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Mazda 626 1989 Workshop Manual

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Owner's manual (16 pages)

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1989

l ¥ 3 a z d a

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.

Mazda Motor Corporation

HIROSHIMA JAPAN

CONTENTS

Title

General Inform ation

Pre-Delivery Inspection and

Scheduled Maintenance Services

Engine

Lubrication System

Fuel and Emission

Control Systems

Engine Electrical System

Transaxle

Front And Rear Axles

Steering System

Wheels and Tires

Body

Body Electrical System

Heater and Air C onditioning System

Wiring Diagram

© 1 9 8 8 M a zd a M o to r C o rp o ra tio n

P R IN T E D IN

1 1 8 7 -1 0 -8 8 F

Non-Turbo

Turbo

Manual

Autom atic

J A P A N , JU N E '88 ®

Table of Contents

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Summary of Contents for Mazda 626 1989

Page 1 Engine Electrical System by service technicians of authorized Mazda dealers to help them service Mazda vehicles. Clutch This manual can be also useful for Mazda own ers in diagnosing certain problems and per Manual forming some repair and maintenance on Transaxle Mazda vehicles.
Page 2: Scheduled Maintenance
PRE-DELIVERY INSPECTION 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...
Page 3: Pre-Delivery Inspection Table
0 PRE-DELSVERY SNSPECTION PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION TABLE EXTERIOR INSPECT and ADJUST, if necessary, the following items to □ Cigarette lighter and clock the specifications: □ Remote control outside rear view mirrors (if equipped) □ Glass, exterior bright metal and paint for damage □...
Page 4 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. c /> This maintenance operation is recommended by Mazda. However, this maintenance is not necessary for emission warranty coverage or manufacturer recall liability. <...
Page 5 Interval Num ber of months or km (miles) whichever comes first Months 22.5 37.5 52.5 Service data and inspection point Page Miles 7,500 15,000 22,500 30,000 37,500 45,000 52,500 60,000 Procedure & item Kilometers 12,000 24,000 36,000 48,000 60,000 72,000 84,000 96,000 Steering operations and linkage...
Page 6 Interval Num ber of months or km (miles) whichever comes first Months 22.5 37.5 52.5 Service data and inspection point Page Miles 7,500 15,000 22,500 30,000 37,500 45,000 52,500 60,000 Procedure & item Kilometers 12,000 24,000 36,000 48,000 72,000 60,000 84,000 96,000 >...
Page 7 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. This maintenance operation is recommended by Mazda. However, this maintenance is not necessary for emission warranty coverage or manufacturer recall liability.
Page 8 Interval Num ber of months or km (miles) whichever comes first Months Miles Service data and inspection point Page (x1,000) Kilometers > Procedure & item (x1,000) Steering operations and linkage • Free play: 0—30 mm (0—1.18 in) 10— 10 • Operation and looseness —...
Page 9 Interval Number of months or km (miles) w hichever comes first Months Miles Service data and inspection point Page (x1,000) > Kilometers Procedure & item (x1,000) Front suspension ball joints • Damage, looseness and grease 13— 14 leakage — i Drive shaft dust boots •...
Page 10: Table Of Contents
GENERAL INFORMATION IMPORTANT IN FO R M ATIO N .., ... . G— 2 FUNDAMENTAL PROCEDURES....G... 2 JACK AND SAFETY STAND (RIGID RACK) POSITIONS ............G— 6 VEHICLE LIFT (2-SUPPORT TYPE} P O S IT IO N S ............G— 6 TOWING ....
Page 11: Important Information/
This workshop manual assumes that you have and know how to properly use certain special tools which are necessary for the safe and efficient performance of service operations on Mazda vehicles. The manual also assumes that you are familiar generally with automobile systems and basic service and repair proce...
Page 12 FUNDAMENTAL PROCEDURES PREPARATION OF TOOLS AND MEASURING EQUIPMENT Be sure that all necessary tools and measuring equipment are available before starting any work activity. 47U0GX-004 SPECIAL TOOLS Use special tools when they are required. 47U0GX-005 REMOVAL OF PARTS While correcting a problem, try also to determine its cause. Begin work only after first learning which parts and subassem...
Page 13 FUNDAMENTAL PROCEDURES 2. Arrangement of parts Al! disassembled parts should be carefully arranged for reas sembly. Be sure to separate or otherwise identify the parts to be replaced from those that will be reused. 47U0GX-009 3. Cleaning parts for reuse All parts to be reused should be carefully and thoroughly cleaned in the appropriate method.
Page 14 FUNDAMENTAL PROCEDURES ELECTRICAL SYSTEM Be sure to disconnect the battery cable from the negative (-) terminal of the battery. Never pull on the wiring when disconnecting connectors. When locking connectors, make sure to listen for a click that will let you know they are securely locked. Handle sensors and relays carefully.
Page 15 JACK AND SAFETY STAND (RIGID RACK) POSITIONS, VEHICLE LIFT (2-SUPPORT TYPE) POSITIONS JACK AND SAFETY STAND (RIGID RACK) POSITIONS FRONT END Jack position: Safety stand positions: At the center of the crossmember On both sides of the body frame REAR END Safety stand positions: Jack position: On both sides of the body frame...
Page 16: Towing
TOWING TOWING Proper lifting or towing procedures are necessary to prevent damage to the vehicle during any towing operation. State and local laws applicable to vehicles in tow must be followed. With eigher automatic or manual transaxle, release the park ing brake, place the selector lever (or shift lever) in neutral and set the ignition key in the “...
Page 17: Chassis Number Location
CHASSIS NUMBER LOCATION/ABBREVIATIONS/UNITS CHASSIS NUMBER LOCATION UNITS N-m (m-kg or cm-kg, ft-lb or in-lb)....Torque rpm ........Revolutions per minute A ........Ampere(s) V ........Volt(s) f i ........Ohm(s) (resistance) kPa (kg/cm2 psi)... Pressure (usually positive) mmHg (in H g )....Pressure (usually negative) W ........
Page 18: Caution
CAUTION, WARNING CAUTION INSTALLATION OF A MOBILE TWO-WAY RADIO SYSTEM If a mobile two-way radio system is installed improperly, or if a wrong type is used, the Fuel Injection system and other systems may be affected. When car is equipped with a mobile two-way radio system, observe the following precautions. 1.
Page 19 INSPECTION AND REPAIR I B 6. Measure the camshaft end play. If It exceeds the maximum, replace the camshaft and/or the cylin der head. End play: 0.08—0.10 mm (0.003—0.004 in) Maximum: 0.20 mm (0.008 in) Hydraulic Lash Adjuster (HLA) 1. Check the HLA face for wear or damage. 2.
Page 20 INSPECTION AND REPAIR 4. Measure the cylinder bore in directions X and Y at three levels in each cylinder as shown. Cylinder bore mm (in) Bore Size 86.000—86.019 (3.3858-3.3866) Standard 0.25 (0.010) oversize 86.250— 86.269 (3.3957—3.3964) 0.50 (0.020) oversize 86.500—86.519 (3.4055-3.4062) 79G01C-070 (1) If the difference between the measurement A and C exceeds the maximum taper, rebore the...
Page 21 INSPECTION AND REPAIR Piston 1. Inspect the outer circumferences of all pistons for seizure or scoring. Replace if necessary. 2. Measure the outer diameter of each piston at a right angle (90°) to the piston pin, 18 mm (0.709 in) below the oil ring land lower edge.
Page 22 INSPECTION AND REPAIR 5. Measure each piston ring end gap with a feeler gauge. Replace if necessary. End gap : 0.20—0.35 mm (0.008—0.014 in) Second: 0.15—0.30 mm (0.006—0.012 in) Oil rail : 0.20—0.70 mm (0.008—0.028 in) Maximum: 1.0 mm (0.039 in) Piston and Piston Pin 1.
Page 23 3. Check each connecting rod for bending or twist ing. Repair or replace if necessary. Bend: 0.24 mm (0.0094 in) max. Twist: 0.57 mm (0.0224 in) max. 76F01B-027 Crankshaft 1. Check the journals and pins for damage, scoring, or oil hole clogging. 2.
Page 24 INSPECTION AND REPAIR Crankpin journal diameter undersize mm (in) Bearing size Journal diameter 0.25 (0.010) undersize 50.690—50.705 (1.9957— 1.9963) 0.50 (0.020) undersize 50.440—50.455 (1.9858— 1.9864) 0.75 (0.030) undersize 50.190—50.205 (1 .9 7 6 0 -1 .9 7 6 6 ) Caution Do not grind the rolled fillet area.
Page 25 INSPECTION AND REPAIR Caution a) Never forcefully twist, turn Inside out, or bend the timing belt. b) Be careful not to allow oil or grease on the belt. Timing Belt Tensioner and Idler Pulley Check the timing belt tensioner and idler pulley for smooth rotation and abnormal noise.
Page 26 ASSEMBLY (CYLINDER BLOCK) ASSEMBLY 1. Clean all parts before reinstallation. 2. Apply new engine oil to all sliding and rotating parts. 3. Replace plain bearings if they are peeling, burned, or otherwise damaged. 4. Tighten all bolts and nuts to the specified torques. Caution Do not reuse gaskets or oil seals.
Page 27 ASSEMBLY (CYLINDER BLOCK) Connecting Rod 1. Align the identification mark to the cap of large end of connecting rod and F mark on the piston as shown in the figure. 2. Apply a coat of engine oil to the circumference of each piston pin and to the small end of each con...
Page 28 ASSEMBLY (CYLINDER BLOCK) 2. Check that both rails are expanded by the spacer tangs as shown in the figure by checking that both rails turn smoothly in both directions. 69G01A-145 3. Install the second ring to the piston first, then in stall the top ring.
Page 29 ASSEMBLY (CYLINDER BLOCK) Oil clearance inspection (1) Remove any foreign material and oi! from the journals and bearings. (2) install the upper main bearings in the cylinder block. (3) Set the crankshaft into the cylinder block. (4) Position the plasti-gauge on top of the journals in the axial direction.
Page 30 ASSEMBLY (CYLINDER BLOCK) 4. Inspect the crankshaft end play. End play: 0.08—0.18 mm (0.0031—0.0071 mm) Maximum: 0.30 mm (0.012 in) 5. If the end play exceeds specification, grind the crankshaft and use undersize center main bearing. Center main bearing width Standard: 27.94—27.99 mm (1.1000—1.1020 in) 0.25 mm (0.010 in) undersize:...
Page 31 ASSEMBLY (CYLINDER BLOCK) 1 B Connecting Rod Cap 1. Check the connecting rod bearing clearances us ing the same procedure as used for the main bear ing oil clearance. Connecting rod cap tightening torque: 69—73 N m (7.0—7.4 m-kg, 51—54 ft-lb) Oil clearance: 0.027—0.067 mm (0.0011—0.0026 in) Maximum: 0.10 mm (0.0039 in)
Page 32 ASSEMBLY (CYLINDER BLOCK) CYLINDER BLOCK—II Torque Specifications 19—25 N-m (1.9—2.6 m-kg, 14—19 ft-lb) MS: Smaller 19—25 N-m (1.9—2.6 m-kg, 14—19 ft-lb) 19—30 N-m (1.9—3.1 m-kg, 14—22 ft-lb) M10: Bigger 8—12 N-m (80—120 cm-kg, 69—104 In-lb) 37—52 N-m (3.8—5.3 m-kg, 27—38 ft-lb) 8—12 N-m (80—120 cm-kg, 69—104 in-lb)
Page 33 ASSEMBLY (CYLINDER BLOCK) 3. Install the rear cover and a new gasket. Tightening torque: 8—12 N-m (80—120 cm-kg, 69—104 in-lb) 4. Cut away the portion of the gasket that projects out from the rear cover assembly toward the oil pan side.
Page 34 ASSEMBLY (CYLINDER BLOCK) 3. Apply engine oil to the oil seal lip. 4. Remove any dirt or other material from the con tact surfaces. 5. Apply a continuos bead of silicon sealant to the contact surface of the oil pump. Caution Do not aliow any sealant to get into the oil hole.
Page 35 ASSEMBLY (CYLINDER BLOCK) Oil Strainer Install the oil strainer and a new gasket. Tightening torque: 8—12 Nm (80—120 cm-kg, 69—104 in-lb) Oil Pan 1. Apply a continuous bead of silicon sealant to the oil pan along the inside of the bolt holes, and over lap the ends.
Page 36 ASSEMBLY (CYLINDER BLOCK) Clutch Disc and Clutch Cover Install the clutch disc and clutch cover using the SST. (Refer to Section 6.) Tightening torque: 22—32 N-m (2.2—3.3 m-kg, 16—24 ft-lb) 76G01B-083 Water Pump 1. Remove all dirt, grease, and other material from the water pump mounting surface.
Page 37 ASSEMBLY (CYLINDER HEAD) CYLINDER HEAD Torque Specifications 4 * 6 N*m (40—60 cm-kg, 35—52 In-lb) 8—12 N-m (80—120 cm-kg, 69—104 In-lb) 80—88 N-m (8.2—8.8 m-kg, 59—64 ft-lb) 69G01B-152 Valve Seal 1. Apply engine oil to the inside of the new valve seal. 2.
Page 38 ASSEMBLY (CYLINDER HEAD) Valve and Valve Spring Valve spring 1. Install the lower spring seat. 2. install the valve. 3. Install the valve springs and the upper spring seat. Note Install the outer and inner valve spring with ® > ® the closer pitch toward the cylinder head.
Page 39 ASSEMBLY (CYLINDER HEAD) Cylinder Head 1. Thoroughly remove all dirt, oil, or other material from the top of the cylinder block. 2. Place the new cylinder head gasket in position. 3. Install the cylinder head. 4. Apply engine oil to the bolt threads and seat faces. ©...
Page 40 ASSEMBLY (CYLINDER HEAD) Camshaft Cap 1. Apply liberal amount of clean engine oil to the cam lobes and journals. 2. Apply silicon sealant to the front camshaft cap surface. 76G01B-088 3. Position the camshaft caps according to the cap number and mark. 76G01B-089 4.
Page 41 ASSEMBLY (CYLINDER HEAD) Cylinder Head Cover 1. Apply silicon sealant to the shaded area shown in the figure. 2. Install the cylinder head cover. Tightening torque: 4—6 Nm (40—60 cm-kg, 35—52 in-lb)
Page 42 ASSEMBLY (TIMING BELT) TIMING BELT Torque Specifications 47—65 N m (4.8—6.6 m-kg 35—48 ft-lb) 7—10 N-m (70—100 cm-kg, 61—87 In-lb) 157—167 N-m (16.0—17.0 m-kg, 116—123'ft-lb) 12—17 Nm (1.25—1.75 m-kg, 109—152 In-lb) 69G01B-160 1B—64...
Page 43 ASSEMBLY (TIMING BELT) 1 B Camshaft Pulley 1. Install the camshaft pulley on the camshaft with the dowel pin fit into the hole at the I mark (intake side) and E mark (exhanst side). 2. Tighten the camshaft pulley lock bolt. Tightening torque: 47—65 Nm (4.8—6.6 m-kg, 35—48 ft-lb) 3.
Page 44 ASSEMBLY (TIMING BELT) Timing Belt Idler Pulley Install the timing belt idler pulley. Tightening torque: 37—52 N-m (3.8—5.3 m-kg, 27—38 ft-lb) Timing Belt Tensioner 1. Install the timing belt tensioner and tensioner spring. 2. Tentatively secure the tensioner with the spring fully extended.
Page 45 ASSEMBLY (TIMING BELT) 1 B 7. Then turn the crankshaft and align the mating marks. Check the timing belt deflection. If the deflection is not correct, loosen the tensioner lock bolt and repeat steps 3—5 above. Replace the ten sioner spring if necessary. Belt deflection (98 N, 10 kg, 22 lb) New : 8.5—9.5 mm (0.33—0.37 in) Used: 9.0—10.0 mm (0.35—0.39 in)
Page 46 ASSEMBLY (AUXILIARY PARTS) AUXILIARY PARTS Torque Specifications 37—63 N-m 19—30 N-m (1.9— 3.1 m-kg, 14—22 ft-lb) (3.8—6.4 m-kg, 27—46 ft-lb) 31—46 N m (3.2— 4.7 m-kg, 23— 34 ft-lb) 19—30 N-m (1.9—3.1 m-kg, 14—22 ft-lb) 85— 117 N-m (8.7— 11.9 m-kg, 63—86 ft-lb) 19—30 N-m 3 7 -5 2 N-m...
Page 47 ASSEMBLY (AUXILIARY PARTS) 1 1 * Knock Sensor install the knock sensor with the SST. Tightening torque: 20—34 Nm (2.0—3.5 m-kg, 14—25 ft-lb) Oil Pressure Switch Install the oil pressure switch. Tightening torque: 12—18 N-m (1.2—1.8 m-kg, 104—156 in-lb) Oil Cooler Install the oil cooler.
Page 48 ASSEMBLY (AUXILIARY PARTS) Thermostat and Thermostat Cover 1. Install the thermostat into the cylinder head with the jiggle pin at the top. 2. Position a new gasket with the printed side facing the cylinder head. 3. Install the thermostat cover. Tightening torque: 19—30 N-m (1.9—3.1 m-kg, 14—22 ft-lb) Spark Plug...
Page 49 Coolant Inlet Pipe and Bypass Pipe 1. Install the coolant inlet pipe. Tightening torque: 19—25 Nm (1.9—2.6 m-kg, 14—19 ft-lb) 2. Apply vegetable oil to the O-ring. 3. Install the coolant bypass pipe. Tightening torque: 37—63 Nm (3.8—6.4 m-kg, 27—46 ft-lb) Engine Hanger Install the front and rear engine hangers.
Page 50 ASSEMBLY (AUXILIARY PARTS) Exhaust Manifold Assembly 1. Place the new gaskets in position with the ridge facing the cylinder head. 2. Install the exhaust manifold assembly. 3. Tighten the nuts in two or three steps. Tightening torque: 34—49 N-m (3.5—5.0 m-kg, 25—36 ft-lb) P/S Oil Pump Bracket Install the P/S oil pump bracket.
Page 51 INSTALLATION 1 B INSTALLATION t r a n s a x l e a s s e m b ly Assemble the transaxle to the engine in the sequence shown in the figure referring to the installation note. 8—11 N-m (80—110 cm-kg, 69—95 in-lb) —117 N-m...
Page 52: Engine Installation
INSTALLATION ENGINE INSTALLATION Install the engine and transaxle assembly. Warning: Be sure the vehicle is securely supported. Torque Specifications 67— 93 N m (6.8—9.5 m-kg, 49—69 ft-lb) 74— 103 N-m (7.5— 10.5 m-kg, 54— 76 ft-lb) 8 — 11 N-m (80—...
Page 53 INSTALLATION 1 B Engine Mount Install the engine mount. 74—103 N-m (7.5—10.5 m-kg, 54—76 ft-lb) 86U01X-181 Exhaust Pipe 1. install the exhaust pipe. Tightening torque (A): 31—46 N m (3.2—4.7 m-kg, 23—34 ft-lb) ® : 64—89 N m (6.5—9.1 m-kg, 47—66 ft-lb) 2.
Page 54 INSTALLATION Driveshaft 1. Apply grease to the end of the driveshaft. 2. Install the driveshaft and a new clip. Caution a) When installing the driveshaft, be careful not to damage the oil seal. b) After installation, pull the front hub outward to confirm that the driveshaft is securely held by the clip.
Page 55 INSTALLATION P/S Oil Pump 1. Install the P/S oil pump. Tightening torque: 31—46 Nm (3.2—4.7 m-kg, 23—34 ft-lb) 2. Tighten the pulley lock nut. Tightening torque: 39—59 N m (4.0—6.0 m-kg, 29—43 ft-lb) A/C Compressor 1. Install the A/C compressor strap to the P/S oil pump bracket.
Page 56 INSTALLATION Clutch Release Cylinder 1. Set the pipe bracket in position. Tightening torque: 8—11 N-m (80—110 cm-kg, 69—95 in-lb) 2. Install the clutch release cylinder. Tightening torque: 19—25 Nm (1.9—2.6 m-kg, 14—19 ft-lb) Speedometer Cable Install the speedometer cable. Brake Vacuum Hose Connect the brake vacuum hose.
Page 57 INSTALLATION 1 Connector Location Install each harness as shown in the figure. 76G01B-112 U G c o il 10. Linear solenoid 2. Heat gauge unit 11. Solenoid valve (idle speed control) 3. Speed sensor 12. Throttle position sensor 4. P/S switch 13.
Page 58 INSTALLATION Radiator 1. Install the radiator and cooling fan. Tightening torque: 8—11 N-m (80—110 cm-kg, 69—95 in-lb) 2. Connect the radiator harness. 3. Connect the upper and lower radiator hoses. Note a) Position the hose clamp in the original lo cation on the hose.
Page 59 INSTALLATION Air Cleaner Assembly 1. Install the air cleaner assembly. Tightening torque: 16—27 N-m (1.6—2.8 m-kg, 12—20 ft-lb) 2. Connect the air flow sensor connector and air in take pipe. Engine Oil Add the specified amount and type of engine oil. (Re fer to Section 2.) Coolant Close the drain plug, fill the radiator and reservoir tank...
Page 60: Table Of Contents
LUBRICATION SYSTEM OUTLINE............2— 2 LUBRICATION CIRCUIT (DOHC)....2— 2 LUBRICATION CIRCUIT (SOHC)....2— 3 SPECIFICATIONS.......... 2— 4 TROUBLESHOOTING GUIDE......2— 4 INSPECTION...........2— 5 ENGINE O IL ..........2— 5 OIL PRESSURE..........2— 5 ENGINE O IL........... 2— 5 REPLACEMENT..
Page 61: Outline
OUTLINE OUTLINE LUBRICATION CIRCUIT (DOHC) 76G02A-002 1. Oil pump 5. Oil cooler 2. Pressure regulator valve 6. Oil filter 3. Main gallery 7. Oil control plug 4. Oil pressure switch 8. Oil jet 2—2...
Page 62: Lubrication Circuit (Sohc)
OUTLINE LUBRICATION CIRCUIT (SOHC) Turbocharger 76F02X-002 5. Oil cooler (F2 Turbo, FE 12-valve) 1. Oil pump 6. Oil filter 2. Pressure regulator valve 7. Oil control plug 3. Main gallery 4. Oil pressure switch 2 -3...
Page 63: Specifications
TROUBLESHOOTING GUIDE SPECIFICATIONS —— _____ Engine model F6F8FE SOHC FE DOHC Non-Turbo Item — -----_______ Turbo Force-fed Lubrication system Crescent gear Trochoid gear Type 392 (4.0, 57) 490 (5.0, 71) Regulated pressure kPa (kg/cm2, psi) 392 (4.0, 57) Oil pump 1 4 7 -2 4 5 (1 .5 -2 .5 , 2 1 -3 6 ) 1,000 rpm Oil pressure kPa (kg/cm2, psi)
Page 64: Inspection
INSPECTION, ENGINE OIL INSPECTION ENGINE OIL 1. Be sure the vehicle is on level ground. 2. Warm up the engine to normal operating temper ature and stop it. 3. Wait for five minutes. 4. Remove the oil level gauge and check the oil lev el and condition.
Page 65: Oil Filter
OIL FILTER, OIL COOLER 4. install the drain plug and a new gasket. 5. Refill the engine with the specified type and amount of engine oil. 6. Refit the oil filler cap. Oil pan capacity: 3.9 liters (4.1 US qt, 3.4 Imp qt)...F2 3.6 liters (3.8 US qt, 3.2 Imp qt)...F6F8FE 7.
Page 66: Removal
OIL PAN :et. OIL PAN md amount REMOVAL 1. Disconnect the negative battery cable. Drain the engine oil. 3. Remove in the sequence shown in the figure referring to the removal note for specially marked parts. ..F2 76G02A-009 F6F8F E 55—69 ft-lb) been run.
Page 67 INSPECTION Check the following points. Repair or replace if necessary. 1. Cracks, deformation, damage 2. Damaged drain plug threads 4BG02X-037 INSTALLATION Install in the reverse order of removal referring to the installation note. Installation Note Stiffener (DOHC, 12-valve) 1. Remove any dirt or other material from the con tact surface.
Page 68: Oil Pump
OIL PUMP OIL PUMP replace if REMOVAL 1. Disconnect the negative battery cable. 2. Drain the engine oii. 3. Remove in the sequence shown in the figure referring to the removal note for specially marked parts. __ _ — ______________________________ _ ____ ___________ ____ __________________________________ ____________________________76G02A-015 DOHC i n g t o t h e the con-...
Page 69 OIL PUMP M8: (Smaller) 19—25 N-m (1.9—2.6 m-kg, 14—19 ft-lb) M10: (Bigger) 37—52 N m (3.8—5.3 m-kg, 27—38 ft-lb) 157—167 N-m (16.0—17.0 m-kg, 116—123 ft-lb)f 76F02X-012 1. Timing belt (Refer to Section 1) 4. Timing belt pulley 2. Oil pan (Refer to page 2—7.) 5.
Page 70: Disassembly
OIL PUMP d i s a s s e m b l y in the sequence shown in the figure. Disassemble 69G02B-012 1. Pump cover 2. Outer gear 3. Inner gear 4. Pressure relief valve 5. Oil seal 6. Oil pump body INSPECTION (DOHC, F2) 1.
Page 71 !f f: q OIL PUMP .? fifi ' :.( !! ■ 4. Measure the outer gear to pump body clearance. Clearance: 0.20 mm (0.008 in) max. (SOHC, except F2) 1. Check the following and replace any faulty parts. (1) Distorted or damaged oil pump body or cover (2) Worn or damaged plunger (3) Weak or broken plunger spring 2.
Page 72: Assembly
OIL PUMP 5. Measure the outer gear to pump body clearance arance. Clearance: 0.20 mm (0.008 in) max. ASSEMBLY Assemble the pump as follows. y parts. )r cover Oil Seal 1. Apply engine oil to the pump body and the out side of the new oil seal.
Page 73 COOLING SYSTEM OUTLINE............3 - 2 COOLANT FLOW CHART (DOHC)....3— 2 COOLANT FLOW CHART (SOHC)....3— 3 SPECIFICATIONS.........3— 4 TROUBLESHOOTING GUIDE......3— 4 COOLANT............3— 5 INSPECTION..........3— 5 REPLACEMENT......... 3— 5 RADIATOR CAP........... 3— 6 INSPECTION..........3— 6 RADIATOR....
Page 74 OUTLINE OUTLINE COOLANT FLOW CHART (DOHC) 1. Water pump 4. Coolant reservoir 2. Thermostat 5. Oil cooler 3. Radiator 6. Cooling fan...
Page 75 OUTLINE COOLANT FLOW CHART (SOHC) 1. Water pump 4- Coolant reservoir 2. Thermostat 5. Oil cooler (F2 Turbo, FE 12-valve) 3. Radiator 6. Cooling fan 3 -3...
Page 76 TROUBLESHOOTING GUIDE SPECIFICATIONS Engine model «=2, FE-DOHC FE 12-valve FE 8-valve, F8, F6 Item Cooling system Water cooled, forced circulation With heater 7.5 (7.9, 6.6) Coolant capacity liters (US qt, Imp qt) Without heater 7.0 (7.4, 6.2) Type Centrifugal, timing belt driven Water pump Water seal Unified seal...
Page 77 COOLANT COOLANT INSPECTION Coolant Level (Engine cold) E 8-valve, 1. Check that the coolant level is near the radiator inlet port. 2. Check that the coolant level in the coolant reser voir is between the FULL and LOW marks. Add coolant if necessary. Warning a) Never remove the radiator cap while the en...
Page 78 RADIATOR CAP 3. Set the heater control switch to the maximum hi position. 4. Flush the cooling system with water until all trac of color are gone, then let the system drain co pietely. e \ \ 5. Fill with the proper mixture and amount of lene glycol-based coolant.
Page 79 residue)1 j the valve I he SST. 03 kPa 76G03A-005 the pres 1. Coolant reservoir hose 5. Upper and lower radiator hose 2. ATF hose (ATX) 6. Cooling fan and radiator assembly 3. Water thermo switch connector 7. Cooling fan 4.
Page 80 WATER PUMP WATER PUMP REMOVAL 1. Disconnect the negative battery cable. 2. Turn the crankshaft so that the No. 1 cylinder is at TDC of compression. 3. Drain the engine coolant. 4. Remove in the sequence shown in the figure. DOHC 37—...
Page 81 WATER PUMP SOHC 76F03X-005 1 • Timing belt 2. Idler pulley 3. Water pump /F6-F8-FE...Refer to Section 1A,\ 4. O-ring \F2...Refer to Section 1C...
Page 82 WATER PUMP INSTALLATION Install in the reverse order of removal referring to th installation note. Installation Note Rubber seal Install the rubber seals on the water pump. 76G03A-017 Water pump 1. Remove any gasket fragments, dirt, or oil from th contact surfaces.
Page 83 THERMOSTAT THERMOSTAT REMOVAL 1. Drain the engine coolant. 2. Remove the thermostat cover. 3. Remove the thermostat. INSPECTION Check the thermostat. Replace if necessary. 1. Visually check that the valve is airtight. 2. Place the thermostat and a thermometer in water. 3.
Page 84 COOLING FAN COOLING FAN SYSTEM CIRCUIT (M) Main fan No.1 relay Add. relay Add. fan(M) W ater thermo sw. A/C sw. 86U03X-0 CIRCUIT INSPECTION 1. Turn the ignition switch ON. 2. Disconnect the water thermo switch connector, ar check that the fan operates. 3.
Page 85 COOLING FAN FAN MOTOR and Installation Removal in the sequence shown in the figure. 1 Remove 2 Install in the reverse order of removal. 86UQ3X-021 1- Cooling fan assembly (Refer to page 3—7) 3. Fan 2. Cowling 4. Fan motor Inspection 1.
Page 86 COOLING FAN S .-;-. ■ WATER THERMO SWITCH 1. Remove the cooling fan water thermo switch. Note Make sure that the ignition switch is OFF. I not, the fan wifi operate when the connecto is removed. 7 6 G 0 3 A - 0 1 3 2.
Page 87 FUEL AND EMISSION CONTROL SYSTEMS (FUEL INJECTION FE DOHC) OUTLINE........... 4B— 2 PRESSURE REGULATOR COMPONENT APPLICATION..4B— 2 CONTROL (PRC) SYSTEM.... 4B—63 SYSTEM DIAGRAM......4B— 3 COMPONENT DESCRIPTION..4B—64 COMPONENT LOCATION..... 4B— 4 TROUBLESHOOTING..r... 4B—64 VACUUM HOSE ROUTING DECELERATION CONTROL ~ DIAGRAM........
Page 88 OUTLINE OUTLINE COMPONENT APPLICATION Remark Previous Item Improved intake air amount meas Air flow sensor urement Dynamic chamber New: 2 throttle valves Throttle body Previous: 1 throttle valve ‘ Throttle sensor Previous: Combined type Idle switch Idle speed con AIR INTAKE Improved idle smoothness trol (ISC) valve SYSTEM...
Page 89 Fuel filter Distributor !g. switch (ST) Solenoid valve (PRC) Ig. switch (ON) r— A/C switch — 1 - -------J magnet clutch rA /C Enaine ^L J rp/S switch » j i j L i e w i t n h Headlight switch [-Rear defroster switch kCooling fan switch...
Page 90 OUTLINE COMPONENT LOCATION Input and Output Devices Solenoid valve (VIC) 76G04C-004...
Page 91 OUTLINE Fuel System Pulsation damper Pressure Fuel filter regulator Throttle body Injector Shutter valve actuator" Air cleaner Control relay Fuel pump Two-way check valve Separator 76G04C-005 48—5...
Page 92 OUTLINE Exhaust System...
Page 94 OUTLINE SPECIFICATIONS Specification Item With test connector grounded 750 ± 50 Idle speed Throttle body Horizontal draft (2-barrel) Type 46 (1.8) No. 1 Throat diameter mm (in) 40 (1.6) No. 2 Fuel pump Impeller (in-tank) Type 441—588 (4.5—6.0, 64—85) kPa (kg/cm2, psi) Output* pressure 220 (13.4) min.
Page 95 TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE This troubleshooting guide shows the malfunction code numbers and the symptoms of various failures, perform troubleshooting as described below. Output solenoid valve Input sensors and switches Possible cause 4 > > » ■ o 0 ) o >...
Page 96 TROUBLESHOOTING GUIDE The Troubleshooting Guide lists the systems most likely to cause a given symptom. After finding which system(s) to check, refer to the pages shown for detailed guides. The numbers of the list show the priorities of inspections, from the most possible system to that with the lowest possibility.
Page 97 TROUBLESHOOTING WITH SST 4 B TROUBLESHOOTING WITH SST Engine control unit 76F04B-005 When troubles occur in the main input devices or output devices, check for the cause with the SST (Self>Diagnosis Checker 49 H018 9A1 or Digital Code Checker 49 G018 9A0 with Adaptor har ness 49 9200 180).
Page 98 TROUBLESHOOTING WITH SST INSPECTION PROCEDURE Check connector: (Green, 6-pin) 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.
Page 99 TROUBLESHOOTING WITH SST 2. Connect the SST to the check connector. 3. Ground the test connector (Green, 1-pin) with a 49 H 0 1 8 9A1 jumper wire. Test connector: (Green, 1 pin) B6U04A-015 4. Turn the ignition switch ON for six seconds (do not start the engine).
Page 100 TROUBLESHOOTING WITH SST 2. Second digit of malfunction code (ones position) The digit in the ones position of the malfunction code represents the number of times the buzzer is on 0.4 sec during one cycle. Malfunction 1 cycle Malfunction code code: 03 cycle break 1 2 3...
Page 101 TROUBLESHOOTING WITH SST 4 B Malfunction display Sensor or Seif-diagnosis Fail-safe subsystem Malfunction code Malfunction output signal pattern code no. Maintains basic sig Air flow sensor Open or short circuit OFF-iifiiLJii nal at preset value Maintains constant Water thermo sensor Open or short circuit 35 °C (95 °F) oTpJiillJl...
Page 102 TROUBLESHOOTING WITH SST Code No.2 (Ne signal) PC: Possible Cause 76F04B-010 Code No.3 (G signal) PC: Possible Cause 4B—16...
Page 103 TROUBLESHOOTING WITH SST 4 B 76F04B-011 76F04B-012 Code No.08 (Air flow sensor) PC: Possible Cause Next page 4B—17...
Page 104 TROUBLESHOOTING WITH SST Is there continuity between air flow sensor and engine control unit? Air flow sensor Engine control unit PC: Open circuit in wiring harness D (RB wire) E (RW wire) Is there 12V at terminal B of air flow sensor PC: Open or short circuit in wiring harness from connector? (Refer to page 4B—85) terminal B to control relay...
Page 105 TROUBLESHOOTING WITH SST PC: Possible Cause No 11 Code (Intake air thermo sensor) Are there poor connections at intake air thermo Repair or replace connector sensor connectors? ____ ________________ Is there continuity between intake air thermo sensor (dynamic chamber) and engine control unit? Intake air thermo sensor Engine control ------ ►...
Page 106 TROUBLESHOOTING WITH SST Code No. 25 (Solenoid valve—Pressure regulator control (PRC)) PC: Possible Cause 76G04C-026 Code No. 34 (Solenoid valve—Idle speed control (ISC)) PC: Possible Cause 76G04C-0&...
Page 107 TROUBLESHOOTING WITH SST 4 B .41 Code (Solenoid valve—Variable inertia control (VIC)) PC: Possible Cause 76G04C-034...
Page 108 SWITCH MONITOR FUNCTION SWITCH MONITOR FUNCTION Individual switches can be monitored by the SST (Self-Diagnosis Checker 49 G018 9A0 oi Code Checker 49 9200 180). Note The test connector must be grounded and the ignition switch ON (engine stopp Self-Diagnosis Checker (Monitor lamp) Switch Remark Light ON...
Page 109 SWITCH MONITOR FUNCTION INSPECTION PROCEDURE (Green, Check connector: 6-pin)' 1. Warm up the engine to normal operating temper ature and stop it. 3\ x 2. Connect the SST to the check connector (Green, negative Battery 6-pin) and the negative battery terminal. 49 H018 9A1 86U04A-034 3.
Page 110 SWITCH MONITOR FUNCTION Idle switch 76F04B-020 Blower switch 76F04.B-021 Headlight switch Rear defroster switch...
Page 111 IDLE ADJUSTMENT IDLE ADJUSTMENT Check connector (White, 1-pin) \(fo r tachometer). IDLE SPEED Preparation 1) Check the condition of the engine (plugs, leaks in hoses, etc.). 2) Make sure all accessories are OFF. 3) Warm up the engine and run it for three minutes at 2,500—3,000 rpm in neutral.
Page 112 IDLE ADJUSTMENT IDLE MIXTURE Note Before checking or adjusting the idle mixtu check and adjust the idle speed, if necessa 1. Insert a gas analyzer pick-up into the tail pipi 76F04B-025 2. Check that the CO and HC concentrations are w in specification.
Page 113 INTAKE AIR SYSTEM nta k e a ir s y s t e m This system controls the air required by the engine for operation. The system consists of the air duct, resonance chamber, air cleaner, air flow sensqr, throttle body, dynamic chamber, and intake manifold. COMPONENT DESCRIPTION Remark Component...
Page 114 INTAKE AIR SYSTEM REMOVAL Caution Before removing the following parts, release the fuel pressure from fuel system to reduce the possibility of injury or fire. (Refer to page 4B—48.) Remove in the sequence shown in the figure, referring to the removal note. 76F04B.-026 19.
Page 115 INTAKE AIR SYSTEM Delivery pipe assembly 1. Separate the fuel return pipe from the delivery pipe assembly. 2. Remove the delivery pipe assembly and the fuel return pipe. PARTS INSPECTION Air Cleaner Element 1, Check the condition of the air cleaner element. 2.
Page 116 INTAKE AIR SYSTEM Air Cleaner Case 1. Check that the steel plate mounted on the upper case is grounded. 2. Replace, if necessary. Accelerator Cable 1. Inspect the deflection of the cable. If it is not with in 1—3 mm (0.04—0.12 in.), adjust by turning nuts A.
Page 117 INTAKE AIR SYSTEM Dynamic Chamber 1. Visually check the dynamic chamber for damage. ipper 2. Replace, if necessary. Intake Manifold 1. Visually check the intake manifold for damage. A/ith- 2. Replace, if necessary. "iing :on- Jjust Shutter Valves 1. Visually check the shutter valves for damage. 2.
Page 118 INTAKE AIR SYSTEM REPLACEMENT Throttle Lever Removal Caution When loosening the throttle lever nut, hold the throttle valves fully open to prevent damag ing the idle switch. Remove the throttle lever in the sequence shown in the figure. 69G04C-130 Installation 1.
Page 119 INTAKE AIR SYSTEM INSTALLATION Install In the reverse order of removal, referring to the installation note. Torque Specification 86U04A-055...
Page 120 INTAKE AIR SYSTEM Installation Note Water hose spring clamps Face the clamp ends as shown in the figure. Gasket Use new gaskets at the intake manifold, dynamic chamber, and throttle body. 76F04B-Q31 Ground harnesses Make sure that the ground harnesses are tightened securely at the following positions.
Page 121 VIC SYSTEM VARIABLE INERTIA CONTROL (VIC) SYSTEM The VIC system supplements the intake air’s inertial effect to create a torque band that runs from low rpm through the high rpm range. The system consists of the intake manifold, shutter valves, dynamic chambers, actuator, one-way check valve, three-way solenoid valve, and engine control unit.
Page 122 VIC SYSTEM COMPONENT DESCRIPTION Component Function Remark Dynamic chamber Provides chamber for VIC system Integrates one-way check valve operation Engine control unit Monitors engine rpm, controls solenoid ON: above 5400 rpm valve Intake manifold Incorporates short and long intake Contains shutter valve passages 6ne-way check valve Holds vacuum in vacuum chamber...
Page 123 System Inspection . Warm up the engine to normal operating temper ature and run it at idle. 2. Check that the rod has been pulled into the ac tuator. 3. Increase the engine speed and check that the rod is released above specification. Specification: Approx.
Page 124 VIC SYSTEM 3. Disconnect the solenoid valve connector and con nect V and a ground to the terminals of the sole noid valve. 4. Blow through the valve from port A and check that air flows from the air filter. 76G04C-072 Efectrical Signal 1.
Page 125 VIC SYSTEM •One-way Check Valve Inspection pler . Remove the dynamic chamber. 2. Remove the one-way check valve. 3. Connect a vacuum pump as shown in the illus tration. 4. Apply vacuum and check that it is held. 5. Connect the vacuum pump to the opposite port. .
Page 126 ISC SYSTEM IDLE SPEED CONTROL (ISC) SYSTEM 76G04C-077 To improve idle smoothness, the ISC system controls the intake air amount by regulating the bypass air amount that passes through the throttle body. This system consists of the BAC valve and the control system. The BAC valve consists of the air valve which functions only when the engine is cold (below 50°C 1 2 2 °F)) and the ISC valve which works throughout the entire engine speed range.
Page 127: Component Description
ISC SYSTEM COMPONENT DESCRIPTION Remark Component Function A/Cs witch Switch ON when air conditioner Detects air conditioner operation; sends operating signal to engine control unit • Engine speed increased to shorten When cold, supplies bypass air into dy- Air valve namic chamber warm-up period •...
Page 128 ISC SYSTEM TROUBLESHOOTING Check the condition of the wiring harness and connectors before checking the sensors or switches. Note Make the system inspection first. If no problem is found, continue with inspection of the next system of the Troubleshooting Guide. (Refer to pages 4B—10 and 11.) Possible cause Engine control unit...
Page 129 ISC SYSTEM (ISC valve) . Connect the ISC valve connector. Note a) Make sure that the initial idle speed is set to specification. b) All accessory must be OFF. 7. Again disconnect the ISC valve connector (engine at normal operating temperature). .
Page 130 ISC SYSTEM ISC valve . Disconnect the ISC valve connector. . Connect an ohmmeter to the terminals of the ISC valve. 3. Check the resistance. Resistance (at 20°C (68°F)): 6.3—9.9 0 4. If not correct, replace the BAC valve. 76F04B -042 REMOVAL .
Page 131 TECHNICAL DATA MEASUREMENT........... 30— 2 ENGINE (F6,F8,FE SOHC)......30— 2 ENGINE (FE DOHC)........30— 8 ENGINE (F2)..........30—11 LUBRICATION SYSTEM......30—14 COOLING SYSTEM........30—15 FUEL AND EMISSION CONTROL SYSTEM (CARBURETOR).......... 30—16 FUEL AND EMISSION CONTROL SYSTEM (FE DOHC)..........30—18 FUEL AND EMISSION CONTROL SYSTEM (F 2)...............30—19 ENGINE ELECTRICAL SYSTEM....30—20 CLUTCH............
Page 132 TECHNICAL DATA 0. MEASUREMENT Model Sedan Hatchback Item Overall length mm (in) 4,515 (177.8) 4,515(177.8) Overall width mm (in) 1,690 (66.5) 1,690 (66.5) " Overall height (14 inch/13 inch) mm (in) 1,410 (55.5)/1,395 (54.9) 1,375 (54.1)/1,360 ( 5 3 ^ P Wheel base mm (in) 2,575 (101.4)
Page 133 ____ Engine model FE 12-valve Item Valve seat 4 5 ° Seat angle 45° 1 .2 - 1 .6 (0 .0 4 7 -0 .0 6 3 ) Seat contact width mm (in) 1.2— 1.6 (0.047—0.063) Standard 50.2 (1.976) Seat sinking (Measure 51.0 (2.008) Maximum valve protruding length)
Page 134 TECHNICAL DATA Engine model FE 12-valve Item 0.20— 0.35 (0.008—0.0138) Second 0 .1 5 - 0 .3 0 (0 .0 0 6 -0 .0 1 2 ) • . . . Oil (rail) 0.20—0.70 (0 .0 0 8 -0 .0 2 7 6 ) ~~~~ Maximum 1.0 (0.039)
Page 135 TECHNICAL DATA \ ------------ : - ---------- : ----------- - ---------------------------- — _________ Engine model FE 12-valve Item Timing belt Belt deflection mm (in)/98 N (10 kg, 22 lb) 5.5—6.5 (0 .2 2 -0 .2 6 ) 8-valve Engine model FE 8-valve Item Type...
Page 136 TECHNICAL DATA Engine model FE 8-valve Item Valve seat 4 5° Seat angle 45° 1.2— 1.6 (0 .0 4 7 -0 .0 6 3 ) Seat contact width mm (in) 1.2— 1.6 (0.047—0.063) Standard 46.5 (1.831) Seat sinking (Measure Maximum 48.0 (1.890) valve protruding length) Standard...
Page 137 TECHNICAL DATA Engine model FE 8-valve Item 8 1 .6 9 4 -8 1 .7 1 4 0,75 (0.030) oversize — (3.2163—3.2171) 81.944—81.964 1.00 (0.039) oversize — (3.2261—3.2269) Standard 0.036—0.075 (0.0014—0.0030) Piston and cylinder clearance mm (in) Maximum 0.15 (0.0059) Piston ring 1 .4 7 -1 .4 9 (0.0579—0.0587) Thickness...
Page 138 TECHNICAL DATA —— Engi ne model Item FE 8-valve Valve sef item Seat angk Thrust bearing (center main bearing) Standard 0.08—0.18 (0.0031—0.0071) Crankshaft end play mm (in) Maximum 0.30(0.0118) Seat cant; Standard 27.94—27.99 (1.100— 1.102) 0.25 (0.010) oversize 2 8 .0 4 -2 8 .0 9 (1 .1 0 4 -1 .1 0 6 ) Seat sinkii Bearing width mm (in)
Page 139 TECHNICAL DATA Engine model FE DOHC Item Valve seat 45° Seat angle 45° 1.2— 1.6 (0.047—0.063) Seat contact width mm (in) 1.2— 1.6 (0 .0 4 7 -0 .0 6 3 ) Standard 36.8 (1.449) Seat sinking (Measure Maximum 37.8 (1.488) valve protruding length) Standard 36.8 (1.449)
Page 140 TECHNICAL DATA Engine mode! FE DOHC Item 0.20—0.35 (0.008—0.0138) Second 0.15— 0.30 (0 .0 0 6 -0 .0 1 2 ) L IIU y « |J l i l ^ a o u ic u Ml L/yiM IUd MINI \ l l i ; 0.20—...
Page 141 TECHNICAL DATA ■ n — ™ 1C. ENGINE (F2) — ---------_ --- Engine model Non-Turbo Turbo Item " — -------- Gasoline, 4 cycle Type In-line, 4 cylinders Cylinder arrangement and number Pentroof Type of combustion chamber OHC, belt driven Valve system 86.0 x 94.0 (3,39 x 3.70) Bore x Stroke mm (in)
Page 142 TECHNICAL DATA —- Engi ne model ~~~~~~~~~------- Item - - — Turbo Non-Turbo Vaive spring 49.5 (1.949) Standard Minimum 48,3 (1.902) Free length mm (in) 50.4 (1.984) Standard Minimum ----------------- 49,24-1J33Z) Out-of-square (in) Maximum 1.7 (0.067) 2 0 3 - 2 3 0 (20.7—23.4, 4 5 .5 - 5 1 .5)/41 (1.614) Setting load/height N (kg, lb)/mm (in) 2 4 0 -2 7 2 (2 4 .5 -2 7 .7 , 5 3 .9 -6 0 .9 )/4 1 (1.614)
Page 143 Engine model Turbo Item Non-Turbo 0.03—0.07 (0.0012—0.0028) Ulearance OI p is iu n u n y iu n n y Second 0 .0 3 -0 .0 7 (0.0 012-0.0 028) yiuuvc Maximum 0.15 (0.006) Piston pin Diameter mm (in) 2 1 .9 7 4 -2 1 .9 8 0 (0 .86 51-0.8 65 4) Interference in connecting rod mm (in) 0 .0 1 3 -0 .0 3 7 (0.0005—0.0015)
Page 144: Lubrication System
TECHNICAL DATA 2. LUBRICATION SYSTEM ~~~~~~~~-— — - Engi ne model FE DOHC F6,F8,FE SOHC Item — ----- _____ Turbo Non-Turbo Lubrication system Force-fed Oil pump Type Trochoid gear Crescent gear Regulated pressure kPa (kg/cm2 psi) 392 (4.0, 57) 490 (5.0, 71) 392 (4.0, 57) 1,000 rpm 147—245 (1,5—2.5, 21 —36)
Page 145 TECHNICAL DATA COOLING SYSTEM —— -— Engi ne model F6,F8, FE DOHC FE 12-valve FE 8-valve, F2 Doling system Water-cooled, forced circulation ater pump Centrifugal, timing belt driven ipeller diameter mm (in) 70 (2.76) jmber of impeller blades >eed ratio 1 : 1.00 1 : 1.05 ater seal type...
Page 146 TECHNICAL DATA 4A. FUEL AND EMISSION CONTROL SYSTEMS (CARBURETOR) F6 and F8 Engine Engine Specification New Zealand Idle speed 950 +5g 900 +5S ATX (in N range) 2.0 ± 0 . 5 (Without secondary air injection) CO concentration Carburetor Down draft, two barrel Type 3 0 (1 .1 8 ) Primary...
Page 147 TECHNICAL DATA FE Engine Engine BHD and New Australia Specification Zealand 850 +5§ 800 +58 Idle speed 900 +5§ (in N range) 2.0 ± 0.5 (Without secondary air injection) CO concentration Carburetor Down draft, two barrel Type 30 (1.18) Primary Throat diameter mm (in) 34 (1.34)
Page 148 TECHNICAL DATA 4B. FUEL AND EMISSION CONTROL SYSTEM (FE DOHC) Item Specification § Idle speed With test connector grounded 750 ± 50 Throttle body Horizotal draft (2-barrel) Type 46(1 .8 ) No.1 Throat diameter mm (in) 4 0(1.6) ■ . ~ No.
Page 149 TECHNICAL DATA 4C, 4D FUEL AND EMISSION CONTROL SYSTEM (F2) —— --------------------- Engine model Non-Turbo Turbo Item — ------------- Idle speed With test connector grounded 750 ± 25 (ATX: P range) Throttle body Type Horizontal draft (2-barrel) No. 1 MTX: 40 (1.6), ATX: 46 (1.8) Throat diameter mm (in) No.
Page 150 TECHNICAL DATA 5. ENGINE ELECTRICAL SYSTEM — ---------- - Engine ------ (8 VALVE) (12 VALVE) Item ~ ~ ~ ~ ~ -------- (DOHC) Voltage 12, Negative ground Battery Type and capacity 34B19L(S): (33 Ah) (20 hour rate) A.C. Type Output V—A 1 2 - 7 0 Transistorized (built-in IC regulator)
Page 151 TECHNICAL DATA -------____________ Engine Item ---------- --- Non-Turbo Turbo Voltage 12, Negative ground Battery Type and capacity 34B 19L(S): (33 Ah) (20 hour rate) Type A.C. Output V—A 12—70 Regulator type Transistorized (built-in IC regulator) 1 4 .1 -1 4 .7 Regulated voltage Alternator Standard...
Page 152 TECHNICAL DATA 6. CLUTCH Engine model FE DOHC Item Non-Turbo Turbo Clutch control Type Hydraulic Master cylinder inner diameter mm (in) 15.87 (0.625) Release cylinder inner diameter mm (in) 19.05 (0.750) Clutch fluid type DOT-3 or DOT-4, FMVSS 116, or SAE J1703 Clutch pedal Suspended Type...
Page 153 TECHNICAL DATA 7A. MANUAL TRANSAXLE Engine model F 2 Non-Turbo F2 Turbo — MTX model Item G Type H Type Transmission ' Shift lever position Floor shift First 3.307 3.250 Second 1.833 1.772 Third 1.310 1.233 1.194 Gear ratio Fourth 1.030 0.970 0.914...
Page 154 TECHNICAL DATA 7B. AUTOMATIC TRANSAXLE (ELECTRONICALLY CONTROLLED AND 4-SPEED) ~~~~~~~~~~~----- —— — — M odel G4A-EL (EC-AT) G4A-HL (4-Speed) Item — Turbo Non-Turbo FE engine ] F8 enotaT~ :— 2.800 1.540 Gear ratio — 1 .ooo 4th (OD) 0.700 Reverse 2.333 Oil capacity liters (US qt, Imp qt)
Page 155 TECHNICAL DATA ft point (G4A-EL) Drum speed rpm e Throttle condition Vehicle speed km/h (mph) Shift e (Throttle sensor voltage) Non-Turbo Turbo Non-Turbo Turbo 5,000—5,500 4,900—5,500 54—56 (3 3 -3 5 ) 53—59 (3 3 -3 7 ) Fully opened D2->D3 5,300—5,700 5 ,1 0 0 -5 ,5 0 0 1 0 5 -1 1 3 (6 5 -7 0 )
Page 156 TECHNICAL DATA Shift point (G4A-HL) Vehicle speed km/h (mph) Shifting Range Throttle condition FE engine F8 engine 1st -> 2nd 5 0 - 6 5 (31—40) 4 7 - 6 2 (2 9 -3 8 ) Fully opened 2nd -*• 3rd 100—...
Page 157 TECHNICAL DATA Model G4A-EL (EC-AT) G4A-HL (4-speed) Item Turbo Non-Turbo FE engine F8 engine Forward clutch Number of drive/driven plate Standard 1.6 (0.063) Drive plate thickness mm (in) Minimum 1.4 (0.055) rorward clutch clearance mm (in) 1.0—1.2 (0. 040—0.047) 5.9 (0.232), 6.1 (0.240), 6.3 (0.248), detaining plate sizes mm (in) 6.5 (0.256), 6.7 (0.264), 8.9 (0.350)
Page 158 TECHNICAL DATA Control valve spring (G4A-EL) Spring name Outer dia. mm (in) Free length m m (in) Wire dia. mm (in) Spring co join 1-2 accumulator small spring Non-Turbo 10.8 (0.425) 96.1 (3.788) 1.3 (0.051) Light green Non-Turbo 16.0 (0.630) 87.1 (3.429) 2.1 (0.083) 1-2 accumulator large spring...
Page 159 TECHNICAL DATA Spring color Outer dia. mm (in) Free length mm (in) Wire dia. mm (in) — Spring name Maroon 24.1 (0.949) 0.9 (0.035) 6.9 (0.272) 'p ^ ^ r t e r relief ball spring — 5.0 (0.197) 12.5 (0.492) 0.23 (0.009) -orifice check valve spring —...
Page 160 TECHNICAL DATA 7C. AUTOMATIC TRANSAXLE (3-SPEED) — ------------ - Engine model — FE engine F6 engine Item -------- —------- Model 2.841 1.541 Gear ratio 1.000 2.400 Reverse 6.2 (6.6, 5.5) Oil capacity Liters (US qt, Imp qt) ATF Dexron-li or M-lli Fluid type Between F and L marks on gauge Fluid level with the engine idling at P...
Page 161 TECHNICAL DATA Engine model F6 engine FE engine item “Front clutch 'Kjiurnber of driven and drive plates Standard 1.6 (0.063) mm (in) Drive plate thickness Minimum 1.4 (0.055) mm (in) 1 .6 - 1 .8 (0 .0 6 3 -0 .0 7 1 ) ""Front clutch clearance 5.2 (0.205), 5.4 (0.213), 5.6 (0.220), mm (in)
Page 162: Front And Rear Axles
TECHNICAL DATA — — -—_ Engine model FE engine F6 engine Item — - Gear assembly Total end play mm (in) 0 .2 5 -0 .5 0 (0 .0 1 0 -0 .0 1 9 6 ) 1.2 (0.047), 1.4 (0.055), 1.6 (0.063), End play adjust races mm (in) 1.8 (0.071), 2.0 (0.079), 2.2 (0.087)
Page 163: Braking System
TECHNICAL DATA BRAKING SYSTEM Item Specifications LHD & RHD 222 (8.74 _ T ) Height mm (in) Free play mm (in) 4 - 7 (0.16—0.28) 95 (3.74) min. Reserve travel mm (in) Irake iedal (Clearance when pedal is depressed at 5! 39 N (60 kg, 132 lb)) Lever ratio Max.
Page 164: Wheel And Tire
TECHNICAL DATA 12. WHEEL AND TIRE Type Standard Item 5-Jx13 Size 5-Jx14, 5 1/2-JJx14 6JJx15 Offset mm (in) 42 (1.65) Diameter of pitch Wheel 114.3 (4.5) circle mm (in) Material Steel or aluminum alloy 13 inch-wheel Number of 14 inch-wheel fixing nuts 15 inch-wheel 6.45-13-6PR...
Page 165: Body Electrical System
TECHNICAL DATA Item Specification Rear suspension Hype" Strut Toe-in mm (in) 3 (0 ± 0.12) ± i.Bear wheel alignment Camber angle -0 ° 3 0 ' ± 45' Type Torsion bar ^Stabilizer Diameter mm (in) 16 (0.63) Identification color Yellow Brown Blue Green...
Page 166 ) TECHNICAL DATA item Specification (W) Brake Oil pressure Fuel Washer level Rear Door Indicator and warning lights Alternator High beam Turn signal O/D OFF A/T mode A/T position Glove compartment light Interior lights Interior light Luggage compartment light Motor Hazard switch Cigar lighter AAS switch...
Page 167 Mazda North American Operations has established a single toll free phone number to provide technical assistance in support of "Fix It Right The First Time." This toll free number is available nationwide to al! Mazda dealer service departments. It also replaces the Midwest dealers (formerly known as Mazda Great Lakes) technical assistance phone number.
Page 168 Remember, the technical assistance hotline is established to HELP you "FIX IT RIGHT THE FIRST TIME." Technical assistance is available to authorized Mazda Dealer Technicians and Service Managers ONLY. This hotline is not for customer, parts, sales or warranty department personnel inquiries.
Page 169 SEND YOUR NGS VERSION 7.0 CARD TO MNAO Technical Services Department. APPLICATION This card is used with your NGS Tester to properly service 1988 - 2001 Mazda Vehicles. Refer to your Workshop Manual for the application of this card and tester.
Page 170 America Kowa Seiki 13939 Equitable Road Cerritos, CA. 90703 RE: Mazda NGS Card Reprogramming Step 3: Send your package by Federal Express 2 day or UPS Blue label prepaid. It must arrive at America Kowa Seiki by July 26, 2.000.
Page 171 This Service Bulletin is a follow-up to the Mazda Terminal Repair Kit Brochure sent last month which announced that this kit is a Mazda Required Tool for all Mazda Dealers. Automatic shipment of this kit will begin the week of February 26, 2001.
Page 172 This kit will be shipped via UPS to your Service Department during the week of February 29, 2001. If necessary, please use Mazda MNET Order Tracker to track your shipment. Your dealer parts account will be automatically invoiced for this kit and if your Accounting Department has questions regarding this invoice, please call Mazda Special Service Tools (949-442-6597).
Page 173 Service Department by Mazda's tool supplier, America Kowa Seiki, Inc. The replacement terminal pins are the lat est addition to the Mazda Terminal Repair Kit (MNET part number 49L0-88-0A0) which is a Mazda Required Tool (MRT) for all Mazda Dealers. The Mazda Terminal Repair Kit, replacement terminal pins, tools and connectors are only available through Mazda MNET 2000.
Page 174 Accounting Department has questions regarding this invoice, please call Mazda Special Service Tools (949) 442-6596. Do not send your payment to America Kowa Seiki, Inc. Please advise your shipping receiving personnel of this tool shipment.
Page 175 SPECIAL “ORDER IN MARCH 2002 - PAYMENT IN OCTOBER 2002” DELAYED BILLING OPTION (Expires 03/31/02) Mazda is offering dealers the option of ordering a new cabinet on MNET 2000 before March 31, 2002 and delay payment until their October 2002 parts account billing statement. This option is only available on the above four cabinet part numbers: MAZDA-01, MAZDA-02, MAZDA-03 and MAZDA-04.
Page 176 New Model Tool package release. Replacement drawer liner updates (missing or lost) are only available on Mazda MNET 2000 - review the table below for part number, description and price information. The information is organized by SST Service Bulletin distribution and bulletin copies can be accessed through MNET 2000.
Page 177 S ervice B u lletin 004/98, issued 08/05/98 M azda R eq uired T o o l M N E T M N E T P a r t# S S T S C S D ra w e r # S p ec ial T o ol D esc rip tio n N u m b e r# P R IC E...
Page 178 Service Bulletin 002/00, Issued 06/23/00 M N E T M azda R eq uired To ol S ST S C S D raw er # S pecial T o ol D escrip tio n M N E T P a r t# N u m b e r# P R IC E R estraint S ystem D iagn ostic S im u la to r...
Page 179 Service Bulletin 002/01, issued 02/14/01 M N E T M azda R eq u ired Tool S p e c ia l To o l D esc rip tio n S S T S C S D ra w e r # M N E T P a r t# P R IC E N u m b e r#...
Page 180 See attached brochure for further details. APPLICATION Each of the four cabinet systems is designed to store all your Mazda Required Tools with additional space avail able for other tools and equipment.
Page 181 Equipment Solutions, a division of Snap-on Incorporated, gives dealers the easiest, most efficient and cost- effective method of equipping a Mazda Service Department. Ordering is now even easier with Mazda MStore - using your Web Single Logon provides a secure, quick, convenient, and reliable method of purchasing products.
Page 182 7:30 AM until 7:00 PM CST, Monday through Saturday. Please call this toll-free number for warranty questions, product information, shipping and ordering assistance. To arrange a dealer equipment consultation with a Mazda Service Equipment Area Sales Manager please call our Customer Service Representatives (877) 768-6657 to set up an appointment. Area Sales Mangers are an impor...
Page 183 Equipment. This service assures Mazda dealers of receiving the easiest, most efficient and cost-effective method of equipping a Mazda Service Department. Dealers now have the opportunity to place their orders via Mazda MNET 2000 or by phone (877-768-6657). Use Mazda MNET 2000 to order additional Mazda Service Equipment Catalogs (part number MAZCAT001).
Page 184 Customer Service Representatives (877-768-6657) to set up an appointment. Area Sales Mangers are an impor tant link between your dealership and Mazda approved equipment suppliers. They will be calling on you to help determine your equipment needs, answer any product questions and assist in submitting your order on MNET 2000.
Page 185 CUSTOMER SERVICE To obtain a WDS service replacement, please contact the WDS Hotline (877) 722-8336. For return freight billing questions, please contact Mazda Special Tools and Equipment at (949) 442-6596 or e-mail specialtoolseauip ment@mazdau.s.a.co m . C O N S U M E R N O T I C E : T h e in fo r m a iio n a n d in s t r u c tio n s in th is b u lle tin a r e I n t e n d e d f o r u s e b y s k ille d t e c h n ic ia n s . M a z d a t e c h n ic ia n s u t iliz e t h e p r o p e r t o o l s / e q u i p m e n t a n d ta k a tr a in in g t o c o r r e c U y a n d s a f e l y m a in t a in M a z d a v e h i c i e s .
Page 186 April 29, 2002 (dealers who have already ordered the tester on Mazda MNET will not receive an additional unit). Due to the large quantity order, Mazda will include the Micro491 IR Printer and Case for the package price of $599.95 - a savings of $195.05.
Page 187 The Mazda Special Service Tools (SSTs) illustrated on the following pages, will be automatically shipped to your service department by Mazda's tool vendor, America Kowa Seiki, Inc. These tools are the latest addition to the Mazda Required Tools (MRT) list and can be found on Mazda MNET 2000.
Page 188 49N0-17-201 49N0-17-2Q2 49N0-17-203 Stopper ■; Setting Plate Handle <®======= PAGE 2 OF 3...
Page 189 Revised: Date Issued: 06/6/01 Number: 003/01 49N0-17-2Q8 49N0-17-207 49N0-17-204 Guide Pin Shaft Stopper Setting Plate 49N0-17-2A0 49N0-17-2A1 49N0-17-209 Clutch Hub Installer Set Clutch Hub Puller Set Oil Seal Installer <& D ^ > ° PAGE 3 OF 3...
Page 190 Service Bulletin Mazda Motor of America, Inc. 7755 Irvine Center Drive Irvine, California 92718 Telephone (714) 727-1990 Bulletin No. 020/88 Subject Category Applicable Model/s MAINTENANCE FREE BATTERY Issued 11/29/88 All Models CHARGING & TESTING PROCEDURES Revised DESCRIPTION There is a growing concern in the market regarding excessive battery claims as a result o f insufficient charging and/or knowledge o f the appropriate charging procedures.
Page 191 Number: 020/88 Date Issued: 11/29/88 Date Revised: Current manufacturing techniques enable battery makers to isolate one cell from the other. This process is accomplished by using containment envelopes as shown (Type B). Sealeu Raised from Battery Floor INSPECTION PROCEDURE 1. Inspect the battery terminals and cable ends for white crystal deposits. Clean if necessary. Inspect vent surface for acid deposits.
Page 192 Number: 020/88 Date Issued: 1 1/29/88 Date Revised: TESTING PROCEDURE NOTE: Use Sun made equipment (VAT 40) or equivalent. 1. Apply a load three (3) times higher than battery capacity. Results Action Voltage stays above 9.6 V Battery OK Voltage drops below 9 .6 V Replace Battery 2.
Page 193 3 Mazda Motor of America, Inc. Service Bulletin 7755 Irvine Center Drive Irvine, California 92718 Telephone (714) 727-1990 Applicable Model/s Bulletin No. 050/88 Category Subject MX-6/626 1988-89 Issued 11/4/88 MTX PRIMARY SHAFT 1988-89 323 Turbo Revised DESCRIPTION A diameter o f the primary shaft end portion has been increased to 0.94 in (24 mm) from 0.87 in (22 mm) as shown below in order to increase the strength o f the threaded portion o f the primary shaft.
Page 194 Number: 050/88 Date Issued: 11/4/88 Date Revised: VIN OF PRODUCTION CHANGE 1989 M X -6/626 vehicles produced in Japan: J M I G D * * - * * K1709751 August 1, 1988 1989 M X-6 vehicles produced in the U .S .A .: 1YVGD31A7 K 5206170 September 14, 1988 1989 323 Turbo vehicles:...
Page 195 Service Bulletin m g y n g m o w v v l * ' v v W U I I S I I I I 77SS Irvine Center Drive ■ ■ Irvine, California 92718 Telephone (714) 727-1990 041/89 Category Bulletin No.
Page 196 Service Bulletin m g y n g m o w v v l * ' v v W U I I S I I I I 77SS Irvine Center Drive ■ ■ Irvine, California 92718 Telephone (714) 727-1990 041/89 Category Bulletin No.
Page 197 Mazda Motor of America, Inc. m a z o a Service Bulletin 7755 Irvine Center Drive Irvine, California 92718 Telephone (714) 727-1990 Bulletin No. Category Applicable Model/s 042/89 Subject 1988-'89 626/M X-6 Issued 7/19/89 IDLE VIBRATION IN "D" RANGE Revised DESCRIPTION E xcessive vibration may be felt in the steering wheel and seats while idling in “...
Page 198 N um ber 042/89 Date Issued: 7/19/89 Date Revised: BEGINNING YIN OF PRODUCTION CHANGE A. N o .l Engine Mount For vehicles produced in Japan: 1989 626/M X -6 J M 1 G D * - * * * K1725513 October 1, 1988 For vehicles produced in the U .S.A : 1989 M X -6...
Page 199 Number: 042/89 Date Issued: 7/19/89 Date Revised: 4. Check that the A/C pipe (from compressor to condenser) is not interfering with the ra Interference Part diator. If necessary, reposition the A/C pipe to make enough clearance between the A/C pipe and radiator. 5.
Page 200 m a z D B Service Bulletin c i r Z T 7755 Irvine Center Drive Irvine, California 92718 Telephone (714) 727-1990 Bulletin No. Category Subject 005/88 Applicable Model/s 1988-1989 Issued 10/17/88 ALUMINUM WHEEL 626/M X -6 Revised DESCRIPTION Aluminum road wheels that are hard to remove from the vehicle may be caused by galvanic corrosion between the wheel and hub.
Page 201 Service Bulletin Mazda Motor of America, Inc. 7755 Irvine Center Drive Irvine, California 92710 Telephone (714) 727-1990 Bulletin No. 060/88 Category Applicable Model/s Subject Issued 11/4/88 (see below) SUNVISOR ADJUSTMENT Revised DESCRIPTION On 1988-89 323, 626/M X-6, or B2200/2600 models you may notice problems during PDI or encounter customer complaints regarding sunvisor operation (i.e.
Page 202 Service Bulletin Mazda Motor of America, Inc. 7755 Irvine Center Drive Irvine, California 92718 Telephone (714) 727-1990 Bulletin No. 064/89 Category Applicable Model/s Subject 1988-1989 Issued 4/11/89 WIND NOISE 626/M X -6 Revised DESCRIPTION If you receive a complaint o f any o f the conditions listed below, perform repairs applicable to the complaint.
Page 203 Number: 064/89 Date Issued: 4/11/89 Date Revised: VIN OF PRODUCTION CHANGE A) Front W indow Area 626 & M X-6 (Produced in Japan) J M I G D * # * - ^ K 1709751 August 1, 1988 M X -6 (Produced in the U .S .A .) 1 Y V G D 31-** K5208028 October 1, 1988 626 &...
Page 204 Number: 064/89 Date Revised: Date Issued: 4/11/89 LOCATION 1 (DOOR MIRRORS) Manual & Powered Mirrors. 1. Using a flat screwdriver, carefully pry the inner sail garnish out o f its posi tion. (Start prying at top com er o f sail garnish, then work downward).
Page 205 Number: 064/89 Date Issued: 4/11/89 Date Revised: Manual Mirror Add respective (right and left) seal rubber to the mirror base. GJ35 69 11X (RH) GJ25 69 11X (RH) GJ35 69 17X (LH) GJ25 69 17X (LH) Seal Rubber ront ^ Adhesive Tape LOCATION (GLASS INNER WEATHERSTRIP - ALL DOORS)
Page 206 Number: 064/89 Date Issued: 4/11/89 Date Revised: LOCATION 3: GLASS RUN CHANNEL (Front Door) 1. Lower window all the way. Pull back the glass run channel as shown. Attach the pad strip to the back o f the glass run channel from the circled area. Pad Size: Length = 400 mm...
Page 207 Number: 064/89 Date Issued: 4/11/89 Date Revised: Remove the original glass guide rail pad and replace it with a new one. O rigin al Pads A) Install the glass rail pad so that the top o f the pad is 30 mm from the bottom o f the guide rail (see illustration).
Page 208 Number: 064/89 Date Issued: 4/11/89 Date Revised: C) Install a protector between the drip molding and the “ A ” -pillar. D) Reinstall the fixing screw and insert the protector inside the cavity o f the front fender. Front Fender Protector MX-6 A) Cut the boss o ff o f the protector.
Page 209 Number: 064/89 Date Issued: 4/11/89 Date Revised: B) Glue the protector to the drip molding as shown. C) Insert protector into cavity in fender. Condition B: Wind Noise at Rear Door Comer Area Location 4 Lower window all the way. Pull o ff the rear com er section o f the glass run channel.
Page 210 Number: 064/89 Date Issued: 4/11/89 Date Revised: Fold up the glass weatherstrip (see illustra tion [Location I portion]) and install a pad as indicated by the circle in the illustration. Reinstall the Glass Runchannel Pad Length • 4 -Door Sedan = 2 5 7 mm (P/N GK59 72 618B) •...
Page 211 Number: 064/89 Date Issued: 4/11/89 Date Revised: Fold up the glass run channel (see illustra tion [Location 3 portion]) and install a pad as indicated by the circle in the illustration. P ad w ea strip Pad Size: Length (4 & 5-Door) = 100 mm Thickness 2 mm GK59 72 618B...
Page 212 Number: 064/89 Date Issued: 4/11/89 Date Revised: Condition C: Wind Noise/Fluttering N oise at Rear Quarter Window Area Prepare a tube o f silicone sealer as shown in the illustration. Clean the rear quarter window glass and apply silicone between the glass and the garnish.
Page 213 Number: 064/89 Date Issued: 4/11/89 Date Revised: PARTS INFORMATION MX-6 Repair Kit Part Number: GJ83 75 750 (N oiseless Pack) PART NO. DESCRIPTION GJ83 58 618B Glass Runchannel Pad GJ21 58 619 Guide Rail Pad GJ21 58 8 2 IB Weatherstrip-Glass In.
Page 214 Number. 064/89 Date Issued: 4/11/89 Date Revised: 5-Door Hatchback Repair Kit Part Number: GK72 75 750 (Noiseless Pack) PART NO. DESCRIPTION G306 72 7F1A Rear Door Weatherstrip Pad GJ83 58 618B Glass Runchannel Pad-Fr. GK59 72 618B Glass Runchannel Pad-Rr. GK59 72 619 Glass Runchannel Pad-Rr.
Page 215 Date Revised: Number: 064/89 Date Issued: 4/11/89 4-D oor .Sedan Repair Kit Part Number: GK59 75 750 (N oiseless Pack) PART NO. DESCRIPTION G211 72 7F1A Rear Door Weatherstrip Pad GJ83 58 618B Glass Runchannel Pad-Fr. GK59 72 618B Glass Runchannel Pad-Rr. GK59 72 619 Glass Runchannel Pad-Rr.
Page 216 Number: 064/89 Date Issued: 4/11/89 Date Revised: W ARRANTY INFORMATION Customer Comment Code: Damage Code: Part Number o f Main Cause: (e.g .) GK59 75 750 (Part Number o f Repair Kit) Operation Number: (see charts below) Labor Hour: (see charts below) ■...
Page 217 If you encounter the customer complaint on the above condition, spray anti-static agent to the surface of the seat cushion and back trim. The following anti-static agents are recommended for static electricity shock on Mazda vehicles. M ANUFACTURER PRODUCT...
Page 218 Service Bulletin Mazda Motor of America, Inc. 7755 Irvine Center Drive California 92718 Irvine, Telephone (714) 727-1990 Subject Bulletin No. 069/89 Category Applicable Model/s 1988-1989 Issued 9/1/89 CENTER CONSOLE LID LOCK 626/M X -6 Revised DESCRIPTION On some o f the 1988-1989 626/M X -6 models on which the console lid had been replaced with an accessory arm-rest, the hinge pin o f the console lid lock may be loose and create a rattling noise because no stopper had been attached to the accessory arm-rest.
Page 219 Service Bulletin Mazda Motor of America, Inc. 7755 Irvine Center Drive Irvine. California 92718 Telephone (714) 727-1990 Bulletin No. 071/88 Category Applicable Model/s Subject IMPROPER OPERATION OF Issued 11/30/88 (see below) POWER WINDOW REGULATOR (Ball Type) Revised DESCRIPTION If you encounter any o f the following symptoms on 1986-88 RX-7, 1986-89 323/323W , 1988 626/M X -6, 1988 929 models, repair the power window in accordance with the instructions in this Service Bulletin.
Page 220 Number: 071/88 Date Issued: 11/30/88 Date Revised: Change the hose routing as follows: (626 front & rear doors, 929 front door only) a) Make two holes (0.27in or 7mm dia.) at the points indicated by the arrows. b) Remove the burr around the holes by filing.
Page 221 Number: 071/88 Date Issued: 11/30/88 Date Revised: 626 Rear 1. Locate the hose at the inner panel corner as shown. Adjust the clip location to ensure an even curve in the hose. Conversion: 23mm - 0.9in 13mm - 0.5in 32mm - 1.3in 929 Front 1.
Page 222 Number: 071/88 Date Issued: 11/30 <3 Date Revised: PARTS INFORMATION 1. Power Window Regulator Guide Assembly Right Side Left Side Model Door 323 HB Front B112 58 590 B 112 59 590 3-Door 323 HB Front B094 58 590A B094 59 590A 5-Door 323 Sedan B094 59 590A...
Page 223 Number: 071/88 Date Issued: 11/30/88 Date Revised: VIN OF PRODUCTION CHANGE JM 1B F 2-*-** K0302565 July 1, 1988 JM lB W 622it K0200003 323W July 1, 1988 J M 1 G D 2 * * ^ K1700621 June 10, 1988 (produced in Japan) MX-6 JM 1G D 31*-^ J 1589236...
Page 224 W 3Z O B Service Bulletin “ i r " 7755 Irvine Center Drive Irvine, California 92718 Telephone (714) 727-1990 Bulletin No. 077/89 Category Applicable Model/s Subject 1988-89 626/M X -6 Issued 5/5/89 ELECTRICAL M ALFUNCTION OF C .P .U . w/ Burglar Alarm Revised DESCRIPTION...
Page 225 W 3Z O B Service Bulletin “ i r " 7755 Irvine Center Drive Irvine, California 92718 Telephone (714) 727-1990 Category Subject Bulletin No. 077/89 Applicable Model/s 1988-89 626/M X -6 Issued 5/5/89 ELECTRICAL M ALFUNCTION OF C .P .U . w/ Burglar Alarm Revised DESCRIPTION...
Page 226 Service Bulletin a z o a 7755 Irvine Center Drive Irvine, California 92718 Telephone (714) 727-1990 Bulletin No. 078/89 Category Applicable Model/s Subject Issued 5/5/89 All Models AUDIO SYSTEM TROUBLESHOOTING Revised DESCRIPTION To simplify audio system troubleshooting, a flow chart (see next page) has been prepared. It contains essentials o f audio system troubleshooting procedures, focusing on the following: •...
Page 227 Date Issued: 5/5/89 Date Revised: Number: 078/89 AUDIO SYSTEM TROUBLESHOOTING Obtain D E TA ILE D A ND ACCURATE custom er com plaint inform ation by filling out the “ Audio Custom er Q uestionnaire". Reproduce the com plaint. Customer Page 2 of 2...
Page 228 Service Bulletin Mazda Motor of America, Inc. 7755 Irvine Center Drive Irvine, California 92718 Telephone (714) 727-1990 Bulletin No. 037/88 Category Applicable Model/s Subject 1988-1989 Issued 12/7/88 “ REC-FRESH” LEVER 626/M X-6 Revised DESCRIPTION If a customer complains that the manually operated “ Rec-Fresh” control becomes hard to operate in the modes listed below, replace cases “...
Page 229 Blower Unit W ARRANTY INFORMATION Customer Comment Code: Damage Code: Part No. o f Main Cause: GJ21 61 B05 Operation No: XX0307RX Labor Hours: Page 2 of 2...
Page 230 Service Bulletin Mazda Motor of America, Inc. 7755 Irvine Center Drive Irvine, California 92718 Telephone (714) 727-1990 Category Applicable Model/s Subject Bulletin No. 005.89 All Models except Issued 2 /10'89 ENGINE OIL FILTER CARTRIDGE RX-7 & B2600 Revised DESCRIPTION Due to the introduction of miniature oil filter cartridges in the market, caution must be taken when in...
Page 231 USE OF REGULAR UNLEADED GASOLINE w/o Turbocharger Revised DESCRIPTION It is recommended that REGULAR UNLEADED gasoline be used in all Mazda vehicles NOT equipped REGULAR with a turbocharger. All non-turbocharged Mazda vehicles are designed to perform best when UNLEADED fuel is used.
Page 232 r ' > ^ n r r *"1 " * ■ mazos Service Bulletin Irvine, California 92714 Telephone (714) 261-9429 Bulletin No. 056/89 Category Applicable Model/s Subject Issued 4/24/89 1988-89 626/M X-6 IDLE SPEED FLUCTUATION OR HUNTING (w /o Turbo) Revised 6/30/89 DESCRIPTION...
Page 233 Mazda (North America), inc. Service Bulletin »»««»» IT Ic L & D a Irvine, California 92714 Telephone (714) 261-9429 Bulletin No. Applicable Model/s 056/89 Category Subject Issued 1988-89 626/M X-6 4/24/89 IDLE SPEED FLUCTUATION OR HUNTING (w /o Turbo) Revised...
Page 234 Service Bulletin l n c m a z o B Irvine, California 92718 Telephone (714) 727-1990 Bulletin No. 059/89 Category Applicable Model/s Subject All Models Issued 7/19/89 REM ANUFACTURED EGI CONTROL UNIT (except B-Series) PROGRAM Revised DESCRIPTION In an effort to reduce the cost o f repair, remanufactured EGI control units will be available effective July 5, 1989.
Page 235 Number: 059/89 Date Issued: 7/19/89 Date Revised: 323 Models Application Remanufactured Replaces New EGI Control Unit EGI Control Unit B601 18 881R 86-87 All B601 18 880C B6BI 18 881R 88 Non-Turbo FED B6B1 18 880B B6B2 18 8 8 IR 88 Non-Turbo CA B6B2 18 880A B6B3 18 881R...
Page 236 Number: 059/89 Date Issued: 7/19/89 Date Revised: 626/M X-6 Models Remanufactured Application Replaces New EGI Control Unit EGI Control Unit F201 18 881R 88 626/M X -6 Non-Turbo FED, A /T & M/T F201 18 880L Also 89 626/M X -6 Non-Turbo FED, M/T Up to: JM 1G D * ★...
Page 237 Remanufactured EGI units are warranted for the first 12 months (regardless o f mileage) from the date o f installation by a Mazda dealer or sold over the counter. Remanufactured EGI control units installed as a result o f a warranty repair will be warranted for the remainder o f the vehicle’s em ission warranty.
Page 238 W ia W B Service Bulletin Irvine, California 92718 Telephone (714) 727-1990 Revised < DESCRIPTION Since the December, 1988 production, the material used for some o f the terminals o f the connector between the E .C .U . and the engine harness has been changed from gold to tin. In accordance with this design change, there is no interchangeability between new and old parts regarding the E .C .U .
Page 239 Number: 060/89 Date Issued: 10/12/89 Date Revised: NOTE: To identify new and old parts, the color o f the E .C .U . connectors and the engine harness have been chang ed from yellow to white at the time o f the design change. When replacing an E .C .U . or an engine harness, check the color o f the connector first and choose appropriate parts.
Page 240 JTBSZDa Service Bulletin Mazda Motor of America, Inc. 7755 Irvine Center Drive Irvine, California 92718 Telephone (714) 727-1990 Bulletin No. 061/89 Category Applicable Model/s Subject 1988-1989 Issued 11/17/89 ROUGH IDLE AFTER COLD START 626/M X -6 Revised DESCRIPTION If the following conditions occur within 15 seconds after a cold start on a 1988-89 626/M X -6, install a repair kit according to the procedures shown in this bulletin.
Page 241 Number: 061/89 Date Issued: 11/17/89 Date Revised: Installation o f Vacuum Hose (without Turbo) • Before Installation After Installation Vacuum Hose 9935 10 420G Pressure Regulator Solenoid V alve— FE70 18 741A Solenoid Valve , (Pressure Regulator) Page 2 of 7...
Page 242 Date Issued: 11/17/89 Date Revised: Number: 061/89 Installation o f Vacuum Hose (with Turbo) • Before Installation After Installation Solenoid Valve Pressure Regulator FE70 18 741A Solenoid Valve (Pressure Regulator) - Vacuum Hose 9935 10 420G Page 3 of 7...
Page 243 Number: 061/89 Date Issued: 11/17/89 Date Revised: Disconnect the vacuum hose (Green) from the solenoid valve (with Green label) o f the pressure regulator and install it on the solenoid valve o f the kit. 3) Install the vacuum hose (Green) which was assembled with the solenoid valve (kit) at the first step onto the solenoid valve (with Green label) o f the pressure regulator.
Page 244 Date Revised: Number: 061/89 Date Issued: 11/17/89 B. With Turbo 1) Assemble the vacuum hose and the solenoid valve from the kit. ■ Solenoid Valve FE70 18 741A 7.87 in. (Green) 2) Disconnect the vacuum hose (Green) from the solenoid valve (with Green label) o f the pressure regulator (with Green label) and install it onto the solenoid valve o f the kit.
Page 245 Date Issued: Number: 061/89 11/17/89 Date Revised: Installation o f Wire Harness (with & without Turbo) A . Under Dashboard 1) Install the control unit from the kit to lower left side o f the E .C .U . (Emission Control Unit). Connect the single couplers (Black &...
Page 246 Number: 061/89 Date Issued: 11/17/89 Date Revised: B. In Engine Compartment 1) Connect the black coupler to the solenoid valve which was installed in step 1. Disconnect the coupler from the No. 1 main relay and install 2 ends o f the wire harness between the main relay and its coupler.
Page 247 H i * m ayna Service Bulletin Mazda Motor of America, Inc. 7755 Irvine Center Drive Irvine, California 92718 Telephone (714) 727-1990 Bulletin No. 064/89 Category Applicable Model/s Subject 1989 323, 626, Issued 12/15/89 ENGINE STALL W HEN E .C .U . IS COLD &...
Page 248 Number: 064/89 Date Issued: Date Revised: 12/15/89 AFFECTED VIN RANGE 1989 929: J M 1 H C * * * * K 0 2 1 0 4 1 3 - 2 1 7 8 7 9 1989 626: J M I G D * * * * K 1 7 3 1830 - 746266 I Y V G D * ★...
Page 249 H i * m ayna Service Bulletin Mazda Motor of America, Inc. 7755 Irvine Center Drive Irvine, California 92718 Telephone (714) 727-1990 Bulletin No. 064/89 Category Applicable Model/s Subject 1989 323, 626, Issued 12/15/89 ENGINE STALL W HEN E .C .U . IS COLD &...
Page 250 Number: 064/89 Date Issued: Date Revised: 12/15/89 AFFECTED VIN RANGE 1989 929: J M 1 H C * * * * K 0 2 1 0 4 1 3 - 2 1 7 8 7 9 1989 626: J M I G D * * * * K 1 7 3 1830 - 746266 I Y V G D * ★...
Page 251 Service Bulletin Mazda Motor of America, Inc. 7755 Irvine Center Drive & Irvine, California 92718 Telephone (714) 727-1990 Bulletin No. 026/89 Category Applicable Model/s Subject Issued 12/29/89 All Models EC-AT TESTER REFERENCE TABLE w / EC-AT...
Page 252 Service Bulletin IT ia Z D a 7755 Irvine Center Drive Irvine, California 92718 Telephone (714) 727-1990 Bulletin No. 080/88 Applicable Model/s Subject Category Issued 9/19/88 All Models USE OF CORPORATE LOGO Revised DESCRIPTION Federal Motor Vehicle Safety Standard No. 108 prohibits the alteration o f any “ Lamps” , “ Reflective Device” , and “...
Page 253 B Service Bulletin Mazda Motor of America. Inc. 7755 Irvine Center Drive Irvine, California 92718 Telephone (714) 727-1990 Bulletin No. 054/89 Category Applicable Model/s Subject Issued 4/5/89 1987-1989 1987-1989 EC-AT SERVICE & REPAIR 626/M X -6 Revised...
Page 254 Number: 054/89 Date Issued: 4/5/89 Date Revised: 8/18/89 B. Confirm the proper ATF level. Warm up the engine for about 5 - 1 0 minutes (ATF temperature rises to 150°F) and then measure the ATF level. At 150°F, the ATF level should be at the “ F ” level mark with the engine ru nn ing in “...
Page 255 Number: 054/89 Date Issued: 4/5/89 Date Revised: 8/18/89 PARTS INFORMATION PART NUMBER DESCRIPTION INTERCHANGEABILITY FU31 19 9A0E FU31 19 9A 0D Oil Pipe NEW — OLD * — — 9938 11 000 Connector Bolt — — 9956 21 400 Packing (Washer) —...
Page 256 Number: 054/89 Date Issued: 4/5/89 Date Revised: 8/18/89 PARTS INFORM ATION DESCRIPTION PART NO . FU 06 21 100V Valve Body (for ‘87) FU 3H 21 100A Valve Body (for ‘88 T/C) FU4G 21 100A Valve Body (for ‘88 non-T/C) FUY1 21 227 Accumulator Spring (for ‘88 T /C ) NOTE:*...
Page 257 Number: 054/89 Date Issued: 4/5/89 Date Revised: 8/18/89 D. Check if the throttle sensor voltage is within the following specification and is stabilized (not fluctuating). Specification: Throttle Closed: 0 .4 - 0 .6 Volts Throttle Fully Opened: 4 .0 Volts Approximately If the reading is out o f the specified range, adjust the throttle sensor setting as per the workshop manual (page 4A -17).
Page 258 Number: 054/89 Date Issued: 4/5/89 Date Revised: 8/18/89 G . Check the B-25 and the X -09 connectors to deter mine if the LgB, GO, LgW and LgR wires are pro perly connected. NOTE: The connecting point o f the wires may be different depending on the production period o f the vehicle.
Page 259 Date Issued: 4/5/89 Date Revised: 8/18/89 Number: 054/89 B. Throttle Cable (Line Pressure) Adjustment Turn o ff the engine. Remove the splash shield next to the left front tire. Remove the square head plug “ L ” and install the oil pressure gauge set. Shift into “...
Page 260 Number: 054/89 Date Issued: 4/5/89 Date Revised: 8/18/89 NOTE: Transmission in “ P ” range. Turn o ff the engine. Apply “ T eflon” tape to threads and reinstall the square head plug. W ARRANTY INFORM ATION Performance Test Operation Number: K 0001X-D-X Labor Hours: 0 .8 Hr.
Page 261 Number: 054/89 Date Issued: 4/5/89 Date Revised: 8/18/89 Electrical System Malfunction Customer Comment Code: Damage Code: F U 16 19 090 (EC-AT A ssy.) Part Number o f Main Cause: Operation No: XX0277RX Labor Hours: 0 .4 Hr. NOTE: Labor Hours include the following items: •...
Page 262 Service Bulletin Mazda Motor of America, Inc. 7755 Irvine Center Drive Irvine, California 92718 Telephone (714) 727-1990 Bulletin No. 054/89 Category Applicable Model/s Subject 1987-1989 Issued 4/5/89 EC-AT SERVICE & REPAIR 626/M X -6 Revised DESCRIPTION This bulletin contains information compiled from the EC-AT Service & Repair Video, and from previously released Service Bulletins listed below.
Page 263 Number: 054/89 Date Issued: 4/5/89 Date Revised: B. Confirm the proper ATF level. Warm up the engine for about 5 - 1 0 minutes (ATF temperature rises to 150°F) and then measure the ATF level. At 150°F, the ATF level should be at the “ F ” level mark with the engine running in “...
Page 264 Number: 054/89 Date Issued: 4/5/89 Date Revised: PARTS INFORMATION PART NUM BER DESCRIPTION INTERCHANGEABILITY FU31 19 9A0E FU31 19 9A0D Oil Pipe NEW — OLD * — 9938 11 000 — Connector Bolt — — 9956 21 400 Packing (Washer) —...
Page 265 Date Issued: 4/5/89 Date Revised: Number: 054/89 Beginning N o. o f Applicable Transaxle Unit Modification/Addition Non-Turbo Turbo Modification o f rear body and premain separatorf FU--081065 FU--081143 Addition/modification o f 1-2 accumulator springs N .A . FU--083280 Modification o f 1-2 accumulator springs FU--089583 N .A .
Page 266 Number: 054/89 Date Issued: 4/5/89 Date Revised: 4. Electrical (all problems) If vehicle is a 1988 or 1989, use EC-AT tester as per Workshop Manual. If vehicle is a 1987 model, check the electrical system harness as follows: A. Check if the EGI harness is properly grounded at the B32 connector.
Page 267 Number: 054/89 Date Issued: 4/5/89 Date Revised: F. Check the EGI and injection harness and their connector. Check if the LgB, GO, LgW , LgR wires are pro perly connected at B-35 connector. If the terminal is rusted or the harness is cut, clean up the terminal or repair the harness, then apply a suitable anti-rust agent.
Page 268 Date Issued: 4/5/89 Number: 054/89 Date Revised: G. Check the B-25 and the X-09 connectors to deter ^ --------- B-25 Throt mine if the LgB, GO, LgW and LgR wires are pro tle Sensor perly connected. NOTE: The connecting point o f the wires may be different depending on the production period o f the vehicle.
Page 269 Date Revised: Date Issued: 4/5/89 Number: 054/89 B. Throttle Cable (Line Pressure) Ad _ .unent Turn o ff the engine. Remove the splash shield next to the left front tire. Remove the square head plug “ L ” and install the oil pressure gauge set. Shift into “...
Page 270 Number: 054/89 Date Issued: 4/5/89 Date Revised: W ARRANTY INFORMATION Performance Test Operation Number: K 0001X-D-X Labor Hours: 0 .8 Hr. Diagnosis Operation Number: K 0002X-D-X Labor Hours: 1.1 Hr. 1. ATF Condition or Improper Level A. Level Indicator (Warranty covered under diagnosis) B.
Page 271 Number: 054/89 Date Issued: 4/5/89 Date Revised: Electrical System Malfunction Customer Comment Code: Damage Code: Part Number o f Main Cause: FU 16 19 090 (EC-AT A ssy.) Operation No: XX0277R X Labor Hours: 0 .4 Hr. NOTE: Labor Hours include the following items: •...
Page 272 - Mazda Motor of Am erica, Inc. Service Bulletin 7755 Irvine Center Drive Irvine, California 92710 Telephone (714) 727-1990 Bulletin No. 056/89 Category Applicable Model/s Subject PROPER INSTALLATION OF Issued 2/15 89 All MTX Models CHANGE ROD BOOT Revised...
Page 273 Service Bulletin Mazda Motor of America, Inc. 7755 Irvine Center Drive Irvine, California 92718 Telephone (714) 727-1990 Bulletin No. 057/89 Category Applicable Model/s Subject 1988-1989 Issued 9/27/89 REVERSE IDLE GEAR MODIFICATION 626/M X -6 (Turbo) Revised DESCRIPTION To improve the overall durability and operation o f the reverse idle gear assem bly, the following modifica...
Page 274 Number: 057/89 Date Issued: 9/27/89 Date Revised: YIN OF PRODUCTION CHANGE 626/M X -6 vehicles manufactured in Japan: J M 1 G D * * * * K 1 7 6 6 4 0 9 May 1, 1989 M X -6 vehicles manufactured in the U .S .A : 1 Y V G D * * * * K 5 2 4 5 3 1 1 June 19, 1989 PARTS INFORM ATION...
Page 275 m a z o a Service Bulletin “ irc .t.lC 1 "' ' Irvine, California 92718 Telephone (714) 727-1990 Bulletin No. 058/89 Applicable Model/s Category Subject Issued 1987-89 626/M X6 3/10/89 ENGINE STALL AFTER HARD STOP Revised DESCRIPTION When ATF level is low, coming to a quick stop causes air to enter the ATF oil line. This temporarily reduces line pressure and engages the lock-up clutch.
Page 276 m a z o a Service Bulletin “ irc .t.lC 1 "' ' Irvine, California 92718 Telephone (714) 727-1990 Bulletin No. 058/89 Applicable Model/s Category Subject Issued 1987-89 626/M X6 3/10/89 ENGINE STALL AFTER HARD STOP Revised DESCRIPTION When ATF level is low, coming to a quick stop causes air to enter the ATF oil line. This temporarily reduces line pressure and engages the lock-up clutch.
Page 277 Revised DESCRIPTION < J Mazda (North America), Inc. (M ANA) has been supplying rebuilt EC-AT assemblies since October 3, 1988. M ANA has been preparing these assemblies with all up-to-date modifications as described in bulletin Category 7 no. 051/88. This bulletin is being provided for up-to-date information regarding the 1989 model year.
Page 278 Number: 065/89 Date Issued: 9/27/89 Date Revised: For your convenience, the illustration below shows items which should be reinstalled on the rebuilt trans mission (-) and returned (x) with the failed assembly. 1987 626 1988-89 626/M X -6 ■M 1987 1988 626/M A) Pulse Generator...
Page 279 EC-AT INSPECTION SHEET INSTRUCTIONS: Please complete this form and submit it with the return EC-AT unit to repair facility. Date: 1. Dealer Code: 2. Dealer Name: 3. Year/Model: 4. VIN No: 5. Unit No: 6. Mileage: 7. Delivery Date: 8. Problem Date: Customer Comment (please indicate with a ✓...
Page 280 10/31/89 DESCRIPTION Mazda (North America), Inc. (M ANA) has been supplying rebuilt EC-AT assemblies since October 3 ,1 9 8 8 . MAN A has been preparing these assemblies with all up-to-date modifications as described in bulletin Category 7 no. 051/88.
Page 281 Number: 063/89 Date Issued: 9/27/89 Date Revised: 10/31/89 For your convenience, the illustration below shows items which should be reinstalled on the rebuilt trans mission (-) and returned (x) with the failed assembly. 1987 626 1988-89 626/M X-6 ■M 1987 1988-89 626/M X -6 A) Pulse Generator...
Page 282 EC-AT INSPECTION SHEET INSTRUCTIONS: Please complete this form and submit it with the return EC-AT unit to repair facility. Date: 1. Dealer Code: 2. Dealer Name: 3. Year/Model: 4. VIN No: 5. Unit No: . Mileage: 7. Delivery Date: . Problem Date: Customer Comment (please indicate with a ^ mark): ( ) 2-3 ( ) 3-4 ( ) 4*3 ( ) 3-2...
Page 283 mazoa Service Bulletin l n c ' 7755 Irvin* Center Drive Irvin*, California 92718 Telephone (714) 727-1990 Subject Bulletin No. 067/89 Category Applicable Model/a 1 9 8 8 -8 9 Issued 10/12/89 TURBINE SENSOR/PULSE GENERATOR 626/M X -6 & 929 Revised DESCRIPTION On some o f the subject vehicles, the hold lamp goes ON and OFF while driving.
Page 284 Number: 067/89 Date Issued: 10/12/89 Date Revised: PRODUCTION CHANGE To improve this, a connection soldering process has been newly adopted to the wire harness and terminal o f the turbine sensor. Wire Harness Turbine Sensor Terminal Soldering----- 1 V IN OF PRODUCTION CHANGE 929: J M 1 H C * * * * K 0 2 1 0 4 1 3 November 1, 1988...
Page 285 Irvine, California 92718 Telephone (714) 727-1990 Bulletin No. 070/89 Category Applicable Model/s Subject 1988-89 Issued 12/15/89 D1-D 2 SHIFT SHOCK 626/M X -6 Turbo Revised DESCRIPTION If you encounter a customer complaint regarding D1 to D2 shift shock during light throttle (14 opening) during warm-up, repair the problem in accordance with the following procedure.
Page 286 Number: 070/89 Date Issued: 12/15/89 Date Revised: • If the value o f the line pressure ( a ) is higher than ( b ) , the result is OK. • If the line pressure does not change, go back to step 2 and readjust the throttle cable. LINE PRESSURE RESULT ®...
Page 287 0 6 0 0 S 7 CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper toots / equipment and take training to correctly end safeiy maintain Mazda vehicles. These instructions should not be performed by “do-rt-yourseffers" Customers should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern.
Page 288 Place one of these labels on or near each phone in the service department area. CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools / equipment and take training to correcfiy and safely maintain Mazda vehicles.
Page 289 Monday through Friday, 8:30am to 5:00pm within your region Monday through Friday, 8:30am to 5:0Qpm within your region Mazda. Technical Assistance Hotline M azda T e c h n ic a l A s s is ta n c e H o tfin e...
Page 290 0 6 0 0 5 8 CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools / equipment and take training lo correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.' Customers should not assume this bulletin applies to their vehicle or that their vehicle win develop the described concern.
Page 291 CONSUMER NOTICE; The infcmiaSon and instructions in this birttetin are intended for use by staled technicians. Mazda technicians utflize the proper toots / equipment and take training to coroctty and safety maintain Mazda vehicles. These instructions should not be performed by “do-ft-yourseJterv’ Customers should not assume this bufiatin applies to Ihelr vehicle or that their vettide wffl develop the described concern.
Page 292 SPEEDOMETER REPLACEMENT SPEEDOMETER REPLACEMENT Mileage:______________________ Mileage-____________________ __ (Before Replace mem) (Before Replacement) Date Replaced: Date Replaced: Dealer Code: _ Dealer Code: _ SPEEDOMETER REPLACEMENT SPEEDOMETER REPLACEMENT Mileage:______________________ Mileage:______________________ (Before Replacement) (Before Replacement) Date Replaced:____/ ____/ ____ Date Replaced:____/ ____/ ____ Dealer Code:_________________ Dealer Code:__________________ SPEEDOMETER REPLACEMENT...
Page 293 fDBZDB Service Bulletin Irvine, Caiifomia 92718 Telephone (714) 727-1990 Bulletin No. Category Subject *005/94 A pplicab le M odel/s issued 7/5/94 KEY REPLACEMENT (Caiifomia Dealers Only) All Models Revised 7/5/94 The revised portion of this bulletin is indicated by an asterisk(*), Replace the original bulletin with this revised copy. APPLICABLE MODELS All Models DESCRIPTION...
Page 294 Service Bulletin m a Z D a Irvine, Caiifomia 92718 Telephone (714) 727-1990 Bulletin No. *005/94 Applicable Model/s Issued 6/10/94 Al! M odels Revised 7/5/94 T h e revised portion of this bulletin is indicated by an asterisk(*). Replace the original bulletin with this revised copy APPLICABLE MODELS All M o d els DESCRIPTION...
Page 295 Mazda Motor of America, Inc. 7755 Irvine Center Drive Irvine, Caiifomia 92718 Telephone (714) 727-1990 Bulletin No. 006/90 Category Applicable Model/s Subject SERVICE COLLATERAL Issued 3/16/90 All Models HELM PROGRAM Revised DESCRIPTION Effective March 26, 1990 the following collateral material will no longer be available through your regional parts warehousing system.
Page 296 BILLING PROCEDURE If you elect to use the dealer parts account for ordering purposes, you will be billed by MM A (Mazda Motor o f America, Inc.) at month’s end. For those dealerships within the Mazda Distributors Great Lakes area, you will be billed directly from them.
Page 297 1113203 Service Bulletin , n c ' Irvine, California 92718 Telephone (714) 727-1990 Bulletin No. 007/94 Applicable Model/s Subject Category Issued 8/8/94 NATIONAL HIGHWAY TRAFFIC SAFETY All Models ADMINISTRATION NOTICE Revised Important Notice The National Highway Traffic Safety Administration (NHTSA) has amended Section 154 of the National Traffic and Motor Vehicle Safety Act.
Page 298 That’s why Mazda has produced the attached Service Advisor Diagnostic Questionnaire (part No. 9999 95 DIAG 93). Its simple format allows the advisor to quickly and accurately gather key details from the customer about the vehicle’s symptoms.
Page 299 Bulletin No. 027/92 Category Applicable Model/s Subject Issued 6/2/92 NATIONAL HIGHWAY TRAFFIC SAFETY All Models Revised ADMINISTRATION NOTICE Important Notice The National Highway Traffic Safety Administration (NHTSA) has amended Section 154 o f the National Traffic and Motor Vehicle Safety Act. The Amendment [Section 154 (d)] requires that dealers perform all recall campaign repairs to inventory vehicles or replacement parts prior to delivery to customers through sale or lease.
Page 300 Service Bulletin Mazda Motor of America, Inc. 7755 Irvine Center Drive Irvine, California 92718 Telephone (714) 727-1990 028/92 Bulletin No. Category Applicable Model/s Subject 11/30/92 Issued CERTIFICATION OF EMISSION-RECALLED All Models VEHICLES IN CALIFORNIA Revised A FFE C T E D VINS 1.
Page 301 Service Bulletin Mazda Motor of America, Inc. 7755 Irvine Center Drive Irvine, California 92718 Telephone (714) 727-1990 Bulletin No. 001/90 Applicable Model/s Category Subject 1988-90 Issued 4/20/90 IDLE VIBRATION IN “ D ” RANGE 626/MX-6 ATX Revised NOTE: No. 1 and no. 2 engine mounts, which are more effective for this subject matter, are now available as service parts only for field complaints.
Page 302 Date Issued: Date Revised: Number: 001/90 4/20/90 PARTS INFORMATION FIELD COUNTER M ASS-PRODUCTION DESCRIPTION APPLICABLE MEASURE PART PART MODELS ®GNY1 39 040 M002 39 040A #1 Engine Mount ATX w/o Turbo 0 G N Y 2 39 040 GJ28 39 (MOD #1 Engine Mount ATX w/Turbo 0G N Y 1 39 050...
Page 303 Date Revised: Number: 001/90 Date Issued: 4/20/90 Check if the A/C pipe (from compressor to condenser) is not interfering with the radiator. If necessary, reposition the A /C pipe to make enough clearance between the A/C pipe and the radiator. Adjust the hood lock if a rattle noise is heard from the hood.
Page 304 Service Bulletin Mazda Motor of America, Inc. 7755 Irvine Center Drive Irvine, California 92718 Telephone (714) 727-1990 Bulletin No. 004/90 Category Applicable Model/s Subject Issued 6/8/90 1988- 90 HYDRAULIC LASH ADJUSTER (HLA) NOISE Revised 626/M X -6...
Page 305 Service Bulletin Mazda Motor ot America, Inc. '755 Irvine Center Drive Irvine, California 92718 Category Applicable Model/s Subject Bulletin No. 004/94 PA R T IA L E N G IN E (L O N G B LO C K )
Page 306 Number: 004/94 Date Issued: 3/9/94 Revised: NEW ENGINE (LONG BLOCK) REPLACEMENT PROGRAM B-TRUCKS ENGINE P/N GASKET P/N YEAR / MODEL REMARKS HEA4-23-800 8AU1-23-900 1979-84 B2000 . .. FEY3-02-300 8AU1-02-310 1986-87 B2000 Requires the replacement of the Heat Gauge Unit - G607-18-510.
Page 307 • Date Issued: 3/9/94 Revised: Number: 004/94 NEW ENGINE (LONG BLOCK) REPLACEMENT PROGRAM 6 2 6 /M X - 6 YEAR / MODEL ENGINE P/N REMARKS GASKET P/N 1981-82 626 HE41-02-300 8AU1-02-310 1983-85 626 FE01-02-300 8AG1-02-310 1986-87 626 FEY1-02-300 Requires the replacement 8 AG 2-02-310 (NON-TURBO) of the Heat Gauge Unit -...
Page 308 • Date Issued: 3/9/94 Revised: Number: 004/94 NEW ENGINE (LONG BLOCK) REPLACEMENT PROGRAM MX-3 YEAR / MODEL GASKET P/N ENGINE P/N REMARKS 8AE2-02-310 1992-93 MX-3 (1.6L, 1-4) B66S-02-300 8ABD-02-310 1994 MX-3 (1.6L, 1-4) WILL BE AVAILABLE. 8AE3-02-310 1992-94 MX-3 (1.8L. V-6) WILL BE AVAILABLE.
Page 309 Service Bulletin Mazda Motor of America, Inc. 7755 Irvine Center Drive Irvine, California 92718 Telephone (714) 727-1990 Bulletin No. Applicable Model/s Subject 004/94 PARTIAL ENGINE (LONG BLOCK) Issued 3/9/94 All Models AVAILABILITY Revised 6/21/94 DESCRIPTION Partial engines are available as repair components and will replace the need to replace the entire engine.
Page 310 P a g e 2 o f 4 NEW ENGINE (LONG BLOCK) REPLACEMENT PROGRAM B-TRUCKS YEAR / MODEL ENGINE P/N GASKET P/N REMARKS 1979-84 B2000 HEA4-23-800 8AU1-23-900 FEY3-02-300 1986-87 B2000 8AU1-02-310 Requires the replacement of the Heat Gauge Unit - G607-18-510.
Page 311 P a g e 3 o f 4 NEW ENGINE (LONG BLOCK) REPLACEMENT PROGRAM 626/M X -6 YEAR/ MODEL ENGINE P/N GASKET P/N REMARKS 1981-82 626 HE41-02-300 8AU1-02-310 1983-85 626 FE01 -02-300 8AG1-02-310 1986-87 626 8AG2-02-310 FEY 1-02-300 Requires the replacement (NON-TURBO) of the Heat Gauge Unit - G607-18-510.
Page 312 P a g e 4 o f 4 NEW ENGINE (LONG BLOCK) REPLACEMENT PROGRAM MX-3 YEAR / MODEL ENGINE P/N GASKET P/N REMARKS 1992-93 MX-3 (1.6L. I-4) B66S-02-300 8AE2-02-310 1994 MX-3 (1.6L, I-4) B6DC-02-300 8ABD-02-310 1992-94 MX-3 (1.8L, V-6) K8Y1-02-300 8AE3-02-310 MILLENIA YEAR / MODEL...
Page 313 Mazda Motor of America, Inc. Service Bulletin m a z o a 7755 Irvine Center Drive Irvine, Caiifomia 92718 Telephone (714) 727-1990 Bulletin No. 005/95 Category Applicable Model/s Subject Issued 3/28/95 HLA NOISE AFTER LONG STORAGE All HLA Models Revised APPLICABLE MODELS/VINS A primary cause of HLA noise is the result of oil draining back to the crankcase during long periods of storage.
Page 314 Service Bulletin Mazda Motor of America, Inc. 7755 Irvine Center Drive Irvine, California 92718 Telephone (714) 727 -19 90 Bulletin No. 008/91 Category Applicable Model/s Subject IMPROVED CYLINDER HEAD Issued 6/20/91 1988— ’89 COVER GASKET Revised 626/M X-6 DESCRIPTION A cylinder head cover gasket with higher sealing capabilities was introduced into vehicle production as shown below.
Page 315 Service Bulletin Mazda Motor of America, Inc. 7755 Irvine Center Drive Irvine, California 92718 Telephone (714) 727 -1 9 9 0 Bulletin No. 010/91 Category Applicable Model/s Subject Issued 10/3/91 1988 - 9 1 IDLE VIBRATION IN DRIVE...
Page 316 Date Revised: Number: 010/91 Date Issued: 10/3/91 5. If necessary, move the A/C pipe away from the radiator. Figure 1. 6. If hood rattles, adjust the hood lock. 7. Install new No. 1 and No. 2 engine mounts. See Section “ 1” or “B” o f the Workshop Manual.
Page 317 Date Revised: Number: 010/91 Date Issued: 10/3/9h WARRANTY INFORMATION Warranty Type Code: Customer Comment Code: Damage Code: Part No. o f Main Cause: No. 1 Engine Mounts M002 39 040B (Non-Turbo) GJ28 39 040E (Turbo) No. 2 Engine Mounts GJ23 39 050C (All) Lower Radiator Mount F202 15 202B (All) Operation No.
Page 318 Service Bulletin Mazda Motor of America, Inc. 7755 Irvine Center Drive Irvine, Caiifomia 92718 Telephone (714) 727-1990 Bulletin No. 010/91 Category Applicable Model/s Subject Issued 10/3/91 1988 - 9 1 IDLE VIBRATION IN DRIVE Revised...
Page 319 Date Revised: Number: 010/91 Date Issued: 10/3/91 5. If necessary, move the A/C pipe away from the radiator. Figure 1. 6. If hood rattles, adjust the hood lock. 7. Install new No. 1 and No. 2 engine mounts. See Section “ 1” or “B” o f the Workshop Manual.
Page 320 Date Revised: Number: 010/91 Date Issued: 10/3/9h WARRANTY INFORMATION Warranty Type Code: Customer Comment Code: Damage Code: Part No. o f Main Cause: No. 1 Engine Mounts M002 39 040B (Non-Turbo) GJ28 39 040E (Turbo) No. 2 Engine Mounts GJ23 39 050C (All) Lower Radiator Mount F202 15 202B (All) Operation No.
Page 321 Interchangeability Code “ A” = The new part can be used in place of the old part, but the old part can not be used in place of the new part. CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools / take equipment and training lo conectfy and safely maintain Mazda vehicles- These instructions should not be performed by "do-it-yoursetfers.' Customers...
Page 322 Revised: Number; 001/97 Date Issued: 07/01/97 WARRANTY INFORMATION (Applies To Verified Customer Complaints On Vehicles Covered Under Normal Warranty. Refer To The SRT Microfiche For Warranty Term information.) Warranty Type: Symptom Code: Damage Code: Causal Part No.: B367-18-501 Quantity: Operation Number/Labor Hrs: T0504XRX / .04 Hrs. (Millenia) T0504XRX / .03 Hrs.
Page 323 Since Aug. 1996 CONSUMER NOTICE: The information and Instructions in this bulletin are intended for use by stilted technicians. Mazda technicians utilize the proper tools / equipment and tate training to correctly and safely mainasn Mazda vehicles. These Instructions Should not fc v e performed by “do-it-yourselfers.' Customers...
Page 324 Revised: Number. 003/96 Date Issued: 09/23/96 WARRANTY INFORMATION (Applies To Verified Customer Complaints On Vehicles Covered Under Normal Warranty. Refer To The SRT Microfiche For Warranty Term Information.) Warranty Type: Symptom Code: Damage Code: Part Number Main Cause: B367-18-501 Quantity: Operation Number/Labor Hrs: T0504XRX / .04 Hrs.
Page 325 DESCRIPTION <3Z- Mazda Motor Corporation (MC) does not recommend the use o f reconditioned anti-freeze. Please use ethylene glycol base coolant for Mazda’s aluminum engines. Although it is available on the market, reconditioned anti-freeze might contain silicon particles, which could abrade the water pump seal, or it might contain other chemicals, alcohol or methanol, that may erode metal parts.
Page 326 ■ May not provide adequate corrosion protection (to meet Mazda specifications) ■ Freezing temperature is 10 - 20% higher than ethylene glycol based coolants Mazda recommends ethylene giycol and water mixture. Customer's with questions regarding coolant should be directed to the information in Section 7 of their owner’s manual.
Page 327 CONSUMER NOTICE: The information and instructions rn this bulletin are intended tor use by skilled technicians. Mazda technicians utfee the proper tools/ equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “dcwt-yoursetfers." Customers should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern.
Page 328 Service Bulletin Mazda Motor of America, Inc. 7755 Irvine Center Drive Irvine, California 92718 Telephone (714) 727-1990 Category Applicable Model/s Bulletin No. 001/90 Subject 1988-89 INTERCHANGEABILITY OF E.G. Issued 2/14/90 626/M X -6 CONTROL UNIT (E .C .U .)
Page 329 Num ber: 0 0 1 / 9 0 Date Issued: 2 / 1 4 / 9 0 D ate Revised: NOTE: To identify new and old parts, the color o f the E .C .U . connectors and the engine harness has been changed from yellow to white at the time of the design change.
Page 330 To improve fuel injection performance, Mazda has tested and approved a highly effective FUEL INJECTOR CLEANER. The kit and cleaner is recommended for all Mazda fuel injection systems. Mazda’s Fuel Injector Cleaner uses a chemical “reducing agent” rather than the common solvent used in the typical aftermarket cleaners.
Page 331 To improve fuel injection performance, Mazda has tested and approved a highly effective FUEL INJECTOR CLEANER. The kit and cleaner is recommended for all Mazda fuel injection systems. Mazda’s Fuel Injector Cleaner uses a chemical “reducing agent” rather than the common solvent used in the typical aftermarket cleaners.
Page 332 - For 5-speed models: Neutral range should be selected. - For automatic transmission models: “N” or “P” range should be selected. NOTE: All Mazda vehicles meet the U.S. EPA and California emission standards when tested under the EPA certification test procedure.
Page 333 Service Bulletin Mazda Motor of America, Inc. 7755 Irvine Center Drive Irvine, California 92718 Telephone (714) 72 7-1990 Bulletin No. Applicable Model/s Subject 008/90 Category Issued REMANUFACTURED EGI CONTROL UNIT 12/19/90 (listed below) PROGRAM Revised DESCRIPTION In an effort to reduce the cost o f repair, remanufactured EGI control units were available effective July 5 ,1 9 8 9 .
Page 334 Number: 008/90 Date Issued: 12/19/90 Date Revised: 626/M X -6 M odels Remanufactured Replaces New Application EGI Control Unit EGI Control Unit ’8 6 - ’87 626 Non-Turbo FEH1 18 881R FEH1 18 880C FEH4 18 880 FEH5 18 881R ’8 6 - ’87 626 Turbo FEH5 18 880C F220 18 881R...
Page 335 Number: 008/90 Date Issued: 12/19/90 Date Revised: 626/M X -6 M odels (cont’d) Remanufactured Replaces N ew Application EGI Control Unit EGI Control Unit F201 18 881R ’88 626/M X-6 Non-Turbo FED, A/T & M/T F201 18 880L F201 18 8 8 1R ’89 626/M X-6 Non-Turbo FED, M/T F201 18 880L Up to: JM 1GD* ♦...
Page 336 Remanufactured EGI units are warranted for the first 12 months (regardless o f mileage) from the date o f installation by a Mazda dealer or sold over the counter. Remanufactured EGI control units installed as a part o f a warranty repair will be warranted for the remainder o f the vehicle’s emission warranty.
Page 337 / equipment and take training to correctly and safely mamtam Mazda vehicles. These instructions should not be performed by ‘do-it-yourselfers.’ Customers should not assume this bulletin applies to their vehicle or that their vehicle will develop the desorbed concern. To determine if the information applies, customers should contact their nearest authorized Mazda dealership.
Page 338 Revised: N um ber 013/96 Date Issued: 05/24/96 WARM ENGINE - WARM / HOT AMBIENT TEMPERATURES * Recommend that the customer try to identify a source of fresh, good quality gasoline. A station which receiver frequent shipments of fuel will likely be a source of fresh, good quality gasoline. •...
Page 339 CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. .Mazda technicians utilize the proper tools / equipment and take training to correctly and safeiy maintain Mazda vehicles-These instructions should not be performed by "do-rt-yourseffers.’' Customers should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern.
Page 340 Revised: N um ber 014/96 Date Issued: 06/06/96 CaRFG AFFECT ON FUEL ECONOMY A very small reduction in MPG (less than one-half MPG) is possible if the customer uses gasoline without oxygen ates. This is attributed to the lower energy content of oxygenates, which have been included in all Southern Cali fornia gasoline since January 1995 and some gasoline since the 1970s.
Page 341 CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools / equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.’ Customers should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern.
Page 342 0 6 0 3 3 1 CONSUMER NOTICE; The Information and instructions In this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools / equipment and take training to onractty and sately maintain Mazda vehicles. These instructions should not be perioimed by *do-it-youraeHerB.” Constvners should notassunatHs bulletin applies to their vehicle or that their vehicle will develop the descrfoed concern.
Page 343 Sample of battery Maintenance Records and Battery Check Sheet CONSUMER NOTICE: The information and instructions in this bulletin are intended (or use by skilled technicians. Mazda technicians utilize the proper tools / equipment and take training to correctly and safety maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.' Customers should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern.
Page 344 After wholesale delivery, it is the dealer’s responsibil ity to maintain the condition of the batteries in new Mazda vehicles while in inventory and at the time of new car delivery.
Page 345 Date Issued: 04/08/9/ Revised: 06/19/97 Number.001/97 4. SERVICING EQUIPMENT REQUIREMENTS In order to accurately and quickly check the condition of maintenance-free batteries, you should have available a digital w it meter capable of reading to 0.01V and a battery tester utilizing load cells (VAT 40, or equivalent) or electronic testing (Midtronics Power Sensor Pius).
Page 346 Date lssued:04/08/97 N um ber 001/97 Revised: 6. BATTERY DIAGNOSTIC PROCEDURES (USING LOAD TESTER VAT-40 or equivalent on Lead-Acid Bat teries) 1. Start engine and confirm that the alternator warning light is not illuminated. NOTE: If the warning light is illuminated, tie self-diagnostic function is operating. Check the alternator and related harness.
Page 347 Revised: 06/19/97 ! Number 001/97 Date Issued: 04/08/97 6.1 BATTERY DIAGNOTIC PROCEDURES (Using Load Tester VAT-40 or Equivalent on Maintenance-Free Batteries) Diagnostic procedures used for testing lead-acid batteries provide false reading leading to unnecessary if used on maintenance-free batteries. The information below is provided for diagnosing mainte replacement nance-free batteries.
Page 348 Number:001/97 Date Issued:04/08/97 Reused: 06/19/97 6-2 BATTERY DIAGNOSTIC PROCEDURES (Using Midtronics PowerSensor Plus Tester on Lead-Acid Bat teries) 1. Connect the Midtronics PowerSensor Plus tester, if low voltage is found (less than 10.2V) charge the battery for two (2) hours and recheck. If the voltage is greater than 10.2V, test battery condition without precharging. If low voltage is still found after a two (2) hour charge, replace the battery according to the information in the warranty section of this bulletin.
Page 349 Revised: 06/19/97 Number.001/97 Date Issued :04/Q8/97 6.3 BATTERY DIAGNOSTIC PROCEDURES (Using Midtronics PowerSensor Plus Tester on Maintenance- Free Batteries) Diagnostic procedures used testing lead-acid batteries provide false readings leading unnecessary replacement if used on maintance-free batteries. The information below is provided diagnosing mainte- nance-free batteries.
Page 350 Numben001/97 Date Issued :04/08/97 Revised: 06/19/97 7. PARTS INFORMATION (Mazda Finish Line Batteries) Make Year Model O.E.M. CCA Part Number 1981-85 0000-80-026R-WB 1981-85 Optinal For Above 0000-80-0035-WB 1977-80 0000-80-0024-WB 1992-95 All 1.6L 0000-80-026R-WB 1992-95 Optional For Above 0000-80-0035-WB MX-3 1992-95 All V6 1.8L...
Page 351 Revised: 06/19/97 Number:001/97 Date Issued:04/08/97 8. WARRANTABLE CHARGING AND/OR REPLACEMENT The information below outlines when battery charging or replacement is covered under vehicle warranty. • Charging/Testing Charging or testing is not covered under vehicle warranty and is considered part of normal dealer processing responsibility.
Page 352 M a zd a Motor of Am erica, Inc. Service Bulletin a z o a 7 7 5 5 Irvine C enter Drive In/ine, California l^ if e le p h o n e (714) 7 2 7 -1 9 9 0 Bulletin No.
Page 353 Number: 002/93 Revised: Date issued: 9/16/93 SECTION 1 Page Outline ECU Diagnostics ECU Check Sheet Page SECTION 2 Outline Air Flow Meter Diagnostics Air Flow Meter Check Sheet Page SECTION 3 Outline Fuel Pump Diagnostics Fuel Pump Check Sheet S ection 4 Page Outline Charging System Diagnostics...
Page 354 Number: 002/93 Date Issued: 9/16/93 Revised: ECU - OUTLINE OF DIAGNOSTICS, PARTS ORDERING AND WARRANTY APPLICATION DEALER Return Repl. Part With Check Sheet To Your Servicing PDC Warranty Claim Application P age 3 of 18...
Page 355 N um ber: 0 0 2 /9 3 D a te Issued: 9 /1 6 /9 3 Revised: Section 1- ECU DIAGNOSTICS PROCEDURE 1. Disconnect ECU connectors 2. Connect SST (Engine Signal Monitor and Adapter) as shown. Place application panel sheet on the Application Panel Sheet Engine Signal Monitor.
Page 356 Num ber: 0 0 2 /9 3 Date Issued: 9 /1 6 /9 3 Revised: ECU CHECK SHEET Dealer Name_____________________________ Technician Number:_ _ Vehicle Year:_______ Model:________ M/T:___ A/T:___ VIN:_________ Repair Date: Mileage:____________ Repair Order Number:. 1. Customer Complaint:_______________________________________ 2. Was the customer’s complaint verified:_____Yes_____No 3.
Page 357 N um ber: 0 0 2 /9 3 Revised: D ate Issued: 9 /1 6 /9 3 AIR FLOW METER - OUTLINE OF DIAGNOSTICS, PARTS ORDERING AND WARRANTY APPLICATION DEALER Page 6 of 18...
Page 358 Num ber: 0 0 2 /9 3 D ate Issued: 9 /1 6 /9 3 Revised: Section 2 - AIR FLOW METER DIAGNOSTIC PROCEDURES NOTE: Procedures listed below do not apply to the following model/year vehicles: 1988-92 B2600 1989 - 90 RX-7 (up to and including vehicles with a VIN JM1FC3“...
Page 359 Number: 002/93 Revised: Date Issued: 9/16/93 Section 2 - AIR FLOW METER DIAGNOSTIC PROCEDURES CONT’D. NOTE: The following models have airflow meters with measuring plates and should be diagnosed using the methoc listed below: 1986 - 89 323 1990 - 93 323/Protege 1990 - 92 626/M X-6 1990 - 91 929 1988-93 MPV...
Page 360 According to DSM or Hot Line Authorization:__________(Authorization Number) Other:__________________________________________________________ Technician’s Signature:_______________________________________ Date: NOTE: Attach the check sheet to the repair order. If requested to return the failed air flow meter to Mazda, attach a copy of the check sheet and repair order. Page 9 of 18...
Page 361 Number: 002/93 Revised: Date Issued: 9/16/93 FUEL PUMP - OUTLINE OF DIAGNOSTICS, PARTS ORDERING AND WARRANTY APPLICATION DEALER P ag e 10 of 18...
Page 362 Number: 002/93 Date Issued: 9/16/93 Revised: Section 3 - FUEL PUMP DIAGNOSTIC PROCEDURES 1. Disconnect negsave terminal and check battery volt age. Voltage should be 12.4V or more. Reconnect terminal. 2. Start engine and run at idle. 3. Disconnect circuit opening relay. Engine will continue to run until all fuel in the supply line is used.
Page 363 Number: 002/93 Revised: Date Issued: 9/16/93 FUEL PUMP DIAGNOSTIC PROCEDURES C O NTD. 9. If the value of fuel pressure (Max.) is below standard, measure the voltage at the fuel pump connector (vehicle side) using the procedures below. a) Reinstall the jumper wire and turn the Ignition on. Refer to steps 6 and 7 of the previous page.
Page 364 According to DSM or Hot Line Authorization:_________ (Authorization Number) Other:__________________________________________________________ Technician’s Signature:_______________________________________ Date:_ NOTE: Attach the check sheet to the repair order. If requested to return the failed fuel pump to Mazda, attach a copy of the check sheet and repair order. Page 13 of 18...
Page 365 Num ber: 0 0 2 /9 3 D a te Issued: 9 /1 6 /9 3 Revised: CHARGING SYSTEM - OUTLINE OF DIAGNOSTICS, PARTS ORDERING AND WARRANTY APPLICATION DEALER Complete Check Sheet, Review Authorize Order Part Replacement (Auth. No. Required)N Page 1 4 of 18...
Page 366 Number: 002/93 Date Issued: 9/16/93 Revised: Section 4 - CHARGING SYSTEM DIAGNOSTIC PROCEDURES 1. Start the engine and confirm that the alternator warn ing light is not illuminating. NOTE: If the wamr.g light is illuminated, the self diagnosis cceration is functioning. Check the alternator and related harness’...
Page 367 N um ber: 0 0 2 /9 3 D a te Issued: 9 /1 6 /9 3 Revised: Section 4 - CHARGING SYSTEM DIAGNOSTICS CONTD. 4. Start the vehicle and raise the RPM to 2500. 5. Connect a battery load tester (VAT 40/70 or equivalent) 6.
Page 368 N um ber: 0 0 2 /9 3 D a te Issued: 9 /1 6 /9 3 Revised: ALTERNATOR AND BATTERY CHECK SHEET Dealer Name______________________________Technician Number:_ _ Vehicle Year:________ ________ M/T:___ A/T:___ VIN:_________ Model: Repair Date: Mileage:_____________Repair Order Number:. 1. Customer Complaint:_______________________________________ 2.
Page 369 Number: 002/93 D a te Issued: 9 /1 6 /9 3 Revised: Section 5 - WARRANTY INFORMATION Symptom Code: Complete Applicable Code Damage Code: Complete Applicable Code Part Number Main Cause: Complete Applicable Part Number Operation Number and Labor Hours: Operation Number Labor Hours Engine Control Unit(ECU), Diagnosis...
Page 370 Mazda Motor of America, Inc. m a z o a Service Bulletin 7755 Irvine Center Drive In/ine, California l^ifelephone (714) 727-1990 Bulletin No. 002/93 Category Subject Applicable Model's DIAGNOSTIC PROCEDURES Issued 9/16/93 All Models (See Itemized List Below) Revised APPLICABLE MODELS All 1988 model vehicles through 1994 model vehicles except Navajo and 1994 B-Series.
Page 371 Number: 002/93 Revised: Date issued: 9/16/93 SECTION 1 Page Outline ECU Diagnostics ECU Check Sheet Page SECTION 2 Outline Air Flow Meter Diagnostics Air Flow Meter Check Sheet SECTION 3 Page Outline Fuel Pump Diagnostics Fuel Pump Check Sheet Section 4 Page Outline Charging System Diagnostics...
Page 372 Number: 002/93 Date Issued: 9/16/93 Revised: ECU - OUTLINE OF DIAGNOSTICS, PARTS ORDERING AND WARRANTY APPLICATION DEALER Return Repl. Part With Check Sheet To Your Servicing PDC Warranty Claim Application Page 3 of 18...
Page 373 Number: 002/93 Revised: Date Issued: 9/16/93 Section 1- ECU DIAGNOSTICS PROCEDURE 1. Disconnect ECU connectors 2. Connect SST (Engine Signal Monitor and Adapter) as shown. Place application panel sheet on the Application Panel Sheet Engine Signal Monitor. Engine Signal Monitor 3.
Page 374 Number: 002/93 Date Issued: 9/16/93 Revised: ECU CHECK SHEET Dealer Name_____________________________ Technician Number:_ _ Vehicle Year:_______ Model:________ M/T:___ A/T:___ VIN:_________ Repair Date: Mileage:____________ Repair Order Number:. 1. Customer Complaint:_______________________________________ 2. Was the customer’s complaint verified:_____Yes_____No 3. Reason for replacement: Terminal Voltage Out Of Specification:____Yes____No Terminal Number Voltage Reading Factory Specifications...
Page 375 Revised: N um ber: 0 0 2 /9 3 Date Issued: 9/16/93 AIR FLOW METER - OUTLINE OF DIAGNOSTICS, PARTS ORDERING AND W ARRANTY APPLICATION DEALER Page 6 of 18...
Page 376 Number: 002/93 Date Issued: 9/16/93 Revised: Section 2 - AIR FLOW METER DIAGNOSTIC PROCEDURES NOTE: Procedures listed below do not apply to the following model/year vehicles: 1988-92 B2600 1989 - 90 RX-7 (up to and including vehicles with a VIN of JM1FC3“...
Page 377 Number: 002/93 Revised: Date Issued: 9/16/93 Section 2 - AIR FLOW METER DIAGNOSTIC PROCEDURES CONT’D. NOTE: The following models have airflow meters with measuring plates and should be diagnosed using the methoc listed below: 1986 - 89 323 1990 - 93 323/Protege 1990 - 92 626/M X-6 1990 - 91 929 1988-93 MPV...
Page 378 According to DSM or Hot Line Authorization:__________(Authorization Number) Other:__________________________________________________________ Technician’s Signature:_______________________________________ Date: NOTE: Attach the check sheet to the repair order. If requested to return the failed air flow meter to Mazda, attach a copy of the check sheet and repair order. Page 9 of 18...
Page 379 Number: 002/93 Revised: Date Issued: 9/16/93 FUEL PUMP - OUTLINE OF DIAGNOSTICS, PARTS ORDERING AND WARRANTY APPLICATION DEALER Page 10 of 18...
Page 380 Number: 002/93 Date Issued: 9/16/93 Revised: Section 3 - FUEL PUMP DIAGNOSTIC PROCEDURES 1. Disconnect negative terminal and check battery volt age. Voftage should be 12.4V or more. Reconnect terminal. 2. Start engine and run at idle. 3. Disconnect circuit opening relay. Engine will continue to run until all fuel in the supply line is used.
Page 381 Number: 002/93 Revised: Date Issued: 9/16/93 FUEL PUMP DIAGNOSTIC PROCEDURES C O NTD. 9. If the value of fuel pressure (Max.) is below standard, measure the voltage at the fuel pump connector (vehicle side) using the procedures below. a) Reinstall the jumper wire and turn the Ignition on. Refer to steps 6 and 7 of the previous page.
Page 382 According to DSM or Hot Line Authorization:_________ (Authorization Number) Other:__________________________________________________________ Technician’s Signature:_______________________________________ Date:_ NOTE: Attach the check sheet to the repair order. If requested to return the failed fuel pump to Mazda, attach a copy of the check sheet and repair order. Page 13 of 18...
Page 383 Num ber: 0 0 2 /9 3 D a te Issued: 9 /1 6 /9 3 Revised: CHARGING SYSTEM - OUTLINE OF DIAGNOSTICS, PARTS ORDERING AND WARRANTY APPLICATION DEALER Complete Check Sheet, Review Authorize Order Part Replacement (Auth. No. Required)N Page 1 4 of 18...
Page 384 Number: 002/93 Date Issued: 9/16/93 Revised: Section 4 - CHARGING SYSTEM DIAGNOSTIC PROCEDURES 1. Start the engine and confirm that the alternator warn ing light is not illuminating. NOTE: If the wamr.g light is illuminated, the self diagnosis cceration is functioning. Check the alternator and related harness’...
Page 385 N um ber: 0 0 2 /9 3 D a te Issued: 9 /1 6 /9 3 Revised: Section 4 - CHARGING SYSTEM DIAGNOSTICS CONTD. 4. Start the vehicle and raise the RPM to 2500. 5. Connect a battery load tester (VAT 40/70 or equivalent) 6.
Page 386 N um ber: 0 0 2 /9 3 D a te Issued: 9 /1 6 /9 3 Revised: ALTERNATOR AND BATTERY CHECK SHEET Dealer Name______________________________Technician Number:_ _ Vehicle Year:________Model:________ M/T:___ A/T:___ VIN:_________ Repair Date: Mileage:_____________Repair Order Number:. 1. Customer Complaint:_______________________________________ 2.
Page 387 Num ber: 0 0 2 /9 3 D a te Issued: 9 /1 6 /9 3 Revised: Section 5 - WARRANTY INFORMATION Symptom Code: Complete Applicable Code Damage Code: Complete Applicable Code Part Number Main Cause: Complete Applicable Part Number Operation Number and Labor Hours: Operation Number Labor Hours...
Page 388 Mazda Motor of America, Inc. Service Bulletin 7755 Irvine Center Drive In/ine, California l^ifelephone (714) 727-1990 Bulletin No. 002/93 Category Subject Applicable Model's DIAGNOSTIC PROCEDURES Issued 9/16/93 All Models (See Itemized List Below) Revised APPLICABLE MODELS All 1988 model vehicles through 1994 model vehicles except Navajo and 1994 B-Series.
Page 389 Number: 002/93 Revised: Date issued: 9/16/93 SECTION 1 Page Outline ECU Diagnostics ECU Check Sheet Page SECTION 2 Outline Air Flow Meter Diagnostics Air Flow Meter Check Sheet SECTION 3 Page Outline Fuel Pump Diagnostics Fuel Pump Check Sheet Section 4 Page Outline Charging System Diagnostics...
Page 390 Number: 002/93 Date Issued: 9/16/93 Revised: ECU - OUTLINE OF DIAGNOSTICS, PARTS ORDERING AND WARRANTY APPLICATION DEALER Return Repl. Part With Check Sheet To Your Servicing PDC Warranty Claim Application P age 3 of 18...
Page 391 N um ber: 0 0 2 /9 3 D a te Issued: 9 /1 6 /9 3 Revised: Section 1- ECU DIAGNOSTICS PROCEDURE 1. Disconnect ECU connectors 2. Connect SST (Engine Signal Monitor and Adapter) as shown. Place application panel sheet on the Application Panel Sheet Engine Signal Monitor.
Page 392 Num ber: 0 0 2 /9 3 Date Issued: 9 /1 6 /9 3 Revised: ECU CHECK SHEET Dealer Name_____________________________ Technician Number:_ _ Vehicle Year:_______ Model:________ M/T:___ A/T:___ VIN:_________ Repair Date: Mileage:____________ Repair Order Number:. 1. Customer Complaint:_______________________________________ 2. Was the customer’s complaint verified:_____Yes_____No 3.
Page 393 N um ber: 0 0 2 /9 3 Revised: D ate Issued: 9 /1 6 /9 3 AIR FLOW METER - OUTLINE OF DIAGNOSTICS, PARTS ORDERING AND W ARRANTY APPLICATION DEALER Page 6 of 18...
Page 394 Num ber: 0 0 2 /9 3 D ate Issued: 9 /1 6 /9 3 Revised: Section 2 - AIR FLOW METER DIAGNOSTIC PROCEDURES NOTE: Procedures listed below do not apply to the following model/year vehicles: 1988-92 B2600 1989 - 90 RX-7 (up to and including vehicles with a VIN JM1FC3“...
Page 395 Number: 002/93 Revised: Date Issued: 9/16/93 Section 2 - AIR FLOW METER DIAGNOSTIC PROCEDURES CONT’D. NOTE: The following models have airflow meters with measuring plates and should be diagnosed using the methoc listed below: 1986 - 89 323 1990 - 93 323/Protege 1990 - 92 626/M X-6 1990 - 91 929 1988-93 MPV...
Page 396 According to DSM or Hot Line Authorization:__________(Authorization Number) Other:__________________________________________________________ Technician’s Signature:_______________________________________ Date: NOTE: Attach the check sheet to the repair order. If requested to return the failed air flow meter to Mazda, attach a copy of the check sheet and repair order. Page 9 of 18...
Page 397 Number: 002/93 Revised: Date Issued: 9/16/93 FUEL PUMP - OUTLINE OF DIAGNOSTICS, PARTS ORDERING AND WARRANTY APPLICATION DEALER P ag e 10 of 18...
Page 398 Number: 002/93 Date Issued: 9/16/93 Revised: S e c tio n 3 - F U E L P U M P D IA G N O S T IC P R O C E D U R E S 1. D isconnect negative term inal and check battery volt age.
Page 399 Number: 002/93 Revised: Date Issued: 9/16/93 FUEL PUMP DIAGNOSTIC PROCEDURES C O NTD. 9. If the value of fuel pressure (Max.) is below standard, measure the voltage at the fuel pump connector (vehicle side) using the procedures below. a) Reinstall the jumper wire and turn the Ignition on. Refer to steps 6 and 7 of the previous page.
Page 400 Number: 002/93 Revised: Date Issued: 9/16/93 F U E L P U M P C H E C K S H E E T D e ale r N a m e ________________ __________ Technician N um ber:, Model: Vehicle Year:___ M /T: A/T: V IN :_________...
Page 401 Number: 002/93 Revised: Date Issued: 9/16/93 CHARGING SYSTEM - OUTLINE OF DIAGNOSTICS, PARTS ORDERING AND WARRANTY APPLICATION DEALER Complete Check Sheet, Review Authorize Order Part Replacement (Auth. No. Required)N Page 14 of 18...
Page 402 Number: 002/93 Date Issued: 9/16/93 Revised: Section 4 - CHARGING SYSTEM DIAGNOSTIC PROCEDURES 1. Start the engine and confirm that the alternator warn ing light is not illuminating. NOTE: If the wamr.g light is illuminated, the self diagnosis cceration is functioning. Check the alternator and related harness’...
Page 403 N um ber: 0 0 2 /9 3 D a te Issued: 9 /1 6 /9 3 Revised: Section 4 - CHARGING SYSTEM DIAGNOSTICS CONTD. 4. Start the vehicle and raise the RPM to 2500. 5. Connect a battery load tester (VAT 40/70 or equivalent) 6.
Page 404 N um ber: 0 0 2 /9 3 D a te Issued: 9 /1 6 /9 3 Revised: A L T E R N A T O R A N D B A TTE R Y C H E C K S H E E T D e a le r N a m e _____________________________________ Technician Num ber:___ Vehicle Year:__________Model:__________ M /T:____ A /T:____ V IN :____________ R epair D ate:...
Page 405 Num ber: 0 0 2 /9 3 D a te Issued: 9 /1 6 /9 3 Revised: Section 5 - WARRANTY INFORMATION Symptom Code: Complete Applicable Code Damage Code: Complete Applicable Code Part Number Main Cause: Complete Applicable Part Number Operation Number and Labor Hours: Operation Number Labor Hours...
Page 406 m a z o a M a zd a Motor of Am erica, Inc. Service Bulletin 7 7 5 5 Irvine C enter Drive In/ine, California l^ if e le p h o n e (714) 7 2 7 -1 9 9 0 Bulletin No.
Page 407 Number: 002/93 Revised: Date issued: 9/16/93 SECTION 1 Page Outline ECU Diagnostics ECU Check Sheet Page SECTION 2 Outline Air Flow Meter Diagnostics Air Flow Meter Check Sheet SECTION 3 Page Outline Fuel Pump Diagnostics Fuel Pump Check Sheet Section 4 Page Outline Charging System Diagnostics...
Page 408 Number: 002/93 Date Issued: 9/16/93 Revised: ECU - OUTLINE OF DIAGNOSTICS, PARTS ORDERING AND WARRANTY APPLICATION DEALER Return Repl. Part With Check Sheet To Your Servicing PDC Warranty Claim Application P age 3 of 18...
Page 409 N um ber: 0 0 2 /9 3 D a te Issued: 9 /1 6 /9 3 Revised: Section 1- ECU DIAGNOSTICS PROCEDURE 1. Disconnect ECU connectors 2. Connect SST (Engine Signal Monitor and Adapter) as shown. Place application panel sheet on the Application Panel Sheet Engine Signal Monitor.
Page 410 Num ber: 0 0 2 /9 3 Date Issued: 9 /1 6 /9 3 Revised: ECU CHECK SHEET Dealer Name_____________________________ Technician Number:_ _ Vehicle Year:_______ Model:________ M/T:___ A/T:___ VIN:_________ Repair Date: Mileage:____________ Repair Order Number:. 1. Customer Complaint:_______________________________________ 2. Was the customer’s complaint verified:_____Yes_____No 3.
Page 411 N um ber: 0 0 2 /9 3 Revised: D ate Issued: 9 /1 6 /9 3 AIR FLOW METER - OUTLINE OF DIAGNOSTICS, PARTS ORDERING AND WARRANTY APPLICATION DEALER Page 6 of 18...
Page 412 Num ber: 0 0 2 /9 3 D ate Issued: 9 /1 6 /9 3 Revised: Section 2 - AIR FLOW METER DIAGNOSTIC PROCEDURES NOTE: Procedures listed below do not apply to the following model/year vehicles: 1988-92 B2600 1989 - 90 RX-7 (up to and including vehicles with a VIN of JM1FC3“...
Page 413 Number: 002/93 Revised: Date Issued: 9/16/93 Section 2 - AIR FLOW METER DIAGNOSTIC PROCEDURES CONT’D. NOTE: The following models have airflow meters with measuring plates and should be diagnosed using the methoc listed below: 1986 - 89 323 1990 - 93 323/Protege 1990 - 92 626/M X-6 1990 - 91 929 1988-93 MPV...
Page 414 According to DSM or Hot Line Authorization:__________(Authorization Number) Other:__________________________________________________________ Technician’s Signature:_______________________________________ Date: NOTE: Attach the check sheet to the repair order. If requested to return the failed air flow meter to Mazda, attach a copy of the check sheet and repair order. Page 9 of 18...
Page 415 Number: 002/93 Revised: Date Issued: 9/16/93 FUEL PUMP - OUTLINE OF DIAGNOSTICS, PARTS ORDERING AND WARRANTY APPLICATION DEALER P ag e 10 of 18...
Page 416 Number: 002/93 Date Issued: 9/16/93 Revised: Section 3 - FUEL PUMP DIAGNOSTIC PROCEDURES 1. Disconnect negative terminal and check battery volt age. Voltage should be 12.4V or more. Reconnect terminal. 2. Start engine and run at idle. 3. Disconnect circuit opening relay. Engine will continue to run until all fuel in the supply line is used.
Page 417 Number: 002/93 Revised: Date Issued: 9/16/93 FUEL PUMP DIAGNOSTIC PROCEDURES CONTD. 9. If the value of fuel pressure (Max.) is below standard, measure the voltage at the fuel pump connector (vehicle side) using the procedures below. a) Reinstall the jumper wire and turn the Ignition on. Refer to steps 6 and 7 of the previous page.
Page 418 According to DSM or Hot Line Authorization:_________ (Authorization Number) Other:__________________________________________________________ Technician’s Signature:_______________________________________ Date:_ Attach the check sheet to the repair order. If requested to return the failed fuel pump to Mazda, NOTE: attach a copy of the check sheet and repair order.
Page 419 Num ber: 0 0 2 /9 3 D a te Issued: 9 /1 6 /9 3 Revised: CHARGING SYSTEM - OUTLINE OF DIAGNOSTICS, PARTS ORDERING AND WARRANTY APPLICATION DEALER Complete Check Sheet, Review Authorize Order Part Replacement (Auth. No. Required)N Page 1 4 of 18...
Page 420 Number: 002/93 Date Issued: 9/16/93 Revised: Section 4 - CHARGING SYSTEM DIAGNOSTIC PROCEDURES 1. Start the engine and confirm that the alternator warn ing light is not illuminating. NOTE: If the wamr.g light is illuminated, the self diagnosis cceration is functioning. Check the alternator and related harness’...
Page 421 N um ber: 0 0 2 /9 3 D a te Issued: 9 /1 6 /9 3 Revised: Section 4 - CHARGING SYSTEM DIAGNOSTICS CONTD. 4. Start the vehicle and raise the RPM to 2500. 5. Connect a battery load tester (VAT 40/70 or equivalent) 6.
Page 422 N um ber: 0 0 2 /9 3 D a te Issued: 9 /1 6 /9 3 Revised: ALTERNATOR AND BATTERY CHECK SHEET Dealer Name______________________________Technician Number:_ _ Vehicle Year:________ ________ M/T:___ A/T:___ VIN:_________ Model: Repair Date: Mileage:_____________Repair Order Number:. 1. Customer Complaint:_______________________________________ 2.
Page 423 Number: 002/93 D a te Issued: 9 /1 6 /9 3 Revised: Section 5 - WARRANTY INFORMATION Symptom Code: Complete Applicable Code Damage Code: Complete Applicable Code Part Number Main Cause: Complete Applicable Part Number Operation Number and Labor Hours: Operation Number Labor Hours Engine Control Unit(ECU), Diagnosis...
Page 424 7 7 5 5 Irvine Center Drive Irvine, California 92718 Telephone (714) 7 2 7 -1 9 9 0 Bulletin No. 002/95 Category Applicable Model/s Subj6Ct MAINTENANCE FREE BATTERY Issued 4/5/95 All Models DIAGNOSTIC AND CHARGING PROCEDURE Revised DESCRIPTION The following information describes the correct inspection and servicing procedures for original equipment Mazda_ batteries.
Page 425 Revised: D a te Issued: 4 /5 /9 5 N um ber: 0 0 2 /9 5 2. CHARGING INFORMATION The chart below gives specific charging amps, times and load test amps for 1993 -'95 vehicles. Refer to the applicable workshop manual for other model year vehicles and additional troubleshooting information.
Page 426 Revised: Date Issued: 4/5/95 Number: 002/95 3. BATTERY DIAGNOSTIC PROCEDURES (Load Test Using VAT-40 o r Equivalent) Diagnostic procedures used for testing lead-acid batteries provide false readings leading to unnecessary replace ment if used on maintenance-free batteries. Follow the table below when diagnosing systems with maintenance-free batteries.
Page 427 Revised: D a te Issued: 4 /5 /9 5 N um ber: 0 0 2 /9 5 3. BATTERY DIAGNOSTIC PROCEDURES (Using Midtronics PowerSensor Plus) Diagnostic procedures used for testing lead-acid batteries provide false readings leading to unnecessary replace ment if used on maintenance-free batteries. Follow the table below when diagnosing systems with maintenance- free batteries.
Page 428 Revised: Number: 002/95 D ate Issued: 4/5 /9 5 4. CHARGING SYSTEM DIAGNOSTIC PROCEDURE (Equipment Procedures) 1. Check the following: • Connectors • Grounds • Alternator Condition • Fuses (USING VAT-40 OR EQUIVALENT) 2. Start engine and confirm that alternator warning light is not illuminated. NOTE: If the warning light is illuminated, the self diagnostic function is operating.
Page 429 D a te Issued: 4 /5 /9 5 Revised: N um ber: 0 0 2 /9 5 5. B A T T E R Y C O L D C R A N K IN G A M P E R A G E (C C A ) R A T IN G S N O T E : C C A Rating N um bers (stam ped on battery covers) are required for use with M ID T R O N IC S P o w e rS e n s a r Plus Battery Tester.
Page 430 Revised: D ate Issued: 4 /5 /9 5 N um ber: C 02/95 6. W A R R A N T Y IN F O R M A T IO N Charging S y stem Diagnosis Sym ptom Code: Com plete Actual Code D a m a g e C ode: Com plete Actual Code P a rt N u m b e r M ain C ause:...
Page 431 BATTERY CHECK SHEET NOTE: Attach this Check Sheet to the reverse side o f the Repair Order. 1. W a s the custom er’s com plaint ve rifie d ? _____Y e s _____ No 2 . Battery Inspection Results information Reading Instrum ent U sed For Test...
Page 432 BATTERY MAINTENANCE RECORD VIN: Charging and Load Test if the Inspection battery voltage measures less than 12.4V Signature Date Voltage Removal of A fte r Charging Load Test ROOM Fuse • Battery voltage should be checked according to the Service Bulletin C at. G , N o. 0 0 2 /9 5 . •...
Page 433 Service Bulletin M azd a M otor of Am erica, Inc. 7 7 5 5 Irvine C en ter Drive Irvjne, Caiifom ia 927 1 8 ^^Telephone (71 4 ) 7 2 7 -1 9 9 0 Category Applicabie Model/s Bulletin No.
Page 434 N um ber: 0 0 3 /9 3 D ate Issued: 9 /1 5 /9 3 R evised: D IA G N O S T IC P R O C E D U R E S B ecause of their design, m aintenance free batteries m ust not be diagnosed using procedures d eveloped for lead storage batteries.This will provide a false reading an d result in unnecessary replacem ent.
Page 435 N um ber: 0 0 3 /9 3 D ate Issued: 9 /1 5 /9 3 Revised: C H A R G IN G IN F O R M A T IO N T h e chart below gives specific charging amps, charging tim es and test load am p s for 1 9 9 3 m odel y e a r vehi cles an d th eir original batteries.

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