air condition MAZDA 626 1987 Repair Manual

TROUBLESHOOTING
7C

ON VEHICLE -OFF VEHICLE
-

\ Inspection point
\
and
reference
\ page
Condition


in cd
ra
CM CM CM
I
I I
o
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I—
r~—
r—
7C—27
7C—23,24
Section
4A

7C—14
7C—20,22
7C-75

CM
0>
[—
CO
LO I
I I
O
O O
r^ r—
Section

5
CD CM
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I I
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w
CM
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I I
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r-— I—
r-—
7C—54
7C-71
7C—66,

98

7C-68,

71 \ Inspection point
\
and
reference
\ page
Condition

ATR

level
and
condition

Selector

lever

Inhibitor

switch
and
wiring

Vacuum

diaphragm
and
piping

Kick-down
solenoid,
kick-down
switch

and

wiring

Engine

idle

speed

and
condition
Engine
stall

speed

Fluid

pressure
(Line
and
governor)
Control
valves

Governor

valve
Band
servo

Transaxle

air
check
Ignition
switch
and

starter

Front
clutch

Rear

clutch

Brake

band

Low
and

reverse

brake
Oil
pump
Hydraulic
circuit

Torque

converter

One-way

clutch
Parking
linkage

Planetary

gear

Snift
sequence

Shifts from
1st to
2nd
or
2nd
to
3rd
in 1
range

Slipping

Practically
no
shift shock,
or
slip-page while 1st
to
2nd shifting 1
2 •
3
• •
•
4 5
•
7 6
• •
• ©
•
• ©
•
• •
•

Slipping

Pracatically
no
shift shock
or
slip-page while 2nd
to
3rd shifting 1
2 •
3
• •
•
4 5
•
7 6
•

Slipping

No shift shock
or
engine runaway
in 1 to 2
range shift 1
2 •
3
• 4
5
• 6
•
• 7
• •
• ©
•
© •
•
• •
•
Slipping

Engine runaway
or
slip when shifting
3rd to 2nd
1
• •
2
• •
•
3 4
•
5 6
• ®
• ©
•
• ®
•
• •
•

Slipping

Slippage evident when vehicle starts moving 1
2 •
5
• •
•
3 4
•
• 6
• •
• •
•
® ©
•
• •
•

Noise

Transaxle noisy
in P and N
range

Noise
Transaxle noisy
in D, 2, 1 and
R ranges •
(D •
•
© •
•
© •
©

Others

No engine brake
in 1
range •
1 •
•
• •
•
2 3
•
• 4
• •
• •
©
• ©
•
• •
•

Others

Vehicle moves
in P
range
or
parking gear
not
disengaged when
P
range disengaged
•

Others
Transaxle overheats 3
4 5
•
2 6
• ®
©
(D ©
© ©
©
• •
©
Others

White smoke from exhaust while running 1
• •
2
• •
3
4 5
•
• 6
• ®
© ©
©
© ©
©
• •
@

Others

Abnormal odor from
oil
level gauge pipe ©
® ©
©
© ®
©
• •
©
76G07C-016
Differential
Problem Probable Cause Remedy Page
Noise Insufficient fluid Add 7C—25
Low fluid quality Replace with specified
ATF
7C-25
Worn bearing Adjust
or
replace 7C-79
Contact surface
of
gears worn Replace 7C-79
Tooth surface
of
gears damaged Replace 7C-79
Contaminated
ATF
Repair
or
replace 7C-25
Differential gear damaged, excessive backlash Replace 7C-79
Excessive bearing preload Adjust 7C—94
76G07C-017
7C—11

POWER BRAKE UNIT 1 1
86U11X-038
0
o
X
\ V^ Third
Second
^ First
86U11X-039
O X

fiSy

V
86U11X-040
Pedal-depression Pre!tur!9au9e
force gauge
^Intake manifold
86U11X-041
POWER BRAKE UNIT
FUNCTION CHECK
Simple Method
First step
1. With the engine stopped, depress the pedal a few
times.
2. With the pedal depressed, start the engine
3. If immediately after the engine starts the pedal
moves down slightly, the unit is operating.
Second step
1. Start the engine.
2. Stop the engine after it has run for
1
or 2 minutes.
3. Depress the pedal with the usual force.
4.
If
the first pedal stroke is long and becomes short-
er with subsequent strokes, the unit is operating.
5. If a problem is found, inspect for damage of the
check valve or vacuum hose, and examine the in-
stallation condition. Repair if necessary, and inspect
it once again.
Third step
1. Start the engine.
2. Depress the pedal with the usual force.
3. Stop the engine with the pedal still depressed.
4. Hold the pedal down for about 30 seconds.
5. If the pedal height does not change, the unit is
operating.
6. If there is a problem, check for damage to the
check valve or vacuum hose, and check the con-
nection. Repair if necessary, and check once
again.
If the nature of the problem is still not clear after fol-
lowing the 3 steps above, follow the more detailed
check described in "Method using tester".
Method Using Tester
Connect a pressure gauge, vacuum gauge, and ped-
al depression force gauge as shown in the figure. Af-
ter bleeding the air from the pressure gauge, conduct
the test as described in the 3 steps below.
Note
Use commercially available gauges and ped-
al depression force gauge.
11—27

1 1 ANTI-LOCK BRAKE SYSTEM (ABS)
Flow Chart (Refer to Wiring Diagram, Page 11—72.)
ABS-1
Possible failure
Right front wheel speed sensor, Harness, Hydraulic unit
Disconnect Q-01 (11-pin) connec-tor. Check continuity
at
harness side.
Q-01 (11-pin)
I
Continuity
Y (2C) Ground No

OK

Measure resistance
at
harness side.
Q-01 (11-pin) Resistance
Y (2C)
i 0
(2D) 800—1200
Q
OK
NG
Repair harness.

(Control unit — Right front sensor)
NG

Disconnect Q-03. Measure resistance
at
sensor.
Q-03 Resistance
Y
[ O
800—1200 Q

NG
Replace right front wheel speed sensor.

OK
Repair harness.

(Control unit — Right front sensor)

Check followings*
• Clearance between sensor and rotor standard: 0.3—1.1
mm
(0.012-0.043
in)
• Objects sticking
to
sensor
or
rotor
• Damaged sensor
or
rotor
• Sensor installation Tightening torque: 16-23 N-m (1.6-2.3 m-kg, 12—17 ft-lb)

OK

Connect Q-01 (11-pin) connector. Jump GB
to B at
Q-07 connector. Start engine. Check that warning light stays ON. Drive vehicle and check that warning light flashes (0.25 sec ON OFF)
at 15
km/h
(9
mph).

NG
Repair
or
replace
as
necessary
* All conditions can
be
verified
as
follows,
if an AC
voltmeter
is
available. 1. Jack
up
vehicle. 2. Measure sensor voltage while rotating right front wheel
one
revolution
per
second.
Q-01 (11-Din) Voltage (AC)
Y (2C) O (2D) More than 0.25V

NG
Check Q-01 connector,
or
Replace control unit.

OK

Replace hydraulic unit.

76G11X-055
11—76

ANTI-LOCK BRAKE SYSTEM (ABS) 1 1
ABS-2
Possible failure
Left front wheel speed sensor, Harness, Hydraulic unit
Disconnect
Q-01
(11-pin)
con-
nector.
Check continuity
at
harness side.
Q-01 (11-pin) Continuity
W (2A) Ground No

OK

Measure side.
Q-01 (11-pin) Resistance
W (2A) R (2B) 800-1200
fl
OK

Connect Q-01 (11-pin) connector. Jump GB
to B
at (Q-07) connector. Start engine.
Check that warning light stays ON. Drive vehicle and check that warn-ing light flashes (0.25 sec ON OFF) at
15
km/h
(9
mph).

NG
Repair harness (Control unit
—
Left front sensor)
resistance
at
harness

NG

Disconnect Q-02 Measure resistance
at
sensor.
Q-02 Resistance
W
| R
800-1200
0
OK

Check followings*
• Clearance between sensor and rotor standard: 0.3—1.1
mm
(0.012-0.043
in)

• Objects sticking
to
sensor
or
rotor • Damaged sensor
or
rotor
• Sensor installation Tightening torque: 16-23 N m
(1.6—2.3 m-kg, 12-17 ft-lb)

NG
OK
NG
Repair
or
replace
as
necessary

NG
Check Q-01 connector,
or
Replace control unit.

OK

Replace hydraulic unit.
Replace left front wheel speed
sensor.
Repair harness.
(Control unit
—
Left front sensor)
"All conditions can
be
verified
as
follows,
if an AC
voltmeter
is
available. 1. Jack
up
vehicle. 2. Measure sensor voltage while rotating left front wheel
one
revolution
per
second.
Q-01 (11-pin) Voltage (AC)
W (2 A)
|
R (2B) More than
0
25V

86U11X-146
11-77

1 1 ANTI-LOCK BRAKE SYSTEM (ABS)
ABS-3
Possible failure
Rear wheel speed sensor, Harness, Hydraulic unit
Disconnect
Q-01
(11-pin)
con-

nector.
Check continuity
at
harness side.
Q-01 (11-pin) Continuity
G (2H) Ground No YG (2E) Ground No
Measure side.
Q-01 (11-pin) Resistance
YG (2E) YL (2F) 800—1200
fi
G (2H)
] L
(2J) 800—1200
fi
OK

Connect Q-01 (11-pin) connector. Jump GB
to B at
Q-07 connector. Start engine.
Check that warning light stays ON. Drive vehicle and check that warn-ing light flashes (0.25 sec ON OFF) at
15
km/h
(9
mph).

NG
Repair harness (Control unit
—
Rear speed sensor)

OK

resistance
at
harness

NG

Disconnect Q-09 and Q-05 Measure resistance
at
sensor.
Q-09, Q-05 Resistance
YG YL 800-1200
0
G L 800-1200
0
OK

Check followings* • Clearance between sensor and rotor standard: 0.3—1.1
mm
(0.012-0.043
in)
• Objects sticking
to
sensor
or
rotor
• Damaged sensor
or
rotor
• Sensor installation Tightening torque: 16-23 N-m
(1.6—2.3 m-kg, 12—17 ft-lb)

NG
Repair
or
replace
as
necessary

NG
Check Q-01 connector. Replace control unit.
or

OK

Replace hydraulic unit,
Replace rear wheel speed
sensor.

OK
Repair harness.
(Control unit
—
Rear speed sensor)
* All conditions can
be
verified
as
follows,
if an AC
voltmeter
is
available. 1. Jack
up
vehicle. 2. Measure sensor voltage while rotating rear wheel
one
revolution
per
second.

fi
wheel Q-01 (11-pin) Voltaqe (AC)
Left |YG (2E) YL (2F) More than 0.25V Right G (2H) L(2J)
More than 0.25V

86U11X-147
11-78

SIDE
PROTECTOR MOLDING
1
4
Removal
1. Using a screwdriver or knife, twist the molding end,
being careful not to damage the painted surface,
and separate the adhesive for 20—30 mm
(0.79—1.18 in).
2. Pull the separated portion to remove it.
3. Use a knife to remove any adhesive remaining on
the body or molding.
Note
Remove as much adhesive as possible with-
out damaging the painted surface.
7BU14X-034
7BU14X-035
7BU14X-036
4. If the adhesive is difficult to remove, soften it with
a hot air blower.
Installation
1. Remove any grease or dirt from the molding adhe-
sion surface and the body surface.
2. Mark the installation position on the body with
masking tape.
3. Attach double-sided adhesive tape to the molding
adhesion surface.
4. Align the molding on the body, and attach it se-
curely.
Note
Adhesion conditions deteriorate if air temper-
ature is 20°C (68°F) or less; heating of the
body is thus recommended.
7BU14X-037
14—43

METER 15
Water Temperature Gauge
1. Remove the connector from the water thermo
sensor.
2. Connect the red lead of the SST to the connec-
tor, and the black lead to a body ground.
86U15X-041
C -&TEMP H
r
•
|
7 •
V i y
86U15X-042
3. Set the SST to the resistance values shown in the
following table.
4. Turn the ignition switch ON and check that the seg-
ment displays the correct values. If the segment
displays the correct values, check the gauge unit.
If not, replace the digital meter assembly or repair
wiring harness.
Caution
Continue the above checks for at least two
minutes each to correctly judge the condition.

Segment Resistance
(Q)
Segment Resistance
(Q)
1-10
less than
17
1-5
33-89

1-
9
17—20
1-4
89-120

1—
8
20—26
1-3
120-145

1—
7
26-28
1-2
145-177

1-
6
28-33
1
more than
177
INSPECTION OF METER SENDER
Fuel tank unit (except 4WS model)
1. Disconnect the connector from the fuel tank unit.
2. Remove the fuel tank unit from the tank.
3. Connect an ohmmeter to terminal "b" of con-
nector.
4. Move the unit arm slowly from point (F) to point
(E), and read the resistance values. If not as speci-
fied, replace the unit.
86U15X-043
15—29

1 5 TURN AND HAZARD LIGHT
TROUBLESHOOTING
Note
Check the TURN 15A fuse in the fuse box before troubleshooting.

Terminal Voltage
H (BG) 12V

OK

Check the voltage between each terminal
of
flasher unit connector and
a
body ground with each con-dition.
Terminal Condition Voltage
A(B) Any time OV
E (BR) Turn switch
is
Riaht 12V
F (GY) Turn switch
is
left 12V
H (Br) Anv time 12V

OK
Turn function does not operate.

Check the flasher unit. Refer
to
page 15—47

OK

Check the turn signal switch. Refer
to
page 15—14

OK
NG
NG

Check the voltage
at H
(BG) terminal
of
the combina-tion switch (Turn).
Replace the unit.
Replace the switch.

NG
Repair harness. (Fuse box
to
combination switch)
Repair harness.

NG

Terminal Wiring harness
A (B) Flasher unit
to
ground
E (BR) Flasher unit
to
combination switch
F (GY) Flasher unit
to
combination switch
H (Bri Fuse box
to
Flasher unit
Check the lights and wiring harness (Each bulb
to a

body ground)

NG
Replace the lights
or
repair the wiring harness.

OK

Repair harness. (Flasher unit
to
each bulb)
76G15X-045
Hazard function does not operate. (Turn func-tion is normal)

Check the hazard switch. Refer
to
page 15—19,
20
OK
NG
Replace the switch.
Check the voltage
at
each terminal
of
the hazard
switch connector.
Terminal Voltage
B (GR) 12V
D (B) OV

15-46
NG
Repair the wiring harness. (Flasher unit
to
hazard
switch, hazard switch
to
ground)

OK

Check the flasher unit. Refer
to
page 15—47
NG
Replace the unit.

76G15X-046

SLIDING SUNROOF 1 5
TROUBLESHOOTING
Sunroof does not operate correctly.

Check SUNROOF 15A fuse.
Turn ignition switch
ON

Check the voltage
at
each terminal
of
the sunroof
re-
lay No.
1
and No.
2.

Relay Terminal Voltage
No.
1

G 12V
No.
1
G 12V No.
1

B OV
No.
2

G 12V
No.
2
G 12V No.
2

B OV

OK

Check the sunroof relays. Refer
to
page 15—92.

OK

Check the voltage
at
each terminal
of
the sunroof motor.

OK

Check the sunroof motor and limit switch. Refer
to
page 15—92,
93.
OK

Check
for
12V
at L
terminal
of
the sunroof motor connector.

OK

Check the voltage
at
each terminal
of
the sunroof switch connector with each roof condition.

OK

Terminal Voltage
Y OV
YR OV
YG 12V
Terminal Roof condition Voltaae
L Close 12V
LY Close 12V
LG Open 12V
LW Tilt
up
12V
LR Any time 12V
B Any time OV
Check the sunroof switch. Replace
if
necessary.
Re-
fer
to
page 15—92.

NG
Repair the harness. (Fuse box
to
relay, Relay
to

body ground)

NG
Replace the relays.

NG
Repair the harness. (Relay
to
motor).

NG
Replace the motor and limit switch.

NG
Repair the harness. (Relay
to
motor)

NG
Repair the harness. (Motor
to
switch Fuse box
to

switch Switch
to
body ground)

76G15X-078
15—91

1 5 POWER DOOR LOCK
TROUBLESHOOTING

Terminal Voltage
WG 12V
B OV
Check the voltage
at GB
terminal
of
the power door lock relay with each switch condition.
Terminal Condition Voltage
GB Lock 12V GB Unlock OV

OK

Check the voltage
at R
and
G
terminal
of
the power door lock relay with each switch condition.
Terminal Condition Voltaae
R Lock OV R Unlock 12V
G Lock 12V G Unlock OV

Power door lock does not operate.

Check DOOR LOCK 30A fuse.

OK
NG
Short circuit.
Check the voltage
at
each terminal
of
the power door lock relay connector.

NG
Repair the harness. (Fuse box
to
relay, Relay
to
ground)

OK

Check the power door lock switch. Refer
to
page 15-107.

OK
NG
Replace the switch.

NG
Repair the harness. (Door lock switch
to
relay)

NG
Replace the door lock relay.

OK

Check the power door lock motor. Refer
to
page
15-107.

OK

Repair the harness. (Relay
to
each motors)

NG
Replace the door lock motor.

76G15X086
15—106