MAZDA 626 1987 Workshop Manual
Manufacturer: MAZDA, Model Year: 1987, Model line: 626, Model: MAZDA 626 1987Pages: 1865, PDF Size: 94.35 MB
Page 921 of 1865
TROUBLESHOOTING (G4A-HL) 7B
1 Range Test
Shift pattern
1. Shift the selector lever to 1 range.
2. Accelerate the vehicle with half (4/8) and full (8/8) throttle valve opening.
3. Check that the 1-2 up- and down-shifts are obtained and that no 3rd gear, no OD, and no lock-up
are obtained. The shift points must be as shown in the 1 range shift diagram.
Note
Vehicle speed on a chassis roller may not meet the specified shift diagram because of tire
size.
4. Check the up and down-shifts for shift shock or slippage.
5. Drive in 1st gear then decelerate and check that engine braking effect is felt.
1 range shift diagram
FE engine
8/8-1 i
7/8-
6/8-2
2 CT>
I 4/8-a> a. o a> 3/8-
o
2/8-
1/8-
20 40 60 80 (25) (37) (50)
Vehicle speed km/h (mph)
80 100 120 140 (63) (74) (87) (12)
76G07B-059
7B—55
Page 922 of 1865
7B TROUBLESHOOTING (G4A-HL)
F8 engine
8/8-1
7/8-
6/8-
O) I
i ! O) Q.
o 3/8- [ ^ I o
jE 2/8-1 I
1/8- |
0/8 ' 1 ' 1 ' 1 1 1 1 1 1— ' l 0 20 40 60 80 100 120 140 (12) (25) (37) (50) (63) (74) (87)
Vehicle speed km/h (mph)
76G07B-060
Noise and vibration
Drive the vehicle in 1st gear 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.
Vehicle Speed at Gearshift Table
Range Throttle condition Shifting Vehicle speed km/h (mph) Range Throttle condition Shifting FE engine F8 engine
D
Fully opened 1st ->• 2nd 50-65 (31-40) 47-62 (29-38)
D
Fully opened 2nd - 3rd 100-115 (62-71) 94-109 (58—68)
D
Half throttle (1/2)
1st - 2nd 17-32 (11-20) 16—31 (10—19)
D
Half throttle (1/2) 2nd -> 3rd 42-57 (26-35)
D
Half throttle (1/2) 3rd -> OD 79-94 (49-58) 74-89 (46-55)
D
Half throttle (1/2)
Lock-up 74-89 (46-55) D
Kick-down
OD - 3rd More than 88 (55) More than 82 (51) D
Kick-down
OD -> 2nd 34-103 (21-64) 33-97 (20-60)
D
Kick-down OD - 1st 27-49 (17-30) 26-48 (16-30)
D
Kick-down 3rd - 2nd 34—103 (21-64) 33-97 (20-60)
D
Kick-down
3rd - 1st
11
-49 (7—30) 10-48 (6-30)
D
Kick-down
2nd - 1st
1st - 2nd
4-49 (2-30) 3-48 (2-30)
1
Fully opened
2nd - 1st
1st - 2nd 56-71 (35-44) 52—67 (32—42)
1 Half throttle (1/2) 1st - 2nd 56-71 (35-44) 52-67 (32—42) 1
Kick-down 2nd -> 1st 46-61 (29-38) 43-58 (27-36)
D Fully opened 3rd lock-up 106-121 (66—75) 100-115 (62-71)
7B-56
Page 923 of 1865
TROUBLESHOOTING (G4A-HL) 7B
Evaluation
Condition Possible Cause
No 1-2 shift
Insufficient governor pressure
No 1-2 shift
Stuck 1 range control valve
No 1-2 shift Stuck 1-2 shift control valve No 1-2 shift
Stuck 1-2 shift valve
No 1-2 shift
No check ball (rubber ball)
No 2-3 shift
Insufficient governor pressure
No 2-3 shift
Stuck 2 range control valve
No 2-3 shift Stuck servo control valve No 2-3 shift
Stuck 2-3 shift valve
No 2-3 shift
No check ball (rubber ball)
No 3-OD shift
Insufficient governor pressure
No 3-OD shift
Excessive throttle pressure
No 3-OD shift Stuck OD release valve No 3-OD shift Stuck needle valve of the OD release solenoid valve No 3-OD shift
Stuck 3-4 shift valve
No 3-OD shift
No check ball (rubber ball)
No. Lock-up (Electric circuit is OK)
Insufficient governor pressure
No. Lock-up (Electric circuit is OK)
Stuck OD release valve
Stuck needle valve of the OD release solenoid valve No. Lock-up (Electric circuit is OK)
Stuck OD lock-up valve
No. Lock-up (Electric circuit is OK)
Stuck lock-up control valve
Shift occurred in 2 range Stuck 1-2 control valve Shift occurred in 2 range Stuck 2 range control valve
No kick-down Stuck throttle valve No kick-down Stuck kick-down valve
Incorrect shift point In D and 1 range
Excessive or insufficient governor pressure
Incorrect shift point In D and 1 range Excessive or insufficient throttle pressure Incorrect shift point In D and 1 range
Excessive or insufficient line pressure Incorrect shift point
In 1 range Stuck 1 range control valve
No engine braking effect
Stuck coasting bypass valve
No engine braking effect Fluid leakage from 2-3 accumulator seal rings No engine braking effect
No check ball (rubber ball)
Shift shock or slippage
In 1-2 and/or 3-OD shift
Fluid leakage from 1-2 accumulator seal rings
Shift shock or slippage
In 1-2 and/or 3-OD shift No check ball (rubber ball) or leakage
Shift shock or slippage
In 1-2 and/or 3-OD shift
No one-way check orifice or leakage
Shift shock or slippage In 2-3 shift
Fluid leakage from 2-3 accumulator seal ring
Shift shock or slippage In 2-3 shift
Stuck bypass valve
Shift shock or slippage In 2-3 shift
Stuck 2-3 timing valve
Shift shock or slippage In 2-3 shift Stuck coast bypass valve Shift shock or slippage In 2-3 shift
Stuck servo control valve Shift shock or slippage In 2-3 shift
No one-way check orifice or leakage
Shift shock or slippage In 2-3 shift
No check ball (rubber ball) or leakage
Shift shock or slippage
In 3-2 shift
Fluid leakage from 1-2 accumulator seal ring
Shift shock or slippage
In 3-2 shift No check ball (rubber ball) or leakage
Shift shock or slippage
In 3-2 shift Stuck 3-2 timing valve
Shift shock or slippage
In 3-2 shift
Stuck 3-2 capacity valve
83U07B-046
7B—57
Page 924 of 1865
7B TROUBLESHOOTING (G4A-HL)
Line Pressure Test
Preparation
1. Connect the SST to the line pressure output point
(square head plug L).
2. Connect a tachometer to the engine.
3. Perform the preparation procedure shown in STEP
3 (STALL TEST).
STEP 6 (OIL PRESSURE TEST)
This step checks line, throttle, and governor pressures to check the operation of hydraulic compo-
nents and for oil leakage.
83U07B-047
Procedure
76G07B-062
1. Start the engine and check that the idle speed is 900 rpm.
2. Shift the selector lever to D range.
3. Read the line pressure at idle.
4. Depress the brake pedal firmly with the left foot and gradually depress the accelerator pedal with
the right foot.
5. Read the line pressure as soon as the engine speed becomes constant, then release the accelera-
tor pedal.
Caution
Steps 4 to 5 must be performed within 5 seconds.
5. Shift the selector lever to N range and run the engine at idle for at least one minute.
6. Read the line pressure at idle and engine stall speeds for each range in the same manner.
7B—58
Page 925 of 1865
TROUBLESHOOTING (G4A-HL) 7B
Specified Line pressure:
Condition Line pressure kPa (kg/cm2, psi)
Range DSL R
When idling 350-490 (3.6-5.0, 51-71) 600-830 (6.1-8.5, 87-121)
At stall speed 980-1230 (10.0—12.5, 142—178) 1470-1960 (15.0-20.0, 213-284)
76G07B-063
Evaluation
Condition Possible Cause
Below specification
In all ranges
Worn oil pump
Below specification
In all ranges
Fluid leakage from the oil pump, control valve body
and/or transaxle case
Below specification
In all ranges Stuck pressure regulator valve
Below specification
In all ranges
Stuck throttle valve
Below specification
In all ranges
Stuck pressure modulator valve
Below specification
In D, 2 and 1 range
Fluid leakage from the forward clutch hydraulic circuit
Below specification
In D, 2 and 1 range Fluid leakage from the governor valve hydraulic circuit
Below specification
In D, 2 and 1 range
Fluid leakage from the N-R accumulator seal rings
Below specification In D and 1 range Fluid leakage from the 2-3 accumulator seal rings Below specification In D and 1 range Fluid leakage from the 1-2 accumulator seal rings Below specification
In D and R range Fluid leakage from the N-D accumulator seal rings
Below specification
In 2 and 1 range Fluid leakage from the coasting clutch hydraulic circuit
Below specification
In 2 and 1 range Stuck throttle backup valve
Below specification
In R and 1 range Fluid leakage from the low and reverse brake hydraulic
circuit
Below specification
In 2 range only Fluid leakage from 2-4 brake servo hydraulic circuit
Below specification
In 1 range only Stuck low reducing valve
Below specification
In R range only Fluid leakage from reverse clutch hydraulic circuit
Excessive line pressure
Stuck throttle valve
Excessive line pressure Stuck throttle modulator valve Excessive line pressure Stuck pressure regulator valve Excessive line pressure
Stuck throttle backup valve
76G07B-216
7B—59
Page 926 of 1865
7B TROUBLESHOOTING (G4A-HL)
Throttle Pressure Test
Preparation
1. Connect the SST to the throttle pressure output
point (Square head plug T).
2. Connect a tachometer to the engine.
3. Perform the preparation procedure shown in STEP
3 (STALL TEST).
83U07B-052
Procedure
76G07B-064
1. Start the engine and check that the idle speed is 900 _5o rpm.
2. Shift the selector to D range.
3. Read the throttle pressure at idle.
4. Depress the brake pedal firmly with the left foot and gradually depress the accelerator pedal with
the right foot.
5. Read the throttle pressure as soon as the engine speed becomes constant, then release the ac-
celerator pedal.
Caution
Steps 4 to 5 must be performed within 5 seconds.
7B-60
Page 927 of 1865
TROUBLESHOOTING (G4A-HL) 7B
Specified throttle pressure:
Condition Throttle pressure kPa (kg/cm2, psi)
When idling 83-113 (0.85-1.15, 12-16)
At stall speed 540-610 (5.5-6.2, 78-88)
Evaluation
Condition Possible Cause
Stuck throttle valve
Not within specification Stuck pressure regulator valve
Improper adjustment of throttle cable
7B-61
Page 928 of 1865
7B TROUBLESHOOTING (G4A-HL)
Governor Pressure Test
Preparation
1. Connect the SST to the governor pressure output
point.
2. Place the pressure gauge inside the vehicle.
3. Warm up ATF and check ATF level.
83U07B-054
Procedure
76G07B-065
1. Drive the vehicle in D range.
2. Read the governor pressure at the speeds listed in the table below.
Specified governor pressure:
Vehicle Speed km/h (mph) Governor Pressure kPa (kg/cm2, psi) Vehicle Speed km/h (mph) FE engine F8 engine
30 (19) 79-114 (0.81-1.16, 12-16) 82-117 (0.84-1.19, 12-17)
55 (34) 146-190 (1.49-1.94, 21-28) 157-201 (1.60-2.05, 23-29)
85 (53) 276-339 (2.81-3.46, 40-49) 302-366 (3.08-3.73, 44-53)
Evaluation
Condition Possible Cause
Not within specification
Fluid leakage from the line pressure hydraulic circuit
Not within specification Fluid leakage from the governor pressure hydraulic circuit Not within specification
Defective or stuck governor valve
7B-62
Page 929 of 1865
ELECTRICAL SYSTEM COMPONENTS 7B
Economy position
Power position • POWER
•ECONO
76G07B-066
86U07B-049
86U07B-050
ELECTRICAL
SYSTEM COMPONENTS
MODE SWITCH (G4A-EL)
Inspection of Operation
1. Turn the ignition switch ON.
2. Check that the mode indicator illuminates at each
model.
3. If it is not working properly, check terminal voltage
of mode switch.
Inspection of Continuity
1. Disconnect the mode switch.
2. Turn the ignition switch ON and light switch OFF.
3. Check the voltage between each terminal and
ground.
Mode Voltage Mode a b d e f
Power Approx. 12V
Below 1.5 V Below 1.5 V Below 1.5 V Below 1.5 V
Economy Below
1.5 V
Below
1.5 V Below 1.5 V
Below
1.5 V
Approx.
12V
4.
If
correct, check for continuty between the terminal.
Inspection of Terminal Voltage
1. Disconnect the mode switch connector.
2. Check continuity of the terminals.
Mode
Economy
Power
Connector terminal
O
O
f
o
-o
o
o
-o
-o
O—O: Indicates continuity
3. If not correct, replace the mode switch.
HOLD SWITCH (G4A-EL)
Inspection of Operation
1. Turn the ignition switch ON.
2. Check that the hold indicator illuminates while
switch depressed. Release the switch and mode
indicator lights are out.
3. If it is not working properly, check terminal voltage
of hold switch.
76G07B-067
7B—63
Page 930 of 1865
7B ELECTRICAL SYSTEM COMPONENTS
Inspection of Terminal Voltage
1. Remove the consol box.
2. Turn the ignition switch ON.
3. Check the voltage between the terminal (B) and
ground while depressing the switch.
Terminal voltage Switch
Approx. 12V Depressed
Below 1.5V Released
4. If correct, check continuty between the terminal.
86U07B-052
Inspection of Continuity
1. Disconnect the hold switch connector.
2. Check for continuity between the terminals while
depressing the switch.
Continuity Switch
YES Released
NO Depressed
3. If not correct, replace the hold switch.
86U07B-053
OD OFF SWITCH (G4A-HL)
Inspection of Continuity
1. Remove the selector lever knob.
2. Check the continuity of the terminals.
Switch Continuity
Depressed No
Released Yes
3. If not correct, replace the selector lever knob.
Inspection of Terminal Voltage
1. Check that continuity of the switch is OK.
2. Turn the ignition switch ON.
3. Check the voltage between terminal A and B, and
between terminal A and ground.
Terminal Voltage
A and B Approx. 12V
A and ground Approx. 12V
4. If not correct, check the wiring harness.
7B-64