torque MAZDA PROTEGE 1992 Workshop Manual

CLUTCH RELEASE CYLINDER
Installation Note
Clutch pipe
H
1. Tighten the clutch pipe with the SST.
Tightening torque:
13-22 N-m (1.3-2.2 m-kg, 9-16 ft-lb)
Air Bleeding
1. After installation, bleed the clutch system.
(Refer to page below.)
23UOHX-011
OVERHAUL
Caution
l Clean the disassembled parts in solvent and blow through all ports and passages with com-
pressed air.
l Before assembly, make sure all parts are completely clean.
l Apply the specified clutch fluid to the piston and cup assembly and cylinder bore before as-
sembly.
1. 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.
@ 5.9-8.8 (60-90, 52-78)
N.m (cm-kg, in-lb)
23UOHX-012
1. Boot 5. Bleeder cap
2. Push rod 6. Bleeder screw
3. Piston and cup assembly 7. Steel ball
Disassembly Note . . . . . . . . . . . . . . . . . . . . . . page H-l 4 8. Release cylinder body
Inspect for wear, scoring
and cracks inspect cylinder bore for scoring and
4. Spring corrosion
H-13

H CLUTCH UNIT
/ 6fs 23UOHX-015
Removal Note
Clutch cover and disc
1. Install the SST or equivalent.
2. Loosen each bolt one turn at a time in a crisscross pattern
until spring tension is released. Then remove the clutch COV-
er and disc.
‘6
I
23UOHX-016
23UOHX-01
Pilot bearing
1. Remove the pilot bearing with the SST if necessary.
Flywheel
Note
l After removing the flywheel, inspect for oil leakage
past the crankshaft rear oil seal.
If necessary, replace the oil seal.
(Refer to Section B.) -J
1. Hold the flywheel with the SST or equivalent.
2. Remove the flywheel.
Installation Note
Flywheel
1. Wipe the bolts clean and apply sealant to the bolt threads.
2. Install the flywheel and the
SST or equivalent.
3. Tighten the bolts in the pattern shown.
Tightening torque:
96-103 N,m (9.6-10.5 m-kg, 71-76 ft-lb)
Pilot bearing
Note
l Install the pilot bearing flush with the flywheel.
1. Install the new bearing with a suitable pipe.
Bearing outer diameter: 35mm (1.376 in) .-’

CLUTCH UNIT, RELEASE BEARING, CLUTCH COVER, CLUTCH DISC H
L
13UOHX-01;
03UOHX-03 8
23UOHX-018
5
03UOHX-032
03UOHX-03
Clutch disc
1. Clean the clutch disc splines and main drive gear splines;
then apply organic molybdenum sulfide grease.
2. Hold the clutch disc in position with the
SST.
Clutch cover
1. Install the SST or equivalent.
2. Align the dowel holes with the flywheel dowels.
3. Tighten the bolts evenly and gradually in the pattern shown.
Tightening torque:
18-26 Nom (1.8-2.7 m-kg, 13-20 ft-lb)
RELEASE BEARING
INSPECTION
Note
l The clutch release bearing Is a sealed bearlng and
must not be washed in solvent.
1. Turn the bearing while applying force in the axial direction.
If the bearing sticks or has excessive resistance, replace it.
CLUTCH COVER
INSPECTION
Note
l Minor scoring or burning should be removed with
emery paper.
1. Inspect the contact surface of the clutch disc for scoring,
cracks, and burning. Repair or replace as necessary.
2. Inspect the contact surface of the clutch release bearing
for wear and cracks.
If there is wear or cracks, replace the clutch cover.
CLUTCH DISC
INSPECTION
Note
l Use sandpaper if the trouble is minor.
1. Inspect the lining surface for burning and oil contamination.
Replace the clutch disc if it is badly burned or oil soaked.
2. Inspect for loose facing rivets and rubbers.
Replace the clutch disc if either is loose.
H-17

TRANSAXLE OIL Jl
/
03UOJl-00
03UOJl-O(
TRANSAXLE OIL
INSPECTION
Note
l Park the vehicle on level ground.
1. Disconnect the speedometer cable and remove the speedo-
meter driven gear.
2. Verify that the oil level is between the F and L.
3. Install the speedometer driven gear.
Tightening torque:
7.8-12 N,m (80-120 cm-kg, 89-l 04 in-lb)
4. Connect the speedometer cable.
REPLACEMENT
1. Disconnect the speedometer cable and remove the speedo-
meter driven gear.
2. Remove the drain plug and washer. Drain the oil into a suita-
ble container.
3. Install a new washer and the drain plug.
Tightening torque:
39-54 N#rn (4.0-5.5 m-kg, 29-40 ft-lb)
4. Add the necessary amount of the specified oil through the
speedometer driven gear mounting.
Specified oil
Grade: API service GL-4
Viscosity: SAE 75W-90
Capacity: 2.88 liters (2.83 US qt, 2.38 Imp qt)
5. Verify the oil level.
6. Install the speedometer driven gear and connect the
speedometer cable.
Jl-7

TRANSAXLE Jl
Shim selection
Adjust the bearing preload and select the shim(s) as follows.
Primary shaft assembly
1, Set the primary shaft assembly into the clutch housing.
2. Install the transaxle case to the clutch housing and tighten
the bolts to the specified torque.
Tightening torque:
19-26 N#m (1.9-2.6 m-kg, 14-19 ft-lb)
03UOJl-083 3. Mount a dial indicator to the transaxle hanger and meas-
ure the primary shaft thrust clearance.
03UOJl-064
03UOJl-Of%!
03UOJl-086
Clearance: 0.005-0.1 OOmm (0.0002-0.0039 in)
4. Select the closest shim on the thin side from the table.
Adjustment shim thickness: mm (in)
0.1 (0.004) 0.2 (0.008) 0.3 (0.012)
1 0.4 (0.016)
0.5 (0.020) 0.6 (0.024)
Secondary shaft bearing preload
1. Install the funnel and bearing outer race into the clutch
housing.
2. Set the secondary shaft into the clutch housing.
3. Install the secondary shaft bearing outer race into the trans-
axle case.
4. Install the transaxle case to the clutch housing and tighten
the bolts to the specified torque.
Tightening torque:
19-26 N-m (1.9-2.6 m-kg, 14-19 ft-lb)
5. Mount a dial indicator to the transaxle case and measure
the secondary shaft end play.
6. Select the shim as follows.
(a) Add 0.03mm (0.0012 in) to the thrust clearance.
(b) Add 0.08mm (0.0031 in) to the thrust clearance.
(c) Select the thickest shim in the range from (a) to (b) from
the table.
I
13UOJl.004
Jl-37

Jl TRANSAXLE
51-38
03UOJ l-08!
RACE
OWOJ i-09
ONJOJl-09 , _.
03UOJ I-09
Example: 0.22mm (0.009 in)
0.22mm (0.009 in) + 0.03mm (0.001 in)
= 0.25mm (0.010 in)
0.22mm (0.009 in) + 0.08mm (0.003 in)
= 0.30mm (0.012 in)
Range: 0.25mm (0.010 in)-0.30mm (0.012 in)
Select the 0.30mm (0.012 in).
Adjustment shim thickness:
mm (in)
0.15 (0.006) 0.20 (0.008) 0.25 (0.010) 0.30 (0.012)
0.35 (0.014) 0.40 (0.016) 0.45 (0.018) 0.50 (0.020)
93GOJ I-524
Differential
1. Install the bearing outer race into the clutch housing.
2. Set the differential assembly into the clutch housing.
Note
l Turn A and B until the gap shown in the figure is
eliminated.
3. Install the transaxle case side bearing outer race to the SST
(selector).
4. Set the
SST (collars) in the positions shown in the figure.
5. Tighten the
SST (bolts) to the specified torque.
Tightening torque:
19-26 N-m (1.9-2.6 m-kg, 14-19 ft-lb)

TRANSAXLE Jl
03UOJl-09:
03UOJi-09
03UOJl-09
03UOJl-09
03UOJl-0:
Note
l Turn the bars until the SST (selector) can no longer
be moved.
6. To seat the bearings, mount the bars on parts @ and @I
of the selector, and turn the selector so the gap is widened.
7. Turn in the reverse direction until the gap is eliminated.
8. Install the
SST to the differential pinion gear through the
transaxle case.
9. Turn the
SST with a torque wrench. Adjust the SST (selec-
tor) with the bars until the specified preload is obtained.
Preload:
0.03-0.74 N#m (0.3-7.6 cm-kg, 0.26-6.60 in-lb)
10. Remove the SST.
11. Measure the clearance around the entire circumference of
the
SST (selector).
12. Select the proper adjust shim(s) to be used for the differen-
tial by referring to the table and selecting the shim which
is nearest (on the thick side) to the largest measured clear-
ance in the selector.
Adjust shim thickness:
0.20 (0.008)
0.25 (0.010)
0.40 (0.016)
0.45 (0.018) mm (in)
0.30 (0.012) 0.35 (0.014)
0.50 (0.020) 0.55 (0.022)
13. Remove the SST (bolts).
14. Remove the transaxle case and the
SST (collars).
Jl-39

Jl TRANSAXLE
,
,,
03UOJi-09
03UOJl-10
Jl-40
OSUOJl-1C
15. Remove the bearing outer race from the SST (selector).
16. install the selected shim(s) and bearing outer race to the
transaxle case.
-’
Bearing preload (Differential)
Measure the preload as follows.
1. Set the differential assembly into the clutch housing.
2. Install the transaxle case onto the clutch housing.
Tightening torque:
19-26 N-m (1.9-2.6 m-kg, 14-19 ft-lb)
3. Install the SST to the differential side gear through the trans-
axle case.
4. Measure the bearing preload.
Preload:
0.03-0.74 N,m (0.3-7.6 cm-kg, 0.26-6.60 in-lb)
5. If not as specified, readjust the bearing preload.
6. Remove the SST.
7. Remove the transaxle case and differential assembly.

TRANSAXLE Jl
- 23UOJl-01
03UOJl-11
03UOJl-14
I 03UOJl-11
Transaxle case assembly
1, Apply a thin coat of sealant to the contact surfaces of the
clutch housing and transaxle case, tighten the transaxle case
installation bolts to the specified torque.
Tightening torque:
19-26 Nom (1.9-2.6 m-kg, 14-19 ft-lb)
Clutch hub assembly (6th) and 6th shlft fork
1. Install the clutch hub assembly (5th) and the 5th shift fork
together.
Locknut
1. Shift to 1 st gear.
2. Lock the primary shaft with the
SST.
3. Tighten new locknuts on the primary and secondary shafts.
Tightening torque:
126-206 N*m (13.0-21 m-kg, 94-152 ft-lb)
4. Stake the locknuts.
5. Measure the 5th gear thrust clearance with a dial indicator.
Clearance: 0.06-0.26mm (0.0024-0.0102 in)
Maximum : 0.31 mm (0.0122 in)
6. If not as specified, reassemble the transaxle.
Jl-47

TRANSAXLE Jl
1. Transaxle
Installation Note ..,......,.............. page Jl-49
2. Engine mount No.4
3. Driveshaft
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page Jl-50
4. Stabilizer (BP SOHC)
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page Jl-50
5. Tie-rod end
Installation Note ,........,..,........... page Jl-50
6. Clutch release cylinder
7. Engine mount No.2
8. Exhaust pipe
9. Engine mounting member
Installation Note . . . . . . . . . . . . . . . . . . . . . . . .
page Jl-50
10. Control rod
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page Jl-51 11. Extension bar
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . page Jl-51
1 12. Starter
13. Ground
Installation Note .,..,...,......,........ page Jl-5
14. Neutral switch connector
15. Back-up light switch connector
16. Speedometer cable
Installation Note . . . . . . . . . . . . . . . . . . . . . . . .
page Jl-5
17. Battery carrier
18. Battery
19. Air hose and resonance chamber
20. Splash shield
21. Wheel and tire 1
Installation Note
Transaxle
1. Set the transaxle on a jack and lift it into place.
Install tne transaxle oorts.
Tightening torque:
64-69 N*rn (6.5-9.1 m-kg, 47-66 ft-lb)
Loosely tighten engine mount No.4 bolts.
Jl-49