clutch MAZDA 626 1987 User Guide

INSTALLATION 1A
INSTALLATION
TRANSAXLE ASSEMBLY
Assemble the transaxle to the engine in the sequence shown in the figure referring to the installation note.
37—52 N-m (3.8—5.3 m-kg, 27—38 ft-lb)
8—11 N-m (80-110 cm-kg, 69-95 In-lb) (2)
37—52 N-m (3.8—5.3 m-kg, 27—38 ft-lb) (3.) B9—117 N-m (9.1—11.9 m-kg, 66—86 ft-lb)
76G01A-143
1. Transaxle
2. Clutch under cover
3. Gusset plate
4. Starter
Installation Note
Clutch under cover
Before installation, fill the notches with silicon as
shown in the figure.

76G01A-096

1A—91

1A INSTALLATION
Clutch Release Cylinder (MTX)
1. Set the pipe bracket in position.
Tightening torque:
8—11 Nm (80—110 cm-kg, 69—95 in-lb)
2. Install the clutch release cylinder.
Tightening torque:
19—25 Nm (1.9—2.6 m-kg, 14—19 ft-lb)
86U01X-192
Control Cable (ATX)
Install the control cable and adjust the shift selector
position. (Refer to Section 7.)
Tightening torque
@: 44—64
N
m
(4.5—6.5 m-kg, 33—47 ft-lb)
(§): 16—23
N
m
(1.6—2.3 m-kg, 12—17 ft-lb)
Speedometer Cable
Install the speedometer cable.
76G01A-097
Three-Way Solenoid Assembly
Install the three-way solenoid assembly.
Tightening torque:
8—11 N-m (80—110 cm-kg, 69—95 in-lb)
76G01A-098
Brake Vacuum Hose
Connect the brake vacuum hose.
Canister Hose
Connect the canister hoses.

86U01X-180

1A—96

TROUBLESHOOTING GUIDE 1 B
Problem Possible Cause Remedy Page
Insufficient power Insufficient compression Malfunction of HLA Compression leakage from valve seat Seized valve stem Weak or broken valve spring Failed cylinder head gasket Cracked or distorted cylinder head Sticking, damaged, or worn piston ring Cracked or worn piston
Replace Repair
Replace
Replace Replace Replace Replace Replace
1B—60 1B—37 1B—35 1B—38 1B-16 1B—34 1B—43 1B—43
Malfunction of fuel system Refer to Section 4C
Others Slipping clutch Dragging brakes Wrong size tires
Refer to Section 6 Refer to Section 11 Refer to Section 12
Abnormal combustion Malfunction of engine-related components Malfunction of HLA Sticking or burned valve
Weak or broken valve spring Carbon accumulation in combustion chamber
Replace Replace Replace
Eliminate carbon
1B-60
1B-35
1B—38
Malfunction of fuel system Refer to Section 4C
Engine noise Crankshaft or bearing related parts
Excessive main bearing oil clearance Main bearing seized or heat-damaged Excessive crankshaft end play Excessive connecting rod bearing oil clearance Connecting rod bearing seized or heat-damaged
Replace or repair Replace
Replace or repair Replace or repair Replace
1B-51 1B—51 1B—52 1B—53 1B—53
Piston related parts
Worn cylinder Worn piston or piston pin Seized piston Damaged piston ring Bent connecting rod
Replace or repair
Replace
Replace Replace Replace
1B—41 1B-44 1B—43 1B—43 1B-44
Valves or timing related parts Malfunction of HLA* Broken valve spring Excessive valve guide clearance Malfunction of timing belt tensioner
Replace Replace Replace Replace
1B-60 1B—38 1B—35 1B—47
Malfunction of cooling system Refer to Section 3A
Malfunction of fuel system Refer to Section 4C
Others Malfunction of water pump bearing Improper drive belt tension Malfunction of alternator bearing Exhaust gas leakage
Replace Adjust Replace Repair
1B— 6
1B—34
* Tappet noise may occur if the engine is not operated for an extended period of time. The noise should stop after the engine has reached normal operating temperature. 76G01B-004
1B—4

REMOVAL 1B
1. Battery and battery carrier
2. Air cleaner assembly
3. High-tension lead
4. Accelerator cable
5. Fuel hose
6. Radiator hose
7. Radiator harness
8. Radiator and electric fan
9. EGI harness
10. Engine harness
11. Brake vacuum hose
12. Canister hose (Unleaded
fuel)
13. Heater hose
14. Transaxle harness
15. Speedometer cable
16. Clutch release cylinder
17. Drive belt
18. A/C compressor and
bracket
19. P/S oil pump
20. Engine side cover
21. Front wheel
22. Tie-rod end
23. Stabilizer control rod
24. Lower arm bushing
25. Driveshaft
26. Change rod
27. Extension bar
28. Exhaust pipe
29. Engine mount
30. Engine and transaxle
31. Transaxle
76G01B-037
Removal Note
Fuel hose
Warning
a) Cover the hose with a rag because fuel will
spray out when disconnecting.
b) Keep sparks and open flame away from the
fuel area.
Plug the disconnected hoses to avoid fuel leakage.
76G01A-11£
P/S pump, A/C compressor
Remove the P/S pump and A/C compressor with the
hoses still connected to them, secure the pump and
compressor as shown in the figure.
67U01X-029
Driveshaft
Remove the driveshafts. (Refer to Section 9.) Slide
the SST into the transaxle.
86U01X-060
1B—23

1 B DISASSEMBLY (CYLINDER BLOCK)
CYLINDER BLOCK-I
76G01B-043
1. Clutch cover 6. Oil strainer
2. Clutch disc 7. Rear cover
3. Flywheel 8. Water pump assembly
4. End plate 9. Oil pump assembly
5. Oil pan 10. Oil jet
1B—30

DISASSEMBLY (CYLINDER BLOCK) 1 B
76G01B-044
Bolt hole
Oil pan • ,„
Cylinder block
76G01B-045
Disassembly Note
Clutch cover and flywheel
Remove the clutch cover and flywheel with the SST.
Oil pan
1. Remove the oil pan mounting bolts.
2. Install the bolt ©from the mounting bolt or 10 mm
(0.39 in) bolts in the specified bolt holes ©(both
sides).
3. Screw in the bolts gradually and alternately to re-
move the oil pan.
Caution
a) Do not pry the oil pan to prevent damaging
the contact surface.
b) Do not damage or scratch the contact sur-
face when removing the oil sealant.
4. Remove the oil pan.
1B—31

ASSEMBLY (CYLINDER BLOCK) 1 B
Oil Pan
1. Apply a continuous bead of silicon sealant to the
oil pan around inside of the bolt holes and over-
lap the ends.
2. Install the oil pan.
Tightening torque:
7—12 Nm (70—120 cm-kg, 61—104 in-lb)
Caution
Oil pan projection and recession from the end
of the cylinder block must not be more than
1.5 mm (0.06 in).
76G01 B-080
Flywheel
1. Remove any old sealant from the bolts and bolt
holes. If old sealant can not be removed from the
bolt, replace it.
2. Apply sealant to the bolt threads.
76G01B-081
3. Install, and tighten the flywheel with the SST.
Tightening torque:
96—103
N
m (9.8—10.5 m-kg, 71—76 ft-lb)
76G01B-082
Clutch Disc and Clutch Cover
Install the clutch disc and clutch cover using the SST.
(Refer to Section 6.)
Tightening torque:
22—32
N m
(2.2—3.3 m-kg, 16—24 ft-lb)
76G01 B-083
1B—57

1 B INSTALLATION
Clutch Release Cylinder
1. Set the pipe bracket in position.
Tightening torque:
8—11 N-m (80—110 cm-kg, 69—95 in-lb)
2. Install the clutch release cylinder.
Tightening torque:
19—25 N-m (1.9—2.6 m-kg, 14—19 ft-lb)
76G01B-110
Speedometer Cable
Install the speedometer cable.
Brake Vacuum Hose
Connect the brake vacuum hose.
Canister Hose (Unleaded fuel)
Connect the canister hoses.
76G01B-111
1B-78

1 C TROUBLESHOOTING GUIDE
Problem Possible Cause Remedy Page
Insufficient power Insufficient compression Improper valve clearance Compression leakage from valve seat Seized valve stem Weak or broken valve spring Failed cylinder head gasket Cracked or distorted cylinder head Sticking, damaged, or worn piston ring Cracked or worn piston
Adjust
Repair
Replace Replace Replace Replace Replace Replace
1C-85 1C-50 1C-48 1C-52 1C—16 1C-47 1C-57 1C-56
Malfunction of fuel system Refer to Section 4D
Malfunction of Comprex supercharger Refer to Section 4D
Others Slipping clutch Dragging brakes Wrong size tires
Refer to Section 6 Refer to Section 11 Refer to Section 12
Abnormal
combustion
Malfunction of engine-related components
Improper valve clearance
Sticking or burned valve
Weak or broken valve spring
Carbon accumulation in combustion chamber
Adjust
Replace
Replace Eliminate carbon
1C-85
1C-48
1C-52
Malfunction of fuel system Refer to Section 4D
Malfunction of Comprex supercharger Refer to Section 4D
Engine noise Crankshaft or bearing related parts Excessive main bearing oil clearance Main bearing seized or heat-damaged Excessive crankshaft end play Excessive connecting rod bearing oil clearance Connecting rod bearing seized or heat-damaged
Replace or repair Replace
Replace or repair Replace or repair Replace
1C-64 1C-64 1C-65 1C-66 1C-66
Piston related parts Worn cylinder Worn piston or piston pin Seized piston Damaged piston ring Bent connecting rod
Replace or repair Replace
Replace Replace Replace
1C-55 1C-58 1C-56 1C-57 1C-59
Valves or timing related parts Excessive valve clearance Broken valve spring Excessive valve guide clearance Malfunction of timing belt tensioner
Adjust Replace Replace Replace
1C-85 1C-52 1C-48 1C-61
Malfunction of cooling system Refer to Section 3B
Malfunction of fuel system Refer to Section 4D
Malfunction of Comprex supercharger Refer to Section 4D
Others Malfunction of water pump bearing Improper drive-belt tension Malfunction of alternator bearing Exhaust gas leakage
Replace Adjust Replace Repair
1C-7
1C—47
76G01C-004
1C—4

1C TUNE-UP PROCEDURE
Comprex supercharger
Deflection mm (in)
New 4 0-6.0 (0.16—0.23)
Used 8.0-10 0 (0 31-0.39)
If necessary, loosen the idler lock nut and adjust
the belt deflection by turning the adjust bolt.
Tightening torque:
16—23 Nm (1.6—2.3 m-kg, 12—17 ft-lb)
76G01C-011
o
INJECTION TIMING
1. Disconnect the negative battery cable.
2. Release the CSD using the screw driver.
3. Remove the cover on the clutch housing.
4. Turn the flywheel and set the indicator at ATDC.
5. Disconnect the injection pipes from the injection
pump.
76G04D-008
6. Remove the hydraulic head plug from the injec-
tion pump.
7. Mount the SST into the plug hole on the hydraulic
head so the tip of the dial gauge pointer touches
the plunger end of the pump and the dial gauge
indicates approx. 2.0 mm (0.08 in).
76G04D-009
8. Turn the crankshaft slowly counterclockwise to
30-50° BTDC.
9. Make sure the dial indicator pointer no longer
moves by slightly turning the crankshaft.
10. Set the dial gauge scale to Zero at the pointer.
76G04D-010
1C-8