Cluth System
Cluth System
SECTION CL CLUTCH
B
CL
E
CONTENTS
PRECAUTION ............................................... 2 Inspection and Adjustment ....................................... 9 F
WARNING:
After cleaning clutch disc, wipe it with a dust collector. Never use compressed air.
CAUTION:
• Clutch fluid use refer to MA-11, "Fluids and Lubricants".
• Never reuse drained clutch fluid.
• Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.
• Never use mineral oils such as gasoline or kerosene. It will ruin the rubber parts of the hydraulic sys-
tem.
• Never reuse CSC (Concentric Slave Cylinder). Because CSC slides back to the original position
every time when removing transaxle assembly. At this timing, dust on the sliding parts may damage
a seal of CSC and may cause clutch fluid leakage. Refer to CL-16, "Removal and Installation".
• Never disassemble clutch master cylinder and CSC.
Precautions for Removing Battery Terminal INFOID:0000000010418078
• When removing the 12V battery terminal, turn OFF the ignition
switch and wait at least 30 seconds.
NOTE:
ECU may be active for several tens of seconds after the ignition
switch is turned OFF. If the battery terminal is removed before ECU
stops, then a DTC detection error or ECU data corruption may
occur.
• For vehicles with the 2-batteries, be sure to connect the main bat-
tery and the sub battery before turning ON the ignition switch.
NOTE:
If the ignition switch is turned ON with any one of the terminals of
SEF289H
main battery and sub battery disconnected, then DTC may be
detected.
• After installing the 12V battery, always check "Self Diagnosis Result" of all ECUs and erase DTC.
NOTE:
The removal of 12V battery may cause a DTC detection error.
Tool number
Description C
Tool name
ST20050240 Adjusting unevenness of diaphragm spring le-
Diaphragm adjusting wrench ver
CL
E
ZZA0508D
I
MCIB0404E
Use the chart below to find the cause of the symptom. The numbers indicate the order of the inspection. If nec-
essary, repair or replace these parts.
FLYWHEEL (Distortion)
CLUTCH DISC (Oily)
EM-79
EM-87
CL-16
CL-18
CL-5
CL-7
Reference
Clutch grabs/chatters 1 2 2 2 2 2
Clutch pedal spongy 1 2
Symptom Clutch noisy 1
Clutch slips 1 2 2 3 4 5
Clutch does not disengage 1 2 3 3 3 3 3 3 3 4 4 5
INSPECTION
The Height of Clutch Pedal C
1. Turn the floor carpet.
2. Check that the clutch pedal height (H1) from the dash lower
panel is within the reference value. CL
JPFIA0065ZZ
G
Clutch Pedal Height When Disengaging The Clutch
1. Securely engage the parking brake.
2. Turn the floor carpet. H
3. Start the engine and run at idle.
4. Fully depress clutch pedal and shift to the 1st gear.
CAUTION: I
Securely depress the brake pedal with shifter lever in 1st gear.
5. Gradually release the clutch pedal and check that the clutch
pedal height (H2) from the dash lower panel is within the ref- J
erence value with a scale immediately before the clutch is
engaged.
K
Clutch pedal height at clutch : Refer to CL-20, "Clutch
disengagement H2 Pedal".
NOTE: L
Although the clutch pedal height differs according to whether the
clutch gets disengaged or engaged, clutch-engaged case is
regarded as clutch-disengaged case for easier inspection. JPFIA0068ZZ
M
6. Replace clutch pedal if the height is outside the reference value.
Clutch Pedal Play
1. Push the pedal pad by hand until a resistance can be felt and N
check that the play (A) on the upper surface of the pedal pad is
within the reference value.
O
Clutch pedal play A : Refer to CL-20, "Clutch Pedal".
2. Replace clutch pedal if the play is outside the reference value.
P
JPFIA0121ZZ
FLUID LEAKAGE
• Check clutch line for cracks, deterioration or other damage. Replace any damaged parts.
• Check for fluid leakage by fully depressing clutch pedal while engine is running.
CAUTION:
If leakage occurs around joints, reinstall the joints or, if necessary, replace damaged parts.
FLUID LEVEL
• Check that the fluid level in the reservoir tank is within the specified
range (MAX – MIN lines).
• Visually check for any clutch fluid leakage around the reservoir
tank.
• Check the clutch system for any leakage if the fluid level is
extremely low (lower than MIN).
JPFIA0007ZZ
Draining INFOID:0000000010418049
CAUTION:
Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.
1. Remove the rubber cap from clutch tube .
JSDIA5688ZZ
JSDIA5689ZZ
CAUTION:
CL
E
JSDIA5688ZZ
JSDIA5689ZZ
I
4. Slowly depress clutch pedal to the full stroke position and then release the pedal.
CAUTION:
Since the inside of clutch tube is under hydraulic pressure, hold the tube to prevent it from getting J
disconnected.
5. Repeat step 4 at intervals of 2 or 3 seconds until new clutch fluid is discharged.
CAUTION: K
Monitor clutch fluid level in reservoir tank so as not to empty the tank.
6. Rotate the air bleeding connector 360° clockwise to close the valve.
7. Perform the air bleeding. Refer to CL-7, "Air Bleeding". L
CAUTION: M
• Monitor clutch fluid level in reservoir tank so as not to empty the tank.
• Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water. N
NOTE:
Do not use a vacuum assist or any other type of power bleeder on this system. Use of a vacuum assist or
power bleeder will not purge all the air from the system.
O
1. Fill reservoir tank with new clutch fluid.
CAUTION:
Never reuse drained clutch fluid.
P
JSDIA5688ZZ
6. Depress the clutch pedal soon and hold it, and then bleed the air from the piping.
CAUTION:
Since the inside of clutch tube is under hydraulic pressure, hold the tube to prevent it from getting
disconnected.
7. Rotate the air bleeding connector to its original position.
8. Release clutch pedal and wait for 5 seconds.
9. Repeat steps 4 to 8 until no bubbles are observed in the clutch fluid.
10. Check that the fluid level in the reservoir tank is within the specified range after air bleeding. Refer to CL-
6, "Inspection".
CL
JSDIA5420GB
H
Clutch pedal Pedal stopper rubber Pedal pad
REMOVAL J
JSDIA5694ZZ
N
INSTALLATION
Note the following, and install in the reverse order of removal. O
CAUTION:
Press master cylinder rod end into clutch pedal until it stops.
Inspection and Adjustment INFOID:0000000010418057 P
CL
JPDIB0222ZZ
H
REMOVAL
CAUTION:
• Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately I
and wash the affected area with water.
• Never disassemble clutch master cylinder.
1. Remove air cleaner case. Refer to EM-25, "Removal and Installation". J
2. Remove master cylinder rod end from clutch pedal .
3. Drain clutch fluid. Refer to CL-6, "Draining".
K
M
JSDIA5694ZZ
JSDIA5695ZZ
JPDIB0169ZZ
INSTALLATION
CAUTION:
Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.
1. Tilt master cylinder clockwise by 45° (A) and insert it to the
mounting hole. Rotate counterclockwise and secure it. At this
time, nipple is upward of the vehicle.
: Mounting condition
JPDIB0114ZZ
JSDIA5696ZZ
JSDIA5695ZZ
JPDIB0169ZZ
CL
5. Fill the container with clutch fluid. Refer to CL-6, "Refilling".
6. For the next step and after, install in the reverse order of removal.
E
Inspection and Adjustment INFOID:0000000010418063
JSDIA5692ZZ
JSDIA5693ZZ
CAUTION:
Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.
REMOVAL
Note the following, and refer to CL-14, "Exploded View" for removal procedure.
JPDIB0146GB
CAUTION:
• Never reuse CSC (Concentric Slave Cylinder). Because CSC slides back to the original position
every time when removing transaxle assembly. At this timing, dust on the sliding parts may damage
a seal of CSC and may cause clutch fluid leakage.
• Never disassemble CSC.
• Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.
REMOVAL
1. Remove transaxle assembly. Refer to TM-23, "Removal and Installation".
2. Remove CSC from clutch housing.
INSTALLATION
1. Install CSC to clutch housing and then tighten CSC mounting bolts to the specified torque.
CAUTION:
• Never reuse CSC.
• Never insert and operate CSC because piston and stopper of CSC components may fall off.
2. For the next step and after, install in the reverse order of removal.
Inspection and Adjustment INFOID:0000000010418070
CL
G
JPDIB0235GB
J
CAUTION:
• Never reuse CSC (Concentric Slave Cylinder). Because CSC slides back to the original position
every time when removing transaxle assembly. At this timing, dust on the sliding parts may damage
K
a seal of CSC and may cause clutch fluid leakage. Refer to CL-16, "Removal and Installation".
• Never bring any grease to the clutch disc facing, pressure plate surface and flywheel surface.
• Never clean clutch disc using solvent.
L
REMOVAL
1. Remove transaxle assembly. Refer to TM-23, "Removal and Installation".
2. Remove clutch cover mounting bolts while holding clutch cover. M
CAUTION:
Never drop clutch disc.
3. Remove clutch cover and clutch disc. N
CAUTION:
Never drop clutch disc.
INSTALLATION O
1. Clean clutch disc and input shaft splines to remove powder arisen from abrasion.
JSDIA5690ZZ
JSDIA5691ZZ
Inspection INFOID:0000000010418073
JPDIB0026ZZ
Clutch Cover
• Check clutch cover thrust ring for wear or breakage. If wear or breakage is found, replace clutch cover.
NOTE:
• Worn thrust ring will generate a beating noise when tapped at the rivet with a hammer.
• Broken thrust ring will make a clinking sound when cover is shaken up and down.
• If a trace of burn or discoloration is found on the clutch cover pressure plate to clutch disc contact surface,
repair the surface with sandpaper. If surface is damaged or distorted, replace clutch cover.
CL
JPDIB0160ZZ
Unit: mm (in)
Unit: mm (in)
172.4 – 182.4
Clutch pedal height
(6.79 – 7.18)
Clutch pedal height at clutch disengagement 81 (3.19) or more
Clutch pedal play 2 – 8 (0.08 – 0.31)
[Looseness at clutch pedal pin] [0 – 1.3 (0 – 0.051)]
Unit: mm (in)
Runout limit / diameter of the area to be measured 1.0 (0.039) / 180 (7.09) dia.
Maximum allowable spline backlash (at outer edge of disc) 0.8 (0.031)
Facing wear limit (depth to the rivet head) 0.3 (0.012)
Unit: mm (in)