check engine MAZDA 626 1987 Workshop Manual

0 PRE-DELIVERY INSPECTION
PRE-DELIVERY INSPECTION TABLE
EXTERIOR
INSPECT and ADJUST, if necessary, the following items
to the specifications:
• Glass, exterior bright metal and paint for damage
• Wheel lug nuts
88—118 N m (9—12 m-kg, 65—87 ft-lb)
• Tire pressures (Refer to section 12)
• All weatherstrips for damage or detachment
• Operation of bonnet release and lock
• Operation of fuel lid and trunk lid (Back door) opener
• Door operation and alignment
• Headlight aiming
INSTALL following parts:
• Wheel caps or rings (if equipped)
• Outside rear view mirror(s)
UNDER BONNET—ENGINE OFF
INSPECT and ADJUST, if necessary, the following items
to the specifications:
• Fuel, coolant and hydraulic lines, fittings, connections and
components for leaks
• Engine oil level
• Power steering fluid level (if equipped)
• Brake and clutch master cylinder fluid level (if equipped)
• Windshield washer reservoir fluid level
• Radiator coolant level and specific gravity
Protection °C (°F) Specific gravity at 20°C (68°F)
-4 (25) 1.028
-16(3) 1.054
-26 (-15) 1.066 -40 (-40) 1.078
• Tightness of water hose clamps (including heater hoses)
• Tightness of battery terminals
• Manual transaxle oil level
• Drive belt tensions (Refer to section 1)
• Accelerator cable and its linkage for free movement
• Headlight cleaner fluid level (if equipped)
CLEAN spark plugs
INTERIOR
INSTALL the following parts:
• Rubber stopper for inside rear view mirror
• Fuse for accessories
CHECK the operations of the following items:
• Seat controls (sliding and reclining) and head rest
• Door locks including childproof door locks (if equipped)
• Seat belts and warning system
• Ignition switch and steering lock
• Inhibitor switch (ATX only)
• All lights including warning and indicator lights
• Sound warning system
• Headlight cleaner (if equipped)
• Horn, wipers and washers (front and rear, if equipped)
• Radio and antenna (if equipped)
• Cigarette lighter and clock
• Remote control outside rear view mirrors (if equipped)
• Power windows (if equipped)
• Heater, defroster and air conditioner at various mode
selection (if equipped)
• Sunroof (if equipped)
ADJUST antenna trimmer on radio (if equipped)
CHECK the following items:
• Presence of spare fuse
• Upholstery and interior finish
CHECK and ADJUST, if necessary, the following items:
• Operation and fit of windows
• Pedal height and free play of brake and clutch pedal
Pedal height mm (in) free play mm (in)
Clutch pedal 216.5-221.5 (8.52-8.72) 5-13 (0.2-0.51)
Brake pedal 222-227 (8.74-8.94) 4-7 (0.16-0.28)
• Parking brake
5-7 noches/98 N (10 kg, 22lb)
UNDER BONNET—ENGINE RUNNING AT
OPERATING TEMPERATURE
CHECK the following items:
• Operation of idle-up system for air conditioner or power
steering (if equipped)
• Automatic transaxle fluid level
• Operation of dash pot
• Initial ignition timing
• Idle speed
ON HOIST
CHECK the following items:
• Underside fuel, coolant and hydraulic lines, fittings, con-
nections and components for leaks
• Tires for cuts or bruises
• Steering linkage, suspension, exhaust system and all un-
derside hardware for looseness or damage
REMOVE protective cover from brake discs
ROAD TEST"
CHECK the following items:
• Brake operation
• Clutch operation
• Steering control
• Operation of meters and gauge
• Squeaks, rattles or unusual noise
• Engine general performance (including turbo)
• Emergency locking retractors
• Cruise control system (if equipped)
AFTER ROAD TEST
REMOVE seat and floor mat protective covers
CHECK for necessary owner information materials, tools and
spare tire in vehicle
-76G00X-002
0-2

For ECE Leaded gasoline
Chart symbols:
I
A
R
T
O
X
Inspect: Visual examination or functional measurement of a system's operation (performance)
Adjust : Examination resulting in adjustment or replacement
Replace or change
Tighten
Applicable
Not applicable
F8 engine with carbretor, MTX, ATX
FE engine with carbretor, MTX, ATX
FE DOHC engine with fuel injection, 4WS, MTX
RF-CX, RF-N engine with MTX
REMARKS:
Major service interval at 12 months/20,000 km (12,000 Miles), Lubrication service based on distance only 10,000 km (6,000 Miles) not time
After 80,000 km (48,000 Miles) or 48 months, continue to follow the described maintenance items and intervals periodically.
As for * marked items in this maintenance chart, please pay attention to the following points.
*1 Replacement of the timing belt is required at every 100,000 km (60,000 Miles). Failure to repace the timing belt may result in damage to the engine.
*2 If the vehicle is operatie under the following conditions, it is suggested that the engine oil and oil filter be changed more often than at usual recommended intervals.
a) Driving in dusty conditions.
b) Extended periods of idling or low speed operation.
c) Driving for a prolonged period in cold temperatures or driving only short distances regulary.
*3. If the vehicle is operated in very dusty or sandy areas, inspect and, if necessary, replace more often than at usual recommended intervals.
*4. This is a full function check of all electrical systems, i.e., all lights, washers (including condition of blades) electrical windows, sunroof, horn, etc....
*5. Replace every two years.
If there has been continuous hard driving, mountain driving, or if the brakes are used extensively or the vehicle is operated in extremely humid climates, the
brake fluid should be changed annually.
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Emission Control and Related Systems
The ignition and fuel systems are vitally important to the proper operation of the emissions control and related systems, as well as for efficient engine operation.
It is strongly recommended that all servicing related to these systems be done by your Authorized Mazda Dealer.
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0 1 Interval
Procedure & item
Number of Months or km, whichever corns first
©1 ©2 ©3 ©4 Service data and inspection point Page
Interval
Procedure & item
Months — 6 12 18 24 30 36 42 48 ©1 ©2 ©3 ©4 Service data and inspection point Page
Interval
Procedure & item
x 1000 Km 1 10 20 30 40 50 60 70 80 ©1 ©2 ©3 ©4 Service data and inspection point Page
Interval
Procedure & item
Miles x
1000 0.6 6 12 18 24 30 36 42 48
©1 ©2 ©3 ©4 Service data and inspection point Page
Clutch pedal I 1 I I I I I I O O o o
• Operation
• Pedal height: 216.5—221.5 mm
(8.524—8.720 in) • Free play: 5—13 mm (0.20-0.51 in)
6-4
Brake pedal I 1 I I I I I I O o o o
• Operation
• Pedal height: 222—227 mm (8.74-8.94 in)
• Free play: 4—7 mm (0.16—0.28 in)
11—11
11—11
Parking brake A A A A o o o o
• Operation
• Lever stroke:
5—7 notches
11—65
Power brake unit and hoses 1 I I I o o o o • Operation • Check the vacuum hoses and con-nectors
11—27
Brake fluid " I 1 I R I I I R o o o o • Fluid level 11-6
Clutch fluid I 1 I I I I I I o o o o • Fluid level 6—4
Power steering fluid I 1 I I I I I I
I
o
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o
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o o • Fluid level 10—11
Power steering system and hoses 1 I I
I I
I
o
o"
o
o o o • Fluid leakage or oozing 10—13
Air cleaner element *3 1 R I R —
1A—6 1B—5 1C—5
Choke system 1 I I o o X X
• Carburetor linkage • Choke diaphragm • Choke valve clearance
• Choke Unloader system
4A-26 4A—34 4A—34 4A—33
Cooling system (including coolant level adjustment) 1 I I I o o o o • Hoses for cracks or wear
• Coolant level
3A—5 3B—4
Engine coolant Replace every 2 years o o o o -3A-5 3B-4

r
For ECE Unleaded gasoline
Chart symbols:
I
A
R
T
O
X
Inspect: Visual examination or functional measurement of a system's operation (performance)
Adjust: Examination resulting in adjustment or replacement
Replace or change
Tighten
Applicable
Not applicable
FE engine with fuel injection, MTX, ATX
FE DOHC engine with fuel injection, 4WS, MTX
FE engine with carburetor, MTX, ATX
RF-CX, RF-N engine with MTX
REMARKS:
Major service interval at 12 months/20,000 km (12,000 Miles), Lubrication service based on distance only 10,000 km (6,000 Miles) not time
After 80,000 km (48,000 Miles) or 48 months, continue to follow the described maintenance items and intervals periodically.
As for * marked items in this maintenance chart, please pay attention to the following points.
*1 Replacement of the timing belt is required at every 100,000 km (60,000 Miles). Failure to repace the timing belt may result in damage to the engine.
*2 If the vehicle is operated under the following conditions, it is suggested that the engine oil and oil filter be changed more often than at usual recommended
intervals.
a) Driving in dusty conditions.
b) Extended periods of idling or low speed operation.
c) Driving for a prolonged period in cold temperatures or driving only short distances regulary.
*3. If the vehicle is operated in very dusty or sandy areas, inspect and, if necessary, replace more often than at usual recommended intervals.
*4. This is a full function check of all electrical systems, i.e., all lights, washers (including condition of blades) electrical windows, sunroof, horn, etc....
*5. Replace every two years.
If there has been continuous hard driving, mountain driving, or if the brakes are used extensively or the vehicle is operated in extremely humid climates, the brake fluid
should be changed annually.
Emission Control and Related Systems
The ignition and fuel systems are vitally important to the proper operation of the emissions control and related systems, as well as for efficient engine operation. It is
strongly recommended that all servicing related to these systems be done by your Authorized Mazda Dealer.
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interval
Procedure & Item
Number of Months or km, whichever corns first
©1 ©2 ©3 ©4 Service data and inspection point Page
interval
Procedure & Item
Months — 6 12 18 24 30 36 42 48 ©1 ©2 ©3 ©4 Service data and inspection point Page
interval
Procedure & Item
x
1000 Km
1 10 20 30 40 50 60 70 80 ©1 ©2 ©3 ©4 Service data and inspection point Page
interval
Procedure & Item
Miles x 1000
0.6 6 12 18 24 30 36 42 48
©1 ©2 ©3 ©4 Service data and inspection point Page
Clutch pedal I I I I I I I I O o o o
• Operation
• Pedal height: 216.5—221.5 mm (8.524—8.720 in)
• Free play: 5—13 mm (0.20—0.51 in)
6-4
Brake pedal I I I I I I I I O o o o
• Operation • Pedal height: 222—227 mm (8.74—8.94 in)
• Free play: 4—7 mm (0.16—0.28 in)
11-11
11—11
Parking brake A A A A o o o o
• Operation • Lever stroke: 5—7 notches
11-65
Power brake unit and hoses I I I I o o o o
• Operation • Check the vacuum hoses and connectors
11—27
Brake fluid *5 I I I R I I I R 0 o o o • Fluid level 11—6
Clutch fluid I I I I I I I I o o o 0 • Fluid level 6-4
Power steering fluid I I I I I I I I o o o o • Fluid level 10—11
Power steering system and hoses I I I I 0 o o 0 • Fluid leakage or oozing 10—13
Air cleaner element *3 I R I R o o o o —
1 A—6 1B—5 1C-5
Cooling system (including coolant level adjustment) I I I I o o o o • Hoses for cracks or wear • Coolant level
3A—5
3B-4
Engine coolant Replace every 2 years 0 o 0 0 — 3A-5 3B—4
a> a o o X o o

Interval
Procedure & item
Number of Months or km, whichever corns first
Months
x 1000 Km
Miles x 1000
Engine oil
Oil filter
Fuel filter (R) only for carbretor
Fuel lines and hoses (I) only for Diesel
Spark plugs
Initial ignition timing
Idle speed (I) only for carbretor
0.6
(I)
6
10
(0
12
20
12
(R)
18
30
18
(I)
24
40
24
30
50
30
(I)
36
60
36
(R)
42
70
42
(I)
48
80
48
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Service data and inspection point
Oil pan capacity F6, F8, FE 3.6 liters (3.8 US qt, 3.2 Imp qt)
Oil filter capacity F8, FE 12-valve (SOHC)
0.3 liters (0.32 US qt, 0.26 Imp qt)
FE (DOHC) 0.2 liters (0.21 US qt, 0.18 Imp qt) RF-N
0.4 liters (0.42 US qt, 0.35 Imp qt)
Fittings, connections and compo-
nents for leaks
Plug gap FE DOHC 0.7—0.8 mm (0.028-0.031 in) Others 0.75—0.85 mm (0.030—0.033 in) Recommended spark plugs
F6,F8,FE FE
12 VALVE,
DOHC
NGK BPR 5ES BPR 6ES BCPR 5E
BCPR 6E
Nippon
Denso W16EXR-U
W20EXR-U
Q16PR-U* Q20PR-U
Initial ignition timing F6 F8 FE (8 VALVE) (12 VALVE)
6 ±
1
° BTDC FE (DOHC) 12 ± 1° BTDC
Check the idle speed
MTX 80015? rpm
ATX F6 900 rpm (in "N" range) ATX F8, FE 900 t5? rpm (in "N" range)
FE DOHC 700—800 rpm
§ *Only FE 12 VALVE
Page
2A—6
2A-6
2B-6
4D—21
5-9
5-11
4A—38
4C-29
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1A TUNE-UP PROCEDURE
76G01A-102
76G01A-103
76G01A-104
TUNE-UP PROCEDURE
Tune the engine according to the procedures
described below.
Battery
1. Check for corrosion on the terminals, or loose ca-
ble connections.
If necessary, clean the clamps and tighten firmly.
2. Check that the electrolyte level is between the UP-
PER and LOWER marks.
Add distilled water if necessary.
3. Check the specific gravity by using a hydrometer.
If the specific gravity reading is 1.200 or less,
recharge the battery. (Refer to Section 5.)
Air Cleaner Element
Visually check the air cleaner element for excessive
dirt, damage, or oil. Replace if necessary.
Caution
Do not clean the air cleaner element with com-
pressed air, replace if necessary.
Engine Oil
Check the engine oil level and condition with the oil
level gauge.
Add oil, or change it, if necessary.

76G01A-019

1A—6

1A TUNE-UP PROCEDURE
Coolant Level (Cold engine)
1. Check that the coolant level is near the radiator inlet
port.
2. Check that the level in the coolant reservoir is be-
tween the FULL and LOW marks.
Add coolant if necessary.
Warning
a) Never remove the radiator cap while the en-
gine is hot.
b) Wrap a thick cloth around the cap and care-
fully remove it.
86U01X-008
When set
When measured
Drive Belt
1. Check the drive belt for wear, cracks, or fraying.
Replace if necessary.
2. Check the drive belt tension by using the tension
gauge.
Standard belt tension N (kg, lb)

Belt New Used
Alternator 589-785 (60-80, 132-176) 491-687 (50-70, 110-154)
P/S 687-883 (70-90, 154-198) 589-785 (60-80, 132-176)
A/C 687-883 (70-90,154-198) 589-785 (60-80, 132-176)

76G01A-006
76G01A-007
Adjusting bolt
3. Check the drive belt deflection by applying moder-
ate pressure (98 N, 10 kg, 22 lb) midway between
the pulleys.
(1) Alternator belt deflection
New : 6—8 mm (0.24—0.31 in)
Used: 7—9 mm (0.27—0.35 in)
If necessary, loosen the alternator mounting
bolts and adjust the belt deflection by turning
the adjusting bolt.
Tightening torque
31—46 Nm (3.2—4.7 m-kg, 23—34 ft-lb)
(§): 37—52 Nm (3.8—5.3 m-kg, 27—38 ft-lb)
(2) P/S belt deflection
New : 8—10 mm (0.31—0.39 in)
Used: 9—11 mm (0.35—0.43 in)
If necessary, loosen the idler pulley lock bolt
and adjust the belt deflection by turning the ad-
justing bolt.
Tightening torque of lock bolt:
37—52 Nm (3.8—5.3 m-kg, 27—38 ft-lb)

76G01A-019

1A—7

TUNE-UP PROCEDURE 1A
High-Tension Lead
Check the following points. Clean or replace if
necessary.
1. Damaged lead
2. Carbon deposits
86U01X-014
76G01A-012
49 0187 280
76G01A-013
Carburetor Float Level (Carburetor)
1. Run the engine at idle.
2. Check that the fuel level is at the center of the float
level indicator window.
If necessary, adjust the fuel float level. (Refer to Sec-
tion 4A.)
Hydraulic Lash Adjuster (12 valve)
Note
Tappet noise may occur if the engine is not
operated for an extended period of time. The
noise should stop after the engine has
reached normal operating temperature.
1. Check for tappet noise. If noise exsits, check the
following points.
(1) Engine oil condition and level
(2) Engine oil pressure (Refer to Section 2A)
2. If the noise does not stop, check for movement of
each HLA by pushing down each rocker arm by
hand while at TDC of compression stroke.
3. If the rocker arm moves down, replace the HLA.
(Refer to page 1A—75.)
76G01A-014

1
A—9

1A TUNE-UP PROCEDURE
No.1 IN No.2 IN
No.1 EX No.3 EX
76G01A-015
Adjust bolt
^N^^^^^Lock nut
SsKs&b ' Valve
Camshaft >Nw clearance
76G01A-016
76G01A-017
Valve Clearance (8-valve)
1. Warm up the engine to the normal operating tem-
perature.
2. With the piston of the No.1 cylinder at TDC of com-
pression stroke.
Adjust the valve clearance as shown in the figure.
Valve clearance (valve side)
IN : 0.30 mm (0.012 in)
EX: 0.30 mm (0.012 in)
3. Turn the crankshaft one full turn so that the piston
of the No.4 cylinder is at TDC of compression
stroke.
Adjust the clearances of the remaining valves.
Ignition Timing
1. Warm up the engine and run it at idle.
2. Turn all electric loads OFF.
3. Connect a timing light tester.
4. Disconnect the vacuum hose from the vacuum
control, and plug the hose.
5. Check that the ignition timing mark (yellow) on the
crankshaft pulley and the timing mark on the tim-
ing belt cover are aligned.
Ignition timing: 6° ±
1
° BTDC (at idle speed)
6. If necessary adjust the ignition timing by turning
the distributor.
69G01B-518
1A—10