Mazda 626/MX-6 1996 Workshop Repair Manual (P/N 9999-95-019B-96)

This Mazda factory workshop manual covers the 1996 626 and MX-6 with FS and KL engines: P/N 9999-95-019B-96, Form No. 1492-10-95F, printed June 1995. Application begins at sequence 500001 for 626 VIN families 1YV GE22C*T5 and 1YV GE22D*T5, and MX-6 families 1YV GE31C*T5 and 1YV GE31D*T5.

PDF Search, Bookmarks, and Diagram Detail

Navigation and small labels: PDF text search is unavailable. Embedded bookmarks are largely unlabeled and do not provide useful chapter navigation. Small connector numbers and wire-color codes in the checked engine-control and ABS diagrams are readable with zooming.

One printable, English-language 1,730-page PDF, including three opening warning, VIN, and title/contents pages and four memo pages within the transaxle chapters.

Engine Overhaul, Transaxle Testing, and Chassis Repair

This selected coverage is only part of the manual; other topics include scheduled-maintenance tables and pre-delivery inspection checks.

• Engine repair: FS and KL removal and installation, engine-stand mounting, timing-belt and cylinder-head service, HLA and oil-seal work, and step-by-step disassembly and assembly procedures.

• Lubrication and cooling: Oil-pressure testing, oil-pump overhaul, oil-pan service, and radiator, cap, thermostat, water-pump, cooling-fan motor, and relay procedures.

• Fuel and emissions: Separate FS MTX, KL, and FS ATX sections with on-board diagnostics, component tests, quick diagnosis charts, and symptom troubleshooting.

• Transaxle service: G25M-R teardown and assembly; GF4A-EL and LA4A-EL mechanical tests, electrical checks, hydraulic circuits, valve-body service, and internal overhaul.

• Brakes and chassis: Conventional and ABS diagnosis, hydraulic bleeding, steering service, axle and drive-shaft repair, wheel alignment, and front and rear suspension work.

• Body hardware: Door, window, lock, glass, sunroof, trim, and seat removal, installation, and adjustment procedures for the applicable body configuration.

• Separate electrical/HVAC volume: Body Electrical System and Heater and Air Conditioner Systems service requires the 1996 626/MX-6 Body Electrical Troubleshooting Manual, P/N 9999-95-084F-96, which is not included.

Written with Mazda-trained technicians in mind, this manual also supports other technicians with service training, repair experience, and familiarity with general shop safety.

Internal Engine Repair and Workshop Tools

Engine and transmission configurations have separate sections so the appropriate diagnostic path, parts layout, and repair data can be selected before work begins. Compression tests and HLA troubleshooting accompany cylinder-head-gasket and front/rear oil-seal work.

Internal inspection: Cylinder-head and block procedures address valves, guides, camshafts, HLAs, pistons, rings, connecting rods, crankshafts, bearings, oil jets, and timing components. Exploded assemblies identify seals, gaskets, clips, and fasteners that require replacement; related tables supply tightening sequences, torque-angle instructions, wear limits, and clearances.

Special service tools: References include engine support 49 G017 5A0 and engine stand 49 0107 680A. Engine-stand hanger set 49 L010 1A0 and crankshaft holder set 49 E011 1A1 are identified with their applications.

The FS timing-belt cautions explain damage from twisting, reverse bending, and oil or grease contamination. FS oil-jet service warns that twisting the slide hammer can damage the block, while nozzle misalignment can damage the jet, block, and piston.

Fuel Control and Engine Electrical Diagnosis

Sections F1, F2, and F3 distinguish the fuel and emission systems by engine and transaxle configuration. They cover intake and idle-air control, KL VRIS, fuel-pressure and injector tests, EGR, EVAP, PCV, cooling-fan and A/C cut-off controls, ECM/PCM inputs, and sensor checks.

NGS-based code checks and ECM/PCM terminal-voltage tables support fault tracing alongside the symptom charts.

Diagnostic references: Vacuum-hose routing diagrams and control-system structural views support component identification. System wiring diagrams, charging/ignition/starting circuits, and the associated tests cover engine electrical faults; automatic-transaxle power-flow diagrams and ABS relationship charts extend the illustrated diagnosis to other systems.

Transaxle Overhaul and Clutch Hydraulics

G25M-R: The manual-transaxle chapter distinguishes FS and KL gearing and includes differential inspection, bearing setup, and shift-mechanism overhaul.

Automatic transaxles: GF4A-EL applies to KL engines; LA4A-EL applies to FS engines. Their chapters document line-pressure, stall, time-lag, torque-converter-clutch, range, and road tests, plus electrical signal checks and DTC diagnosis.

Internal coverage extends to valve bodies, bearing preload, clutches, bands, geartrains, and differentials. Oil-cooler and drive-plate procedures accompany complete unit overhaul, with cross-sectional views and hydraulic circuit diagrams explaining the assemblies.

Clutch service: Hydraulic bleeding and master-/release-cylinder overhaul are supported by pedal adjustments and inspection of the disc, cover, release collar, pilot bearing, and flywheel.

Axles, Steering, Brakes, and Suspension

Axle coverage distinguishes rear drum- and disc-brake arrangements and MTX double-offset versus ATX tripod drive shafts. Wheel hubs, steering knuckles, joint shafts, and transaxle-oil-seal protection are addressed alongside drive-shaft service.

Engine-speed-sensing power steering includes gear, linkage, and pump work. Brake chapters cover calipers, rear wheel cylinders, parking brakes, the ABS hydraulic unit, wheel-speed sensors, and their diagnostic circuits.

Tire service and balancing accompany front/rear alignment data. Suspension procedures cover struts, lower arms, stabilizers, control links, lateral and trailing links, and crossmembers.

Mechanical Body Service and Repair Precautions

Section S distinguishes applicable 626 and MX-6 body layouts. Window regulators, glass guides, door locks, trunk and fuel-filler lids, bumpers, grilles, mirrors, wipers, and washers have component-specific procedures.

Fixed-glass work and inner- versus outer-sliding sunroof arrangements are covered separately. Interior work includes the dashboard, console, trim, headliner, seat belts, and seats; this volume ends with section S.

Engine/transaxle lifting, pressurized fuel and cooling systems, brake hydraulics, and suspension springs require the specified support and protective equipment. Follow the manual's warnings for electrical isolation, pressure release, and supported assemblies.

Selected Oil-Pressure and Thermostat Test Data

For the FS engine, the lubrication chapter specifies 393–490 kPa at 3,000 rpm with the engine at normal operating temperature. The test notes that pressure varies with oil viscosity and temperature.

The FS thermostat inspection gives an initial-opening range of 80–84°C and a minimum full-open lift of 8.5 mm at 95°C. These checks accompany the thermostat removal, inspection, and installation material.