wiring 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

FUNDAMENTAL PROCEDURES G
Depending on where they are;
1. Sealant should be applied to gaskets
2. Oil should be applied to the moving components
of parts
3. Specified oil or grease should be applied at the
prescribed locations (oil seals, etc.) before as-
sembly.
47U0GX-012
ADJUSTMENTS
Use suitable gauges and/or testers when making var-
ious adjustments.
67U0GX-002
ELECTRICAL SYSTEM
Be sure to disconnect the battery cable from the nega-
tive (-) terminal of the battery.
Never pull on the wiring when disconnecting con-
nectors.
When locking connectors, make sure to listen for a
click that will let you know they are securely locked.
Handle sensors and relays carefully. Be careful not
to drop them or strike them against other parts.
47U0GX-014
RUBBER PARTS AND TUBING
Always prevent gasoline or oil from getting on rub-
ber parts or tubing.
47U0GX-015
G—5

3A COOLING FAN
COOLING FAN
SYSTEM CIRCUIT
IG1 IG Relay
*
No.1
relay
Water thermo switch
I With A/C

CM)
Main fan
1
L..±
No.2
relay
IG2
Add.
relay ol
(M)
A/C sw.
Add fan
86U03X-019
CIRCUIT INSPECTION
1. Turn the ignition switch ON.
2. Disconnect the water thermo switch connector, and
check that the fan operates.
3. If the fan doesn't operate, check the fuse, fan re-
lay, fan motor, thermo switch and wiring harness.
76G03A-010
3 A—12

3B COOLING FAN
COOLING FAN
SYSTEM CIRCUIT
I
IG1 IG Relay Main fuse
©
Main fan motor
V-f motor
IG1
Water thermo switch OFF: over 91°C (208 °F)
Water thermo switch ON:
below 84°C
(183°F)
76G03B-015
CIRCUIT INSPECTION
1. Turn the ignition switch ON.
2. Disconnect the water thermo switch connector, and
check that the fan begins to operate.
3. If the fan doesn't operate, check the fuse, fan re-
lay, fan motor, thermo switch, and wiring harness.
76G03B-016
3B—10

4 A DECELERATION CONTROL SYSTEM
TROUBLESHOOTING
Check the condition of the wiring harness and connectors before checking the engine control unit
or switches.
FE 12Valve and F8 (ECE, Hong Kong and Singapore)—MTX
Possible cause
Page
Symptom

Anti-afterburn

valve
Dashpot Bypass
air
control
system
Idle

switch
main
air

bleed

control
system

Engine

control

unit

terminal
Possible cause
Page
Symptom

Anti-afterburn

valve
Dashpot Bypass
air
control
system
Idle

switch
main
air

bleed

control
system
E L M
Possible cause
Page
Symptom 4A—50 4A—50 4A—48 4A—93 4A—51 4A—88
Runs rough on deceleration 2 1 3 5 4
Afterburn in exhaust system 1 2 4 3 5 6
Poor fuel consumption 1 2 3
Fails emission test 7 6 1 2 3 4 5
High idle speed after warm up 1 2 3
Engine stalls during warm up 1
Rough idle during warm up 1
Poor acceleration, hesitation, or lack of power 1
76G04A-079
FE 12Valve and F8 (ECE, Hong Kong and Singapore)—ATX
Possible cause o> o 4-* uT u. E 3
(0 >
c k_ 3 •Q L-
2 ST c
o o "O at 0)
_>. c O
£ O
o w c o
• 1
\Page a •
C
3 i CO V S.
v>

5 E c ® 5 »
5 w a> in m
< BO M S «T 2 B D 2N
Symptom 4A—50 4A—48 4A—51 4A—93 4A—86
Runs rough on deceleration 2 3 1 5 4
Afterburn in exhaust system 1 2 3 4 5
Poor fuel consumption 1 2
Fails emission test 7 6 2 1 3 4 5
High idle speed after warm up 1 2
Engine stall during warm up 1
Rough idle during warm up 1
Poor acceleration, hesitation, or lack of power 1
76G04A-080
4A—46

IGNITION TIMING CONTROL SYSTEM 4A
TROUBLESHOOTING
Check the condition of the wiring harness and components before checking the sensors or switches.
\\ Possible cause , . Engine control unit terminal
\ Page

rater

thermo

switch

itake

manifold)

'ater

thermo

switch

Iadiator)
hibitor

switch

Solenoid

valve

(Ignition

timing

contra

0) >
5 >> n
acuum

control

unit

Ustributor)
Symptom \J

•S-
o 5 t c
Solenoid

valve

(Ignition

timing

contra

O > B 1F 2A 2F 2H 2M Symptom \J 4A—95 4A—95 4A—93 4A—81 4A—82 Section 5 4A—85 4A--86
Poor accelera-
tion, hesitation, 5 6 4 2 3 1 11 7 8 9 10 or lack of power
Fails emission test 4 5 3 2 — 1 10 6 7 8 9
76G04A-161
Solenoid Valve (Ignition Timing Control)
1. Disconnect the vacuum hose from the solenoid
valve and vacuum pipe.
2. Blow through the solenoid valve from vacuum hose
A.
3. Check that air flows from port B.
76G04A-162
4. Disconnect the solenoid valve connector.
5. Connect 12V and a ground to the terminals of the
solenoid valve.
6. Blow through the solenoid valve from vacuum hose
A.
7. Check that air flows from the valve air filter.
76G04A-163
4 A—81

4A CONTROL SYSTEM
ENGINE CONTROL UNIT
Check the engine control unit terminal voltages with
a voltmeter.
Caution
a) Warm up the engine before checking the
control unit.
b) If the proper voltage is not obtained, check
the wiring, connections and finally, check
the component.
FE and F8 Engine — ATX (ECE, Hong Kong, and Singapore)
Terminal
(Wire color) Connected to Condition Voltage

1A
(BW)
Ignition switch Ignition switch ON. Battery voltage

m
ST
'-O
Solenoid valve (Main
air
bleed control) Others Battery voltage
m
ST
'-O
Solenoid valve (Main
air
bleed control) Radiator coolant temperature below 17°C (63°F)
or
intake manifold vacuum more than 200 mmHg (7.9 inHg)
Below 1,5V
1C (GO) Solenoid valve (Choke opener) Radiator coolant temperature below 17°C (63°F)
or
during cranking and
27
sec. after engine starts Below 1,5V
Others Battery voltage
1D
(GL)
Air bypass solenoid valve Idle switch OFF and engine speed above approx. 2,100 rpm Below 1,5V
Others Battery voltage
1E
— — —

1F
(G) Solenoid valve (Ignition timing control system)
Radiator coolant temperature above 17°C (63°F),
en-
gine coolant temperature below 72°C (162°F), inhibi-tor switch OFF and engine speed below 2,300
rpm

Below 1.5 V
Others Battery voltage
1G
— — —

1H
(LW) Solenoid valve (A/C) A/C switch
ON
and engine speed below approx. 2,300
rpm

Below 1,5V
Others Battery voltage
11
(YW) Idle-up solenoid valve Inhibitor switch OFF and, headlight switch ON, rear
defroster switch ON, fan speed control switch
is 3rd

or 4th position, A/C operated,
or
engine coolant tem-
perature below 72°C (162°F)
Below 1,5V
Others Battery voltage
1J
(B)
Ground
—
Below 1,5V

9 MSSirSl
ivj
A 1
k *
76G04A-169
4A—86

4B TROUBLESHOOTING WITH SST
INSPECTION PROCEDURE
1. Connect the SST to the check connector, (Green,
6-pin) and the negative battery terminal.
2. Set the select switch to position A.
Note
The check connector is located at the rear of
the left side wheel housing.
86U04A-011
Test connector: Green (1 pin)
3. Ground the test connector (Green, 1-pin) with a
jumper wire.
Note
The test connector is located near the Self-
Diagnosis Checker check connector.
86U04A-012
OO
uu
SELF-DIAGNOSIS CHECKER
(WPUTOft
SELECT
S*

5


o n==ru
o o o o 49 HO 18 9AI
76G04B-005
4. Turn the ignition switch ON.
5. Verify that 88 flashes on the digital display and that
the buzzer sounds for three seconds after turn-
ing the ignition switch ON.
6. If 88 does not flash, check the main relay (Refer
to page 4B—86), power supply circuit, and check
connector wiring.
7. If 88 flashes and the buzzer sounds continuously
for more than 20 seconds, replace the engine con-
trol unit and perform steps 3 and 4 again.
8. Note the code numbers and check for the causes
by referring to the check sequences shown on
pages from 4B—14 to 4B—24. Repair as
necessary.
Note
Cancel the code numbers by performing the
after-repair procedure after repairing.
AFTER-REPAIR PROCEDURE
1. Cancel the memory of malfunctions by disconnect-
ing the negative battery cable and depressing the
brake pedal for at least 2 seconds; then recon-
nect the negative battery cable.
76G04B-134
4B—10

4B TROUBLESHOOTING WITH SST
If a malfunction code number is shown on the SST, check the following chart along with the wiring
diagram.
Code No. 01 (Ignition pulse) PC: Possible Cause
76G04B-009
4B—14

TROUBLESHOOTING WITH SST 4B
Code No. 08 (Air flow meter) PC: Possible Cause

Are there poor connections
in air
flow meter circuit?

NO

Is there continuity between
air
flow meter and engine control unit?
Air flow meter Control unit

Vb
(RB wire) 31

Vc
(RW wire) 2B

Vs
(RB wire) 2E

E2
(LgY wire) 2C

YES

Is resistance
of air
flow meter OK?
Resistance:
Terminal More then
20

E2
Vs
20—400 20—1,000
E2
Vc
100-300
E2
Vb
200-400

YES
NO
NO
YES

Is same Code.
No.
present after performing after-repair procedure? (Refer
to
page 4B—10)

VES

Are engine control unit terminal voltages OK? Check terminal: 2B, 2C, 2E,
31
(Refer
to
page 4B—89 and 4B—90)

YES
NO
NO

Repair
or
replace connector
PC: Open circuit
in
wiring harness from
air
flow
meter
to
engine control unit
Repair
air
flow meter
Air flow meter and circuit
OK

PC: Short circuit
in
wiring harness
PC: Engine control unit malfunction

76g04b-010
4B—15