clutch MAZDA 626 1987 Owner's Manual

REMOVAL 1C
REMOVAL
1. Disconnect the negative battery cable.
2. Drain the engine oil and coolant.
3. Remove in the sequence shown in the figure referring to the removal note for specially marked parts.
76G01C-071
1. Battery and battery carrier
2. Accelerator cable
3. Air cleaner assembly
4. Radiator harness
5. Radiator hose
6. Radiator and cooling fan
7. Brake vacuum hose
8. Intercooler pipe and hose*
9. Fuel hose
10. Drive belt cover
Note
11. P/S pump
12. No.4 engine mount
13. Clutch release cylinder
14. Speedometer cable
15. Transaxle harness
16. A/C compressor
17. Engine harness
18. Heater hose
19. Front wheel
20. Engine side cover
21. Tie-rod end
22. Stabilizer control rod
23. Lower arm bushing
24. Driveshaft
25. Change rod
26. Extension bar
27. Exhaust pipe and stay
28. Engine mount
29. Engine and transaxle
30. Transaxle
marked parts are equipped only for RF-CX.
1C-31

1C REMOVAL
76G01C-244
76G01C-072
67U01X-029
Removal Note
Fuel hose
Warning
a) Cover the hose with a rag because fuel will
spray out when disconnecting.
b) Keep fire and open flame away from the fuel
area.
After disconnecting the fuel hoses, plug them to avoid
fuel leakage.
Clutch release cylinder
Remove the clutch release cylinder with the pipe still
connected; then avoid the cylinder.
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.
Driveshaft
Remove the driveshafts. (Refer to Section 9.) Slide
the SST into the transaxle.
86U01X-060
1C-32

REMOVAL 1C
Transaxle
Separate the transaxle from the engine in the sequence shown in the figure.
76G01C-073
1. Starter 4. Clutch under cover
2. Water pipe 5. Transaxle
3. Gusset plate
1C-33

DISASSEMBLY (CYLINDER BLOCK) 1 C
CYLINDER BLOCK—I
76G01C-091
1. Clutch cover
2. Clutch disc
3. Flywheel
4. End plate
5. Oil pan
6. Oil strainer
7. Stiffener (RF-CX)
8. Rear cover
9. Timing belt pulley
10. Oil pump assembly
Flywheel
1. Install the SST to the flywheel.
2. Remove the clutch cover, clutch disc and flywheel.
Timing belt pulley
1. Reverse the direction of the SST.
2. Remove the timing belt pulley.
76G01C-092
1C—43

1 C ASSEMBLY (CYLINDER BLOCK)
Clutch Disc and Clutch Cover
Install the clutch disc and clutch cover using the SST.
(Refer to Section 6.)
Tightening torque:
18—26 Nm (1.8—2.7 m-kg, 13—20 ft-lb)
76G01C-169
Timing Belt Pulley
1. Install the timing belt pulley with the semicircular
(woodruff) key.
Tightening torque:
179—193 Nm (18.3—19.7 m-kg,
132—142 ft-lb)
4BG01B-180
2. Release the ring gear brake, turn the flywheel,
move the No.
1
piston to the top position, and then
turn it approximately 45° in the forward direction.
Caution
This is to prevent damage to the pistons and
valves when the cylinder head is installed.
4BG01B-181
1C—72

INSTALLATION 1C
INSTALLATION
TRANSAXLE ASSEMBLY
Assemble the transaxle to the engine in the sequence shown in the figure referring to the installation note.
37—52 (3.8—5. 27—38
37-52 N m (3.8—5.3 m-kg, 27—38 ft-lb)
(80—110 cm-kg, 69—95 In-lb)
89—117 N-m (9.1—11.9 m-kg, 66—86 ft-lb)
7-52 N-m (3.8—5.3 m-kg, 27—38 ft-lb)
76G01C-217
1. Transaxle
2. Clutch under cover
3. Gusset plate
4. Water pipe
5. Starter
Installation Note
Clutch under cover
Before installation, fill the notches with silicon as
shown in the figure.

76G01C-219

1C—91

1C INSTALLATION
76G01C-223
76G01C-224
76G01C-225
A/C Compressor
1. Install the A/C compressor.
Tightening torque:
37—52 N-m (3.8—5.3 m-kg, 27—38 ft-lb)
2. Install the drive belt and adjust the belt deflection.
(Refer to page 1C—7)
Speedometer Cable
Install the speedometer cable.
Transaxle harness
Install the transaxle harness.
Clutch Release Cylinder
1. Set the pipe bracket in position.
Tightening torque:
19—26 N-m (1.9—2.6 m-kg, 14—19 ft-lb)
2. Install the clutch release cylinder.
Tightening torque
19—26 N-m (1.9—2.6 m-kg, 14—19 ft-lb)
No.4 Engine Mount
Install the No.4 engine mount.
Tightening torque:
(A): 55—80 N-m
(5.6—8.2 m-kg, 41—59 ft-lb)
(|): 36—54 N-m
(3.7—5.5 m-kg, 27—40 ft-lb)
©: 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)
76G01C-226
1C-96

OIL PAN 2A
OIL PAN
REMOVAL
1. Disconnect the negative battery cable.
2. Drain the engine oil.
3. Remove in the sequence shown in the figure referring to the removal note for specially marked parts.
76G02A-009
5. Sub frame (RH)
6. Oil pan
7. Oil strainer
8. Stiffener (FE 8-valve...only ECE, 12-valve)
Removal Note
Oil pan
(DOHC)
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
Do not pry the oil pan to prevent damaging the
contact surface.
1. Exhaust pipe
2. Gusset plate (SOHC)
3. Clutch housing under cover (SOHC)
4. Performance plate (4WS)
2A-7

OIL PAN 2B
OIL PAN
REMOVAL
1. Disconnect the negative battery cable.
2. Drain the engine oil and coolant.
3. Remove in the sequence shown in the figure referring to the removal note for specially marked parts.
76G02B-019
1. Sub frame
2. Gusset plate
3. Clutch housing
under cover
4. Water pipe
5. Oil pan
6. Oil strainer
7. Stiffener (RF-CX)
36—54 N-m (3.7-5.5 m-kg, 27—40 ft-lb)"
8—11 Nm (80—110 cm-kg 69—95 In-lb)
N-m (3.6—5.3 m-kg, 27—38 ft-lb)
(80—110 cm-kg, 69—95 in-lb)
76G02B-020
Removal Note
Oil pan
1. Remove the oil pan mounting bolts.
2. Insert a scraper or a suitable tool between the oil
pan and the stiffener to separate them.
3. Remove the oil pan.
4. Remove the oil strainer and stiffener from the
engine.
Caution
Do not bend the oil pan when prying loose.
76G02B-021
2B-9

TROUBLESHOOTING GUIDE
4A

TROUBLESHOOTING GUIDE
F6 (GENERAL)
The Troubleshooting Guide lists the systems most likely to cause
a
given symptom. After finding the
system(s)
to
check, refer
to
the pages shown
for
detailed guides
for
each system.
\\ POSSIBLE CAUSE
\ PAGE


SYMPTOM
Air

cleaner
(Air
cleaner
element)
intake
air
temperature
control

system
Idle

adjustment
Fuel
system
(Carburetor,
Fuel
pump)

idle-up

control
system
Exhaust
system
Positive
crankcase
ventilation

system
Auto-return
choke
system

\\ POSSIBLE CAUSE
\ PAGE


SYMPTOM 4A—23 4A—60 4A—38 4A—24 4A—68 4A—96 4A—67 4A—40
1 Hard start
or
won't start (Cranks
OK)
1 2

2 Engine stalls During warm
up
3 2 1 4
2 Engine stalls After warm
up
4 2 5 1 3

3 Rough Idle During warm
up
3 2 1 4
3 Rough Idle After warm
up
3 2 5 1 4

4 High idle speed after warm
up
1 3 2

5 Poor acceleration, hesitation, or lack
of
power
1 2 3

6 Runs rough
on
deceleration
1

7 Afterburn
in
exhaust system
1

8 Poor fuel consumption
2 1 4 3

9 Fails emission test
2 1 4 5 3

76G04A-015
The numbers of the list show the priorities
of
inspections from the most possible to that with the lowest
possibility.
These were determined
on
the following basis:
• Ease
of
inspection
•
Most possible system
•
Most Possible point
in
system
TROUBLESHOOTING PROCEDURE:
1st Check the following items:
Electrical system
1) Battery condition
2) Fuses
Ignition system
1) Spark plugs
2) Ignition timing
Fuel system
1) Fuel level
2) Fuel leakage
3) Fuel filter
4) Idle speed
Intake
air
system
1) Vacuum
or air
leakage
2) Vacuum hose routing
3) Accelerator cable
4) Choke cable
2nd Check Fuel and Emission Control Systems
Engine
1) Compression
2) Overheating
Others
1) Clutch slippage
2) Brake dragging
4 A-17