1987 MAZDA 626 Exhaust

1 C ON-VEHICLE MAINTENANCE (CYLINDER HEAD)
CYLINDER HEAD
Removal
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.
76G01C-031
1. Accelerator cable
2. Air cleaner
3. Brake vacuum pipe
4. Intercooler pipe and hose*
5. Drive belt cover
6. Vacuum pump drive belt
7. Fuel hose
8. Water temperature switch
connector
9. Glow plug connector
10. Water thermo switch con-
nector
11. Heat gauge unit connector
12. Boost air temperature sen-
sor connector*
13. Injection pipes
14. Upper radiator hose
15. Water hose
(thermostat—FIR)
16. Oil level gauge and stay
bolt
17. Oil pipe bolt
18. Timing belt (Refer to page
1C—11)
19. Cylinder head cover
20. Camshaft pulley
21. Rear camshaft pulley
76G01C-032
22. Injection pump pulley
23. Seal plate
24. Water hose and pipe
25. Comprex supercharger
drive belt*
26. Heat insulator*
27. Exhaust manifold stay
28. Front exhaust pipe
29. Cylinder head bolt
30. Cylinder head
31. Cylinder head gasket
32. Comprex supercharger*
33. Exhaust manifold
34. Intake manifold
Note
* marked parts are equipped only for the RF-CX.
1C-16

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

DISASSEMBLY (AUXILIARY PARTS) 1 C
1. A/C compressor bracket 9. Alternator and drive belt
2. Vacuum pump and drive belt 10. Oil filter
3. Air funnel assembly 11. Oil filter cover
4. Comprex supercharger insulator 12. Oil cooler assembly
5. Comprex supercharger and drive belt 13. Exhaust pipe bracket
6. Exhaust manifold insulator 14. Alternator bracket
7. Exhaust manifold 15. Blow-by chamber
8. Intake manifold
Blow-by chamber
76G01C-074
Disassembly Note
Engine hanger
1. Remove the CSD hose.
2. Loosen the vacuum pump oil pipe bolts.
76G01C-075
3. Install the engine on the SST.
76G01C-076
1C—35

1C INSPECTION AND REPAIR
76G01C-105
Replacement of valve guide
Caution
When the valve guide is replaced, check the
gap between the valve and guide once again.
The valve seal should be installed after in-
spection and repair of the valve seat.
Don't misassemble the valve guides because
intake and exhaust valve guides have a differ-
ent seat.
Intake side valve guide longer
Exhaust side valve guide shorter
Removal
1. Gradually heat the cylinder head in water to ap-
prox. 90°C (194°F).
76G01C-106
2. Remove the valve guide from the side opposite the
combustion chamber with the SST.
86U01X-084
Installation
1. Gradually heat the cylinder head in water to ap-
prox. 90°C (194°F).

76G01C-111

1C-49

ASSEMBLY (TIMING BELT) 1 C
76G01C-198
4BG01B-210
76G01C-199
Timing Belt Cover
Install the left and right timing belt covers.
Tightening torque:
7—10 Nm (70—100 cm-kg, 61—87 in-lb)
Crankshaft Pulley
Install the crankshaft pulley.
Tightening torque:
23—32 Nm (2.3—3.3 m-kg, 17—24 ft-lb)
Valve Clearance
1. Set the No.1 cylinder to compression TDC.
2. Measure the valve clearance at No.1, No.2 (intake),
and No.1, No.3 (exhaust).
Clearance (cold engine)
IN : 0.20—0.30 mm (0.008—0.012 in)
EX: 0.30—0.40 mm (0.012—0.016 in)
3. If the valve clearance is not within the specifica-
tion, adjust the valve clearance.
(1) Face the intake cam lobe straight upward.
(2) Move the tappet so that its notch is at the man-
ifold side.
(3) Press the tappet down until the adjusting disc
is accessible with the SST.
(4) Take out the adjusting disc.
76G01C-200
1C—85

1C ASSEMBLY (TIMING BELT)
Cam (intake)
Adjust disc
Valve clearance
0.30 mm (0.012 in) 4.00 mm (0.157 in)
76G01C-201
(5) Select an appropriate disc depending on the
valve clearance measured. And install it.
Example (intake valve):
Thickness of original adjusting disc + (measured
clearance — standard clearance) = thickness of
new adjusting disc.
4.00 + (0.30 - 0.25) = 4.05 mm
0.157 + (0.012 - 0.010) = 0.159 in
Note
a) The disc thickness is indicated by the num-
ber marked on the disc. For example, 3825
means 3.825 mm (0.1056 in).
b) Adjusting discs are available in 25 different
thicknesses within the 3.40—4.60 mm
(0.134—0.181 in) range, at intervals of 0.05
mm (0.002 in).
(6) Inspect the clearance again.
4. Set the No.4 cylinder to compression TDC.
5. Measure and adjust the valve clearance at No.3,
No.4 (intake), and No.2, No.4 (exhaust) in the same
way.
76G01C-202
Gasket
Head cover Apply sealant
^ 1 §
Cylinder Head Cover
1. Apply sealant to the shaded areas.
2. Install the cylinder head cover.
Tightening torque:
7—10 Nm (70—100 cm-kg, 61—89 in-lb)
3. Install the PVC hose.
76G01C-203
1C—86

AUXILIARY PARTS
Torque Specifications
ASSEMBLY (AUXILIARY PARTS) 1 C
RF-N
19—26 N m (1.9—2.6 m-kg, 14—19 ft-lb)

22—26 N
(2.2-2.7 16—20 ft-lb)
8—11 N m (80—110 cm-kg, '-g 69—95 in-lb)
0—110 cm-kg, 169—95 in-lb)
. 22—26 N m (2.2—2.7 m-kg, 16—20 ft-lb)
37—52 N m (3.8—5.3 m-kg, 27—38 ft-lb) I
8—11 N-m (80—110 cm-kg, 69—95 In-lb)
37—52 N-m (3,8—5.3 m-kg, 27-38 ft-lb)
86U01X-164
Alternator Bracket and Exhaust Pipe Bracket
Install the alternator bracket and exhaust pipe stay.
Tightening torque:
37—52
N
m (3.8—5.3 m-kg, 27—38 ft-lb)
p o
a^z iw rr

76G01C-212

1C—87

ASSEMBLY (AUXILIARY PARTS) 1 C
.JfTjQi
76G01C-209
76G01C-210
76G01C-211
Intake Manifold
Install the intake manifold and gasket.
Tightening torque:
16—23 N-m (1.6—2.3 m-kg, 12—17 ft-lb)
Exhaust Manifold
1. Place the exhaust manifold gasket in position.
2. Install the exhaust manifold.
Tightening torque:
22—26 N-m (2.2—2.7 m-kg, 16—20 ft-lb)
Exhaust Manifold Insulator
Install the exhaust manifold insulator.
Tightening torque:
8—11 N-m (80—110 cm-kg, 69—95 in-lb)
Comprex Supercharger
1. Install the Comprex supercharger with new gasket.
Tightening torque:
22—26 N-m (2.2—2.7 m-kg, 16—20 ft-lb)
2. Install the Comprex supercharger drive belt, and
adjust the belt deflection. (Refer to page 1C—7)
76G01C-212
1C—89