MAZDA 626 1987 Workshop Manual
Manufacturer: MAZDA, Model Year: 1987, Model line: 626, Model: MAZDA 626 1987Pages: 1865, PDF Size: 94.35 MB
Page 901 of 1865
TROUBLESHOOTING (G4A-EL) 7B
Economy
4.3 (8/8)
3.8-(11/8)
3.4-I .^(6/8)
& c 2.9 5 8.(5/8) - °
S 5 2.4H 1 -i (4/8) « >
0)
05 A
(0/8)
0
i
Lock-up OFF
40 (25) 60 (37) 80 (50) 100 (63) 120 (74) 140 (87) 160 (99)
Vehicle speed km/h (mph)
6. Select D range (Hold mode).
7. Accelerate the vehicle and check 2-3 up- and down-shifts, no 1st, and no OD is obtained and that
the 2-3 shift points are as shown in the D range (Hold) shift diagram.
79G07C-094
7B—35
Page 902 of 1865
7B TROUBLESHOOTING (G4A-EL)
Evaluation
Condition Possible Cause
No 1-2 up- or down-shift Stuck 1-2 shift solenoid valve
Stuck
1
-2 shift valve
No 2-3 up- or down-shift Stuck 2-3 shift solenoid valve Stuck 2-3 shift valve
No 3-OD up- or down-shift Stuck 3-4 shift solenoid valve Stuck 3-4 shift valve
No lock-up shift Stuck lock-up control solenoid valve Stuck lock-up control valve
Incorrect shift point Mis-adjusted throttle sensor Sticking shift valves
Excessive shift shock or slippage
Excessive shift shock Stuck accumulators Stuck or no one-way check orifice
Worn clutches, brakes, or one-way clutch
No engine braking effect Worn clutches or brakes
76G07B-035
Noise and vibration
Drive the vehicle in OD (lock-up), OD (no lock-up), 3rd (Hold) and check for abnormal noise or vibration.
Note
Abnormal noise and vibration can also be caused by the torque converter, drive shaft, or
differential. Therefore, checking of cause must be made with extreme care.
Kick-down
Drive the vehicle in OD, 3rd and 2nd gears and check that kick-down occurs for OD->3, OD->2, OD->1,
3->2, 3-+1, 2-> 1, and the shift points are as shown in the shift diagram.
S Range Test
Shift pattern
1. Shift the selector lever to S range and select the Economy mode.
2. Accelerate the vehicle and check that 1-2 and 2-3 up-shifts and down-shifts are obtained, and that
no overdrive and no lock-up are obtained.
Note
a) Inspections of shift shock and shift point are not necessary because these are the same
as those of the D Range Test.
b)ln S range, the shift patterns for Economy and Power modes are the same.
c) Shift points are the same as those of the D range (Power) shift diagram.
3. While driving in S range (Economy mode) and 3rd gear, select the Hold mode and check that 3rd
gear is held until the 3-2 down-shift point as shown in the S range (Hold) shift diagram is achieved.
4. Accelerate the vehicle with S range (Hold mode) and check that 2nd gear is held.
7B i—36
Page 903 of 1865
TROUBLESHOOTING (G4A-EL) 7B
76G07B-036
Noise and vibration
Drive the vehicle in 2nd gear (Hold mode) and check for abnormal noise or vibration.
Note
Abnormal noise and vibration can also be caused by the torque converter, drive shaft or
differential. Therefore, checking of cause must be made with extreme care.
L Range Test
Shift pattern
1. Shift the selector lever to L range and select the mode.
2. Accelerate the vehicle and check that the 1-2 up- and down-shiftings are obtained and that no 3rd
gear, no OD, and no lock-up are obtained.
Note
Inspection of shift shock and shift point are not necessary because these are the same
as those of the D Range Test.
3. Drive in 1st gear then decelerate and check that engine braking effect is felt.
Note
a) In L range, the shift patterns for Economy and Power modes are the same.
b) Shift points are the same as those of the D range (Power) shift diagram.
4. While driving in S range (Hold mode) and 2nd gear, shift the selector lever to L range and check
that 2nd gear is held until the 2-1 down-shift point as shown in the L range (Hold) shift diagram
is achieved.
5. Accelerate the vehicle in L range (Hold mode) and check that 1st gear is held.
7B—37
Page 904 of 1865
7B TROUBLESHOOTING (G4A-EL)
86U07B-044
Noise and vibration
Drive the vehicle in 1st gear (Hold mode) and check for abnormal noise or vibration.
Note
Abnormal noise and vibration can also be caused by the torque converter, drive shaft or
differential. Therefore, checking of cause must be made with extreme care.
P Range Test
1. Shift into P range on a gentle slope, release the brake and check that the vehicle does not roll.
2. Shift into P range while driving the vehicle at maximum of 4 km/h (2.5 mph) on a level surface, and
check that the vehicle stops.
7B-38
Page 905 of 1865
TROUBLESHOOTING (G4A-EL) 7B
Vehicle Speed at Gearshift Table
Mode Range Throttle condition (Throttle sensor voltage) Shifting Drum speed rpm Vehicle speed km/h (mph)
Di -» D2 4930-5480 54-60 (33-37)
Fully opened (4.3 volt) D2 D3 5120—5520 102-110 (63—68)
D3 - OD 5380-5710 165-175 (102—109)
Di -»• D2 3470-4180 38-45 (24-28)
D2 -» D3 4020—4420 80—88 (50—55)
D3 - OD 3820-4530 117-139 (73-86)
Half throttle (1.6—2.2 volt)
Lock-up
ON (OD) 2670-3170 117-139 (73-86)
Powe
Lock-up OFF (OD) 2510-2970 110—130 (68—81)
OD - D3 2150-2630 94-115 (58-71)
D3 ->• D2 2020-2410 62—74 (38—46)
OD - D3 3490—3720 153—163 (95-101)
OD - D2 2050-2240 90-98 (56-61)
Kick-down OD -> Di 980-1120 43-49 (27-30) Kick-down D3 -<• D2 2940-3200 90-98 (56-61)
D3 -»• Di 1400-1500 43—46 (27—29)
D D2 -> Di 2160-2300 43—46 (27-29) D Di -»• D2 4470-5020 49—55 (30-34)
Fully opened (4.3 volt) D2 - D3 4770—5170 95-103 (59-64)
D3 -» OD 5380-5710 165-175 (102-109)
Di -> D2 2830-3380 31-37 (19-23)
D2 D3 2960-3120 59-68 (37-42)
D3 - OD 2870-3460 88-106 (55—66)
>. E o c o o
Half throttle (1.6-2.2 volt)
Lock-up
ON (OD) 2010-2420 88-106 (55-66) >. E o c o o
Lock-up OFF (OD) 1940-2310 85-101 (53-63)
LU OD - D3 1600-1960 70-86 (43-53)
D3 -> D2 1240-1570 38-48 (24—30)
OD ->• D3 3490-3720 153-163 (95-101)
OD - D2 1960—2150 86-94 (53-58)
Kick-down OD - Di 980-1120 43-49 (27-30) Kick-down D3 -> D2 2800-3070 86-94 (53-58)
D3 -> Di 1400—1600 43—49 (27—30)
D2 Di 2160-2460 43—46 (27—30)
S1 - S2 4930-5480 54-60 (33-37)
Fully opened (4.3 volt)
S2 - S3 5120-5520 102—110 (63-68) Fully opened (4.3 volt) S4 -» S3 3720-3950 163—173 (101—107) Fully opened (4.3 volt) S3 - S2 2940-3200 90-98 (56-61)
S S2 S1 2160-2310 43-46 (27-29)
S1 - S2 3470-4180 38-45 (24-28)
Half throttle (1.6-2.2 volt) S2 -» S3 4020—4420 80-88 (50-55) Half throttle (1.6-2.2 volt) S4 - S3 3720-3950 163—173 (101-107)
S3 -> S2 2020-2410 62-74 (38-46)
Fully opened (4.3 volt) Li - L2 4930-5480 54-60 (33-37)
L Fully opened (4.3 volt) L2 - Li 2160-2310 43-46 (27-29)
Half throttle (1.6—2.2 volt) Li - L2 3470-4180 38-45 (24-28)
D2 -» D3 850-1160 17-23 (11—14)
0 D D3 ->• D2 230—420 7-13 (4—8)
o OD - D3 3720-3950 163—173 (101—107) I S Fully closed (0.5 volt) S3 - S2 2940-3200 90-98 (56-61)
L L2 - Li 2160—2310 43-49 (27-30)
76G07B-037
7B-39
Page 906 of 1865
7B TROUBLESHOOTING (G4A-EL)
Slippage Test
This step is performed to inspect slippage of the friction elements.
Preparation 1. Perform the preparation procedure shown in STEP 4 (STALL TEST). 2. Connect a tachometer to the engine and set it in the cabin.
3. Connect the EC-AT Tester and the adaptor harness between the EC-AT control unit and wiring
harness.
Procedure
Drive the vehicle in each of the gears indicated below and check whether the vehicle speed or engine
speed is above or below specification excessively as shown by the drum speed.
Driving condition
Speed
Drum speed (rpm)
No. Gears Other condition Speed
1,000 2,000 3,000 4,000
1 1st L range, Hold mode 11 (7) 22 (14) 33 (20) 44 (27)
2 1st D range, Economy mode 11 (7) 22 (14) 33 (20) 44 (27)
3 2nd S range, Hold mode Vehicle speed km/h (mph) 20 (12) 40 (25) 60 (37) 80 (50)
4 3rd D range, Hold mode 31 (19) 61 (38) 92 (57) 123 (76)
5 OD D range, Economy
mode 44 (27) 88 (55) 131 (81) 173 (107)
6 OD D range, Economy mode, Lock-up Engine speed (rpm) 1,000 2,000 3,000 4,000
76G07B-038
Evaluation
When there is no malfunction in the electrical system or hydraulic system, but vehicle speed or engine
speed is below specification, the problem can be attributed to slippage of the friction elements.
Driving conditions below specification Possible Cause
No.1 condition only Low and reverse brake
No.2 condition only One-way clutch
No.3 condition only 2-4 brake band
No.4 condition only Coasting clutch
No.5 condition only 3-4 clutch
No.1-No,5 conditions Forward clutch
No.6 condition only Lock-up piston (in torque converter)
76G07B-039
7B—40
Page 907 of 1865
TROUBLESHOOTING (G4A-HL) 7B
TROUBLESHOOTING (G4A-HL)
GENERAL NOTE
In the event of a problem with the automatic transaxle, the cause may be in the engine, power train,
hydraulic control system, or electrical control system.
When troubleshooting, therefore, it is recommended to begin from those points that can be judged
quickly and easily. The recommended troubleshooting sequence is described below.
STEP 4: TIME LAG TEST
Check time lag of oil pressure supply
STEP 6: OIL PRESSURE TEST Check line, throttle, and governor pressures
This step checks conditions surrounding the automatic
transaxle.
This step checks the electrical control system.
• Function of the electrical control system
• Components
This step checks the power train. • Friction element slipping • Torque converter capacity
This step checks operation of the hydraulic control system. • Accumulators • Friction elements slipping • Regulating valves
This step checks functions of the electric control system and
hydraulic control system.
This step checks major points of the hydraulic control system.
• Oil pump • Line pressure control • Throttle pressure control
• Governer pressure control
STEP 5: ROAD TEST Check items on road test
• Shift point • Shift schedule
• Kick-down • Shift shock • Lock-up and overdrive inhibition
By following the above 6 steps, the cause of the problem should be located.
As another guide to faster location of the causes of problems, the Quick Diagnosis Chart is included
at pages 7B—42, 43.
In this chart, a circle is used to indicate the components that might be the cause of trouble for 20
types of problems. It is only necessary to check those components indicated by circles, at each step
of the troubleshooting process, in order to quickly locate the cause of the problem.
76G07B-040
7B—41
Page 908 of 1865
7B TROUBLESHOOTING (G4A-HL)
Quick Diagnosis Chart
The Quick Diagnosis Chart shows various problems and the relationship of various components that
might be the cause of the problem.
The following is an explanation of the symbols used in this chart.
1. Components indicated in the "Adjustment" column indicate that there is a possibility that the prob-
lem may be the result of an incorrect adjustment.
Check the adjustment of each component, and readjust if necessary.
2. The components indicated in the "Electrical System Inspection" column can be checked for mal-
function by the results of the checking procedure.
3. Components indicated in the "Stall Test" column can be checked for malfunction by the results
of the stall test.
4. Components indicated in the "Time Lag Test" column can be checked for malfunction by the results
of the time lag test.
5. Components indicated in the "Road Test" column can be checked for malfunction by the results
of the road test.
6. Components indicated in the "Oil Pressure Test" column can be checked for malfunction by the
results of the oil pressure test.
7. The checking, adjusting, repair or replacement procedures for each component is described in the
page(s) noted in the "Reference Page" column.
76G07B-041
Inspection point
Item
Adjustment
Electrical System Inspection
Electrical control system
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Road Test O o o o
7B—42
Page 909 of 1865
TROUBLESHOOTING (G4A-HL) 7B
-ON VEHICLE-OFF VEHICLE-
Accele-rating
Shifting
Slipping
Inspection point and reference page
Electrical
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Shift shock
Noise
Others
Vehicle does not move in D, 2, 1, or R range
Vehicle moves in N
range
Excessive creep
No creep at all
No shift
Abnormal shift
sequence
Frequent shifting
Excessive high or low shift point
No lock-up
No kick-down
Engine run away or slip when starting vehicle
Engine run away or slip when up- or down-shifting
Excessive N to D or N to R shift shock
Excessive shift shock when upshifting or downshifting
Excessive shift shock when changing range
Transaxle noisy in N or
P range
Transaxle noisy in
D, 2, 1, or R range
No engine braking
Transaxle
overheats
Engine will not start O
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76G07B-042
7B—43
Page 910 of 1865
7B TROUBLESHOOTING (G4A-HL)
STEP 1 (PRELIMINARY INSPECTION)
In this step, the fundamental points related to the automatic transaxle are checked. These points must
be kept in the correct condition at all times in order to assure proper operation of the automatic transaxle.
83U07B-025
1. Automatic Transaxle Fluid (ATF)
Check ATF level and condition. (Refer to page
7B-71)
76G07B-043
11
m
0 £
m
0 •
o #
m
Button need not
^ be depressed
Button must be pressed
2. Selector Lever
Check selector lever position and adjust if neces-
sary. (Refer to page 7B—72)
76G07B-044
3. Oil Leakage
Check for oil leakage.
(1) Warm up the ATF.
(2) Apply the parking brake and block the wheels
to prevent the vehicle from rolling.
(3) Shift the selector lever to R range.
(4) Check if oil leaks from the following oil seals
or gaskets.
(5) If oil leaks, replace the oil seal or gasket.
76G07B-215
7B—44