engine MAZDA 626 1987 Workshop Manual

THERMOSTAT 3B
THERMOSTAT
REMOVAL
1. Drain the engine coolant.
2. Disconnect the upper radiator hose, and water
thermo switch connector.
3. Remove the thermostat cover.
4. Remove the thermostat.
76G03B-010
76G03B-011
Sub valve Main valve
I
INSPECTION
Check the thermostat. Replace if necessary.
1. Visually check that the valve is airtight.
2. Place the thermostat and a thermometer in water.
3. Gradually heat the water and check the following:
Valve opening temperature
Sub valve : 78.5—81.5°C (173—179°F)
Main valve : 86.5—89.5°C (188—193°F)
Full open lift
Sub valve : 1.5 mm (0.06 in) min. at
100°C (212°F)
Main valve : 8 mm (0.31 in) min. at
100°C (212°F)
Valve closing temperature
Sub valve : 75°C (167°F)
Main valve : 83°C
(181
°F)
69G03B-012
76G03B-012
INSTALLATION
1. Install the thermostat into the thermostat case with
jiggle pin at the top.
2. Install a new gasket with the seal print side facing
the thermostat case.
3. Install the thermostat cover.
Tightening torque:
7—10 N-m (70—100 cm-kg, 61—87 in-lb)
4. Install the upper radiator hose and water thermo
switch connector.
5. Replenish the coolant.
6. Start the engine and check for leaks.
3B-9

4A
FUEL AND EMISSION
CONTROL SYSTEMS
(CARBURETOR)
OUTLINE 4A— 2
SYSTEM DIAGRAM 4A— 2
VACUUM HOSE ROUTING
DIAGRAM 4A— 5
EMISSION COMPONENTS
LOCATION 4A— 8
COMPONENT DESCRIPTIONS 4A—12
SPECIFICATIONS 4A—15
TROUBLESHOOTING GUIDE 4A—17
PARTS INSPECTION 4A—23
AIR CLEANER ELEMENT 4A—23
ACCELERATOR LINKAGE 4A—23
INTAKE MANIFOLD 4A—23
CHOKE CABLE 4A—23
FUEL SYSTEM 4A—24
TROUBLESHOOTING 4A—25
CARBURETOR 4A—26
FUEL PUMP 4A—35
FUEL TANK 4A—36
SEPARATOR 4A—37
TWO-WAY CHECK VALVE 4A—37
THREE-WAY CHECK VALVE 4A—37
FUEL FILTER 4A—37
IDLE SPEED AND IDLE MIXTURE.. 4A—38
ADJUSTMENT 4A—38
AUTO-RETURN CHOKE SYSTEM... 4A—40
TROUBLESHOOTING 4A—40
PTC HEATER SYSTEM 4A—42
TROUBLESHOOTING 4A—42
DECELERATION CONTROL SYSTEM 4A—45
TROUBLESHOOTING 4A—45
BYPASS AIR CONTROL SYSTEM.. 4A—48
DASH POT 4A—50
ANTI-AFTERBURN VALVE 4A—50
MAIN AIR BLEED CONTROL
SYSTEM 4A—51
SLOW FUEL CUT SYSTEM 4A—53
COAST ENRICHMENT SYSTEM .... 4A—54
COASTING LEANER SYSTEM 4A—56
AIR INJECTION SYSTEM 4A—58
INTAKE AIR TEMPERATURE CONTROL
SYSTEM 4A—60
TROUBLESHOOTING 4A—60
PURGE CONTROL SYSTEM 4A—63
VACUUM SWITCH VALVE 4A—63
EXHAUST GAS RECIRCULATION
(EGR) SYSTEM 4A—64
TROUBLESHOOTING 4A—65
POSITIVE CRANKCASE VENTILATION
SYSTEM 4A—67
PCV VALVE 4A—67
IDLE-UP CONTROL SYSTEM 4A—68
TROUBLESHOOTING 4A—70
IDLE-UP SOLENOID VALVE 4A—76
EVAPORATIVE EMISSION CONTROL
SYSTEM 4A—78
TROUBLESHOOTING 4A—79
IGNITION TIMING CONTROL
SYSTEM 4A-80
TROUBLESHOOTING 4A—81
CONTROL SYSTEM 4A-83
RELATIONSHIP CHART 4A—84
ENGINE CONTROL UNIT 4A—86
INHIBITOR SWITCH 4A—93
IDLE SWITCH 4A—93
VACUUM SWITCH 4A—94
WATER THERMO SWITCH 4A—95
EXHAUST SYSTEM 4A—96
76G04A-001

Engine
control
unit
Engine
control
unit
Ignition coil
Slow fuel cut solenoid
valve ^Reed valve
ATX1
1
MTY

4A OUTLINE
EMISSION COMPONENTS LOCATION
ECE, Hong Kong, and Singapore
Dashpot*
Reed valve
Solenoid valve*2 (Ignition timing control system)
Vacuum switch*5
Anti-afterburn valve
Choke opener
Idle-up solenoid valve^*5
or coasting leaner*6
Water thermo switch
Thermo valve*6
Water thermo switch
PTC heater*5
Air bypass solenoid valve*3
Solenoid valve*5
(Choke opener)
jr'-f
Choke breaker diaphragm
Solenoid valve*5 (Main air bleed control system)
Solenoid valve (P/S)*1
Solenoid valve (A/C)*1
Engine control unit
Fuel pump
*1 If equipped
*2 FE and F8 ATX
*3 F8 MTX and FE
*4 MTX
*5 FE and F8
*6 F6
76G04A-008
4A—8

General and Middle East
OUTLINE 4A
Dashpot
Choke opener
Thermo valve*3
Water thermo switch
Charcoal canister*3
Vacuum switch*2
Solenoid valve*2
(Main air bleed control system)
Solenoid valve (P/S)*1
Solenodi valve (A/C)*1
Engine control unit*2
Water thermo switch
*1 If euqipped
*2 FE and F8 General
*3 Middle East
*4 Middle East MTX
76G04A-009
4A-9

4A OUTLINE
FE 8Valve—Unleaded Fuel
Read valve Vacuum switch valve Air cleaner
Slow fuel cut
.. . solenoid valve Air bypass
solenoid^ valve^. Engine control unit
EGR control valve
Solenoid valve (for P/S)*
Solenoid valve (for A/C)*
Catalytic converter
* If equipped
4 A—10
76G04A-010

OUTLINE
4A

Previous

626
Unlead-
ed

fuel
O O O O O O X O O O X

Previous

626

Leaded
fuel
O X X O O X X X O X

New
626
FE
8
Valve
Unlead-
ed

fuel
o O O O O O X X O O O

New
626
Sin-
gapore

o O X O O m O
O

(FE

&
F8)
O
O

(FE

&
F8)
O O

New
626

Middle
East
o X X O O X X X X X O

New
626

General

X
O

(FE

& F8)
X O O X
O

(FE

&
F8)
O

(FE

&
F8)
O

(FE

&
F8)
X o

New
626
ECE
&

Hong
Kong
o O X O O * O O O O O o

Remark
• Adjustment
speed:

2,200

±
100
rpm
(in
neutral).
• MTX • Operation:
Coolant
tempera-

ture

more
than

50°C

(122°F).

Mechanical
type
Installed
on
carburetor.
Improvement
of
product
quality.

Function

Allows

throttle
to
gradually
close

during

deceleration.

Reduces

CO

and
HC
emission.

Detects

electrical
signal
from
in-
put
devices
and
controls
output
devices. Supplies
exhaust
gas
to
intake
manifold
to
reduce
NOx

Filters

fuel

Provides

fuel
to
carburetor.
Detects
when
throttle
valve
fully
closed. Opens
fuel

passage

to
secon-
dary
stage
of
carburetor.
Controls
shutter
valve
by
intake

air
temperature. Prevents
carburetor

icing.

Supplies
fresh
air
to
exhaust
manifold
to
reduce
CO
and
HC
emissions. Prevents
fuel
from
flowing
into

two-way

or
three-way
check

valve

Component

Dashpot Engine
Contorol
Unit

EGR

Control
Valve

Fuel

Filter

Fuel

Pump
Idle
Switch

Idle-up

Solenoid

Valve
Intake
Air
Temperature
Control
Valve

PTC

Heater

Reed

Valve

Separator

•a a> a -a .2-S
3
9-a a) 5 u- O UJ
z

Ox

111 IL •a c <o
x" Ul
V (-
U.ps •o<eo gfou-™
u.
-
X
_ X
I-
o-t-
s ®
s
*
o *
oo
x to
U. UJ
u.
T- oi CO
4 A—13

OUTLINE 4A
SPECIFICATIONS
F6 & F8 Engine
Engine F6 F8
Specification General Singapore General
ECE,
Hong Kong, &
Singapore

Idle speed
rpm
MTX 800
+58
Idle speed
rpm
ATX 950
t5§
(in N range)|
900 +5§ (in N
range)
CO concentration
%
2.0
± 0.5
(Without secondary
air
injection)

Carburetor

Type Down draft, two barrel
Throat diameter
mm (in)
Primary 30 (1.18) Throat diameter
mm (in)
Secondary 34 (1.34)
Venturi diameter
mm
(in) Primary 23.5 (0.93) Venturi diameter
mm
(in) Secondary 29.0 (1.14)
Main nozzle
mm (in)
Primary 2.6 (0.10) Main nozzle
mm (in)
Secondary 2.8 (0.11)
Main
jet mm (in)
Primary MTX 1.10 (0.0433) 1.09 (0.0429) 1.14 (0.045)
Main
jet mm (in)
Primary ATX 1.10 (0.0433) 1.08 (0.0425) 1.12 (0.044) Main
jet mm (in)

Secondary 1.50 (0.059)
Main
air
bleed mm (in)
Primary MTX 0.60 (0.024) 0.60 (0.024) 0.55 (0.022) Main
air
bleed mm (in)
Primary ATX 0.60 (0.024) 0.80 (0.031) 0.60 (0.024) Main
air
bleed mm (in) Secondary 0.50 (0.020)
Slow
jet mm (in)
Primary 0.48 (0.019) 0.46 (0.018) Slow
jet mm (in)
Secondary 1.00 (0.039) 1.10 (0.043)
Slow
air
bleed mm (in)
Primary No.1 0.80 (0.031)
Slow
air
bleed mm (in)
Primary No.2 1.90 (0.075) Slow
air
bleed mm (in) Secondary No.1 1.00 (0.039) 0.80 (0.031) Slow
air
bleed mm (in) Secondary No.2 0.50 (0.020)
Power
jet mm (in)
0.50 (0.0201
Fast idle adjustment
mm (in)

Clearance between
Drimarv
throttle valve and bore
1.40-1.76 (0.055—0.069) MTX: 0.48-0.64 (0.019-0.025) ATX: 0.56-0.72 (0.022-0.028)
Float level adjustment mm (in)
Max. fuel flow
"L"

Clearance between
flo

44 (17.3)
at and
air
horn without aasket Float level adjustment mm (in) Fuel stop
"H"
12.5(0.49)
Clearance between float and
air
horn without aasket; float lowered
by
own weight
Choke breaker diaphragm mmHg (inHg)
Start 180-240 (7.1—9.5) 100-160 (3.9—6.3) Choke breaker diaphragm mmHg (inHg) Stop 290-350 (11.4—13.8) 220—280 8.7—11.01
Choke opener mmHg (inHg) Start 35-65 (1.4-2.6)
...
35-65 (1.4-2.6) Choke opener mmHg (inHg) Stop
......
130-190 (5.1-7.5) 130-190 (5.1-7.5)

Fuel tank capacity
Liters (US gal, Imp gal) 60 (15.9, 13.2)

Fuel Dump

Delivery pressure kPa (kg/cm2,
psi)
20-26 (0.20-0.27, 2.8—3.8)
Feeding capacity cc/min (cu in/min) More than 860 (52.5)
at
idle

Fuel filter

Type Paper element with magnet

Air cleaner

Fresh-Hot switching Manual Diaphragm type
Element tvoe Oil permeated paper
Fuel specification Leaded regular

76G04A-513
4 A—15

4A OUTLINE
FE Engine
Engine FE 8Valve FE 12Valve FE 8Valve
Specification General Middle East
ECE, Hong Kong, & Singapore Unleaded fuel

Idle speed
rpm
MTX 800
+5§
850
+5§
Idle speed
rpm
ATX 900
+58 (in N
range)
CO concentration
%
2.0
± 0.5
(Without secondary
air
injection)

Carburetor

Type Down draft,
two
barrel
Throat diameter
mm (in)
Primary 30 (1.18) Throat diameter
mm (in)
Secondary 34 (1.34)
Venturi diameter
mm (in)
Primary 23.5 (0.93) Venturi diameter
mm (in)
Secondary 29.0 (1.14)
Main nozzle
mm (in)
Primary 2.6 (0.10) Main nozzle
mm (in)
Secondary 2.8 (0.11)
Main
jet mm (in)
Primary MTX 1.14 (0.045) 1.09 (0.0429) 1.14 (0.045) 1.09 (0.0429) Main
jet mm (in)
Primary ATX 1.12 (0.044) 1.08 (0.0425) 1.12 (0.044) 1.09 (0.0429) Main
jet mm (in)

Secondary 1.55 (0.061) 1.50 (0.059) 1.55 (0.061) 1.50 (0.059)
Main
air
bleed
mm (in)
Primary MTX 0.50 (0.020) 0.60(0.024) 0.50 (0.020) 0.50 (0.020) Main
air
bleed
mm (in)
Primary ATX 0.55 (0.022) 0.80 (0.031) 0.55 (0.022) 0.50 (0.020) Main
air
bleed
mm (in) Secondary 0.50 (0.020)
Slow
jet mm (in)

Primary 0.46 (0.018)
Slow
jet mm (in)
Secondary MTX 1.10 (0.043) 1.00 (0.039) 1.10 (0.043) 0.90 (0.035) Slow
jet mm (in)
Secondary ATX 1.10 (0.043) 1.00 (0.039) 1.10 (0.043) 1.00 (0.039)
Slow
air
bleed
mm (in)
Primary No.1 0.80 (0.031)
Slow
air
bleed
mm (in)
Primary No.2 1.90 (0.075) Slow
air
bleed
mm (in) Secondary No.1 0.80 (0.031) 1.00 (0.039) 0.80 (0.031) 1.00 (0.039)
Slow
air
bleed
mm (in) Secondary No.2 0.50 (0.020)
Power
jet mm (in)
MTX 0.50 (0.020) 0.50 (0.020) Power
jet mm (in)
ATX 0.50 (0.020) 0.40 (0.016)
Fast idle adjustment
mm (in)
Clearance between primary throttle valve and bore
MTX 0.48—0.64
(0.019-0.025) 1.40—1.76
(0.055-0.069)
0.48—0.64
(0.019-0.025) 1.40-1.76
(0.055-0.069)
Fast idle adjustment
mm (in)
Clearance between primary throttle valve and bore ATX 0.56-0.72 (0.022—0.028)
1.40—1.76
(0.055-0.069) 0.56-0.72 (0.022—0.028)
1.40-1.76
(0.055-0.069)
Float level adjust-
ment
mm (in)

Max. fuel flow
"L"

Clearance between
flo

44 (17.3)
at and
air
horn without aasket Float level adjust-
ment
mm (in)
Fuel stop
"H" |
12.5(0.49)
Clearance between float and
air
horn without aasket: float lowered
bv
own weiaht
Choke breaker diaphragm mm-Hg (in-Hg)
Start 100-160 (3.9—6.3) 180—240 (7.1-9.4) 100-160
(3.9-6.3)
180-240
(7.1-9.4) Choke breaker diaphragm mm-Hg (in-Hg) Stop 220—280
(8.7-11.0)
290-350
(11.4-13.8)
220—280
(8.7-11.0)
290-350
(11.4-13.8)
Choke opener mmHg (inHg)
Start 80—120
(3.1-8.7)
30-70 (1.2-2.8) Choke opener mmHg (inHg)
Stop 220-280 (8.7—11.0) 130-190
(5.1-7.5)

Fuel tank capacity
Liters (US aal, Imp aal) 60 (15.9, 13.2)

Fuel DumD

Delivery pressure kPa (kg/cm2,
psi)
20-26 (0.20—0.27, 2.8-3.8) 20-29 (0.20-0.30, 2.8-4.3)
20-26 (0.20-0.27, 2.8-3.8)
Feedina caDacitv cc/min
feu
in/mini More than 860 (52.5)
at
idle

Fuel filter

Type Paper element with magnet

Air cleaner

Fresh-Hot switchina Diaphragm Manual Diaphragm Bimetal
Element
tvDe
Oil permeated paper
Fuel specification Leaded super
Unleaded super Leaded regular Leaded super Unleaded super Unleaded regular

76G04G-514
4A—16

TROUBLESHOOTING GUIDE
4A

TROUBLESHOOTING GUIDE
F6 (GENERAL)
The Troubleshooting Guide lists the systems most likely to cause
a
given symptom. After finding the
system(s)
to
check, refer
to
the pages shown
for
detailed guides
for
each system.
\\ POSSIBLE CAUSE
\ PAGE


SYMPTOM
Air

cleaner
(Air
cleaner
element)
intake
air
temperature
control

system
Idle

adjustment
Fuel
system
(Carburetor,
Fuel
pump)

idle-up

control
system
Exhaust
system
Positive
crankcase
ventilation

system
Auto-return
choke
system

\\ POSSIBLE CAUSE
\ PAGE


SYMPTOM 4A—23 4A—60 4A—38 4A—24 4A—68 4A—96 4A—67 4A—40
1 Hard start
or
won't start (Cranks
OK)
1 2

2 Engine stalls During warm
up
3 2 1 4
2 Engine stalls After warm
up
4 2 5 1 3

3 Rough Idle During warm
up
3 2 1 4
3 Rough Idle After warm
up
3 2 5 1 4

4 High idle speed after warm
up
1 3 2

5 Poor acceleration, hesitation, or lack
of
power
1 2 3

6 Runs rough
on
deceleration
1

7 Afterburn
in
exhaust system
1

8 Poor fuel consumption
2 1 4 3

9 Fails emission test
2 1 4 5 3

76G04A-015
The numbers of the list show the priorities
of
inspections from the most possible to that with the lowest
possibility.
These were determined
on
the following basis:
• Ease
of
inspection
•
Most possible system
•
Most Possible point
in
system
TROUBLESHOOTING PROCEDURE:
1st Check the following items:
Electrical system
1) Battery condition
2) Fuses
Ignition system
1) Spark plugs
2) Ignition timing
Fuel system
1) Fuel level
2) Fuel leakage
3) Fuel filter
4) Idle speed
Intake
air
system
1) Vacuum
or air
leakage
2) Vacuum hose routing
3) Accelerator cable
4) Choke cable
2nd Check Fuel and Emission Control Systems
Engine
1) Compression
2) Overheating
Others
1) Clutch slippage
2) Brake dragging
4 A-17