1987 MAZDA 626 Workshop Manual

4D FUEL SYSTEM
Removal and Installation
1. Remove in the sequence shown in the figure, referring to the removal note for specially marked parts.
2. Install in the reverse order of removal.

59—69 N-m
(6.0—7.0 m-kg, 43-51 ft-lb)
19—26
N m
(1.9—2.6
m-kg,
14—19 ft-lb) 25—29
N-m .5—3.0 m-kg, 18—22
ft-lb)

19—26 N-m
(1.9—2.6
m-kg,
14—19 ft-lb)
76G04D-063
1. Accelerator cable
2. Injection pipe
3. Fuel hose
4. Water hose
5. Fuel cut solenoid valve con-
nector
6. Pick-up coil connector
7. Boost air hose (RF-CX)
8. Injection pump pulley lock
nut
9. Injection pump
Removal note
Injection pipe
Warning
a) Catch leaking fuel with a rag when remov-
ing the injection pipes.
b) Keep fire and open flame away from the fuel
area.
Remove the injection pipes.
76G04D-064
4D—26

FUEL SYSTEM 4D
76G04D-065
76G04D-066
Injection pump pulley
1. Put two 35—40 mm (1.3—1.6 in) long bolts through
the injection pump pulley and affix them in the
threaded holes of the injection pump bracket.
2. Loosen the injection pump pulley bolt.
3. Separate the injection pump pulley from the injec-
tion pump shaft with the SST.
Steps after installation
1. After installation adjust the injection timing. (Refer
to page 4D—24.)
2. Bleed air from the fuel line.
3. Check for fuel leakage.
76G04D-067
4D—27

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

VE-TYPE RF71 13 800C: 104749-0343 For RF-CX
# TEST OIL SAE Standard test oil (SEA 967C)
Fuel injection amount Chamber pressure and timer stroke Load sensing timer and overflowing quantity Measurenment
Item Pump speed (RPM) Fuel injection amount
(cm3/stroke)
Start 100 More than 55/1,000
Full load
600 33.9—38.9/1,000
Full load
1,000 48 9—50.9/1,000
Full load 2,150 39.7—44 7/1,000 Full load
2,250 32.7-37.7/1,000
Full load
2,550 8.0—15.0/1,000
Idling 360 7.6—10.6/1,000
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30
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Pump speed (RPM) Chamber pressure
(kg/cm2)
Timer stroke (mm)
500 500
1,250 4.5—5.1 2.7—3.9
1,500 5.2—5.8 4 3-4.9
2,150 6.8—7 4 7.6-8.8
Item Fuel injectioon amount
(cm3/stroke)
Load sens-ing timer
Start 37.2-39.2/1,000 Load sens-ing timer End 32.2-34.2/1.000
Overflowing quantity 41.0—85.0/1.000
"Checking condition
Pump speed: 1,500 rpm
Lever: Full load
Measuring place Dimension (mm)
KF 5.7—5.9
K 3.2—3.4
MS 1.6-1.8

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100 600 1,000 1,250 1,500
Injection pump speed RPM
10
2,150 2,250 2,550
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VE-TYPE RF79 13 800A: 104748-0343 For RF-N ENGINE
£ TEST OIL SAE Standard test oil (SEA 967C)
Fuel injection amount Chamber pressure and timer stroke Load sensing timer and overflowing quantity Measurenment
Item Pump speed (RPM)
Fuel injection amount
(cm3/stroke)
Start 100 More than 42/1,000
Full load
600 29.0—33.0/1,000
Full load
1.375 34.9—36.9/1,000
Full load 2,325 30 2—34.2/1,000 Full load
2,600 9.8—15 8/1,000
Full load
2,700 Max. 6 0/1,000
Idling 360 8-12/1,000
Pump speed (RPM) Chamber pressure
(kg/cm2)
Timer stroke
(mm)
600 2 2—2.8
1,375 4 4—5,0 3 9—4.5
1,800 5 6—6.2 6.1-7.3
2.325 6.9—7.5 7.2—8.4
Item Fuel injectioon amount
(cm3/stroke)
Load sens- Start 26.7-29.7/1,000
ing timer End 14.6—17.6/1,000
Overflowing quantity 46.3—90.3/1.000
'Checking condition
Pump speed: 1,375 rpm
Lever: Full load
Measuring place Dimension (mm)
KF 5.8—5.9
K 3.2—3 4
MS 1.4—1.6
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50
40
30
20
10
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100 600
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1,375 1,800
Injection pump speed RPM
2,325 2,600 2,700
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FUEL SYSTEM 4D
INJECTION NOZZLE
Removal
Remove in the sequence shown in the figure, referring to the removal note for the specially marked parts.
Removal note
Injection pipe
Warning
a) Catch leaking fuel leakage with a rag when
removing the injection pipes.
b) Keep fire and open flame away from the fuel
area.
Remove the injection pipes.
1. Injection pipe bracket
2. Injection pipe
3. Fuel leak pipe
4. Fuel injection nozzle
76G04D-072
4D—31

4D FUEL SYSTEM
Inspection
Injection starting pressure
1. Set the nozzle on the nozzle tester.
2. Bleed the air by pumping the nozzle tester handle
several times.
3. Slowly lower the nozzle tester handle and check
the pressure when injection starts.
Injection starting pressure:
13,200 kPa (135 kg/cm2, 1,920 lb/in2) at
20°C (36°F) of fuel temperature
76G04D-073
Adjusting shim
4. If the injection starting pressure is higher than
specification, increase the shim thickness. If the in-
jection starting pressure is lower than specification,
decrease the shim thickness.
Note
Adjusting shims are availabe in 0.05 mm
(0.0197 in) thicknesses, from 1.0 mm (0.039
in) to 1.95 mm (0.077 in). When 0.05 mm
(0.0197 in) is added, injection pressure in-
creases approx. 490 kPa (5.0 kg/cm2, 70 psi).
76G04D-074
Nozzle leakage
1. Apply 11,300 kPa (115 kg/cm2,1.640 psi) pres-
sure to the injection nozzle, and check for fuel leaks
from the injection hole.
2. If fuel leaks, overhaul or replace the' injection
nozzle.
76G04D-075
Atomization (spray pattern)
1. Set the injection nozzle on the nozzle tester.
2. Bleed the air by operating the nozzle tester han-
dle several times.
3. Lower the handle several times as quickly as pos-
sible so that a pulsating whistling sound is heard,
and check the atomization.
(1) Uniform and proper atomization
(2) Incorrect injection angle and direction
4. If necessary, overhaul or replace the injection
nozzle.
76G04D-076
4D—32

FUEL SYSTEM 4D
76G04D-077
76G04D-078
^^^
76G04D-079
Red paint
Injection Nozzle Disassembly
Disassemble the injection nozzle.
1. Nozzle holder
2. Adjusting shim
3. Pressure spring
4. Pressure pin
5. Distance piece
6. Nozzle
7. Retaining ring
Cleaning
Clean the parts in clean test oil.
Injection Nozzle Inspection
1. Check the needle valve, nozzle body, and other
parts for damage.
2. Hold the nozzle body upright and insert approxi-
mately two thirds of the needle valve, and check
that the needle valve drops to the valve seat by
its own weight.
Injection Nozzle Assembly
1. Assemble the injection nozzle.
Tightening torque of nozzle body:
29—49 N-m (3.0—5.0 m-kg, 22—36 ft-lb)
2. Check the injection starting pressure, and atomi-
zation. (Refer to page 4D—32.)
Injection Nozzle Installation
1. Install in the reverse order of removal, referring to
the installation note.
2. Check for fuel leakage.
Installation note
Nozzle gasket
Install a new gasket with the red face toward the
nozzle.
76G04D-080
4D-33