light MAZDA 626 1987 Workshop Manual

OUTLINE 16
Discharging the Refrigeration System
1. Connect the manifold gauge set to the system.
2. Place the free end of the center hose on a shop
towel.
3. Slowly open the high pressure manual valve to ad-
just the refrigerant flow. Open the valve only slightly.
Caution
If refrigerant is allowed to escape too fast, the
compressor oil will be drawn out of the
system.
4. Check the shop towel to make sure no oil is being
discharged.
If oil is present, partially close the manual valve.
5. After the manifold gauge reading drops below 343
kPa (3.5 kg/cm2, 50 psi), slowly open the low
pressure manual valve.
6. As the system pressure drops, gradually open both
the high- and low-pressure manual valves until both
gauges read 0 kPa (0 kg/cm2, 0 psi).
76G16X-631
Evacuation of the Refrigeration System
Whenever the air-conditioning system has been ex-
posed to the atmosphere, it must be evacuated.
1. Connect the manifold gauge set.
2. Connect the center hose of the gauge set to the
vacuum pump inlet.
3. Operate the vacuum pump, then open both man-
ual valves.
4. When the low pressure gauge indicates approxi-
mately 710 mmHg (28 inHg), close both manual
valves and stop the vacuum pump.
5. Check to be sure that the degree of pressure does
not change after 10 minutes or more in this condi-
tion.
If
the pressure changes, check the system for
leaks, and repair if necessary.
6. If no leaks are found, once again operate the vacu-
um pump and open both manual valves to obtain
760 mmHg (30 inHg).
7. Close both manual valves, and stop the vacuum
pump.
Disconnect the hose from the vacuum pump.
69G16X-019
16-9

COMPRESSOR 16
Escape groove
^ / / / / j / / ' / / / / /
' / / I / /
1 \ \ x Suction \ \ \/ valve
n W: \ / / y /
I u
Piston— ^
69G16X-044
69G16X-045
Installation of Front Cylinder Head
1. Place the cylinder shaft assembly with the front side
upward.
2. Install the front suction valve so that it matches the
spring pin.
Note:
Check that the valve tallies with the valve es-
cape groove of each cylinder.
3. Install the front valve plate on the front suction
valve.
4. Coat the new gasket with clean compressor oil and
install it on the front valve plate.
5. Install the front cylinder head.
In case difficulty is encountered in fitting, install the
cylinder head lightly with a plastic mallet.
Note:
When installing the front cylinder head, be
careful that you do not scratch the seat sur-
face of the seal seat fitted onto the front cyl-
inder head with the lip of the driveshaft.
Mount the new gasket on the through-bolts. Insert six
through-bolts from the front side and tighten them to
20—24 N m (2.0—2.4 m-kg, 14.5—17.3 ft-lb)
Each bolt should be equally tightened more than three
times to ensure the specified torque.
The bolts should be tightened in the order shown in
the figure.
Place felt on the front cylinder head.
Turn the driveshaft 2 or 3 times by hand, and make
sure that it rotates smoothly.
69G16X046
16—19

TECHNICAL DATA 30
Control valve spring (G4A-EL)
Spring name Outer dia. mm (in) Free length mm (in) Wire dia. mm (in) Spring color

1-2 accumulator small spring 11.0 (0.433) 88.1 (3.348) 1.4 (0.055) Gray
1-2 accumulator large spring 16.0 (0.0630) 78.0 (3.071) 2.0 (0.079) Blue
Bypass, servo control spring 5.0 (0.197) 33.4 (1.315) 0.55 (0.022) Maroon
2-3 timing spring 8.3 (0.327) 26.5 (1.043) 0.8 (0.031)
—

N-R accumulator rear spring 11.1 (0.437) 62.0 (2.441) 1.2 (0.047) Light green
N-D accumulator front spring 9.8 (0.386) 52.9 (2.083) 1.0 (0.039) Brown
Coasting bypass spring 5.8 (0.228) 37.7 (1.484) 0.6 (0.024) Dark blue
3-2 timing spring 8.2 (0.323) 28.6 (0.126) 0.8 (0.031) Red
3-2 capacity spring 5.4 (0.213) 30.6 (1.205) 0.5 (0.020) White
Throttle relief ball spring 6.6 (0.260) 21.6 (0.850) 0.8 (0.031)
—

Pressure modifier spring 8.3 (0.327) 26.5 (1.043) 0.8 (0.031)
—

Low reducing spring 8.7 (0.343) 38.3 (1.508) 0.9 (0.035) Black
1-2 shift spring 8.7 (0.343) 41.3 (1.626) 1.0 (0.039) Yellow
2-3, 3-4 shift spring 7.4 (0.291) 36.6 (1.441) 0.8 (0.031) Gray
Throttle backup spring 9.65 (0.380) 26.9 (1.059) 0.55 (0.022) Red
Throttle modulator spring 6.3 (0.248) 47.9 (1.886) 0.8 (0.031)
—

Throttle assist spring 5.15 (0.203) 32.3 (1.272) 0.55 (0.022) Dark green
Throttle spring 5.4 (0.213) 47.2 (1.858) 0.8 (0.031) Pink
Converter relief ball spring 6.9 (0.272) 24.1 (0.949) 0.9 (0.035) Maroon
Orifice check valve spring 5.0 (0.197) 12.5 (0.492) 0.23 (0.009)
—

Pressure regulator spring 11.5 (0.453) 26.5 (1.043) 1.0 (0.039) Maroon
Lock-up control spring 5.0 (0.197) 35.2 (1.386) 0.6 (0.024) Purple

Control valve springs (G4A-HL)
SDrina name Outer dia. mm (in) Free length mm (in) Wire dia. mm (in) Spring color

1-2 accumulator small spring F8 enaine 9.9 (0.400) 84.7 (3.335) 1.2 (0.047) Red
1-2 accumulator large spring FE engine 13.0 (0.512) 73.2 (2.881) 1.8 (0 071) Pink 1-2 accumulator large spring F8 enaine 16.0 (0.630) 84.7 (3.335) 2.0 (0.079) White
Bypass spring 5.0 (0.197) 25.1 (0.988) 0.7 (0.028) Yellow
Servo control sorina 4.9 (0.193) 27.1 (1.067) 0.5 (0.020) Light blue
2-3 timing soring 8.3 (0.327) 26.5 (1.043) 0.8 (0.031)
—

N-R
accumulator rear SDrina
11.1 (0.437) 68.2 (2.685) 1.0 (0.039) Blue
N-D accumulator front spring 9.8 (0.386) 60.9 (2.398) 1.1 (0.043) Yellow
Low reducing spring 8.7 (0.343) 38.3 (1.508) 0.9 (0.035) Black
OD release spring 6.0 (0.236) 32.6 (1.283) 0.6 (0.024) Orange
Coasting bypass spring 5.8 (0.228) 31.3 (1.232) 0.6 (0.024) Yellow
3-2 timing soring 8.2 (0.323) 28.55 (1.124) 0.8 (0.031) Maroon
3-2 capacity spring 5.55 (0.219) 30.5 (1.201) 0.55 (0.022) Light green
Throttle relief ball soring 6.6 (0.260) 20.3 (0.799) 0.8 (0.031) Light green
1-2 shift control spring 5.5 (0.217) 46.0 (1.811) 0.5 (0.020) Liaht oreen
1-2 shift soring 5.0 (0.197) 24.9 (0.980) 0.5 (0.020) Gray
2-3 shift soring 6.1 (0.240) 39.7 (1.563) 0.65 (0.026) Pink
3-4 shift spring 6.4 (0.252) 37.0 (1.457) 0.6 (0.024)
—

Throttle backup spring 6.4 (0.252) 33.5 (1.319) 0.6 (0.024) Pink
Throttle modulator front spring 5.0 (0.197) 27.8 (1.094) 0.6 (0.024) Red
Throttle modulator rear spring 7.15 (0.281) 30.8 (1.213) 0.85 (0.033) Red
1
ranoe control SDrina
6.15 (0.242) 39.2 (1.543) 0.65 (0.026) White
2 range control spring 3.95 (0.156) 32.1 (1.264) 0.45 (0.018)
—

Kick-down
SDrina
5.4 (0.213) 38.1 (1.500) 0.8 0.031)
—

Throttle assist spring 5.15 (0.203) 32.3 (1.272) 0.55 (0.022) Dark green
Throttle spring 5.4 (0.213) 48.3 (1.902) 0.8 (0.031)
—

Converter relief ball spring 6.9 (0.272) 24.1 (0.949) 0I9 (0.035) Maroon
Orifice check valve soring 5.0 (0.197) 12.5 (0.492) 0.23 (0.009)
—
30—31

30 TECHNICAL DATA
12. WHEEL AND TIRE
* ~— - Type
Item ~ ———_____ Standard Temporary spare
(if equipped)

Wheel
Size
5-Jx13
4-T
x 15

Wheel
Size 5 1/2-JJx14 4-T
x 15

Wheel
Size
6JJx15
4-T
x 15

Wheel
Offset
mm (in)
42 (1.65) 53 (2.09)
Wheel Diameter
of
pitch circle
mm
(in) 114.3 (4.5) Wheel
Material Steel
or
aluminum alloy Steel
Wheel
Number
of

fixing nuts
13 inch-wheel 4
4
or 5

Wheel
Number
of

fixing nuts 14 inch-wheel 5 4
or 5

Wheel
Number
of

fixing nuts 15 inch-wheel 5 4
or 5

Tire
Size
13 inch-wheel
6.45-13-6PR 165SR13 165/80R13 82S
185/70HR13 185/70R13 85H
T125/70D15
Tire
Size
14 inch-wheel
185/70HR14 185/70R14 87H 185/70R14 88H 185/70VR14
T125/70D15
Tire
Size
15 inch-wheel 195/60R15 86H 195/60VR15
T125/70D15
Tire
Air pressure kPa (kg/cm2, psi)
Front 216 (2.2, 31)
or
196 (2.0, 28)
Refer to tire labels for applications 412 (4.2, 60)
Tire
Air pressure kPa (kg/cm2, psi) Rear 177 (1.8,
26)

412 (4.2, 60)
Wheel and tire
Runout
mm (in)
Horizontal Steel wheel: 2.5 (0.098), Alminum allov wheel: 2.0 (0.079) max.
Wheel and tire
Runout
mm (in) Vertical 2.0 (0.079) max.
Wheel and tire Unbalance

g
(oz)
13 inch-wheel 11 (0.39) max. Wheel and tire Unbalance

g
(oz) 14 inch-wheel 10 (0.35) max.
Wheel and tire Unbalance

g
(oz) 15 inch-wheel 9 (0.32) max.

13. SUSPENSION
Item Specification
Front suspension

Type Strut
Toe-in
mm
(in) 0 ±
3 (0
±
0
12)
Front wheel alignment Camber angle 0°17' ±
45'
Front wheel alignment Caster angle 1 °13' ±
45'

King pin angle 12C 47'
Maximum front Inner 36°26'33"
steering angle Outer 30°59'15"
Stabilizer Type Torsion
bar
Stabilizer Diameter
mm (in)
20.0 (0.79)
Shock absorbers Standard suspension Oil type Shock absorbers Auto adjust suspension Low-pressure gas sealed type
Identification color Orange Green Light green Pink Brown Purple Gray Blue
Wire diameter
mm (in)
12.5
(0.49)
12.6
(0.49) 12.8 (0.50) 12.9 (0.51) 13.1 (0.52) 13.3 (0.53) 13.6 (0.54) 13.7 (0.54)
Coil springs* Coil inner diameter mm (in) 147.5 (5.8)
Free length
mm
(in) 344 (13.5)

CO <35
362
(14.3)
370
(14.6)
372 (14.6) 365 (14.4) 350 (13.8) 358 (14.1)
Coil number 4.99 5.09 5.31 5.42 5.53 5.46 5.34 5.45
* Refer
to
pages 13—5,6,7
for
coil spring applications

30-38

TECHNICAL DATA 30
Item Specification
Rear suspension

Type Strut
Rear wheel alignment
Toe-in
mm (in)
2WS 0
± 3 (0 ±
0.12)
Rear wheel alignment
Toe-in
mm (in) 4WS 3
± 3
(0.12
±
0.12) Rear wheel alignment Camber angle
2WS -0°30'
± 45'
Rear wheel alignment Camber angle 4WS 0°00'
± 45'

Maximum rear steering angle (4WS)
Inner 5°00'
± 45'
Maximum rear steering angle (4WS) Outer 5°00'
± 45'

Stabilizer Type Torsion
bar
Stabilizer Diameter
mm
(in) 16 (0.63)
Shock absorbers Standard suspension Oil type Shock absorbers Auto adjust suspension Low-pressure
c
as sealed type
Coil springs*
Identification color Orange White Yellow Brown Blue Green Red Pink
Coil springs*
Wire diameter
mm (in)
11.6 (0.45)
11.7
(0.46)
11.8
(0.46) 11.9
(0.47)
12.1
(0.48)
12.2
(0.48)
12.4
(0.49)
12.6
(0.50)
Coil springs* Coil inner diameter mm (in) 127.5 (5.0) Coil springs*
Free length mm (in) 297 (11.7) 306 (12.0)
314
(12.4) 323 (12.7)
327 (12.9) 332
(13.1)
336
(13.2)
340
(13.4)
Coil springs*
Coil number 5.44 5.58 5.72 5.87 6.03 6.04 6.21 6.36
* Refer
to
pages 13—8,9,10
for
coil spring applications.

15. BODY ELECTRICAL SYSTEM
-—— Body type
Item ~ - -.
Specification (W) -—— Body type
Item ~ - -. MX-6/CouDe Sedan Hatchback

Front exterior lights
Haloaen headliaht 60
+
55/55
Front exterior lights Turn sianal liaht 21 Front exterior lights Position light 5 Front exterior lights
Side turn sianal liaht 5
Rear exterior lights
Back-up light 21
Rear exterior lights
Back-up light 23 (Middle east)
Rear exterior lights
License
Dlate
liaht 5
Rear exterior lights Stop/Tail light 21/5 Rear exterior lights
Turn signal light 21
Rear exterior lights
Turn signal light 23 (Middle east)
Rear exterior lights
Rear foa liaht 21 (ECE)

30—39

30 TECHNICAL DATA
Body type Specification (W) (BULB TRADE NO)
Item MX-6/Coupe Sedan Hatchback

Brake 1.4
Oil pressure 1.4
Fuel 1.4
Washer level 1.4
Rear 1.4
4WS
— —
1.4 (ECE)
Indicator and warning lights
Door 1.4 Indicator and warning lights Seat belt 1.4 Indicator and warning lights ABS 1.4
Alternator 1.4
High beam 3.4
Turn signal 3.4
O/D OFF 0.8
A/T mode 0.8 (ECE)
A/T position 0.8
Glove compartment light 3.4
Interior lights Interior light 10
Luggage compartment light 5
Motor 4.8
Hazard switch 1.4
Cigar lighter 3.4
Auto cruise main switch 0.5
Illumination lights AAS switch 1.4
Rear defroster switch 1.4
A/T switch 1.4
A/T 3.4
IG switch 1.4

STANDARD BOLT AND NUT TIGHTENING TORQUE
Diameter
mm (in)
Pitch
mm (in)
4T 6T 8T Diameter
mm (in)
Pitch
mm (in) N-m m-kg ft-lb N-m m-kg ft-lb N-m m-kg ft-lb

6 (0.236) 1 (0.039) 4.2-6.2 0.43-0.63 3.1-4.6 6.9-9.8 0.7-1.0 5.0-7.2 7.8-11.8 0.8-1.2 5.8—8.8
8 (0.315) 1.25 (0.049) 9.8—14.7 1.0-1.5 7.2-10.8 16-23 1.6-2.3 12-17 18—26 1.8-2.7 13-20
10 (0.394) 1.25 (0.049) 20-28 2.0—2.9 14-21 31-46 3.2-4.1 23—34 36-54 3.7-5.5 27-40
12 (0.472) 1.5 (0.059) 34—50 3.5-5.1 25-37 55-80 5,6-8.2 41-59 63-93 6.4-9.5 46-69
14 (0.551) 1.5 (0.059)
— — —
75-103 7.7-10.5 56-76 102—137 10-14 75-101
16 (0.630) 1.5 (0.059)
— — —
116-157 12-16 85-116 156-211 16-22 115-156
18 (0.709) 1.5 (0.059)
— — —
167-225 17-23 123-166 221-299 23-31 163—221
20 (0.787) 1.5 (0.059)
— — —
231-314 24-32 171-231 308—417 31-43 227-307
22 (0.866) 1.5 (0.059)
— — —
314—423 32-43 231-312 417—564 43-58 307-416
24 (0.945) 1.5 (0.059)
— — —
475—546 41—56 298—403 536-726 55-74 396-536

30—40