1987 MAZDA 626 Workshop Manual

QUICK START SYSTEM (QSS) 5
CONTROL UNIT
Inspection
1. Connect a voltmeter to the control unit as shown
in the figure.
2. Check the voltage of the terminal.
3. Replace the control unit if necessary.
Caution
If the proper voltage is not indicated on the
voltmeter, check all wiring connections and
finally, check that component.
63G05X-337
Control Unit Connector
Terminal Input Output Connection to Operation condition Voltage Remark
for 6 sec. approx. 12V
L (GW) O Glow plug relay Engine switch: ON (No cranking) after 6 sec.
OV 12V Coolant temperature; below 30°C (86°F) after 6 sec.
OV Coolant temperature; above 30°C (86°F)
H
(B) — — Ground OV
E (BW) 0 Engine switch (ON) Engine switch: ON approx. 12V
F
(BR) O Engine switch (START) Engine switch: START approx. 12V
C o
Water
temperature switch
Engine switch: ON (No cranking)
approx. 12V Coolant temperature; below 30°C (86°F)
(BrB) o
Water
temperature switch
Engine switch: ON (No cranking)
approx. OV Coolant temperature;
above 30°C (86°F)
At cranking OV <- 12V
B 0 Glow plug
For 15 sec. after engine has started OV <-> 12V Coolant temperature;
(Gr) 0 Glow plug After 15 sec. OV below 30°C (86 °F)
After engine has started OV Coolant temperature; above 30°C (86°F)
K o Indicator Engine switch: ON
For 3 sec. OV
(WR) o Indicator Engine switch: ON after 3 sec. approx. 12V
76G05X-052
u® x y i © © X 1
© © X ®
5-79

5 QUICK START SYSTEM (QSS)
Glow plug relay GLOW PLUG RELAY
Inspection
1. As shown in the figure, connect the battery and
an ohmmeter to the relay.
2.
If
the ohmmeter shows continuity when the battery
is connected, and no continuity when the battery
is disconnected, the relay is good.
3. Replace the relay if it fails this test.
4BG05X-123
GLOW PLUG
Inspection
1. Check the continuity between the positive termi-
nal of the glow plug and cylinder head with a cir-
cuit tester.
2. If there is no continuity, replace the glow plug.
4BG05X-121
Removal
Remove in the following order:
1. Glow plug connector attaching nut.
2. Glow plug connector.
3. Glow plug
Installation
Install the glow plug, reverse order of removal.
76G05X-053
63G05X-336
5-80
WATER TEMPERATURE SWITCH
Removal
Remove the water temperature switch from the
radiator.
Installation
Install in the reverse order of removal.
Inspection
1. Place the water temperature switch in water with
a thermometer and heat the water gradually.
2. Check the temperature at which continuity exists
between the terminals.
3. Replace the switch, if necessary.
Specified temperature: above 28—32°C
(82—90°F)

CLUTCH
OUTLINE 6— 2
STRUCTURAL VIEW 6— 2
SPECIFICATIONS 6— 3
TROUBLESHOOTING GUIDE 6— 3
ON-VEHICLE MAINTENANCE 6— 4
FLUID LEVEL 6— 4
PEDAL HEIGHT 6— 4
PEDAL FREEPLAY 6— 4
CLUTCH PEDAL 6— 5
REMOVAL 6— 5
INSPECTION 6— 6
INSTALLATION 6— 6
ADJUSTMENT 6— 6
CLUTCH MASTER CYLINDER 6— 7
REMOVAL 6— 7
DISASSEMBLY 6—8
INSPECTION 6— 9
ASSEMBLY 6— 9
INSTALLATION 6—11
CLUTCH RELEASE CYLINDER 6—11
REMOVAL 6—12
DISASSEMBLY 6-12
INSPECTION 6—13
ASSEMBLY 6—13
INSTALLATION 6—14
AIR BLEEDING 6—14
CLUTCH AND FLYWHEEL 6—15
REMOVAL 6—15
INSPECTION 6—16
INSTALLATION 6—19
76G06X-001

6 OUTLINE
OUTLINE
STRUCTURAL VIEW
LHD
86U06X-002
1. Clutch pedal 4. Clutch pipe 7. Clutch release bearing
2. Assist spring 5. Clutch release cylinder 8. Clutch cover
3. Clutch master cylinder 6. Clutch release fork 9. Clutch disc
6-2

TROUBLESHOOTING GUIDE 6
SPECIFICATIONS
Item Engine model F6 F8 FE FE DOHC RF-N RF-CX
Clutch control type Hydraulic
Clutch cover type Diaphragm spring
General 3,434
(350,770) 3,846
(392,862) 4,316 (440,968) 3,846
(392,862) —
Set load
N (kg, lb) ECE (Except UK) — 4,022
(410,902) 4,611 (470, 1,034) 4,022 (410, 902)
UK — 3,846
(392,862)
4,611 (470,1,034) 4,316
(440,968)
3,846 (392,862) 4,022 (410,902)
Clutch disc Outer diameter mm (in) 200 (7.874) 215 (8.465) 225 (8.858)
Inner diameter mm (in) 130 (5.118) 150 (5.906)
Pressure plate side
General 4.1 (0.16) —
Thickness Pressure plate side
ECE
(Except UK) — 3.8 (0.15)
mm(in)
Pressure plate side UK 4.1 (0.16)13.8 (0.15) 4.1 (0.16) 3.8 (0.15)
Flywheel side 3.5 (0.14)
Type Suspended
Pedal ratio LHD 6.00
Clutch pedal Pedal ratio RHD 5.96
Full stroke mm (in) 135 (5.31)
Height mm (in) 216.5-221.5 (8.524-8.720)
Master cylinder inner diameter mm (in) 15.87 (0.625)
Release cylinder inner diameter mm (in) 19.05 (0.750)
Clutch fluid type DOT-3 or DOT-4, FMVSS 116, or SAE J1703
76G06X-002
TROUBLESHOOTING GUIDE
Problem Possible Cause Remedy Page
Slipping Clutch disc facing worn excessively Replace 6—17 Clutch disc facing surface hardened or oil on Repair or replace 6-17
surface Pressure plate deformed Repair or replace 6-16 Diaphragm spring damaged or weakened Replace 6-16 Insufficient clutch pedal play Adjust 6—4 Clutch pedal does not function smoothly Repair or replace 6—4, 5 Flywheel deformed Repair or replace 6-18
Faulty Excessive runout or deformity of clutch disc Replace 6-17 disengagement Clutch disc splines rusted or worn Remove rust or 6—17 replace Oil on clutch cover facing surface Repair or replace 6-16 Diaphragm spring weakened Replace 6-16
Excessive clutch pedal play Adjust 6—4, 5
Insufficient clutch fluid Add fluid 6-4
Leakage of clutch fluid Reoair or reDlace —
Clutch vibrates Oil on clutch disc facing surface Repair or replace 6-17 when starting Torsion spring weakened Replace 6-17 Clutch disc facing surface hardened or deformed Repair or replace 6-17
Clutch disc facing rivets loose Replace 6-17 Pressure plate deformed Replace 6-16
Flywheel surface hardened or deformed Repair or replace 6-18
Loose or worn engine mount Tighten or replace —
Clutch pedal Pedal shaft not properly lubricated lubricate or replace 6-5 does not func-tion smoothlv
Abnormal noise Clutch release bearing damaged Replace 6—17 Poor lubrication of clutch release bearing sleeve Lubricate or replace 6-17
Torsion spring weakened Replace 6-17
Excessive crankshaft end play Repair Refer to Section 1 Pilot bearing worn or damaged by heat Replace 6-16
Worn pivot points of release fork • Reoair or replace 6-18
76G06X-003
6-3

6 ON-VEHICLE MAINTENANCE
6-4
ON-VEHICLE MAINTENANCE
FLUID LEVEL
1. Clean the area around the reservoir and the reser-
voir cap.
2. Check the fluid level. If the level is near or below
the "MIN" mark, add clutch fluid to the "MAX"
mark.
Fluid specification:
DOT-3 or DOT-4
(FMVSS 116, or SAE J1703)
PEDAL HEIGHT
Inspection
Measure the distance from the upper center of the
pedal pad to the firewall and ensure that the distance
is within specification.
Pedal height A:
216.5—221.5 mm (8.524—8.720 in)
Adjustment
To adjust the pedal height, loosen locknut and turn
stopper bolt or clutch switch.
PEDAL FREEPLAY
Inspection
Depress the pedal lightly by hand and measure the
freeplay to ensure that it is within specification.
Pedal freeplay: 5—13 mm (0.20—0.51 in)
Adjustment
1. Adjust the free play by loosening locknut C and
turning push rod D.
2. Check that the distance from the floor to the cen-
ter of the upper surface of the pedal pad is as
specified or more when the clutch is fully dis-
engaged.
Disengagement height B:
LHD 68 mm (2.7 in)
RHD 85 mm (3.3 in)
3. Tighten locknut C after adjustment.

CLUTCH PEDAL 6
CLUTCH PEDAL
REMOVAL
Remove in the sequence shown in the figure referring to the removal note.
1. Clip
2. Bolt and nut
3. Spring washer
4. Flat washer
5. Clutch pedal Assembly
6. Rod
7. Adjusting nut
8. Bushing
9. Spring seat
10. Assist spring
11. Spacer
12. Bushings
13. Clip
14. Pin
15. Spring seat
16. Bushing
17. Spacer
18. Bushing
76G06X-006
19. Clip
20. Wave washer
21. Pin
22. Push rod
23. Bushing
24. Stopper rubber
25. Pad
26. Clutch pedal
(p
U-U 0)
r Adjusting nut % £
/ I / Assist spring
"ci*

Removal Note
Before removing the clutch pedal, loosen adjusting
nut of the assist spring to relieve the spring tension.
76G06X-007
6-5

6 CLUTCH PEDAL
INSPECTION
Check the following, and repair or replace any faulty
parts.
1. Worn or damaged pedal bushing
2. Twisted or bent pedal
3. Worn or damaged pedal pad
76G06X-008
INSTALLATION
Install in the reverse order of removal referring to the
installation note.
Installation Note
Apply grease (lithium base, NLGI No.2) to the
bushings.
76G06X-009
ADJUSTMENT
1. Adjust the pedal height. (Refer to page 6—4.)
2. Check the pedal free play, and adjust if necessary.
(Refer to page 6—4.)
3. Adjust the installation length of the assist spring.
The installation length is adjusted by turning nut
A show in the figure and adjusting dimension B.
Standard dimension:
38.6—39.6 (1.520—1.559 in)
76G06X-010
6-6