WARNING

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-re-
lated training and experience will be at less risk when performing
servicing operations. However, all users of this 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 experi-
ence. They should be followed to reduce the risk of injury and the
risk that improper service or repair may 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 specifically designed for a specific purpose. Nonre-
commended procedures and tools should include consideration
for safety of the technician and continued safe operation of the
vehicle.

Parts should be replaced with genuine Mazda replacement

parts, not parts of lesser quality. Use of a nonrecommended
replacement part should include consideration for safety of the
technician and continued safe operation of the vehicle.
VEHICLE IDENTIFICATION NUMBERS (VIN)
626
1YV GE22C T5 500001—
*
1YV GE22D T5 500001—
*
MX-6
1YV GE 31C T5 500001—
*
1YV GE31D T5 500001—
*
1996 CONTENTS

Mazda General Information

Title Section

626/MX-6 Engine
FS

Workshop KL
FS
Manual Lubrication System
KL
FS
Cooling System
KL

FOREWORD FS (MTX)
For proper repair and maintenance, a Fuel and Emission Control KL
thorough familiarization with this manual is Systems
important, and it should always be kept in FS (ATX)
a handy place for quick and easy refer-
ence. Engine Electrical System
All the contents of this manual, includ-
ing drawings and specifications, are the Clutch
latest available at the time of printing. As G25M-R
modifications affecting repair or mainte- Manual Transaxle
nance occur, relevant information supple- GF4A-EL
mentary to this volume will be made Automatic Transaxle
available at Mazda dealers. This manual LA 4A-EL
should be kept up-to-date.
Front and Rear Axles
Mazda Motor Corporation reserves the
right to alter the specifications and con- Steering System
tents of this manual without obligation or
Braking System
advance notice.
All rights reserved. No part of this book Wheels and Tires w
may be reproduced or used in any form
or by any means, electronic or mechani- Suspension
cal—including photocopying and recording
and the use of any kind of information Body
storage and retrieval system—without per -
mission in writing. *Body Electrical System
*Heater and Air Conditioner Systems
WARRANTY
The manufacturer’s warranty on Mazda * Refer to the 1996 626/MX-6 Body Electrical Trouble-
vehicles and engines can be voided if shooting Manual (Form No.1493-10-95 F, Part
improper service or repairs are performed No.9999-95-084F-96) for servicing of the body elec-
by persons other than those at an Autho- trical components.
rized Mazda Dealer.

Mazda Motor Corporation

HIROSHIMA, JAPAN

APPLICATION: © 1995 Mazda Motor Corporation

This manual is applicable to vehicles PRINTED IN THE U.S.A. JUNE, ’95
beginning with the Vehicle Identification Form No.1492-10-95F
Numbers (VIN) shown on the following Part No.9999-95-019B-96
page.
 Gl

GENERAL INFORMATION
SAFETY INFORMATION Gl- 2
LUBRICANTS Gl- 2
JACKING POSITIONS Gl- 2
SAFETY STAND POSITIONS Gl- 2
VEHICLE LIFT POSITIONS Gl- 3
DYNAMOMETER Gl- 3
COMPRESSED AIR Gl- 3
HOW TO USE THIS MANUAL Gl- 4
ADVISORY MESSAGES Gl- 4
PREPARATION Gl- 4
REPAIR PROCEDURE Gl- 4
SYMBOLS Gl- 5
IDENTIFICATION NUMBER LOCATIONS Gl- 6
UNITS Gl- 7
ABBREVIATIONS Gl- 8
SAE STANDARDS Gl- 9
FUNDAMENTAL PROCEDURES Gl—11
PROTECTION OF THE VEHICLE Gl—11
PREPARATION OF TOOLS AND MEASURING
EQUIPMENT GI-11
SPECIAL TOOLS Gl—11
REMOVAL OF PARTS GI-11
DISASSEMBLY GI-11
REASSEMBLY GI-12
ADJUSTMENTS GI-13
RUBBER PARTS AND TUBING GI-13
HOSE CLAMPS GI-13
TORQUE FORMULAS GI-13
VISE GI-13
ELECTRICAL TROUBLESHOOTING TOOLS . . . GI-14
TEST LIGHT GI-14
JUMPER WIRE GI-14
VOLTMETER GI-14
OHMMETER GI-14
ELECTRICAL PARTS GI-15
BATTERY CABLE GI-15
CONNECTORS GI-15
TERMINALS GI-16
SENSORS, SWITCHES, AND RELAYS GI-16
WIRING HARNESS GI-17
MAIN FUSE BLOCK GI-17
FUSE BLOCK GI-17
INSTALLATION OF RADIO SYSTEM . . . GI-18
TOWING GI-19
PRE-DELIVERY INSPECTION GI-20
PRE-DELIVERY INSPECTION TABLE GI-20
SCHEDULED MAINTENANCE GI-21
MAINTENANCE TABLE (EXCEPT CANADA) . . GI-21
MAINTENANCE TABLE (CANADA) GI-24
Gl SAFETY INFORMATION

SAFETY INFORMATION
LUBRICANTS
Avoid prolonged and repeated contact with petroleum-based oils. Used oil may irritate the skin, and can
cause skin cancer and other skin disorders.
Wash thoroughly after working with oil. We recommend water soluble hand cleaners. Do not use kero-
sene, gasoline, or any other solvent, to remove oil from your skin.
If repeated or prolonged contact with oil is necessary, wear protective clothing. Soiled clothing, particu-
larly those soiled with used oils and greases containing lead, should be cleaned at regular intervals.

JACKING POSITIONS

Warning
• Improperly jacking a vehicle is dangerous. The vehicle can slip off the jack and cause serious
injury. Use only the correct front and rear jacking positions and block the wheels.

Use safety stands to support the vehicle after it has been lifted.

Front Rear
At the center of the crossmember At the center of the crossmember

SAFETY STAND POSITIONS

Front Rear
Both sides of the vehicle Both sides of the vehicle

GI-2
 SAFETY INFORMATION Gl
VEHICLE LIFT POSITIONS

Front Rear
Both sides of the side sill Both sides of the side sill

DYNAMOMETER
When test-running a vehicle on a dynamometer:
• Place a fan, preferably a vehicle-speed proportional type, in front of the vehicle.
• Connect an exhaust gas ventilation unit.
• Cool the exhaust pipes with a fan.
• Keep the area around the vehicle uncluttered.
• Watch the water temperature gauge.
COMPRESSED AIR
When using compressed air to clean or remove parts:
• Wear protective eye wear.
• Hold a rag over the opening to prevent parts from shooting out.
• Take precautions so that people around you are not struck by flying debris.

Gl-3
Gl HOW TO USE THIS MANUAL

HOW TO USE THIS MANUAL

ADVISORY MESSAGES
You’ll find several Warnings , Cautions, and Notes in this manual.

Warning
• A Warning indicates a situation in which serious injury or death could result if the warning is
ignored.

Caution
• A Caution indicates a situation in which damage to the vehicle could result if the caution is
ignored.

Note
• A Note provides added information that will help you to complete a particular procedure.

PREPARATION
This points out the needed SSTs for the service operation. It is best to gather all necessary SSTs before
beginning work.

Example:

FRONT AXLE
PREPARATION SST NUMBER USAGE
SST
49 0118 850C For
49 0118 850C For 4< removal of tie rod
removal of tie rod Puller , ball joint \ end
Puller , ball joint end

SST NAME SST ILLUSTRATION

REPAIR PROCEDURE
1. Most repair operations begin with an overview illustration. It identifies the components, shows how the
parts fit together, and describes visual part inspection. If a damaged or worn part is found, repair or
replace it as necessary.
2. Expendable parts, tightening torques, and symbols for oil, grease, and sealant are shown in the over-
view illustration.
3. Pages related to service procedures are shown under the illustration. Refer to this information when
servicing the related part.

GI-4
 HOW TO USE THIS MANUAL Gl
Example:
SHOWS SPE-
CIAL SERVICE
TOOL (SST) FOR
THE SERVICE
OPERATION
SHOWS
TIGHTENING
TORQUE
SHOWS SPECIFICATIONS
EXPENDABLE
PARTS ^

SHOWS
APPLICATION
POINT OF OIL, SHOWS
ETC.
X" TIGHTENING
TORQUE UNITS

SHOWS SHOWS VISUAL

INSPECTION
RELATED
PAGE FOR INFORMATION
SERVICE

*1: The numbers ( ®, etc.) refer to part identification and servicing procedures.

SYMBOLS
There are six symbols indicating oil, grease, and sealant. These symbols show the points of applying
such materials during service.
Symbol Meaning Kind

Apply oil New engine oil or gear oil as appropriate

Apply brake fluid FMVSS116: DOT-3

g Apply automatic transaxle fluid M-III or Dexron®!!

Apply grease Appropriate grease

Apply sealant Appropriate sealant

© Apply petroleum jelly Appropriate petroleum jelly

GI-5
Gl IDENTIFICATION NUMBER LOCATIONS

IDENTIFICATION NUMBER LOCATIONS

GI-6
 UNITS Gl
UNITS
Electrical current A (ampere)
Electric potential V (volt)
Electric power . . . W (watt)
Length mm (millimeter)
in (inch)
Negative pressure kPa (kilo Pascal)
mmHg (millimeters of mercury)
inHg (inches of mercury)
Positive pressure kPa (kilo Pascal)
kgf/cm2 (kilogram force per square centi-
meter)
psi (pounds per square inch)
Resistance £2 (ohm)
Torque N m (Newton meter)
kgf - m (kilogram force per meter)
kgf cm (kilogram force per centimeter)
ft lbf (foot pound)
in- lbf (inch pound)
Volume L (liter)
US qt (U.S. quart)
Imp qt (Imperial quart)
ml (milliliter)
cc (cubic centimeter)
cu in (cubic inch)
fl oz (fluid ounce)
Weight 9 (gram)
oz(ounce)

Conversion to SI Units (Systeme International d’Unites)

All numerical values in this manual are based on SI units. Numbers shown in conventional units are con-
verted from these values.

Rounding off
Converted values are rounded off to the same number of places are the SI unit value. For example, if
the SI unit value is 17.2 and the value after conversion is 37.84, the converted value will be rounded off
to 37.8.

Upper and lower limits

When the data indicates upper and lower limits, the converted values are rounded down if the SI unit
value is an upper limit and rounded up if the SI unit value is a lower limit. Therefore, converted values
for the same SI unit value may differ after conversion. For example, consider 2.7 kgf/cm2 in the following
specifications:

• —
210—260 kPa {2.1—2.7 kgf /cm2, 30 38 psi}
• 270—310 kPa {2.7—3.2 kgf /cm2, 39—45 psi}

The actual converted values for 2.7 kgf/cm2 are 264 kPa and 38.4 psi. In the top specification, 2.7 is used
as an upper limit, so its converted values are rounded down to 260 and 38. In the bottom specification,
2.7 is used as a lower limit, so its converted values are rounded up to 270 and 39.

GI-7
Gl ABBREVIATIONS

ABBREVIATIONS
ABDC After bottom dead center LINE LINE pressure solenoid valve duty
ABS Antilock brake system value
ACC Accessory LSW Transaxle range switch (L or 1
A/CP SW A/C pressure switch range)
ATDC . . . After top dead center M Motor
ATF Automatic transaxle fluid MAF RTN Mass airflow return
ATFT . Transaxle fluid temperature MAF V . . Mass air flow signal voltage
ATFT V Transaxle fluid temperature signal MTX ... . Manual transaxle
voltage N position Neutral position
ATX Automatic transaxle NL SW . . Neutral/clutch switch
BAC Bypass air control O/D Overdrive
BAROV Barometric pressure signal volt- O/DF LP O/D OFF indicator light
age O/DF SW O/D OFF switch
BBDC Before bottom dead center P position Park position
BDC Bottom dead center PCV ... . Positive crankcase ventilation
BLR SW Fan switch PRC Pressure regulator control
BRK SW Brake switch PRCV PRC solenoid valve
BTDC . . . Before top dead center PRGV Purge solenoid valve
CM Control module P/S Power steering
CTP SW Closed throttle position switch PWR GND Power ground
D range Drive range R Reverse
DEF SW Rear window defroster switch RH Right hand
DRL Daytime running light RH02S . Heated oxygen sensor (rear)
D SW . Transaxle range switch (D range) RH02SL Heated oxygen sensor (rear LH)
ECT V Engine coolant temperature signal RH02SR Heated oxygen sensor (rear RH)
voltage RLY Relay
EGRBV . EGR boost sensor solenoid valve RPM Engine speed
EGRP V EGR valve position signal voltage R SW Transaxle range switch (R posi-
EGRVAC EGR solenoid valve (vacuum) tion)
duty value SAS Sophisticated air bag sensor
EGRVENT EGR solenoid valve (vent) duty SHIFT A Shift solenoid A
value SHIFT B Shift solenoid B
ESPS Engine speed sensing power SHIFT C Shift solenoid C
steering SIG RTN Signal return
EX Exhaust SS1 Shift solenoid No.1
FANC . .. Coolant fan control SS2 Shift solenoid No.2
FANCH . Coolant fan control (hi) SST Special service tool
FANCN . Coolant fan, condenser fan control SSW Transaxle range switch (S or 2
FANNH . Condenser fan control (hi) range)
FH02S . Heated oxygen sensor (front) SW Switch
FH02SL Heated oxygen sensor (front LH) TCC CON Torque converter clutch control
FH02SR Heated oxygen sensor (front RH) solenoid valve
FH02SH Heated oxygen sensor heater TEN TEN terminal (Data link connector)
(front) TFT Transaxle fluid temperature
FH02SHL Heated oxygen sensor heater TNS Tail number side lights
(front LH) TP V Throttle position sensor signal
FH02SHR Heated oxygen sensor heater voltage
(front RH) TSS Turbine shaft speed
FMEM . Failure mode effects management TURBINE Input/turbine speed sensor
HDL SW Headlight switch VAF V . . Volume air flow signal voltage
HLA Hydraulic lash adjuster VPWR . . Vehicle power
HU ABS hydraulic unit VRIS . . . Variable inertia charging system
IACV Idle air control valve VRISV1 . VRIS solenoid valve No.1
IAT V Intake air temperature signal volt- VRISV2 . VRIS solenoid valve No.2
age VS Vehicle speed
IC Integrated circuit 1GR First gear
IDM Ignition diagnostic monitor 2GR Second gear
IG Ignition 3-2T/CCS 3-2 timing/coasting clutch sole-
IG SW Ignition switch noid
IGT Ignition timing 3-2TIME 3-2 Timing solenoid valve
IN Intake
INJ Fuel injection duration
INJ L Fuel injection duration (left bank)
INJ R Fuel injection duration (right bank)
INJ#1 Fuel injector (cylinder No.1)
KAM Keep alive memory
KOEO Key on engine off
KOER Key on engine running
KR Knocking retard
LH Left hand

GI-8
 SAE STANDARDS Gl
SAE STANDARDS
In accordance with new regulations, SAE (Society of Automotive Engineers) standard names and
abbreviations are now used in this manual. The table below lists the names and abbreviations that have
been used in Mazda manuals up to now and their SAE equivalents.
Previous Standard SAE Standard
Abbreviation Name Abbreviation Name Remark
Accelerator Pedal AP Accelerator Pedal
Air Cleaner ACL Air Cleaner
Air Conditioning A/C Air Conditioning
Airflow Meter VAF Volume Air Flow Sensor
Airflow Sensor MAF Mass Air Flow Sensor
Alternator GEN Generator
Transmission (Transaxle) Fluid
ATF Thermosensor
Temperature Sensor
Atmospheric Pressure BARO Barometric Pressure
VB Battery Voltage B+ Battery Positive Voltage
OC Oxidation Catalytic Converter
TWC Three-way Catalytic Converter
Catalytic Converter
Warm Up Three-way Catalytic
WU-TWC #1
Converter
Circuit Opening Relay FPR Fuel Pump Relay #2
Clutch Position CPP Clutch Pedal Position
Crank Angle Sensor CMP Camshaft Position Sensor
Crank Angle Sensor 2 CKP Crankshaft Position Sensor
Diagnosis Connector DLC Data Link Connector
Diagnosis/Seif -Diagnosis OBD On-Board Diagnostic
Direct Ignition DLI Distributorless Ignition
EC-AT Control Unit TCM
Transmission (Transaxle) Control
Module
EGI Electronic Gasoline Injection System CIS Continuous Fuel Injection System
Electronic Spark Ignition El Electronic Ignition #3
PCM Powertrain Control Module #4
ECU Engine Control Unit
ECM Engine Control Module
Engine Modification EM Engine Modification
Engine RPM Signal Engine Speed Input Signal
Evaporative Emission EVAP Evaporative Emission
Exhaust Gas Recirculation EGR Exhaust Gas Recirculation
Fan Control FC Fan Control
Feedback System CLS Closed Loop System
Flexible Fuel FF Flexible Fuel
Fuel Pump FP Fuel Pump
Fully Closed CTP Closed Throttle Position
Fully Open WOT Wide Open Throttle
Ground/Earth GND Ground
#1: Directly connected to exhaust manifold
#2: In some models, there is a fuel pump relay that controls pump speed. That relay is now called the fuel pump relay (speed).
#3: Controlled by the ECM (PCM)
#4: Device that controls engine and powertrain

GI-9
K1 SYMPTOM TROUBLESHOOTING

31 LACK OF POWER
DESCRIPTION • Performance poor under load (i.e., power down when climbing hills)
[TROUBLESHOOTING HINTS]
Inspect parts; repair, adjust, or replace malfunctioning parts as necessary
© Torque converter worn US' page K1-58
@ Powertrain burned (reverse clutch) BS= page K1-64

32 POOR FUEL ECONOMY

DESCRIPTION • Fuel economy unsatisfactory
[TROUBLESHOOTING HINTS]
Inspect parts and wiring; repair, adjust, or replace malfunctioning parts as necessary
© Torque converter clutch solenoid valve worn page K1-35
(2) Torque converter clutch control solenoid valve worn 83= page K1-35

VEHICLE DOES NOT MOVE IN D, 2, 1 RANGES, AND/OR R POSITION

.•
40
DESCRIPTION No creep at all
Vehicle does not move when accelerator pedal depressed after shifted to D, 2, 1 ranges, and/or R position
[TROUBLESHOOTING HINTS]
Inspect parts and wiring; repair, adjust, or replace malfunctioning parts as necessary
© ATF level low B3“ page K1-18
@ Selector lever installation or adjustment incorrect page K1-170
BS^ page K1-11
© Line pressure low
© Powertrain slippage
(forward clutch, coasting clutch, 3-4 clutch, 2-4 brake band, one-way clutch 1, 2, or planetary gear) B®- page K1-45
U3P
© Control valve stuck (manual valve, solenoid reducing valve) page K1-125
© Pressure control solenoid and/or shift solenoid A worn nsr page K1-35
B3f" page K1-45
© Parking mechanism worn
® Powertrain control module malfunction section F2

41 VEHICLE MOVES IN N POSITION

DESCRIPTION • Vehicle creeps in N position
• Vehicle moves when accelerator pedal not depressed
[TROUBLESHOOTING HINTS]
Inspect parts; repair, adjust, or replace malfunctioning parts as necessary
B3=
© Selector lever installation or adjustment incorrect US’
page K1-176
( 2) Powertrain burnt (forward clutch, coasting clutch) page K1-45
I®
® Control valve stuck (manual valve)
1

page K1-125

42 VEHICLE MOVES IN P POSITION

DESCRIPTION • Vehicle rolls in P position, and drivetrain TCC non operation
[TROUBLESHOOTING HINTS]
Inspect parts; repair, adjust, or replace malfunctioning parts as necessary
B3=
© Selector lever installation or adjustment incorrect page K1-170
@ Parking mechanism worn ns* page K1-45

43 EXCESSIVE CREEP

DESCRIPTION • Vehicle moves quickly in D, 2, 1 ranges, and R position (accelerator pedal not depressed)
• Excessive N to R position and N to D range shift shock felt
[TROUBLESHOOTING HINTS]
Inspect parts and wiring; repair, adjust, or replace malfunctioning parts as necessary
S"
© Engine idle speed misadjusted section F2
“ ” page K1-11
ns
© Line pressure at idle high c®” section F2
© Closed throttle position switch malfunction o® section F2
1

© Powertrain control module malfunction

K1-212