Brake MAZDA 626 1987 Workshop Manual

LOCATION OF UNIT, RELAY AND SWITCH 1 5
LOCATION OF
UNIT,
RELAY AND SWITCH
STRUCTURAL VIEW
Door SW
Power window SW
AAS control unit
Cruise control unit
Relay box
(EGI and Diesel model)
Engine control unit
Brake fluid level sensor
Main fuse block
(EGI model)
Main fuse block
(Carburetor model) | \ Relay box
Main fuse block Relay box
(Diesel model) (Carburetor model)
Power window SW
Door SW
Door lock SW
AAS control SW
CPU and joint box
86U15X-002
15-7

1 5 WARNING LIGHT AND SENDER
TROUBLESHOOTING
Note
Check the "Meter 10 or 15A" fuse in the fuse box before troubleshooting. If normal, refer
to the following troubleshooting chart.
Brake System Warning Light
76G15X-033
76G15X034
15-32

WARNING AND SENDER 15
Coolant Level Warning Light
OK

Repair harness (Meter
to
coolant level sensor).

76G15X093
INSPECTION
Brake Fluid Level Sensor
1. Check for continuity of the sensor with an
ohmmeter.

Float level Continuity
Below
min
Yes
Above
min
No

2. If continuity is not as specified, replace the sensor.
86U15X-065
86U14X-066
Parking Brake Switch
1. Check for continuity between (R) terminal and a
body ground with an ohmmeter.

Lever Continuity
Pulled one notch Yes
Released No

2. If continuity is not as specified, adjust the switch
or replace the switch.
15—39

1 5 STOP LIGHT
Both side stop lights do not illuminate when brake on.

Check the voltage
at A
(GW) terminal
of
stop light switch connector.
NG

Terminal Voltage
A (GW) 12V
Repair harness. (Fuse box
to
stop light switch)

OK

Check the stop light switch. Refer
to
page 15—51
NG
Replace the switch.

OK

Check the voltage between each terminal
of
the stop and tail light checker connector and
a
body ground when brake
on.

Terminal Voltage
B(B) OV
C (WG) 12V
NG Repair the wiring harness. (Stop light switch
to
stop and tail light checker, stop and tail light checker
to
body ground)

OK
OK

Repair the wiring harness. (Stop and tail light checker to bulb, bulb
to
body ground)

76G15X-049
Light Checker
1. Check for continuity between terminals of the stop
and tail light checker.
Stop and tail light checker (except West
Germany)
3 c £
r -r •
I i f 1 3
76G15X050

Terminal Continuity Terminal Continuity Terminal Continuity
i + i -
Continuity
+
1
-
Continuity
i + i -
Continuity
a-b
O
c-d
X
f-a
X

a-c
O
c-f
o
f-h
0

a-d
X c-g X g-a o

a-f
o
c-h
o
g-b
o

a-a
X
d-a
o a-c o

a-h
o
d-b
o
g-d
X

b-a
o
d-c
0
a-f
o

b-c
o
d-f
o
g-h
o

b-d
X
d-g
X
h-a
o

b-f
o
d-h
o
h-b
o

b-g
X
f-a
0
h-c
o

b-h
o
f-b
o
h-d
X

c-a
0
f-c
o
h-f
o

c-b
o
f-d
X
h-a
X

O: Indicates continuity
X: No
continuity

15-50

1 5 CRUISE CONTROL SYSTEM
ON-VEHICLE INSPECTION (USING ACC CHECKER 49 9200 010)
76G15X-072
Note:
When checking the actuator on '88 models with EC-AT using this checker, the checker
should be modified as shown below in order to avoid damage of the EC-AT control unit.
Modification Procedure
1. Cut the wire at terminal no.6 indicated on ACC
checker connector.
2. Tape exposed end of wire cut in step 1 as shown.
This modification does not affect the usage of the ACC
checker except when used on the '81 RX-7 and 626
models. When the modified ACC checker is used on
these models, use a jumper wire and jump across
terminal no.6 to 3 indicated on ACC checker connec-
tor as shown.
Function of the ACC CHECKER
A. Check lights
Each item is verified by a check light, as described below.
Check light Check items
MAIN SW.
Ignition switch, fuse, main switch and associated wiring harness terminals and con-
nectors.

ACTUATOR—VAC
VAC coil continuity
in
the actuator and associated harness.

ACTUATOR—VENT 2
VENT
2
coil continuity
in
the actuator and associated harness.

ACTUATOR—VENT 1
VENT
1
coil continuity
in
the actuator and associated harness.

CLUTCH/BRAKE SW.
Clutch switch (M/T vehicles only), brake switch and associated harness

COMBINATION/INH. SW.
"SET", "COAST" and "RESUME" positions
in
the combination switch, inhibitor
switch (A/T vehicles only), and associated harness.

GENERATOR
Speed sensor output and associated harness.

76U15X-193
15-84

1
5
CRUISE CONTROL SYSTEM
Checking
the
System
Check table O:
Represents: Light ON
X: Represents: Light OFF

CHECK LIGHTS (correct response)
ACTUATOR 5
CHECK ITEMS AND CONDITIONS

MAIN
SW

VAC
i
VENT2 VANT1
i
'
CLUTCH/BRAKE
SW

CONBINATION/INH

S

'
GENERATOR

TROUBLESHOOTING (INCORRECT RESPONSE)

1. MAIN SW. CONTINUITY:
• Ignition switch
ON
• Main switch
ON O O O o
X
A/T
O
M/T X

O
or X
ALL LIGHTS OFF: Check ignition switch, main switch, fuse, and associated harness termi-nals and connectors
2. INHIBITOR SW. CONTINUITY:
• Ignition and main switch ON. • Shift lever
to "D"
(A/T)
• Depress brake pedal

o o o o
X X
0
or X
COMBINATION/INH. SW. LIGHT ON:
Check inhibitor switch and associated
harness.
3. BRAKE SW. CONTINUITY: • Ignition and main switch
ON

• Shift lever
to
"D"
(A/T)
• Depress brake pedal

o o o o 0
X
o
or X
CLUTCH/BRAKE SW.LIGHT OFF:
Check brake switch and associated
harness.
4. CLUTCH SW. CONTINUITY:
• Ignition switch
ON
• Main switch
ON
• Depress clutch pedal

o o o 0 o
X
O
or X
CLUTCH/BRAKE SW. LIGHT OFF: Check clutch switch and associated harness.
5. "SET" POSITION
OF
COMBINA-TION SWITCH:
• Ignition switch
ON

• Main switch
ON
• Shift lever
to "D"
(A/T) • Push
to
"SET" position
of
com-bination switch

o o o o
X
o
O
or X
COMBINATION/INH.
SW.
LIGHT OFF: Check "SET" position of combination switch and associated harness.
6. "COAST" POSITION
OF
COMBI-NATION SWITCH • Ignition switch
ON

• Main switch
ON
• Shift lever
to "D"
(A/T) • Turn
to
"COAST" position
of
combination switch

o o o o
X
o
O
or X
COMBINATION/INH.
SW.
LIGHT OFF: Check "COAST" position in combina-tion switch and associated harness.
7. "RESUME" POSITION OF COMBI-NATION SWITCH
• Ignition switch
ON
• Main switch
ON
• Shift lever
to "D"
(A/T)
• Turn
to
"RESUME" position
of
combination switch

o o o o
X
o O
or X
COMBINATION/INH.
SW.
LIGHT OFF: Check "RESUME" position of combi-nation switch and associated harness.

76U15X-198
15—86

CRUISE CONTROL SYSTEM 1 5
CHECK LIGHTS (correct response)
ACTUATOR £
5 (O
W X
CHECK ITEMS AND CONDITIONS £ <0 z
VAC
CM I-1-z
Ul * < IE ffl X o V-
z o F < z ta
DC O 1-< DC Ui
TROUBLESHOOTING
(INCORRECT RESPONSE)
< S VAC UJ > < > -1 o o o UJ O
8. START THE ENGINE
• Shift lever to "N" position (A/T) O O O o X
A/T
O M/T X
O or X —
9. ACTUATOR OPERATION: (EGI model only) • After engine is started, set the slide switch "L" or "H". Then turn on check switch (keep in "D" position) Note: Engine speed should in-crease to 2,000—3,000 rpm. If over 4,000 rpm release the switch immediately.
o
X
1
o
X X X
A/T O M/T X
O or X
If engine speed does not come up to and remain
in
the
2,000
to
3,000
rpm. range, check the actuator and as-sociated harness.
10. SPEED SENSOR OUTPUT
Keeping idling condition, drive ve-
hicle slowly. o o 0 o X X 0 1 X
If GENERATOR LIGHT does not flash, trouble may be with speed sensor and associated harness.
76U15X-199
INSPECTION
Actuator
Measure the actuator solenoid resistance by using
an ohmmeter.
Check terminals Resistance
c-d
Approx. 25 to 35 ohms c — a Approx. 25 to 35 ohms
c — b
Approx. 25 to 35 ohms
76G15X-075
Cruise Control Unit
If there is an operation malfunction of the cruise con-
trol system, and no abnormal condition when check-
ing above, replace the cruise control unit and check
system operation.
Clutch Switch, Brake Switch
When removing these switches, turn each of them
so that the corresponding pedal height agrees with
the standard value.
76G15X-076
Brake pedal height: 222 ±1 mm (8.74 1820
Clutch pedal height:
216.5 ±8 mm (8.52 ±820 In)
in)
15-87

TECHNICAL DATA 30
7B. AUTOMATIC TRANSAXLE (ELECTRONICALLY CONTROLLED AND 4-SPEED)
————Model
Item -————
G4A-EL
(EC-AT)
G4A-HL (4-Speed) ————Model
Item -————
G4A-EL
(EC-AT) FE engine F8 engine

Gear ratio
1st 2.800
Gear ratio
2nd 1.540
Gear ratio 3rd 1.000 Gear ratio
4th (OD) 0.700
Gear ratio
Reverse 2.333
Oil capacity liters (US qt, Imp
qt)
6.2 (6.6, 5.4)
Fluid type ATF Dexron
II or M III

Fluid level with the engine idling
in P
Between
F
and
L
marks
on
gauge

Stall speed

After brake-in D,
S, L rpm
2170-2270 2430-2530 2180—2280 After brake-in R
rpm
2130—2230 2390—2490 2140—2240

Time lag

N
D sec
0.5-1.0 0.4-1.2
N
R sec
0.5-1.0 0.4—1.5

Line pressure

D,
S, L

Idle kPa (kg/cm2,
psi)
353-432 (3.6-4.4, 51—63) 350-490 (3.6-5.0, 51-71)
D,
S, L

Stall kPa (kg/cm2,
psi)
873-1,040 (8.4-10.6, 127-151) 980-1230 (10.0-12.5, 142-178)
R
Idle kPa (kg/cm2,
psi)
598-942 (6.1-9.6, 87-137) 600-830 (6.1-8.5, 87—121)
R
Stall kPa (kg/cm2,
psi)
1,668-2,011 (17.0-20.5, 242-292) 1470-1960 (15.0-20.0, 213-284)

Throttle pressure

D
Idle kPa (kg/cm2,
psi)
39-88 (0.4-0.9, 6-13) 83-113 (0.85-1.15, 12-16)
D
Stall kPa (kg/cm2,
psi)
471—589 (4.8-6.0, 68-85) 540-610 (5.5-6.2, 78—88)

Governor pressure

D
30 km/h (19 mph)
kPa (kg/cm2,
psi) —
79-114
(0.81-1.16, 12-16)
82-117
(0.84-1.19, 12-17)
D 55 km/h (34 mph) kPa (kg/cm2, psi)
—
146-190 (1.49-1.94, 21-28) 157-201 (1.60-2.05, 23-29) D
85 km/h (53 mph) kPa (kg/cm2,
psi) —
276-339 (2.81-3.46, 40-49)
302-366 (3.08-3.73, 44-53)

30-27

30 TECHNICAL DATA
Model G4A-EL G4A-HL (4-speed)
Item (EC-AT) FE engine F8 engine
Forward clutch

Number
of
drive/driven plate 3/3
Drive plate thickness mm (in) Standard 1.6 (0.063) Drive plate thickness mm (in) Minimum 1.4 (0.055)
Forward clutch clearance mm (in) 1.0—1.2 (0.040—0.047)
Retaining plate sizes mm (in) 5.9 (0.232), 6.1 (0.240), 6.3 (0.248),
6.5 (0.256), 6.7 (0.264),
8.9
(0.350)

Coasting clutch

Number
of
drive/driven plates 2/2
Drive plate thickness mm (in) Standard 1.6 (0.063) Drive plate thickness mm (in) Minimum 1.4 (0.055)
Coasting clutch clearance mm (in) 1.0-1.2 (0.040—0.047)
Retaining plate sizes mm (in) 4.6 (0.181), 4.8 (0.189), 5.0 (0.197),
5.2 (0.205), 5.4 (0.213), 5.6 (0.220)
Return spring free length mm (in) 29.8 (1.173)

Reverse clutch

Number
of
drive/driven plates 2/2
Driven plate thickness mm (in) Standard 1.6 (0.063) Driven plate thickness mm (in) Minimum 1.4 (0.055)
Reverse clutch clearance mm (in) 2.1—2.4 (0.083—0.094)
Retaining plate sizes mm (in) 6.6 (0.260),
6.8
(0.268), 7.0 (0.276), 7.2 (0.283), 7.4 (0.291), 7.6 (0.299)

3-4 clutch

Number
of
drive/driven plates 5/5 4/4
Drive plate thickness mm (in) Standard 1.6 (0.063) Drive plate thickness mm (in) Minimum 1.4 (0.055)
3-4 clutch clearance mm (in) 1.3-1.5 (0.051-0.059)
Retaining plate sizes mm (in) 3.8 (0.150), 4.0 (0.157), 4.2 (0.165), 4.4 (0.173), 4.6 (0.181), 4.8 (0.189)
4.8 (0.819), 5.0 (0.197), 5.2 (0.205), 5.4 (0.213), 5.6 (0.220)
Return spring free length mm fin) 33.2 (1.307)

Low and reverse brake

Number
of
drive/driven Dlates 3/3 4/4
Drive plate thickness mm (in) Standard 1.6 (0.063) Drive plate thickness mm (in) Minimum 1.4 (0.055)
Low and reverse brake clearance mm (in) 2.1-2.4 (0.083-0.094)
Retaining plate sizes mm (in) 6.8 (0,268), 7.0 (0.276), 7.2 (0.283), 7.4 (0.291), 7.6 (0.299), 7.8 (0.307)
10.0 (0.394), 10.2 (0.402), 10.4 (0.410),
10.6 (0.417), 10.8 (0.425)
Return spring free length mm (in) 20.5 (0.807)
Sun gear drum bushing mm (in) Maximum 33.425 (1.316)
Small sun gear bushing mm (in) Maximum 24.021 (0.946)

Carrier hub

Clearance between pinion washer and planet carrier
mm (in)
Maximum 0.2-0.7 (0.008-0.028)

Servo

Free length
of
return spring mm (in) Standard 43.25 (1.703) 42.0 (1.654) 43.25 (1.703)

2-3 accumulator valve

2-3 accumulator valve spring mm (in) Standard 83.3
mm
(3.280) 76.0 (2.992)

30—30

TECHNICAL DATA 30
7C. AUTOMATIC TRANSAXLE (3-SPEED)
Engine model Item FE engine F6 engine

Model F3A
Gear ratio
1st 2.841
Gear ratio 2nd 1.541 Gear ratio 3rd 1.000 Gear ratio
Reverse 2.400
Oil capacity Liters (US qt, Imp
qt)
6.2 (6.6, 5.5)
Fluid type ATF Dexron-ll
or
M-lll
Fluid level with the engine idling
at P
Between
F
and
L
marks
on
gauge

Stall revolution

After brake
in rpm
2050-2150 1800—2050

Line pressure

D,
1
Idle kPa (kg/cm2,
psi)
294-392 (3-4, 43-57) D,
1
Stall kPa (kg/cm2,
psi)
883—1079 (9-11, 128-156)
2 Idle kPa (kg/cm2,
psi)
785-1177 (8—12, 114-171) 2 Stall kPa (kg/cm2,
psi)
785-1177 (8-12, 114—171)
R Idle kPa (kg/cm2,
psi)
392-687 (4-7, 57-100) R Stall kPa (kg/cm2,
psi)
1570-1864 (16-19, 228—270)

Governor pressure

D
30 km/h (19 mph) kPa (kg/cm2,
psi)
78-137 (0.8-1.4, 11-20)
D 50 km/h (31 mph) kPa (kg/cm2, psi) 157-226 (1.6-2.3, 23-33) D
85 km/h
(53
mph) kPa (kg/cm2,
psi)
314-402 (3.2—4.1, 46—58)

Line pressure cut back

Vacuum
of
vacuum pump Governor pressure kPa (kg/cm2,
psi)

0 mmHg
(0
inHg) 98-157 (1.0—1.6, 14—23)
200 mmHg (7.87 inHg) 39-98 (0.4 -1.0, 6-14)

Shift point

Range Throttle condition (manifold vacuum) Shifting Shift point speed km/h (mph)
D
Fully opened 0—100 mmHg (0-3.94 inHg)
1st
- 2nd
47-57 (29-35) 44—54 (27—33)
D
Fully opened 0—100 mmHg (0-3.94 inHg)
2nd
- 3rd
106—119 (66-74) 95—108 (59—67)
D
Fully opened 0—100 mmHg (0-3.94 inHg) 3rd
2nd
95-103 (59-64) 86—94 (53-58)
D
Fully opened 0—100 mmHg (0-3.94 inHg) 2nd -<•
1st
35-39 (22-24) 34-38 (21—24) D
Half throttle 130 mmHg (5.12 inHg)
1st
- 2nd
18-31 (11-19) 18-31 (11-19)
D
Half throttle 130 mmHg (5.12 inHg) 2nd
- 3rd
39-68 (24—42) 44-73 (27—45)
D
Fullv closed 2nd
- 1st
10-15 (6-9) 10—15 (6—9)
1 Fully closed 2nd -»•
1st
32—39 (20—24) 33—40 (20—25)

Torque converter

Stall torque ratio 1.800-2.100
: 1

Bushing inner diameter mm (in) Standard 33.000—33.025 (1.299—1.300) Bushing inner diameter mm (in) Maximum 33.075 (1.302)

Oil pump

Clearance
Gear and pump cover
mm
(in) Standard 0.02—0.04 (0.0008—0.0016) Gear and pump cover
mm
(in) Maximum 0.08 (0.0031)
Outer gear and crescent
mm
(in) Standard 0.14-0.21 (0.0055-0.0083) Outer gear and crescent
mm
(in) Maximum 0.25 (0.0098)
Outer gear and housing
mm
(in) Standard 0.05-0.20 (0.002-0.0079) Outer gear and housing
mm
(in) Maximum 0.25 (0.0098)
Oil seal ring and ring groove
mm
(in) Standard 0.04-0.16 (0.0016-0.0063) Oil seal ring and ring groove
mm
(in) Maximum 0.40 (0.0157)
Pump housing sleeve diameter
mm
(in) Standard 37.950-37.975 (1.494-1.495) Pump housing sleeve diameter
mm
(in) Maximum 37.900 (1.492)
Inner gear bushing inner diameter mm (in)
Standard 38.0-38.025 (1.496—1.497) Inner gear bushing inner diameter mm (in) Maximum 38.075 (1.499)

30—33