timing MAZDA 626 1987 Workshop Manual

OUTLINE 5
SPECIFICATIONS
Gasoline Engine
item
Engine
F6 F8 FE
(8 VALVE)
FE (12 VALVE) FE
(DOHC)
Battery
Voltage
Type and capacity
12. Negative ground
(20 hour rate) 34B19L(S) (33 Ah): General 50D20L (50 Ah), 55D23L (60 Ah): ECE
Alternator
Type A.C.
Output V-A 12-70
Regulator type Transistorized (built-in IC regulator)
Regulated voltage 14.1-14.7
Brush length
mm (in) Standard 16.5 (0.650)
Minimum 8.0 (0.315)
Drive belt tension
mm (in)/98 N (10 kg, 22 lb) New: 6-8 (0.24-0.32), Used: 7-9 (0.28-0.35)
Starter
Type Coaxial reduction: Middle East & General (FE • carburetor)
Non-reduction: Others
Output V-kW 12-0.85
Brush length
mm (in)
12-0.95
Standard 17.0 (0.669)
Minimum 11.5 (0.453)

Unleaded fuel
17.0 (0.669)
Others
17.51
Unleaded fuel 11.5(0.453) Others 10,0 (0.394)

12-1.4 12-0.95
17.0 (0.669)
11.5 (0.453)
Ignition timing 6 ± 10 BTDC (Vacuum hose disconnected)

12
±
1° BTDC
(Test connector

grounded)
Distributor
Type Fully transistorized (HEI)
Electronic spark advance
Centrifugal spark advance
(crank angle/engine speed)
degree/rpm
F6
-2-2/1,000 6-10/2,100 14-18/6,100
F8 -2—2/1,000 10-14/2,100 18-22/6,100
FE (8 VALVE)—Carburetor Unleaded fuel
(MTX)-2—2/1,760 12—16/3,360 22—26/5,320 (ATX)-2-2/1,300 12-16/3,360 22-26/5,320
Others
-2—2/1,460 10—14/2,540 22—26/5,540
FE (12 VALVE)—Carburetor -2-2/1,200 10—14/2,400 10—14/4,000 16-20/5,000
FE—Fuel injection (except FE DOHC) -2—2/1,000 10—14/2,600 10—14/4,600 16—20/5,800
Unleaded fuel model 76G05X-503
5-5

TROUBLESHOOTING GUIDE 5
TROUBLESHOOTING GUIDE
Problem Possible cause Remedy Page
Starter does not turn at all, or Its turning speed Is too slow to start the engine.
Battery and related parts Poor contact of battery terminals Poor grounding of negative cable Voltage drop caused by discharged battery Insufficient voltage caused by battery malfunction
Clean and tighten Clean and repair Recharge Replace
5- 8
5- 8 5- 8
Ignition switch and related parts Poor contact of ignition switch Loose ignition switch wiring or connector Broken wire between ignition switch and magnetic switch
Replace Repair Repair or replace 5-38,45,56,66
Magnetic switch and related parts Loose wiring and/or connectors Burnt magnetic switch contact plate or improper contact Broken wire in magnetic switch pull-in coil Broken wire magnetic switch holding coil
Repair Replace
Replace Replace
5-38,45,56,66 5-43,54,64,74
5-43,54,64,74 5-43,54.64,74
Starter Poor contact of brushes
Fatigued brush spring Poor grounding of field coil Poor soldering of field coil Commutator mulfunction Grounded armature Worn parts
Adjust contact or replace Replace Replace Repair Repair or Replace Replace Replace
5-43,54,64,74
Starting problem Gasoline engine Insufficient battery capacity Malfunction of spark plug (s)
Loose positive terminal Damaged distributor cap or rotor Ignition coil malfunction laniter malfunction
Recharge Clean, adjust or replace Tighten Replace Replace Renlane
5— 8 5— 9
5—16 5—10 5-16,20
Diesel engine Insufficient battery capacity QSS svstem malfunction Recharge ReDlace 5— 8 5-76
Starter turns but pinion gear does not mesh with ring gear
Starter Tip of overrunning clutch pinion is worn Weakened overrunning clutch drive spring Worn overrunning clutch Improper sliding of spline
Worn bushing Worn ring gear
Replace Replace Replace Adjust contact and repair, or replace Replace ReDlace
5-40,54,70
Starter turns continuously (does not stop) Magnetic switch Sticking contact place of magnetic switch Layer shorting coil of magnetic switch Ignition switch does not return
Replace Replace Rfinlanfi
5-43,54,64,74 5-43,54,64,74
Misfiring Dirty or damaged spark plug (s) Malfunction of wiring, or open circuit Damaged distributor cap
Clean or replace Repair or Replace Replace
5- 9 5—10 5—16
Discharging of battery Alternator Loose drive belt Grounded or broken stator coil Broken rotor coil Poor contact of brush and slip ring
Malfunction of rectifier Malfunction of IC regulator Battery and related parts Insufficient or unsuitable battery electrolyte Malfunction of battery electrode (internal short-circuit) Poor contact of battery terminal (s) Excessive electric load
Adjust Replace Replace Clean, repair or replace Replace Replace
Adjust Replace
Clean and tighten Check power consump-tion and short circuit
5-37 5-32 5-32 5-32
5-34
5— 8 5- 8
5— 8
Overcharging of battery IC regulator malfunction Operating in extremely high temperature Replace Reoair
Poor acceleration Mis-adjusted ignition timing Distributor malfunction Adjust Repair or replace 5—11 5—11
Knocking Mis-adjusted ignition timing | Distributor malfunction Adjust Repair or replace 5—11 5—11
76G05X-003
5-7

DISTRIBUTOR 5
7BU05X-075
86U05X-048
76G05X-007
DISTRIBUTOR
SPARK TEST
1. Disconnect the distributor lead from the distributor.
2. Hold it with insulated pliers approx. 5—10 mm
(0.20—0.39 in) from a ground.
3. Crank the engine and check that a strong blue
spark is visible.
4. If there is no spark, the ignition coil or pick-up coil
may be bad.
Check once again after replacing the ignition coil
or pick-up coil.
IGNITION TIMING
1. Warm up the engine to the normal operating tem-
perature.
2. Turn all electric loads OFF.
3. Connect a tachometer and timing light to the
engine.
4. Connect a jumper wire between the test connec-
tor and ground. (Only for FE DOHC)
5. Check the idle speed. Set to the specified speed
if necessary.
Idle speed: 750 ± 50 rpm (FE DOHC)
800 t58 rpm (F6, F8 FE—MTX)
900 i58 rpm (F8, FE—ATX
in "P" range)
950 -5o rmp (F6—ATX
in "P" range)
6. Check that the timing mark (Yellow) on the crank-
shaft pulley and the mark on the timing belt cover
are aligned.
Ignition timing:
FE DOHC: 12 ± 1° BTDC
(Test connector grounded)
Others: 6 ± 1°
(Vacuum hoses disconnected and
plugged)
76G05X-008
5—11

DISTRIBUTOR
8.
If
the mark is not aligned, loosen the distributor lock
bolt, and turn the distributor housing to make the
adjustment.
9. Reconnect the vacuum hoses, or disconnect the
jumper wire from the test connector.
10. Tighten the distributor lock bolt to specified torque.
Tightening torque:
18.6—25.5 Nm
(1.9—2.6 m-kg, 13.7—18.8 ft-lb)
86U05X-051
SPARK CONTROL (Except FE DOHC)
Centrifugal Advance
1. Warm up the engine to the normal operating tem-
perature.
2. Check that the idle speed and initial ignition tim-
ing are correct.
3. Disconnect the vacuum hoses from the vacuum
control unit and plug them.
76G05X-009
F6
Engine Speed (rpm)
4. While gradually increasing the engine speed, use
a timing light to check the advance on the pulley.
Excess advance weak governor spring
(If the governor spring is broken,
the advance will rise very high)
Insufficient advance...governor weight or cam
malfunction
86U05X-053
F8
Engine Speed (rpm) Engine Speed (rpm)
5-12

DISTRIBUTOR 5
FE West Germany (MTX)
24c
14<
0 0) O)
a>
®
O) c a> ^
I 0 1.76° 3.36° 5.32°
Engine Speed (rpm)
FE 12 valve (Carb.)
© ©
118°
12° O) c (0
c CO
6 o 1,200 2,400 4,0005,000
Engine Speed (rpm)
FE West Germany (ATX)

oT
24' 0) a> © "D
© O) c CO JX c CO
14c
6 0 1,300 3,350 5,320
Engine Speed (rpm)
EF EGI a) ©
O) a> ©
o> c ©
C CO
O
18°
12°
1,000 2,600 4,600 5,800
Engine Speed (rpm)
F6, F8 © ©
O) © tj, ©
cn
« 8°
c a)
6 o
86U05X-054
100 (3.94) 300 (11.81)
mmHg (inHg)
Vacuum Advance
1. Warm up the engine to the normal operating tem-
perature.
2. Check that the idle speed and ignition timing are
correct.
3. Disconnect the vacuum hoses from the vacuum
control unit, and plug them.
4. Connect a vacuum pump to the vacuum control
unit.
5. Apply vacuum and check the advance with the tim-
ing light.
86U05X-055
5—13

5 DISTRIBUTOR
INSTALLATION
Note
After installing the distributor, adjust the ig-
nition timing (Refer to 5—11).
1. Apply engine oil to the O-ring and driven gear.
76G05X-056
Note
Gear driven type, check that the No.1 cylin-
der is at top dead center and aline the distrib-
utor matching marks.
76G05X-016
2. Install the distributor and connect the high-tension
leads and distributor connector.
3. Tighten lock bolt to the specified torque.
Torque specification:
19—25 Nm (1.9—2.6 m-kg, 14—18 ft-lb)
86U05X-064
5—18

7B TROUBLESHOOTING (G4A-EL)

ON VEHICLE-
-f-
—OFF VEHICLE

\ Inspection point
and

\ reference page

Condition
•

Electronic control system Prelim-
inary
Hydraulic
control
system
Power train \ Inspection point
and

\ reference page

Condition
•
7B-66

m CO I m r--
7B-63

i
cn to I m
Section

4B

|

Section

4B

|

ID to i m
CO CO 1 CD
7B-68
|
en CO 1 IX)
to 1 00 r-.
cn CD 1 CO
7B-69
|

1 CD r--
i no
cn s-1 m
Section
4B

r*-cn
S-1 CD h-
"=1-
rJ CO
7 CD r-
(XI o
1 m
cn CM 1 CD
7B-107

|
CD
7 CD 7 m
I
7B-113
I
CO CM
7 CO r-.
m cn
7 CO r-.
cn
7 DO r-
CM CM
7 CO

|
7B-126

7 00 r-
CO 7 cn
1*-r*-
7 m r-
\ Inspection point
and

\ reference page

Condition
•
Brake

light
switch

|

Inhibitor

switch

|

Mode

switch

|

1
CO. •o o X
Idle

switch

Throttle

sensor

|

Water

temp,

switch

|
0 tn c 0) cn
s
ffi
Q tn 01 o Hi >
Pulse

generator

|

"a o c 0) a to CM
TJ O CL ID s CO C\l 3-4

solenoid

|

Lock-up
solenoid

I

ATF

level
and
condition

|

Selector

lever

m Xj CO CJ 03
1 sz
Idle
speed
and
Ignition
timing

Control

valves

Accumulators
Oil
pump
Hydraulic

circuit

Torque

converter

Forward

clutch
Coasting
clutch

Reverse

clutch
JT O
u TT ro 2-4

brake
band
and

servo
$ 2
B cn cii > £ "O C CO
o
XI y
o >. CO S cb a O
One-way

clutch

2

s CI Cn tz JC 5 0-
Planetary

gear

Differential

assembly
Accelerating

Vehicle does
not
move
in
D,
S,
L,
or R
range
O O O O O O O O O O 0

Accelerating

Vehicle moves
in N
range -0 0 -—

Accelerating
Excessive creep
-0 O O -—

Accelerating
No creep
at all
O o o o
o
G 0 O O

Shifting

|

No shift
O O o
o
0 O 0 0
o
o O

Shifting

|
Abnormal shift sequence
0 o O O 0
o
o 0 O o o 0 O

Shifting

|
Frequent shifting 0 o 0 0 o 0 O O 0

Shifting

|

Excessively high
or
low
shift point 0 o 0 O 0 0 o 0 O 0 0
Shifting

|

No lock-up
0 o 0 0 o 0 O O o O

Shifting

|

No kick-down o o o o

Slipping

Engine
run
away
or
slip when
starting vehicle 0 o 0 O o O

Slipping
Engine
run
away
or
slip when
up-
or
down-shifting o o o 0 o O 0 0 O
8 n cn 4S SI V)
Excessive
N to D or N to R

shift shock o O o o o O
8 n cn 4S SI V)
Excessive shift shock when
up-

shifting
or
downshifting o o o o 0 0 0 8 n cn 4S SI V) Excessive shift shock when
changing range 0 0 o 0 o

j
Noise

Transaxle noisy
in N or P

range o o 0 O

j
Noise

Transaxle noisy
in D, S, L,
or

R range o 0 0 O

I
Others

j

No engine braking o O o 0 o o

I
Others

j

No mode change o 0 o o o o o o o
O
o
0

I
Others

j
Transaxle overheats
o o
0 o 0 o 0

I
Others

j
Vehicle moves
in
"P",
or
park-ing gear
not

disengaged when
"P"
is
dis-
engaged
0 O

I
Others

j

Hold indicator flashes o
0
o
0
o
O
o — — —
I
Others

j

Engine will
not
start
o
o
O — — —
76G07B-014
7B—14

7B TROUBLESHOOTING (G4A-HL)
5. Throttle Cable
(1) Check the inner and outer cable for damage.
(2) Make sure that the accelerator operates
smoothly.
76g07b-046
6. Idle Speed
Check idle speed. (Refer to Section 4A)
7. Tire Inflation Pressure
Check tire inflation pressure. (Refer to Section 12)
8. Ignition Timing
Check ignition timing. (Refer to Section 5)
7B-46

TROUBLESHOOTING (G4A-HL) 7B
Evaluation
Condition Possible Cause
No 1-2 shift
Insufficient governor pressure
No 1-2 shift
Stuck 1 range control valve
No 1-2 shift Stuck 1-2 shift control valve No 1-2 shift
Stuck 1-2 shift valve
No 1-2 shift
No check ball (rubber ball)
No 2-3 shift
Insufficient governor pressure
No 2-3 shift
Stuck 2 range control valve
No 2-3 shift Stuck servo control valve No 2-3 shift
Stuck 2-3 shift valve
No 2-3 shift
No check ball (rubber ball)
No 3-OD shift
Insufficient governor pressure
No 3-OD shift
Excessive throttle pressure
No 3-OD shift Stuck OD release valve No 3-OD shift Stuck needle valve of the OD release solenoid valve No 3-OD shift
Stuck 3-4 shift valve
No 3-OD shift
No check ball (rubber ball)
No. Lock-up (Electric circuit is OK)
Insufficient governor pressure
No. Lock-up (Electric circuit is OK)
Stuck OD release valve
Stuck needle valve of the OD release solenoid valve No. Lock-up (Electric circuit is OK)
Stuck OD lock-up valve
No. Lock-up (Electric circuit is OK)
Stuck lock-up control valve
Shift occurred in 2 range Stuck 1-2 control valve Shift occurred in 2 range Stuck 2 range control valve
No kick-down Stuck throttle valve No kick-down Stuck kick-down valve
Incorrect shift point In D and 1 range
Excessive or insufficient governor pressure
Incorrect shift point In D and 1 range Excessive or insufficient throttle pressure Incorrect shift point In D and 1 range
Excessive or insufficient line pressure Incorrect shift point
In 1 range Stuck 1 range control valve
No engine braking effect
Stuck coasting bypass valve
No engine braking effect Fluid leakage from 2-3 accumulator seal rings No engine braking effect
No check ball (rubber ball)
Shift shock or slippage
In 1-2 and/or 3-OD shift
Fluid leakage from 1-2 accumulator seal rings
Shift shock or slippage
In 1-2 and/or 3-OD shift No check ball (rubber ball) or leakage
Shift shock or slippage
In 1-2 and/or 3-OD shift
No one-way check orifice or leakage
Shift shock or slippage In 2-3 shift
Fluid leakage from 2-3 accumulator seal ring
Shift shock or slippage In 2-3 shift
Stuck bypass valve
Shift shock or slippage In 2-3 shift
Stuck 2-3 timing valve
Shift shock or slippage In 2-3 shift Stuck coast bypass valve Shift shock or slippage In 2-3 shift
Stuck servo control valve Shift shock or slippage In 2-3 shift
No one-way check orifice or leakage
Shift shock or slippage In 2-3 shift
No check ball (rubber ball) or leakage
Shift shock or slippage
In 3-2 shift
Fluid leakage from 1-2 accumulator seal ring
Shift shock or slippage
In 3-2 shift No check ball (rubber ball) or leakage
Shift shock or slippage
In 3-2 shift Stuck 3-2 timing valve
Shift shock or slippage
In 3-2 shift
Stuck 3-2 capacity valve
83U07B-046
7B—57

INSPECTION AND REPAIR 7B
Premain Control Body
Disassembly
Disassemble in the sequence shown in the figure.

21
;i9 21 (?0) !S
(Non-
Turbo)
16 15 16 14 14 13 It
6—8 N-m (66—80 cm-kg, S7—69 ft-lb)
Valve Location
33 (34, 6—8 N-m (66—80 cm-kg, 57—69 ft-lb)
I '
N-R accumulator piston
N-D accumulator piston
Coasting bypass valve
_

1MB
P^raaD WOCE

3-2 timing valve timing
3-2 capacity valve"
-1-2 accumulator piston
-Bypass valve
-Servo control valve
timi 2-3 timing valve
76G07B-150
1. Retainer
2. 2-3 timing spring
3. 2-3 timing valve
4. Stopper pin
5. Stopper plug
6. Servo control valve
7. Servo control spring
8. Stopper pin
9. Stopper plug
10. Bypass valve
11. Bypass spring
12. Bolt
13.1-2 accumulator plate and
gasket
14.1-2 accumulator spring
15.1-2 accumulator piston
16.1-2 accumulator seal rings
17. Bolt
18. N-R accumulator plate and
gasket
19. N-R accumulator piston
20. N-R accumulator rear
spring
21. N-R accumulator seal rings
22. N-D accumulator front
spring
23. N-D accumulator piston
24. N-D accumulator seal rings
25. Coasting bypass spring
26. Coasting bypass valve
27. Coasting bypass plug
28. Retainer
29. 3-2 timing spring
30. 3-2 timing valve
31. Stopper pin
32. Stopper plug
33. 3-2 capacity spring
34. 3-2 capacity valve
7B—141