wiring MAZDA 626 1987 Owners Manual

ELECTRICAL COMPONENTS OF 4-WHEEL STEERING 1 0
Warning light output pattern Malfunction Flow chart No.
ON
ncc
Stepper motor or wiring harness 4WS—6 Stepper motor or wiring harness 4WS—6
ON
r\cc
Oil leakage or oil
level switch
4WS—7 Oil leakage or oil
level switch
4WS—7
ON
OFF
Control unit 4WS—8 Control unit 4WS—8
ON
ncc
Control unit, alter-nator, or wiring harness
4WS—9
ON
ncc
Control unit, alter-nator, or wiring harness
4WS—9 Control unit, alter-nator, or wiring harness
4WS—9
86U10X-226
10—97

1 0 ELECTRICAL COMPONENTS OF 4-WHEEL STEERING
4WS-0 Normal operation or failure of con-trol unit or harness
Start engine.
Disconnect R-01 (7-pin) connector. Check that 4WS warning light flashes or illuminates.
NG
Repair harness. (Fuse box to Control unit or Control unit to Body ground).
YES No electrical problem.
NO
Reconnect connector.
Check voltage between terminals and body ground.
Terminal Voltage
G(B) OV
H(B) OV
K(G) Approx. 12V
L(G) Approx. 12V
N(B) OV
OK Replace control unit.
4WS-1 Failure of speed sensors or wiring
harness
Check speed sensor at transaxle. (Referring to page 10—103)
OK
NG Replace speed sensor.
Check for continuity between terminal of transaxle speed sensor and R (O) terminal of the control unit connector.
NG^ Repair wiring harness (Control unit to Transaxle
speed sensor).
Cont'd 76G10X-028
10—98

1 0 ELECTRICAL COMPONENTS OF 4-WHEEL STEERING
awq a Failure of stepper motor or harness
Disconnect R-01 (17-pin) connector. Check for no
continuity between each terminal of harness side
connector and body ground.
NG
Disconnect stepper motor connector. Check for no
continuity between each terminal and body ground.
Terminal Continuity
NG
Terminal Continuity
A (WB) No NG WB No
B (WL) No WL No
C (WR) No WR No
D (WY) No WY No
L(G) No G No
OK , OK | NG OK
Repair harness (Step-
per motor to Control
unit).
Replace rear steering
gear assembly.
Check for continuity between terminals of R-01
(17-pin) harness side connector.
NG
Disconnect stepper motor connector. Check for con-tinuity between terminals of motor side connector.
Terminal Continuity NG Terminals Continuity
A (WB) - L (G) Yes NG WB — G Yes
B (WL) — L (G) Yes
NG
WL — G Yes
C (WR) — L (G) Yes
NG
WR — G Yes
D (WY) — L (G) Yes
NG
WY — G Yes
NG
OK OK | NG
Replace control unit. Repair wiring harness (Stepper motor to Con-trol unit).
Replace rear steering gear assembly.
Repair wiring harness (Stepper motor to Con-trol unit).
Replace rear steering gear assembly.
4WS-5 Failure of rear to front steering ra-
tio sensor
Go to 4W5-2
76G10X-046
10-100

1 0 ELECTRICAL COMPONENTS OF 4-WHEEL STEERING
flashes
Replace control unit
4WS-9 Failure of control unit, alternator, or wiring harness
Start engine,
I
Check voltage between terminal of control unit con-nector and body ground.
Terminal Voltage
G(B) OV
H (B) OV
K(G) Approx. 12V
L (G) Approx. 12V
N(B) OV
OK
NG
Check 4WS relay and timer (Refer to page 10—103) -
OK
Check battery, harness, and alternator.
NG
Turn ignition switch OFF. Start engine. Check if 4WS warning light flashes or illuminates.
NO
Momentary problem (If warning light often flashes or illuminates, check battery and alter-nator. Replace control unit if necessary).
YES
Replace control unit.
Replace relay and timer
76G10X-031
4WS WARNING LIGHT
1. Turn the ignition switch OFF.
2. Turn the ignition switch ON, and check that the
4WS warning light illuminates.
3. If there is no illumination, check the warning light
bulb and wiring harness.
Replace the control unit if necessary.
86U10X-232
10-102

11
BRAKING SYSTEM
OUTLINE 11—2
STRUCTURAL VIEW 11—2
SPECIFICATIONS 11— 4
TROUBLESHOOTING GUIDE 11— 5
ON-VEHICLE MAINTENANCE 11—6
BRAKE FLUID LEVEL IN MASTER
CYLINDER RESERVOIR 11— 6
BRAKE HYDRAULIC LINE 11—6
STRUCTURAL VIEW 11—6
ON-VEHICLE INSPECTION OF
BRAKE LINES 11— 8
REMOVAL AND INSTALLATION OF
BRAKE LINES 11— 9
REPLACEMENT OF BRAKE
FLUID 11— 9
AIR BLEEDING 11— 9
BRAKE PEDAL 11—11
ON-VEHICLE INSPECTION 11—11
REMOVAL 11—12
INSPECTION 11—13
INSTALLATION 11—13
MASTER CYLINDER 11—14
REMOVAL 11—15
DISASSEMBLY AND ASSEMBLY
(EXCEPT RHD DOHC TURBO).... 11—14
INSPECTION 11—17
DISASSEMBLY AND ASSEMBLY
(RHD DOHC TURBO) 11—18
INSPECTION 11—21
INSTALLATION 11—22
POWER BRAKE UNIT 11—27
FUNCTION CHECK 11—27
INSPECTION OF CHECK VALVE... 11—29
REMOVAL 11—29
DISASSEMBLY AND ASSEMBLY... 11—30
INSPECTION 11—32
INSTALLATION 11—33
VACUUM PUMP 11—35
ON-VEHICLE INSPECTION 11—35
REMOVAL AND INSTALLATION.... 11—35
DISASSEMBLY AND ASSEMBLY... 11—36
INSPECTION 11—37
DUAL PROPORTIONING VALVE 11—38
FUNCTION CHECK 11—38
REMOVAL AND INSTALLATION.... 11—39
FRONT DISC BRAKE 11—40
SIMPLE INSPECTION OF DISC
PAD WEAR 11—40
REPLACEMENT OF DISC PAD 11—40
REMOVAL 11—42
DISASSEMBLY AND ASSEMBLY... 11—43
INSPECTION 11—44
INSTALLATION 11—45
REAR DISC BRAKE 11—46
SIMPLE INSPECTION OF DISC
PAD WEAR 11—46
REPLACEMENT OF DISC PAD 11—46
REMOVAL 11—49
DISASSEMBLY AND ASSEMBLY... 11—50
INSPECTION 11—54
INSTALLATION 11—55
REAR DRUM BRAKE 11—56
REMOVAL 11—56
DISASSEMBLY AND ASSEMBLY
OF WHEEL CYLINDER 11—59
INSPECTION 11—60
INSTALLATION 11—61
PARKING BRAKE 11—65
ON-VEHICLE MAINTENANCE 11—65
REMOVAL AND INSTALLATION
OF PARKING BRAKE LEVER 11—66
REMOVAL OF PARKING BRAKE
CABLE 11—68
INSTALLATION OF PARKING
BRAKE CABLE 11—69
ANTI-LOCK BRAKE SYSTEM
(ABS) 11—71
STRUCTURAL VIEW 11—71
WIRING DIAGRAM 11—72
TROUBLESHOOTING 11—73
DIAGNOSIS INDICATION MODE ... 11—86
MEMORY CANCEL 11—86
ABS WARNING LIGHT 11—87
RELAY BOX 11—87
WHEEL SPEED SENSOR 11—87
SENSOR ROTOR 11—90
HYDRAULIC UNIT FLUID 11—94
HYDRAULIC UNIT 11—94
CONTROL UNIT CIRCUIT 11—99
76G11X-001

1 1 ANTI-LOCK BRAKE SYSTEM (ABS)
WIRING DIAGRAM
o--
m o--
u
£
s-i J-
=—g ^t—• ¥—o
in

3—0 OH

i-i iH
s—0
Q-g
"-i o---s—0 b-t

ii
I—
---OD— -i-OB--
—HI
H:
86U11X-141
11—72

1 1 ANTI-LOCK BRAKE SYSTEM (ABS)
Troubleshooting Main Flow Chart
Check that the ABS warning light operates.

• Turn ignition switch OFF
to
ON, and check that ABS warning light illuminates constantly.

Flashing (Past failure)
OK
Check the ABS for failure.
• Start engine, and observe flashing
of
warning light.
Does not
illuminate
constantly
Warning light Possible cause
Does
not il-

luminate
at all

Refer
to
page 11—86.

ON
Alternator
L
ter-minal output Wiring harness (ALT-control unit) Control unit

OFF
1 sec

Alternator
L
ter-minal output Wiring harness (ALT-control unit) Control unit

ON
Relay box wiring harness (warning light-control unit) Control unit

OFF
1 sec

Relay box wiring harness (warning light-control unit) Control unit

No illumination
(Not diagnosed)
Illuminates constantly
(Present failure)
ABS is usually operating cor-rectly.
Consult table below when ABS failure
is
still suspected.
System Possible cause
ABS Brake light switch
Both rear wheel speed sensors
Control unit Proportioning
valve
in hy-
draulic unit
Other than Refer
to

ABS troubleshoot-ing guide
on

page 11—5.

Repair failures with flow
chart. (Refer to page
11—76.)
76G11X-054
11-74

ANTI-LOCK BRAKE SYSTEM (ABS) 1 1
Diagnosis Table
Note
Flashing of the warning light shows past failure, and its illumination shows present failure.
Diagnosis indication Possible failure Flow chart
No. Warning light Voltmeter Possible failure Flow chart
No.
ON
n
i2vn
OV

Hydraulic unit Harness
Right front wheel speed
sensor ABS-1
ON
n nn
Hydraulic unit Harness Left front wheel speed sensor ABS-2

OFF

Hydraulic unit Harness Left front wheel speed sensor ABS-2

OFF
nnn

Hydraulic unit Harness
Rear wheel speed sensor ABS-3

n
nnnn
Right front sensor rotor ABS-4

n
nnnnn
Left front sensor rotor ABS-5

JLilTUITLTL
Right rear sensor rotor ABS-6

jirLruiJum
Left rear sensor rotor ABS-7

J n
Hydraulic unit Harness
Control unit connector (11-pin)
ABS-8

nnnn

Hydraulic unit Harness
Control unit connector (11-pin)
ABS-8

J nn

Relay box
Hydraulic unit
Harness
ABS-9

jumruiTL

Relay box
Hydraulic unit
Harness
ABS-10

j nnn
Relay box
Hydraulic unit
Harness
ABS-11

jinnjuuL

Relay box
Hydraulic unit
Harness ABS-12

j nnnn

Relay box
Hydraulic unit
Harness
ABS-13

jiruuirirL

Relay box
Hydraulic unit
Harness
ABS-14

j nnnnn
Hydraulic unit Harness Control unit
ABS-15

juuuiruL

Hydraulic unit Harness Control unit ABS-16

j JinjiruifL.
Control unit
ABS-17

jiruinjiri—
JinjiruifL.
Control unit
ABS-18

j
No signal; failure condi-tions not stored
in
memory
Control unit Control unit connector (17-pin) Battery capacity Alternator output voltage Wiring harness (warning light-control unit-check connector)
Inspect, and repair or replace as necessary
j
No signal; failure condi-tions not stored
in
memory
No problem When warning light does
not
illuminate with engine running and
no
jumper wire

76G11X092
11-75

1 1 ANTI-LOCK BRAKE SYSTEM (ABS)
Flow Chart (Refer to Wiring Diagram, Page 11—72.)
ABS-1
Possible failure
Right front wheel speed sensor, Harness, Hydraulic unit
Disconnect Q-01 (11-pin) connec-tor. Check continuity
at
harness side.
Q-01 (11-pin)
I
Continuity
Y (2C) Ground No

OK

Measure resistance
at
harness side.
Q-01 (11-pin) Resistance
Y (2C)
i 0
(2D) 800—1200
Q
OK
NG
Repair harness.

(Control unit — Right front sensor)
NG

Disconnect Q-03. Measure resistance
at
sensor.
Q-03 Resistance
Y
[ O
800—1200 Q

NG
Replace right front wheel speed sensor.

OK
Repair harness.

(Control unit — Right front sensor)

Check followings*
• Clearance between sensor and rotor standard: 0.3—1.1
mm
(0.012-0.043
in)
• Objects sticking
to
sensor
or
rotor
• Damaged sensor
or
rotor
• Sensor installation Tightening torque: 16-23 N-m (1.6-2.3 m-kg, 12—17 ft-lb)

OK

Connect Q-01 (11-pin) connector. Jump GB
to B at
Q-07 connector. Start engine. Check that warning light stays ON. Drive vehicle and check that warning light flashes (0.25 sec ON OFF)
at 15
km/h
(9
mph).

NG
Repair
or
replace
as
necessary
* All conditions can
be
verified
as
follows,
if an AC
voltmeter
is
available. 1. Jack
up
vehicle. 2. Measure sensor voltage while rotating right front wheel
one
revolution
per
second.
Q-01 (11-Din) Voltage (AC)
Y (2C) O (2D) More than 0.25V

NG
Check Q-01 connector,
or
Replace control unit.

OK

Replace hydraulic unit.

76G11X-055
11—76

REAR HATCH 1 4
8. Remove the opening rod.
9. Remove the rear hatch opener.
86U14X-027
10. Remove the retainer, and the key cylinder.
86U14X-028
11. Remove the stay damper mounting bolts.
12. Disconnect the rear washer hose.
13. Remove the wiring harness.
86U14X-029
14. Remove the rear hatch hinge to door mounting
bolts.
15. Remove the rear hatch.
86U14X-030
14—11