belt MAZDA 626 1987 Workshop Manual

TROUBLESHOOTING GUIDE
3B

SPECIFICATIONS

Cooling system Water-cooled, forced circulation
Coolant capacity liters (US
qt,
Imp
qt)

With heater 9.5 (10.0, 8.4) Coolant capacity liters (US
qt,
Imp
qt)

Without heater 9.0 (9.5, 7.9)
Water pump Type Centrifugal, timing belt driven Water pump
Water seal Unified mechanical seal
Thermostat
Type Wax, two stage
Thermostat
Opening temperature °C(°F) Main Sub
Thermostat
Opening temperature °C(°F)
86.5-89.5 (188-193) 78.5—81.5 (173-179) Thermostat
Full-open temperature °C(°F) 100 (212) 100 (212)
Thermostat
Full-open lift
mm (in)
8.0 (0.31) min. 1.5 (0.06) min.
Radiator
Type Corrugated
fin

Radiator Cap valve opening pressure
kPa (kg/cm2,
psi)
74-103 (0.75-1.05, 11—15)
Cooling
fan

Type Electric
Cooling
fan

Capacity
W
120
Cooling
fan
Switching temprature orvopi OFF
- ON ^
91 (196) Cooling
fan

Number
of
blade 4
Cooling
fan

Outer diameter
mm
(in) 340 (13.4)

76G03B-003
TROUBLESHOOTING GUIDE
Problem Possible Cause Remedy Page
Overheating
Insufficient coolant Add 3B-
4

Coolant leakage Repair
—

Radiator fins clogged Clean 3B—
6

Radiator cap malfunction Replace 3B—
5

Cooling fan malfunction Repair 3B-11 Thermostat malfunction Replace 3B—
9

Water passage clogged Clean 3B—
4

Water pump malfunction ReDair
or
replace 3B—
7

Corrosion
Impurities
in
coolant Replace 3B-
4

76G03B-004
3B—3

WATER PUMP 3B
WATER PUMP
REMOVAL
1. Disconnect the negative battery cable.
2. Turn the crankshaft so that the No. 1 cylinder is at TDC of compression.
3. Drain the engine coolant.
4. Remove in the sequence shown in the figure. 69G03A-025
31—46 N m (3.2—4.7 m-kg, 23—34 ft-lb)
19—26 N-m (1.9—2.6 m-kg, 14—19 ft-lb)
(?) 8—11 N-m (80—110 cm-kg, 69—95 In-lb)
37—52 N-m (3.8—5.3 m-kg, 27—38 ft
55—65 N-m (5.6—6.6 m-kg, 41-48 ft-lb)
(80—110 cm-kg, 69—95 In-lb)
59—69 N-m (6.0—7.0 m-kg, 43—51 ft-lb)
76G03B-006
1. Timing belt (Refer to page 1C—11)
2. Camshaft pulley (Refer to page 1C—36)
3. Injection pump pulley (Refer to page
1C—36)
4. Seal plate
Note
Do not disassemble the water pump body, if a problem is found replace it as a unit.
5. Alternator
6. Water pipe
7. Water hose
8. Water pump body
9. Water pump inlet
3B-7

3B WATER PUMP
INSPECTION
Check the following. Replace the pump if necessary.
1. Cracks or damage
2. Abnormal noise, bearing sticking or loose
86U03X-014
INSTALLATION
Install in the reverse order of removal referring to the
installation note.
Installation Note
Water pump
1. Remove any gasket fragments, dirt or oil from the
contact surfaces.
2. Install the water pump and new gasket so that the
printed side of the gasket faces the water pump.
Tightening torque:
Bolt A: 31—46 N-m
(3.2—4.7 m-kg, 23—34 ft-lb)
Bolt B: 8—11 N-m
(80—110 cm-kg, 69—95 in-lb)
Water pipe
1. Apply a coat of vegetable oil to the O-ring.
2. Install the water pipe.
Tightening torque:
8—11 N-m (80—110 cm-kg, 69—95 in-lb)
3. Connect the water hose.
76G03B-008
Alternator
1. Install the alternator.
Tightening torque:
Bolt A: 19—26
N
m
(1.9—2.6 m-kg, 14—19 ft-lb)
Bolt B: 37—52 N-m
(3.8—5.3 m-kg, 27—38 ft-lb)
2. Install the alternator drive belt and Comprex su-
percharger drive belt, and adjust the belt deflec-
tion. (Refer to page 1C—7)
76G03B-009
3B—8

4D OUTLINE
OUTLINE
The Mazda 626 offers two diesel engines; a Comprex supercharged RF-CX engine, and a normally
aspirated RF-N engine.
SPECIFICATIONS
—Engine model
Item ———
ECE UK, GENERAL —Engine model
Item ——— RF-CX RF-N
Fuel tank Capacity liters (US gal, Imp gal) 60 (15.9, 13.2)
Fuel filter Type Cartridge, paper element
Sedimenter Type With detector
Injection pump
Type Bosch VE distributor
Injection pump
Manufacturer Diesel Kiki Co,, Ltd.
Injection pump
Direction of rotation Clockwise Injection pump
Drive method Timing belt
Injection pump
Plunger diameter mm (in) 9.0 (0.35) 8.0 (0.31)
Injection pump
Cam lift mm (in) 2.2 (0.087)
Injection nozzle Type Throttle Injection nozzle
Injection pressure kPa (kg/cm2, psi) 13,240 (135 , 1,920)
Injection timing ATDC
1
° TDC 0°
Idle speed rpm 720 _+f0
Fast idle speed (A/C ON) rpm 700-750
Cold start device Engine speed rpm 1.100 Cold start device
Advance degree 6°
Air cleaner Type Cartridge, paper element Air cleaner Type
Wet Dry
PCV system Type Open Closed
76G04D-002
4D—2

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)
Starting Valve
1. Remove the bypass hose from the starting valve.
2. Check that the bypass valve in the starting valve
opens and closes repeatedly at idle.
3. Check that the bypass valve is closed when the
accelerator pedal is fully depressed when the en-
gine speed is more than 3,000 rpm.
4. If necessary replace the starting valve.
76G04D-026
Comprex Supercharger Drive Belt
1. Check the drive belt for wear, cracks, or fraying.
2. Check the drive belt deflection by applying moder-
ate pressure (98 N, 10 kg, 22 lb) midway between
the pulleys.
3. If necessary, loosen the bolt and adjust the belt
deflection by turning the adjusting bolt.
New : 4.0—5.0 mm (0.16—0.20 in)
Used: 4.5—5.5 mm (0.18—0.22 in)
Tightening torque:
16—23 Nm (1.6—2.3 m-kg, 12—17 ft-lb)
Wastegate
1. Disconnect the boost air hose from wastegate to
the intake manifold, and apply compressed air.
76G04D-028
2. Check that the wastegate actuator pulls the rod at
the specified pressure.
Pressure: 137 kPa (1.4 kg/cm2, 20 psi)
Caution
Do not apply more than 196 kPa (2.0 kg/cm2,
28 psi) pressure.
76G04D-087
4D—12

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

5
ENGINE ELECTRICAL SYSTEM
OUTLINE 5— 2
STRUCTURAL VIEW 5— 2
SPECIFICATIONS 5— 5
TROUBLESHOOTING 5— 7
BATTERY 5— 8
INSPECTION 5— 8
RECHARGE. 5— 8
SPARK PLUG 5— 9
REMOVAL AND INSTALLATION 5— 9
INSPECTION 5— 9
IGNITION COIL 5—10
INSPECTION 5—10
HIGH-TENSION LEAD 5—10
INSPECTION 5—10
DISTRIBUTOR 5—11
SPARK TEST 5—11
IGNITION TIMING 5—11
SPARK CONTROL 5—12
REMOVAL 5—14
DISASSEMBLY 5—15
INSPECTION 5—16
ASSEMBLY 5—17
INSTALLATION 5—18
H.E.I. TROUBLESHOOTING 5—19
IGNITER (FE DOHC) 5—20
INSPECTION 5—20
ALTERNATOR 5—21
CROSS SECTIONAL VIEW 5—21
CHARGING SYSTEM 5—22
TROUBLESHOOTING 5—23
REMOVAL 5—27
DISASSEMBLY 5—28
INSPECTION 5—32
ASSEMBLY 5—35
INSTALLATION 5—36
V-BELT TENSION 5—37
STARTER (GASOLINE ENGINE
0.85, 0.95 KW TYPE) 5—38
STARTING SYSTEM CIRCUIT 5—38
ON-VEHICLE INSPECTION 5—38
REMOVAL AND INSTALLATION 5—39
DISASSEMBLY AND ASSEMBLY 5—39
INSPECTION 5—40
PERFORMANCE INSPECTION 5—43
STARTER
(GASOLINE ENGINE, 1.4 KW TYPE) 5—45
STARTING SYSTEM 5—45
ON-VEHICLE UNSPECTION 5—45
REMOVAL 5—46
DISASSEMBLY 5—46
INSPECTION 5—49
ASSEMBLY 5—53
CHECKING OPERATION 5—54
INSTALLATION 5—55
STARTER
(DIESEL ENGINE, 2.0 kW TYPE) .... 5—56
STARTING SYSTEM CIRCUIT 5—56
ON-VEHICLE INSPECTION 5—56
REMOVAL AND INSTALLATION 5—57
DISASSEMBLY AND ASSEMBLY 5—57
INSPECTION 5—61
PERFORMANCE INSPECTION 5—64
STARTER
(DIESEL ENGINE, 2.2 kW TYPE).... 5—66
STARTING SYSTEM CIRCUIT 5—66
ON-VEHICLE INSPECTION 5—66
REMOVAL AND INSTALLATION 5—67
DISASSEMBLY AND ASSEMBLY 5—67
INSPECTION 5—71
PERFORMANCE INSPECTION 5—74
QUICK START SYSTEM (QSS) 5-76
COMPONENT LOCATION 5—76
CIRCUIT DIAGRAM 5—76
SYSTEM OPERATION 5—77
TROUBLESHOOTING GUIDE 5—78
CONTROL UNIT 5—79
GLOW PLUG RELAY 5—80
BLOW PLUG 5—80
WATER TEMPERATURE SWITCH.... 5—80
76g05x-001

OUTLINE 5
SPECIFICATIONS
Gasoline Engine
item
Engine
F6 F8 FE
(8 VALVE)
FE (12 VALVE) FE
(DOHC)
Battery
Voltage
Type and capacity
12. Negative ground
(20 hour rate) 34B19L(S) (33 Ah): General 50D20L (50 Ah), 55D23L (60 Ah): ECE
Alternator
Type A.C.
Output V-A 12-70
Regulator type Transistorized (built-in IC regulator)
Regulated voltage 14.1-14.7
Brush length
mm (in) Standard 16.5 (0.650)
Minimum 8.0 (0.315)
Drive belt tension
mm (in)/98 N (10 kg, 22 lb) New: 6-8 (0.24-0.32), Used: 7-9 (0.28-0.35)
Starter
Type Coaxial reduction: Middle East & General (FE • carburetor)
Non-reduction: Others
Output V-kW 12-0.85
Brush length
mm (in)
12-0.95
Standard 17.0 (0.669)
Minimum 11.5 (0.453)

Unleaded fuel
17.0 (0.669)
Others
17.51
Unleaded fuel 11.5(0.453) Others 10,0 (0.394)

12-1.4 12-0.95
17.0 (0.669)
11.5 (0.453)
Ignition timing 6 ± 10 BTDC (Vacuum hose disconnected)

12
±
1° BTDC
(Test connector

grounded)
Distributor
Type Fully transistorized (HEI)
Electronic spark advance
Centrifugal spark advance
(crank angle/engine speed)
degree/rpm
F6
-2-2/1,000 6-10/2,100 14-18/6,100
F8 -2—2/1,000 10-14/2,100 18-22/6,100
FE (8 VALVE)—Carburetor Unleaded fuel
(MTX)-2—2/1,760 12—16/3,360 22—26/5,320 (ATX)-2-2/1,300 12-16/3,360 22-26/5,320
Others
-2—2/1,460 10—14/2,540 22—26/5,540
FE (12 VALVE)—Carburetor -2-2/1,200 10—14/2,400 10—14/4,000 16-20/5,000
FE—Fuel injection (except FE DOHC) -2—2/1,000 10—14/2,600 10—14/4,600 16—20/5,800
Unleaded fuel model 76G05X-503
5-5

5 OUTLINE
Item
Engine F6 F8 FE
(8 VALVE)
FE (12 VALVE) FE (DOHC)
F6 and F8
-2-2/100 6-10/300
FE (8 VALVE)—Carbu retor Unleaded fuel -2—2/120 8—12/245
Distributor
Vacuum spark advance (Crank angle/Vacuum)
Others (MTX) -2-(ATX) -2--2/100 16-
-2/100 10-
-20/250
-14/200
degree/mmHg (inHg) FE (12 VALVE)—Carburetor
-2-2/120 11-15/300
FE—Fuel injection (except FE DOHC) [A chamber] -2-2/125 18-22/300
[B chamber] -2-2/125 -6 10/200
Spark plug
Type
FE (8 VALVE)*1 NGK: BPR5ES-11, BPR6ES-11 Nippon Denso: W16EXR-U11, W20EXR-U11 Others
NGK: BPR5ES, BPR6ES Nippon Denso: W16EXR-U, W20EXR-U
NGK:
BCPR5E, BCPR6E Nippon
Denso: Q16PR-U, Q20PR-U
Unleaded fuel
NGK: BCPR5E-11 BCPR6E-11 BCPR7E-11
Leaded fuel NGK: BCPR5E BCPR6E
Plug gap mm (in)
0.75-0.85 (0.030-0.033), FE (8 VALVE)*1 1.0-1.1 (0.039-0.043)
0.7-0.8
(0.028-0.031)
1.0-1.1 "
/n noo
n n/9
0.7-0.8 *2 (0.028-0.031)
Firing order 1-3—4-2 76G05X-504
Diesel Engine
——Engine Item RF-N RF-CX
Battery
Voltage V 12, Negative ground Battery Type and capacity
(20 hour rate) 80D26L (65)
50D20L, 50D20R (50)-ECE 80D26L (65)
65D23L, 65D23R (55)
Alternator
Type A.C.
Alternator
Output V-A 12-70 12-75
Alternator
Regulator type Transistorized (built-in IC regulator)
Alternator Regulated voltage V 14.1-14.7 Alternator
Brush length mm (in)
Standard 16.5 (0.650) 21.5 (0.846)
Alternator
Brush length mm (in) Minimum 8.0 (0.315) 8.0 fO.315)
Alternator
Drive belt tension
mm (in)/98 N (10 kg. 92 lb) New: 9-11 (0.35-0.43), Used: 12-14 (0.47-0.55)
Starter
Type Reduction
Starter Output V—kW 12—2.0, 12-2.2 (Cold area) Starter Brush length
mm (in)
Standard 2.0 kW: 17.0 (0.669). 2.2 kW: 18.0 (0.709) Starter Brush length
mm (in) Minimum 2.0 kW: 11.0 (0.453), 2.2 kW: 11.0 (0.453)
Firing order 1-3-4-2
Unleaded fuel model *2 Leaded fuel model
76G05X-505
5-6