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

1
changingits original position in reassembling.
Fig. 1-19 Removing seals
37. Remove the two sealing
rubbersand 660" ring
from the rear rotor housing.
38. Attach the dowel puller(49 0813 215), and pull
the tubular dowels off the rear rotor housingholding
the rotor housingdown by hand to preventit from
movingup.
Fig. 1-20 Removing tubular dowel
39. Lift the rear rotor housingawayfrom the rotor,
beingcarefulnot to drop the apex sealson the rear
rotor. Remove
the two sealing
rubbersand "O" ring
from the rear rotor housing.
Note:
Replacethe
the engineis and the "O" rings when
40. Remove the each apex sealand spring from the
rear rotor and place them in the sealcase.
41. Removethe rear rotor away from the eccentric
shaft and place it upsidedown on a cleansheetof
cloth.
42. Remove each seal and spring on the other side
of the rear rotor, and place them in the sealcaseas
shownin Fig. l-22.
Fig. 1-22 Removing seals
Note:
1) If some of the sealsdrop off, be careful not to
change
the original position of eachsealon the rotor.
2) Apply identification mark onto the rear rotor,
which is a common part to front rotor, so that when
reassembling
the enginethe rotor can be installed in
its originalposition.
. Fig. 1-23 Putting identification mark
43. Remove the oil sealsand springs,first the outer
oil seal then the inner oil seal, using the oil seal
remover(49 0813 225).
Note:
1) Do not exert strong pressure
at only one placeto
prevent deformation of the oil seal.
2) k careful not to damagethe oil seallip. Use a
suitable
protector shownin Fig. l-24.
3) Replace the "O" rings in the oil seals
when the
engineis overhauled.
a) Apply identification mark onto rear oil sealsprings
of each rotor so that, when reassembling
the engine,
oil seal springs can be installed in their respective
face of the rotor as describedin Par. 1-C-1.
:
t
/
-1e
sealing
rubbers
overhauled.
{
#
a
'r-l
r
-l
Removing tubular dowel
Fig. 1-21 Removing rear rotor housing

.T
li
1
Fig. 1-24 Removing oil seal
-14.
Holding the intermediatehousing down by hand,
pull the tubular dowel off the intermediatehousirg
using
the dowel puller (49 0813 215).
45. Lift the intermediatehousing off the shaft being
careful not to damage the shaft. The intermediate
housing strould be removedby sliding it beyond the
rear rotor journal on the eccentric
shaft while holding
the intermediate housing up and at the same time
pushingup the eccentric shaft.
46. Lift out the eccentricshaft.
47. Repeat the above procedures
to removethe front
rotor housing
and the front rotor assembly.
1_8. INSPECTION
AND REPAIR
1-B-1. Inspecting
Front, Intermediate
and Rear
Housing
,. Removeall carbon on the housings
with an extra-
tlne emery paper. Wtren using a carbon scraper,
be
;areful not to damagethe finished surfaces
of the
housings.
l. Remove the sealingagenton the housings
by using
r cloth or a brush soaked in a solution of ketone
rr thinner.
Fig. 1-26 Removing sealing agent
3. Check for housing distortion by placing a straight
edge on the housing surface. Measurethe clearance
between the straight edge and the housing surface
with a feeler gauge,as shown in Fig. 1-27. If the
distortion exceeds0.04mm (0.0016
inl. refaceor re-
place the housing.
Fig.1-27 Checking
distortion
4. Check for wear on the rotor sliding surfaces
of
the housing and joint surfaces
with rotor housing as
shown in Fig. l-28.
If the wear exceeds0.10
mm (0.0039
in), reface or
replacethe housing.
Caution:
The sidehousings
(front housing,
intermediate
housing
and rear housing) can be reusedby grinding them if
the required finish can be maintained.
Fig. 1-25 Removingintermediate
housing

1
And when this work is performed
the detailed informations of Tovo
them.
on the markets,
ask
Kogyo, and follow
ir. -
-T
l-
1-B-
. i"l
::.
i
Fag. 'I-ZU UnecKmg wear
1-B-2. InspectingFront StationaryGearand
Main Bearing
1. Check the teeth on the stationary
gearfor wear,
crack or damage.
2. Checkthe main bearing
for wear,scratching,
flaking
or other damages.
3. Checkthe clearance
betweenthe main bearingand
eccentric shaft main journal by measuringthe inner
diameter of the main bearingand outer diameter of
the eccentricshaft main journal.
Fis. 1-29 main bearing clearance
The standard clearance
is 0.04 - 0.07mm (0.0016
-
0.0028
in). If the bearing
clearance
exceeds
0.10mm
t0.0039
in), replace
themainbearing.
Note:
To replace
the main bearing,proceeds
as follows:
1) Removethe stationarygear and main bearing
as-
sembly from the housing, using the main bearing
repfacer(49 0813 235), shownin Fig. 1-30.
2) Remove
the adaptoron the main bearingreplacer
and press
the main bearing
out of the stationarygear
by using the main bearingreptacer(49 0813 235),
as
shown
in Fig. l-31.
Fig. 1-30 Removing statiorrary gear assembly
3) Attach the adaptoronto the main bearing
replacer
(49 0813 235), aligning the tang of the bearing and
the slot of the stationarygear,and press
fit the main
bearing into the stationary gear until the adaptor
touches the stationary gear flange.
Fig. 1-31 Removing and installing main bearing
4) Press in the stationary geat to the housing with
the main bearing
replacer
(49 0813 235), aligningthe
slot of the stationary gear flange and the dowel pin
on the housing,as shownin Fig. l-32.
Fig. 1-28 Checking
Checking
Fig. 1-32 Aligning stationary gear

1
'-B-3. Inspecting
Rear
Stationary
Gear
and
Main Bearing
'.:.-k the rear stationary gear and main bearing
--- ,rding
to Par. l-B-2.
To removeand install the stationarygear, proceed
, :-.lllows:
Remove
the bolts attaching
the stationary
gearto
-".rrear
housing.
- Lsing the main bearing
replacer
(49 0813 235),
':::ove the stationary
gearfrom the rear housing.
,:
, Check the c6O"ring in the stationary gear for a
J::tlsg€. Replace
the "O" ring if necessary.
:' .{pply a thin coat of vaseline
on the "O" ring and
:.rce it in the grooveof the stationary
gear.
Fig. 1-33 Assembling stationary gear
: t Apply sealing
agentonto the stationary
gear
flange.
r t Installthe stationarygear
to the rearhousing
being
-areful not to damagethe "O" ring and aligningthe
slot of the stationary gear
with the dowel pin on the
:ear
housing.
- t Tighten the bolts attaching the stationary gear.
1-B-4. Inspecting
Rotor Housing
L Check for traces of gas or water leakagealong
ihe inner margin of each side face of the rotor
housing.
l. Removeall carbon from the inner surfaceof the
:-rrtor
housing by wiping with cloth. Soak the cloth
:r'r
a solution of ketone or thinner if the carbonis
::itlcult to remove"
3. Remove all deposits and rust from the cooling
water passages
on the housing.
4. Remove sealingagent 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 damage.
If any of these
excessive
condition exists,replace
the
rotor housing.
6. Check the rotor housing width at points close to
the trochoid surface by using a micrometer. The
measurements
should be taken at least at 4 points.
If the difference between the value of @ point and
the minimum value of the points @ @ O, exceeds
0.06
mm (0.0024
in). the rotor housing should be
replacedwith a new one.
. Fig.1-36 Checkingrotorhousing
width
1-B-5. Inspecting
Rotor
l. Check the combustion condition and gasleakage.
To a certain extent, the combustioncondition can
be judged as in the case of reciprocating engines
by the color and quantity of carbon on the rotor.
Combustion can be said to be good if the color of
carbon is brown. Generally carbon on the leading
side seen from the direction of rotation is brown,
while the trailing side shows black color. It should
be noted that this color varies
according
to operating
conditions
just before the engineis removed.
The gas leakage
can be judged
by checking
the color
of the rotor sidesurface
for blow-bytraces
originating
from the side seals
and corner seals.
2. Remove
the carbon
on the rotor by using
a carbon
Fig. 1-35 Checking
points
Fig. 1-34 Removing carbon
1n

1
remover or emery paper. Carbon in the seal
grooves
of the rotor shouldbe removedwith a carbonremover
being careful not to damagethe grooves. Washthe
rotor in cleaning solution and dry by blowing with
compressed
air.
The standard
clearance
is 0.04 - 0.08
mm (0.0016
-
0.0031in). Replace the bearing if it is more than
0.10
mm (0.0039
an).
Note:
To replacethe rotor bearing,proceed as follows:
1) Placethe rotor on the support so that the internal
gear is facing downward. Using the rotor bearing
repfacer (49 0813 240) without the adaptor ring,
pressthe bearingout of the rotor, being carefulnot
to damagethe internal gear. If the bearing bore in
the rotor is damaged,finish the bore with emery
paper and blow with compressed
air.
Fig. 1-39 Removing rotor bearing
2) Place the rotor on the support with internal gear
faced upward. And place the new rotor bearing on
the rotor so that the rotor bore is in line with the
bearinglug.
3) Press
fit the new bearing using the rotor bearing
repfacer (49 0813 240) with the adaptor removed
attaching screws,until the bearingis flush with the
rotor boss.
4) Wash the rotor thoroughly and blow with com-
pressed
air.
1-B-7. Inspecting
Rotor Oil Seal
and Spring
l. Check the oil seal
for wear or any damage. If the
lip width of the oil seal
is 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 inspect the rotor and replace
severely
worn or damaged.
4. Check the internal gearfor cracks,score,
if it is
worn or
chipped teeth.
5. Check the gap between the side housing and the
rotor by measuring
the rotor housingwidth and rotor
width. The rotor width should be measured at 3
points as shownin Fig. l-37.
The differencebetween the minimum width of rotor
housing and the maximum width of the rotor should
be within 0.10 - 0.21
mm (0.0039- 0.fi)83 inl.
If the clearance is more than the specifications, replace
the rotor assembly. If the clearanceis less than the
specifications,it indicates that the internal gearhas
come out, so strike the internal gear lightly with
plastic hammer being careful not to damage
and re-
check the gapbetweenthe sidehousing
and the rotor.
1-8-6. InspectingRotor Bearing
l. Check the rotor bearing for wear, flaking, scoring
or any damage. If any of these conditions is found,
replacethe bearing.
2. Check the rotor bearing clearanceby measuring
the inner diameter of the rotor bearing and outer
diameter of the eccentric straft rotor journal.
t
.1*
r*
'*
*l
#
u"@
Fig. 1-37 Checking rotor width
Fig. 1-40 Installing rotor bearing
1
: ll
Fig. 1-38 Checking rotor bearing clearance

1
-11and confirm the free
*::h finger. The protrusion
0.5mm (0.02
in).
Seal
protrusion Lip width
FiS. 1-41 Checking
1-B-8. Inspecting
Apex Seal,
Side Piece and Spring
- Remove all carbon from the apex seal,side piece
nd spring,beingcareful not to damage
the apexseal.
Never
useemery paper asit will damage
the apexseal.
\\'ash them with cleaningsolution.
l. Check the apex seal
and sidepiecefor wear, crack
rn any damage. If any of these conditions is found,
:eplace
the sea[. Check the spring for wear.
3. Measure
the height of the apex seal
with a micro-
meter at two positionsshown in Fig. 142. Replace
if the heigfut
is less
than 7.0mm (0.275
inl.
Fig. 1-42 Apex seal height
4. Checkthe gapbetweenthe apexseal
andthegroove.
To check the gap,place the apex sealin its respective
grooveon the rotor and measure
the gap between
the
apex seal and the groove with a feeler gauge. The
feeler gaugeshould be inserted until the tip of the
gauge
reachesthe bottom of the groove. The standard
gap is 0.05 - 0.09mm (0.0020
- 0.0035in). If the
gap is more than 0.15mm (0.0059
in), replace
the
apex seal.
Fig. 1-44 Checking apex seal and groove
5. Check the gap between the apex seal and side
housing. To check, measurethe length of the apex
sealwith a micrometer.
Compare the measured
_apex seal length with the
minimum value among @ O and @ points of the
rotor housing (see Fig. 1-35). The standard
gap is
0.13 - 0.17
mm (0.0051
- 0.0062
inl.
If it is more than 0.30mm (0.0118
inl, replace
the
apex seal. If necessary,
correct the apex seallength
with emery paper.
movement by pressing
should be more than
Fig.1-45 Measuring
apex
6. Check the free height of the
shownin Fig. l-46. It should be
(0.15
in).
seal length ,
apex sealspring as
more than 3.8
mm
Freeheight
.':,
""i
"j
,'l
n
LJ
Fig. 1-43 Checking
apex seal Fis. 1-46 Apex sealspring
T2

.
1
Rotor housing
width
'a
J
-c
a'6
:J
-c.
0)
a
Clearance-
Clearance-
Side seal, Groove
Fis. 1-47 Clearanceof
1-B-9. Inspecting
Side Sealand Spring
1. Remove all carbon from the side sealand spring
with a carbon remover.
2. Check the side sealprotrusion from the rotor sur-
face, and also confirm the free movementby pressing
with finger. The protrusion should be more than 0.5
mm (0.02
inl.
3. Checkthe gap betweenthe sidesealand the groove
with a feeler gauge as shown in Fig. 1-48. The
standardgap is 0.04 - 0.07mm (0.001G
- 0.0028
inl. If the gap exceeds
0.10mm (0.0040
in), replace
the side seal.
Fig. 1-48 Checking side seal gap
4. Checkthe gap betweenthe side
sealand the corner
sealwith these sealsinstalled on the rotor.
To check, insert a feeler gauge
between the end of
the side seal(againstthe rotating direction of rotor)
and the corner
seal. If thegap
exceeds
0.4mm (0.016
inl, replace
the sideseal.
Whenthe side sealis replaced,
adjust the gapbetween
the side sealand the corner seal
by grinding the one
end of the side seal along the round shape of the
corner seal with a fine file so that the gap will be
0.05 - 0.15mm (0.002
- 0.006
in). And thenmake
respectiveidentification notches on the reverseside
of the side seal. If this gap is too large, gas-sealing
performancewill deteriorate.
I : 13
Fig. 1-49 Checking corner sealand side sealgap
1-8-10. Inspecting
Corner
Seal
and Spring
1. Remove carbon from the corner seal and corner
seal groove.
2. Check the corner seal protrusion from the rotor
surface, and also confirm the free movement by
pressing
with finger. The protrusion should be more
than 0.5mm (0.02
inl.
3. Check the gap between the corner seal and the
corner seal groove by the bar limit gauge
(49 0839
165), This gap enlargement shows uneven wear of
the corner sealgroove, which occurswhen the engine
is operated with dust entering through a clogged
element,damagedair cleaneror any other cause.When
the wear is permitted to increase, the enginepower
will be reduced and the enginewill becomehard to
start. The decision whether the gap has correct di-
mension is made by examining wear of the corner
seal
groove
with bar limit gauge(49 0839 165). The
wear is classified
into three conditions.
a. Neither end of the gauge goes into the groove.
This means that the gap conforms to the specifi-
cations.
b. While the go-endof the gaugegoes
into the groove,
the not-go-end does not. In this case, replace the
corner sealwith a 0.03mm (0.0012
in) oversizeone.
Do not reborethe groove.
I{
i
t

1
c :a the both ends of the gaugego into the bore,
--:eins
that the gap exceeds
the limit of 0.08 mm
i ffi1 in). Rebore the corner seal
groovewith the
.:f -td reamer (49 2ll3 030 and 49 0839 170)
.. I mm (0.4a10
in) diameterand use a 0.2mm
Om79 in) oversizecorner seal.
l{ote:
a. .\ the corner sealgroove tends to strow a heavy
rts3r in the direction of the rotation, the sidearcs
: the gaugearc partially cut off. Be sure to take
:. measurementin the direction of the maximum
*ear of the groove.
b. The dimensionsof the outer diameterof the gauge
::. asfollows:
c. If the bar limit gauge
is not available,
use a feeler
aauge.Thestandard
gap
is 0.020
- 0.048
mm (0.0008
- 0.0019
in) and the limit is 0.08
mm (0.0031
in).
To reborethe cornerseal
groove,
proceed
asfollows:
i ) Remove carbon, rust and other depositsfrom the
groove.
being carefulnot to damage.
I t Install the ii1 @9 2ll3 030) onto the rotor and
::ehten the correct bar being carefulnot to damage
'-.i"!e
rotor bearingand apex sealgroove.
3) Ream the groove
with the Reamer
(49 0839 170)
by hand applying sufficient engine oil as a coolant.
Whenfeedingthe reamer, it must be turned by about
20 rotations or over before the reaming work is
accomplished
completely.
4) Removethe reamerand jig from the rotor.
5) Repeatthe same
procedure
whenreaming the other
grooves
of the rotor.
6) Thoroughly cleanthe rotor, and checkand confirm
by visual inspection the condition of the reaming
groove
and to see if there is any damage
to the rotor.
7) Fit a 0.2mm (0.0079inl oversizecorner sealand
a spring into the groove, and check the corner seal
protrusion from the rotor surface,and also confirm
the free movement by pressing with finger.
8) Recheck the gap between the side seal and the
corner seal. The standardgap is 0.05 - 0.15mm
(0.002
- 0.006
in).
Note:
a. When installing or removing the jig, be careful
not to hit the rotor.
b. If the reaming is carried out without applying
oil, it will be difficult to obtain the proper surface
roughnessno matter how many times the reaming
may be repeated.
c. Avoid two stage reaming, that iS, drawing the
reamer halfway during the reaming work and then
resuming the reaming, because
chips may affect the
surfaceroughness.
d. Before starting the reamingwork, it must be con-
firmed that the reamer diameter is up to specifi-
cations,becausethe reamercould be worn in excess
of the limit if it was usedmany times.
1-B-11. Inspecting Eccentric
Shaft
l. Wash the shaft in a cleaning solution and blow
the oil passage
with compressedair.
2. Check the shaft for cracks,scratches,wear or any
other damage. Be sure that the oil passages
areopen.
3. Check the shaft run-out. To check, mount the
shafton "V"-blocks and apply a dial indicator. Slowly
rotate the shaft and note the reading on the indicator.
If the run-out is more than 0.06mm (0.0024 in),
replacethe shaft with a new one.
Fig. 1-52 Checking
run-out
4. Check
leakage orthe blind plug in the shaft end for oil looseness. If any oil leakage is found,
Fig. 1-50 Checking corner seal groove
Fig. 1-51 Reaming corner seal groove
t4

f
1
remove the blind plug with a hexagonal Allen key
and replacethe "O" ring. 6. The oil jets are installed in the eccentric shaft.
The oil jets open when the number of enginerevolu-
tions increases
and the oil presure rises. Check for
spring weakness,stick or damageof the steel ball.
0s
%,_._
(@@
't
:
3
lii
c
I
It
I
fr
u
i.r
:
i|!
Fis.1-53 Blindplug
5. Check the needle roller bearing in the straft end
for wear or any damage. If any of theseconditions
is found, replace the needle roller bearing. If nec-
essary,supply a lithium grease onto the roller bearing.
(Only the car with manual transmission)
Note:
To replacethe bearing,
use the bearing
replacer
(49
0823 070A).
Fig. 1-54 Removing roller bearing
Fig.1-56 Roller
bearingandoil jet
1-B-12. InspectingNeedle Bearing
Ctreckthe needlebearing for wear or damage.
Inspect the bearinghousingand thrust plate for wear
or any damage.
Fig. 1-57 Needlebearings
Thrust washer 3. Bearinghousing
Needle bearing 4. Thrust plate
1-8-13. InspectingEccentric
Shaft Front and Rear
Oil Seals
Check for oil leaks of the front oil sealfitted into
the front cover and the rear oil sealfitted into the
rear staionary
gear.
If necessary,
replacethe oil sealas follows:
1. Removethe oil sealby using a suitable tool.
2. Removethe oil that adheresto the oil sealmount-
ing bore by wiping with a cloth soakedin a solution
of thinner.
3. Position a new oil seal on its mounting bore and
placea hardwood on the oil sealto preventa damage.
Then, install the oil sealwhile tapping the hardwood
with a hammer. Drive the oil seai-intoposition until
it is firmly seated.
Note:
1. Do not coat the outer surface
of the oil sealwith
any lubricant or sealing
agent. r
2. Do not tap the oil seal directly with a hammer. i.:
l5
Fig. 1-55 Installing roller bearing

i. When installing-
the flywheel or front pulley, apply
a srnallamount of enginelubricant to the oit seaiiip.
I-C. ENGINE
ASSEMBLY
The proceduresfor assembling
the engine when the
engine
is to be completely overhaured
aie asfollows:
l-C-l. Installing
Oil Seal
I- Placethe rotor on a rubber pad or cloth.
l- lnstall the oil seal springs in their respective
grooves on the rotor with each round edgebf the
+ring fitted in the stopperhole shown in F-ig.
1_5g.
Caution:
l: ftr oil seal
springs
havebeenpainted in cream or
blue color. The cream-corored
sptingsmust be fitted
on the front faces of both front and rear rotors.
IVhile the bluecorored springsshould be on the rear
taces
of the rotors.
b. Wtren installing each oil seal spring, the painted
side of springmust be faced to thJ oil-ieal (uiward),
thar -is the .square edge of spring facesto it, oil
seal(upward).
oil seal
then the outer oil seal.
To install the inner oil seal,
the following steps
should
be taken:
1) Placethe oil sealto the grooveso that the square
edggof springfits in the stopper
notch of the oil seal.
2) Pressthe inner oil seal by using a used inner oil
seal so that the lip surfaceof the inner oil sealsinks
into a p-osition
approximately
0.4mm (0.016in) below
the surfaceof the rotor as shown in Fig. f_OO.
Caution:
Apply the above method to the inner oil seal only.
To install the outer oil seal,proceed as follows.
l) Placethe oil sealto the grooveso that the square
edgeof springfits in the stopper
notch of the oil seal.
2) Push the head of the oil sealslowly with fingers.
Note:
a. When replacing the oil seal, confirm the smooth
movement of oil sealby placing the oil sealon the
oil sealspring in the groovebefore insertingthe 0.o,,
ring.
b. Be careful not to deform the rip of the oil sear.
On the front face of rotor
On the rear
Blue
face of rotor
paint
Fig.
1_60Installing
inner
oil seal
4. Apply sufficient engine
lubricant onto eachoil seal
and groove, and confirm the smooth movement of
each oil sealby pressing
the head of oil seal.
5. Check the oil seal protrusion. (Ref. par. l-B_7)
6. Install the oil seal springs and oil sealson the
other side of the rotor.
1-C-2. Installing
EachSeal
l. Placethe rotor which has beenfitted with the oil
seals
on the rubber pad or cloth.
2. Fit- the apex seals
without springsand side pieces
into their respective
groovesso thit each side piece
positions
on the rear sideof eachrotor.
Hold the apex sealsby using the used ..O', ring to
keep the apex seals
in position.
3. Place
the corner seal
springs
and corner seals
into
their respective
grooves.
4. Fit the side sealsprings
and sideseals
into their
respective
grooves
as shown in Fig. l_61.
Fig. 1-b9 Installing
3. Insert a new "O" ring in
sde of the rotor, install the
oil seal
springs
each oil seal. For each
oil seals,
first the inner
Fig. 1-58 Stopperhole of oil sealspring