1987 MAZDA 626 air filter

4D
FUEL AND EMISSION
CONTROL SYSTEM
(DIESEL)
OUTLINE 4D— 2
SPECIFICATIONS 4D— 2
TROUBLESHOOTING GUIDE 4D— 3
ON-VEHICLE MAINTENANCE 4D— 4
AIR CLEANER ELEMENT 4D— 4
WATER DRAINING 4D— 4
AIR BLEEDING 4D— 4
INJECTION TIMING 4D— 5
IDLE SPEED 4D— 6
EXHAUST SMOKE 4D— 6
INTAKE AIR SYSTEM 4D— 7
STRUCTURAL VIEW 4D— 7
AIR DUCT AND AIR CLEANER 4D— 8
INTAKE MANIFOLD 4D— 9
SUPERCHARGING SYSTEM (RF-CX) 4D-10
TROUBLESHOOTING GUIDE 4D—10
ON-VEHICLE INSPECTION 4D—11
COMPREX SUPERCHARGER 4D—13
STARTING VALVE 4D—15
INTERCOOLER 4D—16
BOOST AIR TEMPERATURE SENSOR 4D—17
EXHAUST SYSTEM 4D—18
STRUCTURAL VIEW 4D—18
EXHAUST MANIFOLD 4D—19
EXHAUST PIPE AND MAIN SILENCER .... 4D—20
FUEL SYSTEM 4D—21
STRUCTURAL VIEW 4D—21
FUEL FILTER 4D—22
SEDIMENTER (GENERAL) 4D—22
WATER LEVEL SENSOR 4D—23
INJECTION PUMP 4D—24
INJECTION NOZZLE 4D—31
FUEL TANK 4D—34
76G04D-001

4D OUTLINE
OUTLINE
The Mazda 626 offers two diesel engines; a Comprex supercharged RF-CX engine, and a normally
aspirated RF-N engine.
SPECIFICATIONS
—Engine model
Item ———
ECE UK, GENERAL —Engine model
Item ——— RF-CX RF-N
Fuel tank Capacity liters (US gal, Imp gal) 60 (15.9, 13.2)
Fuel filter Type Cartridge, paper element
Sedimenter Type With detector
Injection pump
Type Bosch VE distributor
Injection pump
Manufacturer Diesel Kiki Co,, Ltd.
Injection pump
Direction of rotation Clockwise Injection pump
Drive method Timing belt
Injection pump
Plunger diameter mm (in) 9.0 (0.35) 8.0 (0.31)
Injection pump
Cam lift mm (in) 2.2 (0.087)
Injection nozzle Type Throttle Injection nozzle
Injection pressure kPa (kg/cm2, psi) 13,240 (135 , 1,920)
Injection timing ATDC
1
° TDC 0°
Idle speed rpm 720 _+f0
Fast idle speed (A/C ON) rpm 700-750
Cold start device Engine speed rpm 1.100 Cold start device
Advance degree 6°
Air cleaner Type Cartridge, paper element Air cleaner Type
Wet Dry
PCV system Type Open Closed
76G04D-002
4D—2

TROUBLESHOOTING GUIDE 4D
TROUBLESHOOTING GUIDE
Condition Condition Cause Remedy
Hard starting Fuel filter
Clogged Replace
Water or air in filter Repair
Fuel injection pump Faulty fuel cut solenoid Replace Incorrect injection timing Adjust
Air in pump Bleed
Faulty pump Replace
Fuel injection nozzle Seized needle valve Replace
Fuel dripping from nozzle Replace Incorrect valve opening pressure Adjust
Faulty glow plug Replace
Faulty cold start device Adjust or replace
Faulty supercharging system Refer to page 4D—10
Rough idle Fuel filter (Refer to "Hard starting") Fuel injection pump (Refer to "Hard starting")
Fuel injection nozzle
Seized needle valve Replace
Incorrect valve opening pressure Adjust
Improper mounting to nozzle holder Repair
Leakage of nozzle holder copper washer Replace
Fuel injection pipe Cranks Replace
Leaking from joint Repair
Improper idle speed adjustment Adjust
Engine knocking Incorrect injection timing Adjust
Low quality fuel Replace
Incorrect injection nozzle opening pressure Ajust
Seized injection nozzle needle valve Replace
Fuel dripping from injection nozzle Replace
Faulty supercharging system Refer to page 4D—10
High fuel Fuel injection pump consumption Incorrect injection timing Adjust consumption High idle speed Adjust, Inspect the dashpot
Fuel injection nozzle Incorrect valve opening pressure Repair
Fuel dripping from nozzle Replace
Leakage of nozzle holder copper washer Replace
Fuel leaking from connection Repair
Clogged fuel filter Replace
Clogged air cleaner Replace
Poor acceleration Fuel injection nozzle (Refer to "Hard starting")
Fuel injection pump (Refer to "Hard starting")
Fuel injection pipe (Refer to "Rough idle") Fuel filter (Refer to "Hard starting") Clogged air cleaner Clean or replace
Faulty supercharging system Refer to page 4D—10
Excessive exhaust Clogged air cleaner Clean or replace
smoke Improper injection timig Adjust
Faulty nozzle or nozzle holder Adjust or replace
Faulty supercharging system Refer to page 4D—10
76G04D-003
4D-3

4D ON-VEHICLE MAINTENANCE
ON-VEHICLE MAINTENANCE
76G04D-004
AIR CLEANER ELEMENT
Check the air cleaner element for excessive dirt, dam-
age, or oil. Replace if necessary.
Caution
(Wet type)
Do not clean the air cleaner element with com-
pressed air, replace if necessary.
(Dry type)
When cleaning the air cleaner element, blow
dust off from the inside first, then blow off the
outside.
(General)
1. Loosen the drain plug of the sedimenter and let
the water drain. If necessary loosen the air bleed-
ing plug.
2. Bleed air from the sedimenter.
AIR BLEEDING
From Fuel Tank to Fuel Filter
1. Loosen the air bleeding plug of the fuel filter.
2. Pump the priming pump until no air bubbles flow
from the air bleeding plug hole.
3. Depress the priming pump and tighten the air
bleeding plug.
Note
Open only the air bleeding plug of the filter.
From Fuel Filter to Injection Pump
Pump the priming pump until it becomes hard to
pump.
76G04D-007
WATER DRAINING
(ECE)
1. Loosen the drain plug of the fuel filter.
2. Pump the priming pump.
3. Bleed air from the fuel filter.
4D—4

4D FUEL SYSTEM
76G04D-047
76G04D-048
76G04D-049
FUEL FILTER
On-Vehicle Inspection
Check for water in the fuel filter. If present drain the
water. (Refer to page 4D—4.)
Replacement
Removal
1. Disconnect the water level sensor connector (ECE).
2. Remove the water level sensor. (ECE).
3. Remove the fuel filter cartridge.
Warning
Keep fire and open flame away from the fuel
area.
Installation
1. Apply fuel to the O-ring of the fuel filter cartridge
and install it onto the filter body.
2. Install the water level sensor (ECE).
3. Connect the water level sensor connector (ECE).
4. Bleed air from fuel filter. (Refer to page 4D—4.)
5. Check for fuel leakage.
SEDIMENTER (GENERAL)
On-Vehicle Inspection
Check for water in the sedimenter. If present, drain
the water. (Refer to page 4D—4.)
4D—22

7C INSPECTION AND REPAIR
GOVERNOR
Disassembly
Disassemble in the sequence shown in the figure. 76G07C-1E
1. Governor body
2. Separate plate
3. Filter
4. Retainer plate
5. Return spring
6. Primary
governor
7. Retainer plate
8. Return spring
9. Secondary
governor
10. Roll pin
11. Governor driven
gear
12. Governor shaft
13. Seal ring
14. Bearing race
15. Thrust bearing
16. Sleeve
76G07C-190
Inspection
Check the following and replace any faulty parts.
1. Damaged or worn valve
2. Clogged filter
3. Weakened return spring
Outer diameter Free length
Primary spring 9.0 mm (0.354 in) 17.2 mm (0.667 in)
Secondary spring 9.25 mm (0.364 in) 13.2 mm (0.520 in)
76G07C-191
76G07C-192
7C-72
Assembly
1. Install the seal rings onto the governor shaft.
2. Apply petroleum jelly to the bearing race to secure
it; then install it onto the governor shaft.
Bearing race outer diameter:
47.0 mm (1.850 in)
3. Apply petroleum jelly to the thrust bearing to se-
cure it; then install it onto the sleeve.
Thrust bearing outer diameter:
46.9 mm (1.846 in)

7C INSPECTION AND REPAIR
8. Install the filter into the separate plate.
76G07C-198
10. Secure the governor in the vise; tighten the gover-
nor body mounting bolts to the specified torque.
Tightening torque:
8—11 N
m
(80—110 cm-kg, 69—95 in-lb)
Note
Use protective plates in the vice to prevent
damage to the governor.
76G07C-199
11. Check that when compressed air is blown through
port A, the valve functions (rattles).
Air Pressure:
491 kPa (5.0 kg/cm2, 71 psi) max.
Caution
Apply air for no more than 5 seconds.
76G07C-200
7C—74

1 1 POWER BRAKE UNIT
Removal Note
Steering Shaft
To remove the mounting nuts of the power brake unit,
the steering shaft must be removed. (Refer to page
10—22 for removal and installation procedures.)
76G11X-102
DISASSEMBLY AND ASSEMBLY
1. Disassemble in the sequence shown in the figure, referring to disassembly note for specially marked
parts.
2. Inspect each part, referring to inspection note.
3. Assemble in the reverse order of disassembly, referring to assembly note for specially marked parts.
8.8—13 N-m (90-130 cm-kg, 78—112 in-lb)
1. Dust boot
2. Rear shell assembly
3. Retainer
4. Bearing
5. Dust seal
6. Retainer
7. Air filters
8. Air silencer
9. Diaphragm and plate
10. Power piston assembly
11. Retainer key
12. Valve rod and plunger as-
sembly
13. Reaction disc
76G11X-070
14. Spring
15. Push rod
16. Front shell assembly
17. Retainer
18. Seal
19. Vacuum switch (RF, RF-CX)
11-30