trunk MAZDA 626 1987 Workshop Manual

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

14
BONNET 14— 2
STRUCTURAL VIEW 14— 2
REMOVAL 14— 3
INSTALLATION 14— 4 ADJUSTMENT 14— 4 TRUNK LID 14— 5 STRUCTURAL VIEW (SEDAN AND COUPE/MX-6) 14— 5 REMOVAL 14— 6 INSTALLATION 14— 7 ADJUSTMENT 14— 8
REAR HATCH 14— 9 STRUCTURAL VIEW 14— 9 REMOVAL 14— 10 INSTALLATION 14— 12 ADJUSTMENT 14— 12 FRONT DOORS 14—13
STRUCTURAL VIEW 14— 13
REMOVAL 14—15
INSTALLATION 14—17 ADJUSTMENT 14— 18 REAR DOORS 14—19 STRUCTURAL VIEW 14— 19 REMOVAL 14— 20
INSTALLATION 14— 21 ADJUSTMENT 14— 22 FRONT BUMPER 14— 23
STRUCTURAL VIEW 14—23 REMOVAL 14— 24 INSTALLATION 14—24 REAR BUMPER 14— 25
STRUCTURAL VIEW 14— 25 REMOVAL 14— 26
INSTALLATION 14— 26 RADIATOR GRILLE 14— 27 REMOVAL AND INSTALLATION 14— 27 HEADLIGHT AND COMBINATION LIGHT 14— 28 REMOVAL AND INSTALLATION 14— 28
AIMING 14— 31 REAR COMBINATION LIGHTS 14— 32 REMOVAL AND INSTALLATION 14— 32
REPLACEMENT OF REAR COMBINATION LIGHT LENS 14— 33
LICENSE PLATE LIGHT AND CARGO ROOM LIGHT 14— 35 REMOVAL AND INSTALLATION 14— 35
INTERIOR LIGHT AND MAP LIGHT 14- 36 REMOVAL AND INSTALLATION 14— 36
MOLDING AND GARNISH 14— 37
STRUCTURAL VIEW 14— 37 WINDSHIELD MOLDING 14— 38 WINDSHIELD LOWER MOLDING 14— 38 DRIP MOLDING 14— 38 BELT LINE MOLDING 14— 38 REAR WINDOW SIDE MOLDING (SEDAN) .14— 39 REAR WINDOW LOWER MOLDING
(SEDAN AND COUPE/MX-6) 14— 39 REAR WINDOW UPPER MOLDING 14— 39
BONNET MOLDING
(SEDAN AND HATCHBACK) 14— 39 QUARTER WINDOW MOLDING (COUPE/MX-6) 14— 40 QUARTER WINDOW MOLDING
(HATCHBACK) 14—40 QUARTER WINDOW MOLDING (SEDAN)... 14— 40 REAR WINDOW SIDE MOLDING (COUPE/MX-6) 14— 40
TRUNK LID MOLDING (SEDAN AND HATCHBACK) 14— 41
CENTER PILLAR GARNISH
(SEDAN AND HATCH BAC K/MX-6) 14— 41 REAR FINISHER (COUPE/MX-6 AND SEDAN) 14— 41 REAR FINISHER (HATCHBACK) 14— 41
SAIL GARNISH 14— 42
SIDE PROTECTOR MOLDING 14— 42 DOOR MIRROR 14— 44 DISASSEMBLY 14— 44 ASSEMBLY 14— 44 TRUNK-LID LOCK REMOTE RELEASE 14— 45 REMOVAL AND INSTALLATION 14— 45 FUEL FILLER LID REMOTE RELEASE 14— 46
REMOVAL AND INSTALLATION 14— 46 WINDSHIELD GLASS 14—47 STRUCTURAL VIEW 14—47 REMOVAL 14— 48 INSTALLATION 14— 49 REAR WINDOW GLASS 14— 52
STRUCTURAL VIEW 14— 52 REMOVAL 14— 54
INSTALLATION 14— 55 REAR HATCH GLASS 14— 58 STRUCTURAL VIEW 14— 58 REMOVAL 14— 59 INSTALLATION 14— 59 QUARTER WINDOW GLASS 14— 62 STRUCTURAL VIEW 14— 62
REMOVAL 14— 64 INSTALLATION 14—64
HEADLINER 14- 67 STRUCTURAL VIEW 14—67 REMOVAL 14— 69 INSTALLATION 14— 72 INSTRUMENT PANEL 14— 73 STRUCTURAL VIEW 14— 73
INSTALLATION VIEW 14— 74
REMOVAL 14— 75 INSTALLATION 14— 80 SLIDING SUNROOF 14— 81 STRUCTURAL VIEW 14— 81 REMOVAL 14— 82 INSTALLATION 14— 85 WINDSHIELD WIPER 14— 91
STRUCTURAL VIEW 14— 91
REMOVAL 14— 92
INSTALLATION 14— 93 ADJUSTMENT 14— 93 REAR WINDOW WIPER 14—94 STRUCTURAL VIEW (HATCHBACK) 14— 94 REMOVAL 14— 95 INSTALLATION 14—95 ADJUSTMENT 14— 96
HEADLIGHT WASHER 14— 97 REMOVAL AND INSTALLATION 14— 97 SEAT 14— 98 STRUCTURAL VIEW 14— 98 INSPECTION 14—100 SEAT BELTS 14—101
STRUCTURAL VIEW 14—101 INSPECTION 14—101
UNDERBODY PROJECTED DIMENSIONS.... 14—102 UNDERBODY STRAIGHT-LINE DIMENSIONS 14—104 76G14X-001

TRUNK LID 14
TRUNK
LID

STRUCTURAL VIEW (SEDAN AND COUPE/MX-6)
1. Trunk lid lock
2. Trunk lid opener protector
3. Opening rod
4. Retainer
5. Trunk lid key cylinder
6. Balance spring
76G14X-040
7. Trunk lid hinge bracket
8. Trunk lid hinge
9. Trunk lid
14—5

1 4 TRUNK LID
86U14X-012
Opening rod
86U14X-013
86U14X-014
REMOVAL
Trunk Lid Opener
1. Remove the nut and the protector.
2. Remove the opening rod.
3. Remove the bolts and the trunk lid opener.
Trunk Lid Key Cylinder
Remove the retainer and the trunk lid key cylinder.
Trunk Lid
1. Remove the trunk lid installation bolts, then remove
the trunk lid.
2. Remove the balance spring.
3. Remove the rear seat. (Refer to page 14—100)
76G14X-041
14—6

TRUNK LID 14
4. Remove the fasteners and remove the rear pack-
age tray.
86U14X-017
INSTALLATION
Install in the reverse order of removal.
Tightening torque:
86U14X-018
14—7

14 TRUNK LID
86U14X-019
86U14X-020
ADJUSTMENT
Trunk Lid
1. Adjust the trunk lid by loosening the lid to hinge
mounting bolts and repositioning it.
2. Align the trunk lid evenly as shown in the figure.
Trunk Lid Striker
1. Loosen the striker mounting bolts.
2. Tighten the bolts after adjusting.
Tightening torque:
7.8—11 N m (0.8—1.1 m-kg, 5.8—8.0 ft-lb)
86U14X-021
14—8

MOLDING AND GARNISH 1 4
MOLDING AND GARNISH
STRUCTURAL VIEW
Coupe/MX-6
Sedan
76G14X-012
1. Windshield molding 6. Rear window lower molding 11. Rear window upper
2. Windshield lower molding 7. Rear window side molding molding
3. Drip molding 8. Bonnet molding 12. Center pillar garnish
4. Beltline molding 9. Front lower molding 13. Rear finisher
5. Quarter window molding 10. Trunk lid molding 14. Sail garnish
14—37

MOLDING AND GARNISH 1 4
TRUNK LID MOLDING
(SEDAN AND HATCHBACK)
Removal and Installation
1. Remove the rear finisher.
2. Remove the nuts and screws and remove the trunk
lid molding.
3. Install in the reverse order of removal.
CENTER PILLAR GARNISH
(SEDAN AND HATCHBACK)
Removal and Installation
1. Remove the seat belts.
2. Remove the front header trim.
3. Remove the center pillar trim.
4. Remove the nuts with a deep socket wrench, then
remove the garnish.
5. Install in the reverse order of removal.
76G14X020
REAR FINISHER (COUPE/MX-6 AND SEDAN)
Removal and Installation
1. Remove the nuts and the rear finisher.
2. Install in the reverse order of removal.
76G14X-021
REAR FINISHER (HATCHBACK)
Removal and Installation
1. Remove the hatchback door side trims.
2. Remove the hatchback door lower trim.
3. Remove the hatchback door screen.
4. Remove the nuts and the rear finisher.
5. Install in the reverse order of removal.
76G14X-022
14—41

TRUNK-LID
LOCK REMOTE RELEASE
1
4
TRUNK-LID LOCK REMOTE RELEASE
REMOVAL AND INSTALLATION
1. Remove in the sequence shown in the figure.
2. Install in the reverse order of removal.
A 8 c D
1—
133
86U14X-108
1. Screws
2. Scuff plate
3. Screws
4. Cover
5. Bolts
6. Release lever
7. Release wire
14—45