1987 MAZDA 626 alternator

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
49 0107 680A Irf^Ys'^
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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

ASSEMBLY (AUXILIARY PARTS) 1 B
Alternator
1. Install the alternator strap and bracket.
Tightening torque:
37—63 Nm (3.8—6.4 m-kg, 27—46 ft-lb)
86U01X-171
Install the alternator.
Tightening torque
(g): 31—46 N-m
(3.2—4.7 m-kg, 23—34 ft-lb)
(§): 37—52 N-m
(3.8—5.3 m-kg, 27—38 ft-lb)
Install the alternator drive belt, and adjust the belt
deflection. (Refer to page 1B—6.)
76G01B-102
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
1B—71

INSTALLATION 1B
Connector Location
Install each harness as shown in the figure.
76G01B-112
1. IG coil 10. Linear solenoid
2. Heat gauge unit 11. Solenoid valve (idle speed control)
3. Speed sensor 12. Throttle position sensor
4. P/S switch 13. Injection harness
5. Engine ground 14. Transmission harness
6. Water temperature sensor 15. Alternator
7. Water thermo switch 16. Oil pressure switch
8. Crank angle sensor 17. Starter
9. Oxygen sensor
1B-79

1 C TROUBLESHOOTING GUIDE
Problem Possible Cause Remedy Page
Insufficient power Insufficient compression Improper valve clearance Compression leakage from valve seat Seized valve stem Weak or broken valve spring Failed cylinder head gasket Cracked or distorted cylinder head Sticking, damaged, or worn piston ring Cracked or worn piston
Adjust
Repair
Replace Replace Replace Replace Replace Replace
1C-85 1C-50 1C-48 1C-52 1C—16 1C-47 1C-57 1C-56
Malfunction of fuel system Refer to Section 4D
Malfunction of Comprex supercharger Refer to Section 4D
Others Slipping clutch Dragging brakes Wrong size tires
Refer to Section 6 Refer to Section 11 Refer to Section 12
Abnormal
combustion
Malfunction of engine-related components
Improper valve clearance
Sticking or burned valve
Weak or broken valve spring
Carbon accumulation in combustion chamber
Adjust
Replace
Replace Eliminate carbon
1C-85
1C-48
1C-52
Malfunction of fuel system Refer to Section 4D
Malfunction of Comprex supercharger Refer to Section 4D
Engine noise Crankshaft or bearing related parts Excessive main bearing oil clearance Main bearing seized or heat-damaged Excessive crankshaft end play Excessive connecting rod bearing oil clearance Connecting rod bearing seized or heat-damaged
Replace or repair Replace
Replace or repair Replace or repair Replace
1C-64 1C-64 1C-65 1C-66 1C-66
Piston related parts Worn cylinder Worn piston or piston pin Seized piston Damaged piston ring Bent connecting rod
Replace or repair Replace
Replace Replace Replace
1C-55 1C-58 1C-56 1C-57 1C-59
Valves or timing related parts Excessive valve clearance Broken valve spring Excessive valve guide clearance Malfunction of timing belt tensioner
Adjust Replace Replace Replace
1C-85 1C-52 1C-48 1C-61
Malfunction of cooling system Refer to Section 3B
Malfunction of fuel system Refer to Section 4D
Malfunction of Comprex supercharger Refer to Section 4D
Others Malfunction of water pump bearing Improper drive-belt tension Malfunction of alternator bearing Exhaust gas leakage
Replace Adjust Replace Repair
1C-7
1C—47
76G01C-004
1C—4

TUNE-UP PROCEDURE 1C
P/S oil pump Checking point
B
Vacuum/^ i V pumpf o ) y ®
v Rear \ camshaft
J
pulley
A-—mP
P/S oil pump \ L^
76G01C-009
Drive Belt
1. Check the drive belt for wear, cracks, or fraying.
Replace if necessary.
2. Check the drive belt deflection by applying moder-
ate pressure (98 N, 10 kg, 22 lb) midway between
the pulleys.
Alternator
Deflection mm (in)
New 8.0-10.0 (0.31-0.39)
Used 9.0—11.0 (0.35—0.43)
If necessary, loosen the idler lock nut and adjust
the belt deflection by turning the adjust bolt.
Tightening torque:
37—52 N-m (3.8—5.3 m-kg, 27—38 ft-lb)
Vacuum pump and P/S oil pump
Deflection mm (in)
Vacuum
pump
New 7.5-8.5 (0.30-0.33) Vacuum
pump Used 8.5-9.5 (0 33-0.37)
P/S oil pump
New 6.5-7.5 (0.26-0 30) P/S oil pump Used 7.0-8.0 (0.28—0.31)
If necessary, adjust the belt deflection as follows.
(1) Loosen the vacuum pump bolts ©and (§).
(2) Lever the vacuum pump outward and apply
tension to the belt.
(3)Tighten the adjust bolt
Tightening torque:
19—26
N
m (1.9—2.6 m-kg, 14—19 ft-lb)
(4)Tighten the mounting bolt
Tightening torque:
37—52
N
m (3.8—5.3 m-kg, 27—38 ft-lb)
A/C compressor
Deflection mm (in)
New 8.5—9.5 (0.33—0.37)
Used 9.5-10.5 (0.37-0.41)
If necessary, loosen the idler lock nut and adjust
the belt deflection by turning the adjust bolt.
Tightening torque:
37—52 Nm (3.8—5.3 m-kg, 27—38 ft-lb)
1C-7

ON-VEHICLE MAINTENANCE (TIMING BELT) 1 C
ON-VEHICLE MAINTENANCE
TIMING BELT
Removal
1. Disconnect the nagative battery cable.
2. Remove in the sequence shown in the figure referring to the removal note for specially marked parts.
76G01C-019
1. Engine side cover
2. A/C and alternator drive belt
3. Crankshaft pulley
4. Left and right timing belt cover
5. Alternator idle pulley
6. Idler pulley
7. No.3 engine mount
8. Timing belt
9. Timing belt tensioner and spring
Note
Loosen the No.3 engine mount nuts and lower the engine to remove the crankshaft pulley.
1C-11

DISASSEMBLY (AUXILIARY PARTS) 1 C
1. A/C compressor bracket 9. Alternator and drive belt
2. Vacuum pump and drive belt 10. Oil filter
3. Air funnel assembly 11. Oil filter cover
4. Comprex supercharger insulator 12. Oil cooler assembly
5. Comprex supercharger and drive belt 13. Exhaust pipe bracket
6. Exhaust manifold insulator 14. Alternator bracket
7. Exhaust manifold 15. Blow-by chamber
8. Intake manifold
Blow-by chamber
76G01C-074
Disassembly Note
Engine hanger
1. Remove the CSD hose.
2. Loosen the vacuum pump oil pipe bolts.
76G01C-075
3. Install the engine on the SST.
76G01C-076
1C—35

AUXILIARY PARTS
Torque Specifications
ASSEMBLY (AUXILIARY PARTS) 1 C
RF-N
19—26 N m (1.9—2.6 m-kg, 14—19 ft-lb)

22—26 N
(2.2-2.7 16—20 ft-lb)
8—11 N m (80—110 cm-kg, '-g 69—95 in-lb)
0—110 cm-kg, 169—95 in-lb)
. 22—26 N m (2.2—2.7 m-kg, 16—20 ft-lb)
37—52 N m (3.8—5.3 m-kg, 27—38 ft-lb) I
8—11 N-m (80—110 cm-kg, 69—95 In-lb)
37—52 N-m (3,8—5.3 m-kg, 27-38 ft-lb)
86U01X-164
Alternator Bracket and Exhaust Pipe Bracket
Install the alternator bracket and exhaust pipe stay.
Tightening torque:
37—52
N
m (3.8—5.3 m-kg, 27—38 ft-lb)
p o
a^z iw rr

76G01C-212

1C—87