1987 MAZDA 626 clutch

ASSEMBLY (CYLINDER BLOCK) 1 B
Oil Pan
1. Apply a continuous bead of silicon sealant to the
oil pan around inside of the bolt holes and over-
lap the ends.
2. Install the oil pan.
Tightening torque:
7—12 Nm (70—120 cm-kg, 61—104 in-lb)
Caution
Oil pan projection and recession from the end
of the cylinder block must not be more than
1.5 mm (0.06 in).
76G01 B-080
Flywheel
1. Remove any old sealant from the bolts and bolt
holes. If old sealant can not be removed from the
bolt, replace it.
2. Apply sealant to the bolt threads.
76G01B-081
3. Install, and tighten the flywheel with the SST.
Tightening torque:
96—103
N
m (9.8—10.5 m-kg, 71—76 ft-lb)
76G01B-082
Clutch Disc and Clutch Cover
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)
76G01 B-083
1B—57

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

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

REMOVAL 1C
REMOVAL
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.
76G01C-071
1. Battery and battery carrier
2. Accelerator cable
3. Air cleaner assembly
4. Radiator harness
5. Radiator hose
6. Radiator and cooling fan
7. Brake vacuum hose
8. Intercooler pipe and hose*
9. Fuel hose
10. Drive belt cover
Note
11. P/S pump
12. No.4 engine mount
13. Clutch release cylinder
14. Speedometer cable
15. Transaxle harness
16. A/C compressor
17. Engine harness
18. Heater hose
19. Front wheel
20. Engine side cover
21. Tie-rod end
22. Stabilizer control rod
23. Lower arm bushing
24. Driveshaft
25. Change rod
26. Extension bar
27. Exhaust pipe and stay
28. Engine mount
29. Engine and transaxle
30. Transaxle
marked parts are equipped only for RF-CX.
1C-31

1C REMOVAL
76G01C-244
76G01C-072
67U01X-029
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.
After disconnecting the fuel hoses, plug them to avoid
fuel leakage.
Clutch release cylinder
Remove the clutch release cylinder with the pipe still
connected; then avoid the cylinder.
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.
Driveshaft
Remove the driveshafts. (Refer to Section 9.) Slide
the SST into the transaxle.
86U01X-060
1C-32

REMOVAL 1C
Transaxle
Separate the transaxle from the engine in the sequence shown in the figure.
76G01C-073
1. Starter 4. Clutch under cover
2. Water pipe 5. Transaxle
3. Gusset plate
1C-33

DISASSEMBLY (CYLINDER BLOCK) 1 C
CYLINDER BLOCK—I
76G01C-091
1. Clutch cover
2. Clutch disc
3. Flywheel
4. End plate
5. Oil pan
6. Oil strainer
7. Stiffener (RF-CX)
8. Rear cover
9. Timing belt pulley
10. Oil pump assembly
Flywheel
1. Install the SST to the flywheel.
2. Remove the clutch cover, clutch disc and flywheel.
Timing belt pulley
1. Reverse the direction of the SST.
2. Remove the timing belt pulley.
76G01C-092
1C—43