1987 MAZDA 626 fuel

1B INSTALLATION
76G01B-113
76G01B-114
76G01B-115
Radiator
1. Install the radiator and cooling fan.
Tightening torque:
8—11 N-m (80—110 cm-kg, 69—95 in-lb)
2. Connect the radiator harness.
3. Connect the upper and lower radiator hoses.
Note
a) Position the hose clamp in the original lo-
cation on the hose.
b) Squeeze the clamp lightly with large pliers
to ensure a good fit.
Heater Hose and Fuel Hose
Connect the heater hoses and the fuel hoses.
High-Tension Lead
Connect the high-tension lead to the ignition coil.
Accelerator Cable
Install the accelerator cable.
76G01A-148
Battery and Battery Carrier
1. Install the battery carrier.
Tightening torque:
9—13 N-m (90—130 cm-kg, 78—113 in-lb)
2. Install the fuse box.
Tightening torque:
8—11
N
m (80—110 cm-kg, 69—95 in-lb)
3. Install the battery tray and battery.
Tightening torque:
5_7
N m
(50—70 cm-kg, 43—61 in-lb)
1B—80

TROUBLESHOOTING GUIDE 1 C
SPECIFICATIONS
———Engine model
Item ^—_______ RF-CX RF-N
Type Diesel, 4 cycle
Cylinder arrangement and number In line, 4 cylinders
Combustion chamber Swirl chamber
Valve system OHC, belt driven
Displacement cc (cu in) 1,998 (121.9)
Bore and stroke mm (in) 86.0 x 86.0 (3.39 x 3.39)
Compression ratio 21.1 : 1 22.7 : 1
Compression pressure
kPa (kg/cm2, psi)-rpm
Standard 2.943 (30, 427)-200 Compression pressure
kPa (kg/cm2, psi)-rpm Minimum 2.649 (27, 384)-200
Valve timing
IN Open BTDC 13° 13°
Valve timing
IN Close ABDC 15° 39° Valve timing
EX Open BBDC 60° 60° Valve timing
EX Close ATDC 8° 8°
Valve clearance mm (in)
Cold IN 0.25 (0.010)
Valve clearance mm (in)
Cold EX 0.35 (0.014) Valve clearance mm (in) Warm (for ref.)
IN 0.30 (0.012) Valve clearance mm (in) Warm (for ref.) EX 0.40 (0.016)
Idle speed (MTX in neutral) rpm 720
Injection timing ATDC 10 TDC 0°
Injection order 1_3_4_2
76G01C-002
TROUBLESHOOTING GUIDE
Problem Possible Cause Remedy Page
Difficult starting Malfunction of engine-related components
Burned valve Worn piston, piston ring, or cylinder Failed cylinder head gasket
Replace Replace or repair Replace
1C-48 1C—55,56 1C-16
Difficult starting
Malfunction of fuel system Refer to Section 4D
Difficult starting
Malfunction of Comprex supercharger Refer to Section 4D
Difficult starting
Malfunction of electrical system Refer to Section 5
Poor idling Malfunction of engine-related components Improper valve clearance Poor valve to valve seat contact Failed cylinder head gasket
Adjust Repair or replace Replace
1C-85 1C-50 1C—16
Poor idling
Malfunction of fuel system Refer to Section 4D
Poor idling
Malfunction of Comprex supercharger Refer to Section 4D
Excessive oil consumption
Oil working up Worn piston ring groove or sticking piston ring Worn piston or cylinder
Replace Replace or repair
1C-57 1C—55,56
Excessive oil consumption
Oil working down Worn valve seal Worn valve stem or guide
Replace Replace
1C-24 1C-48
Excessive oil consumption
Oil leakage Refer to Section 2B
76G01C-003
1C—3

1 C TROUBLESHOOTING GUIDE
Problem Possible Cause Remedy Page
Insufficient power Insufficient compression Improper valve clearance Compression leakage from valve seat Seized valve stem Weak or broken valve spring Failed cylinder head gasket Cracked or distorted cylinder head Sticking, damaged, or worn piston ring Cracked or worn piston
Adjust
Repair
Replace Replace Replace Replace Replace Replace
1C-85 1C-50 1C-48 1C-52 1C—16 1C-47 1C-57 1C-56
Malfunction of fuel system Refer to Section 4D
Malfunction of Comprex supercharger Refer to Section 4D
Others Slipping clutch Dragging brakes Wrong size tires
Refer to Section 6 Refer to Section 11 Refer to Section 12
Abnormal
combustion
Malfunction of engine-related components
Improper valve clearance
Sticking or burned valve
Weak or broken valve spring
Carbon accumulation in combustion chamber
Adjust
Replace
Replace Eliminate carbon
1C-85
1C-48
1C-52
Malfunction of fuel system Refer to Section 4D
Malfunction of Comprex supercharger Refer to Section 4D
Engine noise Crankshaft or bearing related parts Excessive main bearing oil clearance Main bearing seized or heat-damaged Excessive crankshaft end play Excessive connecting rod bearing oil clearance Connecting rod bearing seized or heat-damaged
Replace or repair Replace
Replace or repair Replace or repair Replace
1C-64 1C-64 1C-65 1C-66 1C-66
Piston related parts Worn cylinder Worn piston or piston pin Seized piston Damaged piston ring Bent connecting rod
Replace or repair Replace
Replace Replace Replace
1C-55 1C-58 1C-56 1C-57 1C-59
Valves or timing related parts Excessive valve clearance Broken valve spring Excessive valve guide clearance Malfunction of timing belt tensioner
Adjust Replace Replace Replace
1C-85 1C-52 1C-48 1C-61
Malfunction of cooling system Refer to Section 3B
Malfunction of fuel system Refer to Section 4D
Malfunction of Comprex supercharger Refer to Section 4D
Others Malfunction of water pump bearing Improper drive-belt tension Malfunction of alternator bearing Exhaust gas leakage
Replace Adjust Replace Repair
1C-7
1C—47
76G01C-004
1C—4

1C TUNE-UP PROCEDURE
Coolant Level
Check that the coolant level is near the radiator inlet
port, and that the level in the reserve tank is between
the FULL and LOW marks.
Add coolant up if the level is low.
Warning
Never remove the radiator cap when the en-
gine is hot.
Wrap a thick cloth around cap and carefully
remove the cap.
4BG01B-010
Water Draining
1. Drain the water from the sedimenter or fuel filter.
If it is difficult to drain the water from the drain plug,
loosen the air bleeding plug.
2. Bleed the air from the sedimenter or fuel filter. (Re-
fer to Section 4D)
76G01C-005
Valve Clearance
1. Remove the cylinder head cover.
2. Set the No. 1 cylinder to compression TDC.
Note
Turn the crankshaft so that the intake and ex-
haust cam lobes face upward.
4BG01B-016
3. Measure the valve clearance of No. 1 cylinder by
using a thickness gauge.
Valve clearance (cold engine)
0.20—0.30 mm (0.008—0.012 in)
0.30—0.40 mm (0.012—0.016 in)
If necessary, adjust the valve clearance referring to
the page 1C—85.
76G01C-006
1C-6

1C ON-VEHICLE INSPECTION
ON-VEHICLE INSPECTION
If the engine exhibits low power, poor fuel economy,
or poor idle, check the following:
1. Compression
2. Fuel system (Refer to Section 4D)
COMPRESSION
1. Check that the battery is fully charged, Recharge
it if necessary.
76G01C-016
76G01C-017
2. Warm up the engine to the normal operating tem-
perature.
3. Turn it off for about 10 minutes to allow the exhaust
manifold to cool.
4. Remove all the fuel injection pipes, nozzles, wash-
ers, and corrugate washers.
5. Disconnect the fuel cut valve connector.
Caution
If this is not done, fuel will be injected from
the injection pump while cranking.
6. Connect a suitable cap to the fuel return pipe on
the injection pump.
7. Connect a compression gauge with SST to injec-
tion nozzle hole.
8. Fully depress the accelerator pedal and crank the
engine.
9. Note the maximum gauge reading.
10. Check each cylinder.
Compression pressure kPa (kg/cm2, psi)-rpm
Standard Minimum
2.943 (30, 427)—200 2.649 (27, 384)—200
76G01C-018
Possible Cause
86U01X-022
1C-10

1 C ON-VEHICLE MAINTENANCE (CYLINDER HEAD)
CYLINDER HEAD
Removal
1. Disconnect the negative battery cable.
2. Drain the engine coolant.
3. Remove in the sequence shown in the figure referring to the removal note for specially marked parts.
76G01C-031
1. Accelerator cable
2. Air cleaner
3. Brake vacuum pipe
4. Intercooler pipe and hose*
5. Drive belt cover
6. Vacuum pump drive belt
7. Fuel hose
8. Water temperature switch
connector
9. Glow plug connector
10. Water thermo switch con-
nector
11. Heat gauge unit connector
12. Boost air temperature sen-
sor connector*
13. Injection pipes
14. Upper radiator hose
15. Water hose
(thermostat—FIR)
16. Oil level gauge and stay
bolt
17. Oil pipe bolt
18. Timing belt (Refer to page
1C—11)
19. Cylinder head cover
20. Camshaft pulley
21. Rear camshaft pulley
76G01C-032
22. Injection pump pulley
23. Seal plate
24. Water hose and pipe
25. Comprex supercharger
drive belt*
26. Heat insulator*
27. Exhaust manifold stay
28. Front exhaust pipe
29. Cylinder head bolt
30. Cylinder head
31. Cylinder head gasket
32. Comprex supercharger*
33. Exhaust manifold
34. Intake manifold
Note
* marked parts are equipped only for the RF-CX.
1C-16

ON-VEHICLE MAINTENANCE (CYLINDER HEAD) 1 C
Removal note
Fuel hose
Warning
a) Cover the hose with a rag because fuel will
spray out when disconnecting.
b) Keep fire and open flame away from the fuel
area.
Plug the disconnected hoses to avoid fuel leakage.
76G01C-033
2. Hold the camshaft with a wrench (29 mm, 1.14 in)
and loosen the camshaft pulley lock bolt.
Caution
Do not damage the cylinder head edge with
the wrench.
4BG01B-044
3. Separate the camshaft pulley from the camshaft
with the SST.
Caution
Do not hit the camshaft pulley with a hammer.
Rear camshaft pulley
Remove the rear camshaft pulley in the same man-
ner used for camshaft pulley.

76G01C-044

1C—17

REMOVAL 1C
REMOVAL
1. Disconnect the negative battery cable.
2. Drain the engine oil and coolant.
3. Remove in the sequence shown in the figure referring to the removal note for specially marked parts.
76G01C-071
1. Battery and battery carrier
2. Accelerator cable
3. Air cleaner assembly
4. Radiator harness
5. Radiator hose
6. Radiator and cooling fan
7. Brake vacuum hose
8. Intercooler pipe and hose*
9. Fuel hose
10. Drive belt cover
Note
11. P/S pump
12. No.4 engine mount
13. Clutch release cylinder
14. Speedometer cable
15. Transaxle harness
16. A/C compressor
17. Engine harness
18. Heater hose
19. Front wheel
20. Engine side cover
21. Tie-rod end
22. Stabilizer control rod
23. Lower arm bushing
24. Driveshaft
25. Change rod
26. Extension bar
27. Exhaust pipe and stay
28. Engine mount
29. Engine and transaxle
30. Transaxle
marked parts are equipped only for RF-CX.
1C-31