1990 MAZDA 232 wheel

F2 TURBOCHARGER CONTROL SYSTEM
I 93GOF2-756
93GOF2-75!
93GOF2-761
5. Mark the actuator rod.
Caution
l Do not apply compressed air over 98 kPa (1.0
kg/cm2, 14 psi).
6. Adjust the compressed air pressure to 83 kPa (0.85
kg/cm”, 12 psi).
7. Verify that the rod moves when applying and releasing air
pressure.
WASTEGATE SOLENOID VALVE
Inspection
1, Remove the ,solenoid valve.
2. Verify that air does nut flow from @ through @
3. Apply IN to the solenoid valve and verify that air flows from
@ through @
TURBUCHARGEFI
Inspection
1. Be sure tf7e engine is cool.
2. Remove the air hose.
3. Check that the compressor wheel assembly turns smoothly.
4. If there is excessive drag or noise, replace the turbocharger.
93GOF2-761
FZ-46

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

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

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

H CLUTCH UNIT
PREPARATION
SST
49 E301 060
Brake, ring gear
For removal and
i nstaI\abon of
c!utch cover and
flywl-leel
49 E301 062
Collar
(Part
of 49 E301 060) For
removal and
installation of
cIutch cover and
flywheel
49 1285 071 For
I removal of blot
Puller, bearing
Lj , - e bearing
49 0823 U72A 1 For
I installation of pilot 49 E3OI 061
Body
(Part
of 49 E301 060)
49 SE01 310
Centering tool,
clutch disc
49 1285 073
Chuck
(Part of
49 1285 071)
Installer 1 eccentric
shaft bearing @@D bearing -
For
removal and
installation of
dutch cover and
flywheel
For
support and
alrgnment of
clutch disc 7
For
removal of pilot
bearing
93GOHX-726
H-18