1989
l¥3azda
626
MX-6
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 for Mazda own-
ers in diagnosing certain problems and per-
forming 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 content^ 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.
CONTENTS
Title
General Information
Pre-Delivery Inspection and
Scheduled Maintenance Services
Engine
Lubrication System
Cooling System
Fuel and Emission
Control Systems
Non-Turbo
Turbo
Engine Electrical System
Clutch
Transaxle
Manual
Automatic
Front and Rear Axles
Steering System
Braking System
Wheels and Tires
Suspension
Body
Body Electrical System
Heater and Air Conditioning System
Technical Data
Special Tools
Wiring Diagram
Mazda Motor Corporation
HIROSHIMA JAPAN
© 1988 Mazda Motor Corporation
PRINTED IN JAPAN, JUNE '88 ®
1187-10-88F
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 (SCHEDULE 1) ...... 0— 3
MAINTENANCE TABLE (SCHEDULE 2) ...... Q~ 7
86U00X-001
0 PRE-DELSVERY SNSPECTION
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 hood 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 HOOD—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 oi! 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)
-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 selec-
tion (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 216.5-217 (8.52-8.54) 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 HOOD—ENGINE RUNNING AT
OPERATING TEMPERATURE _________
CHECK the following items:
□ Automatic transaxle fluid level
□ Initial ignition timing
Non-turbo 6° ± 1° BTDC
Turbo 9° ± 1° BTDC (with test connector grounded)
ON HOIST"
CHECK the following items:
□ Underside fuel, coolant and hydraulic lines, fittings, connec-
tions and components for leaks
□ Tires for cuts or bruises
□ Steering linkage, suspension, exhaust system and all under-
side 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
86U00X-002
0-2
96U00X-004
Follow Schedule 1 (Normal Driving Condition) if you mainly operate your vehicle where none of the following conditions apply. (Except Canada)
Follow Schedule 2 (Unique Driving Condition) if one or more of the items below apply;
• Repeated short distance driving.
• Driving in dusty conditions.
• Driving a with extended use of brakes.
• Driving in areas using road salt or other corrosive materials.
• Driving on rough and/or muddy roads.
• Extended periods of idling and/or low-speed operation.
• Driving for a prolonged period in cold temperature and/or extremely humid climates.
SCHEDULE 1 (NORMAL DRIVING CONDITION)
Chart symbols:
I : Inspect, and if necessary correct, clean or replace
R: Replace or change
T : Tighten
L: Lubricate
Remarks;
After 60 months or 60,000 miles (96,000km), continue to follow the described maintenance items and intervals periodically.
As for * marked items in this-jjiaintenance chart, please pay attention to the following points.
*1 Replacement of the timing belt is required at every 60,000 miles (96,000km). Failure to replace the timing belt may result in damage to the engine.
*2 This maintenance operation is recommended by Mazda. However, this maintenance is not necessary for emission warranty coverage or manufacturer recall liability.
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96U00X-001
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Interval
Procedure & item
Number of months or km (miles) whichever comes first
Service data and inspection point Page
Months 7.5 15 22.5 30 37.5 45 52.5 60
Miles 7,500 15,000 22,500 30,000 37,500 45,000 52,500 60,000
Kilometers 12,000 24,000 36,000 48,000 60,000 72,000 84,000 96,000
Steering operations and linkage I I • Free play: 0—30 mm (0— 1.18 in)
• Operation and looseness
• Fluid leakage or oozing
10—10
10-13
Air cleaner element R R — 4A—32
4B-37
Spark plugs
R R
• Plug gap: 1
(0.039—0.0-
• Recommenc
NGK
Nippon
Denso
0—1.1 mm
*3 in)
ted spark plugs
ZFR5A-11
ZFR6A-11
ZFR7A-11
QJ16CR11
QJ20CR11
QJ22CR11
5-27
Cooling system '« I I I I • Hoses for cracks or wear
• Coolant level
3—4
Engine coolant R R — 3—4
Drive belts I I • Cracks or damage
• Tension
1—6
Fuel filter R — 4A—57
4B-69
Fuel lines
| *2
I • Fittings, connections and compo-
nents for leaks
4 A—41
4B-52
Brake lines, hoses and connections I I • Proper attachment and connections 11-7
Engine timing belt*1 Replace every 60,000 miles (96,000 km) — 1-10
Engine oil Non-turbo R R R R R R R R • Oil pan capacity: 3.9 liters
(4.1 US qt, 3.4 Imp qt)
2—4
Turbo Replace every 5,000 miles (8,000 km) or 5 months
Oil filter Non-turbo R R R R R R R R • Oil filter capacity: 0.3 liters
(0.32 US qt, 0.26 Imp qt)
2-5
Turbo Replace every 5,000 miles (8,000 km) or 5 months
Drum brakes I I • Min. lining thickness:
1.0 mm (0.04 in)
® Max. drum inner dia.:
230.1 mm (9.06 in)
11—47
Disc brakes I I • Min. pad thickness:
Front 2.0 mm (0.08 in)
Rear 1.0 mm (0.04 in)
• Min. disc thickness:
Front 22.0 mm (0.87 in)
Rear 8.0 mm (0.31 in)
• Disc run-out: 0.1 mm (0.004 in)
11-33,41
11-33,41
11-33,41
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96U00X-002
Interval
Procedure & item
Number of months or km (miles) whichever comes first
Service data and inspection point Page
Months 7.5 15 22.5 30 37.5 45 52.5 60
Miles 7,500 15,000 22,500 30,000 37,500 45,000 52,500 60,000
Kilometers 12,000 24,000 36,000 48,000 60,000 72,000 84,000 96,000
Front suspension ball joints I I • Damage, looseness and grease
leakage
13— 14
Drive shaft dust boots I I • For cracks, damage, leakage of
grease or looseness of band
9-32
9—35
Rear suspension ball joints
(4-wheel steering vehicle only)
I I • Damage, looseness and grease
leakage
13—31
4-wheel steering system operation and
linkage
I I • Operation and looseness
• Fluid leakage or oozing
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Steering angle of rear wheels (4-wheel
steering vehicle only)
I I • Steering wheel angle:
Inner 5° 00’ ± 45’
Outer 5° 00’ ± 45’
13-47
Solenoid valve oil filter for 4-wheel
steering system
R R — 10-38
Exhaust system heat shield I I • Clearance to body, and exhaust
system
4A—74
Bolts and nuts on chassis and body T T — —
Air conditioner system
(if equipped)
Refrigerant Inspect the refrigerant amount annually 950-1,050 g (33:5—37.1 oz) 16—39
Compressor Inspect the operation annually
— 16-42
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86UOQX-006
9 SCHEDULE 2 (UNIQUE DRIVING CONDITION)
cn Chart symbols:
I : Inspect, and if necessary correct, clean or replace Z (/)
R: Replace or change O
T : Tighten Z -E
L: Lubricate > HJ
O
Remarks: ni
After 60 months or 60,000 miles (96,000km), continue to follow the described maintenance items and intervals periodically. _j jjg
As for * marked items in this maintenance chart please pay attention to the following points. > q
*1 Replacement of the timing belt is required at every 60,000 miles (96,000km). Failure to replace the timing belt may result in damage to the engine. 00
m
*2 This maintenance operation is recommended by Mazda. However, this maintenance is not necessary for emission warranty coverage or manufacturer recall liability.
*3 This maintenance operation is required for Canada and all states except California. However we do recommend that this operation be performed on California vehi- _ ^
cles as well. W 2
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96U00X-Q03
Interval
Procedure & item
Number of months or km (miles) whichever comes first
Service data and inspection point Page
Months 5 10 15 20 25 30 35 40 45 50 55 60
Miles
(x1,000)
5 10 15 20 25 30 35 40 45 50 55 60
Kilometers
(x1,000)
8 16 24 32 40 48 56 64 72 80 88 96
Steering operations and linkage I
'
• Free play: 0—30 mm (0—1.18 in)
• Operation and looseness
• Fluid leakage or oozing
10—10
10— 13
Air cleaner element
j *3
R
j *3
R — 4A—32
4B—37
Spark plug
R R
• Plug gap: 1
(0.039—0.0-
• Recommenc
NGK
Nippon
Denso
0—1.1 mm
43 in)
led spark plugs
ZFR5A-11
ZFR6A-11
ZFR7A-11
QJ16CR11
QJ20CR11
QJ22CR11
5—27
Cooling system I
'
I I • Hoses for cracks or wear ■
• Coolant level
3—4
Engine coolant R R — 3-4
Drive belts I I • Cracks or damage
• Tension
1—6
Fuel filter R
— 4A—57
4B—69
Fuel lines
j *2
I • Fitting, connections and compo-
nents for leaks
4 A—41
4B—52
Brake lines, hoses and connections I I • Proper attachment and connections 11—7
Engine timing belt*1 Replace every 60,000 miles (96,000km) —
1-10
Engine oil Non-turbo R R R R R R R R R R R R • Oil pan capacity:
3.9 liters (4.1 US qt, 3.4 Imp qt)
2—4
Turbo Replace every 3,000 miles (5,000km) or 3 months
Oil filter Non-turbo R R R R R R R R | R R R j R • Oil filter capacity:
0.3 liters (0.32 US qt, 0.26 Imp qt)
2—5
Turbo Replace every 3,000 miles (5,000km) or 3 months
Drum brakes I I • Min. lining thickness:
1.0 mm (0.04 in)
• Max. drum inner dia.:
230.1 mm (9.06 in)
11—47
Disc brakes
'
I I I
• Min. pad thickness:
Front 2.0 (0.08 in)
Rear 1.0 mm (0.04 in)
• Min. disc thickness:
Front 22.0 mm (0.87 in)
Rear 8.0 mm (0.31 in)
• Disc run-out: 0.1 mm (0.004 in)
11-33,41
11-33,41
11-33,41
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. Interval
Procedure & item
Number of months or km (miles) whichever comes first
Service data and inspection point Page
Months 5 10 15 20 25 30 35 40 45 50 55 60
Miles
(x1,000)
5 10 15 20 25 30 35 40 45 50 55 60
Kilometers
(x1,000)
8 16 24 32 40 48
I
56 64 72 80 88 96
Front suspension ball joints I • Damage, looseness and grease
leakage
13—14
Drive shaft dust boots I I • For cracks, damage, leakage of
grease or looseness of band
C \l LO
CO CO
I I
CD CT)
Rear suspension ball joints
(4-wheel steering vehicle only)
I I • Damage, looseness and grease
leakage
13—31
4-wheel steering system operation and
linkage
I I • Operation and looseness
• Fluid leakage or oozing
10—10
10—14
Steering angle of rear wheels
(4-wheel steering vehicle only)
I I • Steering wheel angle:
Inner 5° 00’ ± 45’
Outer 5° 00' ± 45’
13—47
Solenoid valve oil filter for 4-wheel
steering system
R R — 10-38
Exhaust system heat shield ' I I • Clearance to body, and exhaust
system
4A—74
Bolts and nuts on chassis and body T T T T — —
Air conditioner system
(if equipped)
Refrigerant Inspect the refrigerant amount annually 950—1,050 g (33.5—37.1 oz) 16—39
Compressor Inspect the operation annually — 16—42
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G
GENERAL INFORMATION H
IMPORTANT INFORMATION ........ , ........... . G— 2
FUNDAMENTAL PROCEDURES................. . G... 2
JACK AND SAFETY STAND (RIGID RACK)
POSITIONS .............. ............... .......................... G— 6
VEHICLE LIFT (2-SUPPORT TYPE}
POSITIONS ........................................................ G— 6
TOWING .................... ........................................... G— 7
CHASSIS NUMBER LOCATION ...................... G— 8
ENGINE MODEL AND NUMBER
LOCATION ........................................... . G— 8
UNITS .................................................... ................ G— 8
ABBREVIATIONS... ............................ .............. . G- 8
CAUTION ............... ............................................... G— 9
WARNING ................ ........................ .......... ........ G— 9
96U0GX-001
V
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1989 MAZDA 626 GD GV Series All Models Service and Repair MA
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Description
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