tires 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

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

TROUBLESHOOTING GUIDE 1 A
Problem Possible Cause Remedy Page
Insufficient power Insufficient compression Malfunction of HLA Improper valve clearance Compression leakage from valve seat Seized valve stem Weak or broken valve spring Failed cylinder head gasket Cracked or distorted cylinder head Sticking, damaged, or worn piston ring Cracked or worn piston
Replace
Adjust
Repair
Replace Replace Replace Replace Replace Replace
1A—75 1A—10
1
A—51 1A—49 1A—53
1
A—20 1A—48 1A—57
1
A—57
Malfunction of fuel system Refer to Section 4
Others Slipping clutch Dragging brakes Wrong size tires
Refer to Section 6 Refer to Section 11 Refer to Section 12
Abnormal
combustion
Malfunction of engine-related components Malfunction of HLA
Improper valve clearance Sticking or burned valve
Weak or broken valve spring Carbon accumulation in combustion chamber
Replace Adjust Replace Replace
Eliminate carbon

1
A—75 1A—10 1A—49 1A—53
Malfunction of fuel system Refer to Section 4
Engine noise Crankshaft or bearing related parts
Excessive main bearing oil clearance Main bearing seized or heat-damaged Excessive crankshaft end play Excessive connecting rod bearing oil clearance Connecting rod bearing seized or heat-damaged
Replace or repair Replace
Replace or repair Replace or repair Replace
1A—65
1
A—65 1A—66 1A—67
1
A—67
Piston related parts Worn cylinder Worn piston or piston pin Seized piston Damaged piston ring Bent connecting rod
Replace or repair
Replace
Replace Replace Replace
1A—55
1
A—57
1
A—57
1
A—57 1A—59
Valves or timing related parts Malfunction of HLA* Improper valve clearance Broken valve spring Excessive valve guide clearance Malfunction of timing belt tensioner
Replace Adjust
Replace Replace Replace
1A—75 1A—10 1A—53 1A—49 1A—61
Malfunction of cooling system Refer to Section 3A
Malfunction of fuel system Refer to Section 4
Others Malfunction of water pump bearing Improper drive belt tension Malfunction of alternator bearing Exhaust gas leakage
Replace Adjust Replace Repair
1 A— 7

1
A—48
* 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.
76G01A-005
1A—5

TROUBLESHOOTING GUIDE 1 B
Problem Possible Cause Remedy Page
Insufficient power Insufficient compression Malfunction of HLA Compression leakage from valve seat Seized valve stem Weak or broken valve spring Failed cylinder head gasket Cracked or distorted cylinder head Sticking, damaged, or worn piston ring Cracked or worn piston
Replace Repair
Replace
Replace Replace Replace Replace Replace
1B—60 1B—37 1B—35 1B—38 1B-16 1B—34 1B—43 1B—43
Malfunction of fuel system Refer to Section 4C
Others Slipping clutch Dragging brakes Wrong size tires
Refer to Section 6 Refer to Section 11 Refer to Section 12
Abnormal combustion Malfunction of engine-related components Malfunction of HLA Sticking or burned valve
Weak or broken valve spring Carbon accumulation in combustion chamber
Replace Replace Replace
Eliminate carbon
1B-60
1B-35
1B—38
Malfunction of fuel system Refer to Section 4C
Engine noise Crankshaft or bearing related parts
Excessive main bearing oil clearance Main bearing seized or heat-damaged Excessive crankshaft end play Excessive connecting rod bearing oil clearance Connecting rod bearing seized or heat-damaged
Replace or repair Replace
Replace or repair Replace or repair Replace
1B-51 1B—51 1B—52 1B—53 1B—53
Piston related parts
Worn cylinder Worn piston or piston pin Seized piston Damaged piston ring Bent connecting rod
Replace or repair
Replace
Replace Replace Replace
1B—41 1B-44 1B—43 1B—43 1B-44
Valves or timing related parts Malfunction of HLA* Broken valve spring Excessive valve guide clearance Malfunction of timing belt tensioner
Replace Replace Replace Replace
1B-60 1B—38 1B—35 1B—47
Malfunction of cooling system Refer to Section 3A
Malfunction of fuel system Refer to Section 4C
Others Malfunction of water pump bearing Improper drive belt tension Malfunction of alternator bearing Exhaust gas leakage
Replace Adjust Replace Repair
1B— 6
1B—34
* 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. 76G01B-004
1B—4

1 C TROUBLESHOOTING GUIDE
Problem Possible Cause Remedy Page
Insufficient power Insufficient compression Improper valve clearance Compression leakage from valve seat Seized valve stem Weak or broken valve spring Failed cylinder head gasket Cracked or distorted cylinder head Sticking, damaged, or worn piston ring Cracked or worn piston
Adjust
Repair
Replace Replace Replace Replace Replace Replace
1C-85 1C-50 1C-48 1C-52 1C—16 1C-47 1C-57 1C-56
Malfunction of fuel system Refer to Section 4D
Malfunction of Comprex supercharger Refer to Section 4D
Others Slipping clutch Dragging brakes Wrong size tires
Refer to Section 6 Refer to Section 11 Refer to Section 12
Abnormal
combustion
Malfunction of engine-related components
Improper valve clearance
Sticking or burned valve
Weak or broken valve spring
Carbon accumulation in combustion chamber
Adjust
Replace
Replace Eliminate carbon
1C-85
1C-48
1C-52
Malfunction of fuel system Refer to Section 4D
Malfunction of Comprex supercharger Refer to Section 4D
Engine noise Crankshaft or bearing related parts Excessive main bearing oil clearance Main bearing seized or heat-damaged Excessive crankshaft end play Excessive connecting rod bearing oil clearance Connecting rod bearing seized or heat-damaged
Replace or repair Replace
Replace or repair Replace or repair Replace
1C-64 1C-64 1C-65 1C-66 1C-66
Piston related parts Worn cylinder Worn piston or piston pin Seized piston Damaged piston ring Bent connecting rod
Replace or repair Replace
Replace Replace Replace
1C-55 1C-58 1C-56 1C-57 1C-59
Valves or timing related parts Excessive valve clearance Broken valve spring Excessive valve guide clearance Malfunction of timing belt tensioner
Adjust Replace Replace Replace
1C-85 1C-52 1C-48 1C-61
Malfunction of cooling system Refer to Section 3B
Malfunction of fuel system Refer to Section 4D
Malfunction of Comprex supercharger Refer to Section 4D
Others Malfunction of water pump bearing Improper drive-belt tension Malfunction of alternator bearing Exhaust gas leakage
Replace Adjust Replace Repair
1C-7
1C—47
76G01C-004
1C—4

TROUBLESHOOTING GUIDE 9
TROUBLESHOOTING GUIDE
Problem Possible Cause Remedy Page
Faulty operation of
driveshaft
Broken ball joint
Broken tri-pod joint
Worn or seized joint
Replace
Replace
Replace
9—31
9—35
9—31, 35
Abnormal noise from driveshaft Insufficient grease in joint or spline Excessive backlash on spline Worn joint
Add or replace
Replace
Replace
9—33, 36 9—31, 35 9-31, 35
Steering wheel pulls. (Steering wheel pulls toward either right or left side)
Bent steering linkage
Fatigued coil spring
Lower arm bushing worn or damaged Bent knuckle Bent lower arm or loose mounting Incorrect toe-in adjustment Improper tire air pressure Unevenly worn tires (left and right tires) Brake dragging
Refer to Section 10 Refer to Section 13 Refer to Section 13 Replace Refer to Section 13 Refer to Section 13 Refer to Section 12 Refer to Section 12 Refer to Section 11
9-11
Unstable handling Bent steering linkage
Joint in steering system worn or damaged
Incorrect steering pinion preload adjustment Fatigued coil spring
Faulty shock absorber(s) Lower arm bushing worn or damaged Incorrect toe-in adjustment (front or rear) Improper tire air pressure Wheel(s) bent or unbalanced
Refer to Section 10 Refer to Section 10 Refer to Section 10 Refer to Section 13 Refer to Section 13 Refer to Section 13 Refer to Section 13 Refer to Section 12 Refer to Section 12
—
Excessive steering wheel play Faulty front wheel bearing Incorrect steering pinion preload adjustment Rack and pinion worn Joint in steering system worn or damaged Lower arm bushing worn or damaged
Adjust Refer to Section 10 Refer to Section 10 Refer to Section 10 Refer to Section 13
9-11
Tires excessively worn or worn un-evenly
Incorrect toe-in adjustment Improper tire air pressure Unbalanced wheel(s)
Refer to Section 13 Refer to Section 12 Refer to Section 12 —
Abnormal noise
from axle
Faulty wheel bearing Replace 9-11,18,23
86U09X-006
9—7

TROUBLESHOOTING GUIDE 1 0
TROUBLESHOOTING GUIDE
MANUAL STEERING
Problem Probable Cause Remedy Page
Steering "heavy" Poor lubrication, foreign material, or abnormal wear of Refer to Section 13
(vehicle jacked up, steering bail-joints
both wheels off Stuck or damaged ball-joints Replace 10--18 ground) Improperly adjusted steering pinion preload Adjust 10--56
Damaged steering gear Replace 10--28 Worn or damaged steering bushing Replace 10--53 Stuck lower-arm ball-joint Refer to Section 13
Malfunction of steering-shaft joint Replace 10--21
Steering wheel Incorrect tire pressure Refer to Section 12
pulls to one side Unevenly worn tires Refer to Section 12
Weakened front spring Refer to Section 13 Worn or damaged stabilizer and/or lower arm bushing Refer to Section 13
Dragging brake Refer to Section 11
Loose lower arm Refer to Section 13
Improperly adjusted wheel alignment Refer to Section 13
General instability Incorrect tire pressure Refer to Section 12
while driving Damaged or unbalanced wheel Refer to Section 13
Worn or damaged steering joints Replace 10--21 Improperly adjusted steering pinion preload Adjust 10--56
Weakened front spring Refer to Section 13
Worn or damaged stabilizer and/or lower arm bushing Refer to Section 13
Malfunctioning shock absorber Refer to Section 13 Improperly adjusted wheel alignment Refer to Secton 13
Steering wheel Incorrect tire pressure Refer to Section 12
vibrates Unevenly worn tires Refer to Section 12
Worn wheel bearing, or incorrect adjustment Refer to Section 13
Worn or damaged steering joints Replace 10--21
Improperly adjusted steering pinion preload Adjust 10--56
Loose gear housing mounting bolts Tighten 10--30
Worn steering gear bearing Replace
Worn or damaged stabilizer and/or lower arm bushing Refer to Section 13
Improperly adjusted wheel alignment Refer to Section 13
Worn lower-arm ball-joint Refer to Section 13
Damaged unbalanced wheel Refer to Section 13
Malfunctionina or loose shock absorber Refer to Section 13
Excessive steering Improperly adjusted steering gear backlash Adjust 10--56
wheel play Worn rack and pinion gear Replace 10--51
Worn or damaged steering joints Replace 10--21
Worn or damaaed lower-arm bushinq Refer to Section 13
Poor steering Incorrect tire pressure Refer to Section 12
wheel return Stuck or damaged steering joints Replace 10 -21
Improperly adjusted front wheel alignment Refer to Section 13
Improperly adjusted steering pinion preload Adjust 10--56
Abnormal noise Loose steering linkage Tighten 10--28
from steering Worn steering joints Replace 10--21
system ImDroDerlv adiusted steerina aear backlash Adiust 10--56
86U10X-007
10—7

1 0 TROUBLESHOOTING GUIDE
POWER STEERING
Problem Possible cause Remedy Page
Hard steering
Loose
or
damaged belt Low fluid level,
or air in
fluid Leakage
of
fluid
Malfunctioning electrical system* Insufficient oil pump pressure Improperly adjusted wheel alignment Malfunctioning steering gear Linkage ball joint not operating smoothly
Adjust
or
replace Add fluid
or
bleed
air
Repair
or
replace Repair
or
replace Repair
or
replace Refer
to
Section
13
Repair
or
replace Replace
10—12 10-11 10-13 10-87 10-16
10—28,
37
10-18

Poor return
Insufficient tire pressure
Improperly adjusted wheel alignment
Ball-joint not operating smoothly
Steering shaft contacting something
Refer
to
Section
12

Refer
to
Section
13

Replace
Repair
10-20 10-21

Excessive play
Loose gear box housing mounting bolts Worn linkage
or
tie-rod ball joint Worn lower ball joint Worn
or
damaged steering joint Worn rack and pinion gear
Tighten Replace
Refer
to
Section
13

Replace
Replace
10—30
10—18
10—21
10-58,
75
Steering wheel
vibrates

Insufficient tire pressure Damaged
or
unbalanced wheel Improperly adjusted wheel alignment Loose gear box housing mounting bolts Incorrect pinion preload adjustment Worn ball joints
Loose shock absorber mounting Malfunctioning shock absorber
Refer
to
Section
12

Refer
to
Section
13

Refer
to
Section
13

Tighten Adjust
Replace Refer
to
Section
13
Refer
to
Section
13

10-30 10-72,
81
10—18

Steering wheel
pulls

Unevenly worn tires
Incorrect tire pressure
Dragging brake
Improperly adjusted wheel alignment
Refer
to
Section
12

Refer
to
Section
12

Refer
to
Section
11

Refer
to
Section
13 —
Excessively light
steering at high
speed*

Malfunctioning electrical system Repair
or
replace 10-87
*... Only
for
electronically
-
controlled type

76G10X-002
10—8

ANTI-LOCK BRAKE SYSTEM (ABS) 1 1
TROUBLESHOOTING
Precaution
Conditions that are not malfunctions
1. It may happen that vibration is felt in the steering wheel, body, and/or brake pedal when the ABS
is functioning; such vibration is simply an indication that the system is functioning.
2. Sound of the pump motor operating, accumulator pressure being released, or the relay operating
may be heard from the engine compartment when the engine is started as the system is being auto-
matically checked.
3. The ABS pump motor may be automatically activated even though the ABS is not operating.
4. The ABS warning light may illuminate under any of the following conditions:
• When the vehicle is traveling on snow or ice with the parking brake activated or a brake dragging
at one wheel.
• When different-sized tires are used.
• When tires of different gripping performance are used.
• When (while the vehicle is jacked up or stuck) only the front wheels are spun for 20 seconds or more.
• When there is insufficient battery voltage.
Note
Under the above conditions, the warning light will not illuminate a second time when the
ignition is switched OFF then back ON, and there will be no memory entry to the control
unit of a problem.
Troubleshooting notes
The ABS is composed of electrical components, mechanical components (hydraulic unit), and the com-
ponents of the standard brake system.
Fundamentally, malfunction of the ABS electrical or mechanical components is judged by the self-
diagnosis function within the ABS control unit. And malfunctions are indicated by the warning light
in the instrument panel.
The location
of
a malfunction is indicated by the technician switching the system to the diagnosis-indication
mode.
The self-diagnosis and indication functions must be used when malfunctions of the ABS are being
diagnosed.
76G11X-091
11—73

12
WHEELS AND TIRES
OUTLINE 12— 2
SPECIFICATIONS 12— 2
TROUBLESHOOTING GUIDE 12— 2
WHEELS AND TIRES 12—3
INSPECTION AND ADJUSTMENT 12— 3
TIRE ROTATION 12—4
WHEEL BALANCE 12— 5
WHEEL MOUNTING 12— 5
SPECIAL NOTE 12—5
86U12X-001