MAZDA 626 1987 Workshop Manual
Manufacturer: MAZDA, Model Year: 1987, Model line: 626, Model: MAZDA 626 1987Pages: 1865, PDF Size: 94.35 MB
Page 461 of 1865
4A EXHAUST SYSTEM
EXHAUST SYSTEM
EXCEPT FE 8VALVE—UNLEADED FUEL
Removal and Installation
1. Remove in the sequence shown in the figure.
2. Install in the reverse order of removal.
Torque specifications
1. Center silencer and main silencer
2. Brackets
76G04A-187
3. Front silencers
4. Exhaust manifolds
Inspection
Visually check the exhaust system for cracks or
damage.
4A—96
Page 462 of 1865
EXHAUST SYSTEM 4A
FE 8 VALVE-UNLEADED FUEL
Removal and Inspection
1. Remove in the sequence shown in the figure
2. Install in the reverse order of removal.
Torque Specifications
L
22—28 N-m (2.2—2.9 m-kg, 16—21 ft-lb)
34—49 N-m (3.5—5.0 m-kg, 26—36 ft-lb)
55—60 N-m (5.6—8.2 m-kg, 40—59 ft-lb)
.8—11 Nm .8—1.1 m-kg, 69—95 in-lb)
N-m 3 m-kg, 25—38 ft-lb)
76G04A-189
1. Main silencer
2. Middle pipe
3. Pre-silencer
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.
76G04A-190
4A-97
Page 463 of 1865
FUEL AND EMISSION
CONTROL SYSTEMS
(FUEL INJECTION FE)
OUTLINE 4B— 2
SYSTEM DIAGRAM 4B— 2
COMPONENT LOCATION 4B— 3
VACUUM HOSE ROUTING
DIAGRAM 4B— 5
SPECIFICATIONS 4B— 6
TROUBLESHOOTING GUIDE 4B— 7
TROUBLESHOOTING
PROCEDURE 4B— 7
TROUBLESHOOTING WITH SST.... 4B— 9
INSPECTION PROCEDURE 4B—10
AFTER-REPAIR PROCEDURE 4B—10
PRINCIPLE OF CODE CYCLE 4B—12
CODE NUMBER 4B—13
SWITCH MONITOR FUNCTION 4B—25
INSPECTION PROCEDURE 4B—26
IDLE SPEED 4B—29
IDLE MIXTURE 4B—29
INTAKE AIR SYSTEM 4B—30
COMPONENT DESCRIPTIONS 4B—30
REMOVAL 4B—31
PARTS INSPECTION 4B—32
INSTALLATION 4B—34
IDLE-UP SYSTEM 4B—35
COMPONENT DESCRIPTIONS 4B—36
TROUBLESHOOTING 4B—37
AIR VALVE 4B—38
AIR BYPASS SOLENOID VALVE ... 4B—39
FUEL SYSTEM 4B—42
COMPONENT DESCRIPTIONS 4B—43
TROUBLESHOOTING 4B—44
FUEL PRESSURE RELEASE AND
SERVICING FUEL SYSTEM 4B—45
MULTI-PRESSURE TESTER 4B—46
FUEL PRESSURE 4B—48
FUEL PUMP 4B—49
PULSATION DAMPER 4B—50
INJECTOR 4B—51
PRESSURE REGULATOR
CONTROL SYSTEM 4B—53
COMPONENT DESCRIPTIONS 4B—54
TROUBLESHOOTING 4B—55
REPLACEMENT 4B—57
FUEL TANK 4B—61
DECELERATION CONTROL
SYSTEM 4B—64
COMPONENT DESCRIPTIONS 4B—65
TROUBLESHOOTING 4B—66
AIR INJECTION SYSTEM 4B—68
COMPONENT DESCRIPTIONS 4B—68
TROUBLESHOOTING 4B—69
EXHAUST GAS RECIRCULATION
(EGR) SYSTEM 4B—71
COMPONENT DESCRIPTIONS 4B—71
TROUBLESHOOTING 4B—72
EVAPORATIVE EMISSION
CONTROL (EEC) SYSTEM 4B—74
COMPONENT DESCRIPTIONS 4B—74
TROUBLESHOOTING 4B—75
POSITIVE CRANKCASE
VENTILATION (PCV) SYSTEM 4B—80
COMPONENT DESCRIPTION 4B—80
EXHAUST SYSTEM 4B—81
REMOVAL AND INSTALLATION ... 4B—82
INSPECTION 4B—82
CONTROL SYSTEM 4B—83
RELATIONSHIP CHART 4B—84
EGI MAIN FUSE 4B—86
MAIN RELAY 4B—86
CIRCUIT OPENING RELAY 4B—86
ENGINE CONTROL UNIT 4B—87
NEUTRAL SWITCH 4B—91
CLUTCH SWITCH 4B—91
BRAKE LIGHT SWITCH 4B—91
P/S PRESSURE SWITCH 4B—92
INHIBITOR SWITCH 4B—92
E/L CONTROL UNIT 4B—93
AIR FLOW METER 4B—94
THROTTLE SENSOR 4B—95
WATER THERMO SENSOR 4B—97
WATER THERMO SWITCH 4B—97
OXYGEN SENSOR 4B—98
ATMOSPHERIC PRESSUFfE
SENSOR 4B—99
76G04B-001
Page 464 of 1865
4B OUTLINE
OUTLINE
SYSTEM DIAGRAM
S6U04A-0Q2
4B—2
Page 465 of 1865
OUTLINE
4B
COMPONENT LOCATION
76g04b-002
4B—3
Page 466 of 1865
4B OUTLINE
Exhaust System
4B—4
Page 467 of 1865
OUTLINE 4B
VACUUM HOSE ROUTING DIAGRAM
86U04A-006
4B—5
Page 468 of 1865
4B OUTLINE
SPECIFICATIONS
Item Specification
Idle speed rpm MTX: 800 +5„° (Neutral), ATX: 900 +5S
(P
range)
Throttle body
Type Horizontal draft (1 -barrel)
Throat diameter mm (in) 50 (2.0)
Air flow meter
E2-VS More than
20
E2-VC 100-300
Resistor
Q
E2-VB 200—400 Resistor
Q
E2-THA -20°C
(
—4°F) 13,600-18,400 20°C
(
68°F) 2,210-2,690 60°C (140°F)
493- 667
Air cleaner
Element type Oil permeated
Fuel pump
Type Impeller
(in
tank)
Output pressure kPa (kg/cm2,
psi)
441-588 (4.5-6.0, 64—85)
Feeding capacity cc (cu in)/10 sec. 220 (13.4) minmum
Fuel filter
Type Low pressure side Nylon element Type High pressure side Paper element
Pressure regulator
Type Diaphragm
Regulating pressure kPa (kg/cm2,
psi)
235-275 (2.4—2.8, 34—40)
Injector
TvDe
Hiqh-ohmic
Type
of
drive Voltage
Resistance
fi
12-16
Injection amount cc (cu
in) 15
seconds 38—53 (2.3-3.2)
Fuel tank
Capacity liters (US gal, Imp gal) 60 (15.9, 13.2)
Fuel
Soecification Unleaded reaular
76G04B-506
4B—6
Page 469 of 1865
TROUBLESHOOTING GUIDE 4B
TROUBLESHOOTING GUIDE
This troubleshooting guide shows the malfunction numbers and the symptoms of various failures.
Perform troubleshooting as described below.
Possible cause
Symptom
Input sensors and switches
o>
C
0
Jh c 01
4B-14
a> 4)
E
o
4B-1S
o in c « m o E k_ 0) c.
0 <0 £
4B-16
o CO c a> 0) o E
a>
.x
co
4B-17
o 10 c a) co
4B-18
o in c a> (0
o> o> a>
a) £ a VI o E
4B-19
0 <0 c a> 0) c a> 01
S? o
4B-20
E a> in (0
o 10 A •o 0) 0> u.
4B-21
Output solenoid valves
o «
3 O) 0)
0) 0) 01
0> > 10 >
•o o c V o tt)
4B-22
0)
OI
0> > CO >
TJ
O c 0> o CO
4B-23
oc O u
o> > 75 >
•o o c a> o 05
4B-23
0 a. 3 1
2
0) > (0 >
"D O
o 0> in in a a >. £
4B-23
ffl a 3 • a>
2
a> > 10 >
"O o c a> o
CO Q. >. JO
4B-24
Fault Indicated by SST
Code No. 01 08 09 10 12 14 15 17 25 26 28 34 35
Hard start or won't start
(Cranks OK)
Engine stalls
Rough
idle
While warming up
After warming up
While warming up
After warming up
High idle speed after
warming up
TROUBLESHOOTING PROCEDURE
Note
Step 1 under symptom is to quickly determine what system or unit may be at fault by use of the SST. (Self-Diagnosis Checker 49 H018 9A1)
1st:
Check input sensors and output solenoid valves with the
SST.
(Refer
to
page 4B—10.)
2nd:
Check other switches with the
SST.
(Refer
to
page 4B—26.)
3rd:
Check the following items:
11
Poor acceleration, hesita-
tion or lack of power
Runs rough on deceleration
Afterburn in exhaust system
Poor fuel consumption
Engine stalls or rough after hot starting
Electrical system
1) Battery condition
2) Fuses
Fuel system
1) Fuel level 2) Fuel leakage
3) Fuel filter 4) Idle speed
Engine
1) Compression 2) Overheating
Ignition system
1) Ignition spark 2) Ignition timing
Intake air system
1)
Air
cleaner element 2) Vacuum
or air
leakage 3) Vacuum hose routing
4) Accelerator cable
Others
1) Clutch slippage 2) Brake dragging
Fails emission test 4th:
Check Fuel and Emission Control Systems. (Refer
to
page 4B—8.)
76G04B-003
4B—7
Page 470 of 1865
4B TROUBLESHOOTING GUIDE
The Troubleshooting Guide lists the systems most likely
to
cause
a
given symptom. After finding
sys-
tems
to
check, refer
to
the
pages shown
for
detailed guides
for
each system.
Possible
cause
Fuel
and
Emission Control Systems
Possible
cause
Intake
Air
System
(Poor
connection
of
components,
throttle
body)
Fuel
System
(Fuel
injection,
Fuel
pressure)
Pressure
Regulator
Control
System
Idle-up
System
(Air
valve,
solenoid
valve
malfunction)
EGR
System
(EGR
control
valve
stuck
and
open)
EEC
system
(Vacuum
switch
valve,
No.1
purge
control
valve
malfunction)
PCV
System
(System
clogged)
Deceleration
System
(Dashpot,
fuel
cut
operation
malfunction)
Air
injection
system
(Reed
valve
malfunction)
Exhaust
system
(System
clogged)
Page 4B—30 4B—42 4B—53 4B—35 4B—71 4B—74 4B—80 4B—64 4B—68 4B—81
Symptom
2
2 1
Symptom
3
4 3 1 2
Symptom
3
5 4 2 3 1
Symptom
4
6 5 1 4 2 3
Symptom
4
7 6 2 4 5 1 3
Symptom
5
3 1 2
Symptom
6
3 4 1 2 5
Symptom
7
3 2 1
Symptom
8
3 4 1 2
Symptom
9
2 3 1 4
Symptom
10
2 1
Symptom
11
7 8 5 2 6 3 4 1
76G04B-004
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
4B—8