water pump MAZDA 626 1987 Service Manual

4C OUTLINE
OUTLINE
COMPONENT APPLICATION
Item Unleaded fuel Leaded fuel
Air flow sensor (Hot wire type) O O
Dynamic chamber with vacuum chamber o o
INTAKE AIR SYSTEM Throttle body (Two bore) o o
Throttle sensor o X
Idle switch o o
Resonance chamber o o
VARIABLE INERTIA CONTROL SYSTEM o 0
IDLE SPEED CONTROL SYSTEM o o
Injector o o
Pressure regulator o o
Pulsation damper o o
FUEL SYSTEM Intank filter o o
Transfer pump 0 (4WS) O (4WS)
Transfer pump switch O (4WS) O (4WS)
Fuel pump control unit O (4WS) O (4WS)
PRESSURE REGULATOR CONTROL SYSTEM o o
Canister o x
EVAPORATIVE Three-way check valve o x
EMISSION CONTROL Two-way check valve X o SYSTEM Separator o o
Solenoid valves o x
EGR control valve o x
EGR SYSTEM EGR modulator valve o X
Solenoid valve o X
ELECTRONIC SPARK
ADVANCE CONTROL
SYSTEM
Igniter o o ELECTRONIC SPARK
ADVANCE CONTROL
SYSTEM Knock control function X o
Water thermo sensor o o
Water thermo switch o X
Intake air thermo sensor o o
Oxygen sensor o X
CONTROL SYSTEM Distributor o o CONTROL SYSTEM Ne signal o o
G signal o o
Clutch switch o o
Neutral switch o o
Knock sensor x o
FAIL-SAFE CONTROL SYSTEM o o
MONITOR FUNCTION o o
76G04C-002
4C—2

Fuel filter Solenoid valve *1 Solenoid valve *1
(No.2 purge control) (No.1 purge control)
Separator Three way
Injector
,Distributor
Fuel pump
In-take filter
Air flow sensor
Water thermo sensor
Knock sensor
switches
Intake air thermo sensor
— Water thermo switch *1 __ j—Ig. switch (ST) j_J,—lg. switch (ON) -A/C switch 'A/C magnet clutch P/S switch —Head light switch —Rear defroster switch —Cooling fun switch —Blower switch —Neutral and clutch
O) <
{/> H m
g >
o 3D >
^Throttle sensor *1
Air valve
Solenoid valve
(ISC)
EGR control valve *1
EGR modulator valve *1
0 1 CO
a *1...Unleaded fuel only
*2...Leaded fuel only
Oxygen
sensor *1
One-way check valve
Shutter valve actuator Catalytic
converter *1 Solenoid valve (VIC)
O c
m
o

4C FUEL SYSTEM
COMPONENT DESCRIPTION
Component Function Remark
Air flow sensor Detects amount of intake air;
sends signal to engine control unit
Clutch switch Detects in-gear condition; sends signal to engine control unit Switch ON when clutch pedal released
Engine control unit Detects signals from input sensors and switches; controls injector and fuel pump operations
Fuel filter Filters fuel
Fuel pump Provides fuel to injectors • Operates while engine running
• Installed in fuel tank
Fuel pump control unit (4WS) Monitors fuel level in left section; controls transfer pump operation
G signal pick-up Detects No.1 cylinder TDC; sends signal to engine control unit Installed in distributor
Idle switch Detects when throttle valve fully closed; sends signal to engine control unit Installed on throttle body
Ignition switch (ST position) Sends engine cranking signal to engine control unit
Injector Injects fuel into intake port • Controlled by signals from engine control unit • High-ohmic injector
Intake air thermo sensor Detects intake air temperature; send signal to engine control unit
Control relay Supplies electric current to injectors fuel pump and engine control unit
Ne signal pick-up Detects crank angle at 180° intervals; sends signal to engine control unit Installed in distributor
Neutral switch Detects in-gear condition; sends signal to engine control unit
Switch ON when in gear
Oxygen sensor (Unleaded fuel) Detects oxygen concentration; sends signal to engine control unit
• Zirconia ceramic and platinum coating • Integrated heater coil
Pressure regulator Adjusts fuel pressure supplied to injectors
Pulsation damper Absorbs fuel pulsation
Throttle sensor Detects throttle valve opening angle;
sends signal to engine control unit
Installed on throttle body
Transfer pump (4WS) Pumps fuel from the left to the right side Controlled by fuel pump control unit
Transfer pump switch (4WS) Detects fuel level in left section;
sends signal to control unit
Water thermo sensor Detects coolant temperature; sends signal to engine control unit
Water thermo switch (Unleaded fuel) Detects radiator coolant temperature; sends signal to engine control unit ON: above 17°C (63°F)
76G04C-088
4C-50

4C CONTROL SYSTEM
RELATIONSHIP CHART
Output Devices
and
Input Devices (Unleaded fuel)
IGNITION SWITCH
(ON POSION) X X X X X O X X X X X X X X O
TEST CONNECTOR X X X O X X X X X X X X X O X
ELECTRICAL LOAD CONTROL UNIT X X X o X X X X X X X X X X X
P/S PRESSURE SWITCH X X X o X X X X X X X X X X X
A/C SWITCH X X X o X X X X X X X X O X X
IGNITION SWITCH
(STA POSITION) O O X o O X X X X O X X X O X
NEUTRAL
AND

CLUTCH SWITCH O X X o X X X X X X X X X X X
OXYGEN SENSOR o X X X X X X X X X X X X X X
WATER THERMO
SWITCH (RADIATOR) o X X X X X X X o X X X X X X
INTAKE
AIR

THERMO SENSOR X X X X X X X X X O X X X X X
WATER
THERMO SENSOR o X X o X X o o O O X X X O o
IDLE SWITCH o X X o X X X X X o X X X O X
THROTTLE SENSOR o X X X X X X X O X X X X o X
AIR FLOW SENSOR o X X X X X X o X X X X X o O
Ne SIGNAL o o X O o X X O O O o o X o O
G SIGNAL X O X X X X X X X X X X X X X

\
INPUT

DEVICE
OUTPUT
DEVICE
FUEL
INJECTION
AMOUNT FUEL

INJECTION

TIMING
AIR
VALVE

ISC
VALVE
FUEL
PUMP

CONTROL
MAIN
POWER
CONTROL
SOLENOID
VALVE
(No.1
PURGE)
SOLENOID
VALVE
(No.2
PURGE)
SOLENOID
VALVE
(EGR)
SOLENOID

VALVE

(PRESSURE

REGULATOR
CONTROL)
SOLENOID
VALVE

(VARIABLE

INERTIA
CONTROL)

OXYGEN

SENSOR
RELAY
I A/C

RELAY

IGNITER
AIR

FLOW
SENSOR
(BURN-OFF)
\
INPUT

DEVICE
OUTPUT
DEVICE
INJECTOR
BAC
VALVE

CONTROL
RELAY
SOLENOID
VALVE
(No.1
PURGE)
SOLENOID
VALVE
(No.2
PURGE)
SOLENOID
VALVE
(EGR)
SOLENOID

VALVE

(PRESSURE

REGULATOR
CONTROL)
SOLENOID
VALVE

(VARIABLE

INERTIA
CONTROL)

OXYGEN

SENSOR
RELAY
I A/C

RELAY

IGNITER
AIR

FLOW
SENSOR
(BURN-OFF)

76G04C-167
4C—92

CONTROL SYSTEM 4C
Output Devices and In put Devices (Leaded fuel)
IGNITION SWITCH
(ON POSITION) X X X X X O X X X X O
TEST CONNECTOR X X X O X X X X X O X
KNOCK SENSOR X X X X X X X X X o X
ELECTRICAL LOAD
CONTROL UNIT X X X O X X X X X X X
P/S PRESSURE SWITCH X X X o X X X X X X X
A/C SWITCH X X X o X X X X O X X
IGNITION SWITCH (STA POSITION) O O X o O X O X X O X
NEUTRAL AND
CLUTCH SWITCH O X X o X X X X X X X
INTAKE AIR THERMO SENSOR X X X X X X O X X X X
WATER THERMO SENSOR O X X o X X O X X O o
IDLE SWITCH o X X o X X o X X O X
VARIABLE RESISTOR (IN AIR FLOW SENSOR) o X X X X X X X X X X
AIR FLOW SENSOR o X X X X X X X X O O
Ne SIGNAL o o X O o X O o X o O
G SIGNAL X O X X X X X X X X X

INPUT

DEVICE

OUTPUT

DEVICE

FUEL

INJECTION

AMOUNT
FUEL

INJECTION

TIMING
AIR
VALVE
ISC

VALVE

FUEL

PUMP

CONTROL
MAIN

POWER

CONTROL

SOLENOID

VALVE

(PRESSURE

REGULATOR

CONTROL)

SOLENOID

VALVE

(VARIABLE

INERTIA

CONTROL)

A/C
RELAY

IGNITER
AIR

FLOW

SENSOR

(BURN-OFF)

INPUT

DEVICE

OUTPUT

DEVICE

INJECTOR
BAC

VALVE

CONTROL
RELAY
SOLENOID

VALVE

(PRESSURE

REGULATOR

CONTROL)

SOLENOID

VALVE

(VARIABLE

INERTIA

CONTROL)

A/C
RELAY

IGNITER
AIR

FLOW

SENSOR

(BURN-OFF)

76G04C-168
4C—93

4C CONTROL SYSTEM
Terminal Input Output Connection to Voltage (After warming-up) Remark Terminal Input Output Connection to Ign: ON Idle Remark
10 o Air flow sensor
(Burn-off control) Below 2.5V White burning off:
Approx. 8—12V
1P o
Control relay (Power supply circuit) Below 2.5V Ignition switch OFF:
Approx. 12V
1Q 0 Control relay (Fuel pump circuit) Approx. 12V Below 2.5V
1R
(L/F) O Knock sensor OV or 2—7V While knocking:
Approx. 0.001
1S — — — — —
1T o Ignition switch
(ON position) Approx. 12V
1U — — — — —
1V — — — — —
1W o Test connector Test connector grounded: OV Test connector not grounded: approx. 12V Green connector, 1-pin
1X o Igniter Approx. 12V *Approx.1V 'Engine Signal
Monitor: green and
red lights flash
2A (U/F) o V ref 4.5—5.5V
2B o Air flow sensor
(Ground) OV
2C — — Ground (E2) OV
2D (U/F) o Oxygen sensor OV 0-1.0V
• Cold engine: 0V at idle
• After warming-up: Increase engine speed: 0.7—1.0V Deceleration: 0—0.2V
2E o Air flow sensor
(Intake air mass) 1.0—1.6V 1.7—2.3V Increase engine speed: voltage increases
2F — — — .— —
2G (U/F) o Throttle sensor Accelerator pedal released: approx. 0.5V
Max. voltage (Throt-tle valve fully opened): approx. ,4.3V
2H (L/F) o Air flow sensor (Variable resister) 0-5V Depends on
adjustment
21 o Water thermo sensor Approx. 0.4V
Engine coolant
temp. 20°C (68°F):
approx. 2.5
2J o Intake air thermo sensor (Dynamic chamber)
Approx. 2.5V at 20°C (68°F)
2K o
Solenoid valve (Pressure regula-tor control)
For 120 sec. after ignition switch OFF - ON: below 2.5V
For 120. sec after starting: below 2.5V
During hot condi-tion: Coolant temp, above 70°C (158°F) Intake air temp, above 30°C (86°F) ...Unleaded fuel above 50°C (122°F) ...Leaded fuel
2K o
Solenoid valve (Pressure regula-tor control)
ADDrox. 12V Other conditions
2L — — — — —
Note
a) Terminal labeled "U/F" are only for unleaded fuel.
b)Terminal labeled "L/F" are only for leaded fuel.
4C-100

4D
FUEL AND EMISSION
CONTROL SYSTEM
(DIESEL)
OUTLINE 4D— 2
SPECIFICATIONS 4D— 2
TROUBLESHOOTING GUIDE 4D— 3
ON-VEHICLE MAINTENANCE 4D— 4
AIR CLEANER ELEMENT 4D— 4
WATER DRAINING 4D— 4
AIR BLEEDING 4D— 4
INJECTION TIMING 4D— 5
IDLE SPEED 4D— 6
EXHAUST SMOKE 4D— 6
INTAKE AIR SYSTEM 4D— 7
STRUCTURAL VIEW 4D— 7
AIR DUCT AND AIR CLEANER 4D— 8
INTAKE MANIFOLD 4D— 9
SUPERCHARGING SYSTEM (RF-CX) 4D-10
TROUBLESHOOTING GUIDE 4D—10
ON-VEHICLE INSPECTION 4D—11
COMPREX SUPERCHARGER 4D—13
STARTING VALVE 4D—15
INTERCOOLER 4D—16
BOOST AIR TEMPERATURE SENSOR 4D—17
EXHAUST SYSTEM 4D—18
STRUCTURAL VIEW 4D—18
EXHAUST MANIFOLD 4D—19
EXHAUST PIPE AND MAIN SILENCER .... 4D—20
FUEL SYSTEM 4D—21
STRUCTURAL VIEW 4D—21
FUEL FILTER 4D—22
SEDIMENTER (GENERAL) 4D—22
WATER LEVEL SENSOR 4D—23
INJECTION PUMP 4D—24
INJECTION NOZZLE 4D—31
FUEL TANK 4D—34
76G04D-001

TROUBLESHOOTING GUIDE 4D
TROUBLESHOOTING GUIDE
Condition Condition Cause Remedy
Hard starting Fuel filter
Clogged Replace
Water or air in filter Repair
Fuel injection pump Faulty fuel cut solenoid Replace Incorrect injection timing Adjust
Air in pump Bleed
Faulty pump Replace
Fuel injection nozzle Seized needle valve Replace
Fuel dripping from nozzle Replace Incorrect valve opening pressure Adjust
Faulty glow plug Replace
Faulty cold start device Adjust or replace
Faulty supercharging system Refer to page 4D—10
Rough idle Fuel filter (Refer to "Hard starting") Fuel injection pump (Refer to "Hard starting")
Fuel injection nozzle
Seized needle valve Replace
Incorrect valve opening pressure Adjust
Improper mounting to nozzle holder Repair
Leakage of nozzle holder copper washer Replace
Fuel injection pipe Cranks Replace
Leaking from joint Repair
Improper idle speed adjustment Adjust
Engine knocking Incorrect injection timing Adjust
Low quality fuel Replace
Incorrect injection nozzle opening pressure Ajust
Seized injection nozzle needle valve Replace
Fuel dripping from injection nozzle Replace
Faulty supercharging system Refer to page 4D—10
High fuel Fuel injection pump consumption Incorrect injection timing Adjust consumption High idle speed Adjust, Inspect the dashpot
Fuel injection nozzle Incorrect valve opening pressure Repair
Fuel dripping from nozzle Replace
Leakage of nozzle holder copper washer Replace
Fuel leaking from connection Repair
Clogged fuel filter Replace
Clogged air cleaner Replace
Poor acceleration Fuel injection nozzle (Refer to "Hard starting")
Fuel injection pump (Refer to "Hard starting")
Fuel injection pipe (Refer to "Rough idle") Fuel filter (Refer to "Hard starting") Clogged air cleaner Clean or replace
Faulty supercharging system Refer to page 4D—10
Excessive exhaust Clogged air cleaner Clean or replace
smoke Improper injection timig Adjust
Faulty nozzle or nozzle holder Adjust or replace
Faulty supercharging system Refer to page 4D—10
76G04D-003
4D-3

4D ON-VEHICLE MAINTENANCE
ON-VEHICLE MAINTENANCE
76G04D-004
AIR CLEANER ELEMENT
Check the air cleaner element for excessive dirt, dam-
age, or oil. Replace if necessary.
Caution
(Wet type)
Do not clean the air cleaner element with com-
pressed air, replace if necessary.
(Dry type)
When cleaning the air cleaner element, blow
dust off from the inside first, then blow off the
outside.
(General)
1. Loosen the drain plug of the sedimenter and let
the water drain. If necessary loosen the air bleed-
ing plug.
2. Bleed air from the sedimenter.
AIR BLEEDING
From Fuel Tank to Fuel Filter
1. Loosen the air bleeding plug of the fuel filter.
2. Pump the priming pump until no air bubbles flow
from the air bleeding plug hole.
3. Depress the priming pump and tighten the air
bleeding plug.
Note
Open only the air bleeding plug of the filter.
From Fuel Filter to Injection Pump
Pump the priming pump until it becomes hard to
pump.
76G04D-007
WATER DRAINING
(ECE)
1. Loosen the drain plug of the fuel filter.
2. Pump the priming pump.
3. Bleed air from the fuel filter.
4D—4

4D FUEL SYSTEM
Removal and Installation
1. Remove in the sequence shown in the figure, referring to the removal note for specially marked parts.
2. Install in the reverse order of removal.

59—69 N-m
(6.0—7.0 m-kg, 43-51 ft-lb)
19—26
N m
(1.9—2.6
m-kg,
14—19 ft-lb) 25—29
N-m .5—3.0 m-kg, 18—22
ft-lb)

19—26 N-m
(1.9—2.6
m-kg,
14—19 ft-lb)
76G04D-063
1. Accelerator cable
2. Injection pipe
3. Fuel hose
4. Water hose
5. Fuel cut solenoid valve con-
nector
6. Pick-up coil connector
7. Boost air hose (RF-CX)
8. Injection pump pulley lock
nut
9. Injection pump
Removal note
Injection pipe
Warning
a) Catch leaking fuel with a rag when remov-
ing the injection pipes.
b) Keep fire and open flame away from the fuel
area.
Remove the injection pipes.
76G04D-064
4D—26