diagram MAZDA 626 1987 Workshop Manual

Mazda
626
Workshop
Manual
FOREWORD
This workshop manual is intended for use
by service technicians of authorized Mazda
dealers to help them service Mazda vehicles.
This manual can be also useful in diagnosing
certain problems and performing some repair
and maintenance on Mazda vehicles.
For proper repair and maintenance, it is im-
portant to be thoroughly familiarized with this
manual. It is recommended that this manual al-
ways be kept in a handy place for quick and
easy reference.
All the contents of this manual, including pho-
tographs, drawings, and specifications, are the
latest available at the time of printing. As modifi-
cations affecting repair or maintenance occur,
relevant information supplementary to this
volume will be made available at Mazda deal-
ers. This manual should be kept up-to-date.
Mazda Motor Corporation reserves the right
to alter the specifications and contents of this
manual without obligation or advance notice.
All rights reserved. No part of this book may
be reproduced or utilized in any form or by any
means, electronic or mechanical, including
photocopying, recording, or by any informa-
tion storage and retrieval system, without per-
mission in writing.
Mazda Motor Corporation
HIROSHIMA JAPAN
Refer to the following wiring diagrams if
necessary.
Refer to From No.
5095-10-87 G L.H.D.
5096-10-87 G R.H.D.
5096-20-871 Germany
5095-30-871 French
CONTENTS
Title Section
General Information G
Pre-Delivery Inspection and Scheduled
Maintenance 0
Gasoline F6, F8, FE 1A
Engine
Gasoline
FE (DOHC) 1B
Diesel RF-CX, RF-N 1C
Lubrication System
Gasoline 2A
Lubrication System
Diesel 2B I
Cooling System
Gasoline 3A 1
Cooling System
Diesel 3B
Carburetor F6, F8, FE 4A
Fuel and Emission Fuel FE 4B I
Control Systems Injection FE (DOHC) 4C
Diesel RF-CX, RF-N 4D j
Engine Electrical System 5
Clutch 6
Manual 7A
Transaxle
Automatic
EC-AT
and
4-Speed
7B
3-Speed 7C
Front and Rear Axles 9
Steering System 10
Braking System 11
Wheels and Tires 12
Suspension 13
Body 14 |
Body Electrical System 15
Air Conditioning System 16
Technical Data 30
Special Tools 40
© 1987 Mazda Motor Corporation
PRINTED IN JAPAN, JULY'87 ©
1163-10-87G
expert22 flna http://rutracker.org

4A
FUEL AND EMISSION
CONTROL SYSTEMS
(CARBURETOR)
OUTLINE 4A— 2
SYSTEM DIAGRAM 4A— 2
VACUUM HOSE ROUTING
DIAGRAM 4A— 5
EMISSION COMPONENTS
LOCATION 4A— 8
COMPONENT DESCRIPTIONS 4A—12
SPECIFICATIONS 4A—15
TROUBLESHOOTING GUIDE 4A—17
PARTS INSPECTION 4A—23
AIR CLEANER ELEMENT 4A—23
ACCELERATOR LINKAGE 4A—23
INTAKE MANIFOLD 4A—23
CHOKE CABLE 4A—23
FUEL SYSTEM 4A—24
TROUBLESHOOTING 4A—25
CARBURETOR 4A—26
FUEL PUMP 4A—35
FUEL TANK 4A—36
SEPARATOR 4A—37
TWO-WAY CHECK VALVE 4A—37
THREE-WAY CHECK VALVE 4A—37
FUEL FILTER 4A—37
IDLE SPEED AND IDLE MIXTURE.. 4A—38
ADJUSTMENT 4A—38
AUTO-RETURN CHOKE SYSTEM... 4A—40
TROUBLESHOOTING 4A—40
PTC HEATER SYSTEM 4A—42
TROUBLESHOOTING 4A—42
DECELERATION CONTROL SYSTEM 4A—45
TROUBLESHOOTING 4A—45
BYPASS AIR CONTROL SYSTEM.. 4A—48
DASH POT 4A—50
ANTI-AFTERBURN VALVE 4A—50
MAIN AIR BLEED CONTROL
SYSTEM 4A—51
SLOW FUEL CUT SYSTEM 4A—53
COAST ENRICHMENT SYSTEM .... 4A—54
COASTING LEANER SYSTEM 4A—56
AIR INJECTION SYSTEM 4A—58
INTAKE AIR TEMPERATURE CONTROL
SYSTEM 4A—60
TROUBLESHOOTING 4A—60
PURGE CONTROL SYSTEM 4A—63
VACUUM SWITCH VALVE 4A—63
EXHAUST GAS RECIRCULATION
(EGR) SYSTEM 4A—64
TROUBLESHOOTING 4A—65
POSITIVE CRANKCASE VENTILATION
SYSTEM 4A—67
PCV VALVE 4A—67
IDLE-UP CONTROL SYSTEM 4A—68
TROUBLESHOOTING 4A—70
IDLE-UP SOLENOID VALVE 4A—76
EVAPORATIVE EMISSION CONTROL
SYSTEM 4A—78
TROUBLESHOOTING 4A—79
IGNITION TIMING CONTROL
SYSTEM 4A-80
TROUBLESHOOTING 4A—81
CONTROL SYSTEM 4A-83
RELATIONSHIP CHART 4A—84
ENGINE CONTROL UNIT 4A—86
INHIBITOR SWITCH 4A—93
IDLE SWITCH 4A—93
VACUUM SWITCH 4A—94
WATER THERMO SWITCH 4A—95
EXHAUST SYSTEM 4A—96
76G04A-001

FUEL AND EMISSION
CONTROL SYSTEMS
(FUEL INJECTION FE)
OUTLINE 4B— 2
SYSTEM DIAGRAM 4B— 2
COMPONENT LOCATION 4B— 3
VACUUM HOSE ROUTING
DIAGRAM 4B— 5
SPECIFICATIONS 4B— 6
TROUBLESHOOTING GUIDE 4B— 7
TROUBLESHOOTING
PROCEDURE 4B— 7
TROUBLESHOOTING WITH SST.... 4B— 9
INSPECTION PROCEDURE 4B—10
AFTER-REPAIR PROCEDURE 4B—10
PRINCIPLE OF CODE CYCLE 4B—12
CODE NUMBER 4B—13
SWITCH MONITOR FUNCTION 4B—25
INSPECTION PROCEDURE 4B—26
IDLE SPEED 4B—29
IDLE MIXTURE 4B—29
INTAKE AIR SYSTEM 4B—30
COMPONENT DESCRIPTIONS 4B—30
REMOVAL 4B—31
PARTS INSPECTION 4B—32
INSTALLATION 4B—34
IDLE-UP SYSTEM 4B—35
COMPONENT DESCRIPTIONS 4B—36
TROUBLESHOOTING 4B—37
AIR VALVE 4B—38
AIR BYPASS SOLENOID VALVE ... 4B—39
FUEL SYSTEM 4B—42
COMPONENT DESCRIPTIONS 4B—43
TROUBLESHOOTING 4B—44
FUEL PRESSURE RELEASE AND
SERVICING FUEL SYSTEM 4B—45
MULTI-PRESSURE TESTER 4B—46
FUEL PRESSURE 4B—48
FUEL PUMP 4B—49
PULSATION DAMPER 4B—50
INJECTOR 4B—51
PRESSURE REGULATOR
CONTROL SYSTEM 4B—53
COMPONENT DESCRIPTIONS 4B—54
TROUBLESHOOTING 4B—55
REPLACEMENT 4B—57
FUEL TANK 4B—61
DECELERATION CONTROL
SYSTEM 4B—64
COMPONENT DESCRIPTIONS 4B—65
TROUBLESHOOTING 4B—66
AIR INJECTION SYSTEM 4B—68
COMPONENT DESCRIPTIONS 4B—68
TROUBLESHOOTING 4B—69
EXHAUST GAS RECIRCULATION
(EGR) SYSTEM 4B—71
COMPONENT DESCRIPTIONS 4B—71
TROUBLESHOOTING 4B—72
EVAPORATIVE EMISSION
CONTROL (EEC) SYSTEM 4B—74
COMPONENT DESCRIPTIONS 4B—74
TROUBLESHOOTING 4B—75
POSITIVE CRANKCASE
VENTILATION (PCV) SYSTEM 4B—80
COMPONENT DESCRIPTION 4B—80
EXHAUST SYSTEM 4B—81
REMOVAL AND INSTALLATION ... 4B—82
INSPECTION 4B—82
CONTROL SYSTEM 4B—83
RELATIONSHIP CHART 4B—84
EGI MAIN FUSE 4B—86
MAIN RELAY 4B—86
CIRCUIT OPENING RELAY 4B—86
ENGINE CONTROL UNIT 4B—87
NEUTRAL SWITCH 4B—91
CLUTCH SWITCH 4B—91
BRAKE LIGHT SWITCH 4B—91
P/S PRESSURE SWITCH 4B—92
INHIBITOR SWITCH 4B—92
E/L CONTROL UNIT 4B—93
AIR FLOW METER 4B—94
THROTTLE SENSOR 4B—95
WATER THERMO SENSOR 4B—97
WATER THERMO SWITCH 4B—97
OXYGEN SENSOR 4B—98
ATMOSPHERIC PRESSUFfE
SENSOR 4B—99
76G04B-001

4B OUTLINE
OUTLINE
SYSTEM DIAGRAM
S6U04A-0Q2
4B—2

OUTLINE 4B
VACUUM HOSE ROUTING DIAGRAM
86U04A-006
4B—5

4B TROUBLESHOOTING WITH SST
If a malfunction code number is shown on the SST, check the following chart along with the wiring
diagram.
Code No. 01 (Ignition pulse) PC: Possible Cause
76G04B-009
4B—14

4C
FUEL AND EMISSION
CONTROL SYSTEMS
(FUEL INJECTION FE DOHC)
OUTLINE 4C— 2
COMPONENT APPLICATION 4C— 2
SYSTEM DIAGRAM 4C— 3
COMPONENT LOCATION 4C— 4
VACUUM HOSE ROUTING
DIAGRAM 4C— 7
SPECIFICATIONS 4C— 8
TROUBLESHOOTING GUIDE 4C— 9
TROUBLESHOOTING WITH SST.. 4C— 11
INSPECTION PROCEDURE 4C— 12
PRINCIPLE OF CODE CYCLE 4C— 13
CODE NUMBER 4C— 14
SWITCH MONITOR FUNCTION 4C— 25
INSPECTION PROCEDURE 4C— 26
IDLE ADJUSTMENT 4C— 29
IDLE SPEED 4C— 29
IDLE MIXTURE 4C— 30
INTAKE AIR SYSTEM 4C— 31
COMPONENT DESCRIPTION 4C— 31
REMOVAL 4C— 32
PARTS INSPECTION 4C— 33
REPLACEMENT 4C— 36
INSTALLATION 4C— 37
VARIABLE INERTIA CONTROL
(VIC) SYSTEM 4C— 39
COMPONENT DESCRIPTION 4C— 40
TROUBLESHOOTING 4C— 40
IDLE SPEED CONTROL
(ISC) SYSTEM 4C— 44
COMPONENT DESCRIPTION 4C— 45
TROUBLESHOOTING 4C— 46
REMOVAL 4C— 48
FUEL SYSTEM 4C— 49
COMPONENT DESCRIPTION 4C— 50
TROUBLESHOOTING 4C— 51
FUEL PRESSURE RELEASE AND
SERVICING FUEL SYSTEM 4C— 52
MULTI-PRESSURE TESTER 4C— 53
FUEL PUMP 4C— 56
PULSATION DAMPER 4C— 57
INJECTOR 4C— 57
TRANSFER PUMP CONTROL
SYSTEM 4C— 59
REPLACEMENT 4C— 60
FUEL TANK 4C— 65
PRESSURE REGULATOR
CONTROL (PRC) SYSTEM 4C— 68
COMPONENT DESCRIPTION 4C— 69
TROUBLESHOOTING 4C— 69
DECELERATION CONTROL
SYSTEM 4C— 72
COMPONENT DESCRIPTION 4C— 73
TROUBLESHOOTING 4C— 73
ELECTRONIC SPARK ADVANCE
(ESA) CONTROL SYSTEM 4C— 75
COMPONENT DESCRIPTION 4C— 76
TROUBLESHOOTING 4C— 76
EXHAUST GAS RECIRCULATION
(EGR) SYSTEM 4C- 77
COMPONENT DESCRIPTION 4C— 77
TROUBLESHOOTING 4C— 78
EVAPORATIVE EMISSION
CONTROL (EEC) SYSTEM 4C— 80
COMPONENT DESCRIPTION 4C— 80
TROUBLESHOOTING 4C— 81
POSITIVE CRANKCASE
VENTILATION (PCV) SYSTEM.... 4C— 86
COMPONENT DESCRIPTION 4C— 86
PCV VALVE 4C— 86
EXHAUST SYSTEM
(UNLEADED FUEL) 4C— 87
REMOVAL AND INSTALLATION.. 4C— 88
INSPECTION 4C— 88
EXHAUST SYSTEM
(LEADED FUEL) 4C— 89
REMOVAL AND INSTALLATION.. 4C— 90
CONTROL SYSTEM 4C— 91
RELATIONSHIP CHART 4C— 92
EGI MAIN FUSE 4C— 96
CONTROL RELAY 4C— 96
NEUTRAL SWITCH 4C— 97
CLUTCH SWITCH 4C— 97
P/S PRESSURE SWITCH 4C— 97
ENGINE CONTROL UNIT 4C— 98
E/L CONTROL UNIT 4C—102
AIR FLOW SENSOR 4C—103
THROTTLE SENSOR 4C—104
IDLE SWITCH 4C—106
WATER THERMO SWITCH 4C—106
WATER THERMO SENSOR 4C—107
OXYGEN SENSOR 4C—107
DISTRIBUTOR 4C—108
OXYGEN SENSOR HEATER 4C—109
KNOCK SENSOR 4C—109
INTAKE AIR THERMO SENSOR .. 4C—110
76G04C-001

5
ENGINE ELECTRICAL SYSTEM
OUTLINE 5— 2
STRUCTURAL VIEW 5— 2
SPECIFICATIONS 5— 5
TROUBLESHOOTING 5— 7
BATTERY 5— 8
INSPECTION 5— 8
RECHARGE. 5— 8
SPARK PLUG 5— 9
REMOVAL AND INSTALLATION 5— 9
INSPECTION 5— 9
IGNITION COIL 5—10
INSPECTION 5—10
HIGH-TENSION LEAD 5—10
INSPECTION 5—10
DISTRIBUTOR 5—11
SPARK TEST 5—11
IGNITION TIMING 5—11
SPARK CONTROL 5—12
REMOVAL 5—14
DISASSEMBLY 5—15
INSPECTION 5—16
ASSEMBLY 5—17
INSTALLATION 5—18
H.E.I. TROUBLESHOOTING 5—19
IGNITER (FE DOHC) 5—20
INSPECTION 5—20
ALTERNATOR 5—21
CROSS SECTIONAL VIEW 5—21
CHARGING SYSTEM 5—22
TROUBLESHOOTING 5—23
REMOVAL 5—27
DISASSEMBLY 5—28
INSPECTION 5—32
ASSEMBLY 5—35
INSTALLATION 5—36
V-BELT TENSION 5—37
STARTER (GASOLINE ENGINE
0.85, 0.95 KW TYPE) 5—38
STARTING SYSTEM CIRCUIT 5—38
ON-VEHICLE INSPECTION 5—38
REMOVAL AND INSTALLATION 5—39
DISASSEMBLY AND ASSEMBLY 5—39
INSPECTION 5—40
PERFORMANCE INSPECTION 5—43
STARTER
(GASOLINE ENGINE, 1.4 KW TYPE) 5—45
STARTING SYSTEM 5—45
ON-VEHICLE UNSPECTION 5—45
REMOVAL 5—46
DISASSEMBLY 5—46
INSPECTION 5—49
ASSEMBLY 5—53
CHECKING OPERATION 5—54
INSTALLATION 5—55
STARTER
(DIESEL ENGINE, 2.0 kW TYPE) .... 5—56
STARTING SYSTEM CIRCUIT 5—56
ON-VEHICLE INSPECTION 5—56
REMOVAL AND INSTALLATION 5—57
DISASSEMBLY AND ASSEMBLY 5—57
INSPECTION 5—61
PERFORMANCE INSPECTION 5—64
STARTER
(DIESEL ENGINE, 2.2 kW TYPE).... 5—66
STARTING SYSTEM CIRCUIT 5—66
ON-VEHICLE INSPECTION 5—66
REMOVAL AND INSTALLATION 5—67
DISASSEMBLY AND ASSEMBLY 5—67
INSPECTION 5—71
PERFORMANCE INSPECTION 5—74
QUICK START SYSTEM (QSS) 5-76
COMPONENT LOCATION 5—76
CIRCUIT DIAGRAM 5—76
SYSTEM OPERATION 5—77
TROUBLESHOOTING GUIDE 5—78
CONTROL UNIT 5—79
GLOW PLUG RELAY 5—80
BLOW PLUG 5—80
WATER TEMPERATURE SWITCH.... 5—80
76g05x-001

5 QUICK START SYSTEM (QSS)
QUICK START SYSTEM (QSS)
COMPONENT LOCATION
76G05X-048
CIRCUIT DIAGRAM
76G05X-049
5—76

OUTLINE 7B
Operation Table (G4A-HL)
Range Gear
Operation elements
Range Gear Engine braking effect
Forward
clutch
Coasting
clutch
3-4 clutch Reverse clutch
2-4 brake Low & One-way
clutch 1
One-way
clutch 2
Range Gear Engine braking effect
Forward
clutch
Coasting
clutch
3-4 clutch Reverse clutch Applied Released reverse brake
One-way
clutch 1
One-way
clutch 2

P
— —

R
—
Yes O 0
N
— —

D
1st No O O O
D 2nd No
o
O
o
D 3rd Yes
o
O 0
®
0
o
D
OD Yes
© O 0

2 2nd Yes
o o o o

1 1st Yes
o o o o o
1 2nd Yes
o o o o
76G07B-007
® : Indicates fluid pressure to servo but band not applied due to pressure difference in servo.
® : Indicates that it does not function to transmit power.
POWER FLOW DIAGRAM
Neutral
1st gear
7B-7