1987 MAZDA 626 brake

ASSEMBLY (TIMING BELT) 1 A
Camshaft Pulley
1. Install the camshaft pulley on the camshaft with the
dowel pin fit into the hole at the 2 mark (FE) or 3
mark (F8, F6).
76G01A-083
2. Tighten the camshaft pulley lock bolt.
Tightening torque:
47—65 N-m (4.8—6.6 m-kg, 35—48 ft-lb)
76G01A-141
3. Align the mating mark on the pulley with the align-
ment mark on the front housing.
Note
For FE engine, align "2" mark.
For F8, F6 engine, align "3" mark.
76G01A-084
Timing Belt Pulley
1. Reverse the direction of the SST (ring gear brake).
2. Install the crankshaft key.
3. Install the timing belt pulley on the crankshaft.
Tightening torque: 157—167 N-m
(16.0—17.0 m-kg, 116—123 ft-lb)
4. Release the ring gear brake.
5. Align the timing belt pulley and the pump body
alignment marks.
86U01X-160

1
A—83

1A INSTALLATION
Clutch Release Cylinder (MTX)
1. Set the pipe bracket in position.
Tightening torque:
8—11 Nm (80—110 cm-kg, 69—95 in-lb)
2. Install the clutch release cylinder.
Tightening torque:
19—25 Nm (1.9—2.6 m-kg, 14—19 ft-lb)
86U01X-192
Control Cable (ATX)
Install the control cable and adjust the shift selector
position. (Refer to Section 7.)
Tightening torque
@: 44—64
N
m
(4.5—6.5 m-kg, 33—47 ft-lb)
(§): 16—23
N
m
(1.6—2.3 m-kg, 12—17 ft-lb)
Speedometer Cable
Install the speedometer cable.
76G01A-097
Three-Way Solenoid Assembly
Install the three-way solenoid assembly.
Tightening torque:
8—11 N-m (80—110 cm-kg, 69—95 in-lb)
76G01A-098
Brake Vacuum Hose
Connect the brake vacuum hose.
Canister Hose
Connect the canister hoses.

86U01X-180

1A—96

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

1 B ON-VEHICLE MAINTENANCE (CYLINDER HEAD)
1. Center cover
2. High-tension lead and spark plug
3. Accelerator cable
4. Air intake pipe assembly
5. Fuel hose
6. Upper radiator hose
7. Heater hose
8. Brake vacuum hose
9. Canister hose (Unleaded fuel)
10. Engine harness connector and ground
11. EGR pipe (Unleaded fuel)
12. A/C compressor and bracket
13. Exhaust manifold insulator
14. Exhaust pipe
15. Exhaust manifold
16. Intake manifold bracket
17. Intake manifold assembly
18. Distributor
19. Engine mount stay
20. Upper timing belt cover
21. Timing belt tensioner spring
22. Timing belt
23. Cylinder head cover
24. Cylinder head and gasket
76G01B-030
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.
86U01X-032
Timing belt
1. Before removing the timing belt, turn the crankshaft
to 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.
76G01B-031
2. Loosen the timing belt tensioner lock bolt.
3. Shift the tensioner outward as far as possible, then
temporarily tighten it.

76G01B-034

1B—17

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

ASSEMBLY (TIMING BELT) 1 B
Camshaft Pulley
1. Install the camshaft pulley on the camshaft with the
dowel pin fit into the hole at the I mark (intake side)
and E mark (exhanst side).
76G01B-127
2. Tighten the camshaft pulley lock bolt.
Tightening torque:
47—65 Nm (4.8—6.6 m-kg, 35—48 ft-lb)
76G01A-141
3. Align the mating mark on the camshaft pulleys with
the alignment mark on the seal plate.
Note
For intake side camshaft pulley, align "I"
mark.
For exhanst side camshaft pulley, align "E"
mark.
76G01B-094
Timing Belt Pulley
1. Reverse the direction of the SST (ring gear brake).
2. Install the crankshaft key.
3. Install the timing belt pulley on the crankshaft.
Tightening torque: 157—167 N m
(16.0—17.0 m-kg, 116—123 ft-lb)
4. Release the ring gear brake.
5. Align the timing belt pulley and the pump body
alignment marks.
86U01X-160
1B—65

1 B INSTALLATION
Clutch Release Cylinder
1. Set the pipe bracket in position.
Tightening torque:
8—11 N-m (80—110 cm-kg, 69—95 in-lb)
2. Install the clutch release cylinder.
Tightening torque:
19—25 N-m (1.9—2.6 m-kg, 14—19 ft-lb)
76G01B-110
Speedometer Cable
Install the speedometer cable.
Brake Vacuum Hose
Connect the brake vacuum hose.
Canister Hose (Unleaded fuel)
Connect the canister hoses.
76G01B-111
1B-78

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