1987 MAZDA 626 Workshop Manual

TROUBLESHOOTING GUIDE 5
TROUBLESHOOTING GUIDE
Problem Possible cause Remedy Page
Starter does not turn at all, or Its turning speed Is too slow to start the engine.
Battery and related parts Poor contact of battery terminals Poor grounding of negative cable Voltage drop caused by discharged battery Insufficient voltage caused by battery malfunction
Clean and tighten Clean and repair Recharge Replace
5- 8
5- 8 5- 8
Ignition switch and related parts Poor contact of ignition switch Loose ignition switch wiring or connector Broken wire between ignition switch and magnetic switch
Replace Repair Repair or replace 5-38,45,56,66
Magnetic switch and related parts Loose wiring and/or connectors Burnt magnetic switch contact plate or improper contact Broken wire in magnetic switch pull-in coil Broken wire magnetic switch holding coil
Repair Replace
Replace Replace
5-38,45,56,66 5-43,54,64,74
5-43,54,64,74 5-43,54.64,74
Starter Poor contact of brushes
Fatigued brush spring Poor grounding of field coil Poor soldering of field coil Commutator mulfunction Grounded armature Worn parts
Adjust contact or replace Replace Replace Repair Repair or Replace Replace Replace
5-43,54,64,74
Starting problem Gasoline engine Insufficient battery capacity Malfunction of spark plug (s)
Loose positive terminal Damaged distributor cap or rotor Ignition coil malfunction laniter malfunction
Recharge Clean, adjust or replace Tighten Replace Replace Renlane
5— 8 5— 9
5—16 5—10 5-16,20
Diesel engine Insufficient battery capacity QSS svstem malfunction Recharge ReDlace 5— 8 5-76
Starter turns but pinion gear does not mesh with ring gear
Starter Tip of overrunning clutch pinion is worn Weakened overrunning clutch drive spring Worn overrunning clutch Improper sliding of spline
Worn bushing Worn ring gear
Replace Replace Replace Adjust contact and repair, or replace Replace ReDlace
5-40,54,70
Starter turns continuously (does not stop) Magnetic switch Sticking contact place of magnetic switch Layer shorting coil of magnetic switch Ignition switch does not return
Replace Replace Rfinlanfi
5-43,54,64,74 5-43,54,64,74
Misfiring Dirty or damaged spark plug (s) Malfunction of wiring, or open circuit Damaged distributor cap
Clean or replace Repair or Replace Replace
5- 9 5—10 5—16
Discharging of battery Alternator Loose drive belt Grounded or broken stator coil Broken rotor coil Poor contact of brush and slip ring
Malfunction of rectifier Malfunction of IC regulator Battery and related parts Insufficient or unsuitable battery electrolyte Malfunction of battery electrode (internal short-circuit) Poor contact of battery terminal (s) Excessive electric load
Adjust Replace Replace Clean, repair or replace Replace Replace
Adjust Replace
Clean and tighten Check power consump-tion and short circuit
5-37 5-32 5-32 5-32
5-34
5— 8 5- 8
5— 8
Overcharging of battery IC regulator malfunction Operating in extremely high temperature Replace Reoair
Poor acceleration Mis-adjusted ignition timing Distributor malfunction Adjust Repair or replace 5—11 5—11
Knocking Mis-adjusted ignition timing | Distributor malfunction Adjust Repair or replace 5—11 5—11
76G05X-003
5-7

5 BATTERY
BATTERY
INSPECTION
Terminal and Cable
1. Check the tightness of the terminals to ensure good
electrical connections. Clean the terminals and coat
them with grease after tightening the terminal.
2. Inspect for corroded or frayed battery cables.
3. Check the rubber protector on the positive termi-
nal for proper coverage.
4BG05X-006
Electrolyte Level
1. Check whether or not the electrolyte level lies be-
tween the "UPPER LEVEL" and the "LOWER
LEVEL" lines.
2. If low, add distilled water by the "UPPER LEVEL".
Do not overfill.
4BG05X-007
Specific Gravity
1. Measure the specific gravity by using a
hydrometer.
2. If the specific gravity reading is standard or less,
recharge the battery.
Standard gravity: 1.22
Fully charged gravity: 1.27—1.29
76G05X-004
RECHARGE
Quick Charge
1. Remove the battery from the vehicle.
2. Remove all the vent caps.
3. Perform a quick charge (6A or above, but max.
20 A).
4. Add distilled water if necessary while charging.
5. Cool the battery not to exceed the electrolyte tem-
perature over 55°C (131 °F) while charging.
6. Charge once more if the specific gravity is under
fully charged gravity.
4BG05X-009
5-8

SPARK PLUG 5
Slow Charge
1. Stop the engine
2. Turn all the accessories off.
3. Remove the negative battery cable.
4. Perform a slow charge (3.5A to 4.5A).
5. Add distilled water if necessary while charging.
6. Charge once more if the specific gravity is under
fully charged gravity.
4BG05X-010
SPARK PLUG
REMOVAL AND INSTALLATION
Note the following points:
1. When the high-tension lead is to be pulled off, be
sure to pull the boot itself, and not the wire.
2. Tighten the spark plugs to the specified torque.
Tightening torque: 15—23 N-m
(1.5—2.3 m-kg, 10.8—16.6 ft-lb)
76G05X-054
Wear and adhesion or cabon
INSPECTION
Check the following points. If a problem is found, re-
place the spark plug.
1. Damaged insulation
2. Worn electrodes
3. Carbon deposits
If cleaning is necessary, use a plug cleaner or a
wire brush. Clean the upper insulator also.
4. Damaged gasket
5. Burnt condition of spark insulator
6. If it is black with carbon deposits, either misfiring
due to improper proportions of gas and air or over-
heating of the plug may have occurred.
Plug gap:
FE (12VALVE) and FE DOHC Leaded fuel
model:
0.70—0.80 mm (0.028—0.031 in)
FE (8VALVE) and FE DOHC Unleaded fuel
model:
1.0—1.10 mm (0.039—0.043 in)
Others:
0.75—0.85 mm (0.030—0.034 in)
76G05X-005
5-9

5 IGNITION COIL, HIGH-TENSION LEAD
IGNITION COIL
INSPECTION
Primary Coil
Use an ohmmeter and check for resistance in the pri-
mary coil. If it is not within the specification, replace
the coil.
Primary coil resistance: (at 20°C 68°F)
FE DOHC...0.72—0.88 Q
Others 1.04—1.27 Q
76G05X-006
Secondary Coil
Use a ohmmeter to measure the resistance of the
secondary coil. If it is not within specification, replace
the coil.
Secondary coil resistance: (at 20°C 68°F)
FE DOHC 10.3—13.9 kQ
Others 7.1— 9.7 k«
76G05X-055
Insulation of Case
Use a 500V megger tester to measure the insula-
tion resistance between the primary terminal and the
case.
The standard reading is 10 MQ or more.
86U05X-046
HIGH-TENSION LEAD
INSPECTION
Measure the resistance using an ohmmeter.
Resistance: 16 kQ per 1m (3.28 ft)
5—10

DISTRIBUTOR 5
7BU05X-075
86U05X-048
76G05X-007
DISTRIBUTOR
SPARK TEST
1. Disconnect the distributor lead from the distributor.
2. Hold it with insulated pliers approx. 5—10 mm
(0.20—0.39 in) from a ground.
3. Crank the engine and check that a strong blue
spark is visible.
4. If there is no spark, the ignition coil or pick-up coil
may be bad.
Check once again after replacing the ignition coil
or pick-up coil.
IGNITION TIMING
1. Warm up the engine to the normal operating tem-
perature.
2. Turn all electric loads OFF.
3. Connect a tachometer and timing light to the
engine.
4. Connect a jumper wire between the test connec-
tor and ground. (Only for FE DOHC)
5. Check the idle speed. Set to the specified speed
if necessary.
Idle speed: 750 ± 50 rpm (FE DOHC)
800 t58 rpm (F6, F8 FE—MTX)
900 i58 rpm (F8, FE—ATX
in "P" range)
950 -5o rmp (F6—ATX
in "P" range)
6. Check that the timing mark (Yellow) on the crank-
shaft pulley and the mark on the timing belt cover
are aligned.
Ignition timing:
FE DOHC: 12 ± 1° BTDC
(Test connector grounded)
Others: 6 ± 1°
(Vacuum hoses disconnected and
plugged)
76G05X-008
5—11

DISTRIBUTOR
8.
If
the mark is not aligned, loosen the distributor lock
bolt, and turn the distributor housing to make the
adjustment.
9. Reconnect the vacuum hoses, or disconnect the
jumper wire from the test connector.
10. Tighten the distributor lock bolt to specified torque.
Tightening torque:
18.6—25.5 Nm
(1.9—2.6 m-kg, 13.7—18.8 ft-lb)
86U05X-051
SPARK CONTROL (Except FE DOHC)
Centrifugal Advance
1. Warm up the engine to the normal operating tem-
perature.
2. Check that the idle speed and initial ignition tim-
ing are correct.
3. Disconnect the vacuum hoses from the vacuum
control unit and plug them.
76G05X-009
F6
Engine Speed (rpm)
4. While gradually increasing the engine speed, use
a timing light to check the advance on the pulley.
Excess advance weak governor spring
(If the governor spring is broken,
the advance will rise very high)
Insufficient advance...governor weight or cam
malfunction
86U05X-053
F8
Engine Speed (rpm) Engine Speed (rpm)
5-12

DISTRIBUTOR 5
FE West Germany (MTX)
24c
14<
0 0) O)
a>
®
O) c a> ^
I 0 1.76° 3.36° 5.32°
Engine Speed (rpm)
FE 12 valve (Carb.)
© ©
118°
12° O) c (0
c CO
6 o 1,200 2,400 4,0005,000
Engine Speed (rpm)
FE West Germany (ATX)

oT
24' 0) a> © "D
© O) c CO JX c CO
14c
6 0 1,300 3,350 5,320
Engine Speed (rpm)
EF EGI a) ©
O) a> ©
o> c ©
C CO
O
18°
12°
1,000 2,600 4,600 5,800
Engine Speed (rpm)
F6, F8 © ©
O) © tj, ©
cn
« 8°
c a)
6 o
86U05X-054
100 (3.94) 300 (11.81)
mmHg (inHg)
Vacuum Advance
1. Warm up the engine to the normal operating tem-
perature.
2. Check that the idle speed and ignition timing are
correct.
3. Disconnect the vacuum hoses from the vacuum
control unit, and plug them.
4. Connect a vacuum pump to the vacuum control
unit.
5. Apply vacuum and check the advance with the tim-
ing light.
86U05X-055
5—13

5 DISTRIBUTOR
FE General (MTX)
© a>
|18° ©
o> c (0 J*
c CO
O o 100 (3.94)250 (9.84)
mmHg (inHg)
o> c (0
c (0
FE 12 valve (Carb.)
13e
O 0 300
(11.81) mmHg (inHg)
FE West Germany (MTX)
© ©
O) ©
© 0)10° CO
c CO 6 0
FE West Germany MTX
120 245
(4.72) (9.65) mmHg (inHg)
FE General ATX
© S> o> © •o
O) 12 © CJ) c (0
c <0
O
100 200
(3.94) (7.87) mmHg (inHg)
FEE
© ©
O) ©
© O) C cd JC c CO
20 A chamber
/200
/(7-87) Vacuum
co -8 w
300
|(11.81)
[mm Hg (in Hg)]
B chamber
REMOVAL
1. Remove the high-tension leads.
2. Disconnect the vacuum hose(s) and wiring.
3. Loosen the distributor lock bolt(s).
4. Remove the distributor.
Note
Do riot turn the crankshaft after the distribu-
tor has been removed.
76G05X-010
5—14