Mazd 626 1994 Instruction manual

1994
Mazda
626/MX-6
Workshop
Manual
FOREWORD
A thorough familiarization with this manual
is important for proper repair and maintenance.
It should always be kept in a handy place for
quick and easy reference.
The contents of this manual, including draw
ings and specifications, are the latest availa
ble at the time of printing. As modifications
affecting repair or maintenance occur, relevant
information supplementary to this volume will
be made available at Mazda dealers. This
manual should be kept up-to-date.
Mazda Motor Corporation reserves the righ:
to alter the specifications and contents of this
manual without obligation or advance notice.
All rights reserved. No part of this book may
be reproduced or used in any form or by any
means, electronic or mechanical— "eluding
photocopying and recording and the use of
any kind of information storage and retrieval
system—without permission in writing.
WARRA TY
The manufacturer’s warranty on Mazda ve
hicles and engines can be voided if improper
service or repairs are performed by persons
other than those at an Authorized Mazda
Dealer.
Mazda Motor Corporation
HIROSHIMA, JAPA
APPLICATION:
This manual is applicable to vehicles beginning
with the Vehicle Identification Numbers (VIN)
shown on the following page.
CO TE TS
Title
General Information
Pre-Delivery Inspection and
Scheduled Maintenance
Engine FS
KL
Lubrication
System FS
KL
Cooling
System FS
KL
Fuel and Emission
Control Systems
FS (MTX)
KL
FS (ATX)
Engine Electrical System
Clutch
Manual Transaxle G25M-R
Automatic
Transaxle GF4A-EL
LA4A-EL
Front and Rear Axles
Steering System
Braking System
Wheels and Tires
Suspension
Body
*Body Electrical System
Technical Data
Special Tools
Wiring Diagram (Form o.5266-10-93G)
y y (Part o.9999-95-021G-94)
* Heater and Air Conditioner Systems
* Refer to the 1994 626/MX-6 Body Electrical Troubl
shooting Manual (Form o.1359-10-93G, Pa
o.9999-95-084F-94) for servicing of the body electric
components.
© 1993 Mazda Motor Corporatior
Printed in the U.S.A. (6/93)
Form o. 1355-10-93G
Part o. 9999-95-019B-94

VEHICLE IDE TIFICATIO UMBERS (VI )
626
1YV GE22C*R5 100001-
1YV GE22D*R5 100001 —
MX-6
1YV GE31C*R5 100001 —
1YV GE31D*R5 100001 —

1994 Mazda 626/MX-6
Workshop Manual
WAR I G
Servicing a vehicle can be dangerous. If you have not received
service-related training, the risks of injury and property damage
increase. The recommended servicing procedures for the vehicle
in this workshop manual were developed with Mazda-trained
technicians in mind. This manual may be useful to non-Mazda
trained technicians, but a technician with our service-related training
and experience w I be at less risk when performing servicing
operations. However, all users ofThis manual are expected to know
general safety procedures.
This manual contains "Warnings” and “Cautions" applicable to
risks not normally encountered in a general technician’s experience.
They should be followed to reduce the risk of injury and the risk
that improper se^. ce or repair may damage the vehicle or render
it unsafe. It s a so "iportant to understand that the “Warnings”
and Cautors are not exhaustive. It is impossible to warn of all
the hazardous consequences that might result from failure to follow
the procedures.
The procec^es recommended and described in this manual are
effective methods of performing service and repair. Some require
tools specif ca resigned for a specific purpose. Nonrecommended
procedures arc :ools should include consideration for safety of the
technician a^c continued safe operation of the vehicle.
Parts shou;d be replaced with genuine Mazda replacement parts,
not parts of lesser quality. Use of a nonrecommended replacement
part should nclude consideration for safety of the technician and
continued safe operation of the vehicle.
© 1993 Mazda Motor Corporation
Printed in the U.S.A. (6/93)
Form o. 1355-10-93G
Part o. 9999-95-019B-94

A
PRE-DELIVERY I SPECTIO
A D
SCHEDULED MAI TE A CE
PRE-DELIVERY I SPECTIO .............. A - 2
PRE-DELIVERY INSPECTION
TABLE ...............................................A - 2
SCHEDULED MAI TE A CE.............A - 3
MAINTENANCE TABLE (USA) .......... A - 3
MAINTENANCE TABLE (CANADA)... A - 6
INSPECTION AND ADJUSTMENT OF
DRIVE BELTS...................................A - 8
ENGINE OIL REPLACEMENT ........... A-11
ENGINE TIMING BELT
REPLACEMENT ...............................A-11
ENGINE OIL FILTER
REPLACEMENT...............................A-12
INSPECTION OF COOLING
SYSTEM.............................................A—13
ENGINE COOLANT
REPLACEMENT...............................A-14
ADJUSTMENT OF IDLE SPEED........A-15
FUEL FILTER REPLACEMENT ......... A-16
INSPECTION OF FUEL LINES .......... A-17
INSPECTION OF EMISSION HOSES
AND TUBES ..................................... A-17
SPARK PLUG REPLACEMENT ......... A-17
INSPECTION OF BRAKE LINES,
HOSES AND CONNECTIONS ......... A-17
INSPECTION OF DISC BRAKE ......... A-17
INSPECTION OF DRUM BRAKE ...... A-17
INSPECTION OF STEERING
OPERATIONS AND LINKAGES ...... A-18
BRAKE FLUID REPLACEMENT........A-18
INSPECTION OF FRONT
SUSPENSION BALL JOINTS .......... A-18
INSPECTION OF DRIVE SHAFT
DUST BOOTS...................................A-19
INSPECTION OF PCV VALVE ........... A-19
INSPECTION OF BRAKE AND
CLUTCH FLUID...............................A-19
INSPECTION OF POWER STEERING
FLUID LEVEL .................................. A-20
INSPECTION OF TIRES ..................... A-20
TIRE ROTATION ................................. A-20
MANUAL TRANSAXLE OIL
REPLACEMENT...............................A-20
INSPECTION OF AUTOMATIC
TRANSAXLE FLUID LEVEL ............ A-21
INSPECTION OF EXHAUST SYSTEM
HEAT SHIELD .................................. A-22
INSPECTION OF REFRIGERANT
AND A/C COMPRESSOR ................ A-22
AIR CLEANER ELEMENT
REPLACEMENT...............................A-23
TIGHTENING OF BOLTS AND NUTS
ON CHASSIS AND BODY ............... A-23
46U0AX-001

APRE-DELIVERY I SPECTIO
PRE-DELIVERY I SPECTIO
PRE-DELIVERY I SPECTIO TABLE
The following items may be done at any time prior to delivery to your customer.
EXTERIOR
I SPECT and ADJUST, if necessary, the following items to
specification:
□ Glass, exterior bright metal and paint for damage
□ Wheel lug nuts, and locks (if equipped)
88-118 N-m (9-12 kgf-m, 65-87 ft-lbf)
□ All weatherstrips for damage or detachment
□ Operation of hood release and lock
□ Operation of trunk lid, and fuel lid opener
□ Door operation and alignment
□ Headlight aim
I STALL the following parts:
□ Wheel caps
U DER HOOD—E GI E OFF
I SPECT and ADJUST, if necessary, the following items to
specification:
□ Fuel, coolant and hydraulic lines, fittings, connections,
and components for leaks
□ Engine oil level
□ Power steering fluid level
□ Brake (clutch) fluid level
□ Windshield washer reservoir fluid level
□ Radiator coolant level
□ Tightness of battery terminals
□ Manual transaxle oil level
I TERIOR
CHECK operations of the following items:
□ Seat controls (sliding and reclining) and head restraints
□ Folding rear seat
□ Door locks, including childproof door locks (if equipped)
□ Seat belts and warning system
□ Ignition switch and steering lock
□ Air bag system using warning light
□ Shift-lock system and transmission range sensor switch
(ATX only)
□ Starter interlock switch (clutch pedal, MTX only)
□ All lights including warning, and indicator lights
□ Sound warning system
□ Horn, wipers, and washers
□ Audio system (if equipped)
□ Cigarette lighter and clock
□ Sunroof (if equipped)
□ Power outside mirrors (if equipped)
□ Power windows (if equipped)
□ Heater, defroster and air conditioner at various mode
selections (if equipped)
CHECK the following items:
□ Presence of spare fuse
□ Upholstery and interior finish
CHECK and ADJUST, if necessary, the following items:
□ Pedal height and free play of brake and clutch pedal
□ Parking brake
5—7 notches/98 N (10 kgf, 22 Ibf)
U DER HOOD—E GI E RU I G AT
OPERATI G TEMPERATURE _________
CHECK the following items:
□ Automatic transaxle fluid level
O HOIST
CHECK the following items:
□ Underside fuel, coolant, and hydraulic lines, fittings, con
nections, and components for leaks
□ Tires for cuts or bruises
□ Steering linkage, suspension, exhaust system, and all un
derside hardware for looseness or damage
ROAD TESf~
CHECK the following items:
□ Brake operation
□ Clutch operation
□ Steering control
□ Operation of gauge
□ Squeaks, rattles or unusual noises
□ Emergency locking retractors
□ Cruise control system (if equipped)
AFTER ROAD TEST
CHECK for necessary owner information materials, tools and
spare tire in vehicle
Pedal height mm (in) Free play mm (in)
Clutch
pedal 186-211
(7.32-8.31)
(with carpet)
5-14
(0.20-0.55)
Brake
pedal 191.5-196.5
(7.54-7.74)
(with carpet)
4-12
(0.16—0.47)
The following items must be done just before the delivery to your customer.
□ Load test battery and charge if necessary
□ Adjust tire pressure to specification
(Refer to section Q)
□ Clean outside of vehicle
Volts
Load test result □ Install fuses for accessories
□ Remove seat and cabin carpet protective covers
□ Vacuum inside of vehicle
46 U0 AX-041
A—2

SCHEDULED MAI TE A CE A
SCHEDULED MAI TE A CE
MAI TE A CE TABLE (USA)
Schedule 1 ( ormal driving conditions)
If the vehicle is mainly operated where none of the “unique driving conditions” apply.
Schedule 2 (Unique driving conditions)
• Repeated short-distance driving.
• Driving in dusty conditions.
• Driving with extended use of brakes.
• Driving in areas where road salt or other corrosives are used.
• Driving on rough or muddy roads.
• Extended periods of idling or low-speed operation.
• Driving for long periods in cold temperatures or extremely humid climates. 46U0AX-002
o
A-3

ASCHEDULED MAI TE A CE
Schedule 1 ( ormal Driving Conditions)
Maintenance umber of months or kilometers (miles), whichever comes first
Interval Months 612 18 24 30 36 42 48
x 1000 kilometers 12 24 36 48 60 72 84 96
Maintenance lt e m ^ \ Miles 7.5 15 22.5 30 37.5 45 52.5 60
Engine
Engine oil R R R R R R R R
Oil filter R R R R R RR R
Tension of all drive belts I I
Engine timing belt Replace every 96,000 km (60,000 miles)
Engine timing belt (California) *2 Inspect at 96,000 km (60,000 miles), and
again at 144,000 km (90,000 miles)
Replace every 168,000 km (105,000 miles)
Hose and tube for emission I
Air cleaner
Air cleaner element
Ignition system
Spark plugs
Fuel system
Idle speed *2 I*2 I*1
Fuel filter R *1
Fuel lines and hose I*2 r i
Fuel hose (California) Inspect every 168,000 km (105,000 miles)
Cooling system
Cooling system 1 1
Engine coolant R R
Chassis and body
Brake lines, hoses and connections 11
Disc brakes 11
Drum brakes 11
Steering operation and linkage 11
Front suspension ball joints 11
Driveshaft dust boots 11
Bolts and nuts on chassis and body 1 1
Exhaust system heat shield 11
All locks and hinges L L L L L L L L
Air conditioner system (if equipped)
Refrigerant Inspect the refrigerant amount annually
A/C compressor Inspect the operation annually
Chart symbols:
I : Inspect, and repair, clean, or replace if necessary
R: Replace
L: Lubricate
Remarks:
• After 48 months or 96,000 km {60,000 miles}, continue to follow the described maintenance at the recom
mended intervals.
‘ ‘ This a maintenance is required for all states except California. However we recommend that it also be
performed on California vehicles.
*2 This maintenance is recommendded by Mazda. However, it is not necessary for emission warranty cover
age or manufacturer recall liability. 46U0AX-003

SCHEDULED MAI TE A CE A
Schedule 2 (Unique Driving Conditions)
Maintenance umber of months or kilometers miles), whichever comes first
Interval Months 4 8 12 16 20 24 28 32 36 40 44 48
x 1000 kilometers 8 16 24 32 40 48 56 64 72 80 88 96
Maintenance l t e m ^ \ Miles 5 10 15 20 25 30 35 40 45 50 55 60
Engine
Engine oil R R R R RR R R R R R R
Engine oil (For Puerto Rico) Replace every 4,800 km (3,000 miles (or 3 months)
Oil filter R R RRRR R RRRRR
Tension of all drive belts II
Engine timing belt Replace every 96,000 km 60,000 miles)
Engine timing belt (California) *2 Inspect at 96,000 km (60,000 miles), and again at
144,000 km (90,000 miles)
Replace every 168,000 km (105,000 miles)
Hose and tube for emission I*2
Air cleaner
I Air cleaner element I *2 R I*2 R
Ignition system
I Spark plugs RR I
Cooling system
Cooling system II
Engine cooling RR
Fuel system
Fuel filter R.i
Fuel lines and hoses I*2 I*1
Idle speed r i I*1
Fuel hoses (California) Inspect every 168,000 km 105,000 miles)
Chassis and body
Brake lines hoses and connections 11
Drum brakes 11
Disc brakes 11 1 1
Steering operation and linkage 1 1
Front suspension ball joints 11
Driveshaft dust boots 11
Bolts and nuts on chassis and body 1 1 1 1
Exhaust system heat shield 11
All lock and hings L L L L L L L L L L L L
Air conditioner system (if equipped)
Refrigerant Inspect the refrigerant amount annually
A/C compressor Inspect the operation annually
Chart symbols:
I : Inspect, and repair, clean, or replace if necessary. (Inspect, and replace if necessary.... Air cleaner ele
ment only)
R: Replace
L: Lubricate
Remarks:
• After 48 months or 96,000 km {60,000 miles}, continue to follow the described maintenance at the recom
mended intervals.
This a maintenance is required for all states except California. However we recommend that it also be
performed on California vehicles. , .
*2This maintenance is recommendded by Mazda. However, it is not necessary for emission warranty cover
age or manufacturer recall liability.
a 46U0AX-004
A—5

ASCHEDULED MAI TE A CE
MAI TE A CE TABLE (CA ADA)
Maintenance umber of months or kilometers miles), whichever comes first
Interval Months 510 15 20 25 30 35 40 45 50 55 60
x 1000 kilometers 8 16 24 32 40 48 56 64 72 80 88 96
Maintenance Ite m "^ ^ Miles 5 10 15 20 25 30 35 40 45 50 55 60
Engine
Engine oil R R R R R R R R R R RR
Oil filter R R R R R R R R R R R R
Tension of all drive belts 11 1 1 1 1 1 1 1 1 11
Engine timing belt *1 R
Air cleaner
Air cleaner element
Ignition system
Spark plugs
Cooling system
Engine coolant level and strength 111 1 1 1 1 1 1 1 1 1
Cooling system for leaks 1 1 1 1
Engine coolant RR
Fuel system
Idle speed 1 1 1 1
Fuel lines and hoses 1 *2 1
Fuel filter R R
PCV valve *2 1
Emission hoses and tubes 1
Chassis and body
Automatic transaxle fluid level 1 I I I I I I I I I II
Transaxle oil (MTX and ATX) R
Driveshaft dust boots II
Brake lines and hoses II
Brake and clutch fluid level 1 I I I I I I I I I I I
Brake fluid *3 R
Disc brakes (front and rear) IIII
Rear drum brakes II
Tire inflation pressure and tire wear 1 I I I I I I I I III
Rotate tires Rotate every 24,000 kilometers or every 15 months
Power steering fluid level I I I I I I I I I II I
Steering operation and linkage
(Includes four wheel alignment) I I
Suspension components front and rear II
All chassis and body nuts and bolts I I I I
Exhaust system heat shield II
All locks and hinges LL L L L L L L L L L
Washer fluid level I I I I I I I I I I I I
Function of all lights I I II I I I I I I I I
Air conditioner system (if equipped)
Refrigerant Inspect the refrigerant amount annually
A/C compressor Inspect the operation annually
A—6

SCHEDULED MAI TE A CE A
Chart Symbols:
I : Inspect, and repair, clean, or replace if necessary, and replace if necessary... Air cleaner element only
R : Replace or change
L : Lubricate
Remarks:
After 60 months or 96,000 km {60,000 miles), continue to follow the described maintenance and intervals.
As for * marked items in this maintenance chart, please pay attention to the following points.
*1: Replacement of the timing belt is required every 96,000 km {60,000 miles). Failure to replace this
belt may result in damage to the engine.
*2: This maintenance operation is recommended by Mazda. However this maintenance is not necessary
for emission warranty coverage or manufacturer recall liability.
*3: This maintenance operation is recommended by Mazda. 46U0AX-005

ASCHEDULED MAI TE A CE
V-RIBBED BELT
x o x
46U0AX-006
/p/s oilN
/ [ PUMP
/ XPULLEY/
y
f --- 'N ''s' ---
/CRANK-\ //( A/C ^
SHAFT I'/ COMPRESSOR
\pulley/ ^PULLEY/
I SPECTIO A D ADJUSTME T OF DRIVE BELTS
Inspection
(FS)
1. Check the drive belts for wear, cracks, and fraying. Replace
if necessary.
2. Verify that the drive belts are correctly mounted on the
pulleys.
3. Check the drive belt deflection when the engine is cold, or
at least 30 minutes after engine has stopped. Apply moder
ate pressure 98 {10 kgf, 22 Ibf} midway between speci
fied pulleys.
Deflection mm (in)
Drive belt *New Used Limit
Alternator 6.5—7.0 7.0--9.0 10
(0.26-0.27) (0.28--0.35) (0.39)
P/S, P/S + A/C 7.5—9.0
(0.30-0.35) 8.0- (0.32--9.5 -0.37) 11
(0.43)
*A belt that has been on a running engine for less than five minutes.
4. If the deflection is not within specification, adjust it.
46U0AX-008 Drive belt tension check
Belt tension can be checked in place of belt deflection.
1. Check the drive belt tension when the engine is cold, or
at least 30 minutes after the engine has stopped. Using the
SST, check the belt tension between any two pulleys.
Tension N (kgf, Ibf)
’ New Used Limit
Alternator 740-830
(75-85,170-180) 500-680
(50-70, 110-150) 390 (40, 88)
P/S, P/S + A/C 590-780
(60-80, 140-170) 500-680
(50-70,110-150) 390 (40, 88)
*A belt that has been on a running engine for less than five minutes.
2. If the tension is not within specified, adjust it.
A—8

SCHEDULED MAI TE A CE A
t m m
46U0AX-010
<8r
/c r a n k - \
SHAFT I
V PULLEY I
yp/s oilN
A PUMP
y \PULLEYv
y f /
r " ©
A/C
COMPRESSOR
PULLEY
Adjustment
Alternator belt
1. Loosen the alternator mounting bolts A and B and adjust
the belt deflection by turning the adjusting bolt C.
2. Tighten the mounting bolts A and B and recheck the
defleciton.
Tightening torque
A: 16—22 m [1.6—2.3 kgf m, 12—16 ft Ibf)
B: 32—46 m {3.2—4.7 kgf m, 24—33 ft Ibf)
P/S belt, P/S + A/C belt
1. Loosen the bolt ® and (§) and adjust the belt deflection
by turning the adjusting bolt (5).
2. Tighten the mounting bolts ® and (D and recheck the
deflection.
Tightening torque
® : 44—60 m {4.4—6.2 kgf m, 32—44 ft Ibf)
(§): 32—46 m {3.2—4.7 kgf-m, 24—33 ft-lbf)
46U0AX-Q42
V-RIBBED BELT
A A A A Im s m J
X O X
(KL)
1. Check the drive belts for wear, cracks, and fraying. Replace
if necessary.
2. Verify that the drive belts are correctly mounted on the
pulleys.
16E0AX-013 3. Check the drive belt deflection by applying moderate pres
sure 98 {10 kgf, 22 Ibf) midway between the pulleys.
ote
• A belt is considered “ New” if it has been used on a run
ning engine for less than five minutes.
Set the deflection as specified below.
• Check the belt deflection when the engine is cold, or at
least 30 minutes after the engine has stopped.
46U0AX-043
A-9

ASCHEDULED MAI TE A CE
Deflection mm (in)
Drive belt New Used Limit
Alternator 6.0—7.0
(0.24-0.27)
I I
O 00
o
-8.0
-0.31) 9.0
(0.35)
Alternator + 5.5—6.5 6.5--7.5 8.0
A/C (0.22-0.25) (0.26--0.29) (0.31)
P/S 6.0—7.0 7.0--8.0 9.0
(0.24-0.27) (0.28--0.31) (0.35)
4. If the deflection is not within specifications, adjust it.
Drive belt tension check
ote
• Belt tension can be checked in place of belt deflection.
• Belt tension can be measured between any two pulleys.
1. Using the SST, check the belt tension.
16E0AX-016 Tension N {kgf, Ibf)
Drive belt New Used Limit
Alternator 690-880
{70-90, 160-190) 500-680 (50-70, 110-150) 440 (45, 99)
Alternator +
A1C 690-880
(70-90, 160-190) 500-680
(50-70, 110-150) 440
(45, 99)
P/S 540-680
(55-70, 130-150) 400-530 (40-55, 88-120) 340 (35, 77)
2. If the tension is not within specification, adjust it.
Adjustment
ote
• A belt is considered “ New” if it has been used on a run
ning engine for less than five minutes.
Alternator + A/C belt
1. Loosen the idler pulley locknut.
2. Adjust the belt deflection by turning the adjusting bolt.
Deflection
ew: 5.5—6.5mm {0.22—0.25 in)
Used: 6.5—7.5mm {0.26—0.29 in)
Limit: 8.0mm {0.32 in)
3. Tighten the pulley.
Tightening torque:
32—46 m {3.2—4.7 kgf m, 24—33 ft-lbf)46U0AX-045
A—10

SCHEDULED MAI TE A CE A
46U0AX-046
Alternator, P/S
1. Loosen the idler pulley locknut.
2. Adjust the belt deflection by turning the adjusting bolt.
Deflection
ew : 6—7mm {0.24—0.27 in)
Used: 7—8mm {0.28—0.31 in)
Limit: 9.0mm {0.35 in)
3. Tighten the pulley.
Tightening torque:
32—46 m {3.2—4.7 kgf m, 24—33 ft Ibf}
E GI E OIL REPLACEME T
1. Remove the oil filler cap and the oil pan drain plug.
2. Drain the oil into a container.
3. Install a new gasket and the drain plug.
Tightening torque:
30—41 -m {3.0—4.2 kgf-m, 22—30 ft-lbf}
4. Refill the engine with the specified type and amount of en
gine oil.
Oil capacity L (US qt, Imp qt)
Engine type FS KL
Total (dry engine) 3.7 [3.9, 3.3) 4.9 (5.2, 4.3)
Engine oil replacement 3.3 {3.5, 2.9) 3.7 (3.9, 3.3)
Engine oil replacement (with oil filter) 3.5 (3.7, 3.1) 4.0 (4.2, 3.5)
5. Refit the oil filler cap.
6. Run the engine and check for leaks.
7. Check the oil level and add oil if necessary.
E GI E TIMI G BELT REPLACEME T
Refer to sectios B1, B2. 46U0AX-013
46U0AX-011
A-11

ASCHEDULED MAI TE A CE
E GI E OIL FILTER REPLACEME T
(FS)
1. Remove the oil filter with the SST.
2. Use a clean rag to wipe off the mounting surface on the
engine.
3. Apply a small amount of clean engine oil to the O-ring of
the new filter.
46U0AX-014 4. Install the oil filter and hand tighten it until the O-ring con
tacts the cylinder block.
5. Tighten the filter 1 and 1/6 turns with the SST.
Tightening torque:
13.8—17.6 m {140—180 kgf cm, 122—156 inlbf}
6. Start the engine and check for leaks.
7. Check the oil level and add oil if necessary.
Oil filter capacity: 0.2 L {0.21 US qt, 0.18 Imp qt}
(KL)
1. Remove the oil filter with the SST.
2. Use a clean rag to wipe off the mounting surface on the
oil cooler base.
3. Apply a small amount of clean engine oil to the O-ring of
the new filter.
36UOAX-O11 4. Install the oil filter and tighten it by hand until the O-ring con
tacts the oil cooler base.
5. Tighten the filter 1 and 1/6 turns with the SST.
Tightening torque:
13.8—17.6 m {140—180 kgf cm, 122—156 in lbf)
36U0F2-012 6. Start the engine and check for leaks.
7. Check the oil level and add oil if necessary.
Oil filter capacity: 0.3 L {0.3 US qt, 0.3 Imp qt}
46U0AX-016
A—12
46U0AX-015

SCHEDULED MAI TE A CE
I SPECTIO OF COOLI G SYSTEM
Warning
• Removing the radiator cap or radiator drain plug while the engine is running or when the en
gine and radiator are hot is dangerous. Scalding coolant and steam may shoot out and cause
serious injury.
Turn off the engine and wait until it is cool. Wrap a thick cloth around the cap and slowly turn
it counterclockwise to the first stop. Step back while the pressure escapes.
After all the pressure is gone, press down on the cap with the cloth and turn the cap to re
move it. 46U0AX-017
49 9200 146
Coolant Level (Engine cold)
1. Verify that the coolant level is near the filler neck of the
radiator.
2. Remove the coolant level dipstick from the coolant reser
voir and verify that the coolant level is between the F and
L marks. Add coolant if necessary.
Coolant Quality
1. Verify that there is no buildup of rust or scale around the
radiator cap, and filler neck.
2. Verify that coolant is free of oil. Replace the coolant if
necessary.
Coolant Leakage
1. Connect a radiator tester (commercially available) and the
SST to the radiator filler neck.
2. Apply 123 kPa {1.25 kgf/cm2, 17.8 psi) (FS)or103 kPa
{1.05 kgf/cm2, 15.0 psi} (KL) pressure to the system.
3. Verify that the pressure is held. If not, check for coolant
leakage.
36U0AX-014
A—13

ASCHEDULED MAI TE A CE
Coolant Protection
Caution
• Do not use alcohol or methanol in the cooling sys
tem. The engine has aluminum parts that can be
damaged by alcohol or methanol antifreeze. Use
only ethylene-glycol-based coolant.
Caution
• Use only soft (demineralized) water in the coolant
mixture. Water that contains minerals will cut down
on the coolant’s effectiveness.
1. Measure the coolant temperature and specific gravity with
a thermometer and a hydrometer.
2. Determine the coolant protection by referring to the graph
shown.
3. If the coolant protection is not proper, add water or coolant
as necessary.
Antifreeze solution mixture percentage
Coolant protection Volume percentage Cravity at
20°C (68°F)
Water Coolant
Above -16°C (3°F) 65 35 1.054
Above -26°C {—15°FJ 55 45 1.066
Above -40°C |-40°F) 45 55 1.078
E GI E COOLA T REPLACEME T
Warning
• Removing the radiator cap or radiator drain plug
while the engine is running or when the engine and
radiator are hot is dangerous. Scalding coolant and
steam may shoot out and cause serious injury.
Turn off the engine and wait until it is cool. Wrap
a thick cloth around the cap and slowly turn it coun
terclockwise to the first stop. Step back while the
pressure escapes.
After all the pressure is gone, press down on the
cap with the cloth and turn the cap to remove it.
Caution
• Do not use alcohol or methanol in the cooling sys
tem. The engine has aluminum parts that can be
damaged by alcohol or methanol antifreeze. Use
only ethylene-glycol-based coolant.
Caution
• Use only soft (demineralized) water in the coolant
mixture. Water that contains minerals will cut down
on the coolant’s effectiveness.
A—14

SCHEDULED MAI TE A CE A
1. Remove the radiator cap and loosen the drain plug.
2. Disconnect the oil cooler hoses. (KL)
3. Drain the coolant into a suitable container.
4. Flush the cooling system with water until all traces of color
are gone; then, let the system drain completely.
5. Install the drain plug.
6. Fill with the proper amount and mixture of ethylene glycol
based coolant by referring to the table above.
Coolant capacity
FS: 7.0 L {7.4 US qt, 6.2 Imp qt}
KL: 7.5 L {7.9 US qt, 6.6 Imp qt}
7. Run the engine with the radiator cap removed until the up
per radiator hose is hot.
8. With the engine idling, add coolant to the radiator until it
reaches the bottom of the filler neck.
9. Install the radiator cap.
ADJUSTME T OF IDLE SPEED
1. Warm up the engine to normal operating temperature.
2. Shift the selector lever to P range (ATX) or Neutral (MTX).
3. Turn off all electric loads.
• Headlight
• Blower
• Rear window defroster
• Power steering
4. Wait until the coolant fan is stopped.
5. Connect a tachometer to the data link connector terminal
IG- as shown.
6. Verify that the idle speed is within the specification.
Idle speed ( eutral): 600—700 (650 ± 50) rpm
7. If not within the specification, connect the SST to the data
link connector.
8. Set switch A to position 1.
9. Set test switch to SELF TEST.
10. If the SST is not used, connect a jumper wire between the
TE terminal and the G D terminal of the data link con
nector.
11. Adjust the idle speed by turning the air adjusting screw.
Idle speed (TE terminal grounded):
600—700 (650 ± 50) rpm
12. Disconnect the SST.
46U0AX-022
AIR ADJUSTI G
SCREW'
46U0AX-023 A—15

ASCHEDULED MAI TE A CE
46U0AX-024
FUEL PUMP
(GREE )
FUEL FILTER REPLACEME T
Warning
• Fuel vapor is hazardous. It can very easily ignite,
causing serious injury. Keep sparks and flames
away from fuel.
Warning
• Fuel line spills and leaks are dangerous. Fuel can
ignite and cause serious injuries or death and dam
age. Fuel can also irritate skin and eyes. To prevent
this, always complete the following “Fuel Line Safe
ty Procedures.”
Fuel Line Safety Procedures
Fuel in the fuel system is under high pressure when the en
gine is not running.
A. Release the fuel pressure before disconnecting a fuel line.
1. Start the engine.
2. Remove the fuel pump relay.
3. After the engine stalls, turn the ignition switch to OFF.
4. Install the fuel pump relay.
B. Avoid leakage.
1. When disconnecting a fuel line hose, wrap a rag around
it to protect against fuel leakage.
2. Plug the hose after removel.
High-pressure side
The fuel filter must be replaced at the intervals outlined in the
maintenance schedule.
1. Disconnect and plug the fuel hoses from the fuel filter.
2. Remove the fuel filter and bracket.
3. Install in the reverse order of removal.
Tightening torque:
7.9—10.7 m [80—110 kgf cm, 70—95.4 in Ibf)
4. Verify that the fuel hoses are pushed fully onto the fuel filter
nipples.
5. Secure the fuel hoses with clips.
6. Start the engine and verify that the fuel line joints do not leak.
A—16

SCHEDULED MAI TE A CE A
I SPECTIO OF FUEL LI ES
1. Check the fuel line fittings, connections and components
for leaks.
2. There should be no wetness or stained areas that might in
dicate leaks.
3. Replace any defective hoses or clips.
I SPECTIO OF EMISSIO HOSES A D TUBES
1. Check the emission hoses and tubes fitings, connections
and components for leaks.
2. There should be no wetness or stained areas that might in
dicate leaks.
3. Replace any defective hoses, tubes or clips. 36U0AX-O29
SPARK PLUG REPLACEME T
Caution
• Pulling on the wire part of the spark plug lead may
break the wire. To remove the lead, pull only on the
boot.
1. Remove and install the high-tension leads carefully.
2. Remove and install the spark plug with a plug socket.
3. Apply anti-seize compound or molybdenum-based lubricant
to the spark plug threads.
4. Tighten the spark plug to the specified torque.
Tightening torque:
15—22 -m {1.5—2.3 kgf m, 11—16 ft-lbf)
46U0AX-047 I SPECTIO OF BRAKE LI ES, HOSES A D
CO ECTIO S
Check the points below; replace parts if necessary.
1. Cracking, damage or corrosion of the brake hose.
2. Damage to the brake hose threads.
3. Scars, cracks or swelling of the flexible hose.
4. All lines for fluid leakage.
I SPECTIO OF DISC BRAKE
Check the following disc brake components.
1. Check the caliper operation and inspect for leaks.
2. Check the pads for wear.
3. Check the condition and thickness of the disc plate.
Limit
Brake pad thickness
Front: 2.0mm {0.08 in)
Rear: 1.0mm {0.04 in)
Disc plate thickness
Front: 22.0mm {0.87 in)
Rear: 8.0mm {0.31 in)
16E0AX-108
46U0AX-048 A-17