MAZDA 626 1987 Workshop Manual

ASSEMBLY 7A
86U07A-111
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86U07A-112
76U07A-284
1. Install the magnet and the differential assembly.
2. Install the primary shaft gear assembly and the
secondary shaft gear assembly together.
3. Shift to 2nd gear and position the shift fork and shift
rod assembly as shown.
Insert the spring seat and spring into the reverse
lever shaft, install the steel ball, and place a scraper
knife so that it contacts the steel ball.
With the edge of the control end against the knife,
when the control end is pushed in the direction of
the arrow in the figure so that the ball goes into
the shaft, the rod will at the same time line up with
the shift rod coupling hole in the clutch housing.
6. Set each clutch hub sleeve to the neutral position,
and tap the shift rod from above so that the steel
ball goes into the center groove (of the 3 grooves
in the control end).
7. Pull the ball part of the control end forward so that
the steel ball goes into the detent in the groove.
76U07A-119
7A—45

7A ASSEMBLY
8. Fit the crank lever in between the change arm and
the control end, and connect the crank lever shaft
to the crank lever.
9. Align the pin holes of the crank lever shaft and the
clutch housing, and insert the pin.
Note
Use a new O-ring for the crank lever shaft.
86U07A-113
10. Install the gate © and the shift rod ©, and tight-
en the gate mounting bolt.
Note
The mark (indicated by the arrow in the fig-
ure) and the gate mounting bolt hole must be
in the same direction.
76U07A-121
11. Install the reverse idle gear and the reverse idle
shaft.
12. Connect the magnet to the clutch housing.
13. Align the end of the interlock sleeve with the con-
trol lever indicated by the arrow, and, at the same
time, face the reverse idle shaft screw hole in the
direction shown in the figure.
76U07A-122
14. Apply a thin coat of sealant to the contact surfaces
of the clutch housing and transmission case, tight-
en the transaxle case installation bolts to the speci-
fied torque.
Tightening torque:
18—26 N m (1.8—2.7 m-kg, 13—18.8 ft-lb)
15. Insert the SST to driveshaft coupling hole.
7A-46

ASSEMBLY 7A
76G07A-048
86U07A-116
86U07A-117
16. Install the lock bolt 0, the guide bolt ©.
17. Install the ball, spring and lock bolt (5).
Tightening torque:
(1) 18—26
N
m
(1.8—2.7 m-kg, 13—19 ft-lb)
(2) 9—14 N-m
(90—140 cm-kg, 78—121 in-lb)
(3) 15—21 N-m
(150—210 cm-kg, 129—181 in-lb)
Note
Check that gear change operation is smooth.
18. Install the secondary 5th gear as shown.
19. Install the gear sleeve, the 5th gear and synchroniz-
er ring to primary shaft.
20. Tap in the roll pin.
21. Install the synchronizer ring and the reverse syn-
chronizer gears.
86U07A-118
7A—47

7A ASSEMBLY
22. Shift to 1st gear.
23. Lock the primary shaft with the SST.
24. Tighten new lock nuts.
Tightening torque: 128—196 N-m
(13.0—20.0 m-kg, 94—145 ft-lb)
25. Stake the lock nuts.
86U07A-119
26. Clean and coat the both surfaces and install the
rear cover.
Tightening torque: 8—11 N-m
(80—110 cm-kg, 69—95 in-lb)
76G07A-049
7A-48

INSTALLATION 7 A
INSTALLATION
(Fl
except DOHC)
Torque Specifications
31—46 N m (3.2—4.7 m-kg, 23—34 ft-lb) 5—7 N m (50—70 cm-kg, 43—61 In-lb)
10—12 N-m (100—120 cm-kg, 87—104 in-lb)
9—13 N-m (90—130 cm-kg, 78—113 in-lb)
16—27 N-m (1.6—2.8 m-kg, 12—20 ft-lb)
8—11 N-m (80—110 cm-kg, 69—95 in-lb)
64—89 N-m (6.5—9.1 m-kg, 47—66 ft-lb) 85—117 N-m (8.7—11.9 m-kg, 63—86 ft-lb)
55—80 N-m '(5.6—8.2 m-kg,41—59 ft-lb)
.—88—118 N-m (9.0—12.0 m-kg, 65—87 ft-lb)
67—93 N-m (6.8—9.5 m-kg, 49—69 ft-lb)
19—26 N-m (1.9—2.6 m-kg 14-19 ft-lb)
16—23 N-m - (1.6—2.3 m-kg, 12—17 ft-lb)
36—54 N-m (3.7—5.5 m-kg, 27—40 ft-lb)
78—117 N-m (8.0—11.9 m-kg, 58—86 ft-lb)
8—11 N-m (80—110 cm-kg 69—95 in-lb)
37—52 N-m (3.8—5.3 m-kg, 27—38 ft-lb)
36—54 N-m (3.7—5.5 m-kg, 27—40 ft-lb) 75—93 N-m (7.6—9.5 m-kg, 55—69 ft-lb)
76G07A-050
7A—49

7A INSTALLATION
INSTALLATION (DOHC)
Torque Specifications
5—7 N-m (50—70 cm-kg, 43—61 In-lb)
9—13 N-m (90—130 cm-kg, 78—113 in-lb)
31—46 N-m (3.2—4.7 m-kg, 23-
16—23 N-m (1
-34 ft-lb)
6—2.3 m-kg, 12—17 ft-lb)
16-27 N-m {1.6—2.8 m-kg, 12—20 ft-lb)
43—62 N-m (4.3—6.3 m-Rg, 31—46 ft-lb)
7—10 N-m
(70—100 cm-kg, 60—86 in-lb)
37—52 N-m (3.8—5.3 m-kg, 27—38 ft-lb)
(80—110 cm-kg, 69—95 in-lb)
88—118 N-m (9.0-12.0 m-kg, 65—87 ft-lb)
85—117 N-m
(8.7—11.9 m-kg, 63—86 ft-lb)
55—117 N-m (5.6—8.3 m-kg, 41—59 ft-lb)
67—93 N-m (6.B—9.5 m-kg, 49—69 ft-lb)
4WS & 4WS
85—117 N-m (8.7—11.9 m-kg, 63—86 ft-lb) , j 36-54 N-m W7<3.7-5.5 m-kg, [15,27-40 ft-lb)
~67--93 N-m (6.B--9.5 m-kg, 49--69 ft-lb)
11 N-m (80--110 cm-kg, 69+ -95 in-lb)
V -23 N-m (1.6 —2.3 m-kg, 12--17 ft-lb)
~78--117 N-m (6.0--11.9 m-kg, 56-66 ft-lb)
36—54 N-m (3.7—5.5 m-kg, 27—40 ft-lb)
75—93 N-m (7.6—9.5 m-kg, 55—69 ft-lb)
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7A—50

INSTALLATION
7 A

INSTALLATION (Carburator)
Torque Specifications

7 A—51

7A INSTALLATION
INSTALLATION (RF-N and RF-CX)
Torque Specifications
8—11 N-m (80—110 cm-kg, 69—95 in-lb)
31—46 N-m (3.2—4.7 m-kg, 23—34 ft-lb)
16—23 N-m (1.6—2.3 m-kg, 12—17 ft-lb)
' 16—27 N-m (1.6—2.8 m-kg, 12—20 ft-lb)
10—12 N-m (100—120 cm-kg,.. 87—104 In-lb)
19—26 N-m
7"P~.-~
(1.9-2.6 m-kg, ^F'-f 14-19 ft-lb)
8—11 N-m (80—110 cm-kgT 69—95 In-lb)
67—93 N-m (6.8—9.5 m-kg, 49—69 ft-lb)
8—11 N-m (80—110 cm-kg, 69—95 in-lb)
85—117 N-m (8.7—11.9 m-kg, 63—86 ft-lb)
64—89 N-m (6.5—9.1 m-kg, 47—66 ft-lb)
S—7 N-m (50—70 cm-kg, ^
88—118 N-m (9.0—12.0 m-kg, 12-17 ft-lb)
16-23 N-m (1.6—2.3 m-kg, 12—17 ft-lb)
78—117 N-m (8.0—11.9 m-kg, 56—86 ft-lb)
19—26 N-m (1.9—2.6 m-kg, 14—19 ft-lb) 85—117 N-m (8.7—11.9 m-kg, 63—86 ft-lb) I
67—93 N-m (6.8—9.5 m-kg, 49—69 ft-lb)
9—13 N-m (90—130 cm-kg, 78—113 in-lb)
66—85 ft-lb)
36—54 N-m (3.7—5.5 m-kg, 27—40 ft-lb)
75—93 N-m (7.6—9.5 m-kg, 55—69 ft-lb)
76G07A-053
7A—52

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)
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5. Install the engine mount bracket.
Tightening torque:
55—80 N-m (5.6—8.2 m-kg, 41—59 ft-lb)
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7A—53

7A INSTALLATION
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76G07A-057
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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