power steering MAZDA 626 1987 Workshop Manual

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

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
o"
o
o
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

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
Idle-up solenoid valve I I I I O MTX o X X — 4A—56
All electrical system *4 I I I I I I I I o o o o • Check the all electrical system Section 15
Head light aligment A A A A o o o o • Check the head light aiming 14-31
Steering and front suspension I I I I o o o 0 • Damage 10—28
Front and rear power steering system
and hoses (For 4WS) I I X X o X • Operation and looseness • Fluid leakage or oozing 10—44 10—14
4-Wheel steering system operation
and linkage (For 4WS) I I X X o X • Operation and looseness
• Fluid leakage or oozing
10—33 10—14
Rear wheel steering steering angle
(For 4WS) I I X X o X • Steering wheel angle: Inner 5°00' ± 45' Outer 5°00' ± 45'
13-54
Solenoid valve oil filter (For 4WS) R R X X o X — 10-41
Rear suspension outer ball joints
(For 4WS) I I X X o X • Damage, looseness and grease
leakage 13—37
Manual transaxle oil A R o o o 0 • Oil capacity 3.35 liters (3.6 US qt, 3.0 Imp qt) 7A-6
Automatic transaxle fluid level A A o o X X • Oil capacity 4-Speed 6.8 liters (7.2 US qt, 6.0 Imp qt) 3-Speed 6.2 liters (6.6 US qt, 5.5 Imp qt)
7B-2
Bolts and nuts on chasis and body T T T T T o o o o — —
Disk brakes/Drum brakes I I I I o o o o
• Min. pad thickness: Front 2.0 mm (0.08 in) Rear 1.0 mm (0.04 in) • Min. disc thickness: Front 14 or 15 inch-wheel
22 mm (0.87 in) 13 inch-wheel 18 mm (0.71 in) Rear 8.0 mm (0.31 in)
• Disc run out:
Front 0.1 mm (0.004 in) Rear 0.1 mm (0.004 in)
• Min. lining thickness: 1.0 mm (0.04 in) • Max, drum inner dia: 230.1 mm (9.06 in)
11—45
11—54
11—45
11—54
11-45 11—54
11-60
11—60

0
1
o
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

GO
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
Dashpot (only for MTX) I I I I X X o X • Operation 4A—50
Coast enrichment solenoid valve I I I I X X o X — 4A—54
All electrical system *4 I I I I I I I I o o o o • Check the all electrical system Section 15
Head light aligment A A A A o o o o • Check the head light aiming 14-31
Steering and front suspension I I I I o o o o 10—28
Front and rear power steering system
and hoses (For 4WS) I I X o X X • Operation and looseness
• Fluid leakage or oozing 10—44
10-14
4-Wheel steering system operation
and linkage (For 4WS) I I X o X X • Operation and looseness
• Fluid leakage or oozing
10—33 10—14
Rear wheel steering angle (For 4WS) I I X o X X • Steering wheel angle: Inner 5°00' ± 45' Outer 5°00' ± 45'
13-54
Solenoid valve oil filter (For 4WS) R R X o X X — 10—41
Rear suspension outer ball joints
(For 4WS) I I X o X X • Damage, looseness and grease
leakage 13-37
Manual transaxle oil A R o o o o • Oil capacity 3.35 liters (3.6 US qt, 3.0 Imp qt) 7A—6
Automatic transaxle fluid level A A o o o X
• Oil capacity 4-Speed and EC-AT 6.8 liters (7.2 US qt, 6.0 Imp qt) 3-Speed 6.2 liter (6.6 US qt, 5.5 Imp qt)
7B—71
7C—25
Bolts and nuts on chasis and body T T T T T o o o o — —
Brake lines, Hoses, and connections I I I l_
I
o o o o • Proper attachment and connections 11-8
Disk brake/Drum brake I I I
l_
I o o o 0
• Min. pad thickness: Front 2.0 mm (0.08 in) Rear 1.0 mm (0.04 in)
• Min. disc thickness: Front 14 or 15 inch-wheel 22 mm (0.87 in)
13 inch-wheel 18 mm (0.71 in) Rear 8.0 mm (0.31 in)
• Disc run out:
Front 0.1 mm (0.004 in) Rear 0.1 mm (0.004 in) • Min. lining thickness: 1.0 mm (0.04 in)
• Max. drum inner dia: 230.1 mm (9.06 in)
11—45 11—54
11—45
11-54
11—45
11-54
11—60
11-60

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

0 1
CO
interval Number of Months or km, whichever corns first
Months — 6 12 18 24 30 36 42 48 ©1 ©2 ©3 ©4 Service data and inspection point Page x 1000 Km 1 10 20 30 40 50 60 70 80 ©1 ©2 ©3 ©4 Service data and inspection point Page
Procedure & item Miles x 1000 0.6 6 12 18 24 30 36 42 48
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 I I I I I I I I 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 *s I I I R I I I R o o o o • Fluid level 11-6
Clutch fluid I I I I I I I I o o o o • Fluid level 6-4
Power steering fluid and line (if equipped) I I I I I I I I o o o o • Fluid level • Fluid leakage or oozing
10—11
10—13
Steering operation and gear housing I I I I I o o o o
• Free play: 0—30 mm (0—1.18 in) • Operation and looseness • Fluid leakage or oozing
10—10
10-28
Air Cleaner element *3 I I I R I I I R X X X o — 1C—5
Air Cleaner element *3 (1) For FE (DOHC) (0 R (I) R o o o X — 1A—6
1B—5

IDLE-UP CONTROL SYSTEM 4A
DUAL-SERVO DIAPHRAGM TYPE
With P/S and A/C
Solenoid valve (for P/S)
69G04B-124
Operation
A/C ON and compressor operating
Current flows through the A/C relay to the two-way solenoid valve for the A/C. Vacuum port A is opened,
and vacuum is applied to the servo diaphragm, which in turn pulls the throttle plates slightly open
at low speeds.
P/S operating
Current flows through the P/S switch to the three-way solenoid valve for power steering. Vacuum port
B is opened and vacuum is applied to the servo diaphragm, which in turn pulls the throttle plates slightly
open.
Relationship
Equipment
Type P/S A/C P/S & A/C
Single-servo
diaphragm type O O
Dual-servo
diaphragm type O
4A—69

4A IDLE-UP CONTROL SYSTEM
76G04A-144
76G04A-145
76G04A-146
Vacuum Signal [Equipped with A/C, only FE and
F8 (Except Middle East and General)]
1. Start the engine and run it at idle.
2. Disconnect the vacuum hose from the servo di-
aphragm.
3. Place a finger over the hose.
4. Increase the engine speed, and check for vacuum.
Engine model Engine speed Vacuum
pj| (Except Middle) Below 2,300 rpm Yes pj| (Except Middle) Above 2,300 rpm No
FE (Unleaded fuel) Below 1,500 rpm Yes FE (Unleaded fuel) Above 1,500 rpm No
F6 (Singapore) Below 2,100 rpm Yes F6 (Singapore) Above 2,100 rpm No
General and Middle East
1. Start the engine and run it at idle.
2. Disconnect the vacuum hose from the servo di-
aphragm.
3. Place a finger over the hose.
4. Operate the A/C or P/S.
5. Check that vacuum is felt.
P/S Switch
1. Start the engine and run it at idle.
2. Disconnect the power steering switch connector.
3. Connect an ohmmeter to the power steering
switch.
4. Turn the steering wheel all the way to either the
right or left, and check for continuity.
P/S Continuity
Operated Yes
Not operated No
5. Replace if necessary.
Solenoid Valve (A/C)
1. Disconnect vacuum hose A from the servo di-
aphragm.
2. Disconnect vacuum hose B from the solenoid
valve.
3. Disconnect the solenoid valve connector.
4. Blow air through the valve from hose A and check
that it comes out of port C.
76G04A-147
4A-74