1992 MAZDA PROTEGE clutch

CLUTCH MASTER CYLINDER H
CLUTCH MASTER CYLINDER
PREPARATION
SST
49 0259 770B
Wrench, flare nut For
disconnecting
and connecting
clutch pipe
I I 03UOHX-01
REMOVAL / INSPECTION / INSTALLATION
Caution
l Clutch fluid will damage painted surfaces. Be sure to use a container or rags to collect it. If
fluid gets on a painted surface, wipe it off immediately with a rag.
1. Remove in the order shown in the figure, referring to Removal Note.
2. Inspect all parts and repair or replace as necessary.
3. Install in the reverse order of removal, referring to
Installation Note.
N.m (m-kg, R-lb
23UOHX-007
1. Battery
2. Diagnosis connector
3. Clutch pipe
Removal Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page H- 8
Installation Note . . . . . . . . . . . . . . . . . . . . . . . . . . page H-
8
4. Clip
5. Nut
6. Clutch master cylinder
Check for fluid leakage from the cylinder
bore
Overhaul . . . . . . . ..*........*................ page H-10
Air bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page H- 8
7. Gasket
H-7

H CLUTCH MASTER CYLINDER
23UOHX-Ot ,a
\ I 03UOHX-016
7
I
03UOHX-014
Removal Note
Clutch pipe
1, Disconnect the clutch pipe with the SST.
2. Disconnect the clutch hose from the reservoir.
3. Plug the outlet of the reservoir.
Installation Note
Clutch pipe
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
I. After installation, bleed the clutch system.
(Refer to page below.)
Inspection and Adjustment
Clutch pedal height and free play
(Refer to page H-5.)
AIR BLEEDING
The clutch hydraulic system must be bled to remove air in-
troduced whenever a hydraulic line is disconnected.
Note
l The fluid in the reservoir must be maintained at the
3/4 level or higher during air bleeding.
Caution
l Clutch fluid will damage a painted surface. If 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. __,

CLUTCH MASTER CYLINDER H
/I f-------i- OWOHX-01
1. Remove the bleeder cap from the clutch release cylinder
and attach a vinyl hose to the bleeder plug.
2. Insert 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:
5.9-8.8 N#rn (80-90 cm-kg, 52-78 in-lb)
7. Check for correct clutch operation.
8. Verify that there is no fluid leakage.
H-9

H CLUTCH MASTER CYLINDER
OVERHAUL
Caution
l Clean the disassembled parts in solvent and blow through all ports and passages wlth com-
pressed air. .-J
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, referring to
Assembly Note.
I
1. Clip 7. Spacer
2. Hose 8. Primary cup
3. Joint Inspect for wear and cracks
4. Bushing 9. Return spring
5. Snap ring 10. Master cylinder body
Disassembly Note ..,.,..,.........,,,.,......... below Inspect cylinder bore for scoring and
Assembly Note . . . . . . . . . . . . . . . . . . . . . . . . . . . page H-l 1 corrosion
6. Piston and secondary cup assembly
Disassembly Note ,..................... page H-l 1
Assembly Note .,.,.......,...,......,.,,, page H-l 1
Inspect for wear, scoring and cracks
H-10
03UOHX-01
Disassembly Note
Snap ring
Caution
l Do not damage the push rod contact surface of the
piston.
1. Press the piston down and remove the snap ring with snap
ring pliers. -

CLUTCH MASTER CYLINDER H
SMUOHX-Ol!
03UOHX-02(
03UOHX-02
Piston and secondary cup assembly
Caution
l Hold a rag over the master cylinder to prevent the
piston and secondary cup assembly from jumping
out.
1. Remove the piston and secondary cup assembly, spacer,
and primary cup by applying compressed air through the
clutch pipe installation hole.
Assembly Note
Caution
l Before assembly, make sure all parts are completely
clean.
l Do not mix different brands of clutch fluid.
l Do not reuse the clutch fluid that was drained.
l Apply the specified clutch fluid to the piston and
secondary cup assembly, spacer, primary cup, and
cylinder bore before assembly.
l Replace parts with new ones whenever specified to
do so.
03UOHX-019
Piston and secondary cup assembly
1. Install the spring, primary cup, spacer, and piston and
secondary cup assembly, noting the proper direction of the
parts.
Snap ring
Caution
l Do not damage the push rod contact surface of the
piston.
1. While pressing the piston, install the snap ring.
H-l 1

H CLUTCH RELEASE CYLINDER
CLUTCH RELEASE CYLINDER
PREPARATION
SST
49 0259 7708 For
Wrench, flare nut e c$on;;;;;!&
clutch pipe
03UOHX-022
REMOVAL / INSTALLATION
Caution
l 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.
1. Remove in the order shown in the figure, referring to Removal Note.
2. Install in the reverse order of removal, referring to Installation Note.
(MOLYBDENUM DISULFIDE)
(1.3-2.2, S-16)
16-23 (1.6-2.3, 12-17) N.m (m-kg, ft-lb
23UOi-K011
1, Clutch pipe 2. Bolt
Removal Note . . . . . . . . . . . . . . . . . . . . . . . ,........... . . below 3. Clutch release cylinder
installation Note . . . . . . . . . . . . . . . . . . . . . . . . . . page
H-13 Remove boot and check for fluid leakage
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...*. page H-13
Removal Note
Clutch pipe
03UOHX-024
Caution
l After removing the clutch pipe, plug the clutch pipe
to avoid fluid leakage.
1. Disconnect the clutch pipe with the SST.
H-12 .

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 RELEASE CYLINDER, CLUTCH UNIT
Disassembly Note
Piston and cup assembly
Caution
l Hold a rag over the release cylinder to prevent the
piston and cup assembly from suddenly popping
out.
1. Remove the piston and cup assembly by applying com-
pressed air through the clutch pipe installation hole.

I
I
13UOHX-017
CLUTCH UNIT
PREPARATION
SST
49 EOll IA0
Brake set,
ring gear
49 EOll 104
Collor
(Part of
49 EOl 1 1 AO)
49 SE01 310A
Clutch disc
centering tool
49 1285 073
Chuck
IPart of
b9 1285 071) For
prevention of
engine rotation 49 EOll 103
Shaft
(Part of
49 EOl 1 1 AO)
For 49
EOI 1 105 prevention of
engine rotation Stopper 453
(Part of
49 EOl 1 IA0
4
For
installation of
clutch disc 49 1285 071
Puller, bearing
For
removal of pilot
bearing For
prevention of
engine rotation
For
prevention of
engine rotation
23UOHX-013
For
removal of pilot
H-14