1987 MAZDA 626 Exhaust

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

DISASSEMBLY (AUXILIARY PARTS) 1 B
1. Oil level gauge
2. P/S oil pump bracket
3. EGR pipe(Unleaded fuel)
4. Exhaust manifold insulator
5. Exhaust manifold assembly
6. Coolant inlet pipe and bypass pipe
7. Engine hanger
8. Alternator
9. Alternator strap and bracket
10. Engine mount bracket
11. Center cover
12. Distributor and high-tension lead
13. Spark plug
14. Thermostat and thermostat cover
15. Intake manifold bracket
16. Intake manifold assembly
17. Oil filter
18. Oil cooler
19. Oil pressure switch
76G01B-039
49 0107 680A Irf^Ys'^
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49 G030 D05A
76G01A-120
Disassembly Note
Engine hanger
Remove the exhaust manifold; then connect the SST
to the engine.
69G01X-000
1B—25

1 B INSPECTION AND REPAIR
Valve guide

-Valve stem
I/
Clearance
6. Measure the valve stem to guide clearance by sub-
tract the outer diameter of the valve stem from the
inner diameter of the corresponding valve guide.
Clearance
IN : 0.025—0.060 mm (0.0010—0.0024 in)
EX: 0.030—0.065 mm (0.0012—0.0026 in)
Maximum: 0.20 mm (0.0079 in)
7. If the clearance exceeds the maximum, replace the
valve and/or valve guide.
76G01B-122
76G01B-054
8. Check that the valve guide projection height
(dimension A in the figure). Replace if necessary.
Height: 11.4—11.9 mm (0.449—0.469 in)
Replacement of valve guide
Note
Although the shapes of the intake and exhaust
valve guides are different.
76G01B-123
Removal
1. Gradually heat the cylinder head in water to ap-
prox. 90°C (194°F).
86U01X-083
1B-36

1 B ASSEMBLY (AUXILIARY PARTS)
Exhaust Manifold Assembly
1. Place the new gaskets in position with the ridge
facing the cylinder head.
2. Install the exhaust manifold assembly.
3. Tighten the nuts in two or three steps.
Tightening torque:
34—49
N
m (3.5—5.0 m-kg, 25—36 ft-lb)
76G01B-105
Exhaust Manifold Insulator
Install the exhaust manifold insulator.
Tightening torque:
19—30 Nm (1.9—3.1 m-kg, 14—22 ft-lb)
EGR Pipe (Unleaded fuel)
Install the EGR pipe.
Tightening torque:
34—44 N-m (3.5—4.5 m-kg, 25—33 ft-lb)
76G01B-106
P/S Oil Pump Bracket
Install the P/S oil pump bracket.
Tightening torque:
37—63 N-m (3.8—6.4 m-kg, 27—46 ft-lb)
86U01X-178
1B—72

INSTALLATION 1 B
Engine Mount
Install the engine mount.
86U01X-181
Exhaust Pipe
1. Install the exhaust pipe.
Tightening torque
(A): 31—46 Nm
(3.2—4.7 m-kg, 23—34 ft-lb)
(§): 64—89 N-m
(6.5—9.1 m-kg, 47—66 ft-lb)
2. Tighten the bracket bolt.
Tightening torque:
19—25 N-m (1.9—2.6 m-kg, 14—19 ft-lb)
Extension Bar
Install the extension bar to the transaxle.
Tightening torque:
31—46 N-m (3.2—4.7 m-kg, 23—34 ft-lb)
Change Rod
Install the change rod to the transaxle.
Tightening torque:
16—23 Nm (1.6—2.3 m-kg, 12—17 ft-lb)
1B—75

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

TUNE-UP PROCEDURE 1C
11. Turn the crankshaft clockwise to align the indica-
tor pin at ATDC 1° (RF-CX), ATDC 2° (RF-N)
12. Read the dial gauge.
Cam lift: 0.98—1.02 mm (0.038—0.040 in)
13. If not within the specification, adjust the injection
timing. (Refer to page 4D—24.)
76G04D-011
Idle Speed
1. Warm up the engine to normal operating tem-
perature.
2. Be sure the A/C switch is OFF.
3. Connect a tachometer and check the engine
speed.
Idle speed: 720 ±20 rpm
If the idle speed is not within the specification, adjust
the idle speed referring to Section 4D.
76G01C-014
Exhaust Smoke
Increase and decrease the engine speed several
times and check that black smoke is not emitted.
If there is, refer to Section 4D for the appropriate
procedure.
76G01C-015
1C—9

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