Exhaust MAZDA 626 1987 Owners Manual

INTAKE AIR SYSTEM 4D
INTAKE MANIFOLD
Removal and Installation
1. Remove in the sequence shown in the figure.
2. Install in the reverse order of removal.
3. Check for air/exhaust leakage.
76G04D-020
3. Vacuum hose (RF-CX)
4. Water thermo switch connector
5. Intake manifold
Inspection
1. Check the intake manifold for cracks and damage.
2. Inspect the flatness of the mounting surface using
a straight edge and a feeler gauge. Replace if
necessary.
Distortion: 0.05 mm (0.002 in) max.
19—26 N m (1.9—2.6 m-kg, 14—21 ft-lb)
8—11 N-m (80—110 cm-kg, 69—95 in-lb)
8—11 N-m (B0—110 cm-kg, 69—95 In-lb)
8—11 Nm (80—110 cm-kg, 69—95 In-lb)
19—26 N-m (1.9—2.6 m-kg, 14—19 ft-lb)
34—49 N-m (3.5—5.0 m-kg, 25—36 ft-lb)
8—11 N-m (80—110 cm-kg, 69—95 in-lb)
19—26 N-m (1.9—2.6 m-kg, 14—19 ft-lb) 22—26 N-m (2.2—2.7 m-kg, 16—20 ft-lb)
22—26 N m (2.2—2.7 m-kg, 16—20 ft-lb)
8—11 N-m (80—110 cm-kg, 69—95 in-lb)
1. Comprex supercharger
(Refer to page 4D—13.: RF-CX)
2. Exhaust manifold
(Refer to page 4D—19.: RF-CX)
76G04D-021
4D-9

4D SUPERCHARGING SYSTEM (RF-CX)
SUPERCHARGING SYSTEM (RF-CX)
TROUBLESHOOTING GUIDE

Engine
hard
starting

Poor

acceleration

Excessive

blue
smoke

Excessive

black
smoke

Excessive

compressed
air
temperature
(Buzzser
sounds)

Excessive

noise
Possible Cause Remedy (reference page)
*
*
Comprex supercharger Rotor stuck Casing damaged Rotor bearing damaged
Replace (4D—14)
* * * Drive system
of
Comprex supercharger Drive belt loose
or
worn Repair
or

replace
(4D-12) * Idler pulley damaged
Repair
or

replace
(4D-12) * Pulley bolt loose
or
worn
Repair
or

replace
(4D-12)
* Wastegate
Valve
not
open Clean
or
repace (4D-12) ik * Valve
not
closed
Clean
or
repace (4D-12)
* * Starting valve
Valve
not
open Repair
or
replace (4D-15)
* * Valve
not
closed
Repair
or
replace (4D-15) * Bypass valve
not
open
Repair
or
replace (4D-15)
* * Bypass valve
not
closed
Repair
or
replace (4D-15)
* Intercooler dirty Clean
or
replace (4D-16)
* * * * Intake
air
system Fresh
air
side clogged (Air cleaner
ele-
ment,
etc.)

Repair
or
replace * Compressed
air
side clogged (Intercool-
er,
etc.)
Repair
or
replace
* Fresh
air
side leaks
Repair
or
replace
* * * Compressed
air
side leaks
Repair
or
replace
* Exhaust system
Exhaust
gas
breaked Repair
* * * * * Exhaust pipe clogged
Repair
* Silencer damaged
(in
fender,
in air
clean-er,
in air
funnel, Comprex insulator) Repair
or
replace
* Bolt
and nut
loosend Repair
76G04D-022
4D—10

4D SUPERCHARGING SYSTEM (RF-CX)
ON-VEHICLE INSPECTION
Boost Pressure
1. Connect a pressure gauge to the hose from the
intake manifold.
2. (On chassis dynomometer, full load)
(1) Set the vehicle on a chassis dynomometer.
(2) Run the vehicle in gear at 3,000 rpm with the
acceleration pedal fully depressed.
(3) Measure the boost pressure.
Boost pressure:
82 kPa (0.87 kg/cm2, 8.1 psi)
Note
The above inspection should be done on a
chassis dynomometer. If a dynomometer is
not available follow the below procedure.
3. (Off chassis dynomometer, no load)
(1) Shift the transaxle out off gear.
(2) Run the engine in neutral at 3,000 rpm of the
engine no load.
Measure the boost pressure.
Boost pressure:
5 kPa (0.05 kg/cm2, 0.7 psi)
Note
The boost pressure is varied by engine speed
and engine load.
(3) Remove the starting valve bypass hose.
(4) Check that the bypass valve is closed at 3,000
rpm.
4.
If
the pressure is below specification, check the fol-
lowing. Replace the Comprex supercharger if
necessary.
(1) Intake air and exhaust passages leakage
(2) Intake air and exhaust passages clogged
(3) Wastegate (Refer to 4D—12.)
(4) Starting valve (Refer to 4D—15.)
(5) Fuel system (Injection nozzle... refer to page
4D—31, injection pump...refer to page 4D—24,
etc.)
5. If the pressure exceeds specification, check the
wastegate operation. (Refer to page 4D—12.)
4D—11

SUPERCHARGING SYSTEM (RF-CX) 4D
COMPREX SUPERCHARGER
Removal and Installation
1. Remove in the sequence shown in the figure.
2. Install in the reverse order of removal.
3. Check for air/exhaust leakage.
8—11 N m ''"'^'gs , (80—110 cm-kg, 69—95 In-lb)
8—11 N-m (80—110 cm-kg, 69—95 In-lb)
IsSJ 19-26 N-m (1.9—2.6 m-kg, 14—19 ft-lb)
34—49 N m (3.5—5.0 m-kg, 25—36 ft-lb)
22—26 N-m (2.2—2.7 m-kg, 16—20 ft-lb)
76G04D-029
1. Air hose
2. Air funnel assembly
3. Exhaust pipe
4. Supercharger insulator
5. Exhaust manihold stay
6. Drive belt
7. Exhaust joint pipe
8. Idle pulley
9. Comprex supercharger
Caution
a) Be careful not to bend the rod or bracket
of the wastegate.
b) Cover the intake and exhaust ports to pre-
vent dirt or other material from entering.
76G04D-030
4D—13

4D SUPERCHARGING SYSTEM (RF-CX)
Inspection
Air casing, exhaust casing, rotor housing
Check the air casing, exhaust casing, and rotor hous-
ing for cracks or damage. Replace the Comprex su-
percharger if necessary.
76G04D-031
Rotor and rotor bearing
Check that the rotor turns smoothly. Replace the Com-
prex supercharger if necessary.
76G04D-032
L sSRs^w^
j^r^SllfeJN
I^glji
H/yxA
Air funnel
Check the air funnel and insulator for cracks or
damaged. Replace if necessary.
76G04D-033
4D—14

4D EXHAUST SYSTEM
EXHAUST SYSTEM
STRUCTURAL VIEW
1. Exhaust manifold 4. Pre-silencer
2. Comprex supercharger (RF-CX) 5. Main silencer
3. Air funnel assembly
4D-18

EXHAUST SYSTEM 4D
EXHAUST MANIFOLD
Removal and Installation
1. Remove in the sequence shown in the figure.
2. Install in the reverse order of removal.
3. Check for exhaust leakage.
Inspection
1. Check the exhaust manifold for cracks and
damage.
2. Inspect the flatness of the mounting surface using
the straight edge and a feeler gauge. Replace if
necessary.
Distortion: 0.05 mm (0.002 in) max.
1. Comprex supercharger (Refer to page 4D—13.: only RF-CX)
2. Exhaust manifold
4D—19

EXHAUST SYSTEM 4D
EXHAUST PIPE AND MAIN SILENCER
Removal and Installation
1. Remove in the sequence shown in the figure.
2. Install in the reverse order of removal.
3. Check for exhaust leakage.
64—89 N-m
37—52 N-m (3.8—5.3 m-kg, 27—38 ft-lb)
76G04D-045
1. Front exhaust pipe bracket 4. Silencer hanger
2. Front exhaust pipe 5. Middle pipe
3. Pre-silencer 6. Main silencer
4D—20

REMOVAL 7A
RF-N and RF-CX
1. Battery
2. Air cleaner assembly
3. Vacuum hose
4. Intercooler pipe and hose
(RF-CX)
5. Electric fan
6. Speedometer cable
7. Ground(s)
8. Clutch release cylinder
9. Pressure and return hoses
(power steering)
10. Starter
11. Wheel
12. Splash shield
13. Stabilizer
14. Joint shaft
15. Extension bar
16. Control rod
76G07A-011
17. Exhaust pipe bracket
18. Water pipe
19. Gusset plate (rear)
20. Gusset plate (front)
21. Under cover
22. Engine mount No.4
23. Engine mount No.2
24. Crossmember
7 A—13

REMOVAL 7B
REMOVAL
PRECAUTION
(1) Drain the ATF before removal.
(2) Jack up the vehicle and support it with safety stands after attaching the engine support.
Components
1. Battery
2. Battery carrier
3. Main fuse block
4. Distributor lead
5. Air flow meter connector
(G4A-EL)
6. Air cleaner assembly
(G4A-EL)
7. Air cleaner hose (G4A-EL)
8. Fresh air duct (G4A-HL)
9. Speedometer cable
10. Connectors
11. Grounds
12. Selector cable
13. Throttle cable
14. Front wheels
15. Splash shields
16. Oil cooler outlet and inlet
hoses
17. Tie-rod ends
18. Stabilizer bar control links
19. Lower arm ball joints
20. Driveshaft
21. Joint shaft bracket
76G07B-106
22. Joint shaft and driveshaft
23. Exhaust pipe bracket
24. Gusset plates
25. Under cover
26. Torque converter nuts
27. Manifold bracket (G4A-EL)
28. Starter
29. Engine mount No.4
30. Engine mount No.2
31. Crossmember and left side
lower arm
32. Transaxle
7B—83