check oil MAZDA 626 1987 Workshop Manual

15 WARNING AND SENDER
86U15X-068
86U15X069
86U15X-070
Door Switch
1. Check for continuity of the switch with an
ohmmeter.
2. If continuity is not as specified, replace the switch.
Washer Level Sensor
1. Check for continuity between C (LY) terminal and
D (B) terminal of the washer level sensor con-
nector.
Oil Pressure Switch
1. Disconnect the connector from the oil pressure
switch.
2. Check for continuity between the switch and a
body ground with each condition.
Coolant Level Sensor
1. Remove the level sensor and connect the con-
nector.
2. With the sensor not grounded to the body, start
the engine.
3. After checking that the warning light illuminates,
ground the threaded part of the sensor.
4. If the warning light remains illuminated, the sen-
sor is faulty and replace it.
73G15X-013
15—40

Engine Continuity
Running Yes
Stop No
Terminals Float level Continuity
C (LY)—D
(B)
Bottom Yes C (LY)—D
(B)
Above bottom No

2. If continuity is not as specified, replace the sensor.

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

OUTLINE 16
TROUBLESHOOTING GUIDE
Problem Probable cause Remedy Reference page
No blower
1. Main fuse (30
A) is
open Replace
operation
2 Malfunction
of
the blower motor Replace 3. Faulty resistor Replace 4. Malfunction
of
the blower switch Replace 5. Open
or
loose connection
in an
electrical circuit Repair 16—6,
7
Insufficient
1. Obstruction
in
the inlet
of
the blower unit Remove the obstruction 16-26
air
2. Clogged evaporator Clean the evaporator
with compressed
air
16-27 3. Frosted evaporator Check the thermostat 16-30 4. Air leakage Check for leakage
at
16-26 both sides
of
the cool-
ing unit

Compressor
1. Malfunction
of
the A/C relay Check operation 16—30
does not run,
2. Malfunction
of
the thermostat Check operation 16—30
or runs
3. Malfunction
of
the refrigerant-pressure switch Check operation 16—31
insufficiently
4.
Air
conditioner fuse (15
A)
failure Replace 5. Compressor drive belt
is
loose Readjust 16—23
6. Internal problem
of
the compressor Repair
or
replace
the
16—13
compressor 7. Battery voltage too low Recharge the battery 8. Layer short
in
the magnet coil Replace 9. Clutch face dirty with
oil
Clean
or
replace the 16-13
clutch 10. Excessive gap between the drive plate and
the
Adjust the gap 16-13
pulley
11. Open circuit
in
the magnet coil Replace 16—13
12 Open circuit Repair 16-6,
7
Refrigeration
Normal pressures are:

pressure is
High pressure
1472—1765 kPa
abnormal (15—18 kg/cm2, 214—255 psi)
Low pressure
197—294 kPa
(2—3 kg/cm2, 29—42 psi)
when: ambient temperature 35°C (95°F)
engine speed 1,500
rpm
Low pressure
1. Internal malfunction
of
the compressor Repair
or
replace the 16-13

is too high
compressor
2. Faulty contact
of
the sensing bulb
of
the expan-Repair 16-26
sion valve 3. Faulty insulation
of
the sensing bulb
of
the expan-Repair 16—26
sion valve
4. Expansion valve open too much Replace 16—26

Low pressure
1. Insufficient refrigerant Charge with refrigerant 16-8

is too low
2. Receiver-drier
is
clogged Replace 16-25
3. Expansion valve
is
clogged Replace 16-26
4. Faulty thermostat Check operation 16-30 5. Frosted piping Clean
or
replace the 16—29
piping

High pres-
1. Poor cooling
of
condenser Check and clean 16-24

sure is too
2. Loose cooling fan drive belt Readjust 16—23

high
3. Too much refrigerant Discharge the excess 16-8
refrigerant 4.
Air in
the system Evacuate and charge 16-8
the system

High pres-
1. Insufficient refrigerant Charge with refrigerant 16-8
sure is too
2. Internal malfunction
of
the compressor Repair
or
replace the 16-13

low
compressor

76G16X-004
16—5

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
69G16X-026
M10X1.25^45
Low-pressure x pressure
hose hose Compressor
COMPRESSOR
ON-VEHICLE INSPECTION
1. Connect the manifold gauge set.
2. Run the engine at 1,500 rpm.
3. Check the compressor flow:
a) High pressure is not low and low pressure is not
higher than normal.
b) Metallic sound.
c) Check to be sure that the high-pressure and low-
pressure gauges show the same value immedi-
ately after the air conditioner is switched OFF.
If both gauges show the same value immediate-
ly, it can be assumed that the gasket or the valve
inside the compressor is damaged.
4. Stop the engine.
5. Check the shaft seal and others for leakage.
6. Inspect the drive plate pulley magnetic clutch for
signs of oil.
7. Check the clearance between the drive plate and
pulley. (Refer to page 16—21.)
If any of the above checks reveal faults, repair the
compressor or magnetic clutch.
76G16X-635
Bracket No.2 Adjusting Bolt Bracket

, ,shaft

' stay _ M8XI. 25^20 MIO X 1.25 Compressor
69G16X-028
REMOVAL OF COMPRESSOR
1. Perform the Oil Return Operation. (See below.)
2. Disconnect the battery ground cable.
3. Disconnect the clutch lead wire from the wiring
harness.
4. Discharge the refrigerant from the refrigeration
system.
5. Disconnect the two flexible hoses. Plug the open
fittings immediately to keep moisture out of the
system.
6. Loosen the drive belt.
7. Remove the compressor mounting bolts and the
compressor.
Bracket No.1 M
to* 1.25

^Compressor
MIOxl. 25^110 MIOxl. 25^125
Oil Return Operation
1. If the refrigerant level is low, charge the system to
the specified amount.
2. Run the engine and air conditioner at idle and at
maximum cooling for at least 20 minutes.
76G16X-636
16—13

COMPRESSOR 16
4. Using external snap ring pliers, remove the snap
ring and then the cover.
69G16X-033
7.
8.
69G16X-035
Place the SST on the hub of the front head and
use it to remove the pulley assembly.
Note:
To keep it from changing shape, hook the pul-
ley puller's hook onto the V-pulley section.
Remove the coil lead wire from the wire holder on
the compressor.
Remove the coil by removing the screws.
Note:
Do not suspend the coil by holding the lead
wire.
Inspection
a) Drive plate
If the frictional surface shows signs of damage
due to excessive heat, the drive plate and pul-
ley should be replaced.
b) Pulley assembly
Check the appearance of the pulley assembly.
If the frictional surface of the pulley shows signs
of excessive grooving due to slippage, both the
pulley and drive plate should be replaced. The
frictional surfaces of the pulley assembly should
be cleaned with a suitable solvent before rein-
stallation.
c) Coil
Check the coil for a loose connector or cracked
insulation.
Remove the felt.
16—15

16 COMPRESSOR
DISASSEMBLY OF COMPRESSOR
Shaft Seal Assembly
1. Using the SST, remove the shaft seal cover as fol-
lows: attach the remover hook to the shaft seal cov-
er hook and draw the cover out slowly.
76G16X-608
Compressor Oil
1. Remove the drain plug and the oil filler plug, then
drain out the oil.
2. Measure the drained oil with a measuring cylinder.
3. Check the drained oil for any of the following con-
ditions:
a) Whether the opacity of the oil has increased.
b) Whether the oil color has changed to red.
c) Whether foreign matter, such as metal filings,
etc., is present in the oil.
Note:
If the oil drained from the compressor is as
described above, replaced it with new oil.
69G16X-037
16—16

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

16 CONDENSER
CONDENSER
ON-VEHICLE INSPECTION
1. Check the condenser fins for blockage or damage.
If the fins are clogged, clean them with compressed air.
If the fins are bent, straighten them with a screwdriver or pair of pliers.
2. Check the condenser fittings for leakage.
Repair or replace, if necessary.
REMOVAL OF CONDENSER
1. Discharge the air conditioning system. (Refer to page 16—9.)
2. Remove the front grille and the air seal cover.
3. Disconnect the discharge flexible hose from the condenser inlet fitting.
4. Disconnect the liquid line pipe from the condenser outlet fitting.
Note:
Plug the open fittings immediately to keep moisture out of the system.
6. Remove the condenser.
Condenser Radiator
Hole
76G16X-637
INSTALLATION OF CONDENSER
1. Install the condenser by using the two bolts and two nuts.
2. Connect the liquid line pipe and the discharge flexible hose to the condenser.
Tightening torque:
Liquid line pipe: 15—25 Nm (1.5—2.5 m-kg, 11—18 ft-lb)
Discharge flexible hose: 15—22 N-m (1.5—2.2 m-kg, 11—16 ft-lb)
3. Install the front grille and the air seal cover.
4. If the condenser is replaced with a new one, supply compressor oil.
Compressor oil: 30 cc (1.83 cu in)
5. Evacuate, charge, and test the air conditioning system.
16—24

RECEIVER-DRIER 16
RECEIVER-DRIER
ON-VEHICLE INSPECTION
1. Use a leak detector to check the sight glass, the
fusible plug, and the fittings for leakage.
Repair or replace, if necessary.
2. Check the receiver-drier for clogging.
a) Run the engine at fast idle with the air conditioner
on.
b) Check both inlet and outlet temperatures.
If there is a great difference between the two tem-
peratures, replace the receiver-drier.
76G16X-622
Receiver-drier
Condenser bolt
76G16X-638
REMOVAL OF RECEIVER-DRIER
1. Discharge the air conditioning system.
(Refer to page 16—9)
2. Disconnect the two liquid line pipes from the
receiver-drier.
Note:
Plug the open fittings immediately to keep
moisture out of the system.
3. Remove the receiver-drier from the bracket.
INSTALLATION OF RECEIVER-DRIER
1. Install the receiver-drier onto the bracket.
Note:
Do not remove the blind plugs until ready for
connection.
2. Connect the two liquid line pipes to the
receiver-drier.
Tightening torque:
15—25 N m (1.5—2.5 m-kg, 11—18 ft-lb)
3.
If
the receiver-drier is replaced with a new one, add
compressor oil to the compressor.
Compressor oil: 10 cc (0.61 cu in)
16-25