lock MAZDA 626 1987 Workshop Manual

1 6 A/C RELAY
A/C RELAY
REMOVAL OF RELAY
1. Disconnect the negative battery cable.
2. Disconnect the wire harness connector
3. Remove the relay from the seal plate.
INSPECTION OF A/C RELAY
1. Using a circuit tester, check that there is continui-
ty between terminals (a) and (b).
2. Apply 12 volts across terminals (a) and (b), and
check whether there is continuity between termi-
nals (c) and (d). Replace if necessary.
INSTALLATION OF A/C RELAY
1. Install the relay to the seal plate.
2. Connect the wire harness connector.
3. Connect the negative battery cable.
THERMOSTAT
ON-VEHICLE INSPECTION
1. Operate the air conditioner at MAX. COOLING.
2. Turn the ECO switch to ON.
3. Block the air inlet of the blower unit with a thick
piece of paper.
4. Check whether the relay is turned OFF when the
temperature of the evaporator drops below 7°C
(44.6°F).
5. Turn the ECO switch to OFF.
6. Check whether the relay's turned OFF when the
temperature of the evaporator drops below 1°C
(33.8°F).
REMOVAL OF THERMOSTAT
1. Disconnect the negative battery cable.
2. Disconnect the A/C wiring harness.
3. Remove the thermostat from the cooling unit.
INSTALLATION OF THERMOSTAT
1. Install the thermostat by using the two screws.
2. Connect the A/C wiring harness.
3. Connect the negative battery cable.
76G16X-007
16-30

TECHNICAL DATA 30
FE 12-valve Item FE 12-valve
Valve seat

Seat angle IN 45° Seat angle EX 45°
Seat contact width mm (in) IN 1.2-1.6 (0.047-0.063) Seat contact width mm (in) EX 1.2-1.6 (0.047-0.063)
Seat sinking (Measure valve protruding length) mm (in)
IN Standard 50.2 (1.976) Seat sinking (Measure valve protruding length) mm (in)
IN Maximum 51.0 (2.008) Seat sinking (Measure valve protruding length) mm (in) EX Standard 50.2 (1.976)
Seat sinking (Measure valve protruding length) mm (in) EX Maximum 51.0 (2.008)

Valve spring

IN Standard 49.5 (1.949)
Free length
mm
(in)
IN Minimum 49.0 (1.929) Free length
mm
(in)
EX Standard 50.4 (1.984) EX Minimum 48.7 (1.917)
Out-of-square mm (in) Maximum 1.8 (0.071)
Setting load/height
N
(kg, lb)/mm (in) IN 203-230 (20.7-23.4, 45.5-51,5)/41 (1.614) Setting load/height
N
(kg, lb)/mm (in) EX 240-272 (24.5—27.7, 53.9-60.9)/41 (1.614)

Camshaft

IN Standard 41.290-41.390 (1.6256-1.6295)
Cam lobe height
mm
(in)
IN Minimum 41.140 (1.6197) Cam lobe height
mm
(in)
EX Standard 41.797-41.897 (1.6455—1.6495) EX Minimum 41.647 (1.6396)
Front and Rear (No.
1,5)
31.940-31.965 (1.2575-1.2585)
Journal diameter
mm (in)
Center (No. 2,3,4) 31.910-31.935 (1.2563-1.2573)
Out-of-round Maximum 0.05 (0.002)
Camshaft bearing
oil

clearance
mm
(in)
Front and Rear (No.
1,5)
0.035—0.085 (0.0014-0.0033) Camshaft bearing
oil

clearance
mm
(in) Center (No. 2,3,4) 0.065-0.115 (0.0026-0.0045) Camshaft bearing
oil

clearance
mm
(in) Maximum 0.15 (0.0059)
Camshaft runout mm (in) Maximum 0.03 (0.0012)
Camshaft end play mm (in) Standard 0.08-0.16 (0.003—0.0061 Camshaft end play mm (in) Maximum 0.20 (0.008)

Rocker arm and rocker arm shaft

Rocker arm inner diameter mm (in) 19.000—19.033 (0.748—0.749)
Rocker arm shaft diameter mm (in) 18.959-18.980 (0.746-0.747)
Rocker arm
to
shaft clearance mm (in) Standard 0.020-0.074 (0.0008-0.0029) Rocker arm
to
shaft clearance mm (in) Maximum 0.10 (0.004)

Cylinder block

Height mm (in) 289.0 (11.38)
Distortion mm (in) Maximum 0.15 (0.006)
Grinding limit mm (in) 0.20 (0.008)
Cylinder bore diameter
mm (in)
Standard 86.000—86.019 (3.3858-3.3866) Cylinder bore diameter
mm (in) 0.25 (0.010) oversize 86.250-86.269 (3.3957-3.3964) Cylinder bore diameter
mm (in) 0.50 (0.020) oversize 86.500-86.519 (3.4055-3.4062)
Cylinder bore taper and out-of-round mm (in) Maximum 0.019 (0.0007)

Piston

Piston diameter measured at 90°
to
pin bore axis and 18.0 mm (0.709
in)
below oil ring groove
mm (in)
Standard 85.944-85.964 (3.3836-3.3844) Piston diameter measured at 90°
to
pin bore axis and 18.0 mm (0.709
in)
below oil ring groove
mm (in)
0.25 (0.010) oversize 86.194-86.214 (3.3935—3.3942)
Piston diameter measured at 90°
to
pin bore axis and 18.0 mm (0.709
in)
below oil ring groove
mm (in) 0.50 (0.020) oversize 86.444-86.464 (3.4033—3.4041)
Piston
to
cylinder clearance mm (in) Standard 0.036-0.075 (0.0014-0.0030) Piston
to
cylinder clearance mm (in) Maximum 0.15 (0.0059)

Piston ring

Thickness mm (in)
TOD
1.47-1.49 (0.0579—0.05871 Thickness mm (in) Second 1.47-1.49 (0.0579-0.0587)

30-3

30 TECHNICAL DATA
Engine model FE 8-valve
Item ECE Middle East General
F8 F6
Valve seat

Seat angle IN 45° Seat angle EX 45°
Seat contact width mm (in) IN 1.2—1.6 (0.047-0.063) Seat contact width mm (in) EX 1.2-1.6 (0.047-0.063)
Seat sinking (Measure valve protruding length)
mm (in)
IN Standard 46.5 (1.831) Seat sinking (Measure valve protruding length)
mm (in)
IN Maximum 48.0 (1.890) Seat sinking (Measure valve protruding length)
mm (in) EX Standard 46.5 (1.831)
Seat sinking (Measure valve protruding length)
mm (in) EX Maximum 48.0 (1.890)

Valve spring

Free length mm (in)
Outer
Inner
Standard
Minimum
51.5(2.028)

Standard
44.0 (1.732)

Minimum
43.3 (1.705)
51.2 (2.016)
52.0 (2.047)

50.6 (1.992)
51.5 (2.028)

45.7 (1.799)
44.0 (1.732)

437 (1.720)1
43.3 (1.705)
Out-of-square mm (in) Maximum 1.8 (0.071)
Setting load/height
N
(kg, lb)/mm
(in)
Outer
128(13.1,29) 136.5
(1
44)

Inner
189 (19,2, 42) 141 (1.61)
124 (12.7, 28) 136.5
(1
44)
193 (19.6,43) 141 (1.61)

128 (13.1, 29)/36.5 (1.44)
189 (19.2, 42)/41 (1.61)

Camshaft

Cam lobe height
mm (in)

IN
EX
Standard
Minimum
Standard
Minimum
38.107-38.207 (1.5003-1.5042)
37.957 (1.4944)
38.110-38.210 (1.5004-1.5043)
37.960 (1.4945)
Journal diameter
mm (in)

Front and Rear (No.
1,5)
31.940-32.035 (1.2575-1.2612)
Center (No. 2,3,4)
Out-of-round Maximum
31.910-32.065 (1.2563-1.2624)
0.05 (0.002)
Camshaft bearing
oil
clearance
mm (in)

Front and Rear (No.
1,5)
0.035-0.085 (0.0014-0.00331
Center (No. 2,3,4) 0.065-0.115 (0.0026—0.0045)
Maximum 0.15 (0.0059)
Camshaft runout mm (in) Maximum 0.03 (0.00121
Camshaft end play mm (in) Standard 0.08—0.16 (0.003—0.006)

Maximum 0.20 (0.008)
Rocker arm and rocker arm shaft

Rocker arm inner diameter mm (in) 16.000-16.027 (0.6299-0.6310)
Rocker arm shaft diameter mm (in) 15.966-15.984 (0.6286-0.6293)
Rocker arm
to
shaft clearance
mm (in)
Standard 0.016—0.061 (0.0006-0.0024)
Maximum 0.10 (0.004)

Cylinder block

Heiaht mm
fin)
289.0 (11.38) 268.5 (10.57)
Distortion mm (in) Maximum 0.15 (0.006)
Grindina limit mm (in)
0.20 (0.008)

Cylinder bore diameter
mm (in)
Standard 86.000—86.019 (3.3858—3.3866)
0.25 (0.010) oversize 86.250-86.269 (3.3957-3.3964)
0.50 (0.020) oversize 86.500-86.519 (3.4055-3.4062)
0.75 (0.030) oversize
1.00 (0.039) oversize

81.000-
(3.1890-
-81.019 -3.1897)
81.250-(3.1988-
-81.269
-3.1996) 81.500-(3.2087-
-81.519 -3.2094)
81.750-(3.2185-
-81.769
-3.2192)

82.000-

(3.2283-
-82.019
-3.2291)
Cylinder bore taper and out-of-round mm (in) Maximum 0.019 (0.0007)

Piston

Piston diameter measured at 90°
to pin
bore axis and 18.0
mm
(0.709
in)
below
oil
ring groove
mm (in)
Standard 85.944-85.964 (3.3836—3.3844) 80.944-80.964
(3.1868—3.1876) Piston diameter measured at 90°
to pin
bore axis and 18.0
mm
(0.709
in)
below
oil
ring groove
mm (in)
0.25 (0.010) oversize 86.194—86.214 (3.3935—3.3942) 81.194—81.214
(3.1966-3.1974)
Piston diameter measured at 90°
to pin
bore axis and 18.0
mm
(0.709
in)
below
oil
ring groove
mm (in) 0.50 (0.020) oversize 86.444-86.464 (3.4033-3.4041) 81.444-81.464
(3.2065-3.2072)

30—6

TECHNICAL DATA 30
——Engine model
Item -
FE DOHC ——Engine model
Item -Leaded fuel Unleaded fuel
Valve seat

Seat angle IN 45° Seat angle EX 45°
Seat contact width
mm
(in) IN 1.2-1.6 (0.047-0.063) Seat contact width
mm
(in) EX 1.2-1.6 (0.047-0.063)
Seat sinking (Measure valve protruding length) mm (in)
IN Standard 36.8 (1.449) Seat sinking (Measure valve protruding length) mm (in)
IN Maximum 37.8 (1.488) Seat sinking (Measure valve protruding length) mm (in) EX Standard 36.8 (1.449)
Seat sinking (Measure valve protruding length) mm (in) EX Maximum 37.8 (1.488)

Valve spring

Free length mm (in)
Outer Standard 39.1 (1.539)
Free length mm (in)
Outer Minimum 38.7 (1.524) Free length mm (in)
Inner Standard 38.0 (1.496) Free length mm (in)
Inner Minimum 37.7 (1.484)
Out-of-square
mm
(in) Maximum Outer 1.4 (0.055), Inner 1.3 (0.051)
Setting load/height
N
(kg, lb)/mm
(in)
Outer 78 (8.0, 17.6)/31.5 (1.240) Setting load/height
N
(kg, lb)/mm
(in)
Inner 123 (12.5, 27.5)/33.0 (1.299)

Camshaft

Cam lobe height
mm (in)

IN Standard 45.005-45.105 (1.772-1.776) 45.002-45 102 (1.772-1.776)
Cam lobe height
mm (in)

IN Minimum 44.855 (1.7659) 44.852 (1.7658) Cam lobe height
mm (in)

EX Standard 45.005—.45.105 (1.772-1.776) 45.002-45.102 (1.772-1.776) Cam lobe height
mm (in)

EX Minimum 44.855 (1.7659) 44.852 (1.7658)
Journal diameter
mm
(in) 29.940-29.965 (1.1787-1.1797) Journal diameter
mm
(in) Out-of-round
|
Maximum 0.05 (0.002)
Camshaft bearing
oil
clearance mm (in) 0.035-0.085 (0.0014-0.0033) Camshaft bearing
oil
clearance mm (in) Maximum 0.15 (0.0059)
Camshaft runout
mm (in)
Maximum 0.03 (0.0012)
Camshaft end play
mm
(in) Standard 0.08-0.10 (0.003-0.004) Camshaft end play
mm
(in) Maximum 0.20 (0.008)

Cylinder block

Height
mm
(in) 289.0 (11.38)
Distortion
mm
(in) Maximum 0.15 (0.006)
Grindino limit
mm
fin) 0.20 (0.008)
Cylinder bore diameter mm (in)
Standard 86.000—86.019 (3.3858-3.3866) Cylinder bore diameter mm (in) 0.25 (0.010) oversize 86.250—86.269 (3.3957—3.3964) Cylinder bore diameter mm (in) 0.50 (0.020) oversize 86.500-86.519 (3.4055-3.4062)
Cylinder bore taper and out-of-round mm (in) Maximum 0.019 (0.0007)

Piston

Piston diameter measured at 90°
to pin
bore axis and 18.0
mm
(0.709
in)
below oil ring groove
mm (in)
Standard 85.944-85.964 (3.3836-3.3834) Piston diameter measured at 90°
to pin
bore axis and 18.0
mm
(0.709
in)
below oil ring groove
mm (in)
0.25 (0.010) oversize 86.194-86.214 (3.3935-3.3942)
Piston diameter measured at 90°
to pin
bore axis and 18.0
mm
(0.709
in)
below oil ring groove
mm (in) 0.50 (0.020) oversize 86.444-86.464 (3.4033-3.4041)
Piston
to
cylinder clearance
mm
(in) Standard 0.036-0.075 (0.0014-0.0030) Piston
to
cylinder clearance
mm
(in) Maximum 0.15 (0.0059)

Piston ring

Thickness mm (in)
TOD
1.47-1.49 (0.0579-0.0587) Thickness mm (in) Second 1.47-1.49 (0.0579-0.0587)

30-9

30 TECHNICAL DATA
—— Engine model Item RF-CX RF-N

0..t cy sui.aro
mm
(in) 1.6 (0.063)/2° max.
Setting load/height
N
(kg. Ib)/mm (in) 275 (28.0, 62)/39.0 (1.535)

Tappet

Tappet outer diameter
mm
(in) 34.95-34.97 (1.3764-1.3768)
Tappet hole diameter
mm
(in) 34.99-35.01 (1.3776-1.3787)
Tappet
to
tappet hole
,. ,
clearance
mm (in)

Standard 0.02-0.06 (0.0008-0.0024) Tappet
to
tappet hole
,. ,
clearance
mm (in)
Maximum 0.10 (0.004)

Camshaft and camshaft caps

Cam lobe height
mm (in)

IN Standard 42.521 (1.6741) 44.306 (1.7443)
Cam lobe height
mm (in)

IN Minimum 42.11 (1.658) 43.90 (1.728) Cam lobe height
mm (in)

EX Standard 45.300 (1.7835) Cam lobe height
mm (in)

EX Minimum 44.90 (1.768)
Journal diameter
mm (in)
Standard 31.959-31.975 (1.2582-1.2589) Journal diameter
mm (in)
Out-of-round 0.05 (0.0020) max.
Camshaft bearing
oil
clearance
mm (in)
Standard 0.025—0.066 (0.0010-0.0026) Camshaft bearing
oil
clearance
mm (in) Maximum 0.10 (0.004)
Camshaft run-out (deflection)
mm
(in) 0.10 (0.004) max.
Camshaft end play
mm (in)
Standard 0.02-0.15 (0.0008-0.0059) Camshaft end play
mm (in)
Maximum 0.20 (0.008)

Cylinder block

Height
mm (in)
301.5 (11.87)
Distortion
mm (in)
0.10 (0.004) max.
Cylinder bore diameter
mm (in)
Standard size 86.000-86.022 (3.3858-3.3867) Cylinder bore diameter
mm (in) 0.25 (0.010) oversize 86.250-86.272 (3.3957-3.3965) Cylinder bore diameter
mm (in) 0.50 (0.020) oversize 86.500-86.522 (3.4055-3.4064)
Cylinder bore taper and out-of-round
mm
(in) 0.022 (0.0009) max.

Piston

Piston diameter (Measured at 90°
to pin
bore axis and
19
mm (0.75
in)
above the bottom
of
pis-ton) mm (in)
Standard size 85.957—85.983 (3.3841—3.3852) Piston diameter (Measured at 90°
to pin
bore axis and
19
mm (0.75
in)
above the bottom
of
pis-ton) mm (in)
0.25 (0.010) oversize 86.207-86.233 (3.3940-3.3950)
Piston diameter (Measured at 90°
to pin
bore axis and
19
mm (0.75
in)
above the bottom
of
pis-ton) mm (in) 0.50 (0.020) oversize 86.457-86.483 (3.4038-3.4048)
Piston and cylinder clearance
mm
(in) Standard 0.032-0.050 (0.0013-0.0020) Piston and cylinder clearance
mm
(in) Maximum 0.15 (0.0059)

Piston ring

Thickness
mm
(in)
TOD
1.97-1.99 (0.0776-0.0783) Thickness
mm
(in) Second 1.97-1.99 (0.0776—0.0783)
End gap (measured
in
the cylinder)
mm (in)

TOD
0.20-0.35 (0.008-0.014) 0.20-0.40 (0.008-0.016)
End gap (measured
in
the cylinder)
mm (in)
Second 0.20-0.35 (0.008-0.014) 0.20-0.40 (0.008-0.016) End gap (measured
in
the cylinder)
mm (in) Oil (rail) 0.20-0.40 (0.008-0.016)
End gap (measured
in
the cylinder)
mm (in)
Maximum 1.0 (0.039)
Ring groove width
in
piston
mm
(in)

TOD
2.17-2.19 (0.0854-0.0862) 2.04-2.06 (0.0803-0.0811)
Ring groove width
in
piston
mm
(in) Second 2.03-2.05 (0.0799—0.0807) Ring groove width
in
piston
mm
(in)
Oil 4.02-4.04 (0.1583-0.1591)
Clearance
of
piston ring
to
ring groove
mm (in)

TOD
0.18-0.22 (0.0071-0.0087) 0.05—0.09 (0.0020-0.0035) Clearance
of
piston ring
to
ring groove
mm (in) Second 0.04-0.08 (0.0016-0.0031) Clearance
of
piston ring
to
ring groove
mm (in) Maximum 0.2 (0.008)

Piston pin

Piston pin hole diameter
(in
piston) 29.997-30.007 (1.1810-1.1814) 24.997-25.007 (0.9841-0.9845)
Diameter
mm
fin) 29.994-30.000 (1.1809-1.1811) 24.994-25.000 (0.9840-0.9843)
Clearance
in
connecting rod bushing
mm
(in) 0.05 (0.002) max.

30—12

30 TECHNICAL DATA
Shift point (G4A-EL)
Range
Mode
Throttle condition (Throttle sensor voltage) Shifting Drum speed rpm Vehicle speed km/h (mph)

Fully opened
(4.3 volt)
Di
-• D2
4930-5480 54-60 (33—37) Fully opened
(4.3 volt)
D2 ->• D3
5120-5520 102-110 (63—68) Fully opened
(4.3 volt)
D3 - OD
5380-5710 165-175 (102-109)
Di
D2
3470—4180 38-45 (24-28)

D2 D3
4020-4420 80-88 (50-55)
Half throttle (1.6 2.2 volt)

D3 - OD
3820-4530 117-139 (73-86) Half throttle (1.6 2.2 volt) Lock-up
ON
(OD) 2670—3170 117—139 (73-86)
CD 5

Half throttle (1.6 2.2 volt) Lock-up OFF(OD) 2510-2970 110-130 (68-81)
o CL
OD
- D3
2150-2630 94-115 (58-71)

D3 D2
2020-2410 62-74 (38-46)
OD
- D3
3490-3720 153-163 (95—101)
OD
- D2
2050—2240 90-98 (56-61)
Kick-down OD
- Di
980-1120 43-49 (27-30) Kick-down
D3 -» D2
2940-3200 90-98 (56—61)

D3
->•
Di
1400-1500 43—46 (27—29)
D
D2
->•
Di
2160-2300 43-46 (27—29) D
Fully opened (4.3 volt)
Di
D2
4470-5020 49-55 (30-34) Fully opened (4.3 volt)
D2 -» D3
4770—5170 95-103 (59-64) Fully opened (4.3 volt)
D3 - OD
5380—5710 165—175 (102—109)
Di
-> D2
2830-3380 31-37 (19—23)

D2 D3
2960-3120 59-68 (37-42)
Half throttle
(1.6 2.2 volt)

D3 -> OD
2870-3460 88-106 (55—66) >, E o c
Half throttle
(1.6 2.2 volt) Lock-up
ON
(OD) 2010—2420 88-106 (55—66) >, E o c
Half throttle
(1.6 2.2 volt) Lock-uo OFF (OD) 1940-2310 85-101 (53-63) o o OD
- D3
1600-1960 70-86 (43-53)
LU D3 -» D2
1240-1570 38-48 (24-30)
OD
D3
3490—3720 153-163 (95-101)
OD
- D2
1960—2150 86-94
(53—58)

Kick-down OD
- Di
980-1120 43-49 (27-30) Kick-down
D3 -»• D2
2800-3070 86-94 (53—58)

D3 -> Di
1400-1600 43-49 (27-30)

D2
->•
Di
2160-2460 43-49 (27-30)
S1
- S2
4930-5480 54-60 (33-37)
Fully opened (4.3 volt)

S2 -» S3
5120—5520 102—110 (63-68) Fully opened (4.3 volt)
S4 S3
3720-3950 163—173 (101-107) Fully opened (4.3 volt)
S3 - S2
2940-3200 90-98 (56-61)

s S2 - S1
2160-2310 43—46 (27-29)

S1 -» S2
3470-4180 38-45 (24-28)
Half throttle
S2 - S3
4020—4420 80-88 (50-55)
(1.6-2.2 volt)
S4 S3
3720-3950 163-173 (101-107)

S3 - S2
2020—2410 62-74 (38—46)
Fully opened Li
-> L1
4930-5480 54-60 (33-37)
(4.3 volt)
L2 - Li
2160-2310 43-46 (27—29)
Half throttle
(1.6-2.2 volt) Li
- L2
3470-4180 38-45 (24-28)

D2 -»• D3
850-1160 17—23 (11—14)
D
D3 D2
230-420 7-13 (4—8)
"O o
Fully closed (0.5 volt)
OD
-» D3
3720-3950 163-173 (101-107)
I
S Fully closed (0.5 volt)
S3 - S2
2940-3200 90-98 (56-61)
L
Fully closed (0.5 volt)
L2 - Li
2160-2460 43—49 (27—30)

30-28

TECHNICAL DATA 30
Shift point (G4A-HL)
Range Throttle condition Shifting Vehicle speed km/h (mph) Range Throttle condition Shifting FE engine F8 engine
Fully opened 1st -> 2nd 50-65 (31-40) 47-62 (29—38) Fully opened 2nd ->• 3rd 100-115 (62-71) 94-109 (58-68)
1st 2nd 17-32 (11-20) 16-31 (10-19)
Half throttle (1/2) 2nd 3rd 42-57 (26-35) Half throttle (1/2) 3rd - OD 79-94 (49-58) 74—89 (46—55)
D Lock-up 74-89 (46—55) D OD - 3rd More than 88 (55) More than 82 (51)
OD -> 2nd 34-103 (21-64) 33-97 (20-60)
Kick-down OD - 1st 27-49 (17-30) 26-48 (16—30) Kick-down 3rd - 2nd 34-103 (21-64) 33-97 (20—60)
3rd ->• 1st 11-49 (7-30) 10—48 (6-30)
2nd -> 1st 4-49 (2-30) 3-48 (2-30)
Fully opened 1st 2nd 56-71 (35—44) 52-67 (32-42)
1 Half throttle 1st -> 2nd 56-71 (35-44) 52-67 (32—42)
Kick-down 2nd - 1st 46-61 (29-38) 43-58 (27-36)
D Fully opened 3rd lock-up 106-121 (66-75) 100—115 (62-71)
—___ Model
Item -
G4A-EL
(EC-AT)
G4A-HL (4-speed) —___ Model
Item -
G4A-EL
(EC-AT) FE engine F8 engine
Torque converter

Stall torque ratio 1.700-1.900
: 1
1.900-2.100
: 1

Bushing diameter
mm
(in) Standard 53.030 (2.088) Bushing diameter
mm
(in) Maximum 53.076 (2.090)

Oil pump

Clearance
Cam ring
to
oil pump cover mm (in) Standard 0.005—0.020 (0.0002—0.0008) Cam ring
to
oil pump cover mm (in) Maximum 0.080 (0.003)
Rotor
to oil
pump cover
mm
(in) Standard 0.005-0.020 (0.0002-0.0008) Rotor
to oil
pump cover
mm
(in) Maximum 0.030 (0.0012)
Vane
to oil
pump cover mm (in) Standard 0.015—0.050 (0.0006—0.0020) Vane
to oil
pump cover mm (in) Maximum 0.080 (0.003)
Seal pin
to oil
pump cover
mm
(in) Standard 0.005-0.020 (0.0002-0.0008) Seal pin
to oil
pump cover
mm
(in) Maximum 0.060 (0.002)
Vane
to
rotor groove
mm
(in) Standard 0.010-0.045 (0.0004-0.0018) Vane
to
rotor groove
mm
(in) Maximum 0.065 (0.0026)
Sleeve outer diameter
mm
(in) Standard 28.00 (0.102)
Rotor bushing
in
inner diameter
mm
(in) Standard 28.00 (1.102) Rotor bushing
in
inner diameter
mm
(in) Maximum 28.05 (1.104)
Seal pin outer diameter mm (in) Standard 5.00(0.197) Seal pin outer diameter mm (in) Minimum 4.90 (0.193)
Guide ring outer diameter
mm
(in) Standard 57.85 (2.278) Guide ring outer diameter
mm
(in) Minimum 57.70 (2.272)
Valve outer diameter
mm
(in) Standard 12.00 (0.472) Valve outer diameter
mm
(in) Minimum 11.86 (0.467)

30—29

TECHNICAL DATA 30
Control valve spring (G4A-EL)
Spring name Outer dia. mm (in) Free length mm (in) Wire dia. mm (in) Spring color

1-2 accumulator small spring 11.0 (0.433) 88.1 (3.348) 1.4 (0.055) Gray
1-2 accumulator large spring 16.0 (0.0630) 78.0 (3.071) 2.0 (0.079) Blue
Bypass, servo control spring 5.0 (0.197) 33.4 (1.315) 0.55 (0.022) Maroon
2-3 timing spring 8.3 (0.327) 26.5 (1.043) 0.8 (0.031)
—

N-R accumulator rear spring 11.1 (0.437) 62.0 (2.441) 1.2 (0.047) Light green
N-D accumulator front spring 9.8 (0.386) 52.9 (2.083) 1.0 (0.039) Brown
Coasting bypass spring 5.8 (0.228) 37.7 (1.484) 0.6 (0.024) Dark blue
3-2 timing spring 8.2 (0.323) 28.6 (0.126) 0.8 (0.031) Red
3-2 capacity spring 5.4 (0.213) 30.6 (1.205) 0.5 (0.020) White
Throttle relief ball spring 6.6 (0.260) 21.6 (0.850) 0.8 (0.031)
—

Pressure modifier spring 8.3 (0.327) 26.5 (1.043) 0.8 (0.031)
—

Low reducing spring 8.7 (0.343) 38.3 (1.508) 0.9 (0.035) Black
1-2 shift spring 8.7 (0.343) 41.3 (1.626) 1.0 (0.039) Yellow
2-3, 3-4 shift spring 7.4 (0.291) 36.6 (1.441) 0.8 (0.031) Gray
Throttle backup spring 9.65 (0.380) 26.9 (1.059) 0.55 (0.022) Red
Throttle modulator spring 6.3 (0.248) 47.9 (1.886) 0.8 (0.031)
—

Throttle assist spring 5.15 (0.203) 32.3 (1.272) 0.55 (0.022) Dark green
Throttle spring 5.4 (0.213) 47.2 (1.858) 0.8 (0.031) Pink
Converter relief ball spring 6.9 (0.272) 24.1 (0.949) 0.9 (0.035) Maroon
Orifice check valve spring 5.0 (0.197) 12.5 (0.492) 0.23 (0.009)
—

Pressure regulator spring 11.5 (0.453) 26.5 (1.043) 1.0 (0.039) Maroon
Lock-up control spring 5.0 (0.197) 35.2 (1.386) 0.6 (0.024) Purple

Control valve springs (G4A-HL)
SDrina name Outer dia. mm (in) Free length mm (in) Wire dia. mm (in) Spring color

1-2 accumulator small spring F8 enaine 9.9 (0.400) 84.7 (3.335) 1.2 (0.047) Red
1-2 accumulator large spring FE engine 13.0 (0.512) 73.2 (2.881) 1.8 (0 071) Pink 1-2 accumulator large spring F8 enaine 16.0 (0.630) 84.7 (3.335) 2.0 (0.079) White
Bypass spring 5.0 (0.197) 25.1 (0.988) 0.7 (0.028) Yellow
Servo control sorina 4.9 (0.193) 27.1 (1.067) 0.5 (0.020) Light blue
2-3 timing soring 8.3 (0.327) 26.5 (1.043) 0.8 (0.031)
—

N-R
accumulator rear SDrina
11.1 (0.437) 68.2 (2.685) 1.0 (0.039) Blue
N-D accumulator front spring 9.8 (0.386) 60.9 (2.398) 1.1 (0.043) Yellow
Low reducing spring 8.7 (0.343) 38.3 (1.508) 0.9 (0.035) Black
OD release spring 6.0 (0.236) 32.6 (1.283) 0.6 (0.024) Orange
Coasting bypass spring 5.8 (0.228) 31.3 (1.232) 0.6 (0.024) Yellow
3-2 timing soring 8.2 (0.323) 28.55 (1.124) 0.8 (0.031) Maroon
3-2 capacity spring 5.55 (0.219) 30.5 (1.201) 0.55 (0.022) Light green
Throttle relief ball soring 6.6 (0.260) 20.3 (0.799) 0.8 (0.031) Light green
1-2 shift control spring 5.5 (0.217) 46.0 (1.811) 0.5 (0.020) Liaht oreen
1-2 shift soring 5.0 (0.197) 24.9 (0.980) 0.5 (0.020) Gray
2-3 shift soring 6.1 (0.240) 39.7 (1.563) 0.65 (0.026) Pink
3-4 shift spring 6.4 (0.252) 37.0 (1.457) 0.6 (0.024)
—

Throttle backup spring 6.4 (0.252) 33.5 (1.319) 0.6 (0.024) Pink
Throttle modulator front spring 5.0 (0.197) 27.8 (1.094) 0.6 (0.024) Red
Throttle modulator rear spring 7.15 (0.281) 30.8 (1.213) 0.85 (0.033) Red
1
ranoe control SDrina
6.15 (0.242) 39.2 (1.543) 0.65 (0.026) White
2 range control spring 3.95 (0.156) 32.1 (1.264) 0.45 (0.018)
—

Kick-down
SDrina
5.4 (0.213) 38.1 (1.500) 0.8 0.031)
—

Throttle assist spring 5.15 (0.203) 32.3 (1.272) 0.55 (0.022) Dark green
Throttle spring 5.4 (0.213) 48.3 (1.902) 0.8 (0.031)
—

Converter relief ball spring 6.9 (0.272) 24.1 (0.949) 0I9 (0.035) Maroon
Orifice check valve soring 5.0 (0.197) 12.5 (0.492) 0.23 (0.009)
—
30—31

30 TECHNICAL DATA
Spring name Outer dia. mm (in) Free length mm (in) Wire dia. mm (in)
I
Spring color

Pressure regulator spring 9.5 (0.374) 30.7 (1.209) 0.7 (0.028)
—

Lock-up control spring 7.3 (0.287) 46.2 (1.819) 0.8 (0.031) Blue
Lock-up support spring 6.1 (0.240) 43.5 (1.713) 0.65 (0.026) Blue
OD lock-up spring 7.1 (0.280) 66.5 (2.618) 0.8 (0.031) Red

Model G4A-EL G4A-HL 4-speed)
Item (EC-AT) FE engine F8 engine
Gear assembly

Total end play mm (in) 0.25-0.50 (0.010-0.020)
End play adjust race mm (in) 1.2 (0.047),
1.4
(0.055),
1.6
(0.063),
1.8 (0.071), 2.0 (0.079),
2.2
(0.087)
Idle gear bearing preload N
m
(cm-kg, in-lb) 0.03--0.9 (0.3—9.0, 0.26 -7.8)
Preload adjust shims mm (in) 0.10 (0.004), 0.12 (0.005), 0.14 (0.006), 0.16 (0.0063), 0.18 (0.007), 0.20 (0.008)
Output gear bearing preload N-m (cm-kg, in-lb) 0.03--0.9 (0.3—9.0, 0.26 -7.8)
Preload adjust shims mm (in) 0.10 (0.004), 0.12 (0.005), 0.14 (0.006), 0.16 (0.0063),
0.18 (0.007), 0.20 (0.008), 0.50 (0.020)

Drive and differential

Final gear Type Helical gear Final gear Reduction ratio 3,700
: 1

Side bearing preload N-m (cm-kg, in-lb) 2.9 —3.9 (30-40,
26-
35)
Preload adjust shims mm (in)
0.10 (0.004), 0.12 (0.005), 0.14 (0.006), 0.16 (0.0063), 0.18 (0.007), 0.20 (0.008), 0.50 (0.020), 0.70 (0.028), 1.00 (0.039)
Backlash
of
side gear and pinion
mm (in)
Standard 0.025-0.1 (0.001-0.004) Backlash
of
side gear and pinion
mm (in)
Maximum 0.5 (0.020)
Torque converter distance "A" (Refer to page 7B— 214) mm (in) 25 (0.984)

30-32

30 TECHNICAL DATA
Item Engine model FE engine F6 engine
Front clutch

Number
of
driven and drive plates 3
Drive plate thickness mm (in) Standard 1.6 (0.063) Drive plate thickness mm (in) Minimum 1.4 (0.055)
Front clutch clearance mm (in) 1.6-1.8 (0.063-0.071)
Retaining plate sizes mm (in) 5.2 (0.205), 5.4 (0.213), 5.6 (0.220),
5.8 (0.228), 6.0 (0.236), 6.2 (0.244)
Return spring free length mm (in) 26.2 (1.031)
Drum bushing inner diameter mm (in) Standard 44.000-44.025 (1.732-1.733) Drum bushing inner diameter mm (in) Maximum 44.075 (1.735)
Front clutch drum end play mm (in) 0.5-0.8 (0.197-0.0315)
End play adjust shims mm (in) 1.3 (0.0512), 1.5 (0.0591), 1.7 (0.0669), 1.9 (0.0748), 2.1 (0.0827), 2.3 (0.0906),
2.5
(0.0984), 2.7 (0.1063)

Rear clutch

Number
of
driven and drive plates 4
Drive plate thickness mm (in) Standard 1.6 (0.063) Drive plate thickness mm (in) Minimum 1.4 (0.055)
Rear clutch clearance mm (in) 0.8--1.0 (0.0315- 0.0394)
Retaining plate sizes mm (in) 4.8 (0.189), 5.0 (0.197), 5.2 (0.205), 5.4 (0.213),
5.6 (0.220), 5.8 (0.228), 6.0 (0.236), 6.2 (0.244)
Return spring free length mm (in) 26.2 (1.031)

Low and reverse brake

Number
of
low and reverse brake plates 4
Drive plate thickness mm (in) Standard 1.6 (0.063) Drive plate thickness mm (in) Minimum 1.4 (0.055)
Low and reverse brake clearance mm (in) 0.8-1.05 (0.032-0.041)
Retaining plate sizes mm (in) 4.6 (0.181),
4.8
(0.189), 5.0 (0.197), 5.2 (0.205), 5.4 (0.213), 5.6 (0.220)
Return spring free length mm (in) 27.7 (1.091)

Servo

Return sprina free lenath mm (in) 48.0 (1.89) 45.5 (1.79)

Governor

Primary spring mm (in) Outer diameter 9.0 (0.354) Primary spring mm (in) Free lenath 17.2 (0.667)
Secondary spring mm (in) Outer diameter 9.25 (0.364) Secondary spring mm (in) Free lenath 13.2 (0.520)

One-wav clutch

Bushing diameter mm (in) Standard 129.987-130.013 (5.118--5.119) Bushing diameter mm (in) Maximum 130.063 (5.121)

Control valve SDrinas
Spring name Outer dia. mm (in) Free length mm (in) Wire dia. mm (in)

Throttle backup spring 7.3 (0.287) 36.0 (1.417) 0.8 (0.031)
Downshift sorina 5.55 (0.219) 21.9 (0.862) 0.55 (0.022)
2-3 shift spring 6.9 (0.272) 41.0 (1.614) 0.7 (0.028)
1-2 shift spring 6.4 (0.252) 31.63 (1.245) 0.4 (0.016)
Second lock spring 5.55 (0.219) 33.5 (1.319) 0.55 (0.022)
Pressure reaulator sprina 11.7 (0.461) 43.0 (1.693) 1.2 (0.047)
Throttle relief ball spring 7.0 (0.276) 11.2 (0.441) 0.9 (0.035)
Orifice check valve sprina 5.0 (0.197) 15.5 (0.610) 0.23 (0.009)

30-34