Mazda 626 Station Wagon Instruction manual

Mazda
Station Wagon
Workshop Manual
Supplement
JM Z G F 1 *
JMZ G W 1 *
JM Z G W 6 *
w
v.- 9/1999 1671-1E-99
European (L.H.D. U.K.) specs.

WARN NG
Servicing a vehicle can be dangerous. If ou have not received
service-related training, the risks of injur , propert damage, and
failure of servicing increase. The recommended servicing procedures
for the vehicle in this workshop manual were developed with
Mazda-trained technicians in mind. This manual ma be useful to
non-Mazda trained technicians, but a technician with our
service-related training and experience will be at less risk when
performing service operations. However, all users of this manual are
expected to at least know general safet procedures.
This manual contains “Warnings” and “Cautions” applicable to risks
not normall encountered in a general technician’s experience. The
should be followed to reduce the risk of injur and the risk that
improper service or repair ma damage the vehicle or render it unsafe.
It is also important to understand that the “Warnings” and “Cautions”
are not exhaustive. It is impossible to warn of all the hazardous
consequences that might result from failure to follow the procedures.
The procedures recommended and described in this manual are
effective methods of performing service and repair. Some require tools
specificall designed for a specific purpose. Persons using procedures
and tools which are not recommended b Mazda Motor Corporation
must satisf themselves thoroughl that neither personal safet nor
safet of the vehicle will be jeopardized.
The contents of this manual, including drawings and specifications, are
the latest available at the time of printing, and Mazda Motor Corporation
reserves the right to change the vehicle designs and alter the contents
of this manual without notice and without incurring obligation.
Parts should be replaced with genuine Mazda replacement parts or
with parts which match the qualit of genuine Mazda replacement
parts. Persons using replacement parts of lesser qualit than that of
genuine Mazda replacement parts must satisf themselves thoroughl
that neither personal safet nor safet of the vehicle will be
jeopardized.
Mazda Motor Corporation is not responsible for an problems which
ma arise from the use of this manual. The cause of such problems
includes but is not limited to insufficient service-related training, use of
improper tools, use of replacement parts of lesser qualit than that of
genuine Mazda replacement parts, or not being aware of an revision
of this manual.

Mazda
626
626
Station Wagon
Workshop
Manual
Supplement
FOREWORD
This manual contains the changes
and/or additions relating to on vehicle
service and diagnosis procedures for the
Mazda 626 and 626 Station Wagon.
For proper repair and maintenance, a
thorough familiarization with this manual is
important, and it should alwa s be kept in a
hand place for quick and eas reference.
All the contents of this manual, including
drawings and specifications, are the latest
available at the time of printing. As
modifications affecting repair or
maintenance occur, relevant information
supplementar to this volume will be made
available at Mazda dealers. This manual
should be kept up-to-date.
Mazda Motor Corporation reserves the
right to alter the specifications and contents
of this manual without obligation or
advance notice.
All rights reserved. No part of this book
ma be reproduced or used in an form or
b an means, electronic or mechanical—
including photocop ing and recording and
the use of an kind of information storage
and retrieval s stem—without permission in
writing.
Mazda Motor Corporation
H ROSH MA, JAPAN
APPLICATION:
This manual is applicable to vehicles
beginning with the Vehicle Identification
Numbers (VIN), and related materials
shown on the following page.
CONTENTS
Fuel and
Emission
Control Systems
FP, FS, FS (Hi-power)
RF Turbo,
RF Turbo (Hi-power)
Engine Electrical System
Manual Transaxle
Automatic
Transaxle
GF4A-EL
FN4A-EL
Front and Rear Axles
Steering System
Braking System
Suspension
Body
Body Electrical System
Heater and Air Conditioner Systems
Technical Data
Special Tools
There are explanations given onl for the sections marked
with shadow ( ) .
1999 Mazda Motor Corporation
PR NTED N THE NETHERLANDS, SEPT.1999
1671-1E-99

VEH CLE DENT F CAT ON NUMBERS (V N)
U.K. specs.
JMZ GF12P20# 400001
JMZ GF12F20# 400001 —
JMZ GF12R20# 400001 —
JMZ GF14P20# 400001 —
JMZ GF14F*0# 400001 —
JMZ GF14S*0# 400001 —
European (L.H.D.) specs.
JMZ GF12P20# 400001 —
JMZ GF12P2Y# 400001 —
JMZ GF12F50# 400001 —
JMZ GF12F5Y# 400001 —
JMZ GF12F20# 400001 —
JMZ GF12F2Y# 400001 —
JMZ GF12S50# 400001 —
JMZ GF12S5Y# 400001 —
JMZ GF12S20# 400001 —
JMZ GF12S2Y# 400001 —
JMZ GF12T2Y# 400001 —
JMZ GF12R2Y# 400001 —
JMZ GF12T20# 400001 —
JMZ GF12R20# 400001 —
JMZ GF14P20# 400001 —
JMZ GF14P2Y# 400001 —
JMZ GF14F50# 400001 —
JMZ GF14F5Y# 400001 —
JMZ GF14F20# 400001 —
JMZ GF14F2Y# 400001 —
JMZ GF14S50# 400001 —
JMZ GF14S5Y# 400001 —
JMZ GF14S20# 400001 —
JMZ GF14S2Y# 400001 —
JMZ GF14T2Y# 400001 —
JMZ GF14R2Y# 400001 —
JMZ GF14T20# 400001 —
JMZ GF14R20# 400001 —
JMZ GF14R20# 400001 —
JMZ GF12S*0# 400001 —
JMZ GW19F20# 200001 —
JMZ GW19S20# 200001 —
JMZ GW19R20# 200001 —
JMZ GW19P20# 200001 —
JMZ GW19P2Y# 200001 —
JMZ GW69P2Y# 200001 —
JMZ GW69P20# 200001 —
JMZ GW19F50# 200001 —
JMZ GW19F5Y# 200001 —
JMZ GW69F5Y# 200001 —
JMZ GW69F50# 200001 —
JMZ GW19F20# 200001 —
JMZ GW19F2Y# 200001 —
JMZ GW69F2Y# 200001 —
JMZ GW69F20# 200001 —
JMZ GW19S50# 200001 —
JMZ GW19S5Y# 200001 —
JMZ GW69S5Y# 200001 —
JMZ GW69S50# 200001 —
JMZ GW19S20# 200001 —
JMZ GW19S2Y# 200001 —
JMZ GW69S2Y# 200001 —
JMZ GW69S20# 200001 —
JMZ GW69T2Y# 200001 —
JMZ GW69R2Y# 200001 —
JMZ GW19T2Y# 200001 —
JMZ GW19R2Y# 200001 —
JMZ GW69T20# 200001 —
JMZ GW69R20# 200001 —
JMZ GW19T20# 200001 —
JMZ GW19R20# 200001 —

RELATED MATER ALS
626 Training Manual (Europe) ...................................... 3303-10-97D
626 Workshop Manual (Europe) .................................. 1577-10-97D
626 Station Wagon Workshop Manual Supplement
(Europe)
........................................................................... 1603-10-97J
626 626 Station Wagon Workshop Manual
Supplement RF Turbo
.................................................. 1614-10-98D
626 626 Station Wagon Wiring Diagram
(Europe (L.H.D.)) ............................................................. 5468-1*-99l
626 626 Station Wagon Wiring Diagram (U K ) 5469-1 *-991
Engine Workshop Manual FP FS
................................ 1579-10-98D
Engine Workshop Manual RF Turbo ........................... 1615-10-98D
Manual Transaxle Workshop Manual G25M-R ........ 1441-10-94F
ATX Workshop Manual GF4A-EL ................................ 1414-10-931
ATX Workshop Manual GF4A-EL ................................ 1393-10-93H
ATX Workshop Manual FN4A-EL
................................ 1623-10-98E
626 Bodyshop Manual .................................................. 3310-10-97D
626 Station Wagon Bodyshop Manual Supplement 3317-10-97J
*: ndicates the printing location
E—Europe
0—Japan

GENERAL NFORMAT ON B
HOW TO USE TH S MANUAL ............................ G -2
RANGE OF TOPICS ........................................ G -2
TROUBLESHOOTING PROCEDURE .......... G -2
ELECTR CAL SYSTEM ........................................ G -8
PRECAUTIONS BEFORE WELDING G -8
ABBREV AT ONS .................................................. G -8
SCHEDULED MA NTENANCE .......................... G -9
SCHEDULED MAINTENANCE TABLE G -9
G -1

HOW TO USE TH S MANUAL
HOW TO USE TH S MANUAL
RANGE OF TOP CS
• This manual indicates onl changes/additions, as it is the supplemental for the related materials. Therefore it
ma not contain the necessar referential service procedures to operate
the services indicated in this manual. Onl
the referential section, e.g. (See Section B), is indicated, so refer to the appropriate section of
the related materials for details.
TROUBLESHOOT NG PROCEDURE
Basic flow of troubleshooting
NG L GHT, CRU SE SET
ND CATOR L GHT, A R BAG SYSTEM
WARN NG L GHT, SECUR TY L GHT,
GENERATOR WARN NG L GHT
DTC troubleshooting flow (on-board diagnostic)
• Diagnostic trouble codes (DTCs) are important hints for repairing malfunctions that are difficult to simulate.
Perform the specific DTC diagnostic inspection to quickl and accuratel diagnose the malfunction.
• The on-board diagnostic function is used during inspection. When a DTC is shown specif ing the cause of a
malfunction, continue the diagnostic inspection according to the items indicated b the on-board diagnostic
function.
Diagnostic index
• The diagnostic index lists the s mptoms of specific malfunctions. Select the s mptoms related or most closel
relating to the malfunction.
Quick diagnosis chart ( f mentioned)
• The quick diagnosis chart lists diagnosis and inspection procedures to be performed specificall relating to the
cause of the malfunction.
Symptom troubleshooting
• S mptom troubleshooting quickl determines the location of the malfunction according to s mptom t pe.
G -2

HOW TO USE TH S MANUAL
Procedures for Use
Using the basic inspection (section K)
• Perform the basic inspection procedure before s mptom troubleshooting.
• Perform each step in the order shown.
• The reference column lists the location of the detailed procedure for each basic inspection.
• Although inspections and adjustments are performed according to the reference column procedures, if the
cause of the malfunction is discovered during basic inspection, continue the procedures as indicated in the
remarks column.
SHOWS NSPECT ON
ORDER
REFERENCE
COLUMN
SHOWS TEM NAMES FOR
DETA LED PROCEDURES
AU rOMAT C TRANSAXLE BAS C NSPECT ON
STEP NSPECT ON
SHOW PO NTS REQU R NG
ATTENT ON BASED ON
NSPECT ON RESULTS
Turn ignition switch is on.
Does O/D OFF indicator light (illuminate/go out)
correspond to O/D OFF switch position (on/off)?
Turn ignition switch is on.
When selector lever is moved, are selector lever
position and indicator aligned? Also, when other
ranges are selected from N or P during idling,
does vehicle creep within 1 to 2 seconds?
Inspect the ATF color condition.
Are ATF color and odor normal?
1 Perform line pressure test.
See K-2 Line Pressure Test
1 Is line pressure oka ?
1 Perform stall test.
See K-2 Stail Speed Test
1 Is stall speed is oka ?
Yes
No
Yes
No
Yes
No
Yes
No
No
ACT ON
Go to next step.
Perform s mptom troubleshooting No.26 “O/D OFF
indicator light does not illuminate when O/D OFF switch
is turned to on”, or No.27 “O/D OFF indicator light
illuminates when O/D OFF switch is not turned to on".
Go to next step.
Inspect selector lever.
Repair or replace defective areas.
Go to next step.
Repair or replace an defective parts according to
inspection result.
Rush ATX and cooler line as necessar
Go to next step.
Adjust accelerator cable as necessar .
Repair or replace an defective parts according to
inspection result.
Go to next step.
Repair or replace defective parts according to
inspection result.
G -3

HOW TO USE TH S MANUAL
Using the DTC troubleshooting flow
• DTC troubleshooting flow shows diagnostic procedures, inspection methods, and proper action to take for
each DTC.
TROUBLE COND T ON
DTC P0103
DETECT ON COND T ON
describes the condition
under which the DTC is
detected. ,
PTC PO 03
POSS BLE
CAUSE describes
possible point(s)
of malfunction
DETECT ON
COND T ON
ndicates the
inspection step
No. to be
performed
(F1, F2 and K
section)
POSS BLE
CAUSE
MAF circuit high nput /
PCM monitors input voltage from TP sensor after ignition ke is turned on. If input voltage at PCM terminal 68 is/
above 8.25 V, PCM determines that TP circuit has a malfunction.
Diagnostic support note
This is a continuous monitor (CCM).
MIL illuminates if PCM detects the above malfunction condition during first drive c cle. Therefore,
PENDING CODE is not available.
FREEZE FRAME DATA is available.
DTC is stored in the PCM memor . __________________________________________________________
MAF sensor malfunction
Connector or terminal malfunction
Open circuit in wiring between MAF sensor terminal D and PCM terminal 36
Open circuit in MAF sensor ground circuit ______________________________
ndicates the
circuit to be
inspected
(F1, F2and K
section)
STEP shows the
order of
troubleshooting
HARN ESS SIDE CONNECTOR
(V1EWFH0M TERMINAL SI DE) HARN ESS SID E CONNECTOR
M E W FROM HA RNE SS SID P
NSPECT ON
describes the
method to quickly
determine the
failed part(s).
' ' STEP NSPECT ON ACT ON
1VER FY FREEZE FRAME DATA HAS BEEN
RECORDED
Has FREEZE FRAME DATA been recorded?
Yes Go to next step.
No Record FREEZE FRAME DATA on repair order, then go /
to next steD.
2VER FY RELATED REPAR NFORMAT ON
AVA LAB L TY
• Are related Service Bulletins and/or on-line
repair information available?
Yes Perform repair or diagnosis according to available repair
information.
If vehicle is not repaired, then qo to next step.
No Go to next step.
3VER FY CURRENT NPUT S GNAL STATUS S
CONCERN NTERM TTENT OR CONSTANT
- • Connect NGS tester to DLC-2.
Start engine.
* Access MAF V PID using NGS tester.
• Is MAF V PID within 0.2 - B.3 V?
Yes Intermittent concern is existing. Go to INTERMITTENT
CONCERNS TROUBLESHOOTING procedure.
See F1 -33 INTERMITTENT CONCERN - ----------
TROUBLESHOOTING
No Go to next step.
4NSPECT POOR CONNECT ON OF MAF
SENSOR CONNECTOR
Turn ignition ke to OFF.
• Disconnect MAF sensor connector.
• Check for poor connection (damaged, pulled-
out terminals, corrosion etc.).
• Are there anv malfunctions?
Yes Repair or replace terminals, then go to Step 8.
ndicates the
. connector
related to
the nspection
ACT ON
describes the
^/appropriate
action to take as
according to the
result (Yes/No).
Reference
item(s) to
perform
ACT ON.
G -4

HOW TO USE TH S MANUAL
Using the diagnosis index
• The s mptoms of the malfunctions are listed in the diagnostic index for s mptom troubleshooting.
• The exact malfunction s mptoms can be selected b following the index.
No. TROUBLESHOOT NG TEM DESCR PT ON Page
_Melting of main or other fuses See F2-6 MELT NO.1 MAIN OR
OTHER FUSE
Will not crank Starler does not work See F2 7 NO. 2 MIL COMES ON
3Hard slart/long crank/erratic start/erratic
crank
Starter cranks engine at normal
speed but engine requires flxcessive
cranking lime before starting. See F2-B NO. 3 WILL NOT CRANK
4Engine stalls Alter start/at idle Engine stops unexpectedl at idle
and/or after start. See F2-9 NO.4 HARO START/
LONG CRANK/ERRATIC CRANK
5Cranks normall but will not star! Starter cranks engine at normal
speed but engine will not run. See F2 11 NO. 5 ENG1NE-S TALLS
AFTER START/AT IDLE
6Slow return lo Idle Engine takes more time than normal
lo relurn to Idle speed. See F2-15 NO.6 CRANKS
NORMALLY BUT WILL NOT START
7 Engine runs rough/rotiing idle
Engine speed fluctuates between
specified idle speed and lower
speed and engine shakes exces
sivel .
See F2-19 NO. 7 SLOW RERUN TO
IDLE
8Fast idle/runs on
Engine speed continues at fast idle
after warm-up.
Engine runs afler ignition ke is
turned to OFF.
See F2-20 NO. 8 ENGINE RUNS
ROUGH/ROLLING IDLF
9 Low idle/stalls during deceleration Engine slops unexpectedl al begin-
ning of deceleration or recover
1rom deceleration.
See F2-23 NO 9 FAST IDLE/RUNS
ON
G -5

HOW TO USE TH S MANUAL
Using the quick diagnosis chart
The chart lists the relation between the s mptom and the cause of the malfunction.
The chart is effective in quickl narrowing down the relation between s mptom and cause of the malfunction,
also specifies the area of the common cause when multiple malfunction s mptoms occur.
The appropriate diagnostic inspection relating to malfunction cause as specified b the s mptoms can be
selected b looking down the diagnostic inspection column of the chart.
(2) PARTS WH CH MAY BE THE CAUSE OF
PROBLEMS
QU CK D AGNOS S CHART
G -6

HOW TO USE TH S MANUAL
Using the symptom troubleshooting
• S mptom troubleshooting shows diagnostic procedures, inspection methods, and proper action to take for
each trouble s mptom.
DESCR PT ON
describes what
kind of TROUBLE
SYMPTOM TROUBLESYMPTOM
POSS BLE
CAUSE
describes
possible
point of
malfunction
STEP shows the
order of
troubleshooting.
Reference
item(s)for
additional
information to
perform
NSPECT ON.
NSPECT ON
describes the
method to
quickly
determine the
failed part.
DESCRIPTION
POSSIBLE
CAUSE
Engine flares up or slips when upshlftlng or down shifting
• When accelerator pedal is depressed for drivewa , engine speed increase but vehicle speed increase
slowl .
»When accelerator is depressed while driving, engine speed increases but vehicle not. __________________
• There is clutch slip because clutch is stuck or line pressure is low.
— Clutch stuck, slippage (forward clutch, 3-4 clutch, 2-4 brake band, one-wa clutch 1, one-wa clutch 2)
• Line pressure low
• Malfunction or mis-adjustment of TP sensor
• Malfunction of VSS
» Malfunction of input/turbine speed sensor
• Malfunction of sensor ground
• Malfunction of shift solenoid A, 8 or C
• Malfunction of TCC solenoid valve
• Malfunction of bod ground
• Malfunction of throttle cable
• Malfunction of throttle valve bod
— Poor operating of mechanical pressure
• Selector lever position disparit
• TR switch position disparit
Note
«Before following troubleshooting steps, make sure that Automatic Transaxle On-board Diagnostic and
Automatic Transaxle Basic Inspection are conducted.
'"'STEP INSPECTION ACTION ACT ON
• Is fine pressure oka ? Yes Go to next step. _ _ describes the
No Repair or replace an defective parts according to -—-
inspection results. appropriate
action to take
2• Is shift point oka ? Yes Go to next step. as a result
—See K-5 Road Test Preparation No Go to s mptom troubleshooting No.9 “Abnormal shift”. (Yes/No) of
3* Stop engine and turn ignition switch on.
* Connect NGS tester to DLC-2.
■ Simulate SHIFT A, SHIFT B and SHIFT C PIDs
for ON.
* Is operating sound of shift solenoids heard?
Yes • Overhaul control valve bod and repair or replace an
defective parts.
See ATX Workshop Manual GF4A-EL 0666-1A-99F)^
* If problem remains, replace or overhaul transaxle and
repair or replace defective parts.
NSPECT ON.
Howto perform
ACT ON is
described in the
relative material
shown.
No • Inspect for bend, damage, corrosion or loose
connection if shift solenoid A, B, or C terminal on ATX.
• Inspect for shift solenoid mechanical stuck.
See K-14 Inspection of Operation--, ___
• If shift solenoids are oka , inspectfoPupeo^or short
circuit between PCM connector terminal A, B or CT*"“-'- — Reference
4 • Verif test results.
— If oka , return to diagnostic index to service an additional s mptoms.
— If malfunction remains, inspect related Service Bulletins and/or On-line Repair Information and perform repair or
diagnosis.
— If vehicle is repaired, troubleshooting completed.
— If vehicle is not repaired or additional diagnostic information is not available, replace or reprogram PCM.
ltem(s) to
perform
ACT ON.
G -7

ELECTR CAL SYSTEM, ABBREVAT ONS
ELECTR CAL SYSTEM
PRECAUT ONS BEFORE WELD NG
Vehicles have various electrical parts. To protect the
parts from excessive current generated when welding,
be sure to perform the following procedure.
1. Turn the ignition switch to the LOCK position.
2. Disconnect the batter cables.
3. Securel connect the welding machine ground
near the welding area.
4. Cover the peripheral parts of the welding area to
protect them from weld spatter.
ABBREV AT ONS
ABDC ...................... After bottom dead center
ABS ........................ Anti-lock brake s stem
ACC........................ Accessories
ATDC ...................... After top dead center
ATF ......................... Automatic transaxle fluid
ATX ........................ Automatic transaxle
BBDC
...................... Before bottom dead center
BTDC ...................... Before top dead center
CM ......................... Control module
CPU ....................... Central processing unit
DEF ........................ Defroster
DOHC .................... Double over head camshaft
Dl ........................... Distributor ignition
DTC ....................... Diagnostic trouble code
EBD ....................... Electronic Brakeforce Distribution
EX ......................... Exhaust
HI ........................... High
HU ......................... ABS h draulic unit
IG ........................... Ignition
IN ........................... Intake
LED ....................... Light emitting diode
L.H.D ....................... Left hand drive
MAX ....................... Maximum
MTX........................ Manual transaxle
OFF ........................ Switch off
ON ......................... Switch on
PCM ....................... Powertrain control module
P/W CM .................. Power window control module
REC ....................... Recirculate
R.H.D
....................... Right hand drive
SAS ........................ Sophisticated air bag sensor
SST ........................ Special service tool
SW ......................... Switch
TCS ....................... Traction control s stem
TNS ....................... Tail number side lights
1G R ....................... First gear
2G R ....................... Second gear
3G R ........................ Third gear
4G R ....................... Fourth gear
5HB ....................... 5 door hatchback
G -8

SCHEDULED MA NTENANCE
SCHEDULED MA NTENANCE
SCHEDULED MA NTENANCE TABLE
Chart symbols:
I : Inspect
Inspect and clean, repair, adjust, or replace if necessar . (Oil-permeated air cleaner elements cannot be
cleaned using the air-blow method.)
R: Replace
T : Tighten
L: Lubricate
Remarks:
• To ensure efficient operation of the engine and all s stems related to emission control, the ignition and fuel
s stems must be serviced regularl . It is strongl recommended that all servicing related to these s stems be
done b an authorized Mazda Dealer.
• After the described period, continue to follow the described maintenance at the recommended intervals.
• Refer below for a description of items marked* in the maintenance chart.
*1: Also inspect and adjust the power steering and air conditioner drive belts, if installed.
*2: Replacement of the timing belt is required at ever 90,000 km (54,000 miles). Failure to replace the
timing belt ma result in damage to the engine.
*3: If the vehicle is operated under an of the following conditions, change the engine oil and oil filter ever
10,000 km (6,000 miles) or shorter.
a. Driving in dust conditions.
b. Extended periods of idling or low speed operation.
c. Driving for long period in cold temperatures or driving regularl at short distance onl .
*4: If the vehicle is operated in ver dust or sand areas, inspect and if necessar , clean or replace the air
cleaner element more often than the recommended intervals.
*5: This is a full function check of electrical s stems such as lights, wiper and washer s stems (including
wiper blades), and power windows.
*6: If the brakes are used extensivel (for example, continuous hard driving or mountain driving) or if the
vehicle is operated in extremel humid climates, change the brake fluid annuall .
Maintenance tem
Maintenance nterval (Number of months or km (miles), whichever comes first)
Months 12 24 36 48 60 72 84 96 108 120 132 144
x 1000 Km 15 30 45 60 75 90 105 120 135 150 165 180
(x 1000 Miles) 0) (18) (27) (36) (45) (54) (63) (72) (81) (90) (99) (108)
GASOUNE ENG NE
Engine valve clearance Inspect ever 90,000 km (54,000 miles).
Idle speed IIIII I
Fuel filter R R
Spark plugs
(Except for platinum-
tipped t pe)
Except for Sweden I III
For Sweden Inspect ever 50,000 km (30,000 miles).
Spark plugs (Platinum-tipped t pe) Replace ever 90,000 km (54,000 miles).
Evaporative s stem Except for Sweden I I I
For Sweden Inspect ever 80,000 km (48,000 miles).
E.G.R. s stem Except for Sweden I I I
For Sweden Inspect ever 80,000 km (48,000 miles).
DESEL ENG NE (RF Turbo)
Engine valve clearance I I I III
Fuel filter R R RR
G -9

SCHEDULED MA NTENANCE
Maintenance tem
Maintenance nterval (Number of months or km (miles), whichever comes first)
Months 12 24 36 48 60 72 84 96 108 120 132 144
x 1000 Km 15 30 45 60 75 90 105 120 135 150 165 180
(x 1000 Miles) 0) (18) (27) (36) (45) (54) (63) (72) (81) (90) (99) (108)
GASOL NE & D ESEL ENG NE
Drive belts *1 I I I I I I I I I I I I
Engine timing belt *2 Replace ever 90,000 km (54,000 miles).
Engine oil *3 R R R R R R R R R R R R
Oil filter *3 R RR R R R R R R R R R
Cooling s stem
(Including coolant level adjustment) I I III I
Engine coolant Replace at first 4 ears or 90,000 km (54,000 miles);
after that, ever 2 ears.
Air cleaner element *4 IIR I I R I I R I I R
Fuel lines & hoses I I I I I I
Batter electrol te level & specific gravit I I I I I I I I I I I 1
All electrical s stem *5 I I I I I II I I I I 1
Headlight alignment I I I I I 1
Brake & clutch pedals I I I I I I I II I I1
Clutch fluid I I I I I I I I I I I 1
Brake lines, hoses & connections I I I I I I I I I I I1
Brake fluid *6 IIIR I R I R I R
Parking brake I I I I I I I I I I I 1
Power brake unit & hoses I I I I I I I I I I I 1
Disc brakes IIIII I I I I I I 1
Drum brakes I I II I I I I I I I 1
Power steering fluid & lines I I II I I I I I I I
Steering operation & gear housing II I I I 1
Steering linkage, tie rod ends & arms I I I I I 1
Manual transaxle oil RR
Automatic transaxle fluid level I I I I I 1
Front & rear suspension & ball joints I I I I I
Driveshaft dust boots I I I I I
Exhaust s stem heat shields I I II I 1
Wheel nuts T T T T T T T T T T T T
Bolts & nuts on chassis & bod T T T T T T T T T T T T
Bod condition
(for rust, corrosion & perforation) Inspect annuall .
Tires (including spare tire)
(with inflation pressure adjustment) I I I I I I I I I I I 1
Hinges & catches L L L L L L IL L L L L
Underside of vehicle I I I I I I I I I I I 1
Road test I I I I I I I I I I I 1
Cabin air filter (if installed) R R R R R R R R R R R R
G -10

SCHEDULED MA NTENANCE
(Scheduled Maintenance Service (Specific Work Required)
Maintenance tem Specific Work Required
ENGNE
Engine valve clearance Measure clearance.
Drive belts Inspect for wear, cracks and fra ing, and check tension.
Replace drive belt.
Engine tinning belt Replace engine timing belt.
Engine oil Replace engine oil and inspect for leakage.
Oil filter Replace oil filter and inspect for leakage.
Oil b -pass filter Replace oil b -pass filter and inspect for leakage.
COOUNG SYSTEM
Cooling s stem
(including coolant level adjustment) Check coolant level and qualit , and inspect for leakage.
Engine coolant Replace coolant.
FUEL SYSTEM
Idle speed Check engine idle rpm.
Idle mixture
(for CIS & carburetor leaded fuel) Check the CO and HC concentrations (See W/M).
Choke s stem (for carburetor) Check s stem operation.
Air cleaner element Inspect for dirt, oil and damage.
Clean air cleaner element (b blowing air).
Replace air cleaner element.
Fuel filter Replace fuel filter.
Fuel lines & hoses Inspect for cracks, leakage and loose connection.
GNTON SYSTEM (FOR GASOL NE)
Initial ignition timing Check initial ignition timing.
Spark plugs Inspect for wear, damage, carbon, high-tension lead condition and mea sure plug gap.
Replace spark plugs.
EMSSON CONTROL SYSTEM (FOR GASOL NE)
Evaporative s stem Check s stem operation (See W/M), vapor lines, vacuum fitting hoses
and connection.
Throttle positioner s stem (if equipped) Check the diaphragm and s stem operation, vacuum fitting hoses and
connection.
Dash pot (for carburetor) Check s stem operation.
E.G.R. s stem Check s stem operation (See W/M), vacuum fitting hoses and connec
tion.
ELECTRCAL SYSTEM
Batter electrol te level & specific gravit Check level and specific gravit .
Batter condition Check the batter for corroded or loose connections and cracks in the
case (for maintenance free t pe).
All electrical s stem Check function of lighting s stem, windshield wiper (including wiper blade
condition) and washer and power windows.
Headlight alignment Check headlight alignment
CHASSS & BODY
Brake & clutch pedals Check pedal height and free pla .
Brake fluid Check fluid level and inspect for leakage.
Replace brake fluid.
Clutch fluid Check fluid level and inspect for leakage.
Brake lines, hoses & connections Inspect for cracks, damage, chafing, corrosion, scars, swelling and fluid
leakage.
Parking brake Check lever stroke.
Power brake unit & hoses Check vacuum lines, connections and check valve for improper attach
ment, airtightness, cracks chafing and deterioration.
Gl—11

SCHEDULED MA NTENANCE
Maintenance tem Specific Work Required
Disc brakes Test for judder and noise. Inspect caliper for correct operation and fluid
leakage, brake pads for wear. Check disc plate condition and thickness.
Drum brakes Test for judder and noise. Inspect brake drum for wear and scratches; brake lining for wear, peeling and cracks; and wheel c linder for fluid
leakage.
Manual steering gear oil Check gear oil level.
Power steering fluid & lines Check fluid level and lines for improper attachment, leakage, cracks,
damage, loose connections, chafing and deterioration.
Power steering fluid Check fluid level.
Power steering s stem & hoses Check lines for improper attachment, leakage, cracks, damage, loose
connections, chafing and deterioration.
Steering & front suspension Check free pla of steering s stem, inspect shock absorbers for correct
damping force, oil leakage, damage and looseness, and inspect coil
springs, arms, links and stabilizer for damage and looseness.
Steering operation & gear housing
Check that the steering wheel has the specified pla . Be sure to check for
changes, such as excessive pla , hard steering or strange noises.
Check gear housing and boots for looseness, damage and grease/gear
oil leakage.
Steering linkages tie rod ends & arms Check ball joint, dust cover and other components for looseness, wear,
damage and grease leakage.
Front & rear suspension ball joints Inspect for grease leakage, cracks, damage and looseness.
Manual transmissionAransaxle oil Check oil level and inspect for leakage.
Replace manual transmission/transaxle oil.
Automatic transaxle oil level Check oil level.
Automatic transmission/transaxle fluid level Check fluid level.
Automatic transmission/transaxle fluid Replace automatic transmission/transaxle fluid.
Front & rear differential oil Check oil level and inspect for leakage.
Replace front & rear differential oil.
Rear differential oil Check oil level and inspect for leakage.
Replace rear differential oil.
Transfer oil (for 4x4) Check oil level and inspect for leakage.
Replace transfer oil.
Upper arm shafts (for B-Series) Lubricate the upper arm shafts for looseness or damage.
Front & rear wheel bearing grease Remove wheel bearing and replace the grease.
Propeller shaft joints (with grease nipple) Lubricate propeller shaft joints.
Driveshaft dust boots Inspect for grease leakage, cracks, damage and looseness.
Wheel nuts Tighten wheel nuts.
Bolts & nuts on chassis & bod Tighten bolts and nuts fastening suspension components, members and
seat frames.
Bod condition
(for rust, corrosion & perforation) Inspect bod surface for paint damage, rust, corrosion and perforation.
Exhaust s stem heat shields Inspect for damage, corrosion, looseness of connections and gas leak
age.
Tires
(including spare tire)
(with inflation pressure adjustment)
Check air pressure and inspect tires for tread wear, damage and cracks;
and wheels for damage and corrosion.
Hinges & catches Lubricate hinges and catches of doors, trunk lid and hood.
Seat belts Inspect seat belt webbing for scratches, tears and wear, and check an
chor bolt tightness.
Rear suspension uni-bail & sliding rubber
bushing (for RX-7) Inspect for cracks, damage and looseness.
Underside of vehicle Inspect underside of vehicle (floor pans, frames, fuel lines, around ex
haust s stem, etc.) for damage and corrosion.
G -12

SCHEDULED MA NTENANCE
| Maintenance tem Specific Work Required
Road test Check brake operation/clutch operation/steering control/operation of me
ters and gauges/squeaks, rattles or unusual noises/engine general per
formance/emergenc locking retractors.
AR COND T ONER SYSTEM ( F EQU PPED)
Refrigerant amount Check refrigerant amount.
Compressor operation Check compressor operation, and inspect for noise, oil leakage, cracks
and refrigerant leakage.
Cabin air filter Replace cabin air filter.
4WS SYSTEM
Front & rear power steering s stem & hoses Check lines for improper attachment, leaks, cracks, damage, loose con
nections, chafing and deterioration.
4WS operation & linkages Inspect for leakage, cracks, damage and looseness.
Rear wheel steering angle Inspect for rear wheel steering angle.
Rear suspension outer ball joints Inspect for grease leakage, cracks, damage and looseness.
G -13

ENG NE
(FP, FS, FS (Hi-power)) Q
FEATURES
OU TL NE ................................................................... B1-2
OUTLINE OF CONSTRUCTION .................... B1-2
FEATURES ..................................................... B1-2
SPECIFICATIONS .......................................... B1-2
ENG NE MECHAN SM ........................................... B1-3
CYLINDER HEAD ............................................ B1-3
B1-1

OUTL NE
OUTL NE
OUTUNE OF CONSTRUCT ON
• The construction and operation of the face-lifted FP, FS, FS (Hi-power) engine models are essentiall carried
over from those of the current 626 (GF), 626 Station Wagon (GW) (FP, FS, FS (Hi-power)) engine models,
except for the following features. (See 626 Training Manual 3303-10-97D.)
FEATURES
mproved Engine Performance
• The shape of the intake port has been modified. (FP)
• The valve timing of exhaust valve has been changed from BBDC 48° to BBDC 44°, and ATDC 2° to ATDC 6°.
(FP)
• The compression ratio has been increased from 9.6:1 to 9.7:1. (FP)
SPEC F CAT ONS
tem Specification
FP FS FS (Hi-power)
T pe Gasoline, 4-c cle
C linder arrangement and number In-line, 4-c linder
Combustion chamber Pentroof
Valve s stem DOHC, timing belt driven, 16 valves
Displacement (ml {cc, cu in}) 1,840 {1,840, 112.2} 1,991 {1,991, 121.5}
Bore x stroke (mm {in}) 83.0 x 85.0
{3.27x3.35} 83.0x92.0 {3.27 x 3.62}
Compression ratio 9.7:1 9.7:1
Compression pressure (kPa {kgf/cm2, psi} [rpm]) 1,471 {15.0, 213} [300]
Valve
timing
IN Open BTDC (°) 025
Close ABDC (°) 35 48 56
EX Open BBDC (°) 44 48
Close ATDC (°) 6 2
Valve clearance
[Engine colcj] IN (mm {in}) 0.26 {0.010}
EX (mm {in}) 0.26 {0.010}
~~~l Indicates new specificatinn
B1-2