Mazda 626 1989 Workshop Manual Download Page 689

Page: 689 / 768

N u m b e r :

0 0 2 /9 0

Date Issued:

4/23/90

Date Revised:

REPAIR PROCEDURE

If the “ IF ” voltage was incorrect, the E .C .U . has an internal failure. Replace the E .C .U . and the A /C

relay (AC 2-09).

Since the E .C .U . has not been modified, the

A/C relay (A C 2-09) should be replaced with

a new, resistance-type relay. Used in the 1990

626/M X -6 m odels, the resistance-type relay

prevents the surge current from flowing into

the control unit.

The A/C relay (A C 2-09) is located below the

right headlamp. There are three relays in one

place. Locate the A/C relay by referring to the

wire colors illustrated.

PARTS INFORMATION

PART NUM BER

DESCRIPTION

NEW

OLD

H 310 67 740

FB11 67 740

A /C Relay

Front

A/C Relay

(A C 2 -0 9)

JZL

G/W

G/B

W ARRANTY INFORMATION

Warranty Type Code:

Customer Comment Code:

Damage Code:

Part No. o f Main Cause:

U se E

Quantity:

1 pc.

Operation No:

E .G .I

A/C Relay R&R - U0601X-R-X (0.3 Hr.)

Page 2 o f 3

Summary of Contents for 626 1989

Page 1: ...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 ...

Page 2: ...SPECTION AND SCHEDULED MAINTENANCE SERVICES PRE DELIVERY INSPECTION 0 2 PRE DELIVERY INSPECTION TABLE 0 2 SCHEDULED MAINTENANCE SERVICES 0 3 MAINTENANCE TABLE SCHEDULE 1 0 3 MAINTENANCE TABLE SCHEDULE 2 Q 7 86U00X 001 ...

Page 3: ...ion switch and steering lock Inhibitor switch ATX only All lights including warning and indicator lights Sound warning system Headlight cleaner if equipped Horn wipers and washers front and rear if equipped Radio and antenna if equipped Cigarette lighter and clock Remote control outside rear view mirrors if equipped Power windows if equipped Heater defroster and air conditioner at various mode sel...

Page 4: ... 1 NORMAL DRIVING CONDITION Chart symbols I Inspect and if necessary correct clean or replace R Replace or change T Tighten L Lubricate Remarks After 60 months or 60 000 miles 96 000km continue to follow the described maintenance items and intervals periodically As for marked items in this jjiaintenance chart please pay attention to the following points 1 Replacement of the timing belt is required...

Page 5: ...racks or damage Tension 1 6 Fuel filter R 4A 57 4 B 6 9 Fuel lines 2 I Fittings connections and compo nents for leaks 4A 41 4 B 5 2 Brake lines hoses and connections I I Proper attachment and connections 1 1 7 Engine timing belt 1 Replace every 60 000 miles 96 000 km 1 1 0 Engine oil Non turbo R R R R R R R R Oil pan capacity 3 9 liters 4 1 US qt 3 4 Imp qt 2 4 Turbo Replace every 5 000 miles 8 00...

Page 6: ...vehicle only I I Damage looseness and grease leakage 13 31 4 wheel steering system operation and linkage I I Operation and looseness Fluid leakage or oozing o o o Steering angle of rear wheels 4 wheel steering vehicle only I I Steering wheel angle Inner 5 00 45 Outer 5 00 45 1 3 4 7 Solenoid valve oil filter for 4 wheel steering system R R 1 0 3 8 Exhaust system heat shield I I Clearance to body a...

Page 7: ...se pay attention to the following points q 1 Replacement of the timing belt is required at every 60 000 miles 96 000km Failure to replace the timing belt may result in damage to the engine 00 m 2 This maintenance operation is recommended by Mazda However this maintenance is not necessary for emission warranty coverage or manufacturer recall liability 3 This maintenance operation is required for Ca...

Page 8: ... Fuel filter R 4A 57 4B 69 Fuel lines j 2 I Fitting connections and compo nents for leaks 4A 41 4B 52 Brake lines hoses and connections I I Proper attachment and connections 11 7 Engine timing belt 1 Replace every 60 000 miles 96 000km 1 1 0 Engine oil Non turbo R R R R R R R R R R R R Oil pan capacity 3 9 liters 4 1 US qt 3 4 Imp qt 2 4 Turbo Replace every 3 000 miles 5 000km or 3 months Oil filt...

Page 9: ...hicle only I I Damage looseness and grease leakage 13 31 4 wheel steering system operation and linkage I I Operation and looseness Fluid leakage or oozing 10 10 10 14 Steering angle of rear wheels 4 wheel steering vehicle only I I Steering wheel angle Inner 5 00 45 Outer 5 00 45 13 47 Solenoid valve oil filter for 4 wheel steering system R R 1 0 3 8 Exhaust system heat shield I I Clearance to body...

Page 10: ...NDAMENTAL PROCEDURES G 2 JACK AND SAFETY STAND RIGID RACK POSITIONS G 6 VEHICLE LIFT 2 SUPPORT TYPE POSITIONS G 6 TOWING G 7 CHASSIS NUMBER LOCATION G 8 ENGINE MODEL AND NUMBER LOCATION G 8 UNITS G 8 ABBREVIATIONS G 8 CAUTION G 9 WARNING G 9 96U0GX 001 V ...

Page 11: ...pardized by the use of incorrect methods or tools POSSIBLE LOSS OF WARRANTY The manufacturer s warranty on Mazda vehicles and engines can be voided if improper service or repairs are performed by persons other than an authorized Mazda dealer FUNDAMENTAL PROCEDURES As you read through the procedure you will come across NOTES CAUTIONS and WARNINGS Each one is there for a specific purpose NOTES give ...

Page 12: ...y after first learning which parts and subassem blies must be removed and disassembled for replacement or repair 47U0GX 006 DISASSEMBLY If the disassembly procedure is complex requiring many parts to be disassembled all parts should be disassembled in a way that will not affect their performance or external appearance and be identified so that reassembly can be performed easily and efficiently DIS...

Page 13: ...orques and certain adjustments must be strictly observed in the reassembly of al parts If removed these parts should be replaced with new ones 1 Oil seals 2 Gasket 3 O rings 4 Lock washers 5 Cotter pins split pins 6 Nylon nuts Depending on where they are 1 Sealant should be applied to gaskets 2 Oil should be applied to the moving components of parts 3 Specified oi or grease should be applied at th...

Page 14: ...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 Be careful not to drop them or strike them against other parts RUBBER PARTS AND TUBING Always prevent gasoline or oil from getting on rubber parts or tubing 47U0GX 014 47U0GX 015 G 5 ...

Page 15: ...NT END Jack position At the center of the crossmember Safety stand positions On both sides of the body frame REAR END Jack position At the center of the rear crossmember Safety stand positions On both sides of the body frame VEHICLE LIFT 2 SUPPORT TYPE POSITIONS FRONT END Frame Side sills front REAR END Frame Side sills rear G 6 ...

Page 16: ... other conditions prevent towing the vehicle with the driving wheels off the ground use wheel dollies Caution Do not tow the vehicle backward with driving wheels on the ground This may damage the transaxle internal parts Do not start or run the engine while vehicle is being towed Only for 4WS vehicle When towing the vehicle with the front wheels raised be sure the rear wheels are in the straight a...

Page 17: ...fter top dead center ATX Automatic transaxle ATF Automatic transaxle fluid A B S Anti lock brake system B BD C Before bottom dead center BTDC Before top dead center EX Exhaust EC AT Electronically controlled automatic transaxle ESPS Engine speed sensing power steering ECPS Electronically controlled pow er steering H LA Hydraulic Lash Adjuster IG Ignition IN Intake 1C Integrated circuit INT Intermi...

Page 18: ...LUBRICANTS AND GREASES Avoid all prolonged and repeated contact with mineral oils especially used oils Used oils contaminated during service e g engine sump oils are more irritating and more likely to cause serious effects including skin cancer in the event of gross and prolonged skin contact Wash skin thoroughly after work involving oil Proper hand cleaners may be of value provided they can be re...

Page 19: ...moves replace it Caution Do not disassemble the HLA Cylinder Block Note If the cylinder block is replaced install the dowel pin to the cylinder block 1 Check the cylinder block Repair or replace if necessary 1 Leakage damage 2 Cracks 3 Scoring of wall 2 Measure the distortion of the top surface of the cyl inder block in the six directions as shown in the figure Distortion 0 15 mm 0 006 in max 3 If...

Page 20: ... 4062 1 If the difference between the measurement A and C exceeds the maximum taper rebore the cylinder to oversize Taper 0 019 mm 0 0007 in max 2 If the difference between the measurement X and Y exceeds the maximum out of round re bore the cylinder to oversize Out of round 0 019 mm 0 0007 in max Caution The boring size should be based on the size of an oversize piston and be the same for all cyl...

Page 21: ...4 0 0030 in Maximum 0 15 mm 0 0059 in 4 Ifthe clearance exceeds the maximum replacethe piston or rebore the cylinders to fit oversize pistons Caution If the piston is replaced replace the piston rings also 76G01A 130 Piston and Piston Ring 1 Measure the piston ring to ring land clearance around the entire circumference using a new pis ton ring Clearance Top and Second 0 03 0 07 mm 0 001 0 003 in M...

Page 22: ...points Diameter 21 988 21 998 mm 0 8657 0 8661 in 2 Measure the piston pin diameter Diameter 21 987 21 993 mm 0 8656 0 8659 in 3 Determine the piston pin to piston clearance by subtracting the two figures Clearance 0 005 0 011 mm 0 0002 0 0004 in 4 If the clearance exceeds the specification replace the piston and or piston pin Connecting Rod 1 Measure the connecting rod small end bore Diameter 22 ...

Page 23: ...urnal Diameter 59 937 59 955 mm 2 3597 2 3604 in Out of round 0 05 mm 0 0020 in max Crankpin journal Diameter 50 940 50 955 mm 2 0055 2 0061 in Out of round 0 05 mm 0 0020 in max 5 Ifthe diameter is less than the minimum grind the journals to match undersize bearings Undersize bearing 0 25 mm 0 010 in 0 50 mm 0 020 in 0 75 mm 0 030 in Main journal diameter undersize mm in Bearing size Journal diam...

Page 24: ...6 Caution Do not grind the rolled fillet area Main Bearing and Connecting Rod Bearing Check the main bearings and the connecting rod bearings for peeling scoring or other damage Oil Jet 1 Check that the oil passage is not clogged 2 Check that the check ball is not stuck Timing Belt 1 Replace the timing belt if there is any oil or grease on it 2 Check the timing belt for damage wear peeling cracks ...

Page 25: ...r with cleaning fluids If necessary use a soft rag to wipe it clean and avoid scratching it Timing Belt Tensioner Spring Check the free length of the tensioner spring Replace if necessary Free length 53 3 mm 2 098 in Timing Belt Pulley and Camshaft Pulley Inspect the pulley teeth for wear deformation or other damage Replace if necessary Caution Do not clean the pulley with cleaning fluids If neces...

Page 26: ...ding 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 CYLINDER BLOCK I Torque Specifications ii 69 73 N m 7 0 7 4 m kg 51 54 ft lb 82 88 N m 8 4 9 0 m kg 61 65 ft lb 69G01A 139 ...

Page 27: ...o the piston and connect ing rod from the opposite side of the piston with the SST 5 Tap the piston pin in until it touchs the clip Install the other clip into the groove in the piston 6 Check the oscillation torque of the connecting rod Refer to page 1B 33 Piston Ring 1 Install the three piece oil rings on the pistons 1 Apply engine oil to the oil ring spacer and rails 2 Install the oil ring spac...

Page 28: ...n first then in stall the top ring Use a piston ring expander Caution The rings must be installed with the R marks facing upward 4 Apply a liberal amount of clean engine oil to the second and top piston rings 86U01X 121 69G01A 147 Crankshaft 1 Before installing the crankshaft inspect the main bearing oil clearances as described Note The bearing with thrust shoulders is the cen ter bearing in the c...

Page 29: ...ng torque 82 88 N m 8 4 9 0 m kg 61 65 ft lb Caution Do not rotate the crankshaft when measuring the oil clearances 7 Remove the main bearing caps and measure the plasti gauge at each journal at the widest point for the smallest clearance and at the nar rowest point for the largest clearance If the oil clearance exceeds specification grind the crankshaft and use undersize maih bear ings Refer to p...

Page 30: ... Note Wider thrust width is available only in under size center main bearing Pilot Bearing 1 Apply engine oil to the outer circumference of the bearing 2 Set a piece of pipe outer diameter 30 34 mm 1 18 1 34 in against the outer race of the bear ing then tap it evenly into the crankshaft 3 Lubricate the bearing with grease 76G01B 075 Piston and Connecting Rod Assembly 1 Apply a liberal amount of c...

Page 31: ...ecting rod when installing the con necting rod cap 2 If the oil clearance exceeds specification grind the crankshaft and use undersize bearings Refer to page 1B 46 3 Check the side clearance of each connecting rod without the cap installed Side clearance 0 110 0 262 mm 0 004 0 0103 in Maximum 0 30 mm 0 012 in Ifthe clearance exceeds the maximum replace the connecting rod 4 Apply a liberal amount o...

Page 32: ...ger 37 52 N m 3 8 5 3 m kg 27 38 ft lb 19 30 N m 1 9 3 1 m kg 14 22 ft lb 8 12 N m 80 120 cm kg 69 104 In lb 8 12 N m 80 120 cm kg 69 104 in lb 22 32 N m 2 2 3 3 m kg 16 24 ft lb 7 12 N m 70 120 cm kg 61 104 In lb 69G01A 166 Rear Cover 1 Apply engine oil to the rear cover oil seal and oil seal lip 2 Press the oil seal into the rear cover 1B 54 4BG01A 158 ...

Page 33: ...n ofthe gasket that projects out from the rear cover assembly toward the oil pan side Caution Do not scratch the rear cover assembly End Plate Install the end plate Tightening torque 19 30 N m 1 9 3 1 m kg 14 22 ft lb Oil Pump 1 Apply engine oil to a new oil pump oil seal and the oil pump body 2 Press the oil seal into the oil pump body 1B 55 ...

Page 34: ... 14 19 ft lb 37 52 N m 3 8 5 3 m kg 27 38 ft lb 8 Remove any sealant which has been squeezed out Oil Jet Install the oil jet as shown in the figure Tightening torque 12 18 N m 1 2 1 8 m kg 104 156 in lb Caution The shapes of the No 1 3 cylinders jet valves and No 2 4 jet valves are different 76G01B 079 Stiffener 1 Remove any dirt of other material from the con tact surface 2 Apply a continuous bea...

Page 35: ...ong the inside of the bolt holes and over lap the ends 2 Install the oil pan Tightening torque 7 12 Nm 70 120 cm kg 61 104 in lb Flywheel 1 Remove any old sealant from the bolts and bolt holes If old sealant can not be removed from the bolt replace it 2 Apply sealant to the bolt threads 3 Install and tighten the flywheel with the SST Tightening torque 96 103 Nm 9 8 10 5 m kg 71 76 ft lb 76G01B 082...

Page 36: ... 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 2 Place a new O ring in position Caution Do not reuse the original O ring 86U01X 142 3 Install the water pump Tightening torque 19 25 N m 1 9 2 6 m kg 14 19 ft lb 78U01B 1Q3 ...

Page 37: ...ions 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 Install the valve seal onto the valve guide with the SST 86U01X 143 1B 59 ...

Page 38: ... cylinder head 4 Compress the valve spring with the SST then in stall the valve keepers 5 Tap the end of the valve stem lightly two or three times with a plastic hammer to confirm that the keepers are all fully seated Hydraulic Lash Adjuster HLA 1 Apply engine oil to the sliding surface 2 Install the HLA inthe position from which they were removed 3 Check for free movement Valve spring Cylinder he...

Page 39: ...reads and seat faces 5 Tighten the cylinder head bolts in two or three steps in the order shown in the figure Tightening torque 80 86 Nm 8 2 8 8 m kg 59 64 ft lb Camshaft 1 Apply a liberal amount of engine oil to the journals and bearings 2 Place the camshaft in position with the dowel pin facing straight up Camshaft Oil Seal 1 Apply liberal amount of clean engine oil to the cam shaft oil seal and...

Page 40: ...m lobes and journals 2 Apply silicon sealant to the front camshaft cap surface 3 Position the camshaft caps according to the cap number and mark 4 Install the camshaft caps Tighten the bolts in two or three steps in the order shown in the figure Tightening torque 18 26 Nm 1 8 2 7 m kg 13 20 ft lb Seal Plate Install the seal plate Tightening torque 8 12 N m 80 120 cm kg 69 104 in lb 1B 62 ...

Page 41: ...ASSEMBLY CYLINDER HEAD 1B 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: ...Y TIMING BELT TIMING BELT Torque Specifications 47 65 Nm 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 1B 64 69G01B 160 ...

Page 43: ...Align the mating mark on the camshaft pulleys with the alignment mark on the seal plate Note For intake side camshaft pulley align I mark For exhanst side camshaft pulley align E mark Timing Belt Pulley 1 Reverse the direction of the SST ring gear brake 2 Install the crankshaft key 3 Install the timing belt pulley on the crankshaft Tightening torque 157 167 Nm 16 0 17 0 m kg 116 123 ft lb 4 Releas...

Page 44: ... a If the timing belt is being reused it must be reinstalled to rotate in the original direction b Check that there is no oil grease or dirt on the timing belt 2 Loosen the tensioner lock bolt 3 Turn the crankshaft twice inthe direction of rotation 4 Check that the mating marks are correctly aligned If not aligned remove the timing belt and tension er and repeat the above mentioned procedure 79G01...

Page 45: ...g 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 Baffle Plate Position the baffle plate on the timing belt pulley Timing Belt Cover Install the lower timing belt cover upper timing belt cover and new gaskets Tightening torque 7 10 N m 70 100 cm kg 61 87 in lb Crankshaft Pulley Install the crankshaft pulley Tightening torque 12 17 Nm 1 25 1 7...

Page 46: ...11 9 m kg 63 86 ft lb 19 30 N m 1 9 3 1 m kg 14 22 ft lb 19 25 N m 1 9 2 6 m kg 14 19 ft lb 37 63 N m 3 8 6 4 m kg 27 46 ft lb 34 49 N m 3 5 5 0 m kg 25 36 ft lb 19 30 N m 1 9 3 1 m kg 14 22 ft lb 37 52 N m 3 8 5 3 m kg 27 38 ft lb 19 30 N m 1 9 3 1 m kg 14 22 ft lb 19 30 N m 1 9 3 1 m kg 14 22 ft lb 15 23 N m 1 5 2 3 m kg 11_17 ft b 19 30 N m 1 9 3 1 m kg 14 22 ft lb 86U01X 164 1B 68 ...

Page 47: ...lter 1 Apply a small amount of engine oil to the rubber seal of the new filter 2 Install the oil filter and tighten it by hand until the rubber seal contacts the base 3 Then tighten the filter 1and 1 6turn with a wrench Intake Manifold Assembly 1 Place the new gasket in position 2 Install the intake manifold assembly 3 Tighten the nuts in two or three steps Tightening torque 19 30 N m 1 9 3 1 m kg...

Page 48: ...23 Nm 1 5 2 3 m kg 11 17 ft lb Distributor 1 Apply engine oil to the O ring and position it on the distributor 2 Apply engine oil to the blade 3 Install the distributor 4 Loosely tighten the distributor mounting bolt Note The distributor blade and the distributor drive groove are offset to prevent mistake instal lation Center Cover Install the center cover Tightening torque 8 12 Nm 80 120 cm kg 69...

Page 49: ...que 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 Tightening torque 19 30 Nm 1 9 3 1 m kg 14 22 ft lb 76G01A 092 1B 71 ...

Page 50: ...ge 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 J jc r K l Isi S WtvS P S Oil Pump Bracket Install the P S oil pump bracket Tightening torque 37 63 N m 3 8 6 4 m kg 27 46 ft lb a 86U01X 178 ...

Page 51: ...ure referring to the installation note 8 11 N m 80 110 cm kg 69 95 in lb 37 5 3 8 5 3 m kg 27 38 ft lb 117 N m 1 11 9 m kg 66 86 ft lb 76F01B 024 1 Transaxle 2 Clutch under cover 3 Gusset plate 4 Starter Installation Note Clutch under cover Before installation fill the notches with silicon as shown in the figure 76G01A 144 ...

Page 52: ... ft l 39 59 N m 4 0 6 0 m 29 43 ft lb 8 11 N m 80 110 cm 69 95 in lb 31 46 N m 3 2 4 7 m l 23 34 ft lb 19 25 N m 1 9 2 6 m kg 14 19 ft lb 19 25 N m 1 9 2 6 m kg 14 19 ft lb 16 23 N m 1 6 2 3 m kg 12 17 ft lb 4 89 N m 6 5 9 1 m kg 47 66 ft lb 36 54 N m 3 7 5 5 m kg 27 40 ft lb 31 46 N m 3 2 4 7 m kg 23 34 ft lb 5 7 N m 50 70 cm kg 43 61 in lb 6 23 N m 1 6 2 3 m kg 17 ft lb 9 13 N m 90 130 cm kg 78 ...

Page 53: ...ue A 31 46 Nm 3 2 4 7 m kg 23 34 ft lb 64 89 Nm 6 5 9 1 m kg 47 66 ft lb 2 Tighten the bracket bolt Tightening torque 19 25 Nm 1 9 2 6 m kg 14 19 ft lb Extension Bar Install the extension bar to the transaxle Tightening torque 31 46 Nm 3 2 4 7 m kg 23 34 ft lb Change Rod Install the change rod to the transaxle Tightening torque 16 23 N m 1 6 2 3 m kg 12 17 ft lb 1B 75 ...

Page 54: ...er Arm Install the lower arm ball joint to the knuckle then tight en the lock nut Tightening torque 43 54 Nm 4 4 5 5 m kg 32 40 ft lb Tie Rod End 1 Install the tie rod end to the knuckle Tightening torque 29 44 Nm 3 0 4 5 m kg 22 33 ft lb 2 Install the cotter pin Stabilizer Control Rod Install and adjust the front stabilizer control rods Dimension A 20 1 mm 0 79 in Tightening torque 16 23 Nm 1 6 2...

Page 55: ...mp bracket Tightening torque 19 25 Nm 1 9 2 6 m kg 14 19 ft lb 2 Install the A C compressor bracket Tightening torque 37 63 Nm 3 8 6 4 m kg 27 46 ft lb 3 install the A C compressor 4 Install the A C compressor upper bracket Tightening torque 37 63 Nm 3 8 6 4 m kg 27 46 ft lb 5 Tighten to the lock nut and mounting bolts Tightening torque 37 52 N m 3 8 5 3 m kg 27 38 ft lb Drive Beit Install the dri...

Page 56: ...t 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 76F01B 025 ...

Page 57: ...oid 2 Heat gauge unit 11 Solenoid valve idle speed control 3 Speed sensor 12 Throttle position sensor 4 P S switch 13 Injection harness 5 Engine ground 14 Transmission harness 6 Water temperature sensor 15 Alternator 7 Water thermo switch 16 Oil pressure switch 8 Crank angle sensor 17 Starter 9 Oxygen sensor 1B 79 ...

Page 58: ...pliers to ensure a good fit Heater Hose and Fuel Hose Connect the heater hoses and the fuel hoses High Tension Lead Connect the high tension lead to the ignition coil Accelerator Cable Install the accelerator cable 76G01A 148 Battery and Battery Carrier 1 Install the battery carrier Tightening torque 9 13 N m 90 130 cm kg 78 113 in lb 2 Install the fuse box Tightening torque 8 11 Nm 80 110 cm kg 6...

Page 59: ...ake 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 with the specified amount and type of coolant Re fer to Section 3 Check Engine Condition 1 Check for leaks 2 Perform engine adjustments if necessary 3 Perform a road test 4 Recheck the oil and coolant levels 86U01X 204 1B 81 ...

Page 60: ...NG GUIDE 2 4 INSPECTION 2 5 ENGINE O IL 2 5 OIL PRESSURE 2 5 ENGINE OIL 2 5 REPLACEMENT 2 5 OIL FILTER 2 6 REPLACEMENT 2 6 OIL COOLER 2 6 REMOVAL AND INSTALLATION 2 6 OIL PAN 2 7 REMOVAL 2 7 INSPECTION 2 8 INSTALLATION 2 8 OIL PUMP 2 9 REMOVAL 2 9 DISASSEMBLY 2 11 INSPECTION 2 11 ASSEMBLY 2 13 INSTALLATION 2 13 76F02X 001 ...

Page 61: ...2 OUTLINE OUTLINE LUBRICATION CIRCUIT DOHC 1 Oil pump 2 Pressure regulator valve 3 Main gallery 4 Oil pressure switch 5 Oil cooler 6 Oil filter 7 Oil control plug 8 Oil jet 76G02A 002 2 2 ...

Page 62: ...UTLINE 2 LUBRICATION CIRCUIT SOHC Turbocharger 76F02X 002 1 Oil pump 2 Pressure regulator valve 3 Main gallery 4 Oil pressure switch 5 Oil cooler F2 Turbo FE 12 valve 6 Oil filter 7 Oil control plug 2 3 ...

Page 63: ...il API service SF SD SE or SF 76F02X 003 Recommended SAE Viscosity Temperature 30 20 10 0 10 20 30 40 50 I I I i l l I I 1 i i i i t i 20 0 20 40 60 80 100 120 Engine oil 5W 30 X 30 5W 20 20W 20 T 40 X 10W 30 10W 40 10W 50 20W 40 20W 50 Temperature range anticipated before next oil change C F TROUBLESHOOTING GUIDE Problem Possible Cause Remedy Page Engine hard starting Improper engine oil Insuffic...

Page 64: ...il pressure switch 2 Screw the SST into the pressure switch installa tion hole 3 Warm up the engine to normal operating tem perature 4 Run the engine at 3 000 rpm and note the gauge reading Oil pressure 343_44 kpa 3 5 4 5 kg cm2 50 64 psi DOHC kPa 3 0 4 0 kg cm2 43 57 psi SOHC 5 If the pressure is not as specified check for the cause and repair if necessary Refer to Troubleshooting Guide ENGINE OI...

Page 65: ...F02X Q06 3 DOHC Install the oil filter until the rubber seal contacts the base and then tighten the filter 1 and 1 6 turn with a wrench SOHC Install the oil filter and tighten it by hand only Do not use a wrench 4 Start the engine and inspect around the filter seal for leaks 5 Check the oil level and add oil if necessary Oil filter capacity 0 20 liters 0 21 US qt 0 18 Imp qt DOHC 0 30 liters 0 32 ...

Page 66: ...8 11 N m 60 110 cm kg 69 95 in lb 37 52 N m 3 8 5 3 m kg 27 38 ft lb 8 11 N m 80 110 cm kg 69 95 In lb kg 23 30 ft lb N m 7 m kg 23 34 ft lb 19 25 N m 1 9 2 6 m kg 14 19 ft lb 89 N m 6 5 9 1 m kg 4 7 6 6 ft lb 76F02X 007 1 Exhaust pipe 2 Gusset plate 3 Clutch housing under cover 4 Sub frame RH 5 Oil pan 6 Oil strainer 7 Stiffener DOHC 12 valve Removal Note Oil pan 1 Remove the oil pan mounting bol...

Page 67: ...fener DOHC 12 valve 1 Remove any dirt or other material from the con tact surface 2 Apply silicon sealant to the stiffener around inside of the bolt holes and overlap the ends 3 Install the stiffener Tightening torque 7 12 N m 70 120 cm kg 61 104 in lb Oil pan 1 Apply a confinuous bead of silicon sealant to the oil pan around inside of the bolt holes and over lap the ends 2 Install the oil pan Tig...

Page 68: ...oval note for specially marked parts __ _ ______________________________ _ ____ ___________ ____ __________________________________ ____________________________76G02A 015 DOHC 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 1 Timing belt Refer to Section 1B 2 Oil pan Refer to page 2 7 3 Timing belt pulley lock bolt 4 Timing belt pulle...

Page 69: ... lb 157 167 N m 16 0 17 0 m kg 116 123 ft lb f 1 Timing belt Refer to Section 1 2 Oil pan Refer to page 2 7 3 Timing belt pulley lock bolt 76F02X 012 4 Timing belt pulley 5 Oil pump Removal Note Timing belt pulley lock bolt Hold the timing belt pulley with the SST and remove the lock bolt 76G02A 026 ...

Page 70: ...er gear 3 Inner gear 4 Pressure relief valve 5 Oil seal 6 Oil pump body INSPECTION DOHC 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 Measure the side clearance Clearance 0 10 mm 0 004 in max 2 1 1 ...

Page 71: ...e 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 Measure the side clearance Clearance 0 10 mm 0 004 in max 2 1 2 ...

Page 72: ...dy 2 Fit the snap ring Outer and Inner Gear Install the gears to the pump body Oil Pump Cover 1 Apply thread locking compound to the cover mounting screws threads 2 Attach the oil pump cover to the body Tightening torque 6 9 N m 60 90 cm kg 52 78 in lb INSTALLATION Install in the reverse order of removal referring to the installation note Installation Note Oil pump 1 Apply grease to a new O ring a...

Page 73: ...ION 3 5 REPLACEMENT 3 5 RADIATOR CAP 3 6 INSPECTION 3 6 RADIATOR 3 7 REMOVAL AND INSTALLATION 3 7 INSPECTION 3 7 WATER PUMP 3 8 REMOVAL 3 8 INSPECTION 3 10 INSTALLATION 3 10 THERMOSTAT 3 11 REMOVAL 3 11 INSPECTION 3 11 INSTALLATION 3 11 COOLING FAN 3 12 SYSTEM CIRCUIT 3 12 CIRCUIT INSPECTION 3 12 FAN MOTOR 3 13 WATER THERMO SWITCH 3 14 76F03X 001 ...

Page 74: ...J OUTLINE OUTLINE COOLANT FLOW CHART DOHC 1 Water pump 4 Coolant reservoir 2 Thermostat 5 Oil cooler 3 Radiator 6 Cooling fan 3 2 ...

Page 75: ...OUTLINE 3 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: ...n lift mm in Sub 1 5 0 06 min Main 8 0 0 31 min 8 5 0 33 min Radiator Type Corrugated Cap valve opening pressure kPa kg cm21psi 7 4 1 0 3 0 7 5 1 0 5 1 1 1 5 Cooling fan Capacity W MTX 80 ATX 120 160 only F2 turbo Number of blade 4 Outer diameter of blade mm in MTX 320 12 6 ATX 340 13 4 76F03 003 TROUBLESHOOTING GUIDE Problem Possible Cause Remedy Page Overheating Insufficient coolant Coolant leak...

Page 77: ...around the radiator cap or radiator filler neck 2 Check that coolant is free from oil 3 Replace the coolant if necessary Coolant Leakage 1 Connect a tester and SST to the radiator inlet port 2 Apply 103 kPa 1 05 kg cm2 15 psi pressure to the system 3 Check that the pressure is held If not check for coolant leakage Warning When removing either the radiator cap or the tester loosen it slowly until t...

Page 78: ... 1 078 6 Run the engine at idle with the radiator cap n moved Let any air bleed from the system and ad more coolant 7 Install the radiator cap and inspect all connection for leakage RADIATOR CAP INSPECTION Radiator Cap Valve 1 Remove foreign material such as water residue from between the radiator cap valve and the valve seat 2 Attach the radiator cap to a tester with the SST Apply pressure gradua...

Page 79: ...rmo switch connector 4 Cooling fan connector 76G03A 005 5 Upper and lower radiator hose 6 Cooling fan and radiator assembly 7 Cooling fan INSPECTION Check the following points Repair or replace if necessary 1 Cracks damage or water leakage 2 Bent fins Repair with a screwdriver 3 Distorted or bent radiator inlet 3 7 ...

Page 80: ...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 52 N m 3 8 5 3 m kg 27 38 ft lb 76G03A 1 Timing belt Refer to Section 1B 4 Idler pulley 2 Camshaft pulley Refer to Section 1B 5 Water pump 3 Seal plate 6 O ring 3 8 ...

Page 81: ...WATER PUMP SOHC 76F03X 005 1 Timing belt F6 F8 FE Refer to Section 1A F2 Refer to Section 1C 2 Idler pulley 3 Water pump 4 O ring ...

Page 82: ...r pump 76G03A 017 Water pump 1 Remove any gasket fragments dirt or oil from th contact surfaces 2 Install a new O ring on the water pump 3 Install the water pump Tightening torque 19 25 Nm 1 9 2 6 m kg 14 19 ft lb Note To prevent dropping the O ring when instal ing put silicon sealant in the O ring groov shaded areas as shown Do not apply it t the contact surfaces ...

Page 83: ...re Sub valve 83 5 86 5 C 182 188 F Main valve 86 5 89 5 C 188 193 F 86 5 89 5 C 188 193 F 80 5 83 5 C 177 182 F Full open temperature 100 C 212 F 95 C 203 F Full open lift Sub valve 1 5 mm 0 06 in min Main valve 8 0 mm 0 31 in min 8 5 mm 0 33 in min 76F03X 007 Jiggle pin 86U03X 018 INSTALLATION 1 Install the thermostat into the cylinder head with jiggle pin at the top 2 Install a new gasket with t...

Page 84: ...1 relay Add relay Add fan M 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 If the fan doesn t operate check the fuse fan r lay fan motor thermo switch and wiring harnes 76G03A 010 ...

Page 85: ...3X 021 1 Cooling fan assembly Refer to page 3 7 3 Fan 2 Cowling 4 Fan motor Inspection 1 Connect an ammeter and battery to the fan motor connectors 2 Check that the fan motor operates smoothly at the specified current or less Current MTX 5 6 7 6 A ATX except F2 turbo 8 0 11 0 A F2 turbo 10 6 16 6 A 3 Replace the fan motor if necessary 3 13 ...

Page 86: ...hen the connecto is removed 7 6 G 0 3 A 0 1 3 2 Place the water thermo switch in water 3 Heat the water gradually and check for continu ty of the switch with an ohmmeter Replace necessary Water thermo switch ON OFF 97 C 207 F FE DOHC FE 12 valve 91 C 196 F F2 FE 8 valve F8 F6 4 Install the water thermo switch and a new O ring Caution Do not use sealing tape ...

Page 87: ... TROUBLESHOOTING 4B 47 FUEL PRESSURE RELEASE AND SERVICING FUEL SYSTEM 4B 48 MULTI PRESSURE TESTER 4B 49 FUEL PUMP 4B 52 PULSATION DAMPER 4B 53 INJECTOR 4B 53 REPLACEMENT 4B 55 FUEL TANK 4B 60 PRESSURE REGULATOR CONTROL PRC SYSTEM 4B 63 COMPONENT DESCRIPTION 4B 64 TROUBLESHOOTING r 4B 64 DECELERATION CONTROL SYSTEM 4B 67 COMPONENT DESCRIPTION 4B 68 TROUBLESHOOTING 4B 68 ELECTRONIC SPARK ADVANCE ES...

Page 88: ... ISC valve Dashpot X o MTX System simplified Secondary air in jection x o System simplified FUEL SYSTEM Pressure regulator control o X Injector 0 o Injection amount increased CONTROL Fuel injection pattern Sequential injec tion once per two revolutions 1 group injection once per two revolutions Improved engine response SYSTEM Fuel cut operation Overspeed O O ELECTRONIC SPARK ADVANCE ESA CONTROL SY...

Page 89: ... rA C magnet clutch Enaine LJ rp S switch j i j L i e w itn h Air cleaner Throttle body Idle switch Air valve Solenoid valve ISC Solenoid valve VIC Shutter valve actuator Headlight switch Rear defroster switch kCooling fan switch Blower switch Neutral and clutch switches Test connector ...

Page 90: ...4B OUTLINE COMPONENT LOCATION Input and Output Devices Solenoid valve VIC 76G04C 004 ...

Page 91: ...OUTLINE 4B Fuel System Pulsation damper Pressure regulator Fuel filter Throttle body Injector Shutter valve actuator Control relay Fuel pump Air cleaner Two way check valve Separator 76G04C 005 48 5 ...

Page 92: ...4B OUTLINE Exhaust System ...

Page 93: ...76G04C 007 ...

Page 94: ...c 220 13 4 min Fuel filter Type Low pressure side Nylon element High pressure side Paper element Pressure regulator Type Diaphragm Regulating pressure kPa kg cm2 psi 235 275 2 4 2 8 34 40 Iniector Type High ohmic Type of drive Voltage Resistance a 1 2 1 6 Injection amount cc eu in 15 sec 66 91 4 03 5 55 Idle speed control valve Solenoid resistance a 6 3 9 9 Fuel tank Capacity liters US gal Imp gal...

Page 95: ...stem or unit may be at fault by use of the SST Self Diagnosis Checker 49 H018 9A1 or Digital Code Checker 49 G018 9A0 with Adaptor harness 49 9200 180 1st Check input sensors and output solenoid valves with the SST Refer to page 4B 11 2nd Check other switches with the SST Refer to page 4B 22 3rd Check the following items Poor acceleration hesita tion or lack of power Runs rough on deceleration Aft...

Page 96: ...ing 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 These were determined on the following basis Ease of inspection Most possible system Most possible point in system 4B 10 ...

Page 97: ...Code Checker 49 G018 9A0 with Adaptor har ness 49 9200 180 Failure of individual input and output devices is indicated and retrieved from the control unit as mal function code numbers Note The control unit constantly checks for malfunction of the input devices But the control unit checks for malfunction of output devices only in a 3 second period after the ignition switch is turned ON and with the...

Page 98: ...igital display and that the buzzer sounds for three seconds after turn ing the ignition switch ON 6 If 88 does not flash check the control relay refer to page 4B 78 power supply circuit and check connector wiring 7 If 88 flashes and the buzzer sounds continuously for more than 20 seconds check the check con nector wiring or replace the engine control unit and perform steps 3 and 4 again 8 Note the...

Page 99: ...gnition switch ON for six seconds do not start the engine 5 Start and warm up the engine then run it at 2 000 rpm for two minutes 6 Verify that no code numbers are displayed 76G04C Q14 PRINCIPLE OF CODE CYCLE Malfunction codes are determined as shown beiow I 86U04A 017 j 1 Code cycle break The time between warning code cycles is 4 0 sec the time the light is off 1 cycle Malfunction code cycle brea...

Page 100: ...es the buzzer is on 1 2 sec during one cycle It should also be noted that the light goes off for 1 6 sec between the long and short pulses of the buzzer 1 cycle Malfunction code 0 4 1 2 sec sec h 1 2 fin First digit 1 6 sec cycle break 4 0 sec Malfunction code 22 nr Second digit 76G04C 016 CODE NUMBER Malfunction display Sensor or subsystem Self diagnosis Fail safe Malfunction code no Malfunction ...

Page 101: ...Short circuit Maintains constant 20 C 68 F command 25 O f f J J IL Solenoid valve pres sure regulator control Open or short circuit 34 0 f N f _ M 1 U 1 1 Solenoid valve Idle speed control 41 o JIWIJLJM Solenoid valve Vari able inertia control 76F04B 009 Caution a If there is more than one failure present the lowest number malfunction code is dis played first the remaining codes are displayed sequ...

Page 102: ...4 B 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: ... Water thermo sensor Are there poor connections in water thermo sensor circuit NO Is there continuity between water thermo sensor and engine control unit YES Is same Code No present after performing after repair procedure Refer to page 4B 12 YES YES Water thermo sensor Engine control unit A YB wire 2 B LgY wire 2C YES Is resistance of the water thermo sensor OK Resistance Coolant temp Resistance 2...

Page 105: ...circuit in wiring harness A RC wire 2J B LgY wire 2C YES Is resistance of intake air thermo sensor dynamic chamber OK Resistance Temperature Resistance 20 C 68 F 2 9 7 36 3 kO 50 C 122 F 8 4 1 0 2 kfi 85 C 185 F 2 5 3 1 M YES NO Replace intake air thermo sensor dynamic chamber Is same Code No present after performing after repair procedure Refer to page 4B 12 No Intake air thermo sensor and circui...

Page 106: ...4B 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 No 41 Code Solenoid valve Variable inertia control VIC PC Possible Cause 76G04C 034 ...

Page 108: ...nector must be grounded and the ignition switch ON engine stopp Switch Self Diagnosis Checker Monitor lamp Remark Light ON Light OFF Clutch switch Pedal released Pedal depressed In gear Neutral switch In gear Neutral Clutch pedal release Idle switch Pedal depressed Pedal released Headlight switch ON OFF Rear defroster switch ON OFF Blower switch ON OFF Blower motor positior or A ...

Page 109: ... 2 Connect the SST to the check connector Green 6 pin and the negative battery terminal 3 Connect a jumper wire between the test connec tor Green 1 pin and a ground 4 Turn the ignition switch ON Check if the monitor lamp illuminates as each switch is operated as described below Caution a If any one of the switches remains activat ed the monitor lamp will stay on b Do not start the engine 76F04B 01...

Page 110: ...4 B SWITCH MONITOR FUNCTION Idle switch 76F04B 020 Blower switch 76F04 B 021 Headlight switch Rear defroster switch ...

Page 111: ... the test connector Green 1 pin Specification Applied load Idle speed No load 750 50 rpm P S load 750 50 rpm A C and or E L load 800 50 rpm 2 If not correct adjust the initial idle speed Adjustment 1 Ground the test connector Green 1 pin with a jumper wire 2 Turn all accessories and loads OFF 3 Remove the blind cap and adjust the initial idle speed to specification by turning the air adjust screw ...

Page 112: ...e 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 CO concentration 1 5 0 5 HC concentration Less than 1 000 PPM 3 If the CO or HC concentration is not within spe cation turn the adjust screw with the SST to adji ...

Page 113: ...r throttle body dynamic chamber and intake manifold COMPONENT DESCRIPTION Component Function Remark Air cleaner Filters air entering throttle body Dry type Air flow sensor Detects amount of intake air sends signal to engine control unit Hot wire type Resonance chamber Minimizes intake air noise JThrottle body Controls intake air quantity Integrated throttle sensor and idle switch 4B 27 ...

Page 114: ...nectors Idle switch ISC 5 Water hoses 6 Vacuum hose 7 Accelerator cable 8 Throttle body 9 Gasket 10 PCV hose 4B 28 11 Dynamic chamber brackets 12 Connectors Knock sensor Intake air thermo sensor 13 Dynamic chamber 14 One way check valve 15 Gasket 16 Wiring harness injectors 17 Fuel hoses 18 Delivery pipe assembly mounting bolt 76F04B 026 19 Heat insulator 20 Injectors 21 Delivery pipe assembly 22 ...

Page 115: ...ent 1 Check the condition of the air cleaner element 2 Blow clean with compressed air if necessary Caution a The air cleaner must be replaced at the in tervals outlined in the maintenance schedule b Never drive the vehicle without the air cleaner element otherwise damage to the air flow sensor hot wire will occur c Never use an oil permeated air cleaner ele ment otherwise contamination of the hot ...

Page 116: ...e floor and con firm that the throttle valve is fully opened Adjust by turning bolt B if necessary Throttle Body Note The No 2 throttle valve is preset at the facto ry to begin opening after the No 1 throttle valve has opened approx 25 degrees 1 Check that the No 1 and No 2throttle valves move smoothly when the throttle lever is moved from fully closed to fully open 2 Replace if necessary Caution ...

Page 117: ...if necessary Intake Manifold 1 Visually check the intake manifold for damage 2 Replace if necessary Shutter Valves 1 Visually check the shutter valves for damage 2 Check that the shutter valves close and open fully 3 Adjust or replace them if necessary j Resonance Chamber 1 Visually check the resonance chamber for damage 2 Replace if necessary 69G04C 054 4B 31 ...

Page 118: ...install them onto the throttle shaft 3 Install the throttle lever onto the throttle shaft Caution When tightening the throttle lever nut hold the throttle valves fully closed to prevent bending the stop lever 4 Tighten the throttle lever nut Tightening torque 16 23 N m 1 6 2 3 m kg 12 17 ft lb 5 Check that the inner and outer washer and spacer are assembled correctly as shown 6 Check that No 1 and...

Page 119: ...INTAKE AIR SYSTEM 4B INSTALLATION Install In the reverse order of removal referring to the installation note Torque Specification 86U04A 055 ...

Page 120: ...sure that the ground harnesses are tightened securely at the following positions 1 Air cleaner upper case 2 Solenoid valve bracket 3 Engine hanger 76G04C 062 Solenoid valve connectors Connect the solenoid valve connectors at the posi tions shown in the figure 76G04C 063 Inspection after installation 1 After completing installation fill the engine with the specified engine coolant 2 Warm up the eng...

Page 121: ...uring the first half of the air intake process This air flow pushes air into the cylinder by its own inertial force during the second half of the air intake process This improves the charging of the cylinder To most effectively put this inertia charging to use the length of the manifold leading to the dynamic chamber needs to be changed in response to the engine rpm Length of intake manifold Intak...

Page 122: ...hutter valve Closes short intake port Shutter valve actuator Actuates shutter valve according to vacuum from solenoid vaive 76F04B 033 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 ...

Page 123: ...eased above specification Specification Approx 5 400 rpm Shutter Valve Actuator 1 Disconnect the vacuum hose from the actuator and connect a vacuum pump to the actuator 2 Apply approx 200 mmHg 7 9 inHg vacuum and check that the rod is pulled into the actuator VIC Solenoid Valve 1 Disconnect the vacuum hoses from the solenoid valve 2 Blow through the valve from port A and check that air flows from ...

Page 124: ...m Vacuum Signal 1 Disconnect the vacuum hose from the actuator 2 Place a finger over the port opening and check that vacuum is felt at idle 3 Increasethe engine speed above specification and check that no vacuum is felt Specification Approx 5 400 rpm 4 Connect the vacuum hose Vacuum Chamber 1 Disconnect the vacuum hose from the dynamic chamber 2 Connect a vacuum pump to the dynamic chamber 3 Apply...

Page 125: ...s tration 4 Apply vacuum and check that it is held 5 Connect the vacuum pump to the opposite port 6 Apply vacuum and check that it is not held 7 If not correct replace the valve Replacement 1 Remove the dynamic chamber Refer to page 4B 28 2 Remove the one way check valve 3 Install a new valve with the white side of the valve facing port A 76F04B 039 or o k nd ic r s 4B 39 ...

Page 126: ...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 122 F and the ISC valve which works throughout the entire engine speed range ...

Page 127: ...control Idle switch Detects when throttle valve fully closed sends signal to engine control unit Installed on throttle body Ne signal pick up Detects crank angle at 180 intervals sends signal to engine control unit Installed in distributor Neutral switch Detects in gear condition sends signal to engine control unit Switch ON when in gear P S pressure switch Detects P S operation sends signal to en...

Page 128: ...6 C D I 03 O 4B 42 Engine stalls During warm up 2 _ 3 4 5 6 1 After warm up 4 2 3 5 6 1 Rough idle During warm up 2 3 4 5 1 After warm up 4 2 3 5 6 1 High idle speed after warm up 2 5 3 4 6 7 1 Runs rough on deceleration 2 3 4 1 Afterbum in exhaust system 2 3 4 5 1 Fails emission test 2 3 4 5 1 76F04B 040 System inspection Air valve 1 Ground the test connector Green 1 pin with a jumper wire 2 Disc...

Page 129: ...he engine speed decreases 9 Reconnect the ISC valve connector 10 Remove the jumper wire from the test connector and make sure that the idle speed is within specifi cations Load Test 11 Apply power steering electrical and air conditioner loads and check that the idle speed is controlled to within specifications Load Idle speed P S 750 50 E l 800 50 A C 800 50 E L and A C 800 50 BAC Valve Air valve ...

Page 130: ...k the resistance Resistance at 20 C 68 F 6 3 9 9 0 4 If not correct replace the BAC valve REMOVAL 1 Remove the screws 2 Remove the BAC valve from the throttle body Installation Caution Install a new gasket 1 Remove any dirt or old sealant from the contact surfaces 2 Apply sealant to both sides of the gasket 3 Tighten the screws 4B 44 ...

Page 131: ...YSTEM FE DOHC 30 18 FUEL AND EMISSION CONTROL SYSTEM F2 30 19 ENGINE ELECTRICAL SYSTEM 30 20 CLUTCH 30 22 MANUAL TRANSAXLE 30 23 AUTOMATIC TRANSAXLE ELECTRONICALLY CONTROLLED AND 4 SPEED 30 24 AUTOMATIC TRANSAXLE 3 SPEED 30 30 FRONT AND REAR AXLES 30 32 STEERING SYSTEM 30 32 BRAKING SYSTEM 30 33 WHEEL AND TIRE 30 34 SUSPENSION 30 34 BODY ELECTRICAL SYSTEM 30 35 STANDARD BOLT AND NUT TIGHTENING TOR...

Page 132: ...6 10 2 144 280 Maximum difference between cylinders 196 2 0 28 Valve timing IN Open BTDC 14 Close ABDC 56 EX Open BBDC 69 Close ATDC 13 Valve clearance mm in IN 0 Maintenance free EX 0 Maintenance free Cylinder head Height mm in 91 95 92 05 3 620 3 624 Distortion mm in Maximum 0 15 0 006 Grinding limit mm in Maximum 0 20 0 008 Valve and valve guide Valve head diameter mm in IN 32 4 32 6 1 276 1 28...

Page 133: ...4 0 065 0 115 0 0026 0 0045 Maximum 0 15 0 0059 Camshaft runout mm in Maximum 0 03 0 0012 Camshaft end play mm in Standard 0 08 0 16 0 003 0 006 Maximum 0 20 0 008 Rocker arm and rocker arm shaft Rocker arm inner diameter mm in 19 000 19 033 0 748 0 749 Rocker arm shaft diameter mm in 18 959 18 980 0 746 0 747 Standard 0 020 0 074 0 0008 0 0029 n o c K e r a rm 10 sn a n c le a ra n c e m m inj Ma...

Page 134: ...1 2 3501 2 3508 Main journal diameter mm in undersize No 3 59 687 59 705 2 3499 2 3506 0 50 0 020 No 1 2 4 5 59 443 59 461 2 3403 2 3410 undersize No 3 59 437 59 455 2 3400 2 3407 0 75 0 030 No 1 2 4 5 59 193 59 211 2 3304 2 3311 undersize No 3 59 187 59 205 2 3302 2 3309 Main journal taper and out of round mm in Maximum 0 05 0 0020 Standard 50 940 50 955 2 0055 2 0061 Crankpin diameter 0 25 0 010...

Page 135: ... BTDC 20 17 Close ABDC 65 56 EX Open BBDC 65 64 Close ATDC o O CM 15 Valve clearance mm in IN 0 30 0 012 EX 0 30 0 012 Cylinder head Height mm in 91 95 92 05 3 620 3 624 Distortion mm in Maximum 0 15 0 006 Grinding limit mm in Maximum 0 20 0 008 Valve and valve guide Valve head diameter mm in IN 43 9 44 1 1 728 1 736 EX 35 9 36 1 1 413 1 421 Valve head thickness margin mm in IN 0 8 1 2 0 031 0 047...

Page 136: ...5 0 0026 0 0045 Maximum 0 15 0 0059 Camshaft runout mm in Maximum 0 03 0 0012 Camshaft end play mm in Standard 0 08 0 16 0 003 0 006 Maximum 0 20 0 008 Rocker arm and rocker arm shaft Rocker arm inner diameter mm in 16 000 16 027 0 6299 0 6310 Rocker arm shaft diameter mm in 15 966 15 984 0 6286 0 6293 Rocker arm to shaft clearance mm in Standard 0 016 0 061 0 0006 0 0024 Maximum 0 10 0 004 Cylind...

Page 137: ...nd bore mm in 21 943 21 961 0 8640 0 8646 ig end bore mm in 54 002 54 017 2 1261 2 1266 ig end width mm in 26 838 26 890 1 0566 1 0587 onnecting rod side clearance mm in Standard 0 110 0 262 0 004 0 010 Maximum 0 30 0 012 rankshaft ankshaft runout mm in Maximum 0 03 0 0012 ain journal diameter mm in Standard size 59 937 59 955 2 3597 2 3604 0 25 0 010 undersize Standard 59 693 59 711 2 3051 2 3508...

Page 138: ...ree EX 0 Maintenance free Cylinder head Height mm in 133 95 134 05 5 274 5 278 Distortion mm in Maximum 0 15 0 006 Grinding mm in Maximum 0 20 0 008 HLA to cylinder head clearance mm in Standard 0 025 0 066 0 0010 0 0026 Maximum 0 18 0 0071 Valve and valve guide Valve head diameter mm in IN 3 3 6 3 3 8 1 323 1 331 EX 28 8 29 0 1 134 1 142 Valve head thickness margin mm in IN 1 0 1 7 0 039 0 067 EX...

Page 139: ...Maximum 0 05 0 002 Camshaft bearing oil clearance mm in 0 035 0 085 0 0014 0 0033 Maximum 0 15 0 0059 Camshaft runout mm in Maximum 0 03 0 0012 Camshaft end play mm in Standard 0 0 8 0 1 0 0 003 0 004 Maximum 0 20 0 008 Cylinder block Height mm in 289 0 11 38 Distortion mm in Maximum 0 15 0 006 Grinding limit mm in 0 20 0 008 Cylinder bore diameter mm in Standard 86 000 86 019 3 3858 3 3866 0 25 0...

Page 140: ... 3508 Main journal diameter mm in undersize No 3 59 687 59 705 2 3499 2 3506 0 50 0 020 No 1 2 4 5 59 443 59 461 2 3403 2 3410 undersize No 3 59 437 59 455 2 3400 2 3407 0 75 0 030 No 1 2 4 5 59 193 59 211 2 3304 2 3311 undersize No 3 59 187 59 205 2 3302 2 3309 Main journal taper and out of round mm in Maximum 0 05 0 0020 Standard 50 940 50 955 2 0055 2 0061 Crankpin diameter mm in 0 25 0 010 und...

Page 141: ...ing limit mm in Maximum 0 20 0 008 Valve and valve guide Valve head diameter mm in IN 32 4 32 6 1 276 1 283 EX 33 9 34 1 1 335 1 343 Valve head thickness margin mm in IN 0 8 1 2 0 031 0 047 EX 1 3 1 7 0 051 0 067 Valve face angle IN 45 EX 45 Valve length mm in IN Standard 115 81 4 5594 Minimum 115 31 4 5398 EX Standard 116 21 4 5752 Minimum 115 71 4 5555 Valve stem diameter mm in IN 6 970 6 985 0 ...

Page 142: ...0 748 0 749 Rocker arm shaft diameter mm in 18 959 18 980 0 746 0 747 Rocker arm to shaft clearance mm in Standard 0 020 0 074 0 0008 0 0029 Maximum 0 10 0 004 Cylinder block Height mm in 301 5 11 87 Distortion mm in Maximum 0 15 0 006 Grinding limit mm in 0 20 0 008 Cylinder bore diameter mm in Standard 86 000 86 019 3 3858 3 3866 0 25 0 010 oversize 86 250 86 269 3 3957 3 3964 0 50 0 020 oversiz...

Page 143: ...10 undersize No 3 59 437 59 455 2 3400 2 3407 0 75 0 030 No 1 2 4 5 59 193 59 211 2 3304 2 3311 undersize No 3 59 187 59 205 2 3302 2 3309 Main journal taper and out of round mm in Maximum 0 05 0 0020 Standard 50 940 50 955 2 0055 2 0061 Crank pin diameter mm in 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 97...

Page 144: ...ear tooth tip to crescent clearance mm in Standard 0 20 0 32 0 008 0 0126 Maximum 0 35 0 0138 Outer gear to body clearance mm in Standard 0 09 0 184 0 0035 0 0072 Maximum 0 20 0 008 Side clearance mm in Standard 0 03 0 063 0 0012 0 0025 Maximum 0 10 0 004 Oil filter Type Full flow paper element Relief pressure differential kPa kg cm2 psi 7 8 1 1 8 0 8 1 2 1 1 1 7 Oil cooler Type Water cooled Oii p...

Page 145: ...in 8 0 0 31 min 8 5 0 33 min idiator pe Corrugated fin ip opening valve pressure kPa kg cm2 psi 7 4 1 0 3 0 75 1 05 1 1 1 5 oling system pressure kPa kg cm2 psi 103 1 05 15 Oling fan pe Electric ipacity W MTX 80 ATX 120 160 only F2 Turbo irrent A MTX 5 6 7 6 ATX 8 0 11 0 10 6 16 6 only F2 Turbo imber of blades 4 iter diameter mm in MTX 320 12 6 ATX 340 13 4 itching temperature OFF ON C F 97 207 j ...

Page 146: ... 020 Fast idle adjustment mm in Clearance between primary throttle valve and bore 1 40 1 76 0 055 0 069 MTX 0 48 0 64 0 019 0 025 ATX 0 56 0 72 0 022 0 028 1 40 1 73 0 055 0 063 Float level adjustment mm in Max fuel flow L Clearance between float ano 44 1 73 air horn without gasket Fuel stop H I 12 5 0 49 Clearance between float and air horn without gasket float lowered by own weight Choke breaker...

Page 147: ...n Clearance between primary throttle valve and bore MTX 1 40 1 76 0 055 0 069 0 48 0 64 0 019 0 025 ATX 0 56 0 72 0 022 0 028 Float level adjustment mm in Max fuel flow L Clearance between float and 44 1 73 air horn without gasket 49 1 93 Fuel stop H 12 5 0 49 Clearance between float and air horn without gasket float lowered b 13 5 0 53 y own weight Choke breaker diaphragm mmHg in Hg Start 180 240...

Page 148: ...n iH0 seconds 220 13 4 min Fuel filter Type Low pressure side Nylon element High pressure side Paper element Pressure regulator Type Diaphragm Regulating pressure kPa kg cm2 psi 2 3 5 2 7 5 2 4 2 8 34 40 Injector Type High ohmic Type of drive Voltage Resistance Q 12 16 Injection amount cc cu in 15 seconds 6 6 9 i 4 03 5 55 Idle speed control valve Solenoid resistance n I i I I I I 05 C O I CO CO I...

Page 149: ...ty cc cu in 10 seconds 220 13 4 min Fuel filter Type Low pressure side Nylon element High pressure side Paper element Pressure regulator Type Diaphragm Regulating pressure kPa kg cm2 psi 235 275 2 4 2 8 3 4 4 0 Injector Type High ohmic Type of drive Voltage Resistance 0 1 2 1 6 11 15 Injection amount cc cu in 15 seconds 4 4 6 1 2 68 3 72 73 90 4 45 5 49 idle speed control valve Solenoid resistance...

Page 150: ...spark advance crank angle engine speed degree rpm F6 2 2 1 000 6 10 2 100 14 18 6 100 F8 2 2 1 000 10 14 2 100 18 22 6 100 FE 8 VALVE Unleaded fuel MTX 2 2 1 760 12 16 3 360 22 26 5 320 ATX 2 2 1 300 12 16 3 360 22 26 5 320 Others 2 2 1 460 10 14 2 540 22 26 5 540 FE 12 VALVE 2 2 1 200 10 14 2 400 10 14 4 000 16 20 5 000 Vacuum spark advance Crank angleA acuum degree mmHg inHg F6 and F8 2 2 100 3 ...

Page 151: ...eduction Others Output V kW 1 2 1 4 Brush length mm in Standard 17 5 0 689 Minimum 10 0 0 394 Ignition timing 6 1 BTDC Vacuum hose disconnected 9 1 BTDC Test connector ground Distributor Type Fully transistorized HEI Electronic spark advance Centrifugal spark advance crank angle engine speed degree rpm F2 Non Turbo 1 2 2 1 200 9 8 16 2 400 12 16 3 500 16 20 4 500 Vacuum spark advance crank angle v...

Page 152: ...ce to floor when clutch LHD 68 2 7 or more fully disengaged mm in RHD 85 3 3 or more Flywheel Deflection mm in 0 2 0 008 max Grinding limit mm in 0 5 0 020 max Clutch disc Type Single dry plate Set load N kg lb 3434 350 770 3846 392 862 4316 440 968 5499 560 1235 Runout mm in 1 0 0 039 max Wear limit mm in 0 3 0 012 from rivet head Outer diameter mm in 200 7 874 215 8 465 225 8 858 240 9 449 Inner...

Page 153: ... clearance mm in First 0 0 5 0 2 8 0 002 0 011 0 130 0 354 0 0051 0 0139 Second 0 1 8 0 4 6 0 007 0 018 0 150 0 262 0 0059 0 0103 Third 0 0 5 0 2 0 0 002 0 008 0 150 0 262 0 0059 0 0103 Fourth 0 17 0 37 0 0064 0 014 0 150 0 262 0 0059 0 0103 Bearing preload of primary shaft gear N m cm kg in lb Primary shaft 0 1 0 25 1 0 2 5 0 86 2 18 Secondary shaft 0 2 0 4 2 0 4 0 1 7 3 4 Bearing preload adjust ...

Page 154: ... 1 5 Line pressure D S L Idle kPa kg cm2 psi 353 432 3 6 4 4 51 63 350 490 3 6 5 0 51 71 Stall kPa kg cm2 psi 873 1 040 8 4 10 6 127 151 980 1230 10 0 12 5 142 178 R Idle kPa kg cm2 psi 598 942 6 1 9 6 87 137 600 830 6 1 8 5 87 121 Stall kPa kg cm2 psi 1 668 2 011 17 0 20 5 242 292 1470 1960 15 0 20 0 213 284 Throttle pressure D Idle kPa kg cm2 psi 3 9 8 8 0 4 0 9 6 13 8 3 1 1 3 0 85 1 15 12 16 St...

Page 155: ... 2 900 3 450 3 350 4 000 8 9 1 0 7 55 66 Lock up ON 0D 2 050 2 500 2 400 2 850 9 1 1 0 9 56 68 Lock up OFF 0D 1 950 2 350 2 250 2 700 8 5 1 0 3 53 64 OD D3 1 600 1 950 1 400 1 850 7 0 8 6 43 5 3 54 70 33 43 D3 D2 1 200 1 550 1 250 1 550 3 8 4 8 24 3 0 34 42 21 26 OD D3 3 500 3 700 3 550 3 800 153 163 95 101 OD D2 2 050 2 250 9 0 9 8 56 61 8 9 9 7 5 5 6 0 Kick down OD Di 950 1 100 1 000 1 150 4 2 4...

Page 156: ...urbo Non Turbo FE engine F8 engine Torque converter Stall torque ratio 1 600 1 800 1 O 0 1 CD O o 1 900 2 100 1 Bushing diameter mm in Standard 53 030 2 088 Maximum 53 076 2 090 Oil pump Clearance Cam ring to oil pump cover mm in Standard 0 005 0 020 0 0002 0 0008 Maximum 0 080 0 003 Rotor to oil pump cover mm in Standard 0 005 0 020 0 0002 0 0008 Maximum 0 030 0 0012 Vane to oil pump cover mm in ...

Page 157: ... 0 0 276 7 2 0 283 7 4 0 291 7 6 0 299 i 4 clutch lumber of drive driven plates 5 5 4 4 rive plate thickness mm in Standard 1 6 0 063 Minimum 1 4 0 055 4 clutch clearance mm in 1 3 1 5 0 051 0 059 ietaining plate sizes mm in 3 8 0 150 4 2 0 165 4 6 0 181 4 0 0 157 4 4 0 173 4 8 0 189 4 8 0 819 5 0 0 197 5 2 0 205 5 4 0 213 5 6 0 220 leturn spring free length mm in 33 2 1 307 ow and reverse brake l...

Page 158: ...aroon Lock up control spring 5 0 0 197 35 2 1 386 0 6 0 024 Purple Control valve springs G4A HL Spring name Outer dia mm fn Free length mm in Wire dia mm in Spring color 1 2 accumulator small spring F8 engine 9 9 0 400 84 7 3 335 1 2 0 047 Red 1 2 accumulator large spring FE engine 13 0 0 512 73 2 2 881 1 8 0 071 Pink F8 engine 16 0 0 630 84 7 3 335 2 0 0 079 White Bypass spring 5 0 0 197 25 1 0 9...

Page 159: ...e mm in 1 2 0 047 1 4 0 055 1 6 0 063 1 8 0 071 2 0 0 079 2 2 0 087 Idle qear bearing preload N m cm kg in lb 0 03 0 9 0 3 9 0 0 26 7 8 preload adjust shims mm in 0 10 0 004 0 12 0 005 0 14 0 006 0 16 0 0063 0 18 0 007 0 20 0 008 Output gear bearing preload N m cm kg in lb 0 03 0 9 0 3 9 0 0 26 7 8 Preload adjust shims mm in 0 10 0 004 0 12 0 005 0 14 0 006 0 16 0 0063 0 18 0 007 0 20 0 008 0 50 0...

Page 160: ...9 8 0 4 1 0 6 1 4 Shift point Range Throttle condition manifold vacuum Shifting Shift point speed km h mph D Fully opened 0 100 mmHg 0 3 94 inHg 1st 2nd 4 7 5 7 29 35 4 4 5 4 27 33 2nd 3rd 1 0 6 1 1 9 6 6 7 4 9 5 1 0 8 59 67 3rd 2nd 95 103 59 64 8 6 9 4 53 58 2nd 1st 35 39 2 2 2 4 3 4 3 8 21 24 Half throttle 130 mmHg 5 12 inHg 1st 2nd 18 3 1 11 19 18 31 11 19 2nd 3rd 39 68 24 42 4 4 7 3 27 45 Full...

Page 161: ...nd reverse brake Number of low and reverse brake plates 4 Drive plate thickness mm in Standard 1 6 0 063 Minimum 1 4 0 055 Low and reverse brake clearance mm in 0 8 1 05 0 032 0 041 Retaining plate sizes mm in 4 6 0 181 4 8 0 189 5 0 0 197 5 2 0 205 5 4 0 213 5 6 0 220 Return spring free length mm in 27 7 1 091 Servo Return spring free length mm in 48 0 1 89 45 5 1 79 Governor Primary spring mm in...

Page 162: ...0 028 1 00 0 039 Backlash of side gear and pinion mm in Standard 0 025 0 1 0 001 0 004 Maximum 0 5 0 020 Torque converter distance A Refer to 7C 118 mm in 20 0 787 9 FRONT AND REAR AXLES Item Engine model F6 F8 FE F2 Non Turbo F2 Turbo Driveshaft Length of joint MTX 368 5 14 51 360 0 14 17 355 5 14 00 between centers of joints mm in ATX 359 5 14 15 355 5 14 00 348 8 13 73 Shaft diameter mm in MTX ...

Page 163: ...25 0 98 b 30 1 18 Length of lining mm in a 191 9 7 56 b 219 3 8 63 Inner diameter of drum mm in Standard a 200 0 7 87 b 228 6 9 00 Maximum a 201 5 7 93 b 230 1 9 06 Wheel cylinder bore mm in 17 46 0 687 tear disc jrake Type Disc solid Thickness of pad mm in Standard 8 0 0 31 Minimum 1 0 0 04 Area of pad mm2 in2 2 900 4 5 Outer diameter of disc plate mm in 259 10 2 Thickness of disc plate mm in Sta...

Page 164: ...e Unbalance 9 oz 13 inch wheel 11 0 39 max 14 inch wheel 10 0 35 max 15 inch wheel 9 0 32 max 13 SUSPENSION Item Specification Front suspension Type Strut Front wheel alignment Toe in mm in 3 3 0 12 0 12 Camber angle 0 17 45 Caster angle 1 13 45 King pin angle 12 47 Maximum front steering angle Inner 36 26 33 a 34 00 2 Outer 30 59 15 a 29 00 2 Stabilizer Type Torsion bar Diameter mm in 20 0 0 79 C...

Page 165: ... 46 11 9 0 47 12 1 0 48 12 2 0 48 12 4 0 49 Coil inner diameter mm in 127 5 5 0 Free length mm in 314 12 4 323 12 7 327 12 9 332 13 1 336 13 2 I Coil number 5 72 5 87 6 03 6 04 6 21 Refer to pages 13 5 tor coil spring applications 15 BODY ELECTRICAL SYSTEM Item Specification W Front exterior lights Halogen headlight 60 55 Side turn and turn signal light 21 Position light 5 Rear exterior lights Bac...

Page 166: ... Nm m kg ft lb 6 0 236 1 0 039 4 2 6 2 0 43 0 63 3 1 4 6 6 9 9 8 0 7 1 0 5 0 7 2 7 8 11 8 0 8 1 2 5 8 8 8 8 0 315 1 25 0 049 9 8 14 7 1 0 1 5 7 2 10 8 1 6 2 3 1 6 2 3 12 17 18 26 1 8 2 7 1 3 2 0 10 0 394 1 25 0 049 20 28 2 0 2 9 14 21 3 1 4 6 3 2 4 1 2 3 3 4 36 54 3 7 5 5 2 7 4 0 12 0 472 1 5 0 059 3 4 5 0 3 5 5 1 2 5 3 7 55 80 5 6 8 2 41 59 63 93 6 4 9 5 4 6 6 9 14 0 551 1 5 0 059 75 103 7 7 10 5...

Page 167: ...troduction greeting Time Available Monday through Friday 6 00am to 5 00pm PST IMPORTANT STEPS TO FOLLOW BEFORE CONTACTING THE TECHNICAL ASSISTANCE HOTLINE 1 Perform related Workshop Manual diagnostic procedures and check related Service Bulletins Electronic Service Information ESI M T ip s O n L in e in fo rm a tio n W a rra n ty h is to ry fo r p re vio u s re la te d re p a ir a tte m p ts Speci...

Page 168: ...up phone survey This survey is conducted three to five days after your initial call to the Hotline You may be asked nine short questions on how your initial call was handled These calls are made on a random basis so you will not be surveyed on every call you make to the Hotline Your input is very important to us and we will use it to improve the services that we provide Remember the technical assi...

Page 169: ... of this card and tester MNET 2000 ORDER PROCEDURE If you want to receive a new NGS V9 0 Card earlier before the cutoff date of July 26 2000 please submit an order thorough M NET Mazda s computer based information and order fulfillment system You will find information describing the ordering process in the M NET Operations Guide PRICING The price for the NGS V9 0 reprogramming exchange is 279 07 p...

Page 170: ...small box with your Service Manager s business card taped to the NGS card Send the package to the following address 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 Note DO NOT SEND YOUR V8 0 NGS CARD Use this V8 0 card until you...

Page 171: ...ctors for the positive connection needed to insure the best electrical contact in order to provide accurate feedback through the vehicle s WDS NGS Testing system 14 44 14 44 8 75 49 L088 001 Solder Heating Tool Portable butane tool used to melt the Butt s connecting solder and shrink the plastic tube to fuse waterproof the repair 28 00 49 L088 005 Wire Stripper Used to cut and strip the wire of th...

Page 172: ... your shipping I receiving personnel of this tool shipment MNET 2000 ORDER PROCEDURE Please submit any additional Mazda Special Service Tool orders through MNET 2000 Mazda s computer based information and order fulfillment system You will find information describing the ordering process in the MNET 2000 Operations Guide CUSTOMER SERVICE Mazda s tool supplier America Kowa Seiki 800 824 9655 will sh...

Page 173: ...acement Pin w Pigtail 10 Pack 19 00 49L0 88 0A3 024 Replacement Pin w Pigtail 10 Pack 19 00 49L0 88 0A3 025 Replacement Pin w Pigtail 10 Pack A 19 00 49L0 88 0A3 026 Replacement Pin w Pigtail 10 Pack m i i tT kr 19 00 49L0 88 0A3 027 Replacement Pin w Pigtail 10 Pack 19 00 49L0 88 0A3 028 Replacement Pin w Pigtail 10 Pack 19 00 C O N S U M E R N O T IC E T h e in fo rm a tio n a n d in stru ctio n...

Page 174: ... Guide or by using the MNET 2000 Help feature SHIPPING AND BILLING INFORMATION This kit will be shipped via RPS to your service department during the week of January 21 2002 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 6596 Do not send your payment to Amer...

Page 175: ...ZDA 02 unit 750 00 789 00 MAZDA 20 Replacement drawer pull inserts pkg 21 20 00 20 00 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 ca...

Page 176: ...call Mazda Special Service Tools 949 442 6596 Monday through Friday 9 00 am to 5 00 pm PST SST STORAGE CABINET SYSTEM UPDATE INFORMATION New Model Tool drawer liner updates are automatically sent to your Service Department enclosed in drawer numbered envelopes This information consists of easy update instructions drawer liner update stickers storage cabinet drawer index and any necessary drawer di...

Page 177: ...2 211 185 Pump Pulley Replacer 4 00 303 463 Cam shaft Seal Protector 303 464 Cam shaft Seal Replacer 303 384 Rear C rankshaft Adapter Bolts 49L0 18 001 0 2 Sensor W rench MZ00299C 15 49L0 14 001 Pressure Gauge Adapter 4 00 MZ00299D 19 303 335 C rankshaft Seal Installer 4 00 Service Bulletin 005 99 issued 10 14 99 MNET P art SST SCS D raw er Mazda Required Tool N um be r Special Tool Description MN...

Page 178: ...rvice Bulletin 002 00 issued 06 23 00 MNET P a rt SST SCS Drawer Mazda Required Tool N um ber Special Tool Description MNET PRICE 307 428 307 429 RH Half shaft Fluid Seal Installer RH Half shaft Fluid Seal Remover 308 427 PTO Shaft InnerVOuter Oi Seal Installer MZ00200K 21 308 428 PTO Driven Gear Oil Seal Remover 4 00 308 429 PTO Driven Gear Oil Seal Installer 308 430 PTO Drive Gear Oil Seal Insta...

Page 179: ...9N0 17 209 Oil Seal Installer MZ00301C 16 49N0 17 2A0 Clutch Hub Installer Set 4 00 MZ003D1D 16 49N0 17 2A1 Clutch Hub Puller Set 4 00 Service Bulletin 005 01 issued 06 06 01 MZ00501A 14 49B0 66 8010 Radio Removal Tool 4 00 49B0 66 8020 Radio Removal Tool Service Bulletin 008 01 issued 10 15 01 MZ00801A 9 205 126 Holding Tool 4 00 204 069 Front W heel Hub Installer MZ00801B 14 303 507 Crankshaft T...

Page 180: ...rdered at the existing prices however effective October 1 2000 new prices will take effect as shown in the table below SST Storage Cabinet System Current Price New Price Mazda 01 3 low cabinets with 21 drawers 2 395 00 2 629 00 Mazda 02 3 low cabinets with 21 drawers and steel top 2 595 00 2 849 00 Mazda 03 3 low cabinets with 21 drawers shelf riser and 3 bookcases 3 195 00 3 599 00 Mazda 04 2 hig...

Page 181: ...ethod Equipment shall be sold F O B Manufacturer s shipping point commercial carrier freight pre paid Equipment and shipping charges will be automatically invoiced to your dealer parts account Questions regarding this invoice should be directed to Mazda Special Service Tools Equipment 949 442 6596 Do not send your payment to Equipment Solutions and advise your shipping receiving personnel of this ...

Page 182: ...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 tant link between your dealership and MazdaAppr...

Page 183: ...ecessary please use Mazda MNET 2000 Order Tracker to track your shipment Equipment shall be sold F O B Manufacturer s shipping point commercial carrier freight pre paid Your dealer parts account will be automatically invoiced for the equipment and shipping charges Questions regarding this invoice should be directed to Mazda Special Service Tools Equipment 949 442 6596 Do not send your payment to E...

Page 184: ...is 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 tant link between your dealership and Mazda approved equipment suppliers They will be callin...

Page 185: ...t and shipping agent 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 specialtoolseauipment mazdau s a com C O N S U M E R N O T IC E T h e in fo rm a iio n an d in stru ctio n s in th is bulletin a r e In te n d e d fo r u s e b y skilled ...

Page 186: ...575 00 162 00016 Mazda IR Printer and Carrying Case 220 00 220 00 SHIPPING AND BILLING INFORMATION Automatic shipment should occur during the week of April 29 2002 Your dealer parts account will be automati cally invoiced for this tester kit and if your Accounting Department has questions regarding this invoice please call Mazda Special S e rvice Tools 9 4 9 4 4 2 6 5 9 6 P le a s e ad v is e y o ...

Page 187: ...ing the ordering process in the MNET 2000 Operations Guide CUSTOMER SERVICE Mazda s tool supplier America Kowa Seiki 800 824 9655 will ship the tools to your service department Please call this toll free number for warranty questions product information pricing shipping and ordering assistance Customer Service Representatives are available from 9 00 AM until 5 00 PM PST Monday through Friday SST S...

Page 188: ...C 49N0 17 201 Setting Plate 49N0 17 2Q2 Handle V 49N0 17 203 Stopper PAGE 2 OF 3 ...

Page 189: ...ate Issued 06 6 01 Revised 49N0 17 204 Setting Plate 49N0 17 207 Shaft Stopper 49N0 17 2Q8 Guide Pin 49N0 17 209 Oil Seal Installer 49N0 17 2A0 Clutch Hub Installer Set 49N0 17 2A1 Clutch Hub Puller Set D PAGE 3 OF 3 ...

Page 190: ...ventory are the dealer s responsibility Refer to the Warranty Policies and Procedures Manual concerning inventory vehicles If you encounter a discharged Maintenance Free MF type calcium based battery from a customer com plaint follow the procedures described in this Service Bulletin for inspection charging and testing operations NOTE The MF type battery can recover its original performance by boos...

Page 191: ...or skin rinse off immediately with water Always wear safety goggles or face shield when servicing a battery CHARGING PROCEDURE Recharge an MF type battery at a rate of 20 30A for two 2 hours NOTE Most battery chargers require a boost range setting to obtain a sufficient amperage 20 30A x 2 hrs 40 60 A H CAUTION The battery must be removed from the vehicle and put in a well ventilated area Do not e...

Page 192: ...9 6 V Replace Battery 2 Check current draw from battery as described in Service Bulletin Category 5 no 017 88 3 Check charging system as per Workshop Manual WARRANTY INFORMATION Customer Comment Code 5A Damage Code 62 Part No of Main Cause Part No of Applicable Battery Operation No G0501X C X Inspection Charging Testing o f Battery Labor Hour 0 3 Hr NOTE In ALL circumstances record the results of ...

Page 193: ...as shown below in order to increase the strength of the threaded portion o f the primary shaft Due to the modification the synchronizer gear sleeve and lock nut shown in the illustration have also been modified accordingly Therefore the modified primary shaft must be installed together with the modified synchronizer gear sleeve and lock nut 0 1 3 5 8 1 IMPORTANT Service and Parts Managers should r...

Page 194: ...er 14 1988 1989 323 Turbo vehicles JM 1BF234 K0314527 August 1 1988 PARTS INF rlMATION PART NUMBER DESCRIPTION INTERCHANGEABILITY APPLIED MODEL NEW OLD G512 17 201F G512 17 201E Primary Shaft NO 88 323 T C 4WD G511 17 201F G511 17 201E Primary Shaft NO 88 323 T C 2WD 88 626 MX 6 F520 17 628 G502 17 629A Lock Nut NO 88 323 T C 88 626 MX 6 G501 17 328A G501 17 328 Synchronizer Gear Sleeve NO 88 323 ...

Page 195: ...ust pipe PROBLEM CONDITIONS 1 Spark plugs are fouled with oil and fuel 2 Oil level is low A modification has been introduced in produc tion since March 1989 In connection with that modification clips have been installed on the inlet valve guides VIN OF PRODUCTION CHANGE 1988 1989 626 M X 6 Vehicles manufactured in Japan J M 1 G D K 1 7 5 3 7 1 1 March 1989 1989 MX 6 Vehicles manufactured in the U ...

Page 196: ...ust pipe PROBLEM CONDITIONS 1 Spark plugs are fouled with oil and fuel 2 Oil level is low A modification has been introduced in produc tion since March 1989 In connection with that modification clips have been installed on the inlet valve guides VIN OF PRODUCTION CHANGE 1988 1989 626 M X 6 Vehicles manufactured in Japan J M 1 G D K 1 7 5 3 7 1 1 March 1989 1989 MX 6 Vehicles manufactured in the U ...

Page 197: ...hat the customer may also describe this complaint as a low or rough idle and not necessarily complain of vibration Therefore confirm the customer complaint carefully before attempting any repair PRODUCTION CHANGE No 1 Engine Mount and Radiator Lower Mount Rubbers have been changed as follows No 1 Engine Mount The diameter o f the rubber has been increased from 3 15 in to 3 54 in since the November...

Page 198: ...2A Radiator Lower Mount NEW OLD ATX w o Turbo B61A 15 202 F202 15 202B Radiator Lower Mount NEW OLD ATX w Turbo REPAIR PROCEDURE 1 Check that the idle speed is within the specification Idle Speed 750 25 RPM in P range If the idle speed is not within the specification adjust it to 750 RPM with test connector grounded 2 Replace the radiator lower mounts with the modified ones if the vehicle was prod...

Page 199: ...e and discard the No 2 silencer hanger and rubbers which are located in front of the pre silencer After removing the hangers from the body reinstall bolts into the body to pre vent water from entering 8 In a case where the idle vibration is not solv ed to a satisfactory level ground the test con nector and adjust the idle speed to 9 5 0 1 0 0 0 RPM WARRANTY INFORMATION Customer Comment Code Damage...

Page 200: ...on SERVICE PROCEDURE 1 Remove the four 4 wheel and tire assemblies 2 Using a wire brush steel wool or other suitable material remove the corrosion from front hubs rear axle flanges and wheel center bore 3 Apply grease lithium base NLGL No 2 to the wheel center bore NOTE Do not allow grease in the wheel lug nut seats or on the wheel stud 4 Reinstall the wheels on the vehicle VIN OF PRODUCTION CHANG...

Page 201: ...s during PDI or encounter customer complaints regarding sunvisor operation i e sunvisor will not adjust up or down or will not remain at a set position Check the adjustment screw as shown prior to replacement Adjust the screw to enable the driver and or passenger to rotate the sunvisors to any set position Adjust Screw 0 1 3 5 8 6 Im p o r t a n t Service and Parts Managers should read this bullet...

Page 202: ...ns Category 14 No s 051 88 and 055 88 NOTE Repair parts for this bulletin are available as a kit for each model described Condition of Complaint A Wind noise at front door area during high speed driving B Wind noise at rear door corner area C Wind noise fluttering noise at rear comer window area NOTE For examples of areas mentioned see illustration below C Rear Quarter Window Area A Front Window A...

Page 203: ...5 MX 6 Produced in Japan JM 1G D 31 K1709751 MX 6 Produced in the U S A 1Y V G D 31 K5204343 August 1 1988 October 1 1988 March 1 1988 May 1 1988 Febniary 1 1988 Ap 1988 Al 1 1988 Set iber 1 1988 B Rear Window Area except MX 6 1 2 626 4 Door 5 Door JM IG D J1573274 3 Production change has not been made yet March 1 1988 C Quarter Window Area 626 4 Door 5 Door MX 6 Produced in Japan MX 6 Produced in...

Page 204: ...e sail garnish 2 Remove mirror and install pad on lower side of base as shown in the illustration 3 Install seal rubber P N GJ25 69 1IX RH P N GJ25 69 17X LH B Power Mirror 1 Remove seal rubber 2 While holding mirror assembly between thighs push the assembly in the direction indicated by the arrows shown in the illustration and install new seal rubber Seal Rubber P N GJ35 69 IIX RH P N GJ35 69 17X...

Page 205: ...ION 2 GLASS INNER WEATHERSTRIP ALL DOORS 1 Remove door trim 2 Replace glass inner weatherstrip with new strip NOTE New strip has an added length in the lip area MX 6 P N GJ21 58 82IB RH GJ21 59 82IB LH 4 Door Sedan 5 Door Hatchback P N G211 58 821A Front RH G 211 59 821A Front LH G211 72 82IB Rear RH G211 73 82IB Rear LH 3 If item 4 repair is to be performed do not reinstall the door pan at otherw...

Page 206: ...ip to the back of the glass run channel from the circled area Pad Size Length 400 mm Thickness 2 mm Width 10 mm LOCATION 4 GLASS GUIDE RAIL Front Door 1 Remove the 3 screws which secure the glass guide rail and remove door panel 2 Pull the glass guide rail toward the inside of the window frame and up Move the window glass toward the front o f the vehi cle as shown Page 5 of 15 ...

Page 207: ...emaining length of the pad 10 mmj should be pinched so that the sides stick together 4 Reinstall glass guide rail and door panel CAUTION For ease of installation door glass must be up approximate ly 4 in LOCATION 5 A PILLAR AREA 1 4 5 Door Models A Open front door and remove the fix ing screw from the lower side of the drip molding B For 4 5 Door models remove original screw boss from pillar and d...

Page 208: ...evised C Install a protector between the drip molding and the A pillar D Reinstall the fixing screw and insert the protector inside the cavity of the front fender Front Fender Protector 2 MX 6 A Cut the boss off o f the protector Page 7 of 15 ...

Page 209: ...d 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 1 Lower window all the way 2 Pull off the rear comer section of the glass run channel Pare 8 15 ...

Page 210: ...ed by the circle in the illustration Reinstall the Glass Runchannel Pad Length 4 Door Sedan 257 mm P N GK59 72 618B 5 Door Hatchback 286 mm P N G306 72 7F1 A Pad Thickness 3 mm Pad Width 5 mm 4 Install a pad P N GK59 72 619 on the reverse side of the comer lip see illustra tion Location 2 Portion to improve the sealing effectiveness Page 9 of 15 ...

Page 211: ...6 Using a flat screwdriver remove the in ner sail garnish by prying it out at the area shown by illustration and install a new level inner sail garnish NOTE Using a flat screwdriver pry sail garnish out of its location starting from the lower rear comer then working forward as per illustra tion Also care must be taken not to damage paint on the sur rounding area 7 Perform rear door weatherstrip im...

Page 212: ... of silicone sealer as shown in the illustration 2 Clean the rear quarter window glass and apply silicone between the glass and the garnish 3 Using a spatula push the silicone into the area between the glass and garnish 4 Remove all protruding silicone NOTE Silicone will cure and become hard in approximately 24 hours Page 11 of 15 ...

Page 213: ...ip Glass In LH 1 GJ21 50 517 A Pillar Protect H 1 GJ21 50 537 A Pillar Protec H 1 GJ21 50 G27 t Rear Quarter Window Protector GJ25 69 1IX Manual Mirror Seal Rubber RH 1 GJ25 69 I7X Manual Mirror Seal Rubber LH 1 GJ35 69 1IX Power Mirror Seal Rubber RH 1 GJ35 69 17X Power Mirror Seal Rubber LH 1 GJ21 69 12X Seal Packing 2 NOTE The parts indicated by t are not necessary Please discard them Repair pa...

Page 214: ...In Rr RH 1 G211 73 821B Weatherstrip Glass In Rr LH 1 G211 50 517 A Pillar Protector RH 1 G 211 50 537 A Pillar Protector LH 1 G225 50 G27 t Rear Quarter Window Protector 2 G225 50 807 t Rear Quarter Window Seal Rubber 2 G225 68 4BX Sail Garnish Assembly RH 1 G225 68 4BY Sail Garnish Assembly LH 1 GJ25 69 1IX Manual Mirror Seal Rubber RH 1 GJ25 69 17X Manual Mirror Seal Rubber LH 1 GJ35 69 11X Pow...

Page 215: ...In Rr RH 1 G211 73 8 2 IB Weatherstrip Glass In Rr LH 1 G211 50 517 A Pillar Protector RH 1 G211 50 537 A Pillar Protector LH 1 G211 50 G27 t Rear Quarter Window Protector 2 G 211 50 807 t Rear Quarter Seal Rubber 2 G211 68 4BX Sail Garnish Assembly RH 1 G 211 68 4BY Sail Garnish Assembly LH 1 GJ25 69 U X Manual Mirror Seal Rubber RH 1 GJ25 69 17X Manual Mirror Seal Rubber LH 1 GJ35 69 1IX Power M...

Page 216: ... Wind noise fluttering noise from rear quarter garnish XX0252RX 0 3 Hr B Wind noise at rear door area XX0274RX 0 5 Hr C Wind noise at front door area and door mirror XX0312RX 1 2 Hr D A B C XX0311RX 2 0 Hr Condition 2 MX 6 REPAIR OPERATION NO LABOR HOURS A Wind noise fluttering noise from rear quarter garnish XX0252RX 0 3 Hr B Wind noise at front door area and door mirror XX0312RX 1 2 Hr C A B XX0...

Page 217: ...ray 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 MANUFACTURER PRODUCT Tech Spray Anti stat National System Corporation antistat ACL Incorporation Staticide Chemtronics Inc Static Free Before using the spray carefully read the instructions of each product IMPORTANT Service and Parts...

Page 218: ... 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 If you encounter this problem replace the lock plate in the accessory arm rest with a modified one PARTS INFORMATION PART NUMBER DESCRIPTION NEW OLD GJ30 VO 636A GJ30 VO 636 Lock Plate Arm Rest 4 Z L i u Stopper GJ30 VO 636A 0 1 6 0 0 4 IMPORTANT S w vic and Paita M...

Page 219: ... the hose causes the hose and balls to get out of position resulting in improper operation of the power window regulator REPAIR PROCEDURE Replace the power window regulator guide assembly the motor bracket and the sprocket with the new one and change the hose routing according to the following instructions 1 Remove the power window regulator from the door 2 Disconnect the power window motor from t...

Page 220: ...the door and route the hose as shown Refer to the following 1988 or 198 Workshop Manual pages for proper disassembly assembly and adjustment procedures Model 1988 1989 323 323W 626 MX 6 929 RX 7 14 15 14 17 14 13 14 15 14 13 14 22 14 9 14 17 14 27 14 33 14 15 14 17 14 12 14 14 14 13 14 20 14 9 14 17 CHANGE OF HOSE ROUTING 626 Front Rear Doors and 929 Front Door 626 Front 1 Fix the hose at the two ...

Page 221: ...on 11mm 0 4in Quick Reference of Repairs for Each Model Model Door Repair 323 323W Front Power window regulator guide assembly R R 626 Front Rear Change of hose routing Power window regulator guide assembly R R Motor bracket and sprocket R R MX 6 Front Power window regulator guide assembly R R Motor bracket and sprocket R R RX 7 Front Power window regulator guide assembly R R Sprocket R R 929 Fron...

Page 222: ...12 59 590 Rear G212 590 G212 73 590 626 HB 5 Door Front G226 590 G226 59 590 Rear G226 72 590 G226 73 590 MX 6 Front GJ22 58 590A GJ22 59 590A 929 Front H261 58 590 H261 59 590 Rear H261 72 590 H261 73 590 RX 7 Front FB05 58 590B FB05 59 590B 2 Motor Bracket Model Door Right Side Left Side 626 Front H261 58 598 H261 59 508 Rear G212 72 598 G212 73 MX 6 Front H261 58 598 H261 59 s 929 Front H261 58...

Page 223: ...0202471 July 8 1988 RX 7 JM 1FC33 J0626331 July 1 1988 WARRANTY INFORMATION Customer Comment Code Damage Code Part No of Main Cause Operation No Labor Hours 7J 82 Part No of Power Window Regulator Guide Assembly see Page 4 of 5 Regulator R R Refer to S R T Manual Hose Rerouting XX0299RX Original Motor R R XX0298RX Regulator R R Refer to S R T Manual Hose Rerouting 0 2 Hr exclude regulator R R Orig...

Page 224: ...ay crack and this will cause electrical malfunction of C P U In this case replace the C P U with the modified one as shown The modified C P U has been installed in the production vehicles since November 1 1988 VIN OF PRODUCTION CHANGE 1989 MX 6 produced in the U S A 1YVGD31 K5212501 November 1 1988 1989 626 MX 6 produced in Japan JM 1G D K 1731830 November 1 1988 PARTS INFORMATION PART NUMBER DESC...

Page 225: ...l may crack and this will cause electrical malfunction of C P U In this case replace the C P U with the modified one as shown The modified C P U has been installed in the production vehicles since November 1 1988 VIN OF PRODUCTION CHANGE 1989 MX 6 produced in the U S A 1YVGD31 K5212501 November 1 1988 1989 626 MX 6 produced in Japan JM 1G D K 1731830 November 1 1988 PARTS INFORMATION PART NUMBER D...

Page 226: ...mplaint results from specific characteristics o f FM radio waves If so the complaint cannot be corrected by audio component replacement Use the following materials with the attached flow chart when carrying out inspection and repair of the audio system Audio System Troubleshooting Procedures plastic sheet Service Bulletin Category 15 050 87 FM Reception Audio Customer Questionnaire Workshop Manual...

Page 227: ... Date Issued 5 5 89 Date Revised AUDIO SYSTEM TROUBLESHOOTING Obtain DETAILED AND ACCURATE customer com plaint information by filling out the Audio Customer Questionnaire Reproduce the complaint Customer Page 2 of 2 ...

Page 228: ...n 4th speed Hard to change Rec Fresh Modified parts have been incorporated into production vehicles since September 1988 VIN OF PRODUCTION CHANGE J M I G D K 1716188 September 1988 PARTS INFORMATION PART NUMBER DESCRIPTION INTERCHANGEABILITY NEW OLD GJ21 61 140E GJ21 61 HOD Blower Unit NEW OLD GJ21 61 B01A GJ21 61 B01 Case A NEW P OLD GJ21 61 B02A GJ21 61 B02 Case B NEW P OLD GJ21 61 B05 Rec Fresh...

Page 229: ...Blower Unit WARRANTY INFORMATION Customer Comment Code 7J Damage Code 83 Part No of Main Cause GJ21 61 B05 Operation No XX0307RX Labor Hours 0 7 Page 2 of 2 ...

Page 230: ...the market caution must be taken when in stalling these filters When installing after contact is made between the oil filter O ring and the O ring sealing surface use a suitable wrench and tighten the filter 1 1 6 turns more NOTE Six dots are printed on the cartridge at even intervals to facilitate tightening instructions see illustration below IMPORTANT Service and Parts Managers should read this...

Page 231: ...hen REGULAR UNLEADED fuel is used Due to the low volatility of some SUPER UNLEADED fuels an overlean air fuel condition may occur especially when cold This may result in start and driveability problems We urge you to NOT recommend the use of SUPER UNLEADED gasoline to your customers Also if a customer complains about a rough idle after starting inquire as to what type of fuel the customer has been...

Page 232: ...arm up the engine and check that the idle speed is within the specifi cation Idle Speed 750 25 RPM in Neutral with Test Connector grounded 2 With the test connector NOT ground ed check for a fluctuation in the idle when the head lights and rear defroster are turned ON If fluctuation is pre sent ground the test connector and ad just the idle speed to 950 1Q00 RPM in neutral with the parking brake a...

Page 233: ...r procedure REPAIR PROCEDURE 1 Warm up the engine and check that the idle speed is within the specifi cation Idle Speed 750 25 RPM in Neutral with Test Connector grounded 2 Check if the idle fluctuation occurs when the head light and rear defrost er are turned on If the fluctuation is still present adjust the idle speed to 950 1000 rpm with the test connector grounded in Neutral or N Range Engine ...

Page 234: ...st This information is critical to the program s success Do not Include the bracket when returning the core The bracket should be used when Installing the remsnufsctured control unit Please return cores WITHIN 7 DAYS to Insure continued avsllablllty of remsnufsctured units PARTS INFORMATION RX 7 Models Remanufactured EGI Control Unit Application Replaces New EGI Control Unit N304 18 881R 84 85 GSL...

Page 235: ... 881R 88 89 626 M X 6 Turbo CA A T M T 2WS F222 18 880J F225 18 88IR 88 89 626 MX 6 Turbo FED 4WS F225 18 880B F226 18 8 8 IR 88 89 626 MX 6 Turbo CA 4WS F226 18 880B F285 18 88IR 90 626 MX 6 Non Turbo FED M T Japan Make F286 18 88 IR 90 626 MX 6 Non Turbo FED A T Japan Make F287 18 88IR 90 626 M X 6 Turbo FED 2WS Japan Make F289 18 881R 90 MX 6 Turbo 4WS Japan Make F294 18 881R 90 626 M X 6 Non T...

Page 236: ... CA A T M T Also 89 626 MX 6 Non Turbo CA M T Up to JM 1G D K 1737082 1Y V G D K5223617 F203 18 880L ZPA3 18 881R 89 626 M X 6 Non Turbo CA M T From J M 1 G D K 1 7 3 7 0 8 3 1YVGD K5223618 F203 18 880M F204 18 881R 89 626 MX 6 Non Turbo CA A T Up to JM 1G D K1737083 1YVGD K5223617 F204 18 880A ZPA4 18 881R 89 626 MX 6 Non Turbo CA A T From J M 1 G D K 1 737082 1Y V G D K5223618 F204 18 880B F262 ...

Page 237: ...nit JE15 18 881R 89 3 0 Liter JE15 18 880F NOTE 89 2 6 Liter uses G601 18 880A which is NOT included in the remanufactured EGI control unit program Miata Model Remanufactured EGI Control Unit Application Replaces New EGI Control Unit B61P 18 88IR 90 Miata WARRANTY INFORMATION Remanufactured EGI units are warranted for the first 12 months regardless o f mileage from the date of installation by a Ma...

Page 238: ...re to check the generation o f the parts and use a replacement part of the same generation E C U Federal Specifications California Specifications with A T with M T with A T j with M T 1988 626 MX 6 F201 18 880L F203 18 880L 1989 626 MX 6 Up to J M 1 G D 1 1737081 or 1 Y V G D 1 5223616 F204 18 880A F201 18 880L F206 18 880A F203 18 880L 1989 626 MX 6 After JM 1GD K1737082 or 1Y V G D 1 5223617 F20...

Page 239: ... at the time of the design change When replacing an E C U or an engine harness check the color of the connector first and choose appropriate parts Yellow Old E C U and engine harness White New E C U and engine harness VIN OF PRODUCTION CHANGE 626 MX 6 w o Turbo Produced in Japan JM1GD A A K1737082 December 1 1988 Produced in the U S A IY V G D K5223617 January 18 1989 Page 2 of 2 ...

Page 240: ...for a few seconds after starting and then occasional ly stalls B Engine speed drops excessively when shift ing from N P to D R and then occasionally stalls NOTE This repair kit only functions for 15 seconds after the engine is started PARTS INFORMATION A PART NO DESCRIPTION 8AG2 13 SPX Repair Kit NO PART NO DESCRIPTION QTY NON TURBO TURBO 1 F2Y1 18 701 Control Unit 1 2 FE70 18 741A 3 Way Solenoid ...

Page 241: ...ued 11 17 89 Date Revised Installation of Vacuum Hose without Turbo Before Installation After Installation Vacuum Hose 9935 10 420G Solenoid Valve FE70 18 741A Pressure Regulator Solenoid Valve Pressure Regulator Page 2 of 7 ...

Page 242: ...sued 11 17 89 Date Revised Installation of Vacuum Hose with Turbo Before Installation After Installation Solenoid Valve FE70 18 741A Solenoid Valve Pressure Regulator Vacuum Hose 9935 10 420G Pressure Regulator Page 3 of 7 ...

Page 243: ...r 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 4 Install the solenoid valve onto the solenoid bracket Yellow Yellow Solenoid Valve FE70 18 741A Yellow Green Black White Page 4 of 7 ...

Page 244: ...e vacuum hose Green from the solenoid valve with Green label of the pressure regulator with Green label and install it onto the solenoid valve of 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 4 Install the solenoid valve onto the solenoid bracket Page 5 of 7 ...

Page 245: ...n Control Unit 2 Connect the single couplers Black Blue from the wire harness of the kit 3 Connect the wire harness to the control unit 4 Connect the 2 ends of the wire harness of the E C U at DEM 01 5 Install the ground wire with bolt 0 10 and tighten it 6 Fasten the wire harness with bands 7 Pass the 3 ends of the wire harness through the rubber seal in the firewall E C U Bolt 10 Page 6 of 7 ...

Page 246: ...o the passenger compartment 3 Adjust the idle speed to the upper limit of specification according to the Workshop Manual 4 Verify that no negative pressure is applied to the pressure regulator for 15 seconds after starting the engine 5 Attachment o f Vacuum Hose Label for California specifications only A Clean the present vacuum hose label B Attach the new label on the cleaned part Vacuum Hose Lab...

Page 247: ...the engine starts while the I G key is turned to the START position but immediate ly stalls when the key is returned to the ON position This occurs only when the temperature of the Emission Control Unit E C U is approximately 0 C or less However the engine operates normally when the temperature is higher than 0 C Problem Phenomenon REPAIR PROCEDURE 1 Verify whether the engine stalls under the abov...

Page 248: ...881R 89 323 Non Turbo Turbo Non Turbo Turbo Federal Federal California California F201 18 881R F220 18 881R F225 18 881R F203 18 881R F222 18 881R F226 18 881R 89 626 Non Turbo 2WS Turbo 2WS Turbo 4WS Non Turbo 2WS Turbo 2WS Turbo 4WS Federal Federal Federal California California California JEY6 18 881R JEY7 18 881R 89 929 Federal California JE15 18 881R 89 MPV 3 0L WARRANTY INFORMATION Customer C...

Page 249: ...the engine starts while the I G key is turned to the START position but immediate ly stalls when the key is returned to the ON position This occurs only when the temperature of the Emission Control Unit E C U is approximately 0 C or less However the engine operates normally when the temperature is higher than 0 C Problem Phenomenon REPAIR PROCEDURE 1 Verify whether the engine stalls under the abov...

Page 250: ... 89 323 Non Turbo Turbo Non Turbo Turbo Federal Federal California California F201 18 881R F220 18 881R F225 18 881R F203 18 881R F222 18 881R F226 18 881R 89 626 Non Turbo 2WS Turbo 2WS Turbo 4WS Non Turbo 2WS Turbo 2WS Turbo 4WS Federal Federal Federal California California California JEY6 18 881R JEY7 18 881R 89 929 Federal California JE15 18 881R 89 MPV 3 0L WARRANTY INFORMATION Customer Comme...

Page 251: ... 87 626 49 G019 902 88 89 626 49 G019 911 49 G019 912 90 626f 49 G019 918 49 G019 912 90 626 T C f 49 F019 901 49 G019 915 88 89 929 49 H019 901 49 H019 904 90 929 49 F019 901 49 H019 904 89 90 MPV 49 L019 901 49 L019 902 90 B2600i 4x4 49 L019 901 49 L019 902 90 323t 49 F019 901 49 B019 904 89 90 RX 7 49 F019 901 49 F019 902 t Also requires selector 49 BO19 9A1 EC AT Tester Adapter 49 G019 901 49 ...

Page 252: ...Lamps Reflective Device and Associated Equipment We urge you to remind dealer personnel and respective customers that the application of corporate logos and dealership names to any of the above mentioned surfaces i e high mount stoplamps is a violation of the aforementioned safety standard IMPORTANT Service and Parts Managers should read this bulletin carefully sign and convey all information to t...

Page 253: ...s Warranty Information for diagnosis and repairs are listed on page 8 o f 8 of this bulletin Slipping Engine Flare Vibration Shift Shock Surging Hunting Stall Failure Erratic Converter Lock Up The following possible causes are addressed in this bulletin 1 ATF Condition or Improper Level 2 Internal Failure 3 Valve Body Modifications 4 Electrical System Malfunction 5 Adjustments needed REPAIR PROCED...

Page 254: ...t the thermo switch box have been replaced with an oil line as shown below If you observe any leakage from this part replace the oil pipe with the modified one according to the repair procedure in this bulletin MODIFICATION B To provide more clamping force the length o f the bolts at the hose clamps on the cooler line has been increased If you encounter a complaint o f oil leakage at the oil hose ...

Page 255: ...rform the following performance and stall tests repair or replace with rebuild as needed 3 Valve Body Modifications shudder surging slip flare chatter shift shock For 1988 626 MX 6 the following four modifications A B C D to the valve body and the inner parts have been incorporated in order to correct the slippage and or chatter when shifting from D 1 D 2 and to reduce the shift shock when shiftin...

Page 256: ...stallation to e iinate shift shock 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 If the terminal is rusted or the bolt is loose repair it and apply a suitable anti rust agent Then go to step B B Connect an EC...

Page 257: ... If not check or adjust the idle switch as per the workshop manual Check the throttle sensor voltage If the throttle sensor voltage fluctuates go to step F 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 suita...

Page 258: ...iod of the vehicle 5 Adjustments all problems A 2 4 Brake Band Adjustment Remove the oil pan and gasket located on the underside o f the transmission Loosen the lock nut and tighten the piston stem exactly at the specified torque Tightening Torque 10 N m 1 1 m kg 98 in lbs Loosen the piston stem exactly 2 turns Tighten the locknut Tightening Torque 31 N m 1 8 2 9 ft lbs NOTE Quick Reference materi...

Page 259: ...s ing the following procedure Step 1 Initially install the locknuts fully away from the throttle cam Loosen the cable all the way Step 2 Adjust the locknuts in a clockwise direc tion as viewed from the front o f the vehi cle until the line pressure begins to increase above the specification shown Step 3 Adjust the locknuts in a counterclockwise direction until the line pressure decreases to the sp...

Page 260: ...sis B Leakage from Cooler Line Customer Comment Code 2J Damage Code 38 Part Number o f Main Cause FU31 19 9A0E Operation No 19930X R 1 Labor Hours 0 4 Hr 2 Internal Failure Warranty Information for Performance Test and Diagnosis 3 Valve Body Modifications A Valve Body Assembly Replacement Customer Comment Code 2E Damage Code 31 Part Number o f Main Cause FU31 21 100N or FU32 21 100R Operation No 1...

Page 261: ... Labor Hours NOTE Labor Hours include the following items Throttle sensor and idle switch inspection and adjustment EGI harness and dash harness inspection and repair 5 Adjustments Needed Customer Comment Code 99 Damage Code 99 Part Number o f Main Cause FU17 19 880 Operation No XX0268RX Labor Hours 1 5 Hr NOTE Includes 2 4 brake band adjustment ATF level check and throttle cable adjustment Page 9...

Page 262: ...nd repairs are listed on page 8 o f 8 o f this bulletin Slipping Engine Flare Vibration Shift Shock Surging Hunting Stall Failure Erratic Converter Lock Up The following possible causes are addressed in this bulletin 1 ATF Condition or Improper Level 2 Internal Failure 3 Valve Body Modifications 4 Electrical System Malfunction 5 Adjustments needed REPAIR PROCEDURES Follow these procedures in order...

Page 263: ... switch box Make sure the modified oil pipe is installed on 1988 models If leakage is found refer to the illustration below for repair procedures Connector Pipe VIN OF PRODUCTION CHANGE Modification A 1988 626 M X 6 vehicles manufactured in Japan J M 1 G D K 1703425 July 11 1988 1988 MX 6 vehicles manufactured in the U S A 1 Y V G D K5200001 August 1 1988 Modification B 1988 626 M X 6 vehicles man...

Page 264: ...ing performance and stall tests repair or replace with rebuild as needed 3 Valve Body Modifications shudder surging slip flare chatter shift shock For 1988 626 MX 6 the following four modifications A B C D to the valve body and the inner parts have been incorporated in order to correct the slippage and or chatter when shifting from D 1 D2 and to reduce the shift shock when shifting from D 1 D 2 or...

Page 265: ... Date MC Make MMUC Make T C non T C T C non T C A Modification of rear body and premain separatorf Sept 87 D ec 87 B Addition modification o f 1 2 accumulator springs O ct 87 N A D ec 87 N A C Modification of 1 2 accumulator springs N A Oct 87 N A Jan 88 D Addition o f one way orifice Oct 87 Jan 88 NOTE tPremain Separator only for non turbo model PARTS INFORMATION PART NUMBER DESCRIPTION INTERCHAN...

Page 266: ... 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 of the specified range adjust the throttle sensor setting as per the workshop manual page 4A 17 If the throttle sensor voltage fluctuates go to step F E Start the engine If any inspection code is shown on the EC AT Tester perform...

Page 267: ...e anti rust agent Inspect the EGI harness for water or a poor connec tion under the foam protector area near the B 35 connector Check the point where the throttle sensor wires LgB LgW and GO segments are joined by a crimp connection If it is rusted or moisture is found solder these con nectors and protect them with insulated tape Make sure the harness is not touching the steering pipe If the probl...

Page 268: ...erent depending on the production period o f the vehicle B 25 Throt tle Sensor DHEGI 5 Adjustments all problems A 2 4 Brake Band Adjustment Remove the oil pan and gasket located on the underside of the transmission Loosen the lock nut and tighten the piston stem exactly at the specified torque Tightening Torque 10 N m 1 1 m kg 96 in lb Loosen the piston stem exactly 2 turns Tighten the locknut Pag...

Page 269: ...cable locknuts to correct position us ing the following procedure Step 1 Initially install the locknuts fully away from the throttle cam Loosen the cable all the way Step 2 Adjust the locknuts in a clockwise direc tion as viewed from the front o f the vehi cle until the line pressure begins to increase above the specification shown Step 3 Adjust the locknuts in a counterclockwise direction until t...

Page 270: ...e Code 38 Part Number o f Main Cause FU31 19 9A0E Operation No 19930X R 1 Labor Hours 0 4 Hr 2 Internal Failure Warranty Information for Performance Test and Diagnosis 3 Valve Body Modifications A Valve Body Assembly Replacement Customer Comment Code 2E Damage Code 31 Part Number of Main Cause FU31 21 100N or FU32 21 100R Operation No 19750X R X Labor Hours 1 8 Hr B Valve Body Assembly Overhaul Cu...

Page 271: ...or Hours NOTE Labor Hours include the following items Throttle sensor and idle switch inspection and adjustment EGI harness and dash harness inspection and repair 5 Adjustments Needed Customer Comment Code 99 Damage Code 99 Part Number of Main Cause FU17 19 880 Operation No XX0268RX Labor Hours 1 5 Hr NOTE Includes 2 4 brake band adjustment ATF level check and throttle cable adjustment Page 10 of ...

Page 272: ...ith the air breather hole directed downward This is to prevent water or mud from collecting inside the boot through the air breather hole If water or mud does come into the boot area it will cause corrosion on the change rod and as a result the oil seal will be damaged which may cause oil leakage Air Breather Hole IMPORTANT Service and Parts Managers should read this bulletin carefully sign and co...

Page 273: ... been improved 2 The hardening process has been applied on the surface o f reverse idle gear to which needle bearing touches 3 The reverse idle shaft has been redesigned NOTE If complaints of erratic operation or excessive wear are found please replace both the reverse idle gear assembly including needle bearings and reverse idle shaft with modified ones Needle Bearings Reverse Idle Gear Assembly ...

Page 274: ...3 1 1 June 19 1989 PARTS INFORMATION PART NUMBER DESCRIPTION QTY INTERCHANGEABILITY NEW OLD H501 17 310G H501 17 310F Reverse Idle Gear Assembly 1 NEW OLD H501 17 315F H501 17 315E Reverse Idle Shaft 1 NEW O LD H505 17 283A H505 17 283 Needle Bearing 1 NEW O LD WARRANTY INFORMATION Customer Comment Code 2B Damage Code 99 Part No o f Main Cause H501 17 310G Operation No J0311X R X Labor Hour 4 1 Hr...

Page 275: ...ain o f engine stalling after a sudden stop check the following 1 ATF leakage especially around thermo switch box Refer to Service Bulletin Category 7 No 053 88 2 Proper level of ATF 3 Correct ATF level gauge for 1987 vehicles refer to the parts information below PARTS INFORMATION PART NUMBER DESCRIPTION INTERCHANGEABILITY NEW OLD FU17 19 880 FU16 19 880 Level Gauge NEW OLD NOTE Distinction of new...

Page 276: ...ain o f engine stalling after a sudden stop check the following 1 ATF leakage especially around thermo switch box Refer to Service Bulletin Category 7 No 053 88 2 Proper level of ATF 3 Correct ATF level gauge for 1987 vehicles refer to the parts information below PARTS INFORMATION PART NUMBER DESCRIPTION INTERCHANGEABILITY NEW OLD FU17 19 880 FU16 19 880 Level Gauge NEW OLD NOTE Distinction of new...

Page 277: ...to this program 3 Refer to Mazda Parts Bulletin E 7 88 for Western Regions and V 32 for Eastern Regions for pro cedures required for ordering rebuilt EC ATs and preparation regarding the return of the failed assembly PRIOR to shipping i e draining instructions parts to be removed and or retained see figure on page 2 of 3 and the installation o f assorted plugs brackets holders and mounts 4 Refer t...

Page 278: ...7 626 1988 89 626 MX 6 M NOTE 1987 1988 626 626 M A Pulse Generator X X B Cord X X C Throttle Cable X X D Oil Pipes X X E Thermo Switch Box X X F Inhibitor Switch X X G Engine Mounting Rubber N o l X X H Bands for Cord X X I Protector for Cord X X J Clip for Cord X X K Throttle Cable Bracket X L Throttle Cable Clip X M Oil Level Gauge X moving T f m vehich n ow e drain plug and irain ATn f om f s ...

Page 279: ...6 Mileage 7 Delivery Date 8 Problem Date 9 Customer Comment please indicate with a mark Slip 1 2 2 3 3 4 4 3 3 2 2 1 Shock 1 2 2 3 3 4 4 3 3 2 2 1 Flare 1 2 2 3 3 4 4 3 3 2 2 1 Noise 1 2 3 4 R No Movement 1 2 3 4 R Oil Leakage Location 10 Checking Results Condition of ATF ATF Level OK Burned Other indicate with an arrow 11 J EC AT Tester Result Code No Comments 12 Technician s Signature ...

Page 280: ...gram 3 Refer to Mazda Parts Bulletin E 7 88 for Western Regions and V 32 for Eastern Regions for pro cedures required for ordering rebuilt EC ATs and preparation regarding the return of the failed assembly PRIOR to shipping i e draining instructions parts to be removed and or retained see figure on page 2 of 3 and the installation of assorted plugs brackets holders and mounts 4 Refer to Mazda Warr...

Page 281: ...9 626 MX 6 M 1987 1988 89 626 626 MX 6 A Pulse Generator X X B Cord X X C Throttle Cable X X D Oil Pipes X X E Thermo Switch Box X X F Inhibitor Switch X X G Engine Mounting Rubber No 1 X X H Bands for Cord X X I Protector for Cord X X J Clip for Cord X X K Throttle Cable Bracket X L Throttle Cable Clip X M Oil Level Gauge X Before removing EC AT from vehicle remove drain plug and drain ATF from f...

Page 282: ...6 Mileage 7 Delivery Date 8 Problem Date Customer Comment please indicate with a mark Slip 1 2 2 3 3 4 4 3 3 2 2 1 Shock 1 2 2 3 3 4 4 3 3 2 2 1 Flare 1 2 2 3 3 4 4 3 3 2 2 1 Noise 1 2 3 4 R No Movement 1 2 3 4 R Oil Leakage Location 10 Checking Results Condition of ATF OK Burned Other ATF Level F indicate with an arrow w EC AT Tester Result Code No 11 Comments 12 Technician s Signature ...

Page 283: ...tact of the turbine sensor is probable When judging the performance o f the turbine sensor wiggle the wire harness o f the turbine sensor as illustrated below and check whether the resistance value is within the specification If a poor contact exists in the turbine sensor resistance value changes and the value reads out of specifica tion when wiggling the wire harness Model Resistance Specificatio...

Page 284: ...ring 1 l Terminal VIN OF PRODUCTION CHANGE 929 JM 1 H C K 0 2 1 0 4 1 3 November 1 1988 626 MX 6 JM 1G D 10731830 November 1 1988 MC Production MX 6 1 Y V G D K 5 2 4 3 8 3 4 January 1 1989 MMUC Production PARTS INFORMATION The part numbers have not been changed PART NUMBER DESCRIPTION INTERCHANGEABILITY APPLIED MODEL NEW OLD FU31 21 550B Pulse Generator NEW OLD 626 MX 6 BV02 21 571A Turbine Senso...

Page 285: ...e is within 4 0 4 6 kg cm2 5 7 6 6 psi at idle 7 2 5 7 7 5 rpm in P range at normal operating temperature If the line pressure is out of the specification adjust the line pressure by adjusting the lock nuts of the throttle cable 3 Verify that the throttle cable is free of slack in accordance with the following procedure a Read the line pressure a indicated on the pressure gauge P N 49B0 19 901 b D...

Page 286: ... line pressure throttle cable be sure to verify the condition of shift shock by road testing If the result is still unacceptable proceed to the next step 5 Replace the valve body with one for the 1990 model P N FU3H 21 100A WARRANTY INFORMATION 1 When Repair Prodedure steps Customer Comment Code Damage Code Part No of Main Cause Operation No Labor Hours 2 When Repair Prodedure steps Customer Comme...

Page 287: ...ohibit offering for sales or lease such vehicles or items of equipment 2 Dealers must attach an AUTHORIZATION NOTIFICATION label to the designated location when Recall Campaign and SSP repairs are completed In most recall campaigns Federal or State law requires attaching an Authorization Modification Recall Completion label to a designated location on the vehicle for future reference Dealers must ...

Page 288: ...eter Identification PID Simulation Tests LMA EL Transmission identification Number Automatic Transmission Diagnostic Sheet System Voltage Resistance WHEN CONTACTING THE TECHNICAL ASSISTANCE HOTLINE Provide the following information Vehicle identification Number VIN Current Vehicle Mileage Customer Concem Symptoms Conditions Previous RepairAttempt information Results and Specification from Diagnost...

Page 289: ... Fix it Right the First Time Mondaythrough Friday 8 30am to 5 00pm within your region M azda T echnical A ssistance H ntline 888 TEC TIPS 832 8477 Fixit Right the First Time Monday through Friday 8 30am to 5 00pm within your region M azda T echnical A ssistance H otline 888 TEC TIPS 832 8477 Fix it Right the First Time Monday through Friday 8 30am to 5 00pm within your region M azda T e ch n ica l...

Page 290: ... provid ers follow the procedure when towing is necessary Dealer personnel responsible for towing arrangements should provide a copy of the owner s manual instructions to towing service providers NOTE Damage due to impropertowing is not a warrantable repair 0 6 0 0 5 8 CONSUMER NOTICE The information and instructions in this bulletinare intended for use by skilled technicians Mazda technicians uti...

Page 291: ...eter replacement Date of replacement Dealer code 3 Attach the label to the driver s side B pillar 4 Complete the Speedometer Replacement Record in the Warranty Information Booklet referenced below SPEEDOMETER REPLACEMENT Mileage ____ ________________ Before Replacement Date Replaced ___ ___ ___ Dealer Code ________________ Complete Information and Install On Driver s Side B Pillar SPEEDOMETER REPL...

Page 292: ...____________ SPEEDOMETER REPLACEMENT Mileage Before Replacement Date Replaced ____ ____ ____ Dealer Code _________________ SPEEDOMETER REPLACEMENT Mileage Before Replacement Date Replaced ____ ____ ____ Dealer Code _________________ SPEEDOMETER REPLACEMENT Mileage Before Replacement Date Replaced ____ ____ ____ Dealer Code _________________ SPEEDOMETER REPLACEMENT Mileage Before Replacement Date R...

Page 293: ...ilable for inspection by any peace officer or the Bureau Of Collections And Investigative Services during nor mal business hours or submitted to the bureau upon request Details of this requirement are outlined under Caiifomia Penal Code No 466 6 information Required 1 Customer Name 2 Address 3 Telephone Number if any 4 Date Of Birth 5 Driver s License Number or I D No 6 VIN Of The Vehicle 7 Vehicl...

Page 294: ...r inspection by any peace officer or the Bureau Of Collections And Investigative Services during nor mal business hours or submitted to the bureau upon request Details of this requirement are outlined under Caiifomia Penal Code No 466 6 Inform ation Required 1 Customer Name 2 Address 3 Telephone Number if any 4 Date Of Birth 5 Driver s License Number or I D No 6 VIN Of The Vehicle 7 Vehicle Licens...

Page 295: ...criptions and prices wholesale and retail for all items covered by this program As items are added to and deleted from this program and maintenance is required to the order form you will be informed by Service and or Parts Bulletins until a revised order form is printed and distributed ORDERING PROCEDURE The following methods have been established for dealerships wishing to place collateral orders...

Page 296: ...l be billed by MMA Mazda Motor of America Inc at month s end For those dealerships within the Mazda Distributors Great Lakes area you will be billed directly from them In addition to items listed on the order form you will from time to time receive other collateral from HELM which represents items slated for all dealer mailings Page 2 of 2 ...

Page 297: ...s prior to delivery to customers through sale or lease Under this Amendment if there has been a recall campaign dealers must assure that all new vehicles and new items or replacement equipment are free of safety defects and comply with all applicable Federal Motor Vehicle Safety Standards at the time of delivery to the consumer It is also applicable to all used vehicles This does not prohibit offe...

Page 298: ...llows the advisor to quickly and accurately gather key details from the customer about the vehicle s symptoms We have provided 50 copies for your initial use INSTRUCTIONS 1 Ensure an ample supply of questionnaire copies exists in the service reception area for service advisor use 2 When customers complain of problems related to NVH driveability steering stability or the audio system ask the applic...

Page 299: ...54 d requires that dealers perform all recall campaign repairs to inventory vehicles or replacement parts prior to delivery to customers through sale or lease Under this Amendment if there has been a recall campaign dealers must assure that all new vehicles and new items of replacement equipment are free of safety defects and comply with all applicable Federal Motor Vehicle Safety Standards at the...

Page 300: ...se provide the Recall Campaign number when placing an order 2 Vehicle owners must be instructed to keep the certificate During vehicle registration renewal and if the registration renewal form indicates a certification requirement the owner must submit the Proof of Correction certificate with the registration renewal form to the DMV Vehicle Emission Recall Proof of Correction License Number Make Y...

Page 301: ...cal load is applied For the proper repair procedure refer to the instructions in this Service Bulletin Please note that the customer may also describe this complaint as a low rough idle and may not necessarily complain of vibration Therefore confirm the customer complaint carefully before attempting any repair PRODUCTION CHANGE No 1 engine mount and radiator lower mount rubbers have been changed a...

Page 302: ... than the mass production parts REPAIR PROCEDURE 1 Check that the idle speed is within the specification Idle Speed 750 25 RPM in P range If the idle speed is not within the specification adjust it to 750 RPM with test connector grounded 2 Replace the radiator lower mounts with modified ones 3 Check that the radiator is centered in the radiator upper brackets so that it can move more effectively a...

Page 303: ...ncer After removing the hangers from the body reinstall the bolts into the body to prevent water from entering 8 In a case where the idle vibration is not corrected to a satisfactory level ground the test connector and adjust the idle speed to 950 1000 RPM Then disconnect the test connector WARRANTY INFORMATION Warranty Type Code Customer Comment Code Damage Code Part No of Main Cause Operation No...

Page 304: ... 130B Rocker Arm Assembly 6 F201 12 150B Rocker Arm Assembly 6 NOTE There are two different configurations for the Rocker Arm Assembly See page B 63 in the 1990 Workshop Manual for more information REPAIR PROCEDURE 1 When removed from the rocker arm shaft inspect the contact area of the rocker arm If it is scratched replace the rocker arm shaft Otherwise due to oil pressure leakage may result 2 Pl...

Page 305: ...ystem Parts 3 Intake And Exhaust System Parts 4 Fuel And Emission Control Parts 5 Clutch And Or Flywheel PARTS INFORMATION See the following pages for applicable models and part numbers ft WARRANTY INFORMATION Partial engines are warranted for the remainder or the origtpal vehicle warranty or for the first 12 months after installation of the partial engine whichever is longer A ll warranty repairs...

Page 306: ... YEAR MODEL ENGINE P N GASKET P N REMARKS 1989 94 MPV 2 6U NONE NONE Use G601 02 200 Short Block 1989 94 MPV 3 0L NONE NONE Use JE22 02 200B Short Block NAVAJO YEAR MODEL ENGINE P N GASKET P N REMARKS 1991 93 NAVAJO NONE NONE 323 YEAR MODEL ENGINE P N GASKET P N REMARKS 1986 89 323 1 6L 4 x 2 B630 02 300 8AB1 02 310 1988 89 323 1 6L TURBO 4 x2 4 x4 WILL BE AVAILABLE 8AB2 02 310 WILL BE AVAILABLE 8...

Page 307: ...ABLE 8AGB 02 310 1993 626 MX 6 2 0L A T WILL BE AVAILABLE 8AGB 02 310 1994 626 MX 6 2 0L A T WILL BE AVAILABLE 8AGB 02 310 1993 94 626 MX 6 2 5L WILL BE AVAILABLE 8AE3 02 310 929 YEAR MODEL ENGINE P N GASKET P N REMARKS 1988 89 929 3 0L SOHC JE15 02 300 8AH1 02 310 1990 91 929 3 0L SOHC JE39 02 300 8AJA 02 310 DOHC NONE NONE Use JE48 02 200B Short Block 1992 93 929 3 0L DOHC NONE NONE Use JE48 02 ...

Page 308: ...REMARKS 1992 93 MX 3 1 6L 1 4 B66S 02 300 r 8AE2 02 310 1994 MX 3 1 6L 1 4 WILL BE AVAILABLE 8ABD 02 310 1992 94 MX 3 1 8L V 6 WILL BE AVAILABLE 8AE3 02 310 M IL L E N IA YEAR MODEL ENGINE P N GASKET P N REMARKS 1994 MILLENIA 2 3L V 6 MILLER 2 5L V 6 WILL BE AVAILABLE 8AK1 02 310A WILL BE AVAILABLE 8AK2 02 310 Page 4 of 4 ...

Page 309: ...haust System Parts 4 Fuel And Emission Control Parts 5 Clutch And Or Flywheel PART INFORMATION See the following pages for applicable models and part numbers WARRANTY INFORMATION Partial engines are warranted for the remainder of the original vehicle warranty or the first 12 months after installa tion of the partial engine whichever is longer A ll warranty repairs of the partial engine replacement...

Page 310: ...KET P N REMARKS 1989 94 MPV 2 6L G6Y5 02 300 8AL1 02 310 1989 94 MPV 3 0L 4X2 4X4 JE57 02 300 JE58 02 300 8AL2 02 310 8AL2 02 310 NAVAJO YEAR MODEL ENGINE P N GASKET P N REMARKS 1991 93 NAVAJO NONE NONE 323 YEAR MODEL ENGINE P N GASKET P N REMARKS 1986 89 323 1 6L 4x2 B630 02 300 8AB1 02 310 Does Not Fit 86 87 w Std Strg A C 1988 89 323 1 6L TURBO 4x2 4x4 WILL BE AVAILABLE 8AB2 02 310 WILL BE AVAI...

Page 311: ...S01 02 300A 8AGB 02 310 1993 626 MX 6 2 0L A T FS01 02 300A 8AGB 02 310 1994 626 MX 6 2 0L A T FS71 02 300A 8AGB 02 310 1993 94 626 MX 6 2 5L KLY1 02 300A 8AE3 02 310 929 YEAR MODEL ENGINE P N GASKET P N REMARKS 1988 89 929 3 0L SOHC JE15 02 300 8AH1 02 310 1990 91 929 3 0L SOHC JE39 02 300 8AJA 02 310 DOHC JE27 02 300 8AJB 02 310 1992 93 929 3 0L DOHC NONE NONE Use JE48 02 200B Short Block 1994 9...

Page 312: ...KET 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 ENGINE P N GASKET P N REMARKS 1994 MILLENIA 2 3L V 6 MILLER 2 5L V 6 KJY2 02 300 8AK1 02 31OA KL47 02 300 8AK2 02 310 ...

Page 313: ...ture 3 Increase the idle to 2 000 3 000rpm and maintain this speed until HLA noise stops or 20 minutes NOTE Do not exceed 20 m inutes Currently the workshop manual states 10 minutes this will be revised in the 1996 workshop manual Watch the engine tem perature during this operation If the temperature exceeds norm al range reduce the engine speed to idle until the temperature returns to normal If t...

Page 314: ...procedures in section 1 or B of your Workshop Manual YIN OF PRODUCTION CHANGE Japan Made JM1GD K1746266 January 1 1989 USA Made 1YVGD31A8K5229795 February 16 1989 PARTS INFORMATION PART NUMBER DESCRIPTION INTERCHANGE ABILITY NEW OLD F201 10 235D F201 10 235C Cylinder Head Cover Gasket New Old WARRANTY INFORMATION Warranty Type Code A Customer Comment Code 76 Damage Code 9E Part No of Main Cause F2...

Page 315: ...rvice Bulletin replaces Service Bulletins Category 1 No 042 89 and Category B No 001 90 VIN OF PRODUCTION CHANGE No 1 2 Engine Mounts 1991 Lower Radiator Mount 1989 Non Turbo 1991 Turbo JM1GD4 4M 1902957 1YVGD4 4 M 5131853 JM1GD4 K1769601 1YVGD4 K5245888 JM1GD4 M 1901869 1YVGD4 4 M 5 120718 October 1 1990 November 7 1990 June 1 1989 June 24 1989 September 1 1990 October 2 1990 INSPECTION REPAIR PR...

Page 316: ...r hangers and rubbers Figure 2 9 Install the hanger bolts into the body to prevent water entry 10 If the steering wheel and seat still vibrate too much ground the test connector Adjust idle speed to 950 1000 rpm in P Disconnect the test connector PARTS INFORMATION PART NUMBER DESCRIPTION APPLICABLE MODEL M002 39 040B No 1 Engine Mount Non Turbo GJ28 39 040E No 1 Engine Mount Turbo GJ23 39 050C No ...

Page 317: ...rt No of Main Cause Operation No Labor Hour A 83 97 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 XX0376RX Includes R R of No 1 No 2 Engine Mounts 1 0 Hr XX0331R2 All repairs except R R of No 1 No 2 Engine Mounts 0 4 Hr I V Page 3 of 3 ...

Page 318: ...rvice Bulletin replaces Service Bulletins Category 1 No 042 89 and Category B No 001 90 VIN OF PRODUCTION CHANGE No 1 2 Engine Mounts 1991 Lower Radiator Mount 1989 Non Turbo 1991 Turbo JM1GD4 4M 1902957 1YVGD4 4 M 5131853 JM1GD4 K1769601 1YVGD4 K5245888 JM1GD4 M 1901869 1YVGD4 4 M 5 120718 October 1 1990 November 7 1990 June 1 1989 June 24 1989 September 1 1990 October 2 1990 INSPECTION REPAIR PR...

Page 319: ...r hangers and rubbers Figure 2 9 Install the hanger bolts into the body to prevent water entry 10 If the steering wheel and seat still vibrate too much ground the test connector Adjust idle speed to 950 1000 rpm in P Disconnect the test connector PARTS INFORMATION PART NUMBER DESCRIPTION APPLICABLE MODEL M002 39 040B No 1 Engine Mount Non Turbo GJ28 39 040E No 1 Engine Mount Turbo GJ23 39 050C No ...

Page 320: ...rt No of Main Cause Operation No Labor Hour A 83 97 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 XX0376RX Includes R R of No 1 No 2 Engine Mounts 1 0 Hr XX0331R2 All repairs except R R of No 1 No 2 Engine Mounts 0 4 Hr I V Page 3 of 3 ...

Page 321: ...ig 1 Lot Number DeterminesWhen Sealant IsApplied Month Jan 1 Feb 2 Aug 8 Sept 9 Oct O Nov N Dec D Year 1996 6 1997 7 No Related Meaning Sealant Applied Since Aug 1996 PARTS INFORMATION Part Number Description Qty Int Mode New Old B367 18 501 w sealant FS11 18 50X Oil Pressure Switch 1 A 626 MX 6 Millenia MX 3 K8 B367 18 501 w sealant B367 18 501 w o sealant Oil Pressure Switch j 1 I A 323 MX 6 Mil...

Page 322: ... Warranty Terminformation Warranty Type A Symptom Code 76 Damage Code 9A Causal Part No B367 18 501 Quantity 1 Operation Number Labor Hrs T0504XRX 04 Hrs Millenia T0504XRX 03 Hrs 626 MX 6 T0504XRX1 03 Hrs MX 3 VEHICLE APPLICATION CHART Model Mass Production Change 323 B6 Protege BP Z5 8 1 96 Miata B6 BP 626 MX 6 FSD KLD 9 12 96 Millenia KLD KJS 8 1 96 MX 3 K8 Page 2 of 2 ...

Page 323: ...1207D or Loctite Ultra Black 598 or equivalent 3 Verify repair PARTS INFORMATION Part Number Description Qty Inter Model New Old B367 18 501 w sealant FS11 18 50X Oil Pressure Sw 1 A 626 MX 6 Millenia MX 3 K8 B367 18 501 w sealant B367 18 501 w o sealant Oil Pressure Sw 1 A 323 Protege MX 5 MX 3 B6 Interchangeability Code A The new part can be used in place of the old part but the old part can not...

Page 324: ...tyTermInformation Warranty Type A Symptom Code 76 Damage Code 9A Part Number Main Cause B367 18 501 Quantity 1 Operation Number Labor Hrs T0504XRX 04 Hrs Millenia T0504XRX 03 Hrs 626 MX 6 T0504XRX 03 Hrs MX 3 VEHICLE APPLICATION CHART Model MassProduction Change 323 B6 Protege BP Z5 8 1 96 Miata B6 BP MX 3 B6 626 MX 6 FSD KLD 9 12 96 Millenia KLD KJS 8 1 96 MX 3 K8 Page2 of 2 ...

Page 325: ...ines 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 Since MC does not advocate the use of reconditioned anti freeze any problems caused by its use cannot be covered by the warranty r 3Z 0 1 7 5 5 8 IMPORTANT S r r t t tnd P rt M...

Page 326: ...s Provides less heat transfer 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 IMPORTANT Service and Parts Managers should read thi...

Page 327: ...hat Mazda does not recommend reconditioned anti freeze and that problems mechanical and otherwise related to the use of reconditioned anti freeze are not warrantable Caution Anti freeze is considered a hazardous and toxic substance Handled and disposed must be done in accordance with local state and federal laws CONSUMER NOTICE The information and instructions rnthis bulletin are intended tor use ...

Page 328: ...plating The corrosion at the terminals may result in poor driveability Thus when you replace an E C U or an engine harness please be sure to check the generation of the parts and use a replacement part o f the same generation E C U Federal Specifications California Specifications with A T with M T with A T with M T 1988 626 MX 6 F201 18 881R F203 18 881R 1989 626 MX 6 Up to JM 1G D K1737081 or 1YV...

Page 329: ...e harness check the color of the connector first and choose appropriate parts Yellow Old E C U and engine harness White New E C U and engine harness VIN OF PRODUCTION CHANGE 626 MX 6 w o Turbo Produced in Japan JM 1G D K1737082 December 1 1988 Produced in the U S A 1YVGD K5223617 January 18 1989 IMPORTANT This bulletin replaces Service Bulletin Category 4 no 060 89 Please reference this bulletin w...

Page 330: ...ts such as gum resin and sulfur These deposits can cause stalling difficult starting rough idle and diminished power Mazda s Fuel Injector Cleaner and Fuel Injection Tool Kit are available through the Parts Department Also available is a Fuel Injector Service Brochure that is free of charge from Helm Inc 1 800 782 4356 This brochure outlines to your customer the importance and advantages of a clea...

Page 331: ...ts such as gum resin and sulfur These deposits can cause stalling difficult starting rough idle and diminished power Mazda s Fuel Injector Cleaner and Fuel Injection Tool Kit are available through the Parts Department Also available is a Fuel Injector Service Brochure that is free of charge from Helm Inc 1 800 782 4356 This brochure outlines to your customer the importance and advantages of a clea...

Page 332: ...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 PREPARATION PROCEDURE Perform the following before conducting the emission inspection and maintenance test 1 Before testing bring the engine s operating temperature to normal by o...

Page 333: ...t Request This information is critical to the program s success Do not include the bracket when returning the core The bracket should be used when installing the remanufactured control unit Please return cores W ITHIN 7 DAYS to insure continued availability of remanufactured units PARTS INFORMATION 323 Proteg6 Models Remanufactured EGI Control Unit Application Replaces New EGI Control Unit B601 18...

Page 334: ...0 626 MX 6 Non Turbo FED A T Japan Make F287 18 881R 90 626 MX 6 Turbo FED 2WS Japan Make F289 18 881R 90 MX 6 Turbo 4WS Japan Make F294 18 881R 90 626 MX 6 Non Turbo CA M T Japan Make F295 18 88IR 90 626 MX 6 Non Turbo CA A T Japan Make F296 18 881R 90 626 MX 6 Turbo CA 2WS Japan Make F298 18 881R 90 626 MX 6 Turbo CA 4WS Japan Make F290 18 881R 90 626 MX 6 Non Turbo FED M T USA Make F291 18 881R...

Page 335: ...18 880L ZPA3 18 881R 89 626 MX 6 Non Turbo CA M T From JM1GD K1737083 1Y V G D K 5223618 F203 18 880M F204 18 881R 89 626 MX 6 Non Turbo CA A T Up to JM1GD K1737083 1YVGD K5223617 F204 18 880A ZPA4 18 881R 89 626 MX 6 Non Turbo CA A T From JM1GD K1737082 1YVGD K5223618 F204 18 880B F262 18 881R 89 626 MX 6 Non Turbo FED A T Up to JM1GD 1 1737082 1YVGD K5223617 F206 18 880A ZPA2 18 881R 89 626 MX 6...

Page 336: ... Control Unit N304 18 881R 8 4 85 GSL SE N304 18 880A N3Y6 18 881R 8 6 87 Non Turbo N326 18 880 N3Y6 18 880 N332 18 881R 87 Turbo N332 18 880 N327 18 881R 88 Non Turbo Coupe N327 18 880 N333 18 881R 88 Turbo N333 18 880 N338 18 881R 88 Convertible N338 18 880 N350 18 881R 8 9 91 Non Turbo Coupe CA N350 18 880 N351 18 881R 8 9 91 Non Turbo Coupe FED N351 18 880 N352 18 881R 89 91 Convertible CA N35...

Page 337: ...fire Stalls Similar symptoms caused by lean operation during initial cold starts and drive away NOTE Gasoline s volatility is higher vaporizes easily inthe winter and lower in the summer REPAIR PROCEDURE 1 Verifythe concern 2 Perform the diagnostics in section Fof the workshop manual NOTE Often no trouble codes arefound if the concem s are caused by gasoline 3 Ifthe concem s isstill present the fu...

Page 338: ... than regular octane grade gasoline Only advise using a higher octane grade gasoline to avoid potentially damaging spark knock or ping Recommend this octane only after diagnostic procedures are ineffective Advise customers using the recommended octane grade unleaded gasoiine to try another brand If customers are using a gasoline containing an oxygenate advise them to try another brand of oxygenate...

Page 339: ...less due to cieaner burning com ponents and fewer toxic components These components provide Reduced aromatic hydrocarbons to form less smog emissions Added oxygenates to reduce emissions Decreases the amount of vehicle fuel evaporation Lower sulfur to provide more efficient catalytic converter operation Reduced benzene by approximately 50 CaRFG AFFECT ON VEHICLE PERFORMANCE Properly blended CaRFG ...

Page 340: ...aRFG Older vehicles are expected to operate satisfactorily on CaRFG because these vehicles have been operating on gasoline similar to CaRFG for a number of years However considerable testing indicates that older high mileage vehicles are more susceptible to fuel system problems due to age and normal wear and tear regardless of whether they are operated on conventional or CaRFG gasoline NOTE Owners...

Page 341: ...MOVAL PROCEDURE CAUTION DO NOT remove the two 2 screws on the air flow meter Removing these screws and pulling on the con nector will damage the air flow meter circuitry This instruction applies to other type air flow meters as well 1 Remove wire clip from groove at both sides using a small screwdriver 2 Remove connector NOTE Connector may be hard to remove apply steady force on connector body CON...

Page 342: ... speed should have their vehicle repaired using the Workshop Manual Note Tampering with this screw will affect the idle contact switch and orthrottle position sensor settings This can lead to rough idle and difficulty in diagnosis of idle quality concerns The TAS locations on the examples below may vary depending on model year of vehicle TAS B6 BP ZM TAS TAS FP FS F2 G6 0 6 0 3 3 1 CONSUMER NOTICE...

Page 343: ...ments 3 5 Charging And Load Testing Information 3 6 Battery Diagnostic Procedures 4 Using Load Tester Vat 40 Or Equivalent 6a Battery Diagnostic Procedures 6 Using MIDTRONICS POWERSENSOR PLUS Tester 7 Parts Information 9 8 Warrantable Charging And or Replacement 9 9 Warranty Claim Submission 9 10 Warranty Information 9 For Battery Inspection Charging And Testing Attachments Sample of battery Maint...

Page 344: ...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 Batteries must be periodically recharged to maintain a measured 12 4 volts or better Loss of battery voltage is dependent on ambient temperature demo use and lime in inventory Mazda recommends voltage checks at one month intervals and j...

Page 345: ...ation 5 CHARGING AND LOAD TESTING INFORMATION The chart beiow gives specific charging amps times and load test amps for 1993 97 vehicles Refer to the applicable workshop manual for other model year vehicles and additional troubleshooting informa tion FACTORY INSTALLED BATTERIES Model Battery Max Charge Current AMP Charge Time Min Load Test AMP Protege 323 55D23L 30 30 180 626 MX 6 GROUP58R 30 30 1...

Page 346: ...ltage Charge the battery is less than 12 4V If the voltage is less than the minimum quick or boosf charge the battery for 30 minutes CAUTION DO NOT quick or boosf charge MX 5 Miata batteries These batteries are gef type and must not be charged at more than 20 amps Perform a load test again If the battery is still below the minimum replace the battery and proceed to step 8 7 Start the vehicle and r...

Page 347: ...e free batteries Measurethe open circuit voitage of the batterywth a digitalvc meter capableof reading 0 01V NOTE Chuckcharge battery trysettingthe charge rate the WghesTor Boosr position When testing inthe vehide turn the beadSghts ON fa 15 secondsto removethe surface charge beforeteSfog Turn The HeadtighteOn For 15 SecondsTo RemoveAnySurface Voltage Charge Appiy Test Load ToBatteiy Referto Chart...

Page 348: ...tery has at least 10 2V and can therefore be tested without pre charging This position requires thatthe CCA rating for the specific battery type undertest be set on the Midtronics PowerSensor Plus Tester dial Referto the attached chart on page3 of 9 to determines actual CCA The Midtronics PowerSensor Pluse Tester then determines actual CCA by measuring the condition ofthe battery voltage and plate...

Page 349: ...r diagnosing mainte nance free batteries ConnectTest Leads To Battery And Switch To Position A Pretest NOTE When testmg in the vehicle turn the headlights ON for 15 seconds to remove the surface charge before testing Battery Has Less Than 10 Volts Recharge Once And Re Test Switch To NO Red LightNv YES PosBon B Condition ON i 1 r f Bad Ceil Replace Battery Battery Has At Least 10 2V Dtal In Rated C...

Page 350: ...00 80 026R WB 525 1979 83 Ail 370 0000 80 0024 WB 460 323 Protege 1988 97 An 310 0000 80 026R WB 525 1988 97 Optional For Above 585 0000 80 0035 WB 525 929 1988 95 All w o Cold Package 320 0000 80 0035 WB 550 1988 95 All w Cold Packages 585 0000 80 124F WB 700 MiOerna 1995 97 AD 490 0000 80 124F WB 700 B2000 B2200 1973 93 AI Except Diesel 375 0000 80 0024 WB 460 1973 93 Optional ForAbove 375 0000 ...

Page 351: ...etail Delivery Replacement is covered under normal warranty if the battery is judged defective after charging and diagnos ing the battery according to the procedures in this bulletin The Battery Check Sheet must be completed and attached to the repair order If the documents are not attached to the repair order the claim Is subject to debit 9 WARRANTY CLAIM SUBMISSION Dealers submitting warranty cl...

Page 352: ...procedures for the following components Engine Control Units ECU Air Flow Meters Fuel Pumps Alternators Each procedure includes the following 1 Outline Of Diagnostics Parts Requirements and Warranty Application Illustrates the steps from diag nostics through parts return and warranty submission 2 Diagnostic Procedures Step by step testing of the component and circuit 3 Component Check Sheet Detail...

Page 353: ... 9 SECTION 3 Page Outline 10 Fuel Pump Diagnostics 11 Fuel Pump Check Sheet 13 Section 4 Page Outline 14 Charging System Diagnostics 15 Alternator and Battery Check Sheet 17 Section 5 Page Warranty Information 18 Refer to the applicable workshop manual for symptoms not described in this bulletin If further reference is required contact the Technical Hotline in your area Page 2 of 18 ...

Page 354: ...r 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 355: ...s different than specified check the related input and output devises and wiring for dam age If no problem is found and the reading remains out of specification replace the ECU 5 If the voltage is within specification and the problem still exists contact the Technical Hotline for assis tance CAUTION Terminals A B are for external voltmeter con nections Use these terminal to attach a digi tal voltm...

Page 356: ...___No 3 Reason for replacement Terminal Voltage Out Of Specification ____Yes____No Terminal Number Voltage Reading Factory Specifications According to Service Bulletin instructions ______Category______Number According to DSM or Hot Line Authorization __________ Authorization Number Other __________________________________________________________ 4 Repair Type Warranty____ Customer Pay Technician s...

Page 357: ...Number 002 93 Date Issued 9 16 93 Revised AIR FLOW METER OUTLINE OF DIAGNOSTICS PARTS ORDERING AND WARRANTY APPLICATION DEALER Page 6 of 18 ...

Page 358: ...ic temperature at that time NOTE Use a multi tester with an accuracy equivalent of the FLUK 70 series CAUTION Refer to the illustration at the right and the Standard Values table when measuring resistance Standard Values _ 1 F c Ei Ea Ve E i Vs THAa U p Measure Resistance Ambient Temp F Resistance K Ohms Ambient Temp F Resistance K Ohms 0 11 1 18 7 70 1 9 2 9 10 8 2 13 7 80 1 5 2 3 20 6 4 10 3 90 ...

Page 359: ...nd should be diagnosed using the methoc listed below 1986 89 323 1990 93 323 Protege 1990 92 626 MX 6 1990 91 929 1988 93 MPV 1990 93 MX 5 1993 MX 3 1 6 Litre 1 Check for smooth movement of the measuring plate If no problem is found reinstall the air flow meter 2 If no problem is found in the air flow meter contact the Technical Hotline for assistance Page 8 of 18 ...

Page 360: ... Out Of Specification ____Yes____No Measurement Factory Specifications Intake Air Temperature Sensor Base Resistance E2 VC Measuring Plate Does Not Move Smoothly___ Yes____No According to Service Bulletin instructions _____ Category______Number According to DSM or Hot Line Authorization __________ Authorization Number Other __________________________________________________________ Technician s Si...

Page 361: ...Number 002 93 Date Issued 9 16 93 Revised FUEL PUMP OUTLINE OF DIAGNOSTICS PARTS ORDERING AND WARRANTY APPLICATION DEALER Page 10 of 18 ...

Page 362: ...side of the fuel filter 6 Short circuit the fuel pump test terminals yellow 2 pin connector with a jumper wire on the following vehicles 1988 89 323 1990 91 929 1989 91 RX 7 1993 626 MX 6 1989 92 MPV 7 Short circuit the fuel pump check terminal and the ground terminal of the diagnostic connector with a jumper wire on the following vehicles 1990 93 323 Protege 1992 93 929 1990 93 MX 5 1993 626 MX 6...

Page 363: ...e the voltage at the fuel pump connector vehicle side NOTE Do not disconnect the fuel pump connec tor If the voltage is above the standard value replace the fuel pump If the voltage is below standard check for a dam aged harness relay or a poor ground at the pump Standard Value 8 5V and over 93 RX 7 9 5V and over Other Models 10 After restoring the standard voltage value measure the fuel pump pres...

Page 364: ...Insufficient Fuel Pressure ___ Yes____No Maximum Fuel Pump Pressure ____ PSI Factory Specification _____ According to Service Bulletin instructions _____ Category______Number According to DSM or Hot Line Authorization _________ Authorization Number Other __________________________________________________________ Technician s Signature _______________________________________ Date _ NOTE Attach the ...

Page 365: ... 93 Date Issued 9 16 93 Revised CHARGING SYSTEM OUTLINE OF DIAGNOSTICS PARTS ORDERING AND WARRANTY APPLICATION DEALER Complete Check Sheet Order Part Authorize Replacement Auth No Required N Review Page 14 of 18 ...

Page 366: ...4D or equivalent 4 Apply the load test referring to the chart to the right The final voltage r L St be above the standard mini mum value shown below STANDARD MINIMUM VOLTAGE LOAD TEST CHART Approx Bat tery Temper ature Minimum Voltage 70F 21C 9 6V 60F 15C 9 5V 50F 10C 9 4V 40F 4C 9 3V 30F 1C 9 1V 20F 7C 8 9V If the voltage measures at or above the minimum pro ceed to step 4 If the voltage is below...

Page 367: ... load equal to the alternator rating The generated voltage should be 14 1V to 14 7V LOAD TEST RESULTS Over 14 7V Replace Alternator Under 14 1V Check tor resistance between the battery and terminals B and S If resistance is present repair the damaged harness and retest If the voltage is still below 14 1V replace the alternator 14 1V to 14 7V No trouble with the alternator or battery Page 16 of 18 ...

Page 368: ... output or battery voltage was out of specification ____Yes____No Reading Factory Spec Output Voltage Output Amp Instrument Used Battery Voltage Open Terminal Battery Voltage Load Test According to Service Bulletin instructions _____ Category______Number According to DSM or Hot Line Authorization __________ Authorization Number Other __________________________________________________________ 4 Rep...

Page 369: ...mplete Applicable Part Number Operation Number and Labor Hours Operation Number Labor Hours Engine Control Unit ECU Diagnosis F0005XDX 0 9 Air Flow Sensor AFM Diagnosis F0006XDX 0 4 Fuel Pump Diagnosis F0007XDX 0 5 Charging System Diagnosis G0003XDX 1 4 NOTE Labor hours shown are the maximum allowable time Claim only the actual time used for these operations Page 18 of 18 ...

Page 370: ...es for the following components Engine Control Units ECU Air Flow Meters Fuel Pumps Alternators Each procedure includes the following 1 Outline Of Diagnostics Parts Requirements and Warranty Application Illustrates the steps from diag nostics through parts return and warranty submission 2 Diagnostic Procedures Step by step testing of the component and circuit 3 Component Check Sheet Details of the...

Page 371: ... 9 SECTION 3 Page Outline 10 Fuel Pump Diagnostics 11 Fuel Pump Check Sheet 13 Section 4 Page Outline 14 Charging System Diagnostics 15 Alternator and Battery Check Sheet 17 Section 5 Page Warranty Information 18 Refer to the applicable workshop manual for symptoms not described in this bulletin If further reference is required contact the Technical Hotline in your area Page 2 of 18 ...

Page 372: ...r 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: ...s different than specified check the related input and output devises and wiring for dam age If no problem is found and the reading remains out of specification replace the ECU 5 If the voltage is within specification and the problem still exists contact the Technical Hotline for assis tance CAUTION Terminals A B are for external voltmeter con nections Use these terminal to attach a digi tal voltm...

Page 374: ...___No 3 Reason for replacement Terminal Voltage Out Of Specification ____Yes____No Terminal Number Voltage Reading Factory Specifications According to Service Bulletin instructions ______Category______Number According to DSM or Hot Line Authorization __________ Authorization Number Other __________________________________________________________ 4 Repair Type Warranty____ Customer Pay Technician s...

Page 375: ...Number 002 93 Date Issued 9 16 93 Revised AIR FLOW METER OUTLINE OF DIAGNOSTICS PARTS ORDERING AND WARRANTY APPLICATION DEALER Page 6 of 18 ...

Page 376: ...ic temperature at that time NOTE Use a multi tester with an accuracy equivalent of the FLUK 70 series CAUTION Refer to the illustration at the right and the Standard Values table when measuring resistance Standard Values _ 1 F c Ei Ea Ve E i Vs THAa U p Measure Resistance Ambient Temp F Resistance K Ohms Ambient Temp F Resistance K Ohms 0 11 1 18 7 70 1 9 2 9 10 8 2 13 7 80 1 5 2 3 20 6 4 10 3 90 ...

Page 377: ...nd should be diagnosed using the methoc listed below 1986 89 323 1990 93 323 Protege 1990 92 626 MX 6 1990 91 929 1988 93 MPV 1990 93 MX 5 1993 MX 3 1 6 Litre 1 Check for smooth movement of the measuring plate If no problem is found reinstall the air flow meter 2 If no problem is found in the air flow meter contact the Technical Hotline for assistance Page 8 of 18 ...

Page 378: ... Out Of Specification ____Yes____No Measurement Factory Specifications Intake Air Temperature Sensor Base Resistance E2 VC Measuring Plate Does Not Move Smoothly___ Yes____No According to Service Bulletin instructions _____ Category______Number According to DSM or Hot Line Authorization __________ Authorization Number Other __________________________________________________________ Technician s Si...

Page 379: ...Number 002 93 Date Issued 9 16 93 Revised FUEL PUMP OUTLINE OF DIAGNOSTICS PARTS ORDERING AND WARRANTY APPLICATION DEALER Page 10 of 18 ...

Page 380: ... side of the fuel filter 6 Short circuit the fuel pump test terminals yellow 2 pin connector with a jumper wire on the following vehicles 1988 89 323 1990 91 929 1989 91 RX 7 1993 626 MX 6 1989 92 MPV 7 Short circuit the fuel pump check terminal and the ground terminal of the diagnostic connector with a jumper wire on the following vehicles 1990 93 323 Protege 1992 93 929 1990 93 MX 5 1993 626 MX ...

Page 381: ...e the voltage at the fuel pump connector vehicle side NOTE Do not disconnect the fuel pump connec tor If the voltage is above the standard value replace the fuel pump If the voltage is below standard check for a dam aged harness relay or a poor ground at the pump Standard Value 8 5V and over 93 RX 7 9 5V and over Other Models 10 After restoring the standard voltage value measure the fuel pump pres...

Page 382: ...Insufficient Fuel Pressure ___ Yes____No Maximum Fuel Pump Pressure ____ PSI Factory Specification _____ According to Service Bulletin instructions _____ Category______Number According to DSM or Hot Line Authorization _________ Authorization Number Other __________________________________________________________ Technician s Signature _______________________________________ Date _ NOTE Attach the ...

Page 383: ... 93 Date Issued 9 16 93 Revised CHARGING SYSTEM OUTLINE OF DIAGNOSTICS PARTS ORDERING AND WARRANTY APPLICATION DEALER Complete Check Sheet Order Part Authorize Replacement Auth No Required N Review Page 14 of 18 ...

Page 384: ...D or equivalent 4 Apply the load test referring to the chart to the right The final voltage r L St be above the standard mini mum value shown below STANDARD MINIMUM VOLTAGE LOAD TEST CHART Approx Bat tery Temper ature Minimum Voltage 70F 21C 9 6V 60F 15C 9 5V 50F 10C 9 4V 40F 4C 9 3V 30F 1C 9 1V 20 F 7C 8 9V If the voltage measures at or above the minimum pro ceed to step 4 If the voltage is below...

Page 385: ... load equal to the alternator rating The generated voltage should be 14 1V to 14 7V LOAD TEST RESULTS Over 14 7V Replace Alternator Under 14 1V Check tor resistance between the battery and terminals B and S If resistance is present repair the damaged harness and retest If the voltage is still below 14 1V replace the alternator 14 1V to 14 7V No trouble with the alternator or battery Page 16 of 18 ...

Page 386: ... output or battery voltage was out ot specification ____Yes____No Reading Factory Spec Output Voltage Output Amp Instrument Used Battery Voltage Open Terminal Battery Voltage Load Test According to Service Bulletin instructions _____ Category______Number According to DSM or Hot Line Authorization __________ Authorization Number Other __________________________________________________________ 4 Rep...

Page 387: ...mplete Applicable Part Number Operation Number and Labor Hours Operation Number Labor Hours Engine Control Unit ECU Diagnosis F0005XDX 0 9 Air Flow Sensor AFM Diagnosis F0006XDX 0 4 Fuel Pump Diagnosis F0007XDX 0 5 Charging System Diagnosis G0003XDX 1 4 NOTE Labor hours shown are the maximum allowable time Claim only the actual time used for these operations Page 18 of 18 ...

Page 388: ...s for the following components Engine Control Units ECU Air Flow Meters Fuel Pumps Alternators Each procedure includes the following 1 Outline Of Diagnostics Parts Requirements and Warranty Application Illustrates the steps from diag nostics through parts return and warranty submission 2 Diagnostic Procedures Step by step testing of the component and circuit 3 Component Check Sheet Details of the ...

Page 389: ... 9 SECTION 3 Page Outline 10 Fuel Pump Diagnostics 11 Fuel Pump Check Sheet 13 Section 4 Page Outline 14 Charging System Diagnostics 15 Alternator and Battery Check Sheet 17 Section 5 Page Warranty Information 18 Refer to the applicable workshop manual for symptoms not described in this bulletin If further reference is required contact the Technical Hotline in your area Page 2 of 18 ...

Page 390: ...r 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 391: ...s different than specified check the related input and output devises and wiring for dam age If no problem is found and the reading remains out of specification replace the ECU 5 If the voltage is within specification and the problem still exists contact the Technical Hotline for assis tance CAUTION Terminals A B are for external voltmeter con nections Use these terminal to attach a digi tal voltm...

Page 392: ...___No 3 Reason for replacement Terminal Voltage Out Of Specification ____Yes____No Terminal Number Voltage Reading Factory Specifications According to Service Bulletin instructions ______Category______Number According to DSM or Hot Line Authorization __________ Authorization Number Other __________________________________________________________ 4 Repair Type Warranty____ Customer Pay Technician s...

Page 393: ...Number 002 93 Date Issued 9 16 93 Revised AIR FLOW METER OUTLINE OF DIAGNOSTICS PARTS ORDERING AND WARRANTY APPLICATION DEALER Page 6 of 18 ...

Page 394: ...ic temperature at that time NOTE Use a multi tester with an accuracy equivalent of the FLUK 70 series CAUTION Refer to the illustration at the right and the Standard Values table when measuring resistance Standard Values _ 1 F c Ei Ea Ve E i Vs THAa U p Measure Resistance Ambient Temp F Resistance K Ohms Ambient Temp F Resistance K Ohms 0 11 1 18 7 70 1 9 2 9 10 8 2 13 7 80 1 5 2 3 20 6 4 10 3 90 ...

Page 395: ...nd should be diagnosed using the methoc listed below 1986 89 323 1990 93 323 Protege 1990 92 626 MX 6 1990 91 929 1988 93 MPV 1990 93 MX 5 1993 MX 3 1 6 Litre 1 Check for smooth movement of the measuring plate If no problem is found reinstall the air flow meter 2 If no problem is found in the air flow meter contact the Technical Hotline for assistance Page 8 of 18 ...

Page 396: ... Out Of Specification ____Yes____No Measurement Factory Specifications Intake Air Temperature Sensor Base Resistance E2 VC Measuring Plate Does Not Move Smoothly___ Yes____No According to Service Bulletin instructions _____ Category______Number According to DSM or Hot Line Authorization __________ Authorization Number Other __________________________________________________________ Technician s Si...

Page 397: ...Number 002 93 Date Issued 9 16 93 Revised FUEL PUMP OUTLINE OF DIAGNOSTICS PARTS ORDERING AND WARRANTY APPLICATION DEALER Page 10 of 18 ...

Page 398: ...the fuel filter 6 Short circuit the fuel pump test terminals yellow 2 pin connector with a jumper wire on the following vehicles 1 9 8 8 8 9 323 1 9 9 0 9 1 929 1 9 8 9 9 1 RX 7 1993 626 M X 6 1 9 8 9 9 2 MPV 7 Short circuit the fuel pump check terminal and the ground terminal of the diagnostic connector with a jumper wire on the following vehicles 1990 93 323 P rotege 1 9 9 2 9 3 929 1 9 9 0 9 3 ...

Page 399: ...e the voltage at the fuel pump connector vehicle side NOTE Do not disconnect the fuel pump connec tor If the voltage is above the standard value replace the fuel pump If the voltage is below standard check for a dam aged harness relay or a poor ground at the pump Standard Value 8 5V and over 93 RX 7 9 5V and over Other Models 10 After restoring the standard voltage value measure the fuel pump pres...

Page 400: ...ient Fuel Pressure ____ Y es_____No Maximum Fuel Pump Pressure ______ PSI Factory Specification ______ According to Service Bulletin instructions _______ C ategory_______ Number According to DSM or Hot Line Authorization ____________ Authorization Number O th e r _________________________________________________________________________ Technician s Signature _______________________________________...

Page 401: ... 93 Date Issued 9 16 93 Revised CHARGING SYSTEM OUTLINE OF DIAGNOSTICS PARTS ORDERING AND WARRANTY APPLICATION DEALER Complete Check Sheet Order Part Authorize Replacement Auth No Required N Review Page 14 of 18 ...

Page 402: ...4D or equivalent 4 Apply the load test referring to the chart to the right The final voltage r L St be above the standard mini mum value shown below STANDARD MINIMUM VOLTAGE LOAD TEST CHART Approx Bat tery Temper ature Minimum Voltage 70F 21C 9 6V 60F 15C 9 5V 50F 10C 9 4V 40F 4C 9 3V 30F 1C 9 1V 20F 7C 8 9V If the voltage measures at or above the minimum pro ceed to step 4 If the voltage is below...

Page 403: ... load equal to the alternator rating The generated voltage should be 14 1V to 14 7V LOAD TEST RESULTS Over 14 7V Replace Alternator Under 14 1V Check for resistance between the battery and terminals B and S If resistance is present repair the damaged harness and retest If the voltage is still below 14 1V replace the alternator 14 1V to 14 7V No trouble with the alternator or battery Page 16 of 18 ...

Page 404: ...r output or battery voltage was out of specification _____Y es_____No Reading Factory Spec Output Voltage Output Amp Instrument Used Battery Voltage Open Terminal Battery Voltage Load Test According to Service Bulletin instructions _______ C ategory_______ Number According to D SM or Hot Line Authorization ____________ Authorization Number O th er __________________________________________________...

Page 405: ...mplete Applicable Part Number Operation Number and Labor Hours Operation Number Labor Hours Engine Control Unit ECU Diagnosis F0005XDX 0 9 Air Flow Sensor AFM Diagnosis F0006XDX 0 4 Fuel Pump Diagnosis F0007XDX 0 5 Charging System Diagnosis G0003XDX 1 4 NOTE Labor hours shown are the maximum allowable time Claim only the actual time used for these operations Page 18 of 18 ...

Page 406: ...edures for the following components Engine Control Units ECU Air Flow Meters Fuel Pumps Alternators Each procedure includes the following 1 Outline Of D iagnostics Parts Requirements and Warranty Application Illustrates the steps from diag nostics through parts return and warranty submission 2 Diagnostic Procedures Step by step testing of the component and circuit 3 Component Check Sheet Details o...

Page 407: ... 9 SECTION 3 Page Outline 10 Fuel Pump Diagnostics 11 Fuel Pump Check Sheet 13 Section 4 Page Outline 14 Charging System Diagnostics 15 Alternator and Battery Check Sheet 17 Section 5 Page Warranty Information 18 Refer to the applicable workshop manual for symptoms not described in this bulletin If further reference is required contact the Technical Hotline in your area Page 2 of 18 ...

Page 408: ...r 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 409: ...s different than specified check the related input and output devises and wiring for dam age If no problem is found and the reading remains out of specification replace the ECU 5 If the voltage is within specification and the problem still exists contact the Technical Hotline for assis tance CAUTION Terminals A B are for external voltmeter con nections Use these terminal to attach a digi tal voltm...

Page 410: ...___No 3 Reason for replacement Terminal Voltage Out Of Specification ____Yes____No Terminal Number Voltage Reading Factory Specifications According to Service Bulletin instructions ______Category______Number According to DSM or Hot Line Authorization __________ Authorization Number Other __________________________________________________________ 4 Repair Type Warranty____ Customer Pay Technician s...

Page 411: ...Number 002 93 Date Issued 9 16 93 Revised AIR FLOW METER OUTLINE OF DIAGNOSTICS PARTS ORDERING AND WARRANTY APPLICATION DEALER Page 6 of 18 ...

Page 412: ...ic temperature at that time NOTE Use a multi tester with an accuracy equivalent of the FLUK 70 series CAUTION Refer to the illustration at the right and the Standard Values table when measuring resistance Standard Values _ 1 F c Ei Ea Ve E i Vs THAa U p Measure Resistance Ambient Temp F Resistance K Ohms Ambient Temp F Resistance K Ohms 0 11 1 18 7 70 1 9 2 9 10 8 2 13 7 80 1 5 2 3 20 6 4 10 3 90 ...

Page 413: ...nd should be diagnosed using the methoc listed below 1986 89 323 1990 93 323 Protege 1990 92 626 MX 6 1990 91 929 1988 93 MPV 1990 93 MX 5 1993 MX 3 1 6 Litre 1 Check for smooth movement of the measuring plate If no problem is found reinstall the air flow meter 2 If no problem is found in the air flow meter contact the Technical Hotline for assistance Page 8 of 18 ...

Page 414: ... Out Of Specification ____Yes____No Measurement Factory Specifications Intake Air Temperature Sensor Base Resistance E2 VC Measuring Plate Does Not Move Smoothly___ Yes____No According to Service Bulletin instructions _____ Category______Number According to DSM or Hot Line Authorization __________ Authorization Number Other __________________________________________________________ Technician s Si...

Page 415: ...Number 002 93 Date Issued 9 16 93 Revised FUEL PUMP OUTLINE OF DIAGNOSTICS PARTS ORDERING AND WARRANTY APPLICATION DEALER Page 10 of 18 ...

Page 416: ... side of the fuel filter 6 Short circuit the fuel pump test terminals yellow 2 pin connector with a jumper wire on the following vehicles 1988 89 323 1990 91 929 1989 91 RX 7 1993 626 MX 6 1989 92 MPV 7 Short circuit the fuel pump check terminal and the ground terminal of the diagnostic connector with a jumper wire on the following vehicles 1990 93 323 Protege 1992 93 929 1990 93 MX 5 1993 626 MX ...

Page 417: ...e the voltage at the fuel pump connector vehicle side NOTE Do not disconnect the fuel pump connec tor If the voltage is above the standard value replace the fuel pump If the voltage is below standard check for a dam aged harness relay or a poor ground at the pump Standard Value 8 5V and over 93 RX 7 9 5V and over Other Models 10 After restoring the standard voltage value measure the fuel pump pres...

Page 418: ...nsufficient Fuel Pressure ___ Yes____No Maximum Fuel Pump Pressure ____ PSI Factory Specification _____ According to Service Bulletin instructions _____ Category______Number According to DSM or Hot Line Authorization _________ Authorization Number Other __________________________________________________________ Technician s Signature _______________________________________ Date _ NOTE Attach the c...

Page 419: ... 93 Date Issued 9 16 93 Revised CHARGING SYSTEM OUTLINE OF DIAGNOSTICS PARTS ORDERING AND WARRANTY APPLICATION DEALER Complete Check Sheet Order Part Authorize Replacement Auth No Required N Review Page 14 of 18 ...

Page 420: ...4D or equivalent 4 Apply the load test referring to the chart to the right The final voltage r L St be above the standard mini mum value shown below STANDARD MINIMUM VOLTAGE LOAD TEST CHART Approx Bat tery Temper ature Minimum Voltage 70F 21C 9 6V 60F 15C 9 5V 50F 10C 9 4V 40F 4C 9 3V 30F 1C 9 1V 20F 7C 8 9V If the voltage measures at or above the minimum pro ceed to step 4 If the voltage is below...

Page 421: ... load equal to the alternator rating The generated voltage should be 14 1V to 14 7V LOAD TEST RESULTS Over 14 7V Replace Alternator Under 14 1V Check for resistance between the battery and terminals B and S If resistance is present repair the damaged harness and retest If the voltage is still below 14 1V replace the alternator 14 1V to 14 7V No trouble with the alternator or battery Page 16 of 18 ...

Page 422: ... output or battery voltage was out of specification ____Yes____No Reading Factory Spec Output Voltage Output Amp Instrument Used Battery Voltage Open Terminal Battery Voltage Load Test According to Service Bulletin instructions _____ Category______Number According to DSM or Hot Line Authorization __________ Authorization Number Other __________________________________________________________ 4 Rep...

Page 423: ...mplete Applicable Part Number Operation Number and Labor Hours Operation Number Labor Hours Engine Control Unit ECU Diagnosis F0005XDX 0 9 Air Flow Sensor AFM Diagnosis F0006XDX 0 4 Fuel Pump Diagnosis F0007XDX 0 5 Charging System Diagnosis G0003XDX 1 4 NOTE Labor hours shown are the maximum allowable time Claim only the actual time used for these operations Page 18 of 18 ...

Page 424: ...he minimum specification contact your DCSM for authorization prior to replacing the battery See the Warranty Information on page 7 NOTE Do not install the ROOM fuse until retail delivery Following this procedure will minimize the amount of dark current drawn from the battery Dark current is current drawn by various electronic circuits which are constantly ON Examples of these circuits are engine a...

Page 425: ...Current AMP Charge Time Min Load Test AMP Protege 323 55D23L 30 30 180 626 MX 6 GROUP58R 30 30 174 929 55D23L 30 30 180 80D26L 35 30 195 Millenia 75D26L 80D26L 35 30 195 MX 3 50D20L 25 30 150 55D23L 30 30 180 65D23L 30 30 165 MX 5 S46A24L 20 30 105 RX 7 55D23L 30 30 180 65D23L 30 30 165 75D26L 35 30 195 MPV 50D20L 25 30 150 80D26L 35 30 195 B Series 50D20R 25 30 150 75D26R 35 30 195 80D26R 35 30 1...

Page 426: ...ing 0 01V N O TE Quick charge battery by setting the charge rate at the Highest or B oost position W hen testing in the vehicle turn the headlights ON for 15 seconds to remove the surface charge before testing Turn The Headlights On For 15 Seconds To Remove Any Surface Voltage Charge Apply Test Load To Battery Refer to Chart Record Battery Voltage After 15 Seconds Measure Open Circuit Voltage Of B...

Page 427: ...ect Test Leads To Battery And Switch To Position A Pretest Switch To NO Red L ig h t YES Bad Cell Position B Condition n ON Replace Battery Battery Has At Least 10 Volts Dial In Ratted CCA And Read Condition Scale Of The Meter Battery Has Less Than 10 Volts Recharge Once And Re Test NO Green 0 K To Test Light ON YES Switch To C GOOD Position To 4 Check Voltage r LOAD TEST SPECIFICATION Recharge Un...

Page 428: ...still less than 14 1V replace the alternator USING MIDTRONICS PowerSensor Plus TESTER 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 pre charging If low voltage is still found replace the battery according to the information in the warranty se...

Page 429: ...5 50D20L 306 G R 26R 310 525 0000 80 026R WB 1989 95 Cold Pack 80D26L 582 GR58R 585 675 0000 80 124F WB RX 7 1986 88 50D20L 306 GR26R 310 460 0000 80 0024 WB 1989 93 55D23L 356 GR35 360 525 0000 80 0035 WB 1986 93 65D23L 420 GR35 420 460 0000 80 0024 WB 1992 95 75D 26L G R 24 415 500 0000 80 224F WB 1992 95 24F 490 675 0000 80 1 24F W B M X 3 1992 93 I 4 50D 23L G R 26R 310 525 0000 80 026R WB 199...

Page 430: ...of vehicles in dealer inventory is the responsibility of the dealer and is not covered under vehicle warranty If a battery problem results from defects in material workmanship battery replacem ent is covered under vehicle warranty with D CSM authorization Maintain the battery according to the schedules and procedures listed on page 1 of this bulletin C om plete th e B attery M aintenance Record an...

Page 431: ...o 2 Battery Inspection Results information Reading Instrument Used For Test Battery Voltage Open Terminal Battery Voltage Load Test 3 Authorization N um ber____________________________ If battery was replaced prior to retail sale or within 90days of retail sale S ee R e verse S id e F o r B a tte ry D ia g n o s tic F lo w C h a rt 9999 95 037G 95 ...

Page 432: ...spec tion Date voltage and signature must be filled out on inspection The record should be retained at the dealer when the vehicle is retailed NOTE If the battery voltage measures less than 12 4V driving the vehicle will not sufficiently charge the battery Do not release a vehicle with a battery that is below full charge Install the R OOM fuse just prior to vehicle delivery Removing the ROOM fuse ...

Page 433: ...to the table on page 3 4 Load test the battery Refer to the table on page 2 for minimum voltage specifications 5 If not within specification contact your DCSM for authorization prior to replacing the battery See war ranty information on page 3 6 Do not install the R O O M fuse This will minimize the drainage on the battery from the CPU instru ment panel etc N O TE Remove ROOM fuse on Navajo and B ...

Page 434: ...lacement The table below should be followed when diagnosing maintenance free batteries Measure the cpen circuit voltage of the battery with a digital volt meter capable of reading 0 01V Below 12 4 V 12 4V and Above NOTE Quick charge the battery by setting the charge rate at the highest or boost position LOAD TEST SPECIFICATION Approx Battery Temp Min Volts 21C 70F 9 6 15C 60F 9 5 10C 50F 9 4 4C 40...

Page 435: ...mal dealer processing responsibility Boost charging is covered This will require completion of the inspection sheet Replacement Requires DCSM authorization Additionally the diagnostic check sheet must be com pleted and attached to the repair order If the inspection sheet is not attached the claim may be denied 2 V E H IC LE S IN DEALER INVENTORY Battery problems that occur after the wholesale deli...

Page 436: ...tion Results Reading Instrument Used Battery Voltage Open Terminal Battery Voltage Load Test 3 Authorization number it battery was replaced prior to retail sale of the vehicle NOTE This check sheet must be attached to the reverse side of the repair order Copy this check sheet at the dealer and keep in file for future use ...

Page 437: ...is step if the battery cables are disconnected with any circuits which still operate when the ignition switch is removed the problem symptom may not be duplicated and the correct dark current can not be measured even if the cable is reconnected 4 Use a jumper wire to connect the negative bat tery cable to the negative battery post Refer to Fig 1 5 Confirm that jumper wire is connected and dis conn...

Page 438: ...ore than 20 mA perform the following Disconnect the ROOM fuse and measure dark current Reconnect ROOM fuse to determine if current has changed If the current measurement is more than 2 5 mA disconnect and connect each fuse to determine which circuit is drawing abnormal current 9 Repair or replace faulty component s according to the workshop manual CHECKING POINT FOR DEAD BATTERY 1 Measure the dark...

Page 439: ... ice or snow build up from windshield with a suitable tool Confirm the wiper is free by carefully raising blades from glass NEVER operate wipers on dry windshield If the wiper operation stops Guide the vehicle to the side of road and stop Turn wipers OFF Wait approximately 5 minutes and turn the wiper switch ON If the wipers activate the wiper motor and circuitry are functioning properly circuit b...

Page 440: ...mer complaint 2 Turn off all electrical loads including accessories remove key from ignition and close all doors Note Disable hood light if equipped 3 To avoid deleting the audio memory presets or OBD II fault memory prepare ajumper wire as shown 4 Carefully loosen the negative battery clamp without disconnect ing it fromthe post JUMPER WIRE 5 Slightly lift clamp and wrap the jumper wire around th...

Page 441: ... to wait a minimum of one 1 minute after removingthe key from tineignition and closing all doors before measuring back up current This is the time nec essaryfor dome lights and CPU s to shut down and back up current to achieve specification If back up current exceeds specification a short exists or a defective component is causing excessive current flow Locate the source of excessive current draw ...

Page 442: ...t with the customer This inspection sheet which should be returned with the failed unit and a copy retained with the repair order contains information regarding this program 3 Refer to Mazda Parts Bulletin E 7 88 Western Regions revised 3 5 90 and V 32 Eastern Regions revised 3 5 90 for procedures required for ordering rebuilt EC ATs and for instructions regarding the return o f the failed assembl...

Page 443: ... 002 90 Date Issued 3 16 90 Date Revised The following parts should remain on the core before returning to MANA Refer to the illustrations below and the reference chart on the next page 1987 626 c Page 2 of 4 ...

Page 444: ...r for cord X X J Clip for cord X X K Throttle Cable Bracket X L Throttle Cable Clip X M Oil Level Gauge X NOTE The oil level gauge for the 1987 626 has been modified as shown in Service Bulletin Category 7 no 045 88 The modified oil level gauge will be supplied with the rebuilt EC AT from MANA please return the old oil level gauge with the core The following parts should be REMOVED from the core b...

Page 445: ...__________ 6 Mileage ____________________ 7 Delivery Date ____________________ 8 Problem Date ____________________ Customer Comment please indicate with a mark Slip 1 2 2 3 3 4 4 3 3 2 2 1 Shock 1 2 2 3 3 4 4 3 3 2 2 1 Flare 1 2 2 3 3 4 4 3 3 2 2 1 Noise 1 2 3 4 R No Movement 1 2 3 4 R Oil Leakage Location ________________________ 10 Checking Results Condition of ATF OK Burned Other ATF Level F in...

Page 446: ...itional pads of fifty 50 are available free of charge from Helm Inc For additional information regarding transmission transaxle diagnostics referto the applicable workshop man ual and or contact your regional distributor hot line NOTE If the transmission oil cooler is not cleaned with the proper power flushing equipment prior to repair completion and comeback problems occur due to clogged oil cool...

Page 447: ...blem list if yes Trans Fluid Cond Milky ____Burnt Parfcles Sludge__ Normal_ Trans Fluid Level High__ Low__Normal__ Trans Leaks Yes No list area s If yes Engine Electrical System Battery Voltage engine running Volts KOEO KOER Key On Engine Off Key On Engine Running LA4A EL Transmission Only TEST RESULTS Problem Category Codes______________________Leaks___Fluid Cond __ Driveability__ Unusual Noise l...

Page 448: ...CHART PRE CHECK PROCEDURES Review Repair History Check Engine Electrical System Performance Check For Non Factory Equipment Check Shift Linkage Adjustment Vehicles With Ford Components KOEO and KOER Tests Call Hotline NO Complete A T Check Sheet Request Authorization Order Trans Replace Trans ...

Page 449: ...re is within 4 0 4 6 kg cm2 57 66 psi at idle 7 2 5 7 7 5 rpm in P range at normal operating temperature If the line pressure is out of the specification adjust the line pressure by adjusting the lock nuts of the throttle cable 3 Verify that the throttle cable is free of slack in accordance with the following procedure a Read the line pressure a indicated on the pressure gauge P N 49B0 19 901 b Di...

Page 450: ...result is still unacceptable proceed to the next step 5 Replace the valve body with one for the 1990 model P N FU3H 21 100A WARRANTY INFORMATION 1 When Repair Prodedure steps 1 4 were conducted Warranty Type Code A Customer Comment Code 26 Damage Code 9H Part No of Main Cause FU32 21 600B Operation No XX0355 R X Labor Hours 0 8 Hr 2 When Repair Prodedure steps 1 5 were conducted Warranty Type Code...

Page 451: ...isted below Lock TIGHTENING TORQUE 1986 9 0 626 1988 89 323 1990 323 Protege 44 64 N m 33 47 ft lb 4 5 6 5 kg cm 44 64 N m 33 47 ft lb 4 5 6 5 kg cm 31 46 N m 23 34 ft lb 3 2 4 7 kg cm IMPORTANT NOTE The use of a powerwrench air or electric impact wrench is not recommended when installing the lock nut Reac tion force applied to the shaft during installation may cause internal transaxle damage IMPO...

Page 452: ...e to the end of its travel full throttle and read the line pressure Line pressure should be higher than 8 0 kg cm2 115 psi B Next quickly and smoothly pull the throttle cable out to one half way of its travel half throttle and hold Check for line pressure spike maxi mum and drop minimum readings using a line pressure gauge A good oil pump should show a smooth increase of pressure and level off at ...

Page 453: ...he partially closed end pointing outward 5 Insert the spring until it becomes flush with the oil pump housing 6 Replace the copper washer on the spool valve plug and reinstall the plug onto the oil pump housing Tighten the plug by the specified torque Specified Torque 2 4 3 6 m kg 17 25 ft lbs 7 Check the ATF level and add fluid if necessary 8 Recheck the line pressure and adjust if necessary Spec...

Page 454: ...X 6 vehicles manufactured in the U S A 1YVGD22B 1YVGD22D I 1YVGD31B L5244868 1Y V G D 31D J March 8 1990 WARRANTY INFORMATION Warranty Type Code A Customer Comment Code 99 Damage Code 99 Part No of Main Cause FU02 19 735F Operation No XX0379 R 1 Max 0 8 Hr Check Adjustment X X 0379 R 2 Max 1 0 Hr Check Adjustment Repair NOTE Labor operation no XX0379 R 1 is included in labor operation no XX0379 R ...

Page 455: ...sing The illustrations shown below indicate where these ID numbers are stamped NOTE Matching vehicle and transaxle VIN numbers indicate a factory installed powertrain 1987 626 EC AT 1988 91 626 MX 6 EC AT MANA Stamp MANA Stamp 1988 89 323 HAT MANA Stamp WARNING Federal law prohibits the removal of VIN tags from any transaxle assembly 0 2 1 6 2 4 ____________ ______________________________ IMPORTAN...

Page 456: ...housing The illustrations shown below indicate where these ID numbers are stamped NOTE Matching vehicle and transaxle VIN numbers indicate a factory installed powertrain 1987 626 EC AT 1988 91 626 MX 6 EC AT MANA Stamp MANA Stamp 1988 89 323 HAT MANA Stamp WARNING Federal law prohibits the removal of VIN tags from any transaxle assembly 0 2 1 6 2 4 ____________ ______________________________ IMPOR...

Page 457: ...triction is usually caused by an accumulation of metal particles and debris from a previous A T failure on the internal mesh type baffle of the oil cooler Power flushing will remove the restriction by back flushing the cooler lines followed by forward flushing to ensure full ATF flow See FIG U R E 1 of a typical ATF cooler O IL OUT 060403 CONSUMER NOTICE The information and instructions in mis bul...

Page 458: ...le Inspecting Oil Lines Clamps Be sure to inspect the lines hoses pipes for cuts crimps pinched cracks or any other damage before reusing them If any problem exists or the hose comes off when applying oil pressure replace it Caution Always use new clamps when replacing hoses Back Flushing 1 Using the Power Flushing Equipment manufacturer s instructions connect equipment so the flushing fluid flows...

Page 459: ...cement add any of the following operation numbers and labor hours to the operation number and labor hours for automatic transmission com plete R R Operation Number Labor Hours MPV L4 K0101XRU 0 4 MPV V6 2WD K0101XRU 0 4 MPV V6 4WD K0101XRU 0 4 Millenia 2 3L K0101XRU 0 4 Millenia 2 5L K0101XRU 0 4 RX 7 K01Q1XRU 0 4 MX 5 K0101XRU 0 4 MX 3 L4 K0101ARU 0 4 MX 3 V6 K0101BRU 0 4 929 K0101XRU 0 4 626 MX ...

Page 460: ...Transmission Transaxle Normal Fluid Flow Cooler Line Fitting Locations Refer to applicable WSM for specific details FRONT WHEEL DRIVE fTRANSAXLE PROTEGE MILLENIA KL 626 FS MILLENIA KJ 626 KL REAR WHEEL DRIVE MPV RX 7 929 MIATA NA B TRUCKS f SIDE VIEW MIATA NB PAGE 4 OF 4 ...

Page 461: ...ve the steering wheel and install in the correct position If the steering wheel is still off center go to step 3 3 Measure the distance as shown in step 2 If less than 30m m 1 18in loosen both left and right tie rod end lock nuts Turn the tie rods in opposite directions by the same amount until the steering wheel is centered 4 Road test the vehicle to confirm the steering wheel is centered If not ...

Page 462: ...ARRANTY INFORMATION A p p lie s T o V e h icle s C o v e re d U n d e r N o rm a l W a rran ty Warranty Type A Customer Com ment Code 30 Damage Code 9H Part Num ber Main Cause 5555 FE 001 Operation Number X X0640R X Labor Hours 0 5Hr Page 2 of 2 ...

Page 463: ...ecifications during alignment adjustment N E W SPEC IFIC A TIO N S ITEM S STA N D A R D TO LER A N C E N O TE Front Camber Difference between right and left 1 1 5 degrees Caster Difference between right and left 1 1 5 degrees Toe Total toe in 4mm Angle indicated is also described O ne side toe is not mentioned No specification R ear Cam ber Difference between right and left 1 1 5 degrees Toe Total...

Page 464: ...5 to 5 degrees 05 1 4 3 degrees 10 to 5 degrees 10 1 2 3 degrees 15 to 5 degrees 15 3 4 3 degrees 2 0 to 5 degrees 20 Full 3 degrees 2 5 to 5 degrees 25 N O TE Specifications may differ between models 3 Follow the operating procedures specified for the alignment equipment being used 4 Prior to measuring the current settings firmly push the vehicle bumper up and down to stabilize the vehicle s heig...

Page 465: ... bottom of the power steering reservoir 3 Lift the reservoir to access the lower mounting bracket NOTE When raising the reservoir take care not tospillthepowersteeringfluidon painted surfaces If fluid does spill clean up immediately 4 Insert grommet into the locator hole in the lower mounting bracket 5 Lubricate the grommet to facilitate installation of the locator pin on the reservoir 6 Install t...

Page 466: ...E Front Camber Difference between right and left 1 1 5 degrees Caster Difference between right and left 1 1 5 degrees Toe Total toe in 4mm Angle indicated is also described One side toe is not mentioned No specification Rear Camber Difference between right and left 1 1 5 degrees Toe Total toe in 4mm Angle indicated is also described One side toe is not mentioned No specification Thrust Angle 0 8 d...

Page 467: ... 05 to 5 degrees 05 1 4 3 degrees 10 to 5 degrees 10 1 2 3 degrees 15 to 5 degrees 15 3 4 3 degrees 20 to 5 degrees 20 Full 3 degrees 25 to 5 degrees 25 NOTE Specifications may differ between models 3 Follow the operating procedures specified for the alignment equipment being used 4 Prior to measuring the current settings firmly push the vehicle bumper up and down to stabilize the vehicle s height...

Page 468: ...m that it is not coming from another part of the vehicle 2 Remove the 2 mounting bolts from the bottom of the power steering reservoir 3 Lift the reservoir to access the lower mounting bracket NOTE When raising the reservoir take care not to spill the power steering fluid on painted surfaces If fluid does spill clean up immediately 4 Insert grommet into the locator hole in the lower mounting brack...

Page 469: ...he boot for contamination dirt water etc If there is a large quantity of red fluid inside the boot this indicates insufficient sealing Replace the side seal and the power steering gear according to section N of the workshop manual If a minimal quantity of red fluid is present proceed to step 4 4 Start the engine and turn the steering wheel right and left lock to lock If the fluid is leaking replac...

Page 470: ...n both left and right tie rod end lock nuts Turn the rods in the opposite directions by the same amount until the steering wheel is centered 4 Road test the the vehicle to confirm the steering wheel is centered If not centered repeat step 3 The chart below shows the approximate distance that the outside circumference will move per 90 degree turn on the tie rod both left and right in opposite direc...

Page 471: ... Loosen both right and left hand tie rod end lock nuts b Turn the tie rod ends in opposite directions by equal amounts until the steering wheel is centered 3 Verify the repair The chart below shows the approximate distance the outside diameter will move for every 1 4 90 degree turn of the tie rod end WARRANTY INFORMATION Applies To Verified Custom er Com plaints On Vehicles Covered U n der N orm a...

Page 472: ...nd off car brake lathes and has determined that on car lathes are more precise and greatly reduce comeback repairs The steps necessary for correction of brake judder are as follows 1 If the vehicle is in dealer inventory and the condition is rotor rust a Clean the rotor surface by driving the vehicle several miles while frequently applying the brakes b If vibration pulsation is still felt proceed ...

Page 473: ...lathe will be available soon from MMA s National Accounts Program at a substantial savings When the national account is established a Special Tools Service Bulletin will be released which will contain further details How ever if you wish to receive a brochure on this brake lathe please call Accu Turn at 800 551 2228 WARRANTY INFORMATION A p p lie s To V e h icles C o v e re d U n d e r N o rm a l ...

Page 474: ...R I PQ204ARX P0204BRX 0 4 0 6 0 5 0 8 OS 1995 0 3 0 8 1995 0 5 0 4 0 6 07 1 0 P0204XRX P0204XRX 10 1 0 1 0 1 0 To submit for reimbursement on warranty brake repairs follow these examples 1 Machine brake drams and replace brake shoes 3 Rcplacc brake drums and replace brake shoes Labor Operation Time Description of Repair P0201BRX per chart brake shoes R R Labor Operation Time Description of Repair ...

Page 475: ...ide both sides P0209ARX P0209BRX 0 3 0 5 0 4 0 5 0 3 0 5 0 4 0 5 0 5 0 6 0 5 0 9 0 3 0 5 0 4 1995 0 3 0 5 1995 0 5 NOTE After February 1 1995 the on vehicle lathe will be required for disc rotor machining To submit for reimbursement on warranty brake repairs follow these examples 1 Replace brake pads Labor Operation Time Description of Repair P0209BRX per chart pads R R 3 Replace disc plates and r...

Page 476: ...aides P0113BM Y 1 2 1 2 1 2 S B B 1 2 1 2 1 2 1 2 POt 13BMX 2wd 1 5 P0113BMX 2wd 1 5 Includes brake pads R R and brake caliper R R P0113DMX 4wd 1 1 4wd 1 1 P0113DMX 4wd 1 1 Pad s R R one side P0104ARX 0 5 i l i i i l l 0 3 0 4 0 4 0 4 0 S 0 4 0 4 0 4 0 4 1995 0 3 P01048RX 0 6 0 5 0 4 0 6 0 5 0 G 0 0 0 6 0 7 0 7 0 6 1995 0 4 NOTEs After February 1 1995 the on vehicle lathe will be required for dlto...

Page 477: ...otorthickness meets or exceeds allowable thickness proceed to step 2 2 Machine the rotors using an on the car brake lathe 3 Follow the detailed repair procedures located in Service Bulletin Category P 001 95 and the applicable work shop manual Other Than Brake Judder 1 Inspect the rotor s for cracks if cracks are not found refer to the table on page 2 for repair replacement criteria Do not replace...

Page 478: ... audio record LIGHT SCRATCHES No No Cracks In Rotor CRACKS IN ROTOR No Yes SeeNote 1 RotorThicknessWill Be LessThan Specified After Machining Referto the WSM for limit specifications N A No Yes SeeNote 1 New Rotor Replacement See Note 1 N A Yes NOTE 1 When rotor replacement is necessary machine the newly installed disc with an on the car brake lathe 2 MMA may request within 30 days after the claim...

Page 479: ... If the rotors do not contain cracks or deep grooves and the remaining rotor thickness allows for machining the rotors should be resurfaced NOTE Minimum allowed rotor thickness is stamped on rotor surface Rotor Thickness Specification MPV 1992 4X2 New 30 0 mm 1 18 in Minimum 28 0 mm 1 10 in 4X4 New 28 0 mm 1 10 in Minimum 26 0 mm 1 02 in MPV 1989 91 4X2 4X4 New 24 0 mm 0 94 in Minimum 22 0 mm 0 87...

Page 480: ...n MX 3 1992 Front New 22 0 mm 0 87 in Minimum 20 0 mm 0 79 in Rear New 9 0 mm 0 35 in Minimum 8 0 mm 0 31 in 626 MX 6 1989 92 Front New 24 0 mm 0 94 in Minimum 22 0 mm 0 87 in Rear New 10 0 mm 0 39 in Minimum 8 0 mm 0 31 in MX 5 1990 92 Front New 18 0 mm 0 71 in Minimum 16 0 mm 0 63 in Rear New 9 0 mm 0 35 in Minimum 7 0 mm 0 28 in RX 7 1989 91 Front New 22 0 mm 0 87 in Minimum 20 0 mm 0 79 in Rea...

Page 481: ...side diameter is not exceeded NOTE Maximum allowed drum inside diameter is stamped on the exterior drum surface Brake Drum Specification MPV 1989 92 Inside Diameter Inside Diameter B Series 1989 92 Inside Diameter Inside Diameter Navajo 1991 92 Inside Diameter 323 Protege 1989 Inside Diameter Inside Diameter 323 Protege 1990 Inside Diameter Inside Diameter MX 3 1992 Inside Diameter Inside Diameter...

Page 482: ...duce comeback repairs The steps necessary for correction of brake judder are as follows 1 If the vehicle is in dealer inventory and the condition is rotor rust a Clean the rotor surface by driving the vehicle several miles while frequently applying the brakes b If vibration pulsation is still felt proceed to step c c Machine the rotor surface enough to remove all rust or surface staining generally...

Page 483: ...ntial savings When the national account is established a Special Tools Service Bulletin will be released which will contain further details How ever if you wish to receive a brochure on this brake lathe please call Accu Tum at 800 551 2228 WARRANTY INFORMATION Applies To Vehicles Covered Under Normal Warranty Warranty Type Code A Customer Comment Code 83 Damage Code 9B Parts No Of Main Cause 33 25...

Page 484: ...at on car lathes are more precise and greatly reduce comeback repairs The steps necessary for correction of brake judder are as follows 1 If the vehicle is in dealer inventory and the condition s rotor rust a Clean the rotor surface by driving the vehicle several miles while frequently applying the brakes b If vibration pulsation is still felt proceed to step c c Machine the rotor surface enough t...

Page 485: ...The brake lathe will be available soon from MMA s National Accounts Program at a substantial savings When the national account is established a Special Tools Service Bulletin will be released which will contain further details How ever ifyou wish to receive a brochure on this brake lathe please call Accu Tum at 800 551 2228 WARRANTY INFORMATION Applies To Vehicles Covered Under Normal Warranty War...

Page 486: ...g tire chains 2 Use only SAE Class S chains and make sure they fit the vehicle s tires 3 Follow the chain manufacturer s instructions 4 Remove the steel wheel covers if equipped to avoid scratches or damage 5 Front Wheel Drive Vehicles Secure the chains on the front tires as tightly as possible Retighten after one half mile of driving Rear Wheel Drive Secure the chains to the rear wheels as tightl...

Page 487: ...e for installation of previous repair kits If modifications have been made verify location of wind noise If noise is still present inspect installation quality Verify location of complaint The illustration below shows the general areas where wind noise may occur A D Specific locations of wind noise are shown numerically A Wind noise at front door area during high speed above 40 mph driving pages 2...

Page 488: ... door area during high speed above 40 mph driving Location 2 LOCATION 1 DOOR MIRRORS ALL MODELS YEARS Manual and Power Mirrors 1 Using a flat screwdriver carefully pry the inner sail garnish out of its position Start prying at the top comer of the sail garnish then work down ward CAUTION TAKE CARE NOT TO BREAK THE FASTENING TAB AT THE BOTTOM OF THE SAIL GARNISH 2 Remove mirror and install comer br...

Page 489: ...Mirrors Only 6 Add respective right and left seal rubber to the mirror Figure 2 Figure 2 Power Door Mirror Manual Mirrors Only 7 Add respective right and left seal rubber to the mirror base Figure 3 Lip Adhesive Tape Figure 3 Door Mirror Manual and Power Mirrors 8 Reinstall mirror Page 3 of 14 ...

Page 490: ...Replace glass inner weatherstrip with new strip Figure 4 Figure 4 Top of inner door panel LOCATION 3 GLASS RUN CHANNEL FRONT D O O R 1988 89 MODELS ONLY Cross Section X X 1 Lower window all the way 2 Pull back the glass run channel Figure 5 3 Attach the pad strip to the back of the glass run channel from the circled area Pad size Length 400 mm Thickness 2 mm Width 10 mm Figure 5 Front Door Page 4 ...

Page 491: ...Figure 6 2 Lower the window glass to about 4 showing Pull the glass guide rail toward the inside of the window frame and up Move the window glass toward the front of the vehicle Figure 7 3 Remove the original glass guide rail pad and replace it with a new one Figure 8 A Install the new glass guide rail pad so that the top of the pad is 30 mm from the bottom of the guide rail Figure 9 Figure 8 Orig...

Page 492: ...ck to gether Figure 9 4 Reinstall the glass guide rail and door inner trim panel CAUTION For ease of installation door glass must be up ap proximately 4 inches LOCATION 5 A PILLAR A R EA 1988 89 4 and 5 door models 1 Open the front door and remove the mounting screw from the lower side of the drip molding Figure 10 Drip Molding Figure 10 A pillar area Page 6 of 14 ...

Page 493: ...nd insert the pro tector inside the front fender cavity Figure 12 MX 6 1 Cut the boss off of the protector Figure 13 Figure 13 Protector 2 Glue the protector to the drip molding Figure 14 3 Insert protector into fender cavity Figure 14 A Pillar Drip Molding A Glue Protector Figure 14 Front of A pillar area Page 7 of 14 ...

Page 494: ...CEDURE CONT D Condition B Wind noise at rear door area 1 9 8 8 89 models only Front of Vehicle Location 5 Location 4 LOCATION 1 TOP REAR OF WINDOWS 1 Lower window all the way 2 Pull off the rear comer section of the glass run channel Figure 15 Figure 15 Rear door Page Sof 14 ...

Page 495: ...ndicated by the circle in Figure 16 Pad size Length D 4 Door Sedan 257 mm D 5 Door Hatchback 286 mm Thickness 3mm Width 5 mm 4 Reinstall the glass run channel LOCATION 2 MIDDLE REAR OF WINDOWS Install a pad on the reverse side of the comer lip circled area to improve the sealing effectiveness Figure 17 Figure 16 Top of rear door Page 9 of 14 ...

Page 496: ...SAIL GARNISH Using a flat screwdriver remove the inner sail gar nish by prying it out and installing a new level inner sail garnish Figure 20 NOTE Using a flat screwdriver pry sail garnish out of its lo cation Start from the lower rear comer and work forward Also be careful not to damage the paint on the surrounding area Figure 20 Figure 18 Rear top ofrear door Pad to be trimmed to 200 ram NS SSv ...

Page 497: ...EAR GLASS WEATHERSTRIP Perform rear door weatherstrip improvements following the same steps as used on the front door Condition A Location 2 Condition C Wind noise fluttering noise at rear corner window area 1 9 8 8 91 2 Door Coupe 1 Prepare a tube of silicone sealer as shown Figure 21 Page 11 of 14 ...

Page 498: ...oving any re maining sponge tape around them 2 Clean the above mentioned area with alcohol or degreaser to remove grease and oil 3 Apply the primer to the glass Allow the primer to dry for approximately 10 minutes 4 Adhere double coated tape to the garnish in the previously taped area Figure 24 NOTE When adhering the double coated tape set the tape beforehand to make sure the tape is positioned co...

Page 499: ...arts according to Workshop Manual pro cedures section S a Black Plastic Inner Sail Garnish b Window Frame Weatherstrip 3 Remove the weatherstrip to access the glass run channel frame 4 Carefully bend the weatherstrip frame slightly outward 1 16 to increase the pressure of the weatherstrip against the glass Use a sheet metal bending tool Snap on P N VP8R or equivalent NOTE Protect the painted surfa...

Page 500: ...IR OPERATION NO one side only LABOR HOURS one side only A Wind noise at front door area during high speed driving XX0312RX 1 2 B Wind noise at rear door area XX0274RX 0 5 C Wind noise fluttering noise at rear comer window area XX0252RX 0 3 D A B C XX0311RX 2 0 NOTE If applicable to R L sides use given operation no and labor hours twice 2 MX 6 CONDITION REPAIR OPERATION NO one side only LABOR HOURS...

Page 501: ...ough 6 II Left Front Side of Passenger Compartment Pages 6 through 9 EH Trunk Compartment and Under Rear Seat Pages 9 through 13 IV Sunroof of Headliner Area Pages 13 through 15 LOCATION I RIGHT FRONT SIDE OF PASSENGER COMPARTMENT Location of Water Leak Source 1 Remove the dash undercover scuff plate and kick panel Pull back the carpet and pad Remove the front seat carpet and pad if necessary 2 At...

Page 502: ...the assistant slowly direct water along the window beltline molding if the vehicle is a four door perform this test on both the front and rear doors Figures 1 and 2 NOTE DO NOT direct water into blower motor opening under cowl panel 6 Note which area the water enters the vehicle Re fer to the appropriate location s repair procedure Figure 3 AREA A KICK PANEL pages 3 and 4 AREA B UNDER DASH pages 4...

Page 503: ... Seal any suspected sealer defects Figure 5 4 Open the sunroof Using a squeeze bottle filled with water pour water down the front drain holes Check for signs of leakage at the sunroofdrain tu be to drain hose Figure 4 Checking the Sunroof Drain Hose 5 If the leak is still present remove cap and screw from the front windshield header Remove the A pillar side molding Check the drain hose for kinks F...

Page 504: ...tains 3 Set the heater control air intake control lever to the first position Remove the blower fan 3 screws and look for water entering the blower motor opening 4 Check all grommets shown in Figure8 forleaks by spraying water on each one Replace any grommets that leak NOTE Apply silicone sealer to the bottom of the grommet during installation 5 If the grommets do not leak seal the baffle seam by ...

Page 505: ...ge or moisture AREA C CORNER OF FIREWALL AND INNER FENDER 1 Lift carpet and pad and feel for water If water is present remove windshield wipers and cowl plate Check for missing sealer or holes among the lower A pillar to cowl seam Apply sealer to any suspected areas Figure 9 NOTE This procedure should only be done by experienced body shop personnel 2 Remove the doorjamb nut and bolt also remove th...

Page 506: ...over scuffplate and kick panel Pull back the carpet and pad Remove the front seat carpet and pad if necessary 2 At least 12 minutes should be spent during initial hose testing because the water may have to move through several body seams before being de tected 3 Turn the water pressure to the hose so that a 12 to 18 stream of water is present while the hose is in a vertical position 4 Get inside t...

Page 507: ...re are no loops kinks or pinched areas If the hose cannot be corrected or is out remove the damaged sec tion of hose Install a replacement piece of hose 4 7 mm 3 16 in outside diameter which pro vides a tight Fit to the existing hose 4 If the leak persists inspect the antenna bezel molding and gasket for correct sealing and mounting Confirm that the mounting screw is fully seated and that the gask...

Page 508: ...pected areas Figure 15 NOTE This procedure should only be done by experienced body shop personnel 2 Remove the doorjamb nut and bolt also remove the four 4 upper fender bolts Using a mechan ic s mirror inspect sealer hidden by the upper fender for skips and pinholes Figure 15 NOTE The illustration shows the fender re moved Complete fender removal is not required CAUTION USE CARE WHEN MOVING FENDER...

Page 509: ... 4 Lower the rear seat backs From inside the ve hicle close the door and using a flashlight look for water leaks during the hose test 5 Have an assistant direct the water stream over the entire rearof the vehicle concentrating on the fol lowing areas Figure 17 Along the deck lid to body gap Up each C pillar and across the upper portion of the rear window Along the key lock cylinder reardeck lid fi...

Page 510: ...TIC AND OR TRUNK WEATHERSTRIP ALSO REAR COMBINATION LAMPS AREA 1 If water is running down over the interior trunk end panel trim or over under the trunk weather strip pull up the trunk weatherstrip and check grey sealer material and any body seams near the linkage area Confirm that grey sealer covers the top of the flange in one solid strip Check for pin holes missing sealer or burrs Figure 21 and...

Page 511: ...riD AREA B INNER WHEEL WELL TO TRUNK FLOOR PAN SEAM 1 If water leaks into the forward area of the trunk make sure that the weatherstrip is properly seated and not leaking Figure 23 2 If no problems are found check all trunk opening seams and the inner wheel well to trunk floor pan seam for missing sealer or pin holes Seal any sus pected areas and retest for leaks If no problems are found go to ste...

Page 512: ... for any leaks at the grommet and plug be tween the quarter panel and bumper Examine seams for missing sealer or pin holes Seal any suspected defects Figures 26 and 27 3 Check for any leaks at the fuel filler neck to body in the left quarter If moisture is present re move the filler neck 4 Apply sealer to both sides of the gasket and rein stall AREAD INNER WHEEL WELL TO FLOOR PAN UNDER REAR SEAT A...

Page 513: ...A page 13 AREAB REAR PASSENGER COMPART MENT AREA page 14 AREAC REAR HEADLINER OR SUNROOF SLIDING PANEL pages 14 and 15 AREA A FORWARD HEADLINER AREA 1 Open the sunroof and make sure that the sunroof drain tubes are intact and that no holes are present If welds are damaged or have holes repair or replace the sunroof frame 2 If welds and drain tubes are OK remove the front header and side trim piece...

Page 514: ...f necessary position the hose so that there are no loops kinks or pinched areas Check for kinks at the drain hose clip Repeat the water test Make sure that the sunroof drains properly and does not leak Figure 31 5 If necessary install a new hose 6 If hose routing is OK and hose is intact check for leaks at the rear window AREA C REAR HEADLINER OR SUNROOF SLIDING PANEL 1 Remove the rear header trim...

Page 515: ...rranty Type Code Customer Comment Code Damage Code Part No of Main Cause Operation No Labor Hours Location Code A 77 9K 5555 WA 001 See Chart Below See Chart Below Applicable location code necessary Codes found in SRT microfiche or Warranty Policies and Procedures Manual PROCEDURE OPERATION NUMBER LABOR HOURS Water Testing YY0064RX 0 5 Repair of Right Front Side of Passenger Compartment YY0033RX N...

Page 516: ...ront Side of Passenger Compartment Pages 6 through 9 HI Trunk Compartment and Under Rear Seat Pages 9 through 13 IV Sunroof of Headliner Area Pages 13 through 15 LOCATION I R IG H T FRONT SIDE O F PASSENGER COM PARTM ENT Location of Water Leak Source 1 Remove the dash undercover scuff plate and kick panel Pull back the carpet and pad Remove the front seat carpet and pad if necessary 2 At least 12 ...

Page 517: ...the assistant slowly direct water along the window beltline molding if the vehicle is a four door perform this test on both the front and rear doors Figures 1 and 2 NOTE DO NOT direct water into blower motor opening under cowl panel 6 Note which area the water enters the vehicle Re fer to the appropriate location s repair procedure Figure 3 AREA A KICK PANEL pages 3 and 4 AREA B UNDER DASH pages 4...

Page 518: ...s Seal any suspected sealer defects Figure 5 4 Open the sunroof Using a squeeze bottle filled with water pour water down the front drain holes Check for signs of leakage at the sunroofdrain tu be to drain hose Figure 4 Checking the Sunroof Drain Hose 5 If the leak is still present remove cap and screw from the front windshield header Remove the A pillar side molding Check the drain hose for kinks ...

Page 519: ...tains 3 Set the heater control air intake control lever to the first position Remove the blower fan 3 screws and look for water entering the blower motor opening 4 Check all grommets shown in Figure8 forleaks by spraying water on each one Replace any grommets that leak NOTE Apply silicone sealer to the bottom of the grommet during installation 5 If the grommets do not leak seal the baffle seam by ...

Page 520: ...r leakage or moisture AREA C CORNER OF FIREWALL AND INNER FENDER 1 Lift carpet and pad and feel for water If water is present remove windshield wipers and cowl plate Check for missing sealer or holes among the lower A pillar to cowl seam Apply sealer to any suspected areas Figure 9 NOTE This procedure should only be done by experienced body shop personnel 2 Remove the doorjamb nut and bolt also re...

Page 521: ...cover scuffplate and kick panel Pull back the carpet and pad Remove the front seat carpet and pad if necessary 2 At least 12 minutes should be spent during initial hose testing because the water may have to move through several body seams before being de tected 3 Turn the water pressure to the hose so that a 12 to 18 stream of water is present while the hose is in a vertical position 4 Get inside ...

Page 522: ...e are no loops kinks or pinched areas If the hose cannot be corrected or is out remove the damaged sec tion of hose Install a replacement piece of hose 4 7 mm 3 16 in outside diameter which pro vides a tight Fit to the existing hose 4 If the leak persists inspect the antenna bezel molding and gasket for correct sealing and mounting Confirm that the mounting screw is fully seated and that the gaske...

Page 523: ...o any suspected areas Figure 15 NOTE This procedure should only be done by experienced body shop personnel 2 Remove the doorjamb nut and bolt also remove the four 4 upper fender bolts Using a mechan ic s mirror inspect sealer hidden by the upper fender for skips and pinholes Figure 15 NOTE The illustration shows the fender re moved Complete fender removal is not required CAUTION USE CARE WHEN MOVI...

Page 524: ... 4 Lower the rear seat backs From inside the ve hicle close the door and using a flashlight look for water leaks during the hose test 5 Have an assistant direct the water stream over the entire rearof the vehicle concentrating on the fol lowing areas Figure 17 Along the deck lid to body gap Up each C pillar and across the upper portion of the rear window Along the key lock cylinder reardeck lid fi...

Page 525: ...RIM PLASTIC AND OR TRUNK WEATHERSTRIP ALSO REAR COMBINATION LAMPS AREA 1 If water is running down over the interior trunk end panel trim or over under the trunk weather strip pull up the trunk weatherstrip and check grey sealer material and any body seams near the linkage area Confirm that grey sealer covers the top of the flange in one solid strip Check for pin holes missing sealer or burrs Figur...

Page 526: ...riD AREA B INNER WHEEL WELL TO TRUNK FLOOR PAN SEAM 1 If water leaks into the forward area of the trunk make sure that the weatherstrip is properly seated and not leaking Figure 23 2 If no problems are found check all trunk opening seams and the inner wheel well to trunk floor pan seam for missing sealer or pin holes Seal any sus pected areas and retest for leaks If no problems are found go to ste...

Page 527: ... 2 Check for any leaks at the grommet and plug be tween the quarter panel and bumper Examine seams for missing sealer or pin holes Seal any suspected defects Figures 26 and 27 3 Check for any leaks at the fuel filler neck to body in the left quarter If moisture is present re move the filler neck 4 Apply sealer to both sides of the gasket and rein stall AREAD INNER WHEEL WELL TO FLOOR PAN UNDER REA...

Page 528: ...A page 13 AREAB REAR PASSENGER COMPART MENT AREA page 14 AREAC REAR HEADLINER OR SUNROOF SLIDING PANEL pages 14 and 15 AREA A FORWARD HEADLINER AREA 1 Open the sunroof and make sure that the sunroof drain tubes are intact and that no holes are present If welds are damaged or have holes repair or replace the sunroof frame 2 If welds and drain tubes are OK remove the front header and side trim piece...

Page 529: ...f necessary position the hose so that there are no loops kinks or pinched areas Check for kinks at the drain hose clip Repeat the water test Make sure that the sunroof drains properly and does not leak Figure 31 5 If necessary install a new hose 6 If hose routing is OK and hose is intact check for leaks at the rear window AREA C REAR HEADLINER OR SUNROOF SLIDING PANEL 1 Remove the rear header trim...

Page 530: ...rranty Type Code Customer Comment Code Damage Code Part No of Main Cause Operation No Labor Hours Location Code A 77 9K 5555 WA 001 See Chart Below See Chart Below Applicable location code necessary Codes found in SRT microfiche or Warranty Policies and Procedures Manual PROCEDURE OPERATION NUMBER LABOR HOURS Water Testing YY0064RX 0 5 Repair of Right Front Side of Passenger Compartment YY0033RX N...

Page 531: ...event short circuits from occurring Figure 1 NOTE Red yellow wire applies to 1988 and 1989 626 models only Red Yellow Wire Cut and tape before installing 1990 91 626 Only Door Switch Harness Figure 1 Door Switch Harness Wire Location PARTS INFORMATION PART NUMBER DESCRIPTION APPLICABLE MODEL GJ35 57 930E Right Passive Shoulder Belt Assy 1988 91 626 4 Door GJ35 57 990E Left Passive Shoulder Belt As...

Page 532: ...ent short circuits from occurring Figure 1 NOTE Red yellow wire applies to 1988 and 1989 626 models only Red Yellow Wire Cut and tape before installing 1990 91 626 Only Door Switch Harness Figure 1 Door Switch Harness Wire Location PARTS INFORMATION PART NUMBER DESCRIPTION APPLICABLE MODEL GJ35 57 930E Right Passive Shoulder Belt Assy 1988 91 626 4 Door GJ35 57 990E Left Passive Shoulder Belt Assy...

Page 533: ...e rear combination lamp and inspect the body to lamp assembly seal Refer to the illustration for signs of water leakage 5 If the lamp seal is leaking replace the seal and confirm that the installation studs are tight and no cracks exist in the assembly 6 Install the lamp assembly with a new seal NOTE Prior to installing the lamp assembly apply sealant to both sides of the seal and confirm that the...

Page 534: ...25 51 168 Rear Combination Lamp Gasket 626 5 door Left WARRANTY INFORMATION Applies To Vehicles Covered Under Normal Warranty Warranty Type Customer Comment Code Damage Code Part Number Main Cause Quantity Operation Number Labor Hours A 77 9A See Part Information 1 T0318AR X 0 3Hr one side 626 M X 6 T0318C R X 0 4Hr both sides 626 M X 6 T0318BR X 0 3Hr one side 5 door T0318D R X 0 4Hr both sides 5...

Page 535: ...e rear combination lamp and inspect the body to lamp assembly seal Refer to the illustration for signs of water leakage 5 If the lamp seal is leaking replace the seal and confirm that the installation studs are tight and no cracks exist in the assembly 6 Install the lamp assembly with a new seal NOTE Prior to installing the lamp assembly apply sealant to both sides of the seal and confirm that the...

Page 536: ...25 51 168 Rear Combination Lamp Gasket 626 5 door Left WARRANTY INFORMATION Applies To Vehicles Covered Under Normal Warranty Warranty Type Customer Comment Code Damage Code Part Number Main Cause Quantity Operation Number Labor Hours A 77 9A See Part Information 1 T0318AR X 0 3Hr one side 626 M X 6 T0318C R X 0 4Hr both sides 626 M X 6 T0318BR X 0 3Hr one side 5 door T0318D R X 0 4Hr both sides 5...

Page 537: ...9 August 1990 REPAIR PROCEDURE Replace the driver s seat adjuster unit according to procedures in Section S or 14 of your Workshop Manual PARTS INFORMATION PART NUMBER DESCRIPTION APPLICABLE MODEL GK88 88 61XA Adjuster Unit 1 988 90 626 GJ23 88 61XA Adjuster Unit 198 8 90 M X 6 WARRANTY INFORMATION Warranty Type Code Customer Comment Code Damage Code Part No of Main Cause Quantity Operation No Lab...

Page 538: ...rd ry NOTE Thebum perm u stbeco m p letelyd rybeforep a in tin g 4 R em ovean ylin tth read srem ain in gonth ebu m perw ithcom presseda ir 5 P ain tth ebu m p eraccord in gtoth ep a in tm an u factu rer sin stru c tio n s NOTE Asam pleofp a in tin gprocedu reisattach ed B odyshopsu sin go th erp ain tm an u factu rerssh o u ldfo llo wth e ir bum perp a in tin gprocedures SUPPLIES REQUIRED T erryC...

Page 539: ...ral detergent CAUTION Do not use volatile solvent for cleaning this substance may affect the seat belt strength 2 Verify seat belt operation If the seat belt Is not operating smoothly referto the workshop manual for troubleshooting procedures NOTE The seat belt will not retract smoothly while wet Allow seat belt to dry before verifying operation CONSUMER NOTICE The information and instructions in ...

Page 540: ...vents ex PPG DX 330 may remove the bumper s factory primer If this occurs the bumper w ill require primer applica tion prior to painting 2 Clean entire surface with alcohol soaked towel or equivalent solvent 3 Allow bumper to air dry NOTE H ie bumper must be completely dry priorto painting 4 Remove any Bntthreads remaining on bumperwith compressed air 5 Paint bumper according to paint manufacturer...

Page 541: ...er Compartment Pages 6 through 9 III Trunk Compartment and Under Rear Seat Pages 9 through 13 IV Sunroof of Headliner Area Pages 13 through 15 LOCATION I RIGHT FRONT SIDE OF PASSENGER COMPARTMENT Location of Water Leak Source 1 Remove the dash undercover scuff plate and kick panel Pull back the carpet and pad Remove the front seat carpet and pad if necessary 2 At least 12 minutes should be spent d...

Page 542: ...dow beltline molding if the vehicle is a fourdoor perform this teston both the front and rear doors Figures 1 and 2 NOTE DO NOT direct water into blower motor opening un der cowl panel Direct Water Along Top of Door and A Pillar Figure 2 Locating Source of Front Water Leak 6 Note which area the water enters the vehicle Refer to the appropriate location s repair procedure Figure 3 AREA A AREA B ARE...

Page 543: ... or pinholes Seal any sus pected sealer defects Figure 5 4 Open the sunroof Using a squeeze bottle filled with water pour waterdown the front drain holes Check for signs of leakage at the sunroof drain tube to drain hose 5 If the leak is still present remove cap and screw from the front windshield header Remove the A pillar side molding Check the drain hose for kinks Figure 6 6 If necessary reposi...

Page 544: ...trol air intake control lever to the first position Remove the blower fan 3 screws and look for waterenter ing the blower motor opening 4 Check all grommets shown in Figure 8 for leaks by spraying water on each one Replace any grommets that leak Note Apply silicone sealer to the bottom of the grommet during installation 5 If the grommets do not leak seal the baffle seam by reaching up through the ...

Page 545: ...ad and feel for water If water is pres ent remove windshield wipers and cowl plate Check for missing sealeror holes among the lower A pillar to cowl seam Apply sealer to any suspected areas Figure 9 Note This procedure should only be done by expe rienced body shop personnel 2 Remove the doorjamb nut and bolt also remove the four 4 upper fender bolts Using a mechanics mirror inspect sealer hidden b...

Page 546: ...k the carpet and pad Remove the front seat carpet and pad if necessary 2 At least 12 minutes should be spent during initial hose testing because the water may have to move through several body seams before being detected 3 Turn the water pressure to the hose so that a 12 to 18 stream of water is present while the hose is in a vertical position 4 Get inside the vehicle and use a flashlightto help l...

Page 547: ...loops kinks or pinched areas If the hose cannot be corrected or is out remove the damaged section of hose Install a replacement piece of hose 4 7 mm 3 16 in outside diameter which provides a tight fit to the existing hose 4 If the leak persists inspect the antenna bezel molding and gasket for correct sealing and mounting Confirm that the mounting screw is fully seated and that the gas ket is firml...

Page 548: ...ted areas Figure 15 N ote This procedure should only be done by expe rienced body shop personnel 2 Remove the door jamb nut and bolt also remove the four 4 upper fender bolts Using a mechanic s mirror inspect sealer hidden by the upper fender for skips and pinholes Figure IS Note The illustration shows the fender removed Complete fender removal is not required Caution Use care when moving fender f...

Page 549: ... backs From inside the vehicle close the door and using a flashlight look for water leaks during the hose test 5 Have an assistant direct the water stream over the en tire rear of the vehicle concentrating on the following areas Figure 17 Along the deck lid to body gap Up each C pillar and across the upperportion ofthe rear window Along the key lock cylinder rear deck lid finisher and combination ...

Page 550: ...ANEL TRIM PLASTIC AND OR TRUNK WEATHER STRIP ALSO REAR COMBINATION LAMPS AREA 1 If water is running down overthe interiortrunkend pa nel trim or over under the trunk weatherstrip pull up the trunk weatherstrip and check grey sealer material and any body seams nearthe linkage area Confirm that grey sealer covers the top of the flange in one solid strip Check for pin holes missing sealer or burrs Fi...

Page 551: ...ip AREA B INNER WHEEL WELL TO TRUNK FLOOR PAN SEAM r 1 If water leaks into the forward area of the trunk make sure that the weatherstrip is properly seated and not leaking Figure 23 2 If no problems are found check all trunk opening seams and the inner wheel well to trunk floor pan seam for missing sealer or pin holes Seal any sus pecied areas and retest for leaks If no problems are found go to st...

Page 552: ... the grommet and plug between the quarter panel and bumper Examine seams for missing sealerorpin holes Seal any suspected defects Figures 26 and 27 3 Check for any leaks at the fuel filler neck to body in the left quarter If moisture is present remove the filler neck 4 Apply sealer to both sides of the gasket and reinstall AREA D INNER WHEEL WELL TO FLOOR PAN UNDER REAR SEAT AND INSIDE THE ROCKER ...

Page 553: ...HEADLINER AREA page 13 AREA B REAR PASSENGER COMPART MENT AREA page 14 AREA C REAR HEADLINER OR SUNROOF SLIDING PANEL pages 14 and 15 AREA A FORWARD HEADLINER AREA 1 Open the sunroof and make sure that the sunroof drain tubes are intact and that no holes are present If welds are damaged or have holes repair or replace the sunroof frame 2 If welds and drain tubes are OK remove the front header and ...

Page 554: ... the hose so that there are no loops kinks or pinched areas Check for kinks at the drain hose clip Repeat the water test Make sure that the sunroof drains properly and does not leak Figure 31 5 If necessary install a new hose 6 If hose routing is OK and hose is intact check for leaks at the rear window AREA C REAR HEADLINER OR SUNROOF SLIDING PANEL 1 Remove the rear header trim rear shoulder seatb...

Page 555: ...ge Code Part No of Main Cause Operation No Labor Hours Location Code A 6D 38 5555 WA 0010 See Chart Below See Chart Below Applicable location code necessary Codes found in SRT microfiche or Warranty Policies and Procedures Manual PROCEDURE OPERATION NUMBER LABOR HOURS Water Testing YY0064RX 0 5 Repair of Right Front Side of Pas senger Compartment YY0033RX Not to exceed 0 9 Repair of Left Front Sid...

Page 556: ...er Compartment Pages 6 through 9 III Trunk Compartment and Under Rear Seat Pages 9 through 13 IV Sunroof of Headliner Area Pages 13 through 15 LOCATION I RIGHT FRONT SIDE OF PASSENGER COMPARTMENT Location of Water Leak Source 1 Remove the dash undercover scuff plate and kick panel Pull back the carpet and pad Remove the front seat carpet and pad if necessary 2 At least 12 minutes should be spent d...

Page 557: ...dow beltline molding if the vehicle is a fourdoor perform this teston both the front and rear doors Figures 1 and 2 NOTE DO NOT direct water into blower motor opening un der cowl panel Direct Water Along Top of Door and A Pillar Figure 2 Locating Source of Front Water Leak 6 Note which area the water enters the vehicle Refer to the appropriate location s repair procedure Figure 3 AREA A AREA B ARE...

Page 558: ... or pinholes Seal any sus pected sealer defects Figure 5 4 Open the sunroof Using a squeeze bottle filled with water pour waterdown the front drain holes Check for signs of leakage at the sunroof drain tube to drain hose 5 If the leak is still present remove cap and screw from the front windshield header Remove the A pillar side molding Check the drain hose for kinks Figure 6 6 If necessary reposi...

Page 559: ...rol air intake control lever to the first position Remove the blower fan 3 screws and look for waterenter ing the blower motor opening 4 Check all grommets shown in Figure 8 for leaks by spraying water on each one Replace any grommets that leak N ote Apply silicone sealer to the bottom of the grommet during installation 5 If the grommets do not leak seal the baffle seam by reaching up through the ...

Page 560: ...ad and feel for water If water is pres ent remove windshield wipers and cowl plate Check for missing sealeror holes among the lower A pillar to cowl seam Apply sealer to any suspected areas Figure 9 N ote This procedure should only be done by expe rienced body shop personnel 2 Remove the doorjamb nut and bolt also remove the four 4 upper fender bolts Using a mechanics mirror inspect sealer hidden ...

Page 561: ...k the carpet and pad Remove the front seat carpet and pad if necessary 2 At least 12 minutes should be spent during initial hose testing because the water may have to move through several body seams before being detected 3 Turn the water pressure to the hose so that a 12 to 18 stream of water is present while the hose is in a vertical position 4 Get inside the vehicle and use a flashlightto help l...

Page 562: ...loops kinks or pinched areas If the hose cannot be corrected or is out remove the damaged section of hose Install a replacement piece of hose 4 7 mm 3 16 in outside diameter which provides a tight fit to the existing hose 4 If the leak persists inspect the antenna bezel molding and gasket for correct sealing and mounting Confirm that the mounting screw is fully seated and that the gas ket is firml...

Page 563: ...ted areas Figure 15 N ote This procedure should only be done by expe rienced body shop personnel 2 Remove the door jamb nut and bolt also remove the four 4 upper fender bolts Using a mechanic s mirror inspect sealer hidden by the upper fender for skips and pinholes Figure 15 Note The illustration shows the fender removed Complete fender removal is not required Caution Use care when moving fender f...

Page 564: ... backs From inside the vehicle close the door and using a flashlight look for water leaks during the hose test 5 Have an assistant direct the water stream over the en tire rear of the vehicle concentrating on the following areas Figure 17 Along the deck lid to body gap Up each C pillar and across the upperportion ofthe rear window Along the key lock cylinder rear deck lid finisher and combination ...

Page 565: ...ANEL TRIM PLASTIC AND OR TRUNK WEATHER STRIP ALSO REAR COMBINATION LAMPS AREA 1 If water is running down overthe interiortrunkend pa nel trim or over under the trunk weatherstrip pull up the trunk weatherstrip and check grey sealer material and any body seams nearthe linkage area Confirm that grey sealer covers the top of the flange in one solid strip Check for pin holes missing sealer or burrs Fi...

Page 566: ...rip AREA B INNER WHEEL WELL TO TRUNK FLOOR PAN SEAM r 1 If water leaks into the forward area of the trunk make sure that the weatherstrip is properly seated and not leaking Figure 23 2 If no problems are found check all trunk opening seams and the inner wheel well to trunk floor pan seam for missing sealer or pin holes Seal any sus pecied areas and retest for leaks If no problems are found go to s...

Page 567: ... the grommet and plug between the quarter panel and bumper Examine seams for missing sealerorpin holes Seal any suspected defects Figures 26 and 27 3 Check for any leaks at the fuel filler neck to body in the left quarter If moisture is present remove the filler neck 4 Apply sealer to both sides of the gasket and reinstall AREA D INNER WHEEL WELL TO FLOOR PAN UNDER REAR SEAT AND INSIDE THE ROCKER ...

Page 568: ...HEADLINER AREA page 13 AREA B REAR PASSENGER COMPART MENT AREA page 14 AREA C REAR HEADLINER OR SUNROOF SLIDING PANEL pages 14 and 15 AREA A FORWARD HEADLINER AREA 1 Open the sunroof and make sure that the sunroof drain tubes are intact and that no holes are present If welds are damaged or have holes repair or replace the sunroof frame 2 If welds and drain tubes are OK remove the front header and ...

Page 569: ... the hose so that there are no loops kinks or pinched areas Check for kinks at the drain hose clip Repeat the water test Make sure that the sunroof drains properly and does not leak Figure 31 5 If necessary install a new hose 6 If hose routing is OK and hose is intact check for leaks at the rear window AREA C REAR HEADLINER OR SUNROOF SLIDING PANEL 1 Remove the rear header trim rear shoulder seatb...

Page 570: ...ge Code Part No of Main Cause Operation No Labor Hours Location Code A 6D 38 5555 WA 0010 See Chart Below See Chart Below Applicable location code necessary Codes found in SRT microfiche or Warranty Policies and Procedures Manual PROCEDURE OPERATION NUMBER LABOR HOURS Water Testing YY0064RX 0 5 Repair of Right Front Side of Pas senger Compartment YY0033RX Not to exceed 0 9 Repair of Left Front Sid...

Page 571: ...ions have been made verify location of wind noise If noise is still present inspect installation quality Verify location of complaint The illustration below shows the general areas where wind noise may occur A D Specific locations of wind noi c are shown numerically A Wind noise at front door area during high speed above 40 mph driving pages 2 through 7 B Wind noise at rear door area pages 8 throu...

Page 572: ...h speed above 40 mph driving Location 2 LOCATION 1 DOOR MIRRORS ALL MODELS YEARS Manual and Power Mirrors 1 Using a flat screwdriver carefully pry the inner sail garnish out of its position Start prying at the top comer of the sail garnish then work down ward CAUTION Take care not to break the fastening tab at the bottom of the sail garnish 2 Remove mirror and install comer bracket 3 Install Pad 1...

Page 573: ...spective right and left seal rubber to the mirror Figure 2 Figure 2 Power Door Mirror Manual Mirrors Only 7 Add respective right and left seal rubber to the mirror base Figure 3 Lip Adhesive Tape Figure 3 Door M irror M anual and Power Mirrors 8 Reinstall mirror Page 3 of 14 ...

Page 574: ...ce glass inner weatherstrip with new strip Figure 4 1 5mm Figure 4 Top of inner door panel LOCATION 3 GLASS RUN CHANNEL FRONT DO O R 1988 89 MODELS ONLY 1 Lower window all the way 2 Pull back the glass run channel Figure 5 3 Attach the pad strip to the back of the glass run channel from the circled area Pad size Length Thickness Width 400 mm 2 mm 10 mm Page 4 of 14 ...

Page 575: ...about 4 showing Pull the glass guide rail toward the inside of the window frame and up Move the window glass toward the front of the vehicle Figure 7 Figure 7 Front door 3 Remove the original glass guide rail pad and replace it with a new one Figure 8 A Install the new glass guide rail pad so that the top of the pad is 30 mm from the bottom of the guide rail Figure 9 Figure 8 O riginal glass guide...

Page 576: ...ON For ease of installation door glass must be up ap proximately 4 inches LOCATION 5 A PILLAR A REA 1988 89 4 and 5 door models 1 Open the front door and remove the mounting screw from the lower side of the drip molding Figure 10 Drip Molding Figure 10 A pillar area 2 Remove the original screw boss from the pillar and discard 3 Install a protector between the drip molding and the A pillar Figure 1...

Page 577: ...t the pro tector inside the front fender cavity Figure 12 MX 6 1 Cut the boss off of the protector Figure 13 2 Glue the protector to the drip molding Figure 14 3 Insert protector into fender cavity Figure 14 A Pillar t f Drip Molding A Glue Figure 14 Front o f A pillar area Page 7 of 14 ...

Page 578: ...rea 1988 89 models only Front of Vehicle s 37 i i t Location 1 Location 2 Location 3 Location 5 Location 4 LOCATION 1 TOP REAR OF WINDOWS 1 Lower window all the way 2 Pull off the rear comer section of the glass run channel Figure 15 Glass Run Channel Figure 15 Rear door Page 8 o f 14 ...

Page 579: ...6 Pad size Length D 4 Door Sedan 257 mm D 5 Door Hatchback 286 mm Thickness 3mm Width 5 mm 4 Reinstall the glass run channel LOCATION 2 MIDDLE REAR OF WINDOWS Install a pad on the reverse side of the comer lip circled area to improve the sealing effectiveness Figure 17 Figure 16 Top of rear door Figure 17 Rear of rear door Page 9 of 14 ...

Page 580: ...m 10 mm LOCATION 4 SAIL GARNISH Using a flat screwdriver remove the inner sail gar nish by prying it out and installing a new level inner sail garnish Figure 20 NOTE Using a flat screwdriver pry sail garnish out of its lo cation Start from the lower rear comer and work forward Also be careful not to damage the paint on the surrounding area Figure 20 Figure 19 Sail garnish area OLD NEW Figure 20 Sa...

Page 581: ...mprovements following the same steps as used on the front door Condition A Location 2 Condition C Wind noise fluttering noise at rear corner window area 1 9 8 8 91 2 Door Coupe 1 Prepare a tube of silicone sealer as shown Figure 21 Figure 21 Tube of silicone sealer Figure 22 Rear quarter window glass Page 11 of 14 ...

Page 582: ...g sponge tape around them 2 Clean the above mentioned area with alcohol or degreaser to remove grease and oil 3 Apply the primer to the glass Allow the primer to dry for approximately 10 minutes 4 Adhere double coated tape to the garnish in the previously taped area Figure 24 NOTE When adhering the double coated tape set the tape beforehand to make sure the tape is positioned cor rectly Figure 24 ...

Page 583: ...rkshop Manual pro cedures section S a Black Plastic Inner Sail Garnish b Window Frame Weatherstrip 3 Remove the weatherstrip to access the glass run channel frame 4 Carefully bend the weatherstrip frame slightly outward 1 16 to increase the pressure of the weatherstrip against the glass Use a sheet metal bending tool Snap on P N VP8R or equivalent NOTE Protect the painted surface of the vehicle by...

Page 584: ...n No See charts below Labor Hours See charts below 1 4 door Sedan and 5 door Hatchback CONDITION REPAIR OPERATION NO LABOR HOURS A Wind noise at front door area during high speed driving XX0312RX 1 2 B Wind noise at rear door area XX0274RX 0 5 C Wind noise fluttering noise at rear comer window area XX0252RX 0 3 D A B C XX0311RX 2 0 2 MX 6 CONDITION REPAIR OPERATION NO LABOR HOURS A Wind noise at f...

Page 585: ...nce this driver door lock problem should have switches replaced with the original switch The replacement switch must be water proofed to prevent problem reoccurrence See Repair Procedure for instructions VIN OF PRODUCTION CHANGE Japan Made 626 MX 6 JM1GD M 1917355 June 3 1991 USA Made 626 1YVGD22B8M5186161 June 25 1991 REPAIR PROCEDURE 1 Inspect switch See Section 14 or S of the Workshop Manual 2 ...

Page 586: ...ER DESCRIPTION QTY APPLICABLE MODEL MODIFIED ORIGINAL G212 58 312A Vehicles produced on or after June 3rd G212 58 312 Vehicles produced prior to June 3rd Left Front Door Lock Switch 1 1988 91 626 GJ24 58 312A Vehicles produced on or after June 25th GJ24 58 312 Vehicles produced prior to June 25th Left Front Door Lock Switch 1 1988 9 1 MX 6 WARRANTY INFORMATION Warranty Type Code Customer Comment C...

Page 587: ...any location along the A pillar the sealing contact between the door is insufficient and requires adjustment Proceed to DOOR ADJUSTMENT If there is consistent resistance proceed to the White Grease Test Note The card test can only be used to evaluate the A pillar seal ing contact Use the following White Gease Test to evalu ate the rest of the weather strip Whfte Grease Test A Roll down windows and...

Page 588: ... the door into alignment In addition to Workshop Manual procedures for door alignment the following information tips are provided As a guideline if the weather strip contact is insuf ficient the door hinge s should be adjusted 2 4 OUTLINING mm inward Determine the amount of movement by outlining the hinge mount area before door adjustment and after Adjusting one hinge at a time will prevent any ex...

Page 589: ...he total price for these tools is 28 75 individual prices are illustrated below SHIPPING BILLING INFORMATION These tools will be shipped prepaid via UPS to dealers during the specified week as shown in the illus tration Your parts account will be billed for this tool upon its receipt Please advise your shipping receiving personnel of this tool shipment iJ S viij l r ISrOH IClOr Ship Date Week of 9...

Page 590: ...s service Note If your service department chooses not to participate orcannot participate in this reprogramming service a new V5 0 card will be automatically shipped to your service department APPLICATION This card is used with your NGS Testerto properly service 1988 1999 Mazda Vehicles Refer to your Workshop Manual for the application of this card and tester PRICING The price for the V5 0 reprogr...

Page 591: ...rd Send the package to the following address j I America Kowa Seiki Inc 20013 S Rancho Way Rancho Dominguez CA 90220 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 inc by March 4 1998 Note DO NOT SEND YOUR V4 0 NGS CARD Use this V4 0 card until yciur new V5 0 card arrives at your service department Pl...

Page 592: ...connecting the 6 pin connector the adapter harness can be used for further diagnosis Control Unit refers to EC AT Control Unit except for 1990 626 M X 6 non Turbo For these models the EC AT Control Unit is incorporated into the Engine Control Unit REPAIR PROCEDURE Please affix the attached label on the left side of the EC AT Tester body to the left of the adapter harness connector On versions with...

Page 593: ...Inc The cost of the new card is 235 75 This cost will be charged to your parts account upon its receipt NOTE 1 Please advise your shipping receiving personnel of this shipment 2 This program card is small Therefore we recommend that your service manager shop foreman or lead technician install this card in your NGS tester and discard the discontinued card immediately This will prevent misapplicatio...

Page 594: ...0 0 0 1994 626 MX 6 WITH KL ENGINE 0 0 0 0 1994 929 0 0 0 0 1994 MX 3 0 0 0 1994 MIATA 0 0 0 1994 RX 7 0 0 1994 MPV WITH G6 ENGINE 0 0 0 1994 MPV WITH JE ENGINE 0 0 1994 NAVAJO 0 O 1994 B2300 2 3L 49S 0 O 0 1994 B2300 2 3L CAL o 0 1994 B3000 B4000 0 0 1993 NAVAJO 0 0 1992 1993 ALL VEHICLES EXCEPT NAVAJO 0 0 0 0 0 1991 1992 NAVAJO 0 1991 ALL VEHICLES EXCEPT NAVAJO 0 0 1988 1990 ALL VEHICLES o 0 1 P...

Page 595: ...Kowa Seiki Inc The cost of the new card is 235 75 This cost will be charged to your parts account upon its receipt NOTE 1 Please advise your shipping receiving personnel of this shipment 2 This program card is small Therefore we recommend that your service manager shop foreman or lead technician install this card in your NGS tester and discard the discontinued card immediately This will prevent mi...

Page 596: ...0 0 o 1994 626 MX 6 WITH KL ENGINE o 0 0 0 1994 929 0 0 0 0 1994 MX 3 0 0 0 1994 MIATA o o o 1994 RX 7 0 o 1994 MPV WITH G6 ENGINE o o 0 1994 MPV WITH JE ENGINE 0 0 1994 NAVAJO 0 O 1994 B2300 2 3L 49S o O 0 1994 B2300 2 3L CAL 0 O 1994 B3000 B4000 o O 1993 NAVAJO 0 o 1992 1993 ALL VEHICLES EXCEPT NAVAJO o 0 0 0 0 1991 1992 NAVAJO 0 1991 ALL VEHICLES EXCEPT NAVAJO o 0 1988 1990 ALL VEHICLES 0 o 1 P...

Page 597: ... is to be used by your dealer to assist you with maintaining a complete inventory of these required tools ORDERING TOOLS Directly contact America Kowa Seiki Inc using the toll free telephone numbers listed below to order any M azda Special Service Tool 800 824 9655 2K 800 535 5455 Hours Monday Friday 9 00 AM 5 00 PM Pacific Standard Time BILLING FOR TOOLS Your dealer will be billed directly by Ame...

Page 598: ...ARING INSTALLER 20 80 4908 39 305A C O U N TER W EIG H T PULLER A T 63 85 4908 39 425C BEARING PULLER SET 203 95 4912 32 670A P S OIL PRESSURE GAUG E SET 246 10 4912 43 465A M AINSHAFT LO C K NUT W R EN C H 41 05 4912 85 0710 ECCENTRIC SHAFT BEARING PULLER 42 20 4918 81 055A C O U N TER W EIG H T STOPPER 40 71 4985 1Q1 631A REAR AXLE SHAFT PULLER ATTACHM EN 71 55 4985 31 5550 G AUGE BLOCK 62 16 49...

Page 599: ...0 49B0 25 0010 DUST SEAL INSTALLER 23 40 49B0 26 1A00 REAR HUB PULLER 98 90 49B0 27 0010 D IFFERENTIAL SIDE GEAR HOLDER 10 90 49B0 27 0030 ATTAC H M EN T M 17 60 49B0 27 0040 M EASURING PLATE 26 70 49B0 27 0060 D IFFERENTIAL S IDE GEAR HOLDER 9 70 49B0 32 3040 PO W ER STEERING G AUG E ADAPTO R 49 45 49B0 43 0010 AD JUST G AUG E 63 25 49B0 43 0020 BEARING INSTALLER 9 40 49B0 61 0050 A C SEAL PLATE ...

Page 600: ... E L HUB PULLER 69 00 49F0 26 1040 SENSOR ROTO R INSTALLER 48 30 49F0 27 0A00 PINION H EIG H T ADJ GAUGE 557 80 I 49F0 27 0A10 BEARING INSTALLER SET 126 50 49F0 28 2A00 RUBBER BU SH IN G PLR INST SET 149 50 49F0 33 0010 DISC BRAKE PISTO N STOPPER 31 10 49F0 43 0010 A DJUST GAUGE 19 00 49F0 61 0010 LOG ICON CHECKER ADAPTO R 16 30 49F4 01 330B BEARING INSTALLER SET 56 95 49F4 01 380E SH IM SELECTOR ...

Page 601: ...0 1 9 0310 WRENCH 20 59 49GO 19 OAOO TRANSAXLE HANGER 264 50 49G 0 19 0A 20 TURBINE SHAFT HOLDER SET 31 40 49G 0 19 0A7A RETURN SPRING COMPRESSOR SET 159 85 49G 0 19 9110 ADAPTOR HARNESS 139 65 B49G0 19 9120 PANEL 27 80 J49G0 19 9150 PANEL MMC 31 06 4 9 G 0 1 9 9180 HARNESS 258 75 I49G 0 25 0010 DRIVESHAFT SENSOR ROTOR INSTALLE 37 15 49G 0 26 1010 BEARING REPLACER 13 30 49G 0 26 1020 BEARING REPLA...

Page 602: ... 80 49H 0 17 1010 HOOK 70 40 49H 0 17 5010 ENGINE SUPPORT 24 73 49H 0 18 0010 KNOCK SENSOR WRENCH 22 20 49H 0 18 9100 ADAPTOR HARNESS 37 38 4 9 H 0 18 9120 INJECTOR CHECK HARNESS 16 68 49H 0 18 9A 10 SELF DIAGNOSIS CHECKER 244 00 49H 0 19 0020 ADAPTOR 23 05 49H 0i 19 9050 ADAPTOR HARNESS 197 80 49H 0 19 9080 ADAPTOR HARNESS 194 35 49H 0 19 9090 PANEL 35 08 49H 0 19 9A 10 ECAT TESTER 803 74 49HO 25...

Page 603: ... 0010 BEARING INSTALLER 19 55 49J0 27 0020 COLLAR 24 56 49L0 11 0A0B PISTON PIN SETTING TOOL SET 240 36 49L0 11 2A 00 BALANCE SHAFT BUSHING REPLACER S 102 12 49L0 12 0A 00 VALVE SEAL GUIDE INSTALLER SET 47 69 49L0 17 3020 ADAPTOR CHANGE MOTOR 11 27 49L0 19 0010 BOLT A T CLUTCH SPRING COMPRESSO 21 53 49L0 19 9020 PANEL 29 81 49L0 28 0A 00 AIR PRESSURE GAUGE SET 171 67 49L0 33 1010 INSTALLER OIL SEA...

Page 604: ... PROTECTOR INSTALLER 47 05 49U 0 27 0010 COLLAR M 14 55 49UO 27 0030 OIL SEAL INSTALLER M 27 55 491 0 27 0050 BEARING INSTALLER 20 13 49U 0 27 0060 BEARING OIL SEAL INSTALLER 19 55 49U 0 27 0070 OIL SEAL INSTALLER 24 54 49U 0 33 1010 BEARING INSTALLER M 16 05 49U 0 34 2A 00 LOWER ARM BUSHiNG PULLER INSTALLE 91 70 49U 0 43 0030 ANGLE GAUGE 35 10 49U B 39 585A ADJUSTWRENCH 33 40 49U N 01 0010 CRANKS...

Page 605: ...EARING REPLA 11 45 4 9U N 01 0250 INPUT SHAFT BUSH BEARING REPLACER 34 31 4 9U N 01 0260 DIFFERENTIAL HOUSING SPREADER 265 00 49U N 01 0270 SPREADER ADAPTORS 66 23 49U N 01 0280 AXLE BEARING SEAL INSTALLER 39 20 49U N 01 0290 PINION CARRIER BEARING PULLER 451 02 49U N 01 0300 DUMMY BEARING SET 105 10 4 9U N 01 0310 DIFFERENTIAL BEARING REPLACER 12 05 49U N 01 0320 AXLE BEARING REMOVER 41 43 49U N ...

Page 606: ...P SENSOR TESTER 81 00 49U N 01 0600 FIXED ORIFICE TUBE TOOLS 16 54 49U N 01 0610 BROKEN ORIFICE TUBE EXTRACTOR 9 23 49U N 01 0620 TEVES ABS ADAPTOR BLEEDER 248 58 4 9 U N 0 1 0630 TEVES ABS ADAPTOR JUMPER 155 72 49U N 01 0640 REAR MAIN SEAL INSTALLER 59 82 49U N 01 0650 VALVE SPRING COMPRESSOR 36 42 4 9 U N 0 1 0660 VALVE STEM SEAL INSTALLER 18 89 49 U N 01 0670 CAMSHAFT BELT TENSION TOOL 34 79 49...

Page 607: ... ATF OIL PRESSURE 44 86 49U N 01 1290 SEAL REPLACER 11 65 49U N 01 1300 104 PIN BREAKOUT BOX 540 93 49U N 01 1310 AIR BAG SIMULATOR 10 63 49U N 01 1320 4R44E 4R55E CABLE OVERLAY 78 33 49U N 01 1360 REAR MAIN SEAL INSTALLER 54 71 49U N 11 1010 THREADEDADAPTOR 22 31 4 9U N 17 1010 BEARING DRIVER ATTACHMENT 31 90 49U N 27 0010 GAUGE BLOCK FRONT 55 04 49U N 27 0020 GAUGE BLOCK REAR 44 39 49U N 27 0030...

Page 608: ...ard version 5 1996 626 MX 6 FS A T only DTCs are displayed by performing quick test Quick test procedures missing from Workshop Manual WSM correction sent to dealers April 18 1996 The Exchange Program Mazda is implementing an exchange program to provide dealers an updated card version 2 02 that will resolve items 1 and 2 The remainder of the items will be resolved with the next version of the card...

Page 609: ...ler then A Puts their old NGS card version 2 01 in stay flat and seals stay flat DO NOT ENCLOSE THE RPS VENDOR RETURN PICK UP RECORD B Telephones RPS for next day pick up 800 937 4587 NOTE 1 THE DEALER MUST SEND THEIR EXISTING CARD 2 01 WITHIN 2 DAYS OF RECEIPT OF THE ENVELOPE OTHERWISE THEIR PARTS ACCOUNT WILLBE DEBITED 235 75 NOTE 2 The dealer is to contact Hickok Inc 800 342 5080 rfthey do not ...

Page 610: ... It Is not necessary to provide a P O on the brochure s order form Your parts account will be debited SHIPPING BILLING INFORMATION See attached brochure Please contact your District Customer Support Manager America Kowa Seiki 800 824 9655 or 800 535 5455 or Tools Equipment Manager 714 442 6564 if you have any questions regarding this information CONSUMER NOTICE The information and instructions in ...

Page 611: ...as been established which allows you to order it directly from the manufacturer at a substantial savings This lathe is available at a special introductory_price of 2995 until December 15 1994 This price includes the lathe with universal adapters Mazda specially designed adapters and in dealer training After December 15 1994 the price will go to 3850 Attached is a flyer that gives more details and ...

Page 612: ...T O o 0 1994 626 MX 6 WITH KL ENGINE O O 0 o 1994 929 O O 0 0 1994 MX 3 0 O 0 1994 MIATA 0 0 0 1994 RX 7 0 0 1994 MPV WITH G6 ENGINE 0 0 0 1994 MPV WITH JE ENGINE 0 0 1994 NAVAJO 0 O 1994 B2300 2 3L 49S 0 O 0 1994 B2300 2 3L CAL o 0 1994 B3000 B4000 0 0 1993 NAVAJO 0 0 1992 1993 ALLVEHICLES EXCEPT NAVAJO o 0 0 0 0 1991 1992 NAVAJO 0 1991 ALL VEHICLES EXCEPT NAVAJO 0 0 1988 1990 ALLVEHICLES 0 0 1 P...

Page 613: ...ghlights of this account For further details refer to the attached flyer Pricing The special package is available at the introductory price of 598 50 This price is effective up to and includ ing July 31 1995 After this date the price will be 680 00 TH ER E ARE NO EXCEPTIONS Order information U se the easy ordering procedures on the attached flyer to order your tester package Shipping Billing Infor...

Page 614: ... this recommended equip ment we are offering a special introductory price which is only available until July 31 1995 Benefits No need to pre charge battery tests batteries as low as 10 2 volts Fast less than 10 seconds for a complete battery test Locates discharged only and marginal batteries that will fail soon Compensates for low temperature no need for the battery to be at room temperature Port...

Page 615: ... R E PL Y FO R M Dealer N a m e _____________________________________________________________ Dealer No Please send me 1 Mazda Package Nflme _____________________________________________________________ Street A ddress ________________________________________________________________________ Please contact me about the battery City ________________________________________________________ Countv ___...

Page 616: ...M NET Mazda s computer based information and order fulfillment system You will find information describing the process of using M NET in the M NET Operations Guide PRICING Summer 1998 Promotional Pricing During July August and September you can order cabinets at the discounted prices listed below In addition the cabinet manufacturer Stanley Storage Systems is providing free shipping during this pr...

Page 617: ...ls ORDERING TOOLS Directly contactAmerica KowaSeiki Inc using the toll free telephone numbers listed below to order any Mazda Special Service Tool 600 824 9655 QR 800 535 5455 BILLING FOR TOOLS Your dealer will be billed directly by America Kowa Seiki YOU CANNOT BILL TOOL ORDERS TO YOUR PARTS ACCOUNT Ifyou have any questions regarding this information contact your District Customer Support Manager...

Page 618: ... 5650 MIDDLE PINION 245 78 4992 00 162A ENGINE SIGNAL MONITOR 432 85 _ 4992 00 1670 ADAPTOR HARNESS 198 73 4992 02 0200 PRESSURE PLATE REMOVER 26 01 4992 02 0300 SEAL PLATE REMOVER 118 01 __ 4992 02 0400 SHAFT SEAL REMOVER 64 25 49B0 12 0060 VALVE SPRING LIFTERARM PIVOT 18 00 49B0 12 0A20 PIVOT 56 791 49B0 17 1020 PRELOAD ADAPTOR 25 561 49B0 17 1A00 BEARING REMOVER SET 239 75 49B0 19 0020 BODY RET...

Page 619: ...LER SET 71 19 49F4 01 4400 PRIMARYSHAFTHOLDER 18 88 49FT 01 3610 BEARING REMOVER 40 19 49FT 01 4390 IDLER GEAR SHAFT HOLDER 14 25 0 49GO 17 1AOO BEARING REMOVER SET 356 25 49G0 17 2020 ATTACHMENT PRELOADADAPTOR 28 44 I 49G0 18 9010 THROTTLE SENSORADAPTOR HARNESS 14 25 49G0 18 9030 ADAPTOR HARNESS 395 31 8 49G0 18 9040 SHEET 6 46 49G0 18 9060 SHEET 16 61 49GO 19 OHO BEARING INSTALLER M 19 25 49G0 1...

Page 620: ... BLOCK 43 25 49H0 26 1080 REMOVING PLATE 124 50 49HO 27 0010 COLLAR M 14 38 B 49HD 27 0020 BEARING REMOVER M 79 44 I 49HO 28 3010 DUST BOOTINSTALLER 25 00 I 49H0 32 321A HEX WRENCH 13 99 49H0 32 3220 ADAPTOR 56 06 I 49H0 33 1010 BEARING REMOVER 20 06 1 49H0 33 1020 INSTALLER SENSOR ROTOR 32 35 49HO 61 0040 A CSEAL SEATREPLACER A C 13 50 9 49HD 66 0020 DEPLOYMENTTOOL 145 90 i 49H0 66 0030 HARNESS A...

Page 621: ...NSTALLER M 34 44 49UO 27 OOSO BEARING INSTALLER 25 16 49U0 27 0060 BEARING OIL SEAL INSTALLER 24 44 49U0 27 0Q70 OIL SEAL INSTALLER 30 68 49U0 33 1010 BEARING INSTALLER M 20 06 49UO 34 2AOO LOWERARM BUSHING PULLER INSTALLER 114 63 49UB 39 585A ADJUST WRENCH 41 75 49UN 01 0010 CRANKSHAFT DAMPER REMOVER 39 16 49UN 01 0020 CRANKSHAFT DAMPER REPLACER 41 37 49UN 01 0030 FRONT COVER SEAL REMOVER 80 10 4...

Page 622: ...40 49UN 01 0370 HEXLOCKNUT WRENCH 16 90 49UN 01 0380 SPINDLE BEARING REPLACER 20 48 49UN 01 0400 SEALREPLACER 32 20 49UN 01 0410 BEARING CUP REPLACER 22 46 49UN 01 0420 LOCKNUT WRENCH 24 95 49UN 01 0430 SHAFT SEAL INSTALLER 12 83 49UN 01 0440 SHAFTSEAL REMOVER 30 32 49UN 01 0450 SHAFT SEAL PROTECTOR 8 23 49UN 01 0460 COIL PRESSINGTOOL 30 32 49UN 01 0470 COIL REMOVER SHAFT PROTECTOR 26 84 49UN 01 0...

Page 623: ... CD4E MLP CABLE MANUAL 63 33 49UN 01 1040 SERVO COVER REMOVER REPLACER 33 24 49UN 01 1280 ADAPTOR ATF OIL PRESSURE 54 20 49UN 01 1290 SEAL REPLACER 13 74 49UN 01 1300 104 PIN BREAKOUT BOX 540 93 I 49UN 01 1310 AIR BAG SIMULATOR 10 63 j 49UN 01 1320 4R44E 4R55E CABLE OVERLAY 78 33 49UN 01 1340 VALVE SEAL REPLACER 26 25 49UN 01 1350 VALVE SPRING COMPRESSOR 54 58 49UN 01 1360 REAR MAIN SEAL REPLACER ...

Page 624: ...ler chooses notto participate or cannot participate in this reprogramming service a newcard with V4 0 will automatically be shipped to your dealer at a substantially higherprice APPLICATION This card is usedwith your NGStester to property service 1988 1998 Mazda Vehides Refer to yourWorkshop Manual for the application ofthis card and the tester PRICING The price forthe V4 0 reprogrammingservice is...

Page 625: ...ge your card and address it to the following address America Kowa Seiki Inc 20013 S Rancho Way Rancho Dominguez CA 90220 RE MAZDA NGS CARD REPROGRAMMING STEP 3 Send your package prepaid Your dealer is responsible for shipping costs Be sure it arrives at America Kowa Seiki Inc no laterthan October 31 1997 NOTE 1 DO NOTSEND YOURV3 0 CARD You areto usethis card with your NGS testerwhile your older ca...

Page 626: ...or cannot participate in this reprogramming service a new V6 0 card wiEI be automatically shipped to your service department APPLICATION This card is used with your NGS Tester to properly service 1988 1 9 9 9 Mazda Vehicles Refer to your Workshop Manual for the application of this card and tester PRICING The price for the V6 0 reprogramming exchange is 216 09 plus shipping costs If MNAO Technical ...

Page 627: ...vice Manager s business card taped to the NGS card Send the package to the following address MNAO Technical Services Department 1444 McGaw Avenue Irvine CA 92614 RE Mazda NGS Card Reprogramming Step 3 Send your package by Federal Express 2 day or UPS Blue label prepaid It must arrive at MNAO Techni cal Services Department by September 4 1998 NOTE DO NOT SEND YOUR V5 0 NGS CARD Use this V5 0 card u...

Page 628: ...u only for reprogramming instead of the card plus reprogramming and eliminates NGS down time If you lose or dispose of your card you will be required to purchase both a new card and pro gramming at a substantially higher price Bebw is an illustration ofthis new card It is a Mazda Required Tool MRT and will be automatically shipped to your dealer by Mazda stool vendor America Kowa Seiki Inc APPLICA...

Page 629: ...hipping receiving personnel of this tool ship ment NOTE This program card is small Therefore we recommend that your service manager shop foreman or lead technician install this card in the NGS tester This will prevent misapplication or misdiagnosis when using the NGS tester to service a Mazda vehicle Ifyou have any questions regarding this information contact your District Customer Support Manager...

Page 630: ...TA with BP engine MT 0 o 0 X 1997 MIATA with BP engine AT 0 0 0 0 X 1997 MPV with JE engine AT 0 O p 0 0 X 1997 MILLENIA with KL engine AT 0 0 o 7 0 o r X 1997 MILLENIA with KJ engine AT 0 O o 7 0 0 X 1997 B2300 AT 0 0 0 0 o 0 X 1997 B2300 MT 0 0 o 0 o X 1997 B4000 AT 0 O 0 o 0 0 X 1997 B4000 MT 0 0 0 0 0 1995 96 MILLENIA 0 8 0 0 9 0 0 1996 PROTEGE MT 0 8 0 0 1996 PROTEGE AT o 8 0 0 0 1996 626 MX ...

Page 631: ... 2 TCM Transmission Control Module 7 Include Traction Control System 3 CCM Cruise Control Module 8 on vehicle control unit equipped with OBD II 4 GEM Generic Electronic Module 9 includes Traction Control System 5 IABM Integrated Air Bag Module O meansthere is no TCM but It is possible to diagnose the TCM fromthe PCM menu X meansthese year models are newly added to the program card SERVICE NOTE Whe...

Page 632: ...e COM black and SIG red terminal on the NGS tester and note the reading A reading of 0 ohms indicates that the test lead and connections do not have excess resistance A reading other than 0 ohms may indicate a poor connection go to STEP 3 3 Disassemble the connectors and check for corrosion solder breakage or looseness Resolder connections to repair as necessary Refer to illustration below CONSUME...

Page 633: ... B IL U N G INFORMATION This tool will be shipped prepaid via UPS to your dealer during the week of October 23 1995 Your parts account will be billed for this tool upon its receipt Please advise your shipping receiving personnel of this tool shipment NOTE This program card is small Therefore we recommend that your service manager shop foreman or lead technician install this card in the NGS tester ...

Page 634: ...5 B2300 B3000 B4000 O 4 0 o 1994 323 PROTEGE 0 0 1994 626 MX 6 WITH FS ENGINE EC AT 0 0 0 0 1994 626 MX 6 WITH FS ENGINE MT 0 0 0 1994 626 MX 6 WITH KL ENGINE 0 o 0 0 1994 929 0 0 0 0 1994 MX 3 O 0 0 1994 MIATA O 0 0 1994 RX 7 O 0 1994 MPV WITH G6 ENGINE O 0 o 1994 MPV WITH JE ENGINE 0 0 1994 NAVAJO 0 O 1994 B2300 2 3L 49S O O 0 1994 B2300 2 3L CAL O 0 1994 B3000 B4000 O O 1993 NAVAJO O o 1992 199...

Page 635: ...er explains this law and addresses some general concerns Foryour conveinence the lists of approved certifying training organizations and approved equipment referenced in the fact sheet are also attached Ifyour dealership works with and makes A C repairs be sure you have the approved training and equipment to conform to this new law by November 15 1995 If you have any questions concerning this info...

Page 636: ...ity to establish re quirements to prevent the release of refrigerants during the servicing of motor vehicle air conditioners Recycfing of CFCs can occur at minimal cost and without damaging motor vehicle A C systems The following sections describe the requirements of the law and its potential impact on the service industry Clean Air Act Reqiarements processes it through an oil separa tor a filter ...

Page 637: ...ting cars when the sup ply of CFC 12 is no longer available owners may motfify their a c sys tems to accept the HFC 134a Since the HFC 134a works at a higher pressure than the CFC 12 retrofitting w i require that some components be replaced EPA estimates that retrofits will cost between 100 and 800 The specific requirements wiH vary depending on the make model and age of the car and on the car s h...

Page 638: ...recycle equipment approved by Underwriters Laboratory UL and ETL Testing Laboratories Inc Table II contains recover recycle equipment determined to be substantially identical to approved equipment Table IK contains recover only equipment approved by Underwriters Laboratory UL and ETL Testing Laboratories Inc Table IV contains recover only equipment determined to be substantially identical to appro...

Page 639: ... 679125 679137 Automotive Diagnostics Division of SPX Corporation 40 375 Multiple Listing Bear SPX Robinair 40 310 17352C I7352 17355C 40 327 40 370 Belco Controls Inc 08 Carquest Corporation 209990 Multiple Listing Carrier 12RA001100 Caterpillar Inc SPX Robinair 4C8754 4C8755 905786 905787 905788 905789 905790 Century Mfg Co MR 1991 A R ME 1991 A 160 002 003 004 005 013 014 015 016 Solar 5090 510...

Page 640: ... Products Inc FICS 9000 Multiple Listing Environmental Technologies Corporation SYSTEM I 102 12 Everco SPX Robinair A9990 Everco Industries Inc A9950 Firestone SPX Robinair TE 48 30 960 7 Fluoro Tech Inc Fluoromizer 3000R FM3000R FM3000 with RM3 module Flouromizer 3000 FM4000 120 O Certified by ETL Inc Multiple Listing Ford Motor Company 158 00001 00002 01400900 02300100 Multiple Listing Ford New ...

Page 641: ... J 38100 B J 38750 J 38550 B J 39770 42 17400 43 40015 HDE 43 KK 18 HDE 42 175250 C 43 40017 HDE 42 I7350 C 43 40014 HDE J 38100 D Kolpak Mfg Co ZRM2000 Lexus SPX Robinair 00002 01396 02 MAC Tools Inc ACRRC 750 AC650 AC751 AC760 AC600 AC7O0tf AC800 Multiple Listing Multiple listing by ETL Inc MAC Tools Inc SPX Robinair AC17350C AC 17400 AC17500B AC17700 AM 6000 Mateo Tools Corp ACRM120 ACRM3412 Mu...

Page 642: ... Technologies PF 8 Power Manufacturing R 12a Promax Industries Inc Roger 1 front and back Roger IQ Consists of front and back systems R D Fountain Industries AM6000 Refrigerant Recovery Systems Inc ST100A Refrigerant Recovery Technologies Inc Fluoromizer 3000R FM3000R FM3000 with RM3 module Fluoromizer 3000 FM4OOO I20 Certified by ETL Inc Refrigerant Technologies Inc RRC 1000 RRC 750 RRC 750X RRC ...

Page 643: ...ls 17350C 17351C 17500 17500B I7501B and 17625A only Sun Electric Corporation MRC 150 300 312 400 500 MTC 4000 NAPA 1100 5000 A9950 ATC 1000 1100 5000 078 00800 00801 00802 00805 ACT 3120 3540 4100 Technical Chemical Company SERCON 8000 M A MA MAH MV MAV H 9000 M A MA MV MAH MAV H 9220 9220M 5000H with SR4000 or 4000A filter unit 5000A 5000AB 5000MB or 5000MBJ with SR4000 4000A or 4000H filter uni...

Page 644: ... the name of company that appears on equipment that is basically UL Listed for another company It would be similar to a private brand except that the basic company name need not appear anywhere on the product This equipment has been evaluated to determine the minimum purity specifications for recycled CFC 12 for use in mobile automotive air conditioning systems Such equipment is provided with the ...

Page 645: ...nc P O Box 7224 St Louis MO 63177 314 385 3400 CFC SAV R with Robinair retrofit kit 17217 LSK Inc Mcpherson KS 67460 Everco A9989 with Robinair retrofit kits 17217 and 17216 Everco Industries P O Box 7224 St Louis MO 63177 314 385 3400 Robinair 17200 with retrofit kits 17216 and 17217 17500 RTB17200 RTB17500 Robinair Division SPX Corporation Robinair Way Montpelier OH 43543 0193 419 485 8300 MODEL...

Page 646: ...zone Inc RSB Engineering Econozone 29A Environmental Products Amalgamated PTY Ltd EP10A Environmental Technologies Corp The Pro A Fluoro Tech Inc FM3000 Certified by ETL Inc MDI 51SOD National Refrigeration Products Inc ULV63 Power Manufacturing Inc 012B FRSPORT Ol Power Rl Refrigerant Recovery Systems Inc RC l A Refrigerant Recovery Technologies Inc FM3000 0 Certified by ETL Inc Refrigerant Techn...

Page 647: ...ars on equipment that is basically UL Listed for another company It would be similar to a private brand except that the basic company name need not appear anywhere on the product This equipment has been evaluated to determine the minimum purity specifications for recycled CFC 12 for use in mobile automotive air conditioning systems Such equipment is provided with the following auxiliary marking De...

Page 648: ...Table IV Substantially Identical Kecovei onlv Equipment None approved as of this date ...

Page 649: ...Retailers should continue to accept Ryder cards C F C Reclamation and Recycling Service Inc P O Box 560 Abilene Texas 79604 915 675 5311 Mechanic s Education Association 10 Main Street Neteong New Jersey 07857 1111 201 426 9001 approval date 3 31 93 approval date 3 30 93 The Greater Cleveland Automobile Dealers Association 6100 Rockside Woods Boulevard Suite 235 Independence Ohio 44131 216 328 150...

Page 650: ... 91331 818 897 3018 approval date 7 13 93 E5CO Institute 1350 West Northwest Highway Suite 205 Mount Prospect IL 60056 800 726 9696 approval date 12 27 94 New York State Department of Motor Vehicles Division of Vehicle Safety Technical Training Unit Empire State Plaza Swan Street Building Room 111 Albany New York 12228 518 474 4049 approval date 5 10 95 Air Conditioning Contractors of America Ferr...

Page 651: ...ifornia 90012 213 972 5159 Potomac Electric Power Company 8400 B Old Marlboro Pike Upper Marlboro Maryland 20772 301 967 5294 approval date 8 12 92 Whayne Supply Company P O Box 35900 Louisville KY 40323 5900 502 7744441 approval date 7 19 93 U S Army Ordnance Center and School Attn TP SB TSED C10 SFC Powell Aberdeen Proving Ground Aberdeen Maryland 21005 5201 410 278 4099 approval date 8 12 92 Ye...

Page 652: ...oses for flush ing procedure Does not recycle its flushing fluid Each flushing procedure requires the disposal of 18 20 gallons of waste water ATF flushing fluid that cannot be dumped in shop drain Dealer must consult stale and local authori ties for proper disposal of waste OTC 60081 M Portable Oil Cooler Torque Converter Cleaner Cleaner recycles its solvent Therefore it does not require the disp...

Page 653: ...Moore J35944 MAZ A T Oil Cooler and Une FIusher 226 00 272 55 OTC 60081 M Portable Oil Cooler Torque Converter Cleaner 2 151 65 2 541 00 Order Information Use the easy ordering procedures inthe attached flyers Shipping and Billing Information Yourorder will be shipped directly fromthe manufacturer Your parts accountwill be billed upon receipt NOTE ONLYTHE INTRODUCTORYPRICE OFTHE KENT MOORE EQUIPME...

Page 654: ...0 freight included Upon receipt of your order your parts account will be billed 226 applicable taxes After the introductory price expires you will be billed directly by Kent Moore After December 31 1995 this introductory price expires The package will then be available directly from Kent Moore forthe price of 272 55 freight not included Three Easy Ways to Order Mail Order Form Phone 800 345 2233 F...

Page 655: ...ed to perform a back flush Shop air is used to dry the circuit To assist you with the purchase of this recommended equipment we are offering a special introductory price which is only good until December 31 1995 Benefits Vehicle Cooter Out Una Cost Effective This flusher is one of the less expensive flushers available in today s market Time Efficient The actual flushing proce dure takes approximat...

Page 656: ...reight not included Upon receipt of your order your parts account will be billed 2151 65 freight applicable taxes After the introductory price expires you will be billed directly by OTC After December 31 1995 this introductory price expires The pack age will then be available directly from OTC for the price of 2541 00 freight taxes not included Three Easy Ways to Order MAIL PHONE FAX Order Form 80...

Page 657: ...vent continues to be re circulated until the flow from the cooler lines is clear To assist you with the purchase of this recommended equipment we are offering a special introductory price which is only good until December 31 1995 Benefits Saves Money The cleaner has an Internal 5 micron filter which allows Its 5 gallons of solvent to be recycled and reused Therefore solvent costs and waste disposa...

Page 658: ...hen an aftermarket cruise control system is installed there is a possibility that the system will not function properly To avoid malfunction recommend that customers purchase the Genuine Cruise Control System Mazda will not bear responsibility for an accident resulting from the use of an aftermarket cruise control system 0 1 8 9 5 2 IMPORTANT Service and Parts Managers should read this bulletin ca...

Page 659: ...ut with snap ring pliers or a spanner wrench 2 Hold the m ast and have an assistant turn the radio O N If the antenna mast does not pop up use slip joint pliers to pull the mast up N O TE Holding the antenna mast is necessary to prevent paint dam age 3 Rem ove any debris from the ground plate rubber bushing and mounting nut 4 Apply a small amount of lubricant to these pieces 5 Bend the plastic rac...

Page 660: ...6 1993 94 MX 5 Miata 1995 97 MX 5 Miata 1990 94 Protege 1995 97 RX 7 Conv 1988 91 See Note 2 Millenia 1995 97 RX 7 1993 95 929 1992 95 MX 3 1994 95 CAUTION Never attempt to repair the air bag system wiring always replace any damaged wiring NOTE 1 1993 MPV incorporated air bag systems during a mid year production change 2 1992 RX 7 convertibles were available only in the Canadian market CONSUMER NO...

Page 661: ...ting I Operating I Stop Motor Operation Operating _ Time CUSTOMER NOTE To prevent wiper motor binding Remove ice or snow build up from windshield with a suitable tool Confirm the wiper is free by carefully raising blades from glass NEVER operate wipers on dry windshield If the wiper operation stops Guide the vehicle to the side of road and stop Turn wipers OFF Wait approximately 5 minutes and tom ...

Page 662: ...vice Advisors should relay the following to customers with this concern CUSTOMER NOTE If the circuit breaker opens and stops operation of the wiper motor operation will resume once the circuit resets itself approx 5 minutes If while the circuit breaker is open the wiperswitch is turned OFF the wiper will automatically move to the PARK position once the circuit breaker resets If the wiper motor sto...

Page 663: ...are not mixed com pletety 8 Brush on the resin overlapping both ends of the broken grid line NOTE Use paint remover to clean brush for future applications 9 Repeat application total of 3 times when the sur face is tack free approximately one 1 minute 10 Allow to dry twenty 20 minutes 11 Carefully peel stencil from glass 12 Allow twenty four 24 hours before activating rear defroster PARTS INFORMATI...

Page 664: ... car is moved away from the dooropenerunit Metal wall surroundings and fluorescent lights common in service shops may also interfere with the system s function You may need to move the car to an open area if you re re programming the transmitter Mazda is currently working to improve the system s operation inthese circumstances Re programming an Inoperative Transmitter 1 Confirm the transmitter is ...

Page 665: ...chnical Hotline to be the most helpful possible tool for you Sowhen you call the Hotline with transaxle questions please be prepared to offer the following information Dealercode VIN and mileage Customer complaint and problem condition Transmission fluid level and condition Trouble codes pages K1 3 to K1 6 in the Millenia Workshop Manual SystemVoltages pages K1 100 to K1 103 in Millenia Workshop M...

Page 666: ...knut 2 Tighten piston stem 114 turn Tighten locknut reassemble components and test drive one last time Lookfor a service bulletin and a Workshop Manual correctiononthissubject inthe nearfuture GloveboxDoor 1993 4 626 MX 6 A glovebox door and hinge that rattles or squeaks may be a result of loose screws To eliminate thiscondition make sure the two hinge screws and the eight inner glove box lid scre...

Page 667: ...minal Tightness ofX 13 connectorterminal you ll find thisterminalundertheplasticcarpet pro tectorjust below the left side of the radio Tightness of PCME connector s terminal PCME is under the radio If DATA LINK ERROR still appears after you cycle the ignition key check whether the NGS tester is operating properly by testing it on a known good vehicle same model If the DATA LINK ERROR appears on th...

Page 668: ...e brake rotor sand aroundbolts FuseBoxCover 95 Millenia In September the Mazda factory began placing the cabin fuse box cover in the glove box instead of installing it The reason the cover gets scuffed up during transport if it s installed Please retrieve the cover from the glove box and install it during PDI Index 040355 Owner s Manual 95 Millenia Page 4 50 ofthe Owner s Manual offers information...

Page 669: ...ough the firewall grommet O Timing Belt C92 94929 The engine mayhave a rough idle losepower below4500 rpm orstall but it doesn t misfire and there are no codes Your next step See ifthe timing belt has jumped one or more teeth Mice may cause the belt to jump teeth In cold climates especially they can crawl through a gap between the two cylinder heads and possibly build a nest on the belt When the e...

Page 670: ...s builtafter September 8 1993 Afield service repair kit is not available so call Pioneer s service center at 1 800 553 3756 for a modified exchange unit in Audio System Speaker 94 RX 7 On some 94 vehicles the front center speaker may work intermittently because of a poor ground connection at the speaker s ampli fier mounting bracket The amplifier is located behind the gear shift lever The poor con...

Page 671: ...ealers make the Millenia Best in Class on the upcoming J D Power customer satisfac tion surveys The program aims to establish the industry s highest quality pre delivery service and the most thorough new delivery forthe Millenia Look for special program instructions materials and promotional tools in the mail WarrantyCodes Starting this month Mazda requests that technicians verifythe warranty Cust...

Page 672: ...met hole This bulletin outlines the procedures to effectively troubleshoot and repair the air leak condition INSPECTION AND REPAIR PROCEDURE A INSPECTING AIR LEAKAGE AROUND THE SEALING PLATE 1 Remove the glove box If the vehicle is equipped with A C see Figure 1 If the vehicle has no A C refer to Figure 2 Sealing Plate 2 Possible leak here Heater Unit Sealing Plate 1 Possible leak here Cooler Unit...

Page 673: ...e next Repair Procedure B REPAIRING AIR LEAK BETWEEN BLOWER UNIT AND COOLER UNIT W A C 1 Make sure the 2 hooks of the sealing plate 1 Figure I attach properly on the blower case If not adjust the hook and lock 2 Make sure the sealing plate clip locks securely If not lock the clip 3 Make sure the sealing plate is installed between the blower unit and cooling unit properly and securely locked If not...

Page 674: ...ock is securely fastened If not readjust 3 Make sure the sealing plate is properly installed in between the cooler and heater units If not readjust and lock 4 Check that the air does not leak according to Procedure A Then install the glove box SEALING PLATE 2 CROSS SECTION VIEW D REPAIRING AIR LEAK VEHICLES W O A C I Make sure the sealing plalcs between the blower unit and the air duct and between...

Page 675: ...on is correct but air leaks because the shape of the sealing plate is distoned replace the seal ing plate with a new one E AIR LEAK THROUGH THE GROMMET HOLE Make sure that each firewall grommet is installed properly If dislocated apply soap water or spray lubricant to the grommet sleeve and reinstall Check the A C drain hose grommet the vehicle harness grommet and the speedometer cable grommet for...

Page 676: ... 4 91 94 Navajo 1 6mm 6 9x1 78 LB51 61 J1X 6 5 4 4 6 6 5 5 2 5 16in 6 8x1 5 LB52 61 J1X 3 3 3 3 8in 7 65x1 78 LB53 61 J1X 1 1 4 4 12mm 10 8x1 78 LB54 61 J1X 3 3 3 1 2 1 3 2 2 2 2 5 12mm 10 8x2 4 LB55 61 J1X 1 1 1 1 axial 6 16mm 14 0x1 78 LB56 61 J1X 2 2 3 2 3 2 2 1 3 3 4 7 16mm 13 4x2 4 LB57 61 J1X 1 1 1 axial 8 3 8 3 3 9 1 2 ZZLO 61 J19 4 4 10 5 8 3 3 NOTE Part numbers ending in M IX are delivere...

Page 677: ...Number 001 94 Date Issued 2 28 94 Revised 323 PROTEGE Page 2 of 8 ...

Page 678: ...Number 001 94 Date Issued 2 28 94 Revised MX 3 J Page 3 of 8 ...

Page 679: ...Num ber 001 94 Date Issued 2 28 94 Revised RX 7 P age 4 of 8 ...

Page 680: ...Number 001 94 Date Issued 2 28 94 Revised ...

Page 681: ...Page 6 of 8 tt V ...

Page 682: ...Number 001 94 Date Issued 2 28 94 Revised MIATA P age 7of 8 ...

Page 683: ...Num ber 001 94 Date Issued 2 28 94 Revised NAVAJO 94 B TRUCK P age 8 of 8 ...

Page 684: ...eries 91 94 Navajo A 6mm 6 9x1 78 LB51 61 J1X 5 5 4 4 6 6 5 5 B 5 16in 6 8x1 5 LB52 61 J1X 3 3 C 3 8in 7 65x1 78 LB53 61 J1X 1 1 4 D 12mm 10 8x1 78 LB54 61 J1X 3 3 3 1 2 1 3 2 2 2 2 E 12mm 10 8x2 4 LB55 61 J1X 1 1 1 1 axial F 16mm 14 0x1 78 LB56 61 J1X 2 2 3 2 3 2 2 1 3 3 4 G 16mm 13 4x2 4 LB57 61 J1X 1 1 1 axial H 3 8 3 3 J 1 2 ZZLO 61 J19 4 4 K 5 8 Kit 3 3 N O TE Part numbers ending in J1X are d...

Page 685: ...Number 001 94 Date Issued 2 28 94 Revised 4 28 94 Page 7of 8 ...

Page 686: ...01 94 Date Issued 2 28 94 Revised 4 28 94 NAVAJO 94 B TRUCK Reference Chart Code Size Qtv H 3 J 4 K 5 8 3 K Quantity 1 for low side J Quantity 1 for high side H Quantity 2 H Quantity 1 J Quantity 2 Page 8 of 8 ...

Page 687: ...r drier when the A C system has been ruptured and ALL system pressure is lost Receiver drier will require replacement if the compressor oil becomes discolored or foriegn substances become visible as indicated in the flow chart below NOTE Refer to section U of the workshop manual for additional receiver drier diagnostic procedures If an A C component has failed extract the compressor oil from the f...

Page 688: ... Although the surge current caused the E C U damage it has been found that the root of the cause is a faulty transistor installed in some control units TEST PROCEDURE a Connect the engine signal monitor 49 9200 162 and the adaptor harness 49 9200 163 b Set the selector switch and monitor switch to IF c Check the voltage at idle with the blower switch ON With the A C switch ON voltage should be bel...

Page 689: ...pe relay prevents the surge current from flowing into the control unit The A C relay AC2 09 is located below the right headlamp There are three relays in one place Locate the A C relay by referring to the wire colors illustrated PARTS INFORMATION PART NUMBER DESCRIPTION NEW OLD H310 67 740 FB11 67 740 A C Relay Front A C Relay AC2 09 JZL G W G W G B B WARRANTY INFORMATION Warranty Type Code A Cust...

Page 690: ... G D K 5223617 F201 18 880L ZPAl 18 881R 89 626 MX 6 Non Turbo FED M T From J M 1 G D K 1 7 3 7 0 8 3 1YVGD K5223618 F201 18 880M F203 18 88IR 88 626 MX 6 Non Tubo CA A T M T Also 89 626 MX 6 Non Turbo CA M T Up to J M 1 G D K 1 7 3 7 0 8 2 1YVGD K5223617 F203 18 880L ZPA3 18 88IR 89 626 MX 6 Non Turbo CA M T From J M 1 G D K 1 7 3 7 0 8 3 1Y V G D K5223618 F203 18 880M F204 18 88IR 89 626 MX 6 No...

Page 691: ... Although the surge current caused the E C U damage it has been found that the root of the cause is a faulty transistor installed in some control units TEST PROCEDURE a Connect the engine signal monitor 49 9200 162 and the adaptor harness 49 9200 163 b Set the selector switch and monitor switch to IF c Check the voltage at idle with the blower switch ON With the A C switch ON voltage should be bel...

Page 692: ...pe relay prevents the surge current from flowing into the control unit The A C relay AC2 09 is located below the right headlamp There are three relays in one place Locate the A C relay by referring to the wire colors illustrated PARTS INFORMATION PART NUMBER DESCRIPTION NEW OLD H310 67 740 FB11 67 740 A C Relay Front A C Relay AC2 09 JZL G W G W G B B WARRANTY INFORMATION Warranty Type Code A Cust...

Page 693: ... V G D K 5223617 F201 18 880L ZPAl 18 881R 89 626 MX 6 Non Turbo FED M T From J M 1 G D K 1 7 3 7 0 8 3 1YVGD K5223618 F201 18 880M F203 18 881R 88 626 MX 6 Non Tubo CA A T M T Also 89 626 MX 6 Non Turbo CA M T Up to J M 1 G D K 1 7 3 7 0 8 2 1YVGD K5223617 F203 18 880L ZPA3 18 881R 89 626 MX 6 Non Turbo CA M T From J M 1 G D K 1 7 3 7 0 8 3 1Y V G D K5223618 F203 18 880M F204 18 881R 89 626 MX 6 ...

Page 694: ... Sn 10 16x1 85 9XG0 19 9201 3 3 2 K 5 fin 1255x1 85 9XG0 19 9400 2 2 3 2 L 5 Sn 0 1 78 C003 61 J17 4 2 5 M 16mm axial 14x1 78 C004 61 J17 N 5 9in 10 x1 7S COOS 61 J17 P 12mm 103 2 4 W257 61 J17 3 Q 5 16n 6 7X1 8 W326 61 J17 10 R 16mm 13 4x2 4 W32 61 17 5 NOTE Part numbers ending with J1X are deliv ered in quantities often 10 These vehicles are equipped with Ford air condi tioning systems The illus...

Page 695: ...Page 2 of 10 ...

Page 696: ...Page 3 of 10 ...

Page 697: ...Number 005 97 Date Issued 03 10 97 Revised 1989 94323 PROTEGE Page 4 of 10 ...

Page 698: ...1995 RX 7 Page 5 of 10 ...

Page 699: ...Page 6 of 10 ...

Page 700: ...Number 005 97 Date Issued 03 10 97 Revised Page 7 of 10 ...

Page 701: ...Number 005 97 Date Issued 03 10 97 Revised Page 8 of 10 ...

Page 702: ...Number 005 97 Date Issued 03 10 97 Revised 1990 93 B Series 1994 97 B Series Top F Bottom D Page 9 of 10 ...

Page 703: ...Number 005 97 Date Issued 03 10 97 Revised Page 10 of 10 ...

Page 704: ... the models 1isted below because the A C compressor used in early production of A C kits for these models did not have the relief valve When replacing the receiver drier tank during A C service check whether the A C compressor has a pressure relief valve or not CAUTION The receiver drier tank without the fuse plug should not be installed on vehicles in which the A C compressor does not have a pres...

Page 705: ... pipe and the steel clip This condition is more likely to develop in geographic areas that use large amounts of salt on the roads and highways SERVICE HINTS If a refrigerant leak is suspected inspect the pipes of the receiver drier tank The inlet outlet pipes are available as a service part Refer to the parts information in this bulletin In order to prevent galvanic corrosion from recurrence place...

Page 706: ... fan in front of condenser 3 Remove the receiver drier tank and replace the necessary pipe NOTE When replacing the pipes place the vinyl tape insulator tape between the steel clip and the aluminum pipe in order to prevent galvanic corrosion from recurrence 4 Reinstall the parts removed during step 2 5 Evacuate and charge the system Make sure that there is no leak and that the A C works properly Ch...

Page 707: ...ler Pipe No 3 1 GJ51 61 467 Cooler Pipe No 4 1 WARRANTY INFORMATION Warranty Type Code Customer Comment Code Damage Code Part No of Main Cause Operation No Related Part Number Labor Hour A AI AG GJ51 61 466A or GJ51 61 4670 YY0020RX 0000 00 0837 max qty 2 0 lbs 1 0 Hr evacuation gas charge included Page 3 of 3 ...

Page 708: ...urrent leak 3 When diagnosing an A C leak on a vehicle that previously had tracer dye installed thoroughly clean the sus pected area and re verify the leak prior to repairing 4 After repairing the leak evacuate and recharge the system as outlined in the workshop manual NOTE DO NOT add additional A C tracer dye when recharging the system Flushing or changing the A C oil is not necessary Small amoun...

Page 709: ...A 93 and prior R12 ND7 94 and after R134a ND9 RX 7 94 and prior1 R12 ND7 95 and after R134a ND9 MX 3 93 and prior R12 ATMOS S150 94 and after Rl34a ATMOS GU10 MPV 93 and prior R12 ND6 94 and after R134a ND8 MILLENIA 95 and after R134a ATMOS GU10 929 93 and prior R12 ATMOS S150 94 and after R134a ATMOS GU10 NAVAJO 93 and prior R12 ESHM2C31A2 94 and after R134a WSHM1C231B B SERIES Built before 9 20 ...

Page 710: ...X 3 3 13 C 3 8in 7 65x1 78 LB53 61 J1X 1 1 4 3 D 12mm 10 8X1 78 LB5461 J1X 3 3 3 1 2 1 3 2 1 2 2 2 3 E 12mm axial 10 8X2 4 LB55 61 J1X 1 1 1 11 F 16mm 14 0x1 78 LB56 61 J1X 2 2 3 2 3 2 2 1 3 3 4 3 9 G 16mm axial 13 4x2 4 LB57 61 J1X 1 1 1 3 3 3 H 3 8m 7 36x1 80 22L0 61 J19 KIT 3 3 3 J 1 2m 10 16 x 1 85 4 4 2 K 5 Sin 12 95 x 1 85 3 3 3 2 2 L 5 8in 6 1 x 1 8 CD03 61 J17 4 5 NOTE Part numbers ending ...

Page 711: ...Protege 1989 94 Protege 1995 MX 3 1992 96 RX 7 1993 96 ...

Page 712: ......

Page 713: ......

Page 714: ...Millenia 1995 High Side J Low Side K ...

Page 715: ...wn good recycled refrigerant NOTE A C systems designed to operate on R 134a can be recharged using only HFC 134a Using R 12 substitutes may result in a hazardous condition and or A C component damage CONSUMERNOTICE The informationand Instructionsin this bulletin areintendedforusebyskflled technicians Ma2datechnicians utilize thepropertools equipmentandtake training tocorrectlyandsafely maintain Ma...

Page 716: ...otege 626 MX 6 1990 Vehicles built prior to the above dates experiencing this symptom should have the modified evaporator installed Replace the A C evaporator according to procedures in the appropriate Workshop Manual section 16 or U Contact your District Service Manager for an authorization number before beginning work PARTS INFORMATION PART NUMBER DESCRIPTION APPLICABLE MODEL NEW OLD BR70 61 J10...

Page 717: ...MX 5 Miata NA01 61 J10A B S eries 0000 67 B31A OP Quantity 1 Related Part Number 0000 00 0837 Refrigerant Quantity 2 Operation No Labor Hour Evaporator R R 323 Protege U0604XRX 0 6 Hrs 626 MX 6 U0604XRX 0 6 Hrs MX 5 Miata U0604XRX 0 6 Hrs B S eries U0604XRX 0 5 Hrs Evacuation Recharge All Models U0003XRX 0 5 Hrs NOTE An authorization number must be obtained from your District Service Manager prior...

Page 718: ...93 3 2 3 P r o teg e 19X9 91 R X 7 N o n T u rb o l9X9 93 M P V single A C only 1 9 9 0 9 3 M X 5 Miata 1 9 9 2 9 3 M X 3 INSJIVVLI A l l O N P R X L I Ij R K 1 B efo re installing the O ring inspect the pip e hose lor any d a m a g e 2 Verily the O ring is clean and free from defects PI aee O ring on pipe He sure it is seated pro p erly f i g u r e 1 3 L ig htly ap p ly oil to the O ring with ref...

Page 719: ...on and repairs a list of torque specifications for all hose and pipe connections has been compiled The list only applies to A C kits manufactured by Mazda North America For he location of each of the fittings refer to the applied location section of chart 1 The letters in this section correspond to locations shown in figures 6 12 APPLIED LOCATION IDEAL TORQUE SPEC l t lb TORQUE SPECIFICATION WRENC...

Page 720: ...Figure 8 MX 6 626 A C System Figure 9 B Series A C System Pace 3 of 4 ...

Page 721: ...Figure 12 323 Protege AtC System Page 4 of 4 ...

Page 722: ...visions Please replace the current pages with the replacement pages provided i 1988 626 MX 6 1 27 1 71 i 1989 626 MX 6 1 19 1 58 i 1989 B2200 B2600i R 7 R 8 R 21 R 2 2 1 R 2 2 2 R 2 2 3 11991 323 Protege J1 24 J l 3 1 I 1991 626 MX 6 B 1 9 B 65 i 1991 B2200 B2600i R 7 R 8 R 21 R 2 2 1 R 2 2 2 R 2 2 3 i 1990 626 MX 6 B 1 9 B 6 5 i 1990 B2200 B2600i P 51 R 7 R 8 R 21 R 2 2 1 R 2 2 2 R 2 2 3 IMPORTAN...

Page 723: ...areas shown inthefigure 4 Install the cylinder head cover Tightening torque 6 8 N m 60 80 cm kg 52 69 in lb Distributor 1 Apply engine oil to the O ring and position it on the distributor 2 Apply engine oil to the blade 3 Install the distributor into the rear housing 4 Loosely tighten the distributor mounting bolt Steps After Installation 1 Fill the radiator with the specified amount and type of c...

Page 724: ... Release the fuel pressure Refer to Section 4 1 Disconnect the negative battery cable 2 Drain the engine oil and coolant 3 Remove in the sequence shown in the figure for the specially marked parts referring to removal note 1 28 ...

Page 725: ...and a ew gasket Tightening torque 19 25 Nm 1 9 2 6 m kg 14 19 ft lb 86U01X 57 Cylinder head cover and gasket 1 Clean o u tusedsilico nsealantfromthe gasketand gasket groove 2 Apply new silicon sealant to the back of the gasket 3 Apply siliconsealant tothe shaced areas shown inthe figure 4 Install the cylinder head cove Tightening torque 6 8 Nm 60 80 cm kg 52 69 in lb 86U01X 1Se Revised 5 91 1988 6...

Page 726: ...1 ASSEMBLY TIMING BELT TIMING BELT To que Specifications i 1 25 1 75 m kg 109 152 in tbl 1 7 2 69G D 1B160 ...

Page 727: ... used silicon sealant from the gasket and gasket groove 2 Apply new silicon sealant to the back of the gasket 3 Apply siliconsealant tothe shaded areasshown in the figure 4 Install the cylinder head cover Tightening torque 6 8 Nm 60 80 cm kg 52 69 in lb Timing belt 1 Align the f1 mark of the camshaft pulley with the front hous ing matching mark 2 Install the timing belt Refer to TIMING BELT of ON ...

Page 728: ...sor 12 Waste gate solenoid valve turbo 13 Heat gauge unit 14 Water thermo switch Steps After Installation 1 Fill the radiator with the specified amount and type of en gine coolant 2 Perform the necessary engine adjustments Refer to TUNE UP PROCEDURE 1 Knock sensor turbo 2 EGR position sensor turbo 3 Water thermo switch 4 Injector 5 Engine ground 6 Oxygen sensor 7 Crank angle sensor turbo 96U 01X02...

Page 729: ... intake side shaft has twice as many oil holes as the exhaust side shaft b The stepped ends are the rear of the shafts 2 Apply silicon sealant tothe shaded areas shown inthe figure 3 Apply liberal amount of clean engine oil to the cam lobes and journals 4 Position the camshaft caps according to the mark Note The No 3 camshaft cap has an oil passage from the cylinder head be certain it is installed...

Page 730: ...ng and a rew gasket Tightening torque 19 25 Nm 1 9 2 6 m kg 14 19 ft lb r Rear Housing Install the rear housing and a new gasket Tightening torque 19 25 Nm 1 9 2 6 m kg 14 19 ft lb Cylinder head cover and gasket 1 Cleane x itusedsiliconsealantfro mthegasketandgasket groove 2 Apply newsiliconsealanttoth ebackofthegasket 3 Apply silicon sealant tothe shadedareasshown inthefigure 4 Install the cylind...

Page 731: ... left and right tie rods are both right threaded To increase the toe in turn the right tie rod toward the front of the vehicle and turn the left tie rod by the same amount toward the rear b One turn of the tie rod both sides changes the toe in by about 30mm 1 21 in Camber and Caster Inspection 4x2 1 Position the front wheels on a turning radius gauge 2 Remove the wheel hub cap 3 Remove the wheel h...

Page 732: ... front and rear of the left and right sides 2 side 3 Shim No 6 is for models equipped with power steer ing and is used at the rear only of the left and right sides 1 side 4 Camber A change of shim thickness at front and rear of 1mm 0 004 in results in a change of about 15 5 Caster A change of shim thickness at front or rear only of 1mm 0 004 in results in a change of about 30 2 After adjustment re...

Page 733: ...ions b After installation check the wheel alignment and adjust it if necessary Refer to page R 7 4 2 7 4 93 7 S 9 5 S 4 S 9 s T 4 4 9 3 117 9 5 1 1 9 6 9 85 COTTER PIN N m m kg ft lb 1 Clip 2 Cotter pin and nut 3 Bolts and washers 4 Upper arm ball joint Removal note page R 22 1 Inspection page R 22f 1 5 Upper arm ball joint boot Removal note page R 221 1 Installation note page R 22 t 12 Dust seal ...

Page 734: ...ball Joint stud 3 or 4 times Pull scale reading 20 34 N 2 0 3 5 kg 4 4 7 7 lb While ball stud is rotating Removal note Upper arm ball joint Knuckle arm Using the SST separate the upper arm ball joint from the knuckle arm r 1BU0RX 019 Upper arm ball joint boot 1 Secure the upper arm in a vise 2 Use a chisel as shown to remove the upper arm ball joint boot Note Use protective plates in the jaws of t...

Page 735: ...he threaded bushings iBuonx o i Installation note Upper arm shaft Threaded bushing 1 Apply the specified grease to the upper arm shaft and threaded bushings 1BUORX 02 2 Secure the upper arm shaft in a vise 3 Install the dust seals and upper arm shaft to the upper arm 4 Alternately tighten the threaded bushings in steps Tightening torque 98 390 Nm 10 40 m kg 72 290 ft lb Caution If the specified ti...

Page 736: ...MEMO if A R FRONT SUSPENSION DOUBLE WISHBONE R 22 3 1989 B2200 B2600i Revised 5 91 New page ...

Page 737: ... gasket 1 Clean out used silicon sealant from the gasket and gasket groove 2 Apply new silicon sealant to the back of the gasket 3 Apply silicon sealant tothe shaded areas shown inthefigure 4 Install the cylinder head cover Tightening torque 6 8 Nm 60 80 cm kg 52 69 in lb Timing belt 1 Align the f1 mark of the camshaft pulley with the front hous ing matching mark 2 Install the timing belt Refer to...

Page 738: ... ground 6 Oxygen sensor 7 Crank angle sensor turbo 86U C 0 1 0 8 Solenoid valve idle speed control 9 Idle switch 10 Throttle sensor 11 Water thermo sensor 12 Waste gate solenoid valve turbo 13 Heat gauge unit 14 Water thermo switch Steps After Installation 1 FII the radiator with the specified amount and type ot en cne coolant 2 Perform the necessary engine adjustments Refer to TUNE UP PROCEDURE B...

Page 739: ...ylinder head cover and gasket 1 Clean out used silicon sealant from the gasket and gasket groove 2 Apply new silicon sealant to the back of the gaskeU 3 Apply silicon sealant tothe shaded areas shown_iQ thefigure 4 Install the cylinder head cover Tightening torque 6 8 Nm 60 80 cm kg 52 69 in lb 9GU0 5S Revised 5 91 1990 626 MX 6 B 65 ...

Page 740: ...B ______________ ASSEMBLY TIMING BELT TIMING BELT 69G 01B160 B 66 ...

Page 741: ... 3 Count a flashing number of the ABS warning lamp Note a A flashing pattern consists of a number of short flashes and ends with a long flash Count the short flashes and include the long flash in the count b A same flashing pattern repeats until ignition switch is turned off After the ignition switch is turned off then when the ignition switch is turned on again a same flashing pattern appears c I...

Page 742: ...ABS 8 9 10 Speed sensor High speed sensor resistance Low speed sensor resistance ABS 9 ABS 10 11 Stoplight switch Stoplight switch circuit defective Condition indicated only when driving above 56 km h 35 mph ABS 11 12 12 flashes should not occur ABS 12 13 Control unit speed circuit phase lock loop failure detected during self test ABS 13 14 Control unit Control unit program check sum failure detec...

Page 743: ... Specifications 4x2 4x4 Total toe in mm in 3 3 0 12 A 0 12 degree 18 J t 18 Maximum steering Inner 35 00 2 33 30 2 Front wheel alignment angle Outer 33 00 2 30 00 2 C Unladen Camber angle 0 45 1 00 Caster angle M S 0 50 45 PIS 1 50 45 2 0O 45 Kingpin angle 8 15 10 20 M S Manual steering P S Power steering OBUORX O CM Fuel tank full radiator coolant and engine oil at specified level gnd spare tire ...

Page 744: ... the upper arm shaft and insert or remove adjust ment shims No Thickness mm in No Thickness mm in 1 1 0 0 004 7 1 0 0 004 2 1 6 0 063 8 1 6 0 063 3 2 0 0 079 9 2 0 0 079 4 3 2 0 126 10 3 2 0 126 5 4 0 0 157 11 4 0 0 157 6 2 0 0 079 1BU0RX 017 Note 1 Shims No 1 5 are used at the left and right sides 2 side 2 Shims No 7 11 are used at the front and rear of the left and right sides 2 side 3 Shim No 6...

Page 745: ...check the wheel alignment and adjust it if necessary Refer to page R 7 _ REPLACE x 9 4 9 5 9 0 0 5 0 6 3 6 4 3 98 390 10 40 72 290 4 2 7 4 93 7 5 9 5 5 4 69 4x4 9 3 11 7 9 S 11 9 6 9 85 COTTER PIN N m m kg ft lb 1BU0HX O18 1 Clip 7 2 Cotter pin and nut 8 3 Bolts and washers 9 4 Upper arm ball joint 10 Removal note page R 22 1 Inspection page R 22 1 5 Upper arm ball joint boot 11 Removal note page ...

Page 746: ... stud 3 or 4 times Pull scale reading 20 34 N 2 0 3 5 kg 4 4 7 7 lb While ball stud is rotating Removal note Upper arm ball joint Knuckle arm Using the SST separate the upper arm ball joint from the knuckle arm 1BU0RX 019 Upper arm ball joint boot 1 Secure the upper arm in a vise 2 Use a chisel as shown to remove the upper arm ball joint boot Note Use protective plates in the jaws of the vise to p...

Page 747: ...3 Remove the threaded bushings Installation note Upper arm shaft Threaded bushing 1 Apply the specified grease to the upper arm shaft and threaded bushings 2 Secure the upper arm shaft in a vise 3 Install the dust seals and upper arm shaft to the upper arm 4 Alternately tighten the threaded bushings in steps Tightening torque 98 390 Nm 10 40 m kg 72 290 ft lb Caution If the specified tightening to...

Page 748: ...R FRONT SUSPENSION DOUBLE WISHBONE MEMO i 4 R 22 3 1990 02200 B2600I Revised 5 91 New page ...

Page 749: ...mm 0 026 in _ __ 2 If the clearance exceeds the maximum check the contact surfaces of the 4th gear ball bearing and clutch hub 3rd 4th Replace worn or damaged parts 03U0J1 040 Disassembly note Bearing and 4th gear Caution Hold the shaft with one hand so that it does not fall 1 Remove the ball bearing and 4th gear with the SST 03U0J1 041 Clutch hub assembly 3rd 4th synchronizer ring 3rd and 3rd gea...

Page 750: ... 27 Disassembly Note page J1 25 10 1st gear 3 Retaining ring Disassembly Note page J1 25 4 Secondary 3rd gear Inspection page J1 29 Disassembly Note page J1 25 11 Bearing inner race 5 2nd gear Disassembly Note page J1 26 Disassembly Note page J1 25 12 Secondary shaft Inspection page J1 29 Inspection page J1 28 6 Synchronizer ring 2nd 13 Synchronizer spring Inspection page J1 27 14 Clutch hub sleev...

Page 751: ...mbly Note page J1 32 4 Synchronizer ring 1st Assembly Note page J1 32 5 Clutch hub assembly 1st 2nd Assembly Note page J1 32 6 Retaining ring 7 Synchronizer ring 2nd Assembly Note page J1 32 Revised 5 91 03U0J1 068 8 2nd gear Assembly Note page J1 32 9 Secondary 3rd gear Assembly Note page J1 32 10 Retaining ring 11 Secondary 4th gear Assembly Note page J1 32 12 Bearing inner race Assembly Note pa...

Page 752: ...synchronizer ring 1st and clutch hub assembly 1st 2nd 1 Install the 1st gear synchronizer ring 1st and clutch hub assembly 1st 2nd with the SST Synchronizer ring 2nd 2nd gear and secondary 3rd gear 1 Install the synchronizer ring 2nd 2nd gear and secon dary 3rd gear with the SST r Secondary 4th gear 1 Install the secondary 4th gear with the SST Bearing inner race 4th gear 1 Install the new bearing...

Page 753: ... and gasket 1 Clean out used silicon sealant from the gasket and gasket groove 2 Apply new silicon sealant to the back of the gasket 3 Apply silicon sealant tothe shaded areas shown inthe figure 4 Install the cylinder head cover Tightening torque 6 8 Nm 60 80 cm kg 52 69 in lb Timing belt 1 Align the f1 mark of the camshaft pulley with the front hous ing matching mark 2 Install the timing belt Ref...

Page 754: ...und 6 Oxygen sensor 7 Crank angle sensor turbo ee jcmx c m o 8 Solenoid valve idle speed control 9 Idle switch 10 Throttle sensor 11 Water thermo sensor 12 Waste gate solenoid valve turbo 13 Heat gauge unit 14 Water thermo switch Steps After Installation 1 Fill the radiator with the specified amount and type of en gine coolant 2 Perform the necessary engine adjustments Refer to TUNE UP PROCEDURE B...

Page 755: ... 157 Cylinder head cover and gasket 1 Cleano u tusedsiliconsealantfromth egasket andgasket groove 2 Apply newsilico nsealant toth e back o f th e gasket 3 Apply silicon sealant tothe shaded areas shown inthe figure 4 Install the cylinder head cover Tightening torque 6 8 Nm 60 80 cm kg 52 69 in lb 96LQ1X 055 Revised 5 91 1991 626 MX 6 B 65 ...

Page 756: ...ELT TIMING BELT Torque Specifications o 7 10 N m 70 100 cm kg 61 87 ln lb 45 65 4 6 6 6 35 48 7 10 N m 70 100 cm kg 61 87 In lb 157 167 16 0 17 0 116 123 12 17 Nm 125 1 75cm kg 109 152 in lb c N m m kg 1 lb B 66 69G01B 160 ...

Page 757: ... Item Specifications 4x2 4x4 Total toe in mm in 3 3 0 12 0 12 degree 18 18 Maximum steering Inner 35 00 2 33 30 2 Front wheel alignment Unladen angle Outer 33 00 2 30 00 2 Camber angle 0 45 i oo Z Caster angle M S 0 50 45 P S 1 50 45 2 00 45 Kingpin angle 8 15 10 20 M S Manual steering P S Power steering 0BU0RX004 Fuel tank full radiator coolant and engine oil at specified level and spare tire jac...

Page 758: ...he upper arm shaft and insert or remove adjust ment shims No Thickness mm in No Thickness mm in 1 1 0 0 004 7 1 0 0 004 2 1 6 0 063 8 1 6 0 063 3 2 0 0 079 9 2 0 0 079 4 3 2 0 126 10 3 2 0 126 5 4 0 0 157 11 4 0 0 157 6 2 0 0 079 1BU0RX 017 Note 1 Shims No 1 5 are used at the left and right sides 2 side 2 Shims No 7 11 are used at the front and rear of the left and right sides 2 side 3 Shim No 6 i...

Page 759: ...heck the wheel alignment and adjust it if necessary Refer to page R 7 __REPLACE REPLACE 9 4 9 5 9 0 5 0 6 3 6 4 3 98 390 10 40 72 290 4x2 74 93 7 S 9 5 54 1 4x4 93 117 9 5 11 9 69 85 COTTER PIN N m m kg ft lb 1BU0RX O18 1 Clip 7 Adjustment shims 2 Cotter pin and nut 8 Upper arm assembly 3 Bolts and washers 9 Plug 4 Upper arm ball joint 10 Threaded bushing Removal note page R 22 1 Removal note page...

Page 760: ...joint stud 3 or 4 times Pull scale reading 20 34 N 2 0 3 5 kg 4 4 7 7 lb While ball stud is rotating Removal note Upper arm ball joint Knuckle arm Using the SST separate the upper arm ball joint from the knuckle arm 1BU0RX 019 Upper arm ball joint boot 1 Secure the upper arm in a vise 2 Use a chisel as shown to remove the upper arm ball joint boot Note Use protective plates in the jaws of the vise...

Page 761: ...aded bushings _ 1BU0RX021 Installation note Upper arm shaft Threaded bushing 1 Apply the specified grease to the upper arm shaft and threaded bushings 1BUORX 022 1BU0RX 027 2 Secure the upper arm shaft in a vise 3 Install the dust seals and upper arm shaft to the upper arm 4 Alternately tighten the threaded bushings in steps Tightening torque 98 390 Nm 10 40 m kg 72 290 ft lb Caution If the specif...

Page 762: ...R FRONT SUSPENSION DOUBLE WISHBONE MEMO 4 R 22 3 1991 B2200 B2600i Revised 5 91 New page ...

Page 763: ... DESCRIPTION Attached are revised pages for the 1989 91 626 MX 6 Wiring Diagrams Note Wiring diagrams are in a bound book Revised pages have adhesive strips for attaching over current pages see below 023773 IMPORTANT Service and Parts Managers should read this bulletin carefully sign and convey all informationto those concerned Signature______________________________________ Signature_____________...

Page 764: ... Y W W B L G Y L 0 R 0 02 CHECK CONNECTOR R B G R L A G B 0 03 ABS RELAY F 0 04 ABS PELAY F B L L 0 B G L Y B 0 05 ABS HYDRAULIC UNIT F B B W Y G L B Y W BR G R L Y R 0 06 ABS HYDRAULIC MOTOR F R Y Z y 0 10 WHEEL SPEED SENSOR REAR LH IR r s i 0 07 CONNECTOR BETWEEN ABS RELAY fi ABS HYDRAULIC UNIT o oe WHEEL SPEED SENSOR FRONT LH F 0 09 WHEEL SPEED SENSOR FRONT RH D b r 0 11 WHEEL SPEED SENSOR REAR...

Page 765: ...FR Ol FRONT F REAR R F r L J WITH ABS TI EFT DETERRENT SYSTEM EC AT NON TURBO MODEL F R 0 2 FRONT F REAR R F W R W Y X I 0 fr W L W B O L W Y G Y B R X m Y w R K Y G C L W w b W L DR 01 DASH D REAR R D J T T il D R 0 2 DASH D REAR R D t I TlRBO MOOEL S EC AT NON TUR80 CANADA MOOEL WITH THEFT DETERRENT SYSTEM TURBO MOOEL WITH 4 W S SYSTEM II WITH ABS WITH AAS SYSTEM U WITHOUT PASSIVE SHOULDER BELT ...

Page 766: ...3 SOLENOIO VALVE CH1 LEFT IN EH 3 SOLENOID VALVE CH2 REAR IN S MOTOR CONTROL PRESSURE SWITCH f S E h LOW PRESSURE WARNING SWITCH S p i J i S i S i SSi 3 J3 T V wr r j L 5 i 3D P J O I o FAIL STOP RELAY o Ck O MOTOR RELAY J J V w O w w ct 4 ST 4 o C O t l CDQ I 3 3 58i B r D S mm m 2 3 0 m s p 38 s s P g p 3C0M ro s 3 IN z I r O O t CD X I 7 m cn if I m CD cn W IRING DIAGRAM ...

Page 767: ... 03 FRONT F DASH D ABS AT WITH THEFT DETERRENT AT W ITHOUT THEFT DETERRENT FR 01 FRONT F REAR R ______________ JJ SL B L B W L O L B BR L Y W R Y FI Y R R W L Y L B L O B W B L Y W Y G m l 1 BR 0 WITH 4W S R FR 02 FRONT F REAR R F 0 4W S R DR 01 DASH D REAR R TttFT D J W R W Y X 0 V W L w B L W Y B Y G G Y r 0 K X W Y r G Y B y s L W W B VJ L M y l G ti R L X L Y G W Y 6J G L B L L m r iW Y 4 Y 3R...

Page 768: ... 1989 626 MX 6 50 96 Revised B 91 ...

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