oil MAZDA 626 1987 Workshop Manual

INSPECTION AND REPAIR 7C
OIL PUMP
Disassembly
Disassemble in the sequence shown in the figure, referring to the disassembly note for specially marked
parts.
76G07C-130 1. Seal ring
2. Seal ring
3. Pump cover
4. Pump flange
5. Inner gear
6. Outer gear
7. Pump housing
63U07B-089
Disassembly note
Inner gear and outer gear
Mark the inner and outer gears with paint before
removing them.
76G07C-131
Inspection
Check for the following and replace any faulty parts:
1. Damaged or worn inner or outer gear tooth
surfaces.
2. Broken or worn seal ring.
76G07C-132
7C—55

7C INSPECTION AND REPAIR
3. Clearance
Measured location Standard Maximum
1 Gear to pump cover 0.02—0.04 mm (0.001—0.002 in) 0.08 mm (0.003 in)
2 Outer gear to crescent 0.14-0.21 mm (0.006-0.008 in) 0.25 mm (0.010 in)
3 Outer gear to housing 0.05—0.20 mm (0.002—0.008 in) 0.25 mm (0.010 in)
4 Oil seal ring to ring groove 0.04-0.16 mm (0.002-0.006 in) 0.40 mm (0.016 in)
76G07C-133
Pump
housing
Bushing.
Sleeve
Pump cover
4. Damaged or worn inner gear bushing of pump
housing sleeve.
Sleeve outer diameter:
37.900 mm (1.492 in) max.
Bushing inner diameter:
38.075 mm (1.499 in) max.
76G07C-134
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INSPECTION AND REPAIR 7C
76G07C-135
76G07C-136
76G07C-137
Assembly
1. Assemble so that the marks on the inner and out-
er gears are at the pump cover side.
2. Install the pump flange.
3. Install the oil pump cover.
Tightening torque: 11—14 N-m
(110—140 cm-kg, 95—122 in-lb)
4. Install the seal rings.
Seal ring outer diameter
A: 44 mm (1.732 in)
B: 43 mm (1.693 in)
5. When the assembly is completed, install the oil
pump shaft and make sure the gears turn easily.
76G07C-138
7C—57

INSPECTION AND REPAIR 7C
9. Check the front clutch operation.
(1) Set the clutch assembly onto the oil pump.
(2) Check the front clutch operation by applying
compressed air through the fluid passage
shown.
Air pressure:
392 kPa (4.0 kg/cm2, 57 psi) max.
Caution
Apply air for no more than 3 seconds.
76G07C-150
(3) Pour ATF into the front clutch until the clutch
piston is fully submerged.
76G07C-151
(4) Check that no bubbles come from between the
piston and drum seal while applying com-
pressed air through the fluid passage shown.
Air pressure:
392 kPa (4.0 kg/cm2, 57 psi) max.
Caution
Apply air for no more than 3 seconds.
76G07C-152
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7C INSPECTION AND REPAIR
5. Install the snap ring.
(1) Place the SST on the spring retainer and com-
press only enough to install the snap ring.
(2) Install the snap ring in the groove.
(3) Remove the SST.
76G07C-160
6. Install the dished plate with the beveled side fac-
ing the piston as shown; then install the drive and
driven plates.
Note
Installation order:
Driven-Drive-Driven-Drive-Driven-Drive-
Driven-Drive
7. Install the retaining plate with the step facing up-
ward; then install the snap ring.
76G07C-161
76G07C-162
7C-64
8. Check the rear clutch clearance.
(1) Measure the clearance between the snap ring
and retaining plate of the rear clutch with a feel-
er gauge.
Rear clutch clearance:
0.8—1.0 mm (0.031—0.039 in)
(2) If the clearance is not with in specification, ad-
just it by selecting a proper retaining plate.
Retaining plate sizes mm (in)
4.8 (0.189) 5.0 (0.197) 5.2 (0.205) I 5.4 (0.213)
5.6 (0.220) 5.8 (0.228) 6.0 (0.236) 6.2 (0.244)
9. Check the rear clutch operation.
(1) Assemble the front clutch, and rear clutch; then
set the clutch assembly onto the oil pump.
(2) Check the rear clutch operation by applying
compressed air through the fluid passage as
shown.
Air pressure:
392 kPa (4.0 kg/cm2, 57 psi) max.
Caution
Apply air for no more than 3 seconds.

INSPECTION AND REPAIR 7C
CONTROL VALVE BODY
Precaution
(1) Pay close attention when handling the control valve because it consists of the most precise and
delicate parts of the transaxle.
(2) Neatly arrange the removed parts in order to avoid mixing up similar parts.
(3) Disassemble the control valve assembly and thoroughly clean it when the clutch and/or brake
bands are burned, and/or when the automatic transaxle fluid is degenerated.
Disassembly
Disassemble in the sequence shown in the figure.
2.5—3.4 N m _ (25—35 cm-kg, (7) 22—30 in-lb)
2.5—3.4 N-m (25—35 cm-kg 22—30 in-lb)
. 2.5—3.4 N-m (25—35 cm-kg, 22—30 In-lb)
2.5—3.4 N-m (25—35 cm-kg, 22—30 in-lb)
5—7 N-m {50—70 cm-kg, 43—61 In-lb)
2.5—3.4 N-m (25—35 cm-kg, 22—30 in-lb)
2.5—3.4 N-m (25—35 cm-kg, 22—30 in-lb)
5—7 N-m (50—70 cm-kg, 43—61 in-lb)
^ - 3—4 N-m (30—40 cm-kg, 26—35 in-lb)
76G07C-201
1. Manual valve
2. Oil strainer
3. Lower body
4. Separator plate
5. Throttle relief ball and
spring
6. Orifice check valve and
spring
7. Sub-body
8. Orifice check valve
9. Side plate
10. Vacuum throttle valve
11. Spring
12. Throttle backup valve
13. Downshift valve
14. Spring
15. Side plate
16. Modifier valve
17. 2-3 shift valve
18. Spring
19. 2-3 shift plug
20.1-2 shift valve
21. Spring
22. Side plate
23. Spring
24. Second lock valve
25. Pressure regulator sleeve
26. Pressure regulator plug
27. Spring seat
28. Spring
29. Pressure regulator valve
30. Upper body
7C-75

7C INSPECTION AND REPAIR
Inspection
Check the following and replace any faulty parts.
1. Damaged or worn valves
2. Damaged oil passage
3. Cracked or damaged valve body
4. Operation of each valve
5. Weakened spring 76go7c-2o2
Spring
Name Outer dia. mm (in) Free length mm (in) Wire dia. mm (in)
Throttle backup 7.3 (0.287) 36.0 (1.417) 0.8 (0.031)
Downshift 5.55 (0.219) 21.9 (0.862) 0.55 (0.022)
2-3 shift 6.9 (0.272) 41.0 (1.614) 0.7 (0.028)
1-2 shift 6.4 (0.252) 31.63 (1.245) 0.4 (0.016)
Second lock 5.55 (0.219) 33.5 (1.319) 0.55 (0.022)
Pressure regulator 11.7 (0.461) 43.0 (1.693) 1.2 (0.047)
Throttle relief 7.0 (0.276) 11.2 (0.441) 0.9 (0.035)
Orifice check 5.0 (0.197) 15.5 (0.610) 0.23 (0.009)
76G07C-203
Valve Location
63U07B-500
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7C INSPECTION AND REPAIR
—® Orifice 2.0 mm (0.079 in)
76G07C-208
76G07C-209
76G07C-210
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13. Install the orifice check valve (<£2.0 mm (0.079 in))
in the upper body as shown.
14. Install the separator plate on the lower body, and
hold it with clips; then install them onto the upper
body.
15. Tighten the mounting bolts to the specified torque.
Tightening torque:
A: 2.5—3.4 N-m (25—35 cm-kg, 22—30 in-lb)
B: 5—7 N m (50—70 cm-kg, 43—61 in-lb)
16. Install the oil strainer.
Tightening torque:
3—4 Nm (30—40 cm-kg, 26—35 in-lb)
17. Turn the valve body assembly over, and install the
sub-body.
Tightening torque:
2.5—3.4 N-m (25—35 cm-kg, 22—30 in-lb)
18. Install the manual valve.
76G07C-211
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7C INSPECTION AND REPAIR
76G07C-221
5. If the specified preload can not be obtained with-
in the specified tightening torque, adjust it by select-
ing the proper adjust shims.
Thickness of shim
0.10 mm (0.004 in) 0.12 mm (0.005 in) 0.14 mm (0.006 in) 0.16 mm (0.0063 in) 0.20 mm (0.008 in) 0.50 mm (0.020 in)
Note
a) The maximum allowable number of shims
is 7.
b) Preload is reduced by increasing the thick-
ness of the shims, or increased by reduc-
ing the thickness of the shims.
BEARING COVER ASSEMBLY
Disassembly
Disassemble in the sequence shown in the figure, referring to the disassembly note for specially marked
part.
1. Oil seal
2. Bearing outer
race
3. O-ring
4. Bearing cover
76G07C-222
7C—86
expert22 .q/ifl http://rutracker.org

INSPECTION AND REPAIR 7C
Disassembly note
Bearing outer race
Remove the bearing outer race with the SST.
Inspection
Check the following and replace any faulty parts.
1. Damaged bearing cover
2. Damaged or worn bushing
76G07C-223
Assembly
1. Press the bearing outer race into the cover.
2. Press the oil seal into the cover.
76G07C-224
BEARING HOUSING
Disassembly
Remove the bearing outer race with the SST.
Note
Install the bearing outer race during reassem-
bly of the transaxle to adjust the preload.
76G07C-225
Inspection
Check the following and replace any faulty parts.
1. Damaged bearing housing
2. Damaged bearing outer race
86U07B-351
7C-87