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Subject: MAZDA R2, RF (MZR-CD), WL, WL-T-Guide to repair and maintenance.


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    MAZDA R2, RF (MZR-CD), WL, WL-T-Guide to repair and maintenance.    




    MAZDA MOTOR R2, RF (MZR-CD), WL, WL-T-user guide/instruction on repair, maintenance and operation.
    Repair manual, operation and maintenance of diesel engines for Mazda R2 (2.2 l), RF (MZR-CD) (2.0 l) and WL, WL-t (2.5 l).
    Modifications of these engines were mounted on Mazda Bongo/Kia Besta, Mazda B2200/E2200, Mazda Bongo Friendee/Ford Freda, Mazda Familia, Mazda 323/626/Capella, Mazda MPV, Mazda 6, Mazda Premacy/Mazda B2500, Ford Ranger, Mazda Proceed, Mazda Cronos, Suzuki Escudo/Suzuki Grand Vitara, Kia Sportage, Asia Rocsta.
    This publication contains detailed information on repair and adjustment mechanisms, fuel pump, engine starting systems and charging. In a separate chapter covers self-diagnostic engine management systems and the EGR (exhaust gas recirculation) equipped with an electronic FUEL PUMP. See checking the voltage on the findings of the electronic blocks. Submitted to the electrical circuit.
    The possible faults and remedies, matched the size of the main components and their allowable wear, recommended lubricants and hydraulic fluids.
    The book is designed for car owners, employees of service stations and garages.


    Content:

    3 identification
    Abbreviations and symbols 4
    General instructions for repair 4
    Maintenance and general procedures for checking and adjusting 5
    5 the maintenance intervals
    Engine oil and filter 5
    Precautions when working with oils 5
    Check the engine oil level 5
    The choice of engine oil 6
    Change engine oil and filter 6
    6 coolant
    Fuel system 9
    Checking and replacing the air filter 9 (Mazda Bongo)
    Check and replace the air filter (Suzuki Escudo) 10
    Check the battery 10
    Checking the pressure end of compression stroke 11
    Checking valve clearance in the drive of heat 11
    Belts mounted units 11
    Checking and adjusting the idling speed (R2, RF) 12
    Checking and adjusting the idling speed (WL-T) 12
    Check and adjust the system to increase the speed of idling when Conditioner (Suzuki Escudo (model 1994 g.)) 13
    Check and adjust the system to increase the speed of idling (WL-T (model 1995 g.)) 13
    Checking smoke 13
    RF engines, R2-mechanical part 14
    Seat and frame the parking brake (Kia Besta) 14
    Removal and installation of 14
    Parking brake cable 14
    Check and adjust thermal gaps in valves drive 14
    Adjust thermal gaps in valves drive {Mazda Capella), 15.
    The timing belt 15
    Removal and installation of 15
    Check timing belt 17
    Belts mounted units 19
    19 withdrawal
    Installing drive belts mounted units 19
    Cylinder head 19
    19 withdrawal
    Check the bypass valve oil line (Suzuki Escudo) 22
    22 installation
    The cylinder block 24
    Disassembly and Assembly of 24
    24 front crankshaft oil seal
    Removal and installation 24
    Rear crankshaft oil seal 25
    Removal and installation of 25
    Power unit 26
    Removal and installation (except Suzuki Escudo) 26
    Removing and installing (Suzuki Escudo) 29
    Stand assembly-disassembly of engine 31
    Assembly and disassembly of the power unit (Mazda) 31
    Motors, WL, WL-T-mechanical part 33
    Check and adjust thermal gaps in valves drive 33
    The timing belt 33
    The head of the cylinder block 34
    The cylinder block 36
    39 the front crankshaft oil seal
    39 rear crankshaft oil seal
    Power unit 39
    Removal and installation 39
    Assembly and disassembly of the power unit 40
    The engine-general repair procedures 43
    The head of the cylinder block 43
    The cylinder block 51
    Cooling system 60
    Checking and replacing the coolant level 60
    Radiator Cap (RF Engine) 60
    Radiator 60
    Thermostat, 60
    Coolant pump 62
    Fan cooling system (Kia Spoilage, Suzuki Escudo (model year 1994)) 63
    Motor cooling fan 65
    Cooling fan relay 65
    Lubrication system 66
    Precautions when working with oils 66
    Oil pump 66
    Oil cooler and oil filter housing 67
    Oil injection nozzles (Kia Spoilage) 68
    Oil pan 69
    Fuel injection system 72
    Precautions when working with fuel system 72
    Before carrying out repairs, 72
    72 after repairs
    Fuel filter 72
    Replacement of 72
    Remove the water from the fuel system of 72
    Check sensor availability of water 72
    Fuel heater (model for cold climate regions. 72
    Validation (Mazda Capella (model 1997 g.)) 72
    Validation (Mazda Bongo (model 1999) 72
    Checking the fuel heater relay 73
    The angle of injection of fuel (Kia, Suzuki Escudo Spoilage) 73
    Check and adjust 73
    The angle of injection of fuel (Mazda Familia, 323) 74
    Check and adjust 74
    The angle of injection of fuel (Mazda Bongo (models from 1995 g.)) 74
    High pressure pump (Kia Spoilage (1994 model), the Suzuki Escudo) 75
    Removing and replacing the 75
    Test 76
    High pressure pump (Mazda Capella (model 1997 g.)) 77
    Removal and installation of 77
    Solenoid diverter valve 77
    Fuel temperature sensor 77
    Solenoid valve fuel cut-off 77
    Solenoid valve angle of injection of fuel 77
    Sensor shaft speed fuel pump 77
    High pressure pump (Mazda Familia, 323) 78
    Removal and installation of 78
    Location of connectors 78
    The valve position sensor angle of injection of 78
    Regulator 78
    Solenoid fuel control 78
    Solenoid valve fuel cut-off 78
    Fuel temperature sensor 79
    Solenoid valve angle of injection of fuel 79
    An adjustment resistor 80
    Sensor shaft speed fuel pump 80
    ROM check FUEL PUMP 80
    High pressure pump (Mazda Bongo) 80
    Removal and installation of 80
    Check (model 1999) 80
    The valve position sensor angle of injection (model 1999) 80
    Electronic regulator (model 1999) 80
    The valve position sensor fuel control (model 1999) 81
    Fuel temperature sensor (model 1999) 81
    Solenoid, fuel shut-off 81
    Solenoid valve angle of injection of fuel (model 1999) 81
    ROM check FUEL INJECTION PUMP (model 1999) 81
    High pressure pump (Suzuki Escudo) 82
    The valve position sensor angle of injection 82
    Additional resistance valve position sensor angle of injection of fuel 82
    Fuel temperature sensor 82
    Solenoid valve fuel cut-off 82
    Solenoid valve angle of injection of fuel 83
    Sensor shaft speed fuel pump 83
    Injector 83
    Crankshaft position sensor 85
    Intake air temperature sensor 86
    Coolant temperature sensor, air temperature sensor in the engine compartment space (Mazda Bongo) 86
    Coolant temperature sensor (Suzuki Escudo) 87
    Throttle (Mazda Familia) 87
    Throttle position sensor (Suzuki Escudo (model 1996 g.)) 87
    Accelerator pedal 87
    Removal and installation of 87
    Disassembly and reassembly (Mazda Bongo (model 1999)} 88
    Tilt limiter full pushing pedal (Mazda 323, Familia, Capella, Mazda Bongo (model 1999)) 88
    Removing and replacing the accelerator pedal position sensor (Mazda 323, Familia, Capella) 88
    Adjust the accelerator pedal position sensor (Mazda 323, Familia, Capella, Bongo (model 1999)) 88
    Check and adjust the throttle cable (Kia Sportage, Mazda Bongo) 89
    Accelerator pedal position sensor (Mazda Bongo (models from 1995 g.)) 89
    Accelerator pedal position sensor (Suzuki Escudo) 89
    Additional resistance of the accelerator pedal position sensor (Suzuki Escudo) 89
    Idling speed switch 89
    The main relay (323, Mazda Bongo (model 1995). Capella (1997), the Familia) 91
    Relay solenoid valve angle of injection (Mazda Capella (model 1997 g.)) 93
    Fuel cutoff valve relay (Mazda Capella (model 1997 g.)) 93
    Clutch pedal switch on 94
    Switch ban starting 94
    Drive systems increase the idle speed (F1CD) (Suzuki Escudo (model 1994 g.)) 95
    Switch speed warmup (Mazda Bongo) 96
    Fuel tank capacity: 96
    Control unit 98
    The system of diagnosing 98
    98 description
    The procedure conducted before the 98 Diagnostics
    The output of diagnostic codes 98 voltmeter
    Deleting diagnostic code 99
    The output of diagnostic codes with a scanner 99
    The output of diagnostic codes using the indicator GLOW " " (Suzuki Escudo) 99
    Remove Adaptive data (Mazda Familia, 323) 99
    Learning procedure of the control unit (Mazda Familia, 323) 100
    Diagnostic trouble codes management system 100
    Conclusions the electronic control unit 118
    Exhaust gas recirculation 147
    Exhaust gas recirculation 147
    Fuel vapor recovery system 150
    The air intake system and exhaust 151
    The air intake system of 151
    Turbocharger (Mazda Bongo) 152
    Exhaust system 155
    Starting system 158
    Starter 158
    Assist starting system 160
    Glow plug 161
    The charging system 163
    Precautions 163
    Check car 163
    163 generator
    Electrical circuit 168
    [collapse]





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