1987 MAZDA 626 Workshop Manual

ON-VEHICLE MAINTENANCE (TIMING BELT) 1 C
Installation
Install in the reverse order of removal referring to the installation note.
Torque Specifications
85—117 N-m (8.7—11.9 m-kg, 63—86 ft-lb)
67—93 N-m (6.8—9.5 m-kg, 49—69 ft-lb)
37—52 N-m (3.8—5.3 m-kg, 27—38 ft-lb)
7—10 Nm (70—100 cm-kg, 61—87 In-lb)
11 N-m (80—110 m-kg, 69—95 ft-lb)
76G01C-239
Installation note
Timing belt
1. Check that the timing marks of camshaft pulley,
timing belt pulley and injection pump pulley align
with the timing marks.

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1C-13

ON-VEHICLE MAINTENANCE (TIMING BELT) 1 C
2. Install the timing belt tensioner and spring.
3. Temporarily secure the tensioner with it shifted
outwards.
63G01D-330
4. Install the timing belt.
Caution
a) The timing belt must be reinstalled in the
same direction of previous rotation, if it is
to be reused.
b) Be sure that there is no oil, grease, or dirt
on the timing belt.
76G01C-024
Install the idler pulley.
Tightening torque:
37—52
N
m (3.8—5.3 m-kg, 27-38 ft-lb)
Remove the affixing bolts from the injection pulley.
76G01C-025
7. Loosen the tensioner lock bolt.
8. Turn the crankshaft twice in the direction of rota-
tion (clockwise).
Caution
Do not rotate reverse direction.
9. Check that each timing mark is correcty aligned.
If not aligned, remove the timing belt. Repeat step
1-8.

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1C-14

ON-VEHICLE MAINTENANCE (TIMING BELT) 1 C
76G01C-027
76G01C-028
76G01C-029
Checking
point
Idler pulley
Crankshaft pulley zQi A/C
Checking point compressor
76G01C-030
10. Tighten the timing belt tensioner lock bolt.
Tightening torque:
37—52
N
m (3.8—5.3 m-kg, 27—38 ft-lb)
11. Check the timing belt tension.
If the tension is not correct, loosen the tensioner
lock bolt and repeat step 7—10, or replace the ten-
sioner spring.
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.
No.3 engine mount
Install the No.3 engine mount.
Tightening torque:
Nut A: 85—117 N-m
(8.7—11.9 m-kg, 63—86 ft-lb)
Nut B: 67—93 N-m
(6.8—9.5 m-kg, 49—69 ft-lb)
Drive belt
Install each drive belt, and check the belt deflection.
(Refer to page 1C—7.)
Steps after installation
Perform the necessary engine adjustment. (Refer to
TUNE-UP PROCEDURE,)
1C-15

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

ON-VEHICLE MAINTENANCE (CYLINDER HEAD) 1 C
Removal note
Fuel hose
Warning
a) Cover the hose with a rag because fuel will
spray out when disconnecting.
b) Keep fire and open flame away from the fuel
area.
Plug the disconnected hoses to avoid fuel leakage.
76G01C-033
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.

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1C—17

1 C ON-VEHICLE MAINTENANCE (CYLINDER HEAD)
76G01C-241
76G01C-035
69G01A-031
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.
Cylinder head bolt
Loosen the cylinder head bolts in two or three steps,
and in the order shown in the figure.
Disassembly of Cylinder Head
Refer to page 1C—40.
Inspection of Cylinder Head
Refer to page 1C—47.
Assembly of Cylinder Head
Refer to page 1C—73.

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1C-18

ON-VEHICLE MAINTENANCE (CYLINDER HEAD) 1 C
Installation
Install in the reverse order of removal referring to the installation note.
Note a) Position the hose clamp in the original location on the hose.
b) Squeeze the clamp lightly with large pliers to ensure a good fit.
Torque Specifications
59—69 N m (6.0—7.0 m-kg, 43—51 ft-lb)
55—65 N-m (5.6—6.6 m-kg, 41—48 ft-lb)
7-10 N-m (70—100 cm-kg, 61-87 in-lb)
8—11 N-m (80—110 cm-kg, 69—95 in-lb)
8—11 N-m (80—110 cm-kg. 69—95 In-lb)
55—65 N-m i—6.6 m-kg, 48 ft-lb)
—11 N-m (80—110 cm-kg, 69—95 in-lb)
7—10 N-m (70—100 cm-kg, 61—87 in-lb)
8—11 N-m (80—110 cm-kg, 69—95 in-lb)
34—49 N-m (3.5—!
\, - 16—27 N-m (1.6—2.8 m-kg, N > 12—20 ft-lb)
19—26 N-m (1.9—2.6 m-kg, 14—19 ft-lb)
76G01C-242
1C—19

ON-VEHICLE MAINTENANCE (CYLINDER HEAD) 1 C
76G01C-037
Apply engine oil
/
Cylinder head bolt
below head length
76G01C-038
(8) (4; D (5)
® ®
76G01C-039
3m-kg
(21.7ft-lb
Installation
Cylinder head
1. Throughly remove all dirt and grease from the top
of the cylinder block with a rag.
2. Place the new cylinder head gasket in position.
3. Remove any dirt and grease from the bottom sur-
face of the cylinder head.
4. Place the cylinder head in position.
5. Measure the length of the cylinder head bolt be-
low the head. If the length exceeds the maximum,
replace the bolt.
Length: 113.2—113.8 mm (4.457—4.480 in)
Maximum: 114.5 mm (4.508 in)
6. Apply engine oil to the threads and the seat face
of the cylinder head bolts.
7. Tighten the cylinder head bolts.
(1) Tighten the bolts to the specified torque, in the
order shown in the figure.
Tightening torque:
29 N-m (3.0 m-kg, 22 ft-lb)
(2) Make paint marks on the bolt heads, as shown
in the figure.
(3) With the paint marks as a reference point, turn
the cylinder head bolts another 90°
(90°—105°) in the tightening direction. Tight-
en them in the order.
(4) Then tighten them once again 90°
(90°—105°) in the tightening order.
Caution
Be absolutely sure that the bolts are tightened
in the proper order.

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1C—20