1987 MAZDA 626 fuel pump

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 SUPERCHARGING SYSTEM (RF-CX)
ON-VEHICLE INSPECTION
Boost Pressure
1. Connect a pressure gauge to the hose from the
intake manifold.
2. (On chassis dynomometer, full load)
(1) Set the vehicle on a chassis dynomometer.
(2) Run the vehicle in gear at 3,000 rpm with the
acceleration pedal fully depressed.
(3) Measure the boost pressure.
Boost pressure:
82 kPa (0.87 kg/cm2, 8.1 psi)
Note
The above inspection should be done on a
chassis dynomometer. If a dynomometer is
not available follow the below procedure.
3. (Off chassis dynomometer, no load)
(1) Shift the transaxle out off gear.
(2) Run the engine in neutral at 3,000 rpm of the
engine no load.
Measure the boost pressure.
Boost pressure:
5 kPa (0.05 kg/cm2, 0.7 psi)
Note
The boost pressure is varied by engine speed
and engine load.
(3) Remove the starting valve bypass hose.
(4) Check that the bypass valve is closed at 3,000
rpm.
4.
If
the pressure is below specification, check the fol-
lowing. Replace the Comprex supercharger if
necessary.
(1) Intake air and exhaust passages leakage
(2) Intake air and exhaust passages clogged
(3) Wastegate (Refer to 4D—12.)
(4) Starting valve (Refer to 4D—15.)
(5) Fuel system (Injection nozzle... refer to page
4D—31, injection pump...refer to page 4D—24,
etc.)
5. If the pressure exceeds specification, check the
wastegate operation. (Refer to page 4D—12.)
4D—11

FUEL SYSTEM 4D
FUEL SYSTEM
STRUCTURAL VIEW
RF-CX
RF-N
76G04D-046
1. Fuel tank
2. Fuel filter
3. Fuel injection pump
4. Fuel injection nozzle
5. Sedimenter
4D—21

4D FUEL SYSTEM
INJECTION PUMP
On-Vehicle Inspection
Fuel cut solenoid valve
1. Run the engine at idle.
2. Disconnect the solenoid valve connector, and let
the engine stop.
3. If the engine does not stop, replace the fuel cut
solenoid valve.
76G04D-055
Pick up coil
1. Disconnect the pick up coil connector.
2. Check for continuity of the coil using an ohmmeter.
3. Replace it if there is not continuity.
76G04D-056
O
o
>=
=<
t= —i V
' 1 -4
n
5-
U
o
1 mm (0.39 in) Injection Timing Adjustment
Inspection
Check the injection timing. (Refer to page 4D—5.)
Injection timing
RF-CX: ATDC 10
RF-N : TDC 0°
76G04D-057
Adjustment
1. Loosen the injection pump mounting nut.
2. Loosen the injection pump bracket bolt.
76G04D-058
4D—24

FUEL SYSTEM 4D
RF-CX
o
M
o
10-
RF-N
M
m
M
o TO"
5-
76G04D-059
76G04D-060
76G04D-061
3. Turn the crankshaft, and align the flywheel indica-
tor pin at ATDC 10 (RF-CX), or TDC 0° (RF-N).
4. Turn the injection pump until the dial indicator in-
dicates 1 mm (0.04 in).
Note
Refer to page 4D—4 for initial setting of the
dial indicator.
Cam Height Inspection
1. Set the SST into the injection pump as for injec-
tion timing adjustment. (Refer to page 4D—4.)
2. Turn the crankshaft clockwise and read the maxi-
mum difference of the indicator value, which gives
the cam height.
Cam height: 2.2 mm (0.08 in)
76G04D-062
4D—25

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

FUEL SYSTEM 4D
76G04D-065
76G04D-066
Injection pump pulley
1. Put two 35—40 mm (1.3—1.6 in) long bolts through
the injection pump pulley and affix them in the
threaded holes of the injection pump bracket.
2. Loosen the injection pump pulley bolt.
3. Separate the injection pump pulley from the injec-
tion pump shaft with the SST.
Steps after installation
1. After installation adjust the injection timing. (Refer
to page 4D—24.)
2. Bleed air from the fuel line.
3. Check for fuel leakage.
76G04D-067
4D—27