Mazda 3 Service Manual: Clutch Unit Removal/Installation [C66 M R]

1. Remove the battery cover..

2. Disconnect the negative battery cable..

3. Remove the aerodynamic under cover No.2 and the splash shield as a single unit..

4. Drain the manual transaxle oil..

5. Disconnect and/or remove the following parts in the engine compartment.

a. Remove the battery component. (ex: battery, battery tray and PCM component).

b. Remove the air cleaner component. (ex: air cleaner, air hose).

c. Disconnect the control cable from MTX..

d. Disconnect the connectors and GND wiring harness from the MTX.

e. Remove the brackets from MTX.

6. Disconnect and/or remove the following parts related to the suspension and axle.

a. Remove the front tires..

b. Disconnect the clip securing the brake hose from the shock absorber..

c. Disconnect the ABS wheel-speed sensors from the steering knuckles..

d. Disconnect the tie-rod end ball joints from the steering knuckles..

e. Disconnect the stabilizer control links (upper side) from the shock absorbers..

f. Disconnect the front lower arms from the steering knuckles..

g. Disconnect the drive shaft (LH) from the MTX..

h. Disconnect the drive shaft (RH) from the joint shaft..

i. Remove the joint shaft..

7. Disconnect and/or remove the following parts from the underside of the vehicle.

a. Remove the hanger rubber from the exhaust manifold.

b. Disconnect the clutch release cylinder from MTX..

c. Remove the starter..

8. Install the SST

using the following procedure.

CAUTION:

• Refer to the SST instruction manual for the basic handing procedure.

  

  
  

a. Remove the windshield wiper arm and blade..

b. Remove the front fender molding..

c. Remove the cowl grille..

d. Remove the cowl panel..

e. Protect the windshield using tape.

f. Replace the hood stay to the position shown in the figure.

NOTE:

• The hood opening angle is increased by placing the hood stay to the position shown in the figure. A space for installing the SST

  can be secured by increasing the hood opening angle.

i. Disconnect the washer tank and set it aside.

ii. Tilt the hood stay in the direction of the arrow shown in the figure.

iii. Pull out the hood stay in the direction of the arrow shown in the figure.

iv. Rotate the hood stay at the pivot fulcrum shown in the figure.

v. Remove the hood stay.

vi. Install the hood stay as shown in the figure.

CAUTION:

• If the hood stay is not hooked to the hood hole, the hood may fall down. Lightly shake the hood to verify that the hood stay is hooked securely.

g. To enable to install the SST

, disconnect the clip shown in the figure and set the wiring harness aside.

h. Install the SST

using part number 99794 1025

or an M10×1.25

, length

25 mm {0.98 in}

bolt as shown in the figure.

Engine front side

Tightening torque

• 38—51 N·m {3.9—5.2 kgf·m, 29—37 ft·lbf}

Engine rear side

Tightening torque

• 38—51 N·m {3.9—5.2 kgf·m, 29—37 ft·lbf}

i. Align the bolt of the shock absorber (RH) shown in the figure with the rear shaft hole for the right side of the SST

.

j. Align the bolt of the shock absorber (LH) shown in the figure with the rear shaft hole for the left side of the SST

.

k. Install one front foot No.2 to each of the left and right front shafts of the SST

, and then align the holes of the SST

front shafts with the bolt on the left and right side of each front side frame.

l. Install the SST (49 L017 5A0)

to the SST (49 C017 5A0)

as shown in the figure.

m. Install the SST (49 L017 5A0)

to the SST (49 UN30 3050)

with the hook of the SST (49 L017 5A0)

facing outward.

CAUTION:

• Install the SST (49 L017 5A0) so that it does not interfere with parts such as the fuel pipe. If the SST (49 L017 5A0) interferes, parts such as the fuel pipe could be damaged.

n. Adjust the height of the left and right side bars so that they are leveled, then tighten each part of the SST

.

o. Apply tension to the chain to secure the engine.

9. Remove the MTX..

10. Remove in the order indicated in the table.

11. Install in the reverse order of removal.

12. Add the specified amount of specified transaxle oil..

Clutch Cover and Disc Removal Note

1. Hold the clutch unit using the SST

.

2. Loosen each bolt one turn at a time in a crisscross pattern until spring tension is released.

3. Remove the clutch cover and disc.

Pilot Bearing Removal Note

NOTE:

• The pilot bearing does not need to be removed unless you are replacing it.

1. Use the SST

to remove the pilot bearing.

Flywheel Removal Note

1. Hold the flywheel using the SST

.

2. Remove the lock bolts, and remove the plate and the flywheel.

3. Inspect for oil leakage from the crankshaft rear oil seal.

• If there is any malfunction, replace the crankshaft rear oil seal..

Flywheel Installation Note

1. Clean the crankshaft thread holes.

2. Install the flywheel and the plate to the crankshaft, and temporarily tighten a new lock bolts.

3. Hold the flywheel using the SST

.

4. Tighten the lock bolts completely in the order shown in the figure.

Tightening torque

• 108—116 N·m {11.1—11.8 kgf·m, 80—85 ft·lbf}

Pilot Bearing Installation Note

1. Install new pilot bearing to the specified position using the following tools.

Tool

• Snap-on brand millimeter size bushing driver set (A160M) adapter A160M7 (20—22 mm)

• Use the adapter with the 20 mm side of the A160M7 (20—22 mm) facing the pilot bearing side.

Substitution tool

• Outer diameter: 21 mm {0.83 in}

• Inner diameter: 19 mm {0.75 in}

Standard position

• Distance A of pilot bearing from crankshaft end: 1.5—2.5 mm {0.060—0.098 in}

  

  
  

Clutch Disc and Cover Installation Note

1. Hold the clutch disc position using the SST

.

2. Hold the clutch unit using the SST

.

3. Tighten the bolts in Min. 2 stages.

a. Temporarily tighten the bolts in the order shown in the figure.

b. Tighten the bolts completely in the order shown in the figure and install the clutch disc and cover.

Tightening torque

• 25—33 N·m {2.6—3.3 kgf·m, 19—24 ft·lbf}

4. Remove the SST

s.