ignition MAZDA 626 1987 Workshop Manual

G TOWING
76GOGX-OQ2

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76UQGX-003
86U0GX-004
G—8
TOWING
Proper towing equipment is necessary to prevent
damage to the vehicle during any towing operation.
Laws and regulations applicable to vehicles in tow
must always be observed.
Whether the vehicle is equipped with either an auto-
matic or manual transaxle, release the parking brake,
place the selector lever (shift lever) in neutral, and set
the ignition key in the "ACC" position. As a rule,
towed vehicles should be pulled with their drive
wheels off the ground.
If excessive vehicle damage or other conditions pre-
vent towing a vehicle with its drive wheels up, use
wheel dollies. With all four wheels on the ground, the
vehicle may be towed only forward. In this case, it
cannot be towed at a speed exceeding 56 km/h (35
mph) for more than 80 km (50 miles) without danger
of damaging the transaxle.
If the towing speed will exceed 56 km/h (35 mph),
or if the towing distance will exceed 80 km (50 miles),
use either of these two methods:
1. Place the front wheels on dollies.
2. Tow with the front wheels off the ground.
CAUTIONS
a) The power assist for the brakes and steer-
ing (if so equipped) will be inoperable while
the engine is off.
b)When either of the towing hooks is used,
always pull the cable or chain straight away
from the hook and do not apply any side-
ways force to it. To further help prevent
damage, do not take up slack too quickly
in the cable or chain.
c) The rear towing hook should be used only
in an emergency situation, (e.g., to pull the
vehicle from a ditch, a snowbank, or mud).

CHASSIS NUMBER LOCATION/ABBREVIATIONS/UNITS G
CHASSIS NUMBER LOCATION UNITS
67U0GX-005
ENGINE MODEL AND
NUMBER LOCATION
Nm (m-kg, ft-lb or in-lb). Torque
rpm Revolutions per minute A Ampere(s) V Volt(s) U Ohm(s) (resistance) kPa (psi) Pressure
(usually positive) mrriHg (in Hg) Pressure
(usually negative) W Watt
76G0GX-004
ABBREVIATIONS
67U0GX-007
AAS Auto adjusting suspension A/C Air conditioner ACC Accessories ABDC After bottom dead center ATDC After top dead center ATX Automatic transaxle ATF Automatic transmission fluid ABS Anti-lock brake system BBDC Before bottom dead center BTDC Before top dead center EX Exhaust EC-AT Electronically controlled automatic transaxle ESPS Engine speed sensing power steering EC PS Electronically-controlled power steering HLA Hydraulic lash adjuster IG Ignition IN Intake IC Integrated circuit INT Intermittent LH Left hand
MTX Manual transaxle M Motor OFF Switch off ON Switch on PCV Positive crankcase ventilation P/S Power steering P/W Power window RH Right hand RF-CX Comprex supercharged RF
engine
RF-N Normally aspirated RF engine ST Start sw Switch SST Special tools 4WS 4-wheel steering
PWS 2-wheel steering
4HAT 4-speed hydraulic automatic
transaxle Fl Fuel injection
76GQGX-005
G—9

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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Interval
Procedure & item
Number of Months or km, whichever corns first
Months

x 1000 Km

Miles x 1000
Fuel lines and hoses
Spark plugs
Initial ignition timing
Idle speed
Idle mixture
Dash pot (MTX)
0.6
6
10
12
20
12
18
30
18
24
40
24
30
50
30
36
60
36
42
70
42
48
80
48
©1
O
o
o
o
o
o
©2
O
o
o
o
o
o
©3
O
O
O
O
O
©4
O
Service data and inspection point
Fittings, connections and compo-
nents for leaks
Plug gap: F8, FE (8-VALVE) 0.75—0.85 mm (0.030—0.033 in) FE (12-VALVE) FE (DOHC) 0.7—0.8 mm (0.028—0.031 in) Recommended spark plugs
F6,F8,FE 8-VALVE 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 6 ±
1
° BTDC 12 ± 1° BTDC (FE DOHC)
Check the idle speed (rpm) FE DOHC 700—800 Carburetor MTX 800—850, ATX 900—950 (N range)
CO concentration FE DOHC 1.5 ±0.5 % Others 2.0 ± 0.5 % HC concentration FE DOHC Less than 1000 rpm
Operation
Page
4B—42
5-9
5-11
4A-38 4C-29
4A-38 4C—30
4A-50
4B-67
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Only FE 12-VALVE
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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
Months

x
1000 Km
Miles x 1000
Fuel filter (R) for carbretor model
Fuel lines and hoses
Spark plugs
Initial ignition timing
Idle Speed
E.G.R. System
Evaporative system (if equipped)
O) O
X o
Choke system
0.6
6
10
12
20
12
(R)
18
30
18
24
40
24
30
50
30
36
60
36
(R)
42
70
42
48
80
48
©1
O
O
o
o
o
o
o
o
o
o
o
o
o
o
©3
o
o
o
o
o
o
o
©4
o
o
Service data and inspection point
Fittings, connections and compo-
nents for leaks
Plug gap: Carburetor, FE (DOHC) 1.0—1.1 mm (0.039—0.043 in) FE 0.75—0.85 mm (0.030-0.033 in) Recommended spark plugs
NGK
Carbureter BPR5ES-11 BPR6ES-11
NGK FE
(Fuel injection)
BPR 5ES
BPR 6ES NGK
FE DOHC
BCPR 5E-11 BCPR 6E-11 BCPR 7E-11
Nippon Denso
Carbureter W16EXR-U11 W20EXR-U11 Nippon Denso FE
(Fuel injection)
W16EXR-U
W20EXR-U
Nippon Denso
FE DOHC Q16PR-U
Initial ignition timing
6 ±
1
° BTDC
12 ± 1° BTDC (FE DOHC)
Check the idle speed (rpm) Carburetor MTX 850—900,
ATX 900-950 (N range) FE DOHC 700-800 FE MTX 800—850,
ATX 900-950 (N range)
System inspection
System inspection
Carburetor linkage Choke diaphragm Choke valve clearance Unloader system
Page
4A-37
4B-42
5-9
5-11
4A—38 4B-29 4C—29
4B—72 4A—64
4B—76
4C-81
4A-26 4A—34 4A—34 4A—33
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For General
Chart symbols:
I : Inspect: Visual examination and/or functional measurement of a system's operation or performance.
A : Adjust: Examination resuiting in adjustment or replacement.
R : Replace or change
T : Tighten
O : Applicable
X : Not applicable
© 1 : F6, F8 engine with carburetor, MTX, ATX
© 2 : FE engine with carbretor, MTX, ATX
©3 : FE DOHC engine with fuel injection, MTX
® 4 : RF-N engine with MTX
NOTE:
As the result of visual examination or functional measurement of a system's operation(performance), correct, clean or replace as required.
REMARKS:
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. 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 regularly.
"2. 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.
*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 Adjust or inspect alternator and water pump drive belt, and power steering and air conditioner drive belt, vacuum pump belt, super charger belt if equipped.
*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.
*6. Only F6 carbretor for Singapore (MTX Model)
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 i
strongly recommended that all servicing related to these systems be done by your Authorized Mazda Dealer.
o CJ1

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
®1
O
o
o
o
o
o
o
©2
O
o
o
o
o
o
o
©3
O
o
o
o
o
o
©4
O
o
o
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 TROUBLESHOOTING GUIDE
SPECIFICATIONS
——Engine model
Item ^ FE 12 -valve FE 8-valve F8 F6 ——Engine model
Item ^ FE 12 -valve ECE Except ECE ECE General F6
Type Gasoline, 4 cycle
Cylinder arrangement and number In line, 4 cylinders
Combustion chamber Pentroof Multispherical
Valve system OHC, belt driven
Displacement cc (cu in) 1,998 (121.9) 1,789 (109.1) 1,587 (96.8)
Bore and stroke mm (in) 86.0 x 86.0 (3.39 x 3.39) 86.0 x 77.0 (3.39 x 3.03) 81.0 x 77.0 (3.19 x 3.03)
Compression ratio 9.5 : 1 8.6 : 1 9.0 : 1
Compression pressure kPa (kg/cm2, psi)—rpm
Standard 1,422 (14.5,
206)—280 1,275 (13.0, 185)—270 1,128 (11.5, 164)—270 Compression pressure kPa (kg/cm2, psi)—rpm Minimum 996 (10.2,
144)—280 893 (9.1, 129)—270 790 (8.1, 114)—270
Valve timing
IN Open BTDC 14° 16° 20° 20° 17° 17°
Valve timing
IN Close ABDC 56° 54° 65° 65° 56° 56° Valve timing
EX Open BBDC 69° 54° 65° 65° 64° 64° Valve timing
EX Close ATDC 13° 16° 20° 20° 15° 15°
Valve clearance mm (in)
IN 0; Mainte-nance-free 0.30 (0.012)
Valve clearance mm (in)
EX 0; Mainte-nance-free 0.30 (0.012)
Idle speed rpm
MTX 800 _+5S ... carb., 850 ± 50 ... Fl
Idle speed rpm ATX 900 _+5g ... carb., 850 ± 50 ... Fl 950 _+5§ carb. 850 ±
50
.Fl
Ignition timing BTDC 6° ± 1°
Firing order
1
-3-4-2
76G01A-003
TROUBLESHOOTING GUIDE
Problem Possible Cause Remedy Page
Difficult starting Malfunction of engine-related components
Burned valve Worn piston, piston ring, or cylinder Failed cylinder head gasket
Replace Replace or repair Replace
1A-49
1A-57

1
A—20
Malfunction of fuel system Refer to Section 4
Malfunction of electrical system Refer to Section 5
Poor idling Malfunction of engine-related components Malfunction of HLA Improper valve clearance Poor valve to valve seat contact Failed cylinder head gasket
Replace Adjust Repair or replace Replace

1
A—75 1A-10 1 A—51
1
A—20
Malfunction of fuel system Refer to Section 4
Excessive oil
consumption
Oil working up Worn piston ring groove or sticking piston ring Worn piston or cylinder Replace Replace or repair

1
A—57 1A—57
Oil working down
Worn valve seal
Worn valve stem or guide Replace
Replace
1A—26
1A—49
Oil leakage Refer to Section 2A
76G01A-004
1A—4