Mazda 1975 Rotary Pickup Instruction manual

ll
I
1975
tlz0t
frOTTNT
PIEKUP
WORKSHOP
MANUAL
FOREWORD
This wgrkshop manual was preparedas reference
material
for the service
personnel
of authorizedMazdadealers
to enable
them to correcily carry out the task of rendering
services
and
maintenance
on Mazda vehicles.
In order to ensure that the customers are satisfied with
Mazda products, proper servicing and maintenancemust be
provided. For thii purpose, the service
personnelmust fully
understandthe contents of this workshop manual and at the
same time, are recommended
to keep the manual in a place
where reference
can readily be made.
The information, photographs,drawings and specifications
enteredin this manuil were the best available
at the time of
printing this manual. A11
alterationsto this manual occurring
is the result of modifications will be notified by the issuance
of Service Informations or supplementary volumes. It is,
therefore, requested
that the manual be kept up to date by
carefully maintaining a follow-up of thesematerials.
Toyo Kogyo reserves
the right to alter the specifications
and iontenti of this manual without any obligation and ad'
vance
notice.
All rights reserved.
No part of this book may be repro-
duced or utilized in any form or by any means,
electronic
or mechanical.
including photocopying,
recording,
or by any
informational stonge and retrievalEystem.
without permission
in writing.
rologlo tLLn
I{IROS}|IA J PA]I
@
rszo
roYo KoGYo
co.,
LTD.
PRINTED IN JAPAN OEC.,'74
MAZDA ROTARY ENGINE;
LICENSE NSU-WANKEL
1010410
SECTION
INDEX
Name Section
Engine 1
Emission
ControlSYstem 1A
Lubricating
System 2
Cooling
System 3
Fuel System 4
Electrical System
(Engine) 5
Clutch 6
Transmission 7
Automatic Transmission 7A
Propellar
Shaft 8
Rear
Axle I
Steering 10
Brakes 11
Wheels
and Tires 12
Suspension 13
Body 14
Electrical
System
(Body) 15
Technical Data T

1i
ENGINE
NTJ lDln
rLr
H
hreyGar
+i _.....*................I
hfrrycar i
frt -..-......................1
n h3 -.......................
I
b- ............r
b Dfrg ....,......................
I
h (n Sctt and Spring.....l
|t td, SidePiece ,1
-a....rirerr r r o
r r o r r. r r. r r r r r r 1.... r r r r. r
tre Seal
andSpring...............1
Cornff Seal
and Spring..........l
Eocentric
Shaft...............
j:........
1
NeedleBearing...............
j.........
I
Eccentric Shaft Front
rd Rear Oil Seals....................................
I
ASSEIIIBLY
................................................
1
Instailing
Oil Seal
......................................
I
lostafling
Each
Sea1......... .........,1
lnstalling
FrontRotor.....................
;.........I
Installing
Eccentric
Shaft
..........................
1
lnstallingFront RotorHousing................I
InstallingIntermediate
Housing......,.........I
InstallingRearRotor andRearRotor
Housing.......................................................
I
InstallingRear
Housing...........................;I
Tightening
Tension
Bolts ..........1
Installing
Flywheel
or Counter
Weight....l
Adjusting
Eccentric
StiaftEnd P1ay.........I
Installing
Front Coverand Eccentric
Shaft
Pulley...................... ..........1
l-C-13. Installing
Oil Strainer
andOil Pan..........1
1-C-14.InstallingWaterPump ...............1
I
-C- 15.InstallingDistributor..................................I
I
-C-1 6.InstallingExhaust
Manifold
......................I
I
-C- I7.InstallingIntakeManifold.........................
I
1-C-18. InstallingAlternatorandAir hrmp.........1
SPECIALTOOLS................
l:4
l:8
....I
t{-1.
1L-2.
l4-3.
l4-4.
l{-s.
r{-6.
t-c-7.
r-c-8.
1-C-9.
1-C-10.
1-C-1
1.
r-c-12.
9
10
10
10
11
11
L2
t3
L3
t4
l5
15
t6
t6
L6
t7
L7
t7
18
t9
19
L9
l9
20
2l
2;2
22
23
23
23
23
24
)

1
Fig. 1-1 Engine cross section (1)

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:{i-
{:
It,
t'
lr
ala
t
E
II
tri
n
l. Water
pump body
2. Water pump pulley
3. Eccentric shaft pulley
4. Eccentric shaft pulley (for compressor)
5. Key
6. Eccentricstraft
pulley bolt
7. Eccentric shaft front oil seal
8. Eccentricshaftpulley boss
9. Distributor drivegear
10. Oil pump drive qprocket
11. Drivengear(for metering
oil pump)
12.Front cover
13. Oil pump drivensprocket
14. Oit pump body
15. Oil strainer
16.Oil pan
17. Thermostat
18. Waterpump casing
19. Balance
weight
20. Front housing
21. Bearing
housing
22. Needle
bearing
23. Thrust plate
24. Spacer
25. Oil filter
26. Intermediate
housine
27. Orl filter cover
28. Rear rotor housing
29. Rear housing
30. Apex seal
31.Rear
rotor
32. Oil seal
(outer)
33. Oil seal (inner)
34. Rear rotor bearing
35. Rear main bearing
36. Flywheel
lock nut
37.Key
38. Nee4le
bearing
39. Eccentric
shaft
40. Eccentricshaft rear oil seal
41.Oiljet
42. Sealing
washer
43. Tension
bolt
n€}
Y
F
t
@
\

I
-.
g:llF":
o
o
e
e
o
o
e
1. Oil filler cap
2. Distributor
3. Dipstick gauge
4. Rotor housing
5. Tubular dowel
6. Sealingrubber (outer)
7. Sealingrubber (inner)
8. Trailing spark plug
9. Leading spark plug
Fig. 1-2 Engine crosssection(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
19. PCV valve
20. Intake manifold
2L. At control valve
22. Thermal reactor
23. Apex seal (side piece)
24. Corner seal
25. Air injection nszzle
26. Oil strainer
27. On drain plug

1
1. Thermostat
2. Water pump casing
3. Distributor drive gear
4. Eccentric shaft
5. Metering pump drive gear
6. Meteringpump
Fig. 1-3 Engine crosssection(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 pump chain adjuster
15. Oil pump chain
1.6.
Pressurecontrol valve
17. Oil level sensor
l:3

1
1-A. ENGINE
DISASSEMBLY
i . .:ne disassembly
should be done in the following
'jer aiter removing
the enginefrom the vehicle.
\ote:
i1::.-eiorth, on this occasion
when the '74 year-type
:' :.rraryengineis being
introduced,
we have
adopted
'"j'.:
method of supporting
the front housing
by using
:i.e engine
hanger
(49 lll4 005) for the purpose
of
:',:ilitating
the working procedure.
The engine
hanger
:rn be usedfor any type of enginenow in service.
I. Remove the oil hose support bracket from the
iront housing.
l. Mount the engineon the enginework stand (49
0839 000) with the ensinehanger
(49 1114 005).
3. Removethe engine
mounting bracketfrom thefront
cover.
4. Disconnect
the vacuumhoses,
air hoses
and wires,
then remove the valves.
5. Remove
the air pump attaching
bolts and bar, and
removethe air pump and V-belt.
Remove the alternator attaching bolts, and remove
the alternator and V-belt.
6. Disconnect
the meteringoil pump connecting
rod
and oil tubesfrom the carburetor.
7. Remove the intake manifold attaching nuts, and
removethe carburetorand intake manifold assembly.
remove it with gaskets.
9. Remove the distributor securing nut and pull it
out from the front cover.
10. Removethe eccentric
from the pulley boss.
11. Remove the water
r-emove
the pump and
shaftpulley (for compressor)
pump attaching bolts, and
gasket.
Fig.
1-7 Removingwater
pump
12. lnvert the engine on the work stand.
13. Remove the bolts attaching the oil p&fl, and
removethe oil pan and gasket.
j;
a" ", {
,,.-j''{
rl a{i.
c-
-
Then removethe gasket
and two
8. Remove the thermal reactorrubberrings.
attaching nuts and
Fig. 1-6 Removing
distributor
Fig. 1-4 Engine
work stand
Fig. 1-5 Removing intake manifold ass'y
IT
Fis.1-8

1
Fig. 1-9 Removing oil strainer
15. Apply identification marks onto the front rotor
housingand rear rotor housing,which are common
parts, so that they will be as they were when re-
assembling
the engine.
14. Remove the bolts
removethe oil strainerattaching
the oil strainer,
and
and gasket.
t:laa
!ailiili
ilfi,';:
*Li4it
Fis.
1-10 Putting identification marks
16. Turn the engine
on the work standso that the
top of the engine is uP.
lf. Attach the ring gear
brake(49 lSSl 060) to the
flywheel or drive Plate.
lb. Remove
the eccentric
shaft
pulleybolt andremove
the pulley.
19. Turn the engineon the work stand so that the
front end of the engine
is uP.
20. Remove the front cover attaching bolts, and
remove the front cover and gasket'
21. Remove the '60" ring from the oil passage
on
the front housing.
22. Slidethe distributor drive gear off the shaft'
23. Remove
the nuts attaching
the chainadjuster
and
remove the chain adjuster.
Fig. 1-
24. Straighten
the
the nut and lock
sprocket.
25. Slide the oil
sprocket together
centric shaft and
tab of the lock washer
and remove
washer from the oil PumP driven
pump drive sProcket and driven
with the drive chain off the ec-
oil pump shaft simultaneouslY.
Fig. 1-12 Removing front cover
1-13 Removing chain adjuster
Removing eccentric shaft PulleY
Fis.1-11 Fig. 1-14 Removing chain and sprockets

1
[,
16. Remove the keys on the eccentric shaft and
oil pump shaft.
17. Slide the balance weight,thrust washerandneedle
bearingoff the shaft.
18. Removethe bolts attaching
the bearinghousing,
and slide the bearing
housing,needle
bearing,
spacer
and thrust plate off the shaft.
29. Turn the engineon the work stand so that the
top of the engine
is up.
30. To removethe flywheel in case
of engine mounted
with manual transmission,
proceedas follows:
1) Removethe clutch pressure plateassemblyattaching
bolts, and remove the pressure plate assembly
and
clutch disk.
2) Straightenthe tab of the lock washerand remove
the flywheel nut using the specialwrench (49 0820
03s).
Fig. 1-15 Removing flywheel nut
3) Remove
the flywheel by usingthe flywheel puller
(49 0823 3004), turning the handle of the puller and
lightly hitting the head of the puller.
Fig. 1-16 Removing flywheel
3l . To remove the counter weight in caseof engine
mounted with automatic transmission, proceed as
follows.
I) Removethe drive plate, and then remove
the ring
sear
brake
(49 1881060).
l) Attach the counterweight brake(49 l88l 055).
Thenstraiehten
the tab of thelock washer
andremove
the counter weight nut using the specialwrench (49
082003s).
3) Remove the counter weight by using the counter
weight puller (49 0839 3054), turning the handle
of the puller and lightly hitting the head of the
puller.
32. Remove the key on the eccentric shaft and turn
the engineon the work standso that the rear of the
engineis up.
33. Loosen the tension bolts in the sequence
shown
in Fig. I-17, and removethe tensionbolts.
Fis.1-17 loosening order
Note:
Do not loosen
the tension
boltsat onetime. Perform
the removalin two or three procedures.
34. Llft the rear housing off the shaft.
Fig. 1-18 Removing rear housing
35. Remove
anysealsstuckto the rotor sliding
surface
of the rear housing and placethem back into their
respective
originalpositions.
36. Removethe all corner seals,
corner sealsprings.
side seals,side seal springsand side piecesfrom the
rearside
of the rotor, and place
them in the sealcase
(49 0813 250), in accordance
with the numbers
near
eachrespectivegroove
on the faceof the rotor. These
marks are made in order to prevent
eachsealfrom
Tensionbolts