engine MAZDA 626 1987 Workshop Manual

INSPECTION AND REPAIR 7B
Inspection
Check the following and replace any faulty parts.
1. Damaged or worn valves
2. Damaged oil passage
3. Cracked or damaged valve body
4. Operation of each valve
5. Weakened spring
Spring

Spring name Outer dia.
mm
(in) Free length
mm (in)
Wire dia.
mm
(in) Spring color
1-2 accumulator small spring F8 engine 9.9 (0.400) 84.7 (3.335) 1.2 (0.047) Red
1-2 accumulator large spring
FE engine 13.0 (0.512) 73.2 (2.881) 1.8 (0.071) Pink 1-2 accumulator large spring F8 engine 16.0 (0.630) 84.7 (3.335) 2.0 (0.079) White
Bypass spring 5.0 (0.197) 25.1 (0.988) 0.7 (0.028) Yellow
Servo control spring 4.9 (0.193) 27.1 (1.067) 0.5 (0.020) Light blue
2-3 timing spring 8.3 (0.327) 26.5 (1.043) 0.8 (0.031)
—

N-R accumulator rear spring 11.1 (0.437) 68.2 (2.685) 1.0 (0.039) Blue
N-D accumulator front spring 9.8 (0.386) 60.9 (2.398) 1.1 (0.043) Yellow
Low reducing spring 8.7 (0.343) 38.3 (1.508) 0.9 (0.035) Black
OD release spring 6.0 (0.236) 32.6 (1.283) 0.6 (0.024) Orange
Coasting bypass spring 5.8 (0.228) 31.3 (1.232) 0.6 (0.024) Yellow
3-2 timing spring 8.2 (0.323) 28.55 (1.124) 0.8 (0.031) Maroon
3-2 capacity spring 5.55 (0.219) 30.5 (1.201) 0.55 (0.022) Light green
Throttle relief ball spring 6.6 (0.260) 20.3 (0.799) 0.8 (0.031) Light green

76G07B-165
Assembly
1. Install the 3-2 capacity valve, 3-2 capacity spring,
stopper plug, and stopper pin.
2. Install the 3-2 timing valve, 3-2 timing spring, and
retainer.
83U07B-287
3. Install the coasting bypass plug, coasting bypass
valve, and coasting bypass spring.
4. Apply ATF to the O-rings, and install them onto the
piston; then insert the N-R accumulator rear spring,
and N-R accumulator piston.
5. Apply ATF to the O-rings, and install them onto the
piston; then insert the N-D accumulator piston, and
N-D accumulator front spring.
83U07B-288
7B—161

7B ASSEMBLY
/ O-ring
17. Install the oil pump shaft.
18. Install a new O-ring onto the turbine shaft.
76G07B-194
76G07B-195
19. Fill the torque converter with ATF if it has been
drained and washed.
ATF type: Dexron II or M III
20. Install the torque converter in the converter hous-
ing while rotating it to align the splines.
Caution
a) Hold the torque converter in an erect posi-
tion when filling it with ATF, do not allow
the fluid to overflow.
b) If the converter does not fit in easily, do not
try to force it; install carefully.
21. To ensure that the torque converter is installed ac-
curately, measure distance A between the end of
the torque converter and the end of the converter
housing.
(A): approx. 25 mm (0.98 in)
22. Install the engine mount No.1
Tightening torque:
58—67
N
m (5.9—6.8 m-kg, 43—49 ft-lb)
76G07B-197
7B-214

7B INSTALLATION
1. Attach rope at 2 places on the transaxle. Place a
flat board on a jack and set the transaxle on it.
Caution
The transaxle is not well balanced; be care-
ful when positioning it on the jack.
2. Move the transaxle into place and attach the rope
to the SST.
86U07B-441
3. Mount the transaxle to the engine.
Tightening torque:
89—117
N m
(9.1—11.9 m-kg, 66—86 ft-lb)
Note
a) Lift the transaxle with the jack while pull-
ing the rope.
b) Align the torque converter bolts and drive
plate holes.
86U07B-442
4. Install engine mount No. 4 and bracket.
Tightening torque:
Bolt
36—54 Nm (3.7—5.5 m-kg, 27—40 ft-lb)
Nut
64—89
N
m (6.5—9.1 m-kg, 47—66 ft-lb)
86U07B-443
5. Install engine mount No. 2.
Tightening torque:

(A)
85—117
N
m
(8.7—11.9 m-kg, 63—86 ft-lb)
(|)67—93 Nm
(6.8—9.5 m-kg, 49—69 ft-lb)
86U07B-444
7B—216

7B INSTALLATION
86U07B-449
Standard bolt Reamer bolt
86U07B-450
86U07B-451
14. Replace the clips at the end of the driveshaft and
joint shaft with new ones.
15. Install the joint shaft and right driveshaft as follows:
(1) Remove the SST and insert the joint shaft into
the transaxle.
(2) Mount the joint shaft bracket onto the engine.
(3) Install and tighten the reamer bolts; then install
and tighten the standard bolts.
Tightening torque:
Reamer bolts 6.9—9.8 N-m
(70—100 cm-kg, 61—87 in-lb)
Standard bolts 42—62 N-m
(4.3—6.3 m-kg, 31.1—45.6 ft-lb)
(4) Pull the front hub outward to connect the
driveshaft to the joint shaft.
(5) Push the joint from the differential side to se-
curely connect the driveshaft to the joint shaft.
Caution
a) Do not damage the oil seal.
b) After installation, pull the front hub outward
to verify that the driveshaft does not come.
16. Install the left driveshaft as follows:
(1) Pull the front hub outward to insert the
driveshaft into the transaxle.
(2) Push the joint from the differential side to con-
nect the driveshaft to the differential side gear.
Caution
a) Do not damage the oil seal.
b) After installation, pull the front hub outward
to verify that the driveshaft does not come
out.
17. Install the lower arm ball joints to the knuckles and
tighten the bolts and nuts.
Tightening torque:
43—54 N-m (4.4—5.5 m-kg, 32—40 ft-lb)
18. Install the undercover.
19. Install the stabilizer bar control link as follows:
(1) Install the stabilizer bar control link.
(2) Adjust protrusion A to 20.1 mm (0.79 in).
(3) Tighten bolt B to the specified torque.
Tightening torque:
16—23 N-m (1.6—2.3 m-kg, 12—17 ft-lb)
86U07B-452
7B-218

7B INSTALLATION
27. Connect the connectors as follows:
(1) Inhibitor switch
(2) Solenoid valve
(3) Pulse generator (G4A-EL)
(4) Fluid temperature switch (G4A-EL)
28. Connect the speedometer cable.
76G07B-199
76G07B-200
76G07B-201
29. Install the fresh air duct. (G4A-HL)
30. Install the air cleaner hose. (G4A-EL)
31. Install the air cleaner assembly; then connect the
air flow meter connector and inlet hose. (G4A-EL)
Tightening torque:
Bolt
31—40 N-m (3.2—4.1 m-kg, 23—30 in-lb)
Nut
8—11 N-m (80—110 cm-kg, 69—95 in-lb)
32. Connect the distributor lead.
33. Install the main fuse block.
Tightening torque:
8—11 N-m (80—110 cm-kg, 69—95 in-lb)
34. Install the battery carrier and battery.
Tightening torque:
31—40 N-m (3.2—4.1 m-kg, 23—30 in-lb)
35. Pour in ATF and check the following:
(1) With the engine idling, check that the fluid lev-
el is between the F and L marks on the dip-
stick. (Refer to page 7B—71)
(2) Check the manual linkage, and adjust if neces-
sary. (Refer to page 7B—72)
(3) Check the inhibitor switch operation. (Refer to
page 7B—65)
(4) Conduct a road test. (Refer to page 7B—34,
35)
(5) Check that there is no fluid leakage from the
transaxle. (Refer to page 7B—71)
76G07B-202
7B—220

7C OUTLINE
OUTLINE
SPECIFICATIONS
Model F3A Model FE engine F6 engine
Torque converter stall torque ratio 1.800-2.100 : 1
Gear ratio
First 2.841
Gear ratio Second 1.541 Gear ratio
Third 1.000
Gear ratio
Reverse 2.400
Final gear ratio 3.450 : 1 3.631 : 1
Number of drive plates/ driven plates
Front clutch 3/3
Number of drive plates/ driven plates Rear clutch 4/4 Number of drive plates/ driven plates
Low and reverse brake 4/4
Servo diameter (Piston outer dia./retainer inner dia.) mm (in) 64/36 (2.52/1.42) 64/44 (2.52/1.73)
Speedometer gear ratio (Driven/Drive gear) 0.80 (20/25) 0.84 (21/25)
Automatic transaxle fluid
Type Dexron-II or M-III
Automatic transaxle fluid Capacity liters
(US qt, Imp qt) 6.2 (6.6, 5.5)
76G07C-002
7C—2

7C TROUBLESHOOTING
TROUBLESHOOTING
GENERAL NOTE
In the event of a problem with the automatic transaxle, the cause may be in the engine, powertrain,
hydraulic control system, or electrical control system. When troubleshooting, it is recommended to
begin from those points that can be judged quickly and easily. The recommended troubleshooting
sequence is described below.
STEP 1: PRELIMINARY INSPECTION Check preliminary items • ATF level and condition
• Oil leakage • Selector lever position
• Vacuum leakage
• Idle speed and ignition timing
• Tire inflation pressure • Inhibitor switch
This step checks conditions surrounding the automatic
transaxle.
STEP 2: STALL TEST Check engine stall speed This step checks the powertrain.
• Friction element slipping
• Torque converter capacity
STEP 3: TIME LAG TEST Check time lag of oil pressure supply This step checks operation of the hydraulic control system. • Friction elements slipping
• Regulating valves
STEP 4: ROAD TEST Check items on road test
• Shift point • Shift schedule
• Kick-down • Shift shock
This step checks functions of the electrical control system
and hydraulic control system.
STEP 5: OIL PRESSURE TEST Check line pressures and governor pressure This step checks major points of the hydraulic control system.
• Oil pump • Line pressure control • Governer pressure control
By following the above five steps, the cause of the problem should be located.
As another guide to faster location of the causes of problems, the Quick Diagnosis Chart is included
at pages 7C—9 to 7C—11.
In this chart, a circle is used to indicate the components that might be the cause of trouble for 54
types of problems. It is only necessary to check those components indicated by circles, at each step
of the troubleshooting process, in order to quickly locate the cause of the problem.
76G07C-012
7C—8

TROUBLESHOOTING
7C

QUICK DIAGNOSIS CHART
How
to use
Quick Diagnosis Chart
1.
The
numbers indicate
the
order
of
inspection
for
troubleshooting.
2. Circled numbers indicate that
the
transaxle must
be
removed from
the
vehicle.
76G07C-013
Transaxle ON VEHICLE OFF VEHICLE
•

\ Inspection point
\
and
reference
\ page
Condition


7C-25
7C-26
7C-23
10—21
7C—23,24
Section

4A

7C-14
7C—20,22
10—lb
10-12 10—69
7C—5
Section

5

7C—58
7C-62
7C-70
7C-71
7C-55
7C-125
7C-54 7C-71
7C-66,

98

7C-68,

71
\ Inspection point
\
and
reference
\ page
Condition

ATF

level
and
condition

Selector

lever
Inhibitor
switch
and
wiring

^

Vacuum
diaphragm
and

piping

|

Kick-down
solenoid,
kick-down
switch
and
wiring
Engine

idle

speed

and

condition

Engine
stall

speed

Fluid

pressure

(Line

and
governor)
Control
valves

Governor

valve
Band
servo
Transaxle
air
check
Ignition
switch
and
starter
Front
clutch

Rear

clutch
Brake

band

Low

and
reverse
brake

Oil
pump Hydraulic
circuit

Torque

converter

One-way

clutch
Parking

linkage

Planetary
gear

I

Engine

starting
Engine does
not
start
in
N or P
range •
2 3
1

Engine

starting
Engine starts
in
ranges other than
N
and P
ranges •
1 2

Accelerating
Vehicle does
not
move
in
D
range (moves
in 1, 2 & R
ranges) •
• •
•
Accelerating
Vehicle does
not
move
in
forward ranges (moves
in R
range)
Ex-
tremely poor acceleration •
• 5
• •
© •
•
• ©
•
• •
•
Accelerating
Vehicle does
not
move
in R
range (moves
in
forward range) Extremely poor acceleration 1
2 •
•
• •
•
3 4
•
• 5
• ©
© •
©
• ©
•
• •
•
Accelerating
Vehicle does
not
move
in any
range 1
2 •
•
• •
•
3 4
•
• 5
• •
• •
•
© ©
•
• ©
•
Accelerating Slippage felt when accelerating 1
2 •
6
• •
•ST
CO
•
•
• 5
• •
• •
•
© ©
•
• •
• Accelerating
Vehicle moves
in
N
range
Accelerating
Excessive creep
Accelerating
No creep
at all
©
© •
•
© ©
•
• •
•
Accelerating
Low maximum speed
and
poor acceleration 1
2 •
•
• 7
3
4 6
•
5 •
• ©
© ©

No shifting

Does
not
shift from
1
st to 2nd
•
1 •
2
3 •
•
• 4
5
6 7
• •
© ©
•
• ©
•
• •
•

No shifting
Does
not
shift from
2nd to 3rd
•
1 •
2
3 •
•
• 4
5
6 7
•

No shifting

Does
not
shift from
3rd to 2nd
1
• •
2
• •
•
• 3
4
5 6
• ©
• ©
•
• ©
•
• •
•
76G07C-014
7C-9

7C TROUBLESHOOTING
ON VEHICLE OFF VEHICLE
-

\ Inspection point
\ and reference
\ page
Condition


LO
(O
CO CJ OJ CM I
I I
O
O
CJ
r-~
r—
7C-27
7C—23,24
Section

4A

7C—14
7C—20,22
7C-75

CO
O)
<o
in
I
I I
o
o o
r—
r—
Section

5
CO CO
o
WON I
I I
o
o o
1— 1—
m i-
in co
S
IO
i-
1
1 1
o
o o
—
I—
7C—54
7C-71
7C-66,

98

7C—68,

71
\ Inspection point
\ and reference
\ page
Condition

A.TF

level
and

condition

Selector
lever
Inhibitor
switch
and
wiring

Vacuum

diaphragm
and

piping

Kick-down

solenoid,

kick-down

switch
and

wiring

Engine

idle
speed
and
condition
Engine
stall
speed
Fluid
pressure
(Line
and
governor)

Control

valves

Governor

valve
Band
servo

Transaxle

air
check
Ignition
switch
and

starter

Front

clutch

Rear

clutch

Brake

band

Low

and
reverse
brake
Oil pump Hydraulic
circuit
Torque
converter

One-way

clutch

Parking

linkage
Planetary
gear

No
shifting

Does
not
shift from 2nd
to
1
st or from
3rd to
1
st 1
• •
2
• •
•
• 3
4
5 6
•
No
shifting

Does
not
kick-down when accelerator
is
depressed
in 3rd
within
the
kick-down range 1
• •
3
2*
•
• 4
5
• •
• •
• ©
•
• ©
•
• •
•
No
shifting
Excessive engine speed when accelerated
in 3rd
due
to
delayed kick-down 5
• 6
• ©
• •
•
• ©
•
• •
• No
shifting

Does
not
shift from
3rd to 2nd
on
D to
2
range shift 1
2 •
5
6 •
• ©
• ®
•
• ®
•
• •
•
No
shifting

Does
not
shift from
3rd to 2nd
on
D to 1
range shift 5
7 6
• ©
• ®
•
• ®
•
• •
•

Shift

shock

Excessive
N to
D
range shift shock •
• •
2
• 1
•
3 4
•
• •
• •
© •
•
• •
•
• •
•

Shift

shock

Excessive
1
st
to
2nd shift shock 1
• •
2
• •
3
• 4
•
5 6
• •
• ©
•
• •
•
• •
•

Shift

shock

Excissive 2nd
to 3rd
shift shock •
• •
1
• •
•
2 3
•
4 5
• ©
• ©

Shift

shock

Vehicle braked when shifted from
1
st
to 2nd

Shift

shock
Vehicle braked when shifted from 2nd
to 3rd
1
• •
•
• •
•
• 3
.
2 •
•

Shift

shock

Vehicle braked when shifted
to
R range 1
• •
•
• •
•
• •
•
3 2
• •
© ©
•
• •
•
• ©
•
Shift

shock

Shift shock felt when accelerator
is
released
and
deceleration occurs •
1 •
2
3*
•
4 5
6
• •
• •
• •
•
• ©
•
• *
•

Shift

shock

Excessively large 2nd
to 1st
shift shock
in 1
range 1
• •
2
• •
3
4 5
•
• •
•
Shift

point

Excessively high
1st to 2nd
and 2nd
to
3rd shift 1
• •
2
3 •
•
4 5
6
• •
•
Shift

point

Excessively high
3rd to 2nd
and
2nd to
1
st shift point •
1 •
2
3 •
•
4 5
6
• •
• •
• •
•
• ©
•
• •
•
Shift

point
Kick-down operates
or
engine overruns when depressing
ped-
al
in 3rd
beyond kick-down speed limit
1
2 •
3
• •
•
4 5
6
• 7
•

Shift
sequence

Shifts directly from 1st
to 3rd
1
• •
•
• •
•
• 2
3
• 4
• •
• ©
•
• ©
•
• •
•

Shift
sequence
Shifts from
2nd to 1st or
2nd
to
3rd
in
2
range •
1 •
•
• •
•
2 3
•
• •
•
7C-10

TROUBLESHOOTING
7C

ON VEHICLE -OFF VEHICLE
-

\ Inspection point
\
and
reference
\ page
Condition


in cd
ra
CM CM CM
I
I I
o
o o
I—
r~—
r—
7C—27
7C—23,24
Section
4A

7C—14
7C—20,22
7C-75

CM
0>
[—
CO
LO I
I I
O
O O
r^ r—
Section

5
CD CM
O
in (D
s
I
I I
o
o o
r—
r^

w <f>
CM
r-
m f-
I
I I
o
o o
r-— I—
r-—
7C—54
7C-71
7C—66,

98

7C-68,

71 \ Inspection point
\
and
reference
\ page
Condition

ATR

level
and
condition

Selector

lever

Inhibitor

switch
and
wiring

Vacuum

diaphragm
and
piping

Kick-down
solenoid,
kick-down
switch

and

wiring

Engine

idle

speed

and
condition
Engine
stall

speed

Fluid

pressure
(Line
and
governor)
Control
valves

Governor

valve
Band
servo

Transaxle

air
check
Ignition
switch
and

starter

Front
clutch

Rear

clutch

Brake

band

Low
and

reverse

brake
Oil
pump
Hydraulic
circuit

Torque

converter

One-way

clutch
Parking
linkage

Planetary

gear

Snift
sequence

Shifts from
1st to
2nd
or
2nd
to
3rd
in 1
range

Slipping

Practically
no
shift shock,
or
slip-page while 1st
to
2nd shifting 1
2 •
3
• •
•
4 5
•
7 6
• •
• ©
•
• ©
•
• •
•

Slipping

Pracatically
no
shift shock
or
slip-page while 2nd
to
3rd shifting 1
2 •
3
• •
•
4 5
•
7 6
•

Slipping

No shift shock
or
engine runaway
in 1 to 2
range shift 1
2 •
3
• 4
5
• 6
•
• 7
• •
• ©
•
© •
•
• •
•
Slipping

Engine runaway
or
slip when shifting
3rd to 2nd
1
• •
2
• •
•
3 4
•
5 6
• ®
• ©
•
• ®
•
• •
•

Slipping

Slippage evident when vehicle starts moving 1
2 •
5
• •
•
3 4
•
• 6
• •
• •
•
® ©
•
• •
•

Noise

Transaxle noisy
in P and N
range

Noise
Transaxle noisy
in D, 2, 1 and
R ranges •
(D •
•
© •
•
© •
©

Others

No engine brake
in 1
range •
1 •
•
• •
•
2 3
•
• 4
• •
• •
©
• ©
•
• •
•

Others

Vehicle moves
in P
range
or
parking gear
not
disengaged when
P
range disengaged
•

Others
Transaxle overheats 3
4 5
•
2 6
• ®
©
(D ©
© ©
©
• •
©
Others

White smoke from exhaust while running 1
• •
2
• •
3
4 5
•
• 6
• ®
© ©
©
© ©
©
• •
@

Others

Abnormal odor from
oil
level gauge pipe ©
® ©
©
© ®
©
• •
©
76G07C-016
Differential
Problem Probable Cause Remedy Page
Noise Insufficient fluid Add 7C—25
Low fluid quality Replace with specified
ATF
7C-25
Worn bearing Adjust
or
replace 7C-79
Contact surface
of
gears worn Replace 7C-79
Tooth surface
of
gears damaged Replace 7C-79
Contaminated
ATF
Repair
or
replace 7C-25
Differential gear damaged, excessive backlash Replace 7C-79
Excessive bearing preload Adjust 7C—94
76G07C-017
7C—11