water MAZDA 626 1987 Workshop Manual
[x] Cancel search | Manufacturer: MAZDA, Model Year: 1987, Model line: 626, Model: MAZDA 626 1987Pages: 1865, PDF Size: 94.35 MB
Page 654 of 1865
CONTROL SYSTEM 4C
Output Devices and In put Devices (Leaded fuel)
IGNITION SWITCH
(ON POSITION) X X X X X O X X X X O
TEST CONNECTOR X X X O X X X X X O X
KNOCK SENSOR X X X X X X X X X o X
ELECTRICAL LOAD
CONTROL UNIT X X X O X X X X X X X
P/S PRESSURE SWITCH X X X o X X X X X X X
A/C SWITCH X X X o X X X X O X X
IGNITION SWITCH (STA POSITION) O O X o O X O X X O X
NEUTRAL AND
CLUTCH SWITCH O X X o X X X X X X X
INTAKE AIR THERMO SENSOR X X X X X X O X X X X
WATER THERMO SENSOR O X X o X X O X X O o
IDLE SWITCH o X X o X X o X X O X
VARIABLE RESISTOR (IN AIR FLOW SENSOR) o X X X X X X X X X X
AIR FLOW SENSOR o X X X X X X X X O O
Ne SIGNAL o o X O o X O o X o O
G SIGNAL X O X X X X X X X X X
INPUT
DEVICE
OUTPUT
DEVICE
FUEL
INJECTION
AMOUNT
FUEL
INJECTION
TIMING
AIR
VALVE
ISC
VALVE
FUEL
PUMP
CONTROL
MAIN
POWER
CONTROL
SOLENOID
VALVE
(PRESSURE
REGULATOR
CONTROL)
SOLENOID
VALVE
(VARIABLE
INERTIA
CONTROL)
A/C
RELAY
IGNITER
AIR
FLOW
SENSOR
(BURN-OFF)
INPUT
DEVICE
OUTPUT
DEVICE
INJECTOR
BAC
VALVE
CONTROL
RELAY
SOLENOID
VALVE
(PRESSURE
REGULATOR
CONTROL)
SOLENOID
VALVE
(VARIABLE
INERTIA
CONTROL)
A/C
RELAY
IGNITER
AIR
FLOW
SENSOR
(BURN-OFF)
76G04C-168
4C—93
Page 660 of 1865
CONTROL SYSTEM 4C
Terminal Voltage
If the input and output devices wiring are normal, but the engine control unit terminal voltage is incor-
rect, replace the engine control unit.
Terminal Input Output Connection to Voltage (After warming-up) Remark Terminal Input Output Connection to Ign: ON Idle Remark
1A — — — — — —
1B o Self-Diagnosis Checker (Code No.)
For 3sec. after ignition switch OFF ->• ON: below 2.5V (Buzzer sounds) After 3sec.: approx. 12V (Buzzer does not sound)
• Using Self-Diagnosis Check-er and test con-nector grounded • Buzzer sounds: below 2.5V • Buzzer does not sound: approx. 12V
1C o
Solenoid valve (Variable inertia control) Approx. 12V
Above 5200 rpm (Unleaded fuel) or 5400 rpm (Leaded fuel): Below 2.5V
1D o Self-Diagnosis Checker (Monitor lamp)
For 3sec.after igni-tion switch OFF -» ON:
approx. 5V (light il-luminates)
After 3sec.: approx. 12V (light does not illuminate)
(Test connector grounded) approx. 5V (Test connector not grounded) Monitor lamp ON: approx. 5V Monitor lamp OFF: approx. 12V
With Self-Diagnosis
Checker
1E O Idle switch Accelerator pedal released: OV
Accelerator pedal depressed: approx. 12V
1F o A/C relay A/C switch ON: below 2.5V
A/C switch OFF: approx. 12V Blower motor ON
1G O Neutral or clutch switch
In-gear condition Clutch pedal depressed: approx. 12V Clutch pedal released: OV
MTX (Neutral: con-stant approx. 12V)
1H
(U/F) o Water thermo
switch
Approx. 12V Radiator temp.: be-low 17°C (63°R 1H
(U/F) o Water thermo
switch OV Radiator temp.:
above 17°C (63°F)
11 o Electrical load control unit E/L switch ON: below 2.5V
E/L switch OFF: approx. 10—12V
Electrical load: Rear defroster switch
Headlight switch Blower motor switch (3rd & 4th position) Electrical fan switch
1J — — — — —
1K o P/S pressure
switch
Constant approx.
12V
P/S ON: below 2.5V P/S OFF: approx. 12V
1L o A/C switch A/C switch ON: below 2.5V A/C switch OFF: aDDrox. 12V Blower motor: ON
1M o Distributor
(Ne signal) OV or 5V Approx. 2.0V
1N o Distributor (G signal) OV or 5V Approx. 1.2V
Note
Terminals labeled "U/F" are only for unleaded fuel.
4C-99
Page 661 of 1865
4C CONTROL SYSTEM
Terminal Input Output Connection to Voltage (After warming-up) Remark Terminal Input Output Connection to Ign: ON Idle Remark
10 o Air flow sensor
(Burn-off control) Below 2.5V White burning off:
Approx. 8—12V
1P o
Control relay (Power supply circuit) Below 2.5V Ignition switch OFF:
Approx. 12V
1Q 0 Control relay (Fuel pump circuit) Approx. 12V Below 2.5V
1R
(L/F) O Knock sensor OV or 2—7V While knocking:
Approx. 0.001
1S — — — — —
1T o Ignition switch
(ON position) Approx. 12V
1U — — — — —
1V — — — — —
1W o Test connector Test connector grounded: OV Test connector not grounded: approx. 12V Green connector, 1-pin
1X o Igniter Approx. 12V *Approx.1V 'Engine Signal
Monitor: green and
red lights flash
2A (U/F) o V ref 4.5—5.5V
2B o Air flow sensor
(Ground) OV
2C — — Ground (E2) OV
2D (U/F) o Oxygen sensor OV 0-1.0V
• Cold engine: 0V at idle
• After warming-up: Increase engine speed: 0.7—1.0V Deceleration: 0—0.2V
2E o Air flow sensor
(Intake air mass) 1.0—1.6V 1.7—2.3V Increase engine speed: voltage increases
2F — — — .— —
2G (U/F) o Throttle sensor Accelerator pedal released: approx. 0.5V
Max. voltage (Throt-tle valve fully opened): approx. ,4.3V
2H (L/F) o Air flow sensor (Variable resister) 0-5V Depends on
adjustment
21 o Water thermo sensor Approx. 0.4V
Engine coolant
temp. 20°C (68°F):
approx. 2.5
2J o Intake air thermo sensor (Dynamic chamber)
Approx. 2.5V at 20°C (68°F)
2K o
Solenoid valve (Pressure regula-tor control)
For 120 sec. after ignition switch OFF - ON: below 2.5V
For 120. sec after starting: below 2.5V
During hot condi-tion: Coolant temp, above 70°C (158°F) Intake air temp, above 30°C (86°F) ...Unleaded fuel above 50°C (122°F) ...Leaded fuel
2K o
Solenoid valve (Pressure regula-tor control)
ADDrox. 12V Other conditions
2L — — — — —
Note
a) Terminal labeled "U/F" are only for unleaded fuel.
b)Terminal labeled "L/F" are only for leaded fuel.
4C-100
Page 667 of 1865
4C CONTROL SYSTEM
4. Make sure that the throttle valve is fully closed.
5. Turn the throttle sensor so that the BLUE wire volt-
age indicates within the specified closed range.
6. Tighten the throttle sensor mounting screw.
7. Recheck that the BLUE wire voltage is within the
specified range.
76G04C-195
8. Turn the ignition switch OFF.
9. Disconnect the SST and reconnect the throttle sen-
sor connector.
10. Disconnect the negative battery terminal and de-
press the brake pedal for 5 seconds to eliminate
the from the malfunction memory from the control
unit.
76G04C-196
76G04C-198
4C-106
IDLE SWITCH
Inspection
1. Disconnect the idle switch connector.
2. Check continuity between the switch and a ground.
Throttle valve condition Continuity
Fully closed Yes
Open No
3. If not correct, check condition of the wiring harness
of the idle switch. Replace the idle switch and throt-
tle body as an assembly, if necessary.
WATER THERMO SWITCH
Inspection
1. Remove the switch from the radiator.
2. Place the switch in water with a thermometer and
heat the water gradually.
3. Check for continuity of the switch with an
ohmmeter.
Coolant temp. Continuity
More than approx. 17°C (63°F) Yes
Less than approx. 10°C (63°F) No
4. If not correct, replace the water thermo switch.
Page 668 of 1865
CONTROL SYSTEM 4C
WATER THERMO SENSOR
Inspection
1. Remove the water thermo sensor.
76G04C-199
86U04A-203
2. Place the sensor in water with a thermometer and
heat the water gradually.
3. Check resistance of the sensor with an ohmmeter.
Coolant Resistance
-20°C ( —4°F) 14.5—17.8 kfl
20°C ( 68°F) 2.2-2.7 kQ
40°C (104°F) 1.0—1.3 kQ
60°C (140°F) 500—640 O
80°C (176°F) 280—350 fl
4. If not correct, replace the water thermo sensor.
OXYGEN SENSOR
Inspection of Output Voltage
1. Warm up the engine and run it at idle.
2. Disconnect the oxygen sensor connector.
3. Connect a voltmeter between the oxygen sensor
and a ground.
4. Run the engine at 4,500 rpm until the voltmeter
indicates approx. 0.7V.
76G04C-200
5. Increase and decrease the engine speed suddenly
several times. Check to see that when the speed
is increased the meter reads between 0.5V—1 .OV,
and when the speed is decreased it reads between
OV—0.4V.
6. If the voltmeter dosen't indicate as specified, re-
place the oxygen sensor.
86U04A-206
4C—107
Page 672 of 1865
4D
FUEL AND EMISSION
CONTROL SYSTEM
(DIESEL)
OUTLINE 4D— 2
SPECIFICATIONS 4D— 2
TROUBLESHOOTING GUIDE 4D— 3
ON-VEHICLE MAINTENANCE 4D— 4
AIR CLEANER ELEMENT 4D— 4
WATER DRAINING 4D— 4
AIR BLEEDING 4D— 4
INJECTION TIMING 4D— 5
IDLE SPEED 4D— 6
EXHAUST SMOKE 4D— 6
INTAKE AIR SYSTEM 4D— 7
STRUCTURAL VIEW 4D— 7
AIR DUCT AND AIR CLEANER 4D— 8
INTAKE MANIFOLD 4D— 9
SUPERCHARGING SYSTEM (RF-CX) 4D-10
TROUBLESHOOTING GUIDE 4D—10
ON-VEHICLE INSPECTION 4D—11
COMPREX SUPERCHARGER 4D—13
STARTING VALVE 4D—15
INTERCOOLER 4D—16
BOOST AIR TEMPERATURE SENSOR 4D—17
EXHAUST SYSTEM 4D—18
STRUCTURAL VIEW 4D—18
EXHAUST MANIFOLD 4D—19
EXHAUST PIPE AND MAIN SILENCER .... 4D—20
FUEL SYSTEM 4D—21
STRUCTURAL VIEW 4D—21
FUEL FILTER 4D—22
SEDIMENTER (GENERAL) 4D—22
WATER LEVEL SENSOR 4D—23
INJECTION PUMP 4D—24
INJECTION NOZZLE 4D—31
FUEL TANK 4D—34
76G04D-001
Page 674 of 1865
TROUBLESHOOTING GUIDE 4D
TROUBLESHOOTING GUIDE
Condition Condition Cause Remedy
Hard starting Fuel filter
Clogged Replace
Water or air in filter Repair
Fuel injection pump Faulty fuel cut solenoid Replace Incorrect injection timing Adjust
Air in pump Bleed
Faulty pump Replace
Fuel injection nozzle Seized needle valve Replace
Fuel dripping from nozzle Replace Incorrect valve opening pressure Adjust
Faulty glow plug Replace
Faulty cold start device Adjust or replace
Faulty supercharging system Refer to page 4D—10
Rough idle Fuel filter (Refer to "Hard starting") Fuel injection pump (Refer to "Hard starting")
Fuel injection nozzle
Seized needle valve Replace
Incorrect valve opening pressure Adjust
Improper mounting to nozzle holder Repair
Leakage of nozzle holder copper washer Replace
Fuel injection pipe Cranks Replace
Leaking from joint Repair
Improper idle speed adjustment Adjust
Engine knocking Incorrect injection timing Adjust
Low quality fuel Replace
Incorrect injection nozzle opening pressure Ajust
Seized injection nozzle needle valve Replace
Fuel dripping from injection nozzle Replace
Faulty supercharging system Refer to page 4D—10
High fuel Fuel injection pump consumption Incorrect injection timing Adjust consumption High idle speed Adjust, Inspect the dashpot
Fuel injection nozzle Incorrect valve opening pressure Repair
Fuel dripping from nozzle Replace
Leakage of nozzle holder copper washer Replace
Fuel leaking from connection Repair
Clogged fuel filter Replace
Clogged air cleaner Replace
Poor acceleration Fuel injection nozzle (Refer to "Hard starting")
Fuel injection pump (Refer to "Hard starting")
Fuel injection pipe (Refer to "Rough idle") Fuel filter (Refer to "Hard starting") Clogged air cleaner Clean or replace
Faulty supercharging system Refer to page 4D—10
Excessive exhaust Clogged air cleaner Clean or replace
smoke Improper injection timig Adjust
Faulty nozzle or nozzle holder Adjust or replace
Faulty supercharging system Refer to page 4D—10
76G04D-003
4D-3
Page 675 of 1865
4D ON-VEHICLE MAINTENANCE
ON-VEHICLE MAINTENANCE
76G04D-004
AIR CLEANER ELEMENT
Check the air cleaner element for excessive dirt, dam-
age, or oil. Replace if necessary.
Caution
(Wet type)
Do not clean the air cleaner element with com-
pressed air, replace if necessary.
(Dry type)
When cleaning the air cleaner element, blow
dust off from the inside first, then blow off the
outside.
(General)
1. Loosen the drain plug of the sedimenter and let
the water drain. If necessary loosen the air bleed-
ing plug.
2. Bleed air from the sedimenter.
AIR BLEEDING
From Fuel Tank to Fuel Filter
1. Loosen the air bleeding plug of the fuel filter.
2. Pump the priming pump until no air bubbles flow
from the air bleeding plug hole.
3. Depress the priming pump and tighten the air
bleeding plug.
Note
Open only the air bleeding plug of the filter.
From Fuel Filter to Injection Pump
Pump the priming pump until it becomes hard to
pump.
76G04D-007
WATER DRAINING
(ECE)
1. Loosen the drain plug of the fuel filter.
2. Pump the priming pump.
3. Bleed air from the fuel filter.
4D—4
Page 680 of 1865
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
Page 693 of 1865
4D FUEL SYSTEM
76G04D-047
76G04D-048
76G04D-049
FUEL FILTER
On-Vehicle Inspection
Check for water in the fuel filter. If present drain the
water. (Refer to page 4D—4.)
Replacement
Removal
1. Disconnect the water level sensor connector (ECE).
2. Remove the water level sensor. (ECE).
3. Remove the fuel filter cartridge.
Warning
Keep fire and open flame away from the fuel
area.
Installation
1. Apply fuel to the O-ring of the fuel filter cartridge
and install it onto the filter body.
2. Install the water level sensor (ECE).
3. Connect the water level sensor connector (ECE).
4. Bleed air from fuel filter. (Refer to page 4D—4.)
5. Check for fuel leakage.
SEDIMENTER (GENERAL)
On-Vehicle Inspection
Check for water in the sedimenter. If present, drain
the water. (Refer to page 4D—4.)
4D—22