low oil pressure MAZDA 626 1987 Owners Manual

1 3 TROUBLESHOOTING GUIDE
Problem Possible Cause Remedy Page
Excessive steering wheel play
Worn or damaged lower arm bushing
Improperly adjusted pinion preload
Worn rack and pinion
Loose steering shaft universal joint
Replace
Refer to section 10
Refer to section 10
Refer to section 10
13-20, 38
General instability Weak coil springs
Shock absorber malfunction Worn or damaged lower arm or stabilizer bushing
Improperly adjusted wheel alignment Improperly adjusted pinion preload
Loose steering shaft universal joint Incorrect tire pressure Damaged or unbalanced wheel Malfunction of wheel bearing
Replace Replace Replace Adjust
Refer to section 10 Refer to section 10 Refer to section 12 Refer to section 12 Refer to section 9
13-15, 32
13-13, 29
13-20, 38
13-50, 52
76G13X-009
13-12

WARNING LIGHT AND SENDER 1 5
Washer Fluid Low Level Warning Light
76G15X-039
76G15X-040
Engine Oil Pressure Warning Light
76G15X-041
15—35

OUTLINE 16
TROUBLESHOOTING GUIDE
Problem Probable cause Remedy Reference page
No blower
1. Main fuse (30
A) is
open Replace
operation
2 Malfunction
of
the blower motor Replace 3. Faulty resistor Replace 4. Malfunction
of
the blower switch Replace 5. Open
or
loose connection
in an
electrical circuit Repair 16—6,
7
Insufficient
1. Obstruction
in
the inlet
of
the blower unit Remove the obstruction 16-26
air
2. Clogged evaporator Clean the evaporator
with compressed
air
16-27 3. Frosted evaporator Check the thermostat 16-30 4. Air leakage Check for leakage
at
16-26 both sides
of
the cool-
ing unit

Compressor
1. Malfunction
of
the A/C relay Check operation 16—30
does not run,
2. Malfunction
of
the thermostat Check operation 16—30
or runs
3. Malfunction
of
the refrigerant-pressure switch Check operation 16—31
insufficiently
4.
Air
conditioner fuse (15
A)
failure Replace 5. Compressor drive belt
is
loose Readjust 16—23
6. Internal problem
of
the compressor Repair
or
replace
the
16—13
compressor 7. Battery voltage too low Recharge the battery 8. Layer short
in
the magnet coil Replace 9. Clutch face dirty with
oil
Clean
or
replace the 16-13
clutch 10. Excessive gap between the drive plate and
the
Adjust the gap 16-13
pulley
11. Open circuit
in
the magnet coil Replace 16—13
12 Open circuit Repair 16-6,
7
Refrigeration
Normal pressures are:

pressure is
High pressure
1472—1765 kPa
abnormal (15—18 kg/cm2, 214—255 psi)
Low pressure
197—294 kPa
(2—3 kg/cm2, 29—42 psi)
when: ambient temperature 35°C (95°F)
engine speed 1,500
rpm
Low pressure
1. Internal malfunction
of
the compressor Repair
or
replace the 16-13

is too high
compressor
2. Faulty contact
of
the sensing bulb
of
the expan-Repair 16-26
sion valve 3. Faulty insulation
of
the sensing bulb
of
the expan-Repair 16—26
sion valve
4. Expansion valve open too much Replace 16—26

Low pressure
1. Insufficient refrigerant Charge with refrigerant 16-8

is too low
2. Receiver-drier
is
clogged Replace 16-25
3. Expansion valve
is
clogged Replace 16-26
4. Faulty thermostat Check operation 16-30 5. Frosted piping Clean
or
replace the 16—29
piping

High pres-
1. Poor cooling
of
condenser Check and clean 16-24

sure is too
2. Loose cooling fan drive belt Readjust 16—23

high
3. Too much refrigerant Discharge the excess 16-8
refrigerant 4.
Air in
the system Evacuate and charge 16-8
the system

High pres-
1. Insufficient refrigerant Charge with refrigerant 16-8
sure is too
2. Internal malfunction
of
the compressor Repair
or
replace the 16-13

low
compressor

76G16X-004
16—5

OUTLINE 16
Discharging the Refrigeration System
1. Connect the manifold gauge set to the system.
2. Place the free end of the center hose on a shop
towel.
3. Slowly open the high pressure manual valve to ad-
just the refrigerant flow. Open the valve only slightly.
Caution
If refrigerant is allowed to escape too fast, the
compressor oil will be drawn out of the
system.
4. Check the shop towel to make sure no oil is being
discharged.
If oil is present, partially close the manual valve.
5. After the manifold gauge reading drops below 343
kPa (3.5 kg/cm2, 50 psi), slowly open the low
pressure manual valve.
6. As the system pressure drops, gradually open both
the high- and low-pressure manual valves until both
gauges read 0 kPa (0 kg/cm2, 0 psi).
76G16X-631
Evacuation of the Refrigeration System
Whenever the air-conditioning system has been ex-
posed to the atmosphere, it must be evacuated.
1. Connect the manifold gauge set.
2. Connect the center hose of the gauge set to the
vacuum pump inlet.
3. Operate the vacuum pump, then open both man-
ual valves.
4. When the low pressure gauge indicates approxi-
mately 710 mmHg (28 inHg), close both manual
valves and stop the vacuum pump.
5. Check to be sure that the degree of pressure does
not change after 10 minutes or more in this condi-
tion.
If
the pressure changes, check the system for
leaks, and repair if necessary.
6. If no leaks are found, once again operate the vacu-
um pump and open both manual valves to obtain
760 mmHg (30 inHg).
7. Close both manual valves, and stop the vacuum
pump.
Disconnect the hose from the vacuum pump.
69G16X-019
16-9

COMPRESSOR 16
69G16X-026
M10X1.25^45
Low-pressure x pressure
hose hose Compressor
COMPRESSOR
ON-VEHICLE INSPECTION
1. Connect the manifold gauge set.
2. Run the engine at 1,500 rpm.
3. Check the compressor flow:
a) High pressure is not low and low pressure is not
higher than normal.
b) Metallic sound.
c) Check to be sure that the high-pressure and low-
pressure gauges show the same value immedi-
ately after the air conditioner is switched OFF.
If both gauges show the same value immediate-
ly, it can be assumed that the gasket or the valve
inside the compressor is damaged.
4. Stop the engine.
5. Check the shaft seal and others for leakage.
6. Inspect the drive plate pulley magnetic clutch for
signs of oil.
7. Check the clearance between the drive plate and
pulley. (Refer to page 16—21.)
If any of the above checks reveal faults, repair the
compressor or magnetic clutch.
76G16X-635
Bracket No.2 Adjusting Bolt Bracket

, ,shaft

' stay _ M8XI. 25^20 MIO X 1.25 Compressor
69G16X-028
REMOVAL OF COMPRESSOR
1. Perform the Oil Return Operation. (See below.)
2. Disconnect the battery ground cable.
3. Disconnect the clutch lead wire from the wiring
harness.
4. Discharge the refrigerant from the refrigeration
system.
5. Disconnect the two flexible hoses. Plug the open
fittings immediately to keep moisture out of the
system.
6. Loosen the drive belt.
7. Remove the compressor mounting bolts and the
compressor.
Bracket No.1 M
to* 1.25

^Compressor
MIOxl. 25^110 MIOxl. 25^125
Oil Return Operation
1. If the refrigerant level is low, charge the system to
the specified amount.
2. Run the engine and air conditioner at idle and at
maximum cooling for at least 20 minutes.
76G16X-636
16—13

1 6 COOLING UNIT
INSTALLATION OF COOLING UNIT
1. Install the cooling unit by using the two nuts.
Note
Adjust and position the unit so that its con-
nections match those of the heater unit and
the blower unit.
2. Connect the drain hose.
76G16X-625
Sealing plate
Heater I _ .. ' . . - V
unit Evaporator dealing plate Blower unit
3. Join the connections on both sides by using the
seal plates.
4. Connect the A/C harness to the cooling unit.
76G16X-626
76G16X-627
5. Connect the liquid line high-pressure pipe and suc-
tion low-pressure pipe to the cooling unit.
Tightening torque:
15—22 Nm (1.5—2.5 m-kg, 11—18 ft-lb)
6. Install the instrument lower panel, shower duct and
glove box.
7. If the evaporator is replaced, add compressor oil
to the compressor.
Compressor oil: 50 cc (3.05 cu in)
16-28

30 TECHNICAL DATA
2A. LUBRICATION SYSTEM (GASOLINE)
Engine model Item ____ FE DOHC F6, F8, FE SOHC

Lubrication method Force-fed

Oil pump

Type Trochoid gear Crescent gear
Regulated pressure kPa (kg/cm2
psi)
490 (5.0,
71)
392 (4.0, 57)
Oil pressure kPa (kg/cm2,
psi)
1,000 rpm 147-245 (1.5-2.5, 21-36) Oil pressure kPa (kg/cm2,
psi)
3,000
rpm
343—441 (3.5-4.5, 50-64) 294—392 (3.0—4.0, 43-57)
Inner rotor tooth
tip to
outer rotor
clearance
mm
(in)
Standard 0.044-0.084 (0.0017-0.0033)

—

Inner rotor tooth
tip to
outer rotor
clearance
mm
(in) Maximum 0.18 (0.0071)

—
Outer rotor
to
body clearance
mm
(in) Standard 0.09-0.176 (0.0035-0.0069)
—
Outer rotor
to
body clearance
mm
(in) Maximum 0.20 (0.008)
—

Side clearance
mm
(in) Standard 0.03-0.09 (0.0012-0.0035)

—

Side clearance
mm
(in) Maximum 0.10 (0.004)

—

Inner gear tooth tip
to
crescent clearance
mm
(in)
Standar

—

0.267-0.38 (0.011-0.015) Inner gear tooth tip
to
crescent clearance
mm
(in) Maximum

—

0.40 (0.016)
Outer gear tooth tip
to
crescent clearance
mm
(in)
Standard

—

0.20-0.32 (0.008-0.0126) Outer gear tooth tip
to
crescent clearance
mm
(in) Maximum
—
0.35 (0.0138)
Outer gear
to
body
clearance
mm
(in)
Standard
—
0.09-0.184 (0.0035-0.0072) Outer gear
to
body
clearance
mm
(in) Maximum

—

0.20 (0.008)
Side clearance mm (in) Standard

—

0.03-0.063 (0.0012-0.0025) Side clearance mm (in) Maximum

—

0.10 (0.004)

Oil filter

Type Full flow, paper element
Relief pressure differential kPa (kg/cm2,
psi)
78-118 (0.8-1.2, 11-17)

Oil cooler

Type
!
Water cooled

Oil pressure switch

Activation pressure kPa (kg/cm2,
psi)
29 (0.3, 4.3)

Enaine oil

Capacity liters (US qt, Imp
qt)

Total (drv enaine) 4.3 (4.5, 3.8)
Capacity liters (US qt, Imp
qt)
Oil
Dan
3.6 (3.8, 3.2) Capacity liters (US qt, Imp
qt)

Oil filter 0.2(0.21,0.18)
|
0.3 (0.32,0.26)
Grade (API service) SD, SE,
or
SF
Viscosity
number
30°C (86°F)
or
over SAE
40

Viscosity
number
0°C—40°C (32°F—104°F) SAE
30

Viscosity
number
-10°C—20°C (14°F—68°F) SAE 20W-20
Viscosity
number
-10°C—50°C (14°F—122°F)
or
over SAE 20W-40
or
20W-50 Viscosity
number -25°C—30°C (-13°F—86°F) SAE 10W-30 Viscosity
number
-25°C—50°C (-13°F—122°F)
or
over SAE 10W-40
or
10W-50
Viscosity
number
0°C—30°C (32°F—22°F)
or
below SAE 5W-30
Viscosity
number
-20°C (—4°F)
or
below SAE 5W-20

30-14

TECHNICAL DATA 30
2B. LUBRICATION SYSTEM (DIESEL)
Engine moded Item RF-CX RF-N

Lubrication method Force-fed type

Oil pump

Type Trochoid gear
Gear width
mm
(in) 7 (0.28)
Regulated pressure kPa (kg/cm2,
psi)
510-618 (5.2-6.3, 74-90)
Oil pressure kPa (kg/cm2,psi) 1,000 rpm 147-245 (1.5-2.5, 21-36) Oil pressure kPa (kg/cm2,psi) 3,000 rpm 343—441 (3.5—4.5, 50—64)
Inner rotor tooth
tip to
outer rotor clearance
mm
(in)
Standard 0.2 (0.008)
or
less Inner rotor tooth
tip to
outer rotor clearance
mm
(in) Maximum 0.24 (0.009)
Outer rotor
to
pump body clearance
mm (in)
Standard 0.09-0.184 (0.0035-0.0071) Outer rotor
to
pump body clearance
mm (in) Maximum 0.22 (0.009)
Side clearance
mm
(in) Standard 0.03-0.09 (0.0012-0.0036) Side clearance
mm
(in) Maximum 0.14 (0.006)

Oil filter

Type Combined, paper element
Relief pressure differential kPa (kg/cm2,
psi)
78-118 (0.8-1.2, 11-17)

Oil cooler

Type Water cooled,
10
layer Water cooled,
4
layer

Oil filter body

Regulated pressure kPa (kg/cm2,
psi)
402-481 (4.1-4.9, 58—70)
Oil cooler relief pressure differential kPa (kg/cm2,
psi)
177-216 (1.8-2.2, 26-31)

Oil pressure switch

Activation pressure kPa (kg/cm2,
psi)
20-39 (0.2—0.4, 2.8-5.7)

Engine oil

Capacity liters (US qt, Imp
qt)

Total (drv enaine) 6.1 (6.4, 5.4)
Capacity liters (US qt, Imp
qt)
Oil pan 5.0 (5.3, 4.4) Capacity liters (US qt, Imp
qt)

Oil filter 0.5 (0.52, 0.44)
Grade API service CC CC,
CD

Viscosity number
40°C
or
over (104°F)
or
over SAE
40

Viscosity number
0°C—40°C (32°F—100°F) SAE
30

Viscosity number
-10°C—35°C (15°F—90°F) SAE 15W-40 Viscosity number -10°C—25°C (15°F—77°F) SAE 20W-20 Viscosity number
-25°C—30°C (-18°F—86°F) SAE 10W-30
Viscosity number
-20°C
or
below (4°F
or
below) SAE 5W-30

30—15

30 TECHNICAL DATA
4A. FUEL AND EMISSION CONTROL SYSTEM (CARBURETOR)
F6 and F8 Engine
Engine F6 F8
Spec. General Singapore General
ECE, Hong
Kong, &
Singapore

Idle speed rpm MTX 800
+ 50
0 Idle speed rpm ATX (in
N
range)
—
950 +58 900
+ 50
0
CO concentration °/o 2.0
± 0.5
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)
Primary MTX 1.10 1.09 (0.0429) 1.14 (0.045)
Main
jet
mm (in) Primary ATX (0.0433) 1.08 (0.0425) 1.12 (0.044)
Secondary 1.50 (0.059)
Primary MTX 0.60 0.60 (0.024) 0.55 (0.022)
Main
air
bleed mm (in) Primary ATX (0.024) 0.80 (0.031) 0.60 (0.024)
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)
Primary No.
1
0.80 (0.031)
Slow
air
bleed Primary No.
2
1.90 (0.075)
mm (in) Secondary No.
1
1.00 (0.039) 0.80 (0.031) Secondary No.
2
0.50 (0.020)
Power
jet
mm (in) 0.50 (0.020)
Fast idle adjustment
mm (in)
Clearance between primary 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)
Max. fuel flow
"L"
44 (17.3)
Float level adjustment Clearance between float and
air
horn without gasket
mm (in) Fuel stop
"H •
12.5 (0.49)
Clearance between float and
air
horn/without gasket; float lowered
by
own weight
Choke breaker diaphragm Start 180-240 (7.1-9.5) 100—160 (3.9-6.3)
mmHg
(in Hg)
Stop 290—350 (11.4-13.8) 220-280 (8.7-11.0)
Choke opener Start
—
35-65 (1.4-2.6)
—
35-65 (1.4-2.6)
mmHg
(in Hg)
Stop
—
130-190 (5.1-7.5)
—
130-190
(5,1-7.5)

Accelerator linkage

Free plav
of
cable
at
carburetor mm (in) 1-3 (0.039—0.118)

Fuel tank

Capacity Liters (US gal, Imp gal) 60 (15.9, 13.2)

Fuel pump

Type Mechanical pump
Delivery pressure kPa (kg/cm2,
psi)
20-26 (0.20-0.27, 2.8-3.8)
Feedina 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
tvDe
Oil permeated paper
Fuel specification Leaded regular

30-18

TECHNICAL DATA 30
FE Engine
Engine 8 Valve 12 Valve 8 Valve
Spec. General Middle
East
ECE,
Hong Kong, &
Singapore
Unleaded
Fuel
(West Germany)

Idle speed rpm MTX 800
+5§
850 Idle speed rpm ATX 900 +5S
(ir
N range)
CO concentration
%
2.0
± 0,5
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)
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)
Secondary 1.55 (0.061) 1.50 (0.059) 1.55 (0.061) 1.50 (0.059)
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)
Secondary 0.50 (0.020)
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) Secondary ATX 1.10 (0.043) 1.00 (0.039) 1.10 (0.043) 1.00 (0.031)
Primary No.
1
0.80 (0.031)
Slow
air
bleed Primary No.
2
1.90 (0.075)
mm (in) Secondary No.
1
0.80 (0.031) 1.00 (0.039) 0.80 (0.031) 1.00 (0.039) 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) MTX 0.48-0.64 (0.019-0.025) 1 40—1
76

0.48-0.64 (0.019-0.025) 1
40
1
76
Clearance between primary throttle valve and bore ATX 0.56-0.72
(0.022-0.028) (0.055-0.069) 0.56-0.72 (0.022-0.028) (0.055-0.069)
Max. fuel flow
"L"
44 (17.3)
Float level adjustment Clearance between float and
air
horn without aasket
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 Start
100-160 (3,9-6.3) 180-240 (7.1-94) 100-160 (39-6.3) 180-240 (7.1-9,4)

mmHg
(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 (in
Hg)
Start
—
80-120 (3.1-8.7) 30-70 (1.2-2.8)
—
Choke opener mmHg (in
Hg)
Stop
—
220-280 (87-11.0) 130-190 (5.1-7.5)
—
Accelerator llnkaae

Free play
of
cable
at
carburetor mm (in) 1-3 (0.039-0.118)

Fuel tank

Capacity Liters (US gal, Imp gal) 60 (15.9, 13.2)

Fuel pump

TvDe
Mechanical pump
Delivery pressure kPa (kg/cm2,
psi)
20-26 (0.20-0.27, 2.8-3.8)
20-29 (0.20-030, 2.8-4.3) 20-26
(020-0.27, 28-38)

Feeding capacity cc/min (cu in/min) More than 860 (52.5)
at
idle

Fuel filter

TvDe
Paoer element with maanet

Air cleaner

Fresh-Hot switchina Diaohraam Manual Diaohraam Bimetal
Element tvoe Oil oermeated oaoer
Fuel specification Leaded super Unleaded super Leaded regular Leaded super Unleaded super Unleaded regular

30-19