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REPAIR MAINTENANCE OPERATION OF MOTOR VEHICLES
Mazda 626 (from 1991 to 1998, the year of issue)

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Mazda 626
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Mazda
626
Instructions
Maintenance
Engines
Petrol engines (1,6 and 1,8 liters)
Gasoline 4-cylinder engine (2 liters)
Gasoline engine V6 (2,5 liters)
A partition of engines (1,6 and 1,8 liters)
Introduction
Specifications
Repair work without dismantle of the engine from the vehicle
Engine Overhaul
Check Engine
Removing and installing engine
Preparation for a partition
ENGINE OVERHAUL
A partition and check of a head of cylinders
Valve Repair
Assembling the cylinder head
Removal of pistons and rods
Removing the crankshaft
Check and clean the cylinder
Honing cylinders
Check of pistons and rods
Checking crankshaft
Check of radical bearings and bearings of rods
The order of assembly of the engine
Installation of the piston rings
Installing the crankshaft
Installing the crankshaft rear oil seal
Installation of pistons and rods
Start the engine after repair and running
Bulkhead engine (2.0 liters and 2.5 V6)
The diesel engine of 2.0 liters
Systems of an electric motor
Heating and ventilation
Fuel system
An exhaust system
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Specifications



The following technical details are only required to check the technical condition of parts in the repair procedures described below.

Engine capacity
1.6 l
1598 cm 3
1.8 l
1840 cm 3
The pressure in the compression cylinder (300 rev / min)
1,6 l:
- Nominal
13.2 Bar
- Minimum
9.3 Bar
- The maximum difference in pressure between the cylinder
1.9 Bar
1.8 l:
- Nominal
12.8 Bar
- Minimum
9.6 Bar
- The maximum difference in pressure between the cylinders
1.9 Bar
The oil pressure (engine warmed up)
1.6 liters and 1.8 liters
2.0 - 2.9 bar
Cylinder head
The maximum deformation of the surface:
- 1.6 liter
0.15 mm
- 1.8 L
0.10 mm
Deformation of the surface of the head adjacent to the collector
0.15 mm
Valves and related components
The height of the valve head of the chamfer (minimum):
- 1.6 liters:
??? Intake
0.9 mm
??? prom
1.0 mm
- 1.8 liters:
??? Intake
0.850 mm
??? prom
0.925 mm
The diameter of the valve stem:
- Intake
5,970 - 5,985 mm
- Exhaust
5,965 - 980 mm
The gap between the valve stem and guide bushing:
- Intake
0.025 - 0.060 mm
- Exhaust
0,030 - 0,065 mm
- The maximum gap
0.20 mm
Valve springs
Limit deviations from the right angle:
- 1.6 liters:
??? Intake
1.61 mm
??? prom
1,50 mm
Free length:
- 1.6 liters:
??? Intake
39.0 mm minimum
??? prom
38.0 mm minimum
- 1.8 L
39.5 mm minimum
Cylinder block
Bore:
- 1.6 liters:
78.006 - 78.013 mm
??? 1 size
78.256 - 78.263 mm
??? size 2
78.506 - 78.513 mm
- 1.8 liters:
83.006 - 83.013 mm
??? 1 size
83.256 - 83.263 mm
??? size 2
83.506 - 83.513 mm
The camshaft and connecting rods
The diameter of the bearing of a camshaft:
- 1.6 liter
19.943 - 19.961 mm
- 1.8 L
20.003 - 20.014 mm
Bearings rods:
- diameter:
??? 1,6 l and 1,8 l
44.940 - 44.956 mm
- Roundness
0.05 mm
- Grease the gap:
??? nominal
0.028 - 0.068 mm
??? wear limit
0.10 mm
Bearing shell
Diameter:
- 1.6 liters and 1.8 liters:
??? 44,690 - 44,706 mm
0.25 mm
??? 44,440 - 44,456 mm
0.50 mm
??? 44,190 - 44,206 mm
0.75 mm
Main bearing
Diameter
49.938 - 49.956 mm
Roundness
0.05 mm
Maximum Wear
0.04 mm
Oil clearance:
- nominal
0.018 - 0.036 mm
- Maximum wear
0.10 mm
The bearing shells:
- diameter:
??? 49,704 - 49,708 mm
0.25 mm
??? 49,454 - 49,458 mm
0.50 mm
??? 49,204 - 49,208 mm
0.75 mm (not 1.6 liters)
The connecting rod side clearance:
- nominal
0.110 - 0.262 mm
- Maximum wear
0.30 mm
Free wheeling of the crankshaft:
- nominal
0.080 - 0.282 mm
- Maximum wear
0.30 mm
The thickness of the thrust washer
2,500 - 2,925 mm
Roundness
0.019 mm
Pistons and piston rings
Bore:
- 1.6 liters:
77.954 - 77.974 mm
??? 1 envelope
78.211 - 78.217 mm
??? 2 Dimensions
78.461 - 78.467 mm
- 1.8 liters:
82.954 - 82.974 mm
??? 1 envelope
83.211 - 83.217 mm
??? 2 Dimensions
83.461 - 83.467 mm
The clearance between the piston and the cylinder:
- nominal
0.039 - 0.052 mm
- Maximum wear
0.15 mm
End clearance:
- Upper compression ring
0.15 - 0.30 mm
- The second compression ring
0.15 - 0.30 mm
- Oil ring
0.20 - 0.70 mm
- Maximum wear
1.0 mm
The clearance between the ring and the groove:
- 1.6 liters:
??? upper compression ring
0.030 - 0.070 mm
??? the second compression ring
0.030 - 0.070 mm
??? the maximum wear
0.15 mm
- 1.8 liters:
??? upper compression ring
0.030 - 0.65 mm
??? the second compression ring
0.030 - 0.070 mm
??? the maximum wear
0.15 mm

Torques Nm

Bolts and nuts of covers of rods:
- 1.6 liter
47 - 52
- 1.8 L
50 - 54
Bolts main bearing caps
54 - 58
Oil jets
12 - 18

* For more information, see. Subsection 3.1.2.




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