1990 MAZDA 232 air bleeding

H
CLUTCH
iNDEX ..*..*.............*..*..............................* l-l- 2
OUTLINE .................................................. l-b- 4
OUTLtNE OF CONSTRUCTION
................. H- 4
SPECtFlCATtUNS ....................................
H- 4
CLUTCH CONTROL
.................................... t-i- 5
CLUTCH PEDAL ..................................... H- 5
CLUTCH MASTER CYLINDER ................... H-
7
RELEASE 5EARlNG ................................ H- 8
1 SERVICE /
SUPPLEMENTAL SERVICE INFORMATION.. H- 9
TROUBLESHOOTlNG
GUIDE.. .................... Ii- 9
CLUTCH FLUID (WITH ABS) ......................
H-l 0
PREPARATION ....................................... u-IO
REPLACEMENT ......................................
H-10
CLUTCH PEDAL (BP DOHC TURBO) ........... H-1 1
REMOVAL I INSPECTION / INSTALLATtON . . H-11
CLUTCH MASTER CYLINDER
(BP DOHC TURBO OR WITH ABS)
............ H-f 3
PREPARATION .......................................
u-1 3
REMOVAL I INSPECTION I INSTALLATION
(BP DOHC TURBO) ............................... H-13
AIR BLEEDlNG (-WtTH ABS) ...................... ti-14
OVERHAUL
(BP DOHC TURBO). ............... H-15
CLUTCH RELEASE CYLINDER (WITH ABS). H-l 7
PREPARATION .......................................
H-l 7
AtR
BLEEDING (WITH ABS). ..................... H-17
CLUTCH UNIT
.......................................... u-1 8
PREPARATION
....................................... H-f 8
REMOVAL I INSTALLATION ...................... H-19
93GOHX-701

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

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 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

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