timing belt MAZDA 626 1987 Repair Manual

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 (CYLINDER HEAD)
76G01C-045
Gasket
Head cover Apply sealant
J
76G01C-046
76G01C-047
Timing marks
Timing marks
Timing
marks-
Injection pump pulley
1. Install the injection pump pulley with the semicir-
cular (woodruff) key to the injection pump shaft.
2. Rotate the injection pump pulley until the timing
marks are aligned.
3. Affix the injection pump pulley to the bracket us-
ing two bolts (35—40 mm, 1.4—1.6 in).
4. Tighten the lock nut.
Tightening torque:
59—69 Nm (6.0—7.0 m-kg, 43—51 ft-lb)
Cylinder head cover
1. Apply sealant to the shaded areas.
2. Install the cylinder head cover.
Tightening torque:
7—10
N
m (70—100 cm-kg, 61—87 in-lb)
3. Install the PCV hose.
Timing belt
1. Return the crankshaft about 45° to the timing mark
on the oil pump housing.
2. Check that the timing marks of the camshaft pul-
ley and the injection pump pulley align with the tim-
ing marks on the seal plate.
3. Install the timing belt. (Refer to TIMING BELT of
ON-VEHICLE MAINTENANCE)
76G01C-048
1C-22

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

ON-VEHICLE MAINTENANCE (VALVE SEAL) 1 C
Removal note
Camshaft pulley
1. After removing the timing belt, turn the crankshaft
45° clockwise.
76G01C-054
2. Hold the camshaft with a wrench (29 mm, 1.14 in)
and loosen the camshaft pulley lock bolt.
Caution
Do not damage the cylinder head edge with
the wrench.
4BG01B-044
3. Separate the camshaft pulley from the camshaft
with the SST.
Caution
Do not hit the camshaft pulley with a hammer.
Rear camshaft pulley
Remove the rear camshaft pulley in the same man-
ner used for camshaft pulley.
76G01C-055
Camshaft cap
Loosen the camshaft nuts in two or three steps in the
order shown in the figure.

76G01C-066

1C—25

1 C ON-VEHICLE MAINTENANCE (VALVE SEAL)
2. Check that the timing marks of the camshaft pul-
ley and the injection pump pulley align with the tim-
ing marks on the seal plate.
3. Install the timing belt. (Refer to TIMING BELT of
ON-VEHICLE MAINTENANCE)
76G01C-067
Valve clearance
Measure the valve clearance, and adjust if necessary.
(Refer to page 1C—85).
76G01C-068
Gasket
Head cover App|y sealant
Cylinder head cover
1. Remove the rag pluged oil return hole.
2. Apply sealant to the shaded areas as shown in the
figure.
3. Install the cylinder head cover.
Tightening torque:
7—10 Nm (70—100 cm-kg, 61—87 in-lb)
4. Perform the necessary engine adjustments by
referring to TUNE-UP PROCEDURE section.
76G01C-069
1C-30

1 C DISASSEMBLY (TIMING BELT)
TIMING BELT
76G01C-077
1. Cylinder head cover
2. Crankshaft pulley
3. Left and right timing belt covers
4. Idler pulley
5. Timing belt tensioner and spring
6. Timing belt
7. Injection pump pulley
8. Camshaft pulley
9. Rear camshaft pulley
10. Seal plate
1C-36

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

1 C DISASSEMBLY (TIMING BELT)
Injection pump pulley
1. Put two bolts of 35—40 mm (1.4—1.6 in) length
into the arms of the injection pump pulley and af-
fix them in the threaded hole of the injection pump
bracket.
2. Loosen the injection pump pulley lock bolt.
3. Separate the injection pump pulley from the injec-
tion pump shaft with the SST.
Camshaft pulley
1. Hold the camshaft with a wrench (29 mm, 1.14 in)
and loosen the camshaft pulley lock bolt.
Caution
Do not damage the cylinder head edge with
the wrench.
2. Separate the camshaft pulley from the camshaft
with the SST.
Caution
Do not hit the camshaft pulley with a hammer.
Rear camshaft pulley
Remove the rear camshaft pulley in the same man-
ner used for camshaft pulley.
4BG01B-087
76G01C-081
1C—38

DISASSEMBLY (INJECTION PUMP) 1 C
INJECTION PUMP
76G01C-082
1. No.3 engine mount and idler
2. Injection pipe
3. Injection pump
4. Oil level gauge and stay
5. Oil pipe
6. Fuel feed pipe
7. Oil pressure switch
8. Water pipe
9. Water pump
Disassembly Note
Injection pump
Remove the injection pump with its brackets.
If separate them, adjust the injection timing after in-
stalling the timing belt referring to Section 4D.
76G01C-083
1C-39

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