TRANSMISSION & DRIVELINE

SECTION CL CLUTCH
B

CL

E
CONTENTS
SYMPTOM DIAGNOSIS ............................... 2 Removal and Installation .........................................10 F

NOISE, VIBRATION AND HARSHNESS CLUTCH PIPING ............................................... 13

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(NVH) TROUBLESHOOTING ............................. 2 Exploded View .........................................................13
G
NVH Troubleshooting Chart ...................................... 2 Hydraulic Layout ......................................................13
Removal and Installation .........................................14
PRECAUTION ............................................... 3
REMOVAL AND INSTALLATION ............... 15 H
PRECAUTIONS ................................................... 3
Service Notice or Precautions for Clutch .................. 3 CSC (CONCENTRIC SLAVE CYLINDER) ....... 15
Exploded View .........................................................15
I
PREPARATION ............................................ 4 Removal and Installation .........................................15

PREPARATION ................................................... 4 CLUTCH DISC AND CLUTCH COVER ............ 16

Special Service Tools ................................................ 4 J
HR16DE, MR20DE .....................................................16
Commercial Service Tools ........................................ 4
HR16DE, MR20DE : Exploded View .......................16
ON-VEHICLE MAINTENANCE ..................... 5 HR16DE, MR20DE : Removal and Installation .......16
HR16DE, MR20DE : Inspection ..............................17 K
CLUTCH PEDAL ................................................. 5
Inspection and Adjustment ........................................ 5 K9K ............................................................................18
K9K : Exploded View ...............................................18 L
CLUTCH FLUID ................................................... 6 K9K : Removal and Installation ...............................18
Inspection .................................................................. 6 K9K : Inspection ......................................................19
Air Bleeding Procedure ............................................. 6
SERVICE DATA AND SPECIFICATIONS M
ON-VEHICLE REPAIR .................................. 8 (SDS) ............................................................ 20
CLUTCH PEDAL ................................................. 8 SERVICE DATA AND SPECIFICATIONS N
Exploded View .......................................................... 8 (SDS) ................................................................. 20
Removal and Installation ........................................... 8 Clutch Control System .............................................20
Inspection .................................................................. 8 Clutch Pedal ............................................................20
O
Clutch Disc ..............................................................20
CLUTCH MASTER CYLINDER ..........................10 Clutch Cover ............................................................20
Exploded View ........................................................ 10
P

CL-1
 Symptom
Reference

Clutch slips
Clutch noisy
< SYMPTOM DIAGNOSIS >

Clutch pedal spongy

SUSPECTED PARTS (Possible cause)

Clutch grabs/chatters
NVH Troubleshooting Chart

Clutch does not disengage

CLUTCH PEDAL (Inspection and adjustment) CL-5

1
1
SYMPTOM DIAGNOSIS

tion. If necessary, repair or replace these parts.

CLUTCH LINE (Air in line) CL-6

2
1
ENGINE MOUNTING (Loose) EM-83 (HR16DE), EM-194 (MR20DE),EM-298 (K9K)

1
CSC (Concentric Slave Cylinder) (Worn, dirty or damaged) CL-15

3
1
2

CL-2
CLUTCH DISC (Out of true)

3
CLUTCH DISC (Runout is excessive)

3
2
CLUTCH DISC (Lining broken)

3
CLUTCH DISC (Dirty or burned)

3
CLUTCH DISC (Oily)

3
2
2
CLUTCH DISC (Worn out) CL-16

2
2
CLUTCH DISC (Hardened)

2
CLUTCH DISC (Lack of spline grease)

3
DIAPHRAGM SPRING (Damaged)

4
3
DIAPHRAGM SPRING (Out of tip alignment)

4
2
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

PRESSURE PLATE (Distortion)

5
4
FLYWHEEL (Distortion) EM-101 (HR16DE), EM-219 (MR20DE),EM-326 (K9K)

5
Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-
INFOID:0000000001043505

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 PRECAUTIONS
< PRECAUTION >
PRECAUTION A
PRECAUTIONS
Service Notice or Precautions for Clutch INFOID:0000000001043506
B
CAUTION:
• Recommended clutch fluid is brake fluid “DOT 4”. Refer to MA-21, "Fluids and Lubricants".
• Never reuse drained clutch fluid. C
• Never splash clutch fluid on painted areas.
• Never use mineral oils such as gasoline or kerosene. It will ruin the rubber parts of the hydraulic sys-
tem. CL
• If transaxle assembly is removed from the vehicle, always replace CSC (Concentric Slave Cylinder).
Return CSC insert to original position to remove transaxle assembly. Dust on clutch disc sliding
parts may damage seal of CSC and may cause clutch fluid leakage.
• Never disassemble master cylinder and CSC. E
WARNING:
After cleaning clutch disc, wipe it with a dust collector. Never use compressed air.
F

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G

CL-3
 PREPARATION
< PREPARATION >
PREPARATION
PREPARATION
Special Service Tools INFOID:0000000001043507

Tool number
Description
Tool name
ST20050240 Adjusting unevenness of diaphragm spring of
Diaphragm adjusting wrench clutch cover

ZZA0508D

Commercial Service Tools INFOID:0000000001043508

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Tool name Description
Clutch aligner Installing clutch disc
1: Center shaft
2: Attachment
3: Guide

PCIB0017E

CL-4
 CLUTCH PEDAL
< ON-VEHICLE MAINTENANCE >
ON-VEHICLE MAINTENANCE A
CLUTCH PEDAL
Inspection and Adjustment INFOID:0000000001043509
B

INSPECTION
1. Check to see if the master cylinder rod end moves freely. It C
should not be bound by the clutch pedal.
• If the rod end does not move freely, remove the rod end and
check for deformation or damage on the rod end. Leave the
CL
rod end removed for step 2.
2. Check the clutch pedal stroke for free range of movement.
a. With the master cylinder rod end removed, manually move the E
clutch pedal up and down to determine if it moves freely.
b. If any sticking is noted, replace the clutch pedal assembly.
Reverify that the master cylinder rod end moves freely.
PCIB1491E F
3. Inspect the ASCD clutch switch position.
a. If the rod end does not move freely, check that the ASCD clutch switch is not applying pressure to the

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clutch pedal causing the rod end to bind. To adjust, disconnect the ASCD clutch switch electrical connec-
tor and turn the ASCD clutch switch. G
b. Connect the ASCD clutch switch electrical connector.
4. Check the clutch hydraulic system components (master cylinder assembly, CSC) for sticking or binding.
H
a. If any sticking or binding is noted, repair or replace the related parts as necessary.
b. If any hydraulic system repair was necessary, bleed the clutch hydraulic system. Refer to CL-6, "Air
Bleeding Procedure".
I
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 of the air from the system.
J
ADJUSTMENT
Adjust ASCD clutch switch (1) position so that clearance between
clutch pedal (2) and thread end of ASCD clutch switch, with clutch
pedal fully released, is within specification “A”. K

Clearance “A” : Refer to CL-20, "Clutch Pedal".

L

JPDIB0043ZZ

CL-5
 CLUTCH FLUID
< ON-VEHICLE MAINTENANCE >
CLUTCH FLUID
Inspection INFOID:0000000001092869

CLUTCH 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

Air Bleeding Procedure INFOID:0000000001043510

NOTE:
Do not use a vacuum assist or any other type of power bleeder on this system. Use of a vacuum assist or

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power bleeder will not purge all the air from the system.
CAUTION:
• Monitor clutch fluid level in reservoir tank to make sure it does not empty.
• 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.
• Bleed the air of bleeding connector (1).
1. Fill reservoir tank with new clutch fluid.
2. Connect a transparent vinyl hose to air bleeder of bleeding con-
nector.
3. “Depress” and “release” the clutch pedal slowly and fully 15
times at an interval of 2 to 3 seconds and release the clutch
pedal.

PCIB1494E

4. Push the lock pin (1) of the bleeding connector (2), and maintain the position.
• RS5F92R

PCIB1495E

CL-6
 CLUTCH FLUID
< ON-VEHICLE MAINTENANCE >
• RS6F94R and RS6F52A
CAUTION: A
Hold it to prevent releasing clutch tube from bleeding con-
nector when fluid pressure is applied in the tube.
B

JPDIB0041ZZ

CL
5. Slide clutch tube (1) in the direction of the arrow as shown in the figure.
• RS5F92R
E
Dimension “A” : 5 mm (0.20 in)

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G

JPDIB0045ZZ

H
• RS6F94R and RS6F52A

2 : Clutch housing
I

Dimension “A” : 10 mm (0.39 in)

6. Depress the clutch pedal soon and hold it, and then bleed the air J
from the piping.
CAUTION:
Hold it to prevent releasing clutch tube from bleeding con-
K
nector when fluid pressure is applied in the tube. JPDIB0042ZZ

7. Return clutch tube (1) and lock pin to their original positions.
8. Release clutch pedal and wait for 5 seconds. L
9. Repeat steps 3 to 8 until no bubbles are observed in the clutch fluid.

CL-7
 CLUTCH PEDAL
< ON-VEHICLE REPAIR >
ON-VEHICLE REPAIR
CLUTCH PEDAL
Exploded View INFOID:0000000001043511

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JPDIB0034GB

1. Clutch pedal assembly 2. ASCD clutch switch 3. Pedal pad

Refer to GI-4, "Components" for the symbols in the figure.

Removal and Installation INFOID:0000000001043512

REMOVAL
1. Remove front kicking plate inner and dash side finisher. Refer to INT-14, "Removal and Installation".
2. Remove lower instrument panel, driver side. Refer to IP-12, "Removal and Installation".
3. Disconnect ASCD clutch switch harness connector and then disconnect clip of harness from clutch pedal
assembly.
4. Remove master cylinder rod end from clutch pedal assembly.
5. Remove clutch pedal assembly.

PCIB1491E

INSTALLATION
Install in the reverse order of removal.
Inspection INFOID:0000000001043513

CL-8
 CLUTCH PEDAL
< ON-VEHICLE REPAIR >
INSPECTION AFTER REMOVAL
Check clutch pedal for bend, damage, or a cracked weld. If bend, damage, or a cracked weld is found, replace A
clutch pedal assembly.

CL

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G

CL-9
 CLUTCH MASTER CYLINDER
< ON-VEHICLE REPAIR >
CLUTCH MASTER CYLINDER
Exploded View INFOID:0000000001043514

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JPDIB0035ZZ

1. Reservoir tank assembly 2. Hose 3. Master cylinder assembly

Removal and Installation INFOID:0000000001043515

REMOVAL
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.
• Never disassemble master cylinder.
1. Remove the air cleaner case and air duct (inlet) or air ducts. Refer to EM-27, "Removal and Installation"
(HR16DE), EM-144, "Removal and Installation" (MR20DE), or EM-265, "Removal and Installation" (K9K).
2. Remove the battery. Refer to PG-118, "Removal and Installation".
3. Disconnect the connectors (A) and then remove the bracket (1).
4. Drain clutch fluid in reservoir tank assembly and then remove
hose.

JPDIA0240ZZ

5. Remove master cylinder rod end from clutch pedal assembly.

PCIB1491E

CL-10
 CLUTCH MASTER CYLINDER
< ON-VEHICLE REPAIR >
6. Remove lock pin (1) from connector of master cylinder (2) and
separate clutch tube (3). A
7. Rotate master cylinder assembly clockwise by 45° and then
remove master cylinder assembly from the vehicle.
B

PCIB1497E
CL
INSTALLATION
CAUTION:
Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
E
and wash the affected area with water.
1. Tilt master cylinder assembly clockwise by 45° and insert it to
the mounting hole. Rotate counterclockwise and secure it. At
this time, nipple is upward of the vehicle. F
2. Install master cylinder rod end to clutch pedal assembly.

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3. Install hose to reservoir tank assembly and master cylinder
assembly. G
CAUTION:
Set hose with painted mark facing upward.
H

SCIA1286E

4. Install clutch tube (1) into connector of master cylinder assembly I

(2) until it stops.
5. Install lock pin (3) into connector of master cylinder assembly
until it stops. J
6. Fill new clutch fluid according to the following.
a. Fill reservoir tank assembly with new clutch fluid.
K
b. Connect a transparent vinyl hose to air bleeder of bleeding con-
nector.

L
PCIB1500E

c. Push the lock pin (1) of the bleeding connector (2).

• RS5F92R M

PCIB1495E P

CL-11
 CLUTCH MASTER CYLINDER
< ON-VEHICLE REPAIR >
• RS6F94R and RS6F52A

JPDIB0041ZZ

d. Slide clutch tube (1) in the direction of the arrow as shown in the figure.
• RS5F92R

Dimension “A” : 5 mm (0.20 in)

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JPDIB0045ZZ

• RS6F94R and RS6F52A

2 : Clutch housing

Dimension “A” : 10 mm (0.39 in)

e. Depress clutch pedal slowly to full stroke and then release it.
Repeat this until new clutch fluid comes out.
CAUTION:
• Hold it to prevent releasing clutch tube from bleeding
connector when fluid pressure is applied in the tube. JPDIB0042ZZ
• Monitor clutch fluid level in reservoir tank to make sure it
does not empty.
f. Place clutch tube (1) and lock pin back into position with clutch pedal depressed.
g. Bleed the air from the clutch hydraulic system. Refer to CL-6, "Air Bleeding Procedure".
7. After completing this procedure, inspect for clutch pedal. Refer to CL-5, "Inspection and Adjustment".
8. Install the bracket (1) and then connect the connectors (A).
9. Install the battery. Refer to PG-118, "Removal and Installation".
10. Install the air cleaner case and air duct (inlet) or air ducts. Refer
to EM-27, "Removal and Installation" (HR16DE), EM-144,
"Removal and Installation" (MR20DE), or EM-265, "Removal
and Installation" (K9K).

JPDIA0240ZZ

CL-12
 CLUTCH PIPING
< ON-VEHICLE REPAIR >
CLUTCH PIPING
A
Exploded View INFOID:0000000001043518

RS5F92R B

CL

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G
JPDIB0036ZZ

1. CSC (Concentric Slave Cylinder) 2. Clutch tube 3. Bracket

H
4. Clutch damper 5. Master cylinder assembly

RS6F94R and RS6F52A

I

JPDIB0037ZZ
N
1. CSC (Concentric Slave Cylinder) 2. Clutch tube 3. Bracket
4. Clutch damper 5. Master cylinder assembly
O
Hydraulic Layout INFOID:0000000001043519

CL-13
 CLUTCH PIPING
< ON-VEHICLE REPAIR >

PCIB1499E

1. Clutch tube 2. Lock pin 3. CSC (Concentric Slave Cylinder)

4. Clutch damper 5. Master cylinder assembly 6. Clutch pedal assembly

Removal and Installation INFOID:0000000001043520

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

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Refer to the figure for removal procedure.
INSTALLATION
Refer to the figure for installation procedure.
• When installing clutch tube to connector of CSC, connector of clutch damper and connector of master cylin-
der, push it as far as it goes.
• When installing lock pin to connector of CSC, connector of clutch damper and connector of master cylinder,
push it as far as it goes.
• After installation, bleed the air from the clutch hydraulic system. Refer to CL-6, "Air Bleeding Procedure".
CAUTION:
Never scratch or damage clutch hose.

CL-14
 CSC (CONCENTRIC SLAVE CYLINDER)
< REMOVAL AND INSTALLATION >
REMOVAL AND INSTALLATION A
CSC (CONCENTRIC SLAVE CYLINDER)
Exploded View INFOID:0000000001043521
B

CL

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G

JPDIB0040GB
H
1. Transaxle assembly 2. CSC (Concentric Slave Cylinder)
Refer to GI-4, "Components" for symbols not described on the above.
I
Removal and Installation INFOID:0000000001043522

CAUTION:
• If transaxle assembly is removed from the vehicle, always replace CSC (Concentric Slave Cylinder). J
Return CSC insert to original position to remove transaxle assembly. Dust on clutch disc sliding
parts may damage seal of CSC and may cause clutch fluid leakage.
• Never disassemble CSC. K
• 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 L
1. Remove transaxle assembly from the vehicle. Refer to TM-23, "Removal and Installation" (RS5F92R),
TM-69, "Removal and Installation" (RS6F94R), or TM-123, "Removal and Installation" (RS6F52A).
2. Remove mounting bolts and then remove CSC from clutch housing. M

INSTALLATION
1. Install CSC to clutch housing and then tighten bolts to the specified torque. N
CAUTION:
• Never reuse CSC.
• Never insert and operate CSC because piston and stopper of CSC components may fall off.
O
2. Install transaxle assembly. Refer to TM-23, "Removal and Installation" (RS5F92R), TM-69, "Removal and
Installation" (RS6F94R), or TM-123, "Removal and Installation" (RS6F52A).
3. Bleed the air from the clutch hydraulic system. Refer to CL-6, "Air Bleeding Procedure".
P

CL-15
 CLUTCH DISC AND CLUTCH COVER
< REMOVAL AND INSTALLATION >
CLUTCH DISC AND CLUTCH COVER
HR16DE, MR20DE
HR16DE, MR20DE : Exploded View INFOID:0000000001043523

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JPDIB0038GB

1. Flywheel 2. Clutch disc 3. Clutch cover

4. Input shaft
A. First step (MR20DE) B. First step (HR16DE) C. Final step
: Apply lithium-based grease including molybdenum disulphide.
Refer to GI-4, "Components" for symbols not described on the above.

CAUTION:
• If transaxle assembly is removed from the vehicle, always replace CSC (Concentric Slave Cylinder). Return CSC insert to
original position to remove transaxle assembly. Dust on clutch disc sliding parts may damage seal of CSC and may cause
clutch fluid leakage.
• Never bring any grease to the clutch disc facing, pressure plate surface and flywheel surface.
• When installing, be careful that grease applied to input shaft does not adhere to clutch disc.
• Never clean in solvent on clutch disc.

HR16DE, MR20DE : Removal and Installation INFOID:0000000001043524

CAUTION:
If transaxle assembly is removed from the vehicle, always replace CSC (Concentric Slave Cylinder).
Return CSC insert to original position to remove transaxle assembly. Dust on clutch disc sliding parts
may damage seal of CSC and may cause clutch fluid leakage.
REMOVAL
1. Remove transaxle assembly from the vehicle. Refer to TM-23, "Removal and Installation" (RS5F92R),
TM-69, "Removal and Installation" (RS6F94R), or TM-123, "Removal and Installation" (RS6F52A).
2. Loosen clutch cover mounting bolts.
3. Remove clutch cover and clutch disc.
CAUTION:
Never drop clutch disc.
INSTALLATION
1. Clean clutch disc and input shaft splines to remove grease and powder arisen from abrasion.
2. Apply recommended grease to clutch disc and input shaft splines.
CAUTION:

CL-16
 CLUTCH DISC AND CLUTCH COVER
< REMOVAL AND INSTALLATION >
Be sure to apply grease to the points specified. Otherwise, noise, poor disengagement, or damage
to the clutch may result. Excessive grease may cause slip or judder. And if it adheres to seal of A
CSC, it cause clutch fluid leakage. Wipe off excess grease. Wipe off any grease oozing from the
parts.
3. Install clutch disc using a suitable clutch aligner (A). B

B : HR16DE
C : MR20DE C
4. Install clutch cover. Pre-tighten clutch cover mounting bolts.
5. Tighten clutch cover mounting bolts evenly to the specified
torque in two steps in the order shown in the figure. CL
6. Install transaxle assembly to the vehicle. Refer to TM-23,
"Removal and Installation" (RS5F92R), TM-69, "Removal and
Installation" (RS6F94R), or TM-123, "Removal and Installation" JPDIB0044ZZ E
(RS6F52A).
HR16DE, MR20DE : Inspection INFOID:0000000001043525

F
INSPECTION AFTER REMOVAL

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CLUTCH DISC
G
• Measure circumferential runout relative to clutch disc center spline.
If it is outside the specification, replace clutch disc.

Runout limit/diameter of the : Refer to CL-20, H

area to be measured "Clutch Disc".
• Measure backlash to clutch disc spline and main drive gear spline
at the circumference of clutch disc. If outside the specification, I
replace clutch disc.

Maximum allowable spline : Refer to CL-20, J

SCL221
backlash (at outer edge of disc) "Clutch Disc".
• Measure the depth “A” to clutch disc facing rivet heads using cali-
pers. If it exceeds the allowable facing wear limit, replace clutch K
disc.

Facing wear limit (depth to the : Refer to CL-20, L

rivet head) "Clutch Disc".

JPDIB0026ZZ
N
CLUTCH COVER
Check diaphragm spring lever claws for unevenness with the lever
still on the vehicle. If they exceed the tolerance, adjust lever height
O
using the diaphragm adjusting wrench [SST: ST20050240].

Tolerance for diaphragm : Refer to CL-20,

spring lever unevenness "Clutch Cover". P
• 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. PCIB0276E

• Broken thrust ring will make a clinking sound when cover is

shaken up and down.
CL-17
 CLUTCH DISC AND CLUTCH COVER
< REMOVAL AND INSTALLATION >
• 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.
K9K
K9K : Exploded View INFOID:0000000001043557

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JPDIB0039GB

1. Flywheel 2. Clutch disc 3. Clutch cover

4. Input shaft
: Apply lithium-based grease including molybdenum disulphide.
Refer to GI-4, "Components" for symbols not described on the above.

CAUTION:
• If transaxle assembly is removed from the vehicle, always replace CSC (Concentric Slave Cylinder). Return CSC insert to
original position to remove transaxle assembly. Dust on clutch disc sliding parts may damage seal of CSC and may cause
clutch fluid leakage.
• Never bring any grease to the clutch disc facing, pressure plate surface and flywheel surface.
• When installing, be careful that grease applied to input shaft does not adhere to clutch disc.
• Never clean in solvent on clutch disc.

K9K : Removal and Installation INFOID:0000000001043558

CAUTION:
If transaxle assembly is removed from the vehicle, always replace CSC (Concentric Slave Cylinder).
Return CSC insert to original position to remove transaxle assembly. Dust on clutch disc sliding parts
may damage seal of CSC and may cause clutch fluid leakage.
REMOVAL
1. Remove transaxle assembly from the vehicle. Refer to TM-69, "Removal and Installation".
2. Loosen clutch cover mounting bolts.
3. Remove clutch cover and clutch disc.
CAUTION:
Never drop clutch disc.
INSTALLATION
1. Clean clutch disc and input shaft splines to remove grease and powder arisen from abrasion.
2. Apply recommended grease to clutch disc and input shaft splines.
CAUTION:
Be sure to apply grease to the points specified. Otherwise, noise, poor disengagement, or damage
to the clutch may result. Excessive grease may cause slip or judder. And if it adheres to seal of

CL-18
 CLUTCH DISC AND CLUTCH COVER
< REMOVAL AND INSTALLATION >
CSC, it cause clutch fluid leakage. Wipe off excess grease. Wipe off any grease oozing from the
parts. A
3. Install clutch disc using a suitable clutch aligner (A).
4. Install clutch cover. Pre-tighten clutch cover mounting bolts.
5. Tighten clutch cover mounting bolts evenly to the specified B
torque in the order shown in the figure.
6. Install transaxle assembly to the vehicle. Refer to TM-69,
"Removal and Installation". C

CL
PCIB1503E

K9K : Inspection INFOID:0000000001043559

E

INSPECTION AFTER REMOVAL

CLUTCH DISC F
• Measure circumferential runout relative to clutch disc center spline.
If it is outside the specification, replace clutch disc.

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G
Runout limit/diameter of the : Refer to CL-20,
area to be measured "Clutch Disc".
• Measure backlash to clutch disc spline and main drive gear spline H
at the circumference of clutch disc. If outside the specification,
replace clutch disc.
I
Maximum allowable spline : Refer to CL-20,
SCL221
backlash (at outer edge of disc) "Clutch Disc".
• Measure the depth “A” to clutch disc facing rivet heads using cali- J
pers. If it exceeds the allowable facing wear limit, replace clutch
disc.

Facing wear limit (depth to the : Refer to CL-20, K

rivet head) "Clutch Disc".

JPDIB0026ZZ M
CLUTCH COVER
Check diaphragm spring lever claws for unevenness with the lever
still on the vehicle. If they exceed the tolerance, adjust lever height N
using the diaphragm adjusting wrench [SST: ST20050240].

Tolerance for diaphragm : Refer to CL-20, O

spring lever unevenness "Clutch Cover".
• Check clutch cover thrust ring for wear or breakage. If wear or
breakage is found, replace clutch cover. P
NOTE:
• Worn thrust ring will generate a beating noise when tapped at the
rivet with a hammer. PCIB0276E

• 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-19
 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
Clutch Control System INFOID:0000000001043459

Type of clutch control Hydraulic

Clutch Pedal INFOID:0000000001043460

Unit: mm (in)

Clearance “A” between clutch pedal and ASCD switch threaded

0.74 - 1.96 (0.0291 - 0.0772)
end while clutch pedal is fully released.

Clutch Disc INFOID:0000000001043462

Unit: mm (in)

Engine type HR16DE MR20DE K9K

Model 200 225

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Facing size (Outer dia. × Inner dia. × 200 × 140 × 3.5 (7.87 × 5.51 225 × 160 × 3.2 (8.86 × 6.30 225 × 150 × 3.1 (8.86 × 5.91
Thickness) × 0.138) × 0.126) × 0.122)
Runout limit/diameter of the area to be
1.0 (0.039) /200 (7.87) dia. 1.0 (0.039) /215 (8.46) dia.
measured
Maximum allowable spline backlash
0.8 (0.031) 1.0 (0.039) 0.507 (0.0200)
(at outer edge of disc)
Facing wear limit (depth to the rivet
0.3 (0.012) 1.0 (0.039)
head)

Clutch Cover INFOID:0000000001043463

Engine type HR16DE MR20DE K9K

Transaxle type RS5F92R RS6F94R RS6F52A RS6F94R
4,658 N (475.1 kg, 6,300 N (642.6 kg,
Set-load 5,390 N (549.8 kg, 1,211.7 lb)
1,047.1 lb) 1416.2 lb)
Tolerance for diaphragm
0.7 mm (0.028 in) or less 1.2 mm (0.047 in) or less
spring lever unevenness
Diaphragm spring lever 29 - 31 mm (1.14 - 1.22 21 - 23 mm (0.83 -0.91 31.8 - 33.8 mm (1.252 -
—
height in) in) 1.331 in)

CL-20