water MAZDA 626 1987 Owner's Manual

1 B INSPECTION AND REPAIR
Valve guide

-Valve stem
I/
Clearance
6. Measure the valve stem to guide clearance by sub-
tract the outer diameter of the valve stem from the
inner diameter of the corresponding valve guide.
Clearance
IN : 0.025—0.060 mm (0.0010—0.0024 in)
EX: 0.030—0.065 mm (0.0012—0.0026 in)
Maximum: 0.20 mm (0.0079 in)
7. If the clearance exceeds the maximum, replace the
valve and/or valve guide.
76G01B-122
76G01B-054
8. Check that the valve guide projection height
(dimension A in the figure). Replace if necessary.
Height: 11.4—11.9 mm (0.449—0.469 in)
Replacement of valve guide
Note
Although the shapes of the intake and exhaust
valve guides are different.
76G01B-123
Removal
1. Gradually heat the cylinder head in water to ap-
prox. 90°C (194°F).
86U01X-083
1B-36

INSPECTION AND REPAIR 1 B
2. Remove the valve guide from the side opposite the
combustion chamber with the SST.
86U01X-084
Installation
1. Gradually heat the cylinder head in water to ap-
prox. 90°C (194°F).
2. Tap the valve guide in from the side opposite the
combustion chamber with the SST until the projec-
tion height is as specified.
76G01B-124
- d
O") (o o
/y^X'/i— l/o\ 1| 1
Valve Seat
1. Inspect the contact surface of the valve seat and
valve face for the following.
(1) Roughness
(2) Damage
2. If necessary, resurface the valve seat with a 45°
valve seat cutter and/or resurface the valve face.
86U01X-087
3. Apply a thin coat of prussian blue to the valve face.
4. Check the valve seating by rotating the valve
against the seat.
(1) If blue does not appear 360° around the valve
face, replace the valve.
(2) If blue does not appear 360° around the valve
seat, resurface the seat.
69G01A-101
1B—37

1 B ASSEMBLY (CYLINDER BLOCK)
Water Pump
1. Remove all dirt, grease, and other material from
the water pump mounting surface.
2. Place a new O-ring in position.
Caution
Do not reuse the original O-ring.
86U01X-142
3. Install the water pump.
Tightening torque:
19—25 Nm (1.9—2.6 m-kg, 14—19 ft-lb)
7BU01B-103
1B-58

INSTALLATION 1B
Connector Location
Install each harness as shown in the figure.
76G01B-112
1. IG coil 10. Linear solenoid
2. Heat gauge unit 11. Solenoid valve (idle speed control)
3. Speed sensor 12. Throttle position sensor
4. P/S switch 13. Injection harness
5. Engine ground 14. Transmission harness
6. Water temperature sensor 15. Alternator
7. Water thermo switch 16. Oil pressure switch
8. Crank angle sensor 17. Starter
9. Oxygen sensor
1B-79

1 C TROUBLESHOOTING GUIDE
Problem Possible Cause Remedy Page
Insufficient power Insufficient compression Improper valve clearance Compression leakage from valve seat Seized valve stem Weak or broken valve spring Failed cylinder head gasket Cracked or distorted cylinder head Sticking, damaged, or worn piston ring Cracked or worn piston
Adjust
Repair
Replace Replace Replace Replace Replace Replace
1C-85 1C-50 1C-48 1C-52 1C—16 1C-47 1C-57 1C-56
Malfunction of fuel system Refer to Section 4D
Malfunction of Comprex supercharger Refer to Section 4D
Others Slipping clutch Dragging brakes Wrong size tires
Refer to Section 6 Refer to Section 11 Refer to Section 12
Abnormal
combustion
Malfunction of engine-related components
Improper valve clearance
Sticking or burned valve
Weak or broken valve spring
Carbon accumulation in combustion chamber
Adjust
Replace
Replace Eliminate carbon
1C-85
1C-48
1C-52
Malfunction of fuel system Refer to Section 4D
Malfunction of Comprex supercharger Refer to Section 4D
Engine noise Crankshaft or bearing related parts Excessive main bearing oil clearance Main bearing seized or heat-damaged Excessive crankshaft end play Excessive connecting rod bearing oil clearance Connecting rod bearing seized or heat-damaged
Replace or repair Replace
Replace or repair Replace or repair Replace
1C-64 1C-64 1C-65 1C-66 1C-66
Piston related parts Worn cylinder Worn piston or piston pin Seized piston Damaged piston ring Bent connecting rod
Replace or repair Replace
Replace Replace Replace
1C-55 1C-58 1C-56 1C-57 1C-59
Valves or timing related parts Excessive valve clearance Broken valve spring Excessive valve guide clearance Malfunction of timing belt tensioner
Adjust Replace Replace Replace
1C-85 1C-52 1C-48 1C-61
Malfunction of cooling system Refer to Section 3B
Malfunction of fuel system Refer to Section 4D
Malfunction of Comprex supercharger Refer to Section 4D
Others Malfunction of water pump bearing Improper drive-belt tension Malfunction of alternator bearing Exhaust gas leakage
Replace Adjust Replace Repair
1C-7
1C—47
76G01C-004
1C—4

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
Coolant Level
Check that the coolant level is near the radiator inlet
port, and that the level in the reserve tank is between
the FULL and LOW marks.
Add coolant up if the level is low.
Warning
Never remove the radiator cap when the en-
gine is hot.
Wrap a thick cloth around cap and carefully
remove the cap.
4BG01B-010
Water Draining
1. Drain the water from the sedimenter or fuel filter.
If it is difficult to drain the water from the drain plug,
loosen the air bleeding plug.
2. Bleed the air from the sedimenter or fuel filter. (Re-
fer to Section 4D)
76G01C-005
Valve Clearance
1. Remove the cylinder head cover.
2. Set the No. 1 cylinder to compression TDC.
Note
Turn the crankshaft so that the intake and ex-
haust cam lobes face upward.
4BG01B-016
3. Measure the valve clearance of No. 1 cylinder by
using a thickness gauge.
Valve clearance (cold engine)
0.20—0.30 mm (0.008—0.012 in)
0.30—0.40 mm (0.012—0.016 in)
If necessary, adjust the valve clearance referring to
the page 1C—85.
76G01C-006
1C-6

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

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

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