MAZDA 626 1987

e x p e r t 2 2 fl/ia http://rutracker.org
by service technicians of authorized Mazda
dealers to help them service Mazda vehicles.
This manual can be also useful in diagnosing
certain problems and p erforming some repair
and maintenance on Mazda vehicles.
For proper repair and maintenance, it is im-
portant to be thoroughly familiarized with this
manual. It is recom mend ed that this manual al-
ways be kept in a handy place for quick and
easy reference.
tographs, drawings, a nd specifications, are the
latest available at the time of p rinting. As m odifi-
cations affecting repair or maintenance occur,
relevant information supplementary to this
volume will be made available at Mazda deal-
ers. This manual should be kept up-to-date.
Mazda Motor Corporation reserves the right
to alter the specifications and contents of this
manual w ithout obligation or advance notice.
All rights reserved. No part of this book may
be rep roduc ed or utilized in any form or by any
means, electronic or mechanical, including
photocopying, recording, or by any informa-
tion storage and retrieval system, without per-
mission in writing.
Mazda Motor Corporation
necessary.
Lubrication System
Gasoline 2A
Lubrication System
Engine Electrical System 5
Steering System 10
POSITIONS G— 6
ENGINE MODEL AND NUMBER
IMPORTANT INFORMATION
BASIC ASSUMPTIONS
This workshop manual assumes that you have arid know how to properly use certain special tools
which are necessary for the safe and efficient performance of service operations on Mazda vehicles.
The manual also assumes that you are familiar generally with automobile systems and basic service
and repair procedures. You should not attempt to use this manual unless these assumptions are cor-
rect and you understand the consequences described below.
SAFETY RISK
This manual contains certain notes, warnings, etc., which you should carefully read and follow in or-
der to eliminate the risk of personal injury to yourself or others and the risk of improper service which
may damage the vehicle or render it unsafe. The fact that there are no such notes, etc., with respect
to any spec ific service me thod d oes not mea n that there is no possibility that personal safety or vehicle
safety will be jeopardized by the use of incorrect methods or tools.
POSSIBLE LOSS OF WARRANTY
The manufacturer's warranty on Mazda vehicles and engines can be voided if improper service or
repairs are performed by persons other than an authorized Mazda dealer.
FUNDAMENTAL PROCEDURES
As you read through the procedure, you wil l come
across NOTES, CAUTIONS, and WARNINGS. Each
one is there for a specific purpose . NOTES give you
added information that will help you to complete a
particular procedure. CAUTIONS are given to pre-
vent you from making an error that could damage
the vehicle. WARNINGS remind you to be espe-
cially careful in those areas where carelessness can
cause personal injury. The following list contains
some general WARNINGS that you should follow
when you work on a vehicle.
PROTECTION OF THE VEHICLE
areas before starting work.
A WORD ABOUT SAFETY
jacking up the vehicle.
3. Support vehicle with safety stands (rigid racks).
Start the engine only after making certain the engine
compartment is clear of tools and people.
G—2
EQUIPMENT
Be sure that all necessary tools and m easuring e quip-
ment are available before starting any work activity.
47U 0GX-00 4
47U 0GX-00 5
REMOVAL OF PARTS
and subassemblies must be removed and disassem-
bled for replacement or repair.
47U 0GX-00 6
many parts to be disassembled, all parts should be
disassembled in a way that will not affect their per-
formance or external appearance, and be identif ied
so that reassembly can be performed easily and effi-
ciently.
Each part when rem oved sho uld be carefully inspect-
ed for malfunctioning, deformation, damage, and
other problems.
All disassembled parts should be carefully arranged
for reassembly.
Be sure to separate or otherwise identify the parts to
be replaced from those that will be reused.
3. Cleaning p arts for reuse
All parts to be reused should be carefully and
thoroughly cleaned in the appropriate method.
REASSEMBLY
of all parts.
ones:
6. Nylon nuts
1. Sealant should be applied to gaskets
2. Oil should be applied to the moving compo nents
of parts
3. Specified oil or grease should be applied at the
sembly.
Use suitable gaug es and/or testers when m aking var-
ious adjustments.
Be sure to disconnect the battery cable from the nega-
tive (-) terminal of the battery.
Never pull on the wiring when disconnecting con-
nectors.
click that will let you know they are securely locked.
Handle sensors and relays carefully. Be careful not
to drop them or strike them against other parts.
47U 0GX-01 4
ber parts or tubing.
FRONT END
Jack position:
Safety stand positions:
47U 0GX-01 7
2WS
Safety stand positions:
4WS
FRONT END
r
— I
76UQGX-003
86U0GX-004
dama ge to the vehicle during any towing operation.
Laws and regulations applicable to vehicles in tow
must always be observed.
matic or manual transaxle, release the parking brake,
place the selector lever (shift lever) in neutral, and set
the ignition key in the "ACC" position. As a rule,
towed vehicles should be pulled with their drive
wheels off the ground.
vent towing a vehicle with its drive wheels up, use
wheel dollies. With all four wheels on the grou nd, th e
vehicle may be towed only forward. In this case, it
cannot be towed at a speed exc eeding 56 km/h (35
mph) for more than 80 km (50 miles) without danger
of damaging the transaxle.
or if the towing distance will exceed 80 km (50 miles),
use either of these two methods:
1. Place the front wheels on dollies.
2. Tow with the front wheels off the ground.
CAUTIONS
the engine is off.
always pull the cable or chain straight awa y
from the hook and do not apply any side-
ways force to it. To further help prevent
damage, do not take up slack too quickly
in the cable or chain.
c) The rear towing hook should be used only
in an emergen cy situation, (e.g., to pull the
vehicle from a ditch, a snowbank, or mud).

CHASSIS NUMBER LOCATION
NUMBER LOCATION
N m ( m - k g , f t- l b o r in - l b ) . T o r q u e
r p m
R e v o l u t i o n s p e r m i n u t e
A
V
U
O h m ( s ) ( r e s i s t a n c e )
k P a ( p s i )
P r e s s u r e
( u s u a l l y p o s i t i v e )
m r r i H g ( i n H g )
P r e s s u r e
( u s u a l l y n e g a t i v e )
W
A A S
A u t o a d j u s t i n g s u s p e n s i o n
A / C
A i r c o n d i t i o n e r
A C C
A c c e s s o r i e s
A B D C
A f t e r b o t t o m d e a d c e n t e r
A T D C
A f t e r t o p d e a d c e n t e r
A T X
A u t o m a t i c t r a n s a x l e
A T F
A u t o m a t i c t r a n s m i s s i o n f l u i d
A B S
A n t i - l o c k b r a k e s y s t e m
B B D C
B e f o r e b o t t o m d e a d c e n t e r
B T D C
B e f o r e t o p d e a d c e n t e r
E X
E C - A T
E l e c t r o n i c a l l y c o n t r o l l e d
a u t o m a t i c t r a n s a x l e
E S P S E n g i n e s p e e d s e n s i n g p o w e r
s t e e r i n g
E C P S
E l e c t r o n i c a l l y - c o n t r o l l e d p o w e r
s t e e r i n g
H L A
H y d r a u l i c l a s h a d j u s t e r
IG
IN
IC
I n t e g r a t e d c i r c u i t
I N T
I n t e r m i t t e n t
L H
L e f t h a n d
M T X M a n u a l t r a n s a x l e
M
O F F
O N
P C V
P o s i t i v e c r a n k c a s e v e n t i l a t i o n
P/S
P o w e r s t e e r i n g
P/W P o w e r w i n d o w
R H
R i g h t h a n d
R F - C X C o m p r e x s u p e r c h a r g e d R F
e n g i n e
R F - N N o r m a l l y a s p i r a t e d R F e n g i n e
S T
S S T
S p e c i a l t o o l s
4 W S 4 - w h e e l s t e e r i n g
P W S 2 - w h e e l s t e e r i n g
4 H A T 4 - s p e e d h y d r a u l i c a u t o m a t i c
t r a n s a x l e
F l F u e l i n j e c t i o n
76GQGX-005
INSTALLATION OF A MOBILE TWO-WAY RADIO SYSTEM
If a mobile two-way radio system is installed improperly, or if a wrong type is used, the Fuel Injection
system and other systems may be affected.
When car is equipped with a mobile two-way radio system, observe the following precautions.
1. Install the antenna at the farthest point from the control unit.
2. Keep the antenna feeder away from the control unit harness as far as possible,
(at least 30cm (11.8 in))
3. Insure that the antenna and feeder are properly adjusted.
4. Do not install a powerful mobile two-way radio system.
Feeder control unit

MAINTENANCE TABLE
MAINTENANCE TABLE
76G00X-001
EXTERIOR
I N S P E C T an d A D J U S T , i f necessary, the following items
to the speci f icat ions:
• Glass, exter ior br ight metal and paint for dam age
• Whee l lug nuts
88— 118 N m (9—12 m -kg, 65—87 f t - lb)
• Tire press ures (Refer to section 12)
• Al l weatherst r ips for damage or detachment
• Operat ion of bonnet re lease and lock
• Operat ion of fuel l id and t runk l id (Back door) opener
• Door operat ion and a l ignment
• Headl ight a iming
I N S T A L L fo l lowing par ts :
• Wheel caps or r ings ( if equipped)
• Outs ide rear view mirror(s)
UNDER BONNET—ENGINE OFF
an d
to the specifications:
• Fuel, coolant and hydraulic l ines, f itt ings, connection s and
• Engi ne oil level
• Brake and clutch master cylinder fluid level (if equi pped )
• Windshie ld washer reservoi r f lu id level
• Radiator coolant level and speci f ic grav i ty
Protect ion °C (°F)
- 4 (25)
- 4 0 ( - 4 0 )
• Tightness of battery termin als
• Manu al transa xle oil level
• Drive belt tension s (Refer to section 1)
• Accelerator cable and i ts l inkage for f ree movem ent
• Head light cleaner fluid level (if equip ped)
C L E A N spark p lugs
INTERIOR
the fo l lowing par ts :
• Rubber stopper for ins ide rear v iew mirror
• Fuse for access ories
C H E C K the operat ions of the fo l lowing i tems:
• Seat contro ls (s l id ing and rec l in ing) and head rest
• Door locks inc luding chi ldproof door locks ( if equipped)
• Seat bel ts and warning system
• Igni t ion swi tch and steer ing lock
• Inhibitor switch (ATX only)
• Al l l ights inc luding warnin g and indicator l ights
• Sound warning system
• Horn, wipers and washers ( f ront and rear , if equipped)
• Radio and antenna (i f equipped )
• Cigaret te l ighter and c lock
• Remote contro l outs ide rear v iew mirrors (i f equipped)
• Power window s ( if equipped )
• Heater , defroster and a ir condi t ioner at var ious mod e
select ion ( i f equipped)
• Sunroof ( if equipped )
antenna t r immer on radio ( i f equipped)
C H E C K
the fo l lowing i tems:
• Presence of spare fuse
C H E C K
an d
• Operat ion and f i t o f windows
• Pedal height and f ree p lay of brake and c lutch pedal
Pedal height mm (in) free play mm (in)
Clutch pedal
Brake pedal
• Parking brake
UNDER BONNET—ENGINE RUNNING AT
OPERATING TEMPERATURE
the fo l lowing i tems:
• Operat ion of id le-up system for a i r condi t ioner or power
steer ing ( i f equipped)
• Automat ic t ransaxle f lu id level
• Operat ion of dash pot
• Init ial ignition timin g
• Id le speed
ON HOIST
C H E C K the fo l lowing i tems:
• Unde rside fuel, coolant and hydraulic l ines, f itt ings, con-
nect ions and components for leaks
• Tires for cuts or bruises
• Steering l inkage, suspension, exhaust system and all un-
ders ide hardware for looseness or damage
R E M O V E
protect ive cover f rom brake d iscs
ROAD TEST"
C H E C K the fo l lowing i tems:
• Brake operat ion
• Clutch operat ion
• Emer gency lock ing ret ractors
• Cruise contro l system ( if equipped)
AFTER ROAD TEST
R E M O V E seat and f loor mat protect ive covers
CHECK
Char t symbols :
I
A
R
T
O
X
Inspect : V isual examinat ion or funct ional measurement of a system's operat ion (per formance)
Adjust : Examinat ion result ing in adjustment or replacement
Replace or change
F8 engine wi th carbretor , MTX, ATX
FE engine wi th carbretor , MTX, ATX
FE DOHC engine wi th fuel in ject ion, 4WS, MTX
RF-CX, RF-N engine with MTX
R E M A R K S :
Major serv ice in terval at 12 months/20,000 km (12,000 Mi les) , Lubr icat ion serv ice based on d is tance only 10,000 km (6,000 Mi les) not t ime
After 80,000 km (48,000 Mi les) or 48 months, cont inue to fo l low the descr ibed maintenance i tems and intervals per iodical ly .
As for * marked i tems in th is maintenance char t , p lease pay at tent ion to the fo l lowing points.
*1 Replaceme nt of the t iming bel t is requi red at every 100,000 km (60,000 Mi les). Fai lure to repace the t iming bel t may resul t in dam age to the engine.
*2 If the vehicle is operatie under the following conditions, it is sugges ted that the engine oil and oil f i l ter be chang ed m ore often than at usual recom men ded intervals.
a) Driving in dusty conditions.
b) Extended per iods of id l ing or low speed operat ion.
c) Dr iv ing for a pro longed per iod in cold temperatures or dr iv ing only shor t d is tances regulary.
*3. If the vehicle is ope rate d in very dusty or sandy areas, inspect and, if necessa ry, repla ce more often than at usual rec om me nde d intervals.
*4. This is a full funct ion chec k of all electrical systems, i.e., all l ights, washers (inclu ding con ditio n of blades) electrical windo ws, sun roof, horn , etc....
*5. Replace every two years.
I f there has bee n cont inuous hard dr iv ing, m ounta in dr iv ing, or i f the brakes are used extensively or the vehic le is operated in ext remely hum id c l imates, the
brake f lu id should be changed annual ly .
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Emiss ion Cont ro l and Re la ted Sys tems
The igni t ion and fuel systems are v i ta l ly important to the p roper o perat ion of the emiss ions contro l and re lated systems, as well as for ef f icient engine operat ion.
I t is s t rongly recommended that a l l serv ic ing re lated to these systems be done by your Author ized Mazda Dealer .
m
a
m
z
Number of Months or km, whichever corns f i rst
©1 ©2
© 3
© 4 Serv ice da ta and inspect ion po in t
Page
Interval
© 3
Page
Interval
© 3
Page
Interval
© 3
Page
(8.524—8.720 in)
6 - 4
Brake pedal
(8 .74 -8 .94 i n )
• Free p lay: 4—7 mm (0.16—0.28 in)
11—11
11—11
1
I
o
nectors
1 I
10—13
3
adjustment)
• Coola nt level
Procedure & i t em
Number o f Months o r km, wh ichever corns f i rs t
© 1 © 2
Page
Page
Page
Page
gravi ty
Replace every 100,000 Km
FE-12-valve, FE (DOHC)
RF-CX, RF-N (Cold engine)
1A-10
bolts
mani fo ld nuts
bolts
bolts
bolts
F8, FE:
RF-CX, RF-N:
2A—6
2
R
F8, FE 12-valve
FE (DOHC)
RF-CX, RF-N
2A—6
2 B - 6
Fuel f i l ter (R) for carbre tor mod el
(R)
R
(R)
R
o
0
o
o
I n te rva l
P rocedure & i t em
Numbe r o f Months o r km, wh ichever corns f i r s t
M o n t h s
x 1000 Km
Miles x 1000
S p a r k p l u g s
In i t ia l ign i t ion t iming
Id le speed
© 1
O
o
o
o
o
©2
O
o
o
o
o
o
© 3
O
O
O
O
O
© 4
O
Serv ic e da ta and inspec t ion po i n t
F i t t i n g s , c o n n e c t i o n s a n d c o m p o -
nents for leaks
Plug gap: F8, FE (8-VALVE)
0 . 7 5 — 0 . 8 5 m m ( 0 . 0 3 0 — 0 . 0 3 3 i n )
FE (12-VALVE) FE (DOHC)
0 . 7 — 0 . 8 m m (0 . 0 2 8 — 0 . 0 3 1 i n )
R e c o m m e n d e d s p a r k p l u g s
F6,F8,FE 8-VALVE FE 12-VALVE DOHC
N G K
D e n s o
W 1 6 E X R - U
W 2 0 E X R - U
Q 1 6 P R - U *
Q 2 0 P R - U
Init ial ignit ion t iming
6 ± 1 ° B T D C
12 ± 1 ° BTDC (FE DOHC)
Check the id le speed ( rpm)
F E D O H C 7 0 0 — 8 0 0
C a r b u r e t o r M T X 8 0 0 — 8 5 0 ,
A T X 9 0 0 — 9 5 0 ( N ra n g e )
C O c o n c e n t r a t i o n
F E D O H C 1 . 5 ± 0 . 5 %
Others 2.0 ± 0 .5 %
H C c o n c e n t ra t i o n
F E D O H C L e s s t h a n 1 0 0 0 r p m
O p e r a t i o n
P a g e
4 B — 4 2
I n te rva l
P rocedure & i t em
Numbe r o f Months o r km, wh ichever c orns f i r s t
©1
© 4
P a g e
In te rva l
M o n t h s
—
© 4
P a g e
In te rva l
x 1000 Km
© 4
P a g e
In te rva l
Miles x 1000
© 4
P a g e
I
4
o
o
• Che ck the a l l e lec t r ica l system
Section 15
A
A
• Che ck the hea d l ight a imin g
1 4 - 3 1
S t e e r i n g a n d f r o n t s u s p e n s i o n
I I I
1 0 — 2 8
and hoses (For 4WS)
X
• O p e ra t i o n a n d l o o s e n e s s
• F lu id leaka ge or ooz in g
1 0 — 4 4
1 0 — 1 4
and l inkage (For 4WS)
I I X X o
X
• O p e r a t i o n a n d l o o s e n e s s
• F lu id leakag e or ooz ing
1 0 — 3 3
1 0 — 1 4
(For 4WS)
Inner 5°0 0 ' ± 4 5 '
Outer 5°0 0 ' ± 4 5 '
1 3 - 5 4
Solenoid va lve o i l f i l te r (For 4WS)
R
Rear suspens ion outer ba l l jo in ts
(For 4WS)
X
• D a m a g e , l oo s e n e s s a n d g re a s e
l e a k a g e
1 3 — 3 7
A R
• Oi l capa c i ty
3.35 l i te rs (3 .6 US qt , 3 .0 Imp qt )
7 A - 6
Automat ic t ransax le f lu id leve l
A A
o o
X X
4 - S p e e d
6.8 l i ters (7.2 US qt, 6.0 Imp qt)
3 - S p e e d
7 B - 2
T T T
— —
D i s k b r a k e s / D ru m b r a k e s
I I
• Min. d isc th ickness :
Front 14 or 15 inch-wheel
22 mm (0.87 in)
• Disc run out:
1.0 mm (0.04 in)
230.1 mm (9.06 in)
1 1 — 4 5
1 1 — 5 4
1 1 — 4 5
1 1 — 5 4
1 1 - 4 5
1 1 — 5 4
1 1 - 6 0
1 1 — 6 0
Procedure & i t em
© 1
© 4
Serv ice da ta and inspec t ion po in t Page
In te rva l
Procedure & i t em
© 4
In te rva l
Procedure & i t em
30 40
5 0
60 70
8 0
© 4
In te rva l
Procedure & i t em
© 4
Brake l ines, Hoses, and connect ions
I I
1 1 - 8
pressure adjustment
I I
I I o O
o o • Check the a i r pressure 1 2 - 2
Hinges and cathes
I I 0 0
1 4 - 1 0 1
Road test
Char t symbols :
I
A
R
T
O
X
Inspect : V isual examinat ion or funct ional measurement of a system's operat ion (per formance)
Adjust : Examinat ion resul t ing in adjustment or replacement
Replace or change
FE engine with fuel injection, MTX, ATX
FE DOHC engine wi th fuel in ject ion, 4WS, MTX
FE engine wi th carburetor , MTX, ATX
RF-CX, RF-N engine with MTX
R E M A R K S :
Major serv ice in terval at 12 months/20,000 km (12,000 Mi les) , Lubr icat ion serv ice based on d is tance only 10,000 km (6,000 Mi les) not t ime
As for * marked items in this maintenance chart, please pay attention to the following points.
*1 Replacement of the t iming bel t is requi red at every 100,000 km (60,000 Mi les) . Fai lure to repace the t iming bel t may resul t in dama ge to the engine.
*2 I f the vehic le is operated under the fo l lowing condi t ions, i t is suggested that the engine o i l and o i l fi l ter be chang ed m ore of ten than at usual rec omm ende d
intervals.
a) Dr iv ing in dusty condi t ions.
c) Dr iv ing for a pro longed per iod in cold temperatures or dr iv ing only shor t d is tances regulary.
*3. If the vehicle is ope rate d in very dusty or sandy areas, inspect and, if necessa ry, replac e more often than at usual rec om me nde d intervals.
*4. This is a full functi on chec k of all electrical system s, i.e., all l ights, washers (in cludin g conditi on of blades) electrical wind ows, sunroof , horn, etc....
*5. Replace every two years.
I f there has been cont inuo us hard dr iv ing, mounta in dr iv ing, or i f the brakes are used extensively or the vehic le is operated in ext remely humid c l imates, the brake f lu id
should be changed annual ly .
The ignition and fuel systems are vitally important to the proper operation of the emissions control and related systems, as well as for efficient engine operation. It is
st rongly recommended that a l l serv ic ing re lated to these systems be done by your Author ized Mazda Dealer .
Z
H
m
z
Procedure & I t em
©1
© 2
© 3
© 4 Serv ice da ta and inspec tion po in t
Page
©1
© 2
© 3
Page
©1
© 2
© 3
Page
©1
© 2
© 3
Page
• Operat ion
(8.524—8.720 in)
(0.20—0.51 in)
(8.74—8.94 in)
• Free p lay: 4—7 m m (0.16—0.28 in)
1 1 - 1 1
• Operat ion
• Lever stroke:
I
connec to rs
11—6
0
I
I
I
I
I
I
I
I
I I
10—13
3
—
I I
• Coolan t level
3 A — 5
3 B - 4
Months
Page
m
z
gravi ty
O o
o o
Electroyte level
Specific gravity
5 - 8
Drive belts
O o o
bolts
O
O
FE (DOHC)
RF-CX, RF-N (Cold engine)
O
IN
EX
FE
mani fo ld nuts
Oil filter
RF-CX, RF-N: 5.0 l iters
(5.3 US qt, 4.4 Imp qt)
O
FE 8-valve
FE (DOHC)
RF-CX, RF-N
2 A - 6
2 B - 6
2 A - 6
2 B - 6
I n te rva l
P rocedure & i t em
M o n t h s
x 1000 K m
S p a r k p l u g s
Id le Speed
O)
O
X
o
C h o k e s y s t e m
0.6
6
10
12
20
12
(R)
18
© 1
O
O
o
o
o
o
o
o
o
o
o
o
o
o
© 3
o
o
o
o
o
o
o
© 4
o
o
nents for leaks
P l u g g a p : C a r b u re t o r , F E ( D O H C )
1 . 0 — 1 . 1 m m
( 0 . 0 3 9 — 0 . 0 4 3 i n )
F E 0 . 7 5 — 0 . 8 5 m m
( 0 . 0 3 0 - 0 . 0 3 3 i n )
R e c o m m e n d e d s p a rk p l u g s
N G K
C a r b u r e t e r
B P R 5 E S - 1 1
B P R 6 E S - 1 1
N G K
BCPR 5E-11
BCPR 6E-11
BCPR 7E-11
D e n s o
C a r b u r e t e r
W 1 6 E X R - U 1 1
W 2 0 E X R - U 1 1
N i p p o n
D e n s o
FE
W 1 6 E X R - U
W 2 0 E X R - U
N i p p o n
D e n s o
F E D O H C
Q 1 6 P R - U
6 ± 1 ° B T D C
12 ± 1 ° BTDC (FE DOHC)
Check the id le speed ( rpm)
C a r b u r e t o r M T X 8 5 0 — 9 0 0 ,
A T X 9 0 0 - 9 50 ( N r a n g e )
F E D O H C 7 0 0 - 8 0 0
F E M T X 8 0 0 — 8 5 0 ,
A T X 9 0 0 - 9 5 0 ( N ra n g e )
S y s t e m i n s p e c t i o n
S y s t e m i n s p e c t i o n
Carburetor l inkage
C h o k e d i a p h r a g m
C h o k e v a l v e c l e a ra n c e
U n l o a d e r s y s t e m
P a g e
4 A - 3 7
4 B - 4 2
I n te rva l
P rocedure & i t em
©1 ©2
© 3
© 4
Page
M o n t h s
— 6 12
18 24
3 0
© 3
© 4
Page
x 1000 Km 1
© 3
© 4
Page
Miles x 1000
42 48
©1 ©2
© 3
© 4
Page
I I X
4 A — 5 0
C o a s t en r i c h m e n t s o l e n o i d v a l v e
I I
4
I
I I
o
o o o • Chec k the a l l e lec t r ica l system
Section 15
A
1 4 - 3 1
I I I
Front and rear power s teer ing system
and hoses (For 4WS)
I X o X X
• O p e r a t i o n a n d l o o s e n e ss
• F lu id leakage or ooz ing
1 0 — 4 4
1 0 - 1 4
and l inkage (For 4WS)
I
I
X
X
• O p e r a t i o n a n d l o o s e n e ss
• F lu id leakage or ooz ing
1 0 — 3 3
1 0 — 1 4
I I
Inner 5°0 0 ' ± 4 5 '
Outer 5°0 0 ' ± 45 '
1 3 - 5 4
R
X
o
Rear suspens ion outer ba l l jo in ts
(For 4WS)
o
X
X
• D a m a g e , l o o s e n e s s a n d g re a s e
l e a k a g e
1 3 - 3 7
A
R
7 A — 6
Automat ic t ransax le f lu id leve l
A A
• Oi l capa c i ty
4 - S p e e d a n d E C - A T
3 - S p e e d
6.2 l i ter (6.6 US qt, 5.5 Imp qt)
7 B — 7 1
7 C — 2 5
T T T T T
o o o o
I I I l _
I
o o o o • P r o p e r a t t ac hm e n t a n d c o n n e c t i o n s
1 1 - 8
D i s k b r ak e / D ru m b ra k e
I I I
• Min. d isc th ickness:
Front 14 or 15 inch-wheel
22 mm (0.87 in)
• Disc run out:
Rear 0 .1 mm (0 .004 in)
• Min. l in ing th ickness:
1.0 mm (0.04 in)
230.1 mm (9.06 in)
1 1 — 4 5
1 1 — 5 4
1 1 — 4 5
1 1 - 5 4
1 1 — 4 5
1 1 - 5 4
1 1 — 6 0
1 1 - 6 0
I n te rva l
M o n t h s
—
© 3
© 4
P a g e
© 3
© 4
P a g e
Procedure & i t em
I I
O O O O
• C l ea r a n c e t o b o d y , a n d e x h a u s t
system
Inspect annual ly o
—
Tyres ( inc lud ing spare ty re) In f ra t ion
p r e s s u re a d j u s t me n t
I
12-2
H i n g e s a n d c a t h e s
A
A
A
A
o
—
—
U n d e r s i d e o f v e h i c l e
I
I
I o o o o
• O p r a t i o n an d l o o s e n e s s
1 4 — 1 0 1
Road test
For Genera l
Char t symbols :
I : Inspect : V isual examinat ion and/or funct ional measurem ent of a system's operat ion or per formance .
A
: Adjust : Examinat ion resui t ing in adjustment or replacement .
R
© 2
© 3
: FE DOHC engine wi th fuel in ject ion, MTX
® 4
N O T E :
As the resul t o f v isual examinat ion or funct ional measurement of a system's operat ion(per formance), correct , c lean or replace as requi red.
R E M A R K S :
As for * m arked i tems in th is maintenance char t , p lease pay at tent ion to the fo l lowing points.
*1. I f the vehic le is operated under the fo l lowing condi t ions, i t is suggeste d that the engine o i l and o i l f i lter be chang ed m ore of ten than at usual rec omm ende d
intervals.
a) Driving in dusty conditions.
c) Dr iv ing for a pro longed per iod in cold temperatures or dr iv ing only shor t d is tances regular ly .
2. Replacement of the t iming bel t is requi red at every 100,000 km (60,000 Mi les). Fai lure to repace the t iming bel t may resul t in dama ge to the engine.
*3 I f the vehic le is operated in very dusty or sandy areas, inspect and, if necessary, replace more of ten than at usual recom men ded intervals .
*4 Adjust or inspect a l ternator and water pum p dr ive bel t, and power steer ing and a ir condi t ioner dr ive belt , vacuum pu mp bel t , super charger bel t i f equipped.
*5 Replace every two years.
I f there has been cont inuous hard dr iv ing, mounta in dr iv ing, or i f the brakes are used extensively or the vehic le is operated in ext remely humid c l imates, the
brake f lu id should be changed annual ly .
*6. Only F6 carbretor for Singapore (MTX Model)
The ignition and fuel systems are vitally importan t to the prop er ope ration of the emissions contro l and related system s, as well as for efficient engine oper ation. It i
s t rongly recommended that a l l serv ic ing re lated to these systems be done by your Author ized Mazda Dealer .
o
CJ1
i n te rva l
M o n t h s
—
© 1 © 2 © 3 © 4
Page
© 1 © 2 © 3 © 4
Page
Procedure & i t em Miles x 1000 0 .6 6
12
1 8
2 4
3 0
3 6
4 2
4 8
C l u t c h p e d a l
I I
• Operat ion
• P e d a l h e i g h t : 2 1 6 . 5 — 2 2 1 . 5 m m
( 8 . 5 2 4 — 8 . 7 2 0 i n )
• F re e p l a y : 5 — 1 3 m m
(0.20—0.51 in)
B r a k e p e d a l
I
I
• O p e r a t i o n
• P e d a l h e i g h t : 2 2 2 — 2 2 7 mm
(8.74—8.94 in)
1 1 - 1 1
1 1 — 1 1
I I I
I I I
• Lever s t roke
1 1 - 6 5
I
I
• O p e r a t i o n
• C h e c k t h e v a c u u m h o s e s a n d
c o n n e c t o r s
1 1 — 2 7
Brake f lu id *
Power s teer ing f lu id and l ine
( i f equipped)
I I I
1 0 — 1 1
1 0 — 1 3
S t e e r i n g o p e r a t i o n a n d g e a r ho u s i ng
I I I I I o o o
o
• Free p lay: 0— 30 mm (0—1.18 in)
• O p e ra t i o n a n d l o o s e n e s s
• F lu id leaka ge or ooz in g
1 0 — 1 0
1 0 - 2 8
3
Procedure & i t em
©1
Page
Page
©1
Page
Page
• Choke valve c learance
3 A - 5
Reprace every 24 months O
O o
gravi ty
• Electrolyte level
• Specific gravity
5—8
2
O
FE-12-valve, FE (DOHC)
RF-N (Cold engine)
1A—10
1C—85
T T
mani fo ld nuts
T T
T T
T T
Replace every 5000 km or 6 months X X o
o
FE DOHC: 3.6 l i ters
(3.8 US qt, 3.2 Imp qt)
RF-N: 5.0 l iters
2 A - 6
I n te rva l
P rocedure & i t em
M o n t h s
x 1000 Km
Miles x 1000
Fuel l ines and hoses (I) only for Diesel
S p a r k p l u g s
Id le speed
0.6
(I)
6
®1
O
o
o
o
o
o
o
©2
O
o
o
o
o
o
o
© 3
O
o
o
o
o
o
© 4
O
o
o
Oi l pan capaci ty
F6, F8, FE
Oil f i l ter capacity
F8, FE 12-va lve (SOHC)
F E ( D O H C )
RF-N
nents for leaks
P l u g g a p
F E D O H C 0 . 7 — 0 . 8 m m
( 0 . 0 2 8 - 0 . 0 3 1 i n )
O t h e r s 0 . 7 5 — 0 . 8 5 mm
( 0 . 0 3 0 — 0 . 0 3 3 i n )
R e c o m m e n d e d s p a r k p l u g s
F6,F8,FE FE 12 VALVE, DOHC
N G K
N i p p o n
Denso
Q 1 6 P R - U *
Q 2 0 P R - U
F6 F8 FE (8 VALVE) (12 VALVE)
6 ± 1 ° B TDC
1 2 ± 1 ° B T D C
C h e c k t h e i d l e s pe e d
MTX 8001
(in "N " range)
(in "N " range)
F E D O H C 7 0 0 — 8 0 0 r p m
§ *Only FE 12 VALV E
P a g e
Procedure & i t em
© 1 © 2
© 3
© 4
In te rva l
Procedure & i t em
© 3
© 4
In te rva l
Procedure & i t em
© 3
© 4
In te rva l
Procedure & i t em
© 3
© 4
Idle mixtu re (1) only for carbre tor
(I)
• CO concentrat io n
HC concentrat ion
4 A - 3 8
4 C - 3 0
X X X
Brake l ines, hoses and connect ions
I I I I o o o o • P rope r a t t achmen t and connec t i ons 1 1 - 8
Disc brakes
o o
• Min. disc thickne ss:
22 mm (0.87 in)
Rear 8.0 mm (0.31 in)
• Disc run out:
11—45
11—54
11—45
11—54
11—45
11—54
Drum brakes
1.0 mm (0.004 in)
14 or 15 inch-wheel
230.1 mm (9.06 in)
rod ends
1 0 - 1 1
0 o
7A—6
Auto mat ic transax le fluid level I I I
I o o X
3-Speed
7B—71
Procedure & i t em
Number of Months or km, whichever corns f i rst
©1
© 2
© 3
© 4
Page
Page
Page
0.6
6
12
18
Page
leakage
9 - 3 2
T
T
T
TUNE-UP PROCEDURE 1A— 6
COMPRESSION 1A—13
ASSEMBLY 1A—62
OUTLINE
The new 626 is equipped with F-series gasoline engine and R-series diesel engine. (R-series diesel
engine — explained in section 1C.) F-series engine has following variations.
1. SOHC model
(2) 8-valve mod el 1.6 I = F6 engine
1.8 £ = F8 engine
2.0 £ = FE engine
2.0 £ 16-valve = FE DOHC engine
STRUCTURAL VIEW
— — E n g i n e m od e l
I tem ^
— — E n g i n e m od e l
I tem ^
Pentroof Multispherical
Valve system
1,99 8 (121.9 ) 1,78 9 (109.1 ) 1,587 (96.8)
Bore and st roke mm ( in)
86.0 x 86.0 (3.39 x 3.39) 86.0 x 77.0 (3.39 x 3.03)
81.0 x 77.0
(3.19 x 3.03)
Compression rat io
65° 65° 56° 56°
IN
EX
Id le speed rpm
950 _
+5
§ carb.
6° ± 1°
Possible Cause Rem edy Page
Di f f i cu l t s ta r t ing Ma l func t ion o f eng ine - re la ted compon ents
Burned valve
Worn p is ton, p is ton r ing, or cy l inder
Fai led cy l inder head gasket
Replace
Mal func t ion o f fue l sys tem
Refer to Section 4
Mal func t ion o f e lec t r i ca l sys tem
Refer to Section 5
Poor idl ing
Ma l func t ion o f eng ine - re la ted components
Malfunct ion of HLA
Improper valve c learance
Replace
Adjust
Refer to Section 4
Oil working up
Worn p is ton r ing groove or s t ick ing p is ton r ing
Worn p is ton or cy l inder
Replace
Worn valve seal
Replace
Replace
Insu f f i c ien t compress ion
Malfunct ion of HLA
Seized valve stem
Cracked or d is tor ted cy l inder head
St ick ing, damaged, or worn p is ton r ing
Cracked or worn p is ton
Replace
Adjust
Repair
Replace
Replace
Replace
Replace
Replace
Replace
Refer to Section 4
Refer to Section 6
Refer to Section 11
Refer to Section 12
combust ion
Ma l func t ion o f eng ine - re la ted com ponents
Malfunct ion of HLA
Carbon accumu lat ion in combus t ion chambe r
Replace
Adjust
Replace
Replace
A—75
1A—10
1A—49
1A—53
Mal func t ion o f fue l sys tem Refer to Section 4
Engine noise
Excessive main bear ing o i l c learance
Main bear ing seized or heat-damaged
Excessive crankshaf t end p lay
Excessive connect ing rod bear ing o i l c learance
Connect ing rod bear ing seized or heat-damaged
Replace or repair
Worn p is ton or p is ton p in
Seized piston
Bent connect ing rod
A—57
1A—59
Va lves o r t im ing re la ted par ts
Malfunct ion of HLA*
Broken valve spr ing
Malfunction of t iming belt tensioner
Replace
Adjust
Replace
Replace
Replace
Refer to Section 3A
Malfunction of fuel system
Refer to Section 4
Improper dr ive bel t tension
Mal funct ion of a l ternator bear ing
Exhaust gas leakage
1 A — 4 8
* Tappet noise may occur i f the engine is not operated for an extended per io d of t ime. The noise should stop af ter the
engine has reached normal operat ing temperature.
76G01A-005
described below.
Battery
1. Check for corro sion o n the terminals, or loose ca-
ble connections.
If necessary, clean the clamps and tighten firmly.
2. Ch eck that the electrolyte level is between the UP-
PER and LOWER marks.
3. Check the specific gravity by using a hydrometer.
If the specific gravity reading is 1.200 or less,
recharge the battery. (Refer to Section 5.)
Air Cleaner Element
dirt, damage, or oil. Replace if necessary.
Caution
pressed air, replace if necessary.
Engine Oil
Check the engine oil level and condition with the oil
level gauge.
76G01A-019
Coolant Level (Cold engine)
1. Check that the coolant level is near the radiator inlet
port.
2. Check that the level in the coolan t reservoir is be-
tween the FULL and LOW marks.
Add coolant if necessary.
gine is hot.
b) Wrap a thick cloth around the cap and care-
fully remove it.
1. Check the drive belt for wear, cracks, or fraying.
Replace if necessary.
2. Check the drive belt tension by using the tension
gauge.
Standard belt tension N (kg, lb)
B e l t N e w U s e d
A l t e r n a t o r 5 8 9 - 7 8 5 ( 6 0 - 8 0 , 1 3 2 - 1 7 6 ) 4 9 1 - 6 8 7 ( 5 0 - 7 0 , 1 1 0 - 1 5 4 )
P / S 6 8 7 - 8 8 3 ( 7 0 - 9 0 , 1 5 4 - 1 9 8 )
5 8 9 - 7 8 5 (6 0 - 8 0 , 1 3 2 - 1 7 6 )
A / C
6 8 7 - 8 8 3 ( 7 0 - 9 0 , 1 5 4 - 1 9 8 ) 5 8 9 - 7 8 5 ( 6 0 - 8 0 , 1 3 2 - 1 7 6 )
76G01A-006
76G01A-007
ate pressure (98 N, 10 kg, 22 lb) midway between
the pulleys.
If necessary, loosen the alternator mounting
bolts and adjust the belt deflection by turning
the adjusting bolt.
31—46 Nm (3.2—4.7 m-kg, 23—34 ft- lb)
(§): 37—52 Nm (3.8—5.3 m-kg, 27—38 ft- lb)
(2) P/S belt deflection
If necessary, loosen the idler pulley lock bolt
and adjust the belt deflection by turn ing the ad-
justing bolt.
37—52 Nm (3.8—5.3 m-kg, 27—38 ft- lb)
76G01A-019
76G01A-009
76G01A-010
W e a r a n d a d h e s i o n
of carbon
deterioration
76G01A-011
and adjust the belt deflection by turning the ad-
justing bolt.
Tightening torque
37—52 Nm (3.8—5.3 m-kg, 27—38 ft- lb)
(§): 37—52 Nm (3.8—5.3 m-kg, 27—38 ft- lb)
(4) P/S and A/C belt deflection
New : 7—9 mm (0.27—0.35 in)
Used: 8—10 mm (0.31—0.39 in)
If necessa ry, adjust the belt deflection using the
same procedure as used for the A/C belt
deflection.
necessary.
Distributor Cap
1. Cracks or carbon deposits
2. Burnt or corroded terminals
3. Worn distributor center contact
86U01X-013
necessary.
76G01A-013
1. Run the engine at idle.
2. Ch eck that the fuel level is at the center of the float
level indicator window.
If necessary, adjust the fuel float level. (Refer to Sec-
tion 4A.)
Note
noise should stop after the engine has
reached normal operating temperature.
1. Check for tappet noise. If noise exsits, check the
following points.
(2) Engine oil pressure (Refer to Section 2A)
2. If the noise does not stop, check for movement of
each HLA by pushing down each rocker arm by
hand while at TDC of compression stroke.
3. If the rocker arm moves dow n, replace the HLA.
(Refer to page 1A—75.)
76G01A-014
1
SsKs&b ' Valve
Valve Clearance (8-valve)
1. Warm up the e ngine to the normal operating tem-
perature.
2. With the piston of the No.1 cylinder at TDC of com-
pression stroke.
Adjust the valve clearance as show n in the figure.
Valve clearance (valve side)
IN : 0.30 mm (0.012 in)
EX: 0.30 mm (0.012 in)
3. Turn the crank shaft on e full turn so that the piston
of the No.4 cylinder is at TDC of compression
stroke.
Ignition Timing
1. Warm up the engine and run it at idle.
2. Turn all electric loads OFF.
3. Connect a timing light tester.
4. Disconnect the vacuum hose from the vacuum
control, and plug the hose.
5. Chec k that the ignition timing m ark (yellow) on the
crankshaft pulley and the timing mark on the tim-
ing belt cover are aligned.
Ignition timing: 6° ±
6. If necessary adjust the ignition timing by turning
the distributor.
2. Turn all electric loads OFF.
3. Confirm that the choke valve has fully returned at
idling speed.
4. Check the idle speed. If necessary, turn the throt-
tle adjust screw and adjust the idle speed.
Idle speed
MTX: 800 ±
900 I
Idle Speed (Fl)
2. Check the idle speed.
Idle speed
3. If necessary, remove the blind cap from the throt-
tle body a nd adjust by turning the air adjust screw.
4. Install the blind cap.
76G01A-018
valves and then plug the hoses (if equipped).
2. Connect a n exhaust gas analyzer to the vehicle as
shown in the figure and measure the CO concen-
tration.
76G01A-106
screw.
Note
The blind cap will be broken when it is re-
moved, do not attempt to reinstall it.
76G01A-019
Mixture adjust screw
4. Turn the mixture adjust screw and adjust the CO
concentration to the specified level.
CO concentration: 2.0 ± 0.5 %
5. If the idle spee d fails to meet the s pecification, ad-
just the idle speed again, then adjust the CO con-
centration.
6. Fit a new blind cap onto the mixture adjusting
screw.

or poor idle, check the following points.
1. Ignition system (Refer to Section 5)
2. Compression
COMPRESSION
if necessary.
76G01A-107
2. Warm up the en gine to the normal operating tem-
perature.
3. Turn it off for about 10 minutes to allow the exha ust
manifold to cool.
5. Disconnect the primary wire connector from the
ignition coil.
6. Connect a compression gauge to No. 1 spark plug
hole.
engine.
9. Check each cylinder.
Compression pressure kPa (kg/cm
790 (8.1, 114)—270
893 (9.1, 129)—270
FE 12-valve 1,422 (14.5, 206)—2 80 996 (10.2, 14 4)—2 80
76G01A-023
1 A ON-VEHICLE MAINTENANCE (TIMING BELT)
O N - V E H I C L E M A I N T E N A N C E
TIMING BELT
1. Disconnect the negative battery cable.
2. R emove in the seq uence shown in the figure referring to the removal n ote for specially marke d parts.
76G01A-108
76G01A-024
3. Drive belt
4. Crankshaft pulley
6. Lower timing belt cover
7. Baffle plate
10. Timing belt
Timing belt tensioner
1. Turn the cranksh aft to align the ma ting mark of the
camshaft pulley with the front housing timing mark.
Note
For F8, F6 engine, al ign "3" mark.
2. Remove the tensioner.
if it is reused.
on the belt.
1. Timing belt
3. Timing belt idler pulley
4. Timing belt pulley
Installation
Install in the reverse order of removal referring to the installation note.
Torque Specif ications
7—10 N-m
12—17 N-m
8- 11 N-m
(80—110 cm-kg,
Installation note
Timing belt
1. Chec k that the mark on the timing belt pulley is
aligned with the mating mark.
86U01X-220
76G01A-027
76G01B-024
76G01A-028
/Jf
ry.
2. Check that the mating mark of the camshaft pul-
ley is aligned with the timing mark. If it is not
aligned, turn the camshaft to align.
Note
For F8, F6 engine, al ign "3" mark.
3. Install the timing belt tensioner and spring. Tem-
porarily secure it with the spring fully extended.
Caution
tensioner pulley.
4. Install the timing belt. (Keep the tension side of belt
as tight as possible).
Caution
a) If the timing belt is being reused, it must be
reinstalled to rotate in the original direction.
b) Check that th ere is no oil, grease, or dirt on
the timing belt.
6. Turn the crankshaft twice in the direction of rota-
tion, and align the mating marks.
7. Check that the timing marks are correctly aligned.
If not aligned, remove the timing belt tensioner and
timing belt, and repeat steps 1—6.
69G01B-027
8. Tighten the timing belt tensioner lock bolt.
Tightening torque:
37—5 2 N-m (3.8—5.3 m-kg, 27— 38 ft- lb)
69G01B-028
above.
F8, F6: 4.0—5.0 mm (0.16—0.20 in)
/98 N (10 kg, 22 lb)
Caution
of the tensioner spring.
69G01B-030
Drive belt
Install each drive b elt, and chec k the belt deflection.
76G01A-030
2. Install the spark plugs.
Tightening torque:
15—23 N-m (1.5—2 .3 m-kg, 11— 17 ft- lb)
79G01C-021
TUNE-UP PROCEDURE.)
CYLINDER HEAD
2. Drain the engine coolant.
3. R emove in the sequ ence shown in the figure referring to the removal note for specially marked parts.
76G01A-110
2. Accelerator cable
6. Fuel hose
12. Three-way solenoid assembly
General)
16. Exhaust manifold insulator
21. Intake manifold assembly
26. Timing belt
76G01A-031
Warning
a) Cover the hose with a rag becaus e fuel w ill
spray out when disconnecting.
fuel area.
Timing belt
1. Before removing the timing belt, turn the crankshaft
to align the mating m ark of the camshaft pulley with
the front housing timing mark.
Note
For F8, F6 engine, align "3" mark.
2. Loosen the timing belt tensioner lock bolt.
3. Shift the tensioner ou tward as far as possible, then
temporarily tighten it.
69G01B-037
76G01A-111
4. R emove the timing belt and secure it out of the way
to prevent damage during removal and installation
of the cylinder head.
Loosen the cylinder head bolts in two or three steps
in the order shown in the figure.
Disassembly of Cylinder Head
Inspection of Cylinder Head
Assembly of Cylinder Head
76G01A-033
Installation
Note
a) Position the hose clamp in the original location on the hose.
b) Squee ze the clam p lightly with large pliers to ensure a good fit.
27-46 ft-lb)
Installation note
Cylinder head
1. Thoroughly remove all dirt and oil from the top of
the cylinder block with a rag.
2. Place a new cylinder head gasket in position.
86U01X-035
3. Set the cylinder head in place.
4. App ly eng ine oil to the bolt threads an d seat faces.
5. Tighten the cylinder head bolts in two or three steps
Tightening torque:
80—86 N-m (8.2—8.8 m-kg, 59—64 ft- lb)
86U01X-036
Cylinder head cover
1. Apply silicon sealant to the shade d area shown in
the figure.
Tightening torque:
6— 8
86U01X-037
1. Align the mating mark of the camshaft pulley with
the front housing timing mark.
Note
2. Install the timing belt. (Refer to TIMING BELT of
ON-VEHICLE MAINTENANCE.)
76G01A-035
Distributor
1. Apply engine oil to the O-ring, and position it on
the distributor.
2. Apply engine oil to the blade or gear.
3. Align the m ating marks as s hown in the figure
. . .8 -va lve.
4. Install the distributor with the marks fac ing straight
up.
1. IG coil
2. Engine ground
3. Water tempera-
Steps After Installation
1. Fill the radiator with the specified amo unt and type
of coolant.
fer to TUNE-UP PROCEDURE.)
VALVE SEAL
2. Drain the engine coolant.
3. R emove in the seque nce sh own in the figure referring to the removal note for specially marked parts.
76G01A-114
14. Camshaft cap (12-valve)
18. Valve spring
20. Valve seal
2. Air intake pipe (Fl)
3. High-tension lead and spark plug
4. Upper t iming belt cover
5. Timing belt
Rocker arm and shaft assembly
Loosen the rocker a rm shaft bolts in two or three steps
76G01A-037
8-valve
rocker arm shaft.
onto the cylinder head.
3. Plug the oil drain hole with a rag to prevent the pos-
sibility of the valve keepers from falling into the oil
pan.
86U01X-045
valve seal to be replaced at top dead center.
5. Remove the valve keepers with the SST.
6. Remove the valve spring and spring seats.
86U01X-046
7. Remove the valve seal from the valve guide with
the SST.
spring is removed.
86U01X-047
Installation
Torque Specifications
1 6 — 2 7 N - m (1 . 6 — 2 . 8 m - k g , 1 2 — 2 0 f t - lb )
76G01A-115
Installation note
Valve seal
1. Apply engine oil to the inside of the new valve seal.
2. Push it on gently with the SST.
86U01X-049
Install the valve spring with the na rrower pitch to-
ward the cylinder head side.
(8-valve)
toward the cylinder head side.
2. Install the valve keepers, and 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.
76G01A-038
12-valve
1. Remove the rocke r arm shafts and camshaft caps.
2. (12-valve)
Assemble the rocker arms and sp rings to the shaft.
Note
a) The intake side sh aft has twice as many oil
holes as the exhaust side shaft.
b) The stepped ends are the rear sides of bo th
intake and exhaust shafts.
springs, to the shafts.
Be sure both rocker arm shaft oil holes (in the
center camshaft cap) face each other.
76G01A-040
Camshaft
1. Apply sealant to the shaded areas as shown in the
figure.
76G01A-041
76G01A-042
12-valve
(12-valve)
2. Install the rocker arm and shaft assemblies on the
cylinder head, and tighten them in three steps in
the order shown in the figure.
Tightening torque:
18—26 Nm (1.8—2.7 m-kg, 13—20 ft- lb)
76G01A-043
Caution
Be careful that the rocker arms or spacers d o
not get caught between the shaft and cam-
shaft cap.
76G01A-044
86U01X-212
76G01A-045
(8-valve)
Install the rocker arm a nd shaft assemblies on the cyl-
inder head and tighten them in three steps in the or-
der shown in the figure.
Tightening torque:
18—26 N-m (1.8—2.7 m-kg, 13—20 ft- lb)
Front housing
3. Install the front housing along with a new gasket.
Tightening torque:
19—25 N-m (1.9—2 .6 m -kg, 14—19 ft- lb)
Rear housing
Tightening torque:
19—25 N-m (1.9—2 .6 m -kg, 14—19 ft- lb)
Camshaft pulley
1. Install the cam shaft pulley so that the mating mark
is aligned with the cam shaft dow el pin straight up.
Note
2. Tighten the lock bolt.
Tightening torque:
47—65 N-m (4.8—6.6 m-kg, 35—48 ft- lb)
Timing belt
Install the timing belt. (Refer to TIMING BELT of ON-
VEHICLE MAINTENANCE.)
Adjust the valve clearance. (Refer to page 1 A—10.)
Cylinder head cover
in the figure.
Tightening torque:
76G01A-116
Distributor
1. Apply engine oil to the O-ring, and position it on
the distributor.
2. Apply engine oil to the blade or gear.
3. Align the mating m arks as shown in the figure
. . .8-va lve.
4. Install the distributor w ith the m arks facin g straight
up.
76G01A-035
Steps After Installation
1. Fill the radiator with the specified am ount a nd typ e
of coolant.
fer to TUNE-UP PROCEDURE.)
REMOVAL
2. Drain the engine oil and coolant.
3. Re move in the seq uenc e show n in the figure referring to the remova l note for specially marke d parts.
76GG1A-117
13. Three-way solenoid
Engine side cover
27. Lower arm bushing
Driveshaft
Clutch release cylinder 29.
10. Radiator and coo ling fan 19. Control cable (ATX)
31. Exhaust pipe
A/C compressor and 33. Engine and transaxle
bracket
34.
Transaxle
76G01A-046
Warning
a) Cover the hose with a rag because fu el will
spray out when disconnecting.
b) Keep sparks and open f lame away from the
fuel area.
76G01A-11E
Remove the P/S pump and A/C compressor with the
hoses stil l connected to them, s ecure the pum p and
compressor as shown in the figure.
67U01X-029
Driveshaft
the SST into the transaxle.
86U01X-060
1 A DISASSEMBLY (AUXILIARY PARTS)
D I S A S S E M B L Y
1. Remove in the sequenc e shown in the figure referring to the disassembly note for specially marked
parts.
2. Code all identical parts (such as pistons, piston rings, connecting rods, and valve springs) so that
they can be reinstalled in the cylinder from which they were removed.
3. Clean the parts with steam, blow off any remaining water with compressed air.
Note
Care should be taken during the disassembly of any part or system to study its order of
assembly. Any deformation, wear, or damage should also be noted.
AUXILIARY PARTS
1. Oil level gauge
3. Secondary air pipe assembly (except
General)
5. Exhaust manifold insulator
6. Exhaust manifold assembly
8. Engine hanger
11. Engine mount bracket
13. Spark plug
16. Intake manifold assembly
19. Oil pressure switch
to the engine.
TIMING BELT
7. Timing belt
8. Camshaft pulley
3. Lower timing belt cover
4. Baffle plate
1 A — 3 8
Mark the
direction of
2. Remove the crankshaft pulley.
Timing belt
1. Loosen the tensioner lock bolt, and remove the ten-
sioner spring.
tion if it is reused.
3. Remove the timing belt.
Caution
Be careful not to allow oil or grease on the
belt.
Remove the pulley lock bolt using a screw driver to
prevent the camshaft from turning.
76G01A-123
CYLINDER HEAD (12-valve)
10. Valve keeper
Disassembly Note
Before removing the rocker arm and shaft assembly,
clean the bearings a nd journals, and m easure the fol-
lowing points.
1. Cams haft end play. (Refer to pag e 1A—54 .)
2. Cams haft journal oil clearance. (Refer to p age
1 A—54.)
1. Loosen the bolts in two or three steps in the o rder
shown in the figure.
2. Remove the rocker a rm and shaft assembly togeth-
er with the bolts.
Caution
a) Do not mix up the various parts of the rock-
er arm and shaft assembly.
b) Do not remove the HLA unless n ecessa ry.
86U01X-067
86U01X-068
4 9 0 6 3 6 1 0 0 A
Valve
SST.
86U01X-069
5. Camshaft
76G01A-049
76G01A-057
clean the bearings a nd journals, and measure the fol-
lowing points.
2. Cams haft journal oil clearance. (Refer to p age
1A—54.)
1. Loosen the bolts in two or three steps in the order
er with the bolts.
Caution
Do not mix up the various pa rts of the rocker
arm and shaft assembly.
86U01X-068
Valve
SST
86U01X-069
CYLINDER BLOCK—I
3. Flywheel (MTX), Adaptor (ATX)
4. End plate
5. Oil pan
8. Rear cover
76G01A-125
Remove the clutch cover and flywheel (MTX), or drive
plate (ATX) with the SST.
Oil pan
1. Remove the oil pan mounting bolts.
2. Insert a scraper or a suitable tool between the oil
pan and the stiffener or the cylinder block to sep-
arate them.
Caution
76G01A-052
CYLINDER BLOCK—II
following points.
1. Con necting rod side clearance. (Refer to pag e
1A—67.)
2. Cran kpin oil clearance.(Refer to page 1A—6 7.)
1. Conne cting rod cap
2. Conne cting rod bearing
3. Conne cting rod and piston
4. Piston ring
Main bearing cap
following points.
1. Cranksh aft end play. (Refer to pag e 1A —66.)
2. Main journal oil clearance. (Refer to pag e
1
Remove the pilot bearing from the cranksh aft with the
SST.
86U01X-076
1. Before disassembling the piston and connec ting
rod, check the oscil lation torque as show n in the
figure.
If the large end do es not drop by its own weight,
replace the piston or the piston pin.
79G01C-050
If it is lower than 5kN (500kg, 1,100 lb), replace
the piston pin or connecting rod.
76G01A-139
INSPECTION AND REPAIR1A
INSPECTION AND REPAIR
1. Clean all parts, taking care to remove any gasket fragments, dirt, oil or grease, carbon, moisture
residue, or other foreign materials.
2. Inspect and repair must be performed in the order specified.
Caution
Be careful not to dam age the joints or friction surfaces of aluminum alloy comp onents (such
as the cylinder head or pistons).
86U01X-077
Cylinder Head
1. Inspect the cylinder head for damag e, cracks, a nd
leakage of water or oil. Replace if necessary.
2. Measu re the cylinder head distortion in the six
directions shown in the figure.
Distortion: 0.15 mm (0.006 in) max.
79G01C-106
tion, grind the cylinder head surface.
If the cylinder head height is not within specifica-
tion, replace it.
Grinding limit: 0.20 mm (0.008 in) max.
Note
the following. Replace if necessary.
• Sinking of valve seat
• Camsh aft oil clearance and end play
Measure the manifold contact surface distortion in
the six directions shown in the figure.
Distortion: 0.15 mm (0.006 in) max.
If distortion exceeds s pecification grind the surface
or replace the cylinder head.
79G01C-053
S t e m t i p
M a r g i n
t h i c k n e s s
V a l v e f a c e
a n g l e
4 5 °
\
V
resurface if necessary.
(2) Roughness or damage to face
(3) Damage or uneven wear of stem tip
2. Check the valve head margin thickness. Replace
if necessary
Margin thickness
3. Measure the valve length.
Length
Diameter
( 0 . 2 7 4 4 - 0 . 2 7 5 0 )
8 . 0 3 0 — 8 . 0 4 5
( 0 . 3 1 6 1 - 0 . 3 1 6 7 )
EX
( 0 . 2 7 4 2 - 0 . 2 7 4 8 )
8 . 0 2 5 - 8 . 0 4 0
( 0 . 3 1 5 9 - 0 . 3 1 6 5 )
5. Measure the valve guide inner diameter.
Inner diameter mm (in)
12-va lve 8-va lve
( 0 . 2 7 6 0 — 0 . 2 7 6 8 )
8 . 0 7 — 8 . 0 9
( 0 . 3 1 7 7 — 0 . 3 1 8 5 )
EX
( 0 . 2 7 6 0 - 0 . 2 7 6 8 )
8 . 0 7 - 8 . 0 9
( 0 . 3 1 7 7 - 0 . 3 1 8 5 )
6. Measure the valve stem to guide clearance.
(1) Method No. 1
from the inner diameter of the co rrespon ding
valve guide.
V a l v e g u i d e
C y l i n d e r h e a d
76G01A-057
off the valve seat.
EX: 0.030—0.065 mm (0.0012—0.0026 in)
Maximum: 0.20 mm (0.0079 in)
7. If the clearance exceed s the maximum , replace the
valve and/or valve guide.
8. Chec k that the valve g uide projection height
(dimension A in the figure). Replace if necessary.
Height:
Replacement of valve guide
valve guides are different, use the exhaust
valve guide on both sides as a replacement.
86U01X-214
Removal
1. Gradually heat the cylinder head in water to ap -
prox. 90°C (194°F).
76G01A-131
12-valve:
8-valve:
4 9 0 2 4 9 0 1 O A
4 9 0 2 2 1 2 5 1 A
76G01A-058
76G01A-059
V \
86U01X-087
2. Rem ove the valve guide from the side opposite the
combustion chamber with the SST.
3. Remove the valve guide clip (8-valve).
Installation
1. Fit the clip onto the valve guide (8 valve).
2. Gradually heat the cylinder head in water to ap -
prox. 90°C (194°F).
3. Tap the valve guide in from the side opposite the
combustion chamber with the SS T until the projec-
tion height is as specified.
Valve Seat
1. Inspect the contact surface of the valve seat and
valve face for the following.
(1) Roughness
(2) Damage
2. If necessary, resurface the valve seat with a 45°
valve seat cutter and/or resurface the valve face.
3. App ly a thin coat of prussian blue to the valve face.
4. Che ck the valve se ating by ro tating the valve
against the seat.
(1) If blue does not appear 36 0° arou nd the valve
face, replace the valve.
(2) If blue does not appear 36 0° aro und the valve
seat, resurface the seat.
76G01A-128
86U01X-088
Width: 1.2—1.6 mm (0.047—0.063 in)
6. Che ck that the valve seating position is at the cen-
ter of the valve face.
(1) If the seating po sition is too high , correct the
valve seat with a 6 0 ° cutter and a 4 5 ° cutter.
(2) If the seating position is too low, correct the
valve seat with a 35° (IN) or 15° (EX) cutter
and a 4 5 ° cutter.
7. Seat the valve to the va lve seat with a lappin g
compound.
76G01A-060
Measure protruding length (dimension L) of each
valve stem.
46.5 mm (1.831 in).... 8 -valve
(1) If L is as below, it can be used as it is.
50.2—51.0 m m (1.976—2.008 in)..12-valve
46.5— 48.0 mm (1.831— 1.890 in).. 8-valve
(2) If L is as below, insert a spacer between the
spring seat and cylinder head to adjust.
51.0—51.7 mm (2.008—2.035 in)..12-valve
48.0—48.7 mm (1.890—1.917 in). . 8-valve
(3) If L is more than as below, replace the cylin-
der head.
1 A — 5 2
76G01A-062
86U01X-092
76G01A-063
A
1. Inspect each valve spring for cracks or dama ge.
2. Check the free length a nd angle. Replace if
necessary.
Camshaft
Check the camshaft runout. Replace if necessary.
Runout: 0.03 mm (0.0012 in) max.
2. Check the cam for wear or damage . Replace if
necessary.
3. Check the cam lobe height at the two points as
38.160 (1.5024)
37.96 (1.494)
4. M easure wear of the journals in X and Y directions
at the two points as shown in the figure.
Diameter mm (in)
3 1 . 9 4 0 - 3 1 . 9 6 5
(1 .2575-1 .2585)
3 1 . 9 4 0 - 3 2 . 0 3 5
( 1 . 2 5 7 5 - 1 . 2 6 1 2 )
No. 2,3,4
3 1 . 9 1 0 - 3 1 . 9 3 5
(1 .2563-1 .2573)
3 1 . 9 1 0 - 3 2 . 0 6 5
(1.2563—1.2624)
76G01A-129
86U01X-095
camshaft caps.
(1) R emove any oil, or dirt from the journals an d
bearing surface.
(3) Position plasti-gauge on top of the journals in
the axial direction.
(4) Place the camshaft caps and rocker a rm shafts
in position, and tighten them to the specified
torque.
m (1.8—2 .7 m-kg, 1 3—20 ft- lb)
(5) Remove the camshaft caps and measure the
oil clearance at each cap.
Oil clearance
Center three journals:
Maximum: 0.15 mm (0.0059 in)
(6) If the oil clearanc e exce eds the max imum , re-
place the cylinder head.
6. Measure the camshaft end play. If it exceeds the
maximum, replace the camshaft and/or the cylin-
der head.
End play:
Maximum: 0.20 mm (0.008 in)
86U01X-097
76G01A-131
1. Check for wear or damage to the contact surface
of the rocker arm shaft and the rocker arm. Re-
place if necessary.
and shaft. Replace if necessary.
(1) Measure the rocker arm inner diameter.
Diameter:
...12-valve
... 8-valve
76G01A-065
76G01A-066
86U01X-100
Diameter:
...12 valve
... 8 valve
(3) Subtract the shaft diameter from the rocker a rm
diameter.
0.10 (0.0039)
( 0 . 0 0 0 6 - 0 . 0 0 2 4 )
0.10 (0.0039)
if necessary.
prevent damaging the O-ring.
Cylinder Block
1. Che ck the cylinde r block. Repair or re place if
necessary.
(3) Scoring of wall
2. M easure the distortion of the top su rface of the cyl-
inder block in the six directions as shown in the
figure.
3. If the distortion exceeds the maximum, repair by
grinding, or replace the cylinder block.
Grinding limit: 0.20 mm (0.008 in) max.
86U01X-117
4. Measure the cylinder bore in directions X and Y
at three levels in each cylinder as shown.
Cylinder bore
mm (in)
6
F6
1.00 (0.039) oversize 82.0 00-8 2.01 9 (3.228 3-3.2 291)
(1) If the difference b etween the measu rement A
and C exceeds the maximum taper, rebore the
cylinder to oversize.
79G01C-071
(2) If the difference betwee n the measuremen t X
and Y exceeds the maximum out-of-round, re-
bore the cylinder to oversize.
Out-of-round: 0.019 mm (0.0007 in) max.
Caution
of an oversize piston and be the same for all
cylinders.
79G01C-072
5. If the upper part of the cylinder wall shows un even
wear, remove the ridge with a ridge reamer.
86U01X-117
seizure or scoring. Replace if necessary.
2. Measure the outer diameter of each piston at a right
angle (90°) to the piston pin, 18 mm (0.709 in)
below the oil ring land lower edge.
Piston diameter
mm (in)
F6
6
C l G d r s n c G
1
Maximum: 0.15 mm (0.0059 in)
4. If the clearance exceeds the maximum , replace the
piston or rebore the cylinders to fit oversize pistons.
Caution
rings also.
Piston and Piston Ring
1. Measu re the piston ring to ring land cleara nce
around the entire circumference using a new pis-
ton ring.
2. If the clearance exceeds the maximu m, replace the
piston.
69G01A-125
wear, or breakage. Replace if necessary.
4. Insert the piston ring into the cylinder by h and a nd
push it to the bottom of the ring travel in using the
piston.
5. Measure each piston ring end gap with a feeler
gauge. Replace if necessary.
Second: 0.15—0.30 mm (0.006—0.012 in)
Oil rail : 0.20—0 .70 mm (0.00 8—0 .028 in)
Piston and Piston Pin
1. Measure the piston pin hole diameter in X and Y
directions at four points.
Diameter:
3. Determine the piston pin to piston clearance by
subtracting the two figures.
4. If the clearance exc eeds the specification, replace
the piston and/or piston pin.
86U01X-117
76G01A-070
76G01A-071
86U01X-109
Diameter:
2. Check the interference between the small end bore
and piston pin.
3. Check each connecting rod for bending or twist-
ing. Repair or replace if necessary.
Bend: 0.06 mm (0.0024 in) max.
Twist: 0.06 mm (0.0024 in) max.
Crankshaft
1. Check the journals and pins for dam age, scoring,
or oil hole clogging.
3. Check the crankshaft runout at the center journal.
4. Measure each journal diameter in X and Y direc-
tions at two points.
Out-of-round: 0.05 mm (0.0020 in) max.
Crankpin journal
76G01A-131
76G01A-132
5. If the diameter is less than the m inimum , grind the
journals to match undersize bearings.
Undersize bearing: 0.25 mm (0.010 in),
0.50 mm (0.020 in), 0.75 mm (0.030 in)
Main journal diameter undersize mm (in)
Bearing size Journa l diame ter
025 (0.010)
undersize
No.1,2,4,5
5 9 . 6 9 3 - 5 9 . 7 1 1 ( 2 . 3 5 0 1 - 2 . 3 5 0 8 )
25 (0.010)
undersize
No.3
5 9 . 6 8 7 - 5 9 . 7 0 5 ( 2 . 3 4 9 9 - 2 . 3 5 0 6 )
0.50 (0.020)
.50 (0.020)
undersize
No .3 59 .4 37-5 9 .45 5 (2 .3400—2.3407)
0.75 (0.030)
undersize
No.1,2,4,5
5 9 . 1 9 3 - 5 9 . 2 1 1 ( 2 . 3 3 0 4 - 2 . 3 3 1 1 )
.75 (0.030)
undersize
N o .3 5 9 . 1 8 7 - 5 9 . 2 0 5 ( 2 . 3 3 0 2 - 2 . 3 3 0 9 )
Rolled fillet
Bearing size Journa l diameter
0.25 (0.010) undersize
50 .690—50.705 (1 .9957-1 .9963)
0.50 (0.020) unders ize 50 .44 0-5 0.4 55 (1.9858 —1.9864)
0.75 (0.030) undersize
5 0 . 1 9 0 - 5 0 . 2 0 5 ( 1 . 9 7 6 0 - 1 . 9 7 6 6 )
Caution
76G01A-133
bearings for peeling, scoring, or other damage.
79G01C-077
Timing Belt
1. Replace the timin g belt if there is any oil or grea se
on it.
cracks, or hardening. Replace if necessary.
86U01X-117
Caution
bend the timing belt.
b) Be careful not to allow oil or grease on the
belt.
86U01X-114
Check the timing belt tensioner and idler pulley for
smooth rotation and abnormal- noise. Replace if
necessary.
Caution
fluids. If necessary, use a soft rag to wipe it
clean, and avoid scratching it.
86U01X-115
if necessary.
64.1 mm (2.524 in) F8, F6
76G01A-134
Inspect the pulley teeth for wear, deformation, or other
damage. Replace if necessary.
If necessary, use a rag to wipe it clean.
Timing Belt Cover (lower and upper)
Inspect the timing belt covers for damage or cracks.
A S S E M B L Y
1. Clean all parts before reinstallation.
2. Apply new engine oil to all sliding and rotating parts.
3. Replace plain bearings if they are peeling, burned, or otherwise damaged.
4. Tighten all bolts and nuts to the specified torques.
Caution
CYLINDER BLOCK—I
Connecting Rod
2. Apply engine oil to the piston pin.
86U01X-118
3. Set the piston on the S ST with the F mark facing
upward.
4. Set the connecting rod in piston with the oil hole
in the large end opposite the F mark.
76G01A-135
5.
ing rod until the SST contacts the block.
While inserting the piston pin, check the pressure
force. If it is less than s pecified, replace the piston
pin or the connecting rod.
Press force:
Piston Ring
1. Install the three-piece oil rings on the pistons.
(1) Apply engine oil to the oil ring spacer and rails.
(2) Install the oil ring spac er so that the o pen ing
faces upward.
Note
a) The upper rail and lower rail are the same .
b) Each rail can be installed with either face
upward.
69G01A-144
S p a c e r i a n g
Oil r ing
s p a c e r e n d s
Upper rail
Pis ton
/ S e c o n d r i n g
69G01A-147
2. Check that both rails are expanded by the spacer
tangs as shown in the figure by checking that both
rails turn smoothly in both directions.
3. Install the second ring to the piston first, then in-
stall the top ring. Use a piston ring expander.
Caution
marks facing upward.
4. Apply a liberal amount of clean engine oil to the
second and top piston rings.
5. Position the opening of each ring as shown in the
figure.
Crankshaft
bearing oil clearances as described.
Note
ter bearing in the cylinder block.
86U01X-136
86U01X-122
.•I
86U01X-123
76G01A-073
(1) Remo ve any foreign material and oil from the
journals and bearings.
(2) Install the upper main bearing s in the cylinder
block.
(4) Position the plasti-gauge on top of the journals
in the axial direction.
lower main bearings according to the cap num-
ber and ^ mark.
(6) Tighten the caps in two or three steps in the
order in the figure.
82—88 N-m (8.4—9.0 m-kg, 61—65 ft- lb)
Caution
the oil clearances.
point for the smallest clearance, and at the nar-
rowest point for the largest clearance.
If the oil clearance exceed s specification, grind
the crankshaft and use undersize main bear-
ings. (Refer to page 1A—59.)
Oil clearance
0 .025—0.043 mm (0 .0010—0.0017 in)
No. 3:
Maximum: 0.08 mm (0.0031 in)
2. Apply a liberal amount of engine oil to the main
bearings and main journals.
accord ing to the cap number and mark.
86U01X-130
76G01A-074
86U01X-216
86U01X-127
End play:
5. If the end play exceeds specification, grind the
crankshaft and use undersize center main bearing.
Center main bearing width
0.25 mm (0.010 in) undersize:
28.04—28.09 mm (1.1040—1.1059 in)
28.12—28.17 mm (1.1071—1.1091 in)
28.20—28.25 mm (1.1102—1.1122 in)
Note
size center main bearing.
1. Apply engine oil to the outer circumference of the
bearing.
2. Set a piece of pipe (outer diameter 30—34 mm,
1.18—1.34 in) against the outer race of the bear-
ing, then tap it evenly into the crankshaft.
3. Lubricate the bearing with grease.
Piston and Connecting Rod Assembly
1. Apply a liberal amount of clean engine oil to the
cylinder walls, piston, and rings.
2. Check the piston rings for the end gap alignment.
3. Insert each piston assembly into the cylinder block
with the F mark facing the front of the eng ine. Use
a piston installer tool (commercially available).
76G01A-136
69G01B-137
Matin
76G01A-075
69G01B-139
1. Check the connecting rod bearing clearances us-
ing the same proced ure as used for the main bear-
ing oil clearance.
65—69 Nm (6.6—7.0 m-kg, 48—51 ft- lb)
Oil clearance:
Maximum: 0.10 mm (0.0039 in)
Caution
the connecting rod when installing the con-
necting rod cap.
If the oil clearance ex ceeds specification, g rind the
crankshaft and use undersize bearings. (Refer to
page 1A—59.)
without the cap installed.
If the clearance exceeds the m aximum, replace the
connecting rod.
4. Apply a liberal amount of engine oil to the crank-
pin journal and connecting rod bearing.
5. Install the connecting rod cap with the alignment
marks aligned.
Tightening torque:
65—69 Nm (6.6—7.0 m-kg, 48—51 ft- lb)
86U01X-130
CYLINDER BLOCK—II
A T X
19—25 N-m
M10 : B igge r
27—38 f t - lb)
96—103 N-m (9 .8—10.5 m-kg , 71—76 f t - l b )
69G01A-166
Rear Cover
1. Apply engine oil to the rear cover, oil seal and oil
seal lip.
4BG01A-158
e x p e r t 2 2 fl/ifl http:/ /rutracker.org
3. Install the rear cover and a new gasket.
Tightening torque:
86U01X-131
4. Cut away the p ortion of the gasket that projects out
from the rear cover assembly toward the oil pan
side.
Caution
86U01X-132
19—30 N-m (1.9—3.1 m-kg, 14—22 ft- lb)
4BG01A-160
Oil Pump
1. Apply e ngine oil to a new oil pum p oil seal and th e
oil pump body.
2. Press the oil seal into the oil pump body.
79G01C-085
1
86U01X-133
76G01A-137
76G01A-076
4. Remove any dirt or other material from the con-
tact surfaces.
5. Apply a continuos bead of silicon sealant to the
contact surface of the oil pump.
Caution
Do not allow any sealant to get into the oil
hole.
7. Install the oil pump.
Tightening torque
(§): 37—52 N-m
8. Remove any sealant which has been squeezed
out.
1. Remove any dirt or other material from the con-
tact surface.
2. Apply a continuous bead of silicon sealant to the
stiffener along the inside of the bolt holes, and over-
lap the ends.
Oil Strainer
Tightening torque:
86U01X-136
1. Apply a continuous bead of silicon sealant to the
oil pan along the inside of the bolt holes, and over-
lap the ends.
Tightening torque:
Flywheel (MTX), Drive Plate (ATX)
1. Remove any old sealant from the bolts and bolt
holes. If old sealant can not be removed from the
bolt,-replace it.
(MTX)
Tightening torque:
96—103 Nm (9.8—10.5 m-kg, 71—76 ft- lb)
(ATX)
plate, and backing plate with the SST.
Tightening torque:
96—103 Nm (9.8—10.5 m-kg, 71—76 ft- lb)
76G01A-139
86U01X-141
86U01X-142
Clutch Disc and Clutch Cover (MTX)
Install the clutch disc and clutch cove r u sing the SST.
(Refer to Section 6.)
22—32 N-m (2.2—3.3 m-kg, 16— 24 ft- lb)
Water Pump
the water pump mounting surface.
2. Place a new O-ring in position.
Caution
3. Install the water pump.
Tightening torque:
19—25 N-m (1.9—2.6 m-kg, 14—19 ft- lb)
7BU01B-103
(1 .9—2.6 m-kg , 14—19 f t - l b )
18—26 N-m
(1 .8—2.7 m-kg , 13—20 f t - l b )
80—86 N-m
(8 .2—8.8 m-kg , 59—64 f t - l b )
19—25 N-m (1.9—2.6 m -kg, 14— 19 f t - lb)
76G01A-077
Valve Seal
2. Install the valve seal onto the valve g uide w ith the
SST
86U01X-143
1

A S S E M B L Y ( CY LIN DER H EA D)1A
86U01X-144
2. Install the valve.
3. Install the valve springs a nd the upp er s pring seat.
Note
toward the cylinder head.
4. Compress the valve spring with the SST; then in-
stall the valve keepers.
5. 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.
Cylinder Head
1. Thoro ughly remove all dirt, oil, or other m aterial
from the top of the cylinder block.
2. Place the new cylinder head gasket in position.
3. Install the cylinder head.
4. Apply engine oil to the bolt threads and seat faces.
5. Tighten the cylinder head bolts in two or three s teps
Tightening torque:
80—86 Nm (8.2—8.8 m-kg, 59—64 ft- lb)
1 A — 7 4
86U01X-148
86U01X-149
86U01X-150
Camshaft
1. Apply a liberal amount of engine oil to the journals
and bearings.
2. Place the camshaft in position with the dowel pin
facing straight up.
Hydraulic Lash Adjuster (HLA)
1. Pour engine oil into the oil reservoir in the rocker
arm.
3. Carefully install the HLA into the rocker arm.
Caution
stalling the HLA.
1. Assemble the rocker arm and shaft assembly as
Note
a) The intake side shaft has twice as m any oil
holes as the exhaust side shaft.
b)T he stepped end s are the rear of the shafts.
2. Apply si l icon sealant to the shaded areas shown
in the figure.

A S S E M B L Y ( CYL IN DE R H EA D)1A
3. App ly liberal amount of clean engine oil to the cam
lobes and journals.
mark.
Note
stalled correctly.
5. Install the rocker arm an d shaft assemblies. Tight-
en the bolts in two or three steps in the order shown
in the figure.
18—26 Nm (1.8—2.7 m-kg, 13—20 ft- lb)
O i l p a s s a g e
86U01X-152
86U01X-153
Caution
Be careful that the rocker arms or space rs do
not get caught between the shaft and cam-
shaft cap.
Front Housing
1. Apply engine oil to the front housing and a new
oil seal.
86U01X-147
3. Apply engine oil to the oil seal lip.
4. Install the front housing and a new gasket.
Tightening torque:
19—25 Nm (1.9—2.6 m-kg, 14—19 ft- lb)
86U01X-156
Tightening torque:
19—25 N m (1.9—2.6 m-kg, 14— 19 ft- lb)
86U01X-157

A S S E M B L Y ( CYL IN DE R H EA D)1A
1 9 - 2 5 N m ( 1 . 9 — 2 .6 m - k g . 1 4 - 1 9 f t - lb )
18—26 N m
(1 .8—2.7 m-kg , 13—20 t t - l b )
80—86 N-m (8 .2—8.8 m-kg , 59—64 f t - l b )
19—25 N-m (1 .9—2.6 m-kg , 14—19 f t - l b )
76G01A-078
Valve Seal
2. Install the valve seal onto the valve guide with the
SST
86U01X-147
Outer valve spring
®
®
C y l i n d e r h e a d
r
Side
®>d)
76G01A-079
86U01X-145
86U01X-146
2. Install the valve.
3. Install the valve springs and the up per spring seat.
Note
pitch toward the cylinder head.
4. Compress the valve spring with the SST; then in-
stall the valve keepers.
5. 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.
Cylinder Head
1. Thoro ughly remove all dirt, oil, or other material
from the top of the cylinder block.
2. Place the new cylinder head gasket in position.
3. Install the cylinder head.
4. App ly en gine oil to the bolt threads and seat faces.
5. Tighten the cylinder head bolts in two or three steps
in the order shown in the fig

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MAZDA 626 1987

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