1987 MAZDA 626 charging

SUPERCHARGING SYSTEM (RF-CX) 4D
STARTING VALVE
Removal and Installation
1. Remove in the sequence shown in the figure.
2. Install in the reverse order of removal.
3. Check for air leakage.
76G04D-036
1. Air hose
2. Vacuum pipe
3. Starting valve
Note
Resistance will be felt because of the magnet
when opening the valve.
76G04D-034
Inspeciton
Bypass valve
Check that the bypass valve opens smoothly.
Replace the starting valve if necessary.
Starting valve
Check that the starting valve opens smoothly.
Replace the starting valve if necessary.
4D-15

4D SUPERCHARGING SYSTEM (RF-CX)
INTERCOOLER
Removal and Installation
1. Remove in the sequence shown in the figure.
2. Install in the reverse order of removal.
3. Check for air leakage.
76G04D-037
5. Front bumper (Refer to Section 14.)
6. Cooling fan
7. Air pipe
8. Intercooler
Inspection
Check the intercooler for cracks or damage. Replace
if necessary.
8—11 N-m (80—110 cm-kg, 69—95 In-lb)
1. Battery
2. Battery carrier
3. Front grille (Refer to Section 14.)
4. Headlight (Refer to Section 14.)
76G04D-038
4D—16

4D SUPERCHARGING SYSTEM (RF-CX)
BOOST AIR TEMPERATURE SENSOR
Removal
Remove the boost air temperature sensor from the
compressed air funnel.
76G04D-039
Thermometer
Inspection
1. Place the boost air temperature sensor in oil.
2. Heat the oil and check continuity of the sensor with
an ohmmeter. Replace if necessary.
Continuity : over 150°C (302°F)
No continuity: below 143°C (289°F)
76G04D-040
Installation
Install the boost air temperature sensor in the com-
pressed air funnel.
Tightening torque:
29—39 N m (3.0—4.0 m-kg, 22—29 ft-lb)
76G04D-041
4D—17

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

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 BATTERY
BATTERY
INSPECTION
Terminal and Cable
1. Check the tightness of the terminals to ensure good
electrical connections. Clean the terminals and coat
them with grease after tightening the terminal.
2. Inspect for corroded or frayed battery cables.
3. Check the rubber protector on the positive termi-
nal for proper coverage.
4BG05X-006
Electrolyte Level
1. Check whether or not the electrolyte level lies be-
tween the "UPPER LEVEL" and the "LOWER
LEVEL" lines.
2. If low, add distilled water by the "UPPER LEVEL".
Do not overfill.
4BG05X-007
Specific Gravity
1. Measure the specific gravity by using a
hydrometer.
2. If the specific gravity reading is standard or less,
recharge the battery.
Standard gravity: 1.22
Fully charged gravity: 1.27—1.29
76G05X-004
RECHARGE
Quick Charge
1. Remove the battery from the vehicle.
2. Remove all the vent caps.
3. Perform a quick charge (6A or above, but max.
20 A).
4. Add distilled water if necessary while charging.
5. Cool the battery not to exceed the electrolyte tem-
perature over 55°C (131 °F) while charging.
6. Charge once more if the specific gravity is under
fully charged gravity.
4BG05X-009
5-8

SPARK PLUG 5
Slow Charge
1. Stop the engine
2. Turn all the accessories off.
3. Remove the negative battery cable.
4. Perform a slow charge (3.5A to 4.5A).
5. Add distilled water if necessary while charging.
6. Charge once more if the specific gravity is under
fully charged gravity.
4BG05X-010
SPARK PLUG
REMOVAL AND INSTALLATION
Note the following points:
1. When the high-tension lead is to be pulled off, be
sure to pull the boot itself, and not the wire.
2. Tighten the spark plugs to the specified torque.
Tightening torque: 15—23 N-m
(1.5—2.3 m-kg, 10.8—16.6 ft-lb)
76G05X-054
Wear and adhesion or cabon
INSPECTION
Check the following points. If a problem is found, re-
place the spark plug.
1. Damaged insulation
2. Worn electrodes
3. Carbon deposits
If cleaning is necessary, use a plug cleaner or a
wire brush. Clean the upper insulator also.
4. Damaged gasket
5. Burnt condition of spark insulator
6. If it is black with carbon deposits, either misfiring
due to improper proportions of gas and air or over-
heating of the plug may have occurred.
Plug gap:
FE (12VALVE) and FE DOHC Leaded fuel
model:
0.70—0.80 mm (0.028—0.031 in)
FE (8VALVE) and FE DOHC Unleaded fuel
model:
1.0—1.10 mm (0.039—0.043 in)
Others:
0.75—0.85 mm (0.030—0.034 in)
76G05X-005
5-9

5 ALTERNATOR
CHARGING SYSTEM
76G05X-023
86U05X-008
Caution
a) Be sure the battery connections are not
reversed, because this will damage the rec-
tifier.
b) Do not use high-voltage testers such as a
megger, because they will damage the rec-
tifier.
c) Remember that battery voltage is always
applied to the alternator B terminal.
d) Do not ground the L terminal while the en-
gine is running.
e) Do not start the engine while the connec-
tor is disconnected from the L and S ter-
minals.
5—22