1987 MAZDA 626 water

INSPECTION AND REPAIR 1 A
INSPECTION AND REPAIR
1. Clean all parts, taking care to remove any gasket fragments, dirt, oil or grease, carbon, moisture
residue, or other foreign materials.
2. Inspect and repair must be performed in the order specified.
Caution
Be careful not to damage the joints or friction surfaces of aluminum alloy components (such
as the cylinder head or pistons).
86U01X-077
Cylinder Head
1. Inspect the cylinder head for damage, cracks, and
leakage of water or oil. Replace if necessary.
2. Measure the cylinder head distortion in the six
directions shown in the figure.
Distortion: 0.15 mm (0.006 in) max.
79G01C-106
If the cylinder head distortion exceeds specifica-
tion, grind the cylinder head surface.
If the cylinder head height is not within specifica-
tion, replace it.
Height:
91.95—92.05 mm (3.620—3.624 in)
Grinding limit: 0.20 mm (0.008 in) max.
Note
Before grinding the cylinder head, first check
the following. Replace if necessary.
• Sinking of valve seat
• Damage of manifold contact surface
• Camshaft oil clearance and end play
Measure the manifold contact surface distortion in
the six directions shown in the figure.
Distortion: 0.15 mm (0.006 in) max.
If distortion exceeds specification grind the surface
or replace the cylinder head.
79G01C-053
1A—48

INSPECTION AND REPAIR 1 A
86U01X-082
Valve guide
Cylinder head
76G01A-057
(2) Method No. 2
Measure the valve stem play at a point close
to the valve guide with the valve lifted slightly
off the valve seat.
Clearance
IN : 0.025—0.060 mm (0.0010—0.0024 in)
EX: 0.030—0.065 mm (0.0012—0.0026 in)
Maximum: 0.20 mm (0.0079 in)
7. If the clearance exceeds the maximum, replace the
valve and/or valve guide.
8. Check that the valve guide projection height
(dimension A in the figure). Replace if necessary.
Height:
19.8—20.3 mm (0.780—0.799 in)... 12-valve
19.1—19.6 mm (0.752—0.772 in)...8-valve
Replacement of valve guide
Note
Although the shapes of the intake and exhaust
valve guides are different, use the exhaust
valve guide on both sides as a replacement.
86U01X-214
Removal
1. Gradually heat the cylinder head in water to ap-
prox. 90°C (194°F).

76G01A-131

1A—50

INSPECTION AND REPAIR 1 A
12-valve:
8-valve:
49 0249 01 OA
49 0221 251A
76G01A-058
76G01A-059
V
86U01X-087
2. Remove the valve guide from the side opposite the
combustion chamber with the SST.
3. Remove the valve guide clip (8-valve).
Installation
1. Fit the clip onto the valve guide (8 valve).
2. Gradually heat the cylinder head in water to ap-
prox. 90°C (194°F).
3. Tap the valve guide in from the side opposite the
combustion chamber with the SST until the projec-
tion height is as specified.
Valve Seat
1. Inspect the contact surface of the valve seat and
valve face for the following.
(1) Roughness
(2) Damage
2. If necessary, resurface the valve seat with a 45°
valve seat cutter and/or resurface the valve face.
3. Apply a thin coat of prussian blue to the valve face.
4. Check the valve seating by rotating the valve
against the seat.
(1) If blue does not appear 360° around the valve
face, replace the valve.
(2) If blue does not appear 360° around the valve
seat, resurface the seat.

79G01C-053

1A—51

1 A
DISASSEMBLY
(CYLINDER BLOCK)
86U01X-141
86U01X-142
Clutch Disc and Clutch Cover (MTX)
Install the clutch disc and clutch cover using the SST.
(Refer to Section 6.)
Tightening torque:
22—32 N-m (2.2—3.3 m-kg, 16—24 ft-lb)
Water Pump
1. Remove all dirt, grease, and other material from
the water pump mounting surface.
2. Place a new O-ring in position.
Caution
Do not reuse the original O-ring.
3. Install the water pump.
Tightening torque:
19—25 N-m (1.9—2.6 m-kg, 14—19 ft-lb)
7BU01B-103
1A—72

INSTALLATION 1A
Connector Location
Install each harness as shown in the figure.
1. IG coil
2. Engine ground
3. Water temperature sensor
4. P/S switch
5. Oxygen sensor (Fl)
6. Water thermo switch
7. Injection harness (Fl)
8. F/l solenoid (Fl)
76G01A-146
9. Throttle position sensor (Fl)
10. Alternator
11. Oil pressure switch
12. Starter
13. P.T.C. heater (carb.)
14. Solenoid valve (Slow cot) (carb.)
15. Solenoid valve (carb.)
16. Transmission harness
1A—97

TROUBLESHOOTING GUIDE 1 B
Problem Possible Cause Remedy Page
Insufficient power Insufficient compression Malfunction of HLA 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
Replace Repair
Replace
Replace Replace Replace Replace Replace
1B—60 1B—37 1B—35 1B—38 1B-16 1B—34 1B—43 1B—43
Malfunction of fuel system Refer to Section 4C
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 Malfunction of HLA Sticking or burned valve
Weak or broken valve spring Carbon accumulation in combustion chamber
Replace Replace Replace
Eliminate carbon
1B-60
1B-35
1B—38
Malfunction of fuel system Refer to Section 4C
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
1B-51 1B—51 1B—52 1B—53 1B—53
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
1B—41 1B-44 1B—43 1B—43 1B-44
Valves or timing related parts Malfunction of HLA* Broken valve spring Excessive valve guide clearance Malfunction of timing belt tensioner
Replace Replace Replace Replace
1B-60 1B—38 1B—35 1B—47
Malfunction of cooling system Refer to Section 3A
Malfunction of fuel system Refer to Section 4C
Others Malfunction of water pump bearing Improper drive belt tension Malfunction of alternator bearing Exhaust gas leakage
Replace Adjust Replace Repair
1B— 6
1B—34
* Tappet noise may occur if the engine is not operated for an extended period of time. The noise should stop after the engine has reached normal operating temperature. 76G01B-004
1B—4

TUNE-UP PROCEDURE 1 B
76G01A-102
TUNE-UP PROCEDURE
Tune the engine according to the procedures
described below.
Battery
1. Check for corrosion on the terminals, or loose ca-
ble connections.
If necessary, clean the clamps and tighten firmly.
2. Check that the electrolyte level is between the UP-
PER and LOWER marks.
Add distilled water if necessary.
3. Check the specific gravity by using a hydrometer.
If the specific gravity reading is 1.200 or less,
recharge the battery. (Refer to Section 5.)
76G01A-103
Air Cleaner Element
Visually check the air cleaner element for excessive
dirt, damage, or oil. Clean or replace if necessary.
Caution
When cleaning the air cleaner element, blow
dust off from the inside completely first, then
blow from the outside.
76G01B-005
Engine Oil
Check the engine oil level and condition with the oil
level gauge.
Add oil, or change it, if necessary.
4BG01A-010
1B—5

ON-VEHICLE MAINTENANCE (TIMING BELT) 1 B
76G01B-021
Removal note
Timing belt tensioner
1. Turn the crankshaft to align the mating marks of
the camshaft pulleys.
Note
For intake side camshaft pulley, align "I"
mark.
For exhaust side camshaft pulley, align "E"
mark.
2. Remove the tensioner.
Timing belt
Mark the timing belt rotation for proper reinstallation
if it is reused.
Caution
Be careful not to allow oil, grease, or water
on the belt.
86U01X-024
Inspection
Inspect the following parts. (Refer to page 1B—46,
47.)
1. Timing belt
2. Timing belt tensioner and spring
3. Timing belt idler pulley
4. Timing belt pulley
5. Camshaft pulley
76G01B-022
1B—12