1987 MAZDA 626 ignition

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

OUTLINE 5
SPECIFICATIONS
Gasoline Engine
item
Engine
F6 F8 FE
(8 VALVE)
FE (12 VALVE) FE
(DOHC)
Battery
Voltage
Type and capacity
12. Negative ground
(20 hour rate) 34B19L(S) (33 Ah): General 50D20L (50 Ah), 55D23L (60 Ah): ECE
Alternator
Type A.C.
Output V-A 12-70
Regulator type Transistorized (built-in IC regulator)
Regulated voltage 14.1-14.7
Brush length
mm (in) Standard 16.5 (0.650)
Minimum 8.0 (0.315)
Drive belt tension
mm (in)/98 N (10 kg, 22 lb) New: 6-8 (0.24-0.32), Used: 7-9 (0.28-0.35)
Starter
Type Coaxial reduction: Middle East & General (FE • carburetor)
Non-reduction: Others
Output V-kW 12-0.85
Brush length
mm (in)
12-0.95
Standard 17.0 (0.669)
Minimum 11.5 (0.453)

Unleaded fuel
17.0 (0.669)
Others
17.51
Unleaded fuel 11.5(0.453) Others 10,0 (0.394)

12-1.4 12-0.95
17.0 (0.669)
11.5 (0.453)
Ignition timing 6 ± 10 BTDC (Vacuum hose disconnected)

12
±
1° BTDC
(Test connector

grounded)
Distributor
Type Fully transistorized (HEI)
Electronic spark advance
Centrifugal spark advance
(crank angle/engine speed)
degree/rpm
F6
-2-2/1,000 6-10/2,100 14-18/6,100
F8 -2—2/1,000 10-14/2,100 18-22/6,100
FE (8 VALVE)—Carburetor Unleaded fuel
(MTX)-2—2/1,760 12—16/3,360 22—26/5,320 (ATX)-2-2/1,300 12-16/3,360 22-26/5,320
Others
-2—2/1,460 10—14/2,540 22—26/5,540
FE (12 VALVE)—Carburetor -2-2/1,200 10—14/2,400 10—14/4,000 16-20/5,000
FE—Fuel injection (except FE DOHC) -2—2/1,000 10—14/2,600 10—14/4,600 16—20/5,800
Unleaded fuel model 76G05X-503
5-5

TROUBLESHOOTING GUIDE 5
TROUBLESHOOTING GUIDE
Problem Possible cause Remedy Page
Starter does not turn at all, or Its turning speed Is too slow to start the engine.
Battery and related parts Poor contact of battery terminals Poor grounding of negative cable Voltage drop caused by discharged battery Insufficient voltage caused by battery malfunction
Clean and tighten Clean and repair Recharge Replace
5- 8
5- 8 5- 8
Ignition switch and related parts Poor contact of ignition switch Loose ignition switch wiring or connector Broken wire between ignition switch and magnetic switch
Replace Repair Repair or replace 5-38,45,56,66
Magnetic switch and related parts Loose wiring and/or connectors Burnt magnetic switch contact plate or improper contact Broken wire in magnetic switch pull-in coil Broken wire magnetic switch holding coil
Repair Replace
Replace Replace
5-38,45,56,66 5-43,54,64,74
5-43,54,64,74 5-43,54.64,74
Starter Poor contact of brushes
Fatigued brush spring Poor grounding of field coil Poor soldering of field coil Commutator mulfunction Grounded armature Worn parts
Adjust contact or replace Replace Replace Repair Repair or Replace Replace Replace
5-43,54,64,74
Starting problem Gasoline engine Insufficient battery capacity Malfunction of spark plug (s)
Loose positive terminal Damaged distributor cap or rotor Ignition coil malfunction laniter malfunction
Recharge Clean, adjust or replace Tighten Replace Replace Renlane
5— 8 5— 9
5—16 5—10 5-16,20
Diesel engine Insufficient battery capacity QSS svstem malfunction Recharge ReDlace 5— 8 5-76
Starter turns but pinion gear does not mesh with ring gear
Starter Tip of overrunning clutch pinion is worn Weakened overrunning clutch drive spring Worn overrunning clutch Improper sliding of spline
Worn bushing Worn ring gear
Replace Replace Replace Adjust contact and repair, or replace Replace ReDlace
5-40,54,70
Starter turns continuously (does not stop) Magnetic switch Sticking contact place of magnetic switch Layer shorting coil of magnetic switch Ignition switch does not return
Replace Replace Rfinlanfi
5-43,54,64,74 5-43,54,64,74
Misfiring Dirty or damaged spark plug (s) Malfunction of wiring, or open circuit Damaged distributor cap
Clean or replace Repair or Replace Replace
5- 9 5—10 5—16
Discharging of battery Alternator Loose drive belt Grounded or broken stator coil Broken rotor coil Poor contact of brush and slip ring
Malfunction of rectifier Malfunction of IC regulator Battery and related parts Insufficient or unsuitable battery electrolyte Malfunction of battery electrode (internal short-circuit) Poor contact of battery terminal (s) Excessive electric load
Adjust Replace Replace Clean, repair or replace Replace Replace
Adjust Replace
Clean and tighten Check power consump-tion and short circuit
5-37 5-32 5-32 5-32
5-34
5— 8 5- 8
5— 8
Overcharging of battery IC regulator malfunction Operating in extremely high temperature Replace Reoair
Poor acceleration Mis-adjusted ignition timing Distributor malfunction Adjust Repair or replace 5—11 5—11
Knocking Mis-adjusted ignition timing | Distributor malfunction Adjust Repair or replace 5—11 5—11
76G05X-003
5-7

5 IGNITION COIL, HIGH-TENSION LEAD
IGNITION COIL
INSPECTION
Primary Coil
Use an ohmmeter and check for resistance in the pri-
mary coil. If it is not within the specification, replace
the coil.
Primary coil resistance: (at 20°C 68°F)
FE DOHC...0.72—0.88 Q
Others 1.04—1.27 Q
76G05X-006
Secondary Coil
Use a ohmmeter to measure the resistance of the
secondary coil. If it is not within specification, replace
the coil.
Secondary coil resistance: (at 20°C 68°F)
FE DOHC 10.3—13.9 kQ
Others 7.1— 9.7 k«
76G05X-055
Insulation of Case
Use a 500V megger tester to measure the insula-
tion resistance between the primary terminal and the
case.
The standard reading is 10 MQ or more.
86U05X-046
HIGH-TENSION LEAD
INSPECTION
Measure the resistance using an ohmmeter.
Resistance: 16 kQ per 1m (3.28 ft)
5—10

DISTRIBUTOR 5
7BU05X-075
86U05X-048
76G05X-007
DISTRIBUTOR
SPARK TEST
1. Disconnect the distributor lead from the distributor.
2. Hold it with insulated pliers approx. 5—10 mm
(0.20—0.39 in) from a ground.
3. Crank the engine and check that a strong blue
spark is visible.
4. If there is no spark, the ignition coil or pick-up coil
may be bad.
Check once again after replacing the ignition coil
or pick-up coil.
IGNITION TIMING
1. Warm up the engine to the normal operating tem-
perature.
2. Turn all electric loads OFF.
3. Connect a tachometer and timing light to the
engine.
4. Connect a jumper wire between the test connec-
tor and ground. (Only for FE DOHC)
5. Check the idle speed. Set to the specified speed
if necessary.
Idle speed: 750 ± 50 rpm (FE DOHC)
800 t58 rpm (F6, F8 FE—MTX)
900 i58 rpm (F8, FE—ATX
in "P" range)
950 -5o rmp (F6—ATX
in "P" range)
6. Check that the timing mark (Yellow) on the crank-
shaft pulley and the mark on the timing belt cover
are aligned.
Ignition timing:
FE DOHC: 12 ± 1° BTDC
(Test connector grounded)
Others: 6 ± 1°
(Vacuum hoses disconnected and
plugged)
76G05X-008
5—11

DISTRIBUTOR
8.
If
the mark is not aligned, loosen the distributor lock
bolt, and turn the distributor housing to make the
adjustment.
9. Reconnect the vacuum hoses, or disconnect the
jumper wire from the test connector.
10. Tighten the distributor lock bolt to specified torque.
Tightening torque:
18.6—25.5 Nm
(1.9—2.6 m-kg, 13.7—18.8 ft-lb)
86U05X-051
SPARK CONTROL (Except FE DOHC)
Centrifugal Advance
1. Warm up the engine to the normal operating tem-
perature.
2. Check that the idle speed and initial ignition tim-
ing are correct.
3. Disconnect the vacuum hoses from the vacuum
control unit and plug them.
76G05X-009
F6
Engine Speed (rpm)
4. While gradually increasing the engine speed, use
a timing light to check the advance on the pulley.
Excess advance weak governor spring
(If the governor spring is broken,
the advance will rise very high)
Insufficient advance...governor weight or cam
malfunction
86U05X-053
F8
Engine Speed (rpm) Engine Speed (rpm)
5-12

DISTRIBUTOR 5
FE West Germany (MTX)
24c
14<
0 0) O)
a>
®
O) c a> ^
I 0 1.76° 3.36° 5.32°
Engine Speed (rpm)
FE 12 valve (Carb.)
© ©
118°
12° O) c (0
c CO
6 o 1,200 2,400 4,0005,000
Engine Speed (rpm)
FE West Germany (ATX)

oT
24' 0) a> © "D
© O) c CO JX c CO
14c
6 0 1,300 3,350 5,320
Engine Speed (rpm)
EF EGI a) ©
O) a> ©
o> c ©
C CO
O
18°
12°
1,000 2,600 4,600 5,800
Engine Speed (rpm)
F6, F8 © ©
O) © tj, ©
cn
« 8°
c a)
6 o
86U05X-054
100 (3.94) 300 (11.81)
mmHg (inHg)
Vacuum Advance
1. Warm up the engine to the normal operating tem-
perature.
2. Check that the idle speed and ignition timing are
correct.
3. Disconnect the vacuum hoses from the vacuum
control unit, and plug them.
4. Connect a vacuum pump to the vacuum control
unit.
5. Apply vacuum and check the advance with the tim-
ing light.
86U05X-055
5—13

5 IGNITER
(FE
DOHC)
76G05X-018
IGNITER
INSPECTION
1. Disconnect the center high tension lead from the
distributor cap.
2. Hold it with insulated pliers approx. 5—10 mm
(0.20—0.39 in) from a ground.
3. Turn th ignition switch ON.
4. Remove the rubber seal from the igniter connector.
5. Apply battery voltage to terminal A (LR) with a jum-
per wire.
6. Check that a strong blue spark is visible when the
wire is disconnected.
76G05X-019
If no spark is seen, connect a voltmeter between
terminal B (B) and terminal C (YL), and check for
battery voltage.
76G-05X-020
8. Repeat steps 5 and check
that
the voltage changes
to 2—3V.
9.
If
the voltage is not as specified, replace the igniter.
10.
If
the voltage is as specified, check the ignition coil
and high tension lead.
76G05X-021
5-20