MAZDA 626 1987 Workshop Manual
Manufacturer: MAZDA, Model Year: 1987, Model line: 626, Model: MAZDA 626 1987Pages: 1865, PDF Size: 94.35 MB
Page 381 of 1865
4A OUTLINE
FE Engine
Engine FE 8Valve FE 12Valve FE 8Valve
Specification General Middle East
ECE, Hong Kong, & Singapore Unleaded fuel
Idle speed
rpm
MTX 800
+5§
850
+5§
Idle speed
rpm
ATX 900
+58 (in N
range)
CO concentration
%
2.0
± 0.5
(Without secondary
air
injection)
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)
Main
jet mm (in)
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) Main
jet mm (in)
Secondary 1.55 (0.061) 1.50 (0.059) 1.55 (0.061) 1.50 (0.059)
Main
air
bleed
mm (in)
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) Main
air
bleed
mm (in) Secondary 0.50 (0.020)
Slow
jet mm (in)
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) Slow
jet mm (in)
Secondary ATX 1.10 (0.043) 1.00 (0.039) 1.10 (0.043) 1.00 (0.039)
Slow
air
bleed
mm (in)
Primary No.1 0.80 (0.031)
Slow
air
bleed
mm (in)
Primary No.2 1.90 (0.075) Slow
air
bleed
mm (in) Secondary No.1 0.80 (0.031) 1.00 (0.039) 0.80 (0.031) 1.00 (0.039)
Slow
air
bleed
mm (in) 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)
Clearance between primary throttle valve and bore
MTX 0.48—0.64
(0.019-0.025) 1.40—1.76
(0.055-0.069)
0.48—0.64
(0.019-0.025) 1.40-1.76
(0.055-0.069)
Fast idle adjustment
mm (in)
Clearance between primary throttle valve and bore ATX 0.56-0.72 (0.022—0.028)
1.40—1.76
(0.055-0.069) 0.56-0.72 (0.022—0.028)
1.40-1.76
(0.055-0.069)
Float level adjust-
ment
mm (in)
Max. fuel flow
"L"
Clearance between
flo
44 (17.3)
at and
air
horn without aasket Float level adjust-
ment
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 mm-Hg (in-Hg)
Start 100-160 (3.9—6.3) 180—240 (7.1-9.4) 100-160
(3.9-6.3)
180-240
(7.1-9.4) Choke breaker diaphragm mm-Hg (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 (inHg)
Start 80—120
(3.1-8.7)
30-70 (1.2-2.8) Choke opener mmHg (inHg)
Stop 220-280 (8.7—11.0) 130-190
(5.1-7.5)
Fuel tank capacity
Liters (US aal, Imp aal) 60 (15.9, 13.2)
Fuel DumD
Delivery pressure kPa (kg/cm2,
psi)
20-26 (0.20—0.27, 2.8-3.8) 20-29 (0.20-0.30, 2.8-4.3)
20-26 (0.20-0.27, 2.8-3.8)
Feedina caDacitv cc/min
feu
in/mini More than 860 (52.5)
at
idle
Fuel filter
Type Paper element with magnet
Air cleaner
Fresh-Hot switchina Diaphragm Manual Diaphragm Bimetal
Element
tvDe
Oil permeated paper
Fuel specification Leaded super
Unleaded super Leaded regular Leaded super Unleaded super Unleaded regular
76G04G-514
4A—16
Page 382 of 1865
TROUBLESHOOTING GUIDE
4A
TROUBLESHOOTING GUIDE
F6 (GENERAL)
The Troubleshooting Guide lists the systems most likely to cause
a
given symptom. After finding the
system(s)
to
check, refer
to
the pages shown
for
detailed guides
for
each system.
\\ POSSIBLE CAUSE
\ PAGE
SYMPTOM
Air
cleaner
(Air
cleaner
element)
intake
air
temperature
control
system
Idle
adjustment
Fuel
system
(Carburetor,
Fuel
pump)
idle-up
control
system
Exhaust
system
Positive
crankcase
ventilation
system
Auto-return
choke
system
\\ POSSIBLE CAUSE
\ PAGE
SYMPTOM 4A—23 4A—60 4A—38 4A—24 4A—68 4A—96 4A—67 4A—40
1 Hard start
or
won't start (Cranks
OK)
1 2
2 Engine stalls During warm
up
3 2 1 4
2 Engine stalls After warm
up
4 2 5 1 3
3 Rough Idle During warm
up
3 2 1 4
3 Rough Idle After warm
up
3 2 5 1 4
4 High idle speed after warm
up
1 3 2
5 Poor acceleration, hesitation, or lack
of
power
1 2 3
6 Runs rough
on
deceleration
1
7 Afterburn
in
exhaust system
1
8 Poor fuel consumption
2 1 4 3
9 Fails emission test
2 1 4 5 3
76G04A-015
The numbers of the list show the priorities
of
inspections from the most possible to that with the lowest
possibility.
These were determined
on
the following basis:
• Ease
of
inspection
•
Most possible system
•
Most Possible point
in
system
TROUBLESHOOTING PROCEDURE:
1st Check the following items:
Electrical system
1) Battery condition
2) Fuses
Ignition system
1) Spark plugs
2) Ignition timing
Fuel system
1) Fuel level
2) Fuel leakage
3) Fuel filter
4) Idle speed
Intake
air
system
1) Vacuum
or air
leakage
2) Vacuum hose routing
3) Accelerator cable
4) Choke cable
2nd Check Fuel and Emission Control Systems
Engine
1) Compression
2) Overheating
Others
1) Clutch slippage
2) Brake dragging
4 A-17
Page 383 of 1865
4A TROUBLESHOOTING GUIDE
F6 (SINGAPORE)
The Troubleshooting Guide lists the systems most likely
to
cause
a
given symptom. After finding
the
system(s)
to
check, refer
to the
pages shown
for
detailed guides
for
each system.
POSSIBLE CAUSE
\ PAGE
SYMPTOM
Air
cleaner
(Air
cleaner
element)
Intake
air
temperature
control
system
Idle
adjustment
Fuel
system
(Carburetor,
Fuel
pump)
Air
injection
system
Deceleration
control
system
Positive
crankcase
ventilation
system
Exhaust
system
Idle-up
control
system
POSSIBLE CAUSE
\ PAGE
SYMPTOM 4A-23 4A-60 4 A—38 4A—24 4A-58 4A-45 4A-67 4A-SW 4A—68
1 Hard start
or
won't start (Cranks
OK)
1 2
2 Engine stalls During warm
up
3 2 1 4
2 Engine stalls After warm
up
3 2 4 1
3 Rough idle During warm
up
3 2 1 4
3 Rough idle After warm
up
3 2 4 1
4 High idle speed after warm
up
1 4 3* 2
5 Poor acceleration, hesitation,
or
lack
of
power
1 2 3
6 Runs rouah
on
deceleration
2 1
7 Afterburn
in
exhaust svstem
2 1
8 Poor fuel consumption
2 1 4 3
9 Fails emission test
6 4 5 3 2 1
Only MTX
76G04A-016
The numbers
of
the list show the priorities
of
inspections from the most possible to that with the lowest
possibility.
These were determined
on the
following basis:
• Ease
of
inspection
•
Most possible system
•
Most possible point
in
system
TROUBLESHOOTING PROCEDURE:
1st Check
the
following items:
Electrical system
1) Battery condition
2) Fuses
Ignition system
1) Spark plugs
2) Ignition timing
Fuel system
1) Fuel level
2) Fuel leakage
3) Fuel filter
4) Idle speed
Intake
air
system
1) Vacuum
or air
leakage
2) Vacuum hose routing
3) Accelerator cable
Engine
1) Compression
2) Overheating
Others
1) Clutch slippage
2) Brake dragging
2nd Check
the
Fuel
and
Emission Control Systems
4A—18
Page 384 of 1865
TROUBLESHOOTING GUIDE
4A
FE
12
VALVE and
F8
(EXCEPT MIDDLE EAST and GENERAL)
The Troubleshooting Guide lists the systems most likely to cause
a
given symptom. After finding
the
system(s)
to
check, refer
to
the pages shown
for
detailed guides
for
each system.
POSSIBLE CAUSE
\ PAGE
SYMPTOM
Air
cleaner
(Air
cleaner
element)
Intake
air
temperature
control
system
Idle
adjustment
Fuel
system
(Carburetor,
Fuel
pump)
PTC
heater
system
Air
injection
system
Positive
crankcase
ventilation
system
Deceleration
control
system
Idle-up
control
system
Ignition
control
system
POSSIBLE CAUSE
\ PAGE
SYMPTOM
4A-23 4A-60 4A-38 4A-24 4A-42 4A-58 4A-67 4A—45 4A—68 4 A—80
1 Hard start
or
won't start
(Cranks
OK)
1 2
2 Engine stalls During warm
up
5 4 1 6 2 3
2 Engine stalls After warm
up
3 2 4 1
3 Rough idle During warm
up
5 4 1 6 2 3
3 Rough idle After warm
up
3 2 4 1
4 High idle speed after warm
up
1 4 3 2
5 Poor acceleration, hesitation, or lack
of
power
1 4 2 3
6 Runs rough
on
deceleration
2 1
7 Afterburn
in
exhaust system
2 1
8 Poor fuel consumption
3 1 4 2
4
9 Fails emission test
6 2 5 3 1 4
76G04A-017
The numbers of the list show the priorities
of
inspections from the most possible to that with the lowest
possibility.
These were determined
on the
following basis:
• Ease
of
inspection
•
Most possible system
•
Most possible point
in
system
TROUBLESHOOTING PROCEDURE:
1st Check the following items:
Electrical system
1) Battery condition
2) Fuses
Ignition system
1) Spark plugs
2) Ignition timing
Fuel system
1) Fuel level
2) Fuel leakage
3) Fuel filter
4) Idle speed
Intake
air
system
1) Vacuum
or air
leakage
2) Vacuum hose routing
3) Accelerator cable
Engine
1) Compression
2) Overheating
Others
1) Clutch slippage
2) Brake dragging
2nd Check the Fuel
and
Emission Control Systems
4A—19
Page 385 of 1865
4A TROUBLESHOOTING GUIDE
FE and F8 (GENERAL)
The Troubleshooting Guide lists the systems most likely to cause a given symptom. After finding the
system(s) to check, refer to the pages shown for detailed guides for each system.
POSSIBLE CAUSE
\ PAGE
SYMPTOM
Air
cleaner
(Air
cleaner
element)
Intake
air
temperature
control
system
Idle
adjustment
Fuel
system
(Carburetor,
Fuel
pump)
Idle-up
control
system
PTC
heater
system
Positive
crankcase
ventilation
system
Deceleration
control
system
POSSIBLE CAUSE
\ PAGE
SYMPTOM 4A-23 4A—60 4A—38 4A—24 4A—68 4A—42 4A—67 4A—45
1 Hard start or won't start (Cranks OK) 1 2
2 Engine stalls During warm up 5 4 1 6 2 3 2 Engine stalls After warm up 3 2 4 1
3 Rough idle During warm up 5 4 1 6 2 3 3 Rough idle After warm up 3 2 4 1
4 High idle speed after warm up 1 4 2 3
5 Poor acceleration, hesitation, or lack of power 1 4 3 2
6 Runs rough on deceleration 2 1
7 Afterburn in exhaust system 2 1
8 Poor fuel consumption 2 1 3
9 Fails emission test 3 2 4 1
76G04A-018
The numbers of the list show the priorities of inspections from the most possible to that with the lowest
possibility.
These were determined on the following basis:
Ease of inspection Most possible system Most possible point in system
TROUBLESHOOTING PROCEDURE:
1st Check the following items:
Electrical system
1) Battery condition
2) Fuses
Ignition system
1) Spark plugs
2) Ignition timing
Fuel system
1) Fuel level
2) Fuel leakage
3) Fuel filter
4) Idle speed
Intake air system
1) Vacuum or air leakage
2) Vacuum hose routing
3) Accelerator cable
Engine
1) Compression
2) Overheating
Others
1) Clutch slippage
2) Brake dragging
2nd Check the Fuel and Emission Control Systems
4A—20
Page 386 of 1865
TROUBLESHOOTING GUIDE 4A
FE (MIDDLE EAST)
The Troubleshooting Guide lists the systems most likely to cause a given symptom. After finding the
system(s) to check, refer to pages shown for detailed guides for each system.
V. POSSIBLE CAUSE
\ PAGE
SYMPTOM
I
Air
cleaner
(Air
cleaner
element)
Intake
air
temperature
control
system
Idle
adjustment
Fuel
system
(Carburetor,
Fuel
pump)
Idle-up
control
system
Dashpot
(Only
MTX)
Positive
crankcase
ventilation
system
Exhaust
system
Evaporative
emission
control
system
Auto-return
choke
system
V. POSSIBLE CAUSE
\ PAGE
SYMPTOM 4A—23 4A-60 4 A—38 4A-24 4A-68 4A-50 4A-67 4A-96 4A-78 4A-40
1 Hard start or won't start
(Cranks OK) 1 2 3
2 Engine stalls During warm up 3 2 1 4 2 Engine stalls After warm up 3 2 4 1
3 Rough idle During warm up 3 2 1 4 3 Rough idle After warm up 3 2 4 1
4 High idle speed after warm up 1 5 3 4 2
5 Poor acceleration, hesitation, or lack of power 1 2 3
6 Runs rough on deceleration 2 1
7 Afterburn in exhaust system 3 1 2
8 Poor fuel consumption 5 1 6 2 3 4
9 Falls emission test 5 4 6 3 1 2
76G04A-019
The numbers of the list show the priorities of inspections from the most possible to that with the lowest
possibility.
These were determined on the following basis:
• Ease of inspection • Most possible system • Most possible point in system
TROUBLESHOOTING PROCEDURE:
1st Check the following items:
Electrical system
1) Battery condition
2) Fuses
Ignition system
1) Spark plugs
2) Ignition timing
Fuel system
1) Fuel level
2) Fuel leakage
3) Fuel filter
4) Idle speed
Intake air system
1) Vacuum or air leakage
2) Vacuum hose routing
3) Accelerator cable
4) Choke cable
Engine
1) Compression
2) Overheating
Others
1) Clutch slippage
2) Brake dragging
2nd Check the Fuel and Emission Control Systems
4 A—21
Page 387 of 1865
4A TROUBLESHOOTING GUIDE
FE 8VALVE—UNLEADED FUEL
The Troubleshooting Guide lists the systems most likely to cause a given symptom. After finding the
system(s) to check, refer to the pages shown for detailed guides for each system.
V POSSIBLE CAUSE
\ PAGE
SYMPTOM
Air
cleaner
(Air
cleaner
element)
Idle
adjustment
Fuel
system
(Carburetor,
Fuel
pump)
PTC
heater
system
Air
injection
system
Positive
crankcase
ventilation
system
Deceleration
control
system
Exhaust
gas
recirculation
(EGR)
system
Exhaust
system
Intake
air
temperature
control
system
Idle-up
control
system
Purge
control
system
Auto-return
choke
system
V POSSIBLE CAUSE
\ PAGE
SYMPTOM 4A-23 4A-38 4A-24 4A—42 4A-58 4A—67 4A—45 4A-96 4A-97 4A—60 4A—68 4A--63 4A—40
1 Hard start or won't start
(Cranks OK) 1 2
2 Engine stalls During warm up 6 1 2 5 3 4 2 Engine stalls After warm up 4 2 3 1
3 Rough Idle During warm up 5 1 2 4 3 6 3 Rough Idle After warm up 4 2 3 1
4 High idle speed after warm up 1 5 4 3 2
5 Poor acceleration, hesitation, or lack of power 1 2 5 3 4
6 Runs rough on deceleratio 2 1
7 Afterburn in exhaust system 2 1
8 Poor fuel consumption 4 1 2 3 5
9 Fails emission test 5 1 6 4 3 2
76G04A-020
The numbers of the list show the priorities of inspections from the most possible to that with the lowest
possibility.
These were determined on the following basis:
• Ease of inspection • Most possible system • Most possible point in system
TROUBLESHOOTING PROCEDURE:
1st Check the following items:
Electrical system
1) Battery condition
2) Fuses
Intake air system
1) Vacuum or air leakage
2) Vacuum hose routing
3) Accelerator cable
4) Choke cable
2nd Check the Fuel and Emission Control Systems
Ignition system
1) Spark plugs
2) Ignition timing
Engine
1) Compression
2) Overheating
Fuel system
1) Fuel level
2) Fuel leakage
3) Fuel filter
4) Idle speed
Others
1) Clutch slippage
2) Brake dragging
4A-22
Page 388 of 1865
PARTS INSPECTION 4A
PARTS INSPECTION
AIR CLEANER ELEMENT
Visually check the air cleaner element for excessive
dirt, damage, or oil. Replace, if necessary.
Caution
Do not clean the element with compressed air.
76G04A-021
76G04A-022
76G04A-023
ACCELERATOR LINKAGE
Caution
Confirm that the choke valve is fully open and
that the throttle valve is set to the correct idle
opening.
1. Inspect the deflection of the cable. If the deflec-
tion is not within 1—3 mm (0.039—0.118 in), ad-
just nuts A.
2. Depress the accelerator pedal to the floor and verify
that the throttle valve is fully opened. Adjust bolt
B if necessary.
INTAKE MANIFOLD
1. Visually check the intake manifold for damage.
2. Replace it if necessary.
CHOKE CABLE
Except FE and F8 (General, ECE, Hong Kong, and
Singapore)
1. Pull the choke knob and confirm that the choke
valve is fully closed.
2. Return the choke knob and confirm that the choke
valve is fully opened.
3. Adjust the position of the outer cable, if necessary.
76G04A-024
4A-23
Page 389 of 1865
4A FUEL SYSTEM
FUEL SYSTEM
This system consists of the fuel pump, fuel filters, and carburetor, and supplies the necessary fuel for
operation of the engine.
76G04A-025
4A—24
Page 390 of 1865
FUEL SYSTEM 4A
TROUBLESHOOTING
POSSIBLE CAUSE
\ PAGE Carburetor Fuel pump Separator
Two-way check valve (Except Middle East) Three-way check valve (Middle East)
SYMPTOM 4A—26 4A—35 4A—37 4A—37
1 Hard start or won't start (Cranks OK) 2 1
2 Engine stalls During warm up 2 1 2 Engine stalls After warm up 2 1
3 Rough idle During warm up 2 1 3 Rough idle After warm up 2 1
4 High idle speed after warm up 1
5 Poor acceleration, hesitation, or lack of power 2 1
6 Runs rough on deceleration 1
7 Afterburn in exhaust system 1
8 Poor fuel consumption 1 2 3
9 Fails emission test 1
76G04A-026
4A-25