oil type MAZDA 626 1987 Owner's Manual

VE-TYPE RF71 13 800C: 104749-0343 For RF-CX
# TEST OIL SAE Standard test oil (SEA 967C)
Fuel injection amount Chamber pressure and timer stroke Load sensing timer and overflowing quantity Measurenment
Item Pump speed (RPM) Fuel injection amount
(cm3/stroke)
Start 100 More than 55/1,000
Full load
600 33.9—38.9/1,000
Full load
1,000 48 9—50.9/1,000
Full load 2,150 39.7—44 7/1,000 Full load
2,250 32.7-37.7/1,000
Full load
2,550 8.0—15.0/1,000
Idling 360 7.6—10.6/1,000
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Pump speed (RPM) Chamber pressure
(kg/cm2)
Timer stroke (mm)
500 500
1,250 4.5—5.1 2.7—3.9
1,500 5.2—5.8 4 3-4.9
2,150 6.8—7 4 7.6-8.8
Item Fuel injectioon amount
(cm3/stroke)
Load sens-ing timer
Start 37.2-39.2/1,000 Load sens-ing timer End 32.2-34.2/1.000
Overflowing quantity 41.0—85.0/1.000
"Checking condition
Pump speed: 1,500 rpm
Lever: Full load
Measuring place Dimension (mm)
KF 5.7—5.9
K 3.2—3.4
MS 1.6-1.8

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100 600 1,000 1,250 1,500
Injection pump speed RPM
10
2,150 2,250 2,550
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VE-TYPE RF79 13 800A: 104748-0343 For RF-N ENGINE
£ TEST OIL SAE Standard test oil (SEA 967C)
Fuel injection amount Chamber pressure and timer stroke Load sensing timer and overflowing quantity Measurenment
Item Pump speed (RPM)
Fuel injection amount
(cm3/stroke)
Start 100 More than 42/1,000
Full load
600 29.0—33.0/1,000
Full load
1.375 34.9—36.9/1,000
Full load 2,325 30 2—34.2/1,000 Full load
2,600 9.8—15 8/1,000
Full load
2,700 Max. 6 0/1,000
Idling 360 8-12/1,000
Pump speed (RPM) Chamber pressure
(kg/cm2)
Timer stroke
(mm)
600 2 2—2.8
1,375 4 4—5,0 3 9—4.5
1,800 5 6—6.2 6.1-7.3
2.325 6.9—7.5 7.2—8.4
Item Fuel injectioon amount
(cm3/stroke)
Load sens- Start 26.7-29.7/1,000
ing timer End 14.6—17.6/1,000
Overflowing quantity 46.3—90.3/1.000
'Checking condition
Pump speed: 1,375 rpm
Lever: Full load
Measuring place Dimension (mm)
KF 5.8—5.9
K 3.2—3 4
MS 1.4—1.6
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50
40
30
20
10
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100 600
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1,375 1,800
Injection pump speed RPM
2,325 2,600 2,700
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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

5 DISTRIBUTOR
INSTALLATION
Note
After installing the distributor, adjust the ig-
nition timing (Refer to 5—11).
1. Apply engine oil to the O-ring and driven gear.
76G05X-056
Note
Gear driven type, check that the No.1 cylin-
der is at top dead center and aline the distrib-
utor matching marks.
76G05X-016
2. Install the distributor and connect the high-tension
leads and distributor connector.
3. Tighten lock bolt to the specified torque.
Torque specification:
19—25 Nm (1.9—2.6 m-kg, 14—18 ft-lb)
86U05X-064
5—18

5 STARTER (GASOLINE ENGINE, 0.85, 0.95 KW TYPE)
STARTER (GASOLINE
ENGINE, 0.85, 0.95
KW TYPE)
STARTING SYSTEM CIRCUIT
76G05X-039
START
i Turn ON
(S) terminal
0
t* t
Voltmeter
4BG05X-074
ON-VEHICLE INSPECTION
Charge the battery fully before starting the following
inspections.
A. If the magnetic switch dose not function dur-
ing starting.
1. Turn the ignition switch to the start position.
2. Measure the voltage between the S terminal and
ground.
3. If the measured value is standard voltage or more,
there is starter malfunction.
4. If it is less than standard voltage, there is a mal-
function in the wiring.
Standard voltage: 8 V
Caution
If the magnetic switch is hot, it may not func-
tion even though the voltage is standard volt-
age or more.
B.lf the starter won't crank, or if the cranking
speed is slow.
The problem may be a malfunction of the starter
or in the wiring.
Note
The cranking speed is greatly affected by the
viscosity of the engine oil.
5-38

5 STARTER (GASOLINE ENGINE, 0.85, 0.95 KW TYPE)
4BG05X-078
4BG05X-079
4BG05X-080
Drive Pinion
Remove the stopper for the overrunning clutch by us-
ing a pipe as shown in the figure.
Adjustment of Pinion Gap
1. Disconnect the wiring from terminal (M).
2. Apply battery power to the terminal (S) and ground
the starter motor body, the pinion will eject outward
and then stop.
3. Measure the clearance (pinion gap) between the
pinion and the stopper.
Pinion gap: 0.5—2.0 mm (0.020—0.079 in)
Caution
Do not let electricity flow continuously for
more than 10 seconds.
If the pinion gap is not within the specified range,
make the adjustment by increasing or decreasing
the number of washers used between the magnetic
switch and the drive housing. The gap will become
smaller if the number of washers is increased.
Caution
Do not use the washers
(0.079 in) in all.
more than 2 mm
INSPECTION
Armature Coil
1. Ground of the armature coil
(1) Check for continuity between the commutator
and the core by using a circuit tester.
(2) Replace the armature if there is continuity.
4BG05X-081
5—40

STARTER (GASOLINE ENGINE, 0.85, 0.95 KW TYPE) 5
4BG05X-082
4BG05X-083
4BG05X-084
2. Vibration of the commutator
(1) Place the armature on V blocks, and measure
the vibration by using a dial gauge.
(2) If the vibration is Limit or more, repair so that
it becomes standard by using a lathe, or re-
place the armature.
Standard vibration: 0.05 mm (0.002 in)
Limit: 0.4 mm (0.018 in)
Note
Before checking, be sure that there is no play
in the bearings.
3. Outer diameter of the commutator
Replace the armature if the outer diameter of the
commutator is grind limit or less.
4. Roughness of the commutator surface
(1) If the commutator surface is dirty, wipe it with
a cloth.
(2) If it is rough, repair it by using a lathe or fine
sandpaper.
Grind limit: 31 mm (1.22 in)
5. Segment groove depth
If the depth of the mold between segments is limit
depth or less, undercut the grooves by standard
depth.
Standard depth:
0.5—0.8 mm (0.020—0.031 in)
Limit depth: 0.2 mm (0.008 in)
Field Coil
1. Wiring damage
(1) Check for continuity between the connector
and brushes by using a circuit tester.
(2) Replace the yoke assembly if there is no con-
tinuity.
4BG05X-085
5—41

5 STARTER (GASOLINE ENGINE, 0.85, 0.95 KW TYPE)
4BG05X-086
4BG05X-087
4BG05X-088
2. Ground of the field coil
(1) Check for continuity between the connector
and yoke by using a circuit tester.
(2) Repair, or replace the yoke assembly if there
is continuity.
3. Installation of the field coil
Replace the yoke assembly
if
the field coil is loose.
Brush and Brush Holder
1. Brush
If the brushes are worn beyond the wear limit, or
if the wear is near the limit, replace the brushes.
Standard:
Wear limit:
17 mm (0.669 in)
11 mm (0.433 in)
2. Brush spring
(1) Measure the force of the brush spring by us-
ing a spring balance.
(2) Replace the brush spring if the force is Limit
or less.
Limit: 9 N (900 g, 31.75 oz)
3. Brush holder
(1) Check for continuity between the insulated
brush and the plate by using a circuit tester.
(2) Repair or replace if there is continuity.
(3) Also check to be sure that the brush slides
smoothly inside the brush holder.
4BG05X-089
5—42

STARTER (GASOLINE ENGINE, 0.85, 0.95 KW TYPE) 5
4BG05X-090
4BG05X-091
4BG05X-092
Drive Pinion and Housing
1. Pinion gear
(1) Check for wear or damage of the pinion gear.
(2) Replace if necessary.
(3) If the pinion gear is seriously damaged, also
check the flywheel ring gear.
2. Bushing
(1) Check for wear or damage.
(2) Replace if necessary.
3. Switch coil
(1) Check for continuity between the M terminal
and the body by using a circuit tester.
(2) Replace the switch if there is no continuity.
PERFORMANCE INSPECTION
Magnetic Switch
Disconnect the terminal M wire, and make the fol-
lowing tests.
Pull-in Test
The switch is normal
if
the pinion ejects outward when
the battery is connected as shown in the figure.
Caution
Do not supply power continuously for more
than 10 seconds.
Hold-in Test
1. After completing the pull-in test, disconnect the wire
from terminal M (with the pinion left ejected).
2. The hold-in coil is functioning properly if the pin-
ion does not return.
4BG05X-093
5-43

STARTER (GASOLINE ENGINE, 1.4 KW TYPE) 5
STARTER (GASOLINE
ENGINE, 1.4
KW TYPE)
STARTING SYSTEM
76G05X-041
ON-VEHICLE INSPECTION
Charge the battery fully before starting the following
inspection.
1. Turn the ignition switch to the start positron.
2. Check that the starter motor operates.
3. If the starter does not operate, check the voltage
between S terminal and ground using a voltmeter.
4. If the voltage is 8V or more, the starter is mal-
function.
5. If less than 8V, the wiring harness is malfunction.
Caution
If the magnetic switch is hot, it may not func-
tion even though the voltage is standard volt-
age or more.
Note
The cranking speed is greatly affected by the
viscosity of the engine oil.
86U05X-031
5-45