1987 MAZDA 626 stop start

4C SWITCH MONITOR FUNCTION
Check connector: (Green, 6 pin)'
N negative battery
ii cable
49 H018 9A1
INSPECTION PROCEDURE
1. Warm up the engine to normal operating temper-
ature and stop it.
2. Connect the SST to the check connector (Green,
6-pin) and the negative battery terminal.
86U04A-034
Test connector: (Green, 1 pin)
3. Connect a jumper wire between the test connec-
tor (Green, 1-pin) and a ground.
4. Turn the ignition switch ON. Check if monitor lamp
illuminates as each switch is made to function as
described below.
Caution
a) If any one of the switches is activated, the
monitor lamp will stay on.
b)Do not start the engine.
76G04C-036
76G04C-037
Neutral and Clutch switch
4C—26

4C PRC SYSTEM
System Inspection
1. Connect the SST to the engine. (Refer to page
4C-53.)
2. Start the engine.
76G04C-131
Hi?
Jpll ssil
Water thermo sensor ^^^Tta^e air thermo sensor
76G04C-132
Operating time Fuel line pressure kPa (kg/cm2, psi)
After starting: for 120 sec. 235-275 (2.4-2.8, 34-40)
After 120 sec. 186-226 (1.9-2.3, 27-33)
3. Warm up the engine to normal operating temper-
ature and stop the engine.
Warning
Be careful when disconnecting the water ther-
mo sensor connector because the surround-
ing area is very hot.
4. Disconnect the water thermo sensor connector.
Connect a resistor (200 fl) to the sensor connector.
5. Heat the intake air thermo sensor to above specifi-
cation.
Specification: 30°C (86°F)....unleaded fuel
50°C (122°F)....leaded fuel
6. Restart the engine.
7. Check the fuel line pressure and operating times
as shown in the chart.
76G04C-133
Solenoid Valve (Pressure Regulator Control)
Inspection
1. Disconnect the vacuum hose from the vacuum
pipe.
2. Blow through the solenoid valve from vacuum hose
A.
3. Check that air flows from port B.
76G04C-134
4C—70

4C EEC SYSTEM
EVAPORATIVE EMISSION CONTROL
(EEC)
SYSTEM
Water thermo sensor
76G04C-150
Unleaded fuel:
This system stores fuel vapor generated in the fuel tank in the canister when the engine is not running.
The fuel vapor is stored in the canister until it is drawn into the dynamic chamber and burned when
the engine is started.
Leaded fuel:
Fuel vapor generated in the fuel tank flows out to the atmosphere.
COMPONENT DESCRIPTION
Application
Component Function Remark New
model Prevtoui model
Air flow sensor Detects amount of intake air; sends signal to engine control unit
O X
Charcoal canister Stores fuel tank fumes while engine stopped
o X
Engine control unit Detects signals from input sensors and
switches; controls solenoid valves (Purge
control)
o X
Ne signal pick-up Detect crank angle at 180° intervals; sends signal to engine control unit
Installed in distributor o X
Separator Prevents fuel from flowing into charcoal canister
o o
Solenoid valve
(No.1 purge control)
Controls vacuum to solenoid valve (No.2
purge control) and vacuum switch valve
0 X
Solenoid valve (No.2 Purge control)
Controls vacuum to vacuum switch valve o X
Three-way check valve Controls pressure in fuel tank o X
Two-way check valve Controls pressure in fuel tank X o
Vacuum switch valve Regulates evaporative fumes from canis-ter to intake manifold
o X
Water thermo sensor Detects coolant temperature; sends signal to engine control unit
0 X
76G04C-151
4C-80

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

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 STARTER (GASOLINE ENGINE, 0.85, 0.95 KW TYPE)
4BG05X-078
4BG05X-079
4BG05X-080
Drive Pinion
Remove the stopper for the overrunning clutch by us-
ing a pipe as shown in the figure.
Adjustment of Pinion Gap
1. Disconnect the wiring from terminal (M).
2. Apply battery power to the terminal (S) and ground
the starter motor body, the pinion will eject outward
and then stop.
3. Measure the clearance (pinion gap) between the
pinion and the stopper.
Pinion gap: 0.5—2.0 mm (0.020—0.079 in)
Caution
Do not let electricity flow continuously for
more than 10 seconds.
If the pinion gap is not within the specified range,
make the adjustment by increasing or decreasing
the number of washers used between the magnetic
switch and the drive housing. The gap will become
smaller if the number of washers is increased.
Caution
Do not use the washers
(0.079 in) in all.
more than 2 mm
INSPECTION
Armature Coil
1. Ground of the armature coil
(1) Check for continuity between the commutator
and the core by using a circuit tester.
(2) Replace the armature if there is continuity.
4BG05X-081
5—40

5 STARTER (GASOLINE ENGINE, 0.85, 0.95 KW TYPE)
(TM (TM /AgLjM) terminal
xtsfif
4BG05X-094
Return Test
1. Connect the battery between terminal M of the
magnetic switch and the body, as shown in the
figure.
2. Pull the pinion out manually to the pinion stopper
position.
3. The pinion should immediately return to its origi-
nal position when it is released.
No-load Test
1. After adjusting the pinion gap, form a test circuit
with a voltmeter and an ammeter.
Note
Use wires as thick as possible and tighten
each terminal fully.
2. Close switch "K" to run the starter.
3. If the voltmeter and ammeter show the following
values while the starter is running, it is normal.
0.85 kW
type
0.95 kW
type
Battery voltage (volt) 11.5
Current
(ampere) 60 or less
Gear shaft speed (rpm) 6,500 or more
6,600
or more
4. If any abnormality is noted, check it according to
"INSPECTION"
5—44

5 STARTER (GASOLINE ENGINE, 1.4 KW TYPE)
86U05X-034
Snap ring
Internal gear
Drive pinion I Gear shaft
r i
rt
n I I Washer

OC
Stopper
7BU05X-037
Overrunning Clutch Stopper
1. Remove the overrunning clutch stopper using a
pipe.
2. Disassemble the drive pinion, internal gear and
washer from the gear shaft.
Brush and Brush Holder
Remove the brush from the brush holder using a flat-
tip screwdriver.
7BU05X-038
5-48