MAZDA 626 1987 Workshop Manual

ASSEMBLY (CYLINDER BLOCK) 1 C
86U01X-131
86U01X-132
76G01C-161
3. Install the rear cover and a new gasket.
Tightening torque:
8—12 Nm (80—120 cm-kg, 69—104 in-lb)
4. Cut away the portion of the gasket that projects out
from the rear cover assembly toward the oil pan
side.
Caution
Do not scratch the rear cover assembly.
End Plate
Install the end plate.
Tightening torque:
19—26
N
m (1.9—2.6 m-kg, 14—19 ft-lb)
Oil Pump
1. Apply engine oil to a new oil pump oil seal and the
oil pump body.
2. Press the oil seal into the oil pump body.
79G01C-085
1C-69

1 C ASSEMBLY (CYLINDER BLOCK)
86U01X-133
76G01C-162
76G01C-163
3. Apply engine oil to the oil seal lip.
4. Remove any dirt or other material from the con-
tact surfaces.
5. Apply a continuous bead of silicon sealant to the
contact surface of the oil pump.
Caution
Do not allow any sealant to get into the oil
hole.
6. Install a new O-ring into the pump body.
7. Install the oil pump.
Tightening torque:
Bolt A:
19—26 N-m (1.9—2.6 m-kg, 14—19 ft-lb)
Bolt B:
37—52 Nfli (3.8—5.3 m-kg, 27—38 ft-lb)
8. Remove any sealant which has been squeezed
out.
Stiffener (RF-CX)
1. Remove any dirt or other material from the con-
tact surface.
2. Apply a continuous bead of silicone sealant to the
stiffener along the inside of the bolt holes, and over-
lap the ends.
3. Install the stiffener.
Tightening torque:
8—11 N-m (80—110 cm-kg, 69—95 in-lb)
Oil Strainer
Install the oil strainer and a new gasket.
Tightening torque:
8—11 N-m (80—110 cm-kg, 69—95 in-lb)

76G01C-171

1C-70

ASSEMBLY (CYLINDER BLOCK) 1 C
76G01C-165
76G01C-166
Oil Pan
Remove any old sealant from the bolts and bolt holes.
If old sealant can not be removed from the bolt, re-
place it.
Without gasket
(1) Remove any dirt or grease from the contact
surfaces with a rag.
(2) Apply continuous bead of silicon sealant to the
oil pan along the inside of the bolt holes, and
overlap the ends.
(3) Install the oil pan.
Tightening torque:
8—11 N-m (80—110 cm-kg, 69—95 in-lb)
With gasket
(1) Apply sealant to the shaded areas in the figure.
(2) Install the gasket and the oil pan.
Tightening torque:
8—11 N-m (80—110 cm-kg, 69—95 in-lb)
Flywheel
1. Remove any old sealant from the bolts and bolt
holes. If old sealant can not removed from the bolt,
replace it.
2. Apply sealant to the bolt threads.
76G01C-167
Apply the lock
bolt threads
sealant
3. Install, and tighten the flywheel with the SST.
Tightening torque: 176—186 N-m
(18.0—19.0 m-kg, 130—137 ft-lb)

76G01C-172

1C—71

1 C ASSEMBLY (CYLINDER BLOCK)
Clutch Disc and Clutch Cover
Install the clutch disc and clutch cover using the SST.
(Refer to Section 6.)
Tightening torque:
18—26 Nm (1.8—2.7 m-kg, 13—20 ft-lb)
76G01C-169
Timing Belt Pulley
1. Install the timing belt pulley with the semicircular
(woodruff) key.
Tightening torque:
179—193 Nm (18.3—19.7 m-kg,
132—142 ft-lb)
4BG01B-180
2. Release the ring gear brake, turn the flywheel,
move the No.
1
piston to the top position, and then
turn it approximately 45° in the forward direction.
Caution
This is to prevent damage to the pistons and
valves when the cylinder head is installed.
4BG01B-181
1C—72

ASSEMBLY (CYLINDER HEAD) 1 C
CYLINDER HEAD
Torque Specifications
20—26 N-m (2.0—2.7 m-kg, 14—20 ft-lb)
o
29 N-m (3.0 m-kg, 22 ft-lb) + 90° +90°
b
b
19—26 N-m (1.9—2.6 m-kg, 14—19 ft-lb)
16—23 N-m (1.6—2.3 m-kg, 12-17 ft-lb)
31—44 N-m (3.2—4.5 m-kg, 23—33 ft-lb)
59—69 N-m (6.0—7.0 m-kg, 43—51 ft-lb)
15—20 N-m (1.5—2.0 m-kg, 11—15 ft-lb)
69G01 B-152
Valve Seal
1. Apply engine oil to the inside of the new valve seal.
2. Install the valve seal onto the valve guide with the
SST.
86U01X-143
1C—73

1 C ASSEMBLY (CYLINDER
BLOCK)

76G01C-170
Adjusting
disc
Tappet -
Apply engine oil
4BG01B-150
4BG01B-182
Apply engine oil
1.
Cylinder head bolt
below head length
Valve and Valve Spring
1. Install the lower spring seat.
2. Apply molybdenum disulphide grease to the valve
stem.
3. Install the valve.
4. Install the valve springs and the upper spring seat.
5. Compress the valve spring with the SST; then in-
stall the valve keepers.
6. Tap the end of the valve stem lightly two or three
times with a plastic hammer to confirm that the
keepers are all fully seated.
Tappet and Adjusting Disc
1. Apply engine oil to the tappets.
2. Install the tappets in the hole.
3. Install the adjusting discs.
Cylinder Head
1. Thoroughly remove all dirt and grease from the top
of the cylinder block with a rag.
2. Place the new cylinder head gasket in position.
3. Remove any dirt or grease from the bottom sur-
face of the cylinder head.
4. Place the cylinder head in position.
5. Measure the length of the cylinder head bolt be-
low the head. If the length exceeds the maximum,
replace the bolt.
Length: 113.2—113.8 mm (4.457—4.480 in)
Maximum: 114.5 mm (4.508 in)
76G01C-171
1C-74

ASSEMBLY (CYLINDER
BLOCK)
1 C
6. Apply engine oil to the cylinder head bolts.
7. Tighten the cylinder head bolts.
(1) Tighten the bolts to the specified torque, in or-
der shown in the figure.
Tightening torque:
29 Nm (3.0 m-kg, 22 ft-lb)
4BG01B184
(2)Make paint marks on the bolt heads, as shown
in the figure.
(3)With the paint marks as a reference point, turn
the cylinder head bolts another 90°
(90°—105°) in the tightening direction. Tight-
en them in the order.
(4)Then tighten them once again 90°
(90°—105°) in the tightening order.
Caution
Be absolutely sure to tighten all bolts in the
order.
4BG01 B-185
Camshaft
1. Apply engine oil to the camshaft and journal part
of the cylinder head.
2. Set the seal cap.
3. Apply a coat of sealant (1016 77 739) to the area
shown in the figure.
4. Install the camshaft so that the key groove faces
directly upward.
4BG01 B-186
5. Install the camshaft caps according to the number

and
^
mark,
and loosely tighten the camshaft cap
nuts.
76G01C-172
1C—75

1 C ASSEMBLY (CYLINDER HEAD)
6. Apply a coat of engine oil to the new oil seal lip
and insert it.
76G01C-253
76G01C-173
Glow cord
Glow plug
76G01C-174
7. Tighten the camshaft cap nuts evenly in order
shown in the figure.
Tighten torque:
20—26
N m
(2.0—2.7 m-kg, 14—20 ft-lb)
Note
The adjustment of the valve clearance should
be made only after the camshaft pulley injec-
tion pump pulley and timing belt have been
installed.
Glow Plug and Glow Cord
1. Install the glow plugs.
Tightening torque:
15—20 Nm (1.5—2.0 m-kg, 11—15 ft-lb)
2. Install the glow cord.
Tightening torque:
0.8—1.5 Nm (8.0—15 cm-kg, 7—13 in-lb)
Injection Nozzle and Leak Pipe
1. Install the new corrugated washers and the new
copper gaskets in position.
2. Install the injection nozzles.
Tightening torque:
59—69 Nm (6.0—7.0 m-kg, 43—51 ft-lb)
Note
The corrugated washers and copper gaskets
must be replaced with new ones each time the
injection nozzles are removed.
3. Install the leak pipe.
Tightening torque:
31—44
N m
(3.2—4.5 m-kg, 23—33 ft-lb)
76G01C-175
1C—76

ASSEMBLY (CYLINDER HEAD) 1 C
76G01C-176
76G01C-177
Engine Hanger
Install the front and rear engine hanger.
Tightening torque:
Front: 37—52 Nm
(3.8—5.3 m-kg, 27—38 ft-lb)
Rear: 19—26 N-m
(1.9—2.6 m-kg, 14—19 ft-lb)
Thermostat Case
Install the thermostat case with gasket.
Tightening torque:
16—23 N-m (1.6—2.3 m-kg, 12—17 ft-lb)
Thermostat and Thermostat Cover
1. Install the thermostat into the thermostat case with
the jiggle pin at the top.
2. Position a new gasket with the printed side facing
the thermostat case.
3. Install the thermostat cover.
Tightening torque:
7—10 Nm (70—100 cm-kg, 61—87 in-lb)
76G01C-178
1C—77

1 C ASSEMBLY (INJECTION PUMP)
INJECTION PUMP
Torque Specifications
25—29 N-m (2.5-3.0 m-kg, 18—22 ft-lb)
19—26 N-m (1.9—2.6 m-kg, 14—19 ft-lb)
31—46 N-m (3.2—4.7 m-kg, 23—34 ft-lb)
8—12 N-m (80—120 cm-kg, 69—104 in-lb)
8—11 N-m (80—110 cm-kg, 69—95 in-lb)

8—11
N.m (80—110 cm-kg, 69—95 in-lb) ^
/'/ \iiv>• r: \\c
37-52 N-m // V\ J ^ (3.8—5.3 m-kg, 27-3B ft-ib)
12—1B N-m (1.2—1.8 m-kg, 104—156 In-lb)
37-52 N-m (3.8—5.3 m-kg, 27—38 ft-lb}
12—18 N-m (1.2—1.8 m-kg, 104—156 In-lb)
76G01C-179
Water Pump
1. Remove the dirt or old gasket from the water pump
mounting surface.
2. Install the water pump and new gasket so that the
printed side of the gasket faces the water pump.
Tightening torque:
Bolt A: 31—46 N-m
(3.2—4.7 m-kg, 23—34 ft-lb)
Bolt B: 8—11 N-m
(80—110 cm-kg, 69—95 in-lb)
76G01C-180
1C—78