service 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

G IMPORTANT INFORMATION/FUNDAMENTAL PROCEDURES
IMPORTANT INFORMATION
BASIC ASSUMPTIONS
This workshop manual assumes that you have arid know how to properly use certain special tools
which are necessary for the safe and efficient performance of service operations on Mazda vehicles.
The manual also assumes that you are familiar generally with automobile systems and basic service
and repair procedures. You should not attempt to use this manual unless these assumptions are cor-
rect and you understand the consequences described below.
SAFETY RISK
This manual contains certain notes, warnings, etc., which you should carefully read and follow in or-
der to eliminate the risk of personal injury to yourself or others and the risk of improper service which
may damage the vehicle or render it unsafe. The fact that there are no such notes, etc., with respect
to any specific service method does not mean that there is no possibility that personal safety or vehicle
safety will be jeopardized by the use of incorrect methods or tools.
POSSIBLE LOSS OF WARRANTY
The manufacturer's warranty on Mazda vehicles and engines can be voided if improper service or
repairs are performed by persons other than an authorized Mazda dealer.
FUNDAMENTAL PROCEDURES
As you read through the procedure, you will come
across NOTES, CAUTIONS, and WARNINGS. Each
one is there for a specific purpose. NOTES give you
added information that will help you to complete a
particular procedure. CAUTIONS are given to pre-
vent you from making an error that could damage
the vehicle. WARNINGS remind you to be espe-
cially careful in those areas where carelessness can
cause personal injury. The following list contains
some general WARNINGS that you should follow
when you work on a vehicle.
PROTECTION OF THE VEHICLE
Always be sure to cover fenders, seats, and floor
areas before starting work.
A WORD ABOUT SAFETY
The following precautions must be followed when
jacking up the vehicle.
1. Block wheels.
2. Use only specified jacking positions.
3. Support vehicle with safety stands (rigid racks).
Start the engine only after making certain the engine
compartment is clear of tools and people.
G—2 expert22 fl/i* http://rutracker.org

PRE-DELIVERY INSPECTION
AND
SCHEDULED MAINTENANCE
SERVICES
PRE-DELIVERY INSPECTION 0— 2
PRE-DELIVERY INSPECTION TABLE 0— 2
SCHEDULED MAINTENANCE SERVICES .... 0— 3
MAINTENANCE TABLE
(For ECE Leaded gasoline) 0— 3
MAINTENANCE TABLE
(For ECE Unleaded gasoline) 0— 9
MAINTENANCE TABLE (For General) 0—15
76G00X-001

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
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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

U1
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
Battery electrolyte level and specific gravity A A A A O o O O • Electroyte level • Specific gravity 5-8
Drive belts A A A A A O 0 o O • Cracks or damage • Tension

1
A—7
1B—6
1C-7
Engine timing belts Replace every 100,000 Km o o o o — 1A—14 1B—11 1C—11
Engine valve clearance A A A A A o X X o
• Valve clearance: F8 (Hot engine) IN: 0.30 mm (0.012 in) EX: 0.30 mm (0.012 in) FE-12-valve, FE (DOHC) IN: 0; Maintenance free EX: 0; Maintenance free RF-CX, RF-N (Cold engine) IN: 0.25 mm (0.010 in) EX: 0.35 mm (0.014 in)
1A-10
1C—85
Intake and exhaust manifold nuts and
bolts T T T o o X X
• Retighten the intake and exhaust manifold nuts
N-m (m-kg, ft-lb)

1
A—86 1B—68 1C—89
Intake and exhaust manifold nuts and
bolts T T T o o X X IN EX
1
A—86 1B—68 1C—89
Intake and exhaust manifold nuts and
bolts T T T o o X X F8, FE 19-30 (1.9-3.1,
14-22)
22-28 (22—2.9, 16-21)

1
A—86 1B—68 1C—89
Intake and exhaust manifold nuts and
bolts T T T o o X X
RF-CX RF-N 16-23 (1.6-2,3,
12-17)
22-26 (2.2-2.7,
16-20)

1
A—86 1B—68 1C—89
Engine oil *2 R R R R R R R R R o o 0 o
• Oil pan capacity F8, FE: 3.6 liters (3.8 US qt, 3.2 Imp qt) RF-CX, RF-N:
5.0 liters (5.3 US qt, 4.4 Imp qt)
2A—6
2B-6
Oil filter *2 R R R R R R R R o o o o
• Oil filter capacity F8, FE 12-valve
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-CX, RF-N
0.4 liters (0.42 US qt, 0.35 Imp qt)
2A—6
2B-6
Fuel filter (R) for carbretor model (R) R (R) R o 0 o o — 4A—37

0 1 C5
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
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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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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 00 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
Brake lines, Hoses, and connections I I I I O O O O • Proper attachment and connections 11-8
Body condition Inspect annually O O o O -—
Tyres (including spare tyre) Infration pressure adjustment I I I I o O o o • Check the air pressure 12-2
Hinges and cathes A A A A o O o o — —
Underside of vehicle I I I I 0 0 o o — —
Seat belt I I I I o o o o • Opration and looseness 14-101
Road test I I I I o o o o — —
o o o X o o 00

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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