torque MAZDA 626 1987 Workshop Manual

5 DISTRIBUTOR
INSTALLATION
Note
After installing the distributor, adjust the ig-
nition timing (Refer to 5—11).
1. Apply engine oil to the O-ring and driven gear.
76G05X-056
Note
Gear driven type, check that the No.1 cylin-
der is at top dead center and aline the distrib-
utor matching marks.
76G05X-016
2. Install the distributor and connect the high-tension
leads and distributor connector.
3. Tighten lock bolt to the specified torque.
Torque specification:
19—25 Nm (1.9—2.6 m-kg, 14—18 ft-lb)
86U05X-064
5—18

ALTERNATOR 5
Stopper spring
Rear bearing
86U05X-026
86U05X-027
86U05X-028
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ASSEMBLY
Assemble in the reverse order of disassembly, refer-
ring to assembly note.
Assembly Note
Stopper spring installation
1. Fit the stopper spring into the eccentric groove of
the rear bearing circumference.
2. Check that the protruding part of the spring is fitted
into the deepest part of the groove.
Front bracket and rotor
When assembling the front bracket and rotor, tight-
en the locknut to the specified torque.
Tightening torque:
49—88 N-m (5—9 m-kg, 36—65 ft-lb)
Brush lifting
1. Before assembly, use a finger to hold the brushes
into the brush holder; then pass a wire
(2
mm,
40—50 mm, 00.08 in, 1.6—2.0 in) through the
hole shown in the figure.
2. Secure the brushes in position.
Note
Be sure to remove wire after assembly is com-
pleted.
Rear bearing installation
1. Heat the rear bracket.
2. Press the rear bearing into the rear bracket.
3. Check that the rotor turns easily.
4BG05X-054
5-35

5 ALTERNATOR
INSTALLATION
Note
When installing the alternator, tighten the
bolts to the specified torque.
Install in the reverse order of removal.
Tightening torque:
Bolt (1) 37.3—52 N-m
(3.8—5.3 m-kg, 27.5—38.3 ft-lb)
Bolt (2) 18.6—25.5 Nm
(1.9—2.6 m-kg, 13.7—18.8 ft-lb)
69G05X-018
Nut 37—52 N-m
(3.8—5.3 m-kg, 27.5—38.3 ft-lb)
76G05X-036
5—36

STARTER (GASOLINE ENGINE, 0.85, 0.95 KW TYPE) 5
76G05X-040
REMOVAL AND INSTALLATION
1. Disconnect the negative battery cable.
2. Disconnect the wiring from the starter.
3. Raise the front of the vehicle and support it with
safety stands.
4. Remove the intake manifold bracket. (Fuel Injec-
tion Engine)
5. Remove the starter bolts.
6. Draw out the starter from lower side of the vehicle.
Installation in the revers order of removal.
Tightening torque
Bolts 37—52 N m
(3.8—5.3 m-kg, 27—38 ft-lb)
B terminal 9.8—11.8 N-m
(1.0—1.2 m-kg, 87—104 in-lb)
Intake manifold bracket bolt
37—52 N-m (3.8—5.3 m-kg, 27—38 ft-lb)
Nut
19—25 N-m (1.9—2.6 m-kg, 14—19 ft-lb)
DISASSEMBLY AND ASSEMBLY
1. Disassemble in the numbered order shown in the figure.
2. Assembly is the reverse order of disassembly. 4BG05X-049
4BG05X-075
1. Magnetic switch
2. Bolt
3. Rear cover
4. Brush-holder assembly
5. Yoke
6. Lever
7. Drive housing
(front cover)
8. Drive pinion
9. Armature
5-39

STARTER (GASOLINE ENGINE, 1.4 KW TYPE) 5
Ammeter £
Battery 12V
Switch K sf
Voltmeter W Starter
86U05X-040
No-Load Test
1. After adjusting the pinion gap, form a test circuit
with a voltmeter and an ammeter.
Note
Use heavy gauge wires and tighten each ter-
minal fully.
2. Close switch K to run the starter.
3. Check for the following:
Voltage (V) 11.0
Current (A) 90 max.
Gear shaft speed (rpm) 3,000 min.
4. If any abnormality is noted, check for the cause
according to "Inspection".
INSTALLATION
Install in the reverse order of removal.
Note
When installing the starter, tighten the bolts
to the specified torque.
Tightening torque:
Bolts 37—52 N m
(3.8—5.3 m-kg, 27—38 ft-lb)
B terminal 9.8—11.8 N-m
(1.0—1.2 m-kg, 87—104 in-lb)
76G05X-043
5—55

5 STARTER (DIESEL ENGINE, 2.0 KW TYPE)
REMOVAL AND INSTALLATION
Removal is as follows:
1. Disconnect the negative battery cable.
2. Disconnect the wiring from the starter.
3. Remove the starter.
Install in the reverse order of removal.
Tightening torque:
Bolts 64—89 N-m
(6.5—9.1 m-kg, 47—66 ft-lb)
B terminal 9.8—11.8 N-m
(1.0—1.2 m-kg, 87—104 in-lb)
76G05X-044
DISASSEMBLY AND ASSEMBLY
1. Disassemble in the order shown in the figure.
2. Assemble in the reverse order of disassembly.
4BG05X-047
1. Yoke assembly 7. Over-running clutch assembly
2. Brush holder 8. Pinion gear
3. Armature 9. Steel ball
4. Magnetic switch assembly 10. Coil spring
5. Idler gear 11. Housing
6. Retainer and rollers
5—57

5 STARTER (DIESEL ENGINE, 2.0 KW TYPE)
REMOVAL AND INSTALLATION
Removal is as follows:
1. Disconnect the negative battery cable.
2. Disconnect the wiring from the starter.
3. Remove the starter.
Install in the reverse order of removal.
Tightening torque:
Bolts 64—89 N-m
(6.5—9.1 m-kg, 47—66 ft-lb)
B terminal 9.8—11.8 N-m
(1.0—1.2 m-kg, 87—104 in-lb)
76G05X-046
DISASSEMBLY AND ASSEMBLY
1. Disassemble in the numbered order shown in the figure.
2. Assembly in the reverse order of disassembly.
4BG05X-107
1. Magnetic switch 7. Lever
2. Rear cover 8. Cover
3. Brush-holder assembly 9. Drive pinion and over-running
4. Yoke clutch assembly
5. Armature 10. Reduction gear
6. Front housing 11. Center bracket
5—67

6 CLUTCH MASTER CYLINDER
1. Install the one-way valve spring and piston. (FE
DOHC, RF-N, RF-CX)
2. Tighten the joint bolt with new gasket. (FE DOHC,
RF-N, RF-CX)
Tightening torque:
83—113 Nm (8.5—11.5 m-kg, 61—83 ft-lb)
76G06X-017
3. Install the connector and new gaskets. (LHD ABS,
RHD without ABS)
Caution
Install the connector at the angle shown in the
figure.
Tightening torque:
20—29 N m (2—3 m-kg, 14—22 ft-lb)
76G06X-018
4. Install the new bushing.
5. Install the reserve tank, baffle and tank cap.
6. Install the following parts:
(1) Return spring
(2) Primary cup
(3) Spacer
(4) New piston and secondary cup assembly
Caution
A new primary cup, piston, and secondary cup
assembly must be used.
76G06X-019


w

\o/
7. While pressing the piston with a screwdriver, in-
stall the snap ring.
76G06X-020
6-10
•

CLUTCH RELEASE CYLINDER
INSTALLATION
1. Install the clutch master cylinder.
2. Tighten the mounting nuts.
Tightening torque:
19—26 Nm (1.9—2.6 m-kg, 14—19 ft-lb)
3. Tighten the clutch pipe flare nut securely with the
SST.
Tightening torque:
13—22 N m (1.3—2.2 m-kg, 9—16 ft-lb)
76G06X-021 4. Install the ABS relay box. (LHD)
After installation
1. Perform air bleeding. (Refer to page 6—14.)
2. Verify that there is no leakage.
3. Perform a road test.
CLUTCH RELEASE CYLINDER
86U06X-019
6-11

6 AIR BLEEDING
76U06X-031
4. Install the following parts:
(1) Push rod
(2) Boot
INSTALLATION
1. Install the release cylinder.
2. Tighten the installation bolts.
Tightening torque:
19—26 N-m (1.9—2.6 m-kg, 14—19 ft-lb)
3. Tighten the clutch pipe flare nut securely with the
SST
Tightening torque:
13—22 N-m (1.3—2.2 m-kg, 9—16 ft-lb)
After installation
1. Perform air bleeding.
2. Verify that there is no leakage from the hydraulic
circuit.
3. Perform a road test.
49 0259 770B
AIR BLEEDING
The clutch hydraulic system must be bled to remove
air that entered when the pipes were disconnected.
This bleeding is done as described below.
Note
a) The fluid in the reserve tank must be main-
tained at the 3/4 level or higher during air
bleeding.
b) Use only the specified fluid type. (Refer to
page 6—3)
c) Be careful not to spill clutch fluid onto a
painted surface.
1. Remove the bleeder cap, and attach a vinyl hose
to the bleeder screw.
2. Place the other end of the vinyl tube in a glass con-
tainer of the appropriate capacity.
3. Slowly pump the clutch pedal several times by
hand.
4. While the clutch pedal is depressed, loosen the
bleeder screw to let fluid and air escape.
Then close the bleeder screw.
5. Repeat step 3 and 4 until no more air bubbles are
in the fluid.
6. Check for correct clutch operation.
86U06X-027
86U06X-028
49 0259 770B
76G06X-023
6—14
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