1987 MAZDA 626 light

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

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-049
Injection pipe
1. Check that no dirt or other foreign material is on
the pipe coupling.
2. Install the injection pipes.
Tightening torque:
25—29 Nm (2.5—3.0 m-kg, 18—22 ft-lb)
3. Install the pipe clip.
Tightening torque:
4—6 N-m (40—60 cm-kg, 35—52 in-lb)
Vacuum pump drive belt
1. Install the vacuum pump drive belt, and adjust the
belt deflection. (Refer to 1C—7)
2. Install the drive belt cover.
Tightening torque:
8—11 Nm (80—110 cm-kg, 69—95 in-lb)
3. Connect the vacuum hose securely and squeeze
the clamp lightly with pliers to ensure a good fit.
76G01C-050
Steps after installation
1. Fill the radiator with the specified amount and type
of coolant.
2. Perform the necessary engine adjustments. (Re-
fer to TUNE-UP PROCEDURE.)
76G01C-051
1C—23

1 C ASSEMBLY (CYLINDER
BLOCK)

76G01C-170
Adjusting
disc
Tappet -
Apply engine oil
4BG01B-150
4BG01B-182
Apply engine oil
1.
Cylinder head bolt
below head length
Valve and Valve Spring
1. Install the lower spring seat.
2. Apply molybdenum disulphide grease to the valve
stem.
3. Install the valve.
4. Install the valve springs and the upper spring seat.
5. Compress the valve spring with the SST; then in-
stall the valve keepers.
6. Tap the end of the valve stem lightly two or three
times with a plastic hammer to confirm that the
keepers are all fully seated.
Tappet and Adjusting Disc
1. Apply engine oil to the tappets.
2. Install the tappets in the hole.
3. Install the adjusting discs.
Cylinder Head
1. Thoroughly 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 or 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)
76G01C-171
1C-74

INSTALLATION 1C
Heater Hose
Connect the heater hoses.
Note
Position the hose clamp in the original loca-
tion on the hose and squeeze the clamp lightly
with large pliers to ensure a good fit.
86U01X-221
Connector Location
Install each harness as shown in the figure.
1. Alternator
2. Boost air temperature sensor (RF-CX)
3. Heat gauge unit
4. Water thermo switch
5. Pick up coil
6. Glow cord
7. Front harness connector and ground
76G01C-222
8. Fuel cut valve
9. Oil pressure switch
10. Starter
11. Water temperature switch
12. Transaxle harness
13. Grounds
1C—95

INSTALLATION 1C
76G01C-227
P/S Oil Pump
1. Install the P/S oil pump.
Tightening torque:
37—52 Nm (3.8—5.3 m-kg, 27—38 ft-lb)
2. Install the P/S oil pump pully. (Refer to section 10)
Tightening torque:
55—59 Nm (5.6—6.0 m-kg, 41—43 ft-lb)
3. Set the pipe bracket in position.
Tightening torque:
8—11 Nm (80—110 cm-kg, 69—95 in-lb)
4. Install the drive belt and adjust the belt deflection.
(Refer to page 1C—7)
5. Install the drive belt cover.
Tightening torque:
8—11
N
m (80—110 cm-kg, 69—95 in-lb)
76G01C-228
Fuel Hose
Install the fuel hose.
Note
Be careful of the red marks on the hose.
76G01C-229
76G01C-230
Intercooler Pipe and Hose
1. Install the intercooler pipe and hose.
Tightening torque:
19—26 Nm (1.9—2.6 m-kg, 14—19 ft-lb)
2. Install the brake vacuum pipe.
Tightening torque:
8—11
N
m (80—110 cm-kg, 69—95 in-lb)
3. Connect the brake vacuum hose securely and
squeeze the clamp lightly with pliers to ensure a
good fit.
1C-97

1C INSTALLATION
Radiator
1. Install the radiator and cooling fan,
Tightening torque:
8—11 Nm (80—110 cm-kg, 69—95 in-lb)
2. Connect the radiator harness.
76G01C-213
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.
4. Install the solenoid valve and ground.
Tightening torque:
8—11
N
m (80—110 cm-kg, 69—95 in-lb)
76G01C-232
Air Cleaner Assembly
Install the air cleaner assembly.
Tightening torque:
16—27 Nm (1.6—2.8 m-kg, 12—20 ft-lb)
76G01C-233
Battery and Battery Carrier
1. Install the battery carrier.
Tightening torque:
Bolt A: 31—40
N
m
(3.2—4.1 m-kg, 23—30 ft-lb)
Bolt B: 8—11 N-m
(80—110 cm-kg, 69—95 in-lb)
2. Install the battery tray and battery.
Tightening torque:
5—7 N-m (50—70 cm-kg, 43—61 in-lb)

76G01C-226

1C-98

RADIATOR 3A
RADIATOR
REMOVAL AND INSTALLATION
1. Drain the engine coolant.
2. Remove in the sequence shown in the figure.
3. Install in the reverse order of removal.
76G03A-005
5. Upper and lower radiator hose
6. Cooling fan and radiator assembly
7. Cooling fan
INSPECTION
Check the following points. Repair or replace if
necessary.
1. Cracks, damage, or water leakage
2. Bent fins (Repair with a screwdriver)
3. Distorted or bent radiator inlet.
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. 86U03X-010
1. Coolant reservoir hose
2. ATF hose (ATX)
3. Water thermo switch connector
4. Cooling fan connector
86U03X-012
3A-7