1987 MAZDA 626 maintenance

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

ON-VEHICLE MAINTENANCE (CYLINDER HEAD) 1 C
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.
Plug the disconnected hoses to avoid fuel leakage.
76G01C-033
2. Hold the camshaft with a wrench (29 mm, 1.14 in)
and loosen the camshaft pulley lock bolt.
Caution
Do not damage the cylinder head edge with
the wrench.
4BG01B-044
3. Separate the camshaft pulley from the camshaft
with the SST.
Caution
Do not hit the camshaft pulley with a hammer.
Rear camshaft pulley
Remove the rear camshaft pulley in the same man-
ner used for camshaft pulley.

76G01C-044

1C—17

1 C ON-VEHICLE MAINTENANCE (CYLINDER HEAD)
76G01C-241
76G01C-035
69G01A-031
Injection pump pulley
1. Put two bolts of 35—40 mm (1.4—1.6 in) length
into the arms of the injection pump pulley and af-
fix them in the threaded hole of the injection pump
bracket.
2. Loosen the injection pump pulley lock bolt.
3. Separate the injection pump pulley from the injec-
tion pump shaft with the SST.
Cylinder head bolt
Loosen the cylinder head bolts in two or three steps,
and in the order shown in the figure.
Disassembly of Cylinder Head
Refer to page 1C—40.
Inspection of Cylinder Head
Refer to page 1C—47.
Assembly of Cylinder Head
Refer to page 1C—73.

76G01C-048

1C-18

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-037
Apply engine oil
/
Cylinder head bolt
below head length
76G01C-038
(8) (4; D (5)
® ®
76G01C-039
3m-kg
(21.7ft-lb
Installation
Cylinder head
1. Throughly 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 and 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)
6. Apply engine oil to the threads and the seat face
of the cylinder head bolts.
7. Tighten the cylinder head bolts.
(1) Tighten the bolts to the specified torque, in the
order shown in the figure.
Tightening torque:
29 N-m (3.0 m-kg, 22 ft-lb)
(2) Make paint marks on the bolt heads, as shown
in the figure.
(3) With the paint marks as a reference point, turn
the cylinder head bolts another 90°
(90°—105°) in the tightening direction. Tight-
en them in the order.
(4) Then tighten them once again 90°
(90°—105°) in the tightening order.
Caution
Be absolutely sure that the bolts are tightened
in the proper order.

76G01C-044

1C—20

ON-VEHICLE MAINTENANCE (CYLINDER HEAD) 1 C
76G01C-041
76G01C-042
76G01C-043
Seal plate
1. Install the seal plate.
Tightening torque:
8—12
N
m (80—120 cm-kg, 69—104 in-lb)
2. Check that the seal plate sealing rubbers are in-
stalled in position.
Rear camshaft pulley
1. Install the rear camshaft pulley.
2. Hold the camshaft with a wrench (29 mm, 1.14 in),
and tighten to the specification.
Tightening torque:
55—65
N
m (5.6—6.6 m-kg, 41—48 ft-lb)
Camshaft pulley
1. Connect the camshaft pulley onto the camshaft with
the semicircular (woodruff) key.
2. Hold the camshaft with a wrench (29 mm, 1.14 in),
tighten the camshaft pulley lock bolt.
Tightening torque:
55—65 Nm (5.6—6.6 m-kg, 41—48 ft-lb)
3. Align the mark on the camshaft pulley with the mark
on the seal plate.
76G01C-044
1C—21

1 C ON-VEHICLE MAINTENANCE (CYLINDER HEAD)
76G01C-045
Gasket
Head cover Apply sealant
J
76G01C-046
76G01C-047
Timing marks
Timing marks
Timing
marks-
Injection pump pulley
1. Install the injection pump pulley with the semicir-
cular (woodruff) key to the injection pump shaft.
2. Rotate the injection pump pulley until the timing
marks are aligned.
3. Affix the injection pump pulley to the bracket us-
ing two bolts (35—40 mm, 1.4—1.6 in).
4. Tighten the lock nut.
Tightening torque:
59—69 Nm (6.0—7.0 m-kg, 43—51 ft-lb)
Cylinder head cover
1. Apply sealant to the shaded areas.
2. Install the cylinder head cover.
Tightening torque:
7—10
N
m (70—100 cm-kg, 61—87 in-lb)
3. Install the PCV hose.
Timing belt
1. Return the crankshaft about 45° to the timing mark
on the oil pump housing.
2. Check that the timing marks of the camshaft pul-
ley and the injection pump pulley align with the tim-
ing marks on the seal plate.
3. Install the timing belt. (Refer to TIMING BELT of
ON-VEHICLE MAINTENANCE)
76G01C-048
1C-22

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