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Mazda RX-2 Rotary Engine Service Manual

1. Model and Shift Speed imi Thole Condition Gear Shift Nha Capella 74 9 36 Si 72 33 46 qa 027 38 DD 9 1 59477 ssc 36 10 42 6 07 50 mm 1 105 80 65 83 107 5 67 7 LETT Dad 39 59 sea 1 34 832 3 44 18 28 1 8 2 13 28 8 46 Hm 1 45 Hatt throttle 59 Derby 2 63 necio 29 62 18 39 22 8b 3 Full throttle O 80 mmHg testy 4 54 06 30 4n 55 8 35 mns 3045 Fenty eM i a ne rer 0 Model and Shift Speeds Throttle Condition Gear Shits 616 Capella 16 616 for U S A de nex p Disds 48 65 am ar 60 07 38 DD 52 09 I T6401 7 6 51 65 Kickedown 0 30 mmHg DiDa 75 96 0 66 4 55 SI 7 0 54 nm DiDi 33 48 2 9 qsa 3 4 asi Dib 647 2245 2248 7 Half throttle 200 imm Hg i 25 56 16 35 DI 20 52 Mei Foll throrile 0 S0 mavHg 13 13 38 50 04 30 2 0 quam Minimum throttle 3 50 01 38 2 3 Note The shift speeds the above table include the permissible allowance of speedometer on the ear Therefore check the shili speed with the speedometer on
2. Q vaus Tg E Bv Fi as bird se 14 51 Checking of coasting valve When vacuum gauge readings are excessive check the following points 1 Check the current from the control box to the coasting valve solenoid by reference to the procedure mentioned in 1A E 9 2 Make sure that the solenoid operates properly 3 Make sure that the throttle positioner is im pro per adjustment Refer to the adjusting procedure mentioned 1A E 12 4 Make sure that there is clogging in the va cuum relief passage connecting the vacuum chamber and the ait inlet pipe in the cousting valve 5 Make sure that idling fuel flow is proper Pro per flow 18 2 1 1 H or 047 0 54 US gallon b Removing of coasting valve 1 Remove the air cleaner 2 Remove the coasting valve from the air hoses and the vacuum sensing tubes 3 Loosen the mounting bolts and remove the coasting valve Installing of coasting valve Install the coasting valve in the reverse sequence Valve antrafterbur contrat To itae vaa aves Fig 1 62 Checking of throttle positioner TA E 12 Throttle Positioner Checking of throttle positioner 1 Remove the air hose leading to the air cleaner from the coasting valve air inlet und plug the air inlet as in Fig 52 2 Start the engine and run the engine at 2 000 rpm 3 Disconnect the wiring leading
3. av mo TECHNICAL DATA Rotary pistoa engine in Vine 2 rotary water cooled 35 0 eu inx2 sown CT at 220 ij 95 229 rpm 130 HP 7 000 rpm SAE 05 000 SAE Clearance of apex seal and side 2225 A T D C Clearance of apes seal and mtr Limit of distortion Limit of wear Rotor housing Width Limit ol distet Intermediate honing Limit af distort Lisit al war Width Rum Standesit weight with intero al ear bearing mide Clearance ol ende owing amd Prottsm of land Premise ul land Width of apex seat loose Width of side send youre Devil of side seal Wilh of oil seal groove al oil Apex seal Front rese homing 0 64 mm 0 002 in 0 10 mm 0 004 in 2155950 mam 0 008 i 1 04 0 002 0 10 mm 0 004 in Clounnee of carner seal and rotor 1465 20 0008 459 10 08 ij seal spring 10 0051 0 0067 9 008 066 Min 0 085 ran 9 000 0 2283 9 04 Clearance of and 10 3110 Cleaner v side seal and corner 8 2tn 010000 m n i m EXT ELI 026 290 e o 0 2851 0 380 0 01 0 05 mm 0 0
4. 946 949 ien 0 0020 0035 in 19 10 mim 0 0039 i6 0 1540 pyme y m hn 0 2 m Lese han 0 0008 in 0 044 01 em 0 00160002 in 0109 0 0035 in a 0 06 0 08 mm 0 00240 0031 0 05 906 LUBRICATING SYSTEM Oll pem US pint min ay Clean rotor and 0 200 Pimm body 0 008 0 010 in yarane of enter rotor and 0 01 mm m 9 o Roses end llt 10 10 0 20 ot cil jury die 0 08 0 12 peut and driven ar 0 0081 0 0047 in Oil pressure Normal 5 0 kg om 1 1 3 000 rmn Warsi lamp lafaw 4 Preseare mgutater content Free length 46 4 mmn 1 827 Set Feng 35 5 mm 1 390 Set load PA kg 0 8 Th valve opens verme Staria to clone erry Cloves completely aret h 0 2 IF 17 mn 0 650 BF vhermo valve return sprint Froe length 13 52 05 om load de Qoi I Spring comam 0 412 kg mm 24 2 Ih n Oil ser Core arta 1 9 mt 0 5 10 0 8 Wer 9 6 U S pun 9 5 Imp Oi metering pomp lending caya city ling ol lever Full opening of bever 17 041 5 expacity Oil pan Foll expacity Feeding capacity 36 20 emin Q2 0 0025 0 0079 i 2 5 35 6 Regulated premure 1040 2 4 2e2 i in 17420 00 in 6510 min wt 20 5 9
5. 1 5 i n 2 1 1 Idling fuel flow L H aaa idling speed to about 1 800 2 000 rpm by means of the choke 1 50 E ant 1 1 2 b E 3 L3 LJ 1 Tio Fi 14 84 7 mode driving mode and shift points 3 Choke should be set at the position as described above at least for the first 80 seconds 4 Use second for 15 cruising and 15 30 acceleration Note 1 Flywheel Actual 50 1971 2 500 th 94 1972 2 750 th 99 Note 2 Chassis dynamometer load used CLAYTON 1 Pull out the choke button to its full stroke 2 Start the engine with the clutch disengaged 3 Push back the choke button smoothly 10 its fast idle position immediately after engine starts 4 Fast idle speed is set at 1 800 2 000 rpm 5 Push back the choke button completely during the deceleration between 181 and 187 seconds from the engine start 6 The above process is shown schematically as fol low Fig 1A 85 2 The shift patterns The indicated horse power is the value which is cor Acceleration modes rected according to the CLAYTON type load esli 15 mph Ist to 2nd gear bration curve mentioned in the Federal Resister 25 mph 2nd to 3rd gear Note 3 40 mph 3rd to 4th gear the case of hot cycle test it is necessary 10 warm Deceleration modes up the reactor by more than three cycles 1Smph Clutch disenga
6. wheel Max steering sgle inner whee Oute whee Lubricant Backdaal of raek and vei gear Worm bearing preload End cleursoce of sector shalt Recezcalating Vall wut Variable ratio gear iets 10 49 mn 0 41 2 SAE 90 25 0 5 US pim 0 4 mp pint 1640 0 93 5 iod 0 02 08 eus O L Steering geometry 7 King pin inclination Camber Canter Toe in Trail s15 ons m 6 2 mm 16 0 08 in 5 mm 0 2 in Spring constant Spring pressure i 1 dot 240 Wiee diameter Outer coil diameter Free length Fitting length Relief valve thickness Center ting valve thickness Compression valve thickness Spring constant pring Wire diameter Outer coil diameter 1 8520 124 kg mm 00 54 2 Ib in When the spring length is compressed to 194 7 638 in 281 289 ke 619 637 15 289 296 kg 637 655 Ib 295 304 ka 6537 670 b 1 5 mm 0 45 in 121 5 mm 4 78 in 352 wm 13 88 in 194 mm 7 64 in Hydraulic double action 20 mm 0 787 int 10 05 mm 0 002 in 0 240 015 mm 0 0079 0 0006 n 0 140 08 0 00094 0 00041 in 0 15001 mm 0 0059 4 0 0004 in 0 25 mm 0 0098 in Lem than 0 05 mm 0 002 i 30 mim 1 181 i 0 140 008 mm 0 9020 im 9 1540 01 men 0 0088 4 0 0004 in 0 240 035 mm 0 0079 0 006 ia inks
7. 15 Brake band 10 Mount the needle bearing on the rear face of the rear clutch hub and the bearing race on the front face of the front planet carrier Assemble the rear clutch hub and the planet carrier and install its assembly on the sun gear and connecting shell 11 Put the above assembly with the rear clutch hub side facing upward Mount the needle bearing on the front fore of the rear clutch hub and the bearing race on the rear face of the rear clutch assembly and install the rear clutch assembly downward on the tenz clutch hub In doing so turn it little so that the teeth of the clutch plates may come into engage ment with the clutch hub spline 12 lustall the front clutch assembly into the rear one as in the case of the rear clutch assembly gt z Fig 248 clutches 13 Install the assembly including the connecting shell and the front clutch into the transmission case M Temporarily mount the brake band on the front clutch drum and fit the strut 15 Set the frant clutch thrust washer which adjusts the end play of the front clutch drum on the rear face of the pump cover assembly and also set the bearing race which adjusts the total end play on the rear end of the oil pump cover Apply some amount of vaseline to prevent benring race falling Install the oil pump assembly with packing 10 the Transmission case Then tighten the converter bous img omo the transmission case wi
8. Fig 1A 88 Spark plug 8 Checking of Spark Plug 1 Inspect each plug individually for badly worn elect Todes glazed broken or blistered porcelain and re place the plu ss necessary 2 Clean the spark plugs throughly using a sand blast cleaner 3 Adjust the spark plug gap by bending the ground electrode 10 obtain the gap 0 9 mm 0 033 in with a wire gauge Fig 14 69 Adjuiting of electrode yap 4 Inspect each spark plug for make and heat range All spark plugs must be of the same maker and number heat range lf spark plugs show burning white or rapid electrode wear replace with a cold range type spark plugs 1A 20 1 JA G TROUBLE SHOOTING The possible faults ond their remedies are listed in the following table When the symptoms of troubles are detected proper care must be taken immediatly before proceeding to the next probable cause Symptoms and probable causes Remedies 1 Noisy air pump 1 Disconnected or leaky air hose Connect or replace 2 V belt improperly adjusted adjust 3 Loose pump attaching bolts Tighten 4 Defective air pump Replace 3 Rough engine Kling or hard starting Fouled or improperly adjusted spark plugs Clean adjust or replace 2 Burned or improperly adjusted distributor contact point Adjust or replace 3 Defective ignition coil Replace 4 Improper ignition timing adjustment Adjust 5 improper carburettor adjustment le speed Adjust b Float lev
9. Tie rod ball rd bak Steering gear housing Piman amm ier arm Steering jm Bribe Caliper bracket Frant bucking plate From hub attaching bolt Rear backing cylinder joint bolt Master cylinder set bolt Wheel wheel bolt Suspension Suspension um Arm bal joint Front damper cap nur Front damper piston Front dampet base valve Rear suspension Standard 6mm p 1 0 Sano pel 2 5885 z 55888
10. 6 D 1 Checking the Release Bearing 6 D 2 Checking the Pressure Plate Asrembly 6 0 3 Checking the Clutch Disk 6 4 Flywheel Inspection 6 0 5 Ring Gear Replacement 6 D 6 Inspecting the Needle Roller Bearing and Seal ano CLUTCH MASTER CYLINDER 6 3 Checking ihe Clutch Mister Cylinder 6 F 4 Assembling the Clutch Master Cylinder 6 5 Installing the Clutch Master Cylinder 6 6 1 Removing the Clutch Release Cylinder 6 6 2 Checking the Clutch Release Cylinder 6 6 3 Assembling the Clutch Release Cylinder 6 6 4 Installing the anana 6 CLUTCH The clutch is of the single dry disk type The clutch assembly consists of the clutch disk assembly clutch cover and pressure plate assembly and cluich release mechanism The clutch operating mechanism isa hydraulic type 6 CLUTCH PEDAL ADJUSTMENT The free travel of the clutch pedal should be between 20 to 30 mm 0 8 to 1 2 in To adjust the free travel loosen the lock mut and tum the push rod until prop er adjustment made Fig 6 1 Clutch pedal adjustment 5 Stoppet boit 6 Lock mut 7 Clutch pedal 1 1 Mah rod 3 koik mul 4 Retum spring 6 8 RELEASE FORK ADJUSTMENT There should always be safe clearance of 15 mm 0 06 in between the release bearing aud tho di phuyu spring This clearance is essential to di
11. b Governor pressure test Governor pressure has only to be measured when shift point is different from the specified Connect pressure gauge in the inspection hole on the left rear of transmission case and pur it where it is visible during driving Read governor pressure when the caris going at required speeds for each model If the result is out of the specified range shown in the following table disassemble and check the governor valve Governor Pressure 1 Driving Speed Shalt Speed 2 1 080 14 1 890 2 010 iue 2 000 9 070 Capes Tom 1 800 2 080 s 3 000 Low Lio RXS EAs 100 E E 2 5 as Te Capella 16 m s ss XN 6M for USA 3 jo Bm S 8 000 03 101 0 sw s 200 210 E 2 60 3 060 Governor Type M 3 000 ASA int a i es Note The two types of governor are ayairable the rotary engine RX2 Capella Rotary and RX3 depending on the models S5 type is for 1300 808 When indicated by output shaft revolutions the oil series 616 Capella 1600 series and 618 The other pressure characteristics of each governor are shown 38 type is applied exclsively to the models mounded the above table Governov Pressure 2 51 TROUBLE DIAGN
12. Fig 9 15 Pinion adjusting puge 9 15 and lock the dial indicator by the screw to that the needle is pointing toward to 3 mm Then set the reading to Zero by tuming the outer ring of the indicator 2 Make certain that the differential bearing support bores are free of dirt and burrs 3 Install the pinion and bearing model together with spacer into the carrier Fig 9 16 Installing of pinion and bering model 4 Place the gauge block on the pinion carefully place the gauge body as adjusted according to Step 1 on the gauge block so that the feeler of the indicator comes in contact with the lowest portion of the dif ferential bearing support bore Fig 8 17 Measuring of pinion height 5 Record the of hundredths dial indicator moves in a plus or minus direction from zero Remove the gauge body and dial indicator from the cartier and check zero setting on the surface plate to make sure this setting was not disturbed by handi i order to compensate for all of the machinig variables the pinion has a plus or minus reading re corded in hundredth millimeters on the rear face of the pinion a If the pinion is marked plus subtract the amount specified on the pinion IF the pinion is marked minus add the a mount specified on the pinion 9 7 Place the bearing model and the rear pinion bear ing on the surface plate and compare their heigh
13. pump drive pear balance weight thrust plate and needle bearing in that order from the eccentric shafi 15 Straighten the lockwashers of needle bearing hous ing tightened by six bolts and loosen the bolts Remove the needle bearing housing needle bearing and thrust washer Fi 1 17 16 Loosen the tension bolts the order shown Fig 1 18 Fig 1 18 Loosenitig order 17 Remove the front housing 18 Remove the corner seals with springs and the side seals with springs and place them in the seal ease 49 0813 250 following the marks which are made at the nearest portion of each seal on the rotor side face These marks are made order to prevent each seal from changing its original position when reassembling 19 Remove the sealing rubbers and the O rings from between the front housing and the rotor hous ing 20 Hold the rotor housing down by hand to pre vent it from moving up then pull the tubular dowels by using the dowel puller 49 0813 215 21 Install the rotor clamp 49 0813 230 by allow ing the front rotor housing o move up to the requir ed level so as mot to damage the apex seals then remove the front rotor housing Note The rotors are marked as shown in Fig 1 22 F on the internal gear side indicates the front ro tor while R indicates the rear rotor When as sembling be careful to these marks E mks Fig 1 19 Removing front housing 49 0813 AS
14. the atmosphere At the same time the air cut valve closes the secondary passage to cut fresh air supply The relief valve opens and closes in accordance with air pressure in the air injection system and the force of the retum spring When the air pressure in the air injection system exceeds 0 11 0 14 kg em 1 3 2 0 lb in it opem the relief valve against the re tum spring force and proceeds to the thermal reactor to cool It before being expelled to the atmosphere thus controlling the secondary air volume When the pressure decreases the spring closes the valve The safety valve like the relief valve controls ait Pressure in the air injection system and adjusts the volume of secondary air If air in the air injection system should be trapped due to a malfunction the safety valve relieves the trapped air t0 the air cleaner thus preventing dam ages to the elements of the air injection system Thermal reactor The thermal reactor is mounted just outside the exhaust port lt oxidizes the unburned exhaust gas expelled from the engine 10 reduce the noxious Components such as hydrocarbon and carbon mono xide Fig 8 Thermal reactor When the engine speed is more than 4 000 rpm or during deceleration the air control valve feeds fresh air from the air pump to the thermal reactor to maintain the temperature necessary for oxidation of exhaust gas pa Cog ai Fig 7
15. vim anl dished plne Remove the vail sprint re lt wer wap ring by using overhaul of principal lie clutch spring compressor 4 000 090 Mesure ihe ele between the rini and e nlter reassem plate to provide 039 0 059 imi reining plore with n thickness ga and selvervely use remmin the standard elearance 1 0 1 5n Note Fo dj shove elewrnse the remning pare the following six thicknes 425 10 4 mm 0 4 10 0 mm 0 453 m 1 4 mm 0489 10 11 48 0000 022 Ansell the from assembly pun u the oll hole as sh Fig 219 N wi pres wa m and check the cinch operenon Remow the speme 10 voit 4 Re pesto lowing we air dum ile Tules shown io Fit 2 20 Fig ERI Testimi honi Cluich Fi 20 4 REAR CLUTCH ASSEMBLY Te Inspect 5 Check the imer pites lr f Check o thui the Chek see hes phe cent 5 ra OP ring Horde te dh drum jue lay M dahatiye pri ne ahem wiih To Reassemble 10 garcia re nm wuh nd in the reverse 223 dh me Ree clutch ilium 2 Sap md 1 Outer plate Spring tener 1 Sep ying oll mis Herse To
16. Fig 14 55 Checking of retard system 2 7 Start the engine and run it at the idling speed of 900 rpm 8 Aim the on the fror If the timing mark on the eccentric shaft pulley aligns with the timing indicator pin the front caver the leading ignition retard system is satis factory 10 deg iming light at the timing indicator pin Note 1 When checking the No and No 2 control boxes be attentive to the following points 1 The wiring from the control box to each valve solenoid and idle switch should not be earthed or connected faultily 2 When removing or installing the control box the ignition switch should be put off so as to prevent the burning of the transistor diode etc in the control box otherwise It would have to be replaced Fig 14 86 Checking of retard system 3 TA E 12 Anti afterburn Valve Checking of anti afterburn valve 1 Remove the air suction hose 2 Run the engine at idle speed Hold the hand over the opening of the air suction hose for the antiafterbum valve If strong vacuum is felt the antkafterburn valve should be replaced 4 Run the engine 3 500 3800 rpm and make sure that when the throttle valve is fully closed suddenly air is sucked in for 0 4 1 0 see through the air suction hose of the antiafterburn valve 5 Run the engine at idle speed 6 Remove the lead wire leading to the solenoid of the amtafterburn valve Make sure that air continues t
17. STEERING LINKAGE 10 1 Checking of Joint 1 Check the dust seal for wear flaw or any damage If the dust seal is defective this will allow entry of water and dust resulting in ball joint wear Replace the dust seal if found defective 2 The end play of the ball stud is preadjusted at the factory 10 be from to 0 20 mm 0 to 0 008 inl If it exceeds 0 5 mm 0 02 in replace the ball joint in its assembled form Fig 10 12 Ball joint 1 Ball stud 6 Ball seat 2 Dust seal 7 Spring seat 3 Socket 8 Spring 4 Ball seat 9 Cap 5 Set ting 10 2 Replacing of Idler Arm After disconnecting the center link from the idler arm the idler arm be removed by removing the mut attaching the idler arm o the bracket Excessively worn bushes must be replaced Install the idler arm to the bracket and center link and tighten the nut to 5 0 40 10 3 Replacing of Pitman Arm After the center link is removed the pitman arm can be removed from the sector shaft by removing the mut and by using the puller 49 0223 695 10 4 10 Install the pitman arm onto the sector shaft align the marks of the pitman arm and the sector shaft and tighten the nut The tightening torque 15 mg 110 10 4 Replacing of Tie Rod The tie rod can be removed from the center link and knuckle arm by removing the ball joint nut and using the ball joint puller 49 0118 850C Install the tie
18. pan 4 Remove the air injection nozzle from the rotor housing Fig 1442 Air injection nozzle b Installing of air injection nozzle Install the air injection nozzle in the reverse se quence 14 17 1 4 Thermal Reactor Checking of thermal reactor 1 Check to see that the thermal reactor is not dam aged or cracked 2 Remove the air hose leading to the air control valve and check to see that the non return valve works smoothly Pressure quae G 9 3 Md c Fig 4 Checking of non return valve 3 Start the engine and keep it running at idle speed 4 Check to see that each part of the air injection system works properly 5 Make sure that most exhaust gas is not released from the cooling air injection pipe for the thermal reactor the alr pump ove the carburetor and intake manifold as 4 Remove the heat insulator S Loosen the nuts and remove the thermal reactor The lower nut must be loosened with the nut remover 49 2113 001 m Fig YA 44 Nut remover Installing of thermal reactor Install the thermal reactor in the reverse sequence JA E 5 Air Control Valve a Checking of sir control valve 1 Turn off the ignition switch and check the opera tion of the solenoid If the clicking sound is audible the solenoid is normal If direct connector of the solenoid terminal to the battery produces no operation sound the solenoid is de
19. this drive is so designed using silicon oil as the medium for transmitting the torque that even if that the fan the engine revolution increases the revolution of the the fan does not exceed a certain limi 3 1 Checking the Fan Revolution Tn case troubles such as oil leakage etc should take place on the fan drive the revolution decreases If the engine fs apt to overheat check the revolution of the fan in the following manners 1 Stick scotch tape on the fan drive shafi and fan as per Fig 3 3 Fig 3 3 Fan drive asembly 2 Keep the engine revolution at 2 000 rpm by using a photo electrical revolution counter 3 Facing the revolution counter to the fan and read the revolution of the fan and if it is less than the prescribed one replace the fan drive and If it is more than the prescribed one carry out the following check 4 After warming up the engine for 5 minites at more than 3000 rpm keep the engine at 000 rpm by using 4 tacho dwell tester and check if the revo ution of the engine at that time is within the prescribed one Prescribed Revolution Shaft 4 000 rpm 1 900 800 rpm 5 000 rpm Low than 2 400 rpm 3 THERMOSTAT Thermostat is for adjusting the temperature of the cooling water circulation in the engine body The thermostat begins to open at 82 180 F and fully opens at 95 C 203 F The lift at this moment i58 mm 0 31 in
20. 1 Place the gasket on the front housing and install the water pump Tighten the nuts 2 Install the water pump pulley 1 D 19 Installing the Alternator 1 Fix the alternator on the mounting bracket with bolt and nut 2 Fit theV belt on the pulleys 3 Attach the upper end of the alternator flange to the strap 4 Adjust the belt tension so that the slack of the belt may be 15 17 mm 0 59 0 67 in at the center point between alternator and eccentric shaft pulleys pushing the belt by about 10 kg 22 Ib For new belt it should be 11 13 mm 043 0 51 Ib 5 Tighten the bolts and 1 0 20 installing the Manifold and Carburettor 1 Remove the engine from the engine stand 2 Install the inlet manifold exhaust manifold and carburettor with their gaskets 3 Connect the carburettor amd metering pump tink 4 Install the metering oil tube and the distributor vacuum control tube 1 ENGINE INSTALLATION 1s installed by reversing the removing 106 Instalime manifold SPECIAL TOOLS 39 0107 680A Engine stand 49 0813 005 Engine hanger 49 0820 006 Attachment engine hanger 49 O815 215 Dowel pull 49 0813 240 Rotor hearing puller and installer 49 0813 245 Expander rotor bearing 49 0813 225 Oll seal removet 49 0813 230 Rotor clump 49 0813 250 Sex 49 0813 235 Main beating puller and inst 49 0820 360 Lock remover 49 0820 060 Ring gear brake 49 0820 035 B
21. 11 WHEEL CYLINDER 11 1 Removing of Wheel Cylinder 1 Remove the brake shoes as described in Par 11 E 1 2 Disconnect the brake fluid pipe at the wheel cylinder Plug the end of the brake fluid pipe 3 Remove the muts attaching the wheel cylinder to the backing plate Remove the wheel cylinder 11 2 Disassembling of Whee Cylinder 1 Remove the dust boots and pistons from the both ends of the cylinder 2 Press la the piston cup and force out the piston cups filling blocks and return spring 11 3 Checking of Wheel Cylinder 1 Wash all parts in clean alcohol or brake fluid 1 9 Never use gasoline or kerosene 2 Examine the cylinder bore and pistons for weary roughness or scoring 3 Check the clearance between the cylinder and piston If it is more than 0 15 mm 0 006 replace with mew parts 4 Inspect the piston cups for wear softening swelling and other damage If any of these conditions exists replace he cups Fig 11 28 Wheel oy Y Valve S Paton 2 Bkeder amp Prin 3 Cap 4 Seat A 11 4 Assembling of Wheel Cylinder 1 Apply clean brake fluid to the cylinder bore pistons and piston cups 2 Install the piston cup in the cylinder with the flat side outward 3 Install the filling block retum spr piston cup and pistons sequ 4 Install the dust boots filling block 1 5 Installing of Wheel Cyl
22. 19 Install the control valve assembly onto the trans mission case with seven bolts to a specified tightening torque of 0 55 0 75 mkg 4 0 5 4 ft lb 20 If the valve body transmission case or rod were replaced measure the distance L in the condition of 65 the valve fully compressed and select adequate diaph rod according to the table below Diaphragm rod 29 0 sew 1 140 27 2 21 7 mm 1 071 088 im 29 5 mim 1 160 in 21 7 28 2 vu 1 0981 30 0 mm 1 180 28 2 22 7 90 5 mm 1 29 in Over 28 7 mm 1 182 in 210 220 21 In tightening totque of 0 35 0 tall rhe oil pan together with the packing to a mkg 2 53 2 6 INSTALLATION AND ADJUSTMENT OF TRANSMISSON 1 Before installing the transmission measure the of the torque converter drive plate with a dial gauge The runout msi be within 0 3 mm 0 012 in In vase the runout exceeds 0 5 mm 0 020 in replace the drive plate 2 Installation procedure for the transmission is reverse to the removing procedure referring to REMOVAL OF TRANSMISSION Part 2 In tightening the torque converter and the drive plate temporarily tighten four bolts first then lock the drive plate with the ring gear brake And tighten the four bolts 10 a specified torque of 4 5 mkg 29 26 In case of confirming the tightening torque accurately it is recomendable
23. AIR BLEEDING clutch hydraulic system must be bled whenever lid line has been disconnected or air enters the 6 H The system To bleed the clutch system remove the rubber from the bleeder valve and attach the bleeder tube and fixture of the bleeder screw Place the end of the tube in glass jar and submerge in brake pedal and allow it to return slowly Continue this pumping action and watch the flow of fluid in the jar When alr bubbles cease to appear close the bleeder valv During bleeding the reservoir of the master cylinder must be kept filled with fluid at least 3 4 of its capacity After the bleeding operation remove the tube the cap on the bleeder valve fill the reservoir and fit the filler cap SPECIAL TOOLS 49 0820 060 49 0813 310 Ring gear brake Clutch disk centering tool 7 D 7 TRANSMISSION TRANSMISSION REMOVAI DISASSEMBLING THE TRANSMISSION TRANSMISSION INSPECTION 2 1 Inspection of Transmission Case Checking the Bearings Checking the Gears Checking the Synchronizer Mechanism Checking Run Out of Main Shaft ASSEMBLING THE TRANSMISSION 7 0 1 Assembling the transmission 7 D 2 Assembling the Extension 7 0 3 Installing the Extension Assembly 7 D A Installing the Clutch Housin INSTALLING THE TRANSMISSION E ii LR LAU
24. Note When adjusting the preload care must be taken not to affect the backlash of the drive pinion and ring gear 4 Tighten the bearing cap bolts to a torque of 40 m kg 30 ft b 5 Install the adjuster lock plates on the bearing caps to prevent the adjuster from loosening 6 Check the tooth contact of the ring gear and pinion by applying thin coat of red lead both sides of about six or eight of ring gear teeth and rotating the ring gear few times to and fro If the pinion position and backlash have been correctly set the contact pattern should be as shown in Fig 9 30 Fig 9 30 Correct tooth contact 9 REAR AXLE INSTALLATION t Install the rear axle to the rear axle housing and attaching nuts 2 Attach the propeller shaft to the companion Mange of the rear 3 Install the rear axle shafts and adjust the end play as instructed in Par 9 5 4 Refill with the up to the level hole SPECIAL TOOLS 49 0223 630A 49 0259 631 49 0159 745 49 0164 550D 49 0223 561 49 0259 720 49 0259 710 49 0727 570 49 0305 555 Rear axle shaft puller Attachment for puller Bearing remover set Rear axle stand Attachment for stand Backlash adjusting spanner Companion flange bolding tool Pinion adjusting gauge Gauge block and bearing model STEERING 10 A CHECKING OF STEERING WHEEL PLAY 10 STEERING GEAR REMOVAL 10 B 1 Removing of Steering Gea Separate type 10 B 2 Remov
25. sequen 1 Remove the buttery earth 2 Jack up the vehicle and support with safely Remove the heat insul the exh pe br gbi side of the Loosen and remove the bolts f i ibe rear of the pressilencer 4 Loosen and propeller shaft and pull from the extension housing Apply i pl 5 Disconnect rhe speedometer cable from the exten mon housing 6 Ren Remove the vacum hose from the disconnect the wire wires the clip Pig 2 Removing unde 10 Fix th 0877 060 lor with the ring gear brake 49 wy engine model 49 0178 060 for then loosen and remove four bolts to the drive by that using the time make align j the torque convert wrench 4 0877 4 At the same and drive Note In the cose of engine models it is advise le 10 loosen the boite the torque voverter te drive through the hole for starting motor location ported with the trans der remove the tightening of the transmission widen be clear the te arier motor Then loosen and remove that connect the engine and the rop of the orque amp 10 disconnect the iansmis Fig 210 Bolis wi 19 Return the transmission to the level position While slowly plying 8 screw driver or seme between the converter
26. to the center link and steering kouckle Note Whenever the tie rods or ball joints re placed the toein must be reset 10 H 5 Greasing of Idler Arm The idler arm requires lubrication only once in two years or every 48 000 km 30 000 miles Therefore greasing is necessary within this period When lubricating remove the plug and temporarily install the grease nipple Loosen the nut that holds the idler arm to the bracket and then feed Lithium Grease until new grease appears from the brim of the bush After greasing lighten the nut to 5 0 mg 0 5 40 feb Remove the grease nipple und reinstall the plug Fig 10 14 liler arm Note The ball joims for the steering linkage are filled with lithium grease and ate completely sealed which require no lubrication service fig 10 15 Steering linkage 1 Split pin 2 Nur 3 Ball joint 4 Tie rod 5 Boll Joint 6 Dust seal 7 Set ring 3 Spindle 9 Bush 10 11 pim 12 Nut 13 Washer arm 15 Center link 10 FRONT WHEEL ALIGNMENT 10 141 Inspection before Checking Front Wheel Alignment Proper alignment of the front wheels must be main tained in order to ensure steering stability and satis factory tire life Before checking or correcting the front wheel alignment the following points which will affect steering should be inspected 1 Check the tire inflation and bring to recommended pressure 2 Ins
27. 12 Secondary cup 13 Secondary cup 4 Secondary piston 15 Primary cup 16 Primary piston n 2 11 11 4 Assembling of Brake Master Cylinder 1 Dip the pistons and the cups in clean brake fluid 2 Fit the check valve on the spring and place them the outlet hole Install the pipe fitting lo the outlet hole 3 Insert the return spring of large coil diameter into the cylinder 4 Fit the secondary cup and primary cup onto the secondary piston so that the side of the cup goes toward the piston 5 Fit the guide pin into the stop bolt hole and insert the secondary piston assembly together with the spring seat into the cylinder 6 Push the secondary piston as far av it will go remove the guide pin and install the stop bolt 7 Fit the primary cup onto the primary piston so that the flat side of the cup goes toward the piston 8 Fit the secondary cup onto the primary piston with the edge side of the cup facing the secondary piston 9 Insert the return spring of small coil diameter and the primary piston assembly with the spring seat 10 install the stop washer and snap ring Note Make sure that the piston cups do nor cover the compensating ports 11 Install the reservoir 12 Install the dust boot to the cylinder 11 5 Installing of Brake Master Cylinder install the master cylinder carry out the removing operation in the reverse order After installing
28. 23 or 052 0 6 US gallon b Removing of coasting valve Remove the air cleaner 2 Remove the air hoses and the vacuum sensing tubes from the coasting valve 3 Loosen the mounting bolts and remove the coast ing valve 14 Idle Switch Checking of idie switch Remove the idle switch terminal 2 If there is conduction when an external force is not applied to the switch knob when the primary throttle valve opens at idling opening angle and if there is conduction when an external force is ap 14 22 Fig 1A 89 Checking of idie switch plied the idle switch is normal b Removing of idle switch 1 Remove the air cleaner and relevant hoses Remove the coasting vulve and carburetor Loosen the screws und remove the idle switch Install the idle switch in the reverse sequence Warm up the engine until the water temperature rises about 70 C 159 F 3 Make sure that the idle fuel flow and the idle speed are within the normal range 4 Adjust the engine speed to 1 075 1 100 rpm by turning the throttle adjusting screw S Tum the adjust screw of the idle switch until idle switch changes from OFF 10 ON 6 Slowly return the adjust screw of the idle switch and stop just where the switch changes from ON to OFF 7 sure that the idle switch turns on above 1000 rpm when the throttle adjust screw is re Turned 8 the engine speed 0 900 rpm by tuming the throttl
29. Checking of ventilation valve 1 Check 10 see that the air cleaner element is not clogged 2 Install a vacuum gauge as in Fig 14 64 Start the engine When the engine speed is raised to 2 500 3 000 rpm the vacuum reading nusi be under 60 mm Hg Fig 14 64 Checking of ventilation valve b Removing of ventilation valve 1 Remove the fuel return valve 2 Remove the distributor vacuum tubes 3 Remove the ventilation hose at the ventilation valve 4 Loosen and remove the ventilation valve with the ventilation valve wrench 49 2113 005 TA E 18 Charcoal Filter Checking of charcoal filter 1 Check to see that the air cleaner element is not clogged 14 23 Fig 14 65 Removing of ventilation valve 2 Visually check the adhering condition of oil When the whole surface is damp with oil measure the ven tilation resistance 3 Attach a vacuum gauge as in Fig 1 64 Check To see that when the engine speed is raised to 2 500 3 000 rpm the vacuum gauge reads under 60 mm b Removing of charcoal filter Remove the air cleaner cover 2 Loosen and remove the charcoal filter ig 14 66 Removing of charcoal filter 1A E 19 Distributor a Adjusting of ignition timing Adjust the ignition timing as follows 1 Connect timing light to the high tension cord for leading spark plug of front rotor housing 2 Start the engine and run it at idle speed of 900 rpm Aim the timing l
30. Clean Sec IA E 21 See 1A E 13 Replace 1A E 13 1A E 17 1 Symptoms and probable causes Remedies 5 Improper fuel connection between primary and secondary zones Shock w caused when accelerating from running at around 3 000 rpm by depressing the accelerator pedal Shock cauyed when promptly accelerating from the middle speed or the decelerating condition 1 of carburetor jets 2 Excessively low carburetor fuel level 3 Serious clogging of air cleaner clement 4 Continuously opened antiafterbum valve ait supply valve ad coasting wale 6 Large car knocking during cruising dris impossible to cruise constantly in any gear Stock i sometimes caused during running in top gear Note These phenomena are more cr Sess inevitable Therefore unless the car knocking is excessive Il can be regarded to be normal 1 Clogging of carburetor jets or excessively low fuel level 2 Trailing side ignition does no occur 3 Air teak from each hose 4 Air leak fiom tach valve 5 Fouled spark plug 6 Improper distributor vacuum advance no advance 7 Abnormally Urge engine knocking 1 Improper inition timings of leading and trailing sides excessive advance 2 Excessive disinburor vacoum advance 3 Excessive distributor centrifugal advance 4 Too poor fuel 5 Insufficient heat range amd extreme gap erosion of spark plug 8 Presgnition or back Large noise comes from
31. Fig 6 3 Release Dearing hearing i packed with lubricunt which is intended to last the whole life time of the bearing Therefore the bearing must not Ue washed in gasoline or amy other solvent 6 0 2 Checking the Pressure Plats Assembly Check the contact surfaces of the pressure plate with the chitch facing for wear damage or warpage 1f il ty aight correct by Hopping with compound or by turing a lathe But iF severe replace with new one Check the d phragm un cover and if any wear or damage ii found the pressure assembly 6 0 3 Checking the Clutch Disk inspect the clutch disk for warpage with dial Indi cator or a feeler gauge ax shown in Fig 6 4 If it is more than 1 0 mm 0 0394 in repluce with new one Fig 6 4 Checking chitch disk Replace excessive worn facing as it will cause slip page or scores the pressure plate and Aywheel due to the projected heads of rivets If oil is evident the facing clean or replace the facing and eliminate the cause of oi leakage Make certain that the clutch disk slides easily on the main drive shaft without any excessive play If the play exceeds 0 3 mm 0 012 in replace the clutch disk or the main drive shaft Fig 6 5 Checking spina Ai af di 6 0 4 Flywheel Inspection Inspect the contact surface of the flywhoel with the clutch fucmg for burnt surfoce scored surface of rivel grooves Af ie
32. Use the following window tool set 49 0305 870 as shown in Fig 14 2 to remove and install the wind shield glass 14 1 Removing of Windshield Glass 1 Remove the interior mirror and also the tight and eft front pillar trims from the interior of the vehicle 2 Remove the wiper arms 3 Using the mould remover 49 0305 871 remove the mould in the manner shown in Fig 14 2 4 Remove the clips Fie 141 Structure of windshield Fig 14 3 Removing of mould Les Fig 14 2 Window tool set 1 Sealant gun 49 0305 872 5 Dam 9 Cutting knife 2 6 Mould remover 49 0305 871 10 Primer Part 0305 77 734 3 Sealant Past No 0305 77 739 7 Needle eyeleteer 4 Spacer Brush 12 Piano wire 0 5 mm diameter 4 1 14 5 Pierce the windlow sealant with needle eyeleteer Pass piano wire of upproximately 500 mm 20 long through the hole and wrap each end of t around a small bar 14 4 Piercing of pino wit off along the entire circum persons one inside the outside each pulling one of the bur were using Fig 14 5 Cutting of sealant Note a When cutting the sealant with a plano wire cut it along the border between the window glass and the sealant b The piano wire is liable to snap if only certain section is constantly used and becomes hot Therefore when cutting the sealant ensure that the piano wire is k
33. ing a dial indicator The permissible run out is under 0 1 mm 0 004 inl Fig 13 13 Checking of run out 7 Check the contact surface of the piston with the check valve and the relief valve for wear or damage M excessive wear or damages are found replace with new one 8 Check the piston ring for wear or damage 9 Check the relief valve and the check valve for wear damages and flatness 71 i a 10 Check ihe check valve spring for signs of fatigue damages 11 Check the run out of the pressure tube The permissible run out is under 0 2 mm 0 008 in Fig 13 14 Checking of runout 12 Check the inner diameter of the pressure tube The inner diameter of the tube should be less than 30 07 mm 1 184 inl 13 Check the cap nut and seal for damaged threads and check the tip of the oil seal for wear or damages If necessary replace with new one 13 5 14 Check the rod guide for wear damage 15 Check the base valve casing tension valve com pression valve and washer for wear or damages samen T Tes er 010 mm 0004 i 4 Compesason valve 0 30 mm 0 008 a x Waber 030 mm 0020 i x 1 Les ibat 002 ss 8 0008 i 13 A 4 Assembling of Front Shock Absorber 1 Install the piston ring to the piston 2 Place the top end of the piston rod in a vise being ca Teful to protect it with aluminum plates and install the washer check valve spri
34. oll the bolts using Ihe hex head extension 49 4000040 then piston return spring nnd can the low and reverse brake hole with amp bol f m move Ihe inner mwe srap f Remove w blowing comp To Inspect 4 Check the friction plate Jor worn u ing 3 Check 10 dee the piston rouen prihig haa iut lioet uem Check 1 see thut there rine ue p F Check 10 that ibe seul ti isle Hf defective qe ul replice with new one To Rea 10 on the piston the return spring support ring return spring ring wnd oneway clutch in this order Them vighten the race from rear of the vase with eight bolts by using the nex head exension 4 000 040 10 sp torque of 1522 0 mkg 11 15 fill 40 8000 040 Fig 228 Tightening mner tace 11 Resosertible ihe dished plate steel plates friction n ing each and remining plate in the rev order smeur er oil Then fit the 12 After reassembly measure the the ring und plate ond select tew nin plaw to provide stundiitd 08 21 05 0 0820 04 AN Pig 229 chew Note To adjust abive ce ihe retaining plate aille the following
35. spring holder 49 0223 640A and 49 0223 641 compress the coil spring 11 Hold the upper end of the piston rod with a spanner and then remove the lock nut 49 Fig 13 6 Removing of lock nut Remove the mounting rubber bearing rubber seal spring seat upper rubber seat upper adjusting plate seal ring dust boot coll spring and lower seat in that order Fig 13 7 Front shock aborder 1 Shock absorber 6 Bearing 2 Rubber seat lower 7 Dust seal ding 3 spring 8 Spring sest upper 4 Mounting rubber rubber seat upper adjusting 5 Rubber seal plate amd boot 13 13 2 Disassembling of Front Shock Absorber 1 Using the nut wrench 49 0259 700 remove the cap nut and seal from the reservoir tube 0258 Fig 13 8 Removing of cap nut 2 Remove the ring installed on the piston rod guide with suitable tool I te Fig 13 8 Removing of O ring 3 Pull out the piston rod assembly from the pres sure tube 4 Remove the piston rod guide back up ring stop per and stopper guide from the piston rod 5 Hold the upper end of the piston rod a vise being careful to protect it with aluminum plates and remove the piston nut Fig 13 10 Removing of piston mut 6 Remove the washer centering valve relief valves piston check valves check valve springs and the washer from the piston rod in that order 7 Remove the piston ring
36. 46 Check the oil level agai 4 When checking and regulating are over condiscy Mall test road test and hydraulic test referring t0 dingnostic test items IB in order 10 muke sure that the transmission works normally REAR AXLE 9 REAR AXLE SHAFT 9 Removing of Rear Axle Shaft 9 A 2 Replacing of Axle Shaft Bearing 9 A 3 Installing of Rear Axle Shaft 9 REAR AXLE REMOVAL 9 REAR AXLE DISASSEMBLY 9 C 1 Removing of Differential 9 2 Disassembling of Differential 9 3 Removing of Drive Pinion 9 4 Removing of Pinion Bearing Outer Race 9 D REAR AXLE INSPECTION 9 D 1 Checking of Drive Pinion and Ring Gear 9 0 2 Checking of Differential Gears 9 D 3 Checking of Bearings 9 D 4 Checking of Seal 9 0 5 Checking of Companion Flange 9 REAR AXLE ASSEMBLY 9 1 Adjusting of Drive Pinion 9 E 2 Adjusting of Pinion Bearing Preload 9 E 3 Assembling of Differential 9 4 Installing of Differential 9 5 Adjusting of Backlash 9 REAR AXLE INSTALLATION oc we AR es eoo 22229 9 REAR AXLE MAZDA RX2 is equipped with semifloating type rear axle with a hypoid ring gear and pinion set The final reduction ratio is 3 700 9 REAR AXLE SHAFT 8 1 Removing of Rear Axle Shaft 1 Remove the rear wheel and brake drum 2
37. 49 0839 425 15 Remove the snap rings from the ball bearings of the front side of the case Remove the ball beatings from the main drive gear and counter shaft gear using the bearing puller 49 0859 425 Fig 7 8 Removing bill bearing 16 Take out counter shaft gear main drive gear and main shaft assembly from the case 17 Remove the thrust washer low gear and sleeve assembly synchronizer ring low and second clutch hub assembly synchronizer ring and the second gear in that order 18 Remove the snap ring on the front end of the main shaft Remove the third and top clutch hub assembly synchronizer ring and third gear 2 INSPECTING THE TRANSMISSION 7 C 1 Inspecting the Transmission Case Clean the transmission case thoroughly with a suitable solvent and with compressed air Inspect the case for cracks Or any damage 7 2 Checking the Bearings Inspect each bearing for roughness and excessive wear They can be determined by slowly turning the outer Tace by fingers If excessive wear or roughness is found replace with new bearing as it will cause the noises 7 C 3 Checking the Gears Inspect the teeth of each goar If excessively worn broken or chipped replace with new gears Excessive wear of the gears causes increase of backlash which results in producing noises or may cause the pear to work off while running 7 C 4 Checking the Synchronizer Mechanism 1 To check the contact between the inner
38. E 1 Removing of Top Ceiling 1 Remove the rear view mirror sun visors interior lamps assist handles ete 2 Remove the front pillar trims and rear package tray trim 3 Strip off the seaming welts from the body flange 4 Strip off the front and rear polythylene plates from the inserting point of the body 5 remove the listing wire and top ceiling 14 2 Installing of Top Ceiling 1 Affix the head linings top insulations onto the body ceiling with adhesive cement 2 Heat up the top ceiling to a temperature of 30 C to 50 C 86 to 1229 F 3 insert both ends of each of the disting wires to their proper positions in successive order beginning from the rear shown in Fig 14 28 When doing so be careful that the wires do not swing down 4 Insert the front and rear polyethylene plates of the top ceiling to the inserting point of the body 14 7 Fig 14 28 Installing of listing wire Note When inserting the top ceiling if the guide made wf plastic plate is used you can insert it without touching the weaving point Fig 14 29 lmerting of top ceiling 5 Apply neoprene adhesive cement to the outside of the body flange 6 After one or two minutes pull the top ceiling from both side to avoid any slackening and glue both side onto the body flange 7 After the top ceiling is properly attached to the body flange clip off all protruding edges 8 Install the seaming welts rear view mirror
39. For inspection of the thermostat place the thermostat together with a thermometer in water Stir the water 322 3 while gradually heating Measure the temperature under which the thermostat begins to open and the lift If the measured value differs excessively from the stand ard value install a new thermostat lti amp of wax type and bottom bypass type which ie superior in the cooling efficiency The bypass hole is provided at the lower part of the thermostat as shown in Fig 3 4 through which a large volume of cooling water flows when the thermostat is completely closed that localized rise in temperature can be prevented te sealer Fig 3 4 Thermostat On the other hand when the thermostat is completely opened the bypass hole is closed by the thermostat valve and all the quantity of cooling water is cir culated into the radiator which will enable the ra diator to work effectively However in case the ther mostat is taken off the volume of cooling water flow ing through the bypass hole i large due t0 larger bypass hole and water circulating into the radiator will decrease by half which will result in the rise of the temperature of the cooling water Accordingly be sure not to off the thermostat nor to use any other make instead of this type 3 6 WATER PUMP The water pump is of the centrifugal impeller type The i supported in the pump body by two beatings
40. Remove the brake shoe assembly as detailed in Par IIE 3 Remove the nuts holding the brake backing and bearing retainer to the axle housing 4 Extract the axle shaft assembly using the puller 49 0223 630A und 49 0259 631 Fig 9 1 Removing of rear axle shaft 9 2 Replacing of Axle Shaft Bearing 1 Remove the rear axle shaft assembly as described in Par 9 2 Using the bearing ramover set 49 0259 745 sup port the spacer and press the axle shaft out of the collar and bearing as shown in Fig 9 2 Fig 9 2 Removing of beating 1 Rear axle shaft 4 Spacer 2 Collar 5 Retainer 6 Bearing Note In case the pressure necessary to press out the axle shaft exceeds 10 tons 22 000 Ib or if the bear ing remover set is not available grind off the part of 9 1 bearing retaining collar and cut it with the use of a chisel as shown in Fig 9 3 taking care not to damage the axle shaft Fig 9 3 Cutting of bearing collar 3 Remove the bearing retainer from the axle shaft 4 Clean all parts and check the condition of the cok lar spacer axle shaft and the oil seal located in the axle shaft housing 5 Install the bearing retainer and spacer onto the axle shaft 6 Position the bearing on the axle shaft with the sealed side toward the axle shaft flange and press it on until the spacer comes in contact with the shoul der of the shaft 7 Press the bearing
41. Tightening the Tension Bolts 1 Fit the tension bolts 2 Tighten the bolts gradually in the order shown in Fig 1 89 The specified tightening torque is 2 5 mg 18 Note Attach the pulley bolt 10 the front end of the eccentric shaft and by means of a wrench to confirm smooth rotation 1 D 11 Installing the Clutch Assembly 1 Apply grease to the oil seal of the rear housing 2 Mount the flywheel to the rear end of the eccentric shaft through the key 3 Apply sealing agent to the both faces of lock washer apply the locking agent on the thread of the eccentric shaft and place the lock washer in position and install the lock nut 4 Hold the flywheel with the ring gear brake 49 0820 060 and tighten the lock nut to a torque of 45 mg 320 ft lb 5 Bend the tab of the lock washer 6 Holding the clutch disk at the mounting position on the flywheel Insert the clutch disk centering tool 49 0813 310 through the spline of the clutch disk into the needle bearing at the rear end of the eccentric shaft 7 Mount the clutch cover and match the O mark on the clutch cover with the reamed hole of the wheel and fit the securing bolts 8 Tighten the bolts to a torque of 20 mkg 15 Tt4b 1 0 12 Adjustment of Eccentric Shaft End Play 1 Turn the engine so as to place the front side of engine upward 2 Fit the thrust plate spacer and needle bearing on the eccentric shaft and then apply sufficie
42. amp lateral mod 2 22 40 16 kg mm 124 249 2 bfim 10 8 mm 0 43 in 100 8 mm 3 97 in Free length Fitting length Spring Pressure Mor dors 371 14 81 in 247 mm 9 73 in When the spring length is compressed to 247 mm 9 7 in 263 4 271 kg 581 597 1b 21 409 397 615 Ib 279 286 6 615 632 Ib De eatbon 4 1 13 WDC 43x13 WDC 185 SR 13 or 155 HR 13 155 SR 13 or 195 HR 13 155 SR 13 or 155 HR 13 155 SR 13 or 155 HR 13 1 5 21 3 than 100 km h 60 mile h 17 24 2 more 100 km h 60 mile h 1 5 kg ent 21 3 Ib int lese than 100 km h 60 mile 1 7 iem 24 2 dbfint more than 100 km h 60 mile h 0 20 em kg 0 0278 inos Under 1 3 mm 0 0612 in Overall length Overall width Minimum turning radi Rond cesrance Car weight po load 4 180 inm 163 39 1 580 mm 62 21 in 12 mm 55 91 in 2 470 97 25 in 1 285 imm 50 59 in 1 290 50 39 in 4 700 mm 185 01 in 360 mm 6 30 in 645 mm 25 39 in 980 mm 38 58 in 5 955 ke 2105 4 Ib Engine Temin Flywheel Eceentrie ley Spack plu 923 Vim det it Ann bolt amp nui Sun boli amp Church Pressure plate Master cyliuder reserver Transmission Main shalt Jock nut Shift fork lock bolt Trana musice cine Sm dmi bol Piupeller shati Yoke bh Rear anle Companion Wange Rum
43. and remove the caliper assembly from the brake disk 4 Remove the grease cap split pin and beating ad justing mat 5 Remove the thrust washer und outer bearing from the hub 6 Slide ihe hub and brake disk assembly off the spindle 7 Remove the wheel hub 8 Drive oui the besring outer races using a brass drift iw the sluts provided for thit purpose seal amd inner bearing from the 12 F 3 Installing of Front Wheel Bearing Install the wheel bearings in the reverse order of te moving with care tukon on the following points 1 Clean the bewings thoroughly and repack them with lithium grease Do not overpack 2 Fill the hub cavity with lithium grease 3 Adjust the bearing preload instruct following paragraph in the 12 F 4 Adjusting of Front Wheel Bearing The wheel bearing preload is adjusted by the adjust ing nut Adjusting procedure is as follows 1 Check the bearing preload by hooking a spring scale in the wheel hole on the hub Fis 12 5 Checking of beanng preload 2 Pull the spring scale squately amd take a reading on the scale when the hub staris to turn This read ing should be 04 to 09 kg 0 9 to 2 0 Ib 3 Tighten the adjusting mut until the correct read ing is obtained 4 Fit the sel cover onto the adjusting nut and align the slots of the set cover with the hole of the dle Install the split pin 12 6 REAR WHEEL BEARING Servicing the year wheel bearin
44. he ear 2 2 b Other Checks in Driving 1 Check each range for faulty performance or shift ing Check to see for instance that Q Firm locking is efiected when P is selected 9 Reversing is effected when R is selected 8 Completely neutral condition is attained by select ing N 4 Dy DyesDy shifts take place D range 5 Kickdown takes place When 1 is selected from D there occur Dy lel or Dy 1 shifts with engine braking ef fected in 1 and 1 7 The transmission does not shift up in I range 8 In 2 range the transmission is fixed to 2nd speed 2 Check to see that shifting is smooth without con spicuous shock and there is marked creep Slight creep in each range normal 3 Check to see that shifts nre effected promptly with drag 4 Check for abnormal gear noise eluteh band squeal poor acceleration or oil leak 1 8 3 OIL PRESSURE TEST When there is slippage in the gear train or when shifts do not feel proper line pressure and governor pressure must be checked The following chart shows standard lime pressures before cut back which are applied to the all models Time Pressure karen ient Range Engine lating Sell 95 990 on a8 to ov 40 220 0 57 100 701 30 0 ST 935 110 35 156 ROAST 100120170 ao 40 a SB No
45. hose or valve Check 72 7 5 improper operation of trailing side spark plug Replace a Defective thermosensor Replace b Defective vacuum switch Replace Defective control box Replace 5 Much hydrocarbon and carbon monoxide in exhaust gas 1 improper carburettor adjustment A Low ile speed b Lean mixture 2 Fouled or improperiy adjusted spark plugs adjust replace 3 Improper ignition timing adjustment Adjust 4 Improper operation of ignition contro system Check item 4 5 3 Improper operation of air injection system 14 21 1A Symptoms and probable 4 Leaky or disconnected hoses b Bend or clogged hoses Improper pump V belt tension 4 Defective atr pump 2 Defective check valve f Defective air control valve 4 Excessive air leak into intake manifold from each connection hose or valve Connect t replace Repair or replace Adjust Replace Replace Check 2 10 Check 2 7 Ny Defective ventilation valve Replace Defective thermal reactor Replace TECHNICAL DATA Carburettor Distributor Zenith wromberg Dwell angle 38230 speed 800 rpm Contact point gap 0 45 005 mm 0 018 0 002 in le uel flow V 2101 047 04 US Contact point pressure 500 650 gr 1 1 1 4 1b gallonitty Condenser capacity 0 27 80 027 j CO concentration 0 305 Centrif
46. idling driving deceleration or driving in acceleration Probable causes Defective No 2 control box b Defective No 2 thermoseny Defective choke ywiteh Antiafterburn valve Possible troubles Corresponded T Abnormal afierburn occurs during deceleration 1 Abnormal alteibum occurs during Key off 3 Regular car knock surging becomes excessive 3 Flat spot occurs when vehicle speed slightly accelerated from low speed or deceleration 5 Hard engine scaring 6 Rough engine idling 7 Abnormal amounts of idie HC and CO 8 Flat spot occurs during driving Conditions of rouble of system X Remains constantly alowed B Remains constantly open C Excessive ait leakage from valve Possible cause Defective antafterbum valve Cowsing valve Possible troubles Comepondel ium Rough engine idling x 2 Hand engine starting Abnormal amounts of idle HC and CO Ac Abnormal afterbum occurs 5 Flat spot occurs during driving 6 Regular cat knock surging becomes excessive C 7 Fiat spot occurs when vehicle speed is slightly accelerated from low speed or deceleration 8 speed becomes higher ing idling becomes higher AC Conditions of trouble of A Remains constantly open or there delay in closing B Remains constantly clowd of there iv c ly in opening Excessive aic leakage from v
47. the choke valve return spring The return spring is normally hung in the upper hole but the cold districts it is hung in the lower hole to improve the engine startabiity 4 Idling adjustment Adjust the idling speed with the engine sufficiently warmed up and the choke valve fully opened 1 Set the idling to the regular speed with the throttle adjusting screw 2 Adjust the idle adjust screw until the smooth idk ing is obtained When the idle adjusting screw is screwed in the mixture of the fuel and air becomes lean When rhe screw is loosened the mixture be comes rich 3 Adjust the idling so that the engine revolution will be 700 rpm in the above manner of 1 and 2 4 Screw the idle adjust screw from the position adjusted as above until the engine stalls In this case if it is less than 2 4 turn unscrew the idle ad Just screw to the position previously settled if it is more than 3 tum unscrew the adjust screw by 3 4 tum from the position where the engine stalls Note 1 To measure the engine revolution be sure lo a revolution counter intended for general servicing instead of the tachometer equipped on the vehicle 2 Set the adjust screw lightly to avoid dame the needle 4 8 FUEL PUMP 4 8 1 Fuel Pump Test If the fuel pump does not supply the proper amount of fuel to the carburettor the following tests should be made prior to disassembly of the pump Pr
48. 0 002 in If the clearance exceeds 0 03 mm 0 003 in replace the the three ars with those selected from nds Make sure that the inner and outer gears are replaced as set Pig 2 37 Measuring clearance 1 5 Check the clearance between the outer gear teeth and crescent The standard valve 0 14 0 21 mm 0 06 0 008 in 0 010 in If the clearance exceeds 0 25 mm replace the gears ing clearence 2 6 Check the clearance between the outer gear and the housing The standard valve is 0 05 0 20 mm 0 0025 0 008 in If the clearance exceeds 0 25 mm 0 010 in replace the gears as a set Pig 229 Messuring clearance 0 7 Check to see thar the seal rubber attached on the pump housing periphery is not damaged 8 Check to see that the lip is not damaged nd 8 Check see that the seal rings of feed grooves for the fr lost tension Measure the side clearance of the seal dard valve is 0 04 0 16 mm 0 002 When replacing seat ring refer to part he spring has not lost tension and rear clutches are not damaged The i 0 005 in F 16 10 Check that the pump housing and the cover are not damaged 11 any defective part is fou To Reassemble 12 Fix the pump housing t the torque converter amd fit the inner gear and outer gear n the pump housing as were installed al Then fit the pump cover as shown in Fig 2 40 and tighten i
49. 04 mm 00120016 in Back gap 07 1 1 mm 0 028 0 043 in Voltage 14 0 5 Alternatot 4 000 rpm Fig 5 19 Regulator gap 5 G STARTING MOTOR 5 1 Checking the Starting Circuit When the starting motor fails to operate or does not satisfactorily operate check the following points be fore removing the starting motor 1 Weak battery 2 Corroded or loose battery terminal 3 Loose starting motor terminal 4 Broken or loose wires of the starting circuit 5 Faulty ignition switch 5 1 5 G 2 Testing the Starting Motor a Free running test 1 Place the starting motor in vise equipped with soft jaws and connect a fully charged 12 volts battery to the starting motor 2 Connect an ammeter between the terminal of the starting motor und the battery 3 Operate the starting motor und take a reading The current draw should be 70 amperes minimum at 3 600 rpm more Volimeter Fig 5 20 b Lock resistance test 1 Install the starting motor on test bench 2 Test the lock resistance of the surting motor following the instructions of the test equipment manufacturer 3 With applied battery voltage adjusted to 6 0 volts the current flow should be 60 amperes and the tor que should be 2 7 mkg 19 5 feb 17 the starting motor does not perform to the above test requirements repair it referring to the follow ing list 1 Starter rotates slowly
50. 10 proceed follows Install torque wrench t the hole in the center of the special wrench 49 0378 496 and tighten the il the reading on the torpue wrench comes med by the undermentioned bolt to the value be o formula Pig 251 UL length of wrur wrench LY indicates the effective length of the torque wrench In the case of the torque wrench expressed in the mkg unit measure the L in terms of cm and substitute the value for example 30 case of 30 em into formula 2 In the case of the ftJb torque wrench on the other hand measure the L the inch unit and substitute the value into formula 8 The prescribed tightening torque will thus be obtained sL mam o 35L EE wns w que 4 When the installation ia finished rotate the crank shalt and check to we that there ie ho interference in the transmission Then make the following check converter oil The converter when empty can hold 5 5 liers 11 6 us pints 9 7 Imp pints 5 7 ws quarts 1 A 1 Check and regulate the manual linkage I A 4 Check and regulate the inhibitor switch 1 A 5 Check and regulate the engine idling 1 2 Apply the band brake With the engine idling the manual lever N D 2 1 and and check see that there is a slight shock of the transmission 9 Confirm the operation of the kickdown switch and downshaft solenoid 1 A 3
51. 13 SUSPENSION The front suspension is of double action shock ab sorbers integrally made with each steering knuckle coil springs suspension arms and stabilizer bar This front suspension does not require lubrication except the lower ball joints which are provided with plugs to attach grease fittings when required The toein can be adjusted but the camber caster and king pin inclination are set during production and can mor be altered The rear suspension is of a four links lateral rod coil mp and De Carbon type shock absorbers 13 A FRONT SHOCK ABSORBER 13 1 Removing of Front Shock Absorber 1 Jack up the vehicle until the front wheels are clear Of the ground and remove the front wheel 2 Remove the three nuts attaching the mounting rubber to the front fender apron 3 Disconnect the brake pipe from the reservoir tube Plug the end of the brake pipe to prevent leakage of the fluid 4 Remove the bolts attaching the caliper to the dust cover and remove the caliper 5 Remove the hub grease cap split pin set cover and bearing adjusting nut from the steering knuckle spindle 6 Remove the wheel hub and brake disk assembly from the steering knuckle spindle 7 Remove the two bolts attaching the front shock absorber to the steering knuckle arm Fig 13 4 Removing of two bolts 8 Remove the shock absorber w Of shock absorber 9 Hold the shock absorber in a vise 10 Using the
52. 212 F 2 Mount fhe engine tachometer at a locution that allows good visibility from the driver s seat and put 4 mark on specified revolutions on the meter 3 Secure the front and rear wheels completely with chocke and apply the band brake Be sure de press the brako pedal firmly with the left foot be fore depressing down the accelerator pedal 4 Place the manua lever in D Range 5 Gradually step on the accelerator pedal to the wide open position soon ms the engine speed becomes constant read ihe engine speed and release the ac celerator pedal Place the manual lever or P and run the engine a nou 1 200 rpm for more than one minute to cool down the torque converter nnd coolant 7 Proceed 10 do the stall test for 2 1 and in the same manner as for D 4 Note The stall test operation as specified in the item 5 should be made within five seconds If it takes 109 long the oil deteriorates and the churches brake and band are adversely affected Sufficient co oling time should be given between each test for the four ranges D 2 1 and Judgement By comparing the measured stall speed and the spe ified one troubles can be surmised as follows 1 Standard stall revolution Both transmission control elements and engine per formance are normal and the one way clutch of the torque converter is not slipping though whether or not there is sticking is u
53. 641 Screw For coil spring holder 49 0259 700 nut wrench 49 0259 702 Hook wrench 49 0259 560 Ball joint remover and installer BODY 14 A WINDSHIELD GLASS 14 A 1 Removing of Windshield Glas 14 2 Installing of Windshield Glass 14 REAR WINDOW 14 FRONT DOOR 14 C 1 Disassembling of Front Door 14 C 2 Assembling of Front Door 14 3 Adjusting of Front Door 14 D REAR DOOR 14 D 1 Disassembling of Rear Door 14 D 2 Assembling of Rear Door 14 E TOP CEILING 14 E 1 Removing of Top Ceiling 14 E 2 Installing of Top Ceiling 14 REAR SIDE WINDOW 14 F 1 Removing of Rear Side Window 14 F 2 Installing of Rear Side Window nun 14 14 WINDSHIELD GLASS Windshield glass of the type which is bonded on is installed the wind shield glass bonded to the body in order to reduce the noise level of the wind blow ing against the windshield glass during driving obtain tight sealing enhance the body strength and increase the safety at the time of crash Fig 14 1 shows the structure The windshield glass is bonded to the body with a and the dam prevents the sealant from being forced towards the interior of the vehicle when the window glass is being installed The windshield glass positioned to the body with to 4 spacers and the mould is fitted into the clips attached to the body glass
54. 8 mm 051 in high along the entire circum ference of the window glass with the sealant gun 49 0305 872 fitted with a sealant cartridge see Fig 14 13 If the sealant comes apart from the painted surface on the body side use the remainder of the sealant for rectification Sealant Fig 14 14 Detail B of Fig 14 1 Note Shape the nozzle of the sealant cartridge with a cutting knife as shown in Fig 14 13 Then break the film of the sealant with piece of wire and it is ready for application b If the application is unsatisfactory rectify it with wooden spatula If any sealant adheres to your hand it should be removed immediately 7 Install the window glass to the body Adjust the step between the window glass and the body to be 5 8 mm 0 23 in Fig 14 16 Adjusting of step Note a After placing the window glass on the inner side of the spacer push the glass with the fund and check the step at the four positions shown in Fig 14 15 b If possible do not apply any force to the window glass until the sealant has hardened Time required for the sealant to harden after it is applied Summer 20 C 687 5 hours Winter SC 41 F 24 hours 8 If any sealant has been forced or is found to be lacking rectify such portions with a wooden spatula 9 After checking to ensure that there are no water leakages install the mould interior mirror front pillar
55. Air control valve crows section 14 3 Fig 1 9 Thermal reactor cooling air circuit 1 The non return valve which prevents backflow of exhaust gus from the reactor is attached at the air inlet of the reactor 2 Ignition and Air Flow Control System The ignition and ait flow control system consists of thermosensor a thermodetector 4 vacuum switch and control box This system ignites and cuts the trailingspark plug to suit engine temperature and en gine speed in order to enhance the reactivity of the thermal reactor when the engine is cold It has an additional function of regulating the air control valve of the air injection system a Thermosensor The thermioseusor which is attached in the cooling water passage of the engine detects engine tempers and sends signal 10 the control box thereby causing ignition and cutting of the trailing spark plug Fig 10 Thermowmor b Vacuum switch When the engine i cold and the throttle valve js open to near the idle position ot near the f ll open position the vacuum switch signals the control box to ignite the trailing spark plug so as to maintain good drive ability to prevent wpatk plug fouling and to facilitate engine starting The vacuum switch i conmected fu the diaphragm rod of the vacuum advancer for the leading plug distributor changeover ls effected by the intake manifold vacuum The vacuum sensing hole of the
56. B l Fuel Pump Test 4 B 2 Disassembling the Fuel Pump 4 B 3 Fuel Pump Inspection 4 4 Asembling and Adjusting the Pump FUEL FILTER AIR CLEANER e ded ec 4 FUEL SYSTEM The fuel system consists of the fuel tank the fuel lines fuel filter fuel pump the carburettor and the cleaner The capacity of the fuel rank is 65 5 liters 173 US gallons 14 5 Imp gallons The operating fuel is re gular gasoline 4 CARBURETTOR RX 2 is equipped with s 2 stage 4 harrel Zenith Stromberg carburettor This carburettor comprises two sets each of primary batrels for normal use and a secondary barrels for high output In addition a float circuit and a transfer system for the primary and secondary stages are attached The primary barrel is equipped with a choke circuit a Jow speed circuit am auxiliary slow circuit and am accelerating circuit 4 A 1 Carburettor Function 3 Fuel retum circuit This system incorporates a bimetal type fuel return valve to prevent percolation When the fuel tempera ture reaches 559 131 F the valve begins to open to return the fuel to the fuel tank b Float circuit The float chamber is equipped with float and a needle valve to keep the fuel level constant under all operating conditions Especially as a needle valve muterial the special rubber is adopted more 10 pre vent the fuel overflowing An oil level gauge is provided in the float cha
57. Control Box 1A 19 1 8 Checking of No 1 control box 1 Remove the No thermosensor connector and check the following points 1 Warm up the engine up to 70 C 158 F of the coolant temperature 2 Connect the timing light to the high tension cord of the trailing side spark plug distributor Check to see that the timing light does not go on when the engine speed is between 1 900 300 rpm 4 000 200 rpm and goes on when the engine speed is raised to more than 4200 rpm 3 Connect an ammeter to the sir control valve sole noid Check to see that the current flows to the solenoid when the engine speed is between 900 4 000 200 rpm and there is no flow to the solenoid when the engine speed is above 4 200 rpm Fig 1A 50 Checking of No control box 1 Fram No control box mina contro valve 7 Terminal Fig TA 51 Checking of No 1 control box 2 2 With short lt i points 1 Connect the timing light to the high tension cord of the trailing spark plug distributor and check to see that the timing light goes on when the engine speed is between 1 900 300 rpm and 4 000 200 the No thermosensor connector terminal uited in Fig A 52 check the following 14 20 Trermosemar Fig 14 52 Connector shortcircult 3 Connect the No 1 thermosensor connector to the No thermosensor and c
58. Disconnect the connecting rod of the meter ing pump at the carburettor side 28 Remove the intake manifold with carburettor and exhaust manifold 29 Remove the engine bracket 30 Mount the engine on the engine stand 49 0107 680A 49 0813 005 and 49 0820 006 1 DISASSEMBLING THE ENGINE Engine overhaul should be done in the following order after dismounting the engine from the vehicle Remove the water pump pulley Remove the water pump Remove the distributors from the front cover Remove the spark plugs Remove the filter from the rear housing 6 Attach the ring gear brake 49 0820 060 to the flywheel Remove the eccentric shaft pulley with key 7 Remove the clutch assembly and clutch disk 8 Straighten the tab of the lockwasher and remove the flywheel nut using the flywheel box wrench 49 0820 035 9 Remove the flywheel by using the flywheel puller 49 0823 300 turning the handle and lightly hitting the head of the puller 10 Remove the oil pan 11 Remove the oil strainer Fig 1 74 Removing strainer 6 Note Apply identification marks on the from and reat rotor housings which are common parts 40 that they are fitted as they were when reassembling the engine T A Fig 1 78 Apply Remove the meteri pump from the front 13 Loosen the bolts attaching front cover and remove the cover 14 Remove the spacer distributor drive gear
59. Disconnect the wiring from the switch assembly 6 Remove the screws and dismantle the switch as sembly from the body 7 Remove the screws which are fixing the hody to the base and dismantle the body from the base 4 8 3 Fuel Pump Inspection 1 Inspect the air chamber valve chamber for cracks and damages 2 inspect the diaphragm for damage and deteriora tion 3 Inspect the inlet and outlet valves If they do not function normally replace them 4 Inspect the points of the switch assembly for wear burning fusing etc Clean the with a or stone if defects are not serious If serious replace the points 4 8 4 Assembling and Adjusting the Pump To assemble the fuel pump reverse the procedure for disassembling and observe the following points hase 8 Inspecting the diaphragm shaft stroke After the body is attached to the base place dial indicator on the diaphragm shaft as illustrated Push in the diaphragm by hand and read the gradus tion of the dial indicator The reading should be 28 30 mm 0 11 0 12 in When the stroke ix above 3 0 mm 0 12 remove the adjusting plate which is located between the body and the base When the stroke is below 0 28 mm 0 11 in insert additional adjusting plate Three Kinds of adjusting plate are available 01 mm 0 04 in mm 0 010 in 0 5 mm 0 020 Dial indicator Fig 4 13 Checking of diaphragm shaft stroke b In
60. Fig 1 22 Identification mark of rotor Fig 1 25 Removing Tubular dowels Fig 1 26 Removing intermiediaty housing 22 Remove the apex seals and springs after removing the rotor clamp When removing the apex seal put identification mark on the bottom of the apex seal that when reassembling the engine the apex seal be incorporated to the correct location and in the correct direction Never put a mark with a punch notch or the like 23 Remove the Yotor from the eccentric shaft and place it upside down on a clean cloth or rubber Note If some seals drop be careful not to change the original position of each seal on the reverse side of the rotor 24 Remove the seals on the rear side of the rotor 25 Extract the tubular doveli from the intermediate housing with the dowel puller 49 0813 215 26 Remove the intermediate housing Due to the ec centticity of the shaft at the journal portion the inter mediate housing must be removed by sliding t beyond the journal portion of the front rotor while holding the intermediate housing up and at the same time push ing up the eccentric shaft 27 Remove the eccentric shaft 28 Repeat the above procedure to remove the rear totor housing and the rear rotor assembly 1 ENGINE INSPECTION AND REPAIR 1 C 1 Front Housing 2 Inspection of front housing assembly 1 Check for traces of gas or water leakage 2 Check for wear and damage on the s
61. Installing of air pump Mount the ait pump in adjust the tension of the described below teverse sequence and belt in the procedure d Adjusting of air pump V belt Pull the ait pump away from the engine until the Wbeli assumes proper tension A proper lever should be used in adjusting Fig 1 40 Checking of belt deflection 1A When 10 kg 22 1b pressure is given 1o a spot mid way between the air pump pulley and water pump pulley belt deflection should be 9 11 mm 0 35 0 43 in when new the belt should have deflection of 7 9mm 0 280 0 350 in 1 2 Check Valve Checking of check valve 1 Remove the check valve in the procedures men tioned in the following item b 2 Check the seating of the valve and seat and make that there is no spring creep the free length of the spring is 31 mm 1 22 in and the fitting length of spring 15 18 mm 0 682 in Fig 41 Check valve 1 Valve seat 3 Spring 21 b Removing of check valve 1 Remove the air cleaner 2 Remove the air hoses leading to the air control valve Loosen the muts and remove the air control vilve 3 Remove the ch ck valve seat 4 Remove the valve and spring Installing of check valve Install the check valve in the reverse sequence 3 Air Injection Nozzle a Removing of sir injection nozzle 1 Drain the engine 2 Remove the engine under cover 3 Remove the
62. Mess 1 8 US 2535 Inip 509 0 005 in m 0 rpm A Men Wa mec i Wc anis at 2000 pint mn Standard revolution 1 401 980 Number of blades Water pump pulley ratio Last Thermontan ELC US piot 2 000 rpm of Fan diameter 300 mim 14 57 Fully opens Lite Radiator Core ares valve pressure Cooling capacity With hester Without hester FUEL SYSTEM Cor Mose than 8 mm 0 31 in 95 C 4 fin 6 8 nt 73 2 et 9 920 1 kp em Wirt 3 0 fiers 16 9 US pina 1 1 lam pinta 7 0 liem US US pints 12 3 pints Fuel tak capacity Fuel lier Min operating voltage reme Feeding capacity Current on uli discharing Pomi gap Carburettor Type Vested diameter ELECTRICAL SYSTEM 5 3 7 3 US leen 14 5 Tovg gallons Paper element type Less hun 0 0 30 kg em Mya Mone than 90 ec 0 23 US 028 Trp gallon i ese than 1 5 A 1 0 mm 0 039 Zenith ber Primary 20013506 au 0 781 x 0 512 0 256 In Secondary 28x 10 mm 1 M02 x 0 394 la randy 590 Battery Voltage Copecity Terminal ground Specie gravity Distribute
63. Needle valve Float pin 1 Shim 5 Spring amp Float 3 Valve sen Retainer 6 Remove the screw fixing the choke valve to the shaft and dismantle choke valve and shaft from the air hom 4 3 7 Disconnect the vacuum control rod from the sec ondary throttle lever by removing a clip 8 Remove the connecting rod of accelerating pump from the accelerator pump arm by removing a clip 9 Remove the screws which are fixing the throttle body to the main body and disconnect the throttle body from the main body 10 Remove the cover and take out the accelerating pump diaphragm and the return spring Remove the inlet check ball by removing the plug 11 Remove the accelerator nozzle and the outlet check ball 12 Remove the slow jets of the primary and ondary stages and all air bleed connections from the main body 13 Remove the main jets by removing the phigs from the main body Fig 4 8 Removing jets and ait bloedt 1 Secondary slow sir bleed Primary slow jet 2 Secondary dow jet 6 Primary slow bleed 3 Secondary main alt bleed 7 Secondary main jet 4 Primary muin bleed 8 Primary main jet 14 Remove the screws fixing the sub slow diaphragm cover and take out the diaphragm return spring and adjust shim Remove the sub slow jet by removing the phig 15 Remove the cover and tke out diaphragm and the return spring Fig 4 7 Removing of diaphragm 16 Tap the venturi from the bottom
64. No 1 thermosensor Make that there is no boot breakage Or wax leak 2 Connect the ohm meter as Fig 1 46 and Check the resistance The readings as shown below indicate that the No 1 thermosensor is normal Over 7 k2 before warm up the engine when ambient and water temperatures are under 30 C 86 F Under 23 warm up the engine when tem perature is over 70 C 156 F b Removing of No 1 thermosensor 1 Remove the air cleaner 2 Remove the starting motor Fig 1A 48 Checking of No 1 thermosenior 3 Remove the No 1 thermosensor connector 4 Remove the boot 5 Loosen the nuts and remove the No thermo sensor Installing of No 1 thermosansor Install the No thermosensor in the reverse se quence lA E 7 No 2 thermosensor a Checking of No 2 thermosensor 1 Make sure that there is no terminal breakage 2 Connect the ohm meter as in Fig 1 47 and check the resistance The readings as shown below indicate that the No 2 thermosensor is normal Over 5 k l before warm up wh bient and water temperatures are under 30 C 86 F Under 2kQ2 after warm up when water temperature is over 20 C 158 Removing of No 2 thermosensor Drain the engine oil Remove the No 2 thermosensor connector Loosen and remove the No 2 thermosensor 8 Thermodetector Checking of thermodetector Connect the ohm meter as shown in Fig 1A 48 and che
65. No Dy Ds change 1 2 3 Roa T4 w Ne 05 40 change EE 86 7 ICE EIC o AE 52 D ARCA UD Oe T eoru c ere onte PED v nov aca 57 bes lee 3 ane E J D NE Cu datio Dias dn je e e remm ju telas fici oos No Defy change ETE T Prec s sz m aA a NO EG sete IERI PEDE EFT M 7 E LL EE 9 8 mis menea e E NM AE 6 z E aje pees ng ee id Ea 4 em m3 JURE VET I 5 a0 800 a 76 60 2 we a eo ev self ane y 5 ETE UE US IE xf 255 8A gt SRLS No 2 REMOVAL OF TRANSMISSION When dismounting the auton vehicle pay ttention to the following poi Before disemo it by of th he transmission rigidly inspect TroubleDiegnesis Chart and dismount i only when considered 10 be in the following ranamission should be remo
66. TA 18 Coasting value The rise of intake mamTold vacuum during deceleration amd pear shifting causes the valve 10 open and from the sir cleaner is supplied into the intake mani fold preventing afterburn From am cleaner Seine C wee valve reas Fig 14 17 valve crow sectian 1 When the engine speed exceeds 1 200 50 rpm the control box commands the solenoid to open the intake manifold vacuum sensing line leading to the vacuum chamber the pressures in the vacuum und air chamber are equalized and air from the cleaner overcomes the spring fosce and flows into the intake manifold In addition when the coasting valve opens the at mospheric pressure from the air cleaner is led into the vacuum chamber of the control valve and pressures in the vacuum and air chambers of the ar control valve are equalized ullowing the spring force to operate the air cut valve Throttle positioner The throttle positioner which is connected te the carburettor throttle valve holds the throttle valve at certain opening angle during deceleration correcting overrich mixture to prevent afterburn Fig 19 Throttle positioner The diaphragm of the throttle positioner is connected via the vacuum sensing line to the vacuum chamber of the coasting valve As the intake manifold vacuum coming to the vacuum chamber of the coasting valve is
67. The belt deflection should be 11 13mm 0 43 0 51 in when thumb pressure of about 10kg 22 fb is applied onto the middle position of the belt between the water pump pulley and the eccentric shaft pulley To adjust the belt tension loosen the adjusting bar bolt and adjust the alternator on its mounting bracket until the tension of the belt is suf ficient Tighten the adjusting bar bolt belt 58 Checking of defection 5 Adjusting of Air Pump Referring 1 Par 1 1 adjust the sion belt 6 Checking of Air Cleaner 1 The air cleaner element should be cleaned with Fig 1 89 Replacing of element compressed air at Jow pressure every 3 000 km 2 000 miles Under dusty or sandy conditions the element should be cleaned every 1 500 km 1 000 miles and replaced every 18 000 km 12 000 miles 2 Replace the element if damaged or excessively dirty The element should be replace normally every 30 000 km 20 000 miles 7 Adjusting of Carburettor Idle limiter Idle limiter regulates the fuel flow at low speeds and is adjusted by the manufacture The idle limiter should not be adjusted Fig limiter b Adjusting of idle speed 1 Fully warm up the engine 2 Make sure that the return of the secondary throttole valve is proper 3 Adjust the carbon monoxide concentration to 0 3 0 percentages and the idle speed to 800 rpm by manipulatin
68. any air bubbles 11 PARKING BRAKE 11 1 Adjusting of Parking Brake The service brakes must be properly adjusted before adjusting the parking brake Adjust the length of the front cable with the adjusting mul on the rear end of the front cable so that the brake is locked when the parking brake lever pulled 2 or 3 notches After adjustment apply the patking brake several times then release and make sure that the rear wheels rotate freely without dragging SPECIAL TOOLS 49 6500 090 49 0221 6008 Wrench Expanding tool WHEELS AND TIRES 12 A INFLATION OF TIRES 12 TIRE ROTATION 12 C CHANGING OF WHEELS 12 D WHEEL AND TIRE RUN OUT 12 E WHEEL BALANCING 12 F FRONT WHEEL BEA 12 F 1 Checking of Front Wheel Sue Bearing 12 2 Removing of Front Wheel Bearing 12 E 3 Installing of Front Wheel Bearing 12 F 4 Adjusting of Front Wheel Bearing 12 6 GEAR WHEEL BEARING 12 12 WHEELS AND TIRES 12 A INFLATION OF TIRES Maintenance of correct inflation pressure is one of ihe most important elements of tire care Excessive inflation pressure will 1 Hard rides 2 Damage to lire carcass 3 Poor traction 4 Premature tread wear in center of tire Low inflation pressure will cause 1 Hard steering 2 Rapid and uneven wear on the edges of tire tread 3 Increased cord fatigue or broken tire cords 4 High tire temperature 5 Bl
69. arm and pull straight at a right angle to the contact arm Read the tension when the contact points start to separate If the reading is 0 5 kg 1 1 1b or less the movable contact arm Checking the condenser If the condenser is leaky it will cause a weak spark 5 0 8 Assembling the Distributor Assemble the distributor in the reverse order of disas sembling or burned contact points check the capacity of the condenser with a condenser tester The capacity is 0 27 10 microfarads In the absence of tester check by substituting new condenser 5 ALTERNATOR 5 1 Service Precautions When servicing the charging system observe the follow ing precaution If not followed the result will be in serious damage of the system 1 Do not short across or ground any of the terminals the alternator 2 Never operate the alternator with an open with the field terminal connected and the armature terminal disconnected 3 When installing a battery always make sure thai the negative pos of the battery is attached securely to the in the alternator 5 When charging the battery with fast charger disconnect the pg the positive cible ar the battery 5 E 2 Checking the Charging Systm on Car If the electrical system is nol charging properly it is advisable to determine whether the trouble is in the altemator or regulator prior to removing the alter nator 1 Disconnect
70. bat the engine idling speed for the vehi cle with air conditioner should be adjusted 50 rpm higher than those mentioned below NE NN d pu mm LE N RXS 70 on ww 190 2 m amp o w m 1 KICK DOWN SWITCH AND DOWN SHIFT SOLENOID Position the ignition switch at the first stage alter making sure that the accelerator pedal goes through the entire stroke properly Depress the accelerator pedal as far as it goes the throttle nears the wide open position the contact point of the kick down switch is closed with light click from the solenoid Fig 21 Kick down switch and down sbilt solenold The kickdown switch must begin to operate in bet ween 7 8 15 16 of the entire pedal travel or full throttle If nor adjust the kickdown switch If the solenoid should not make any clicking sound it im dicates some abnormality so check with tester must be made Note When the solenoid is removed for replacing some one liter of fluid leaks So receptacle should be made ready to catch 46 1 4 MANUAL LINKAGE The adjustment of linkage is equally important as Inspections of oil level for the automatic transmis sion Therefore great care should be exercised be cause defective adjustment will result in the break down of the transmission Pull the manual lever toward you snd turn it so far as
71. bleed the brake system referring 10 Par 11 6 1 11 POWER BRAKE UNIT 11 1 Checking of Power Brake Unit on Vehicle 1 Road test the brakes by making a brake applica tion at about 30 km 20 miles to determine if the vehicle stops evenly and quickly If pedal hus a spongy feel when applying brakes air may be present in hy draulic system Bleed the system as described in Par 11 6 1 2 With the engine stopped and transmission in neu tral apply brakes several times to deplete all vacuum reserve in power brake unit Depress brake pedal hold lightfuot pressure on the pedal and start the engine If vacuum system is operating pedal will tend to fall away under foot pressure and less pressure will be re quired to hold pedal in applied position 17 no action is felt vacuum system is not functioning 3 Stop the engine Again deplete all vacuum reverse in system Depress the brake pedal and hold foot pressure on the pedal If pedal gradually falls away under foot pressure hydraulic system is leaking inter mally or externally 4 Start the engine with brakes off amd transmission in neutral Run the engine to medium speed and turn off ignition switch Immediately close throttle This build up vacuum Wait no fess 90 seconds then ry brake action If not vacuumassisted for two or more applications vacuum check valve is faulty or there is leak in vacuum system 11 2 Removing of Power Brake Unit 1 Dis
72. compressed sir into the hole on the servo piston apply side to make sure thar the piston operare properly as in Fig 2 32 Fig 2 22 Checking bend ser 9 Back aft u uniformly and apply compressed air into the oil threw attaching Boles lightly hole on the serve piston release side us in Fi If ihe retainer rises by the extent of bolt backing Tighten 0 45 mke rhe piston operation on release img torque of the serv retainer 0 53 2 Fig 2 33 Checking bard se 4 F GOVERNOR VALVE ASSEMBLY Te uu prosas 1 vak 18 To Remove 1 Loosen and remove four bolts hat attach rhe gov ernar Remove the governor from the oil distribuitor 2 Ren Then remove the spring and secondary governor valve wer rel the body f Remove t procedure ws fot the secondary if primary governor primary governor valve in the same is be disassembled for amy purpose 1 f Primary valve plate Inspect 1 Check the vulve and the body see thur there is nothing that may cause vulve sticking or catching f Check to see thit the spring has not lost remuon nnd the retainer plates not deformed ne sealing aad ndard clearance 6 Check the side clearance between gloowe us shown in Fig 2 36 The a 0 040 16 10 002
73. contamination of the element the relief valve is opened by the oil pressure The oil is then discharged directly to the engine without passing through the oil filter The filter element should be replaced in intervals of 12 000 km 8 000 miles 1 Use the oil filter wrench to replace the oil filler cartridge 2 Apply a small quantity of to the rubber packing of the new filter cartridge yd fix the cartridge to the filter bracket 3 Tighten rhe carteidp u farther 2 3 of a turn by hand after the oil seat cont cc with the seal surface but absolutely more 4 Start the engine and check if the oil leaks from the joints 2 6 OIL THERMO VALVE The thermo valve is provided in the front cover and consists of a pellet a sliding valve and a return 2 spring The oil sent from the oil pump to the ther movalve takes two courses thereafter depend upon temperature leading to the oil cooler and the other bypassing the oil cooler and leading di to the filter by way of the housing The passage leading to the oll cooler always opened The passage leading to the housing is also fully opened when the oil temperature is low and most Oil takes this passage and proceeds direct fo the filter via the housing as there is resistance in the cooler When the temperature rises 10 over TIC 160 F the pellet starts functioning and when the temperature reaches 78
74. each other Fig 9 27 Installing of differential assembly L As there are two types of adjusters righttiand threaded and left hand threaded note the identific ion marks on the adjusters and mstall cach to iespective side 3 Install the differential bearing caps making sure that identification marks on the caps correspond with those on the carrier and install the attaching bolts 4 Turn the adjusters with the spanner 49 0259 720 until the bearings are properly positioned in their res pective outer racer und the end play is eliminated with some backlash existing between the ring gear and drive pinion 5 Slightly tighten of the bearing n each side and adjust the backlash at Instructed in be slowing paragraph 8 5 Adjusting of Backlash 1 a dial indicator to the carrier flange so that the feeler comes in contact at right angles with on of the ring gear teeth 2 Check the backlash between the ring geat and drive pinion With the spanner 49 0259 720 hum both beating adjusters equally until the backlash becomes 0 17 to 019 mm 0 0087 to 0 0075 in Fig 9 28 Adjusting of backlash 9 3 The preload the differential bearings is obtained by tightening the adjusters Tighten the adjusters until the distance between both pilot sections on the bear ing caps becomes 185 5 mm 7 06 im as shown Fig 9 29 Fig 9 29 Adjusting of preload
75. ete Precautions 1 If any water leakage is found after the sealant has hardened use repairing agent 2 Keep the door windows open until the sealant has hardened to some extent If the door windows are kept tightly closed the interior atmospheric pressure would suddenly change when the doors are opened and closed This could cause vacant spaces to develop in the un hardened sealant and deteriorate the airdightness and bonding properties of the sealant 3 The time required before the vehicle can be driven after the sealant has been applied is approximately 5 hours in summer 20 C 68 F or 24 hours in winter C 41 F if the sealant is left in open weather for drying A If the vehicle is to be repainted remove all the sealant from the body and then after baking the paint on apply the sealant so that it b 10 mm 0 4 in high Never apply ait setting paint to the surface on which the sealant is to be applied because the uir setting painting method would huve problems in weather proofness and its bonding properties between the paint layer and the sheet metal and between the paint layer and the primer 34 8 REAR WINDOW The removal and installation of the rear window Has be made the same way as those of the windshield lass But care should be taken to the following points 1 In the case of a vehicle equipped with a rear window with printed hot lines perform the work of discon nection und connection of the r
76. f 1 5 Replace 1A E 10 11 Replace f off See e See See See 1A E 21 Clean and replace SeslA E 4 Repair and replace Repair and See 1A E 23 Adjust See 21 Clean and replace See 1A B 20 Adjust See 1A E 20 Clan and replace 1 Remedies Improper operation of air control valve Replace 7 Defective No control box 10 31 Air leak from each valve into intake manifold 9 Breskage of reactor 17 Factors which adversely affect deceleration emissions 1 Improper idling speed and fuel 2 Improper operation of annialteibum valve I suppl valve opens 4 Improper operation of coasting valve 3 Improper operation of ale control vive Ait cui valve Relief vahe and Safety valve 6 Detective switch 2 Breakage of reactor 18 Factors which adversely affect avetleration emissions 1 Improper air pump flow Defective air control valve cut valve Relief valve and Safety valve 3 Trailing side spark plog ignited when the water and tem peratures are low 4 Leading side ignition not retarded 5 Detective No thermosensor 6 Defective No 2 thermosensor 7 Defective thermodetector Defective carburetor improper fuel level and other 9 Defective No conuat box 10 Defective No 2 control box 111 Defective distributor vacuum switch 12 Defective reactor 13 Defective spark
77. f the shoes and backing plste edges with a small amount of grease 2 Install the eye of the parking brake cable onto the parking brake operating lever installed to the tear side shoe 3 Installing the operating strut between the slots of the shoes engage the brake shoes with the slots in the adjusting screw and the wheel cylinder piston 4 Hold the brake shoes to the backing plate with the retaining springs and pins Fig 11 27 Rear brake 11 5 Install the shoe retum springs 6 Sand rhe linings lightly to remove any trace of dirt or grease 7 Install the brake drum to the axle shaft flange and tighten the attaching bolts 8 Apply the brake pedal several the brake as instructed Par 11 4 9 Install the wheel and adjust 11 4 Adjusting of Rear Brake 1 Jack up the vehicle until the wheels are free to turn 2 Remove the adju plate 3 sure the parking brake lever is fully released 4 Insert screwdriver into the star wheel of the ad juster and turn the star wheel foward the arrow di rection marked on the brake backing plate until the wheel is locked Then back off the star wheel 5 notches Which will obtain a brake shoe clearance ls 0 1 mm 0 004 ng hole covers from the backing Fig 11 28 Adjusting of brake 5 Repeat the above adjustment on each wheel The adjustments must be equal at all wheels 6 Install the adjusting hole covers im the backing plate
78. flush 6 Insert the expander 49 0813 254 into the bear ing and then drill a hole of 3 5 mm 0 14 in diameter and about 7 mm 0 28 in depth at approximately 7 mm 0 28 in to the left or right from the original location of the locking screw hole ft must be made to the same direction from each original hole The center of the hole must be 0 5 mm 0 02 in from the rotor bore 7 Thread the hole with an M4 P 0 70 mm tap 1 81 Drilling hole Fig 1 52 Removing rotor bearing Fig 1 53 Installing rotor bearing K Fig 1 54 Making Fig 1 56 Staking locking screws Fig 1 56 Weight mark of rotor Fig 1 57 Mark of internal gear e Fiy 1 58 Mark of S Tighten the locking screws and stake them into positions with a punch to prevent them from work ing out 9 Wash the rotor thoroughly and blow with com pressed air i Replacing the rotor When replacing the rotor note the following points 1 Weight of rotor Rotors are classified into 5 categories according to weight and marked a d and e on the internal gear side In order to balance the front and rear rotors the following combinations are adopted in the factory Combination of Markings Note If it is necessary to replace a rotor use ro tor marked with c im amy case 2 Internal and stationary gear backlash The intermal gears and stationary gears are classified into 3 categories wh
79. friction of the part shown by an arrow Emergency measures 1 Finish the sliding with sand paper 2 Supply oil to the sliding face d Checking of secondary throttle valve for faulty opening 1 Remove the air cleaner 2 Check the secondary throttle valve operation while raising the engine speed from 900 rpm up to around 5000 rpm No load running by fully depressing ihe accelerator pedal 3 If the secondary throttle valve opens smoothly and almost fully opens the opening of the secondary throttle valve Is normal 4 When the valve does not operate at all or smoothly clean the see Fig 1A 78 Checking of accelerator pump 2 1 Checking of secondary throttle valve for faulty closing Remove the air cleaner Set the engine speed to 900 rpm 3 sure whether the idle speed is the normal 900 rpm when slowly returning the accelerator pedal just after fully depressing the pedal so as to raise the engine speed from the idling speed of 900 rpm up to about 4 000 rpm no load running If the dling speed is normal the closing condition of the valve is satisfactory 4 When the idling speed exceeds 970 rpm depress the primary throttle valve with adequate force And im case the engine speed returns to the normal speed the above excess is due to the faulty retuming of the primary throttle valve 5 If the engine speed does not recover the normal speed and is kep
80. from the piston Fig 13 11 Removing of piston ring 8 Remove the pressure tube from the reservior tube 9 Remove the base valve assembly from the pres sure tube 10 Remove the bolt and nut of the base valve as sembly and remove the valve seat relief valves base valve casing and relief valves 13 3 Checking of Front Shock Absorber 1 To test the shock absorber hold the shock ab sorber in an upright position and work the piston rod wp and down in its full length of travel four or five limes 17 a strong resistance is felt due to hydraulic pressure the shock absorber is functioning properly If no resistance is felt or there is a sudden free movement in travel the shock absorber should be repaired If excessive amount of fluid is evident on the exteri or of the shock absorber the shock absorber should be repaired 2 Check the spring for signs of fatigue cracks or any damage 3 Check the mounting rubber for weakness at the rubber cushion roughness or damage al the bearing and damage of the bolts 4 Check the reservior tube for fluid leak or defor mation and check the steering knuckle for crack S Check the piston rod for wear The piston rod Fig 13 12 Checking of piston rod diameter 13 4 13 diameter should be more than 19 94 mm 0 785 The standard diameter is 20 0 mm 0 788 in 6 Chock the run out of the piston rod by supporting both ends of the piston rod on V blocks and apply
81. gears pinion gears or thrust washers if necessary Check the clearance between the pinion gear and shaft If excessive clearance is found due to wear replace with new parts Check the spline fit of the side und rear axle shaft Hf it is 0 3 mm 0 012 in or more replace the side gear or tear axle shafi 9 D 3 Checking of Bearings Inspect the differential bearings and pinion bearings for wear Making or any damage If inspection re veals that either bearing cones or outer race ate unfit for further service replace the bearing 8 0 4 Checking of Oil Seat Check the seal for wear or damage If there is any possibility of leakage replace the oil seal 9 0 5 Checking of Companion Flange Check the companion flange for cracks worn splines or rough oll seal contacting surface Repair or replace the companion fange if necessary 9 REAR AXLE ASSEMBLY 9 E 1 Adjusting of Drive Pinion The drive pinion should be correctly positioned in relation to the ring gear by the use of spacer which 8 placed between the drive pinion and the outer race of the pinion rear bearing The standard distance between the top of the drive pinion and the center of the ring gear mounting dis tance Is 90 0 025 mm To udjust the drive pinion position use the special gouge 49 0727 570 and 49 0305 555 und proceed as follows 1 Install the dial indicator to the gauge body Place the gauge body om the surface as shown in Fig
82. h 1 C 2 Intermediate Housing Inspection for distortion or wear of the intermediate housing should be carried out in the same way described for the front housing Refer 10 par 1 C 1 1 C 3 Rear Housing Inspection of the rear housing is carried out according to Par 1 but the following point must be Inspected as well Checking the seal Check for wear and damage If trace of oil leakage is found replace the oil seal b Replocing the stationary gear 1 Remove the bolts attaching the stationary gear to the rear housing 2 Using the main bearing puller and installer 49 0813 235 extract the stationary gear Fig 1 35 Installing main bearing Fig 1 36 Installing stationary pear Fig 1 38 Remov 1 42 Measuring rotor housing width 3 Put thin film of grease on the ring and place it in the groove of the stationary gear 4 Apply sealing agent to the stationary gear flange 5 Install the stationary gear on the rear housing while being careful not to damage the ring and to match the slot of the stationary gear flange to the dowel pin of the rear housing 6 Tighten the bolts attaching the stationary gear Note Replace the O ring with new one whenever removing or replacing the stationary gear 1 4 Rotor Housing a Checking the rotor housing 1 Check for exfoliation damage or cracks on the omiumplated surface If any of these conditions is f
83. in 0 1 mm 0 0038 in or lem 9020 025 an GI 5454 20 0010 in 9t 12 3 027 049 mw 0 00670 0015 0 4 mm 0 004 in o denn REAR AXLE 202 mm 19 76 in Permissible destane of piston and boe free travel Shoe material Dimension of ling and shoe width x thickness x length Minet allowable thickness of lining and shoe Benke disk outer brake disk runout Rest bale Tye Dram inses diameter Lining material Lining dumemioo Lwidih thickness length Wheel cylinder bore Parking Type Operates at Tandem master cylinder 22 22 7 8 9 15 0 0058 3 45 mm 0 2 0 6 in Bendix type dk beske 152 4 mm 6 0001 m 1 38 Bendix type disk brake 1 214 97 mm 1 810530 m Amm 0 315 230 mm 9 056 0 15 mm 0 0088 Drum type with seeding and mailing 200 mes 7 8741 e 32x44 109 mm 1 260 16x 7 48 in 19 06 amn 3 4 in Mechanics internal expane m Reor wheels 719 mm 8 3 10 4 80 rp 125 0 17 incor 4 9 30 emer 0 28 mot 4 000 0 4 mes 0 016 90 8 mm 2 00 Typ Reduction satio Neanber of Sessi hcating hypoid aT m STEERING Tue Free play af
84. into the Fig 10 8 Position of sector gear and rack 10 3 gear housing being careful not to damage the bushes and cil seal and ensuring that the center of the sector gear is aligned with the center of the rack as shown in Fig 10 8 5 Install the side cover and the gasket onto the adjusting screw turning the adjusting screw counter clockwise until it is screwed into proper position J dde cover 6 Install the side cover attaching bolts and tighten the bolts 7 Adjust the backlash between the sectot gear and ick by applying the procedure explained in Par 10 2 After adjusting tighten the adjusting screw lock nut securely 8 Install the pitman arm onto the sector shaft align ing the identification marks und tighten the nul The tightening torque is 15 0 m kg 110 ftib Fig 10 10 Installing of pliman arm 10 STEERING GEAR ADJUSTMENT 10 1 Adjusting of Worm Bearing Preload To adjust the worm bear ng preload remove the steer ing gear from the vehicle With a torque wrench ro the worm shaft and check the rotating torque The rotating torque preload should be between 6 0 to 6 0 omg 5 2 to 6 9 indb 10 Fig 10 11 Checking of preload If the reading is not within limits adjust the preload follows 1 Remove the end cover attaching bolts and the end cover together with the shims 2 IF the preload is less than 6 0 cmg 5 2 inb reduce the shim and add the
85. iro og g i HIM lin fist i gzs8zt5gtiptt H 1 Reamer Bolt 2 3 Control Lever End 5 Spring 6 Steel Ball 7 Spring 8 Select Lock Spindle 9 Blind Cover Fig 7 2 Transmission 10 Set Screw nd top 11 Spring 12 Bind Cover 13 Set Screw Low amp 2nd 14 Set Screw reverse 15 Reverse Lamp Switch 16 Shift Fork Low amp 2nd 17 Shift Fork reverse 18 Reverse idle Gear Shaft 7 TRANSMISSION RX 2 is equipped with fourspeed manual trans mission of the synchromesh type with helical gears to provide silent operation Gear shifting is of the direct control floorahift type The transmission gear ratio is as follows Gear Ratio Fine Second 3 Thid 1397 1 000 3893 7 A REMOVING THE TRANSMISSION When removing only the transmission from the ve h cle proceed as follows 1 Disconnect the earth wire of the battery 2 Remove the console assembly and dust boot of the gear shift lever Loosen the attaching bolts on the cover plate and remove the dust boots cover plate and bush together with the shift lever from the transmission housing 3 Disconnect the wirings of the starting motor and the reverse lamp switch and then remove the start ing motor 4 Remove the drain plug and drain the
86. of Brake Disk 11D Installing of Brake Disk REAR BRAKE 11 Removing of Rear 11 E 2 Inspection of Rear Brake 11 E 3 Installing of Rear Brake Shoes 11 E 4 Adjusting of Rear Brake WHEEL CYLINDER 11 E 1 Removing of Wheel Cylinder 11 E 2 Disassembling of Wheel Cylinder 11 3 Checking of Wheel Cylinder 11 F 4 Assembling of Wheel Cylinder 11 5 Installing of Wheel Cylinder AIR BLEEDING 11 G 1 Bleeding of Master Cylinder and Front Wheel Cylinder 11 G 2 Bleeding of Rear Wheel Cylinder PARKING BRAKE 11 1 Adjusting of Parking Brake wm mul 11 BRAKES MAZDA RX2 is equipped with a tandem master inder and power brake unit The tandem master cylinder is so constructed that the front and rear brakes are independently actuated by pressure o riginated from the independent system and that in the event of failure of one of the brakes effective braking remains on two wheels thus raising safety The power brake unit is a combined vacuum and hy draulic unit which utilizes intake manifold vacuum and atmospheric pressure to provide power assisted ap phcation of vehicle brakes The front brake unit are of the disk brake type which assure you of still more safety The rear brake are of drum type with leading and trailing shoes The parking brake is operated by means of a brake lever and influences both rear wheels mechanically 11 BRAKE PEDAL ADJUSTMENT 11 1 Adjusting
87. of antiafterburn valve 1 Remove the air suction hose 2 Run the engine at idle speed 3 Hold the hand over the opening of the air suction hose for the antiafterburn valve If strong vacuum ts felt the antrufterbum valve should be replaced 4 Run the engine at 3 500 3 800 rpm and make sure that when the throttle valve is fully closed suddenly air is sucked in for 0 2 1 0 sec through the air suction hose of the antiafterburn valve 5 Run the engine at idle speed 6 Remove the lead wire leading to the solenoid of the antiafterburm valve Make sure that air continues to be sucked in through the air suction hose while the lead wire dison nected b Removing of anti afterburn valve 1 Remove the air cleaner 2 Remove the air hoses from the antiafterburn valve 3 Loosen the mounting nuts and remove the anti afterburn valve c Installing of anti afterburn valva install the anti afterbum valve im the reverse se quence 11 Coasting Valve Checking of coasting valve 1 Attach the vacuum gauge as in Fig 1 51 2 Start and warm up the engine Make sure that the vacuum gauge reads more than 400 mm Hg when the engine speed is 800 rpm 3 Raise the engine speed to about 2 500 rpm Make sure that when the throttle valve is fully closed sud the vacuum gauge reads 0 30 mmHg and when the engine speed is lowered to 1 300 1 100 the reading rises to more than 400 mmHg 1
88. of combustion condition and ges loak age 1 The combustion condition can to certain ex tent be judged as in the case of reciprocating en gines by the color and quantity of carbon on the rotor Combustion can be stid to be good if the color Of carbon is brown Generally carbon on the lead ing side seen from the direction of rotation is brown while the trailing side shows black color I should be noted that this color varies according to operat ing conditions just before the engine 15 dismantled 2 Gas leakage can be Judged by checking the color of the rotor side surface for blow by traces originat ing from the side seals and comer seals b seal inspection 1 Check for wear and damage of the oil seal lip contacted with the sliding surface of the side or inter mediate housing If the contact width is more than OS mm 0 031 in the oi seal should be replaced with new one 2 Check the oil seal protrusion shown in Fig 1 44 1t should be more than 0 5 mm 0 02 in Note Replace the O sing when overhauling the engine Removing the 1 Remove the oil seal by Inserting the re mover 49 0813 225 or screwdriver in the slots of the rotor and prying it off Note 1 Do not exert strong pressure at only one place to prevent deformation of the oil seal 2 Be careful not to damage the lip of the oll seat Use a certain protectior shown in Fig 1 53 2 Install the oil seal referri
89. on the front hous ing Note in case of the rotary engine each rotor makes 1 3 rotation as against one rotation of the eccentric shaft That is one combustion is obtained while the rotor makes 1 3 rotation Therefore when the mark and the needle are aligned the front rotor is always located at T D C in the compression stroke Fig 1 99 Applying seating agent In e Fig 1 100 Installing oll filter Fig 1 108 Adjusting ten 2 Install the trailing distributor socket through the gasket so that the groove on the drive shaft is at an incliation of about 34 to the right against the longi tudinal axis of engine 3 Install the leading side distributor socket through the gasket to the front housing that the groove on the upper side of the drive shaft points about 17 the right against the longitudinal axis of the engine as shown in Fig 1 102 Note The woodruff area at the upper part of the drive shafi varies with the left and right grooves buj this does not affect ignition timing even if it is 180 opposite Install each distributor on the socket so that the key of the distributor shaft matches the slot at the upper side of distributor drive shaft Note The marks of the distributor and front cover T and L must be matched S Turn the distributors as shown in Fig t 103 until the contact point starts to open Then tighten the lockplate 1 D 18 Installing the Water Pump
90. or rusted Check the lateral run out of the disk with a dial in dicator as shown in Fig 11 25 If the run out is more than 0 06 mm 0 0024 in reface the disk Note Make certain that the wheel bearings are correctly adjusted and the disk is fitted securely on the hub before checking the run out of the disk 11 Fig 11 25 Checking When refacing the disk remove only so much mate rial as is necessary to clean up the disk The thickness of the disk after refacing must not be less than 11 mm 0 4331 in Fig 11 26 Checking of disk thickness 11 0 2 Installing of Brake Disk out the removing operation in the reverse or der After installing udjust the bearing preload us instructed n Par 12 4 11 REAR BRAKE 11 1 Removing of Rear Brake Shoes 1 Raise the vehicle and remove the wheel 2 Remove the drum attaching bolts and fit them into the tapped holes and screw them in evenly to force the drum away from the axle shaft flange 3 Remove the brake shoe retum springs 4 Remove the brake shoe retaining spring and guide pin by compressing the retaining spring and turning the guide pin 90 degrees 5 Remove the brake shoes 6 Disengage the parking brake cable from the oper ating lever on the brake shoe 11 2 Inspection of Rear Brake Inspection of brake drum Inspect the brake drum and recondition if it is rough or scored Check the out of roundness with a dial indicat If
91. pin The control pin is camhaped shaft and is im contact with the tip of the plunger and so the stroke of the plunger is controled with the opening angle of the throttle valve When the opening of the throttle valve is small the stroke of the plunger is only little Thus the stroke of the differential plunger which is turned and pushed together with the plunger is small o keep the oil discharge small When the opening of the throttle valve becomes large the stroke of plunger becomes larger to increase the stroke of the differential plunger Thus the supplied amount of oil becomes larger Fig 2 10 Metering oil pump 1 Control lever 6 Differential plunger 2 Adjust screw 7 Pump body 3 Driving worm 8 Plunger 4 Sub plunger 9 Control pin S spring 2 H 1 Inspecting the Metering Pump The amount of discharge from the oil metering pump should be inspected as follows Disconnect the oil tubes which are connected with the carburettor at the carburettor side Disconnect the connecting rod of the oil metering pump at the carburettor side Set the engine so as to revolve at 2 000 rpm Check the amount of dis charged from the oil tube of the oil metering pump and If It is 6 5 1 cc 10 min discharge of ofl is normal Otherwise adjust the metering pump 2 2 Adjusting the Metering Oil Pump For adjustment of the oil metering pump the amount of discharge will be i
92. rotor friction surface of the housing faces vertically 2 Place the rotor on the rear housing taking care not to drop the seals and turn the rear housing with rotor as to be the sliding surface of the rear housing with rotor so as to be the sliding surface of the rear housing upward 3 Mesh the internal gear and stationary gear that one of the rotor apexes is set to any one of the four places shown in Fig 1 79 Note In this case be careful not to drop the corner seal Into the parts 4 e the rotor clamp and apex seals 1 0 4 Installing the rear rotor housing 1 Apply sealing agent to the rear side of he rear rotor housing as shown in Fig 1 80 Be careful not to let the sealing agent penetrate into the cooling water or oil circuits 2 Place the new rings and sealing rubbers on the rear rotor housing Note When installing the rings and sealing rubbers the rear rotor housing slightly apply rubber grease to rings und sealing rubbers to prinent them from coming off 3 Reverse the rotor housing while taking care not to let the sealing rubbers and O rings drop out of the grooves and mount it on the rear housing 4 Insert the tubular dow ls through the rear rotor housing holes to rear housing hole after supplying few drops of lubricant to the tubular dowels 1 0 6 installing the eccentric shaft 1 Lubricate the journal sections Z Insert the ec
93. shift plug 15 24 300 shift spring 16 20d 3d shift valve 17 Pressure modifier spring 18 Pressure modifier valve 19 Solenoid dowrshift spring 20 Solenoid doweshilt valve 21 Throttle back up valve 22 Throttle back up spring 23 Vacuum valve 24 2 3 dming valve 25 2 3 timing spring 26 Side 771 Control valve body 24 Separator plate 29 Lower valve body 30 Oll animer Relief ball and spring 32 Orifice check valve and spring Fig 1 1 Automatic ranmission component 1 L Lever 12 Steel hall 28 Extension housing assembly 2 Coumer shalt pasembly 13 Parking ball spring 3 Rod Parking pawl shaft 4 Select lever 15 Paw retum spring 28 Pump hooting assembly 5 Inhibitor switel 16 Parking paw 37 Inver gent 6 Manual shaft 17 Bolt 28 Outer grar 7 Manual washer 18 Torque converter housing 29 Gasket 5 Manual plate nssembly 19 Transmission case 30 Pump cover assembly 9 Parking lever 29 pun Seal ring 10 Parking rod assembly 21 Vacuum disphragin 52 Inpat shalt Actuator support 22 Domushift solenoid Fig 1 2 Autonatic trammistion component 2 1 Adjusting washer Washer 2 Brake band Band adjust out 3 Front clutch drum assembly Piston atem 4 Seal rng Sea ring 5 Seat ring Seal ring 8 Front pistan servo retainer Bearing race a a 28 Needle beating 29 R
94. shim if the preload is more than 8 0 cm kg 6 9 inb The following shims are available 9 050 mm 0 002 in 0 100 mm 0 004 in 0 075 mm 0 003 0 200 mm 0 008 in 3 Install the end cover and recheck the worm bearing preload Note The preload before installing the sector shaft should be between 1 0 to 4 0 cm kg 0 9 to 3 5 indb 10 2 Adjusting of Sector Gear and Ball Nut Backlash The sector shaft adjusting screw installed in the side cover raises or lowers the sector shaft to provide proper mesh between the tapered teeth of the sector gear and the rack of the ball nut This adjustment can be accurately made only after proper worm bearing preload has been established Adjust the backlash as follows 1 Tum the worm shaft gently and stop it at the center position 2 Loosen the lock nut of the adjusting screw and Fig 10 12 Adjusting of buck screw in or out the adjusting screw until the correct adjustment is obtained The standard backlash is 0 to 0 1 mm 0 to 0 0039 This is equivalent to a move ment of about 3 degrees of the worm shaft 3 After adjusting tighten the adjusting screw lock mut securely 4 Rotate the worm shaft and check to ensure that the sector shaft turns 40 smoothly to the right and left 10 G STEERING GEAR INSTALLATION To install the steering gear assembly reverse the pro cedure in Par 10 After installing fill up to the level hole 10
95. side seal and side seal spring are installed onto the rotor check the protrusion of each seal referring to Par 1 D 2 Fig 1 67 Rebor ng comer veal groove 14 203 11 208 mm 0 4411 94413 in 11200 11 0 4410 0 4419 in Reamer dismeter Rebored corner seal hole diameter Oversize corner seal diameter 11170 11 189 mm 0 4398 0 4402 m Fig 1 68 Checking gap of corner seal and side seal 52 Sios Seni Fig 1 89 Shape of side seal Fig 1 70 Measuring journal diameter Fig 1 71 Checking eccentric run out Fig 1 73 Thrust beatings 1 C 7 Eccentric Shaft 3 Inspecting the eccentric shaft Wash the shaft in a cleaning solution and blow the oil passage with compressed Check for cracks scratches wear or blockage of passages Measure the diameter of all journals of the eccentric shaft with a micrometer Replace the shaft if the wear is excessive The standard diameter of the main journal is 43 0 015 mm 1 6929 9 in while that of the rotor journal is 74 0940 mm 29134 29006 in b Checking the eccentric shaft run out Mount the eccentric shaft on the V blocks Turn the shaft slowly and measure the deflection at the front and rear with a dial gauge If the deflection is more than 0 02 mm 0 0008 in replace the shaft with a new one Inspecting the blind plug An oil passa
96. spring pressure regu second lock valve wit Plug sleeve 3 pressure plug 15 Spring seat 10 Throttle back up valve 6 5 Regulator pressure valve 11 Down shift valve 6 Second lock valve LZ Medier valve 15 62 B then take out with spring soring then uke out 11 2 3 shift plug 2 3 shift valve Side plate A Upper valve body Manual valve 12 wi m To inspect 7 Check each valve for anything that might cause sticking 8 Check to thar valve springs und check valve springs have not lost tension 9 Check see that the oil strainer is not damaged 10 Check for possible abnormal oil passage develop ing on the separate plave 1L Check for possible damages or other abnormali ties in the oil passages of valve body 12 If any defective part is found replace with new one To Reassemble 18 Reassemble in the reverse order to disassembly paying special attention to the following points Install small valves and springs by referring to the components parts of control valve Fig 2 42 Lubricate all valves and springs with converter oll before installing a H there ls ony valve that is dilheult to insert do not force it in bur giye a Tight straight push 0 Make sire thar the followings are strictly tightened to 0 45 0 26 miig 1 6 2 5 Side plate to valve body Lower valve body to valve body nrui
97. start ignition and lighting check the following points periodically and always keep the battery in per fect conditon 1 Check the electrolyte level in each cell of the bat tery and add distilled water to maintain the solution 10 20 mm 0 4 08 above the plates Do not overfill 2 Check the specific gravity of the electrolyte with hydrometer as shown in Fig 5 1 If the reading is 1 26 more it indicates that the battery is fully Fig 8 1 Checking the specific gravity charged If the reading is below 1 20 the battery requires recharging Check the tightness of the torminals to ensure good electrical connections Clean the terminals and coat the terminals with grease 4 Inspect for corroded or frayed battery cables 5 2 Charging the Battery 2 Constant current charge 1 If the exterior of the battery s dirty with sulphu acid or dust and dirt wash these off with clean water and dry thoroughly before charging the battery 2 Check the electrolyte level and add distilled water If necessary Note If addition of distilled water is neglected the plates and seperators will become exposed to air caus ing a sulphation to occur on the plates Do not add dilute sulphuric acid unless the electrolyte has overflown leaked 3 Connect the battery to the charger ensuring that 5 1 the polarities are correct 4 To charge apply an electric current of approxi mately SA until the
98. sun visors interior lamps assist handles front pillar trims rear package tray trim etc 14 REAR SIDE WINDOW COUP 14 1 Removing of Rear Side Window 1 Remove the seat Note When removing seat back pull it out after removing he two nuts from the luggage compartment 2 Remove the seaming welt covers 3 Remove the package tray trim upper as shown Fig 14 30 14 14 30 Removing of seaming wolt cover 4 Remove the pad of the regulstor handle and re move the regulator handle and escutcheon by loosen ing the attaching bolt 5 Remove the arm rest 6 Remove the door trim board 7 Remove the inside screens vinyl which are install ed to prevent water leakages 8 Remove the guide Fig 14 31 Removing of glass guide 9 Remove the window glass With the window glass lowered to half opened position it can be easily taken out Fig 14 32 Removing of window glass 10 Remove the regulator Fig 14 33 Removing of regulator 11 Remove the outer weatherstrip 14 2 Installing of Rear Side Window Carry out the removing operations the reverse order SPECIAL TOOLS 49 0305 871 49 0305 872 49 0305 870 Mould remover Sealant gun Window tool set included above two tools 14 8 BODY CHECKING DIMENSION 14 e 9 am am pams m E n ov wy Duan em ma
99. system is normal the of vapor and ventilation during engine operation are as shown in Fig 1 34 2 If the connecting pipe from the condense tank to the oil separator is clogged frozen or ventilation valve does not work at all and as the result fuel the negative pressure in the fuel tank und the supply 10 the engine is cur off Therefore when the ventilation path to the atmosphere iv opened ventilation of fuel system is clogged a valve is opened 1 1 Lal wk Fig 1 31 Evaporative emission control system 1 10 1 If such condition occurs the pressure in the fuel tank would rise continuously In order to prevent the increase of pressure in the fuel tank the check valve Is opened to release the pressure 10 the atmosphere Fig 1 34 Check valve operation 3 When the fuel the fuel tank is expanded duc to intense heat the pressure in fuel tank will rise The ventilation valve mounted on the intake manifold which regulates the ventilation is not able to adjust the increased pressure due to lis structure and therefore Fig 1A 35 Check valve operation 1A D MAINTENANCE SCHEDULE Maintenance schedules are shown in the following table Maintenance operation stereo Mile Check and adjust distributor point gap dwell angle 4 000 2 Inspect clean adjust and est spark plug replace if necessary 4 000 3 Check and ad
100. tank when the engine is running ty directly channeled 19 the venil lution valve from which it is sucked into the intake manifold to be burned up in the combustion cham ber When running the fuel trapped im the canister is va porized by fresh ait from the cleaner and tht engine temperature and goes to the vil sepa ato and ventilation valve through which it is sucked int the intake manifold together with fresh ait anc blow by gas to be harmed up im the combustion chamber 1A C 1 Canister While the car some of the fuel vapo ated im the fuel tank does not condense in ihi hannelet into the engim space without being fed back tu the fuel tank still cannot be tapped in the alt space Such vapo is absorbed by the canister ile ihe engine is running the fuel vapor trappec in the canister jw released Into the intake manifole with fied air rom the att cleaner and turned up the engine The canister Is always being purged by fresh air ine operation 1A C 2 Condense Tank The condense tank condenses the fuel vapor coming from the fuel tank and retums it to the fuel tank Fig 30 Condens tank 3A C 3 Check Valve The check valve located between the condense tank and the separator in the space works appro pristely when the conditions mentioned below take place relating to the completely sealed ventilation type fuel system 1 Kf the fuel
101. the intake manifold For short time after engine switch off the time lag relay ignites the leading spark plug to burn the unburned components of the charge in conjunction with the air supply valve and the antiafterburn valve then fills the engine with clean alr 3A 8 VENTILATION SYSTEM The ventilation system channels blow by gas into the intake manifold to burn it up in the combustion Fig 1A 23 Ventilation system chamber and helps to control air pollution caused by engine blow by gas This system consists mainly of a ventilation valve separator and hoses necessary to connect these components The ait and blow by gases in the ventilation system as shown in Fig 14 23 Ventilating air from the air cleaner enters the engine air space The ventilating air with blow by gas enters through the separator into the ventilation valve which regulates the amount of ait flow to meet the change of operating conditions and then is directed 10 the engine 1 Ventilation Valve The ventilation valve is operated by the difference of the pressure between the intake manifold and en gine air space Fi 14 24 Vest iron valve When there is no difference of the pressure engine at stall condition or the pressure of the intake mani fold is more than that of the engine air space back fire the ventilation valve is closed by the tension of valve spring as shown in Fig 1A 25 If there is large diff
102. the No 1 control box And this is th source of signal for operating the trailing ignition Fig 14 15 No thetmosensor b No 2 thermosensor The No 2 thermosensor which is placed in th pan detects the oil temperature and sends the signal to the No 2 control box And is a power input for returding the leading ignition timing by 10 degrees when the engine is cold Fig TA 18 No 2 thermosensor Vacuum switch When the engine is cold and the throttle valve is open to near the idle position or near the full open position the vacuum switch signals the No control box to ignite the trailing spark plug so as to maintain good driveability to prevent spark plug fouling and to facilitate engine starting The vacuum switch is connected to the diaphragm of the vacuum advancer for the trailing plug distributor Its changeover is effected by the intake manifold vacuum The vacuum sensing hole of the vacuum switch is located just above the carburetor throttle valve when it is opened to the idling position Fig 1A 18 Fig TA 18 Throttle valve and vacuum switch Therefore when the throttle valve is at the idling or fully opened position the vacuum sensing hole is sub jected to a pressure close to the atmospheric pressure Thus when starting or accelerating the engine the switch connected to the vacuum advancer is energized to signal the 1 control box so that the trailing spark plug wil
103. the coal 1 necessary replace Temperature Below 18 C TT MEC HCAP RSF SAET0W30 18C WF HOF SAE 10 40 HPC 40 C str 00 SAE 20W 40 1 ade Fig 1 58 Checking of ventilation valve 16 Canister a Checking of canister 1 Check 10 see that the air cleaner element is not clogged 2 Attach a vacuum gauge as in Fig 1 55 Check io see that when the engine speed ralsed 1o 2 500 3 000 rpm the vacuum gauge read under 60 mm Ha 1 17 3 Checking of Coolant 1 Check the cooling system for und loose hose clamps If necessary replenish with MAZDA genuine long life coolant The coolant should be replaced normally every 48 000 km 32 000 miles oaks weak hes Fig 1A 57 Checkliy at 1 Note 1 The coolant level should be checked as much us possible when it is cold When checking it while hot it is advisable to do so by first of all releasing the pressure from the expansion chamber by pushing the button on the top of the expansion chamber and then removing the esp of the expansion chamber the set spring of the radiator and the radiator cap in this onder 2 The appropriate coolant level is to have the r distor full and expansion chamber about 1 3 full Do not over fll 4 Checking of Alternator 1 Inspect the V belt condition 2 Check and adjust if necessary for correct tension
104. the current for leading one flows from the Ig terminal to the leading ignition by way of the external re Fig 5 3 Dixgrum of ignition 5 0 DISTRIBUTOR RX 2 is equipped with two distributors ome for the spark plugs on the leading side and one for those on the trailing side Each distributor consists of distributing mechanism Contact breaker mechanism and ignition timing ad vance control of centrifugal and vacuum 5 0 1 Adjusting the Point Gap Adjust the point gap of each distributor as follows 1 Check the contact points alignment If necessary bend the stationary contact bracket so to obtain contact in the center of the contact points 2 Crank and stop the engine when the rubbing block the contact arm just rests on the highest point of the cam 3 Insert a feeler gauge of OAS mm 0 016 in between the contact points loosen the two set screws and move the stationary contact point until the cor rect gap is obtained Fig 5 4 Ayusting point gap 4 Tighten the set screws and recheck the point gap 5 0 2 Adjusting the Ignition Timing To obtain maximum engine performance the distrib must be correctly positioned on the engine 10 give the proper ignition timing If a timing light is available use it to adjust the ignition timing as follows 1 Connect the timing light to the high tension cord for trailing side or leading side of front rotor Start the engin
105. the engine compartment al high speed running on the free way and the engine horse power fall Note IC the car is run continuously under the condition mentioned above the insulator of the spark plug is broken and bites nto the rotor caur ing the vehicle io be inoperable 1 Excessive spark plug gap for trailing side 2 Excessive advance of trailing side ignition Pregnition 3 Excessive advance of leading side ignition 4 Insufficient heat range of spark plug Spit back S Insufficient metering oll 6 Sticky apex seal 7 Improper alignment of high tension cords 9 Large car bucking or deceleration vibration Within the rampe where the coasting vae shook operae when decelerating from 1400 rpm or over large bucking occurs Note Even if the car bucking happens 10 occur within the range of engine Speed less than 1 400 rpm where the coasting valve does not operate may be regarded normal 1 Improper operation of coasting valve 2 Defective No 1 control box 3 Improper idie fuel ar idle speed 4 Air leak from each hose S Air leak from each valve Defective idle switch 7 Fouled spark plug Cean Adjust Clean replace See IA E 12 1 Replace 13 1A E 17 Clem or Check and replace f necessary Repair and replace if necessary Replace if necessary Clean snd replace and replace Se TA E 20 Adjust See IA E 20 Adjust See 1 20 Adju
106. to either solenoid When the engine speed is above 4 200rpm Fig 14 47 Checking of control box 2 1 2 With the thermosensoy connector terminal short citculled as in Fig 1A 48 check the following e Bir Fig 1 48 Connector short circuit 1 Connect the timing light to the high tension cord of the tiling spark plug distributor and check 1o see that the timing light goes on when the engine speed is between 1 900 300 rpm and 4 000 200 pm 3 Connect the thermosensor connector to the thermo sensor and check the following points 1 Connect an ammeter to the coasting valve solenoid amd check o that there is no current flow to the ammeter when idling current flows above 1 250 1 550 When the engine speed is gradually lowered ihe current flow stops at 1 300 1 100 rpm p m Fig 1A 49 Checking of control hox 3 b Removing of control box 1 Remove the control box connector 2 Loosen the control box nuts and remove con trol box e Installing of control box Install the control hox in the reverse sequence 215 9 Thermodatector Checking of thermodetector Check the resistance using an ohm meter If the resistance Is lower than 200 the thermodetector is satisfactory Fig 50 Checking of thermodetector 10 Anthatterburn Valve Checking
107. transmission oil Clean the drain plug and reinstall after draining 5 Disconnect the speedometer cable from the speed ometer driven gear 6 Remove the release fork return spring Loosen the and remove the clutch release cylinder with the push rod from the clutch housing 7 Disconnect the exhaust pipe from the exhaust manifold by loosening the nuts 8 Disconnect the propeller shaft from the trans mission 9 Support the transmission with a jack and a block of wood and remove the muts holding the supporter on to the side frame member 10 Remove the bolts holding the transmission on to the clutch housing 11 Move the transmission toward the rear so to remove the muin drive shaft from the clutch disk Lower the jack and remove the transmission from the vehicle 7 DISASSEMBLING THE TRANSMISSION 1 Remove the release bearing spring and fork 2 Loosen the bolts attaching the clutch housing to the case and remove the clutch 3 Remove the change control case from the exten sion housing 4 Remove the spring seat and spring from the con trol lever end 5 Loosen the nuts attaching the extension housing to the transmission case Slide the extension housing off through the main shaft laying down the control lever end to the left as far as it will go 6 After removing the reamer volt and the friction quss more conte tree and contol lover 7 ARN MGE Sia Keri tension housing by loose
108. und check with a tester to see that the wires protruding rom the inhibitor switch are alive The black and white stranded wire is connected to the starter motor and the green or red and yellow one is connected to the reverse lamp Check also the extent through which the electrical connection is made for and Move the range select lever to both sides from the center position of each range FR and N and it is normal if the electricity on while the lever is within an angle of about 3 on the both side from each lever set line However if anything wrong is revealed as result of the conductivity check of the inhibitor switch make adjustments in the following procedures Remove the nut that holds the range select lever and two bolt holding the inhibitor switch body then remove the serew under the switch body Correctly position the manual shaft in by adjusting the range select lever The proper position is where the slot of the manual shaft is positioned vertically and the detent works to position the shaft correctly with lick sound Fig 34 Iss swich Inhibitor weich f plate Nut 7 Speer Washer K Net Range select lever 2 Manual shalt Transmission case E Move the switch slightly aside so thar the screw hole will be aligned with the pin hole of rhe internal rotor combined with the manual shaft and check their alignment by meerting
109. vacuum switch is located just above the carburettor throttle valve when its opened 10 the idling position Fig 1A 12 Fig YA 12 Throttle valve and vacuum switch Therefore when the throttle valve is at the idling or fully opened position the vacuum sensing hole is sub jected to a pressure close to the atmospheric pressure Thus when starting or accelerating the engine the switch connected to the vacuum advancer is energized to signal the control box so that the trailing spark plug will be ignited Control box and thermodetector The control box is common to the Ignition and air flow control system and the deceleration control ys 14 13 Contro bos Fig A M Vacuum wll Fig YA V4 Thermoderectar 1 teen M wies amd cuts trailing spark plug acconlamce with the engine speed the atate of warm ing up and the engine load controls secondary air and prevents afterburm during deceleration according to engine speed The centro box receives Signals pulses of the leading spark plug ignition coil which indicate engine tevulutiom signals from The thermosensor de the conditron of warming up and signals from Xo the vacuum switch which indicate engine load The thermodetector p a circuit m the control box and prevents the iliermosensor from being influenced by ambiunt temperature JA A 3 Deceleration Control System The deceleration control syst
110. 0 009 in cing Squeeze it up that the joint When disas sembling the joint will rise above the groove and disconne From valve Line pressure F r 336 Croan vice al qvem be valve Ou di Oupa 60 1 Lubricate all paris with converter oll and reinstall them in the revene order of disassembly so as not to confuse prim ry wi ry After reassembly make sure thot the governor spring i4 straight and there is no catch in the Koverner valve movement with mke distribu four holis to standard torque of 0350 45 feb Tighten the governor to the o 9 To determine if secondary governor is in good condition blow air under light pressure into line pressure hole in Fig 2 34 to listen for noise like model plane 4 G OIL PUMP ASSEMBLY Remove 1 Disconnect the pump cover from the pump housing by loosening five bolts that attach them Take out the mer gear and the outer gear from the pump housing At the same time put a 4i indicating the installing side with quickdry ink or something and not wit punch to avoid erroneous assembly To Inspect 4 Check to see that tooth fices of the inner and gears are worn 4 Check the side play of the inner outer gear by using straight edge and thickness gauge as in Fig 2 37 The saruard valve is 0 02 0 04 mm 0 001
111. 0040 0020 m mm 0 0089 0 050 0 072 mm 0 0014 0 028 i 10 40 i 0 0089 in 8 am 0 228 2 0 mm 0 079 0 7404 I 9 64 kg mm 35 8 1178 08 mm E Gani D 00006 10019 in 6 08 0 0001 in 2 7 0 106 LO mm 0 089 in 1340 5 bp 2 92007 thy 0 16 p n 4 6 Win 0 014 10700 ren 0 059470 0006 am 35 mm mm 1000 01 am 9 0016 0 0024 0 10 0 0009 in 0 05 0 002 0 08 n 040 mm 0 016 in 240 0 079 1 0 0 099 in 3 620 3 ke 7 9207 I 2 6 ha rm 201 6 Ibin am 0 216548 wj 4 Ounide diameter of outer cil Contact oil weil Rips Standard Limit Oil seal aping i Free height Ser hesht Ser load Spring comune Mian bearing reer diameter bearing clearance Standard Limit Rotar beating lamer Rone beating chenare Standard 571 Eccentric shalt ecentrivity of tutor journal Main diameter Rotor journal dismeter 92 mm 0 008 n 04 am 0 081 in 0 10 0 088 i e ide 1 5 jo 464 3 40 055 m 0 000548 10 010 07 0 0016 0 0028 0 10 mm 0000 in 41900 20 05
112. 1 298 0 008 DTI Ait gop 0 71 1 tot 0 028 0 043 in gap 0 3 0 4 mm 009 0016 in Back 20 71 1 0 628 0 083 io W SW 3aw sw ow 5W aw 21W SW 0W 10W Outer diameter Single dry plate Diaphragm spring 150 mm 5 91 in 215 mm 847 im 154 mm 5 06 le 215 mm 8 47 in 5203 mm 0 35 20 00 i 3 0 mm 0 12 in 2630 mm 0 81 2 12 87 0 648 in 17 46 mam 9 8874 m Shift lever cation capacity Backlash of gran Main drive amp coume year Fim Seed Third Reverse geur Fourlorward sperd and ore serene speed synchro niring for forward sud selective lor reverse E 1397 sd Above IC SAE 9 Below 18C E EP SAE 2 5 litem 5 2 WS 424 pius 0 00 10 mn 9 1 0 04 in 0 0 4 20 0 004008 in 946 016 e 0 020 006 in 10 050 15 wn 0 002 0 006 in 920 020 0 004 0 008 in Oil capacity Free play of axle shaft Permissible deflection ob ring ger Mounting distance Dew pinion bearing preload Backlash between ring grat and drive Backindy between side gear and Above 18 C 9 F HP SAE 90 Below 18 C HP SAE 90 1 2 Wem 2 5 US pinis 2 1 Imp pints 0 01 mam 0 0 004
113. 1 5 mm 0 099 tn diameter pin into the holes If the alignment is made correct the switch body with the bolts pull out the pin nd tighten up the screw again into the hole sind fasten the select lever before Check over again the continuity with the temer If the malfunction still remains replace the inhibitor switch Pig 25 Adjusting inhibitor switch tB DIAGNOSTIC TEST ITEMS Make sure that all the inspection items described in EA are normal before starting the diagnostic tests test road test and oil pressure test 1 8 1 STALL TEST The purpose of this test is to check the transmission and engine for trouble by measuring the maximum numbers of the engine revolutions while the vehicle is held in stalled condition and the carburetor is in full throttle operation with the manual lever in ranges D 2 I and R respectively and by comparing the m jeured results with the standard values The specified stall revolution for each model is im the following table Stall evolution Irpm pm Im RX i eat N RES 1600 1 900 2 15 1 990 2 200 E SE Stall test procedure L Check the levels of engine coolant engine and torque converter oil Warm up the engine at about 1 200 rpm for several minutes with the manoal lever in P in order ta heat the torque converter oil suitable temperature of 60 100 C 1405
114. 2V between the MT terminal and the magnetic switch body If the plunger is not attract ed there is trouble Fig 5 31 Retum test 5 6 6 Assembling the Starting Motor To assemble the starting motor reverse the proced of Par 5 6 3 noting the following points 1 Adjust the armature shafi end play to 0 1 04 mm 0 004 0015 in with thrust washer on the rear end of the shaft and pinion shaft end play to 0 1 0 3 mm 0 004 0 012 with wash er the end of the shaft 2 When the magnetic switch is closed the clearance between the pinion and stop collar should be 0 3 15 mm 0012 006 in o gt i 011 0 Oi Fig 5 32 Gap of pinion and stop collar 5 H LIGHTING SYSTEM The wiring of the lighting systems is shown in the witing diagrams The wires in the various circuits are of different colors to aid when checking individ val circuits 5 1 Headlight Aim Before adjusting the headlights make sure that the tires are inflated uniformly to recommended pressure amd the vehicle is on the level ground without load To adjust the headlights remove the head lamp frames and turn the three spring loaded screws of the sealed beam unit the hesdlights are aimed pro perly When the high beam is aimed 1 0 39 37 in straight ahead the center of the high intensity should be 129 mm 0 51 lower than the hor izontal lamp center line as shown in Fig 5 33 Fig 5 33 Headl
115. 3 wire brush if they are foul Replace the badly burned or eroded spark plugs Measure the electrode gap of each spark plug with wire gauge If it is improper adjust the yap to the specified valve 0 8 09 mm 0 031 0 035 in by bending the outer electrode Fig 5 2 Adjusting spark plug gap 5 5 lt IGNITION COIL Two types of ignition coil are equipped One is the leading ignition coil with external resist ance which improves ignition performance and start ability of the engine and another is ordinary type the trailing ignition coll When the ignition key is turned on to actuste the starter the S and R terminals of the key switch are closed with the B terminal of the key switch and the lg terminal is opened In this case cur leads fo the S terminal of the relay and mag netizes the relay coil Thus the and B ter minals of the relsy are closed Then the primary current leads from the R terminal to the trailing ignition vis the relay And also the primary current for leading one is led from the R terminal direct o the leading ignition coil by passing the ternal resistor When the ignition key is returned to the Ig posi tion after starting the engine only Ig terminal is closed with B terminal of the key switch There fore the function of the relay is stopped and the primary current flows from the lg terminal to the trailing ignition coil And also
116. 9 MAZDA v RX 2 ROTARY ENGINE SERVICE MANUAL Listed below are the names and addresses of the United States Distributors and the States under their jurisdictio MAZDA MOTORS OF AMERICA INC 3040 E Ana Street Compton California 90221 213 537 2332 California Nevada Arizona New Mexico Colorado MAZDA MOTORS OF AMERICA Eastern Branch Office 60 New England Avenue Piscataway New Jersey 08854 201 752 5800 Connecticut Massachusetts Pennsylvania Washington D Delaware New Hampshire Rhode Island West Vir Maine New Jersey Vermont Maryland New York Virginia MAZDA MOTORS OF AMERICA Midwestern Branch Office 1600 Busse Road Elk Grove Village Illinois 60007 312 593 8090 Illinois Kentucky Nebraska Tennessee Indi Michigan North Dakota Wisconsin Towa Minnesota Ohio Kansas Missouri South Dakota MAZDA MOTORS OF AMERICA NW INC 120 Andover Park Fast Seattle Washington 98188 206 248 0110 Wasftngton Oregon Idaho Utah Wyoming MAZDA MOTORS OF FLORIDA INC 7401 Phillips Highway Jacksonville Florida 2 904 737 2404 16 Florida Georgia Alabama North Carolina South Carolina MAZDA MOTORS OF TEXAS INC 8000 Harwin Drive Houston Texas 713 785 6440 Texas Louisiana Oklahoma Arkansas Mississippi WORKSHOP MANUAL SECTION INDEX MAZDA 5 CAPELLA ROTARY see Transmission SEDAN Transmission T 1 Automatic
117. 96 304 kg 653 670 Ib If possible use springs with the same identification mark on both sides 2 When installing use vegetable grease for the inter ior of the rubber bushes 13 8 SUSPENSION ARM ASSEMBLY 13 8 1 Removing of Suspension Arm Assembly 1 Remove the front shock absorber referring to Pat 13 A 1 2 Remove the suspension arm attaching nut from the tod on the front cross member and remove the front suspension arm assembly Fig 13 23 Removing of suspension arm 13 8 2 Checking of Suspension Arm 1 Check the lower arm and knuckle arm for any crack or damage 2 Check the rubber bushes for weakness wear or dam age If necessary replace with new ones 13 8 3 Installing of Suspension Arm Install the suspension arm referring to Par 13 B 1 and 13 A 1 13 7 13 BALL JOINT The ball joints for the suspension arm are made main tenance free for 48 000 km 30 000 miles and there fore require no greasing during this period When greaseing becomes necessary supply Molybdenum Disulfide Lithium Grease to the ball joints proceed ing as follows 1 Remove the plug from the ball joint and tempo install the grease nipple 2 Feed Molybdenum Disulfide Lithium Grease through the nipple until the grease begins to flow freely from ihe dust seal or the dust seal begins 10 ballon 3 Remove the grease nipple and reinstall the plug Note Never use multipurpose grease or chassis grease If improp
118. C 172 F the passage leading to the housing gets completely closed During the condition of the temperature be tween 71 78 C 160 172 F part of is sent directly to the filter via housing and the rest is cooled in the cooler before being sent to the oil filter After exceeding 78 C 172 as the bil pas sage to the housing is closed all oil is sent to the oil filter through the cooler Fig 2 9 Oll thermo raive 2 6 1 Inspecting the Oil Thermo Valve l Inspoet the sliding surface of the slide valve to see whether there is any damage 2 inspect the return spring for any damage or de terioration If the deterioration is serious replace the spring The free length of the spring should be 438 mm 1 724 in 3 Inspect the pellet by inserting it in water tor gether with a thermometer Stir the water and pad Wally heat iL Check whether the pellet begins to function at 71 C 160 F and lifts by 6 mm 0 236 in at 78 C 172 F 2 METERING OIL PUMP The plunger type meteting oil pump is provided to send proper amount of oll to the carburettor The oil enters the combustion chamber together with the air fuel mixture Thus the sliding faces of seals and housing are lubricated The supplied amount of is controlled by the engine revolutions and the load in the following way control lever of the pump is interlocked with the throttle lever of the carburettor and moves the control
119. COUPE ema a Rear Axle Steering 10 Brake Wheels Tires 12 NOTE Suspension Capella Rotary is the nickname of the MAZDA RX 27 which is used in Body 14 some markets Technical Data T q 1 REMOVING THE ENGINE 1 4 1 B DISASSEMBLING THE ENGINE 1 6 1 ENGINE INSPECTION AND REPAIR 10 1 C 1 Front Housing 1 10 1 C 2 Intermediate Housing 1 12 1 C 3 Rear Housing 1 12 1 4 Rotor Housing 1 13 1 C Rotor 1 14 1 6 Sul 1 18 1 7 Eccentric 1 21 1 0 ENGINE ASSEMBLY 1 22 1 0 1 Installing the Seal 1 22 1 D 2 Installing the Seal 1 2 1 0 3 Installing the Rear Rotor swoon 1 23 1 D 4 Installing the Rear Rotor Housing 1 23 D 5 Installing the Eccentric 1 24 6 Installing the Seal 1 25 1 D 7 Installing the Intermediate Housing 1 25 1 0 8 Installing the Front Rotor and Housing 1 25 1 D 9 Installing the Front Housing 25 1 D 10 Tightening the Tension Bolis 1 25 1 D 11 Installing the Clutch Assembly 26 1 D 12 Adjustment of Eccentric Shaft End Play 276 1 D 13 Installing the Front Cover 1 27 1 D 14 Installing the Metering Dump 28 1 D 15 Installing the Oil Strainer and Oil Pan 1 D 16 Installing the Oil Filter 1 D 17 Installing the Water Pump 1 D 18 Installing the Distributor 1 D 19 Installing the Alternator 1 D 20 Installing the Manifold and Carbure
120. Check valve Air injection nozzles d Air control Thermal reactor 2 Ignition and Air Control System No 1 control box and thermodetector 6 No 2 control box at choke switch eM Deceleration Control System f Anthafterburn valve H Li d Air supply valve VENTILATION SYSTEM 1A B Ventilation Valve EVAPORATIVE EMISSION CONTROL SYSTEM 1A C 1 Charcoal Filter 1A 1 2 Condense Tank 1A MAINTENANCE SCHEDULE MAINTENANCE PROCEDURE 1A Air Pump 2 Check Valve Air Injection Nozzle Thermal Reactor Air Control Valve 1A 1 Thermosensor VA No 2 Thermosemot 1A eS 1A 1A F IA E 8 Thermodetector 1A E 9 Vacuum Switch IA 1 10 No Control Box 1A 1A E 1 No 2 Control Box and Leading Ignition Retard System 1A 1 4 12 Anti afterburn Valve 1A E 13 Coasting Valve TA E 14 Switch 1 1A E 15 Choke Switch 1A E 16 Air Supply Valve 1A 17 Ventilation Valve LA 1A E 18 Charcoal Filter IA 1A E 19 Distributor 1A 1 20 Spark Plu 1A JA E 21 Ignition Coil 1A 1 22 Carburetor IA EXHAUST EMISSION PROCEDURE 1 1 1 14 Factors of Driving Op eration Which Affect Emission 1A 1A F 4 Other Elements Which Affect Emission 1A TROUBLE SHOOTING lA 1A G i Synptoms Causes and
121. ETE 15 Draw out the one way cluteh by removing the snap ring from each end Remove the outer race ring und draw out the outer race rearward from the deum After disassembly check to see thay the oneway dutch is not damaged Check at the sme time whether there is any damage of the outer race or inner the contacting marface Pig 244 One chinch When installing the one way chich it is fitted with the arrow mark at vehicle ke sure 1 on the front Fig 245 Mark on the One way clutch Manua control system and parking lock system Removal and disassembly of these parts are omitted 63 5 REASSEMBLY OF TRANSMISSION Reassembling the major component pers on the transmission case are described below Install them in the procedure reverse to thet of part 3 DISASSEMBLY OF TRANSMISSION and make sure to lubricate each with converter oil before installation All gaskets must te replaced with new ones As to various component parts refer to part 4 OVERHAUL OF MAIN COMPONENT 1 Install the iow and reverse brake assembly on the transmission case See 4 D 2 Turn clockwise and push the connecting drum assembly engaging it with the friction plates 3 the needle bearing and bear the front face of the distributor asse race for y on the transmission case side Then install the oil distributor king care nor ass
122. N COMPLETE 4 OVERHAUL OF MAIN COMPONENT A A TORQUE CONVERTER ae 4 FRONT CLUTCH ASSEMBLY 4 REAR CLUTCH ASSEMBLY 4 D LOW amp REVERSE BRAKE ASSEMBLY 4 BAND SERVO 4 GOVERNOR VAL 4 6 PUMP 4 H CONTROL VALVE ASSEMBLY 4 1 BEARING AND BEARING RACE 4 1 OTHER COMPONENT PART 5 REASSEMBLY OF TRANSMISSION 6 6 INSTALLATION AND ADJUSTMENT OF TRANSMISSION 1 Snap ring 2 Flange 3 Drive flange 4 Snup ring 5 Drive tange asseinbly 6 Drum Snap ring 8 Outer 9 One way clutch 10 Stap ting Stap ring 12 Connecting drum assembly 13 Inner mce Fig 1 3 Automatic transmission component 3 14 Sanp ring 15 Piston retum spring 16 Bolt 17 Retaining plate 16 Friction plate 19 Steel plate 20 Disbed plate 21 Spring ting 22 Low amp reverse brake pinon 723 Pison seal 24 Seat ring 25 Needle benting 26 Bearing tace 38 Output shalt 36 Speedometer drive gear 37 Steel ball 38 Suap ring 1 Side plate 2 Plug sleeve 3 Presware regulator pling 4 Spring seat 5 Pressure regulator spring 6 Presente regulator valve 7 Second lock spring 8 Second lock valve 9 Manual plate spring and 10 Manual valve Side plate A Big 14 Automatic 1emsmiveion componen 4 32 dated shify spring 13 Lat 2nd shill valve 44 20d 3nd
123. OSIS CHART 1 1 ITEMS TO CHECK 1 Inspection with automatic transmission on the car level Range select linkage C Inhibitor switch and wiring D Vacuum diaphragm and piping E Downshift solenoid kickdown switch and wiring F Enging idling speed G Oil pressure Engine stall speed 1 Rear lubrication 1 Manual control valve Governor valve L Band servo Transmission air check 1 2 TROUBLE DIAGNOSIS CHART The numerals show the sequence of inspection for Oil drain check O Ignition switch and starter motor P Engine adjustment and brake inspection 2 Inspection after inspecting automatic transmission on the car Rear clutch by Front clutch Band brake d Low amp reverse brake e Oil pump f Leak from hydraulic passages One way clutch in torque converter h One way clutch in power train 4 Front clutch check ball j Parking linkage k Planetary gear detecting trouble Trouble ABCD EFGH JKL MNOP eb ah iik Egoe wat uN and ii E S E ed Ep ee ov arr Erg D i Sheree n per P 3 Tendency to slip FEF gt Gir mia n z e ess be vs 7 0 3 o mam i Cie ge wen Rr 2 323 lo em Excessive creep 1 Y UE an all 12 5 4 an
124. P to I ranges where clicks will be felt by hand This js the detent ol manual valve in the body and indicates the correct position of the lever Inspect whether the pointer of selector dial corres ponds to this point and also whether the lever comes in alignment with the stepping of position plate when it is released Fig 222 Manual linkage When the position of the manual Jever is found in correct disconnect the joint on the lower rod and place N ybe range select lever on the transmis sion where the slot of the manual shaft is positioned vertically Adjust the position of the manual lever by turning the T joint so to position the marmal lever in Finally make sure that the lever travels to and 1 ranges correctly Check at the same time to see that the linkage has loos Note An aditional counter lever is used only on the 616 Capella 1600 model 1 5 INHIBITOR SWITCH The inhibitor switch permits the reverse lamp to light up only when R range is selected and the starter motor to revolve only when the lever is in or P position so that when D 2 or 1 is selected the reverse lam woes not light up amd the starter motor cannot revolve If any abnormality is found n any range check and adjust tbe manual linkage if the manual linkage is found normal then check the inhibitor switch Engage the manual lever im each range
125. Remedies 1A 1A G 2 Detects Conditions of Trouble and Causes of Defects Related to Each System 1A TECHNICAL DATA 130 vb 43 06 TEA SR eam Wiel VALVE VI vita Ie M 2 E Wu wai pn farses Coote snk 1 VI au jo igi ve 18 478 MOO em E Declaration the enon 1 wormed un VENTILATION VALE amm En LUE THES p FRESH uh Fi mex is tome EU La vens 1 AIR POLLUTION CONTROL SYSTEMS The MAZDA RX 2 is equipped with an exhaust e mission control system a ventilation system and evaporative emission control system EXHAUST EMISSION CONTROL SYSTEM The exhaust emission control system consisting of am air injection system an ignition and air flow con trol system and deceleration control system re
126. Remove 1 Remove the snap ring retuining plate varer plutes inner iul dished plate in the sume procedure Pig 2 21 we lor the frone chuh assembly Remove the coil spring retainer ring by the f the luteh spring Then remove y retainer anit 10 voll Aprins the cul s Y Ren the ail hole we the piston by blowing compressed aie Fig 224 Blowing ony To Inspect 4 Make the assembly and any defective parts with new sume inspection for the front clutch To Re semble All parie are reassembled with red im the teverse sequence of the disassembly as in the case of the front chuch After reussen check 1 that the clearance between the sump r ut plato ie within we of 10 1 5mm 0 034 0 0584 she eour diueh assembly to the oil pup and check the cuh operation blowing compressed sir the oil bole ux shown in Fig 2 25 4 0 LOW REVERSE BRAKE ASSEMBLY Te Remove L Remove the fine ob the ow amt reserve Remove we plau friction plures pressure plate 8 doe devei 2 Finan ti Feleke pl etum V Steel pl 10 Being ving piste n i The inner race of the one way clutch is tightened the rear of the case Loosen
127. SSURE SWITCH The oil pressure switch is provided on the left side of the rear housing This switch is connected to the warming lamp on the instrument panel The normal pressure is 2 5 kg m 35 6 16 02 during engine idling If the oil pressure drops below 0 3 kg cm 43 lb in the warning lamp lights up to indicate some troubles in the lubricating system When the lump comes on immediate checks should be made Fig 2 3 pressure switch 2 0 INSPECTING THE OIL PRESSURE oil pressure should be checked as follows 1 Operate the engine until it is warmed up to the normal operating temperature 2 Remove the off pressure switch and connect an oil pressure gauge instead 3 Operate the engine at 3 000 rpm and read the pressure gauge The pressure should be 0 kg em 71 1 Ib in 20 If the pressure Is found extremely low check the following points T Make sure whether the oil level is between F and 1 on the dipstick gauge or mot 2 See if the oil filter is clogged If clogged replace the filter cartridge refer to 2 3 Inspect the oil pump for defects refer to 2 F 4 Inspect the oil pressure relief valve and check plung ex If found defective replace the valve The specifications of the spring are in the following table Free Length 64mm 1827 Set Length 353mm 1 390 Set Load 71 565 2 OIL PUMP The components of the troc
128. The impeller ix fitted on the rear end of the pump shaft The seal is made of stainless steel carbon and rubber to prevent water leakage Inspect the water pump for water leakage check the end play and looseness of bearings Move the impeller blades by hand IF the play is excessive the bearing must be worn If water leaks from the pump body opening the seal is defective Then it is necessary to overhaul the pump and inspect the seal and seat surfaces If the seal is defective it should be replaced 3 G 1 Disassembling the Water Pump 1 Remove the bolts that attach the cover to the pump body and separate the water pump assembly 2 Remove the pulley boss with the water pump puller No 1 49 0813 145A press the shaft slowly to ex tract the pulley boss from the shaft And then remove the retaining ring with a suitable plier Fig 3 5 Removing pulley bost 3 Support the front side of the water pump cover with the water pump puter No 2 49 0813 145A and apply pressure the rear end of the shaft to press the shaft and remove the impeller and then push the bear 1 Pump casing 2 Packing 3 Impeller 4 Water seal cpt 5 Pulley boss 6 Dust seal plate 7 Retaining ting 8 Ball bearing 9 Spacer 10 Bali bearing 11 Stop ring 12 Shin 13 Duc seat plate 14 Baffle plate 15 Pump cover Fig 3 6 Water pump assembly 3 ing assembly with shafi our through front of the cover 4 Remove the water seal
129. acer as shown in Fig 9 20 9 20 Imtalling of collapsible spacer 2 Place the front pinion bearing in position on the pinion Hold the pinion fully forward and drive the pinion bearing over the pinion until seated 3 Apply grease to the lip of the pinion sea install the pinion seal into the carrier 4 Install the companion flange on the pinion by tapping with a soft hammer 5 Install the pinion washer and nut Before tighten ing the nut When the pinion preload is Zero check the drag by the by using torque wrench 6 Tighten the pinion mut to 13 mg 94 ftib and check the preload as shown in Fig 9 21 and Fig 9 21 Checking of preload Note After preload has been checked final tighten ing should be done very cautiously The pinion mut should be further tightened only a little at x time and preload should be checked after each slight amount of tightening Exceeding preload specifications will compress the collapsible spacer too far and requires Its replacement 7 While observing the proceeding caution carefully set the preload diag at 9 to 14 cmg 7 8 to 122 inib plus the oil seal drag determined in Step 5 9 3 Assembling of Differential 1 Install the thrust washer on each differential side gear and install these in the gear case Fig 9 22 Installing of thnwst washer 2 Through the opening of the gear cas insert each of two pinion gear exactly 180 degrees opposite
130. actor cooling air o suit the engine operating condition and the 14 2 1 safety valve that controls the amount of secondary air alone Fig 1 6 Air control valve The air cut valve opens and closes according to the difference of pressure between the vacuum and air chambers This valve which ls connected 10 the dia phragm is closed during normal operation by the intake manifold vacuum When the engine speed ex ceeds 4 000 200 rpm the box actuutes the solenoid to close the vacuum way This equalizes the pressures the two chambers the spring force canses the valve to open and the ait in the air injection system is channeled to the thermal reactor to cool it before being emitted to the atmosphere At the same time the air cut valve closes the secondary passage to cut secondary air supply into the exhaust port in case the car is decelerated when running at the engine speed below 4 000 200 rpm the coasting valve of the deceleration control system operates to tum the vacuum in the vacuum chamber of the control valve 10 atmospheric pressure This equalizes the pressures in the vacuum and air chambers and causes the spring to open the air cut valve so that the air in the air injection system will go through the thermal reactor to cool it before being expelled to Ti valve xa Sono emirai valve E
131. allowed to act against the throttle positioner diaphragm the throttle valve link ed to the diaphragm is held at a certain opening angle When the engine speed decreases to 1 250 50 rpm during deceleration the control box commands the solenoid attached om the coasting valve to close the vacuum sensing line preventing the intake manifold vacuum from acting against the throttle positioner diaphragm and returning the throttle valve to the idling position d Air supply valve and time lag relay The uir supply valve and the time lag relay have the functions of preventing afterburn when the engine is switched off and filling the engine with fresh air Fig TA 21 Ait supply valve From air cloanor Z Coasting valve To ant afterbutn valve intake mantota ait control valve Vacuum chamber Throttle positioner 1 Throttle valve Fresh air q Vacs Fig 1A 20 valve and thiottle positioner cross section Fig 14 22 Air supply valve antiafterburm valve and time lag relay The solenvid of the air supply valve kecps closing the intake manifold vacuum way while the ignition switch is ON When the engine is switched off the solenoid opens the vacuum way and the resulting difference between the vacuum and air chambers causes the valve leading to the diaphragm to open so that fresh air from the air cleaner is supplied
132. alve or hose Defective b Defective No 1 control box Defective coasting valve Possible troubles Correspanded Mem T Exhaust emission becomes abnormally unfavoursble 2 Driveabillty deteriorates 3 Abnormal afterburn occurs 4 Car bucking becomes abmormally excessive gt 1 Conditions of trouble of X Comming vae constantly open at acceleration and speed Fannin B Coating valve does not open during deceleration Probable cames b Defective coasting valve solenoid v Detective idle wwiich d Improper tetum of the varb reter primary throttle valve Choke ewiteh Pomible trouble T Brey Shows abimana deterioration when the engin ls cold 2 Exhaust emistion becomes abnormally unfavourable Conditions of trouble of device Leading nition dors pot retard when the choke wich is off and the engine cold Leading ignition remains constuntly retarded when the choke je completely pushed back while engine is cold gt Probable cames Defective No 2 control box 5 Defective choke switch Air supply Posible troubles Abnormal occur during 2 Regular cat knock iurging becomes excessive 3 engine starting 4 Rough engine kiling 5 Abnormal amounts of idle HC and CO 6 Flat spot occurs during deiving Conditions o
133. and housing 4 The fuel filter cartridge is held by the clamp which fs attached to the lower side of the service hole cover of the luggage compartment Both ends of the cartridge are connected by nib ber pipes The cartridge should be replaced at intervals of 18 000 km 12 000 miles Fig 4 16 Fuel fiter 4 0 AIR CLEANER The sir cleaner is of the paper element suction type The air cleaner element should be cleaned every 3 000 km 2 000 miles and replaced every 36 000 km 24 000 miles Under sub standard toad condi tions the cleaner element should be cleaned every 1 5000 km 1 000 miles and replaced every 18 000 km 12 000 miles On the air cleaner the intake of fresh alr and hot air are automatically switched over by means of the thermovalve and control diaphragm installed in the sir cleaner The control diaphragm is installed at the bottom of the fresh air duct When the ambient temperature drops below 40 C 104 F the control diaphragm operates the air shutters by utilizing the engine neg ative pressure avilable through the thermo valve This diaphragm starts functioning at negative pres sure exceeds 100 mm Hg aud reaches the maximum stroke of 8 mm when the negative pressure exceeds 200 mmHg Under such a condition the fresh air Shutter is perfectly closed while the hot air shutter linked to the fresh air is fully opened When the ambient temperature exceeds 40 C 104 F the engine negative press
134. and remove the vinyl pipe and the tool 3 Install the new brake shoes 9 Refit the antitattle spring caliper stoppers and fastening clips 10 Install the wheel and tighten the bolts to 90 Fig 11 16 Removing of stop plates mkg 70 3 Remove the caliper and spring 11 0 2 Removing and Disassembling of Caliper 1 Raise the vehicle and remove the wheel 2 Disconnect the brake fluid pipe from the caliper Plug the end of the fluid pipe 10 prevent entran of dirt and loss of fluid 3 Remove the caliper from the brake disk refer to Par 1 0 1 4 Clean the outside of the caliper and remove the boi 5 Place wood im the caliper pit in ordet to avoid damage gradually blow compres pipe hole and remove the piston air from the fluid Fig 11 17 Removing of caliper 4 Remove the shoes Fig 11 18 Removing of shoes Fig 11 20 Removing of piston 11 6 Remove the piston seal from the cylinder gt Fig 11 21 Removing of piston seat 11 0 3 Checking of Caliper 1 Before checking wash all parts in clean alcohol brake fluid Never use gasoline or kerosene Blow out the fluid passages in the caliper with com pressed air 2 Check the cylinder bore and piston for scoring scratches or rust If any of these conditions found replace with new piston ar caliper Minor damage can be eliminated by means of polishing with crocus cloth 3 The piston seal and dust bo
135. and the drive plate pull o the transmis with the converter ot inched to it the holder und dimmu assembly by loosening 3 DISASSEMBLY OF 7 Remove the co TRANSMISSION COMPLETE a be paid vo the following maner equipped pim Low md remove drum 10 Pull erter housing remover 49 000 01 4 OVERHAUL OF MAIN COMPORNENTS anm procedure ural h melde large num precision Se 1 shoul be planed wing sequence Beuring benting mes must lu checked with respect 10 4 A TORQUE CONVERTER Th We eerie 1 wer oll is Found markedly ded rime the inside if he conve approximmely 0 8 HO piti O 0 4 Imp pint ol clean salve the outpur shift rearwned Then remove aribor verher vith governor take 4 B FRONT CLUTCH ASSEMBLY Vig 247 rom Remove the fern ten aid the spacer and pull out the mani 9 Ri the range select lover h acting mut nnd mke out the Inhibitor switch by The ubove operatione complete the disaasemly of the principal rranemissior patte excepti To Remove the snap take plates outer plate brake which still r the transmission wc with driver The low reverse brake can of be removed f plate
136. ase the starting acceleration is poor while acceleration at high speeds is normal the one way clutch of the torque converter is slipping 18 2 ROAD TEST An accurate knowledge of the automatic transmission is prerequisite t0 its exact diagnosis by a road test The purpose of road test is to make a comprehen sive check of the transmission under varying running conditions to detect and analyze troubles and to clear up the cause of troubles Shift Point Check Check to see that the upshift and down shift occur within the range specified in the shift point table 48 below following the checking procedures Shift point check procedure 1 Make sare that the ayre air pressure is im the standard range and preheat the converter oil 10 ap propriate temperature about 60 100 lt 140 212 F in engine idling condition 2 Place the manual lever in D range und acceler me in wide open throttle kickdown switch energiz ed and read the car speed at the instant of Di gt Ds and 0 0 upshifts with speedometer which is in stalled on this 3 Drive the car with the manual lever in D When iris running at a constant speed in Dy depress the accelerator pedal to the full the kickdown switch energized and make sure that Dy sD shift occurs Continue this check at higher speeds until a critical speed from which that downshift does not occur any more is reached Proceed to check the critical speed for Di sD kick
137. ause inferior functioning f the synchronizer ring and make shifting difficult 4 Check the key spring tension Decrease tension or damaged key springs will result in uneven pressure against the three keys and will cause improper function ing of the keys and inferior synchronization 5 5 Checking the Run Out of Main Shaft Check the runout on the main shaft and if the de flection is excessive correct it by using a press The standard reading on the dial indicator for run out should be les than 0 03 mm 0 0012 im Fig 7 8 Checking run out of main shaft 7 0 ASSEMBLING THE TRANSMISSION 7 D 1 Assembling the Transmission Case 1 Assemble the lowsind second clutch hub und sleeve and thirdaind top clutch hub and sleeve 2 Install the second gear synchronizer ring low and second clutch hub assembly synchronizer ring low gear sleeve low gear and thrust washer in 75 that order onto the main shaft from the rear side 3 Install the third year synchronizer ring and third and top clutch hub assembly onto the front side of the main shaft and fit the snap ring on the groove 4 Install the needle roller bearing and synchronizer ring lo the main drive shaft 5 Place the main drive gear assembly and main shaft assembly into the transmission temporari ly without ball bearings Fie 7 9 Placing main shaft assembly 6 Put the lowandsecond shaft fork and third and top on the respective groov
138. centric shaft while being careful not to damage rotor bearing and main beating 1 0 6 installing the seats 1 Fit each apex seal to the rotor groove confirming the position and direction 2 Install the each apex seal spring 10 1 reverse side of the apex seal as shown in Fig 1 85 3 Fit the cormer seals and side seals 10 their respec me positions on the rotor Refer to step 3 and 4 in per 1 0 2 4 Apply some Gil 10 the seuls the rotor and frio tion surface of the rear side housing Fig 1 83 installing tubular dowels 1 0 7 Installing the Intermediate Housing 1 Apply sealing agent on the mating surface of the tear rotor housing 2 Fit the new sealing rubbers and rings on the rotor housing 3 sure that the rotor housing is free from foreign mutter 4 While holding the rear end of the eccentric shaft up as high aa it s rear journal portion does not ex cced the rear rotor bearing install the intermediate housing through the eccentric shaft 1 D 8 Installing the Front Rotor and Housing Refer to Par 1 D 2 3 4 and 6 and assemble the front rotor and front rotor housing 1 D 9 installing the Front Housing 1 Apply sufficient engine oil to the stationary gear and the main bearing 2 Install the front housing over the eccentric shaft If necessary tum ihe rotor slightly to engage the teeth of the from housing statiorinry gear and the ront rotor internal pear 1 0 10
139. ck the resistance The following ohm meter readings indicate that the thermodector is normal Ambient temperature Resistance 20 C 4 F 02 32 F 20 C 68 F 12002 5 40 C 05 050 TA E 9 Vacuum Switch Checking of vacuum switch 1 Remove the cap of the leading spark plug distri butor 2 Remove the vacuum sensing tube from the vacuum advancer of the trailing spark plug distributor then attach the vacuum gauge in its place as in Fig 1A 49 3 Hold the mouth on the vacuum gague and suck reading the vacuum gauge Make sure by the switching er 14 47 Checking of No 2 thermosensor Thermo Fig 1 48 Checking of thermodetector sound that the vacuum switch changes over from ON to OFF when the vacuum gauge reading is under approximately 180 mm Hg and it changes over from OFF to when the vacuum is reduced until the vacuum gauge reads 120 30 mm Hg Vocum gauge Fig 1 49 Checking of vacuum switch 4 Mount the cap of the trailing spark plug distributor and connect the vacuum sensing ube to the vacuum advancer 5 Remove the No 1 thermosensor connector 6 Connect the timing lipht to the high tension cord of the trailing spark plug distributor Run the engine at idle speed and check to see that the timing light goes off the vacuum switch OFF when the engine speed is raised to 1 900 300 rpm 4 000 200 rpm 10 No 1
140. complete 5 Remove the bearings and spacer fiom the shaft with a suitable puller Fig 3 7 Removing Impeller 3 6 2 Assembling the Water Pump When assembling Ihe wale pump weder n Fig 3 6 and proceed as I Fit the Hing ihe groove af Hie shaft 3 Place the dust seal plate on the sop ning and the battle plate onto phe Tapper of the shaft A Press the hearing with the sealed side rearward 4 Press the daty and hearing into the cover using a sullable nl S Anvert the spacer inte the shalt and approxunite ly fill IEE Ihe spuse between the two bearings with grease 6 Prosstit the bearing with sealed sile forward until the retulning ting can he inserted 7 Install snap ring into the groove of the cover to retain the bearings in position After firing the dust seal plate to the pulley boss press the pulley boss onto the shaft until the boss comes tm contact with the bearing Y Install the water seal complete into the cover 10 Press the impeller assembly onto the shaft until Wi ds Mush with the end of the shaft Il the cover and gasket to the body SPECIAL TOOL 49 0813 145A Water pump puller 4 4 c 4 FUEL SYSTEM CARBURETTOR 4 1 Carburettor Function LO Disassembling the Carburettor Carburettor Inspection umn Assembling the Carburettor 4 A 5 Carburettor Adjustment FUEL PUMP 4
141. connect the fluid pipes at the brake master cyl inder outlets 2 Disconnect the vacuum hose at the power brake unit Fig 11 6 Power brake unit I Check valve 1 Puh tod 3 Diaphragm 4 Power piston 5 Resction disk 6 Vacuum passage 7 valve plunger 8 Spring 9 Spring 10 Silencer 11 Silencer iter 12 Front shell 13 Return spring 14 Key 15 Rear shell 16 Atmospheric port 17 Al valve piston 1 Floating cuntrol 11 3 Disconnect the push rod from the brake pedal by removing the split pin at the fork end 4 Loosen the nuts that attach the power brake unit To the dash panel 5 Remove the power brake unit and master cylinder assembly from the dash panel being careful not to allow brake fluid to drip on exterior paint 11 3 Disassembling of Power Brake Unit 1 Remove the master cylinder and the check valve from the power brake unit 2 Place the power brake unit in a vise with push Tod up Clamp the unit firmly on the flange 3 Scribe mark on the bottom center of the front atid reat shells to facilitate reassembly 4 Remove the boot Fig 10 7 Removing of boot 5 Attach the wrench 49 6500 090 to the studs of the shell as shown in Fig 11 8 Rotate the rear shell clockwise to unlocked position Loosen the rear shell carefully as it is spring loaded N 43 6500 10 Fig 11 8 Removing of reat shell 6 Lift the rear shell and plate and valve body valv
142. cuum control unit from the distributor housing and remove the clip holding the breaker base link Remove the vacuum control unit 4 Loosen the primary terminal nut and disconnect the lesd Remove the contact point assembly from breaker base after removing the set screws 5 Remove the primary terminal stud and insulator 6 Remove ihe condemer 7 Remove the screws that attach the breaker base and cap retaining clips t the housing Remove the breaker base and retaining clips 8 off the fell and remove the cum set screw then remove the cam 9 Remove the distributor drive shaft retaining clip and washers Remove the shaft in upward direction through the top of the distributor housing 10 The governor be remaved by removing the governor spring and clip 5 0 6 Distributor Inspection a Inspection of distributor cap Inspect the distributor cap for cracks carbon runners and signs of arcing Replace the cap if any of these are found Clean the high tension terminals b Inspecting the rotor inspect the rotor for cracks or evidence of excessive burning at the end of the metal strip Inspecting the contact points Inspect the points for wear burning transferred metal and pitting If the points are affected only slightly clean with stiff metal brush or oil stone In case of severe damage replace the points 4 Checking the contact arm spring tension For inspection hook a spring scale on the contact
143. d a serious collision Whenever camber caster or king pin Inclination is moved out of its specified angle check all parts of front suspension and body alignment If necessary replace or repair 10 1 4 Adjusting of Steering Ange Adjust the steering angle with the adjusting bolts fitted onto the pitman arm and the side frame so that the front wheels tum 43 inward and 31 outward SPECIAL TOOLS 49 0118 850C Ball joint puller 49 0223 695 Pitman arm puller 10 6 1 A 11 C POWER BRAKE UNIT H E M F 11 6 5 BRAKE PEDAL ADJUSTMENT 11 1 Adjusting of Pedal Height 11 2 Adjusting of Free Play BRAKE MASTER CYLINDER 11 11 B 1 Removing of Brake Master Cylinder 11 2 Disasembling of Brake Master Cylinder 11 3 Checking of Brake Master Cylinder 11 118 4 Assembling of Brake Master Cylinder 11 118 5 Installing of Brake Master Cylinder 11 10 C 1 Checking of Power Brake Unit on Vehicle 11 C 2 Removing of Power Brake Unit 11 C 3 Disassembling of Power Brake Unit 11 4 Checking of Power Brake Unit 11 C 5 Assembling of Power Brake Uni 11 C 6 Installing of Power Brake Unit a I1 FRONT BRAKE _ 1 0 1 Replacing of Disk Brake Shoe 11 D 2 Removing and Disassembling of Caliper 11 D 3 Checking of Caliper 11 D 4 Assembling and Installing of MA AA AAA de 1 0 5 1 0 6 Inspecting
144. d install the base valve assembly into the bottom of the pressure tube Fig 13 19 Installing of oll stop rings 11 Insert the pressure tube assembly into the reser vior tube 12 Fill the reservior tube with shock absorber fluid The capacity of fluid should be exactly 246 0 52 US pint 0 43 Imp pint Fig 13 20 Filling of shock absorber fluid 13 Apply grease to the lip of the oil seal Install the ring and insert the cap nut slowly onto the piston rod 14 Tighten the cap nut temporarily ensuring that the piston rod is extended to its maximum length with the hook wrench 49 0259 702 LEE A Fip 13 21 Tightening of cap nut Tighten the cap nut to a torque of 8 5 mkg 40 ft Fig 12 22 Tighiting of cap mut 13 6 13 th with the eap mut wrench 49 0259 700 after the piston is lowered Note The cap nut is tightened in this condition to raise the air pressure remaining within the reservoir tube 13 5 installing of Front Shock Absorber Install the front shock absorber in the reverse order of removing noting the following points 1 Adjust the vehicle height by using the proper com bination of the spring and adjusting plate The coil springs are available in three sizes according to the strength of the springs Mark rom 352 mm 13 86 in to 194 mm 7 64 in 1dot 284 289 619 637 7 dots 289 196 kg 637 683 1b 3 dot 2
145. ding operate iw all driving ranges even engine i cold or No 1 thermosensor is disconnected with vacuum switch off Probable causes X Damaged diaphragm of switch oF damaged vacuum tube b Diaphragm rod of switch interferes with surrounding parts No 1 control box troubles Exhaust emimion becomes abnormally unfavorable Power drop Driveability shows abnormally deterionation Conditions of wouble of system Trailing ignition does not cut off when engine is cold 44 ranges Trailing Ignition remains constantly off Leading ignition does not retard when engine cold Coasting valve or aircontrol valve operate improperly one Probable causer Defective No control box Defective No 1 thermosensor Defective choke witch Defective vacuum switch pose 1 1 Defective No 2 control box f Defective No 2 thermosensor No 2 control box Posible troubles Conesponded Item T Eskas becomes unfavourable Conditions of trouble of device C Leading Ignition Goes bot retard when choke operated im during ranges over than ing deceleration or wide open throttle at cold start Note 1 Cold start means to start the engine temperature and oil temperature at 20 MC 68 86 F Note 2 idlmg deceleration or wide open throttle means driving
146. down by using the same method Shiftdown be noted by shift shock or change engine sound 4 When the car ix runing in D ata speed more than 60 km h 45 mile h place the manual lever from D into 1 and read the car speed just when 1 41 downshift occurs at the full throttle and mini mum throttle Note Care must be taken not to shift from D to 17 from 2 to 1 in exceeding the speed in 2 range 1 range shown below to avoid the engine overrun E 4 Miley Mile h Roa 6500 man roms L RX 8 5 70445 12005 laid e ae won m wuss se em m s 1600 550 sos seo 5 500 sss 9680 5 Connect vacuum gauge into the socket in the in Take manifold and set it so that it is visible while driving Place the manual lever in D and accele rate with accelerator pressure controlled so that the vacuum gauge will show 200 mm kg and read car speed at the instant of D D and DiD upshifts Note 1 In reading car speeds at shifting accelera aii tion and decleration around shift points must be made gently except for 8 above 2 Checks of 3 3 and w above should indicate general condition of shift point except in very rare instances ltem 6 should be carried out only when the condition in partial throttle must be known Speed at Gear Shift
147. duces air polluting hydrocarbon and carbon monoxide con tained in the exhaust gas of the operating engine TA A 1 Air Injection System The air injection system consisting of an air pump a check valve and an air injection nozzle an air control valve and thermal reactor into the exhaust port secondary air necessary for oxidation of hydrocarbon and carbon monoxide contained in the exhaust gas a Air pump The ait pump Is vane type driven by the V belt mounted on the eccentric shaft pulley It pr Vides to the uir injection system secondary air requir ed for re igniting the exhaust gas e Fig 8 Air pump crow section b Check valve The check valve opens and closes according to the pres sure difference between secondary air and exhaust gas to prevent exhaust gas from backflowing into the ait m jection system and scorching the air pump hoses etc When the pressure of secondary air in the air bo jection system exceeds the exhaust gas pressure the secondary air opens the check valve and flows through the air injection nozzle into the exhaust post When the secondary air pressure drops lower than the ex haust gas pressure due to failure of the pump breaking of the secondary air hose etc the check valve closes to prevent the backflow of the exhaust gas into the air injection system 4 reactor __ Vaan chan
148. during decelera lion and gear shifting causes the valve lo open and air from the air cleaner is supplied the intake manifold preventing afterburn While deceleration when the engine speed is above 1200 rpm the No 1 control box commands the solenoid to open the intake manifold vacuum sensing line leading to the vacuum chamber the pressures in the vacuum and air chamber are equalized and air from the air cleaner overcomes the spring force and flows into the intake manifold In addition when the coasting valve opens the atmospheric pressure from the air cleaner is led into the vacuum chamber 16 es Fig 1A 28 Cos ling valve cross 1 the air control valve and pressures in the vacuum and air chambers of the air contro valve are equalized allowing the spring force 10 operate the air cut valve Idle switch The idle switch is connected im line between the No 1 control box and the coasting valve solenoid and the current from the No control box flows to the idle switch switched on when decelerating the engine and into the coasting valve solenoid Fig 18 27 Idle switch 4 Y Adie verte Adi serem Mero snor Fig 1A 28 switch Therefore the coasting valve operates while deceler ating at the engine speed of more than 1 200 50 rpm The idle switch detects the decelerating c n dition of the car 9 Air supply valve Th
149. e Tod and plunger assembly from the unit Then re move the return spring 7 Remove the plate valve body valve rod and plung er assembly from the rear shell Fig 11 8 Removing of retum spring e Fig 11 10 Removing of plate and valve body assembly Note Do not remove the rear seal from the rear shell unless seal is defective and the new seal is available To remove the rear seal support the rear shell and drive out the rear seal with a punch or a screwdriver 8 Remove the diaphragm from the plate and valve body x Fig 13 11 Removing of disphtagn 9 Remove the air silencer with the air filter from the plate and valve body being careful not to chip plastic 10 Press in on the valve rod to remove the valve re tainer key Remove the valve rod and plunger assembly uos Fig 11 12 Removing of key 51 Fig 11 13 Removing of valve and plunger Note The valve rod and plunger are serviced as an assembly only 11 Press the reaction disk out of the valve body 12 Remove the push rod 13 Remove the front seal from the front shell if necessary 11 4 Checking of Power Broke Unit 1 Inspect the all rubber parts Wipe free of fluid and carefully inspect each rubber part for cuts nicks or other damage 2 Check the plate and valve body for cracks distor tion chipping and damaged seats 3 Inspect the reaction disk for deterioration of rub ber 4 Check the valv
150. e adjust screw 9 Make sure that the engine speed is 900 rpm by carrying out no load running two or three times Adjusting of idle switch 1 Fig 1A 80 Adjusting of idle switch 1 2 f WA PL Ke dle switch lover aiat Fig TA 83 idie switch 1A E 15 Choke Switch Checking of choke switch 1 Remove the choke switch terminal 2 1f the two terminals of the switch are discon ducted by pulling the choke control knob about 10 mm 0 410 and conducted by retuming the knob the choke witch normal Fig 1A GZ Chockiny of choke witch 1 16 Air Supply Valve Checking of air supply valve 1 Remove the air hose rom the sir suction pipe of the air supply valve 2 Start the engine and keep It running at idle speed When the air suction pipe of the air supply valve i closed with the hand reduction of idle speed must be under 30 Make sure that when the wiring to the air supply valve solenoid is discon nected large amount of sir is supplied into the intake manifold b Removing of air supply valve Remove the air cleaner and wir duct 2 Disconnect the air hose vacuum sensing tube and lead wite 3 Loosen the supply valve mounting nuts and remove the ait iq TA 6 Checking of air supply valve Installing of air supply valve Install the ait supply valve the reverse sequence 1A E 17 Ventilation Valve
151. e air supply valve has the functions of preventing afterburn when the engine is switched off and fill ing the engine with fresh air Fig 14 29 Air valve The solenoid of the ait supply valve keeps closing the intake manifold vacuum way while the ignition switch is on When the engine is switched off the solenoid opens the vacuum way and the resulting difference pressure between the vacuum and air cham bers causes the valve leading to the diaphragm to open so that fresh air from the ait cleaner is supplied into the intake manifold 1A B VENTILATION SYSTEM The ventilation system channels blow by gas into the intake manifold to burn it up in the combustio chamber and helps to control ait pollution caused by engine blow by gas This system consists mainly of a ventilation valve and hose necessary to connect the ventilation valve The air and blow by gases flow in the ventilation system as shown in Fig 1 31 ES E Fig 1A 30 Air supply valve and antafterbum valve 1A 13 1 Ventilating air from the air cleaner enters the engine air space The ventilating air with blow by gas en ters into the ventilation valve which regulates the amount of ait flow to meet the change of operat ing conditions and then is directed to the engine pem sr ape mE arta Vp end Mie vy p Fig 14 31 Ventilation system JA B 1 Ventilation Valve The ventilati
152. e and set the idle to 700 rpm 2 Observe the position of the timing mark 3 Loosen the distributor lock nuts and rotate each distributor housing so that each timing mark on the eccentric shaft pulley aligns with needle on the front cover 4 Tighten the distributor lock nuts and recheck the timing Fig 5 8 Timing marks 5 0 3 Testing the Distributor Dwell angle test The dwell angle also called cam angle is degrees of rotation through which the contact points remain closed To test the dwell angle use a distributor tester fol lowing the instructions of the manufacturer If the dwell reading is within 55 and 61 degrees it is cor rect If the reading is not within the specifications 5 2 b Advance Test To test the ignition advancing characteristic of the distributor use a distributor tester The advancing characteristic of each distributor should be within the range shown in Fig 5 6 and 5 7 Certes pam T LJ Num iem m Fig 5 6 Advancing characteristic trailing vide Fig 5 7 Advancing characteristic leading side Fig 5 8 Distributor assembly 5 5 0 4 Disassembling the Distributor 1 Loosen the cap retaining clips and lift off the cap 2 Remove the rotor 3 Remove the screws that attach the va
153. e between the air and vacuum cham bers the valve connecting to the diaphragm is opened thus leading fresh air from the air cleaner into the Intake manifold so as to prevent ufterburn duri deceleration at high engine speeds n audition when the engine is switched off the solenoid opens the sensing line and due to the te sulting pressure difference between he ait and vacuum chambers the valve connected to the diaphragm is opened and fresh is lead from the air cleaner into the intake manifold t prevent afterburn after the engine is switched off The metering orifice in the diaphragm connects the ait and vacuum chambers 10 control the duration of valve opening When the pressures between the two chambers are equal the valve is kept closed by the spring force und when the pressure difference exceeds 100 mmHg the valve is opened to lead fresh aie from air cleaner into the intake manifold Whew the metering orifice equalizes pressure difference the valve s closed to shur off air b Coasting valve The coasting valve connected to the intake mani fold supplies fresh air from the ait cleaner into the intake manifold 10 correct overrich mixture during deceleration a result when the coasting valve opens the intake manifold vacuum counected to the vacuum chamber of the control valve is turned to atmospheric pressure m order to cur secondary ait supply during deceleration Fig
154. e converter is of redwine color and s distinguishable from engine oil 2 tn checking for possibie leak from the transmission breather pipe jack up one of the rear wheels and Tun the engine to simulate the running condition When the ail level is over the limit the oil never fails to spurt out from the breather pipe When water is contained in it the oil sometimes spurts out even when the oil level is within the spe sified rango c Oll condition check In checking the condition of oil by the oil sticking on the dipstick note thet if the oil appears like varnish it might cause control values to stick and if iris black it shows that linings of clutch or brake bund have been scorched In case such oil deteriora tion is found severe it sometimes indicates that over haul should be made without conducting tests listed in TROUBLE DIAGNOSIS CHART If it is difficult to readily determine whether or not to make such tests oil should be drained for confirmation 45 1 A 2 ENGINE IDLING SPEED The engine idling speed should be properly adjusted to the specified revolution by using a tachometer for servicing rather than the one installed on the vehicle H the engine idling speed is too low the engine cannot revolve smoothly and when it is too high shifts from N or P 10 other ranges will be harsh with increased shock or creep Adjust the engine idling to the following revolution range specified for each model
155. e groove The standard value of this gap is 0 036 0 072 mm 0 0014 0 0028 in and Ihe apex seal must be replaced if the gap is more than 0 1 mm 0 0039 in d Inspecting the gap between apex seal and side housing Measure the length of the apex seal with a microme ter Compare this measurement with the minimum value of the rotor housing width Refer to Par 1 C 4 to calculate the gap between the apex seal and side housing The normal value of this gap 001 005 mm 0 0004 0 0020 in and the apex seal must be replaced If it is more than 0 15 mm 0 0059 in Fig 1 59 Cleaning apex i Fig 1 00 Meauiring apex seal height Fig 1 82 Gap between apex seal und dde housing 1 48 Fig 1 83 Checking side seal gap Seil Gerome Fig 1 85 Checking gap of corner seal and groove sum 94 182 1 180 Fig 1 66 Jig ond reamer 8 Inspecting the gap between side seal and groove Measure the gap with a feeler gauge The standard clearnace 0 04 0 07 mm 0 0016 0 0028 in and the side seal must be replaced if it exceeds 0 1 mm 0 0039 in 1 Inspecting the gap between comer and groove The standard gap is 0 020 0 048 mm 0 0008 0 0019 in and the limit is 008 mm 0 0031 in This gap enlargement shows uneven wear of the co ner seal bore which occurs when the enginel is op erated with dust entering through clogged e
156. e of the clutch sleeve Fig 7 10 Fitting shaft forks 7 Place the counter shaft gear in the case Fig 7 11 Placing counter shaft gear 8 Install the needle roller bearing of the counter shaft to the rear side and install the roller bearing of the counter shaft with proper size of adjust shim to the front side and fit the snap ring 9 Install the roller bearings with proper size of shims to the main drive shaft and main shaft and fit the snap ring on the main drive shaft Fig 7 12 Inatlling ball pearing 10 Install the reverse gear and snap ring to the counter shaft 11 Fit the bearing stopper and reverse idle gear shaft to the case Tighten the bolts of the bearing stopper to LO mg 7 12 Install the reverse gear with key onto the main shaft Install the lock washer and lock nut and tighten the lock nut to 23 mg 170 fiib while holding the rear end of the main shaft with main shaft holder 49 0259 440 Then bent the lock washer 13 Install the lowand second shift rod into the case and set the low andsecond shift fork which has been placed on the groove of the clutch hub temporarily with the set screw 14 Place the shift rod on the neutral position and insert the inter lock pin IS Install the third and top shift rod and set shift fork with set screw Insert the inter lock pin Fig 7 13 Securing shift fork 16 Install the reverse shift rod with the reverse idle gear 17 Put the sh
157. e rod and plunger for all seats to be smooth and free of nicks and dents Replace with new one if defective 5 Inspect the front and rear shells for scratches scores pits dents or other damage 6 Check the diaphragm for cuts or other damage 11 Assembling of Power Brake Unit 1 Apply the power brake lubricant to the inner sur face of tube section of the plate and valve body and to the surfaces of the valve rod and plunger 2 Insert the valve rod and plunger assembly into the tube section of the plate and valve body 3 Press down on the valve rod and align the groove is im the valve plunger with the slot of the valve body Insert the retainer key 4 Install the diaphragm om the plate and valve body making certain the diaphragm is seated in the groove 5 Assemble the air filter and rhe air silencer over the rod and position in the valve body 6 Apply the power brake lubricant liberally to the entire surface of the reaction disk and install the re action disk into the plate and valve body 7 Coat the outer bead of the diaphragm with the power brake lubricant where it bears against the outer rim of the front and rear shell to aid in assembly 8 Apply the power brake lubricant to the seal in the rear shell and carefully guide tube end of the plate and valve body through the seal the rear shell 9 Install the and valve body into the front shell 11 14 Posh rod 10 Apply power brake lubrica
158. each other 3 Rotate the gears 90 degrees so that the pinion shaft holes of the case come into alignment with the holes the pinion gears Fig 9 23 Installing of pinion pears 4 the pinion shaft through the case and pin ion gears 5 Check gear the backlash of the side gear and pinion Fig 9 24 Checking of 9 The backlash should be 0 to 0 1 mm 0 to 0 004 m If t is more than 0 2 mm 0 008 in adjost with the side gear thrust washers The following thrust washers are available Taaniification mark Tiicknew vm 0787 in 00827 in 2 22 mm 0 0866 in 6 the Jock pin to secure the pinion shaft and in order to prevent the lock pin from working out stake into position with punch Fig 9 25 Installing of lock pin 7 Install the ring to the case and tighten the bulis to a torque of 5 0 mg 35 Fig 9 26 Installing of Note As there are two kinds of bolts use those which fit the holes of the gear case flange 8 Bend the tabs of the lock plates to prevent loosen ing 9 install each differential bearing to the hubs of the gear case 10 Install the differential bearing outer races to its respective bearing E A installing of Differential 1 Place the differential gear assembly in the carrier marking ensure that the marks for backiash adjustment on the face of the pinion and fing gear teeth are 9 7 aligned
159. ear luteh drum 30 Seat ing 1L Outer St Rear clutch piston 12 Toner plate 32 Retwen spring 13 Retaining plate Spring Soap ring 34 Soap ring 15 Front clutch assembly 16 Band 17 Pion return spring 18 Piston seat 3 19 Servo piston 39 Snap ring 20 Pinton seal 40 Rear clutch assembly 4 Soap sing 42 Beating Nosdi rig M Rear clutch hub 45 Needle beating 48 Bearing 57 imema gear Rent clutch hub 49 Front planet carrier assembly 50 Sup 551 Connecting shell 52 Son ger 53 Beating tace Snap ring 55 Shell amp sun gear assembly 56 Needle besring ST Stap ring 58 Rear planet carrier assembly 39 Bearing HO Needle beating 1 TROUBLE DIAGNOSIS AND ADJUST MENT In troubleshooting an automatic transmission it is necessary first of all to correctly define faulty phe nomenon and then make efficient and orderly check to determine possible causes so that a proper remedy can be effected To grasp faulty phenomenon check whether the automatic transmission functions normally in all aspects under all conditions including starting run ning and stopping Find out a corresponding trouble from among the troubles in the TROUBLE DIAG NOSIS CHART and check Hems to Check in the sequence us indicated In dingnosing according to the TROUDLE DIAG NOSIS CHART make sure to first check and adjust
160. eccentric shaft pas sage lubricates the rotor bearings 8 The eccentric shaft is equipped with two oil plug jets which are faced to front and rear rotor inner holes The oil in the passage of the eccentric shaft is injected through the plug jets into the rotors and cools the rotors 9 Oil passing through the tubular dowel is sent to the distributor and the metering oil pump 10 From the metering oil pump the lubricant is dis charged to the carburettor and is supplied into the combustion chambers together with the air fuel mix lure to lubricate the apex seal comer seal side seal and the housing 2 8 PRESSURE REGULATOR e Fig 2 1 1 Regulstor body 3 Control spring 1 Control plunger 4 TERIMG PUMP 3 DISTRIBUTOR PUMP THERMO varve CARBURETTOR FILTER LLL RELIEF VALVE ROTOR BEARING CONTROL JET MAIN BEARING L SENTAIC SHAFT PRESSURE Fig 2 2 Lubricating circuit 2 2 8 PRESSURE RELIEF VALVE The oil pressure regulator valve is installed In the rear housing The regulator valve opens when the number of engine revolutions increases and the oil pressure in the lubricating system rises Then the pressure is relieved and excess oil is returned 10 the oil sump By this function of the regulator valve the oil pret sure be maintained at a maximum of 5 0 kg cm QA bfin 2 OIL PRE
161. eck Valve a Checking of check valve 1 Remove the check valve in the procedures mem tioned jm the following item b 2 Check the seating of the valve and seat and make sure that there is no spring creep the free length of the spring is 31 mm 1 22 in E gt gt 9 Fig 1A 38 Check rabie 1 Valve seat A 2 Spine b Removing of check vah 1 Remove the air cleaner 2 Remove the air hoses leading to ihe air control ol valve Loosen the nuts and remove the air con valve 3 Remove the check valve seat 4 Remove the valve and spring c Installing of check valve Install the check valve im the reverse sequence 1A E 3 Air Injection Nozzle Removing of air injection nozzle Drain the engine oil 2 Remove the engine und 3 Remove the oll pam 4 Remove ihe air injection nozzle from the housing cover Fig 1 39 Air mele b Installing of air injection nozzle install the air quence ection nozzle im the revere 1 4 Thermal Reactor 4 Checking of thermal reactor 1 Check 10 see that the thermal reactor is not dant oi cracked 2 Remove the hose leading 10 the air control valve and check to see that the non return valve works smoothly SX c Fig 1A 40 Checking of valve 3 Stant the engine and keep it running at idle speed AK Check to see that cach part of the air injection system works properl
162. ections of the primary and secondary stages The average negative pressure of both jets acts in the dia chamber and moves the diaphragm The diaphragm and the secondary throttle valve are connected by 3 link to open the throttle valve according to the negative pressure However the secondary throttle valve cannot be open ed until the primary throttle valve is opened to 50 since the liable range of the secondary throttle valve throttle shat 4 3 Lockoff system 4 10 open or close controled with a connection be tween the lockoff lever installed on the primary shaft and the stopper on the secondary shaft When the opening of the primary throttle valve ex ceeds 50 the secondary throttle valve opens in pro portion to the negative pressure Then the fuel from the main jet is mixed with air fram the main air bleed and sprayed from the main nozzle into the venturi 4 2 Disassembling the Carburettor The carburettor should be disassembled in the fol lowing way 1 Rem lever 2 Remove the screws which are fixing the air hom to the main body and remove the throttle wire bracket Remove the bolt tightening the air cleaner to the carburettor and remove the air horn from the main body the choke connecting rod from the choke Fig 4 4 Removing of air horn 4 Take out the float pin and remove the float 5 Remove the needle valve assembly Fig 4 8 Needle valve assembly Laie 4
163. el Adjust incorect fast idle Adjust 6 Improper return of secondary throttle valve Correct leak into intake manifold from each connection or hose Connect or replace 8 Excessive air leak trio intake manifold from esch valve Defective anthefterbur valve Replace b Defective supply valve Replace Improper operation of coasting valve Check Wem 9 9 Improper operation of coasting valve a Improper throttle positioner adjustment Adjust b Defective control box Replace Defective coasting valve Replace 10 improper operation of air control valve a Defective control box Replace b Defective aix control valve Replace 11 Improper operation of ventilation valve Replace 12 Hot and colt wir intake system stuck in Heaton position Adjust 3 Afterburn in the exhaust system Adjust 1 improper carburettor adjustment Clean adjust or replace 2 Fouled or improperly adjusted spark pluge Clean adjust or replace 3 Improper operation of antiafterburn valve Replace 4 improper operation of coasting valve Check 2 9 5 improper operation of air supply valve Replace 6 Improper operation of time lag relay Replace 7 improper throttle positioner adjustment Adjust 4 Poor accelemtion amd knocking 1 Fouled or improperly adjusted spark plugs Clean adjust or replace 2 Improper ignition timing adjustment Adjust 2 Improper carburettor adjustment Adjust 4 Excessive air leak into intake manifold from euch connection
164. elevant wiring 2 The step between the rear window glass and the body should be adjusted to be 7 8 mm 0 31 in Fig 14 16 Adjusting of 14 3 The directions and positions of each spacer to be bonded are shown in Fig 14 17 Se Sites i ue NS Son Fig 14 17 Positions of spacers Fig 14 18 B B section of Fig 14 17 14 FRONT DOOR 14 1 Disassembling of Front Door 1 Remove the inner lock knob 2 Remove the arm jest 3 Remove the inner handle cover 4 Remove the pad of the regulator handle and re move the regulator handle and escutcheon by loosen ing the attaching bolt Fig 14 19 Removing of regulator handle 5 Remove the door trim board 6 Remove the inside screens vinyl which are stalled to prevent water leakages 7 Remove the outer weatherstrip from the door body 4 5 8 Remove the door window glass With the window glass lowered to half opened position it can be easily taken out 9 Remove the outer handle 10 Pull out the set spring and remove the key cyl inder 11 Remove the door lock complete 12 Remove the window regulator 14 2 Assembling of Front Door 1 Install the outer handle 2 Install the key cylinder and fit the set spring to ihe key cylinder 3 Install the door lock complete Fig 14 22 Installing of door lock complete 14 4 Connect the actuating rod after adjusting the free play of the o
165. em consists of an anti afterburn valve coasting valve a throttle positioner air supply valve a time lag relay and the contr box which is common to the ignition and air flow control system It prevents afterburn during decelera tion and gear shifting and mmediately after the en amne switched off a Anthatterborn valve The antiafverbury valve pievents wfterburn by inject ing air into the intake manifold during deceleration and gear shifting and immediately after the engine is switched off CONTROL FRESH AIR gt VACUUM THAGTTLE POSITIONER TO MIR NOZZLE LNA CONTROL VALVE Fig 1A 15 Decelerstion contol system 1 Fig 14 16 Antrafterbum valve The anti afterbury valve operates by pressure differ ence between the and vacuum chambers und the spring force The intake n nifold vacuum rises during deceleration and gear shifting and the pressure difference between the two chambers apens the valve connected to the disphragm so that fresh from the air cleaner led mo the intake manifold to correct overtich mix thus preventing afterburn During normal running condition the solenoid shuts the atmospheric pressure sensing line leading to the air chamber When the engine speed exceeds 4 000 4 200 the control box commands the solenoid to open the sensing line and due 10 the resulting pressure differenc
166. embly with governor to the case to damage the seal rings 4 Install the output shaft 5 Mount the needle bea faces of the internal drive fange fit the f output shaft and lock it with the snap ring 6 Mount the bearing race on the rear face of the ront igs on the front and rear ge on the rear planet carrier and the needle bearing on face Fit the tear planet carrier into the internal dri flange and lock the carrier by placing the snap ring the connecting drum 7 Push jn the manual shaft into the case and tighten the spacer and manual plate with the mu Then mount the parking lever and parking rod amp Install the band servo on the case See 4 E Install the spacer return spring and parking pawl the shaft Fit the rear end of the parking rod two steel balls in the supporter then Tighten the belts u specified torque of 2 0 2 5 mkg 15 18 fid install the extension housing onto the case Fig 248 Fig 2 47 Main components ol Transmission 1 Torque converter 6 From clutch 2 Converter housing 7 Rear clutch 3 Case 8 Rear clutch hub 4 Entemion bousng 9 Rear planet carrier 5 pump 10 Shell amp sun gear 64 11 Rear planer carrier assy 16 Servo piston 12 Drive flange 17 Oil pan 1 Low amp reverse brake amy 18 Control valve Input shaft 197 Governor sxlve
167. ense 1A F t Checking of Battery 2 Checking of Engine Oil lA F 3 Checking of Coolant 1A F 4 Checking of Alternator Adjusting of Ait Pump V belt Checking of Air Cleaner Adjusting of Carburettor Checking of Distributor lA F 9 Spark Plug TROUBLE SHOOTING SSS e b dh balada era BB5BSSZESELZSSZSSULSEBUUAEZCLZ 1A 1 AIR POLLUTION CONTROL SYSTEMS The MAZDA RX 2 is equipped with an exhaust e mission control system s ventilation system and an evaporative emission control system JA A EXHAUST EMISSION CONTROL SYSTEM The exhaust emission control system consisting of alr injection system an ignition and air flow con trol system and a deceleration control system reduces air polluting hydrocarbon and carbon monoxide con tained in the exhaust gas of the operating engine JA A 1 Air Injection System The air injection system consisting of an air pump 3 check valve and am air injection nozzle an air control valve and a thermal reactor injects into the ex haust port secondary air necessary for oxidation of hydrocarbon and carbon monoxide contained in the exhaust gas a Air pump The air pump is a vane type driven by the belt mounted on the eccentric shaft pulley It pro vides to the air injection sy
168. enting dam ges 10 the elements of the air injection syste Thermal reactor The thermal reactor is mounted just outside the exhaust port It oxidizes the unburned exhaust expelled from the engine to reduce the noxious components such as hydrocarbon and carbon mono xide Fig 13 Thermal reactor When the engine speed is more than 4 000 rpm or during deceleration the air control valve feeds fresh air ftom the air pump to the thermal reactor to keep the reactor temperature reasonably gat oore v Fig 1 12 Air control valve cross section IA B8 Fig YA V4 Thermal reactor cooling ait circuit 1 The non return valve which prevents backflow of exhaust gas from the reactor is attached at the air inlet of the reactor 2 Ignition and Air Flow Control System The ignition and air flow control system consists of two thermosensors a thermodetector a vacuum switch choke switch and two control boxes This system ig nites and cuts the trailing spark plug to suit engine temperature and engine speed in order to enhance the reactivity of the thermal reactor when the engine is cold It has an additional function of regulating the air control valve of the air injection system a No 1 thermosensor The No thermosensor which is placed in the cool ing water passage detects the water temperature and sends the signal to the positive side of the trailing cuil through
169. ept cool it should be cooled siowly or the section of the wire being used is constantly rotated When cutting the sealant off pay special attention that the top ceiling painted surfaces etc are not damaged 7 Remove the window plass from he body moval of the window glass shown in Fig 14 6 should be performed by two persons Fig 14 6 Removing of windshield glass 14 2 Installing of Windshield Glass 1 Using cutting knife cut the sealant off smoothly that approximately to 2 mm 004 to 008 in of sealant remains along the c the windshield framework ire circumference of IF the thickness of sealant Jett alc ence of the window framework cl an with a solvent to remove any grease Then apply primer with for 20 10 30 minutes Then apply sealant thickness of to 2 mm 0 04 to 0 08 in is obtained brush and leave 11 Fig 14 8 Applying of primer 14 2 Using solvent wipe the entire edges of the win dow glass to a width of approximately 50 mm 2 0 from the edge and also the entire circumference of the body on which the glass is to be bonded to remove any grease bond the dam with bonding agent parallel to eu the edge of the window glass at position 7 mm 0 028 in away from it Bond the dam in the di rection shown in Fig 14 9 Fig 14 8 Bonding of dam Note Securely bond the dam so that it is straight and will no
170. er grease is used this will deteriorate the durability of the mechanism Fig 13 24 Ball joint L Knuckle arm 5 Ball joint Assembly 6 Am 7 Ph 13 1 Checking of Ball Joint Check the dust seal for wear flaw or any damage If the dust seal is defective this will allow entry of water and dist resulting in ball joint wear 2 Check the revolving torque of the ball stud To check hook the spring scale in the hole of the knuckle arm for connecting the tie rod and pull the spring scale until tbe ball stud starts to turn The reading of the spring scale should be 6 to 11 kg 13 2 to 22 3 Ib If it is less than 6 kg 13 2 Ib replace the ball joint in its assembled form 13 C 2 Replacing of Ball Joint If it becomes necessary to replace the ball joint pro ceed as follows 1 Remove the suspension arm assembly as described in Par 13 B 1 2 Remove the ball joint nut and remove the ball joint and suspension arm from the knuckle atm 3 Remove the set ring and the dust boot from the bali joint 4 Using the ball joint remover and installer 49 0259 860 press the ball joint out of the suspension arm 13 Note Before pressing out the bull joint clean the ball jomi and suspension arm so as not 1o damage the mounting bore of the suspension atm Fig 13 25 Removing of ball joint 5 Clean the mounting bore of the suspension arm and apply kerosene 6 Press fit the ball Joint to the
171. erence at engine idle or decele lA 8 1 ration dw high vacuum of the intake manifold over comes the tension af the valve spring and the valve is pulled towards intake manifold side by the mani fold vacuum us shown in Fig 1A 26 Therefore the air passes through the restricted passage in the valve iperation Fig TA 26 Ventilation vale When ihe differenze smalt at normal operation the valve balanced by ihe tenilon ef valve spring and intake manifold vacuum This increases the Now blow by gas fig VA 27 Ventitilon salve operation 1A 8 2 Separator The all separatim th integrated Ih the oil filler Fiy 18 28 OU pipe und prevents the engine oil ftu combustion chamber the 1A C EVAPORATIVE EMISSION CONTROL SYSTEM This system prevents emission of fuel vapor generat ed by the ambient temperature around the fuel tank when the car is running or standing The fuel vapor ring rom the surface of fuel the fuel tank due to the ambient temperature chan neleg into the condense tank and then fed back 19 the fuel tank when the engine ls not running Any fuel vapor that has not condensed the condense tank is led into the air space of the engine where such vapor condenses for the most part and the maining vapor goes to the caraster and is trapped there The fuel vapor rising from the
172. es of the High Way Patrol CO under 3 HC under 300 ppm b Federal Test Procedure Cycle 7 mode 7 cycle NOx regulation value during hot cycle of the AR B Calif 3 2 gr m LA 4 mode 72 74 Federal Test Procedure Regulation CO 39 grim 39 grim HC 34 gr m 32 grim Parenthesized values are the regulation values of Cali fornia JA F 2 Test Procedure a Idling emissions 1 Fully warm op the engine until the water tem perature gauge shows the normal reading 2 Check how the secondary throttle valve is closed 3 Check and adjust the idling speed 900 970 rpm 4 Check and adjust the ignition timing Leading side 0 Trailing side 10 ATDC 5 Measure HC and CO with a NDIR analyzer Reference Characteristics of idling emission As the idiing emissions closely related with the idle fuel flow care should be taken when adjusting the idle fuel flow For reference the relation between the number of unturnings of the screw and the fuel flow i shown in the following graphs by the mean value of the fuel flow Subacrew T 3 Number of unturnings of subacrew b FTP Instructions for 7 mode driving Cold start 1 To the engine pull the choke to the full manual travel 2 As soon as th engine has been started adjust the 14 28 Main screw aa 00 gt TE 20 E EJ ling fuel flow L D Fig 1A 82
173. essure test Connect the fuel pressure tester to the discharge port of the pump to test the fuel pressure Feeding pres sure should be 0 2 03 kg cm 28 to 43 bfin If it is out of specifications adjust it by means of the adjust screw If still defective disassemble the pump for inspection b Volume test Conduct volume test of the fuel pump The uel pump should supply more than 900 cc 0 23 US gallon 0 20 Imp gallon of fuel per minute IF de fective disassemble the pump for inspection 4 8 2 Disassembling the Fuel Pump Observe the following procedure to disassemble the fuel pump L Provide the matching marks on the air chamber valve chamber and base so that the locations of the Fig 4 12 Fuel pump assembly 1 Air chamber 6 Outlet valve 2 Gasket 7 Valve seat 3 Valve retamer 8 Valve chamber 4 Valve seat holder 9 Inlet valve 3 Valve spring 10 Diaphragm 11 Adjusting plate 16 Adjusting washer 12 17 Switch 13 Coil 18 Gasket 14 Body 19 Earth wire 15 Body 20 Cover 4 inlet and outlet valves are marked for assembling 2 Remove set screws of air chamber and valve chamber from the base Remove the air chamber gasket and valve chamber 3 Attach the valve retainer and remove the screw Remove the retainer and the valve assembly from the valve chamber 4 Remove the cover by removing the screws which hold the cover to the body 5
174. etected proper care must be taken immediately before proceeding 10 the next probable cause Symptoms and probable 1 Poor uccelesution The engine does not fully respon to the depression oi the accelerator pedal 7 The acceleratve force is poot T The cfimbing capacity is inefficient The speed not be obtuined 1 Mmproper nition timings for an sig plugs 2 Improper opening of cafbaretor secondary throttle valve 3 Fouling amt excemive gap of spark php Poulng Wad or cat 41 oF improperly adjusted distibutor contact point 5 Lack af fuel supply at high speed running 2 Rough engine idling and hand starting The Alling speed tot lowered much engine vibration 4t idling The engine starting too hard 7 The engine stalls immediately ever If H starts 10 Air leak from esch hose 2 Clogging of carburetor jets 3 Improper seating of carburetor secondary throttle valve 4 Fouled spark plug Burned oF improperly adjusted disiributur contaci point Improper ignition timings of leading and trailing 7 Defective ventilation valve 39 Internal disconnection of leading and trailing nition coiis 2 ait intake system 10 Defective casting valve Defective amtyafterburn valve 13 Defective air supply valve 13 Low compression presure 14 Leading side ignition retards constatnly 3 Nohy air pump The 1
175. eutral A lign the groove on the spherical surface of the shift lever with the set screw the control case and insert the tip of the shift lever into the control lever end Then fil the bush into the control case Install the cover plate with the packing and tighten the bolts operation of the shift lever may be adjusted by inserting adjust shims on the 3 bolts between the covet plate and the packing The standard force of the shift lever at the knob is 20 4 0 kg 44 3 8 Ib Install the dust boots to the case After instal ling the starting motor connect the wirings of the starting motor and reverse lamp switch 10 Supply the transmission with the proper amount of transmission though the dipstick gauge inlet The following transmissi n oils are available SAE EP 80 Below 18 C 0 F SAE 90 Above 18 C 11 Connect the earth wire to the battery SPECIAL TOOLS Main shaft holde Bearing puller set AUTOMATIC TRANSMISSION MODEL 3N71B JATCO HOW TO SERVICE 1 TROUBLE DIAGNOSIS AND ADJUSTMENT 45 1 2 ENGINE IDLING 5 1 8 KICK DOWN SWITCH AND DOWNSHIET SOLENOID t A MANUAL LINKAGE 1 5 INHIBITOR SWITC 1 8 DIAGNOSTIC TEST ITEMS 1 1 STALL TEST 1 8 2 ROAD TEST 1 8 3 Oll PRESSURE 1 TROUBLE DIAGNOSIS CHART 1 1 ITEM TO CHECK 1 2 TROUBLE DIAGNOSIS CHART 2 REMOVAL OF TRANSMISSION 3 DISASSEMBLY OF TRANSMISSIO
176. f other ranges in the same manner Be sure to interpose more than one minute cooling time at 1 200 rpm with the man ual lever placed in 7 After uboves check whether the cutback function totelease the shock at gear shifting is operative pro perly The cutback function can Be judged nomal if the line pressure drops suddenly when the is ac celerated gradually and reaches to the certain rum ning speed Diagnosis trom measurement 1 When line pressure ar idling is low in all of R D 527 nd 1 possible causes inchide fault in the pressure supply system e g increased side clear ance in the oil pump reduced pump output because of bolts left unrightened oil leak from valve body or transmission and sticking of regulator valve or vacuum throttle valve 2 In eave line pressure at idling it low one range only there probably ure pressure leaks in some de vices or oil passages for tbe relevant range 3 In case line pressure at idling is high in all ranges possible cause is throttle pressure rise due ro leak from vacuum tube or vacuum dinphragm or regulator valve sticking 4 When pressure does not rise af stall condition the im rod possibly may not be installed 5 When pressure side is not smooth or pressure at I condition does not come within the specified wwe possible cause is sticking of vacuum theorie valve pressure regulator valve or pressure regulator plug
177. f the ground 2 Drain the by removing the drain plug Rein stall the drain plug after draining 3 Remove the rear axle shafts referring to Par 9 1 4 Disconnect the propeller shaft at the companion flange of the rear axle 5 Remove the nuts supporting the rear axle to the rear axle housing and remove the rear axle Fig 8 2 Removing of rear axle 9 C REAR AXLE DISASSEMBLY 8 1 Removing of Differential 1 Mount the rear axle on the stand 49 0164 5500 and 49 0223 561 2 Apply identification punch marks om the carrier differential beating cap and adjuster for reassembly purpose Vr aA Fig 9 8 Applying of identification marks 3 Remove the udjuster lock plates Fig 9 9 Removing of lock 9 4 Loosen the bearing cap attaching nuts and back off the adjuster slightly with the spanner 49 0259 720 to relieve differential bearing preload 5 Remove the differential assembly together with the bearing outer races Make certain that each benr ing outer race remains with its respective bearing Fig 9 10 Removing of differential assembly 9 C 2 Disassembling of Differential 1 Using a suitable puller remove the differential bear ings from the differential gear case 2 Remove the bolts und lockwashers that attach the ring gear 10 the gear case Remove the ring gear Fig 9 11 Removing of sing gear 3 From the back side of the ring goar flange drive the pinion s
178. f trouble of stem B Remains constantly open A Remains constantly closed Excessive air leakage from vilve Trobibke cae 3 Defective supply valve Ventilation valve L Possible troubles Corresponded Mii Trequently occurs during ling and fluctuations im number oF revolutions im emase 2 Number of revolutions at idling decreases Dilution of engine with gasoline increases 4 Defective purging occum in charcoal filet gt gt Conditions of trouble of system Nem Remains conranlly closed Remains constantly open Probable cause 2 Defective ventilation valve TECHNICAL DATA le 23 UH 1052 06 US Contact point pressure Carburetor Distributor esit sromberg Dell angle si speed 970 ipm Contact point gap 945 006 mm 0018 0002 in 500 650 gr 1 4 4 CO concentration 68 304 Condenser capacity 027 0027 uF Thecar diameter Centrifugal advance Primary 28 1102 amp Leading Stars 0 1 at 500 rpm Secondary 54 mm 1 339 Maximum 102 1 at 1 500 pm diameter Trailing Starts 0 1 ar 06 rpm Primar 29 13 65 mm Maximum 7 5 1 at 2 500 0 512 x 0256 in Secondary 23 10 Vacuum advance ALLOR w 0394 in Leading Starts 0 15 at 100 mete Mai
179. face of the oil seal with fingers slowly careful ly not to deform the oil seal as shown in Figl 75 Note 1 When fitting the oil seal comfirm the head face of the oil seal so a not to mistake the head face taper for the bottom face flat 2 Install the seals on the both side of the rotor 1 0 2 installing the Seat 1 Place the rear rotor on a rubber pad or cloth so as to face the internal gear side upward 2 Confirming the identification marks of the apex seal phice each apex seal on the cotor groove with the spring 3 Install the corner seal springs and corner seals and apply the engine oil Note The top surface of the corner seal must be 13 1 5 mm 0 05 0 06 in higher than the rotor sur face It must also move freely when pressed by finger 4 Fit the side seal springs to the rotor so as to face both ends of the side seal upward and apply the engine oil 5 Fit the side seals to their respective grooves Note The side seal must protrude approx 1 0 mm 0 04 im from the rotor surface Also check free movement by pressing manually 6 Apply to the internal gear and seals of the rotor 7 Install the rotor clamp 49 0813 230 Fig 1 74 Position of spring gap Fig 1 77 Fitting aide seal Fig 1 83 Filling sealing 1 0 3 Installing the rear rotor 1 Mount the rear housing on the engine stand 49 0107 680A 49 0813 005 und 49 0820 006 that the
180. fective 1A 18 io o contrat valve Ja Fig TA 45 Checking of air control valve 2 Attach the pressure gauge as in Fig 14 45 3 Remove the air hoses from outlets and 0 4 Start the engine and keep it running at idle speed Check to see that the pressure gauge reads 0 026 0 053 kg em 0 37 0 75 Ib in and that there is mo air leak from outlets and B of the air control valve 5 Make sure that the pressure guage reads 0 14 0 2 kglem 20 2 8 bfin when the engine speed is 3500 rpm and that there is air leak from outlets and 6 Remove the solenoid terminal Make sure that the pressure gauge reads O 0 053 0 0 75 if and that air flows from outlet of the air control valve and air does not flow from outlet B 7 Simply checking of air control valve check every valve Incorporated 7 1 When the relief valve or the air cut valve in faulty the air sent from the air pump during idling flows into the forced air cooling pipe 7 2 When the safety valve is faulty the air sent from the air pump flows into the air cleaner at idle Removing of air control valve Remove the air cleaner Remove the wiring to the solenoid Remove the air hoses from the air control valve Loosen the nuts and remove the air contro valve c Installing of air control valve Install the air control valve in the reverse sequence TA E 6 No 1 Thermosensor 8 Checking of
181. for dismantling 17 Remove the lever by removing the fixing nut of the primary throttle lever on the shaft 4 Remove the throttle valve and the shafi by removing screws fixing the throttle valve 18 Remove the set screws of the secondary thratile valve and dismantle the secondary throttle valve and the shalt Note Do nor dismantle venturi trottle valve and saft und the choke valve und shaft except when they hive 10 be vepliced on account of wear or damage 4 3 Carburettor Inspection After disassembly inspect the carburettor as follows Wash all parts in clean detergent and dry with compressed All passages of the carburettor must be blown very carefully 2 Inspect the air horn amd the main body for eracks and damages also inspect the choke shaft for wear 3 Inspect the valve for we 4 Inspect all jets for clogging W clogged wash the jets in detergent Do not use the wire 5 Inspect the float needle and seat for wear b Inspect the pump diaphragm and the auxiliary slow diaphragm If damaged replace them 1 Imp to see whether they 7 Inspect the valves of the function under all operating conditions Check the dliphrapm of seconda damage 9 Inspect the lle adjusting needle for burrs ridges 10 When assembling only new gaskers should be used control for nd 4 4 Assembling the Carburettor The carburettor can be assembled by reversing t
182. g the idle adjusting screw and throttle ad justing screw The normal idle speed is 800 rpm Fig 14 61 Adjusting of ille Fast idle adjustment When the carburettor is in choked position the pri mary throttle valve is opened 15 degrees When the choke valve is fully closed the clearnace between the primary throttle valve and bore is 1 0 0441 in Measure the clearance using a suitable wire gauge 1 Fig 10 62 adjustment 1 Choke lever 3 Choke connecting lever 2 Fast fever 4 Primary throttle valve and if necessary adjust it by bending the fast idle lever Check the choke valve for smooth movement d Adjusting of choke valve return spring Select and adjust the setting position of choke spring according to the atmospheric temperature and the engine condition The setting positions are as shown Fig 14 63 Adjusting of retorn spring 8 Checking of Distributor a Adjusting of ignition timing Adjust the ignition timing as follows 1 Connect a timing light to the high tension cord 14 1 for leading spark plug of front rotor housing 2 Start the engine and run it at idle speed of 800 rpm 3 Alm the timing light at the timing indicator pin the front cover 4 Loosen the distributor locking nuts and rotate the leading side distributor body until the timing mark the eccentric shaft pulley aligns with the timing indicator p
183. ge is provided inside of the eccentric shaft The rear end ls sealed with a blind plug for pressure of 5 kg cm 71 Ibfin Therefore it is important to check for leakage or loose plug If oil leakage is found remove the blind plug with a hexagonal Allen key and replace the O ring d Inspecting the needle roller bearing Check for wear or damage to the needle roller bearing at the rear end of the eccentric shaft Then insert the pilot part of the main drive shaft and check for smooth operation and proper clearance 6 Inspecting the thrust bearings The end thrust of the eccentruc shaft is taken bythe thrust bearings Check the thrust bearing for wear or damage Also inspect the bearing housing and thrust plate for wear 1 0 ENGINE ASSEMBLY The procedures for assembling the engine when the engine is to be completely overhauled are as follows 1 0 1 Installing the Oil Seal 1 Place the rotor on a rubber pad or cloth to pro tect it from damage 2 Fit the outer amd inner seal springs in their respective grooves of the rotor so that the spring gap is located opposite each other as shown in Fig 1 74 3 Insert new O ting in each oil seal Note When replacing the seal confirm smooth movement by placing the seal on the rotor groove before installing the ring 4 Apply the sufficient engine to the seal and groove 5 Install the oll seal to the rotor groove pushing the head
184. ged LA 4 mode 3 Equivalent weight 1 Engine starting and choke operation 2 750 bs Vehicle roleased Speed moh completely 50 about 3 minutes Start Time Seconds Fig TA 88 LAA driving mode 1A 29 1 4 Signal Input for tachometer should be taken from ignition for leading plugs 5 ling speed 900 970 rpm 6 Ignition timing Trailing plugs 10 deg Leading plugs 0 deg TA F 3 Factors of Dri fact Emissions 8 Operation Which At Choke operation The choke should be operated properly und quickly Over choke There is a possibility of engine stall which increase the emissions Over revolution There is a possibility of engine damage b Changing operation It should be done as smoothly and quickly pos sible Deceleration When the car speed is under 15 it is better to make clutch disengaged 4 Other Elements Which Affect Emissions 1 Improper excessive chassis dynamometer load 2 Too inferior response of driving aid 3 Others Keep the tire pressure of the rear wheels under 4 psi pound per square inch so as to pre vent tire damage Fig YA B6 Construction of air pollution contro system 30 1 1A G TROUBLE SHOOTING 6 1 Symptoms Causes and Remedies The posible faults and thew remedies are listed in the following table When the symptoms of troubles are d
185. generated by the air pump When the engine fe ling The noise lk generated by the air punip when the engine racing 11 Improperly adjusted V belt 21 Defective air pump Jy Disconnecied ve ate hoe 4 tightening of pump attaching bolts 4 Improper fuel conection between slow and main zones Flat spot T Shock Is felt when depressing Ihe accelerator pedal to ac celere from the low speed cruising condition Shock felt when depressing the wvcelerator ater turning left st low 1 Improper injection of carburetor accelerator pump 2 Leading side ignition retards constantly 3 of carburetor jets 4 Fouled Yeading plug 3 Excessively krw carburetor fuel Comtinmonidy opened anibatiednen valve of air supply sihe m coasting vive See 1AsE 20 Adjust See 1A E 22 Se 21 Clean or replace See 1A 20 Replace f necessary See 4 Replace Replace ir necessary Crean See 14 E 23 See 1A E 21 Clean or replace See JA L 20 Clean or replace See 1A E 20 Seo IA E 18 Replace if necessary See 1A F 22 Replace Repair or replice if necessary See 1 1 Replace if necewaty See 12 if See 17 if necesuty Repair See IAEI Check and replace Se 1 1 Adjat See IA E Replace Connect and replace See AED Ade See 1 22 Adjust See 1A E 1t
186. gs is explained in Par Fig 12 6 Front wheel huh assembly 1 Grease cap 2 Split pin 3 Set cover 4 Adjusting nut S Washer 6 7 Disk plate Dust plate Outer beating Wheel hub 0 Inner bearing 1 OM seal 2 Dust cover SUSPENSION 13 FRONT SHOCK ABSORBER a we 13 1 Removing of Front Shcok Absorber 13 13 A 2 Disassembling of Front Shock Absorber 4 13 3 Checking of Front 4 13 4 Assembling of Front Shock Absorber 5 13 5 Installing of Front Shock Absorber 4 13 B SUSPENSION ARM ASSEMBLY 4 13 1 Removing of Suspension Arm Assembly 7 2 Checking of 37 Installing jin Am 13 7 13 C BALL JOINT 13 7 13 C 1 Checking of Ball Joint 13 7 13 2 Replacing of Ball Joint 3 7 13 D REAR SUSPENSION 13 8 13 D 1 Removing of Rear 13 8 13 2 of Rear Shock 8 130 3 of Rear Shock Absorber 8 13 D 4 Assembling of Rear Shock Absorber 13 9 13 D 5 Installing of mes 1419 13 E FOUR LINKS 21329 E 9 13 F 10 10 10 13 F 3 Installing of Lateral Rod 13 10 18 13 13 V Fig 13 2 suspension Y Rear shock alworber assembly 6 Gromer 11 dim 1 Coll spring 2 Sei 12 Upper tink 3 rod 8 Spring sest upper VA Lower fink 4 Retainer 9 Rubber seat 5 Rubber bath 10 Bound stopper
187. h the clean soft water demineralized water 3 Operate the engine for about one hour 4 Drain the water S Fill in a mixture of water and genuine long life coolant Note In case the accumulation of tust and other deposits are excessive detergent be used In this case the instructions of the detergent maker should be followed 3 D RADIATOR The radiator is of the corrugated fin type with sealed filler cap A pressure cap is fixed o the expansion chamber Carefully inspect the radiator for water leakage Any minor leakage must be completely eliminated by solder ing or other means A clogged radiator badly influences the cooling effect and should be cleaned with the compressed air 3 0 1 Pressure Cap pressure cap is provided the expansion chamber The expansion chamber and the radiator ate connected by hose When the cooling water pressuried the boiling point rises and this prevemis overheating and minimizes the loss of water When the pressure in the cooling system exceeds 0 9 kg cm 12 8 Ib in the cap opens When the coolant temperature falls the vacuum release valve open at 0 1 kg em 1 4 to prevent vacuum build up in the cooling system Fig 3 2 Pressure cap 3 COOLING FAN Torque limit type fan drive has been adopted to drive the cooling fan with a view to reducing the loss of the horsepower at 3 high speed under full load and preventing noises due to the fan and also
188. haft lock pin of he gear case with a suitable drift as shown in Fig 9 12 Fig 9 12 Removing of lock pin 4 Remove the pinion shaft 5 Rotate the differential pinion gears 90 degrees and remove each pinion gear and thrust washer 6 Remove the differential side gears and thrust wash ers 9 C 3 Removing of Drive Pinion 1 Hold the companion flange with the holder 49 0259 710 und remove the drive pinion mut Fig 8 13 Removing of drive pinion nut 2 Remove the companion flange 3 Remove the drive pinion and rear beating from the carrier If necessary tap the pinion out with a plastic hummer while being careful to guide the pinion with hand to avoid damage 4 Remove the seal and the front bearing 9 C 4 Ramoving of Pinion Bearing Outer Race The pinion bearing outer races can be removed from the carrier by using drift im slots provided for this purpose Fig 9 14 Removing of pinion bearing outer race 9 D REAR AXLE INSPECTION 9 0 1 Checking of Drive Pinion and Ring Gear Check the drive pinion for damaged or excessively worn teeth damaged bearing journals and splines Inspect the ring gear for worn or chipped teeth If any of above conditions is found replace both 9 drive pinion and ring gear as they are available only in set 9 2 Checking of Differential Gears Inspect the differential side gears and pinion gears for cracks chipped teeth or any damage Replace the side
189. hat attach the brush holder to the housing and remove the brush and holder insu lator and terminal 10 Remove the screw attaching the heat sink and the two terminal screws and remove the diodes and heat sink assemblies from the rear housing 5 4 Alternator Inspection Checking of stator coil Check the stator coil for both open and grounded circuits with a tester p To check for open connect th prods to each of the two leads as shown in Fig 5 10 If there ts no flow of current the is open circuit and must be paired or replaced Fig 5 10 Checking of stator coll for open To check for ground connect prod to the core and the other to each lead wire as shown in Fig 5 11 ground is present the current will and the stator coil must be repaired or replaced Fig 5 11 Checking of stator for ground b Checking the rotor To check for open circuit place both prods of a tester on the slip rings as shown in Fig 5 12 Fig 5 12 Checking of rotor for open 5 13 Alternator assembly Brush holder Stator Ball beating rear Seal washer j Rear bracket Heat sink Heat sink 2 Clamp Insulator Rotor Bearing press plate Ball bearing front Front bracket Pulley Spring washer Nut 5 If the reading 5 to 6 ohms there is no trouble in the rotor To check for ground connect one prod to the slip ring and other pr
190. he engine speed below 4 000 200 rpm the coasting valve of the deceleration control system operates to Turm the vacuum im the vacuum chamber of the air control valve to atmospheric pressure This equalizes the pressures in the vacuum and air chambers and causes the spring to open the air cut valve so that the air in the air injection system will go through the thermal reactor to cool it before being expelled to fj Te an Te at clearer Ad valve Satory valve From at pm pe To thermal reactor Ar chanter Freeh ait Sve the atmosphere At the same time the air cut valve closs the secondary air passage to cur fresh ar supply The relief valve opens and closes in accordance with air pressure in the air injection system and the force of the return spring When the air pressure in the air injection system exceeds 0 14 02 kglem 20 2 8 Ib in Mt opens the relief valve against the re urn spring force and proceeds to the thermal reactor to cool it before being expelled to the atmosphere thus controlling the secondary air volume When the air pressure decreases the spring closes the valve The safety valve like the relief valve controls air pressure in the air injection system and adjusts the volume of secondary air If air in the air injection system should be trapped due to malfunction the safety valve relieves the trapped air to the uit cleaner thus prev
191. he isassembling procedure The following points should kept minit 1 The parts of the primary baire are similar shape to those of the secondary barrel Do not interchange any pari 2 When mounting the valve be careful 10 eliminate the clearance between the throttle valve and the throttle chamber wall 4 5 Carburettor Adjustment Float level adjustment Fig 4 8 Float level adjustment 1 Float seat lip 2 Float Adjust the maximum fuel quantity coming in through the needle valve by bending the float seat lip so that the distance A between the lowest part of the float and the lower face of the air horn 55 56 mm 2 1 2 2 in as shown in Fig 4 8 Then adjust the fuel level by means of the washer at the fuel inlet so that the distance B between the upper face of the float and the lower face of the ai horn is 46 47 mm 1 8 1 9 in as shown in Fig 4 9 Under this condition fuel level is kept at the center of the bowl cover Fig 4 9 Float level adjustment b Fast idling adjustment When the choke valve Is fully closed the throttle valve opens to 15 by action of the connecting rod amd provides easy starting up At this moment the clearance between the throttle valve and the throttle chamber wall is 1 12 mm 0 045 in Adjust by bending the connecting rod until the proper clearance is obtained The choke lever is provided with two holes hanging
192. heck the armature for both grounding and short circuit To check for grounding touch one prod of tester o each segment and the other prod to the core of shaft If there is current the coil of the corresponding segment 16 grounded Fig 5 25 Checking of armature To check for short circult use a growler tester Place the armature against the core of the tester and hold steel strip the armature Then rotate the arms ture slowly by hand im case of short the the steel strip will become magnetized and vibrate b Checking the commutator If the commutator is dirty discolored or worn clean fi with emery paper and wash with clean solvent Alter cleaning undercut the mica between the seg ments to the depth of 05 08 mm 0 020 0 031 in Refer Fig 5 26 Checking the field coil To test the field for ground with tester place One prod on the yoke of pole core and the other prod to the field terminal In case of grounding there will be current and the field coil must be re paired or replaced Refer Fig 5 27 d Checking the brush holder Check the brush hoider for ground Touch one prod of tester to the brush holder aud the other prod to the frame Current flow indicates grounding In that case replace the holder Checking the brushes and brush springs Check the brushes and replace if they worn down more than one third of their original length Ot
193. heck the following points 1 Connect an ammeter to the coasting valve solenoid and check to see that there is no current flow to the ammeter when idling current lows above 1 250 1550 rpm When the engine speed is gradually lowered the current flow stops at 1 300 1 100 rpm Coasting valve From control Fig 14 53 Checking of No 1 control box 3 b Removing of 1 contro box 1 Remove the No control box connector 2 Loosen the No 1 control box nuts and remove the control box Installing of No 1 control box Install the No control box in the reverse sequence 11 No 2 Control Box and Leading igni Retard System a Checking of No 2 control box and leading ignition retard system 1 Remove the No nectors 2 Remove the trailing side vacuum switch connector 3 Connect the timing light to the high tension cord of the leading spark plug of the front rotor housing 1 and No 2 thermosensor con 1 4 Start the engine and run it at 2500 rpm 5 Pull the choke switch ubout B 10 mm 0 2 0 4 In in order to actuate the choke switch In this case if the engine speed goes down 200 300 rpm the choke switch is normal o load 2 000 Fig 1A 54 Checking of retard system 1 6 Disconnect the leading side distribut at minus terminal so as to conduct electricity only by wire a black and white one of the te tarding side
194. her wise reduced spring tension will lead to an increase in the brush commutator contact resistance This towers ihe torque and causes burnt commutator surface The spring tension is 1 130 40 0 oz If the ten sion i too low replace the springs f Checking the bush Check the clearance between the armature shaft and the bush If it exceeds 0 2 mm 0 08 in replace the bush 5 G 5 Magnetic Switch Test a Pullin coil test Apply the specified voltage 12V between the S terminal and MT terminal If the magnetic switch forcefully attacted the pullin coil is in good condition b Holding test Ground the MT terminal to the magnetic switch body with a lead and impose the specified voltage 8V to terminal 8 to pull in the plunger If the plunger Fig 5 28 Starting motor assembly 4 Driving lever 5 Magnet switch 6 Driving lever spring 7 Over running clutch 8 Metal 9 Washer 10 Washer 11 Metal 12 Center bracket 13 Washer 14 Armature 15 tnaslator 16 Washer 17 Pinion shaft 18 Washer 19 Washer 20 Metal 21 Yoke 22 Field 23 Brush 24 Brush spring 25 Metal 26 Rear bracket 27 Bolt 5 Fig 5 29 Pullin coll test emains attracted after disconnecting the lead from the MT terminal the coil functions properly Fig 5 30 Holding test c Return test Push in the plunger by hand and apply the specified voltage 1
195. hoid rotor type oil pump are shown in Fig 2 5 The feeding capacity of the pump is 16 20 liters 34 42 US pint 28 35 Imp pint per minute at 6000 rpm 2 E 1 Oil Pump Inspection For checking proceed as follows 1 Use a feeler gauge to check the clearance between the outer rotor and the inner rotor as shown in Fig 2 4 The standard should be 001 0 09 mm 00004 0 0035 in Fig 2 4 Checking gap of rotors Fig 2 5 pump assembly Snap ring Adjusting washer Olt pump driven gear Oil pump body Thrus washer Woodruff key pump daft Outer rotor inner rotor Intermediate Set bolt washer 2 2 Measure the clearance between the outer rotor and the pump body with the feeler gauge The specified clearance is 0 20 0 25 mm 0 008 0 010 3 Inspect the end float of the rotor with the feeler gauge as shown in Fig 2 6 If the end float is 100 large make corrections by scraping the pump body The standard value of the end float is 0 10 0 20 mm 0 0014 0 008 in Fig 2 6 Checking end Moat af rotors 2 2 Assembling the Oil Pump 1 Attach the stop ring and the key to the pump drive shaft 2 Attach the inner rotor to the shaft by matching the key groove of the inner rotor with the key 3 Fix the thrust washer to the stop ring of the shaft as shown im Fig 2 7 Mount the inner rotor and shaft assembly to the pump bod
196. ich are shown by embossing matkings no mark and C In order to obtain a proper backlash between the internal geat and the stationary gear the identically marked gears are incorporated the factory Note When replacing a stationary gear at dealer use a unmarked stationary gear in any 1 C 6 Seal and spring 3 Cleaning the seal and spring 1 Apex seal Use carbon remover to remove the carbon from both sides while being careful not to damage the apex seal Wash with cleaning solution Note A special carbon material is used for the apex seal This is weaker and easier to damage than metal Therefore take extra care Never use emery paper as it will damage the apex seal 2 Corner seal and side seal Clean with carbon remover and wash Never use emery paper 3 Seal spring Remove carbon with the carbon remover and wash in cleaning solution b Inspecting the apex seal Check apex seal for wear damage or cracks and replace if any of these conditions is found Measure the height of the apex seal with a micrometer Replice if the height is less than 8 0 mm 0 315 in Inspecting the gap between apex seal and groove To measure the gap between apex seal and groove place the apex seal in its respective rotor groove and use a feeler gauge to measure the gap As shown in Fig 1 61 the apex seal tends to wear unevenly and for this reason the feeler gauge should be inserted fully into the bottom of th
197. id shuts the atmospherk pressure sensing line leading 10 the ait chamber When the engine switched off the solenoid opens the sensing line and due to the resulting pressure IE SW Fig 14 23 Deceleration control system Fig 14 24 Antialterbury valve difference between the aif and vacuum chambers the valve connected to the diaphragm is opened and fresh air is lead from the air cleaner into the intake manifold to prevent afterburn after the engine is switched off The metering orifice in the diaphragm connects the air and vacuum chambers to control the duration of valve opening When the pressures between the two chambers are equal the valve is kept closed by the spring force and when the pressure difference exceeds 100 mm Hg the valve is opened 1o lead fresh air from air cleaner into the intake manifold When the metering orifice equalizes pressure dif ference the valve is closed to shut off b Coasting valve The coasting valve connected to the Intake mani fold supplies fresh air from the air cleaner into the intake manifold to correct overrich mixture during deceleration As a result when the coasting valve opens the intake manifold vacuum connected to the vacuum chamber of the air control valve is turned 10 the atmospheric pressure in order to cut secondary ait supply during deceleration Fig YA 25 Coasting valve The rise of intake manifold vacuum
198. ift locking ball and spring to the groove of each shift rod and install the spring caps 18 Install the under cover and two blind covers 19 Install the speedometer drive gear with locking ball onto the main shaft and secure it with snap ring 7 D 2 Assembling the Extension 1 Install the ail seal to the rear side of the exten sion by using suitable tool 2 Insert the control rod install the control lever end with key and tighten the reamer bolts Fig 7 14 Installing control lever end 3 Fit the friction piece and the spring to the ex tension and install the spring cap 7 EX an W ux 7 Fig 7 15 Friction piece of conte rod 4 Install the reverse lamp switch S Install the speedometer driven gear assembly and secure with the lock plate 7 0 3 Installing the Extension Assembly 1 Place the gasket on the rear side of the transmis sion case and install the extension assembly to the Fig 7 16 Installing extension 7 transmission case laying down the control lever end to the left as far as it will go Tighten the nuts and confirm that the control rod operates properly 2 Insert the select lock spindle and return spring Install the locking ball and the spring in alignment with the spindle groove and fit the spring cap Install the set screw to the control case z IT Fig 7 1 Conttol case 1 Control case 4 Spring 2 Locking batt 5 Spring 3 Spring 6 Select lock sp
199. ight aiming 5 H 2 Replacing the Bulbs When replacing bulbs conform to the following table 5 10 Head lamp sow 40w Front tum signal amp side ump 2IW SW Side tura signal mp Fog lamp iw Step amp ow Glove compartment lamp sw Turo signal lamp 2w Stop tall A reverse lamp Licence lump 5 1 INSTRUMENT PANEL Fuel Gauge is equipped with an electric fuel gauge The uel gauge indicates the fuel quantity im the tank when the ignition switch is turned on The fuel gauge is composed of the fuel meter mounted on the instrument panel and the fuel tank unit con nected by a single wire through the ignition switch Should the meter fail to register check and repair the fuel meter circuit as follows 1 Fuel gauge does not register with ignition ON Defective panel unit b Faulty contact in Ig terminal of meter gauge Wiring to tank grounded d Meter gauge improperly grounded 2 Fuel gauge shows F under all conditions 3 Open circuit m tank unit and meter gauge b Break in wiring between tank unit and panel 3 Fuel gauge shows E under all conditions a Loose or fuulty contact of terminals b Short circuit in tank unit or meter gauge Break in P coil and S coil of meter gauge 5 1 2 Water Thermometer The cooling water thermometer is operated electrically like the fuel gauge The circuit consists of the water thermometer on the instrument pane
200. ight at the timing indicator pin the front cover 4 Loosen the distributor locking nuts and rotate the leading side distributor body until the timing mark the eccentric shaft pulley aligns with the timing indicator pin on the front cover S Tighten the locking nuts and recheck the timing 6 Adjust the trailing side distributor in the same way as above 1 24 LH HH Avance degree W w LJ Lm L Veeam imi Fig 14 67 Advancing characteris Trailing ide EH HES F H 296 wo 719 90 Vacs Fig 1A G8 Advancing characteristic Leading side 1 Checking of spark plug Inspect each plug individually for badly worn cle Cold Maker Standard electrode gap NOK ET 09 0036 imi NIPPONDENSO W25EA 08 03 mm Whoa DON CHAMPION 7 033 09 03 0036 in 1 D strodes glazed broken r blistered porcelain and Fig YA 69 Adjusting Of ignition timing replace the plug as necessa 2 Clean the spark plugs throughly using a sand blast b Advance test cleaner To test the ignition advancing characteristic of the 3 Measure the electrode with wire gauge If distributor use a distributor tester the gap exceeds 1 1 mm 0 043 in
201. im board 6 Remove the inside screens vinyl which are in stall to prevent water leakages 7 Remove the outer weatherstrip from the door body 8 Remove the center sash and slide off the quarter window glass with the weatherstrip Fig 14 25 Removing of center sah 9 Remove the door window glass With the window glass lowered to half opened position It can be easi ly taken out Fig 14 26 Removing of glam 10 Remove the outer handle 11 Remove the door lock complete 12 Remove the window regulator 14 0 2 Assembling of Rear Door 1 Install the outer handie 2 Install the door lock complete 3 Connect the actuating rod after adjusting the free 14 6 14 play of the outer handle by the nylon bush to be within 1 5 to 3 0 mm 0 06 to 0 12 inl Fig 14 27 Connecting of actuating 4 Install the window regulator 5 Install the door window glass 6 Install the center sash and temporarily tighten 7 tnstall the glass run channel 8 Install the quarter window 9 Securely tighten the center sash while adjusting the alignment between the window glass and the door sash 10 Install the outer weatherstrip 11 Paste the inside screens 12 To prevent water leakage apply a solid sealing agent on the heads of the bolts attaching the window regulator 13 Install the door trim board and inner lock knob 14 Install the regulator handle 15 Install the arm rest 14 TOP CEILING 14
202. in on the front cover 5 Tighten the locking nuts and recheck the timing 6 Adjust the trailing side distributor in the same way as above b Advance test To test the ignition advancing characteristic of the 9 di Ves Fig 14 66 Advancing characteristic Trailing side ogre Fig 1A 66 Advancing characteristic Leading side distributor use a distributor tester The advancing characteristic of each distributor should be within the range shown in Fig LA 65 and 1A 66 Checking of contact point gap Check and adjust the contact point gap To check the point gap rotate he distributor drive shaft until the contuct arm rubbing block is at the top of the cam Check the point gap with a feeler gauge The ap should be 0 45 mm 0 018 in Check the cam dwell angle with tester The dwell angle should be 55 to 61 If ihe dwell angle was below the specified amount the contact point gap b 100 large If the dwell ungle was above Fig 14 67 Adjusting af point gap 1A the specified amount the contact point gap is too small 9 Spark Plug Spark plugs are of a standard type and a cold type as shown in the following table Note Do not use spark plug which is not specified Maker NGK NIPPONDENSO Wu j CHAMPION N 80B 033 NB 033
203. inder 1 Install the wheel cylinder to the backing plate and connect the fluid pipe 2 Install the brake shoes and the drum as described in Par 1 3 3 Bleed the brake lines as detailed in Par 11 6 2 11 G AIR BLEEDING Whenever the wheel cylinder or muster cylinder is overhauled or air enters the system air bleeding must be carried out The correct sequence of bleeding 1s to bleed master cylinder first and either front or rear wheel cylinder second Note During bleeding operation the reservoir of the master cylinder must be kept at least 3 4 full of the brake fuid 11 G 1 Bleeding of Master Cylinder and Front Wheel Cylinder 1 Remove the bleeder valve cap and connect vinyl pipe to the bleeder valve Submerge the other end 11 of the pipe in the brake fluid im a glass jar 2 Open the bleeder valve Depress the brake pedal full stroke and allow it to return slowly Continue this pumping action until air bubbles cease to appear in the jar Fig 11 30 Air bleeding 3 When bleeding operation is completed close the bleeder valve remove the vinyl pipe and fit the cap 10 the bleoder valve 11 6 2 Bleeding of Rear Wheel Cylinder 1 Depress the brake pedal several times quickly And then with the brake pedal depressed open the valve to expel the air Close the valve before releasing the pedal 2 Repeat above operation until the brake fluid is expelled solid stream without
204. indle 3 insert the spring and seat into the control lever end and install the control case assembly to the ex tension together with the gasket 7 0 4 Installing the Clutch Housing 1 Place the gasket on the front surface of the trans mission case Install the clutch housing being careful mot to damage the oil seal 2 Install the release bearing spring and fork 7 E INSTALLING THE TRANSMISSION 1 Shift the trasmission into top gear Support the transmission with a jack and block of wood and move it under the vehicle 2 Lower the rear end of the tmasmission and align the centers of the main drive shaft and the clutch disk by raining the jack 3 Move the tmasmission forward until the spline on the main drive shaft contacts the spline on the clutch disk Align the splines properly by tuming the main shaft holder 49 0259 440 and after aligning the knock mount the transmission to the engine body Tighten the bolts Secure the earth wire with bolt 4 Raise the jack and install the transmission supporter to the side frame member Tighten the nuts 5 Remove the jack and connect the propeller shaft to the transmission 6 Install the exhaust pipe to the manifold 7 Connect the speedometer cable to the speedometer driven gear assembly 3 Install the release cylinder to the clutch housing and the retum spring If necessary adjust the free play on the release fork See Par 6 B 9 Move the lever end from top gear to n
205. ing from the cylinder Fig 11 2 Brake pedal Master cylinder Power brake unit Push rod Retum spring Stop switch j Lock nut Lock mut Brake pedal PET nad 11 6 Loosen the secondary piston stop balt 7 Pushing in the secondary piston with a screwdriver remove the stop bolt and insert the guide pin in its place Then gradually take out the screwdriver and remove the secondary piston spacer piston cup sev ondary cup spring seat and return spring If necessary blow out with compressed air from the outlet hole Fw 11 3 Guide pin 3 Remove the fluid pipe fittings trom the cylinder and then remove the check valve and spring 11 B 3 Checking of Brake Master Cylinder 1 Wash the parts clean alcohole or brake fluid Never use gasoline or kerosene 2 Check the piston cups and replace if they are dam aged worn softened or swelled 3 Examine the cylinder bore and piston for wear roughness or scoring 4 Check the clearance the cylinder bore and the piston M it is more than 0 15 mm 0 006 in replace the cylinder or piston Ne Fig 11 4 Checking of piston clearance 5 Ensure that the compensating ports on the cylinder open Fig 1 5 Bike master cylinder L Cap 2 Oi bate Reservoir 4 Elbow joint bush 5 Valve stopper 6 Pamary 7 Washer 3 Stop wire 9 Valve rod 10 Spring Spring seat
206. ing of Steering Gear Nonseparate type 10 STEERING GEAR DISASSEMBLY 10 D STEERING GEAR INSPECTION 10 E STEERING GEAR ASSEMBLY 10 F STEERING GEAR ADJUSTMENT 10 Adjusting of Worm Bearing Preload 10 F 2 Adjusting tor Ball Nut Backlash 10 G STEERING GEAR INSTALLATION 10 H STEERING LINKAGE 10 H 1 Checking of Ball Joint 10 2 Replacing of Idler Arm 10 H 3 Replacing of Pitman Arm 10 4 Replacing of Tie Rod 10 5 Greasing of Idler 10 1 FRONT WHEEL ALIGNMENT 10 L I Inspection before Checking Front Wheel Alignment 104 2 Toedn 1041 3 Camber Caster and king pin Inclination 10 1 4 Adjusting of Steering Angle UAR R ARA e ae 10 10 STEERING The steering system consists of the steering pear steer ing column steering wheel and steering linkage The steering gear of a recirculating ball nut type and the steering gear ratio 17 0 to 19 0 1 There fore this steering gear provides easy steering 10 CHECKING OF STEERING WHEEL PLAY The standard free play at the outer circumference of the steering wheel is 5 to 20 mm 0 2 to 0 8 in To check the free play of the steering wheel place the front wheel straight ahead and the stecring wheel slowly The value of the free play is taken when the front wheel begins to move If excessive play is found the following points should be carefully checked because
207. is alight it can be reconditioned by grinding in lathe M the damage amp deep the should be replaced Check the ting gear teeth und replace f the ring eat are broken cracked or seriously buirred 6 0 5 Ring Gear Replacement 1 Heat the old ring geut and remove from the flywheel 2 Heat the new ring gear evenly 250 to 300 C 480 to STF 3 Place the ring gear on the cold flywheel making sure that the chamfer on the teeth ix faced to the engine 4 Allow the ring gear to cool slowly to shrink it onto the flywheel 6 6 0 6 Inspecting the Needle Roller Bearing and Seal Check the needle roller bearing and oil seal at the Tear end the eccentric shaft Then insert the pilot of the main drive shaft and check for smooth operation and proper clearance If the bearing is loosen rums rough it should be replaced Check for weir and damage of the oil seal lip I traces of oil leakage are found replace the oil seal 6 E CLUTCH ASSEMBLY 1 Install the flywheel onto the rear end of the ec centric shaft through the key Place the lockwasher im Its place and the lock mut 2 Use a ring gor brake 49 0820 060 and tighten the Jock nut o 45 mkg 320 fib 3 Bend the lockwasher to prevent loosening 4 Hold the clutch disk and pressure plate assembly in mounting position Then insert a clutch disk center ing tool 49 0813 310 through the spline of the disk and int
208. itis 0 15 mm 0 0059 in more reface the drum When refacing the drum remove only so much material as is necessary 10 obtain a smooth surface on the drum Do not reface more than 1 0 mm 0 0394 The stand ard inner diameter of the drum is 200 mm 7 8741 in b Inspection of brake lining 1 Inspect the brake linings and replace with new parts if the linings are badiy burned or worm 2 Examine the lining contact pattern For inspec Won chalk the entire inner surface of the brake drum and slide the lining along the chalked surface The lining should show a uniform contact across the entire width extending from toe to heel Shoes having sufficient lining but lack of contact should be ground properly 3 If oil or grease is evident on the lining wash off oil or grease in a suituble solvent Then correct the cause of leakage However if the lining is saturated with oil or grease replace it Inspection of wheel cylinders Examine whether the exterior of the wheel cylinder boots is wet with brake fluid Excessive amounts of fluid at this point indicates leakage past the piston cups Therefore the wheel cylinder must be overhauled d Inspection of brake lines Inspect ull brake lines for leakage with the foot brake applied Check ull brake pipes hoses and con nections for signs of chafing deterioration of other damage 11 3 Installing of Rear Brake Shoes 1 Lube ate the adjusting screw threads mating sue
209. ivent misfiring and knocking which are liable to occur at low load and high revolution due to lean mixture This is of the structure that a diaphragm responsive to the negative pressure of the secondary side is pro vided halfway on the circuit with ite valve designed o open at a certain extent of the negative pressure allowing the fuel led from the secondary step system pass and proceed to the auxiliary slow jet and then finally the fuel ls ejected through the auxiliary slow port to the primary venturi Fig 4 2 Auxiliary slow circuit 1 slow hole amp Disphragm 2 Primary throttle ae 9 Shim 3 Pup 10 Cover A Auxiliary slow jet 11 Diaphragm spring 5 Secondary throttle valve 12 Vacuum chamber 6 Vacuum bole 13 Fuel chamber 7 Ball valve 14 From step Primary height speed circuit During operation at part throttle or fulkthrottle the fuel is supplied through the high speed circuit The fuel in the float chamber flows through the main jet i mixed in the emulsion tube with the from the main air bleed and is sprayed through the main nozzle to the ventur f Accelerating circuit The accelerating circuit measures and supplies fuel for the rapid acceleration and smooth engine operation when the throttle valve is opened at lower speed The accelerating pump is connected to the primary throttle valve by a link When the primary throttle valve ts closed the diaphragm of the accelerating pum
210. ix thicknesses 1300 08 1300 15 5 i ww d 46 i 19 The models except above Som 0 68 HO 0 472 2 mm 0 480 in 6 0 496 12 13 Check the operation of the low and reverse brake by blowing air into the oll hole us shown in Fig 2 27 4 E BAND SERVO Pig 2 30 Band serve 1 Adjust nat Paton amp Wah Y pring pon To Remove i Lowen and remove three bolts that anch the tend servo retainer 16 the transmbssi m che and he band servo retainer together with the servo piston Take out the return spring M the servo retainer difficult di it be readily removed by oil hole on the piston release side 2 Blow compressed air the oil hole on the apply side of the servo pistou to remove the piston from the reminer pect from the cme ng air into the To inspect 3 Check t0 see that two O rings on the servo retainer and the seil rubber on the servo piston are not damaged 4 Check 10 that there are no dumiges on the servo retainer piston piston stem and the portion of transmission case where thaw parts are fitted 5 Check the return spring for decline or deformati 6 Check the brake band lining for wear damages To Reassembie 7 Apply converter oil on all parts and reinstall them in the reverse order of disassembly 59 Blow
211. just ignition timing 4 000 4 Check and adjust carburettor 4 000 5 Check air pump V belt tension adjust If necemary 4 000 Check air hoses and vacuum sensing tubes for deterioration and leakage correct or replace Af required 12000 2 Cheek air pump for proper operation replace av required Check check valve for proper operation replace as required s Check control valve for proper operation replace required 12 000 10 Check coasting valve for proper operation replace zs requited 12000 n Check throttle positioner for proper operation adjust if necessary 12 000 an Check anthafterbum valve for proper operation replace as required 12 000 3 Check sir supply valve for proper operation replace as required 12 000 n Check fiie lag for proper operation replace as required 1000 15 Check thermojenvor and thermodetector fot proper operation replace as required 12 000 Check vacuum swiich for proper operation replace as required 12 000 Check control box for proper operation correct or replace ai required 12 000 18 Check ventilation hoses of ventilation system for leakage and deterioration replace as required 12 000 19 Check ventilation valve for proper operation replace as required 12000 3 Check fuel hose of evaporative emission control system for leakage and deterioration correct or seplace required 12000 a Check canister for proper operation
212. k the leaking out of the ignition and replace it when much oil leak is found 2 Disconnect each wiring from the positive and ative terminals of the ignition 3 Measure the primary resistance disconnection of the primary coil Trailing side coil Internal resistance type d check the HPS 10F 3090 Leuding side coil External resistance type HPS 13 1350 Incidentally the above parts are common to RX 2 and R 100 Coup 22 Carburetor A Idle limiter limiter regulates the fuel flow at low speeds and is adjusted by the manufacture The idle limiter should not be adjusted Fig 1A 73 Idi niter Adjusting of idle speed Fully warm wp the engine 2 Make sure that the return of the ive is prope Adjust the idle fuel flow to 20 2 3 L H 052 06 US gallon H and the idle speed to 900 rpm by manipulating the idle adjusting screw and throttle adjusting screw The normal idle speed is 900 rpm ondary throttle Checking of accelerator pump 1 Remove the air cleaner 2 Check the pump for discharge by moving the primary throttle valve 3 Check the pump for lever s movement and hozzle s clogging 4 When the pump nozzle is clogged remove the pump and clean up the nozzle 5 When the pump lever does not operate or operates stuggishly adjust it as follows There are many cases that the pump operation be comes dull because of the Increased
213. l and the sending unit installed on the thermostat case When the water thermometer registers improperly check on the fol lowing points and refer to the wiring diagram for re pair 1 Pointer does not move when ignition switch is turn ed on Defective panel unit b Faulty contact in lg terminal 2 Pointer shows under all conditions a Open circuit in sending wit b Break wiring between both units Loose or faulty contact in terminals 3 Pointer shows C under all conditions a Defective panel b Short circuit ir sending unit Panel unit improperly grounded pm Fig 5 34 Diagram of the gauge Fig 5 35 Diagram of the water temp gaupe 1971 5 5 38 Wiring diagram all model except coupe super deluxe Fig 5 27 Wiring diagram coupe super deluxe 5 5972 jj Tfemmens ey Transit 14 87 Witing diagram CLUTCH PEDAL ADJUSTMENT CLUTCH ASSEMBLY j CLUTCH RELEASE CYLINDER CLUTCH
214. l be ignited d No 1 control box and thermodetector The control box i common to the ignition and air flow control system and the deceleration control sys tem It ignites and cuts the trailing spark plug in accordance with the engine speed the state of warm ing up and the engine load controls secondary air and prevents afterbum during deceleration according 10 engine speed The No control box receives several signals pulses of the leading spark plug ignition coil which indicate engine revolutions signals from the No 1 thermiosensor detecting the condition of warming up and signals from the vacuum switch which indicate engine 1A 9 1 Fig 18 No and No 2 boxes The circuit for the thermodetector is in the No 1 control box and prevents the thermosensor from being influenced by ambient temperature 4 No 2 control box and choke switch The No 2 control box controls the leading ignition timing The No 2 control box receives several sig nals such as signal from the No 2 thermosensor detecting the condition of warm up signal of choke switch which is pulled signal from the No con trol box And No 2 control box operates so as 1o conduct or disconduct between leading side ip nition coil and retarded contact point Fig 14 21 Choke switeh That system ha two contact points inside the lead ing side distributor and one of them is for the normal advance while the other is for the reta
215. lement damaged air cleaner or other cause When the wear is permitted to Increase the engine power will be reduced and the engine will become hard to start The extent of wear of the comer seal bore is deter mined by the bar limit gouge 5619 91 100 and classified Into three conditions 1 Neither end of the gauge does not go into the This means that the gap conforms to the spe cifications 2 While the go end of tlie gauge goes into the bore the notgo end does not This means the gap is more than stnadard dimension and less than the limit this case replace the corner seal with a 0 03 mm 0 0012 in oversize one leaving the rotor side Dy 3 If the both ends of the gauge go into the bore Mt means that the yap exceeds the limit of 0 08 mm 0 0031 in Rework the comer seal bore with the lig 5870 94 1520 and reamer 5363 91 180 to 11 2 mm 02410 00009 in diameter following the procedure in Par 1 6 and fiL 02 mm 0 0079 in oversize corner seal Note 1 As the comer seal bore generally shows heavy wear the direction of the rotation the side arcs on the gaoge are partially cut off Be sure to take measurement in the direction of the maximum wear of the bore 2 If the limit gauge is not availube a feeler gauge arrowed at the forward portian be used for measuring the pap According lo a measurement thus obtained the same corrective step as in case of the limi
216. mber for easy inspection of the fuel level The ventilation system of the float chamber is of the inner circulation type Thus the fuel consumption is not influenced even if Fig 4 1 1L Slow Jet 12 Pump lever 13 Return spring 14 Iniet check valve 15 Flat 16 Primary main jet 17 adjust screw 18 Primary emullion tube 19 Bypass hole 20 Idle hole Carburettar 21 Primary throttle Yale spring 22 Outlet check valve 32 papam 23 Primary large venturi 33 Valve spring 24 Primary small venturi 34 Valve seat 25 Secondary throttle valve 35 Needie valve 26 Bypass hole 36 Secondary slow jet 27 Secondary emulsion tube 37 Secondary slow air bleed 28 Secondary main jot 38 Secondary main air bleed 29 Secondary large venturi 39 Secondary tain nozzle 30 Secondary smali venturi 4 the air cleaner is clogged to a certain extent C Low speed circuit During idling and early part throttle operation the fuel is measured in the low speed circuit The fuel passes through the slow jet fitted in a branch passage of the main jet Then the fuel is mixed with air from the No 1 slow bleed and metered by the slow econonizer And again jt is mixed with air from the No 2 slow air bleed The air fuel mixture then flows through the low speed passage and is ejected from the idle hole or the bypass hole d Auxiliary slow circuit This circuit has been installed to pr
217. n t wide open throttle when the engine warm 12 plays abe ab Probable causes Defective No control box Defective No thermowensor Defective vacuum switch No 2 Thermosemor Fosible troubles 1 Exhaust emision becomes abnormally unfavourable Conditions of trouble of device 1 Leading ignition does not retard when the choke operated in driving ranges other than idling deceleration under 180 mm ig at normal temperature cold start Probable cause Defective No 2 thermosensor Thermodetector Posible trouble Conesponded Wem 1 Trailing ignition does mor cut off at temperature coki condition and 4 plugs arc in operation ALB Ganditions of trouble of system Corresponded Tem Disconnection oF connector B Broken connection of wires inside ihermodectar Probable cause 2 Defective Thermodeiecior Vacuum switch Possibie troubles 1 Exhaust emission becomes sbnormally unfavourable 2 Penalty of power 3 Driveability deteriorates 3 Powibily of reactor being damaged great Conrespoeded item B Conditions of trouble of system Corresponded Wem A Leading nition only operate in all driving ranges until the No 1 hermowmar commences operation with he vacuum witch on B Bath trailing and lea
218. n jet Maximum 1155154 180 Primary Secondary 150 Trailing 0 L5 ar 140 mmidi Man air bleed Maximu 1 3 15 420 Primary 40 mn Secondary 10 Ignition timing Slow jet Leading v Primas 50 Trailing 10 Secondary EIU Vacuum switch Equipped im the trailing side Slow ir bleed distributor Primaty No m Two contact points Equipped im the leading side No 2 distributor Secondary No 60 Wei B60 Spark plug Auxillary dow jer 20 Vacuum port diameter Primary 13 mm 0 0708 im Standard NGK 7 Secondary 06 mm 0 0238 my NIPPONDENSO W22EA pump wozele 0 6 mm 0 0236 CHAMPION N 80B 0337 Ale limiter hole diameter 21 mm 00827 i NGK B 3EM W2SEA CHAMPION N 78B 0337 Thread Flecinde gap 09 0 9 0 031 0 038 i SPECIAL TOOLS 49 2113 001 Thermal reactor nut remover 49 2113 005 Ventilation valve wrench 38 LUBRICATING SYSTEM LUBRICATING CIRCUIT OIL PRESSURE RELIEF VALVE OIL PRESSURE SWITCH INSPECTING THE OIL PRESSURE OIL PUMP Oil Pump Inspection Assembling the Oil Pump 2 E 3 Replacing the Oil Pump Gears OIL FILTER THERMO VALVE 2 6 1 Inspecting the Thermo Valve 2 H METERING OIL PUMP 2 H l Inspecting the Metering Oil Pump lt 2 H 2 Adjusting the Motering Oil Pump mo CUBE EH ree 2 LUBRICATING SYSTEM A twortotor type p
219. n out is the wobble of the wheel To measure the radial run out apply a dial indicator against the center rib of the tire tread and rotate the wheel slowly This measurement should not exceed 20 mm 0 08 in To measure the lateral run out position a dial indi cator against the side of the tire The reading of the indicator should be within 2 5 mm 0 10 in 12 WHEEL BALANCING The allowable unbalance is 360 cmg 5 0 inoz which is less than 20 gr 0 7 at the rim Excessive wheel unbalance causes shimmy at high speed 1f unbalance exceeds 360 cm gr 5 0 in oz or when tire is disassembled for repair the tire and wheel assembly should be statically and dynamically balanced with a wheel balancer in accordance with the manu factuter s instructions 12 F FRONT WHEEL BEARING 12 1 Checking of Front Wheel Bearing To check the front whee bearings mise the vehicle with a jack until the wheels clear the ground Grip the tire and shake it sideways If considerable play Is noticed this indicates that the bearings are tough Fig 12 4 Checking of front wheel beating When disassembled check the wheel bearings for pits brinell marks or any damage If any of above con ditions exists replace with new bearings 12 12 2 Removing of Front Wheel Bearing Raise the vehicle until the front wheels are free of the ground 2 Remove the wheel cap and wheel 3 Remove the bolts attaching the caliper assembly
220. ncreased by turning the adjust screw clockwise and be decreased by turning it counter clockwise COOLING SYSTEM 3 A COOLANT CIRCULATION 3 B GENUINE 3 6 1 Disassembling the Water Pump 3 6 2 Assembling the Water Puny Fig 3 1 Cooling circuit COOLING SYSTEM The completely sealed cooling system consists of a radiator with a sealed filler an expansion cham ber sub tank with a pressure cap centrifugal water pump a thermostat and a fourvane fan The radiator and the expansion chamber connect ed by hose When the engine is heated sufficiently the coolant in the radiator flows out and is led into the expansion chamber through the hose The cool ant is then returned to the radiator by negative pres which builds up in the cooling system when the engine cools down The coolant should be changed every two years or every 48 000 km 30 000 miles 3 COOLANT CIRCULATION water pump is driven by the eccentric shaft pul ley over a V belt and discharges the cooling water to the front housing The water circulates from the front housing through the water passage provided in each housing and flows to the reat housing From the rear housing the water is returned to the front housing At low engine temperature the thermostat is closed to keep ihe water from entering the radiator The water is then recirculated directly to the water pump and discharged to each housing As the the
221. ner lower valve body 4 1 BEARING AND BEARING RACE Check ench bearing atul bearing race after cle carefully Also check to thut the mating parts of each bearing and bearing ate not damaged any defective part is found replace it 4 J OTHER COMPONENT PARTS Check wo see by sight that the following paris ate damaged Disassembly indicated should be maide in the procedure below s Front planet carrier assembly rear pianet assembly input shaft end output shaft he planetary carri r cannot be divided into its dividual compo If part or compor carrier as unit is defective replace the Check the clearance between pinion washer and with feeler vane is 0 20 0 70 mm 0 008 planetary carci The pandard 0 027 im Pig 243 Clearance of planetary wear If the clearance exceeds 0 80 mm 0 032 in replace with new one b Shell and sun gear assenibly jove the snap rings and draw the sun gear from the connecting shell c Internal drive flange assembly Remove the snap ring and disconnect the flange from the internal gear d Connecting drum assembly The operation of the one way clutch be checked by assuring that the connecting drum assembly or outer race turns clockwise and not counterclockwise before removing the connecting drum assembly from the case See part 3 DISASSEMBLY OF TRANS MISSION COMPL
222. ng e Checking the main bearing clearance The main bearing clearance is measured by checking the inner diameter of the main bearing and the outer diameter of the journal section of the eccentric shaft The standard main bearing clearance ts 0 04 007 mm 0 0016 00028 in and the beating must be replaced if the clearance becomes more than0 10 mm 0 0039 in f Removi main bearing When this work is required proceed in the follow ing steps 1 Remove the bolts securing the stationary gear to the housing 2 Press out the stationary gear with the main bear ing puller and installer 49 0813 235 amd assembling the stationary gear and 3 Mount the stationary gear on a vise Remove the bearing lock pin by using the lock pin remover 49 0820 260 4 Remove the adapter from the main bearing puller and installer 49 0813 235 and use to extrac the main bearing as shown in Fig 1 34 5 Attach the adapter on the bearing puller and installer and use It to press the bearing into the gear until the adsper touched the gear flange Be sure to match the oil holes of bearing and gear as shown in Fig 1 35 6 Insert the lock pim to prevent the bearing from turning ar to the housing with Mer 49 0813 235 a ligning the slot of the stationary gear flange and the dowel pin as shown in Fig 1 36 8 Tighten the bolts attaching stationary gear Note When replacing the stationary gear refer to par 1 5
223. ng check valve piston three re lief valves centering valve two relief valves and washer Note The piston should be fitted by making the constant orifice side face toward the upper end of the piston rod Fig 13 15 Piston assembly 1 Nut 6 Washer 1 Relief vave 7 Centering valve 3 Piston 3 Piston cing 4 Chack valve 9 Water S Check valve 3 Tighten the piston nut to 1 5 mkg 10 0 ensuring that the check valve and check valve spring are properly positione Fig 13 16 Tightening of piston nut 4 Punch two positions of the threads between the piston nut and the piston rod with punch to prevent loosening of the piston nut us shown in Fig 13 17 13 yr N7 gt y Fig 13 17 Applying of punch 5 Fit the four tension valves onto the bolt and im stall it into the base valve casing 6 Fit the five compression valves washer and nut to the base valve casing and tighten ihe mut to 015 mg 1 0 FW 13 18 Base valve assembly 1 Bolt 4 Nat 2 Relief valve S Valve seat 3 Bae vale casing 6 Relief valve 7 After tightening the mut punch the center of the bolt with a punch 8 Install the stopper guide stopper back up ring and the piston rod guide into the pressure tube 9 Install the two oil stop ring onto the bottom side of the pressure tube as shown in Fig 13 19 10 Insert the piston rod assembly into the pressure tube from the bottom side an
224. ng to Par 1 0 1 d Cleaning the rotor Remove the carbon on the rotor by using a carbon remover or emery paper Carbon the grooves must be removed with a carbon remover taking care not 10 damage the grooves Wash the rotor in cleaning solution and dry by blowing with compressed air Rotor inspection Check the rotor for wear and damage Check the internal gear for cracks wom chipped teeth Fig 1 43 Combustion condi Drinkin sl 09 Saal I Fig 1 48 Protrision of oll seal Fig 1 46 Cleaning rotor b Fig 1 48 Inspection lind protrusion SA Fig 149 Inspecting bearing clearance Fig 1 80 Fitting expander 1 Inspecting the gop between side housing and rotor The clearance can be measured by taking the width of the rotor housing and the width of the rotor The standard clearance is 0 13 0 17 mm 0 0051 0 0067 in If it is more than 0 17 mm 0 0067 in replace the rotor and gear assembly If the clearance is less than specification there is possiblity that the in ternal gear locked with 6 double pins is loose 8 Inspecting the land protrusion Check the lind protrusion of the rotor by placing a straight edge over the land and measuring the clear ance between the rotor face and straight edge with feeler gauge It should be 0 10 0 15 mm 0 004 0006 in If it is less than specification there is a possibilty of the rotor touching the side housing at places o
225. ning the set screw Fig 7 3 Main shaft assembly 1 Stay sing 9 Synchronizer ring 2n6 17 Thrust washer 2 Key 10 Spring 16 Adjust shim 3 Spring 11 Clutch hub Sed amp Top 19 bearing 4 hub Low 2nd 12 Key 20 Key 5 Clutch hub sleeve Low ad 13 Clutch huh deere 3rd Top 21 Reverse gear 6 Synchronizer ring Cd 14 Synchronizer zing low 22 Lock washer 7 Thin gear 15 Low gear sieeve 23 Loet mut 3 Second gear 16 Low gear 24 Main shaft 1 8 Remove the under cover and two blind covers 9 Remove the shift fork rod locking balls and springs and remove the interlock pins Loosen the shift fork muts and remove the shift forks with reverse idle gear from the case 10 After removing the snap ring on the rear side of the speedometer drive gear slide the speedometer drive gear off from the main shaft and remove the steel ball 11 Mount the main shaft assembly on the main shaft holder 49 0259 440 as shown in Fig 7 4 and loosen the reverse gear lock nut and remove lock nut lock washer reverse gear and key Fig 7 4 Loosening lock nut 12 Remove the snap ring on the counter shaft gear amd remove the counter reverse gear 13 Remove the bearing stopper and then remove the reverse idle gear shaft 14 Remove the ball bearing on the main shaft and needle bearing on the counter shaft from the rear side of the case using the bearing puller set
226. nknown In the road test if the maximum speed cannot be attained and the torque converter oil is found to be at unusually high temperature the one way clutch of the torque converter is diagnosed to be sticking 2 High sall revolution more than standard revolu tion If the engine revolution in stall condition is higher than the standard values it indicates that one or more clutches in the transmission are slipping and therefore no further test is required For the follow ing abnormalities the respective causes are presumed e High rpm in all ranges Line pressure is low or all clutches brake and band are slipping e High rpm in D 2 and 1 normal in R The rear clucth is slipping High rpm in D normal in 2 1 and R The one way clutch is slipping High rpm in R normal in D 2 and 17 front clutch or the low and reverse brake is slipping In the road test if there is no engine braking in I range the low and reverse brake is slipping and if there is engine braking in I range the front clutch is slipping e High rpm in 2 normal in D 1 and The band is slipping 3 Low stall revolution less than standard The one way clutch of the torque converter is slip ping or the engine performance is poor In the road test if poor acceleration is noted at various speeds indicates poor engine performance or incorrect engine adjustment In c
227. nse tank is led into the air space of the engine where such vapor condenses for the most and the re maining vapor goes to the charcoal filter and is trap ped there The fuel vapor rising from the fuel tank when the engine is running is directly channeled to the ventilation valve from which it is sucked into the intake manifold to be burned up m the com bustion chamber When running the fuel trapped jn the charcoal filter 8 vaporized by fresh air fram the ait cleaner and the engine temperaturo and goes to the ventilation valve which i is sucked into the intake manifold together 1 with fresh alr and blow by gas to be burned up in the combustion chamber 1 1 Charcoal Filter While the car is stationary some of the fuel vap generated In the fuel tank does not condense in 4 condense tank and when channeled into the engine air space without being fed back to the fuel tank Fig 14 36 Charcoal filter still cannot be trapped im the air space Such vapor is absorbed by the charcoal filter While the engine i running the fuel vapor trapped the charcoal filter is released into the Intake mani fold together with fresh alr from the ait cleaner and burned up in the engine The canister is always being purged by fresh air during engine operation 1A C 2 Condense Tank The condense tank condenses the fuel vapor coming from the fuel tank and returns it to the fuel tank Furl vap
228. nt the push rod and install the push rod through the front of the plate and valve body 11 Install the return spring 12 Install the rear shell assembly by using the wrench 49 6500 090 to rotate the front shell counter clock wise until scribe marks align Note Press the front shell down firmly maintaining 4 pressure until the shell flanges are fully locked 13 Install the boot down against the rear shell 14 Install the master cylinder 11 6 Installing of Power Brake Unit Install the power brake unit the reverse order of removing After installing the unit bleed the hydraulic system according to the procedure described in Par H G 1 11 0 FRONT BRAKE 11 D 1 Replacing of Disk Brake Shoe The lining should be inspected whenever the wheels are removed for amy reason tire rotation etc The shoe and lining should be replaced if the thick mess of the shoe and lining is 80 mm 0 315 in or lem due to wear To replace the disk brake shoes proceed as follows 1 Jack up the vehicle and remove the front wheel 2 Remove the fastening clips and remove the stop plates 11 5 Attach vinyl pipe to the bleeder screw and sub merge other end of the pipe into glass jar containing brake fluid 6 Open the bleeder valve and press the piston into the cylinder with the expanding tool 49 0221 6008 Fig 11 16 Removing of fastening clipe Fig 13 18 Pressing of piston Tighten the bleeder screw
229. nt cover Mak Tu N FOOT ODT 035833 0 0004 in M 5 04 LOL unm 40 3559 0 0004 in Loa 00 mm 0 3574 0 0004 in 1 0 13 Installing the Front Cover and Eccentric Shaft Pulley cing on the oil passage of the front to the oll seal of the front cover 3 Place the gasket on the front housing and install the front cover 4 Tighten the volts mounting front cover to torque of 2 0 mkg 15 ft lb 5 Install the eccentric shaft pulley aligning the key grooves of the eccentric shaft and pulley 6 Tighten nut mounting the eccentric shaft pulley to a torque of 7 0 mkg 50 fil Cut off surplus front cover gasket along mounting face of the pan 1 0 14 Installing the Metering Pump install the metering pump on the front cover 1 0 16 Installing the Oil Strainer and Oil Pan I Place the gasket on the oil pump and install the oil strainer 2 Fix the strainer stay with a bolt to the rear housing 3 Apply sealing agnet to the matching surface of the pan and each housing 4 Install the pan with a gasket S Install the nuts through the stiffeners 6 Tighten the nuts diagonally until a torque of 0 6 mg 45 fib is attained 1 0 16 Installing the Oil Filter Place the two rings on the oil filler and install the unit to the rear housing 1 0 17 Installing the Distributors 1 Turn the engine and stop when the white mark on the pulley matches the needle
230. nt engine to them 3 Install the bearing housing on the front housing and tighten the bolts and bend the tabs of the lock washers 4 Applying engine install the needle bearing thrust washer balance weight oil pump drive gear distributor drive gear key spacer and beffle plate in that order on the eccentric shaft Note Before installing the thrust washer and balance weight be sure that two needle bearing are in order along the center of the eccentric shaft 5 Install the eccentric shaft pulley with key without front cover and tighten the bolt to 7 0 mkg 50 ft lb holding the flywheel with the ring gear brake 49 0820 060 6 Turn the engine assembly so as to place the eccentric shaft horizontally and i a dial indicator so that a feeler touches on the pulley Fig 1 91 clutch assembly Fig 1 83 Checking end play 26 Ser Fw 1 94 Fod play of eccentric shalt Fig 1 97 Cutting excess gasket 7 Move the pulley fore and aft and read the scale of dial indicator The measured value should be 0 04 0 07 mm 0 0016 0 0018 in If If is not within the limit adjust i by mean of grinding the spacer using the emery paper on the flat place or by re placing the spacer The following three kinds of spacer are available Comfrm the end play again If the measurement is within standard remove the eccentric shaft pulley and key and take next step to ft the fro
231. o 1 thetmosemor 2 Defective No 2 thermosensor 3 Defective No 1 control box 4 Detective No 2 control box 5 Defective vacuum switch 6 Defective choke switch 1S Factors which adversely affect overall emissions under proper procedure Ex In ease of bag sampling 1 Improper operation af alt control valve Air cut valve Relief valve amd Safety valve 2 Defective No control box ot No 2 control box 3 Tralling side spark mot controlled when the water and oil temperstures tow Leading side ignition timing mot retarded when the water and oil temperatures are low 5 Improper ignition timings of lending and trating plugs 6 Improper idling mixture 7 Improper engine Ming speed Proper idling speed 1 900 rpm 8 Defective carburetor improper fuel level jet etc 9 Improper operation of coasting valve 10 Improper operation of anthafterburning valve 11 Fouled spark plug Breakage of reactor 13 Air leak from secondary air passage 14 leak from each sensing Tube to intake manifold Factors which adversely affect idling emissions 1 Improper idling speed or mixture 2 Defective spark plop 3 Improper ignition timings of leading and trailing sides 4 Defective distributor contact point 3 Deteriorated air pump See 1 23 Adjust Repair and parts See dA E 23 Adjust Chean Clean and replace parts Adjust and replace parts Replace if necessary rr Yfffff
232. o be sucked in through the air suction while the lead wire discon nected Fig 57 Checking of antiafterburn valve Removing of antiafterburn valve Remove the air cleaner Remove the air hoses from the antiafterburn valve Loosen the mounting nuts and remove the anti afterburn valve wee c Installing of anti afterburn valve install the anti afterburn valve in the reverse se quence 14 21 1 13 Coasting Valve Checking of coasting valve 1 Attach the vacuum gauge as in Fig 14 58 2 Start und warm up the engine Make sure that the vacuum gauge reads more than 400 mm Hg when the engine speed is 900 rpm 3 Raise the engine speed to about 2 500 rpm Make sure that when the throttle valve is fully closed sud denly the vacuum gauge reads 0 30 mm Hg and when the engine speed is lowered to 1 300 1 100 rpm the reading rises 10 more than 400 mm Hg Fig TA 88 Checking of coasting valve When vacuum gauge readings are excessive check the following points 1 Check the current from the No control box to the cousting valve solenoid by ceferring to the pro cedure mentioned A E 10 2 Make sure that the solenoid operates properly 3 Make sure that there is no clogging in the va cuum relief passage connecting the vacuum chamber amd the air inlet pipe in the costing valve 4 sure that idling fuel flow is proper Pro per flow 20
233. o the pilot bearing a fool is not available use a spare main drive shaft S Match the murk on the pressure plate with the reamer hole of the flywheel and fit the securing bolts 6 8 Installing presiure plate assembly 6 the bolts to 20 mg 15 feb 7 Remove the centering tool and ting gear brake 8 Apply pease to the pivot pin and drive the release fotk imwatd 4o that the retaining spring of the fork fits to the pivot Install the release bearing and hook the return spring After installing check to that the relase bearing slides smoothly back and forth on the retainer wher operating the release fork 9 Install the transmission Care should be taken m order not to bend the clutch disk by allowing the transmission to bang 6 CLUTCH MASTER CYLINDER 6 1 Removing the Clutch Master Cylinder If it becomes necessary o remove the clutch master cylinder for repair or overhaul proceed as follows 6 2 6 1 Disconnect the fluid pipe at the clutch master cyl inder outlet 2 Remove the nuts that attach the clutch master cyl indet 10 the dmh panel 3 Pull the cluich master cylinder straight out and away from the dash panel 6 2 Disassembling the Clutch Master Cylinder disassembling procedures of the master cylinder after removing are as follows 1 Clean the outside of the clutch master cylinder thoroughly and drain the brake fluid 2 Remove the resev
234. od to the core If the current flows the rotor must be repaired or replaced 2 Fig 5 14 Checking of rotor ground Checking the diodes Diodes for use In the alternator are avialable in two different types the positive diode which allows cur tent to flow from the lead wire to the case but not from the case to the lead wire and the negative diode which has the opposite properties To check read the resistance between the lead wire and case with a tester Then reverse the tester leads and note the reading IF both readings are very low or high the diode Is defective A good diode will give one low reading and one high reading Note The diode and heat sink are serviced as assembly only Fig 5 16 Checking of dinde d Checking the brushes The brush should be replaced when one third of its original length is worn The wear limit line is mark ed on each brush surface for warning The standard tension of the brush spring is 350 gr 125 oz f the tension is too low or if excesive corrosion exists the spring must he replaced Checking the bearings There is no need of lubricating as the bearing is pre lubricated In a long spell of use when the bearing is worn or damaged replace it with a new 5 E 5 Assembling the Alternator Assemble the alternator in the reverse order of dis assembling noting the following point 1 When installing the rotor assembly to the rear hous ing and stato
235. of Pedal Height The standard fitting position of the brake pedal is about 20 mm 0 8 in from the toe board insulator shown in Fig 11 2 This adjustment made by loosening the lock nut and turning the stop lamp switch After adjusting tighten the lock mut 11 2 Adjusting of Free Play There should always be 5 to 15 mm 0 2 to 0 6 in free pedal travel before the compensating port is clog ged by the piston cup in the master cylinder To adjust the free play loosen the lock nut and tum the master cylinder push rod connected to the brake pedal After proper adjustment is obtained tighten the lock nut 11 8 BRAKE MASTER CYLINDER 11 1 Removing of Broke Master Cylinder If it becomes necessary to remove the master cylinder for repair or overhaul proceed as follows 1 Disconnect the fluid pipes at the brake master cyt inder outlets 2 Loosen the nuts that attach the brake master cyl inder 10 the power brake unit 3 Pull the master cyhnder straight our and away from the power brake umit Fig 11 1 Removing of Brake Master Cylinder 11 2 Disassembling of Brake Master Cylinder 1 Clean the outside of the master cylinder thoroughly and drain the brake fluid 2 Remove the reservoir from the cylinder Remove the dust boot from the cylinder 4 Using a suitable plier remove the snap ring and remove the stop washer S Remove the primary piston spacer piston cups spring seat and return spr
236. oir tank from the cylinder 3 Remove the dust boot from the cylinder 4 Remove the piston stop wire with a screwdriver and remove the stop washer 5 Remove the piston piston cup and return spring from the cylinder Fig 6 7 Clutch master cylinder 1 Boot 3 Cylinder body 1 Stop wire 9 Reserve tank 3 Stop usher 10 Washer 4 Piston 11 Muy 5 Spacer 12 6 Primary cup 13 Cop 7 Piston spring 6 3 Checking the Clutch Master Cylinder 1 Wash the puris in clean alcohol or brake fluid Never use gasoline or kerosene 2 Check the piston cup and replace if they are dam aged worn softened or swelled 3 Examine the cylinder hore and piston for wear roughness ar scoring 4 Check the clearance between the cylinder bore and the piston If it is more than 015 mm 0 006 in teplace the cylinder or piston 5 Ensure that the compensating port on the cylinder s open 6 4 Assembling the Clutch Master Cylinder 1 Dip the piston and cups in clean brake fuid 2 Install the reservoir tank 3 Insert the return spring into the cylinder 3 Install the primary piston cup so that the Oat side of the cup faces the piston 6 3 Fit the secondary cup onto the piston and install them in the cylinder Install the stop washer and stop wire 7 Fill reservoir half with brake fluid and operate the piston with screwdriver until the fluid is ejected at the outlet 8 Install the dust boo
237. on valve is operated by the difference of the pressure between the intake manifold and en gine air space Fig 14 33 Ventilation valve operation 1 14 When there is no difference of the pressure engine at stall condition or the pressure of the intake mani fold is more than that of the engine air space back fire the ventilation valve closed by the tension of valve spring as shown in Fig 1A 33 If there is large difference at engine idle or decele ration the high vacuum of the intake manifold over comes the tension of the valve spring and the valve is pulled towards intake manifold side by the mani fold vacuum as shown in Fig 1 34 Therefore the air passes through the restricted passage in the valve Fig 14 34 Ventilation valve operation When the difference is small at normal operation the valve is balanced by the tension of valve spring and intake manifold vacuum This increases the flow of blow by gas Fig 14 35 Ventilation valve operation EVAPORATIVE EMISSION CONTROL SYSTEM This system prevents emission of fuel vapor generat ed by the ambient temperature around the fuel tank when the car is running or standing The fuel vapor rising from the surface of fuel the fuel tank due to the ambient temperature is chan meled into the condense tank and then fed back the fuel tank when the engine not canning Any fuel vapor that hes not condensed in the conde
238. ontains high compression gas If it is found to be defective replace it as an assembly 2 Check the coil spring for signs of fatigue cracks or any damage 13 8 13 3 Check the rubber seat rubber bush for weakness at the rubber cushion 4 Check the set plate spring seat for crack wear and damage If necessary replace with new one Fig 13 29 Rear shock absorber assembly 1 Coll spring 6 Rubber stopper 2 Rear shock absorber 7 Spring seat upper 3 Retainer 3 Rubber seat 4 Rubber bush 9 Adjusting shim 5 Set plate 13 0 4 Assembling of Rear Shock Absorber Assemble the rear shock absorber the reverse order of disassembling noting the following point 1 Adjust the vehicle height by using the proper com bination of the coil spring and adjusting plate The springs are available in three sizes according to the strength of the springs Coll spring identification Lond required to reduce spring engi from 371 mm 14 61 279 206 6 ky 61S 631 f possible use springs with the same identification matk on both sides 13 0 5 Installing of Rear Shock Absorber Install the rear shock absorber the reverse order of removing noting the following points 1 The rear shock absorber should be installed by mak ing the protector face toward the front of the vehicle AA ot the vehicle Fig 13 30 Lower of rear shock absorber 13 9 2 Tighten
239. oper operation 12900 19 vacuum mitch tor proper operation 12000 20 Check choke switch for proper operation 12000 Chek No 1 and No 2 conto boxes for proper operation P mas 12000 22 Check ventilation hoses for leakage and deterioration 12006 23 Check fuel hows of evaporative emission control system for Correct or 24 leakage and deterioration 12 000 Check charcoal ilr for proper operation Replace as 12000 Check pump stake Adjust necessary Summer and winter Check sir SW lever or prope position Summer and winter mno choke for proper operation Adjust 1200 28 Check nition coll for proper operation Replace as required 12 000 JA E MAINTENANCE PROCEDURE This section explim the predures for checking adjusting and replacing ihe of the RX 2 air pollution contiol systems 1A E 1 Air Pump Checking of air pump 1 Check to see that air hoses are free of air leaks 2 Anach a pressure gauge as in Fig 1 39 Fig 14 29 Checking of air pump 3 Run the engine at idle speed If the pressure gauge reading is 0 026 0 053 kg em 0 37 0 75 Ib in the air pump is normal b Removing of air pump 1 Remove the air cleaner 2 Remove the V belt of the pump 3 Remove the air hoses from the air pump 4 Loosen the air pump bolts and remove he air pump c
240. or Ventilation air EED Fresh ar fuel vapor AM blow by qus TS Cs Fig 1A 38 Evaporative emission contro system 1 15 1 JA D MAINTENANCE SCHEDULE Maintenance schedules are shown in the following table Ne Maintenance operations Remedies Mies and distribuon pott gap oe duel angie and If 4900 surface a aust fe plat 3 initiat nition timing Adest a 4 m Check mixture and level awo Check for proper operation Rephoc as requimd 4000 7 Chek r pump tension Adjust necessary s Check air hous and vacuum sensing tubes for deterioration Connect or ani 1200 Check ate pump for proper operation v required 12000 check valve for proper D 12000 Check aie control valve for proper operation 12000 gno coasting for proper 12000 Check antvaterburn valve for proper operation E 12 000 14 Check ate supply valve or proper operation 12000 15 Check ventilation salve for proper operation 12000 16 Check thermal reactor for proper operation 12000 Check thermedetcctne for proper 12000 Check No 1 umd No 2 thermosenrs for pr
241. orm shaft and there is roughness the nut and worm shaft assembly should be replaced Note The worm shaft and ball nut are serviced as an assembly only i Fig 10 5 Worm and bill nut assembly 2 Check the worm bearings and cups for wear or any damage If defective replace with new ones 3 Check fit of the sector shaft in the bushes of the housing 1f the bushes are worn replace with new ones 4 Check the oil seal for wear flaw or any damage If there is any possibility of oil leakage replace the seal 10 STEERING GEAR ASSEMBLY 1 Insert the worm shaft and ball nut assembly into the gear housing 2 Install the end cover with the preload adjusting shims and adjust the worm bearings preload to 1 0 to 4 0 emkg 0 9 to 3 5 inib by following the 10 2 10 procedure in Par 10 1 Fig 10 6 Installing of end cover and shim 3 Install the adjusting screw into the slot at the end of the sector shaft Check the end clearance with a feeler gauge and adjust this clearance to be 0 02 to 0 08 mm 0 0008 to 0 0031 by inserting appro priate shims The shims afe available in the following four thicknesses 1 95 mm 0 077 in 2 00 mm 0079 in 205 mm 0081 230 mm 0 083 i Fig 10 7 Checking of end clearance 4 Turn the worm shaft and place the rack in the center position of the worm in the gear housing Insert the sector shaft and adjusting screw
242. ot should be replaced with new ones every time repair work is carried out on the brake caliper 11 0 4 Assembling and installing of Caliper 1 Apply clean brake fluid to the cylinder bore and piston 2 Install the piston seal 3 Install the piston carefully into the cylinder bore Fig 11 22 Installing of piston 4 Fit the boot to the caliper 5 Install the caliper in the reverse order of removing 6 After installing bleed the brake lines referring to 11 G 1 1 7 11 0 5 Removing of Brake Disk Before removing the brake disk check the lateral run out of the brake disk as detailed in Par 11 D 6 1 Raise the vehicle and remove the wheel 2 Remove the bolts attaching the caliper assembly amd remove the caliper assembly from the brake disk 3 Remove the grease cap split pin set cover and bearing adjusting nut 4 Remove the thrust washer and outer bearing the wheel hub 5 Slide the wheel hub and brake disk assembly off the spindle Fig 11 23 Removing of hub and disk assembly 6 Place the wheel hub and brake disk assembly in the vise equipped with soft jaws 7 Mark the position of brake disk and wheel hub Fig 11 24 Applying of identification marks 8 Remove the attaching bolts and separate the brake disk from the wheel hub Do not drive it off 11 0 lt Inspecting of Brake Disk Inspect the friction surfaces of the disk and recon dition if they are scored scrached
243. ound replace the rotor housing 2 Check for traces of gas or water leakage along the inner margin of each side face of the rotor housing b Cleaning the rotor housing 1 Remove the sealing agent by wiping with a cloth or brush soaked im a solution of ketone or thinner 2 Remove carbon from the inner surface of the rotor housing by wiping with cloth Soak the cloth in a solution of ketone or thinner when it i dif ficult to remove 3 Remove deposits and rust from the cooling water passages Inspection of rotor housing distortion Measure the distortion of the rotor housing surface at the position shown in Fig 1 4 by using a straight edge and a feeler gauge Replace the part with a new one if the distortion found to be more than 0 04 mm 0 002 in Note This operation should be done at any time when overhauling the engine d Measuring the rotor housing width Measure the width of the rotor housing at points close 10 the trochoid surface by using a micrometer Measurements must be taken at least 8 points If the difference between the maximum value and the minimum value exceeds 0 08 mm 0 0031 in the rotor housing must be replaced with a new one as there Is a possibility of gas or water leakage The standard width of the rotor is 70 00 mm ur 27559 Q 0008 in Note This operation should be done when the trou ble such as overheating ete has been occurred on engine 1 C 5 Rotor Inspection
244. ow outs Check the inflation pressure with a reliable gauge when the tires are cold The standard pressure is as follows After checking or inflating the pressure place the valve cap back on and tighten by hand It helps to maintain the air pressure in the tires in case of any valve leak and keeps dust and water out of the valve 12 8 TIRE ROTATION To equalize wear and make a set of tires last longer it fs recommended that the tires be rotated as shown Fig 12 3 every 6 000 km 4 000 miles When rotating the tires check for signs of abnormal wear and bulging and any stone nail glass etc should be removed Fig 12 3 rotation 12 CHANGING OF WHEELS 1 Remove the wheel cap and loosen the wheel attach ing bolts bolts are right handed screws which are loosened by tuming counter lockwise 2 Jack up the vehicle until the wheel clears the ground 3 Remove the wheel attaching bolts and change the wheel 2 3 4 Install the wheel attaching bolts and alternately tighten the diametrically opposite bolts until the wheel closely touches the hub flange 5 Lower the vehicle and firmly tighten the bolts to a torque of 9 5 70 fb 6 Refit the wheel 12 D WHEEL AND TIRE RUN OUT Wheel and tire should be measured for both radial and lateral run out The radial run out is the difference between the high and low points on the tread of tire while the lateral ru
245. ox wrench flywheel 49 0823 300 Flywheel puller 49 0815 310 Clutch disk centering tool 5619 9 100 limit gauge corner seal gloove 5870 94 Jig corner seal gloove 363 9 180 Reamer corner seal gloove MAZDA RX 2 1971 AIR POLLUTION CONTROL SYSTEMS AIR POLLUTION CONTROL SYSTEMS A A EXHAUST EMISSION CONTROL SYSTEM IA Air Injection System M Air pump 1A Chock valve Ale injection nozzles JA B 1 1A D 1A E 1A G TECHNICAL DATA ENGINE TUNE UP Air control valve Thermal react JA A 2 Ignition and Air Thermosensor b Vacuum switch Control box and 1A A 5 Decelerution Control System 4 Antiafterburn valve b Cousting valve t Throttle positioner d supply valve and lag relay IA VENTILATION SYSTEM 1A B l Ventilation Valve 1 2 Separutor EVAPORATIVE EMISSION CONTROL SYSTEM IA 1 Canster 1A C 2 Condense Tank TA C 3 Check Valve MAINTENANCE SCHEDULE MAINTENANCE PROCEDURI lA E Air Pump 1A E 2 Check Valve IA E 3 Air Injection Nozzle 4 Thermal Reactor 1 5 Aw Control Valve 6 Thermosensor 1A E 7 Vacuum Switch lA E amp Control Bos 1A E 9 Th mmodetector 1 10 Antiafterburn Valve 1A E 11 Coasting Valve 1A E 12 Throttle Positioner IA E 13 Air Supply Valve 1A E 14 Time Lag Relay 1A E 15 Ventilation Valve 16 Canister p
246. p is pushed forward by a return spring Then the fuel in the float chamber is sucked up into the accel erating pump diaphragm chamber through the inler check valve When the primary throttle valve is opened the dia phragm is pushed backward the inlet check valve is closed and the outlet check valve is opened Then the fuel in the accelerating pump is sprayed through the pump nozzle to the venturi g Choke circuit For easy starting and warmingup the mixture ratio of air and fuel Is controlled by the choke valve The choke valve is am offset spring loaded type and prevents excessive choking When the choke valve is fully closed the throttle valve automatically opened to 15 by the choke connecting rod so as to obtain the most suitable mixture for startingup of the engine h Step circuit The step circuit corresponds to the low speed cir cuit of the primary barrel and improves the connec tion between the primary and secondary barrels fueflow in the secondary slow jet is mixed with air from the secondary slow ait bleed passes through the secondary low speed passage and is ejected through bore located near the fully closed position of the secondary throttle valve 1 Secondary high speed circuit The secondary high speed circuit corresponds to the primary high speed circuit The secondary throttle valve is constructed so as to react to negative pressure in the venturi The vacuum jets are provided in the venturi s
247. pect the front wheel bearing adjustment and correct if necessary 3 Inspect the wheel and tire run out and balance 4 Inspect the ball joints of the front suspension and steering linkage for any excessive looseness 5 The vehicle must be on level ground and have no luggage or passenger load 10 1 2 Toein is the difference in the distance between the front wheels measured at the front and at the rear of the tires the standard toein is 4 to 2 mm 0 16 to 0 08 in Check and adjust the toein as follows 1 Raise the front end of the vehicle until the wheels clear the ground 2 Taming the wheels by hand mark a line the center of each tire tread by using a scribing block 3 Measure the distance between the marked lines at the front and rear of the wheels Both measurements must be taken at equal distances from the ground It the distance between the wheels at the reat is greater than that at the front by 4 to 2 mm 0 16 to 0 08 in it is correct 10 Fig 10 16 Tom If it is found to be incorrect adjust the toein by loosening the lock nuts and turning the tie rods The tie rods threaded with right and left hand threads to provide equal adjustment at both wheels 10 1 3 Camber Caster and King Pin Inclination The camber caster and king inclination are not adjustable These are set properly in production and will not be tered in normal driving unless the vehicle is involve
248. plug 6 2 Detects Conditions of Trouble and Causes of Defects Related to Each System Repair and replace Adjust Replace Replace Replace Replace Replace Air control valve Possible troubles Comespomded item Number of vevolutions during idling decreases 2 Emission during idling becomes unfavorable D Emission during acceleration becomes unfavorable A Emission during crating becomes unfavorable 5 Emission during deceleration becomes unfavourable 6 Damage is liable 10 occur on reactor 7 Rough engine king Conditions of trouble of system Corresponded Hers A Remains constantly open air inject P B Remains constantly closed cut a C Excessive air leakage from valve D D Safety valve _remuins constantly open doo Probable causes Defective No control box b Defective air control valve No 1 thermosensor Possible troubles Conesponded Exhaust emission becomes abnormally unfavourable 2 Possibility of the reactor being damaged is great 3 Penalty in fuel economy 4 Power drop 1 Conditions of of system Cormesponded Tralling dees nor cut off im driving ranges other than ling deceleration wide throtike at normal temperature cold 14 plugs Trailing semains constantly aff jn driving ranges other than idling deceleratio
249. r T amp LY 20 hours rate Negative Fully charged 1 26 Recharge at 1 20 01454006 mm 0 01820 002 in 0 575 0 075 kg 1 27017 0 27 20 007 Stat 0 at 500 ter uf dis 1 S at 1500 rpm of dia Start 0 500 rpm of dis Max 6 1700 rpm uf din Tanding Duell mgle Finng onec lenit ting Masking Spark plug type and Hot type Braki epring tension Magnet switch operating volt ae Altermior Grouod polarity Reted output Numer of No lind Leal eat Brwh spring remeare Slip ring diameter Ratio of altemator ud eccent tie shade Regulator Canta sltoge seloy Regulated volage without dosd Fenat tuna signal amp vide hamp Side van ngpa lamp Fog lamp Imerias lamp Step lamp Glove competit lump Tum signal lump Crear Stop til amp lamp Licence lamp EE ET Mix 11 at 400 mmHg m Trailing AT Lending Eccentric shalt pulley NGK BEE 0 8 0 9 mm 0 01 0 009 in W20EG2 0 8 0 9 mm 0 031 0 088 ie B 7EJ 0 80 9 mm 0 91 0 085 in 0 081 0 085 in Demo W2SEG2 0 8 0 4 mm 0 110 005 in 10 KW Voltage EV Curent i Less than POA at 3 600 rpm oF mote Voltage Current 0 it Tome 2 7imky 09 5 fi V3 ke YN Voltage al 1 080 pm wr lee Current 0A Voltage an 2 209 ipm rim Current 32A har 12 5 o 33 mmz0 2
250. r mostat opens when the engine is warmed up the water flows into the radiator The cooled water lows from the radiator 10 the water pump through the connecting hose and cools the engine by circulation 3 1 3 8 GENUINE LONG LIFE COOLANT The genuine long life coolant is used the cooling system of RX2 The genuine long life coolant was developed for the aluminum engine of RX 2 Antifreeze solution and anti corrosive solution are included in this coolant table below shows the mixing rate of water and genuine long life coolant Follow the table when chang ing the coolant Mixture Ratio Specific Gravity of Freeding Point Coolant Water Mixture at 20 facer 6s 1051 ACA ss as 1078 Note If the genuine long life coolant is not available add genuine untifreeze solution or anticorrosive accord ing to the season Freezing point mixture percentage Specifix gravity Aci of mixture at uno eater 15 8 1 022 20 1 029 as 25 1037 7 1044 E Lost Toss 45 55 106 0 so 1073 ss as Low 3 3 C FLUSHING THE COOLING SYSTEM When the genuine long life coolant is in use the cool ant should be changed every wo years ro every 48 000 km 30 000 miles At the time of the coolant change the cooling system should be cleaned as fol lows 1 Open the drain cocks to drain the coolant 2 Close the cocks Fill wit
251. r assembly hold the brushes in position by inserting a piece of stiff wire into the hole of the brush through the housing shown in Fig 5 16 Fig 5 16 Imtalling of rotor aisembly 5 F REGULATOR 5 F 1 Checking the Constant Voltage Relay To check use an almost fully charged battery and connect a voltmeter between the A and E termi nals of the regulator us shown in Fig 5 17 Then hold the alternator revolution to 4 000 rpm engine revolution 2 000 rpm and take a reading of the voltmeter If the reading is from 13 5 14 5 volts it is in proper order If it is not within the spec cations the voltage relay must be adjusted ss structed in 5 2 Fig 5 12 Checking uf constant voltage relay 5 F 2 Adjusting the Regulator First check the ait gap back gap and point gap with a wire gauge 5 1 they not within the specifications adjust by bending the stationary contact bracket After correct gaps are obtained adjust the voltage setting Bend the upper down to decrease the voltage s t ling up to increase the voltage setting In case of the pilot lamp relay if the voltage when the lamp lights up is adjusted 10 the specification the voltage when the lamp goes out may be with in the specification Fig 5 18 Adjusting of regulator Constant voltage relay Adjustment Standard specification Ait gap 07 1 1 mm 0 028 0 043 in Point gap 03
252. rded advance amd the phase angle is 10 degrees And as the retarded side contact point is not provided with the vacuum advance system TA A 3 Deceleration Control System The deceleration control system consists of am anti afterburn vulve a coasting valve am idle switch an air supply valve and the No control box which is common to the ignition and flow control system It prevents afterburo during deceleration and gear shifting and immediately after the engine is switched off Ant The anthafterburn valve prevents afterburn by sup plying air into the intake manifold during decelera tion and gear shifting and immediately after the en gine is switched off The antiafterburn valve operates by pressure dif Sara gt Metri seen SS he Fig 1A 22 Antiafterburn valve cross section 14 10 ference between the ait and vacuum chambers and the spring force The operating time in this 1 0 7 sec when the pressure difference is 400 mm Hg The intake manifold vacuum rises during deceleration and gear shifting and the pressure difference between the two chambers opens the valve connected to the diaphragm vo that fresh air from the iur cleaner is 1A led into the intake manifold to correct overrich mix tore thus preventing afterburn During normal running condition the soleno
253. replace as required 12 000 22 Check thermal reactor for proper operation replace at required 12000 1 1A E MAINTENANCE PROCEDURE This section explains ihe procedures for checking adjusting and replacing the parts of the RX 2 air pollution control systems TA E 1 Air Pump a Checking of air pump 1 Check to see that air hoses are free of air leaks 2 Attach pressure gauge ax in 1 36 Fig 36 Checking of am ump 3 Run the engine at idle speed If the pressure gauge reading 0 033 0 046 kg em 0 47 0 65 Ib in the dir pump is normal b Removing of air pump 1 Remove the ait cleaner 2 Remove the V belt of the air pump 3 Remove the air hoses from the air pump 4 Loosen the air pump bolts and remove the air pump c Installing of air pump Mount the ait pump im the reverse a quence and adjust the tension of the in the procedure described below 9 Adjusting of sir pump V belt Pull the air pump away from the cngine until the Vb assumes proper tensions A proper lever should be used m adjusting Fig 14 37 Checking ot bell When 10 kg 22 1b pressure is given 0 a spot mid way between the air pump pulley and water pump pulley belt deflection should be 9 11 mm 0 35 0 43 in when new the belt should have a deflection of 7 9 mm 0 28 0 35 in TA E 2 Ch
254. replace the spark ing characteristic of each distributor should plug Fig JA 67 and 1 68 4 Inspect each spark plug for make and heat range spark plugs must be of the same maker and Checking of contact point gap number or heat range If spark plugs shown burning Check adjust the contact point To check the white or rapid electrode wear replace with cold distributor drive shaft which contact arm rubbing block is at the top of the Check the point gap with a feeler gaug should be 0 45 mm 0 018 inl point gap rotate Do use spark range type spark s not specified Fig 70 Adjusting of point gap 7 Check the cam dwell angle with a tester The dwell angle should be 55 to 61 If the dwell angle was below the specified amount the contact Fig 71 Adjusting of electrode xap gap i 100 large 17 the dwell angle was above the specified amount the cantact point gap ts 100 small 1 20 Spark Plug Spark plugs are of a standard type and cold type as shown in the following table Standard anl NGK 09 mm 0051 0038 in 09 m 0 031 0 035 ij NIPPONDENSO W CHAMPION Nine UA 09 4001 0 035 inj Fig YA 2 Adjusting of electrode gap 1 21 Ignition Coil Checking of ignition 1 Chec
255. retaining collar onto the axle shaft using the bearing replacer 49 0259 745 until it is firm contact with the bearing inner race 49 0289 745 Fig 9 4 Installing of bearing collar Note If the bearing retaining collar is press fitted with less than 3 tons 6 600 Ib replace the collar with a new one 9 3 Installing of Rear Axle Shaft 1 Apply grease to the seal located n the axle housing 2 Check the rear axle shaft end play as follows Install the backing plate temporarily and measure the depth of the bearing seat in the axle housing using depth gauge as shown in Fig 9 5 Fig 9 5 of depth Then measure the width of bearing outer race The difference between the two measurements indicates the required thickness of the shims The maximum permissible end play is 0 1 mm 0 004 im Shims are available in thickness of 0 1 mm and 04 mm 0 004 in and 0 016 in X are 1 0 Fig 9 6 Clearance of backing plate and housing 1 Spacer 4 Bearing 2 Axle cating 5 Ott seal 3 Axle shaft 6 Collar 3 Install the rear axle shaft assembly and shims through the brake backing plate to the rear axle housing so as to ft the splines of the differential side gear and the end of the axle shaft Tighten the nuts 4 Install the brake shoe assembly 5 Install the brake drum and the wheel 9 REAR AXLE REMOVAL 1 Jack up the vehicle until the rear wheels are clear o
256. rpm und that there is air leak from outlets a 6 Remove the solenoid terminal Make sure that the pressure gauge reads 0 0 025 kg em 0 0 36 Ib in and that air flows from outlet of the air control valve and air does not flow from outlet fj b Removing of air control valve 1 Remove the air cleaner 2 Remove the wiring to the solenoid 3 Remove the ait hoses from the ait control valve 2 Loosen the nuts and remove the air control valve c Installing of air control valve Install the ait control valve in the reverse sequence 6 Thermosentor a Checking of thermosensor 1 Make sure that there is no boot breakage or wax Fig 1A 3 Checking of thermosensor 1 leak 2 Connect the ohm meter as in Fig A 43 and check the resistance Reading of under 200 indi cates that the thermosensor is normal Removing of thermosansor Remove the air cleaner Remove the starting motor Remove the thermosensor connector Remove the boot Loosen the nuts and remove the thermosensor no Installing of thermosensor Install the thermosensor in the reverse sequence TA E 7 Vacuum Switch Checking of vacuum switch 1 Remove the cap of the leading spark plug distri butor 2 Remove the vacuum sensing tube from the vacuum advancer of the leading spark plug distributor then attach the vacuum gauge in its place as in Fig 1A 44 Fig 1A 44 Checking of vacu
257. sengage the release bearing and to prevent unnecessary wear nd possible slippage This clearance ts obtained when ree play of the release fork Ws adjusted to 3 0 0 12 in To adjust remove the return spting th lock nul and the adjusting nut until the correct play is obtained Alter adjusimg securely tighten the lock nut and hok the return spring 6 CLUTCH REMOVAL To remove the clutch from the vehicle proceed as follows 1 Remove the transmission as detailed in Par 7A 2 Install the ring gear brake 49 0820 060 3 Loosen the bolts holding the clutch cover assembly to the flywheel and remove the clutch cover assembly and the clutch disk 4 Loosen the nut that attaches the flywheel to the eccentric shaft Remove the flywheel 5 Remove the return spring for the clutch release bearing and slide off the release bearing 6 Pull the release fork outward until the retaining spring of the fork releases itself from Ihe pivot pin Remove the fork from the clutch housing 6 0 CLUTCH INSPECTION 6 D 1 Checking the Release Bearing Check the release bearing by turning the bearing race by hand Replace it If any abnormal poise or roughness is felt when turning Examine the front cover of the transmission careful ly to be certain there are burrs on the puter sur face of the front cover which pllots the release bear ing Check the release fark for crack or bend
258. specific gravity of the electrolyte reaches 1 25 1 27 b Fast charge fast charge causes both the temperature and the level of the electrolyte to rise suddenly it does not have a favorable effect on the battery Therefore this should not be performed unless in the case of an emergency When a fast charge is being applied with the battery mounted the vehicle ensure that the cables are removed from the battery terminals before the charge is applied If this is neglected it could cause a damage to the diodes on the alternator The battery should be kept by the use of cooling water to prevent the temperature of the electrolyte from exceeding 45 C 113 F otherwise the charging should be discontinued temporarily when the temper ature rises above this point 5 B SPARK PLUG The two spark plug system is adopted on RX 2 for increasing the combution efficiency There are three kinds of heat range for genuine spark plugs as follows so that they can be used under the driving area or running condition MANUFACTURE HOT STANDARD COLD NGK B 63 ee B 56 Denss 0 EGR Wil EC3 Wis EGI As these spark plugs are designed specially for RX 2 do not replace these with any of other types ot spark plug 5 B 1 Checking the Spark Plug Check the spark plugs for burned and eroded elec trode black deposits fouling and cracked porcelain Clean the spark plugs with spark plug cleaner
259. specting the switch point After the switch assembly is attached to the body place the dial indicator on the diaphragm shaft as illustrated Move the diaphragm shafi by hand and see whether the point of the switch assembly opens and closes at a distance of 0 5 1 0 mm 0 020 0 039 in from the end of each stroke of the shaft Dial Fig 4 14 Checking of switch If defective adjust in either of the following two ways of whitch the methoed 1 is for a big adjustment and the meihoed 2 is for a small one 1 Adjustment with washers If the point opens too early or closes too late de crease the number of washers at the tip of the shaft IF It opens too Jate and closes too early increase the number of washers There are two types of adjusting washers 025 and 06 mm 0 010 and 0 024 2 Adjustment with stoppers If the point opens too early bend the upper stopper upward IF too late bend the stopper downward If the closing action of the point too late bend the lower stopper upward If too early bend it downward Actually when the point opens early the closing position becomes late When the opening position is late i must close early Then it is necessary to the upper and lower stoppers simultaneously The point gap is 1 0 mm 0 039 in when the points are opened Fig 4 19 Point gap 4 FUEL FILTER The fuel fier Is of the cartridge type with an in tegrated element
260. st Chan Adjust and replace See 1A E 13 Replace See 1A E 10 See IA E 23 Adjust Repair and replace if necessary Repair and replace f necessary See 1 14 Replace Clean and replace 1232 Symptoms and probable causes Remedies 10 Afterburning Extremely annoying afterburning occurs during dectlera sion Afterburning occurs when tuming off the ignition switch 1 Air supply valve nol opening properly Replace 2 Antiafieiburs valve not opening properly Replace 3 Coasting valve oat opening property Replace 4 Rich idle mixture 5 Gat teak from exhaust system 6 Too low idle revolution Over Now from carburetor 1 biting into needle valve 2 Improper seating of needle valve 3 Improper movement of float 4 Lame fuel pressure of electric pump 12 The engine brake 4 not work aven if the accelerator pedal re ned Even If the accelerator pedal is telened when ranting the engine btake does not work which causes the over Tunsing and makes the driver uneasy 1 Improper returning of carburetor primary throttle valve 2 Improper returning of carburetor secondary throttle vae 13 The air jew out from the fall pipe for the forced cooling during 1 improper operation of ait control valve 2 Electric current not Mowing fromthe No control box to air com trot valve through opener switch 14 The leading side Ignition is retarded when idling 1 Defective N
261. stem secondary air required for re igniting the exhaust gas Fig 1A 3 Air pump cros section b Chock valve The check valve opens and closes according t the pres sure difference between secondary air and exhaust gas to prevent exhaust gas from backflowing into the air in jection system and scorching the ait pump hoses ete When the pressure of secondary air in the air in jection system exceeds the exhaust gas pressure the secondary air opens the check valve and flows through the air injection nozzle into the exhaust port When the secondary air pressure drops lower than the ex haust gas pressure due to failure of the air pump V belt breaking of the secondary ait hose etc the check valve closes 10 prevent the backflow of the exhaust gas into the air injection system J st alen nozzle Check valve ake To theron reactor An char 5559 SI To coasting valve Fig TA 4 Check valve cross section Air injection nozzles The air injection nozzles are attached to each of the front and rear rotor housings The secondary air chan neled via the air pump and the check valve is inject ed through the nozzle into the exhaust port adjacent to the thermal reactor Fig 1 8 Air injection d Air control valve The air control valve contains three valves the air cut valve and the relief valve which control the a mount of secondary air and thermal re
262. surface the synchronizer ring and the cone surface of the gear apply a thin coat of Prussian Blue ou the cone Surface of the gear and fit the ring to it Fig 7 6 Inspecting synchronizer ring The contact should be ev aid uniform over the contacting surface If the contact i one sided or spotty this must be corrected If the amount of correction is small this may be done by lapping the surfaces lightly together with compound I the defects are excessive replace the synchronizer ting or the gear 2 Even when the synchronizer ring seats well on the gear cone if the ring is wom to the extent of no oil grooves remaining on its inside synchronization not be obtained 7 It is necessary then to check extent wear of the vorm ot ring For this uniformly fit the ring to the gear corn and measure clearance A between the side faces of the ring teeth and gear teeth with u feeler gauge The standard clearance is 1 6 mm 0 06 in If the clearance is less than 0 8 mm 0 031 jn it is an indi cation of excessive wear of the com or the internal surface of the ring In such cases check the corn and ring and replace the defective part with a new one Fig 7 7 3 Check the synchronizer key the inner surface of the clutch sleeve and the key groove on the clutch hub for Wear If wear is excessive it will cause difficulties in maintaining the neutral position of the clutch sleeve will c
263. suspension arm with the ball joint remover and installer 49 0259 860 Note If the pressure necessary to press in the ball is less than 1 500 kg 3 300 Ib the suspension arm should be replaced Fig 19 26 lostalling of ball joint 7 install the ball joint and suspension arm t6 the knuckle arm and tighten the mit 10 6 5 mg 50 feb 13 D REAR SUSPENSION 13 0 1 Removing of Rear Shock Absorber 1 Remove the nuts attaching the upper end of the shock absorbgr from the luggage compartment 2 Remove the mut from the lower end of the shock absorber 3 Place the jack under the rear axle housing and raise the vehicle Then place a stand under the frame side rail 4 Gradually lower the jack under the rear axle housing and remove the rear shock absorber 13 27 Removing of tear shock shsorbet 13 0 2 Disassembling of Rear Shock Absorber Apply the identification mark the rear shock absorber before it i disassembled 2 Hold the shock absorber in vise 3 Using the spring holder 49 0 49 0223 641 compress the coil spring 4 Remove the lock nuts 640A and 43 0228 48 0223 6408 Fig 13 28 Compressing of spring 13 D 3 Checking of Rear Shock Absorber 1 If excessive amount of is evident on the exterior of the shock absarber the shock absorber should be replaced with a new one Note The rear shock absorber should not be disus as it c
264. t temporarily with five bolts replace with new Pig 240 Assembling oll After removing the pump assembly from the torque converter tighten rbe bolts finally with specified orque 0 6 0 8 mkg 14 3 5 8 fb 4 H CONTROL VALVE ASSEMBLY The control valves are composed of the mast acurate of the mission part and so particular Also sinwe u number of similar mus be arranged in the order of disas a facilitate reassembly Remove 1 Loosen anal remove the bolts und nut that otrack the and remove rhe ln loosening the Amm bolt a box wrench should be used as much as possible although screw driver con be used 2 Dior wet the lower valve budy separme plate and upper valve body by removing rhe attaching belts as shown in Fig 2 41 When takihg out the separate plate be careful nnt to lose the orifice yheck valves and springs in the lower valve body 3 Take out the manual valve 4 Remove the side plate A then take out the 1 2 shift valve with spring the 2 2 shift valve with spin the 23 shift plug and the pressure modifier valve with spring ATT TT 1 Side plate sl Fig 2 41 Kemoving sevorate plate 5 Remove the side solenuid downshift valve backop valve with spring the 2 2 timing valve with spr 6 Remove ihe side plate pressure regulator plug sleeve pressure regulator plug spring seut
265. t at high revolution depress the accelerator pedal once or twice case the engine speed return to the normal speed this trouble is due to the faulty closing of the secondary throttle valve 6 Clean up the secondary throttle valve bearing of the throstle body Note Be attentive not to misun that thie trouble is due to the faulty closing of the coasting valve Fig 1A 78 Checking of secondary throttle valve 2 Fast idle adjustment When the choke valve is in choked position the pri Fig 1 70 Fast adjustment 1 Choke valve lever 2 Starting connecting 3 Starting throtite lever 4 Starting adjust lever Primary throttle valve mary throttle valve is opened 15 5 185 degrees When the choke valve is fully closed the clearance between the primary throttle valve and bore 1 17 156 mm 0 0461 0 0616 in Measure the clearance using a suitable wire gauge and if necessary adjust it by bending the starting adjust lever When the choke valve is closed 20 degrees the thrortie valve is opened more than 8 degrees and when the choke valve la fully opened the opening of valve Is under 2 degrees jeck the choke valve for smoot movement TA F EXHAUST EMISSION TEST PROCEDURE 1 Test Mode Idling emissions Regarding emissions during idling CO and HC are regulated but there is no regulation on NOx at present iReterence Regulation valu
266. t come apart 3 Apply primer on the entire circumferences of the bonding areas of the window glass and the body with gauze for the former and a brush for the latter and leave them to dry for 20 10 30 minutes See Fig 14 8 Apply us thin sealant coating as possible to The window glass b Don t allow amy dust water oil etc to get on the coating surface and also don touch the coating with hand UF the window glass which was removed is to be reused remove the sealant adhering to the glass to some extent with a cutting knife Then remove the remaining sealant with a cleaning solvent and wipe it clean with gauze 4 Bond each spacer to the body with bonding a gent Fig 14 10 shows the directions and positions of each spacer There ate two kinds of spacer indentified by color as shown below Tan No Num of Par Dios 70 448 Space 030 70 447A Spacer Black Although bonded on both the right and the left hand sides of the windshield glass in Pig 14 10 spacer on only one side of the glass should be sufficient 14 3 Fig 14 11 section of Fig 14 10 5 Insert each to the clip insertion portion in the manner shown in Fig 14 12 If any clip happens to be loose after it has been inserted replace with a new clip Spacer Fig 14 12 Inserting of clip 6 After the primer is dry apply the sealant so that 14 it is
267. t gauge is applicable 3 The dimension of the outer diameter of the limit gauge is as follows 171 00007 Goed 110 0009 mm 04351 1 00007 im 0044 00017 Notgoend 110 0044 mm 04351 00017 Reboring corner soul groove 1 Remove carbon rust and other deposits from the rotor surface especially the apex seal groove being careful not to damage 2 Install the jig 5870 94 152 the rotor and tighten the collect bar being careful not to damage the rotor bearing and apex seal groove 3 Ream hole with the reamer 5363 91 180 by hand applying sufficient engine oil as the coolant When feeding the reamer it must be turned by about 20 rotations or over before the reaming work is accomplished completely 4 Remove the reamer and jig from the rotor being careful not to damage the rotor Repeat the same manner as above to make other holes of the rotor 5 Thoroughly clean the rotor and check and com firm by visual inspection how the reaming hole of the comer seal is drilled through and if there is any damage to the rotor 6 Fit 200 oversize corner seal of which surface is hard chromium plated Check and comfirm whe ther the gap between corner seal and groove is under specification Note 1 When installing or removing the jig be careful not to hit the rotor 2 If the reaming is carried out without applying it will be difficult to obtain a proper surface roughness no matter how man
268. t to the cylinder 6 5 Installing the Clutch Master Cylinder 1 Install the clutch master cylinder assembly onto the dash panel and tighten the nuts 2 Connect the fluid pipe to the cylinder 3 Fill with brake fluid and bleed the clutch hydraulic system 6 G CLUTCH RELEASE CYLINDER 6 6 1 Removing the Clutch Release Cylinder 1 Disconnect the flexible pipe ut the chitch release cylinder 2 Unhook the release fork return spring 3 Remove the bolts attaching the cylinder to the clutch housing Remove the release cylinder 6 G 2 Checking the Clutch Release Cylinder Refer to Par 6 3 and inspect the clutch release cylinder L Gp 7 Adjust crew 2 Bleeder valve M Release rod 3 Steel ball 9 Piston Cylinder body 10 Secondary cup 5 Boot 1L Primiey cup 6 Lock nut 6 6 3 Assembling the Clutch Release Cylinder 1 Fit the cups to the piston and install them in the cylinder 2 Install the dust boot on the end of the cylinder 3 Install the steel ball and bleeder into the bleeder hole 4 Install the clutch release rod 6 6 6 4 Installing the Clutch Release Cylinder 1 Install the clutch release cylinder assembly to the clutch housing with two bolts 2 Connect the flexible pipe 3 Fill the reservoir of the master cylinder with brake fluid and bleed the system at described Par 6 H 4 Adjust the fiee play of the release fork as described in Par 6 B 5 Hook the return spring
269. te The line pressure at reverse range will be changed 10 these Figures marked near future Line Pressure Place the transmission in D 2 1 and R and check respective line pressure at engine idling amd stall conditions Compare the results with specified pressures to trace the cause of trouble Lino pressure test procedures 1 Warm up the engine to bring the converter oil to operating temperature Q0 100 C 1409 2129 2 Line pressure for range is taken out at an spection hole at the Jeft front of the transmisi ease and for D 1 ranges tbe inspection hole at the right rear Connect pressure sage to the inspection hole and put if where iris visible from the driver s seat Fig 26 tent A For line pressure in R range Far governar presure For libe pressure in forward ranges 3 Firmly chock the front and rear wheels and apply the hand brake as in the stall test 4 With the manual lever pat in the range to be checked run the engine at engine idling condition and read the pressure gauge 5 With the brake pedal depressed fully press the accelerator pedal gradually 10 the wide open position While checking whether tbe pressure rises smoothly read the pressure gauge at the stall condition test time from starting accelerator depression to its release must not exceed 5 seconds 6 Measure line pressure for each o
270. temperature gauge unit 10 Disconnect the high tension cables from the dis tributors and the spark plugs 11 Disconnect the wire of the pressure switch 12 Remove the water hoses from the engine 13 Remove the heater hose from the engine 14 Remove the oil hoses rom the front cover and rear housing of the engine and remove the oil hose clip on the engine mounting bracket 15 Remove the radiator upper shroud 16 Remove the altemator numeum TESTS LOG 35 KON RON TUE tw Fig 1 4 Engine performune carve 17 Remove the cooling fan from the eccentric pulley 18 Remove the starting molor 19 Remove the clutch release cylinder and place i the frame 20 Disconnect the exhaust pipe from the manifold 21 Remove the bolts securing the clutch housing to the rear housing of the engine 22 Remove the hot air duct from the exhaust mani fold 23 Support the transmission with suitable jack 24 Remove the bolts from each engine mounting For easy disconnection it is recommendable to re move the two small bolts on leftshand side and a large nut on right hand side as shown ih Fig 1 9 25 Install a suitable lifting sling on the engine hang er bracket of the front rotor housing Attach the sling to a hoist or other lifting device and take up all slack 26 Pull the engine forward until it clears the clutch shaft Then lift the engine from the vehicle 27
271. th five bolts to 4 0 25 0 mkg 29 36 ftib torque Insert the input shaft Note Above two end plays should be checked after the oil pump is properly installed and adjusted follow ing 16 and 17 16 Push the from clutch drum back and forth and insert thickness gauge in the clearance between the front elutch drum and connecting shell in order to measure the end play between the tear face of the il pump cover and the front face of the front clutch drum Select thrust washer from the following seven washers to adjust the clearance to specified 0 5 0 8 mm 0 020 0 032 in 1 50 mm 0 059 1 70 mm 0 057 in 1 90 mm 0 075 in 2 10 mm 0 089 2 30 mm 0 091 in 2 50 mm 0 038 2 70 mm 0 106 in eem 249 End plays 17 In measuring the total end play apply the dial muge on the of the input shaft und move the connecting shell fore und aft and read the needle vibration The standard clezrance is 0 25 0 50 mm 0 010 0 020 Adjust end play by selecting proper race in the followings 1 20 mm 0 047 in 1 40 mm 0 055 1 80 mmi0 063 in 1 80 mm 0 07 in 2 00 mm 0 079 in 2 20 mm 0 087 in Pig 2 50 Checking end play 18 Tighten the stem of the servo piston to torque of 1 2 1 5 mkg 8 6 11 0 ftib Then loosen it by two turns shd lock with the lock nut to a tightening torque of 3 0 4 0 mkg 22 29 ft lb
272. the following items described in 1 A oil level ailing speed downshift sole noid and kickdown switch iy manual linkage and ifj inhibitor switch Ji is meuningless to proceed to check orher items without checking the above items carefully In the case of the automatic transmission particularly there are a great number of troubles which be solved by inspecting und regulating the above items with the transmission mounted on the vehicle So do not remove of disassemble the transmission with oul checking such items first Also there are some troubles which require further detailed diagnostic test inchuding stall test roa test and hydraulic pressure test before removing the rans mission from the vehicle Such tests are described in HB trouble should prove vot correctable by inspec tion adjustments and repairs made wcverding to TROUBLE DIAGNOSIS CHART with the transmis sion installed that is if removal and overhauling wre indicated by diagnosis only then the transmis sion should removed and overhauled in the prov cedure mentioned later 1 A ITEMS TO CHECK AND ADJUST 1 1 TORQUE CONVERTER OIL Ol level check Pur the vehicle a level surface and move the shift lever through all driving ranges apply ing brake with the engine idling condition Then plac the lever in N or Insert the dipstick fully and take it out qichiy before splashing oil ad heres to the gauge and
273. the rear shock absorber attaching mut and bolt to a torque 11 m kg 80 trib 13 E FOUR LINKS 13 1 Removing of Upper and Lower Link 1 Remove the lower link attaching bolts and nuts and remove the lower link 2 Remove the upper link attaching bolt and nuts and remove the upper link Fig 13 31 Four 13 E 2 Checking of Upper and Lower Links 1 Check the links for crack or damage 2 Check the rubber bushes for weakness Fig 13 32 Upper and lower links 13 E 3 Installing of Upper and Lower Link Install the upper and lower link the reverse order of removing noting the following points 1 When installing the upper and lower link on body Fig 13 33 Tightening of links 13 13 LATERAL ROD 13 1 Removing of Lateral Rod 1 Remove the laters rod attaching nuts to the rear axle housing 2 Remove the lateral rod attaching mut and bolt to the body and remove the lateral rod 13 2 Checking of Laterat Referring to Par 13 2 ek the lateral sod 13 3 Installing of Lateral Rod Install the lateral rod in the reverse order of remove ing noting the following point 1 When installing the lateral rod the torque should be 11 mkg 80 ftib in unloaded condition If they are tightened in rebounding condition the height of the vehicle will get higher or durability of the rubber bushes will deteriorate SPECIAL TOOLS 49 0223 640A Coll spring holder A9 0223
274. the wire from B terminil of the alternator and connect the ammeter with the negative lead of the ammeter to the wire and the positive lead to the terminal as shown in Fig 5 9 2 Connect the positive lead of the voltmeter to the terminal of the alternator and ground the negative lead of the voltmeter 3 Switch the headlight on 4 Start the engine and take the reading of the ammeter and voltmeter holding the engine speed of 2 000 rpm alternator speed 4 000 rpm If the ammeter shows less than 32 ampares the trouble is in the alternator and if the voltagemeter shows without the specifications it is in the regulator Fig 5 9 Checking alternator 5 E 3 Disassembling the Alternator 1 Remove the nut attaching the radio noise suppres sion condenser and remove the condenser 2 Remove the nut attaching the pulley to the shaft and remove the pulley fan and spacer 3 Remove the through bolts 4 Separate the front housing assembly by prying apart with a screwdriver at the slots of the front housing 5 Remove the rotor from the front housing 6 Remove the front bearing retainer attaching screw and remove the retainer Support the front housing close 10 the bearing boss and press out the old bearing from the housing only if the bearing is defective 5 4 5 7 Unsolder the diode leads and stator leads 8 Remove the stator from the rear housing 9 Remove the screws t
275. then observe the level on the cold side of the dipstick when the engine 1 cold oF on the hot side when the engine i hot Be sure to check on the dipstick in either case with the en gine idling The level must be somewhere between Land F marks and never be outside the limits The engine s suid to be cold when the oil temperas ture is the order of 40 C 104 F which is reached by approximately two minutes of i at 1 200 rpm after engine is started and it is said to be hot when the oil temperature is on the order of 80 176 F which is attined by running the vehicle for about Skm 5 miles after engine is started eS Cow gt Vig 2 1 gouge Note 1 The recommended oil is Genuine Auromatic Transmission Fluid Dexron or Automatic Transmis sion Fluid Dexron of any make Do not mix with other type of automatic transmission fluid than mene tioned above 2 Periodic oil change ix mor nevemury but the oil level must be checked a1 least every 6 000 km 4 000 miles 3 The total amount of oil i amp 8 6 liters 11 6 u s pints 9 7 Imp pints 5 8 v s quarts and the diflerence bet ween the amounts shown by L and F marks on the dipstick ia about 0 4 liter 10 9 v s pint 0 7 Imp pint 0 4m s quart b leakage check When the oil level is lower than specified ndd it and at the same tme check carefully for possible leaks and repair any if found Note 1 Torqu
276. ther than the lund causing wear of damage h Inspecting the rotor bearing Check for wear flaking or scratches on the bearing If any of these conditions is found replace the bearing The bearing clearance be measured by taking the inner diameter of the rotor bearing and the outer diameter of the eccentric shaft journal The standard clearance is 0 05 0 09 mm 0 0020 0 0035 in Replace the bearing if it is more than 010 mm 0 0039 in 1 Replacing the rotor bearing 1 Insert the expander 49 0813 245 into the bearing to prevent the deformation of the rotor bearing when drilling a hole 2 Drill a hole of 3 5 mm 0 14 in diameter and about 7 mm 0 28 in depth in the locking screw which holds the bearing on the rotor And then remove the pander 3 Place the rotor on the support so as to face the internal gear upward Using the rotor bearing puller and installer 49 0813 240 without its adapter ring press out the bearing being careful not to damage the internal gear 4 If the bore in the rotor is damaged while remov ing the bearing finish the bore with emery paper and blow with compressed air 5 Place the rotor on the support as 10 face the internal gear upward Press fit a new bearing using the rotor bearing puller and installer 49 0813 240 with its adapter removed screws until the oil hole of the bearing matches the oil hole on the apex side of the Totor and the bearing and the boss become
277. this could cause steering instability in driving 1 Fit of the ball joints of the center link and those Of the tie rods 2 Looseness of the idler arm bushes 3 Looseness of the wheel bearings 4 Backlash between the sector gear and ball mut 10 8 STEERING GEAR REMOVAL 10 1 Removing of Steering Gear Separate type 1 Loosen the worm shaft attaching bolt aching bolt Fig 10 2 Steering gear 1 Oil seal 5 Buh 2 Bosh 6 shim 3 Sector shaft 7 Adjusting screw 4 Rousing 8 Side cover 10 1 9 Plug 13 Bearing 10 Lock mit 14 Warm and ball mut 11 Shim sembly 12 Oil seat 15 Sector gear 10 2 Jack up the vehicle and remove the front wheel 3 Disconnect the center link from the pitman arm by using the puller 49 0118 850C Fig 10 3 Disconnecting of center 4 Remove the bolts and nuts holding the steering gear housing to the frame Note Confirm the position of the shim for conve mience when readjusting the column shaft alignment 10 2 Removing of Steering Gear Nonseparste type 1 Remove the horn cap attaching screws and remove the horn cap 2 Scribe a line mark on the steering wheel and col umn shaft 3 Remove the steering wheel nut and then remove the steering wheel and the hom lever assembly 4 Remove the column cover 5 Remove the combination switch assembly from the column jacket 6 Remove the steering column support bracket 7 Jack
278. tier fien a Fig 14 9 Check valve cros section Air Injection nozzies The air injection nozzles are attached to each of the front and rear rotor housings The secondary air chan neled via the uir pump amd the check valve is Inject ed through the nozzle into the exhaust port adjacent to the thermal reactor Fig 14 10 Injection 4 Air control valve The air control valve contains three valves the air cut valve and the relief valve which control the mount of secondary air and thermal teactor cooling to the engine operating condition and the Ta 1 safely valve that controls the amount of secondary air alone Fig IAI Ait control valve The ait cut vulve opens and closes according to the difference of pressure between the vacuum and air chambers This valve which is connected to the dis phragm is closed during normat operation by the intake manifold vacuum When the engine speed ex ceeds 4 000 200 rpm the control box actuates the solenoid to close the vacuum way This equalizes the pressures in the two chambers the spring force causes the valve to open and the uir in the air in jection system is channeled to the thermal reactor 10 cool it before being emitted to the atmosphere At the same time the ait cut valve closes the sec ondary air passage to cut secondary air supply into the exhaust port In case the car is decelerated when running at t
279. to the coasting valve solenoid and connect in iis place the wiring from the positive terminal of the battery When the accelerator pedal is released suddenly the engine speed will be stays 950 4 50 rpm If the engine speed does nor become stable at that value adjust the throttle po sitioner in the procedure mentioned below Adjusting of throttle positioner Disconnect the wiring leading to the cousting valve solenoid und connect in its place the wiring from the positive terminal of the battery 2 When the accelerator pedal is released from 2 000 rpm adjust the adjusting mut in or out so that the engine speed will be 20 50 rpm 3 Tighten the lock nut 4 Check again to see that when the battery wiring is disconnected from the solenoid the engine speed decreases 10 800 rpm and when it is connected the engine speed rises to 70 50 rpm Fig 1A 53 Throttle positioner 13 Air Supply Valve Checking of air supply valve 1 Remove the air hose fom the air suction pipe of the air supply valve 2 Start the engine and keep it running at ille speed When the air suction pipe of the air supply valve is closed with the hand eduction of idle speed must be under 30 rpm sure that when the wiring to the air supp ve solenoid is discon nected a large amount of is supplied into the intake manifold b Removing of air supply valve 1 Remove the air cleaner and air duct 2 Disconnect the air hose vacu
280. ts as shown in Fig 9 18 a If the bearing is higher than the model subtract the amount equivalent to the difference b If the bearing lower than the model add the a mount equivalent to the difference 9 18 Measuring of beating height 8 Finally select the correct pinion spacer 10 be used during pinion assembly by adding or subtracting the amount determined in Step 5 6 and 7 from the thick ness of the spacer used in Step 3 The spacers are available in the following thickness Identification mark Thickness EJ 3 08 mm 0 1213 n 3 11 mm 0 1224 in 14 3 14 mm 0 1236 in 7 347 mm 0 1248 in 20 3 20 mm 0 1260 in 23 X23 mm 0 1271 in 26 326 0 1283 in 29 3 29 mm 0 1295 in 32 3 32 mm 0 1307 in 35 3 35 mm 0 1319 in 38 3 38 mm 0 1331 in 341 mm 0 1343 in 344 mm 0 1354 in 47 347 mm 0 1366 in 9 Position the correct spacer on stall the rear pinion bearing the pinion and in Fig 9 19 Rear axle 1 Nut 6 Rear pinion bearing 2 Companion flange 7 Spacer 3 Oil seal X Drive pinion 4 Front pinion beating 9 Cartier 5 Collapsible spacer 10 Adjuster 9 5 11 Differential bearing 12 Differential gear cae 17 Pinion gear 13 Thrust washer 18 Side gear 14 Pinion shafi 1 Lock pin 9 9 E 2 Adjusting of Pinion Bearing Preload 1 Position the pinion assembly in the carrier and install the collapsible sp
281. ttor 1 E ENGINE INSTALLATION ee verse n dil dul nd m 5 6 50215254842344235222202231 6 ENGINE RX 2 is mounted with 2 rotar type rotary piston engine of Toyo Kogyos unique design lis single chamber capacity is 573 35 0 cu in and the compression ratio is 9 4 1 The performance is shown im Fig 14 The main component parts of the rotary piston engine are entirely different from those of the conventional reciprocating engine The rotor which corresponds to the piston of the reciprocating engine makes a rotary motion due to the explosion pressure occurring in the chamber formed by the rotor housing and the side housing which correspond to the cylinder of the re ciprocating engine This rotary motion of the rotor is converted into the rotary motion of the eccentric shaft amd is then produced as output through the Dywheel 1 A REMOVING THE ENGINE To remove the engine for overhauling proceed us descreibed in the following 1 Remove the bonnet 2 Protect the fender with a cover 3 Drain the cooling water 4 Drain the engine lubricating oil 5 Remove the aircleaner 6 Remove the fuel pipe from the carburettor 7 ET 8 Disconnect the accelerator cable und the choke ble from the carburettor Disconnect the wiring from the starting motor 9 Disconnect the wiring from the alternator and the Water
282. ugal advance Throat diameter Leading Starts 04 1 at S00 rpm Primary 28 mm 1 1024 in Maximum 101 at 1 500 rpm Secondary 34mm 1 3386 Traing Staris 0 a1 300 spo Venturi diameter Maximum 7 5 1 at 2 500 rpm Primary 20x 32 65 mm Vacuum advance 07874 05118 4 0 2559 in Lending Starts 0 1 59 st 100 mm Secondary 28 x 10 m 0 1024 0 3937 ind Maximum 11515241400 Main jet Trailing Starts O 1 5 at 180 mm Primary Maximum 13 1 59 at 420 mmg Secondary nition timing Main air bleed Leading Di Primary 480 Trailing 10 after top dead center Secondary 150 Vacuum switch Equipped Show jet Primary s Secondary 130 Siow bleed Standard NGK li TEL Primary No V 70 NIPPONDENSO W22EG2 No 2 190 CHAMPION 808 Secondary No 1 0 NGK 033 No 2 60 NIPPONDENSO W2SEJ2 Auxiliary slow jet CHAMPION N 78B 033 Vacuum port diameter Tread Hmm Primacy 18 mm 0 0708 id Electrode gap 03 mm 0 033 Secondary mm 0 0236 in Acceleration pump nozzle 0 6 m 0 0236 in Idle limiter hole diameter 1 8 mm 0 0708 SPECIAL TOOLS 49 2113 00 Thermal reactor nut remover 49 2113 005 Ventilation valve box wrench 1A 22 MAZDA RX 2 S72 AIR POLLUTION CONTROL SYSTEMS 1 AIR POLLUTION CONTROL SYSTEMS EXHAUST EMISSION CONTROL SYSTEM 1 1 Air injection System a pump b
283. um switch 3 Mold the mouth on the vacuum gauge and suck in reading the vacuum gauge Make sure by the switching sound that the vacuum switch changes over rom to OFF when the vacuum gauge reading is under approximately 180 mm Hg and it changes over from OFF to ON when the vacuum is reduced until the vacuum gauge reads 120 30 mm Hg 4 Mount the cap of the leading spark plug distributor and connect the vacuum sensing tube to the vacuum advaticer Remove the thermosensor connector 6 Connect the timing light to the high tensioni sord of the trailing spark plug distributor Run the engine at idle speed and check to see that the timing goes off the vacuum switch OFF when the em speed is raised 10 1 900 300 rpm TA E 8 Control Box a Checking of control box 1 Remove the thermosensor connector and check the following points 1 Connect the timing tight i the high tension cord of the trailing spatk plug distributor Fig 1 46 Checking of control box 1 Check to see that the timing light does not go on when the engine speed ie between 1 900 300 rpm 4 000 200 rpm and goes on when the engine speed is raised to more than 4 200 rpm 2 Connect an ammeter to the air control valve sole noid and the antkafterburn valve solenoid Check to see that the current flows to each solenoid When the engine speed is between 800 4 000 200 und there is no current flow
284. um sensing tube and leal wire 3 Loosen the mounting muts and remove the air supply valve JA 16 1 c Installing of air supply valve Install the air supply valve m the reverse sequence 14 Time Lag Relay 4 Checking of time lag relay 1 Connect am ammeter o the positive side of the ion cell for the leading spark plug ar the engine and keep it running at idle spoed When the current continues to flow for 0 7 1 0 see after turning off the engine switch the time lug relay is satisfactory Fig 14 54 Checking of time elay JA E 15 Ventilation Valve Checking of ventilation valve 1 Check to see that the uit cleaner element is not clogged 2 Install a vacuum gauge us in Fig 1 55 ar the engine When the engine speed raised 10 2500 3 000 the vacuum ceadimg must under 60 TA F ENGINE TUNE UP TA F 1 Checking of Battery Referring 10 Par 5 check the battery 2 Checking of Engine Oil I Check the engine oil f it fs short of normal level eplenish engine ull to bring the level up somewhere between the F and atki The engine oll should be replaced normally every 6 000 km 4 000 miles and ofl filler should be replaced every 12 000 km 8 000 mites Fig 58 Checking of engine oll 2 Check ihe for deterioration ant of fuel is present in the oll with proper grade engine oil Check if
285. ump supplies by forced circu lation The pump installed inside the front cover is driven by gears on the eccentric shaft A full flow oil filter is provided on the rear housing of the engine The metering pump delivers an adequate amount of oil into the float chamber of carburettor to lubricate seals An cooler is fixed beneath the radiator When the temperature rises hermovalve functions to cool the oil in the cooler 2 LUBRICATING CIRCUIT 1 The enters the oil pump through an strain er and is discharged to the filter through the oil passage of the housing 2 When the oil temperature exceeds 71 C 160 F the rhermowalve the front cover starts function ing to discharge the to the cooler from the oil pump 3 The cooled oil passed through hose from cooler is mixed with the uncooled oil passed through the passage of the housing before the oil filter 4 The filtered is discharged to the front main bearing through the tubular dowel and to the rear main bearing through the passage of the rear hous ing 5 After lubricating the front and rear main bearings the oil passes through the holes of the bearings und enters the oil passage provided in the eccentric shaft 6 Stationary gears internal gears and thrust bear ings are lubricated with the oil discharged through the clearance between the main bearing and the shaft 7 The oil circulating through the
286. up the vehicle and remove the front wheel 8 Disconnect the center link from the pitman arm by using the puller 49 0118 850C 9 Remove the bolts and nuts holding the steering gear housing to the frame Note Confirm the position of the shim for conve mience when readjusting the column shaft alignment 10 STEERING GEAR DISASSEMBLY Before disassembling thoroughly clean the outside surface of the steering gear houding 1 Drain oil by removing the filler plug Hold the steering housing in a vise 3 Loosen ihe nut holding the pitman arm and re move the pitman arm with the puller 49 0223 695 as shown in Fig 10 4 4 Remove the sector shaft adjusting screw lock mut 5 Remove the side cover attaching bolts and remove the side cover and gasket by turning the adjusting screw clockwise through the cover 6 Remove the adjusting screw and shims from the slot at the end of the sector shaft 7 Carefully remove the sector shaft from the gear housing so as not to damage the bushes and oil seal LN Fig 10 4 Removing of pitman arm 8 Remove the end cover together with the shims by removing the attaching bolts 9 Remove the worm shaft and ball mut assembly through the bottom of the gear housing worm shaft and ball nut ate serviced as an assembly only 10 D STEERING GEAR INSPECTION 1 Check operation of the ball nut assembly on the worn shaft If the ball nut does not travel smoothly and freely on the w
287. ure working on the control diaphragm is cut by the thermo alve whereby the fresh air shutter is fully opened and the hot air shut ter is completely closed Check the thermowalve every six months as to whether it functions normally at ambient temper ature over 40 C 1049F Fig 4 17 cleaner ELECTRICAL SYSTEM Sit 5 1 1 5 4 5 1 5 2 5 2 5 2 5 2 512 4 4 4 Assembling the Distributor 5 4 5 ALTERNATOR 5 4 S E 1 Service Precautions 5 4 5 2 Checking the Charging System on Car 5 4 5 E 3 Disassembling the Alternat 5 4 5 4 Alternator Inspection 5 5 5 5 Assembling the Alternator 5 6 5 REGULATOR 4 6 5 1 Checking the Constant Voltage Relay S F 2 Adjusting the Regulator 5 6 STARTING 5 6 1 Checking the Starting Circuit 5 0 2 Testing the Starting Motor 5 6 3 Disassembling the Starting Motor 5 6 4 Starting Motor Inspect 5 0 5 Magnetic Switch Test 5 6 6 Assembling the Starting Motor 5 H LIGHTING SYSTEM 5 H 1 Headlight Ai adeo 5 5 5 ELECTRICAL SYSTEM 5 BATTERY RX 2 is equipped with a 12 volts battery consist ing of six cells capacity is 60 ampere hours of 20 hour rating The battery is Jocated at the front right side of the engine compartment 5 1 Checking the Battery As the battery has many important functions to en gine
288. urfaces contact ing each seal 3 Check for wear cracks or broken teeth on the stationary gear 3 Check for wear scratching flaking and other dam ages to the main bearing b Cleaning the front housing It is recommended that the following steps are taken to remove carbon and sealing agent from the front housing 1 Curbon Deposits Use extrafine emery paper When a carbon scraper is to be used be careful not to damage the matching surfaces of the housing 2 Sealing Agent Use cloth or brush soaked in a solution of ketone or thinner Inspection of front housing for distortion Place a straight edge on the housing surface as shown Fig 1 29 and measure the clearance between both with a feeler gauge The housing must be replaced If the distortion Is found 10 be more than 0 04 mmn 0 002 im d Inspection of front housing for wear Weer of the matching surfaces of the front housing and rotor should be measured with a dial indicator The front housing must be replaced if the wear exceeds 0 1 mm 0 004 in There is a tendency of increased wear at both ends of the minor axis of the front housing The effective depth of this wear is small Fig 1 27 Front housing Fig 1 29 Checking front hoi ing distortion Fig 1 30 Checking front housing wear Fig 1 31 Checking oll clearance Fig 1 32 Removing stutionaty gear Fig 1 33 Removing lock pin i Fig 1 24 Removing main beari
289. uter handle by the nylon bush to be Within 1 5 to 3 0 mm 0 06 to 0 12 in 5 Install the glass guides and tighten them with bolts 6 Install the door run channel in the door sash 7 Install the window regulator and temporarily tight enit Fig 14 23 Installing of window regulator 8 Install the door window glass and securely tighten the window regulator while adjusting the alignment between the window glass and the door sash 9 To prevent water leakage apply a solid sealing agent on the heads of the bolts attaching the window regulator 10 Paste the inside screens 11 Install the outer weatherstrip to the door body 12 Install the door trim board and inner lock knob 13 Install the inner handle cover 14 Install the regulator handle 15 Install the arm rest 14 3 Adjusting of Front Door The doors are adjustable ut the hinge mountings on the door and the body The door striker is also ad justable These adjustments are adequate to obtain proper door alignment and adjustment The hinge at taching holes on the door pillars are larger than the bolts permitting adjustment in either direction 14 24 Door striker 14 0 REAR DOOR 140 1 Disassembling of Rear Door 1 Remove the inner lock knob 2 Remove the arm rest 3 Remove the inner handle cover 4 Remove the pad of the regulator handle and re move the regulator handle and escutcheon by loosen ing the attaching bolt 5 Remove the door tr
290. with a current at free running 3 Wom dirty or defective bearings b Short circuit of armature lt Grounded armature and field coil 2 Starter does not rotate with a large current a Defective field circuit b Defective armature circuit Burnt commutator 3 Low torque and low current flow Low free run ning speed Breakage of field circu b Excessive internal resistance 4 Low torque High free running speed 3 Short circuit of field coll 5 6 3 Dis the Starter motor 1 Disconnect the field strap from the terminal on the magnetic switch 2 Remove the magnetic switch attaching screws and remove the magnetic switch spring and washers from the driving housing Fig 5 21 Removing 3 Remove the planger from the driving lever 3 Remove the through bolts and remove the rear bracket D Fig 5 22 Removing of bracket Remove the insulator and washer from the end of ihe armature shaft 6 Loosening the screws attaching field coil separate the field coil assembly rom the center bracket Fig 5 23 Removing the field coil 7 Remove the armature from the center bracket and remove the thrust wash 8 Separate the front bracket and the center bracket 9 Remove the driving lever spring and spring seat 10 Remove the over running clutch assembly from the front bracket ij 6 24 Raving aig vet 5 6 4 Storting Motor Inspection a Checking the armature C
291. y Fig 2 7 Assembling cil pump 4 Apply to the outer rotor Attach the outer rotor to the body with the chamfered side facing the driven gear 5 Attach the intermediate plate to the body Tighten the screw 6 Fix the key to the key groove of the shaft 7 Mount the inner rotor on the shaft with matching the key groove 8 Mount the outer rotor 9 Mount the oil pump assembly on the front cover and fix it with the bolts Rotate the drive shaft by hand 10 see whether jt rotates smoothly 2 3 10 Mount the thrust washer and driven gear on the shaft insert the key Il Insert an available shims between the driven gear and the stop ring so that the clearance between the pump body and the driven gear is 0 1 0 2 mm 0 004 0 008 in The following three kinds of shims are available 0 1 mm 0 004 in 0 3 mm 0 012 in 0 6 mm 0 024 in 12 Then fix the stop ring Fig 2 Clestance of diive gear and body 2 3 Replacing the Pump Gears If the pump drive gear or the driven gear should be replaced they must be replaced In pairs in order to obtain the proper backlash The standard backlash is 0 08 0 12 mm 0003 0 005 in 2 OIL FILTER oil filter is of the cartridge type The element is sealed in its container as a unit The oil filter is equipped witha relief valve When the filter flow resistance exceeds 0 8 1 2 kg cm 114 171 Ib in on account of clogging and
292. y 5 Make sure that most exhaust gas v not released from the cooling sir injection pipe for the thermal reactor b Removing of thermal reactor 1 Remove the air cleaner 2 Remove the pump 3 Remove the carburettor and intake manifold as sembly 4 Remove the heat insulitor 5 Loosen the nuts and remove the thermal reactor The lower mut must be loosened with a special tool 49 2113 001 gan Fig 14 41 Special tool Installing of thermal reactor Install the thermal reactor in the reverse sequence 1 5 Air Control Valve Checking of air control valve 1 Tum off the ignition switch and check the opera 1 213 tion of the solenoid If the clicking sound audible the solenold is normal If direct connector of the solenoid terminal to the battery produces no operation sound the solenoid is defective 2 Attach the pressure gauge as in Fig 1A 42 Pressure quae Vd 6 a al l a AU valve Fig 42 Checking of air contml valve 3 Remove the sir hoses from outlets and Bj 4 Sturt the engine and keep it running at idle speed Check to see that the pressure gauge reads 0 033 0 046 kg cm 047 065 Ib in and that there is no air leak from outlets and B of the control valve 5 Make sure that the pressure gauge reads 011 014 1 3 2 0 Ib ini when the engine speed i 3 000
293. y time the reaming may be repeated 3 Avoid the two stage reaming that is with draw ing the reamer halfway during the reaming work and then resuming the reaming because chips may affect the surface roughness 4 Before starting the reaming work it must be comfirmed that the reamer diameter is under speci fications because the reamer might be worn less than the limit if it was used many time h Inspecting the gap between side seal and comer Check the gap with the side seal and comer seal installed on the rotor Insert a foeler gauge between the rear of the side seal against the turning direc tion of rotor and the corner seal When this clear ance is too large gassealing performance becomes The side seal must be replaced if the gap between the side seal and the comer seal exceeds 0 4 mm 0 016 in When a side seal is replaced adjust the gap between side seal und comer seal by grinding the opposite end of the side seal to the rotor rotating direction along the round shape of comer seal with fine file so that gap may be 0 05 0 15 mm 0 002 0 006 Note Be 10 use the right one when installing new side seal as there are four different types namely the front inner front outer rear inner and rear outer seal i Inspecting the seal spring Check for wear or damage of the seal spring pecially the contacted portions with rotor or seal Note When the corner seal comer seal spring

Mazda RX-2 Rotary Engine Service Manual

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