TRANSMISSION & DRIVELINE

SECTION CL CLUTCH
B

CL

E
CONTENTS
PRECAUTION ............................................... 3 LHD : Removal and Installation ...............................14 F
LHD : Inspection and Adjustment ............................16
PRECAUTIONS ................................................... 3
Precaution for Supplemental Restraint System RHD ............................................................................17
G
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- RHD : Exploded View ..............................................18
SIONER" ................................................................... 3 RHD : Removal and Installation ..............................18
Precaution Necessary for Steering Wheel Rota- RHD : Inspection and Adjustment ...........................20
H
tion After Battery Disconnect ..................................... 3
CLUTCH MASTER CYLINDER ........................ 22
Precaution for Procedure without Cowl Top Cover...... 4
Precautions for Removing Battery Terminal ............. 4 LHD ............................................................................22
Precaution for Stop/Start System Service ................. 5 LHD : Exploded View ...............................................22 I
Service Notice or Precautions for Clutch .................. 5 LHD : Removal and Installation ...............................22
LHD : Inspection and Adjustment ............................23
PREPARATION ............................................ 6 J
RHD ............................................................................23
PREPARATION ................................................... 6 RHD : Exploded View ..............................................24
Special Service Tools ................................................ 6 RHD : Removal and Installation ..............................24
Commercial Service Tools ........................................ 6 RHD : Inspection and Adjustment ...........................25 K
Lubricant or/and Sealant ........................................... 6
CLUTCH PIPING ............................................... 26
SYMPTOM DIAGNOSIS ............................... 8 Exploded View .........................................................26 L
Hydraulic Piping .......................................................27
NOISE, VIBRATION AND HARSHNESS Removal and Installation .........................................27
(NVH) TROUBLESHOOTING ............................. 8 Inspection and Adjustment ......................................28
NVH Troubleshooting Chart ...................................... 8 M
CSC (CONCENTRIC SLAVE CYLINDER) ....... 30
PERIODIC MAINTENANCE .......................... 9 Exploded View .........................................................30
Removal and Installation .........................................30 N
CLUTCH PEDAL ................................................. 9
Inspection and Adjustment ......................................31
Inspection and Adjustment ........................................ 9
CLUTCH DISC AND CLUTCH COVER ............ 32
CLUTCH FLUID ..................................................11 O
Inspection ................................................................ 11 MR20DD .....................................................................32
Draining ................................................................... 11 MR20DD : Exploded View .......................................32
Refilling ................................................................... 12 MR20DD : Removal and Installation .......................32 P
Air Bleeding ............................................................. 13 MR20DD : Inspection ..............................................33
REMOVAL AND INSTALLATION ............... 14 R9M ............................................................................34
R9M : Exploded View ..............................................35
CLUTCH PEDAL ................................................14 R9M : Removal and Installation ...............................35
R9M : Inspection ......................................................39
LHD ............................................................................ 14
LHD : Exploded View .............................................. 14

CL-1
SERVICE DATA AND SPECIFICATIONS General Specifications ............................................ 41
(SDS) ........................................................... 41 Clutch Pedal ............................................................ 41
Clutch Disc .............................................................. 41
SERVICE DATA AND SPECIFICATIONS Clutch Cover ........................................................... 42
(SDS) .................................................................. 41

CL-2
 PRECAUTIONS
< PRECAUTION >
PRECAUTION A
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT B
PRE-TENSIONER" INFOID:0000000010745311

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along C
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the “SRS AIR BAG” and
“SEAT BELT” of this Service Manual.
WARNING: CL
Always observe the following items for preventing accidental activation.
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision that would result in air bag inflation, all maintenance must be performed by E
an authorized NISSAN/INFINITI dealer.
• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
F
Module, see “SRS AIR BAG”.
• Never use electrical test equipment on any circuit related to the SRS unless instructed to in this Ser-
vice Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness
connectors. G
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING: H
Always observe the following items for preventing accidental activation.
• When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the
ignition ON or engine running, never use air or electric power tools or strike near the sensor(s) with
a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing I
serious injury.
• When using air or electric power tools or hammers, always switch the ignition OFF, disconnect the
battery, and wait at least 3 minutes before performing any service. J
Precaution Necessary for Steering Wheel Rotation After Battery Disconnect
INFOID:0000000010745312

K
CAUTION:
Comply with the following cautions to prevent any error and malfunction.
• Before removing and installing any control units, first turn the ignition power source and accessory
power source to the OFF, then disconnect both battery cables. L
• After finishing work, confirm that all control unit connectors are connected properly, then re-connect
both battery cables.
• Always use CONSULT to perform self-diagnosis as a part of each function inspection after finishing M
work. If a DTC is detected, perform trouble diagnosis according to self-diagnosis results.
For vehicle with steering lock unit, if the battery is disconnected or discharged, the steering wheel will lock and
cannot be turned.
If turning the steering wheel is required with the battery disconnected or discharged, follow the operation pro- N
cedure below before starting the repair operation.
OPERATION PROCEDURE
O
1. Connect both battery cables.
NOTE:
Supply power using jumper cables if battery is discharged.
2. Open driver door. P
3. Turn the ignition switch to the ON position.
(At this time, the steering lock will be released.)
4. Turn the ignition switch to OFF position with driver door open.
5. Wait for 3 minutes or longer with driver door open.
NOTE:
• Do not close driver door because the steering wheel locks when driver door is closed.

CL-3
 PRECAUTIONS
< PRECAUTION >
• The auto acc function is adapted to this vehicle. For this reason, even when the ignition switch is turned
to OFF position, the accessory power source does not turned OFF and continues to be supplied for a
certain amount of time.
6. Disconnect both battery cables. The steering lock will remain released with both battery cables discon-
nected and the steering wheel can be turned.
7. Perform the necessary repair operation.
8. When the repair work is completed, re-connect both battery cables. With the brake pedal released, turn
the ignition switch from OFF position to ON position, then to LOCK position. (The steering wheel will lock
when the ignition switch is turned to LOCK position.)
9. Perform self-diagnosis check of all control units using CONSULT.
Precaution for Procedure without Cowl Top Cover INFOID:0000000010745313

When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc to prevent damage to
windshield.

PIIB3706J

Precautions for Removing Battery Terminal INFOID:0000000010745361

• With the adoption of Auto ACC function, ACC power is automatically supplied by operating the intelligent key
or remote keyless entry or by opening/closing the driver side door. In addition, ACC power is supplied even
after the ignition switch is turned to the OFF position, i.e. ACC power is supplied for a certain fixed time.
• When disconnecting the 12V battery terminal, turn off the ACC
power before disconnecting the 12V battery terminal, observing
“How to disconnect 12V battery terminal” described below.
NOTE:
Some ECUs operate for a certain fixed time even after ignition
switch is turned OFF and ignition power supply is stopped. If the
battery terminal is disconnected before ECU stops, accidental DTC
detection or ECU data damage 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:
SEF289H
If the ignition switch is turned ON with any one of the terminals of
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.
HOW TO DISCONNECT 12V BATTERY TERMINAL
Disconnect 12V battery terminal according to Instruction 1 or Instruction 2 described below.
For vehicles parked by ignition switch OFF, refer to Instruction 2.
INSTRUCTION 1
1. Open the hood.
2. Turn key switch to the OFF position with the driver side door opened.
3. Get out of the vehicle and close the driver side door.
4. Wait at least 3 minutes. For vehicle with the engine listed below, remove the battery terminal after a lapse
of the specified time.

D4D engine : 20 minutes

HRA2DDT : 12 minutes

CL-4
 PRECAUTIONS
< PRECAUTION >
K9K engine : 4 minutes
M9R engine : 4 minutes A
R9M engine : 4 minutes
V9X engine : 4 minutes
B
CAUTION:
While waiting, never operate the vehicle such as locking, opening, and closing doors. Violation of
this caution results in the activation of ACC power supply according to the Auto ACC function.
5. Remove 12V battery terminal. C
CAUTION:
After installing 12V battery, always check self-diagnosis results of all ECUs and erase DTC.
CL
INSTRUCTION 2 (FOR VEHICLES PARKED BY IGNITION SWITCH OFF)
1. Unlock the door with intelligent key or remote keyless entry.
NOTE:
At this moment, ACC power is supplied. E
2. Open the driver side door.
3. Open the hood.
F
4. Close the driver side door.
5. Wait at least 3 minutes.
CAUTION:
While waiting, never operate the vehicle such as locking, opening, and closing doors. Violation of G
this caution results in the activation of ACC power supply according to the Auto ACC function.
6. Remove 12V battery terminal.
CAUTION: H
After installing 12V battery, always check self-diagnosis results of all ECUs and erase DTC.
Precaution for Stop/Start System Service INFOID:0000000011045986
I
CAUTION:
When performing an inspection and its related work with the engine at idle, always turn the stop/start
OFF switch ON or open the hood to release the stop/start system. J
Service Notice or Precautions for Clutch INFOID:0000000010745315

K
WARNING:
After cleaning clutch disc, wipe it with a dust collector. Never use compressed air.
CAUTION:
Never reuse CSC (Concentric Slave Cylinder). Because CSC slides back to the original position every L
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-30, "Removal and Installation".
• Use recommended clutch fluid only, refer to MA-23, "Fluids and Lubricants". M
• 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 system. N
• Never disassemble clutch master cylinder and CSC.

CL-5
 PREPARATION
< PREPARATION >
PREPARATION
PREPARATION
Special Service Tools INFOID:0000000010745316

Tool number
(RENAULT tool No.) Description
Tool name
ST20050240 Adjusting unevenness of diaphragm spring le-
( — ) ver
Diaphragm adjusting wrench

ZZA0508D

— Locking flywheel
(Mot.1431)
Flywheel locking tool

JMAIA0431ZZ

— Holding clutch cover

(Emb.1761)
Tool kit for clutch cover removal and
installation

E1BIA0775ZZ

— Rearming clutch cover compensation system

(Emb.1604)
Clutch compression tool

E1BIA0778ZZ

Commercial Service Tools INFOID:0000000010745317

Tool name Description

Clutch aligner Installing clutch disc

MCIB0404E

Lubricant or/and Sealant INFOID:0000000010745318

CL-6
 PREPARATION
< PREPARATION >
Item Use
A
Lithium-based grease including molybdenum disulphide Application to clutch disc and input shaft splines area

CL

CL-7
 Symptom
Reference

Clutch slips
Clutch noisy
Clutch pedal spongy
Clutch grabs/chatters
< SYMPTOM DIAGNOSIS >

SUSPECTED PARTS (Possible cause)

Clutch does not disengage

NVH Troubleshooting Chart

essary, repair or replace these parts.

CL-9, "Inspection and Adjustment" CLUTCH PEDAL (Inspection and adjustment)

1
1
CL-13, "Air Bleeding" CLUTCH LINE (Air in line)

2
1
SYMPTOM DIAGNOSIS

CL-22, "LHD : Exploded View" (LHD), CL-24, "RHD : Exploded View" (RHD) MASTER CYLINDER PISTON CUP (Damaged)

3
2
EM-56, "Exploded View" (MR20DD), EM-365, "Exploded View" (R9M) ENGINE MOUNTING (Loose)

1
CL-30, "Exploded View" CSC (Concentric Slave Cylinder) (Worn, dirty or damaged)

4
1
2

CL-8
CLUTCH DISC (Out of true)

4
CLUTCH DISC (Runout is excessive)

4
2
CLUTCH DISC (Lining broken)

4
CLUTCH DISC (Dirty or burned)

4
CLUTCH DISC (Oily)

4
2
2
CL-33, "MR20DD : Inspection" (MR20DD), CL-39, "R9M : Inspection" (R9M) CLUTCH DISC (Worn out)

2
2
CLUTCH DISC (Hardened)

2
CLUTCH DISC (Lack of spline grease)

4
DIAPHRAGM SPRING (Damaged)

5
3
DIAPHRAGM SPRING (Out of tip alignment)

5
2
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

PRESSURE PLATE (Distortion)

6
4
EM-63, "Inspection" (MR20DD), EM-401, "Inspection" (R9M) FLYWHEEL (Distortion)

5
Use the chart below to find the cause of the symptom. The numbers indicate the order of the inspection. If nec-
INFOID:0000000010745319
 CLUTCH PEDAL
< PERIODIC MAINTENANCE >
PERIODIC MAINTENANCE A
CLUTCH PEDAL
Inspection and Adjustment INFOID:0000000010745320
B

INSPECTION
Clutch Pedal Height C
1. Turn the floor carpet.
2. Check that the clutch pedal height (H1) from the surface for
measurement is within the reference value. CL

Measurement surface : Top surface of floor panel

E
Clutch pedal height : Refer to CL-41, "Clutch Pedal".
• Replace clutch pedal if the height is outside the reference
value. F

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 shift lever in 1st gear.
5. Gradually release the clutch pedal and check that the clutch
pedal height (H2) from the surface for measurement is within J
the reference value with a scale immediately before the clutch is
engaged.
K
Measurement surface : Top surface of floor panel

Clutch pedal height at

L
clutch disengagement : Refer to CL-41, "Clutch Pedal".
• Replace clutch pedal if the height is outside the reference JPFIA0068ZZ
value. M
NOTE:
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.
N
Clutch Pedal Play
Push the pedal pad by hand until a resistance can be felt and check
that the play (A) on the upper surface of the pedal pad is within the
reference value. O

Clutch pedal play : Refer to CL-41, "Clutch Pedal".

P
• Replace clutch pedal if the play is outside the reference value.

JPFIA0121ZZ

Position of Clutch Interlock Switch

CL-9
 CLUTCH PEDAL
< PERIODIC MAINTENANCE >
Check that the clearance (C) between the thread end of clutch inter-
lock switch and clutch pedal lever is within the specified value
while clutch pedal is fully depressed.

Clearance : Refer to CL-41, "Clutch Pedal".

JSDIA5611ZZ

Position of Clutch Pedal Position Switch

Check that the clearance (C) between the thread end of clutch pedal
position switch and clutch pedal lever is within the specified
value while clutch pedal is fully released.

Clearance : Refer to CL-41, "Clutch Pedal".

JSDIA5611ZZ

ADJUSTMENT
Position of Clutch Interlock Switch
1. Disconnect the clutch interlock switch connector.
2. Loosen the clutch interlock switch 45 degrees counterclockwise.
3. With the clutch pedal fully depressed, press into the clutch inter-
lock switch until it reaches the clutch pedal lever and turn
the switch clockwise by 45 degrees to secure it.
CAUTION:
The clearance (C) show in the figure must be within the
specified value.

Clearance : Refer to CL-41, "Clutch Pedal".

NOTE:
Fully depressed clutch pedal means a clutch pedal condition
that the clutch pedal lever contacts the pedal stopper rubber. JSDIA5611ZZ

Position of Clutch Pedal Position Switch

1. Disconnect the clutch pedal position switch connector.
2. Loosen the clutch pedal position switch 45 degrees counterclockwise.
3. Press-fit the clutch pedal position switch until the clutch pedal
position switch hits the clutch pedal lever 45 degrees clock-
wise while pulling the pedal pad slightly.
CAUTION:
The clearance (C) show in the figure must be within the
specified value.

Clearance : Refer to CL-41, "Clutch Pedal".

JSDIA5611ZZ

CL-10
 CLUTCH FLUID
< PERIODIC MAINTENANCE >
CLUTCH FLUID
A
Inspection INFOID:0000000010745321

FLUID LEAKAGE B
• 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: C
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 CL
range (MAX – MIN lines).
• Visually check for any clutch fluid leakage around the reservoir
tank.
E
• Check the clutch system for any leakage if the fluid level is
extremely low (lower than MIN).

SFIA2634J G
Draining INFOID:0000000010745322

CAUTION: H
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. Connect a transparent vinyl hose to air bleeder of bleeding I
connector .

JSDIA5568ZZ L

2. Press the lock pin into the bleeding connector , and main-
tain the position. M

JPDIB0041ZZ

CL-11
 CLUTCH FLUID
< PERIODIC MAINTENANCE >
3. Slide bleeding connector in the direction of the arrow as
shown in the figure.

: Clutch housing

Dimension (A) : 10 mm (0.39 in)

4. Depress clutch pedal to gradually discharge clutch fluid.
CAUTION:
Since the inside of clutch tube is under hydraulic pressure,
hold the tube to prevent it from getting disconnected. JPDIB0042ZZ

Refilling INFOID:0000000010745323

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. Check that there is no foreign material in reservoir tank, and then fill with new clutch fluid.
CAUTION:
Never reuse drained clutch fluid.
2. Connect a transparent vinyl hose to air bleeder of bleeding
connector .

JSDIA5568ZZ

3. Press the lock pin into the bleeding connector , and main-
tain the position.

JPDIB0041ZZ

4. Slide bleeding connector in the direction of the arrow as

shown in the figure.

: Clutch housing

Dimension (A) : 10 mm (0.39 in)

5. 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, JPDIB0042ZZ

hold the tube to prevent it from getting disconnected.

6. Repeat step 5 at intervals of 2 or 3 seconds until new clutch fluid is discharged.
CAUTION:
Monitor clutch fluid level in reservoir tank so as not to empty the tank.

CL-12
 CLUTCH FLUID
< PERIODIC MAINTENANCE >
7. Return clutch tube and lock pin in their original positions while clutch pedal is depressed.
8. Perform the air bleeding. Refer to CL-13, "Air Bleeding". A

Air Bleeding INFOID:0000000010745324

CAUTION: B
• 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. C
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.
CL
1. Fill reservoir tank with new clutch fluid.
CAUTION:
Never reuse drained clutch fluid.
E
2. Connect a transparent vinyl hose to air bleeder of bleeding
connector .
3. “Depress” and “Release” the clutch pedal slowly and fully 15
F
times at an interval of 2 to 3 seconds and release the clutch
pedal.

H
JSDIA5568ZZ

4. Press the lock pin into the bleeding connector , and main-
tain the position. I
CAUTION:
Since the inside of clutch tube is under hydraulic pressure,
hold the tube to prevent it from getting disconnected. J

JPDIB0041ZZ
L
5. Slide bleeding connector in the direction of the arrow as
shown in the figure.
M
: Clutch housing

Dimension (A) : 10 mm (0.39 in) N

6. Depress the clutch pedal soon and hold it, and then bleed the air
from the piping.
CAUTION: O
Since the inside of clutch tube is under hydraulic pressure, JPDIB0042ZZ

hold the tube to prevent it from getting disconnected.

7. Return clutch tube and lock pin in their original positions. P
8. Release clutch pedal and wait for 5 seconds.
9. Repeat steps 3 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-
11, "Inspection".

CL-13
 CLUTCH PEDAL
< REMOVAL AND INSTALLATION >
REMOVAL AND INSTALLATION
CLUTCH PEDAL
LHD
LHD : Exploded View INFOID:0000000010745325

JSDIA6100GB

Clutch interlock switch Clutch pedal stroke sensor Clutch pedal position switch
Clip Clutch pedal assembly

: N·m (kg-m, ft-lb)

LHD : Removal and Installation INFOID:0000000010745326

REMOVAL
1. Remove instrument lower panel LH. Refer to IP-14, "Removal and Installation".
2. Disconnect clutch pedal position switch harness connector.
3. Disconnect clutch interlock switch harness connector.
4. Disconnect clutch pedal stroke sensor harness connector.
5. Disconnect harness clip from clutch pedal bracket .

: Hole for harness clip

JSDIA6104ZZ

CL-14
 CLUTCH PEDAL
< REMOVAL AND INSTALLATION >
6. Remove clutch pedal stroke sensor .
a. Pull sensor lever cover A
b. While turn lever pin and pull it.
c. Remove clutch pedal stroke sensor.
B

JSDIA5591ZZ

CL
7. Remove master cylinder rod end from clutch pedal lever .

G
JSDIA6109ZZ

8. Remove clutch pedal position switch and clip from clutch H

pedal bracket.

JSDIA6105ZZ
K
9. Remove clutch interlock switch and clip from clutch pedal
bracket.
L

N
JSDIA6106ZZ

10. Remove clutch pedal assembly. O

11. Perform inspection after removal. Refer to CL-16, "LHD :
Inspection and Adjustment".
P

JSDIA5589ZZ

CL-15
 CLUTCH PEDAL
< REMOVAL AND INSTALLATION >
INSTALLATION
Note the following, and install in the reverse order of removal.
• Push clip until it clicks.
• Press master cylinder rod end to pin of clutch pedal until it stops.
• Perform inspection and adjustment after installation. Refer to CL-16, "LHD : Inspection and Adjustment".
• Install clutch pedal stroke sensor, according to the following procedure.
CAUTION:
Install clutch pedal position switch before installing clutch pedal stroke sensor.
1. Insert pawl into the hole and hook it, and fit lever pin into
the hole. And then clutch pedal stroke sensor is installed tem-
porary.

JSDIA5601ZZ

2. Push lever pin and insert it into the hole deeply.

JSDIA5602ZZ

3. Turn lever pin as shown in the figure and fix lever pin to stop-
per . And then clutch pedal stroke sensor is installed com-
pletely.

JSDIA5603ZZ

4. Push sensor lever cover , then hold on pin of clutch pedal.

JSDIA5604ZZ

LHD : Inspection and Adjustment INFOID:0000000010745327

INSPECTION AFTER REMOVAL

CL-16
 CLUTCH PEDAL
< REMOVAL AND INSTALLATION >
• Check clutch pedal for bend, damage, or a cracked weld. If bend, damage, or a cracked weld is found,
replace clutch pedal assembly. A
• Check pedal stopper rubber . If damage or deformation is found,
replace clutch pedal assembly.
B

CL
JSDIA6112ZZ

• Check pedal pad . If wear or damage is found, replace clutch E

pedal assembly.

JSDIA6113ZZ H
INSPECTION AFTER INSTALLATION
• Check the clutch pedal height, clutch pedal height at clutch disengagement, and clutch pedal play. Refer to
CL-9, "Inspection and Adjustment". I
• Check the clutch pedal position switch position. Refer to CL-9, "Inspection and Adjustment".
• Check the clutch interlock switch position. Refer to CL-9, "Inspection and Adjustment".
ADJUSTMENT AFTER INSTALLATION J
• Adjust the clutch pedal position switch position. Refer to CL-9, "Inspection and Adjustment".
• Adjust the clutch interlock switch position. Refer to CL-9, "Inspection and Adjustment".
• Perform reset of clutch pedal stroke sensor, after installation clutch pedal or clutch pedal stroke sensor. K
Refer to PB-59, "Work Procedure".
RHD
L

CL-17
 CLUTCH PEDAL
< REMOVAL AND INSTALLATION >
RHD : Exploded View INFOID:0000000010745328

JSDIA5585GB

Clutch pedal assembly Clutch pedal stroke sensor Clutch pedal position switch
Clip Pedal pad Clutch interlock switch

: N·m (kg-m, ft-lb)

RHD : Removal and Installation INFOID:0000000010745329

REMOVAL
1. Remove instrument lower panel RH. Refer to IP-41, "Removal and Installation".
2. Disconnect clutch pedal position switch harness connector.
3. Disconnect clutch interlock switch harness connector.
4. Disconnect clutch pedal stroke sensor harness connector.
5. Disconnect harness clip from clutch pedal bracket .

: Hole for harness clip

JSDIA6110ZZ

CL-18
 CLUTCH PEDAL
< REMOVAL AND INSTALLATION >
6. Remove clutch pedal stroke sensor .
a. Pull sensor lever cover A
b. While turn lever pin and pull it.
c. Remove clutch pedal stroke sensor.
B

JSDIA5591ZZ

CL
7. Remove master cylinder rod end from clutch pedal lever .

G
JSDIA6109ZZ

8. Remove clutch pedal position switch and clip from clutch H

pedal bracket.

JSDIA5592ZZ
K
9. Remove clutch interlock switch and clip from clutch pedal
bracket.
L

N
JSDIA5593ZZ

10. Remove clutch pedal assembly. O

11. Remove pedal pad from clutch pedal.
12. Perform inspection after removal. Refer to CL-20, "RHD :
Inspection and Adjustment". P

JSDIA5594ZZ

CL-19
 CLUTCH PEDAL
< REMOVAL AND INSTALLATION >
INSTALLATION
Note the following, and install in the reverse order of removal.
• Push clip until it clicks.
• Press master cylinder rod end to pin of clutch pedal until it stops.
• Perform inspection and adjustment after installation. Refer to CL-20, "RHD : Inspection and Adjustment".
• Install clutch pedal stroke sensor, according to the following procedure.
CAUTION:
Install clutch pedal position switch before installing clutch pedal stroke sensor.
1. Insert pawl into the hole and hook it, and fit lever pin into
the hole. And then clutch pedal stroke sensor is installed tem-
porary.

JSDIA5601ZZ

2. Push lever pin and insert it into the hole deeply.

JSDIA5602ZZ

3. Turn lever pin as shown in the figure and fix lever pin to stop-
per . And then clutch pedal stroke sensor is installed com-
pletely.

JSDIA5603ZZ

4. Push sensor lever cover , then hold on pin of clutch pedal.

JSDIA5604ZZ

RHD : Inspection and Adjustment INFOID:0000000010745330

INSPECTION AFTER REMOVAL

CL-20
 CLUTCH PEDAL
< REMOVAL AND INSTALLATION >
• Check clutch pedal for bend, damage, or a cracked weld. If bend, damage, or a cracked weld is found,
replace clutch pedal assembly. A
• Check pedal stopper rubber . If damage or deformation is found,
replace clutch pedal assembly.
B

CL
JSDIA6114ZZ

• Check pedal pad . If wear or damage is found, replace pedal E

pad.

JSDIA6115ZZ H
INSPECTION AFTER INSTALLATION
• Check the clutch pedal height, clutch pedal height at clutch disengagement, and clutch pedal play. Refer to
CL-9, "Inspection and Adjustment". I
• Check the clutch pedal position switch position. Refer to CL-9, "Inspection and Adjustment".
• Check the clutch interlock switch position. Refer to CL-9, "Inspection and Adjustment".
ADJUSTMENT AFTER INSTALLATION J
• Adjust the clutch pedal position switch position. Refer to CL-9, "Inspection and Adjustment".
• Adjust the clutch interlock switch position. Refer to CL-9, "Inspection and Adjustment".
• Perform reset of clutch pedal stroke sensor, after installation clutch pedal or clutch pedal stroke sensor. K
Refer to PB-59, "Work Procedure".

CL-21
 CLUTCH MASTER CYLINDER
< REMOVAL AND INSTALLATION >
CLUTCH MASTER CYLINDER
LHD
LHD : Exploded View INFOID:0000000010745331

JSDIA5571ZZ

Master cylinder Reservoir hose Reservoir tank

LHD : Removal and Installation INFOID:0000000010745332

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 clutch master cylinder.
1. Remove the air cleaner case and air duct (inlet). Refer to EM-31, "Removal and Installation" (MR20DD),
EM-308, "Removal and Installation" (R9M)
2. Drain clutch fluid. Refer to CL-11, "Draining".
3. Remove reservoir hose from reservoir tank and master cylinder.
4. Remove master cylinder rod end from clutch pedal.

PCIB1491E

CL-22
 CLUTCH MASTER CYLINDER
< REMOVAL AND INSTALLATION >
5. Pull up the lock pin from connector of master cylinder and
separate clutch tube . A
6. Rotate master cylinder clockwise by 45 degrees, and then
remove master cylinder.
B

JPDIB0167ZZ

CL
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. E
1. Tilt master cylinder clockwise by 45 degrees 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.
CAUTION:
Press master cylinder rod end to clutch pedal until it stops. G
3. Install reservoir hose to reservoir tank and master cylinder.
CAUTION:
Set reservoir hose with painted mark facing upward. H
4. Press down the lock pin into connector of master cylinder until it
JSDIA5573ZZ
stops.
5. Install clutch tube into connector of master cylinder until it stops. I
6. Fill with clutch fluid. Refer to CL-12, "Refilling".
7. Perform inspection and adjustment after installation. Refer to CL-23, "LHD : Inspection and Adjustment".
8. For the next step and after, install in the reverse order of removal. J

LHD : Inspection and Adjustment INFOID:0000000010745333

K
INSPECTION AFTER INSTALLATION
• Check the fluid leakage and the fluid level. Refer to CL-11, "Inspection".
• Check for the clutch pedal condition. Refer to CL-9, "Inspection and Adjustment".
L
ADJUSTMENT AFTER INSTALLATION
Perform the air bleeding. Refer to CL-13, "Air Bleeding".
RHD M

CL-23
 CLUTCH MASTER CYLINDER
< REMOVAL AND INSTALLATION >
RHD : Exploded View INFOID:0000000010745334

JSDIA5572ZZ

Master cylinder Reservoir hose Reservoir tank

RHD : Removal and Installation INFOID:0000000010745335

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 clutch master cylinder.
1. Drain clutch fluid. Refer to CL-11, "Draining".
2. Remove reservoir hose from reservoir tank and master cylinder.
3. Remove master cylinder rod end from clutch pedal.

PCIB1491E

4. Pull up the lock pin from connector of master cylinder and

separate clutch tube .
5. Rotate master cylinder clockwise by 45 degrees, and then
remove master cylinder from the vehicle.

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.

CL-24
 CLUTCH MASTER CYLINDER
< REMOVAL AND INSTALLATION >
1. Tilt master cylinder clockwise by 45 degrees and insert it to
the mounting hole. Rotate counterclockwise and secure it. At A
this time, nipple is upward of the vehicle.
2. Install master cylinder rod end to clutch pedal.
CAUTION: B
Press master cylinder rod end to clutch pedal until it stops.
3. Install reservoir hose to reservoir tank and master cylinder.
4. Press down the lock pin into connector of master cylinder until it C
stops.
5. Install clutch tube into connector of master cylinder until it stops. JSDIA5573ZZ

6. Fill with clutch fluid. Refer to CL-12, "Refilling". CL

7. Perform inspection and adjustment after installation. Refer to CL-25, "RHD : Inspection and Adjustment".
8. For the next step and after, install in the reverse order of removal.
E
RHD : Inspection and Adjustment INFOID:0000000010745336

INSPECTION AFTER INSTALLATION F

• Check the fluid leakage and the fluid level. Refer to CL-11, "Inspection".
• Check for the clutch pedal condition. Refer to CL-9, "Inspection and Adjustment".
ADJUSTMENT AFTER INSTALLATION G
Perform the air bleeding. Refer to CL-13, "Air Bleeding".

CL-25
 CLUTCH PIPING
< REMOVAL AND INSTALLATION >
CLUTCH PIPING
Exploded View INFOID:0000000010745337

MR20DD

JSDIA5583ZZ

CSC (Concentric Slave Cylinder) Clip Clutch tube

Clutch damper Bracket Master cylinder

R9M

CL-26
 CLUTCH PIPING
< REMOVAL AND INSTALLATION >

CL

H
JSDIA6097GB

CSC (Concentric Slave Cylinder) Clutch tube Clip

I
Bracket Clutch damper Bracket
Master cylinder

: N·m (kg-m, ft-lb) J

Hydraulic Piping INFOID:0000000010745338

N
PCIB1499E

Clutch tube Lock pin CSC (Concentric Slave Cylinder)

O
Clutch damper Master cylinder Clutch pedal

Removal and Installation INFOID:0000000010745339

P
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-26, "Exploded View" for removal procedure.
• Drain clutch fluid. Refer to CL-11, "Draining".

CL-27
 CLUTCH PIPING
< REMOVAL AND INSTALLATION >
• Press the lock pin into the bleeding connector of the CSC ,
and then remove clutch tube from CSC.

JSDIA5580ZZ

• Pull the lock pins from the connectors of the clutch damper
until the pins stop, and then remove clutch tubes from clutch
damper.

JSDIA5581ZZ

• Pull the lock pin from the connector of the clutch master cylinder
until the pin stop, and then remove clutch tube from clutch
master cylinder.
• Perform inspection after removal. Refer to CL-28, "Inspection and
Adjustment".

JSDIA5582ZZ

INSTALLATION
Note the following, and refer to CL-26, "Exploded View" for installation procedure.
CAUTION:
Never damage clutch tube.
• Insert each clutch tube into the CSC bleeding connector, the clutch damper connector, and the clutch master
cylinder connector until it contacts the end of each connector.
• Install each lock pin into the clutch damper connector and the clutch master cylinder connector until it con-
tacts the end of each connector.
• Perform inspection and adjustment after installation. Refer to CL-28, "Inspection and Adjustment".
Inspection and Adjustment INFOID:0000000010745340

INSPECTION AFTER REMOVAL

• Check the clutch tube for cracks and damage. If the clutch tube has cracks or damage, replace it with a new
one.
• Check the O-ring of the clutch tube for cracks and damage. If the O-ring of the clutch tube has cracks or
damage, replace clutch tube with a new one.
• Check the clutch damper for cracks and damage. If the clutch damper has cracks or damage, replace it with
a new one.
INSPECTION AFTER INSTALLATION
• Check the fluid leakage and the fluid level. Refer to CL-11, "Inspection".
• Check for the clutch pedal condition. Refer to CL-9, "Inspection and Adjustment".

CL-28
 CLUTCH PIPING
< REMOVAL AND INSTALLATION >
ADJUSTMENT AFTER INSTALLATION
Perform the air bleeding. Refer to CL-13, "Air Bleeding". A

CL

CL-29
 CSC (CONCENTRIC SLAVE CYLINDER)
< REMOVAL AND INSTALLATION >
CSC (CONCENTRIC SLAVE CYLINDER)
Exploded View INFOID:0000000010745341

MR20DD

JPDIB0040GB

Transaxle assembly CSC (Concentric Slave Cylinder)

: N·m (kg-m, ft-lb)

: Always replace after every disassembly.

R9M

JPDIB0048GB

Transaxle assembly CSC (Concentric Slave Cylinder) Sealing bolt

: N·m (kg-m, ft-lb)

: Always replace after every disassembly.

Removal and Installation INFOID:0000000010745342

CAUTION:

CL-30
 CSC (CONCENTRIC SLAVE CYLINDER)
< REMOVAL AND INSTALLATION >
• 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
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
B
and wash the affected area with water.
REMOVAL
1. Remove transaxle assembly. Refer to TM-41, "Removal and Installation" (RS6F94R), TM-122, "Removal C
and Installation" (RS6F52A).
2. Remove CSC from clutch housing.
INSTALLATION CL

1. Install CSC to clutch housing, and then tighten CSC mounting bolts to the specified torque.
• For tightening torque, refer to CL-30, "Exploded View".
CAUTION: E
• Never reuse CSC.
• Never reuse sealing bolt. (R9M only)
• Never insert and operate CSC because piston and stopper of CSC components may fall off. F
2. Install transaxle assembly. Refer to TM-41, "Removal and Installation" (RS6F94R), TM-122, "Removal
and Installation" (RS6F52A).
3. Perform inspection and adjustment after installation. Refer to CL-31, "Inspection and Adjustment". G
Inspection and Adjustment INFOID:0000000010745343

H
INSPECTION AFTER INSTALLATION
Check the fluid leakage and the fluid level. Refer to CL-11, "Inspection".
ADJUSTMENT AFTER INSTALLATION I
Perform the air bleeding. Refer to CL-13, "Air Bleeding".

CL-31
 CLUTCH DISC AND CLUTCH COVER
< REMOVAL AND INSTALLATION >
CLUTCH DISC AND CLUTCH COVER
MR20DD
MR20DD : Exploded View INFOID:0000000010745344

JPDIB0049GB

Flywheel Clutch disc Clutch cover

Input shaft
First step Final step

: N·m (kg-m, ft-lb)

: Apply lithium-based grease including molybdenum disulphide.

MR20DD : Removal and Installation INFOID:0000000010745345

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. Refer to CL-30, "Removal and Installation".
• Never bring any grease to the clutch disc facing, pressure plate surface and flywheel surface.
• Never clean clutch disc using solvent.
REMOVAL
1. Remove transaxle assembly. Refer to TM-41, "Removal and Installation".
2. Remove clutch cover mounting bolts while holding clutch cover.
CAUTION:
Never drop clutch disc.
3. Remove clutch cover and clutch disc.
CAUTION:
Never drop clutch disc.
4. Perform inspection after removal. Refer to CL-33, "MR20DD : Inspection".
INSTALLATION
1. Clean clutch disc and input shaft splines to remove grease and powder arisen from abrasion.

CL-32
 CLUTCH DISC AND CLUTCH COVER
< REMOVAL AND INSTALLATION >
2. Apply recommended grease to clutch disc and input shaft
splines area . For recommended grease, refer to CL-32, A
"MR20DD : Exploded View".
CAUTION:
Be sure to apply grease to the points specified. Otherwise, B
noise, poor disengagement, or damage to the clutch may
result. Excessive grease may cause slip or judder. And if it
adheres to seal of CSC, it cause clutch fluid leakage. Wipe
out excess grease. Wipe out any grease oozing from the C
parts.
JSDIA3617ZZ

CL
3. Install clutch disc using clutch aligner (A) (commercial service
tool), and temporarily install clutch cover.
CAUTION:
E
• Never drop clutch disc and clutch cover.

G
JSDIA3358ZZ

• Be careful with the orientation of the clutch disc. H

: Engine side
I

JSDIA6017ZZ K
4. Tighten clutch cover mounting bolts to the specified torque
evenly in two steps in the numerical order as shown in the fig-
ure. L
• For tightening torque, refer to CL-32, "MR20DD : Exploded
View".
• After installation, perform inspection. Refer to CL-33, M
"MR20DD : Inspection".
5. Install transaxle assembly. Refer to TM-41, "Removal and Instal-
lation". N

PCIB1772E

MR20DD : Inspection INFOID:0000000010745346 O

INSPECTION AFTER REMOVAL

Clutch Disc P

CL-33
 CLUTCH DISC AND CLUTCH COVER
< REMOVAL AND INSTALLATION >
• Measure circumferential runout relative to clutch disc center spline.
If it is outside the specification, replace clutch disc.

Runout limit/diameter of the area to : Refer to CL-41,

be measured "Clutch Disc".
• Measure backlash to clutch disc spline and input shaft spline at the
circumference of clutch disc. If it is outside the specification,
replace clutch disc.

Maximum allowable spline backlash : Refer to CL-41,

SCL221
(at outer edge of disc) "Clutch Disc".
• Measure the depth (A) to clutch disc facing rivet heads, using a
calipers. If it exceeds the allowable wear limit, replace clutch disc.

Facing wear limit (depth to the rivet : Refer to CL-41,

head) "Clutch Disc".

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.
INSPECTION AFTER INSTALLATION
Clutch Cover
Check diaphragm spring lever claws for unevenness with the lever
still on the vehicle. If they exceed the tolerance, adjust lever height,
using the diaphragm adjusting wrench (A) (SST: ST20050240).

Tolerance for diaphragm spring : Refer to CL-42,

lever unevenness "Clutch Cover".

JPDIB0160ZZ

R9M

CL-34
 CLUTCH DISC AND CLUTCH COVER
< REMOVAL AND INSTALLATION >
R9M : Exploded View INFOID:0000000010752997

CL

JSDIA6096GB

G
Flywheel Clutch disc Clutch cover
Input shaft

: N·m (kg-m, ft-lb)

H

: Apply lithium-based grease including molybdenum disulphide.

R9M : Removal and Installation INFOID:0000000010752998

I

CAUTION:
• Never reuse CSC (Concentric Slave Cylinder). Because CSC slides back to the original position J
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-30, "Removal and Installation".
• Never bring any grease to the clutch disc facing, pressure plate surface and flywheel surface.
• Never clean clutch disc using solvent. K

REMOVAL
1. Remove transaxle assembly. Refer to TM-122, "Removal and Installation". L
2. Lock the flywheel using the flywheel locking tool (A) [SST: —
(Mot.1431)].
3. Remove clutch cover and clutch disc according to the following M
procedure.
NOTE:
These instructions must be respected to prevent twisting the
clutch cover. N
a. Remove three clutch cover mounting bolts at 120° intervals.
O
JSDIA6085ZZ

CL-35
 CLUTCH DISC AND CLUTCH COVER
< REMOVAL AND INSTALLATION >
b. Replace these three bolts to the bolts of the tool kit (A)
[SST: — (Emb.1761)].
c. Place the three spacers of the tool kit [SST: — (Emb.1761)]
in contact with the nuts.
d. Gradually remove the remaining bolts.
e. Unscrew and gradually remove by quarter turns the three nuts of
the tool kit [SST: — (Emb.1761)] one by one.
f. Remove clutch cover and clutch disc.
CAUTION:
Never drop clutch disc. JSDIA6086ZZ
g. Perform inspection after removal. Refer to CL-39, "R9M :
Inspection".
INSTALLATION
In Case of Clutch Cover Reused:
NOTE:
The automatic compensation must be repositioned at its first point.
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 area . For recommended grease, refer to CL-35, "R9M
: Exploded View".
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 CSC, it cause clutch fluid leakage. Wipe
out excess grease. Wipe out any grease oozing from the
parts.
JSDIA3617ZZ

3. Place the base plate of clutch compression tool [SST: —

(Emb.1604)] in a vice jaw.

E1BIA0779ZZ

4. Install clutch cover onto the base plate then install the ball bear-
ing or bronze ring (A) and the nut (B) of clutch compression tool
[SST: — (Emb.1604)].

JSDIA6088ZZ

CL-36
 CLUTCH DISC AND CLUTCH COVER
< REMOVAL AND INSTALLATION >
5. Tighten the nut (A) fully.
A

JSDIA6089ZZ

CL
6. Fit a circlip and clamp it at .

G
JSDIA6090ZZ

7. Compress the spring to reprime the automatic compensation. H

Then slacken off the nut (A) completely. (Spring is compressed.)
8. Release clutch cover.
I

JSDIA6091ZZ
K
9. Remove clutch cover from the base plate of clutch compression
tool [SST: — (Emb.1604)].
CAUTION: L
Be sure that the springs are correctly compressed.

N
E1BIA0784ZZ

10. Install clutch disc using clutch aligner (A) (commercial service O
tool), and temporarily install clutch cover.
CAUTION:
• Never drop clutch disc and clutch cover. P

JSDIA3358ZZ

CL-37
 CLUTCH DISC AND CLUTCH COVER
< REMOVAL AND INSTALLATION >

• Be careful with the orientation of the clutch disc.

: Engine side

JSDIA6092ZZ

11. Tighten clutch cover mounting bolts to the specified torque

evenly in the numerical order as shown in the figure.
• For tightening torque, refer to CL-35, "R9M : Exploded View".
• After installation, perform inspection. Refer to CL-39, "R9M :
Inspection".
12. Install transaxle assembly. Refer to TM-122, "Removal and
Installation".

JSDIA3045ZZ

In Case of New Clutch Cover 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 area . For recommended grease, refer to CL-35, "R9M
: Exploded View".
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 CSC, it cause clutch fluid leakage. Wipe
out excess grease. Wipe out any grease oozing from the
parts.
JSDIA3617ZZ

3. Install clutch disc using clutch aligner (A) (commercial service

tool), and temporarily install clutch cover.
CAUTION:
• Never drop clutch disc and clutch cover.

JSDIA3358ZZ

CL-38
 CLUTCH DISC AND CLUTCH COVER
< REMOVAL AND INSTALLATION >
• Be careful with the orientation of the clutch disc.
A
: Engine side

JSDIA6092ZZ

CL
4. Tighten clutch cover mounting bolts to the specified torque
evenly in the numerical order as shown in the figure.
• For tightening torque, refer to CL-35, "R9M : Exploded View".
• After installation, perform inspection. Refer to CL-39, "R9M : E
Inspection".
5. Install transaxle assembly. Refer to TM-122, "Removal and
Installation". F

G
JSDIA3045ZZ

R9M : Inspection INFOID:0000000010752999

H
INSPECTION AFTER REMOVAL
Clutch Disc
I
• Measure circumferential runout relative to clutch disc center spline.
If it is outside the specification, replace clutch disc.

Runout limit/diameter of the area to : Refer to CL-41, J

be measured "Clutch Disc".
• Measure backlash to clutch disc spline and input shaft spline at the
circumference of clutch disc. If it is outside the specification, K
replace clutch disc.

Maximum allowable spline backlash : Refer to CL-41, L

SCL221
(at outer edge of disc) "Clutch Disc".
• Measure the depth (A) to clutch disc facing rivet heads, using a
calipers. If it exceeds the allowable wear limit, replace clutch disc. M

Facing wear limit (depth to the rivet : Refer to CL-41,

head) "Clutch Disc". N

JPDIB0026ZZ
P
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-39
 CLUTCH DISC AND CLUTCH COVER
< REMOVAL AND INSTALLATION >
INSPECTION AFTER INSTALLATION
Clutch Cover
Check diaphragm spring lever claws for unevenness with the lever
still on the vehicle. If they exceed the tolerance, adjust lever height,
using the diaphragm adjusting wrench (A) (SST: ST20050240).

Tolerance for diaphragm spring : Refer to CL-42,

lever unevenness "Clutch Cover".

JPDIB0160ZZ

CL-40
 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS) A
SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications INFOID:0000000010745347
B
Unit: mm (in)

Engine MR20DD R9M C

Type of clutch control Hydraulic
Facing size 230 × 155 × 3.2 239 × 170 × 3.45
Clutch disc
(Outer dia. × Inner dia. × Thickness) (9.06 × 6.10 × 0.126) (9.41 × 6.69 × 0.1358) CL
Recommended clutch fluid Refer to MA-23, "Fluids and Lubricants".

Clutch Pedal INFOID:0000000010745348

E

LHD MODELS
Unit: mm (in)
F
Item Standard
Clutch pedal height 193.6 – 203.6 (7.62 – 8.02)
MR20DD 111.7 (4.40) or more G
Clutch pedal height at clutch disengagement
R9M 96.0 (3.780) or more
Clutch pedal play 2 – 8 (0.08 – 0.31)
H
Between the thread end of clutch interlock switch and
0.2 – 1.96 (0.008 – 0.077)
clutch pedal lever
Clearance
Between the thread end of clutch pedal position switch
0.2 – 1.96 (0.008 – 0.077) I
and clutch pedal lever

RHD MODELS
Unit: mm (in) J
Item Standard
Clutch pedal height 188.5 – 198.5 (7.42 – 7.81)
K
MR20DD —
Clutch pedal height at clutch disengagement
R9M 93.4 (3.677) or more
Clutch pedal play 2 – 8 (0.08 – 0.31) L
Between the thread end of clutch interlock switch and
0.2 – 1.96 (0.008 – 0.077)
clutch pedal lever
Clearance
Between the thread end of clutch pedal position switch
0.2 – 1.96 (0.008 – 0.077)
M
and clutch pedal lever

Clutch Disc INFOID:0000000010745349

N
Unit: mm (in)

Item Standard
O
MR20DD 1.0 (0.039) / 220 (8.66) dia.
Runout limit/diameter of the area to be measured
R9M 1.0 (0.039) / 229 (9.02) dia.
MR20DD 0.9 (0.035) P
Maximum allowable spline backlash (at outer edge of disc)
R9M 1.0 (0.039)
MR20DD
Facing wear limit (depth to the rivet head) 0.3 (0.012)
R9M

CL-41
 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS)
Clutch Cover INFOID:0000000010745350

Unit: mm (in)

Item Standard
MR20DD 0.7 (0.028) or less
Tolerance for diaphragm spring lever unevenness
R9M 0.8 (0.031) or less

CL-42