1987 MAZDA 626 battery

1 B ON-VEHICLE MAINTENANCE (CYLINDER HEAD)
CYLINDER HEAD
Removal
Warning: Release the fuel pressure. (Refer to Section 4C.)
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.
1B—16

76G01B-034

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

1B INSTALLATION
76G01B-113
76G01B-114
76G01B-115
Radiator
1. Install the radiator and cooling fan.
Tightening torque:
8—11 N-m (80—110 cm-kg, 69—95 in-lb)
2. Connect the radiator harness.
3. Connect the upper and lower radiator hoses.
Note
a) Position the hose clamp in the original lo-
cation on the hose.
b) Squeeze the clamp lightly with large pliers
to ensure a good fit.
Heater Hose and Fuel Hose
Connect the heater hoses and the fuel hoses.
High-Tension Lead
Connect the high-tension lead to the ignition coil.
Accelerator Cable
Install the accelerator cable.
76G01A-148
Battery and Battery Carrier
1. Install the battery carrier.
Tightening torque:
9—13 N-m (90—130 cm-kg, 78—113 in-lb)
2. Install the fuse box.
Tightening torque:
8—11
N
m (80—110 cm-kg, 69—95 in-lb)
3. Install the battery tray and battery.
Tightening torque:
5_7
N m
(50—70 cm-kg, 43—61 in-lb)
1B—80

TUNE-UP PROCEDURE 1C
4BG01 B-006
4BG01B-007
76G01C-237
TUNE-UP PROCEDURE
Turn 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 the electrolyte level.
If the level is too low, add distilled water to the "UP-
PER LEVEL" mark.
3. Check the specific gravity by using a hydrometer.
If the specific gravity reading is 1.200 or less,
recharge the battery, by referring to Section 5.
Air Cleaner Element
Visually check the air cleaner element for being ex-
cessively dirty, damaged or oil.
Clean or replace it if necessary.
Caution
(Wet type)
Do not clean the air cleaner element with com-
pressed air, replace if necessary.
(Dry type)
When cleaning the air cleaner element, blow
dust off from the inside first, then blow off the
outside.
Engine Oil
Check the engine oil level and condition with the oil
level gauge.
Add oil, or change it, if necessary.
4BG01B-009
1C—5

1C TUNE-UP PROCEDURE
Comprex supercharger
Deflection mm (in)
New 4 0-6.0 (0.16—0.23)
Used 8.0-10 0 (0 31-0.39)
If necessary, loosen the idler lock nut and adjust
the belt deflection by turning the adjust bolt.
Tightening torque:
16—23 Nm (1.6—2.3 m-kg, 12—17 ft-lb)
76G01C-011
o
INJECTION TIMING
1. Disconnect the negative battery cable.
2. Release the CSD using the screw driver.
3. Remove the cover on the clutch housing.
4. Turn the flywheel and set the indicator at ATDC.
5. Disconnect the injection pipes from the injection
pump.
76G04D-008
6. Remove the hydraulic head plug from the injec-
tion pump.
7. Mount the SST into the plug hole on the hydraulic
head so the tip of the dial gauge pointer touches
the plunger end of the pump and the dial gauge
indicates approx. 2.0 mm (0.08 in).
76G04D-009
8. Turn the crankshaft slowly counterclockwise to
30-50° BTDC.
9. Make sure the dial indicator pointer no longer
moves by slightly turning the crankshaft.
10. Set the dial gauge scale to Zero at the pointer.
76G04D-010
1C-8

1C ON-VEHICLE INSPECTION
ON-VEHICLE INSPECTION
If the engine exhibits low power, poor fuel economy,
or poor idle, check the following:
1. Compression
2. Fuel system (Refer to Section 4D)
COMPRESSION
1. Check that the battery is fully charged, Recharge
it if necessary.
76G01C-016
76G01C-017
2. Warm up the engine to the normal operating tem-
perature.
3. Turn it off for about 10 minutes to allow the exhaust
manifold to cool.
4. Remove all the fuel injection pipes, nozzles, wash-
ers, and corrugate washers.
5. Disconnect the fuel cut valve connector.
Caution
If this is not done, fuel will be injected from
the injection pump while cranking.
6. Connect a suitable cap to the fuel return pipe on
the injection pump.
7. Connect a compression gauge with SST to injec-
tion nozzle hole.
8. Fully depress the accelerator pedal and crank the
engine.
9. Note the maximum gauge reading.
10. Check each cylinder.
Compression pressure kPa (kg/cm2, psi)-rpm
Standard Minimum
2.943 (30, 427)—200 2.649 (27, 384)—200
76G01C-018
Possible Cause
86U01X-022
1C-10

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