engine MAZDA 626 1987 Workshop Manual

7C REMOVAL
REMOVAL
PREPARATION
(1) Drain the ATF before removal.
(2) Attach the engine support.
(3) Jack up the vehicle and support it with safety stands.
Components
1. Battery
2. Battery carrier
3. Fresh air duct
4. Main fuse block
5. Distributor leads
6. Speedometer cable
7. Cnnectors
8. Ground wires
9. Selector cable
10. Vacuum hose
11. Front wheels
12. Splash shields
13. Oil cooler outlet and inlet
hoses
14. Tie-rod ends
15. Stabilizer bar control links
16. Lower arm ball joints
17. Driveshaft
18. Joint shaft bracket
76G07C-056
19. Joint shaft and driveshaft
20. Under cover
21. Torque converter bolts
22. Starter
23. Engine mount No.4
24. Engine mount No.2
25. Crossmember and left side
lower arm
26. Transaxle
7C-30

REMOVAL 7C
22. Remove the under cover.
23. Remove the torque converter bolts.
76GQ7C-065
24. Remove the starter.
76G07C-066
25. Suspend the engine with the SST.
76G07C-067
26. Remove engine mount No.4 and bracket.
76G07C-068
7C-33

7C REMOVAL
27. Remove engine mount No. 2.
76G07C-069
76G07C-070
28. Remove the crossmember and the left side lower
arm as an assembly.
29. Lean the engine toward the transaxle by loosen-
ing the engine support hook bolt.
30. Support the transaxle with a jack.
31. Remove the transaxle mounting bolts.
32. Remove the transaxle.
76G07C-071
7C-34

7C INSPECTION AND REPAIR
76G07C-181
Mr
76G07C-182
76G07C-183
Inspection
Check the following and replace any faulty parts.
1. Damaged or worn piston
2. Weakened return spring
Free length of spring:
FE engine: 48.0 mm (1.89 in)
F6 engine: 45.5 mm (1.79 in)
Assembly
1. Apply ATF to the inner and outer seal rings, and
install them onto the servo piston.
2. Apply ATF to the seal ring, and install it onto the
servo retainer.
3. Assemble the servo retainer and servo piston.
BRAKE BAND
Inspection
Check the following and replace any faulty part.
1. Damaged or worn brake band
76G07C-184
7C-70

INSPECTION AND REPAIR 7C
n Notches
m
«
m
«
i * •"-=- —*
76G07C-218
49FT01 439
86U07B-345
Install the idle gear bearing onto the idle shaft, then
install the idle gear, adjust shim, spacer, and
bearing.
Note
Install the idle gear with the notches in the
teeth facing as shown.
FE engine: 2 notches
F6 engine: 3 notches
Secure the idle shaft in a vise with the SST; then
tighten the locknut to the lower limit of the tighten-
ing torque.
Tightening torque:
128 N-m (13 m-kg, 94 ft-lb)
Note
Use the protective plates in the vice to pre-
vent damage to the SST.
Check and adjust the idle gear bearing preload.
(1) Turn the idle gear assembly and SST over, and
secure the gear in the vice.
Note
Use protective plates in the vice to prevent
damage to the idle gear.
(2) Attach the SST and spring scale or a torque
wrench, and measure the preload while tight-
ening the locknut.
Tightening torque:
128—177 N-m (13—18 m-kg, 94—130 ft-lb)
Preload:
0.03—0.9 Nm
(0.3—9.0 cm-kg, 0.26—7.8 in-lb)
Value indicated on pull scale:
0.3—9 N (0.03—0.9 kg, 0.066—1.98 lb)
Note
Read the preload when the idle shaft starts to
turn.
7C—85

7C ASSEMBLY
76G07C-319

—
"A" dimension
iP^X
'VJjal (
f b
v. r
24. Fill the torque converter with ATF if it has been
drained and washed.
ATF type: Dexron II or M III
25. Install the torque converter in the converter hous-
ing while rotating it to align the splines.
Caution
a) Hold the torque converter in an erect posi-
tion when filling it with ATF, do not allow
the fluid to overflow.
b) If the converter does not fit in easily, do not
try to force it; install carefully.
26. To ensure that the torque converter is installed ac-
curately, measure distance A between the end of
the torque converter and the end of the converter
housing.
(A): approx. 20 mm (0.79 in)
76G07C-320
27. Install engine mount No.1.
Tightening torque:
29—46 N-m (3.0—4.7 m-kg, 22—34 ft-lb)
76G07C-321
7C-118

7C INSTALLATION
86U07B-441
86U07B-442
76G07C-322
1. Attach rope at 2 places on the transaxle. Place a
flat board on a jack and set the transaxle on it.
Caution
The transaxle is not well balanced; be care-
ful when positioning it on the jack.
2. Move the transaxle into place and attach the rope
to the SST.
3. Mount the transaxle to the engine.
Tightening torque:
89—117 Nm (9.1—11.9 m-kg, 66—86 ft-lb)
Note
a) Lift the transaxle with the jack while pull-
ing the rope.
b) Align the torque converter bolts and drive
plate holes.
4. Install engine mount No. 4 and bracket.
Tightening torque:
(A) 36—54 Nm
(3.7—5.5 m-kg, 27—40 ft-lb)
(g) 64—89 N-m
(6.5—9.1 m-kg, 47—66 ft-lb)
5. Install engine mount No. 2.
Tightening torque:
® 67—93 N-m
(6.8—9.5 m-kg, 49—69 ft-lb)
(f) 37—52 N-m
(3.8—5.3 m-kg, 27—38 ft-lb)
76G07C-323
7C—120

INSTALLATION 7C
B
i^sN |
-- f
®4 4-1;
6. Install the crossmember and the left side lower arm
as an assembly.
Tightening torque:

(A)
36—54 N m
(3.7—5.5 m-kg, 27—40 ft-lb)
(|) 75—93 N m
(7.6—9.5 m-kg, 55—69 ft-lb)
©78—117 N m
(18.0—11.9 m-kg, 58—86 ft-lb)
7. Remove the jack and the rope.
8. Remove the SST.
76G07C-324
76G07C-325
76G07C-326
9. Install the starter and harnesses.
Tightening torque:
® 10—12 N-m
(100—120 cm-kg, 87—104 in-lb)
(|)31—46 N-m
(3.2—4.7 m-kg, 23—34 ft-lb)
10. Install the torque converter bolts.
Tightening torque:
34—49 Nm (3.5—5.0 m-kg, 25—36 ft-lb)
11. Install the end plate.
Tightening torque:
8—11 N-m (80—110 cm-kg, 69—95 in-lb)
12. Replace the clip at the ends of the driveshafts and
joint shaft with new ones.
13. Install the joint shaft and right driveshaft as follows:
(1) Remove the SST and insert the joint shaft into
the transaxle.
(2) Mount the joint shaft bracket onto the engine.
76G07C-327
7C—121

7C INSTALLATION
31.
Connect the distributor lead.
Connect the main fuse block.
Tightening torque:
8—11 N-m (80—110 cm-kg, 69—95 in-lb)
Install the fresh air duct.
Install the battery carrier and battery.
Tghtening torque:
Bolts
9—13 N-m (90—130 cm-kg, 78—113 in-lb)
Nut
5—7 N-m (50—70 cm-kg, 43—61 in-lb)
Pour in ATF and check the following:
(1) With the engine idling, check that the fluid lev-
el is between the F and L marks on the dip-
stick. (Refer to page 7C—25.)
(2) Check the manual linkage, and adjust if neces-
sary. (Refer to page 7C—26.)
(3) Check the inhibitor switch operation. (Refer to
page 7C—23.)
(4) Conduct a road test. (Refer to page 7C—18.)
(5) Check that there is no fluid leakage from the
transaxle. (Refer to page 7C—25.)
76G07C-337
7C-124

9 OUTLINE
Rear Axle (4WS)
86U09X-004
1. Lock nut 4. Knuckle spindle
2. Disc plate 5. Wheel speed sensor (ABS)
3. Dust cover 6. Shock absorber
SPECIFICATIONS
—-— Engine model
Item """ ~'
F6, F8, RF-N FE, RF-CX —-— Engine model
Item """ ~' Right Left Right Left
Length of joint mm (in)
(between centers of joints)
MTX 368.5 (14.51) 368.5 (14.51) 360.0 (14.17) 360.0 (14.17) Length of joint mm (in)
(between centers of joints) ATX 359.5 (14.15) 359.5 (14.15) 355.5 (14.00) 355.5 (14.00)
Shaft diameter mm (in) MTX 23.0 (0.91) 24.0 (0.94) Shaft diameter mm (in) ATX 23.0 (0.91) 24.0 (0.94)
76G09X-001
86U09X-082
9—6