engine MAZDA 626 1987 Workshop Manual

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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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10
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

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

TROUBLESHOOTING GUIDE 5
TROUBLESHOOTING GUIDE
Problem Possible cause Remedy Page
Starter does not turn at all, or Its turning speed Is too slow to start the engine.
Battery and related parts Poor contact of battery terminals Poor grounding of negative cable Voltage drop caused by discharged battery Insufficient voltage caused by battery malfunction
Clean and tighten Clean and repair Recharge Replace
5- 8
5- 8 5- 8
Ignition switch and related parts Poor contact of ignition switch Loose ignition switch wiring or connector Broken wire between ignition switch and magnetic switch
Replace Repair Repair or replace 5-38,45,56,66
Magnetic switch and related parts Loose wiring and/or connectors Burnt magnetic switch contact plate or improper contact Broken wire in magnetic switch pull-in coil Broken wire magnetic switch holding coil
Repair Replace
Replace Replace
5-38,45,56,66 5-43,54,64,74
5-43,54,64,74 5-43,54.64,74
Starter Poor contact of brushes
Fatigued brush spring Poor grounding of field coil Poor soldering of field coil Commutator mulfunction Grounded armature Worn parts
Adjust contact or replace Replace Replace Repair Repair or Replace Replace Replace
5-43,54,64,74
Starting problem Gasoline engine Insufficient battery capacity Malfunction of spark plug (s)
Loose positive terminal Damaged distributor cap or rotor Ignition coil malfunction laniter malfunction
Recharge Clean, adjust or replace Tighten Replace Replace Renlane
5— 8 5— 9
5—16 5—10 5-16,20
Diesel engine Insufficient battery capacity QSS svstem malfunction Recharge ReDlace 5— 8 5-76
Starter turns but pinion gear does not mesh with ring gear
Starter Tip of overrunning clutch pinion is worn Weakened overrunning clutch drive spring Worn overrunning clutch Improper sliding of spline
Worn bushing Worn ring gear
Replace Replace Replace Adjust contact and repair, or replace Replace ReDlace
5-40,54,70
Starter turns continuously (does not stop) Magnetic switch Sticking contact place of magnetic switch Layer shorting coil of magnetic switch Ignition switch does not return
Replace Replace Rfinlanfi
5-43,54,64,74 5-43,54,64,74
Misfiring Dirty or damaged spark plug (s) Malfunction of wiring, or open circuit Damaged distributor cap
Clean or replace Repair or Replace Replace
5- 9 5—10 5—16
Discharging of battery Alternator Loose drive belt Grounded or broken stator coil Broken rotor coil Poor contact of brush and slip ring
Malfunction of rectifier Malfunction of IC regulator Battery and related parts Insufficient or unsuitable battery electrolyte Malfunction of battery electrode (internal short-circuit) Poor contact of battery terminal (s) Excessive electric load
Adjust Replace Replace Clean, repair or replace Replace Replace
Adjust Replace
Clean and tighten Check power consump-tion and short circuit
5-37 5-32 5-32 5-32
5-34
5— 8 5- 8
5— 8
Overcharging of battery IC regulator malfunction Operating in extremely high temperature Replace Reoair
Poor acceleration Mis-adjusted ignition timing Distributor malfunction Adjust Repair or replace 5—11 5—11
Knocking Mis-adjusted ignition timing | Distributor malfunction Adjust Repair or replace 5—11 5—11
76G05X-003
5-7

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 5
7BU05X-075
86U05X-048
76G05X-007
DISTRIBUTOR
SPARK TEST
1. Disconnect the distributor lead from the distributor.
2. Hold it with insulated pliers approx. 5—10 mm
(0.20—0.39 in) from a ground.
3. Crank the engine and check that a strong blue
spark is visible.
4. If there is no spark, the ignition coil or pick-up coil
may be bad.
Check once again after replacing the ignition coil
or pick-up coil.
IGNITION TIMING
1. Warm up the engine to the normal operating tem-
perature.
2. Turn all electric loads OFF.
3. Connect a tachometer and timing light to the
engine.
4. Connect a jumper wire between the test connec-
tor and ground. (Only for FE DOHC)
5. Check the idle speed. Set to the specified speed
if necessary.
Idle speed: 750 ± 50 rpm (FE DOHC)
800 t58 rpm (F6, F8 FE—MTX)
900 i58 rpm (F8, FE—ATX
in "P" range)
950 -5o rmp (F6—ATX
in "P" range)
6. Check that the timing mark (Yellow) on the crank-
shaft pulley and the mark on the timing belt cover
are aligned.
Ignition timing:
FE DOHC: 12 ± 1° BTDC
(Test connector grounded)
Others: 6 ± 1°
(Vacuum hoses disconnected and
plugged)
76G05X-008
5—11

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

DISTRIBUTOR 5
FE West Germany (MTX)
24c
14<
0 0) O)
a>
®
O) c a> ^
I 0 1.76° 3.36° 5.32°
Engine Speed (rpm)
FE 12 valve (Carb.)
© ©
118°
12° O) c (0
c CO
6 o 1,200 2,400 4,0005,000
Engine Speed (rpm)
FE West Germany (ATX)

oT
24' 0) a> © "D
© O) c CO JX c CO
14c
6 0 1,300 3,350 5,320
Engine Speed (rpm)
EF EGI a) ©
O) a> ©
o> c ©
C CO
O
18°
12°
1,000 2,600 4,600 5,800
Engine Speed (rpm)
F6, F8 © ©
O) © tj, ©
cn
« 8°
c a)
6 o
86U05X-054
100 (3.94) 300 (11.81)
mmHg (inHg)
Vacuum Advance
1. Warm up the engine to the normal operating tem-
perature.
2. Check that the idle speed and ignition timing are
correct.
3. Disconnect the vacuum hoses from the vacuum
control unit, and plug them.
4. Connect a vacuum pump to the vacuum control
unit.
5. Apply vacuum and check the advance with the tim-
ing light.
86U05X-055
5—13

DISTRIBUTOR 5
DISASSEMBLY
Disassemble in the order shown in the figure.
FE DOHC
1. Cap
2. Distributor rotor
3. Cover
4. Distributor set
5. O-ring
76G05X-011
Caution
Do not disassemble the distributor set.
FE 12 Valve Caburetor Engine
1. Cap
2. Rotor
3. Gasket
4. Cover
5. Signal rotor and pin
6. Pick-up coil with igniter
7. Vacuum control unit
8. Breaker
9. Coupling set
10. Governor set
11. Oil seal
12. Bearing
76G05X-012
5-15