Mazda 626 Gf Workshop Manual a4.pdf

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CONTENTS

I section

Title

FOREWORD

This manual contains on vehicle service

diagnosis for the Mazda 626.

For proper repair and maintenance, a

familiarization with this manual is

and it should always be kept in a

for quick and easy reference.

All the contents of this manual, including

rawings and specifications, are the latest

vailable at the time of printing. As

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 contents

of this manual without obligation or

advance notice.

may be reproduced or used in any form or

by any means, electronic or mechanical-

including photocopying and recording and

the use of any kind of information storage

and retrieval system-without permission in

1 writing.

0 1997 Mazda Motor Corporation

PRINTED IN JAPAN, APR. 1997 @

1577-1 0-97D

WARRANTY

The manufacturer's warranty on Mazda

vehicles and engines can be voided if

improper service or repairs are performed

by persons other than those at an

Authorized Mazda Dealer.

Mazda Motor Corporation

HIROSHIMA, JAPAN

APPLICATION:

This manual is applicable to vehicles

beginning with the Vehicle Identification

Numbers (VIN), and related materials

shown on the following page.

VEHICLE IDENTIFICATION NUMBERS WIN)

JMZ GF12P20# 100001 -

JMZ GF12F50# 100001 -

JMZ GF14P2W 100001 -

JMZ GF14P50# 100001 -

JMZ GF14F20# 100001 -

JMZ GF14F50# 100001 -

JMZ GF14S20# 100001 -

JMZ GF14S5W 100001 -

RELATED MATERIALS

626 Training Manual (Europe) .................... 3303-10-97D

Engine Workshop Manual FP FS ................. 1579-10-97D

Manual Transaxle Workshop Manual G25M-R ..... 1441-1 0-94F

Automatic Transaxle Workshop Manual GF4A-EL . 1393-10-93H

626 Wiring Diagram (Europe (L.H.D.)) ............. 5406-1 0-97D

626 Wiring Diagram (UK) ......................... 5407-10-97D

JMZ GF12F20# 100001 -

GENERAL INFORMATION

HOW TO USE THIS MANUAL .............. GI- 1

HOSE CLAMPS GI-l1

TORQUE FORMULAS ................... GI-12

........................

SERVICING PROCEDURE .............. GI- 1

SYMBOLS ............................. GI- 3

ADVISORY MESSAGES ................. GI- 3

TROUBLESHOOTING PROCEDURE ..... GI- 3

TEXT SEQUENCE ...................... GI- 6

UNITS ................................... GI- 7

VlSE .................................. GI-12

DYNAMOMETER ....................... GI-12

.......

INSTALLATION OF RADIO SYSTEM GI-12

ELECTRICAL SYSTEM .................... GI-13

ELECTRICAL PARTS ................... GI-13

CONNECTORS ......................... GI-13

ELECTRICALTROUBLESHOOTING

TOOLS ............................... GI-15

NEW STANDARDS ....................... GI- 8

FUNDAMENTAL PROCEDURES ........... GI-10

PROTECTION OF THE VEHICLE ......... GI-10

PREPARATION OF TOOLS AND

MEASURING EQUIPMENT ............. GI-10

JACKING POSITIONS ..................... GI-16

VEHICLE LIFT (2 SUPPORTS) POSITIONS . . GI-16

SAFETY STAND POSITONS ............... GI-17

SPECIAL TOOLS

.......................

GI-10

TOWING ................................. GI-l8

- .-

TOWING HOOK ........................ GI-19

DISCONNECTION OF THE NEGATIVE

BAlTERY CABLE ..................... GI-10

TIEDOWN HOOKS ...................... GI-19

....

REMOVAL OF PARTS ................... GI-10

IDENTIFICATION NUMBER LOCATIONS

GI-20

DISASSEMBLY ......................... GI-10

INSPECTION DURING REMOVAL,

DISASSEMBLY.. ...................... GI-10

AFIRANGEMENT OF PARTS ............. GI-10

.....

VEHICLE IDENTIFICATION NUMBER

Gl-20

......

ENGINE IDENTIFICATION NUMBER GI-20

ABBREVIATIONS. ........................ 01-20

PRE-DELIVERY INSPECTION .............. GI-21

CLEANING OF PARTS .................. Gl-l1

REASSEMBLY ......................... GI-l?

ADJUSTMENT ......................... GI-l1

RUBBER PARTS AND TUBING .......... GI-l1

...

PRE-DELIVERY INSPECTION TABLE..

GI-21

.............

...

SCHEDULED MAINTENANCE

GI-22

SCHEDULED MAINTENANCE TABLE..

GI-22

HOW TO USE THIS MANUAL

RANGE OF TOPICS

This manual contains the procedures for performing

all of the required service operations The

procedures are divided into the following five baslc

operations.

(1) Removal/lnstallation

(2) DisassemblyIAssembly

SERVICING PROCEDURE

Inspection, Adjustment

The procedures for inspections and adjustments

are divlded Into steps. Important polnts in regard

to the locat~onand contents of the procedures are

In detail and are shown in the

illustrat~ons.

{3) Replacement

(4) Inspection

(5) Adjustment

Simple operations which can be performed easily

SHOWS PROCEDURE ORDER

FOR SERVICE

just by looking at the vehicle such as

removal/installation of parts, jacking, vehicle lift,

cleaning of parts, and visual inspection, have been

omitted.

Fluid Pressure In

I ASSemDte the SSTs as snow an the tlgure

Tsghtenmg torqua

3949 N m (4.0-5.0 kgf m.29-36 11 lbl l

SHOWS TIGHTENING

TORQUE

SPECIFICATIONS

Cautaon

Connect the gauge set from under the vs-

hlch to prevent contact with the drlve belt

and the cooling tan.

RANGE OF TOPICS .................... Gl- 1

expla~ned

HOW TO USE THIS MANUAL

Repair procedure

1. Most repair operations begin with an overview illustration. It identifies the components, shows how the parts fit

together, and describes visual part inspection. However, only the removal1installation procedures which need to

be performed methodically have written instructions.

2. Expendable parts, tightening torques, and symbols for oil, grease, and sealant are shown in the overview illustration.

In addition, symbols indicating parts which require the use of special service tools for remov~installation

are also

Procedure

SHOWS SERVICE

Indicated any relevant

references which need to be

followed during installation.

2. Remove the un6ercover.(Refer to UNOERCOVER REMOVAL.) (Refer to UNOERCOVER INSTALUTION.) /

"RemOvaVlnsta'latiOnn

Portion

3. Remove ~nthe order indicated ~nthe table.

5. Inspect the rear wheel al~gnmentand adjust 11 IInecessary.

'Inspection After (P

Installation" Portion

/ SHOWS PROCEDURE ORDER

&@-E-

SHOWS SPECIAL

SERVICE TOOL (SST)

FOR SERVICE OPERATION

FOR SERVICE

Install the parts

by performing

steos 1-4 in

--r-

reverse order

SHOWS APPLICATION

POINTS OF GREASE, ETC.

SHOWS TIGHTENING

TORQUE

SPECIFICATIONS

' SHOWS EXPENDABLE PARTS

SHOWS DETAILS

II~-IS(~Z.O-~~.O.W-I~SJ

SHOWS TIGHTENING

SHOWS THERE

TORQUE UNITS

ARE REFERRAL

NOTES FOR SERVICE

Ower trailln Ilnk ball pm1

I rr Removal Note

10 ' NU1

11 ) UDDEI lra~lrng

Bon

Lower tratltng llnk

6 Dust boot (lower trad~na

llnk

Dusl bwr (upper tralltng Ilnkl

I P Removal Nole

/ / R lnstallat~onNote

l~nk)

Ball Jolnt Removal Note

Remove the ball joint by using the SSTs.

m UPPER TRAILING LINK

LOWER TRAILING UNK

SHOWS SPECIAL

SERVICE TOOL (SST)

NO.

KNUCKLE '

SHOWS REFERRAL

NOTES FOR

SERVICE

shown.

3. The procedures are numbered and the part that is the main point of that procedure is shown in the illustration with

the corresponding number. Occasionally, there are important points or information concerning a procedure. Refer

to this information when servicing the related part.

ITEM (S)

Lower Traillng Unk Ball Jolnc. Upper Trelllng LIik

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