MAZDA 232 1990 Workshop Manual Suplement

G SUPPLEMENTAL SERVICE INFORMATION, STARTING SYSTEM
SUPPLEMENTAL SERVICE INFORMATION
The following points in this section are changed in comparison with Mazda 323 Workshop Manual
[1203-l O-89F (Europe), ? 204-I O-89F (Australia)].
Starter
l Removal / InstaHation
Atternator (RI-ID)
l Removal I InstatIation 93GOGX-705
STARTING SYSTEM
STARTER
Removal I Installation
I. Remove in the order shown in the figure.
2. Inspect all parts, and repair or replace as necessary.
3. lnstail in the reverse order of removal.
37-52 (3.8-5.3, 27-38)
9.8-t2 N-m
(IOO-120 cm-kg, 87-104 in-lb)
(3.8-5.3, 27-38)
9.8-12.N.m
It t \
I. Battery
(100-120 cm-kg, 87-104 in-lb)
37-52 27-38)
(3.8-5.3, 27-38)
N-m (m-kg, ft-lb)
5. Starter
Remove tram above
6.
Starter bracket 2. intake manifold bracket
3. S terminal wire
4. B terminal wire
G-4

CHARGWIG SYSTEM G
CHARGING SYSTEM
PREPARATION
SST
49 0118 85OC For
Puller, ball joint removal of ball
joint
93GOGX-707
ALTERNATOR (RHD)
Removal / Installation
I. Remove in the order shown in the figure.
2. Install in the reverse order of removal, referring to Installation Note.
1
37-52 (3.8-5.3, 27 37-52 (3.8-5.3, 27
72.0, 65-81)
37-52 (3.8-5.3, 27-38) 37-52 (3.8-5.3, 27-38)
N-m (m-kg, ft-lb) N-m (m-kg, ft-lb)
93G?GX-70 93G?GX-70
I. Negative battery cable I. Negative battery cable 7. Stabilizer (Right) 7. Stabilizer (Right)
2. Tire and wheel (Right front) 2. Tire and wheel (Right front) Installation Installation Note . . . . . . . . . . . . . -. . I -. . . . - . . . . page G-6 Note . . . . . . . . . . . . . -. . I -. . . . - . . . . page G-6
3. Undercover 3. Undercover 8. Lower arm (Right) 8. Lower arm (Right)
4. Crossmember 4. Crossmember 9. Driveshaft (Right) 9. Driveshaft (Right)
5. Front exhaust pipe 5. Front exhaust pipe IO. Alternator connectors IO. Alternator connectors
6. Tie-rod end 6. Tie-rod end 11. Alternator 11. Alternator
Removal Note ._....._.........._..._ ._..... page G-6 Removal Note ._....._.........._..._ ._..... page G-6 Remove from below Remove from below
G-5 G-5

G CHARG1NG SYSTEM
93GOGX-709
1
93GOGX-710
G-6
Removal Note
Tie-rod end 1. Remove the right side tie-rod end with the
SST.
instailation Note
Stabilizer 1. Install the stabilizer bolt.
Dimension A: 17-19mm (0.67-0.75 in)

H
CLUTCH
iNDEX ..*..*.............*..*..............................* l-l- 2
OUTLINE .................................................. l-b- 4
OUTLtNE OF CONSTRUCTION
................. H- 4
SPECtFlCATtUNS ....................................
H- 4
CLUTCH CONTROL
.................................... t-i- 5
CLUTCH PEDAL ..................................... H- 5
CLUTCH MASTER CYLINDER ................... H-
7
RELEASE 5EARlNG ................................ H- 8
1 SERVICE /
SUPPLEMENTAL SERVICE INFORMATION.. H- 9
TROUBLESHOOTlNG
GUIDE.. .................... Ii- 9
CLUTCH FLUID (WITH ABS) ......................
H-l 0
PREPARATION ....................................... u-IO
REPLACEMENT ......................................
H-10
CLUTCH PEDAL (BP DOHC TURBO) ........... H-1 1
REMOVAL I INSPECTION / INSTALLATtON . . H-11
CLUTCH MASTER CYLINDER
(BP DOHC TURBO OR WITH ABS)
............ H-f 3
PREPARATION .......................................
u-1 3
REMOVAL I INSPECTION I INSTALLATION
(BP DOHC TURBO) ............................... H-13
AIR BLEEDlNG (-WtTH ABS) ...................... ti-14
OVERHAUL
(BP DOHC TURBO). ............... H-15
CLUTCH RELEASE CYLINDER (WITH ABS). H-l 7
PREPARATION .......................................
H-l 7
AtR
BLEEDING (WITH ABS). ..................... H-17
CLUTCH UNIT
.......................................... u-1 8
PREPARATION
....................................... H-f 8
REMOVAL I INSTALLATION ...................... H-19
93GOHX-701

H INDEX
INDEX
I
LHD
@ ,a
1,
FLUID SPEClFlCATlON
OR FMVSS116 DOT-3
(WITH ABS) f . Clutch pedal (8P DOHC Turbo)
Removal I Inspection I
93GOHX-7C 4. Clutch cover
Removal I Installation . . . . . . . . . . . . . . . . . . page H-1 9
Installation . . . . . ..+., ._. . . . . . . -. . . . . . . . . _. . page H-l 1
2. Clutch master cylinder
(BP DOHC Turbo or with ABS)
Removal I Inspection I
Installation (BP DOHC Turbo). . page H-l 3
Air Ueeding (with ABS) . . .._........_ page H-14
Overhaul (BP DOHC Turbo) _...._ page H-15
3. Ctutch release cylinder (with ABS)
Air bleeding .._.,._.......,............._... page H-l 7 5. Clutch disc
Removal I f
6. Pilot bearing
Removal I I
7. Flywheel
Removal /
H-2 nstallation .................. page H-l 9
nstallation. .................
page H-f 9
nstallation .................. page H-l 9

i
1
INDEX H
I. Clutch pedal (BP DOHC Turbo)
Removal I inspection /
Installation ................................ page H-l 1
2. Crutch master cylinder (BP DUHC Turbo)
Overhaul .....................................
page H-l 5
3. Clutch cover
Removal I Installation.. ................
page H-t 9 4. Clutch disc
Removal I Installation..
................ page H-19
5. Pilot bearing
Removal J Installation ..................
page H-l 9
6. Flywheel
Removal I installation.. ................ page H-l 9
H-3

H OUTLINE
OUTLINE
OUTLINE OF CONSTRUCTION
A hydraulic clutch control mechanism is used.
The basic construction is the same as that of 323 2WD model, but there is no interchangeability of parts
except for the release cylinder.
1. An assist/return spring is used on the BP DOHC Turbo model to reduce the required clutch pedal effort..
2. The hydraulic clutch master cylinder for the 8P DOl-lC Turbo model has a built-in check valve.
3. To improve clutch operation feeling and increased parts life, a friction plate and needle roller bearings
are used between the release fork and the release bearing.
93GOHX-704
SPECIFICATIONS
Hem
Clutch control Engine/Transaxle
BP SUHC BP DOHC Turbo
GSMX-R
Hydrautic
Clutch cover
Type
Set load
N (kg, lb) Diaphragm spring
3,846 (392, 862) 5,494 (560, I ,232)
Outer diameter 1
mm (in) 225 (8.858) 230 (9.055)
I 1 nner diameter mm (in)
I 150 (5.906)
I 155 (6.102) I
CI utch disc
Pressure plate side
mm {in) 4.1 (0.161) 3.2 (0.126)
Thickness f
Flywheel side
mm (in) 3.5 (0.138) 3.2 (0. f 26)
I Type I Suspended
I
Clutch pedal LHD 6.55 Pedal
ratio
RHD 6.7
Full stroke mm (in)
I 135 (5.32)
I
Height (With carpet) mm [in)
I I 96-204 (7.72-8.03)
I
Master cylinder Inner diameter
mm {in)
I 15.87 (0.625)
Release cylinder inner diameter
mm (in)
I - 19.05 (0.750)
I
Clutch fluid SAE J1703 or FMVSSI 16 DOT-3
93GOHX-705
H-4

CLUTCH CONTROL H,
CXUTCH CONTROL
CLUTCH PEDAL
l An assistireturn spring is used on BP DO-K Turbo engine-equipped models to reduce the required pedal
effort.
l The assist/return spring is mounted vertical to the pedal for a compact arrangement.
wiNGi B G”3 * RANGE A
RANGE B + + RANGE A
Operation With the clutch pedal fully
released, the assist/return spring is compressed, causing force F to act upon ful-
crum 0,
As a result, force Fy is created, and acts upon fulcrum @ to hold the pedal outward.
1 1 When clutch pedal depressed.
(1) Fukrum @ within range A
When the pedal is depressed, it moves inward, centered upon fulcrum @.
Fy, which is the force opposing pedal movement, acts upon futcrum @ until fulcrum @ crosses the
imaginary line connecting fulcrums
@ and @
As a result, there is a slight feeling of resistance when the clutch pedal is first depressed.
(2) With fulcrum @ within range 8
When fulcrum @ crosses the imaginary line between fulcrums @ and @, Fy now acts in the same
direction as pedal
movement, thus reducing the force required to depress the pedat.
H-5

H CLUTCH CONTROL
RANGE B CT] e RANGE A
RANGE B ++I + RANGE A
93GOHX-70
2. When clutch pedal released.
(1) With fulcrum @ within range B
When the clutch pedal is released, reaction force f (from clutch master cylinder push rod) is applied,
and fy force pushing outward overcomes Fy force, with the result that the clutch pedal moves out-
ward, centered upon fulcrum @.
(2) With fulcrum @ within range A
When futcrum @ crosses the imaginary iine 4etween fulcrums @ and a, force Fy, which is a result
of force F trying to expand the spring, is added to fy and pushes the pedal fully outward.
t-l-6

C1UTCl-i CONTROL H
CLUTCH MASTER CYLINDER
‘CHECK VALVE
RHD
CHECK VALVE
93GOHX-708 A hydraulic clutch master cylinder with a built-in check valve is used on the BP DOHC Turbo model.
This is to provide smooth engagement of the clutch disc by controlling (by the check valve) the flow of fluid
from the clutch release cylinder back to the master cylinder when the clutch pedal is released, thus cushion- ing the impact “shock”.
l-l-7