engine MAZDA 626 1987 Manual Online

1 B ON-VEHICLE MAINTENANCE (CYLINDER HEAD)
Installation note
Cylinder head
1. Thoroughly remove all dirt and oil from the top of
the cylinder block with a rag.
2. Place a new cylinder head gasket in position.
86U01X-035
® © © (D ® 3. Set the cylinder head in place.
4. Apply engine oil to the bolt threads and seat faces.
5. Tighten the cylinder head bolts in two or three steps
in the order shown in the figure.
Tightening torque:
80—86
N
m (8.2—8.8 m-kg, 59—64 ft-lb)
86U01X-036
Cylinder head cover
1. Apply silicon sealant to the shaded area as shown
in the figure.
2. Install the cylinder head cover and gasket.
Tightening torque:
4—6 N-m (40—60 cm-kg, 35—52 in-lb)
76G01B-033
Timing belt
1. Align the mating marks of the camshaft pulleys with
the seal plate timing mark.
Note
For intake side camshaft pulley, align "I"
mark.
For exhaust side camshaft pulley, align "E"
mark.
2. Install the timing belt. (Refer to TIMING BELT of
ON-VEHICLE MAINTENANCE.)
76G01B-034
1B—20

ON-VEHICLE MAINTENANCE (CYLINDER HEAD) 1 B
Distributor
1. Apply engine oil to the O-ring, and position it on
the distributor.
2. Apply engine oil to the blade.
3. Install the distributor.
4. Loosely tighten the distributor mounting bolt.
76G01A-035
Engine harness connector
Install the engine harness connectors.
1. IG coil
2. Heat gauge unit
3. Speed sensor
4. P/S switch
5. Engine ground
6. Water tempera-
ture sensor
7. Water thermo
switch
8. Crank angle
sensor
9. Oxygen sensor
10. Linear solenoid
11. Solenoid valve
(idle speed
control)
12. Throttle position
sensor
13. Injection harness
76G01B-035
Steps After Installation
1. Fill the radiator with the specified amount and type
of coolant.
2. Perform the necessary engine adjustments. (Re-
fer to TUNE-UP PROCEDURE.)
86U01X-041
1B-21

1B REMOVAL
REMOVAL
Warning: Release the fuel pressure. (Refer to Section 4C.)
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.
76G01B-036
1B—22

REMOVAL 1B
1. Battery and battery carrier
2. Air cleaner assembly
3. High-tension lead
4. Accelerator cable
5. Fuel hose
6. Radiator hose
7. Radiator harness
8. Radiator and electric fan
9. EGI harness
10. Engine harness
11. Brake vacuum hose
12. Canister hose (Unleaded
fuel)
13. Heater hose
14. Transaxle harness
15. Speedometer cable
16. Clutch release cylinder
17. Drive belt
18. A/C compressor and
bracket
19. P/S oil pump
20. Engine side cover
21. Front wheel
22. Tie-rod end
23. Stabilizer control rod
24. Lower arm bushing
25. Driveshaft
26. Change rod
27. Extension bar
28. Exhaust pipe
29. Engine mount
30. Engine and transaxle
31. Transaxle
76G01B-037
Removal Note
Fuel hose
Warning
a) Cover the hose with a rag because fuel will
spray out when disconnecting.
b) Keep sparks and open flame away from the
fuel area.
Plug the disconnected hoses to avoid fuel leakage.
76G01A-11£
P/S pump, A/C compressor
Remove the P/S pump and A/C compressor with the
hoses still connected to them, secure the pump and
compressor as shown in the figure.
67U01X-029
Driveshaft
Remove the driveshafts. (Refer to Section 9.) Slide
the SST into the transaxle.
86U01X-060
1B—23

DISASSEMBLY (AUXILIARY PARTS) 1 B
1. Oil level gauge
2. P/S oil pump bracket
3. EGR pipe(Unleaded fuel)
4. Exhaust manifold insulator
5. Exhaust manifold assembly
6. Coolant inlet pipe and bypass pipe
7. Engine hanger
8. Alternator
9. Alternator strap and bracket
10. Engine mount bracket
11. Center cover
12. Distributor and high-tension lead
13. Spark plug
14. Thermostat and thermostat cover
15. Intake manifold bracket
16. Intake manifold assembly
17. Oil filter
18. Oil cooler
19. Oil pressure switch
76G01B-039
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49 G030 D05A
76G01A-120
Disassembly Note
Engine hanger
Remove the exhaust manifold; then connect the SST
to the engine.
69G01X-000
1B—25

1 B ASSEMBLY (CYLINDER BLOCK)
ASSEMBLY
1. Clean all parts before reinstallation.
2. Apply new engine oil to all sliding and rotating parts.
3. Replace plain bearings if they are peeling, burned, or otherwise damaged.
4. Tighten all bolts and nuts to the specified torques.
Caution
Do not reuse gaskets or oil seals.
CYLINDER BLOCK—I
Torque Specifications
69G01A-139
1B—48

ASSEMBLY (CYLINDER BLOCK) 1 B
76G01B-070
76G01B-071
Connecting Rod
1. Align the identification mark to the cap of large end
of connecting rod and F mark on the piston as
shown in the figure.
2. Apply a coat of engine oil to the circumference of
each piston pin and to the small end of each con-
necting rod.
3. Set a clip into the clip groove in one side of the
piston.
4. Insert the piston pin into the piston and connect-
ing rod from the opposite side of the piston with
the SST .
5. Tap the piston pin in until it touchs the clip. Install
the other clip into the groove in the piston.
6. Check the oscillation torque of the connecting rod.
(Refer to page 1B—33.)
Piston Ring
1. Install the three-piece oil rings on the pistons.
(1) Apply engine oil to the oil ring spacer and rails.
(2) Install the oil ring spacer so that the opening
faces upward.
(3) Install the upper rail and lower rail.
Note
a) The upper rail and lower rail are the same.
b)Each rail can be installed with either face
upward.
69G01A-144
1B—49

1 B ASSEMBLY (CYLINDER BLOCK)
Spacer tang
Oil ring
spacer ends
Upper rail
Piston
Lower rail
69G01A-145
86U01X-121
Oil ring —
upper rail / N. ^ Top ring
Oil ring I ^_t30° L^Pistion
T Pin spacer I ^_t30° L^Pistion
T Pin
Oil ring
lower rail N. j/ Second ring
69G01A-147
2. Check that both rails are expanded by the spacer
tangs as shown in the figure by checking that both
rails turn smoothly in both directions.
3. Install the second ring to the piston first, then in-
stall the top ring. Use a piston ring expander.
Caution
The rings must be installed with the "R"
marks facing upward.
4. Apply a liberal amount of clean engine oil to the
second and top piston rings.
5. Position the opening of each ring as shown in the
figure.
Crankshaft
1. Before installing the crankshaft, inspect the main
bearing oil clearances as described.
Note
The bearing with thrust shoulders is the cen-
ter bearing in the cylinder block.

86U01X-136

1B—50

ASSEMBLY (CYLINDER BLOCK) 1 B
Oil clearance inspection
(1) Remove any foreign material and oil from the
journals and bearings.
(2) Install the upper main bearings in the cylinder
block.
(3) Set the crankshaft into the cylinder block.
(4) Position the plasti-gauge on top of the journals
in the axial direction.
86U01X-122
(5) Install the main bearing caps along with the
lower main bearings according to the cap num-
ber and mark.
(6) Tighten the caps in two or three steps in the
order in the figure.
Tightening torque:
82—88 Nm (8.4—9.0 m-kg, 61—65 ft-lb)
Caution
Do not rotate the crankshaft when measuring
the oil clearances.
86U01X-123
(7) Remove the main bearing caps, and measure
the plasti-gauge at each journal at the widest
point for the smallest clearance, and at the nar-
rowest point for the largest clearance.
If the oil clearance exceeds specification, grind
the crankshaft and use undersize main bear-
ings. (Refer to page 1B—45.)
Oil clearance
No. 1, 2, 4, 5:
0.025—0.043 mm (0.0010—0.0017 in)
No. 3:
0.031—0.049 mm (0.0012—0.0019 in)
Maximum: 0.08 mm (0.0031 in)
Apply a liberal amount of engine oil to the main
bearings and main journals.
Install the crankshaft and the main bearing caps
according to the cap number and ^ mark.
86U01X-125
1B—51

1 B ASSEMBLY (CYLINDER BLOCK)
76G01A-074
86U01X-216
76G01 B-075
4. Inspect the crankshaft end play.
End play:
0.08—0.18 mm (0.0031—0.0071 mm)
Maximum: 0.30 mm (0.012 in)
5. If the end play exceeds specification, grind the
crankshaft and use undersize center main bearing.
Center main bearing width
Standard:
27.94—27.99 mm (1.1000—1.1020 in)
0.25 mm (0.010 in) undersize:
28.04—28.09 mm (1.1040—1.1059 in)
0.50 mm (0.020 in) undersize:
28.12—28.17 mm (1.1071—1.1091 in)
0.75 mm (0.030 in) undersize:
28.20—28.25 mm (1.1102—1.1122 in)
Note
Wider thrust width is available only in under-
size center main bearing.
Pilot Bearing
1. Apply engine oil to the outer circumference of the
bearing.
2. Set a piece of pipe (outer diameter 30—34 mm,
1.18—1.34 in) against the outer race of the bear-
ing, then tap it evenly into the crankshaft.
3. Lubricate the bearing with grease.
Piston and Connecting Rod Assembly
1. Apply a liberal amount of clean engine oil to the
cylinder walls, piston, and rings.
2. Check the piston rings for the end gap alignment.
3. Insert each piston assembly into the cylinder block
with the F mark facing the front of the engine. Use
a piston installer tool (commercially available).
76G01A-136
1B—52