MAZDA 232 1990 Workshop Manual Suplement

H CLUTCH CONTROL
RELEASE BEARING
ROLLER BEARING
CLUTCH PEDAL RELEASED
RELEASE FORK RELEASE E?EARfNG
CLUTCH PEDAL DEPRESSED To improve clutch operation feeling and increased parts life, a newly designed friction plate and needle roller
bearings are used between the release fork and the release bearing.
With
the kdusion of this friction plate, the force required to depress the clutch pedal is reduced because
the usual sliding-contact action between the release bearing and the release fork is changed to a rolling
action of the friction plate,
H-8

SUPPLEMENTAL SERVICE INFORMATION, TROU8LESHOOTlNG GUIDE H
SUPPLEMENTALSERVICE INFORMATION
The following points in this section are changed in comparison with 323 Workshop Manual (1206IO-89F).
Troubleshooting guide
Clutch fluid (with ABS)
l Replacement
Clutch pedal (BP DOHC Turbo) Clutch release cylinder (with ABS) l Air bleeding
Clutch unit
l Removal I Inspection I installation
Clutch master cylinder
(BP DOW Turbo or with ABS) l Removal I Inspection I installation
93GOHX-710
l Removal I Inspection I Installation (BP DUHC Turbo)
l Air bleeding (with ABS)
l Overhaul (BP DUHC Turbo)
TROUBLESHOOTING GUlDE
Problem
Possibte Cause Remedy Page
Slipping
Clutch disc facing worn excessively
Replace U-l 9
Clutch disc facing surface hardened or oifed
Repair or replace H-l 9
Pressure plate damaged Replace H-19
Diaphragm spring damaged or weakened
Replace H-l 9
Insufficient clutch pedal piay
Adjust H-12
Clutch pedal sticking
Repair or replace U-11
Flywheel damaged
Repair or replace H-19
Faulty
Excessive runout or damaged clutch disc
Replace H-19
disengagement
Clutch disc spiines rusted or worn ’
Remove rust or replace H-l 9
Clutch disc facing oiled
Repair or replace H-19
Diaphragm spring weakened
Reptace H-19
Excessive clutch pedal ptay
Adjust -
Insufficient clutch fluid
Add fluid H-10
Leakage of clutch fluid
Locate and repair or -
replace
Clutch vibrates
Clutch disc facing oiled
Repair or replace H-l 9
when accelerating
Torsion rubbers weakened
u-19 Clutch disc facing hardened or damaged Replace
Repair or replace H-19
Clutch disc facing rivets loose
Replace H-l 9
Pressure plate damaged or excessive runout
Replace H-l 9
Flywheel surface hardened or damaged
Repair or replace H-19
Loose or worn engine mount
Tighten or replace -
Clutch pedal
sticking Pedal shaft not properly lubricated
Lubricate or replace H-l 1
Asistireturn spring damaged or poor adjust
Replace or adjust H-11, 12
Abnormal noise
Clutch release bearing damaged
Replace N-1 9
Poor iubrication of release bearing sleeve
Torsion rubbers weakened Lubricate or replace H-19
Replace u-t9 Excessive crankshaft
end play
Repalr -
Pilot bearing worn or damaged
Replace H-79
Worn pivot points of reiease fork
Repair or replace H-19

H CLUTCH FLUID (WITH ABS)
CLUTCH FLUID (WITH ABS)
PREPARATION
SST
49 0259 770B
For
Wrench, flare nut
m air
bleeding
1
93GOHX-714 93GOHX-712
REPLACEMENT
Note
l A common reservoir is used for the clutch and brake
system fluids.
l The fIuid in the reservoir must be maintained at 314
tevet or higher during replacement.
Caution
l Be careful not to spill the fluid on a painted surface.
If this should happen, wash it off immediately.
l Do not mix different brands of fluid.
l Do not reuse the clutch fluid that was drained.
1. Drain the brake fluid from the master cylinder by pumping
it through a wheel cylinder bleed screw.
2. Remove the bleeder cap from the clutch release cylinder
and attach a vinyl hose to the bleeder plug.
93GOHX-77 3
3. Place the other end of the vinyl hose in a clear container.
4. Fill the reservoir with new fluid to the MAX mark.
5. Slowly pump the clutch pedal several times.
6. With the clutch pedal depressed, loosen the bleeder screw
with the SST to let the fluid escape. Close the bleeder screw
with the SST.
7. Repeat Steps 4 and 5 until only clean fluid is seen.
8. Tighten the bleeder screw.
Tightening torque:
5.9-8.8 Nom (60-90 cm-kg, 52-78 in-lb)
9. Add fluid to the MAX mark.
IO. Slowly pump the clutch pedal several times.
Verify that there is no fluid leakage.
11.
Check operation of the clutch system.
12. Bleed and check operation of the brake system.
(Refer to Section PJ

CLUTCH PEDAL (BP DOHC TURBO)
CLUTCH PEDAL (BP DOHC TURBO)
REMOVAL I INSPECTION I INSTALLATION
1. Remove in the order shown in the figure, referring to Removal Note.
2. Inspect alf parts, and repair or replace as necessary.
H
Note
l Apply lithium based grease to the bushings and pins before installation.
.‘3 Install in the reverse or&y of removal. p&rrinQ to lnstaI[ation Note. -. _. .-__.. _.. - - -- - -- - - - -
4 @J
/
IS-17
1. Clip
15. Bolt
2. Pin 16. Spacer
3. Spacer 17. Clutch pedal
4. Bushing
18. Bushing
5. Clip 19. Bushing
6. Assistireturn spring
20. Clip
Adjustment . .._..._.._........_....,......*. page H-12 21. Wave washer
7. Spring seat
22. fin
8. Clutch pedal rod
23. Bushing
9. Adjusting nut
24. Nut
IO. Busing 25. Push rod
Il. Spring seat Inspect for damage and bending
f 2. Bushing
26. Clutch fork
13. Nut
27. Pedal pad 14.
Washer Inspect for damage and wear

H CLUTCH PEDAL (BP DOt-iC TURBO)
93GOHX-716
w-12
1 Adjustment
Assist/return spri rtg
I. Measure the installation length B of the assistlreturn spring.
2. Adjust the installation length B by turning nut A shown in
the figure.
Installation length: 35.5-36.5mm (1.398-I .437 in)

CLUTCH MASTER CYLINDER (BP DOHC TURBO OR WITH ABS)
CLUTCH MASTER
CYLINDER (BP DUHC TURBO OR WITH ABS)
PREPARATDN
SST
H
49 0259 770B
Wrench, flare ntlt For
dIsconnecti ng
and connectmg
clutch pipe
93GOHX-717
REMOVAL I INSPECTlON / INSTALLATION (BP DOHC TURBO)
Caution
l Clutch fluid wilt damage painted surfaces. Be sure to use a container or rags to collect it. If
ftuid does get on a painted surface, wipe it off immediately with a rag. I. Remove in the order shown in the figure, referring to
Removal Note. 2. Inspect al parts, and repair or replace as necessary.
3. Install in the reverse order of removal, referring to
InstaIIation Note.
LHD
(1.9-2.6, 14-W)
19-25 (1 A-2.6, 14--19)
N-m (m-kg, Mb)
Q?CflUY.7, 1. Strut bar
2. Battery
3. Diagnosis connector
4. Clutch pipe
Removal Note . . ..._.-...._..._._....._,.. page H-14
Installation Note. . . . . . . . . . .._....._.... .._ page H-14
5. Clip 6. Nut
7. Clutch master cylinder
Check for fluid leakage from cylinder bore
Overtraul .__. . , ._. _. ._.. ._. . . ._. . . . . . . ._. ., . page H-l 5
Air bleeding .,._.._,......._._.I...........- page K-14
8. Gasket
H-13

CLUTCH MASTER CYLINDER (BP DOHC TURBO OR WITH ABS)
‘. I
-K-l
03iJOHX-076 1 ,
93GOHX-720
93GOHX-72’
Removal Note
CIutch pipe
1. Disconnect the clutch pipe with the SST,
Installation Note
Clutch pipe
1. Tighten the clutch pipe with the SST
Tightening torque:
13-22 Mm (1.3-2.2 m-kg, 9.4-l 6 ft-lb)
Air Bleeding
f . After installation, bleed the clutch system. (Refer to betow.)
AIR BLEEDlNG (WITH ABS)
The clutch hydrautic system must be bled to remove air in-
troduced whenever a hydraulic Iine is disconnected.
Note l
The fluid in the reservoir must be maintained at 3/4
level or higher during air bleeding.
Caution l
CMch fluid will damage a painted surface. ff fluid
does get on a painted surface, wipe it off im-
mediately. l
Do not mix different brands of clutch fluid. l
Do not reuse the clutch fluid that was drained.
1. Remove the bleeder cap from the clutch release cylinder
and attach a vinyl hose to the bleeder screw.
2. Inseti the other end of the vinyl hose in a clear container.
3. Slowly pump the clutch pedal several times.
4. While depressing the pedal, loosen the bleeder screw with
the SST to let fluid and air escape.
Close the bleeder screw with the SST.
5. Repeat Steps 3 and 4 until no air bubbles are seen in the
fluid.
6. Tighten the bleeder screw.
Tightening torque:
5-g-8.8 Nm (60-90 cm-kg, 52-78 in-lb)
7. Check for correct clutch operation.
8. Verify that there is no fluid leakage.
H-14

c .
L
CLUTCH MASTER CYLINDER (BP DOHC TURBO OR WfTH ABS) H
OVERHAUL (BP DOHC TURBO)
Caution
l Clean the disassembled parts in solvent and blow through all ports and passages with com-
pressed air.
I. Disassemble in the order shown in the figure, referring to Disassembly Note.
2. Inspect all parts, and repair or replace as necessary.
3. Assemble
in the reverse order of disassembly, referring to Assembly Note.
RHD
83--t 12 (8.5--f1.5, 61.5-83.2)
N-m (m-kg, B-lb)
n?fznuv 7?3
1. Clip
2. Hose 3. Joint
4.
Bushing
5. Snap ring
Disassembly Note ._, . . . ._. . . . . ._.. . . . . .
page t-i-1 6
Assembly Note . . . . . . . . . . . . ..__......_.... page H-l 7
6. Piston and secondary cup
assembly
Disassembly Note .,....-.............,. page H-l 6
Assembly Note . . . . . . . . . . . . . . . . . . . . .._._.. page H-l 6
inspect for wear, scoring and cracks
7. Spacer
JJ”“r 1*- t LC
8. Primary cup
Inspect for wear and cracks
9. Return spring
IO. Joint bolt
1 I. Packing
12. One-way valve piston
Disassembly Note .._......._...I....,.. page H-l 6
13. Return spring . .._.._......_..._..............- page H-l 6 14.
Master cylinder body
Inspect cylinder bore for scoring and
corrosion
w-f5

H CLUTCH MASTER CYLINDER (BP DOHC TURBO OR WITH ABS)
Disassembty Note
Snap ring
Caution
l Do not damage the push rod contact surface of the
piston.
1. Press the piston down and remove the snap ring with snap-
ring pliers.
Piston and secondary cup assembly
Caution
l Hold a rag over the master cylinder to prevent the
piston and secondary cup assembly from jumping
out.
1. Remove the piston and secondary cup assembly, spacer,
and primary cup by applying compressed air through the
clutch pipe installation hole.
One-way vaive piston and return spring
Caution
l Hold a rag over the master cylinder to prevent the
piston and spring from jumping out.
1. Remove the piston by applying compressed air through the
cylinder bore.
Assembly Note
Caution
l Before assembly, make sure all parts are completety
clean.
l Do not mix different brands of clutch ftuid.
l Do not reuse the clutch fluid that was drained.
l Apply the specified clutch fluid to the piston and
secondary cup assembty, spacer, primary cup, and
cylinder bore before assembly.
l Replace parts with new ones whenever specified to
do so.
03uot-!x-019
Piston and secondary cup assembty
1. InstaD the spring, primary cup, spacer, and piston and
secondary cup assembly, noting the proper direction of the
parts.

CLUTCH MASTER CYLlNDER (BP DOHC TURBO OR WITH A8S), CLUTCH RELEASE CYLINDER (WITH AN) H
Snap ring
Caution
l Do not damage the push rod contact surface of the
piston.
t . While pressing the piston, install the snap ring.
CLUTCH RELEASE CYLINDER (WITH ABS)
PREPARATION
SST
49 0259 770B
Wrench, flare nut For disconnecting
and connecting
clutch pipe
93GOHX-724
AIR BLEEDING (WITH ABS)
I_ After installation, bleed the clutch system.
(Refer to page H-16.)
93GOHX-725
H-17