1988-1989 Mazda MX6 626 Service & Repair Manual

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 important 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 dealers. 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 information 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, connections and components for leaks □ Tires for cuts or bruises □ Steering linkage, suspension, exhaust system and all underside 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. m o m H > DO r~ m O) o x m o c r~ m (/> 0 1 m o c r~ m o m O m c/> m J3 < o m (A to 0 1 m D c r~ m D S > m z > z o m to m DO < O m to

96U00X-001 0 1 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 components 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 m o m H > CO I- m w 0 1 m o c i- m to o X m o c r~ m o H m o m TO m u < o m (/>

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 o o ^ o 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 m z > z o m H > W r~ m w 0 1 m o m m o X m o c r~ m o £ > z H m z > z o m co m 30 < O m co

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 O H m m c > s 3 £ m C/5 m 33 < o m O)

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 components 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 m z > z o m — i > co r~ m Tn o x m o c i— m NJ w 0 1 m o c i” m o > z H m z > z o m </> m J3 < o m co O

96U00X-004 0 1 CO I ■ ! . 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 m z > z o m — i > cn i” m w o x m o c r~ m to CO o X m o m O m 2 > Z o m co m 33 < o m co

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

1988-1989 Mazda MX6 626 Service & Repair Manual

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