MAZDA 626 1987 Workshop Manual
Manufacturer: MAZDA, Model Year: 1987, Model line: 626, Model: MAZDA 626 1987Pages: 1865, PDF Size: 94.35 MB
Page 791 of 1865
CLUTCH PEDAL 6
CLUTCH PEDAL
REMOVAL
Remove in the sequence shown in the figure referring to the removal note.
1. Clip
2. Bolt and nut
3. Spring washer
4. Flat washer
5. Clutch pedal Assembly
6. Rod
7. Adjusting nut
8. Bushing
9. Spring seat
10. Assist spring
11. Spacer
12. Bushings
13. Clip
14. Pin
15. Spring seat
16. Bushing
17. Spacer
18. Bushing
76G06X-006
19. Clip
20. Wave washer
21. Pin
22. Push rod
23. Bushing
24. Stopper rubber
25. Pad
26. Clutch pedal
(p
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r Adjusting nut % £
/ I / Assist spring
"ci*
Removal Note
Before removing the clutch pedal, loosen adjusting
nut of the assist spring to relieve the spring tension.
76G06X-007
6-5
Page 792 of 1865
6 CLUTCH PEDAL
INSPECTION
Check the following, and repair or replace any faulty
parts.
1. Worn or damaged pedal bushing
2. Twisted or bent pedal
3. Worn or damaged pedal pad
76G06X-008
INSTALLATION
Install in the reverse order of removal referring to the
installation note.
Installation Note
Apply grease (lithium base, NLGI No.2) to the
bushings.
76G06X-009
ADJUSTMENT
1. Adjust the pedal height. (Refer to page 6—4.)
2. Check the pedal free play, and adjust if necessary.
(Refer to page 6—4.)
3. Adjust the installation length of the assist spring.
The installation length is adjusted by turning nut
A show in the figure and adjusting dimension B.
Standard dimension:
38.6—39.6 (1.520—1.559 in)
76G06X-010
6-6
Page 793 of 1865
CLUTCH MASTER CYLINDER 6
CLUTCH MASTER CYLINDER
LHD RHD
13—22 N-m (1.3—2.2 m-kg, 9-16 ft-lb)
•19—26 N-m (1.9—2.6 m-kg, 14—19 ft-lb)
^13—22 N-m (1.3—2.2 m-kg, 9—16 ft-lb)
1. Clutch pipe
2. Nuts
76G06X-011
3. Clutch master cylinder
4. Gasket
76G06X-012
REMOVAL
1. Remove the ABS relay box. (LHD)
2. Disconnect the clutch pipe with the SST.
3. Remove the mounting nuts.
4. Remove the clutch master cylinder.
Caution
Clutch fluid will damage painted surfaces. Be
sure to use a container or rags to collect it.
If fluid does get on a painted surface, wipe it
off immediately with a rag.
86U06X-010
6-7
Page 794 of 1865
6 CLUTCH MASTER CYLINDER
DISASSEMBLY
Components
LHD RHD
83—113 N-m (8.5—11.5 m-kg, 61—83 ft-lb) 20—29 N-m (2—3 m-kg, 14—22 ft-lb)
20—29 N-m (2—3 m-kg, 14—22 ft-lb)
20—29 N-m (2—3 m-kg, 14—22 ft-lb)
QDQ^dJ) 83—113 N-m (8.5—11.5 m-kg, 61—83 ft-lb)
|
83—113 N-m (8.5—11.5 m-kg, 61—63 ft-lb)
76G06X-013
1. Snap ring
2. Piston and secondary cup
assembly
3. Spacer
4. Primary cup
5. Return spring
6. Tank cap and baffle
7. Reserve tank
8. Bushing
9. Connector bolt
10. Connector
11. Joint bolt
12. One-way valve piston
13. Spring
14. Cylinder body
Caution
When disassembling or assembling the clutch master cylinder, do so in a clean space free
from dirt and dust.
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1. Press down on the piston with a phillips screwdriver
and remove the snap ring with snap ring pliers.
76G06X-014
6-8
Page 795 of 1865
CLUTCH MASTER CYLINDER 6
76G06X-015
76G06X-016
fe
—t
86U06X-014
2. Remove the piston and secondary cup assembly
by blowing compressed air through the clutch pipe
installation hole.
Caution
When doing so, use a rag to prevent the pis-
ton and secondary cup assembly from project-
ing out.
3. Remove the spacer, primary cup, and return
spring.
4. Remove the tank cap and baffle.
5. Remove the tank set screw. (LHD)
6. Remove the reserve tank.
7. Remove the bushing, if necessary.
8. Remove the connector. (LHD ABS, RHD without
ABS)
9. Remove the joint bolt, then remove the one-way
valve piston and spring.(FE DOHC, RF-N, RF-CX)
INSPECTION
After cleaning all parts, check the following points.
Replace any parts with new parts, if necessary. Note
that rubber parts should be cleaned with clutch fluid.
1. Wear or damage of cylinder wall and/or piston.
2. Weakness of return spring.
3. Wear or damage of piston cup.
4. Damaged or bent reserve tank and/or reserve tank
installation part.
ASSEMBLY
Apply clean clutch fluid to the piston cup and the cyl-
inder bore before assembly.
Caution
After applying clutch fluid, check that no for-
eign material is on the cup.
86U06X-015
6-9
Page 796 of 1865
6 CLUTCH MASTER CYLINDER
1. Install the one-way valve spring and piston. (FE
DOHC, RF-N, RF-CX)
2. Tighten the joint bolt with new gasket. (FE DOHC,
RF-N, RF-CX)
Tightening torque:
83—113 Nm (8.5—11.5 m-kg, 61—83 ft-lb)
76G06X-017
3. Install the connector and new gaskets. (LHD ABS,
RHD without ABS)
Caution
Install the connector at the angle shown in the
figure.
Tightening torque:
20—29 N m (2—3 m-kg, 14—22 ft-lb)
76G06X-018
4. Install the new bushing.
5. Install the reserve tank, baffle and tank cap.
6. Install the following parts:
(1) Return spring
(2) Primary cup
(3) Spacer
(4) New piston and secondary cup assembly
Caution
A new primary cup, piston, and secondary cup
assembly must be used.
76G06X-019
w
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7. While pressing the piston with a screwdriver, in-
stall the snap ring.
76G06X-020
6-10
•
Page 797 of 1865
CLUTCH RELEASE CYLINDER
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
SST.
Tightening torque:
13—22 N m (1.3—2.2 m-kg, 9—16 ft-lb)
76G06X-021 4. Install the ABS relay box. (LHD)
After installation
1. Perform air bleeding. (Refer to page 6—14.)
2. Verify that there is no leakage.
3. Perform a road test.
CLUTCH RELEASE CYLINDER
86U06X-019
6-11
Page 798 of 1865
6 CLUTCH RELEASE CYLINDER
REMOVAL
1. Disconnect the clutch pipe, with the SST.
Note
Plug the pipe in order to prevent fluid from
leaking.
86U06X-020
2. Remove the installation bolts.
3. Remove the release cylinder.
86U06X-021
DISASSEMBLY
Components
6—9 N»m (60—90 em-kg, 52-78 In-lb)
1. Boot
2. Push rod
3. Piston.and pis-
ton cup
4. Return spring
5. Bleeder cap
6. Bleeder screw
7. Steel ball
8. Cylinder body
76G06X-022
6-12
Page 799 of 1865
CLUTCH RELEASE CYLINDER 6
86U06X-023
86U06X-024
O^CfVYYTi)
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Piston cup
76U06X-029
1. Pull out the push rod and boot.
2. Remove the piston and piston cup by blowing com-
pressed air through the clutch pipe installation hole.
Caution
When doing so, use a rag to prevent the pis-
ton and piston cup assembly from projecting
out.
3. Remove the return spring.
4. Remove the following parts if necessary:
(1) Bleeder cap
(2) Bleeder screw
(3) Steel ball
INSPECTION
After cleaning all parts, check the following points.
Replace any parts with new parts if necessary. Note
that rubber parts should be cleaned with clutch fluid.
1. Wear or damage of cylinder wall and piston.
2. Weakness of return spring.
3. Wear or damage of piston cup.
ASSEMBLY
1. Install the following parts:
(1) Steel ball
(2) Bleeder screw
(3) Bleeder cap
2. Install the return spring.
3. Install the new piston and piston cup assembly.
Caution
a) A new piston and piston cup assembly must
be used.
b) Make sure the return spring and piston cup
assembly are as illustrated.
86U06X-025
6—13
Page 800 of 1865
6 AIR BLEEDING
76U06X-031
4. Install the following parts:
(1) Push rod
(2) Boot
INSTALLATION
1. Install the release cylinder.
2. Tighten the installation bolts.
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
SST
Tightening torque:
13—22 N-m (1.3—2.2 m-kg, 9—16 ft-lb)
After installation
1. Perform air bleeding.
2. Verify that there is no leakage from the hydraulic
circuit.
3. Perform a road test.
49 0259 770B
AIR BLEEDING
The clutch hydraulic system must be bled to remove
air that entered when the pipes were disconnected.
This bleeding is done as described below.
Note
a) The fluid in the reserve tank must be main-
tained at the 3/4 level or higher during air
bleeding.
b) Use only the specified fluid type. (Refer to
page 6—3)
c) Be careful not to spill clutch fluid onto a
painted surface.
1. Remove the bleeder cap, and attach a vinyl hose
to the bleeder screw.
2. Place the other end of the vinyl tube in a glass con-
tainer of the appropriate capacity.
3. Slowly pump the clutch pedal several times by
hand.
4. While the clutch pedal is depressed, loosen the
bleeder screw to let fluid and air escape.
Then close the bleeder screw.
5. Repeat step 3 and 4 until no more air bubbles are
in the fluid.
6. Check for correct clutch operation.
86U06X-027
86U06X-028
49 0259 770B
76G06X-023
6—14
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