maintenance MAZDA 626 1987 Repair Manual

ON-VEHICLE MAINTENANCE (VALVE SEAL) 1 C
4. Set the camshaft and camshaft cap so that the key
groove faces directly upward.
And tighten the cap nuts loosely.
5. Apply a coat of engine oil to the new oil seal lip
and insert it.
76G01C-063
6. Tighten the camshaft cap nuts gradually and in the
order shown in the figure.
Tightening torque:
20—26 N-m (2.0—2.7 m-kg, 14—20 ft-lb)
76G01C-064
Camshaft pulley and rear camshaft pulley
Hold the camshaft with a wrench (29 mm, 1.14 in),
tighten the camshaft pulley and rear camshaft pul-
ley lock bolts.
Tightening torque:
55—65 N-m (5.6—6.6 m-kg, 41—48 ft-lb)
76G01C-066
1C—29

1 C ON-VEHICLE MAINTENANCE (VALVE SEAL)
2. Check that the timing marks of the camshaft pul-
ley and the injection pump pulley align with the tim-
ing marks on the seal plate.
3. Install the timing belt. (Refer to TIMING BELT of
ON-VEHICLE MAINTENANCE)
76G01C-067
Valve clearance
Measure the valve clearance, and adjust if necessary.
(Refer to page 1C—85).
76G01C-068
Gasket
Head cover App|y sealant
Cylinder head cover
1. Remove the rag pluged oil return hole.
2. Apply sealant to the shaded areas as shown in the
figure.
3. Install the cylinder head cover.
Tightening torque:
7—10 Nm (70—100 cm-kg, 61—87 in-lb)
4. Perform the necessary engine adjustments by
referring to TUNE-UP PROCEDURE section.
76G01C-069
1C-30

4B FUEL SYSTEM
Pressure Regulator
1. Disconnect the vacuum hose and fuel return hose.
2. Remove the pressure regulator.
3. Install in the reverse order of removal.
Tightening torque:
8—11 N-m (0.8—1.1 m-kg, 69—95 in-lb)
76G04B-084
Pulsation Damper
1. Loosen the pulsation damper and remove it.
2. Install in the reverse order of removal.
76G04B-085
^-Fuel hose
ML*? ^-Fuel pump
^silntank filter
ti* e
76G04B-086
h
tS

Is o
Sjfbj
Fuel Filter
Low pressure side
Refer to page 4B—57.
86U04A-116
High pressure side
The fuel filter must be replaced at the intervals out-
lined in the maintenance schedule.
Warning
Always work away from sparks or open
flames.
1. Disconnect the fuel hoses from the fuel filter.
2. Remove the fuel filter and the bracket.
3. Install a new filter and the bracket.
4. Connect the fuel hoses.
Note
When installing the filter, push the fuel hoses
fully onto the fuel filter and secure the hoses
with spring clamps.
4B-60

INTAKE AIR SYSTEM 4C
76G04C-054
76G04C-055
76G04C-056
Removal Note
Water hose
Before disconnecting the water hose, drain two liters
of engine coolant.
Delivery pipe assembly.
1. Separate the fuel return pipe from the delivery pipe
assembly.
2. Remove the delivery pipe assembly and the fuel
return pipe.
PARTS INSPECTION
Air Cleaner Element
1. Check the condition of the air cleaner element.
2. Blow out the dust with compressed air, if
necessary.
Caution
a) The air cleaner must be replaced at the in-
tervals outlined in the maintenance
schedule.
b) Never drive the vehicle without the air
cleaner element, otherwise, damage to the
air flow sensor (hot wire) will occur.
c) Never use an oil permeated air cleaner ele-
ment, otherwise, contamination of the hot
wire will occur.
4C—33

4C FUEL SYSTEM
^ Pulsation
damper
76G04C-121
Pulsation damper
—
Delivery pipe
76G04C-122
Fuel hose
,Fuel pump
-Intank filter
76G04C-123
Insulator
f f r—
/ 0 DM

•
II r
O - ring
Grommet
Manifold
Delivery pipe
Pressure Regulator
1. Remove the engine hanger.
2. Disconnect the vacuum hose and fuel return hose.
3. Remove the pressure regulator.
4. Install in the reverse order of removal.
Tightening torque:
8—11 Nm (0.8—1.1 m-kg, 69—95 in-lb)
Pulsation Damper
1. Remove the delivery pipe assembly. (Refer to page
4C-63.)
2. Remove the pulsation damper.
3. Install in the reverse order of removal.
Tightening torque:
25—34 N m (2.5—3.5 m-kg, 18—25 ft-lb)
Fuel Filter
Low pressure side (In-tank filter)
Refer to page 4C—60.
76G04C-124
High pressure side
The fuel filter must be replaced at the intervals out-
lined in the maintenance schedule.
Warning
Always work away from sparks or open
flames.
1. Disconnect the fuel hoses from the fuel filter.
2. Remove the fuel filter and the bracket.
3. Install a new filter and the bracket.
4. Connect the fuel hoses.
Note
When installing the filter, push the fuel hoses
fully onto the fuel filter and secure them with
spring clamps.
4C-64

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

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

ON-VEHICLE MAINTENANCE 4D
INJECTION TIMING
1. Disconnect the negative battery cable.
2. Release the CSD using the screw driver.
3. Remove the cover on the clutch housing.
4. Turn the flywheel and set the indicator at TDC.
5. Disconnect the injection pipes from the injection
pump.
76G04D-008
6. Remove the hydraulic head plug from the injec-
tion pump.
7. Mount the SST into the plug hole on the hydraulic
head so the tip of the dial gauge pointer touches
the plunger end of the pump and the dial gauge
indicates approx. 2.0 mm (0.08 in).
76.G04D-009
8. Turn the crankshaft slowly counterclockwise to
30—50° BTDC.
9. Make sure the dial indicator pointer no longer
moves by slightly turning the crankshaft.
10. Set the dial gauge scale to Zero at the pointer.
76G04D-010
11. Turn the crankshaft clockwise to align the indica-
tor pin at ATDC 1° (RF-CX), TDC 0° (RF-N).
12. Read the dial gauge.
Cam lift: 0.98—1.02 mm (0.038—0.040 in)
13. If not within the specification, adjust the injection
timing. (Refer to page 4D—24.)
76G04D-011
4D-5

4D ON-VEHICLE MAINTENANCE
IDLE SPEED
1. Warm up the engine to normal operating tem-
perature.
2. Be sure the A/C switch is OFF.
3. Connect a tachometer and check the engine
speed.
Idle speed: 720 :
20
rpm
76G04D-012
4. If necessary, adjust the idle by turning the idle ad-
justing screw.
76G04D-013
Fast Idle Speed (A/C equipped model)
1. Turn ON the A/C switch and blower motor switch.
2. Check the engine speed.
Fast idle speed: 725 ± 25 rpm
3. If necessary, turn the adjusting screw on the idle-
up actuator, and adjust the fast idle speed.
76G04D-014
EXHAUST SMOKE
Increase and decrease the engine speed several
times and check that there is no black smoke.
If
there
is, refer to the Troubleshooting Guide.
76G04D-015
4D—6

4D FUEL SYSTEM
Overhaul
Service point
1. For overhauling the injection pump, see the "Repair Service and Maintenance" manual prepared
by the manufacturer of the pump.
2. If the inside of the injection pump is disassembled for maintenance, be sure to properly use the
checking device such as the pump tester.
76G04D-068
Manufacturer of Injection Pump:
Diesel Kiki Co., Ltd.
63G04D-312
Construction of VE Injection Pump
Servo diaphragm
Boost compensation stopper
p^ ^-Fue! cut solenoid
valve
'Cold start device
63G04D-313
4D—28