battery MAZDA 626 1987 Owner's Manual

TUNE-UP PROCEDURE 1C
4BG01 B-006
4BG01B-007
76G01C-237
TUNE-UP PROCEDURE
Turn the engine according to the procedures
described below.
Battery
1. Check for corrosion on the terminals, or loose ca-
ble connections.
If necessary, clean the clamps and tighten firmly.
2. Check the electrolyte level.
If the level is too low, add distilled water to the "UP-
PER LEVEL" mark.
3. Check the specific gravity by using a hydrometer.
If the specific gravity reading is 1.200 or less,
recharge the battery, by referring to Section 5.
Air Cleaner Element
Visually check the air cleaner element for being ex-
cessively dirty, damaged or oil.
Clean or replace it if necessary.
Caution
(Wet type)
Do not clean the air cleaner element with com-
pressed air, replace if necessary.
(Dry type)
When cleaning the air cleaner element, blow
dust off from the inside first, then blow off the
outside.
Engine Oil
Check the engine oil level and condition with the oil
level gauge.
Add oil, or change it, if necessary.
4BG01B-009
1C—5

1C TUNE-UP PROCEDURE
Comprex supercharger
Deflection mm (in)
New 4 0-6.0 (0.16—0.23)
Used 8.0-10 0 (0 31-0.39)
If necessary, loosen the idler lock nut and adjust
the belt deflection by turning the adjust bolt.
Tightening torque:
16—23 Nm (1.6—2.3 m-kg, 12—17 ft-lb)
76G01C-011
o
INJECTION TIMING
1. Disconnect the negative battery cable.
2. Release the CSD using the screw driver.
3. Remove the cover on the clutch housing.
4. Turn the flywheel and set the indicator at ATDC.
5. Disconnect the injection pipes from the injection
pump.
76G04D-008
6. Remove the hydraulic head plug from the injec-
tion pump.
7. Mount the SST into the plug hole on the hydraulic
head so the tip of the dial gauge pointer touches
the plunger end of the pump and the dial gauge
indicates approx. 2.0 mm (0.08 in).
76G04D-009
8. Turn the crankshaft slowly counterclockwise to
30-50° BTDC.
9. Make sure the dial indicator pointer no longer
moves by slightly turning the crankshaft.
10. Set the dial gauge scale to Zero at the pointer.
76G04D-010
1C-8

1C ON-VEHICLE INSPECTION
ON-VEHICLE INSPECTION
If the engine exhibits low power, poor fuel economy,
or poor idle, check the following:
1. Compression
2. Fuel system (Refer to Section 4D)
COMPRESSION
1. Check that the battery is fully charged, Recharge
it if necessary.
76G01C-016
76G01C-017
2. Warm up the engine to the normal operating tem-
perature.
3. Turn it off for about 10 minutes to allow the exhaust
manifold to cool.
4. Remove all the fuel injection pipes, nozzles, wash-
ers, and corrugate washers.
5. Disconnect the fuel cut valve connector.
Caution
If this is not done, fuel will be injected from
the injection pump while cranking.
6. Connect a suitable cap to the fuel return pipe on
the injection pump.
7. Connect a compression gauge with SST to injec-
tion nozzle hole.
8. Fully depress the accelerator pedal and crank the
engine.
9. Note the maximum gauge reading.
10. Check each cylinder.
Compression pressure kPa (kg/cm2, psi)-rpm
Standard Minimum
2.943 (30, 427)—200 2.649 (27, 384)—200
76G01C-018
Possible Cause
86U01X-022
1C-10

ON-VEHICLE MAINTENANCE (TIMING BELT) 1 C
ON-VEHICLE MAINTENANCE
TIMING BELT
Removal
1. Disconnect the nagative battery cable.
2. Remove in the sequence shown in the figure referring to the removal note for specially marked parts.
76G01C-019
1. Engine side cover
2. A/C and alternator drive belt
3. Crankshaft pulley
4. Left and right timing belt cover
5. Alternator idle pulley
6. Idler pulley
7. No.3 engine mount
8. Timing belt
9. Timing belt tensioner and spring
Note
Loosen the No.3 engine mount nuts and lower the engine to remove the crankshaft pulley.
1C-11

1 C ON-VEHICLE MAINTENANCE (CYLINDER HEAD)
CYLINDER HEAD
Removal
1. Disconnect the negative battery cable.
2. Drain the engine coolant.
3. Remove in the sequence shown in the figure referring to the removal note for specially marked parts.
76G01C-031
1. Accelerator cable
2. Air cleaner
3. Brake vacuum pipe
4. Intercooler pipe and hose*
5. Drive belt cover
6. Vacuum pump drive belt
7. Fuel hose
8. Water temperature switch
connector
9. Glow plug connector
10. Water thermo switch con-
nector
11. Heat gauge unit connector
12. Boost air temperature sen-
sor connector*
13. Injection pipes
14. Upper radiator hose
15. Water hose
(thermostat—FIR)
16. Oil level gauge and stay
bolt
17. Oil pipe bolt
18. Timing belt (Refer to page
1C—11)
19. Cylinder head cover
20. Camshaft pulley
21. Rear camshaft pulley
76G01C-032
22. Injection pump pulley
23. Seal plate
24. Water hose and pipe
25. Comprex supercharger
drive belt*
26. Heat insulator*
27. Exhaust manifold stay
28. Front exhaust pipe
29. Cylinder head bolt
30. Cylinder head
31. Cylinder head gasket
32. Comprex supercharger*
33. Exhaust manifold
34. Intake manifold
Note
* marked parts are equipped only for the RF-CX.
1C-16

1 C ON-VEHICLE MAINTENANCE (VALVE SEAL)
VALVE SEAL
Removal
1. Disconnect the negative battery cable.
2. Remove in the sequence shown in the figure referring to the removal note for specially marked parts.
76G01C-052
76G01C-053
1. Cylinder head cover 7. Tappet and adjusting disc
2. Timing belt (Refer to page 1C—11) 8. Valve keeper
3. Camshaft pulley 9. Upper valve spring seat
4. Rear camshaft pulley 10. Valve spring
5. Camshaft cap 11. Lower valve spring seat
6. Camshaft and oil seal 12. Valve seal
1C—24

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

1C INSTALLATION
Radiator
1. Install the radiator and cooling fan,
Tightening torque:
8—11 Nm (80—110 cm-kg, 69—95 in-lb)
2. Connect the radiator harness.
76G01C-213
3. Connect the upper and lower radiator hoses.
Note
a) Position the hose clamp in the original lo-
cation on the hose.
b) Squeeze the clamp lightly with large pliers
to ensure a good fit.
4. Install the solenoid valve and ground.
Tightening torque:
8—11
N
m (80—110 cm-kg, 69—95 in-lb)
76G01C-232
Air Cleaner Assembly
Install the air cleaner assembly.
Tightening torque:
16—27 Nm (1.6—2.8 m-kg, 12—20 ft-lb)
76G01C-233
Battery and Battery Carrier
1. Install the battery carrier.
Tightening torque:
Bolt A: 31—40
N
m
(3.2—4.1 m-kg, 23—30 ft-lb)
Bolt B: 8—11 N-m
(80—110 cm-kg, 69—95 in-lb)
2. Install the battery tray and battery.
Tightening torque:
5—7 N-m (50—70 cm-kg, 43—61 in-lb)

76G01C-226

1C-98

OIL PAN 2A
OIL PAN
REMOVAL
1. Disconnect the negative battery cable.
2. Drain the engine oil.
3. Remove in the sequence shown in the figure referring to the removal note for specially marked parts.
76G02A-009
5. Sub frame (RH)
6. Oil pan
7. Oil strainer
8. Stiffener (FE 8-valve...only ECE, 12-valve)
Removal Note
Oil pan
(DOHC)
1. Remove the oil pan mounting bolts.
2. Install the bolt ©from the mounting bolt or 10 mm
(0.39 in) bolts in the specified bolt holes ©(both
sides).
3. Screw in the bolts gradually and alternately to re-
move the oil pan.
Caution
Do not pry the oil pan to prevent damaging the
contact surface.
1. Exhaust pipe
2. Gusset plate (SOHC)
3. Clutch housing under cover (SOHC)
4. Performance plate (4WS)
2A-7

OIL PUMP 2A
OIL PUMP
REMOVAL
1. Disconnect the negative battery cable.
2. Drain the engine oil.
3. Remove in the sequence shown in the figure referring to the removal note for specially marked parts. 76G02A-015
DOHC
76G02A-016
1. Timing belt (Refer to Section 1B) 4. Timing belt pulley
2. Oil pan (Refer to page 2A—7.) 5. Oil pump
3. Timing belt pulley lock bolt
2A-9