torque MAZDA 626 1987 Workshop Manual

4C FUEL SYSTEM
^ Pulsation
damper
76G04C-121
Pulsation damper
—
Delivery pipe
76G04C-122
Fuel hose
,Fuel pump
-Intank filter
76G04C-123
Insulator
f f r—
/ 0 DM

•
II r
O - ring
Grommet
Manifold
Delivery pipe
Pressure Regulator
1. Remove the engine hanger.
2. Disconnect the vacuum hose and fuel return hose.
3. Remove the pressure regulator.
4. Install in the reverse order of removal.
Tightening torque:
8—11 Nm (0.8—1.1 m-kg, 69—95 in-lb)
Pulsation Damper
1. Remove the delivery pipe assembly. (Refer to page
4C-63.)
2. Remove the pulsation damper.
3. Install in the reverse order of removal.
Tightening torque:
25—34 N m (2.5—3.5 m-kg, 18—25 ft-lb)
Fuel Filter
Low pressure side (In-tank filter)
Refer to page 4C—60.
76G04C-124
High pressure side
The fuel filter must be replaced at the intervals out-
lined in the maintenance schedule.
Warning
Always work away from sparks or open
flames.
1. Disconnect the fuel hoses from the fuel filter.
2. Remove the fuel filter and the bracket.
3. Install a new filter and the bracket.
4. Connect the fuel hoses.
Note
When installing the filter, push the fuel hoses
fully onto the fuel filter and secure them with
spring clamps.
4C-64

4C FUEL SYSTEM
Inspection
1. Check the fuel tank for cracks and corrosion.
2. If any defect is found, repair or replace the tank.
Warning
Before repairing, clean the fuel tank thorough-
ly with steam to remove all explosive fuel and
fumes.
Installation
Install in the reverse order of removal, referring to the installation note.
Torque Specifications
4C-66
76G04C-126

4C EXHAUST SYSTEM (UNLEADED FUEL)
REMOVAL AND INSTALLATION
1. Remove in the sequence shown in the figure.
2. Install in the reverse order of removal.
Torque Specifications
86U04A-159
4. Catalytic converter
5. Bracket
6. Front pipe
INSPECTION
1. Check the catalytic converter and exhaust pipe for
deterioration or restriction.
2. Check the insulation covers welded onto the cata-
lytic converter for damage.
Note
If the insulation cover is touching the catalytic
converter housing, excessive heat at the floor
will occur.
19—26 N-m (1.9—2.6 m-kg, 14—19 tt-lb)
29—39 N-m (3.0—4.0 m-kg, 22—29 ft-lb)
34—49 N-m (3.5—5.0 m-kg, 26—36 ft-lb)
39—57 N-m (4.0-5.8 m-kg, 29—42 ft-lb)
37—52 N m (3.8—5.3 m-kg, 27—38 ft-lb) 8—11 N-m 8—1.1 m-kg, 69—95 In-lb)
N-m .3 m-kg, 38 ft-lb)
1. Main silencer
2. Middle pipe
3. Pre-silencer
86U04A-160
4C—88

4C EXHAUST SYSTEM (LEADED FUEL)
REMOVAL AND INSTALLATION
1. Remove in the sequence shown in the figure.
2. Install in the reverse order of removal.
Torque Specifications
1. Main silencer
2. Middle pipe
3. No. 2 pre-silencer
76G04C-165
4. No. 1 pre-silencer
5. Bracket
6. Front pipe
4C—90

4C CONTROL SYSTEM
76G04C-207
76G04C-208
Replacement
1. Disconnect the knock sensor connector.
2. Lift the vehicle and remove the intake manifold
bracket.
3. Remove the knock sensor with the SST.
4. Install the knock sensor in the reverse order of
removal.
INTAKE AIR THERMO SENSOR (DYNAMIC
CHAMBER)
Inspection
1. Disconnect the intake air thermo sensor connector.
2. Connect an ohmmeter to the sensor terminals.
3. Check the resistance of the sensor.
Temperature Resistance (kQ)
20°C (68°F) 29.7—36.3
50°C (122°F) 8.4-10.2
85 °C (185°F) 2.5-3.1
4. Reconnect the sensor connector.
Replacement
1. Disconnect the intake air thermo sensor connector.
2. Remove the sensor.
3. Install the sensor.
Note
When installing the sensor, tighten to the
specified torque.
Specified torque:
6.9—8.8 N-m (0.7—0.9 m-kg, 72 in-lb)
76G04C-209
4C—110

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

4D SUPERCHARGING SYSTEM (RF-CX)
BOOST AIR TEMPERATURE SENSOR
Removal
Remove the boost air temperature sensor from the
compressed air funnel.
76G04D-039
Thermometer
Inspection
1. Place the boost air temperature sensor in oil.
2. Heat the oil and check continuity of the sensor with
an ohmmeter. Replace if necessary.
Continuity : over 150°C (302°F)
No continuity: below 143°C (289°F)
76G04D-040
Installation
Install the boost air temperature sensor in the com-
pressed air funnel.
Tightening torque:
29—39 N m (3.0—4.0 m-kg, 22—29 ft-lb)
76G04D-041
4D—17

FUEL SYSTEM 4D
76G04D-077
76G04D-078
^^^
76G04D-079
Red paint
Injection Nozzle Disassembly
Disassemble the injection nozzle.
1. Nozzle holder
2. Adjusting shim
3. Pressure spring
4. Pressure pin
5. Distance piece
6. Nozzle
7. Retaining ring
Cleaning
Clean the parts in clean test oil.
Injection Nozzle Inspection
1. Check the needle valve, nozzle body, and other
parts for damage.
2. Hold the nozzle body upright and insert approxi-
mately two thirds of the needle valve, and check
that the needle valve drops to the valve seat by
its own weight.
Injection Nozzle Assembly
1. Assemble the injection nozzle.
Tightening torque of nozzle body:
29—49 N-m (3.0—5.0 m-kg, 22—36 ft-lb)
2. Check the injection starting pressure, and atomi-
zation. (Refer to page 4D—32.)
Injection Nozzle Installation
1. Install in the reverse order of removal, referring to
the installation note.
2. Check for fuel leakage.
Installation note
Nozzle gasket
Install a new gasket with the red face toward the
nozzle.
76G04D-080
4D-33

SPARK PLUG 5
Slow Charge
1. Stop the engine
2. Turn all the accessories off.
3. Remove the negative battery cable.
4. Perform a slow charge (3.5A to 4.5A).
5. Add distilled water if necessary while charging.
6. Charge once more if the specific gravity is under
fully charged gravity.
4BG05X-010
SPARK PLUG
REMOVAL AND INSTALLATION
Note the following points:
1. When the high-tension lead is to be pulled off, be
sure to pull the boot itself, and not the wire.
2. Tighten the spark plugs to the specified torque.
Tightening torque: 15—23 N-m
(1.5—2.3 m-kg, 10.8—16.6 ft-lb)
76G05X-054
Wear and adhesion or cabon
INSPECTION
Check the following points. If a problem is found, re-
place the spark plug.
1. Damaged insulation
2. Worn electrodes
3. Carbon deposits
If cleaning is necessary, use a plug cleaner or a
wire brush. Clean the upper insulator also.
4. Damaged gasket
5. Burnt condition of spark insulator
6. If it is black with carbon deposits, either misfiring
due to improper proportions of gas and air or over-
heating of the plug may have occurred.
Plug gap:
FE (12VALVE) and FE DOHC Leaded fuel
model:
0.70—0.80 mm (0.028—0.031 in)
FE (8VALVE) and FE DOHC Unleaded fuel
model:
1.0—1.10 mm (0.039—0.043 in)
Others:
0.75—0.85 mm (0.030—0.034 in)
76G05X-005
5-9

DISTRIBUTOR
8.
If
the mark is not aligned, loosen the distributor lock
bolt, and turn the distributor housing to make the
adjustment.
9. Reconnect the vacuum hoses, or disconnect the
jumper wire from the test connector.
10. Tighten the distributor lock bolt to specified torque.
Tightening torque:
18.6—25.5 Nm
(1.9—2.6 m-kg, 13.7—18.8 ft-lb)
86U05X-051
SPARK CONTROL (Except FE DOHC)
Centrifugal Advance
1. Warm up the engine to the normal operating tem-
perature.
2. Check that the idle speed and initial ignition tim-
ing are correct.
3. Disconnect the vacuum hoses from the vacuum
control unit and plug them.
76G05X-009
F6
Engine Speed (rpm)
4. While gradually increasing the engine speed, use
a timing light to check the advance on the pulley.
Excess advance weak governor spring
(If the governor spring is broken,
the advance will rise very high)
Insufficient advance...governor weight or cam
malfunction
86U05X-053
F8
Engine Speed (rpm) Engine Speed (rpm)
5-12