icaew advanced stage study manual
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icaew advanced stage study manualB ody E lectrical Mazda M o to r C o rp o rta tio n Technical Data HIROSHIMA, JAPAN APPLICATION: Special Tools. However, this maintenance is not necessary for emission warranty coverage or manufacturer recall liability. However, this maintenance is not necessary for emission warranty-coverage or manufacturer recall liability. If the indicator sign is blue, the battery is normal. 2. Add coolant if necessary.Clean or replace if necessary. 1. Damaged insulation 2. Worn electrodes 3. Carbon deposits 4. Damaged gasket 5. Burnt spark insulator 6. Plug gap Plug gap: 1.0—1.1 mm (0.039—0.043 in) Distributor Cap Check the following points. Recharge it if necessary. Torque Specifications 86U01X-026 Installation note Timing belt 1. Check that the mark on the timing belt pulley is aligned with the mating mark. 86U01X-220 1 -1 2. If it is not aligned, turn the camshaft to align. 69G01B-025 3. Install the timing belt tensioner and spring.Tightening torque: 37—52 N m (3.8—5.3 m-kg, 27—38 ft-lb) 69G01B-028 9. Check the timing belt deflection. If the deflection is not correct, repeat the adjustment from step 5 above. Tightening torque: 15—23 Nm (1.5—2.3 m-kg, 11—17 ft-lb) Steps After Installation Perform the necessary engine adjustment. (Refer to TUNE-UP PROCEDURE.) 1—15. Plug the disconnected hoses to avoid fuel leakage. 86U01X-032 Timing belt 1. Inspection of Cylinder Head Refer to page 1—42. Assembly of Cylinder Head Refer to page 1—67. Note a) Position the hose clamp in the original location on the hose.Torque Specifications (1.6—2.4 m-kg, (2.2—2.8 m-kg,. Rocker arm and shaft assembly 1. Tightening torque: 18—26 N m (1.8—2.7 m-kg, 13—20 ft-lb) Front 86U01X-051 Caution. Clean out used silicon sealant from the gasket and gasket groove. ' 2. Apply new silicon sealant to the back of the gasket. 3. Engine side cover 4. Accelerator cable 17. After disconnecting the fuel hoses, plug them to avoid fuel leakage. Distributor and high-tension lead 3. Exhaust manifold insulator 14.http://arrowgsc.com/userfiles/hoover-wind-tunnel-vacuum-owners-manual.xml
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Spark plug 4. EGR pipe 15. Thermostat and thermostat cover 5. Turbocharger oil pipe (turbo) 16. Upper spring seat 5. Camshaft cap 12. Valve spring 6. Caution Be careful not to damage the joints or friction surfaces of aluminum alloy components (such as the cylinder head or pistons). Replace or resurface if necessary. (1) Damaged or bent stem (2) Roughness or damage to face (3) Damage or uneven wear of stem tip 2. Check the valve head margin thickness. Replace if necessary Margin thickness IN: 0.5 mm (0.020 in) min. Clearance IN: 0.025—0.060 mm (0.0010—0.0024 in) EX: 0.030—0.065 mm (0.0012—0.0026 in) Maximum: 0.20 mm (0.0079 in) 7. Check the camshaft runout. Replace if necessary. Runout: 0.03 mm (0.0012 in) max. 86U01X-092 2. Check the cam for wear or damage. Replace if necessary. Diameter: 18.959—18.980 mm (0.7464—0.7472 in) (3) Subtract the shaft diameter from the rocker arm diameter. Oil clearance: 0.020—0.074 mm (0.0008—0.0029 in) Maxim um: 0.1 0 mm (0.00 3 9 in) Hydraulic Lash Adjuster (HLA) Check the HLA face for wear or damage. Replace if necessary.Repair or replace if necessary. B end: 0.06 mm (0.0024 in) max. Twist: 0.06 mm (0.0024 in) max. 86U01X-108 Crankshaft 1. Check the journals and pins for damage, scoring, or oil hole clogging. Replace if necessary. Caution Do not clean the tensioner with cleaning fluids. If necessary, use a soft rag to wipe it clean, and avoid scratching it. Caution Do not reuse gaskets or oil seals. Upper rail Oil ring spacer ends Lower rail Piston 69G01A-145 3. Connecting rod cap tightening torque: 65—69 N m (6.6—7.0 m-kg, 48—51 ft-lb) Oil clearance: 0.027—0.067 mm (0.0011—0.0026 in) Maximum: 0.10 mm (0.0039 in) 69G01B-137. Tightening torque: 8—12 Nm (80—120 cm-kg, 69—104 in-ib) 86U01X-131 4. Cut away the portion of the gasket that projects out from the rear cover assembly toward the oil pan side. Caution Do not allow any sealant to get into the oil hole.http://daydala.com/userfiles/hoover-widepath-vacuum-cleaner-manual.xml Tightening torque: 7—12 Nm (70—120 cm-kg, 61—104 in-lb) 86U01X-137 Flywheel (MTX), Drive Plate (ATX) 1. Note Install the valve spring with the closer pitch toward the cylinder head. 86U01X-144 4. Hydraulic Lash Adjuster (HLA) 1. Pour engine oil into the oil reservoir in the rocker arm. Tightening torque: 19—25 Nm (1.9—2.6 m-kg, 14—19 ft-lb) 86U01X-156 Rear Housing Install the rear housing and a new gasket. Tightening torque: 19—25 Nm (1.9—2.6 m-kg, 14—19 ft-lb) 86U01X-157. Tightening torque: 47—65 Nm (4.8—6.6 m-kg, 35—48 ft-lb) 3. Tightening torque: 37—52 N m (3.8—5.3 m-kg, 27—38 ft-lb) Tensioner Timing Belt Tensioner 1. Install the timing belt tensioner and tensioner spring. 2. Tentatively secure the tensioner with the spring fully extended. If the timing belt tension is not correct, loosen the tensioner lock bolt and repeat steps 3—5 above. Replace the tensioner spring if necessary.Tightening torque: 20—34 N m (2.0—3.5 m-kg, 14—25 ft-lb) Oil Pressure Switch Install the oil pressure switch. Tightening torque: 12—18 N-m (1.2—1.8 m-kg, 104—156 in-lb) Oil Cooler (Turbo) Install the oil cooler. Tightening torque: 29—39 N m (3.0—4.0 m-kg, 22—29 ft-lb) Oil Filter. Tightening torque: 19—30 Nm (1.9—3.1 m-kg, 14—22 ft-lb) Spark Plug. Tightening torque: 37—63 N m (3.8—6.4 m-kg, 27—46 ft-lb) 86U01X-171 2. Install the alternator.Tightening torque: 22—28 Nm (2.2—2.9 m-kg, 16—21 ft-lb) 4. Warning: Be sure the vehicle is securely supported.Tightening torque: 19—25 N m (1.9—2.6 m-kg, 14—19 ft-lb) Extension Bar (MTX) Caution a) When installing the driveshaft, be careful not to damage the oil seal.Tightening torque: 31—46 N m (3.2—4.7 m-kg, 23—34 ft-lb) 2. Tighten the pulley lock nut.Tightening torque: 8—11 N m (80—110 cm-kg, 69—95 in-lb) 2. Install the clutch release cylinder. Tightening torque: 19—25 N m (1.9—2.6 m-kg, 14—19 ft-lb) Control Cable (ATX) Install the control cable and adjust the shift selector position. Tightening torque: 8—11 N-m (80—110 cm-kg, 69—95 in-lb) 2.https://www.becompta.be/emploi/eaglemaster-5200-manual Accelerator Cable and Throttle Cable (ATX) 1. Install the accelerator cable and the throttle cable (ATX). 2. Check the deflection of the cable. Deflection: 1—3mm (0.04—0.12 in) Battery and Battery Carrier 1. Oil pan capacity: 3.9 liters (4.1 US qt, 3.4 Imp qt) 6. Repair or replace if necessary. 1. Cracks, deformation, damage 2. Damaged drain plug threads 4BG02X-037 INSTALLATION Install in the reverse order of removal referring to the installation note. Installation Note Stiffener, oil strainer, and oil pan 1. F U L L Lo w Add coolant if necessary. Note a) Position the hose clamp in the original location on the hose.Repair or replace if necessary. 1. INSPECTION Check the thermostat. Replace if necessary. 1. Visually check that the valve is airtight. 2. Place the thermostat and a thermometer in water. 3. Connect an ammeter and battery to the fan motor connectors. 2. Check that the fan motor operates smoothly at the specified current or less. Current 5.6—7.6 Turbo 10.6—16.6 Non-Turbo 86U03X-023 3. Replace the fan motor if necessary.Perform troubleshooting as described below.Fuel and Emission Control Systems 4A—74 4A—68 4 A -8 3 4A—81 4A—45 4A—56. Connect the SST to the check connector. (Green, -pin) and the negative battery terminal. 2. Set the select switch to position A. Note The check connector is located at the rear of the left side wheel housing. Test connector: Green (1 pin) 86U04A-015 4. Turn the ignition switch ON, but do not start the engine for six seconds. Malfunction code cycle cycle break 4.0 sec. Repair or replace connector Is there continuity between air flow meter and engine control unit. Air flow meter Control unit PC: Open circuit in wiring harness from air flow (RB wire) meter to engine control unit. Is there continuity between water thermo sensor and control unit. PC: Open circuit in wiring harness from water thermo Water thermo sensor Control unit sensor to engine control unit. Repair or replace connector Is there continuity between intake air thermo sensor (in air flow meter) and engine control unit. Intake air temperature sensor PC: Open circuit in wiring harness from intake air thermo Control unit. Note The test connector must be grounded and the ignition switch ON (engine stopped). Self-Diagnosis Checker (Monitor lamp) Remarks Switch Light ON Light OFF Gear: IN Pedal released Pedal depressed Clutch switch. Automatic Control Function Engine Control Unit 86U04A-049. The system consists of the air duct, air cleaner, air flow meter, throttle body, dynamic chamber, and intake manifold. This system also has a resonance chamber to improve mid-range torque characteristics. COMPONENT DESCRIPTIONS Application Prevous. Caution Do not use the compressed air to clean the air cleaner element. 69G04A-059 Accelerator Cable 1. Inspect the deflection of the cable.Intake Manifold 1. Visually check the intake manifold for damage. 2. Replace, if necessary. 69G04A-064 Resonance Chamber 1. Visually check the resonance chamber for damage. Remove the throttle lever in the sequence shown in the figure. 69G04C-130 Installation 1. Torque Specification 86U04A-055 4A-36. Gasket Use new gaskets at the intake manifold, dynamic chamber, and throttle body. 86U04A-056. Note Make the system inspection first. If no problem is found, continue with the next system inspection of the Troubleshooting Guide. (Refer to pages 4A—8 and 9.) Possible cause Solenoid. Remove the BAC valve from the throttle body. 2. Blow air throgh the valve from port A and check that air comes out of port B when the BAC valve is cold. 3. If not correct, replace the BAC valve. Note Refer to “. It consists of the fuel pump, fuel filters, delivery pipe, pulsation damper, pressure regulator, injectors, fuel pump switch (incorporated in the air flow meter), and the circuit opening relay. These can easily be inspected by setting the buttons on the tester. Injection Pressure 1. Set the lever on the adapter as shown in the figure. 86U04A-073 2. Engine runs 1. Warm up the engine and run it at idle. 2. Listen for operational sound of the injector with a screwdriver or a sound scope. 86U04A-084 3. Resistance. Remove the injectors from the engine. (Refer to page 4A—59.) 2. Check the resistance of each injector with an ohmmeter. 3. If not correct, replace the injector. Resistance: 12—16 Q Fuel leakage test and volume test 1. Specified time: Approx. After starting: for 120 235-275 sec. (2.4—2.8, 3 4-40) 186-226 After 120 sec. (1.9-2.3, 27-33) 86U04A-097 Solenoid Valve (Pressure Regulator Control) Remove the wiring harness bracket. 2. Remove the EGR modulator valve bracket. 3. Disconnect the vacuum pipe mounting bolts. 86U04A-103 4. Disconnect the air hose from the throttle body. 86U04A-104 5. Remove the engine hanger. Engine. Tightening torque:,19—25 N m Delivery pipe Dynamic chamber (1.9—2.6 m-kg, Engine hanger 14—19 ft-lb) Installation note Injector 1. Use new O-rings. 2. Tightening torque: 8—11 Nm (0.8—1.1 m-kg, 69—95 in-lb) Pulsation Damper. COMPONENT DESCRIPTIONS Application Previous. Note Make the system inspection first. If no problem is found, continue with the next system inspection of the Troubleshooting Guide. (Refer to pages 4A—8 and 9.) System Water Water. EGR Modulator Valve 1. The fuel vapor is stored in the canister until it is drawn into the dynamic chamber and burned when the engine is started. Note Make the system inspection first. If no problem is found, continue with the next system inspection of the Troubleshooting Guide. (Refer to pages 4A—8 and 9.) Possible cause 4A-76 4A-77 4A-77 4A-78 4A-78 4A-76 4A-76 4A-77 4A-101 4A-92 4A-75 Page. When the engine is running at idle, the PCV valve is opened slightly and a small amount of blow-by gas is drawn into the dynamic chamber. At high engine speeds, the PCV valve is further opened and a larger amount of blow-by gas is drawn into the dynamic chamber. The converter contains a compound of platinum and rhodium. It is a three-way catalyst type with a volume of 2,100 cc (128 cu in). 4A—80. Torque Specifications 86U04A-159 1. Main silencer 4. Catalytic converter 2. Middle pipe 5. Bracket 3. Pre-silencer 6. Front pipe INSPECTION 1. COMPONENT DESCRIPTIONS Application Remarks Previous Function Component model model Intake air temp sensor and Air flow meter Detects amount of intake air;. Note Make the system inspection first. If no problem is found, continue with the next system inspection of the Troubleshooting Guide. (Refer to pages 4A—8 and 9.) 86U04A-163 System Inspection 1. MAIN RELAY 1. Check that a “ clicking” sound is heard at the main relay when turning the ignition switch ON and OFF. 2. Apply 12V and a ground to (A) and (B) terminals of the main relay. Voltage (After warming-up) Terminal Input Output Connection to Remarks IGN: ON Idle Malfunction indicator For 3sec. Continuity Turning Not-turning 4. Connect the switch connector after checking.Inspection 1. Remove the air hose from the throttle body. 2. Disconnect the throttle sensor connector (3-pin). 3. Connect the SST between the throttle sensor and the wiring harness. Specification: BLUE wire RED wire BLUE wire RED wire voltage (V) voltage (V) voltage (V) voltage (V) 4.50-4.59 0.37-0.54 5.10-5.19. Throttle valve condition Continuity Fully closed Open 3. If not correct, check condition of wiring harness of the idle switch.Perform troubleshooting as described below.Malfunction code cycle cycle break 4.0 sec. Control unit Distributor Is same Code No. PC: Engine control unit malfunction 86U04B-008 4B-17. Repair or replace connector Is resistance between E and F terminal OK. Replace distributor (Refer to page 4B—88) Is there continuity between distributor and engine control unit. PC: Open circuit in wiring harness from distributor to Distributor. Repair or replace connector Is resistance between C and D terminal OK. PC: Open circuit in wiring harness from distributor to Distributor. Repair or replace connector (all Are knock control unit terminal voltages correct.Repair or replace connector Is there continuity between air flow meter and engine control unit. Air flow meter Control unit PC: Open circuit in wiring harness from air flow (RB wire) Is there continuity between water thermo sensor and control unit. Intake air temperature sensor PC: Open circuit in wiring harness from intake air thermo Control unit. Repair or replace connector Is EGR control valve OK? (Refer to page 4B—94) Replace EGR control valve Is resistance of EGR position sensor OK. Replace EGR control valve (Refer to page 4B—94) Is there continuity between EGR position sensor and. Is there continuity of solenoid valve. Replace solenoid valve Is there battery voltage at (RB) wire of solenoid valve. Repair solenoid valve Is there continuity of solenoid valve. PC: Open circuit in wiring harness from RB wire to. Note The test connector must be grounded and the ignition switch ON (engine stopped).Use caution. 86U04B-032 4B-35. Automatic Control Function Engine Control Unit ---------- 86U04A-049 4B-37. The system consists of the air duct, air cleaner, air flow meter, throttle body, dynamic chamber, and intake manifold. COMPONENT DESCRIPTIONS Application Function Remarks Previous Component. Caution Do not use the compressed air to clean the air cleaner element. 69G04A-059 Accelerator Cable 1. Inspect the deflection of the cable. Intake Manifold 1. Visually check the intake manifold for damage. 2. Replace, if necessary. 69G04A-064 4B—41. Remove the throttle lever in the sequence shown in the figure. CDNut and spring (2) Throttle lever washer 69G04C-130. Torque Specification 86U04A-055 4 B -4 3. Gasket Use new gaskets at the intake manifold, dynamic chamber, and throttle body. 4B—44. This system consists of the BAC valve and the control system. Note Make the system inspection first. If no problem is found, continue with the next system inspection of the Troubleshooting Guide. (Refer to pages 4B—8 and 9.) Possible Solenoid Engine control unit. Note Refer to “. It therefore supplies more than the normal amount of air into the combustion chamber. As a result of the more fully charged combustion chamber, higher output and higher torque can be obtained by a turbocharged engine than that of a comparable non-turbocharged engine. Allow the engine to reach normal operating temperature before using full power. 2. It consists of the fuel pump, fuel filters, delivery pipe, pulsation damper, pressure regulator, injectors, fuel pump switch (incorporated in the air flow meter), and the circuit opening relay. These can easily be inspected by setting the buttons on the tester. 4B—61. Injection Pressure 1. Set the lever on the adapter as shown in the figure. 86U04B-066 2. Engine runs 1. Warm up the engine and run it at idle. 2. Listen for operational sound of the injector with a screwdriver or a sound scope. 3. Resistance 1. Remove the injectors from the engine. (Refer to page 4B—75.) 2. Check the resistance of each injector with an ohmmeter. 3. If not correct, replace the injector. Resistance: 11—15 86U04B-071 Fuel leakage test and volume test. Note Make the system inspection first.After starting: for 120 2 3 5 - 2 7 5 sec. Front 86U04B-084 3. Disconnect the air hose from the throttle body. 86U04B-085 4. Remove the engine hanger. 5. Remove the dynamic chamber mounting bolts and Engine nuts. Tightening torque: 19—25 N m Delivery pipe Dynamic chamber (1.9—2.6 m-kg, 14—19 ft-lb) Engine hanger Installation note Injector 1. Use new O-rings. 2. Tightening torque: 8—11 N m (0.8—1.1 m-kg, 69—95 in-ib) Pulsation Damper. Installation Install in the reverse order of removal, referring to the installation note. Note Make the system inspection first. If no problem is found, continue with the next system inspection of the Troubleshooting Guide. (Refer to page 4B—8 and 9.) Possible cause Water thermo sensor System inspection. Note Make the system inspection first.Vacuum SST wire Terminal color 120 mmHg (4.7 inHg) Specification: 40—60 mmHg (1.6—2.4 inHg) 6. Refer to page 4A—79 page for servicing the system. 4B-97. The converter contains a compound of platinum and rhodium. It is a three-way catalyst type with a volume of 2,300 cc (140 cu in). This system is the same as that of the non-turbo engine. Voltage (After warming-up) Terminal Input Output Connection to Remarks IGN: ON Idle Malfunction indicator For 3 sec. NEUTRAL SWITCH Inspection 1. Disconnect the neutral switch connector. 2. Continuity Turning Not turning 4. Inspection 1. Remove the air hose from the throttle body. 2. Disconnect the throttle sensor connector (3-pin). 3. Connect the SST between the throttle sensor and the wiring harness. Specification: RED wire BLUE wire RED wire BLUE wire voltage (V) voltage (V) voltage (V) voltage (V) 4.50-4.59 0.37-0.54 5.10-5.19. Throttle valve condition Continuity Fully closed Open 3. If not correct, check condition of wiring harness of the idle switch.Clean the terminals and coat them with grease after tightening the terminal. 2. Inspect for corroded or frayed battery cables. 3. B terminal 86U05X-013 TEST 4 1. Turn all electric loads off and release the brake pedal. 2. Use a hand press or a vise. 86U05X-076 5. Replace the rear bearing The bearing can be pulled off by using a bearing puller. When soldering the brush, solder the pigtail so that the wear limit line of the brush projects 2 — 3 mm (0.079—0.118 in) out from the end of the brush holder. Standard: 16.5 mm (0.650 in) Minimum: 8 mm (0.315 in) Wear limit line 86U05X-022 Brush Spring 1. Measure the force of the brush spring using a spring pressure gauge. Negative (Black) Positive (Red) Continuity Pi, P2, P3 P i, 2. Replace the rectifier. 86U05X-025 5—18. Assembly Note Stopper spring installation 1. Fit the stopper spring into the eccentric groove of the rear bearing circumference. 2. Check that the protruding part of the spring is fitted into the deepest part of the groove. Install in the reverse order of removal.Brush and Brush Holder Remove the brush from the brush holder using a flat- tip screwdriver. Replace the overrunning clutch if the pinion turns in both directions or in neither direction.Replace the brush holder if there is continuity. 67U05X-060 2. Brush Replace the brushes if they are worn beyond the wear limit, or if the wear is near the limit. Assembly Note Lubricate During assembly lubricate the following points: 1. Gear of armature shaft 2. Internal gear and planetary gears 3. Plunger circumference 4. Tightening torque: 15—23 N m (1.5—2.3 m-kg, 10.8—16.6 ft-lb) If it is not within the specification, replace the coil.Tightening torque: 18.6—. Turbo Engine 86U05X-057 3. Coupling set 1. Cap 4. Distributor set 2. Distributor rotor Caution Do not disassemble the distributor set. Non-Turbo Engine 9. Coupling set 5. Signal rotor and pin 1. Resistance: 900— 1,200 fl 3. If it is not within specification, replace it. Pick-up Coil (Turbo) Refer to page 4B—88. 86U05X-059 Cap and Rotor 1. Caution Do not misconnect the ohmmeter leads.If the clutch pedal is not depressed during starting, battery power will not be supplied to the starter and it will not operate. If the level is near or below the “ MIN” mark, add brake fluid to the “ MAX” mark. Install in the reverse order of removal. Apply a coat of grease (lithium base, N.L.G.I. No. 2) to the pedal bushing. 86U06X-006 1. INSTALLATION 1. Install the clutch master cylinder. 2. Tighten the mounting nuts. Tightening torque: 19—26 Nm (1.9—2.6 m-kg, 14—19 ft-lb) 3. Tighten the clutch pipe flare nut securely with the 4. Tightening torque: 19—26 N-m (1.9—2.6 m-kg, 14—19 ft-lb) 3. Tighten the clutch pipe flare nut securely with the After installation 1. Note Do not remove the bearing if it is not necessary. 86U06X-031 4. Remove the flywheel. 86U06X-032 5. Remove the release bearing. 6. Remove the release fork. 86U06X-033 INSPECTION Check the following and repair or replace any faulty. Note Use sandpaper if the trouble is minor. 2. Loose facing rivets. 3. Worn clutch disc. Measure the depth to the rivet heads with a slide caliper. Note If the problem is minor, repairs can be made by cleaning with sandpaper. 4BG06X-028 2. Next, use the following procedure to replace the driveshaft oil seals: 1. Remove the front wheel(s). 2. Remove the splash shield(s). 3. Note a) Tap in until the oil seal installer contacts the case.Replace the driveshaft end clip with a new one. Insert the clip with the gap at the top of the groove. Tightening torque: 16—23 Nm (1.6—2.3 m-kg, 12—17 ft-lb) Dimension: 20.1 mm (0.79 in) 86U07A-016 14. Install the drain plug. Tightening torque: 39—59 Nm (4.0—6.0 m-kg, 29—43 ft-lb) 15. Install the wheel. Tightening torque: 88—118 N-m (9.0—12.0 m-kg, 65—87 ft-lb) 16. Extension bar 2. Main fuse block 22. Control rod 12. Clutch release cylinder 3. Distributor lead 23. Surge tank bracket 4. Air flow meter connector 13. Tie-rod end 24. Non-turbo Note Failure to install the SST may cause the differential side gears to become misposi- tioned. 86U07A-027 20. Remove the gusset plates. 21. Remove the under cover. 22. Remove the extension bar and the control rod. 23. Crank lever shaft 2. Selector 28. Spring pin 1. Bearing outer race 16. Oil seal 29. Reverse lever shaft 2. Oil seal 3. Spring pin Align the groove for removal of the clutch housing pin with the position of the spring pin, then tap the pin out using a pin punch. Note a) Replace the bearings with new ones whenever they are disassembled.Caution Hold the shaft with one hand so that it does not fail. 86U07A-046 Secondary 3rd gear and 2nd gear 1. Caution Hold the shaft with one hand so that it does not fall.Note a) If the bearing inner races are removed replace them with new ones.Standard: 0.095—0.318 mm (0.004—0.013 in) Maximum: 0.5 mm (0.020 in) 86U07A-058 Clutch Housing, Transaxle Case, Rear Cover, and Differential Gear Case Cracks or damage. STEP 1 (DIFFERENTIAL) 86U07A-059 Assembly 1. Install the speedometer drive gear and the new bearing inner race with the SST. 49 G030 338 Note Press to 19,620 N (2,000 kg, 4,400 lb). Note a) The sizes of the synchronizer keys are different. Note Press to 19,620 N (2,000 kg, 4,400 lb). 86U07A-069 2. Install the 3rd gear, synchronizer ring, and clutch hub assembly with the SST. Note a) Press to 19,620 N (2,000 kg, 4,400 lb).Clearance: 0.05—0.20 mm (0.0020—0.0079 in) Maximum: 0.25 mm (0.0098 in) 86U07A-073 7. Measure the clearance between the 4th gear and bearing inner race. Clearance: 0.165—0.365 mm (0.0064—0.0144 in) Maximum: 0.415 mm (0.0163 in) 86U07A-074 8. Clearance: 0.05—0.28 mm (0.0020—0.0110 in) Maximum: 0.33 mm (0.0199 in) 86U07A-081 9. Measure the clearance between the 2nd gear and secondary 3rd gear. Clearance: 0.175—0.455 mm (0.0069—0.0179 in) Maximum: 0.505 mm (0.0199 in) 86U07A-082. Then turn it in the reverse direction until the gap is eliminated. 86U07A-255 7. Note a) Check that the correct adjust shims were selected.Note Use a new O-ring for the crank lever shaft. Tightening torque: (1) 18— 26 N m (184— 264 cm-kg, 159— 228 in-lb) (2) 9— 14 N m (90— 140 cm-kg, 78— 121 in-lb) (3) 15—. Tightening torque: 128— 196 N-m (13.0— 20.0 m-kg, 94— 145 ft-lb) 25. Stake the lock nuts. 49 G030 440 86U07A-119 26. Clean and coat the both surfaces and install the rear cover. Caution Uncrimp the tab of the locknuts. Note a) Replace the bearings with new ones whenever they are disassembled.Caution Hold the shaft with one hand so that it does not fall.Note If any of the bearings are removed, replace with new ones. 8 6 U 0 7 M 3 8 61G07X-067 1. Note Insert the rod into the knock-pin hole from the ring gear mounting surface side. 61G07X-181 Side bearing inner race (side opposite ring gear) Remove the bearing inner race with the SST. Clearance: 1.5 mm (0.059 in) Minimum: 0.8 mm (0.031 in) Note a) Place the synchronizer ring on the gear cone and rotate until it stops (approx. Note If the clutch housing or transaxle case is replaced, adjust the bearing preload of the shaft gears and the preload of the differential side bearings. (Refer to page 7A—67) 76G07A-636 Speedometer Driven Gear Assembly 1. Backlash of Side Gear and Pinion Gear Check and adjust by the following procedure. Note Apply transaxle oil to the needle bearing. If clearance is not within specification, replace any part which is worn or damaged. Clearance: 0.150—0.262 mm (0.059—0.0103 in) 86U07A-163 9. Measure the clearance between the 4th gear and bearing inner race. Note Check that the spacer does not rotate. 86U07A-167 8. Install the new bearing inner race with the SST. 86U07A-168 9. Note The boot should be installed as shown in the figure. 86U07A-174 3. Install the new roll pin as shown in the figure. Note Roll pin length is 28 mm (1.10 in) 4. Note Before coating with sealant, clean the contact surfaces. Tightening torque: 37—52 N-m (3.8—5.3 m-kg, 27—38 ft-lb) 15. Install the engine mounting bracket. Tightening torque: 78—117 N-m (8.0—11.9 m-kg, 58—86 ft-lb) 16. Tightening torque: 128—196 N-m (13.0—20.0 m-kg, 94—145 ft-lb) 29. Tightening torque: Bolts, 36—54 N-m (3.7—5.5 m-kg, 27—40 ft-lb) Nut, 75—93 Nm (7.6—9.5 kg, 55—69 ft-lb) 7. Remove the jack and take of the rope. 8. Remove the SST. 86U07A-214 9. Tightening torque: 16—23 N-m (1.6—2.3 m-kg, 12—17 ft-lb) 20. Tightening torque: 8—11 N-m (80—110 cm-kg, 69—95 in-ib) 27. INSPECTION Check the following, and replace if necessary: 1. Bent control rod. 2. Wear, damage, or malfunction of any joint. 3. Damaged gear shift lever ball. 4. Note Apply grease to all joints. Spring Make sure that the hooked part of the spring is properly seated in the bracket groove, as shown in the figure. Idle switch 1. Hold indicator light 12. Fluid temperature switch Mode switch 2. EC-AT control unit 13. EC-AT Hold switch 3. Vehicle speed sensor 14. Pulse genelator Water temperature switch 4. Mode indicator light 15. Control body 14. Oil pump 8. Output gear 2. Forward clutch 15. Inhibitor switch 9. Idle gear 3. Reverse clutch 16. Pulse generator 4. Reverse and forward drum 10. Please try again.Please try again.Please try again later.Please try your search again later.Full content visible, double tap to read brief content. Videos Help others learn more about this product by uploading a video. Upload video To calculate the overall star rating and percentage breakdown by star, we don’t use a simple average. Instead, our system considers things like how recent a review is and if the reviewer bought the item on Amazon. 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