oil cooler MAZDA 626 1987 Owner's Manual

3A OUTLINE
OUTLINE
COOLANT FLOW CHART (DOHC)
ISC solenoid valve 2-stage thermostat
From jo heater heater Main*™, valve ^--^Sub valve
76G03A-002
1. Water pump
2. Thermostat
3. Radiator
4. Coolant reservoir
5. Oil cooler
6. Cooling fan
3A—2

OUTLINE 3A
COOLANT FLOW CHART (SOHC)
76G03A-015
1. Water pump 4. Coolant reservoir
2. Thermostat 5. Oil cooler (8-valve...only ECE, 12-valve)
3. Radiator 6. Cooling fan
3A—3

3B OUTLINE
OUTLINE
COOLANT FLOW CHART
76G03B-002
1. Water pump 4. Coolant reservoir
2. Thermostat 5. CSD coolant passage
3. Radiator 6. Oil cooler
3B-2

7A REMOVAL
1. Remove the battery and battery carrier.
2. Disconnect the main fuse block. (Fl)
3. Disconnect the distributor lead.
4. Remove the air cleaner assembly.
76G07A-012
5. Remove the vacuum hose, the intercooler hose
(RF-CX) and the electric fan. (RF-N and RF-CX)
86U07A-021
8. Remove the front wheels.
9. Remove the splash shields.
10. Drain the transaxle oil.
86U07A-022
7A—14

INSTALLATION 7A
25. Install the grounds to the transaxle case.
Tightening torque:
8—11 N-m (80—115 cm-kg, 69—100 in-lb)
26. Connect the speedometer cable.
76G07A-067
76G07A-068
76G07A-069
76G07A-070
27. Install the intercooler pipe and hose. (RF-CX)
Tightening torque:
19—26 Nm (1.9—2.6 m-kg, 14—19 ft-lb)
28. Install the brake vacuum pipe. (RF-CX)
Tightening torque:
8—11
N
m (80—110 cm-kg, 69—95 in-lb)
29. Connect the brake vacuum hose. (RF-CX)
30. Install the air cleaner assembly and connect the
air flow meter connector.
Tightening torque:
16—27 Nm (1.6—2.8 m-kg, 12—20 ft-lb)
31. Connect the distributor lead.
32. Connect the main fuse block.
Tightening torque:
8—11 N-m (80—110 cm-kg, 69—95 in-lb)
33. Install the battery carrier and battery.
34. Add the correct quantity of the specified transaxle
oil.
Specified
Type
A.T.F.: DEXRON II
Above 0°F:
API: GL-4 or GL-5
SAE 80W-90 or SAE 90
Capacity:
3.35 liters (3.6 US qt, 3.0 Imp qt)
7A-57

7B
AUTOMATIC TRANSAXLE
(Electronically Controlled and 4-Speed)
OUTLINE 7B— 2
SPECIFICATIONS 7B— 2
COMPONENT LOCATION 7B— 3
STRUCTURAL VIEW 7B— 5
OPERATION OF COMPONENTS 7B— 6
FLUID PASSAGE LOCATION 7B— 9
TROUBLESHOOTING (G4A-EL) 7B— 12
GENERAL NOTE 7B— 12
STEP 1
(WARNING CODE RETRIEVAL) 7B— 15
STEP 2
(PRELIMINARY INSPECTION) 7B— 22
STEP 3 (SIGNAL INSPECTION) 7B— 24
STEP 4 (STALL TEST) 7B— 27
STEP 5 (TIME LAG TEST) 7B— 30
STEP 6 (OIL PRESSURE TEST) 7B— 31
STEP 7 (ROAD TEST) 7B— 34
TROUBLESHOOTING (G4A-HL) 7B— 41
GENERAL NOTE 7B— 41
STEP 1
(PRELIMINARY INSPECTION) 7B— 44
STEP 2 (ELECTRICAL
SYSTEM INSPECTION) 7B— 47
STEP 3 (STALL TEST) 7B— 49
STEP 4 (TIME LAG TEST) 7B- 52
STEP 5 (ROAD TEST) 7B— 53
STEP 6 (OIL PRESSURE TEST) 7B— 58
ELECTRICAL SYSTEM
COMPONENTS 7B— 63
MODE SWITCH (G4A-EL) 7B— 63
HOLD SWITCH (G4A-EL) 7B— 63
OD OFF SWITCH (G4A-HL) 7B— 64
INHIBITOR SWITCH 7B- 65
WATER TEMPERATURE SWITCH 7B— 66
FLUID TEMPERATURE SWITCH
(G4A-EL) 7B— 66
BRAKE LIGHT SWITCH
(G4A-EL) 7B— 66
KICK-DOWN SWITCH (G4A-HL) 7B— 67
PULSE GENERATOR (G4A-EL) 7B- 68
VEHICLE SPEED SENSOR
(G4A-EL) 7B— 68
CRUISE CONTROL SWITCH
(CRUISE CONTROL UNIT) 7B— 68
IDLE SWITCH AND THROTTLE
SENSOR (G4A-EL) 7B— 68
OD RELEASE SOLENOID
VALVE (G4A-HL) 7B— 68
SOLENOID VALVES (G4A-EL) 7B— 69
NO LOAD SIGNAL (G4A-EL) 7B— 69
MODE, AND HOLD INDICATOR
LIGHT (G4A-EL) 7B— 69
OD OFF INDICATOR LIGHT
(G4A-HL) 7B— 69
EC-AT CONTROL UNIT
(G4A-EL) 7B— 69
ON-VEHICLE MAINTENANCE 7B— 71
AUTOMATIC TRANSAXLE
FLUID (ATF) 7B— 71
SELECTOR LEVER 7B— 72
THROTTLE CABLE 7B— 73
CONTROL VALVE BODY 7B— 77
OIL STRAINER 7B— 79
ADJUSTMENT OF 2-4 BRAKE
BAND 78— 80
REPLACEMENT OF
DRIVESHAFT OIL SEAL 7B— 80
OIL COOLER 7B— 81
GOVERNOR (G4A-HL) 7B— 82
REMOVAL 7B— 83
PRECAUTION 7B— 83
DISASSEMBLY 7B— 88
DISASSEMBLY-STEP 1 7B— 88
DISASSEMBLY-STEP 2 7B— 94
DISASSEMBLY-STEP 3 7B— 99
DISASSEMBLY-STEP 4 7B—103
INSPECTION AND REPAIR 7B—107
PRECAUTION 7B—107
TORQUE CONVERTER 7B—107
OIL PUMP 7B—108
CLUTCH ASSEMBLY 7B—113
SMALL SUN GEAR AND
ONE-WAY CLUTCH 7B—122
ONE-WAY CLUTCH AND
CARRIER HUB ASSEMBLY 7B-126
3-4 CLUTCH 7B—128
2-3 ACCUMULATOR 7B—132
GOVERNOR ASSEMBLY
(G4A-HL) 7B-133
LOW AND REVERSE BRAKE 7B—134
2-4 BRAKE BAND 7B—135
BAND SERVO 7B—135
OTHER INSPECTION 7B—135
CONTROL VALVE BODY
(G4A-EL) 7B-136
CONTROL VALVE BODY
(G4A-HL) 7B-155
DIFFERENTIAL 7B—177
OUTPUT GEAR 7B—181
IDLE GEAR 7B—182
BEARING COVER ASSEMBLY 7B—185
BEARING HOUSING 7B—186
ASSEMBLY 7B-187
PRECATION 7B—187
ASSEMBLY-STEP 1 7B—187
ASSEMBLY-STEP 2 7B—197
ASSEMBLY-STEP 3 7B—202
ASSEMBLY-STEP 4 7B—208
INSTALLATION 7B—215
TORQUE SPECIFICATIONS 7B—215
HYDRAULIC CIRCUIT (G4A-EL) 7B—221
HYDRAULIC CIRCUIT (G4A-HL) 7B—239
76G07B-001

TROUBLESHOOTING (G4A-EL) 7B
7. Oil Leakage
Check for oil leakage.
(1) Warm up the ATF.
(2) Apply the parking brake and block the wheels
to prevent the vehicle from rolling.
(3) Shift the selector lever to R range.
(4) Check if oil leaks from the following oil seals
or gaskets.
(5) If oil leaks, replace the oil seal or gasket.
76G07B-026
Check for fluid leaks; the following figure shows the locations where fluid leakage may possibly occur.
1. Oil pan
2. Control valve body cover
3. Oil pump
4. Inhibitor switch
5. Speedometer driven gear
6. Pulse generator
7. Oil filler tube
8. Throttle cable
9. Bearing cover
10. Driveshaft
11. Square head plug
12. Transaxle case
13. Drain plug
14. Oil cooler return pipe
15. Oil cooler outlet pipe
16. Fluid temperature switch
17. Blind plugs
76G07B-027
7B—23

TROUBLESHOOTING (G4A-HL) 7B
The following figure shows the locations where fluid leakage may possibly occur.
1. Oil pan
2. Control valve body cover
3. Oil pump
4. Inhibitor switch
5. Speedometer driven gear
6. Oil filler tube
7. Throttle cable
8. Governor cover
9. Bearing cover
10. Driveshaft
11. Square head plug
12. Transaxle case
13. Drain plug
14. Oil cooler return pipe
15. Oil cooler outlet pipe
16. Blind plugs
83U07B-028
4. Inhibitor Switch
Check the inhibitor switch for operation. (Refer to
page 7B—65)
76G07B-045
7B—45

ON-VEHICLE MAINTENANCE 7B
ON-VEHICLE MAINTENANCE
AUTOMATIC TRANSAXLE FLUID (ATF)
Inspection for Fluid Leaks
Check for fluid leaks; the following figure shows the locations where fluid leakage may possibly occur.
1. Oil pan
2. Control valve body cover
3. Oil pump
4. Inhibitor switch
5. Speedometer driven gear
6. Pulse generator (G4A-EL)
7. Oil filler tube
8. Throttle cable
9. Bearing cover
76G07B-085
10. Driveshaft
11. Square head plug
12. Transaxle case
13. Drain plug
14. Oil cooler return pipe
15. Oil cooler outlet pipe
16. Fluid temperature switch (G4A-EL)
17. Blind plugs
18. Governor cover (G4A-HL)
Inspection of Level
1. Apply the parking brake and position wheel chocks
to prevent the car from rolling forward.
Note
Place the car on a flat, level surface.
2. Run the engine so that the automatic transaxle fluid
reaches specified temperature.
3. While the engine is idling, shift the select lever from
P to L or P to 1 and back again.
4. Let the engine idle.
5. Shift the select lever to P.
76G07B-086
7B—71

OH -VEHICLE MAmTENANSl
3. Remove
OIL COOLER
the oil cooler.
cSckmetollowing and repair or replace
2 Bent fins (repair w
any faulty
Installation Install the oi! cooler referring to installation note.
Installation note
OH cooler Install the oil cooler.
Tightening torque: 8—11 N-m (SO—1W cm-kg, 69—95 in-lb)
i5U07B-098 76-81