wheel MAZDA 626 1987 Owner's Manual

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

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

DISASSEMBLY (TIMING BELT) 1 C
76G01C-246
76G01C-078
76G01C-247
Disassembly Note
Crankshaft pulley
1. Set the SST against the flywheel.
2. Remove the crankshaft pulley.
Timing belt
1. Draw a direction arrow in the direction of engine
revolution on the timing belt, if the timing belt is to
be reused.
2. Loosen the timing belt tensioner bolt.
3. Shift the tensioner outward as far as possible and
temporarily tighten it.
4. Remove the timing belt, tensioner and spring.
Caution
Do not allow any oil or grease on the timing
belt.
5. Turn the crankshaft about 45° from the timing mark
which is marked on the oil pump housing.
76G01C-079
1C-37

DISASSEMBLY (CYLINDER BLOCK) 1 C
CYLINDER BLOCK—I
76G01C-091
1. Clutch cover
2. Clutch disc
3. Flywheel
4. End plate
5. Oil pan
6. Oil strainer
7. Stiffener (RF-CX)
8. Rear cover
9. Timing belt pulley
10. Oil pump assembly
Flywheel
1. Install the SST to the flywheel.
2. Remove the clutch cover, clutch disc and flywheel.
Timing belt pulley
1. Reverse the direction of the SST.
2. Remove the timing belt pulley.
76G01C-092
1C—43

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

1C INSTALLATION
Driveshaft
1. Apply grease to the end of the driveshaft.
2. Install the driveshaft and a new clip.
Caution
a) When installing the driveshaft, be careful
not to damage the oil seal.
b) After installation, pull the front hub outward
to confirm that the driveshaft is securely
held by the clip.
Water Hose
Connect the water hose.
76G01C-220
Lower Arm
Install the lower arm ball-joint to the knuckle; then tight-
en the lock nut.
Tightening torque:
43—54 N-m (4.4—5.5 m-kg, 32—40 ft-lb)
86U01X-185
Tie-Rod End
1. Install the tie-rod end to the knuckle.
Tightening torque:
29—44 N-m (3.0—4.5 m-kg, 22—33 ft-lb)
2. Install the cotter pin.
86U01X-186
76G01C-255
Stabilizer Control Rod
Install and adjust the front stabilizer control rods.
Dimension A: 20.1 mm (0.79 in)
Tightening torque: 16—23 N-m (1.6—2.3 m-kg, 12—17 ft-lb)
Front Wheel
Install the front wheel.
Tightening torque:
88—118 N-m (9.0—12.0 m-kg, 65—87 ft-lb)
1C—94

4A IDLE-UP CONTROL SYSTEM
76G04A-144
76G04A-145
76G04A-146
Vacuum Signal [Equipped with A/C, only FE and
F8 (Except Middle East and General)]
1. Start the engine and run it at idle.
2. Disconnect the vacuum hose from the servo di-
aphragm.
3. Place a finger over the hose.
4. Increase the engine speed, and check for vacuum.
Engine model Engine speed Vacuum
pj| (Except Middle) Below 2,300 rpm Yes pj| (Except Middle) Above 2,300 rpm No
FE (Unleaded fuel) Below 1,500 rpm Yes FE (Unleaded fuel) Above 1,500 rpm No
F6 (Singapore) Below 2,100 rpm Yes F6 (Singapore) Above 2,100 rpm No
General and Middle East
1. Start the engine and run it at idle.
2. Disconnect the vacuum hose from the servo di-
aphragm.
3. Place a finger over the hose.
4. Operate the A/C or P/S.
5. Check that vacuum is felt.
P/S Switch
1. Start the engine and run it at idle.
2. Disconnect the power steering switch connector.
3. Connect an ohmmeter to the power steering
switch.
4. Turn the steering wheel all the way to either the
right or left, and check for continuity.
P/S Continuity
Operated Yes
Not operated No
5. Replace if necessary.
Solenoid Valve (A/C)
1. Disconnect vacuum hose A from the servo di-
aphragm.
2. Disconnect vacuum hose B from the solenoid
valve.
3. Disconnect the solenoid valve connector.
4. Blow air through the valve from hose A and check
that it comes out of port C.
76G04A-147
4A-74

4B TROUBLESHOOTING WITH SST
INSPECTION PROCEDURE
1. Connect the SST to the check connector, (Green,
6-pin) and the negative battery terminal.
2. Set the select switch to position A.
Note
The check connector is located at the rear of
the left side wheel housing.
86U04A-011
Test connector: Green (1 pin)
3. Ground the test connector (Green, 1-pin) with a
jumper wire.
Note
The test connector is located near the Self-
Diagnosis Checker check connector.
86U04A-012
OO
uu
SELF-DIAGNOSIS CHECKER
(WPUTOft
SELECT
S*

5


o n==ru
o o o o 49 HO 18 9AI
76G04B-005
4. Turn the ignition switch ON.
5. Verify that 88 flashes on the digital display and that
the buzzer sounds for three seconds after turn-
ing the ignition switch ON.
6. If 88 does not flash, check the main relay (Refer
to page 4B—86), power supply circuit, and check
connector wiring.
7. If 88 flashes and the buzzer sounds continuously
for more than 20 seconds, replace the engine con-
trol unit and perform steps 3 and 4 again.
8. Note the code numbers and check for the causes
by referring to the check sequences shown on
pages from 4B—14 to 4B—24. Repair as
necessary.
Note
Cancel the code numbers by performing the
after-repair procedure after repairing.
AFTER-REPAIR PROCEDURE
1. Cancel the memory of malfunctions by disconnect-
ing the negative battery cable and depressing the
brake pedal for at least 2 seconds; then recon-
nect the negative battery cable.
76G04B-134
4B—10

4B IDLE-UP SYSTEM
COMPONENT DESCRIPTIONS
Component Function Remarks
Air bypass solenoid
valve

Controls bypass
air
amount Operates A: A/C
: ON

B: Intake
air
temp, high
or at
high
al-
titude C: P/S
:
ON, E/L applied
or
hot start

Air valve
When cold, supplies bypass
air
into
dy-

namic chamber
• Engine speed increased
to
shorten
warm-up period
• Bimetal type

Atmospheric pressure sensor

Detects atmospheric pressure; sends sig-
nal
to
engine control unit

E/L control unit
Detects electrical load applied; sends sig-nal
to
engine control unit

Engine control unit
Detects signals from input sensors and switches; controls
air
bypass solenoid valve

Intake air thermo sensor
Detects intake
air
temperature; sends sig-
nal
to
engine control unit
Installed
in air
flow meter

P/S pressure switch
Detects P/S operation; sends signal
to
engine control unit P/S:
ON
when steering wheel turnefl right
or
left

76g04b-044
4B-36