Mazda 1975 Rotary Pickup Workshop Manual Download Page 9

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Summary of Contents for 1975 Rotary Pickup

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Page 2: ...ified by the issuance of Service Informations or supplementary volumes It is therefore requestedthat the manual be kept up to date by carefully maintaining a follow up of these materials Toyo Kogyo re...

Page 3: ...ermediate Housing I InstallingRear Rotor and Rear Rotor Housing I Installing RearHousing I Tightening TensionBolts 1 InstallingFlywheelor CounterWeight l AdjustingEccentricStiaft End P1ay I Installing...

Page 4: ...1 Fig 1 1 Engine cross section 1...

Page 5: ...il pump driven sprocket 14 Oit pump body 15 Oil strainer 16 Oil pan 17 Thermostat 18 Waterpump casing 19 Balanceweight 20 Front housing 21 Bearinghousing 22 Needlebearing 23 Thrust plate 24 Spacer 25...

Page 6: ...plug 9 Leading spark plug Fig 1 2 Engine cross section 2 10 Side seal 11 Rotor 12 Coolant drain plug 13 Oil thermo unit 14 Oil level sensor 15 Air cleaner 16 Alternator L7 Carburetor 18 Hot air hose 1...

Page 7: ...pump drive gear 6 Metering pump Fig 1 3 Engine cross section 3 7 Oil pump outer gear 8 Oil pump inner gear 9 Oil pump body 10 Oil strainer 11 Oil pan 12 Distributor 13 Distributor driven gear 14 Oil...

Page 8: ...ttachingbolts and bar and remove the air pump and V belt Remove the alternator attaching bolts and remove the alternator and V belt 6 Disconnectthe metering oil pump connectingrod and oil tubes from t...

Page 9: ...lley 19 Turn the engine on the work stand so that the front end of the engineis uP 20 Remove the front cover attaching bolts and remove the front cover and gasket 21 Remove the 60 ring from the oil pa...

Page 10: ...ring sear brake 49 1881 060 l Attach the counter weight brake 49 l88l 055 Then straiehtenthe tab of the lock washerand remove the counter weight nut using the special wrench 49 082003s 3 Remove the c...

Page 11: ...in the sealcaseas shown in Fig l 22 Fig 1 22 Removing seals Note 1 If some of the seals drop off be careful not to changethe original position of each sealon the rotor 2 Apply identification mark onto...

Page 12: ...e emery paper Wtren using a carbon scraper be areful not to damagethe finished surfacesof the housings l Removethe sealingagent on the housingsby using r cloth or a brush soaked in a solution of keton...

Page 13: ...bearing proceedsas follows 1 Remove the stationary gear and main bearingas sembly from the housing using the main bearing repfacer 49 0813 235 shown in Fig 1 30 2 Remove the adaptor on the main bearin...

Page 14: ...n the housing 4 Remove sealing agent by wiping with a cloth or brush soakedin a solution of ketone or thinner 5 Check the chromium plated surface on the rotor housing for scoring flaking or any other...

Page 15: ...ring l Check the oil sealfor wear or any damage If the lip width of the oil sealis more than 0 8 mm 0 031 inl replacethe oil seal 2 Check the oil seal protrusion as strown in Fig t tl 3 Carefully insp...

Page 16: ...asurethe gap betweenthe apex seal and the groove with a feeler gauge The feeler gauge should be inserted until the tip of the gaugereachesthe bottom of the groove The standard gap is 0 05 0 09 mm 0 00...

Page 17: ...make respective identification notches on the reverseside of the side seal If this gap is too large gas sealing performance will deteriorate I 1 3 Fig 1 49 Checking corner seal and side seal gap 1 8...

Page 18: ...eand to seeif there is any damageto the rotor 7 Fit a 0 2 mm 0 0079inl oversizecorner seal and a spring into the groove and check the corner seal protrusion from the rotor surface and also confirm the...

Page 19: ...for wear or damage Inspect the bearing housing and thrust plate for wear or any damage Fig 1 57 Needle bearings Thrust washer 3 Bearing housing Needle bearing 4 Thrust plate 1 8 13 InspectingEccentric...

Page 20: ...inner oil seal only To install the outer oil seal proceed as follows l Place the oil seal to the groove so that the square edge of spring fits in the stoppernotch of the oil seal 2 Push the head of t...

Page 21: ...g with thr rotor so that the sliding surface of the front housing facesupward 5 Mesh the internal gear and stationary gear so one of the rotor apexes is set to any one of four placesshown in Fig l 63...

Page 22: ...protector on the front rotor housing in the same manner as on the other side 7 Insert the each apex seal spring confirming the spring direction as shown in Fig I 47 8 Fit the each side piece to its or...

Page 23: ...a new sealingwasher in each tension bolt 2 Apply engine oil onto the thread of the bolt 3 Fit the tension bolts and tighten the bolts gradually in the order shown in Fig I 75 The specified torque is...

Page 24: ...c shaft Hold the counter weight with the counter weight b rake 49 1881 055 and tighten the lock nut to 45 0 m kg 350ft lb using the special wrench 49 0820 03s 3 Fit the drive plate on the counter weig...

Page 25: ...y in the same manner as above Note 1 If the end play is below the specified amount the spacerthicknessis too small If the end play is above the specified amount the spacer thickness is 1 1 1 too big 2...

Page 26: ...le by little in turn until the torque becomes0 85m kg 6 1 ft lb evenly 1 C 14 InstallingWater Pump I Turn the engine on the work stand so that the top of the engineis up 2 Place the gaskets and water...

Page 27: ...aching nuts Note Slightly apply vaseline onto 660 rings to prevent n coming off 2 Connect the oil tubes and metering oil pump con necting rod with the carburetoras describedin Par 2 t 2 3 Install the...

Page 28: ...49 0813 49 0839 4 9 2 r t 3 49 0839 49 1881 49 l88l 49 0877 49 08t3 49 0823 49 1881 49 r88l 000 005 035 300 30sA 2s0 2 t s 235 240 225 165 030 r70 060 055 435 3 1 0 070A 1 3 s r25 Enginework stand Eng...

Page 29: ...3 5 5 5 7 7 8 l3 t3 t4 2l 26 Warning System AutomaticThrottle Release System ControlUnit WaterTemperature Switch Idle Switch ChokeSwitch ChokeRelay VentilationValve CharcoalCanister Evaporativr urc C...

Page 30: ...0 0 04in Fig 1A 3 Adjusting pumpbelttension 1A A 2 CheckValve Air IniectionSystem a Checkingcheckvalve 1 Disconnect the ai hose air pump air control valve from the air control valve 2 Run the engine a...

Page 31: ...cover and remove the cover 5 Remove the bolts attaching the thermal reactor cover and remove the cover Fig 1A 6 Removingthermal reactor 6 Dsconnect the exhaust pipe reactor 7 Remove the nuts attachin...

Page 32: ...4 Keep the engine speedat 2 000 rpm by adjusting the choke control knob 5 Next gradually raise the engine by operating the throttle speed and make sure that the current begins flowing to the voltmeter...

Page 33: ...e is found in the above procedure 6 replace the decelerationcontrol valve b Checkingsignal of control unit 1 Start the engine and keep it running at idle speed 2 Removethe terminal of the solenoidfor...

Page 34: ...fingers and make sure that the engine speed hardly varies at that time 5 Connectthe hose to the evapocompensatorvalve 6 Put the mouth on the pressuresensinghose and blow Make sure that the engine spe...

Page 35: ...rpm and make sure that the timing light goes out when it drops to 2 500 t 200 rpm 7 Further drop the engine speedand make sure that the timing light goes on when the speed drops to 1 150t 100 rpm and...

Page 36: ...ty on terminal in the coupler and ground 9 terminal 4 Using the ohmmeter make sure of continuity between the terminalsCD n the coupler and of non continuity between D Nq Note If a trouble is found in...

Page 37: ...e harnessand faulty contact of the terminals in the coupler in case they are in normal conditions replace the control unit b Checkingheat hazard sensor Inspect the operating temperature of the heat ha...

Page 38: ...mp fuse fuse of the control unit J burnt out when replacing 2 Start the engine and set the engine speed to 2 000 rpm by adjusting the choke control knob Warm up the engine under the above condition 3...

Page 39: ...water temperature switch l Remove the alternator and V belt if necessary Dsconnect the coupler from the water temperature itch Loosen and remove the water temperature switch j Install the water tempe...

Page 40: ...ent flows to the bimetal of the carburetor when the engine speed is set to 2 000 rpm by adjusting the choke control knob Fig 1A 43 Checking choke switch 4 Push the choke control knob in to idle the en...

Page 41: ...rbon 2 Install the vacuum gaugeas shown in Fig l A_50 and check for clogging of the canister The vacuum gaugereading is as follows 60 0mm Hg 2 500 rpm Note If a trouble is found 2 rcplace the canister...

Page 42: ...er end 2 Next breathe out with the pressureof more than 0 04 kg cm2 10 57lblinzl and in with the negative pressureof more than 0 01 kg cmz 0 14 lblinz and make sure that the check valve operatesthen I...

Page 43: ...ouldbe usedfollowinginstnrctionsin Par 1A A Maintenance Procedure AIR CONTROL VALVE Checking Air Gontrol Valve Can air leakagebe stopped by disconnecting coupler Is heat hazad warning light on Is clic...

Page 44: ...ow to the terminal though idle switch is pushedat 2 000 fpm Have the wires from control unit to idle switch and air control valve snapped or is their contact bad The current begins flowing to the term...

Page 45: ...n solenoid terminals are opened and closed with ignition switch turned on Does the current flow to each terminal Has the wire between control unit and deceleration control valve snapped or is its cont...

Page 46: ...Trailing spark plug ig nites at improPer time Are the plug ignition coil distributor hightension cords and wires normal OttV for automatic transmission Is choke switch normal Has the wire belween cont...

Page 47: ...hedat 2 000 rpm Check following the checking procedure for the case where trailing spark plug does not tgnite at all Does the plug ignite at idling A iust or rcplaoe ide switch Has the wire between co...

Page 48: ...in 120 sec from enginestarting Is initial timing normal Is distributor advance characteristic normal Check following the checking procedure for the casewhere trailing spark plug ignites at improper ti...

Page 49: ...n relay Heathazxd waming light is not on when igintion switch is turned on Is choke relay normal j No Replace choke relay No Is the filament of the heat hazard warning light burned out Yes ___ ______...

Page 50: ...starting is too hard The engine stalls immediately even if it starts A Defect of air intake system 1 Clogging of air cleaner 2 Defect of intake air temperature control valve B Defect of fuel system 1...

Page 51: ...istributor contact point D Defect of decelerationcontrol valveor improper signalfrom control unit Abnormallylargeengineknocking A Too poor fuel Octanenumber is low B Defect of ignition system 1 Improp...

Page 52: ...lve G Defect of ventilation valve H Air leak from each hose and each valve I Gasleak from exhaust system Overflow from carburetor A Defect of fuel system 1 Dust f rting into needlevalve 2 Improper sea...

Page 53: ...roper ignition timing and ignition advance 2 Defect of ignition control system control unit etc 3 Burned or improperly adjusted distributor contact point 4 Fouled spark plug etc D Defect of secondarya...

Page 54: ...ourable Evapo compersator valve Hard engine starting Rough engine idling Afterburning Car bucking Deceleration surging Exhaust emissionbecomesunfavourable Ventilation valve Misfiring frequently occurs...

Page 55: ...nrission only Contrrl unit lmproper operation of air control valve Improper operation of deceleration control valve lmproper operation of ignition control system lmproper operation of heat hazafi prot...

Page 56: ...2 LT BRICATING SYSTEM I 2 2 2 3 3 3 3 4 4 4 4 4 4 5 5 5 5 5 6 6 6 7 7 7 7 7 7 7 7 7...

Page 57: ...orced to the front main bearing througlr the tubular dowel and to the rear main bearing through the pas sage of the rear housing 7 The oil that has paised through the oil holes of the bearings lubrica...

Page 58: ...feeler gauge asshown in Fig 2 3 The i Jard clearanceis 0 01 N 0 09mm 0 0004 ti5 in If the clearanceexceeds0 15 mm 0 006 r l replaceboth inner rotor and outer rotor Fig 2 3 Checking rotor clearance 2...

Page 59: ...nt housing and fix it with the bolts Rotate the shaft by hand to see whether it rotates smoothly 2 C OIL PUMP DRIVING 2 C 1 Chain Adiuster InsPection l Check the amount of protrusion of the chain adju...

Page 60: ...1 Repairing Oil Cooler 3 inner pressureof the oil cooler is much higher n the cooling radiator soit should be repairedby aluminumweldingwhen damaged 2_F BY PASSVALVE The by pass valve is installed on...

Page 61: ...280 Fig 2 17 Checking oil pressure Start and warm up the engine to the normal operating temperature 2 Run the engine at 3 000 rpm and take a reading of the gauge If the reading of the gaugeis 5 0 kg...

Page 62: ...g rod by removing the ter pin Dsconnect the 2 metering oil hoses from the buretor Install the tachodwell tester and set the engineat onstant speed of 2 000rpm Wait until the oil scharge from the end o...

Page 63: ...yof replenishmentof the engine lubricant 2 R 1 RemovingOil Level Sensor 1 Removethe bolts attaching the engineunder cover and remove the engine under cover 2 Remove the drain plug and drain the lubric...

Page 64: ...olantkvel Sensor 3 3 E RADrATOR 3 3 E 1 Checking Radiator 3 3 E 2 Repairing Radiator 3 3 E 3 Checking Radiator Pressure Cap 3 3 F FAN DRIVE 3 3 F 1 Checking Fan and Fan Drive 3 3 c THERMOSTAT 3 3 G I...

Page 65: ...ed to the front housing At low engine temperature the thermostat is closed to keep the water from entering the radiator The water is then recirculated direcfly to the water pump and discharged to each...

Page 66: ...of the waming light with the igni tion switched on when its rautt is found replice the bulb with a new one 2 start the engine keep it idling and after removing the expansiontank cap push thJ float of...

Page 67: ...he radiator cap tester The cap slrould be capableof retainingpressure0 91 glcmz 13lb inz1 uvuriurg ra Ilatof plessule cap 3 F FAN DRIVE The fan drive is driven with the water pump pulley The fan speed...

Page 68: ...is fully opened If the reading shows a large difference from the standard specifications replace the thermostat The specifications of the thermostat are strown in the following table Startsto open 82o...

Page 69: ...StartingAssistDevice 4 4 A 8 Fuel Inlet Fitting 4 4 A 9 SafetyThrottleReturnSystem 4 4 A I0 Disassembling Carburetor 4 A A tl Inspecting Carburetor 4 4 A 12 Carburetor Assemb1y 4 4_8 FUEL PUMP 4 4_C...

Page 70: ...Checkingfloat droP Fig 4 8 Float 4 A 4 Choke Svtttl a Adiusting vacuum diaPhragm 1 Firit confitm that the diaphragm plunger has beea pulled out during the engine idling Z puttt the diaphragm plunger i...

Page 71: ...le on a level ground 3 Set the burette at the fuel inlet of the carburetor and fill it with fuel 4 Fully operate the throttle valve about five times and confirm the fuel dischargedfrom the acceleratin...

Page 72: ...the burette at the fuel inlet of the carburetor and fill it with fuel 4 Fully operate the throttle valve about five times and confirm the fuel dischargedfrom the accelerating pump jet 5 Set the fuel...

Page 73: ...e and power jet of the carburetor b Gfieckingsignal of control unit 1 Connect a voltmeter with the coupler of the wire harness 2 Run the engine at the idle speed again Then gradually raise the engine...

Page 74: ...f fuel back to the fuel tank and lower the temperature Fig 4 2O Fuel inlet fitting 4 A 9 Safety Throttle Return System The safety throttle return systemis adopted in order to prevent any possible dang...

Page 75: ...ttaching screws Fig 4 23 Removingthrottle return springs c Removingair horn 1 Dsconnect the choke connecting rod by removiq the cotter pin plain washer and sprlng 2 Remove the acceleratingpump connect...

Page 76: ...body f Disassembling carburetorbody 1 Remove the accelerator injection nozzle weight and ball from the carburetor body 2 Wfite down the numbers and positions of all jets and air bleeds 3 Remove the a...

Page 77: ...ab and worn retaining pin bore 4 Check the float needle valve for wear and for proper seating 5 Inspect the filter for rust and damage 6 Check the choke valve for proper choking smootl movement and ex...

Page 78: ...o the container while observing the expelling amount for one minute Close the re strictor and read the amount If the pump volume is below specifications repeat the test using an auxiliary fuel supply...

Page 79: ...e control system consisting of a control valve and a bimetal is located within the air cleaner and sensesthe engine room temperature for a stabilized intake air temperature Fresh air Fig 4 36 Control...

Page 80: ...Plug 5 E 3 Checking Spark Plug 5 E 4 Installing SparkPlug j 5 5 F ALTERNATOR 5 5 F 1 Precautionson Service 5 F 2 Checking ChargingSystem on Car 5 F 3 Disassembling Alternator 5 F 4 InspectingAlternato...

Page 81: ...the terminals with grease 4 Inspect for corroded or frayed battery cables 5 A 2 Charging Battery a Gonstantcurrent charge l If the exterior of the battery is dirty with sulphrr ric acid or dust and d...

Page 82: ...e from the battery terminals before the charge J a lrd If this is neglected it could cause a hr to the diodes on the alternator hfitcry should be kept by the use of cooling f o prevent the temperatur...

Page 83: ...en the screw of the extemal adjusting lever for trailing timing and adjust the timing by operating the lever and tighten the screw again Then confirm the timing h Exter nal ad justi ng lever Fig 5 6 A...

Page 84: ...tor revolution rpm Fig 5 11 Advance characteristic cations 3 Check the advancecharacteristic The advance characteristic of the distributor should be within the rangeas shown in Fig 5 11 Note The ignit...

Page 85: ...right angle to the contact arm Take a readingwhen the contact points start to separate The reading strould be between 0 5 0 65kg 1 1 N 1 4lb d Checking condenser If the condenseris leaky it will cause...

Page 86: ...lug Heat Range r c types of spark plug standardsparkplug and cold l spark plug are available and they strould be ectedaccordingto the weathercondition and driving dition r Standard e standard spark pl...

Page 87: ...e the A terminal from the alternator or regulator while the engine is running 5 F 2 CheckingChargingSystemon Car If the electrical systemis not chargingproperly check all electrical connections and th...

Page 88: ...rear housing Use care to r the brush holder assemblyintact during removal r the rear housing Removethe brush holder assemblY Unsolder the stator leads from the rectifier lf bearing replacement is nec...

Page 89: ...ckingbrushesand springs The brushes should be replaced when one third of the original length is worn away This is indicated by a wear limit line on the side surface of each brush check the brush sprin...

Page 90: ...If this voltage is 4 2 to volts it is normal i t slide the knob to gradually reduce the voltage i the lamp will light again If the readingis 0 5 3 0 volts at this time it is proper 5 G 3 Adjusting Reg...

Page 91: ...ge adjusted to 5 0 volts the currentflow shouldbe 780amperes 2 0KW 1 100 amperesl or less and the torque should be l l m kg 8 Oift lb 2 0KW 2 4m kg 17 4ft lb or more If the starting motor does not per...

Page 92: ...ck for ground touch one prod of an ohmmeter to each segment and the other prod to the core or shaft An infinite readingshould be obtained for each seg rnent If the meter reading is not infinite the ar...

Page 93: ...th an ohmmeter pole core and the An infinite meter reading other than windings d Checkingbrush holder Check the brush holder for ground Touch one prod of an ohmmeter to the insulated brush holder and...

Page 94: ...the following points Jjust the armature shaft end play to 0 1 0 4 0 004 0 016 in with a thrust washeron the end of the shaft t en the magnetic switch is engaged the clear between the pinion and stop c...

Page 95: ...CLUTCH TNSTALLATION 6 6 E CLUTCH MASTER CYLINDER 6 6 E 1 RemovingClutch MasterCylinder 6 6 E 2 Disassembling Clutch Master Cylinder 6 6 E 3 CheckingClutch Master Cylinder 6 6 E 4 AssemblingClutch Mast...

Page 96: ...ingand turning the front race slowly by hand Replace if the Ur rrng feels rough or seemsnoisy when turning Fig 6 3 Removing flywheel Fig 6 1 Clutch pedal 1 Master cylinder 2 Height adjusting bolt 3 Lo...

Page 97: ...ppage or score the pressure plate and flywheel due to the projected heads of rivets Check the depth between the facing surface and the rivet using a depth gauge as shown in Fig 6 6 If the reading is l...

Page 98: ...cylinder 2 Fit the piston Jup to the piston and install them into the cylinder 3 Install ihe releaserod into the cylinder 4 Install the dust boot 5 Install the valve steel ball and the bleederhole Fit...

Page 99: ...ve Shaft 7 7 C 5 CheckingCounter Shaft 7 7 C 6 Checking Control kver and Shift Fork Shaft 7 7 C 7 CheckingShift Fork 7 7 C 8 CheckingClutch Sleeve 7 7 C 9 CheckingSynchronizerRing 7 7 C 10 Checking Sy...

Page 100: ...the exhaust front pipe 15 Remove the propeller shaft as describedin Par 8 A 1 and insert the transmission oil plug 49 0259 440 into the extension housing 16 Remove the lower bolt securingthe starting...

Page 101: ...and loosen the nain shaft lock nut Slide the reversegear off the ear of the main shaft and remove the key I l Remove the snap ring from the rear end of the ounter shaft and remove the counter reverseg...

Page 102: ...ingBearings Inspect each bearing for roughness or noise by hold ing the outer race and rotating the inner race while applying pressurewith hand Replace the bearingsif necessary Replacethe needlebearin...

Page 103: ...ring 3 Main drive shaft bearing 4 Main drive shaft 5 Synchronizer ring 6 Needlebearing 7 Synchronizer keY sPring 8 Third and fourth clutch hub 9 SynchronizerkeY 10 Clutch hub sleeve 11 Third gear 12...

Page 104: ...s Check the drive gear and driven gear and the driven gear shaft for wear or damage Check the O ring for weaknessor damage 7 D TRANSMISSIONASSEMBLY 1 Assemble the fust and secondsynchromeshmecha nism...

Page 105: ...fourth synchromeshmecha r engagethe notches in the synchronizer ring Install the main shaft and gearsassemblyinto the i rsmissioncase Then engagethe main shaft and rr s assemblywith the main drive sh...

Page 106: ...blein the following riJtness Fig t_25 Checking end play 23 Position the counter straft front bearing and the rear bearing in their respectivebearing borr d prr them in by using a press 24 Install the...

Page 107: ...s2 0 mm 0 079 in ex change the thrust washer selective fit The thrust washersare available as in the following table 2 5 mm 0 098 in 3 5 mm 0 138in 3 0 mm 0 118in If the measurementcorrects bend the t...

Page 108: ...Third and fourth shfit forl 2 Thftd and fourth shift rod 3 First and second shift rod 4 First and second shift fort 5 Reverse shift rod 6 Reverseshift fork 7 Steelball 8 Capspring 9 Cap springgasket...

Page 109: ...51 Check the bearing end play as follows Measure the depth of the main drive shaft bearing bore in the clutch housingusinga depth gauge Then measurethe bearingheight shown in Fig 7 38 The difference b...

Page 110: ...he main drive shaft and clutch disc c Fill the transmission case with lubricant until the lubricant overflows from the level hole SPECIALTOOLS 49 0839 4258 Bearing puller seat 49 0259 440 Main shaft h...

Page 111: ...D z TroubleDiagnosis Chart lA 7 A E REMOVALOF TRANSMISSION iTA 9 7A F DISASSEMBLY OF TRANSMISSION COMPLETE 7A 7A F 1 Disassemble Procedure 7 A 7A_G OVERHAULOF MAIN COMPONENTS 7 A 7A G 1 TorqueConverte...

Page 112: ...7A Tcqrll r Convertertnrsrg planel Re Rq r ulutch Control pan 7A I AUTOTIATIC TRANSMISSIONMODE...

Page 113: ...lglt pllrt carrierass y bodv 0il pan Extension housing Outputshaf t Governor Rear pf anet carrier ass y Low revrsebrake Oil distributor HISSIONMODEL R3A JATCO...

Page 114: ...ake Do not mix with other type of automatic transmission fluid than mentioned above 2 Periodic oil chanp is not necessary but the oil level must be checked at least every 6 250 miles 10 000km 3 The to...

Page 115: ...If the solenoid should not make any clicking sound it in dicatessome abnormality so check witi a testermust be made Note When the solenoid is removed for replacing some one liter of fluid leaks out So...

Page 116: ...ompletely with chocks and apply the hand brake Be sure to de press the brake pedal firmly with the left foot be fore depressingdown the acceleratorpedal 4 Place the manual lever in D range 5 Gradually...

Page 117: ...ccursat the fully closesthrottle condition 5 When the car is running in Da at a speed more than 60 km h 45 mile h place the manual lever from D into 1 and read the car speedjust when lz h downshift oc...

Page 118: ...rr line pressureat idling is low in all of R l and 1 possiblecauses include a fault in riasure supply system e g increasedside clear the oil pump reduced pump output because Fig 74 6 Oil pressure test...

Page 119: ...he numerals show the sequenceof inspection for detecting trouble Trouble A B C D E F G H I J K L M N O P a b c d e f g h i j k Engine won t start in N and P ranges 2 3 1 Engine starts in other ranges...

Page 120: ...eed on ac celeratordepressionin Ds abovekick down upper limit 1 2 3 5 6 7 4 o Engine runaway or slip on Ds Dz change I 2 4 6 s 3 o o Ds 2 change on D 2 rangeshift I 2 4 5 3 1 2 D or 2 Dg changein 2 an...

Page 121: ...r propeller shaft attaching bolts and remove the center bearing attaching bolts Then pull it out from the extension housing Apply a plug to prevent oil leak Fig 7A 7 Removing propellarshaft 9 Dsconnec...

Page 122: ...does not fall down Then remove the parking pawl spring and washer Remove the gasket from the transmissioncase 6 Irorrn and remove out the oil pan bolts and take out the oil Pan and the gaske 7 Turn th...

Page 123: ...tions dents etc and replaceif necessary Note Iftheconverteroilisfoundmarkedlydegeneratedor fouled thorouglrly rinse the inside of the converter with approximiteiy 0 5 liter 1 0 U S pints 0 5 U S q utt...

Page 124: ...315in 8 2mm 0 323in 3 Install the front clutch assemblyto the oil pump Blow compressedair into the oil hole as shown in Fig 7A 22 and check the clutch operation Fig 7A 22 Testingfront clutch 7A G 3 R...

Page 125: ...Back off the three attaching bolts slightly and uniformly and apply compressedair into the oil hole on the servo piston releaseside as in Fig 7A 35 If the retainer risesby the extent of bolt backingo...

Page 126: ...Check the side play of the inner or outer gear V using a straight edge and thickness gauge aJ in Fig 7 A 39 The standard valueis 0 02 0 04 rn 0 001 0 002 in If the clearance exceeds0 08 mm 0 003 in r...

Page 127: ...ach the oil strainer and remove the oil strainer kt loosening the 8 mm bolt a box wrench should be used as much as possible although a screw driver can be used 2 Disconnect the lower valve body separa...

Page 128: ...to upper valvebody ll strainerto lower valve body A G g Bearingand BearingRace eck each bearing and bearing race after cleaning efully Also check to see that the mating parts each bearing and bearing...

Page 129: ...the needle bearings on the front and rear faces of the internal drive flange fit the flange on the output shaft and lock it with the snap ring 7 Mount the bearing race on the rear face of the rear pl...

Page 130: ...106 in 1 70mm 0 067 in 2 I0 mm 0 083 in 2 50mm 0 098 in Fig 7A 49 Checking end play 18 In measuring the total end play apply the dial gauge on the tip of the input shaft and move the connecting shell...

Page 131: ...lutch planet sun 7A 54 Main assembly assembly 11 Rear 12 Drive componentsof transmission J r aque converter Converrer housing L J I i r t nsion housing Ori oump assembly hub assembly 13 Low carrier as...

Page 132: ...drive plate u applying the wrench to the drive pulley lock bolt und tighten the four bolts to a specified torque of 37 5 5 m kg 27 40 ft lb In case of confirm s the tightening torque accurately it is...

Page 133: ...in the oil pressuregaugeset 49 0378 400 49 0378 401 do 49 0378 402 do 49 4378 403 do 49 0378 404 do 49 4378 320 Use for setting transmision 49 0378 390 Use for removing oil pump 49 8000 015 Use for re...

Page 134: ...8 PROPELLER SHAFT SHAFT SHAFT 8 l 8 2 8 2 8 2 8 2 8 3 8 3...

Page 135: ...sing to prevent housing 49 0259 440 into the extension lubricant from running out of the by do 8 A REMOVINGPROPELLERSHAFT 1 To maintain drive line balance mark the mating parts of the companion flange...

Page 136: ...eller shaft in the reverse order oi removing noting the following points 1 Be sure to observelocation marks on the com panion flange yokes and propeller shafts for correcr assembly 2 Torque the nut at...

Page 137: ...g Drive Pinion REAR AXLE INSPECTION 9 D 1 CheckingDrive Pinion and Ring Gear 9 D 2 Checking Differential Gears 9 D 3 CheckingBearings 9 D4 ReplacingPinion Bearing Outer Race 9 9 D 5 CheckingCollapsibl...

Page 138: ...ar Axle Shaft Assemble the rear axle shaft in the reverseorder of disassembling 9 A 4 Installing Rear Axle Shaft 1 Install the rear axle shaft backing plate and bear ing housing assemblyto the rear ax...

Page 139: ...ingidentificationmarks 3 Remove the adjuster lock plates 4 Loosen the bea ring cap attaching nuts and back off the adjuster sliglrtly with the spanner 49 0259 720 to relieve differential bearing prelo...

Page 140: ...rr wear flaking or any damage If inqpection eveats fiat either bearing cones or outer race are unfit for further service replace the bearing only in sets 9 D 4 Replacingpinion BearingOuter Race l it...

Page 141: ...fference b If the bearing is lower than the model add the amount equivalent to the difference 9 In order to compensatefor all of the machining variables the pinion has a plus or minus reading recorded...

Page 142: ...ion nut to 20 m kg 145ftJb and check the preload as strown in Fig 9 16 Fig 9 15 Checking pinion bearing preload Note After preloadhas beenchecked final tightening should be done very cautiously The pi...

Page 143: ...h the hole in the case 7 Install the lock pin to secure the pinion shaft Stake the lock pin into position with a punch to prevent it from working out 8 Install the ring gear to the case and torque the...

Page 144: ...djusters equally until the backlash becomes 0 19 to 0 21mm 0 0075to 0 0083in 3 The preloadon the differentialbearings is obtained by tightening the adjusters Tighten the adjusters until the distancebe...

Page 145: ...ower the vehicle SPECIAL TOOLS 49 0603 622A Spannerfor axle shaft bearing lock nut 49 0164 550D Rear axle stand 49 Ol 5628 Attachment for rear axle stand 49 0259 72O Backlash adjusting spanner 49 0259...

Page 146: ...10 STEERING 10 8 10 c l0 c 3 t0 c 4 l0 c 5 IO_D FRONT 10 D 1 r0 D 2 I0 D 3 10 D 4 SPECIAL TOOLS...

Page 147: ...l oosenessof the wheel bearinp 3 Backlashbetween the sector gear and ball nut 10 A 2 SteeringWheel Removal 1 Pull the steeringwheel pad toward the top of the wheel 2 Punch the mating hub and the colu...

Page 148: ...moval Raise the front end of the vehicle ith stands lnosen the bolt securing the worm eeringjoint and support shaft to the Remove the cotter pin and castellated nut attach 5 Remove the screws attachin...

Page 149: ...ravel smoothly and freely on the worrn shaft the ball nut and worm shaft assemblyshould be replaced Fig 1O 7 Steering gear cross section 1 Plug 2 Lock nut 3 Adjusting screw 4 Side cover 5 Gasket 6 Oil...

Page 150: ...CIrrn shaft and connect a pull scale to the preload checking tool Pull the scale gradually and read the scale keeping the worm shaft rotating If the reading is less than 0 1 kg O 22lb reduce the shim...

Page 151: ...ure that the sector shaft turns 40o smoothly to the right and left 10 Check the worm shaft rotating torque To check attach the checking toot art No 49 0lg0 5l0A onto the worm shaft and connect a pull...

Page 152: ...joint puller art No 49 0727 s7s 4 Remove the pitnan arm attaching nut 5 Remove the pitman arm from the sector shaft usingthe pitman itm puller Part No 49 0223 695D 6 Install the pitman arm onto the se...

Page 153: ...etire wear are to be obtained Before attempting to check the wheel alignment the following points should be investigated and if necessary corrected 1 Tires for correct inflation 2 Unbalancedtires 3 Wo...

Page 154: ...the front wheel at the top from the vertical as shown in Fig 10 23 The Fig 10 23 Camberand kingpin inclination A Camber B Cambertrail C Kingpininclination standard camber angle is 15 2O The purpose of...

Page 155: ...teering knuckle arm Using a turntable check that the front wheelstum outward If necessary the stop screws 33 18 inward and 32 26 adjust the turning angleby SPECIAL TOOLS 49 0727 575 Ball joint puller...

Page 156: ...RAULIC LINSS I I I 1 E 1 CheckingBrake Lines I I 11_F FRONT BRAKE 11 1I F 1 Disc BrakeShoe I I a Replacing discbrakeshoe 11 11 F 2 Caliper 11 a Removing caliper 1 I b Disassembling caliper I I c Ctrec...

Page 157: ...d the brake st oe UV turni the adjuster toward the arow direction 1e marbf on the backing plate until the wheel locks At rb time pump the brake pedal several times to nntr 11 A BRAKE ADJUSTMENT 11 A 1...

Page 158: ...ator remaining in the off center position To centralize the brake fail indicator turn off the warning light after repair operation 1 Turn the ignition switch to the ON position 2 Checkthe fluid level...

Page 159: ...ing from the cylinder bore FiS 11 9 Removing primary piston 6 Depressthe secondary able rod and remove the from the outside of the pin in its place WITHGUIDE PIN Jeconoarycup Secondarypist WITHOUTGUID...

Page 160: ...pring for weakness 11 C 4 Assembling Brake Master Cllinder l Dip all parts except the cylinder in clean brake fluid 2 Insert the check valve springs into the outlets and place the check valves over th...

Page 161: ...ission in neutral Run the exglne to medium speed and turn off ignition switch Immediately close throttre This build up vacuum wait no lessthan 90 seconds then try brake action If not vacuum assisted f...

Page 162: ...rear shell and drive out the rear sealwith a punch or a screwdriver 9 Remove the air silencer with the plate and valve body being plastic the air filter from careful not to chip f 10 Press tainerkey...

Page 163: ...eenprimary piston and the push rod of the mastercylinderand if necessary adjust the push rod so that the correct clearance is obtained The standardclearance is 0 1 0 5 mm 0 004 0 020 inl Fig 11 26 Cle...

Page 164: ...the reaction disc and install the reaction disc into the plate and valve body 7 Coat the outer bead of the diaphragm with power brake lubricant where it bears against the outer rims of the front and...

Page 165: ...the disc brake shoes proceedas follows l Raise the front end of the vehicle and support with stands 2 Remove the front wheel 3 Remove the hair pin retainers and pull out the stopper plates 4 Remove th...

Page 166: ...ve the moving the two bolts b Disassembling caliper 1 Clean outside of the caliper 2 Place a hardwood in front of piston to prevent damage to piston Apply air pressure to the fluid port in the caliper...

Page 167: ...the flange squarely in the inner groove of the caliper bore Install the dust boot retainer e Installingcaliper Follow the removal procedures in the reverse order and bleed the hydraulic system Fis 11...

Page 168: ...facing the brake disc should be replaced Fig 11 43 Checkingbrake disc thickness b Replacing brake disc assembly Replace the brake disc and front wheel hub assembly as described in Par l2 G 1 11 G REAR...

Page 169: ...ar brake comPonents 7 Plug 13 CliP sPring 8 Shoe hold down spring pin 14 Wavewasher 9 Wheel cylinder nut L5 Brake shoe retaining clip 10 Parking brake opening lever 16 Wheel cylinder 11 Operatingstrut...

Page 170: ...ohol If one drum is turn own the opposite drum on the same axle strould also be cut down to the same size 6 Check the condition of the brake shoes return springs hold down springs and drum for signs o...

Page 171: ...sureis as follows Rotary Pickup Front Rear 24 psi 36psl or inflating the pressure place the on and tigfrtenby hand It helpsto pressure in the tires in caseof any keeps dust and water out of the After...

Page 172: ...the side of the tire The readingof the indicator should be within 2 5 mm 0 10 in 12_E WHEEL BALANCING The allowableunbalanceis 600 cm gr 8 3 in oz which is less than 30 gr 1 l oz at the rim Excessivew...

Page 173: ...hub Remove the cotter pin nut lock adjusting nut and flat washer from the spindle 5 Pull the hub and 6 Remove the outer rotor assemblyoff the spindle bearing from the hub Fis 12 7 5 Outer bearing 6 Wa...

Page 174: ...ttury The bearing and bearing iup tttould be replaced as a set if damageto either is encountered Check the rotor for thickness If the thickness of the rotor is lesslthan 11 mm 0 4331 in rotor should...

Page 175: ...any of above con ditions exists replacewith new bearings 12 G 2 Adjusting Front Wheel Bearing The front wheel bearings should be adjusted if the wheel is loose on the spindle or if the wheel does not...

Page 176: ...ion 13 I3 B 2 Checking Front Suspension 13 l3 B 3 hstallingFront Suspension 13 13 B 4 Greasing Front Suspension I 3 13 C REAR SHOCKABSOR8ER 13 13 C 1 Removing RearShockAbsorber 13 l3 C 2 CheckingRearS...

Page 177: ...Bush 6 Retainer 7 Adjusting shim 8 Upper arm shaft 9 Upper arm 10 Plug 11 Set ring 12 Dust seal 15 Coil spring 1 6 Seat 17 Adjusting plate 18 Shock absorber 19 Washer 22 Stopper 23 Stopper 24 Lower ar...

Page 178: ...5 Spacer 6 Bush 7 Shackle plate assembly 8 Shackle plate 9 Nut and washer 10 Bush 11 Spring clamp 12 Pach 13 U bolt 14 Nut and washer 15 Stopper rubber 16 Shock absorber 17 Bustr 18 Retainer 19 Center...

Page 179: ...A 3 Insulling Front Shock Absorber Install the shock absorber in the reverse order of removing Note Tigfutenthe shock absorbernut to the dimension shownin Fig I3 3 5mm 0 25in Fig 13 3 Tightening shoc...

Page 180: ...al and secureit in place with the set ring dd new grease until the dust seal begins to con Then depressthe dust sealwith the fingers hat about half of the greaseremains in the dust rpe off excessgreas...

Page 181: ...e frame bracket so as to align the holes of the rubber busheswith the hole of the frame bracket 2 Insert the spring pin from the outside through the rubber bushes 3 Tighten the nuts and bolts attachin...

Page 182: ...L4 BODY t4 I r4 8 T4 C t4 D 14 F BODY 1 l 1 1...

Page 183: ...the weatherstrip which is fitted to the body flange 3 Fit a string of 4 mm 0 16 in in diameterto the groove of the weatherstripas shown in Fig l4 3 l l I Fig 14 3 Fitting string 4 Place the windshield...

Page 184: ...the screwsthat attach the remote control assemblyto the door inner panel and remove the door lock and remote control as sembly 9 Remove the four screws attaching the regulator assembly to the door in...

Page 185: ...ker and piller The striker should be adjusted so that the door lock enters freely and door will remain in closedposition Fig 14 11 Adjustingdoor striker 14 D HEADLINING Top ceilins 14 D 1 RemovingHead...

Page 186: ...il it becomes tacky then cement headlining in place at front and rear stretching headlining to make it taut the the Install the fixing brackets to the back plate with to rear listing attached bcrews 7...

Page 187: ...ghter from the center panel 4 Removethe nut attachingthe panelresistorto center panel and disconnect the wirings from the resistor Instrumentpanel Lower Fig 14 21 Removing panel resister 5 Loosen the...

Page 188: ...T4 BODY CHECKINGDIMENSION s C D O a t t 3 N o o 3 mm 0 1l 8 l i n 28 9060 in Pz il I 25Tnn 49 I l8 5mm 36 in r 3 N 3 3 N s N o 39 N J 90ro 5 N O _ 308 3 s l NJ I I 1 4 6...

Page 189: ...15 15 B l Checking IgnitionSwitch 15 ls c TNHTBITOR SWITCH 15 15 C 1 Checking lnhibitorSwitch 15 15 D tmATERFAN SWITCH 15 15 D 1 Checking HeaterFan Switch 15 I5_E CENTRALCONTROLUNIT 15 l5 E 1 Ctreckin...

Page 190: ...Passing Switch signal and hazard switch interconnection diagram 2 Light Dimmer and Terminal Switch Positioi TFU HFU TL TR TIG TFB HBA HFB SS SS Right Turn o o Turn Sienal Neutral o a Left Turn F F OF...

Page 191: ...her relay R3 horn luy R4 and flasher unit Ul each of which is a plug socket connection typ9 Each relay and unit are easy to replace In replacing the flasher unit care should be taken that its capacity...

Page 192: ...ond tb Hazard Wren the battery is connectedto the HFU terminal and a prescribed lamp between the battery Q and TFU terminal the lamp must turn on and off 90 t 10 times per minute with the interval bet...

Page 193: ...er earth negutator Generator warning light Coolant level senser Coolant level warning light Combination switch Illumination light naai fuse Ammeter U itt fuse Ammeter W tet thermo unit Water temperatu...

Page 194: ...T TECHNICALDATA...

Page 195: ...0 04 mm 0 0016in 0 10mm 0 0039in 80 mm 3 150in 0 06 mm 0 0024in 79 85mm 3 L44nl 0 10 0 21mm 0 0039 0 0083in 79 85mm 3 144in 3 0mm 0 118in over7 0 mm 0 276in 0 13 0 30mm 0 0051 0 0118 in 0 05 0 15mm 0...

Page 196: ...Peed Number of brushes Brushlength Wearlimit Brush springpressure Control switch Voltage required to closesolenoidcontacts Undercuttingmica Clearancebetweenarmature shaft and brush Armature shaft end...

Page 197: ...ition R 4 0 7 0k cmz 57 100 1b in2 15 5 19 0kg cmz 220 270lbllr 2 D 3 0 4 0 kglcmz 43 57 Ibllr z 9 5 1L 0kg cm2 L35 156lb inz 2 10 0 12 0kglcmz 142 17l lblinz L0 0 t2 0 kglcmz L42 l7I lbllr 2 I 3 0 4...

Page 198: ...n Helper 12 mm 0 47 in DIMENSIONS Overall length Overall width Overall height Wheelbase Tread Front Rear Min road clearance Min turning radius Seating capacity 4402mm 173 in 1695mm 67 in 1540mm 61 in...

Page 199: ...wheel nut 5 5 6 5 4 0 4 7 I 1 6 0 L 8 0 1 1 6 1 3 0 3 2 4 7 2 3 3 4 I I 9 0 1 1 0 o s s o 5 6 8 2 4 1 5 9 rp O 35 0 145 253 3 0 4 0 Z z Z g Steeringgearhousing to tiame Pifrnan arm to sector shaft Idl...

Page 200: ...t1m0r...

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Mazda 1975 Rotary Pickup, Workshop Manual

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