1987 MAZDA 626 alternator

ALTERNATOR 5
Adjusting bar bolt
Mounting bolt
Alternator
drive pulley
Mounting bolt
Drive pulley
76G05X-037
-Adjusting bolt
tidier pulley
v v Ml/v — Locknut
/
Alternator x
V-BELT TENSION (GASOLINE)
Adjustment
1. Loosen the alternator mounting bolt and adjusting
bar bolt.
2. Adjust the alternator belt deflection while pushing
the V-belt with a force of 98 N (10 kg, 22 ft-lb).
Deflection:
New: 6—8 mm (0.24—0.31 in)
Used: 7—9 mm (0.27—0.35 in)
3. Tighten the bolts and recheck the tension.
V-BELT TENSION (DIESEL)
Adjustment
1. Looson the alternator idler pulley locknut.
2. Adjust the alternator belt deflection while pushing
the V-belt with a force of 98 N (10 kg, 22 ft-lb).
Deflection:
Alternator
New: 8—10 mm (0.31—0.39 in)
Used: 9—11 mm (0.35—0.43 in)
76G05X-038
—" , ^Comprex pulley
/ Locknut
/ ^"Wvl If Adjusting bolt^
Idler pulley
Alternator pulley—-V-
(rear) >
Comprex
New: 4.0—5.0 mm (0.16—0.20 in)
Used: 4.5—5.5 mm (0.18—0.21 in)
3. Tighten the bolts and nuts and recheck the tension.
76G05X-058
5—37

1 0 ELECTRICAL COMPONENTS OF 4-WHEEL STEERING
flashes
Replace control unit
4WS-9 Failure of control unit, alternator, or wiring harness
Start engine,
I
Check voltage between terminal of control unit con-nector and body ground.
Terminal Voltage
G(B) OV
H (B) OV
K(G) Approx. 12V
L (G) Approx. 12V
N(B) OV
OK
NG
Check 4WS relay and timer (Refer to page 10—103) -
OK
Check battery, harness, and alternator.
NG
Turn ignition switch OFF. Start engine. Check if 4WS warning light flashes or illuminates.
NO
Momentary problem (If warning light often flashes or illuminates, check battery and alter-nator. Replace control unit if necessary).
YES
Replace control unit.
Replace relay and timer
76G10X-031
4WS WARNING LIGHT
1. Turn the ignition switch OFF.
2. Turn the ignition switch ON, and check that the
4WS warning light illuminates.
3. If there is no illumination, check the warning light
bulb and wiring harness.
Replace the control unit if necessary.
86U10X-232
10-102

1 1 ANTI-LOCK BRAKE SYSTEM (ABS)
Troubleshooting Main Flow Chart
Check that the ABS warning light operates.

• Turn ignition switch OFF
to
ON, and check that ABS warning light illuminates constantly.

Flashing (Past failure)
OK
Check the ABS for failure.
• Start engine, and observe flashing
of
warning light.
Does not
illuminate
constantly
Warning light Possible cause
Does
not il-

luminate
at all

Refer
to
page 11—86.

ON
Alternator
L
ter-minal output Wiring harness (ALT-control unit) Control unit

OFF
1 sec

Alternator
L
ter-minal output Wiring harness (ALT-control unit) Control unit

ON
Relay box wiring harness (warning light-control unit) Control unit

OFF
1 sec

Relay box wiring harness (warning light-control unit) Control unit

No illumination
(Not diagnosed)
Illuminates constantly
(Present failure)
ABS is usually operating cor-rectly.
Consult table below when ABS failure
is
still suspected.
System Possible cause
ABS Brake light switch
Both rear wheel speed sensors
Control unit Proportioning
valve
in hy-
draulic unit
Other than Refer
to

ABS troubleshoot-ing guide
on

page 11—5.

Repair failures with flow
chart. (Refer to page
11—76.)
76G11X-054
11-74

ANTI-LOCK BRAKE SYSTEM (ABS) 1 1
Diagnosis Table
Note
Flashing of the warning light shows past failure, and its illumination shows present failure.
Diagnosis indication Possible failure Flow chart
No. Warning light Voltmeter Possible failure Flow chart
No.
ON
n
i2vn
OV

Hydraulic unit Harness
Right front wheel speed
sensor ABS-1
ON
n nn
Hydraulic unit Harness Left front wheel speed sensor ABS-2

OFF

Hydraulic unit Harness Left front wheel speed sensor ABS-2

OFF
nnn

Hydraulic unit Harness
Rear wheel speed sensor ABS-3

n
nnnn
Right front sensor rotor ABS-4

n
nnnnn
Left front sensor rotor ABS-5

JLilTUITLTL
Right rear sensor rotor ABS-6

jirLruiJum
Left rear sensor rotor ABS-7

J n
Hydraulic unit Harness
Control unit connector (11-pin)
ABS-8

nnnn

Hydraulic unit Harness
Control unit connector (11-pin)
ABS-8

J nn

Relay box
Hydraulic unit
Harness
ABS-9

jumruiTL

Relay box
Hydraulic unit
Harness
ABS-10

j nnn
Relay box
Hydraulic unit
Harness
ABS-11

jinnjuuL

Relay box
Hydraulic unit
Harness ABS-12

j nnnn

Relay box
Hydraulic unit
Harness
ABS-13

jiruuirirL

Relay box
Hydraulic unit
Harness
ABS-14

j nnnnn
Hydraulic unit Harness Control unit
ABS-15

juuuiruL

Hydraulic unit Harness Control unit ABS-16

j JinjiruifL.
Control unit
ABS-17

jiruinjiri—
JinjiruifL.
Control unit
ABS-18

j
No signal; failure condi-tions not stored
in
memory
Control unit Control unit connector (17-pin) Battery capacity Alternator output voltage Wiring harness (warning light-control unit-check connector)
Inspect, and repair or replace as necessary
j
No signal; failure condi-tions not stored
in
memory
No problem When warning light does
not
illuminate with engine running and
no
jumper wire

76G11X092
11-75

ANTI-LOCK BRAKE SYSTEM (ABS) 1 1
CONTROL UNIT CIRCUIT
Inspection of Control Unit Circuit
1. Start the engine, and run it for 10 seconds.
2. Disconnect the connectors from the control unit. Check the connector at the harness side as shown
in the table below.
Terminal Connection or measured item Check item Tester connection Condition Voltage or
resistance

Q-01 11 -pins
2A (W),
2B (R)
Wheel speed sensor
Left front Voltage (AC) 2A (W)
- 2B
(R) Turn wheel
1
revolution
per second More than 0.25V (AC)
Q-01 11 -pins
2A (W),
2B (R)
Wheel speed sensor
Left front
Resistance
2A (W)
- 2B
(R)

—
800-1.2000
Q-01 11 -pins
2C (Y),
2D
(0)
Wheel speed sensor
Right front Voltage (AC) 2C (Y)
-
2D (0) Turn wheel
1
revolution
per second More than 0.25V (AC)
Q-01 11 -pins
2C (Y),
2D
(0)
Wheel speed sensor
Right front
Resistance
2C (Y)
-
2D (0)

—
800-1,2000
Q-01 11 -pins 2E (YG),
2F (YL)
Wheel speed sensor
Left rear Voltage (AC) 2E (YG)
- 2F
(YL) Turn wheel
1
revolution
per second More than 0.25V (AC) Q-01 11 -pins 2E (YG),
2F (YL)
Wheel speed sensor
Left rear
Resistance
2E (YG)
- 2F
(YL)

—
800-1,200G
Q-01 11 -pins
2H (G).
2J
(L)

Wheel speed sensor
Right rear Voltage (AC) 2H (G)
- 2J
(GR)
Turn wheel
1
revolution
per second More than 0.25V (AC)
Q-01 11 -pins
2H (G).
2J
(L)

Wheel speed sensor
Right rear
Resistance
2H (G)
- 2J
(GR)

_
800-1,200fl
Q-01 11 -pins
21 (GR) Low pressure switch Continuity 21 (GR)
-
Ground
—
Continuity
Q-01 11 -pins
2K (LB) High pressure switch Continuity 2K (LB)
-
Ground
—
Continuity
Q-01 11 -pins
2L (WB) Alternator output Voltage 2L (WB)
-
Ground Run engine Approx.
14V

Q-01
17-pins
A (WG) Brake light switch Voltage A (WG)
-
Ground Depress brake pedal 12V
Q-01
17-pins
B (RY) Motor Continuity B (RY)
—
Ground
—
Continuity
Q-01
17-pins
C (LO) Motor relay Resistance C (Lo)(© test-lead)-J
—
Approx. 60—700
Q-01
17-pins
D (GR) Check connector Continuity D (GR)
- A
(GR, Q-07)
—
Continuity
Q-01
17-pins
E (BL) Fail-safe relay Resistance E (BL)
- G
(BG)
—
Approx. 70-800
Q-01
17-pins
F (LY) Warning light Continuity F (LY)
-
Ground
—
Continuitv Q-01
17-pins G (BG) Battery Voltage G (BG)
—
Ground Turn ianition
SW ON
12V Q-01
17-pins H (GB) Check connector Continuitv H (GB)
- B
(GB. Q-07)
—
Continuitv
Q-01
17-pins
J (YG) Solenoid valve
Resistance
JfYG)
- K
(Br)

-
Approx.
5.5—7.00
Q-01
17-pins
K (Br) Solenoid valve
Resistance
JfYG)
- K
(Br)

-
Approx.
5.5—7.00
Q-01
17-pins
M (YR) Solenoid valve Resistance M (YR)
- 0
(BW)
-
Approx.
5.5—7.00
Q-01
17-pins
0 (BW) Solenoid valve Resistance M (YR)
- 0
(BW)
-
Approx.
5.5—7.00
Q-01
17-pins
Q (YW) Solenoid valve
Resistance
Q (YW)
- R
(L)

-
Approx.
5.5—7.00
Q-01
17-pins
R (L) Solenoid valve
Resistance
Q (YW)
- R
(L)

-
Approx.
5.5—7.00
Q-01
17-pins
L (B)
Ground circuit Continuity
L (B)
—
Ground
Continuity
Q-01
17-pins
N
(B)
Ground circuit Continuity N (B)
—
Ground Continuity
Q-01
17-pins
P (B)
Ground circuit Continuity
P (B)
—
Ground
C (B.Q-07)
-
Ground
Continuity
4-pins C(B)
Ground circuit Continuity
P (B)
—
Ground
C (B.Q-07)
-
Ground
Continuity

Control Unit Connector View from harness side
Q-01 (11-pin)

LB
GR YG Y W
>1 ,1 U;.l Ki -X
1 L G VL rf
Q-01 (17-pin)
Q-01 ABS Control Unit [R]
YW BW YR Br 8G BL LO WG
icL olL
MIL
ICL G(=L tl ij^" llyl
>1
CjJ
Lt|J JCjJ fiC|3 H«|3
L B B B ffi SB L* GS RY
Check connector (4-pin)
Q-07 Check Connector [RJ
B GR
LY GB
86U11X-199
11—99

WARNING LIGHT AND SENDER 1 5
Alternator Warning Light
86U15X-050
S6U15X-051
Stop And Tail Light Malfunction Warning Light
76G15X-035
15-33

TECHNICAL DATA 30
Item Engine model RF-CX RF-N
Connecting rod and connecting rod bearing

Length (Center
to
center) mm (in) 151.95-152.05 (5.9823—5.9862)
Maximum twisting and bending mm (in) 0.080 (0.0031)
per 50
(1.969)
Small end bushing inner diameter mm (in) 30.014-30.030 (1.1817-1.1823) 25.014-25.030 (0.9848-0.9854)
Big end bore mm (in) 54.002-54.017 (2.1261-2.1266)
Big end width mm (in) 25.900—26.100 (1.0197—1.0276)
Connecting rod side clearance mm (in) Standard 0.11-0.262 (0.0043-0.0103) Connecting rod side clearance mm (in) Maximum 0.30 (0.012)

Crankshaft

Crankshaft runout mm (in) 0.05 (0.002) max.
Standard Standard 59.937-59.955 (2.3597-2.3604)
size Minimum 59.89 (2.358)
0.25 (0.010) Standard 59.687-59.705 (2.3499-2.3506)
Main journal diameter undersize Minimum 59.64 (2.348) mm (in) 0.50 (0.020) Standard 59.437-59.455 (2.3400-2.3407)
undersize Minimum 59.39 (2.338)
0.75 (0.030) Standard 59.187-59.205 (2.3302-2.3309)
undersize Minimum 59.14 (2.328)
Main journal taper and out-of-round mm (in) 0.05 (0.002) max.
Standard Standard 50.940-50.955 (2.0055—2.0061)
size Minimum 50.89 (2.004)
0.25 (0.010) Standard 50.690-50.705 (1.9957-1.9963)
Crankpin diameter undersize Minimum 50.64 (1.994) mm (in) 0.50 (0.020) Standard 50.440-50.455 (1.9858—1.9864)
undersize Minimum 50.39 (1.984)
0.75 (0.030) Standard 50.190-50.205 (1.9760-1.9766)
undersize Minimum 50.14 (1.974)
Crankpin taper and out-of-round mm (in) 0.05 (0.002) max.

Main bearing

Main journal bearing
oil
clearance Standard 0.031-0.050 (0.0012-0.0020)
mm (in) Maximum 0.08 (0.0031)
Available undersize bearina mm fin) 0.25 (0.010), 0.50 (0.020), 0.75 (0.030)

Crankpin bearing

Crankpin bearing
oil
clearance mm (in) Standard 0.027-0.055 (0.0011-0.0022) Crankpin bearing
oil
clearance mm (in) Maximum 0.08 (0.0031)
Available undersize bearing mm (in) 0.25 (0.010), 0.50 (0.020), 0.75 (0.030)

Thrust bearina (center main bearina)

Crankshaft end play mm (in) Standard 0.04-0.282 (0.0016—0.0111) Crankshaft end play mm (in) Maximum 0.30 (0.012)
Bearing width mm (in) Standard size 2.00-2.05 (0.0787-0.0807) Bearing width mm (in) Oversize 2.175-2.225 (0.0856-0.0876)

Timing belt

Deflection mm (in)/N (ka,
lb)
9.0-11.5 (0.35--0.45V98 (10,
22)
Drive belt deflection

Alternator mm (in) New 8-10 (0.31-0.39) Alternator mm (in) Used 9-11 (0.35-0.43)
A/C compressor mm (in) New 8.5-9.5 (0.33-0.37) A/C compressor mm (in) Used 9.5-10.5 (0.37-0.41)
Vacuum pump mm (in) New 7.5-8.5 (0.30—0.33) Vacuum pump mm (in) Used 8.5-9.5 (0.33-0.37)
P/S pump with vacuum pump mm (in) New 6.5-7.5 (0.26—0.30) P/S pump with vacuum pump mm (in) Used 7.0-8.0 (0.28—0.31)
Pressure wave supercharger
mm
(in) New 4.0-5.0 (0.16-0.20) Pressure wave supercharger
mm
(in) Used 4.5-5.5 (0.18-0.22)

30—13

TECHNICAL DATA 30
5. ENGINE ELECTRICAL SYSTEM
Gasoline Engine
——— Engine
F6 F8 FE FE FE
Item ____ F6 F8 (8 VALVE) (12 VALVE) (DOHC)

Battery
Voltage
Type and capacity
12, Negative ground
(20 hour rate) 34B19L(S) (33 Ah): General 50D20L (50 Ah), 55D23L (60 Ah):
ECE

Alternator
Type A.C.
Output V-A 12-70
Regulator type Transistorized (built-in
IC
regulator)
Regulated voltage 14.1-14.7
Brush length
mm (in) Standard 16.5 (0.650)
Minimum 8.0 (0.315)
Drive belt tension
mm (in)/98
N (10
kg,
22 lb)
New:
6-8
(0.24-0.32), Used:
7-9
(0.28—0.35)
Starter
Type Coaxial reduction: Middle East
&
General (FE
•
carburetor)
Non-reduction: Others
Output V-kW 12-0.85
Brush length mm (in)
12-0.95
Standard 17.0 (0.669)
Minimum 11.5 (0.453)

Unleaded fuel

17,0 (0.669)

Others

17.5 (0.689)

Unleaded fuel
11.5 (0.453)
Others
10.0 (0.394)

12-1.4 12-0.95
17.0 (0.669)
11.5 (0.453)
Ignition timing 6
±
1
°
BTDC (Vacuum hose disconnected) 12
±
1° BTDC
(Test connector
grounded)
Distributor
Type Fully transistorized (HEI)
Electronic spark advance
Centrifugal 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)—Carburetor 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)—Carburetor -2-2/1,200 10-14/2,400 10-14/4,000 16-20/5,000
FE—Fuel injection (except
FE
DOHC)
-2-2/1,000 10-14/2,600 10-14/4,600 16-20/5,800

30—23