timing belt MAZDA 626 1987 Manual PDF

1C INSPECTION AND REPAIR
Rolled fillet
Crankpin journal diameter undersize mm (in)
Bearing size Journal diameter
0.25 undersize 50.690—50.705 (1.9957-1.9963)
0.50 undersize 50.440—50.455 (1.9858-1.9864)
0.75 undersize 50.190-50.205 (1.9760-1.9766)
Caution
Do not grind the rolled fillet area.
76G01C-145
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-113
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
1C—60

INSPECTION AND REPAIR 1C
86U01X-115
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.
Timing Belt Tensioner Spring
Check the free length of the tensioner spring. Replace
if necessary.
Free length:
52.6 mm (2.071 in)
76G01C-251
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
Inspect the timing belt covers for damage or cracks.
Replace if necessary.
76G01C-146
1C—61

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

1 C ASSEMBLY (CYLINDER HEAD)
6. Apply a coat of engine oil to the new oil seal lip
and insert it.
76G01C-253
76G01C-173
Glow cord
Glow plug
76G01C-174
7. Tighten the camshaft cap nuts evenly in order
shown in the figure.
Tighten torque:
20—26
N m
(2.0—2.7 m-kg, 14—20 ft-lb)
Note
The adjustment of the valve clearance should
be made only after the camshaft pulley injec-
tion pump pulley and timing belt have been
installed.
Glow Plug and Glow Cord
1. Install the glow plugs.
Tightening torque:
15—20 Nm (1.5—2.0 m-kg, 11—15 ft-lb)
2. Install the glow cord.
Tightening torque:
0.8—1.5 Nm (8.0—15 cm-kg, 7—13 in-lb)
Injection Nozzle and Leak Pipe
1. Install the new corrugated washers and the new
copper gaskets in position.
2. Install the injection nozzles.
Tightening torque:
59—69 Nm (6.0—7.0 m-kg, 43—51 ft-lb)
Note
The corrugated washers and copper gaskets
must be replaced with new ones each time the
injection nozzles are removed.
3. Install the leak pipe.
Tightening torque:
31—44
N m
(3.2—4.5 m-kg, 23—33 ft-lb)
76G01C-175
1C—76

1 C ASSEMBLY (INJECTION PUMP)
Injection Pump
1. Install the injection pump with the injection pump
brakcet.
Tightening torque:
37—52
N m
(3.8—5.3 m-kg, 27—38 ft-lb)
Note
If the injection pump bracket and the injection
pump are separated, injection timing adjust-
ment is necessary after installing the timing
belt.
2. Connect the CSD water hose and fuel hoses.
Injection Pipe
1. Check that no dirt or other foreign material is on
the pipe coupling.
2. Install the fuel injection pipes.
Tightening torque:
25—29 Nm (2.5—3.0 m-kg, 18—22 ft-lb)
76G01C-186
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No.3 Engine Mount and Idler
Install the No.3 engine mount and idler.
Tightening torque:
37—52
N
m (3.8—5.3 m-kg, 27—38 ft-lb)
76G01C-187
1C—80

ASSEMBLY (TIMING BELT) 1 C
TIMING BELT
Torque Specifications
69G01B-160
Seal Plate
1. Install the seal plate.
Tightening torque:
8—12 N
m
(0.8—1.2 m-kg, 69—104 in-lb)
2. Check that the seal plate sealing rubbers are in-
stalled in position.

76G01C-200

1C—81

1C ASSEMBLY (TIMING BELT)
Rear Camshaft Pulley
1. Install the rear camshaft pulley.
2. Hold the camshaft with a wrench (29 mm, 1.14 in)
and tighten to the specification.
Tightening torque:
55—65 Nm (5.6—6.6 m-kg, 41—48 ft-lb)
76G01C-189
Camshaft Pulley
1. Connect the camshaft pulley onto the camshaft with
the semicircular (woodruff) key.
4BG01B-200
2. Hold the camshaft with a wrench (29 mm, 1.14 in),
tighten the camshaft pulley lock bolt.
Tightening torque:
55—65 Nm (5.6—6.6 m-kg, 41—48 ft-lb)
3. Align the mark on the camshaft pulley with the mark
on the seal plate.
76G01C-190
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 N-m (6.0—7.0 m-kg, 43—51 ft-lb)
1C-82

ASSEMBLY (TIMING BELT) 1 C
63G01D-431
76G01C-191
76G01C-192
Timing Belt Tensioner
1. Install the tensioner spring onto the tensioner.
2. Install the tensioner assembly.
3. Temporarily secure it so the tensioner is shifted
outward.
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 in the sequence shown in the
figure.
Caution
The timing belt must be reinstalled in the same
direction of rotation for continued durability.

76G01C-200

1C—83

1C ASSEMBLY (TIMING BELT)
jf^iLJF'
76G01C-194
Timing marks
Timing marks
76G01C-195
76G01C-196
4. Install the idler pulley.
Tightening torque:
37—52 N
m
(3.8—5.3 m-kg, 27—38 ft-lb)
5. Remove the two affixing bolts from the injection
pump pulley.
6. Loosen the tensioner lock bolt.
7. Turn the crankshaft twice in the direction of rota-
tion (clockwise).
Caution
Do not rotate in reverse direction.
8. Check that each timing mark is correctly aligned.
If not aligned, remove the timing belt. Repeat step
2-9.
9. Tighten the timing belt tensioner lock bolt.
Tightening torque:
37—52
N m
(3.8—5.3 m-kg, 27—38 ft-lb)
10. Check the timing belt tension.
If the tension is not correct, loosen the tensioner
lock bolt and repeat step 6—9, or replace the ten-
sioner spring.
Standard deflection:
9.0—11.5 mm (0.35—0.45 in)
/98 N (10 kg, 22 lb)
Caution
Be sure not to apply tension other than that
of the tensioner spring.
76G01C-197
1C-84

ASSEMBLY (TIMING BELT) 1 C
76G01C-198
4BG01B-210
76G01C-199
Timing Belt Cover
Install the left and right timing belt covers.
Tightening torque:
7—10 Nm (70—100 cm-kg, 61—87 in-lb)
Crankshaft Pulley
Install the crankshaft pulley.
Tightening torque:
23—32 Nm (2.3—3.3 m-kg, 17—24 ft-lb)
Valve Clearance
1. Set the No.1 cylinder to compression TDC.
2. Measure the valve clearance at No.1, No.2 (intake),
and No.1, No.3 (exhaust).
Clearance (cold engine)
IN : 0.20—0.30 mm (0.008—0.012 in)
EX: 0.30—0.40 mm (0.012—0.016 in)
3. If the valve clearance is not within the specifica-
tion, adjust the valve clearance.
(1) Face the intake cam lobe straight upward.
(2) Move the tappet so that its notch is at the man-
ifold side.
(3) Press the tappet down until the adjusting disc
is accessible with the SST.
(4) Take out the adjusting disc.
76G01C-200
1C—85