oil MAZDA 626 1987 Workshop Manual

INTRODUCTION 15
69G15X-006
4BG15X-003
69G15X-007
/Wire
Shield braid wire
Insulation
Replacement of Fuse
1. When replacing a fuse, be sure to replace it with
one of the specified capacity.
If, after a fuse has been replaced, it fails again, there
is probably a short in the circuit, and the wiring
should be checked.
2. Be sure the negative battery terminal is disconnect-
ed before replacing a main fuse.
3. When replacing a fuse, use the supplied fuse puller
in the fuse box cover.
Thin Insulation Wire
To reduce the weight of the wiring harness, a thin
coating of high resistance insulation material is used.
Shielded braid wire
This wire is used to prevent a malfunction in impor-
tant circuits that are susceptible to outside signals or
interference.
Eg.
Ignition coil
02 sensor
69G15X-008
15—5

15 INTRODUCTION
ELECTRICAL SYMBOLS
Switches and Relays
There is an NC (normally closed) and NO (normally open) indication for switches and relays; this indi-
cates the condition when there has been no change of operating conditions.
Relay

NO type relay NC type relay
Switch
NO switch NC switch
Not
in
operation (No power supply)

—Jtfiifij —o o—

Flow Stop Flow
In operation (Power supply)
^
^aijuiy—'

Flow
l=3X

Stop
Flow
Stop

Other Electrical Symbols

Holder
Box —
© ©

Holder
Box —
Holder
Box —

BATTERY BODY GROUND FUSE FUSIBLE LINK

(£)
* 1 fc

MOTOR COIL, SOLENOID RESISTOR VARIABLE RESISTOR

1

ii
-L ©

THERMISTER DIODE CONDENSER LIGHT

1

TRANSISTOR SPEAKER CIGARETTE LIGHTER HEATER

69G15X-009
15—6

WARNING LIGHT AND SENDER 1 5
Washer Fluid Low Level Warning Light
76G15X-039
76G15X-040
Engine Oil Pressure Warning Light
76G15X-041
15—35

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

16 COMPRESSOR
1. Bolt
2. Drive plate
3. Shim
4. Snap ring
5. Cover
6. Pulley assembly
7. Screw
8. Coil
9. Felt
10. Shaft seal cover
11. Front cylinder head
12. Seal seat
13. Shaft seal
14. O-ring
15. Gasket
16. Valve plate
17. Suction valve
18. O-ring
19. Oil filler plug
20. O-ring
21. Drain plug
22. Plate
23. Bolt
24. Gasket
25. Bolt
69G16X-030

(f''
(
(f''
( 1 49 9201 010 H
/
flSt^
ISSP
, —*
76G16X-605
DISASSEMBLY OF MAGNETIC CLUTCH
1. Using the SST to prevent drive plate rotation, re-
move the center bolt.
2. Using the SST, remove the drive plate.
3. Remove the shims from either the drive shaft or
the drive plate.
76G16X-606
16—14

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