belt MAZDA 626 1987 Owner's Guide

INSPECTION AND REPAIR 1 A
Crankpin
,/f
Main journal
76G01A-132
5. If the diameter is less than the minimum, grind the
journals to match undersize bearings.
Undersize bearing: 0.25 mm (0.010 in),
0.50 mm (0.020 in), 0.75 mm (0.030 in)
Main journal diameter undersize mm (in)
Bearing size Journal diameter
025 (0.010)
undersize
No.1,2,4,5 59.693-59.711 (2.3501-2.3508) 025 (0.010)
undersize No.3 59.687-59.705 (2.3499-2.3506)
0.50 (0.020)
undersize
No.1,2,4,5 59.443-59.461 (2.3403—2.3410) 0.50 (0.020)
undersize No.3 59.437-59.455 (2.3400—2.3407)
0.75 (0.030) undersize
No.1,2,4,5 59.193-59.211 (2.3304-2.3311) 0.75 (0.030) undersize No.3 59.187-59.205 (2.3302-2.3309)
Rolled fillet
Crankpin journal diameter undersize mm (in)
Bearing size Journal diameter
0.25 (0.010) undersize 50.690—50.705 (1.9957-1.9963)
0.50 (0.020) undersize 50.440-50.455 (1.9858—1.9864)
0.75 (0.030) undersize 50.190-50.205 (1.9760-1.9766)
Caution
Do not grind the rolled fillet area.
76G01A-133
Main Bearing and Connecting Rod Bearing
Check the main bearings and the connecting rod
bearings for peeling, scoring, or other damage.
79G01C-077
Timing Belt
1. Replace the timing belt if there is any oil or grease
on it.
2. Check the timing belt for damage, wear, peeling,
cracks, or hardening. Replace if necessary.

86U01X-117

1A—60

INSPECTION AND REPAIR 1 A
Caution
a) Never forcefully twist, turn inside out, or
bend the timing belt.
b) Be careful not to allow oil or grease on the
belt.
86U01X-114
Timing Belt Tensioner and Idler Pulley
Check the timing belt tensioner and idler pulley for
smooth rotation and abnormal- noise. Replace if
necessary.
Caution
Do not clean the tensioner with cleaning
fluids. If necessary, use a soft rag to wipe it
clean, and avoid scratching it.
86U01X-115
Timing Belt Tensioner Spring
Check the free length of the tensioner spring. Replace
if necessary.
Free length: 56.9 mm (2.240 in) FE
64.1 mm (2.524 in) F8, F6
76G01A-134
Timing Belt Pulley and Camshaft Pulley
Inspect the pulley teeth for wear, deformation, or other
damage. Replace if necessary.
Caution
Do not clean the pulley with cleaning fluids.
If necessary, use a rag to wipe it clean.
Timing Belt Cover (lower and upper)
Inspect the timing belt covers for damage or cracks.
Replace if necessary.
86U01X-117
1A—61

1 A ASSEMBLY (TIMING BELT)
TIMING BELT
Torque Specifications
6—B N (1.25—1.75 m-kg, 109—152 in-lb)

1
A—82
69G01B-160

ASSEMBLY (TIMING BELT) 1 A
Camshaft Pulley
1. Install the camshaft pulley on the camshaft with the
dowel pin fit into the hole at the 2 mark (FE) or 3
mark (F8, F6).
76G01A-083
2. Tighten the camshaft pulley lock bolt.
Tightening torque:
47—65 N-m (4.8—6.6 m-kg, 35—48 ft-lb)
76G01A-141
3. Align the mating mark on the pulley with the align-
ment mark on the front housing.
Note
For FE engine, align "2" mark.
For F8, F6 engine, align "3" mark.
76G01A-084
Timing Belt Pulley
1. Reverse the direction of the SST (ring gear brake).
2. Install the crankshaft key.
3. Install the timing belt pulley on the crankshaft.
Tightening torque: 157—167 N-m
(16.0—17.0 m-kg, 116—123 ft-lb)
4. Release the ring gear brake.
5. Align the timing belt pulley and the pump body
alignment marks.
86U01X-160

1
A—83

1A ASSEMBLY (TIMING BELT)
Tensioner lock bolt
69G01B-165
76G01A-085
79G01C-097
Timing Belt Idler Pulley
Install the timing belt idler pulley.
Tightening torque:
37—52 Nm (3.8—5.3 m-kg, 27—38 ft-lb)
Timing Belt Tensioner
1. Install the timing belt tensioner and tensioner
spring.
2. Tentatively secure the tensioner with the spring fully
extended.
Timing Belt
1. Install the timing belt, (keep the tension side of belt
as tight as possible.)
Caution
a) If the timing belt is being reused, it must be
reinstalled to rotate in the original direction.
b) Check that there is no oil, grease, or dirt on
the timing belt.
2. Loosen the tensioner lock bolt.
3. Turn the crankshaft twice in the direction of rotation.
4. Check that the mating marks are correctly aligned.
If not aligned, remove the timing belt and tension-
er, and repeat the above-mentioned procedure.
5. Tighten the timing belt tensioner lock bolt.
Tightening torque:
37—52 Nm (3.8—5.3 m-kg, 27—38 ft-lb)
4BGQ1A-186
1A—84

ASSEMBLY (TIMING BELT) 1A
6. Check the timing belt deflection. If the deflection
is not correct, loosen the tensioner lock bolt and
repeat steps 3—5 above. Replace the tensioner
spring if necessary.
Belt deflection:
FE: 5.5—6.5 mm (0.22—0.26 in)
F8, F6: 4.0—5.0 mm (0.16—0.20 in)
/98 N (10kg, 22 lb)
76G01A-086
Baffle Plate
Position the baffle plate on the timing belt pulley.
Timing Belt Cover
Install the lower timing belt cover, upper timing belt
cover, and new gaskets.
Tightening torque:
7—10 Nm (70—100 cm-kg, 61—87 in-lb)
86U01X-163
Crankshaft Pulley
Install the crankshaft pulley.
Tightening torque: 12—17 N-m
(1.25—1.75 m-kg, 109—152 in-lb)
69G01B-170
76G01A-142
Valve Clearance (8-valve)
Adjust the valve clearance. (Refer to page
1
A—10.)
Cylinder Head Cover
1. Apply silicon sealant to the shaded areas shown
in the figure.
2. Install the cylinder head cover.
Tightening torque:
6—8 N-m (60—80 cm-kg, 52—69 in-lb)
1A—85

ASSEMBLY (AUXILIARY PARTS) 1 A
86U01X-171
76G01A-090
76G01A-091
Alternator
1. Install the alternator strap and bracket.
Tightening torque:
37—63 Nm (3.8—6.4 m-kg, 27—46 ft-lb)
2. Install the alternator.
Tightening torque
(A): 31—46 Nm
(3.2—4.7 m-kg, 23—34 ft-lb)
(§): 37—52 N-m
(3.8—5.3 m-kg, 27—38 ft-lb)
3. Install the alternator drive belt, and adjust the belt
deflection. (Refer to page 1A—7.)
Coolant Inlet Pipe and Bypass Pipe
1. Install the coolant inlet pipe.
Tightening torque:
19—25 N-m (1.9—2.6 m-kg, 14—19 ft-lb)
2. Apply vegetable oil to the O-ring.
3. Install the coolant bypass pipe.
Tightening torque:
37—63
N
m (3.8—6.4 m-kg, 27—46 ft-lb)
Engine Hanger
Install the front and rear engine hangers.
Tightening torque:
19—30 N-m (1.9—3.1 m-kg, 14—22 ft-lb)
76G01A-092
1A—89

INSTALLATION 1A
86U01X-188
86U01X-189
P/S Oil Pump
1. Install the P/S oil pump.
Tightening torque:
31—46 N m (3.2—4.7 m-kg, 23—34 ft-lb)
2. Tighten the pulley lock nut.
Tightening torque:
39—59
N
m (4.0—6.0 m-kg, 29—43 ft-lb)
A/C Compressor
1. Install the A/C compressor strap to the P/S oil pump
bracket.
Tightening torque:
19—25 Nm (1.9—2.6 m-kg, 14—19 ft-lb)
2. Install the A/C compressor bracket.
Tightening torque:
37—63 Nm (3.8—6.4 m-kg, 27—46 ft-lb)
3. Install the A/C compressor.
4. Install the A/C compressor upper bracket.
Tightening torque:
37—63
N
m (3.8—6.4 m-kg, 27—46 ft-lb)
5. Tighten to the lock nut and mounting bolts.
Tightening torque:
37—52
N
m (3.8—5.3 m-kg, 27—38 ft-lb)
86U01X-190
Drive Belt
Install the drive belt and adjust the belt deflection. (Re-
fer to page 1A—7.)
76G01A-096
1A—95

1
ENGINE
(DOHC)
OUTLINE 1B— 2
STRUCTURAL VIEW 1B— 2
SPECIFICATIONS 1B— 3
TROUBLESHOOTING GUIDE 1B— 3
TUNE-UP PROCEDURE IB— 5
ON-VEHICLE INSPECTION 1B—10
COMPRESSION 1B—10
ON-VEHICLE MAINTENANCE 1B—11
TIMING BELT 1B—11
CYLINDER HEAD 1B—16
REMOVAL 1B—22
DISASSEMBLY 1B—24
AUXILIARY PARTS 1B—24
TIMING BELT 1B—26
CYLINDER HEAD 1B—28
CYLINDER BLOCK 1B—30
INSPECTION AND REPAIR 1B—34
ASSEMBLY 1B—48
CYLINDER BLOCK 1B—48
CYLINDER HEAD 1B—59
TIMING BELT 1B—64
AUXILIARY PARTS 1B—68
INSTALLATION 1B—73
TRANSAXLE ASSEMBLY 1B—73
ENGINE INSTALLATION 1B—74
76G01B-001

TROUBLESHOOTING GUIDE 1 B
SPECIFICATIONS
Engine model FE DOHC
Item Leaded fuel Unleaded fuel
Type Gasoline, 4 cycle
Cylinder arrangement and number In line, 4 cylinders
Combustion chamber Pentroof
Valve system OHC, belt driven
Displacement cc (cu in) 1,998 (121.9)
Bore and stroke mm (in) 86.0 x 86.0 (3.39 x 3.39)
Compression ratio 10.0 : 1 9.2 : 1
Compression pressure Standard 1,422 (14.5, 206)—290 1,373 (14.0, 199)—310
kPa (kg/cm2, psi)-rpm Minimum 996 (10.2, 144)—290 961 (9.8, 139)—310
IN Open BTDC 10° 10°
Valve timing
IN Close ABDC 60° 55° Valve timing
EX Open BBDC 60° 55° EX Close ATDC 10° 10°
Valve clearance mm (in) IN 0; Maintenance-free Valve clearance mm (in) EX 0; Maintenance-free
Idle speed rpm 750 ± 50
Ignition timing BTDC 12° ± 1°
Firing order 1—3--4-2
76G01B-002
TROUBLESHOOTING GUIDE
Problem Possible Cause Remedy Page
Difficult starting Malfunction of engine-related components
Burned valve
Worn piston, piston ring, or cylinder
Failed cylinder head gasket
Replace
Replace or repair Replace
1B—35 1B—43 1B—16
Malfunction of fuel system Refer to Section 4C
Malfunction of electrical system Refer to Section 5
Poor Idling Malfunction of engine-related components Malfunction of HLA
Poor valve to valve seat contact
Failed cylinder head gasket
Replace
Repair or replace
Replace
1B—60 1B—37 1B—16
Malfunction of fuel system Refer to Section 4C
Excessive oil
consumption Oil working up Worn piston ring groove or sticking piston ring Worn piston or cylinder
Replace
Replace or repair
1B-43 1B-43
Oil working down
Worn valve seal
Worn valve stem or guide
Replace
Replace 1B-35
Oil leakage Refer to Section 2A
76G01B-003
1B—3