1987 MAZDA 626 torque

5 STARTER (DIESEL ENGINE, 2.0 KW TYPE)
REMOVAL AND INSTALLATION
Removal is as follows:
1. Disconnect the negative battery cable.
2. Disconnect the wiring from the starter.
3. Remove the starter.
Install in the reverse order of removal.
Tightening torque:
Bolts 64—89 N-m
(6.5—9.1 m-kg, 47—66 ft-lb)
B terminal 9.8—11.8 N-m
(1.0—1.2 m-kg, 87—104 in-lb)
76G05X-046
DISASSEMBLY AND ASSEMBLY
1. Disassemble in the numbered order shown in the figure.
2. Assembly in the reverse order of disassembly.
4BG05X-107
1. Magnetic switch 7. Lever
2. Rear cover 8. Cover
3. Brush-holder assembly 9. Drive pinion and over-running
4. Yoke clutch assembly
5. Armature 10. Reduction gear
6. Front housing 11. Center bracket
5—67

6 CLUTCH MASTER CYLINDER
1. Install the one-way valve spring and piston. (FE
DOHC, RF-N, RF-CX)
2. Tighten the joint bolt with new gasket. (FE DOHC,
RF-N, RF-CX)
Tightening torque:
83—113 Nm (8.5—11.5 m-kg, 61—83 ft-lb)
76G06X-017
3. Install the connector and new gaskets. (LHD ABS,
RHD without ABS)
Caution
Install the connector at the angle shown in the
figure.
Tightening torque:
20—29 N m (2—3 m-kg, 14—22 ft-lb)
76G06X-018
4. Install the new bushing.
5. Install the reserve tank, baffle and tank cap.
6. Install the following parts:
(1) Return spring
(2) Primary cup
(3) Spacer
(4) New piston and secondary cup assembly
Caution
A new primary cup, piston, and secondary cup
assembly must be used.
76G06X-019


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7. While pressing the piston with a screwdriver, in-
stall the snap ring.
76G06X-020
6-10
•

CLUTCH RELEASE CYLINDER
INSTALLATION
1. Install the clutch master cylinder.
2. Tighten the mounting nuts.
Tightening torque:
19—26 Nm (1.9—2.6 m-kg, 14—19 ft-lb)
3. Tighten the clutch pipe flare nut securely with the
SST.
Tightening torque:
13—22 N m (1.3—2.2 m-kg, 9—16 ft-lb)
76G06X-021 4. Install the ABS relay box. (LHD)
After installation
1. Perform air bleeding. (Refer to page 6—14.)
2. Verify that there is no leakage.
3. Perform a road test.
CLUTCH RELEASE CYLINDER
86U06X-019
6-11

6 AIR BLEEDING
76U06X-031
4. Install the following parts:
(1) Push rod
(2) Boot
INSTALLATION
1. Install the release cylinder.
2. Tighten the installation bolts.
Tightening torque:
19—26 N-m (1.9—2.6 m-kg, 14—19 ft-lb)
3. Tighten the clutch pipe flare nut securely with the
SST
Tightening torque:
13—22 N-m (1.3—2.2 m-kg, 9—16 ft-lb)
After installation
1. Perform air bleeding.
2. Verify that there is no leakage from the hydraulic
circuit.
3. Perform a road test.
49 0259 770B
AIR BLEEDING
The clutch hydraulic system must be bled to remove
air that entered when the pipes were disconnected.
This bleeding is done as described below.
Note
a) The fluid in the reserve tank must be main-
tained at the 3/4 level or higher during air
bleeding.
b) Use only the specified fluid type. (Refer to
page 6—3)
c) Be careful not to spill clutch fluid onto a
painted surface.
1. Remove the bleeder cap, and attach a vinyl hose
to the bleeder screw.
2. Place the other end of the vinyl tube in a glass con-
tainer of the appropriate capacity.
3. Slowly pump the clutch pedal several times by
hand.
4. While the clutch pedal is depressed, loosen the
bleeder screw to let fluid and air escape.
Then close the bleeder screw.
5. Repeat step 3 and 4 until no more air bubbles are
in the fluid.
6. Check for correct clutch operation.
86U06X-027
86U06X-028
49 0259 770B
76G06X-023
6—14
expert22 ajia http://rutracker.org

CLUTCH AND FLYWHEEL 6
INSTALLATION
1. Apply clutch grease (Mori While TA No.2 or
equivalent organic molybdenum grease) to the
clutch release bearing and fork, indicated by the
shaded lines in the figure.
86U06X-038
2. Install the clutch release fork and release bearing.
86U06X-039
Gasoline Diesel
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49 E301 060 g^M 1/ j> •«] 49 V101 060
76G06X-026
3. Install the flywheel, then attach the SST and tight-
en the flywheel installation bolts.
Tightening torque:
Gasoline 96—103 N-m
(9.8—10.5 m-kg, 71—76 ft-lb)
Diesel 177—186 N-m
(18—19 m-kg, 130—137 ft-lb)
Caution
If reusing the flywheel bolts, clean the threads
to remove old sealant, and apply new sealant.
If old sealant cannot be removed, replace the
bolts.
4. Install the pilot bearing in the flywheel using a suit-
able bar and a hammer.
Caution
a) Tap it in until distance A in the figure is
3.8—4.2 mm (0.150—0.165 in).
b) Put a small amount of clutch grease (Mori
White TA No.2 or equivalent organic
molybdenum grease).
86U06X-041
6—19

6 CLUTCH AND FLYWHEEL
86U06X-042
86U06X-043
5. Clean the clutch disc splines and primary shaft
splines, then apply clutch grease (Mori White TA
No. 2 or equivalent organic molybdenum
grease).
6. Install the clutch disc with the SST.
Note
Install the clutch so that it faces in the direc-
tion shown in the figure.
7. Install the SST, and tighten the clutch, cover di-
agonally and evenly.
Tightening torque: 18—26 N-m
(1.8—2.7 m-kg, 13—20 ft-lb)
8. Install the transaxle. (Refer to Section 7A.)
76G06X-027
6-20

7A ON-VEHICLE MAINTENANCE
86U07A-012
86U07A-013
86U07A-014
8. Tap the new oil seal into the transaxle case with
the SST.
Note
a) Tap in until the oil seal installer contacts the
case.
b)Coat the oil seal lip with transaxle oil.
9. Replace the driveshaft end clip with a new one.
Insert the clip with the gap at the top of the groove.
10. Install the driveshaft as follows:
(1) Pull the front hub outward, then
fit
the driveshaft
into the transaxle.
(2) Insert the driveshaft into the transaxle by push-
ing on the wheel hub assembly.
Note
a) Be careful not to damage the oil seal.
b) After installation is finished, pull the front
hub slowly outward to check that the
driveshaft is held securely by the clip.
11. Install the lower arm ball-joint to the knuckle, and
tighten the clinch bolt.
Tightening torque:
43—54 N-m (4.4—5.5 m-kg, 32—40 ft-lb)
12. Install the tie-rod end and new cotter pin.
Tightening torque:
29—44 N m (3.0—4.5 m-kg, 22—33 ft-lb)
86U07A-015
7 A—8

ON-VEHICLE MAINTENANCE 7A
13. Adjust and tighten the stabilizer.
Tightening torque:
16—23 Nm (1.6—2.3 m-kg, 12—17 ft-lb)
Dimension: 20.1 mm (0.79 in)
86U07A-016
76G07A-007
14. Install the drain plug.
Tightening torque:
39—59 Nm (4.0—6.0 m-kg, 29—43 ft-lb)
15. Install the wheel.
Tightening torque:
88—118 Nm (9.0—12.0 m-kg, 65—87 ft-lb)
16. Add the correct quantity of the specified oil.
Type: A.T.F.: DEXRON II
Above -18°C (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—9