow oil or grease on the
belt.
Camshaft pulley
Remove the pulley lock bolt using a screw driver to
prevent the camshaft from turning.
76G01A-123
1A—39

1 A DISASSEMBLY (CYLINDER BLOCK)
CYLINDER BLOCK—I
1. Clutch cover (MTX), Backing plate (ATX)
2. Clutch disc (MTX), Drive plate (ATX)
3. Flywheel (MTX), Adaptor (ATX)
4. End plate
5. Oil pan
76G01A-051
6. Oil strainer
7. Stiffener (FE 8-valve...only ECE, 12-valve)
8. Rear cover
9. Water pump assembly
10. Oil pump assembly
1A—44

DISASSEMBLY (CYLINDER BLOCK) 1 A
76G01A-125
Disassembly Note
Clutch cover, flywheel (MTX) or drive plate (ATX)
Remove the clutch cover and flywheel (MTX), or drive
plate (ATX) with the SST.
Oil pan
1. Remove the oil pan mounting bolts.
2. Insert a scraper or a suitable tool between the oil
pan and the stiffener or the cylinder block to sep-
arate them.
3. Remove the oil pan.
Caution
Do not bend the oil pan when prying loose.
76G01A-052
1A—45

1 A DISASSEMBLY (CYLINDER BLOCK)
CYLINDER BLOCK—II
86U01X-073
6. Crankshaft
7. Pilot bearing (MTX)
8. Main bearing
9. Cylinder block
Disassembly Note
Connecting rod and cap
Before removing the connecting rod, clean the bear-
ing, connecting rod, and crankpin, and measure the
following points.
1. Connecting rod side clearance. (Refer to page
1A—67.)
2. Crankpin oil clearance.(Refer to page 1A—67.)
1. Connecting rod cap
2. Connecting rod bearing
3. Connecting rod and piston
4. Piston ring
5. Main bearing cap

1
A—46

DISASSEMBLY (CYLINDER BLOCK) 1 A
Main bearing cap
Before removing the main bearing caps, clean the
bearings, main journals, and caps, and measure the
following points.
1. Crankshaft end play. (Refer to page 1A—66.)
2. Main journal oil clearance. (Refer to page
1
A—65.)
76G01A-054
Pilot bearing (MTX)
Remove the pilot bearing from the crankshaft with the
SST.
86U01X-076
Piston and connecting rod
1. Before disassembling the piston and connecting
rod, check the oscillation torque as shown in the
figure.
If the large end does not drop by its own weight,
replace the piston or the piston pin.
79G01C-050
2. Remove the piston pin with the SST.
While removing the piston pin, check the pressure.
If it is lower than 5kN (500kg, 1,100 lb), replace
the piston pin or connecting rod.

76G01A-139

1A—47

INSPECTION AND REPAIR 1 A
76G01A-062
86U01X-092
76G01A-063
A vl^k
L^-X
B As^
Valve Spring
1. Inspect each valve spring for cracks or damage.
2. Check the free length and angle. Replace if
necessary.
Free length mm (in)
Standard Minimum
12-valve IN 49.5 (1.949) 49.0 (1.929) 12-valve EX 50.4 (1.984) 48.7 (1.917)
I FE.Middle Outer 51.2 (2.016) 50.6 (1.992)
8-valve East General Inner 45.7 (1.799) 43.7 (1.720) 8-valve
Others Outer 52.0 (2.047) 51.5 (2.028) 8-valve
Others Inner 44.0 (1.732) 43.3 (1.705)
Angle: 1.8 mm (0.071 in) max.
Camshaft
1. Set the front and rear journals on V-blocks.
Check the camshaft runout. Replace if necessary.
Runout: 0.03 mm (0.0012 in) max.
2. Check the cam for wear or damage. Replace if
necessary.
3. Check the cam lobe height at the two points as
shown in the figure.
Height mm (in)
Standard Minimum
12-valve IN 41.340 (1.6276) 41.14 (1.620) 12-valve EX 41.847 (1.6476) 41.65 (1.640)
8-valve IN 38.157 (1.5022) 37.96 (1.494) 8-valve EX 38.160 (1.5024) 37.96 (1.494)
4. Measure wear of the journals in X and Y directions
at the two points as shown in the figure.
Diameter mm (in)
12-valve 8-valve
No. 1,5 31.940-31.965 (1.2575-1.2585) 31.940-32.035 (1.2575-1.2612)
No. 2,3,4 31.910-31.935 (1.2563-1.2573) 31.910-32.065 (1.2563—1.2624)
Out-of-round: 0.05 mm (0.002 in) max.
76G01A-129

1
A—53

INSPECTION AND REPAIR 1 A
76G01A-065
76G01A-066
86U01X-100
(2) Measure the rocker arm shaft diameter.
Diameter:
18.959—18.980 mm (0.7464—0.7472 in)
...12 valve
15.966—15.984 mm (0.6286—0.6293 in)
... 8 valve
(3) Subtract the shaft diameter from the rocker arm
diameter.
Oil clearance mm (in)
Standard Maximum
12-valve 0.020-0.074
(0.0008-0.0029) 0.10 (0.0039)
8-valve 0.016-0.061 (0.0006-0.0024) 0.10 (0.0039)
Hydraulic Lash Adjuster (12-valve)
Check the HLA face for wear or damage. Replace
if necessary.
Caution
Do not remove the HLA unless necessary to
prevent damaging the O-ring.
Cylinder Block
1. Check the cylinder block. Repair or replace if
necessary.
(1) Leakage damage
(2) Cracks
(3) Scoring of wall
2. Measure the distortion of the top surface of the cyl-
inder block in the six directions as shown in the
figure.
Distortion: 0.15 mm (0.006 in) max.
3. If the distortion exceeds the maximum, repair by
grinding, or replace the cylinder block.
Grinding limit: 0.20 mm (0.008 in) max.

86U01X-117

1A—55