1987 MAZDA 626 Workshop Manual

CLUTCH MASTER CYLINDER 6
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76G06X-016
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—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

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.
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7. While pressing the piston with a screwdriver, in-
stall the snap ring.
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6-10
•

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
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6-11

6 CLUTCH RELEASE CYLINDER
REMOVAL
1. Disconnect the clutch pipe, with the SST.
Note
Plug the pipe in order to prevent fluid from
leaking.
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2. Remove the installation bolts.
3. Remove the release cylinder.
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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
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6-12

CLUTCH RELEASE CYLINDER 6
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86U06X-024
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Piston cup
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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.
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6—13

6 AIR BLEEDING
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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.
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49 0259 770B
76G06X-023
6—14
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