water MAZDA 626 1987 Workshop Manual

FUEL SYSTEM 4D
Replacement
1. Remove the sedimenter from the body.
2. Apply fuel to a new O-ring, and install it onto the
sedimenter body with water level sensor.
76G04D-051
WATER LEVEL SENSOR
Inspection
1. Remove the water level sensor.
(ECE)
Remove the water level sensor from the fuel filter.
(GENERAL)
Remove the water level sensor from the sedimenter
body.
76G04D-052
2. Check the water level sensor for continuity with an
ohmmeter. Replace if necessary.
ECE
Continuity : Pulled condition
No continuity: Pushed condition
76G04D-053
GENERAL
Continuity : Pushed condition
No continuity: Pulled condition
3. Apply fuel to a new O-ring and install it onto the
sensor.
4. Install the water level sensor to the fuel filter (ECE)
or the sedimenter (General).
5. Check for fuel leakage.
76G04D-054
4D-23

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

5
ENGINE ELECTRICAL SYSTEM
OUTLINE 5— 2
STRUCTURAL VIEW 5— 2
SPECIFICATIONS 5— 5
TROUBLESHOOTING 5— 7
BATTERY 5— 8
INSPECTION 5— 8
RECHARGE. 5— 8
SPARK PLUG 5— 9
REMOVAL AND INSTALLATION 5— 9
INSPECTION 5— 9
IGNITION COIL 5—10
INSPECTION 5—10
HIGH-TENSION LEAD 5—10
INSPECTION 5—10
DISTRIBUTOR 5—11
SPARK TEST 5—11
IGNITION TIMING 5—11
SPARK CONTROL 5—12
REMOVAL 5—14
DISASSEMBLY 5—15
INSPECTION 5—16
ASSEMBLY 5—17
INSTALLATION 5—18
H.E.I. TROUBLESHOOTING 5—19
IGNITER (FE DOHC) 5—20
INSPECTION 5—20
ALTERNATOR 5—21
CROSS SECTIONAL VIEW 5—21
CHARGING SYSTEM 5—22
TROUBLESHOOTING 5—23
REMOVAL 5—27
DISASSEMBLY 5—28
INSPECTION 5—32
ASSEMBLY 5—35
INSTALLATION 5—36
V-BELT TENSION 5—37
STARTER (GASOLINE ENGINE
0.85, 0.95 KW TYPE) 5—38
STARTING SYSTEM CIRCUIT 5—38
ON-VEHICLE INSPECTION 5—38
REMOVAL AND INSTALLATION 5—39
DISASSEMBLY AND ASSEMBLY 5—39
INSPECTION 5—40
PERFORMANCE INSPECTION 5—43
STARTER
(GASOLINE ENGINE, 1.4 KW TYPE) 5—45
STARTING SYSTEM 5—45
ON-VEHICLE UNSPECTION 5—45
REMOVAL 5—46
DISASSEMBLY 5—46
INSPECTION 5—49
ASSEMBLY 5—53
CHECKING OPERATION 5—54
INSTALLATION 5—55
STARTER
(DIESEL ENGINE, 2.0 kW TYPE) .... 5—56
STARTING SYSTEM CIRCUIT 5—56
ON-VEHICLE INSPECTION 5—56
REMOVAL AND INSTALLATION 5—57
DISASSEMBLY AND ASSEMBLY 5—57
INSPECTION 5—61
PERFORMANCE INSPECTION 5—64
STARTER
(DIESEL ENGINE, 2.2 kW TYPE).... 5—66
STARTING SYSTEM CIRCUIT 5—66
ON-VEHICLE INSPECTION 5—66
REMOVAL AND INSTALLATION 5—67
DISASSEMBLY AND ASSEMBLY 5—67
INSPECTION 5—71
PERFORMANCE INSPECTION 5—74
QUICK START SYSTEM (QSS) 5-76
COMPONENT LOCATION 5—76
CIRCUIT DIAGRAM 5—76
SYSTEM OPERATION 5—77
TROUBLESHOOTING GUIDE 5—78
CONTROL UNIT 5—79
GLOW PLUG RELAY 5—80
BLOW PLUG 5—80
WATER TEMPERATURE SWITCH.... 5—80
76g05x-001

5 BATTERY
BATTERY
INSPECTION
Terminal and Cable
1. Check the tightness of the terminals to ensure good
electrical connections. Clean the terminals and coat
them with grease after tightening the terminal.
2. Inspect for corroded or frayed battery cables.
3. Check the rubber protector on the positive termi-
nal for proper coverage.
4BG05X-006
Electrolyte Level
1. Check whether or not the electrolyte level lies be-
tween the "UPPER LEVEL" and the "LOWER
LEVEL" lines.
2. If low, add distilled water by the "UPPER LEVEL".
Do not overfill.
4BG05X-007
Specific Gravity
1. Measure the specific gravity by using a
hydrometer.
2. If the specific gravity reading is standard or less,
recharge the battery.
Standard gravity: 1.22
Fully charged gravity: 1.27—1.29
76G05X-004
RECHARGE
Quick Charge
1. Remove the battery from the vehicle.
2. Remove all the vent caps.
3. Perform a quick charge (6A or above, but max.
20 A).
4. Add distilled water if necessary while charging.
5. Cool the battery not to exceed the electrolyte tem-
perature over 55°C (131 °F) while charging.
6. Charge once more if the specific gravity is under
fully charged gravity.
4BG05X-009
5-8

SPARK PLUG 5
Slow Charge
1. Stop the engine
2. Turn all the accessories off.
3. Remove the negative battery cable.
4. Perform a slow charge (3.5A to 4.5A).
5. Add distilled water if necessary while charging.
6. Charge once more if the specific gravity is under
fully charged gravity.
4BG05X-010
SPARK PLUG
REMOVAL AND INSTALLATION
Note the following points:
1. When the high-tension lead is to be pulled off, be
sure to pull the boot itself, and not the wire.
2. Tighten the spark plugs to the specified torque.
Tightening torque: 15—23 N-m
(1.5—2.3 m-kg, 10.8—16.6 ft-lb)
76G05X-054
Wear and adhesion or cabon
INSPECTION
Check the following points. If a problem is found, re-
place the spark plug.
1. Damaged insulation
2. Worn electrodes
3. Carbon deposits
If cleaning is necessary, use a plug cleaner or a
wire brush. Clean the upper insulator also.
4. Damaged gasket
5. Burnt condition of spark insulator
6. If it is black with carbon deposits, either misfiring
due to improper proportions of gas and air or over-
heating of the plug may have occurred.
Plug gap:
FE (12VALVE) and FE DOHC Leaded fuel
model:
0.70—0.80 mm (0.028—0.031 in)
FE (8VALVE) and FE DOHC Unleaded fuel
model:
1.0—1.10 mm (0.039—0.043 in)
Others:
0.75—0.85 mm (0.030—0.034 in)
76G05X-005
5-9

QUICK START SYSTEM (QSS) 5
TROUBLESHOOTING GUIDE
Preliminary Checks
When troubleshooting, check below first.
1. Main fuse
2. Fuses
3. Connectors
4. Ground circuit
5. Wiring harness
Condition Cause
Glow plug relay does not close. 1. Faulty glow plug relay 2. Faulty control unit internal circuit
3. Poor contact or disconnection between control unit terminal ©and harness
4. Faulty START harness (open circuit at ©terminal in control unit) 5. Poor contact or disconnection between glow plug relay ter-minal and harness 6. Faulty glow plug
Glow plug relay does not open 1. Faulty glow plug relay 2. Faulty control unit internal circuit
Glow plug relay does not repeat ON and OFF. 1. Faulty poor contact of engine switch 2. Poor contact or disconnection of starter harness 3. Faulty control unit internal circuit
Glow plug relay does not repeat ON and OFF within 15 sec. after turning the engine switch ON. 1. Faulty water temperature switch 2. Faulty control unit internal circuit
3. Faulty glow plug relay
4. Poor contact or disconnection between control unit © and water temperature switch
76G05X-051
5-78

QUICK START SYSTEM (QSS) 5
CONTROL UNIT
Inspection
1. Connect a voltmeter to the control unit as shown
in the figure.
2. Check the voltage of the terminal.
3. Replace the control unit if necessary.
Caution
If the proper voltage is not indicated on the
voltmeter, check all wiring connections and
finally, check that component.
63G05X-337
Control Unit Connector
Terminal Input Output Connection to Operation condition Voltage Remark
for 6 sec. approx. 12V
L (GW) O Glow plug relay Engine switch: ON (No cranking) after 6 sec.
OV 12V Coolant temperature; below 30°C (86°F) after 6 sec.
OV Coolant temperature; above 30°C (86°F)
H
(B) — — Ground OV
E (BW) 0 Engine switch (ON) Engine switch: ON approx. 12V
F
(BR) O Engine switch (START) Engine switch: START approx. 12V
C o
Water
temperature switch
Engine switch: ON (No cranking)
approx. 12V Coolant temperature; below 30°C (86°F)
(BrB) o
Water
temperature switch
Engine switch: ON (No cranking)
approx. OV Coolant temperature;
above 30°C (86°F)
At cranking OV <- 12V
B 0 Glow plug
For 15 sec. after engine has started OV <-> 12V Coolant temperature;
(Gr) 0 Glow plug After 15 sec. OV below 30°C (86 °F)
After engine has started OV Coolant temperature; above 30°C (86°F)
K o Indicator Engine switch: ON
For 3 sec. OV
(WR) o Indicator Engine switch: ON after 3 sec. approx. 12V
76G05X-052
u® x y i © © X 1
© © X ®
5-79

5 QUICK START SYSTEM (QSS)
Glow plug relay GLOW PLUG RELAY
Inspection
1. As shown in the figure, connect the battery and
an ohmmeter to the relay.
2.
If
the ohmmeter shows continuity when the battery
is connected, and no continuity when the battery
is disconnected, the relay is good.
3. Replace the relay if it fails this test.
4BG05X-123
GLOW PLUG
Inspection
1. Check the continuity between the positive termi-
nal of the glow plug and cylinder head with a cir-
cuit tester.
2. If there is no continuity, replace the glow plug.
4BG05X-121
Removal
Remove in the following order:
1. Glow plug connector attaching nut.
2. Glow plug connector.
3. Glow plug
Installation
Install the glow plug, reverse order of removal.
76G05X-053
63G05X-336
5-80
WATER TEMPERATURE SWITCH
Removal
Remove the water temperature switch from the
radiator.
Installation
Install in the reverse order of removal.
Inspection
1. Place the water temperature switch in water with
a thermometer and heat the water gradually.
2. Check the temperature at which continuity exists
between the terminals.
3. Replace the switch, if necessary.
Specified temperature: above 28—32°C
(82—90°F)

REMOVAL 7A
RF-N and RF-CX
1. Battery
2. Air cleaner assembly
3. Vacuum hose
4. Intercooler pipe and hose
(RF-CX)
5. Electric fan
6. Speedometer cable
7. Ground(s)
8. Clutch release cylinder
9. Pressure and return hoses
(power steering)
10. Starter
11. Wheel
12. Splash shield
13. Stabilizer
14. Joint shaft
15. Extension bar
16. Control rod
76G07A-011
17. Exhaust pipe bracket
18. Water pipe
19. Gusset plate (rear)
20. Gusset plate (front)
21. Under cover
22. Engine mount No.4
23. Engine mount No.2
24. Crossmember
7 A—13

7B
AUTOMATIC TRANSAXLE
(Electronically Controlled and 4-Speed)
OUTLINE 7B— 2
SPECIFICATIONS 7B— 2
COMPONENT LOCATION 7B— 3
STRUCTURAL VIEW 7B— 5
OPERATION OF COMPONENTS 7B— 6
FLUID PASSAGE LOCATION 7B— 9
TROUBLESHOOTING (G4A-EL) 7B— 12
GENERAL NOTE 7B— 12
STEP 1
(WARNING CODE RETRIEVAL) 7B— 15
STEP 2
(PRELIMINARY INSPECTION) 7B— 22
STEP 3 (SIGNAL INSPECTION) 7B— 24
STEP 4 (STALL TEST) 7B— 27
STEP 5 (TIME LAG TEST) 7B— 30
STEP 6 (OIL PRESSURE TEST) 7B— 31
STEP 7 (ROAD TEST) 7B— 34
TROUBLESHOOTING (G4A-HL) 7B— 41
GENERAL NOTE 7B— 41
STEP 1
(PRELIMINARY INSPECTION) 7B— 44
STEP 2 (ELECTRICAL
SYSTEM INSPECTION) 7B— 47
STEP 3 (STALL TEST) 7B— 49
STEP 4 (TIME LAG TEST) 7B- 52
STEP 5 (ROAD TEST) 7B— 53
STEP 6 (OIL PRESSURE TEST) 7B— 58
ELECTRICAL SYSTEM
COMPONENTS 7B— 63
MODE SWITCH (G4A-EL) 7B— 63
HOLD SWITCH (G4A-EL) 7B— 63
OD OFF SWITCH (G4A-HL) 7B— 64
INHIBITOR SWITCH 7B- 65
WATER TEMPERATURE SWITCH 7B— 66
FLUID TEMPERATURE SWITCH
(G4A-EL) 7B— 66
BRAKE LIGHT SWITCH
(G4A-EL) 7B— 66
KICK-DOWN SWITCH (G4A-HL) 7B— 67
PULSE GENERATOR (G4A-EL) 7B- 68
VEHICLE SPEED SENSOR
(G4A-EL) 7B— 68
CRUISE CONTROL SWITCH
(CRUISE CONTROL UNIT) 7B— 68
IDLE SWITCH AND THROTTLE
SENSOR (G4A-EL) 7B— 68
OD RELEASE SOLENOID
VALVE (G4A-HL) 7B— 68
SOLENOID VALVES (G4A-EL) 7B— 69
NO LOAD SIGNAL (G4A-EL) 7B— 69
MODE, AND HOLD INDICATOR
LIGHT (G4A-EL) 7B— 69
OD OFF INDICATOR LIGHT
(G4A-HL) 7B— 69
EC-AT CONTROL UNIT
(G4A-EL) 7B— 69
ON-VEHICLE MAINTENANCE 7B— 71
AUTOMATIC TRANSAXLE
FLUID (ATF) 7B— 71
SELECTOR LEVER 7B— 72
THROTTLE CABLE 7B— 73
CONTROL VALVE BODY 7B— 77
OIL STRAINER 7B— 79
ADJUSTMENT OF 2-4 BRAKE
BAND 78— 80
REPLACEMENT OF
DRIVESHAFT OIL SEAL 7B— 80
OIL COOLER 7B— 81
GOVERNOR (G4A-HL) 7B— 82
REMOVAL 7B— 83
PRECAUTION 7B— 83
DISASSEMBLY 7B— 88
DISASSEMBLY-STEP 1 7B— 88
DISASSEMBLY-STEP 2 7B— 94
DISASSEMBLY-STEP 3 7B— 99
DISASSEMBLY-STEP 4 7B—103
INSPECTION AND REPAIR 7B—107
PRECAUTION 7B—107
TORQUE CONVERTER 7B—107
OIL PUMP 7B—108
CLUTCH ASSEMBLY 7B—113
SMALL SUN GEAR AND
ONE-WAY CLUTCH 7B—122
ONE-WAY CLUTCH AND
CARRIER HUB ASSEMBLY 7B-126
3-4 CLUTCH 7B—128
2-3 ACCUMULATOR 7B—132
GOVERNOR ASSEMBLY
(G4A-HL) 7B-133
LOW AND REVERSE BRAKE 7B—134
2-4 BRAKE BAND 7B—135
BAND SERVO 7B—135
OTHER INSPECTION 7B—135
CONTROL VALVE BODY
(G4A-EL) 7B-136
CONTROL VALVE BODY
(G4A-HL) 7B-155
DIFFERENTIAL 7B—177
OUTPUT GEAR 7B—181
IDLE GEAR 7B—182
BEARING COVER ASSEMBLY 7B—185
BEARING HOUSING 7B—186
ASSEMBLY 7B-187
PRECATION 7B—187
ASSEMBLY-STEP 1 7B—187
ASSEMBLY-STEP 2 7B—197
ASSEMBLY-STEP 3 7B—202
ASSEMBLY-STEP 4 7B—208
INSTALLATION 7B—215
TORQUE SPECIFICATIONS 7B—215
HYDRAULIC CIRCUIT (G4A-EL) 7B—221
HYDRAULIC CIRCUIT (G4A-HL) 7B—239
76G07B-001