engine MAZDA 626 1987 Workshop Manual

TROUBLESHOOTING GUIDE 7A
TROUBLESHOOTING GUIDE
Problem Possible cause Remedy Page
Change lever won't Seized change lever ball Replace 7A-58 shift smoothly, or is Seized change control rod joint Replace 7A-58
hard to shift Bent change control rod Replace 7A-58
Too much play in Worn change control rod bushing Replace 7A-58 change lever Weak spring of ball or change lever Replace 7A-58 Worn bushing of ball or change lever Replace 7A—58
Difficult to shift Bent change rod Replace 7A—58
No grease in transmission control Lubricate with grease 7A-58
Insufficient oil Add oil 7A-6
Deterioration of oil quality Replace with oil of 7A-6 specified quality
Wear or play of shift fork or shift rod Replace 7 A—18
Wear of synchronizer ring Replace 7A-27
Wear of synchronizer cone of gear Replace 7A-27
Bed contact of synchronizer ring and cone of Replace 7A-27 gear
Excessive longitudinal play of gears Replace 7A-22
Wear of bearing Adjust or replace 7A—22
Wear of synchronizer key spring Replace 7A-27
Excessive shaft gear bearing preload Adjust 7A-37
Improperly adjusted change guide plate Adjust 7A-20
Won't stay in gear Bent change control rod Replace 7A-58
Worn change control rod bushing Replace 7A-58
Weak change lever ball spring Replace 7A-58
Improperly installed extension bar Tighten 7A-58
Wear of shift fork Replace 7A—22
Wear of clutch hub Replace 7A-27
Worn clutch hub sleeve Replace 7A-27
Worn gear sliding part of both shaft gears Replace 7A-26
Worn gear sliding part of each gear Replace 7A-26
Worn steel sliding groove of control end Replace 7 A—18
Weak spring pressing against steel ball Replace 7A-18
Excessive thrust clearance Replace 7A—33,35
Worn bearing Replace 7A—22
Improperly installed engine mount Tighten 7A—49
Abnormal noise Insufficient oil Add oil 7A-6
Deterioration of oil quality Replace 7A-6
Worn bearing Adjust or replace 7A-22
Worn gear sliding surface of both shaft gears Replace 7A—26
Wear of sliding surfaces of gears Replace 7A-26
Excessive thrust clearance Replace 7A—33,35
Damaged gear teeth Replace with oil of 7A-26
specified quality Foreign material in gears Replace 7A-22
Damaged differential gear, or excessive backlash Adjust or replace 7A—30
76G07A-005
7A-5

7A REMOVAL
REMOVAL
Fl except DOHC
76G07A-008
1. Battery
2. Main fuse block
3. Air cleaner assembly
4. Ventilation hose
5. Air hose
6. Ground(s)
7. Speedometer cable
8. Clutch release cylinder
9. Canister hose
10. Wheel
11. Splash sheild
12. Extension bar
13. Control rod
14. Stabilizer
15. Joint shaft
16. Gusset plate (rear)
17. Gusset plate (front)
18. Surge tank bracket
19. Starter
20. Under cover
21. Engine mount No.4
22. Engine mount No.2
23. Hunger rubber
24. Crossmember
7 A—10

REMOVAL 7A
DOHC
76G07A-009
1. Battery
2. Main fuse block
3. Air cleaner assembly
4. Ventilation hose
5. Air hose
6. Ground(s)
7. Speedometer cable
8. Clutch release cylinder
9. Canister hose
10. Wheel
11. Splash sheild
12. Extension bar
13. Control rod
14. Stabilizer
15. Joint shaft
16. Surge tank bracket
17. Starter
18. Engine mount No.4
19. Engine mount No.2
20. Rear member (4WS)
21. Hunger rubber
22. Crossmember
7A—11

7A REMOVAL
Carburator
76G07A-010
15. Starter
16. Engine mount No.4
17. Engine mount No.2
18. Under cover
19. Hunger rubber
20. Crossmember
1. Battery
2. Air cleaner assembly
3. Ground
4. Speedometer cable
5. Clutch release cylinder
6. Canister hose
7. Wheel
8. Splash sheild
9. Extension bar
10. Control rod
11. Stabilizer
12. Joint shaft
13. Gusset plate (rear)
14. Gusset plate (front)
7 A-12

REMOVAL 7A
RF-N and RF-CX
1. Battery
2. Air cleaner assembly
3. Vacuum hose
4. Intercooler pipe and hose
(RF-CX)
5. Electric fan
6. Speedometer cable
7. Ground(s)
8. Clutch release cylinder
9. Pressure and return hoses
(power steering)
10. Starter
11. Wheel
12. Splash shield
13. Stabilizer
14. Joint shaft
15. Extension bar
16. Control rod
76G07A-011
17. Exhaust pipe bracket
18. Water pipe
19. Gusset plate (rear)
20. Gusset plate (front)
21. Under cover
22. Engine mount No.4
23. Engine mount No.2
24. Crossmember
7 A—13

7A REMOVAL
19. Install the SST to the differential side gear.
Note
Failure to install the SST may cause the
differential side gears to become misposi-
tioned.
86U07A-027
20. Remove the gusset plates, (except DOHC)
21. Remove the under cover, (except DOHC)
22. Remove the extension bar and the control rod.
76G07A-014
23. Remove the surge tank bracket. (Fl)
24. Remove the starter.
76G07A-015
25. Suspend the engine with the SST.
86U07A-030
7 A-16

REMOVAL 7A
26. Remove the engine mount No. 4 and bracket.
86U07A-031
86U07A-032
86U07A-033
27. Remove the engine mount No. 2.
28. Disconnect the hanger rubber then remove the
crossmember and the left side lower arm as an as-
sembly.
29. Lean the engine toward the transaxle.
30. Support the transaxle with a jack.
31. Remove the remaining transaxle mounting bolts.
32. Remove the transaxle.
86U07A-034
7 A—17

INSTALLATION 7A
1. Attach rope at 2 places on the transaxle and place
a board on the jack and position the transaxle on it.
Caution
The transaxle is not well balanced; be care-
ful when positioning on the jack.
2. Move the transaxle into the place and attach the
rope (attached to the transaxle in step 1) to the
SST
86U07A-210
3. Install the transaxle onto the engine.
Note
Lift the transaxle using the jack pulling the
rope.
Tightening torque: 89—117 N-m
(9.1—11.9 m-kg, 66—85 ft-lb)
86U07A-211
4. Install the clutch pipe.
Tightening torque:
(A), (§): 19—26 N-m
(1.9—2.6 m-kg, 14—19 ft-lb)
©: 8—11 N-m
(80—110 cm-kg, 69—95 in-lb)
76G07A-054
5. Install the engine mount bracket.
Tightening torque:
55—80 N-m (5.6—8.2 m-kg, 41—59 ft-lb)
76G07A-055
7A—53

7A INSTALLATION
76G07A-056
76G07A-057
76G07A-058
/vj^C / -(S)
®
T wfryi
®
6. Install the engine mount rubber No.4.
Tightening torque:
(A): 64—89 N-m
(6.5—9.1 m-kg, 47—66 ft-lb)
(|): 67—93 N-m
(6.8—9.5 m-kg, 49—69 ft-lb)
7. Install the engine mount No. 2.
Tightening torque:

(A)
37—52 N-m
(3.8—5.3 m-kg, 27—38 ft-lb)
(§) 67—93 N-m
(6.8—9.5 m-kg, 49—69 ft-lb)
8. Install the crossmember and the left side lower arm
as an assembly.
Tightening torque: Bolts, 36—54 N-m
(3.7—5.5 m-kg, 27—40 ft-lb)
Nut, 75—93 Nm
(7.6—9.5 kg, 55—69 ft-lb)
9. Remove the jack and take off the rope.
10. Remove the SST.
11. Install the end plate.
Tightening torque: 8—11 N-m
(80—110 cm-kg, 69—95 in-lb)
12. Install the starter and harnesses.
13. Install the surge tank bracket and the gusset plate.
Tightening torque:
31—46 N-m
(3.2—4.7 m-kg, 23—34 ft-lb)
(§). 10—12 N-m
(100—120 cm-kg, 87—104 in-lb)
©. 19—30 N-m
(1.9—3.1 m-kg, 14—22 ft-lb)
(§). 43—61 N-m
(4.4—6.2 m-kg, 32—45 ft-lb)
76G07A-059
7A—54

7B OUTLINE
OUTLINE
SPECIFICATIONS
Model G4A-EL (EC-AT) G4A-HL (4-speed) Model G4A-EL (EC-AT)
FE engine F8 engine

Torque converter stall torque ratio 1.710—1.900
: 1
1.900-2.100
: 1

Gear ratio
First 2.800
Gear ratio
Second 1.540
Gear ratio Third 1.000 Gear ratio
Fourth (OD) 0.700
Gear ratio
Reverse 2.333
Final gear ratio 3.700
Number
of
drive plates/ driven plates
Forward clutch 3/3
Number
of
drive plates/ driven plates
Coasting clutch 2/2
Number
of
drive plates/ driven plates 3-4 clutch 5/5 4/4 Number
of
drive plates/ driven plates
Reverse clutch 2/2
Number
of
drive plates/ driven plates
Low and reverse brake 3/3 4/4
Servo diameter (Piston outer dia./retainer inner dia.) mm (in) 78/53 (3.07/2.09) 78/49 (3.07/1.93) 78/56 (3.07/2.20)
Speedometer gear ratio (Driven/Drive gear) 20
: 25 or
21
: 25

Automatic transmission luid
Type Dexron
n or
MED
Automatic transmission luid Capacity
liters (US qt, Imp
qt)
6.8 (7.2, 6.0)

76G07B-002
7 B—2