1987 MAZDA 626 gas type

5 STARTER (GASOLINE ENGINE, 1.4 KW TYPE)
7BU05X-048
86U05X-038
7BU05X-050
Installation of Brush Holder
Install the brush holder assembly and rear cover and
align the through bolts.
CHECKING OPERATION
Magnetic Switch
Make the following tests:
Pull-out test
1. Check that the pinion is pulled out when 12V is con-
nected to the S terminal and the body is grounded.
2. Measure the pinion gap while the pinion is pulled
out.
Specification: 0.5—2.0 mm (0.02—0.08 in)
3. Adjust the pinion gap with an adjust washer (drive
housing front cover—magnetic switch) if it is not
within specification.
Return test
1. Disconnect the motor wire from the M terminal, and
then connect the battery power to the M terminal
and ground the body.
2. Pull out the overrunning clutch with a flat-tip screw-
driver. Check that the overrunning clutch returns
to its original position when released.
86U05X-039
5-54

STARTER (GASOLINE ENGINE, 1.4 KW TYPE) 5
Ammeter £
Battery 12V
Switch K sf
Voltmeter W Starter
86U05X-040
No-Load Test
1. After adjusting the pinion gap, form a test circuit
with a voltmeter and an ammeter.
Note
Use heavy gauge wires and tighten each ter-
minal fully.
2. Close switch K to run the starter.
3. Check for the following:
Voltage (V) 11.0
Current (A) 90 max.
Gear shaft speed (rpm) 3,000 min.
4. If any abnormality is noted, check for the cause
according to "Inspection".
INSTALLATION
Install in the reverse order of removal.
Note
When installing the starter, tighten the bolts
to the specified torque.
Tightening torque:
Bolts 37—52 N m
(3.8—5.3 m-kg, 27—38 ft-lb)
B terminal 9.8—11.8 N-m
(1.0—1.2 m-kg, 87—104 in-lb)
76G05X-043
5—55

5 STARTER (DIESEL ENGINE, 2.2 KW TYPE)
Gear
Wear and damage
Bearing
Replace the bearing when it is noisy or does not ro-
tate smoothly.
4BG05X-117
4BG05X-118
Over-running Clutch
1. Replace the pinion when a worn pinion or
damaged pinion are found.
2.
If
the pinion does not rotate in both directions when
rotating the pinion by hand, replace it.
Note
Do not wash the over-running clutch in gas
or kerosene, this will destroy the grease
packing.
4BG05X-119
PERFORMANCE INSPECTION
Magnetic Switch
Disconnect the terminal M wire, and make the fol-
lowing tests.
Pull-in Test
The switch is normal
if
the pinion ejects outward when
the battery is connected as shown in the figure.
Caution
Do not supply power continuously for more
than 10 seconds.
4BG05X-092
5—74

1 1 ANTI-LOCK BRAKE SYSTEM (ABS)
HYDRAULIC UNIT FLUID
Inspection of Level
1. Run the engine for 10 seconds to let the pump mo-
tor build pressure in the accumulator; then stop the
engine.
2. Check that the fluid level is between the Max and
Min lines of the reservoir.
3. If the level is lower than the Min line and leakage
from cap is not found, replace the hydraulic unit
assembly.
86U11X-187
76G11X-061
Replacement
1. Remove the reservoir cap and retainer.
2. Use a suction pump and a soft vinyl hose to suck
fluid from the reservoir.
Caution
a) A hard hose may damage the filter in the
reservoir.
b)Only the amount of fluid shown can be re-
moved from the reservoir.
3. Fill the reservoir with the specified type and amount
of brake fluid.
Caution
a) Do not allow any foreign material to enter
the reservoir.
b) Do not soak the upper filter with brake flu-
id. Otherwise, pouring fluid may be difficult.
Fluid: DOT-3 or DOT-4 or SAE J1703
4. Check the fluid level as described above.
HYDRAULIC UNIT
Warning
The accumulator contains high-pressure gas;
do not attempt to disassemble it or subject it
to hard shocks or high heat.
When the hydraulic unit is scrapped, the high-
pressure gas must be released. Turn the
screw on the accumulator bottom one full turn
only and allow the gas to escape gradually.
76G11X-097
11—94

13 OUTLINE
SPECIFICATIONS
Front Suspension
Item Specifications
Suspension type Strut
Toe-in mm (in) 0 ± 3 (0 ± 0.12)
Front wheel alignment Camber angle 0C 17' ± 45' Front wheel alignment Caster angle 1c 13' ± 45'
King pin angle 12°47'
Maximum front steering Inner 36 °00' ± 2°
angle Outer 31 °00' ± 2°
Stabilizer Type Torsion bar Stabilizer Diameter mm (in) 20.0 (0.79)
Shock absorbers Standard suspension Oil type Shock absorbers Auto adjust suspension Low-pressure gas sealed type
Identification color Green Light green Pink Brown Purple Gray Orange
Wire diameter mm (in) 12.6 (0.49) 12.8 (0.50)
12.9
(0.51) 13.1 (0.52)
13.3 (0.53)
13.6
(0.54) 12.5 (0.49)
*Coil springs Coil inner diameter mm (in) 147.5 (5.8)
Free length mm (in) 353 (13.9)
362 (14.3) 370 (14.6) 372 (14.6) 365 (14.4)
350
(13.8)
344
(13.5)
Coil number 5.09 5.31 5 42 5.53 5.46 5.34 4.99
* Refer to pages 13—5, 6, 7 spring applications.
Rear Suspension
Item Specifications
SusDension tvDe Strut
Rear wheel alignment
Toe-in
mm (in)
2WS 0 ± 3 (0 ± 0.12)
Rear wheel alignment
Toe-in
mm (in) 4WS 3 ± 3 (0.12 ± 0.12) Rear wheel alignment Camber
anale
2WS -0°30' ± 45' Rear wheel alignment Camber
anale 4WS 0°00' ± 45'
Maximum rear steering angle (4WS) Inner 5°00' ± 45' Maximum rear steering angle (4WS) Outer 5°00' ± 45'
Stabilizer TvDe Torsion bar Stabilizer Diameter mm (in) 16 (0.63)
Shock absorbers Standard susDension Oil tvDe Shock absorbers Auto adiust suspension Low-pressure c las sealed type
'Coil springs
Identification color Orange White Yellow Brown Blue Green Red Pink
'Coil springs
Wire diameter mm (in) 11.6
(0.45)
11.7 (0.46) 11.8
(0.46)
11.9 (0.47)
12.1
(0.48)
12.2
(0.48)
12.4 (0.49) 12.6 (0.50)
'Coil springs Coil inner diameter mm (in) 127.5 (5.0) 'Coil springs
Free length mm (in) 297 (11.7) 306 (12.0)
314 (12.4) 323 (12.7) 327 (12.9) 332 (13.1) 336 (13.21 340 (13.4)
'Coil springs
Coil number 5.44 5.58 5.72 5.87 6.03 6.04 6.21 6.36
'Refer to pages 13—8, 9, 10 spring applications.
13—4

30 TECHNICAL DATA
0. MEASUREMENT
Item Engine model Coupe/MX-6 Sedan Hatchback

Overall length mm (in) 4,450 (175.2) 4,515 (177.8) 4,515 (177.8)
Overall width mm (in) 1,690 (66.5) 1,690 (66.5) 1,690 (66.5)
Overall height (14 inch/13 inch) mm (in) 1,360 (53.5)/1,345 (52.9) 1,410 (55 5)/1,395 (54.9) 1,375 (54.1)/1,360 (53 5)
Wheel base mm (in) 2,515 (99.0) 2,575 (101.4) 2,575 (101.4)
Tread (14 inch/13 inch)
mm (in)
Front 1,455 (57.3)/1,460 (57.5) 1,455 (57.3)/(1,460 (57.5) 1,455 (57.3)/1,460 (57.5) Tread (14 inch/13 inch)
mm (in)
Rear 1,465 (57.7)/1,455 (57.3) 1,465 (57.7)/1,455 (57.3) 1,465 (57 7)/1,455 (57 3)
1
A. ENGINE (SOHC)
12-valve
— Engine model Item FE 12-valve
~vpe
Gasoline, 4-cycle
Cylinder arrangement and number In-line, 4-cylinders
Type
of
combustion chamber Pentroof
Valve system OHC, belt-driven
Bore
x
Stroke
mm (in)
86.0
x
86.0 (3.39
x
3.39)
Total piston displacement
cc
(cu
in)
1,998 (121.9)
Compression ratio 9.5
: 1

Compression pressure
kPa (kg/cm2, psi)-rpm
Standard 1,422 (14.5, 206)—280
Compression pressure
kPa (kg/cm2, psi)-rpm
Minimum 996 (10.2, 144)—280 Compression pressure
kPa (kg/cm2, psi)-rpm Maximum difference
between cylinders 196 (2.0,
28)

Valve timing
IN
Open
BTDC 14°
Valve timing
IN Close ABDC 56° Valve timing
EX Open BBDC 69° Valve timing
EX Close ATDC 13°
Valve clearance
mm (in)
IN 0; Maintenance free Valve clearance
mm (in)
EX 0; Maintenance free

Cylinder head

Heiaht
mm (inl
91.95-92.05 (3.620-3.624)
Distortion
mm (inl
Maximum 0.15 (0.006)
Grinding limit
mm (in)
Maximum 0.20 (0.008)

Valve and valve auide

Valve head diameter
mm (in)
IN 32.4-32.6 (1.276—1.283) Valve head diameter
mm (in)
EX 33.9-34.1 (1.335-1.343)
Valve head thickness (margin)
mm (in)
IN 0.8-1.2 (0.031—0.0471 Valve head thickness (margin)
mm (in)
EX 1.3—1.7 (0.051-0.067)
Valve face angle IN 45° Valve face angle EX 45°
Valve length
mm (in)

IN Standard 115.81 (4.55941
Valve length
mm (in)

IN Minimum 115.31 (4.5398) Valve length
mm (in)
cv Standard 116.21 (4.5752)
Minimum 115.71 (4.55551
Valve stem diameter
mm (in)
IN 6.970-6.985 (0.2744-0.2750) Valve stem diameter
mm (in)
EX 6.965-6.980 (0.2742-0.27481
Guide inner diameter
mm (in)
IN 7.01-7.03 (0,2760-0.2768) Guide inner diameter
mm (in)
EX 7.01-7.03 (0.2760-0.27681
Valve stem
to
guide clearance
mm (in)

IN 0.025-0.060 (0.0010-0.0024)
Valve stem
to
guide clearance
mm (in)
EX 0.030-0.065 (0.0012—0.0026) Valve stem
to
guide clearance
mm (in)

Maximum 0.20 (0.00791
Guide projection (Height "A")
mm (in)
19.8-20.3 (0.780-0.799)

30—2

TECHNICAL DATA 30
" Engine model Item FE 12-valve
Timing belt

Belt deflection
mm
(in)/98
N
(10 kg,
22 lb)
5.5—6.5 (0.22-0.26)

8-valve
Engine model
Item -••--.
FE 8-valve F8
F6
Engine model
Item -••--. ECE Middle
East
General
ECE General F6

Type Gasoline, 4-cycle
Cylinder arrangement and number In-line, 4-cylinders
Type
of
combustion chamber Multispherical
Valve system OHC, belt-driven
Bore
x
Stroke
mm
(in) 86.0
x
86.0 (3.39
x
3.39) 86.0
x
77.0
(3.39
x
3.03)
81.0
x
77.0 (3.19
x
3.03)
Total piston displacement
cc
(cu
in)
1,998 (121.9) 1,789 (109.1) 1,587 (96.8)
Compression ratio 8.6
: 1
9.0
: 1

Compression pressure kPa (kg/cm2, psi)-rpm
Standard 1,275 (13.0, 185)—270 1,128 (11.5, 164)—270
Compression pressure kPa (kg/cm2, psi)-rpm Minimum 893 (9.1, 129)—270 790 (8.1, 114)—270 Compression pressure kPa (kg/cm2, psi)-rpm Maximum difference
between cylinders 196 (2.0,
28)

Valve timing
IN Open BTDC 16° 20° 17°
Valve timing
IN Close ABDC 54° 65° 56° Valve timing
EX Open BBDC 54° 65° 64° Valve timing
EX Close ATDC 16° 20° 15°
Valve clearance
mm
(in) IN 0.30 (0.012) Valve clearance
mm
(in) EX 0.30 (0.012)

Cylinder head

Height
mm (in)
91.95-92.05 (3.620-3.624)
Distortion
mm
(in) Maximum 0.15 (0.006)
Grinding limit mm (in) Maximum 0.20 (0.008)

Valve and valve guide

Valve head diameter
mm
(in) IN 43.9-44.1 (1.728-1.736) Valve head diameter
mm
(in) EX 35.9-36.1 (1.413-1.421)
Valve head thickness (margin)
mm
(in) IN 0.8—1.2 (0.031-0.047) Valve head thickness (margin)
mm
(in) EX 1.3-1.7 (0.051-0.067)
Valve face angle IN 45° Valve face angle EX 45°
Valve length
mm
(in)
IN Standard 111.89 (4.4051)
Valve length
mm
(in)
IN Minimum 111.39 (4.3854) Valve length
mm
(in)
EX Standard 111.69 (4.3972) Valve length
mm
(in)
EX Minimum 111.19 (4.3776)
Valve stem diameter
mm
(in) IN 8.030-8.045 (0.3161-0.3167) Valve stem diameter
mm
(in) EX 8.025-8.040 (0.3159-0.3165)
Guide inner diameter
mm
(in) IN 8.07-8.09 (0.3177-0.3185) Guide inner diameter
mm
(in) EX 8.07-8.09 (0.3177-0.3185)
Valve stem
to
guide clearance
mm
(in)
IN 0.025-0.060 (0.0010-0.0024)
Valve stem
to
guide clearance
mm
(in) EX 0.030-0.065 (0.0012-0.0026) Valve stem
to
guide clearance
mm
(in)
Maximum 0.20 (0.0079)
Guide projection (Height "A")
mm
(in) 19.1-19.6 (0.752-0.772)

30-5

30 TECHNICAL DATA
~ ——Engine model
Item —
FE 8-valve
F8 F6
~ ——Engine model
Item —
Middle ECE East General
F8 F6
Thrust bearing (center main bearing)

Crankshaft end play
mm
(in) Standard 0.08-0.18 (0.0031-0.0071) Crankshaft end play
mm
(in) Maximum 0.30 (0.0118)
Bearing width
mm (in)

Standard 27.94-27.99 (1.100-1.102)
Bearing width
mm (in)
0.25 (0.010) oversize 28.04—28.09 (1.104-1.106) Bearing width
mm (in)
0.05 (0.020) oversize 28.12-28.17 (1.107-1.109) Bearing width
mm (in)

0.75 (0.030) oversize 28.20—28.25 (1.110—1.112)

Timing belt

Belt deflection
mm
(in)/98
N
(10 kg,
22 lb)
|5.5—6.5 (0.22-0 26) 4.0-5.0 (0.16-0.20)

1B. ENGINE (DOHC)
— Engine model FE DOHC
Item ~ Leaded fuel Unleaded fuel

Type Gasoline, 4-cycle
Cylinder arrangement and number In-line, 4-cylinders
Type
of
combustion chamber Pentroof
Valve system OHC. belt-driven
Bore
x
Stroke mm (in) 86.0
x
86.0 (3.39
x
3.39)
Total piston displacement cc (cu
in)
1,998 (121.9)
Compression ratio 10.0
: 1
9.2
: 1

Standard 1,422 (14.5, 206)—290 1,373 (14.0, 199)—310
Compression pressure Minimum 996 (10.2, 144)—290 961 (9.8, 139)—310
kPa (kg/cm2, psi)-rpm Maximum difference
between cylinders 196 (2.0, 28)
IN Open BTDC 10° 10°
Valve timing
IN Close ABDC 60° 55° Valve timing
EX Open BBDC 60° 55° EX Close ATDC 10° 10°
Valve clearance mm (in) IN 0; Maintenance free Valve clearance mm (in) EX 0; Maintenance free

Cylinder head

Heiaht mm (in) 133.95-134.05 (5.274-5.278)
Distortion mm (in) Maximum 0.15 (0.006)
Grinding mm (in) Maximum 0.20 (0.008)
HLA
to
cylinder head clearance mm (in) Standard 0.025-0.066 (0.0010-0.0026) HLA
to
cylinder head clearance mm (in) Maximum 0.18 (0.0071)

Valve and valve guide

Valve head diameter mm (in) IN 33.6-33.8 (1.323-1.331) Valve head diameter mm (in) EX 28.8-29.0 (1.134—1.142)
Valve head thickness (margin)
mm
(in) IN 1.0-1.7 (0.039-0.067) Valve head thickness (margin)
mm
(in) EX 1.1—1.7 (0.043—0.067)
Valve face angle IN 45° Valve face angle EX 45°
IN Standard 103.18 (4.0622)
Valve length
mm (in)

IN Minimum 102.68 (4.0425) Valve length
mm (in)

EX Standard 103.94 (4.0921) EX Minimum 103.44 (4.0724)
Valve stem diameter mm (in) IN 5.970-5.985 (0.2350-0.2356) Valve stem diameter mm (in) EX 5.965-5.980 (0.2348—0.2354)
Guide inner diameter mm (in) IN 6.01-6.03 (0.2366-0.2374) Guide inner diameter mm (in) EX 6.01—6.03 (0.2366-0.2374)
IN 0.025-0.060 (0.0010-0.0024)
Valve stem
to
guide clearance mm (in) EX 0.030-0.065 (0.0012-0.0026)
Maximum 0.20 (0.0079)
| Guide projection (Height "A") mm (in) 11.4-11.9 (0.449-0.469)

30-8