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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100 600
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1,375 1,800
Injection pump speed RPM
2,325 2,600 2,700
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FUEL SYSTEM 4D
INJECTION NOZZLE
Removal
Remove in the sequence shown in the figure, referring to the removal note for the specially marked parts.
Removal note
Injection pipe
Warning
a) Catch leaking fuel leakage with a rag when
removing the injection pipes.
b) Keep fire and open flame away from the fuel
area.
Remove the injection pipes.
1. Injection pipe bracket
2. Injection pipe
3. Fuel leak pipe
4. Fuel injection nozzle
76G04D-072
4D—31

4D FUEL SYSTEM
Inspection
Injection starting pressure
1. Set the nozzle on the nozzle tester.
2. Bleed the air by pumping the nozzle tester handle
several times.
3. Slowly lower the nozzle tester handle and check
the pressure when injection starts.
Injection starting pressure:
13,200 kPa (135 kg/cm2, 1,920 lb/in2) at
20°C (36°F) of fuel temperature
76G04D-073
Adjusting shim
4. If the injection starting pressure is higher than
specification, increase the shim thickness. If the in-
jection starting pressure is lower than specification,
decrease the shim thickness.
Note
Adjusting shims are availabe in 0.05 mm
(0.0197 in) thicknesses, from 1.0 mm (0.039
in) to 1.95 mm (0.077 in). When 0.05 mm
(0.0197 in) is added, injection pressure in-
creases approx. 490 kPa (5.0 kg/cm2, 70 psi).
76G04D-074
Nozzle leakage
1. Apply 11,300 kPa (115 kg/cm2,1.640 psi) pres-
sure to the injection nozzle, and check for fuel leaks
from the injection hole.
2. If fuel leaks, overhaul or replace the' injection
nozzle.
76G04D-075
Atomization (spray pattern)
1. Set the injection nozzle on the nozzle tester.
2. Bleed the air by operating the nozzle tester han-
dle several times.
3. Lower the handle several times as quickly as pos-
sible so that a pulsating whistling sound is heard,
and check the atomization.
(1) Uniform and proper atomization
(2) Incorrect injection angle and direction
4. If necessary, overhaul or replace the injection
nozzle.
76G04D-076
4D—32

FUEL SYSTEM 4D
76G04D-077
76G04D-078
^^^
76G04D-079
Red paint
Injection Nozzle Disassembly
Disassemble the injection nozzle.
1. Nozzle holder
2. Adjusting shim
3. Pressure spring
4. Pressure pin
5. Distance piece
6. Nozzle
7. Retaining ring
Cleaning
Clean the parts in clean test oil.
Injection Nozzle Inspection
1. Check the needle valve, nozzle body, and other
parts for damage.
2. Hold the nozzle body upright and insert approxi-
mately two thirds of the needle valve, and check
that the needle valve drops to the valve seat by
its own weight.
Injection Nozzle Assembly
1. Assemble the injection nozzle.
Tightening torque of nozzle body:
29—49 N-m (3.0—5.0 m-kg, 22—36 ft-lb)
2. Check the injection starting pressure, and atomi-
zation. (Refer to page 4D—32.)
Injection Nozzle Installation
1. Install in the reverse order of removal, referring to
the installation note.
2. Check for fuel leakage.
Installation note
Nozzle gasket
Install a new gasket with the red face toward the
nozzle.
76G04D-080
4D-33

4D FUEL SYSTEM
FUEL TANK
Removal and Installation
1. Drain the fuel from the fuel tank.
2. Remove in the sequence shown in the figure, referring to the removal note for the specially marked
parts.
76G04D-081
1. Fuel level gauge connector 4. Joint hose 7. Fuel tank
2. Fuel main hose 5. Ventilation hose 8. Fuel tank pad
3. Fuel return hose 6. Breather hose
Removal note
Fuel main and return hoses
1. Remove the service hole cover from the body.
2. Disconnect the fuel main and return hoses and
plug them.
Warning
Keep fire and open flame away from the fuel
area.
4D—34

FUEL SYSTEM 4D
Inspection
Fuel tank
Check the fuel tank for cracks or damage. Replace
if necessary.
76G04D-083
Two way check valve
1. Diconncect the hose from the fuel tank.
2. Check that the air flows in both directions through
the valve.
3. Replace the fuel vent hose if necessary.
76G04D-084
Installation
1. Install in the reverse order of removal.
2. Bleed air from fuel line.
3. Check for fuel leakage.
76G04D-085
4D-35

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

5 OUTLINE
OUTLINE
STRUCTURAL VIEW
5-2

OUTLINE 5
FE (12 VALVE)
Spark plug ii^ry®
FE (DOHC)
High
tension
lead
"^M-Spark
U plug
5-3

5 OUTLINE
5-4