transaxle MAZDA 323 1989 Factory User Guide

REMOVAL
REMOVAL
Warning
l Release the fuel pressure. (Refer to Section F.)
PROCEDURE
1. Disconnect the negative battery cable.
2. Drain the engine coolant and transaxle oil.
3. Remove in the order shown in the figure, referring to Removal Note,
Step 1
1. Undercover and side cover
2. Air cleaner assembly 10. Cooling fan connector
3. Battery and battery cover 11. Oil cooler hose (ATX)
4. Battery carrier 12. Radiator and cooling fan assembly
13. P/S and/or A/C drive belt
5. Battery duct
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6. Accelerator cable page Bl- 6
7. Resonance chamber 14. P/S oil pump and bracket
8. Radiator hose Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page 81-29
9. Coolant reservoir hose 15. A/C compressor (if equipped)
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page 81-29
81-28

REMOVAL Bl
Step 4 -
ATX
REPLACE
13UOBl-043
1. Speedometer cable 7. Stabilizer
2. Clutch release cylinder
8. Tie rod end
Removal Note below Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page 61-32
,...............,....................
3. Shift control rod (MTX)
4. Extension bar (MTX)
5. Shift control cable (ATX)
6. Front exhaust pipe 9. Engine mount member
Removal Note ,.......................... page Bl-32
10. Driveshaft
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . page 81-32
Removal note
13UOBl-04 .4
Clutch release cylinder (MTX)
1. Remove the release cylinder pipe bracket from the transaxle.
2. Position the release cylinder away from the transaxle for eas-
ier removal with the hose still connected.
Caution
l Do not damage the pipe or hose.
81-31

Bl REMOVAL
I 03UOBi-05 I
14
‘5
03UOBl-056
Bl-32
Tie-rod end
1. Remove the cotter pin and loosen the nut so that it flushes
with the ball joint edge.
2. Separate the knuckle arm and ball-joint with the
SST.
Caution
l Do not reuse the cotter pin.
Engine mount member
1. Suspend the engine with a chain block.
2. Remove the No.1 and No.2 engine mount nuts.
3. Remove the engine mount member bolts and nuts and the
engine mount member.
Caution
l Be careful so that the engine does not fall when
removing the member.
Driveshaft
1. Remove the bolts and nuts at the left and right lower arm
ball joints.
2. Pull the lower arm downward to separate them from the
knuckles.
Caution
l Do not damage the ball joint dust boots.
3. Separate the driveshafts from the transaxle by prying with
a bar inserted between the shaft and the case.
Caution
l Do not damage the oil seal.

REMOVAL Bl
1 Step 5
I
1. Dynamic damper
2. No.3 engine mount rubber
3. No.4 engine mount rubber and bracket 4. Engine and transaxle assembly
Removal note . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..‘....... below
I 03UOBl-059
Removal note
Engine and transaxle assembly
Caution
l Do not damage any components in the engine com-
partment.
1. Lift the engine and transaxle assembly out as a unit.
Bl-33

REMOVAL
Step 6
Separate the engine and transaxle in the order shown in the figure.
MTX BP SOHC
ATX
BP SOHC
--
03UOB1-060
1. Intake manifold bracket 5. Integrated stiffener (B6 engine)
2. Starter and bracket 6. Torque converter nuts (ATX)
3. Throttle cable (ATX) 7. Transaxle mounting bolts
4. No.2 engine mount rubber and bracket 8. Transaxle
01-34

INSTALLATION
03UOBl-17
No.2 ENGINE /I Ill
03UOBl-171
DYNAMIC DAMPER
03UOBl-17;
03UOBl-178
ATX
1 03UOBl.179
91-96
Engine and transaxle assembly
1. Suspend the engine and transaxle assembly.
Caution
l Do not damage any components in the engine com-
partment.
2. Align the No.1 and No.2 engine mount bolts with the en-
gine mount member mounting holes.
Engine mount
1. Install the No.1 engine mount nut and tighten.
Tightening torque:
37-52 N-m (3.8-5.3 m-kg, 27-38 f&lb)
2. Install the No.2 engine mount nut and tighten.
Tightening torque:
37-52 N-m (3.8-5.3 m-kg, 27-38 ft-lb)
3. Install the engine mount rubber with new washer and tight-
en nut @.
Tightening torque:
74-103 N.m (7.5-10.5 m-kg, 54-76 ft-lb)
4. Install the bolt @, while aligning the engine location and
tighten nut (I!$.
Tightening torque:
67-93 N-m (6.8-9.5 m-kg, 49-69 ft-lb)
5. Install the dynamic damper.
Tightening torque:
55-80 N.m (5.6-8.2 m-kg, 41-59 ft-lb)
6. Install the No.4 engine mount rubber and bracket and loose-
ly tighten nuts @.
7. Align the bracket bolt holes with the body side holes, and
install the bolt @and tighten in the sequence shown in the
figure.
Tightening torque:
43-61 N-m (4.4-6.2 m-kg, 32-45 f&lb)
8. Tighten the nuts @.
Tightening torque: 67-93 N.m (6.6-9.5 m-kg, 49-69 ft-lb)

Bl INSTALLATION
Tie-rod end
1. Install the tie-rod end to the knuckle.
Tightening torque:
42-57 N-m (4.3-5.8 m-kg, 31-42 ft-lb)
2. Install the new split pin.
03UOBl.183
,I / 03UOBl-18
Stabilizer
1. Install and adjust the stabilizer.
Dimension @: 17-19mm (0.67-0.75 in)
Extension bar (MTX)
1. Install the extension bar to the transaxle.
Tightening torque:
31-46 N-m (3.2-4.7 m-kg, 23-34 ft-lb)
Shift control rod (MTX)
1. Install the shift control rod to the transaxle.
Tightening torque:
16-23 N.m (I .6-2.3 m-kg, 12-l 7 ft-lb)
Clutch release cylinder (MTX)
1. Install the clutch release cylinder.
Tightening torque:
16-23 N#m (I .6-2.3 m-kg, 12-17 ft-lb)
2. Set the pipe bracket in position.
Tightening torque
@: 6.9-9.8 N.m (70-100 cm-kg, 61-87 in-lb)
@: 16-23 N.m (I .6-2.3 m-kg, 12-17 ft-lb)
Shift control cable (ATX)
1. Install the shift control cable to the transaxle.
Tightening torque:
6.9-l I N-m (70-l IO cm-kg, 61-95 in-lb)
81-98

INSTALLATION
OWOBX-27!
Resonance chamber
1. Install the resonance chamber.
Tightening torque:
7.8-l 1 N-m (80-I 10 cm-kg, 69-95 in-lb)
Undercover and side cover
1. Install the undercover and side cover.
Steps After Installation
1. If the engine oil was drained, fill with the specified amount and type of engine oil.
(Refer to Section D.)
Accelerator cable
1. Install the accelerator cable.
2. Adjust the cable deflection by turning nut @.
Deflection: I-3mm (0.04-0.12 in)
Battery duct, battery carrier, and battery
1. Install the battery duct.
Tightening torque:
7.8-l 1 N-m (80-l 10 cm-kg, 69-95 in-lb)
2. Install the battery carrier.
Tightening torque:
7.8-11 N.m (80-110 cm-kg, 69-95 in-lb)
3. Install the battery and the battery bracket.
Tightening torque:
2.9-5.9 N*m (30-60 cm-kg, 26-52 in-lb)
Air cleaner assembly
1. Install the air cleaner assembly.
lightening torque
@: 19-25 N-m (1.9-2.6 m-kg, 14-19 ft-lb)
@: 7.8-l 1 N-m (80-I 10 cm-kg, 69-95 in-lb)
2. Connect the airflow sensor connector.
2. Fill the radiator with the specified amount and type of engine coolant.
(Refer to Section E.)
3. If the transaxle oil was drained, fill with the specified amount and type of transaxle oil.
(Refer to Sections J, K.)
4. Connect the negative battery cable.
5. Start the engine and check the following
(1) Engine oil, transaxle oil, and engine coolant leakage.
(2) Ignition timing, idle speed. (Refer to page 61-8.)
(3) Operation of emission control system.
6. Perform a road test,
7. Recheck the engine oil and engine coolant levels.
.-’
23UOBl-057
81-102

B2 ON-VEHICLE MAINTENANCE
Harnesses
1, Disconnect the harness connectors shown in the figure.
.~
DISTRBUTOR
GRqUND
B2-18
Water bypass pipe
1. Remove the transaxle installation bolt as shown in the figure.
2. Remove the exhaust manifold nut as shown in the figure.
3. Remove the water bypass pipe from the cylinder head as-
sembly.
Timing belt
Note
l Remove all spark plugs for easier rotation of the
crankshaft.
1. Turn the crankshaft and align the marks.

B2 ON-VEHICLE MAINTENANCE
REAR OIL SEAL
Replacement
1. Disconnect the negative battery cable.
2. Remove in the order shown in the figure, referring to
Removal Note.
3. install in the reverse order of removal, referring to Installation Note.
t
I 1
ITX 16-26 (1.6-2.7, 13-20)

L
\TX
N.m (m-kg, ft-It 0
23UOBZ-027
1. Transaxle
MTX
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section J2
ATX
Service . . . , . . . . ,.......................... Section K
2. Clutch cover, clutch disc (MTX)
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section H
3. Flywheel (MTX)
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . below
Installation Note .,.....,..,............. page 82-29 4. Drive plate (ATX)
Removal Note ..,........................ page B2-29
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page 62-30
5. Oil seal
Removal Note .,......................... page 52-29
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page B2-29
23UOB2-05
82-28
il
Removal note
Flywheel (MTX)
1. Hold the flywheel with the SST or equivalent.
2. Remove the flywheel lock bolts.
3. Remove the flywheel.