Clutch: Section

TRANSMISSION & DRIVELINE
SECTION CL CLUTCH
B
CL
E
CONTENTS
PRECAUTION ............................................... 3 RHD : Exploded View ..............................................13 F
RHD : Removal and Installation ..............................13
PRECAUTIONS ................................................... 3 RHD : Inspection and Adjustment ...........................14
Precaution for Supplemental Restraint System G
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- CLUTCH MASTER CYLINDER ........................ 16
SIONER" ................................................................... 3
LHD ............................................................................16
Precautions Necessary for Steering Wheel Rota-
LHD : Exploded View ...............................................16 H
tion After Battery Disconnection ................................ 3
LHD : Removal and Installation ...............................16
General Precautions ................................................. 4
LHD : Inspection and Adjustment ............................18
PREPARATION ............................................ 5 RHD ............................................................................18 I
PREPARATION ................................................... 5 RHD : Exploded View ..............................................18
Special Service Tools ................................................ 5 RHD : Removal and Installation ..............................18
Commercial Service Tools ........................................ 5 RHD : Inspection and Adjustment ...........................20 J
CLUTCH PIPING ............................................... 21

SYMPTOM DIAGNOSIS ............................... 6
Exploded View .........................................................21
Hydraulic Layout ......................................................21 K
NOISE, VIBRATION AND HARSHNESS
(NVH) TROUBLESHOOTING ............................. 6 Removal and Installation .........................................21
NVH Troubleshooting Chart ...................................... 6 Inspection and Adjustment ......................................22
L
PERIODIC MAINTENANCE .......................... 7 UNIT REMOVAL AND INSTALLATION ...... 23
CLUTCH PEDAL ................................................. 7 CSC (CONCENTRIC SLAVE CYLINDER) ....... 23

Exploded View .........................................................23 M
Inspection and Adjustment ........................................ 7
Removal and Installation .........................................23
CLUTCH FLUID ................................................... 9 Inspection and Adjustment ......................................23
Inspection .................................................................. 9 N
Draining ..................................................................... 9 CLUTCH DISC AND CLUTCH COVER ............ 24
Refilling ................................................................... 10 HR12DE .....................................................................24
Air Bleeding ............................................................. 11 HR12DE : Exploded View ........................................24 O
HR12DE : Removal and Installation ........................24
REMOVAL AND INSTALLATION ............... 12
HR12DE : Inspection ...............................................25
CLUTCH PEDAL ................................................12 HR15DE .....................................................................26
P
LHD ............................................................................ 12 HR15DE : Exploded View ........................................26

LHD : Exploded View .............................................. 12 HR15DE : Removal and Installation ........................26
LHD : Removal and Installation ............................... 12 HR15DE : Inspection ...............................................27
LHD : Inspection and Adjustment ............................ 12 K9K ............................................................................28
RHD ........................................................................... 13 K9K : Exploded View ...............................................28
Revision: 2012 July CL-1 N17

K9K : Removal and Installation .............................. 28 SERVICE DATA AND SPECIFICATIONS
K9K : Inspection ..................................................... 29 (SDS) ................................................................. 31
General Specifications ............................................ 31
SERVICE DATA AND SPECIFICATIONS Clutch Pedal ............................................................ 31
(SDS) ........................................................... 31 Clutch Disc .............................................................. 31
Clutch Cover ........................................................... 31

PRECAUTIONS
< PRECAUTION >
PRECAUTION A
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT B
PRE-TENSIONER" INFOID:0000000006957275
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
Precautions Necessary for Steering Wheel Rotation After Battery Disconnection
INFOID:0000000006957278
K
CAUTION:
Comply with the following cautions to prevent any error and malfunction.
• Before removing and installing any control units, first turn the ignition switch to the LOCK position,
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. Turn the ignition switch to ACC position. P
(At this time, the steering lock will be released.)
3. Disconnect both battery cables. The steering lock will remain released with both battery cables discon-
nected and the steering wheel can be turned.
4. Perform the necessary repair operation.

PRECAUTIONS
< PRECAUTION >
5. When the repair work is completed, re-connect both battery cables. With the brake pedal released, turn
the ignition switch from ACC position to ON position, then to LOCK position. (The steering wheel will lock
when the ignition switch is turned to LOCK position.)
6. Perform self-diagnosis check of all control units using CONSULT.
General Precautions INFOID:0000000006655960
WARNING:
After cleaning clutch disc, wipe it with a dust collector. Never use compressed air.
CAUTION:
• Clutch fluid use refer to MA-17, "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-23, "Removal and Installation".
• Never disassemble clutch master cylinder and CSC.

PREPARATION
< PREPARATION >
PREPARATION A
PREPARATION
Special Service Tools INFOID:0000000006655961
B
Tool number
Description C
Tool name
ST20050240 Adjusting unevenness of diaphragm spring le-
Diaphragm adjusting wrench ver
CL
E
ZZA0508D
Commercial Service Tools INFOID:0000000006655962 F
Tool name Description G

Clutch aligner Installing clutch disc
I
MCIB0404E

Symptom
Reference
Revision: 2012 July

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-7 CLUTCH PEDAL (Inspection and adjustment)
1
1
CL-11 CLUTCH LINE (Air in line)
2
1
SYMPTOM DIAGNOSIS
EM-87 (HR12DE), EM-214 [HR15DE (TYPE 1*)],

ENGINE MOUNTING (Loose)
1
EM-337 [HR15DE (TYPE 2*)], EM-449 (K9K)
*: Refer to EM-134, "How to Check Vehicle Type".

CL-23 CSC (Concentric Slave Cylinder) (Worn, dirty or damaged)
3
2
CL-6
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)
2
3
2
CL-27 CLUTCH DISC (Worn out)
2
2
CLUTCH DISC (Hardened)
2
CLUTCH DISC (Lack of spline grease)
3
DIAPHRAGM SPRING (Damaged)
3
4
DIAPHRAGM SPRING (Out of tip alignment)
4
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
PRESSURE PLATE (Distortion)
4
5
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
EM-95 (HR12DE), EM-236 [HR15DE (TYPE 1*)],

FLYWHEEL (Distortion)
5
EM-344 [HR15DE (TYPE 2*)]
Use the chart below to find the cause of the symptom. The numbers indicate the order of the inspection. If nec-
INFOID:0000000006655963
N17
CLUTCH PEDAL
< PERIODIC MAINTENANCE >
PERIODIC MAINTENANCE A
CLUTCH PEDAL
Inspection and Adjustment INFOID:0000000006655964
B
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 (1) is within the reference value. CL
Clutch pedal height : Refer to CL-31, "Clutch Pedal".

“H1” E
3. 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 shifter lever in 1st gear.
5. Gradually release the clutch pedal and check that the clutch
pedal height “H2” from the dash lower panel (1) 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-31, "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-31, "Clutch Pedal".
2. Replace clutch pedal if the play is outside the reference value.
P
JPFIA0121ZZ
Position of Clutch Interlock Switch (With Push-Button Ignition Switch System)

CLUTCH PEDAL
Check that the clearance “C” between the thread end of clutch inter-
lock switch (1) and clutch pedal (2) is within the specified value while
clutch pedal is fully depressed.
Clearance “C” : Refer to CL-31, "Clutch Pedal".
JPDIB0118ZZ
Position of Clutch Pedal Position Switch (With Push-Button Ignition Switch System)
Check that the clearance “A” between the thread end of clutch pedal
position switch (1) and clutch pedal (2) is within the specified value
while clutch pedal is fully released.
Clearance “A” : Refer to CL-31, "Clutch Pedal".
JPDIB0165ZZ
ADJUSTMENT
Position of Clutch Interlock Switch (With Push-Button Ignition Switch System)
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 (1) until it reaches the clutch pedal (2) 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 “C” : Refer to CL-31, "Clutch Pedal".

NOTE:
Fully depressed clutch pedal means a clutch pedal condition
that the pedal stopper rubber on the clutch pedal lever contacts JPDIB0118ZZ
the clutch pedal bracket.

Position of Clutch Pedal Position Switch (With Push-Button Ignition Switch System)
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 (1) until the clutch
pedal position switch hits the clutch pedal (2) 45 degrees clock-
wise while pulling the pedal pad slightly.
CAUTION:
The clearance “A” show in the figure must be within the
specified value.
Clearance “A” : Refer to CL-31, "Clutch Pedal".
JPDIB0165ZZ

CLUTCH FLUID
CLUTCH FLUID
A
Inspection INFOID:0000000006655965
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).
JPFIA0007ZZ G
Draining INFOID:0000000006655966
CAUTION: H
Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
1. Connect a transparent vinyl hose to air bleeder of bleeding con- I
nector (1).
JPDIB0144ZZ L
2. Press the lock pin (1) into the bleeding connector (2), and main-
tain the position. M
PCIB1495E

CLUTCH FLUID
3. Slide clutch tube (1) in the direction of the arrow as shown in the
figure.
2 : Bleeding connector
Dimension “A” : 5 mm (0.20 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. JPDIB0147ZZ
Refilling INFOID:0000000006655967
CAUTION:
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 con-
nector (1).
JPDIB0144ZZ
tain the position.
PCIB1495E
figure.
Dimension “A” : 5 mm (0.20 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, JPDIB0147ZZ
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.

CLUTCH FLUID
7. Return clutch tube and lock pin in their original positions while clutch pedal is depressed.
8. Perform the air bleeding. Refer to CL-11, "Air Bleeding". A
Air Bleeding INFOID:0000000006655968
CAUTION: B
• Monitor clutch fluid level in reservoir tank so as not to empty the tank.
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 con-
nector (1).
3. “Depress” and “release” the clutch pedal slowly and fully 15
times at an interval of 2 to 3 seconds and release the clutch F
pedal.
H
JPDIB0144ZZ
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
PCIB1495E
L
figure.
M
Dimension “A” : 5 mm (0.20 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, JPDIB0147ZZ
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-
9, "Inspection".

CLUTCH PEDAL
< REMOVAL AND INSTALLATION >
REMOVAL AND INSTALLATION
CLUTCH PEDAL
LHD
LHD : Exploded View INFOID:0000000006655969
JPDIB0230GB
1. Clutch pedal 2. Pedal stopper rubber 3. Pedal pad

4. Clip 5. Clutch pedal position switch * 6. Clutch interlock switch *
* : With push-button ignition switch system
: N·m (kg-m, ft-lb)
LHD : Removal and Installation INFOID:0000000006655970
REMOVAL
1. Remove master cylinder rod end from clutch pedal.
2. Disconnect clutch pedal position switch connector. (With push-
button ignition switch system)
3. Disconnect clutch interlock switch connector. (With push-button
ignition switch system)
4. Remove harness clip from clutch pedal.
5. Remove clutch pedal from the vehicle.
6. Remove pedal pad from clutch pedal.
7. Remove clutch pedal position switch and clip from clutch pedal.
(With push-button ignition switch system) PCIB1491E
8. Remove clutch interlock switch and clip from clutch pedal. (With
push-button ignition switch system)
9. Remove pedal stopper rubber from clutch pedal, using a suitable remover.
INSTALLATION
Note the following, and install in the reverse order of removal.
CAUTION:
Press master cylinder rod end into clutch pedal until it stops.
LHD : Inspection and Adjustment INFOID:0000000006655971
INSPECTION AFTER REMOVAL

CLUTCH PEDAL
• Check clutch pedal for bend, damage, or a cracked weld. If bend, damage, or a cracked weld is found,
replace clutch pedal. A
• Check pedal stopper rubber. If damage or deformation is found, replace pedal stopper rubber.
• Check pedal pad. If wear or damage is found, replace pedal pad.
INSPECTION AFTER INSTALLATION B
• Check the clutch pedal height, clutch pedal height at clutch disengagement, and clutch pedal play. Refer to
CL-7, "Inspection and Adjustment".
• Check the clutch interlock switch position. (With push-button ignition switch system) Refer to CL-7, "Inspec- C
tion and Adjustment".
• Check the clutch pedal position switch position. (With push-button ignition switch system) Refer to CL-7,
"Inspection and Adjustment".
CL
ADJUSTMENT AFTER INSTALLATION
• Adjust the clutch interlock switch position. (With push-button ignition switch system) Refer to CL-7, "Inspec-
E
• Adjust the clutch pedal position switch position. (With push-button ignition switch system) Refer to CL-7,
RHD
F
RHD : Exploded View INFOID:0000000007697963
L
JPDIB0229GB
1. Clutch pedal 2. Pedal stopper rubber 3. Pedal pad

4. Clip 5. Clutch pedal position switch* 6. Clutch interlock switch*
M
*: With push-button ignition switch system
N
RHD : Removal and Installation INFOID:0000000007697964
1. Remove steering column upper cover, instrument finisher A, and switch panel. Refer to IP-13, "Removal O
and Installation".

CLUTCH PEDAL
2. Remove clutch pedal mounting nut (A).
1 : Clutch pedal
JPDIB0231ZZ
3. Remove master cylinder rod end from clutch pedal.

4. Remove clutch pedal mounting nuts.
5. Lower clutch pedal to the position where the harness clip can be
removed.
6. Remove harness clip from clutch pedal.
7. Remove clutch pedal from the vehicle.
8. Remove pedal pad from clutch pedal.
9. Remove clutch pedal position switch and clip from clutch pedal.
(With push-button ignition switch system)
10. Remove clutch interlock switch and clip from clutch pedal. (With PCIB1491E
push-button ignition switch system)

11. Remove pedal stopper rubber from clutch pedal, using a suitable remover.
INSTALLATION
Note the following, and install in the reverse order of removal.
CAUTION:
Press master cylinder rod end into clutch pedal until it stops.
RHD : Inspection and Adjustment INFOID:0000000007697965

• Check clutch pedal for bend, damage, or a cracked weld. If bend, damage, or a cracked weld is found,
replace clutch pedal.
• Check pedal stopper rubber. If damage or deformation is found, replace pedal stopper rubber.
• Check pedal pad. If wear or damage is found, replace pedal pad.
INSPECTION AFTER INSTALLATION
• Check the clutch interlock switch position. (With push-button ignition switch system) Refer to CL-7, "Inspec-
• Check the clutch pedal position switch position. (With push-button ignition switch system) Refer to CL-7,

CLUTCH PEDAL
• Adjust the clutch interlock switch position. (With push-button ignition switch system) Refer to CL-7, "Inspec-
tion and Adjustment". A
• Adjust the clutch pedal position switch position. (With push-button ignition switch system) Refer to CL-7,
B
CL

CLUTCH MASTER CYLINDER
LHD
LHD : Exploded View INFOID:0000000006655975
JPDIB0222ZZ
1. Reservoir hose 2. Master cylinder
LHD : Removal and Installation INFOID:0000000006655976
REMOVAL
CAUTION:
• Never disassemble clutch master cylinder.
1. Remove air cleaner case. Refer to EM-157, "Removal and Installation" [HR15DE (TYPE 1*)] or EM-284,
"Removal and Installation" [HR15DE (TYPE 2*)].
NOTE:
For “TYPE 1” and “TYPE 2”, refer to EM-134, "How to Check Vehicle Type".
2. Remove battery. Refer to PG-149, "FOR MAINTENANCE REQUIRED BATTERY MODELS : Removal
and Installation" or PG-150, "FOR MAINTENANCE FREE BATTERY MODELS : Removal and Installa-
tion".
3. Remove bolts (A) and nut (B).
: Vehicle front
4. Remove battery bracket (1).
JPDIC0818ZZ

5. Remove nuts (A).
A
: Vehicle front
JPDIB0233ZZ
CL
6. Remove master cylinder rod end ( ) from clutch pedal.
7. Drain clutch fluid. Refer to CL-9, "Draining".
8. Remove reservoir hose from reservoir tank and master cylinder. E
G
PCIB1491E
9. Pull up the lock pin (1) from connector of master cylinder (2) and
separate clutch tube (3). H
10. Rotate master cylinder clockwise by 45 degrees and then
remove master cylinder from the vehicle.
I
JPDIB0169ZZ
K
INSTALLATION
CAUTION:
Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately L
1. Tilt master cylinder clockwise by 45 degrees (A) and insert it to
the mounting hole. Rotate counterclockwise and secure it. At
this time, nipple (1) is upward of the vehicle. M
B : Mounting condition
N
2. Install master cylinder rod end to clutch pedal.
CAUTION:
Press master cylinder rod end into clutch pedal until it
stops. O
3. Install reservoir hose to reservoir tank and master cylinder.
JPDIB0114ZZ
4. Press down the lock pin into connector of master cylinder until it
stops. P
5. Install clutch tube into connector of master cylinder until it stops.
6. Fill with clutch fluid. Refer to CL-10, "Refilling".

7. Install nuts (A).
: Vehicle front
JPDIB0233ZZ
8. Install battery bracket (1).
: Vehicle front
9. Install bolts (A) and nut (B).

10. For the next step and after, install in the reverse order of
removal.
JPDIC0818ZZ
LHD : Inspection and Adjustment INFOID:0000000006655977

• Check the fluid leakage and the fluid level. Refer to CL-9, "Inspection".
Perform the air bleeding. Refer to CL-11, "Air Bleeding".
RHD
RHD : Exploded View INFOID:0000000007697975
JPDIB0222ZZ
1. Reservoir hose 2. Master cylinder
RHD : Removal and Installation INFOID:0000000007697976
REMOVAL

CAUTION:
• Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately A
• Never disassemble clutch master cylinder.
1. Remove air cleaner case. Refer to EM-29, "Removal and Installation" (HR12DE), EM-284, "Removal and B
Installation" (HR15DE) or EM-404, "Removal and Installation" (K9K).
2. Remove master cylinder rod end ( ) from clutch pedal.
3. Drain clutch fluid. Refer to CL-9, "Draining". C
4. Remove reservoir hose from reservoir tank and master cylinder.
CL
PCIB1491E
F
5. Remove clips (A).
: Vehicle front
G
I
JPDIB0226ZZ
6. Pull up the lock pin (1) from connector of master cylinder (2) and
separate clutch tube (3). J
7. Rotate master cylinder clockwise by 45 degrees and then
remove master cylinder from the vehicle.
K
JPDIB0169ZZ
M
INSTALLATION
CAUTION:
and wash the affected area with water. N
1. Tilt master cylinder clockwise by 45 degrees (A) and insert it to
the mounting hole. Rotate counterclockwise and secure it. At
this time, nipple (1) is upward of the vehicle. O
B : Mounting condition
2. Install master cylinder rod end to clutch pedal. P
CAUTION:
Press master cylinder rod end into clutch pedal until it
stops.
3. Install reservoir hose to reservoir tank and master cylinder.
JPDIB0114ZZ
4. Press down the lock pin into connector of master cylinder until it
stops.

5. Install clutch tube into connector of master cylinder until it stops.
6. Install clips (A).
: Vehicle front
7. Fill with clutch fluid. Refer to CL-10, "Refilling".

8. For the next step and after, install in the reverse order of
removal.
JPDIB0226ZZ
RHD : Inspection and Adjustment INFOID:0000000007697977


CLUTCH PIPING
CLUTCH PIPING
A
Exploded View INFOID:0000000006655981
CL
I
JPDIB0181ZZ
1. CSC (Concentric Slave Cylinder) 2. Clutch tube* 3. Clutch damper (Except for China) J
4. Bracket (Except for China) 5. Master cylinder
*: If clutch damper is not equipped, clutch tube is one part.
K
Hydraulic Layout INFOID:0000000006655982
PCIB1499E
O
1. Clutch tube* 2. Lock pin 3. CSC (Concentric Slave Cylinder)
4. Clutch damper (Except for China) 5. Master cylinder 6. Clutch pedal
*: If clutch damper is not equipped, clutch tube is one part. P
Removal and Installation INFOID:0000000006655983
CAUTION:
REMOVAL

CLUTCH PIPING
Note the following, and refer to CL-21, "Exploded View" for removal procedure.
• Drain clutch fluid. Refer to CL-9, "Draining".
• Press the lock pin into the bleeding connector of the CSC and then remove clutch tube from CSC.
• Pull the lock pins from the connectors of the clutch damper until the pins stop and then remove clutch tubes
from clutch damper. (With clutch damper)
• 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.
INSTALLATION
Note the following, and refer to CL-21, "Exploded View" for installation procedure.
CAUTION:
Never damage clutch tube.
• Insert each clutch tube into the CSC bleeding connector, the clutch damper connector (with clutch damper),
and the clutch master cylinder connector until it contacts the end of each connector.
• Install each lock pin into the clutch damper connector (with clutch damper) and the clutch master cylinder
connector until it contacts the end of each connector.

• 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. (With clutch damper)

CSC (CONCENTRIC SLAVE CYLINDER)
< UNIT REMOVAL AND INSTALLATION >
UNIT REMOVAL AND INSTALLATION A
CSC (CONCENTRIC SLAVE CYLINDER)
Exploded View INFOID:0000000006655985
B
CL
JPDIB0146GB
H
1. Transaxle assembly 2. CSC (Concentric Slave Cylinder)
: Always replace after every disassembly.
: N·m (kg-m, ft-lb) I
Removal and Installation INFOID:0000000006655986

J
CAUTION:
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.
• Never disassemble CSC.
L
REMOVAL
1. Remove transaxle assembly. Refer to TM-32, "HR12DE : Removal and Installation" (HR12DE), TM-34, M
"HR15DE : Removal and Installation" (HR15DE) or TM-113, "Removal and Installation" (K9K)
2. Remove CSC from clutch housing.
INSTALLATION N
1. Install CSC to clutch housing and then tighten CSC mounting bolts to the specified torque.
CAUTION:
• Never reuse CSC. O
• 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.
P

Check the fluid leakage and the fluid level. Refer to CL-9, "Inspection".

CLUTCH DISC AND CLUTCH COVER
HR12DE
HR12DE : Exploded View INFOID:0000000007697978
JPDIB0235GB
1. Flywheel 2. Clutch disc 3. Clutch cover

4. Input shaft
A. First step B. Final step
HR12DE : Removal and Installation INFOID:0000000007697979
CAUTION:
• 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-32, "HR12DE : 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:
INSTALLATION
1. Clean clutch disc and input shaft splines to remove powder arisen from abrasion.

2. Install clutch disc, using a clutch aligner (A) [Commercial service
tool]. A
3. Install clutch cover and then temporarily tighten clutch cover
mounting bolts.
4. Tighten clutch cover mounting bolts to the specified torque B
evenly in two steps in the numerical order as shown in the fig-
ure.
5. Install transaxle assembly. Refer to TM-32, "HR12DE : Removal C
and Installation".
PCIB1503E
CL
HR12DE : Inspection INFOID:0000000007697980
INSPECTION AFTER REMOVAL E

Clutch Disc
• Measure circumferential runout relative to clutch disc center spline.
If it is outside the specification, replace clutch disc. F
Runout limit/diameter of the area : Refer to CL-31,

to be measured "Clutch Disc".
G
• Measure backlash to clutch disc spline and main drive gear spline
at the circumference of clutch disc. If it is outside the specification,
replace clutch disc. H
Maximum allowable spline back- : Refer to CL-31,

SCL221
lash (at outer edge of disc) "Clutch Disc".
I
• Measure the depth “A” to clutch disc facing rivet heads, using a
calipers. If it exceeds the allowable wear limit, replace clutch disc.
J
Facing wear limit (depth to the : Refer to CL-31,
rivet head) “A” "Clutch Disc".
L
JPDIB0026ZZ
Clutch Cover
• Check clutch cover thrust ring for wear or breakage. If wear or breakage is found, replace clutch cover. M
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. N
• 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 O
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-31,

lever unevenness "Clutch Cover".
JPDIB0160ZZ
HR15DE
HR15DE : Exploded View INFOID:0000000006655991
JPDIB0148GB

4. Input shaft
A. First step B. Final step
: Apply lithium-based grease including molybdenum disulphide.
HR15DE : Removal and Installation INFOID:0000000006655992
CAUTION:
REMOVAL
1. Remove transaxle assembly. Refer to TM-34, "HR15DE : Removal and Installation".
CAUTION:
CAUTION:

INSTALLATION
1. Clean clutch disc and input shaft splines to remove grease and powder arisen from abrasion. A
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 B
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. C
3. Install clutch disc, using a clutch aligner (A) [Commercial service
tool].
4. Install clutch cover and then temporarily tighten clutch cover CL
mounting bolts.
5. Tighten clutch cover mounting bolts to the specified torque
evenly in two steps in the numerical order as shown in the fig- E
ure.
6. Install transaxle assembly. Refer to TM-34, "HR15DE : Removal
and Installation".
F
PCIB1503E
HR15DE : Inspection INFOID:0000000006655993

G
Clutch Disc H
• Measure circumferential runout relative to clutch disc center spline.
If it is outside the specification, replace clutch disc.
I
Runout limit/diameter of the area : Refer to CL-31,
• Measure backlash to clutch disc spline and main drive gear spline J
at the circumference of clutch disc. If it is outside the specification,
replace clutch disc.
Maximum allowable spline back- : Refer to CL-31, K

SCL221
L
calipers. If it exceeds the allowable wear limit, replace clutch disc.

rivet head) “A” "Clutch Disc". M
JPDIB0026ZZ
O
Clutch Cover
• Check clutch cover thrust ring for wear or breakage. If wear or breakage is found, replace clutch cover.
NOTE: P
• 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.
Clutch Cover


JPDIB0160ZZ
K9K
K9K : Exploded View INFOID:0000000007860114
JPDIB0234GB

4. Input shaft
: Apply lithium-based grease including molybdenum disulphide.
K9K : Removal and Installation INFOID:0000000007860115
CAUTION:
REMOVAL
1. Remove transaxle assembly. Refer to TM-113, "Removal and Installation".
CAUTION:
CAUTION:
INSTALLATION

1. Clean clutch disc and input shaft splines to remove powder arisen from abrasion.
2. Install clutch disc, using a clutch aligner (A) [Commercial service A
tool].
3. Install clutch cover and then temporarily tighten clutch cover
mounting bolts. B
4. Tighten clutch cover mounting bolts to the specified torque
evenly in the numerical order as shown in the figure.
5. Install transaxle assembly. Refer to TM-113, "Removal and C
Installation".
PCIB1503E
CL
K9K : Inspection INFOID:0000000007860116
E
Clutch Disc
• Measure circumferential runout relative to clutch disc center spline. F
If it is outside the specification, replace clutch disc.
Runout limit/diameter of the area : Refer to CL-31, G

• Measure backlash to clutch disc spline and main drive gear spline
at the circumference of clutch disc. If it is outside the specification, H
replace clutch disc.
Maximum allowable spline back- : Refer to CL-31,

SCL221 I
calipers. If it exceeds the allowable wear limit, replace clutch disc. J

rivet head) “A” "Clutch Disc".
K
JPDIB0026ZZ
Clutch Cover M
• 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. N
• Broken thrust ring will make a clinking sound when cover is shaken up and down.
O
Clutch Cover
P


JPDIB0160ZZ

SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS) A
SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications INFOID:0000000006655997
B
Unit: mm (in)
Engine type HR12DE HR15DE K9K C

Type of clutch control Hydraulic
Clutch Facing size (Outer dia. × Inner 190 × 134 × 2.9 200 × 140 × 3.1 216 × 146 × 3.15
disc dia. × Thickness) (7.48 × 5.28 × 0.114) (7.87 × 5.51 × 0.122) (8.50 × 5.75 × 0.1240) CL
Recommended clutch fluid Refer to MA-17, "Fluids and Lubricants".
Clutch Pedal INFOID:0000000006655998

E
Unit: mm (in)
Engine type HR12DE HR15DE K9K
F
Handle RHD LHD RHD
172.4 – 182.4 158.8 – 168.8 172.4 – 182.4
Clutch pedal height
(6.79 – 7.18) (6.25 – 6.65) (6.79 – 7.18)
G
Clutch pedal height at clutch disengagement 81 (3.19) or more 73 (2.87) or more 81 (3.19) or more
Clutch pedal play 2 – 8 (0.08 – 0.31)
Clearance between clutch pedal and clutch H
interlock switch threaded end while clutch — 0.2 – 1.96 (0.008 – 0.0772)
pedal is fully depressed.*
Clearance between clutch pedal and clutch I
pedal position switch threaded end while — 0.2 – 1.96 (0.008 – 0.0772)
clutch pedal is fully released.*
* : With push-button ignition switch system J
Clutch Disc INFOID:0000000006655999
Unit: mm (in) K
Engine type HR12DE HR15DE K9K

Runout limit / diameter of the area to be L
1.0 (0.039) / 180 (7.09) dia. 1.0 (0.039) / 190 (7.48) dia. 1.1 (0.043) / 206 (8.11) dia.
measured
Maximum allowable spline backlash (at
0.8 (0.031) 0.9 (0.035)
outer edge of disc)
M
Facing wear limit (depth to the rivet head) 0.3 (0.012) 1.0 (0.039)
Clutch Cover INFOID:0000000006656000
N
Unit: mm (in)
Engine type HR12DE, HR15DE K9K

Tolerance for diaphragm spring lever unevenness 0.7 (0.028) or less 0.8 (0.031) or less O

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TRANSMISSION & DRIVELINE

CLUTCH PIPING ............................................... 21

CLUTCH PEDAL ................................................. 7 CSC (CONCENTRIC SLAVE CYLINDER) ....... 23

LHD ............................................................................ 12 HR15DE : Exploded View ........................................26

Revision: 2012 July CL-1 N17

Revision: 2012 July CL-2 N17

Revision: 2012 July CL-3 N17

Revision: 2012 July CL-4 N17

Commercial Service Tools INFOID:0000000006655962 F

Tool name Description G

Revision: 2012 July CL-5 N17

Revision: 2012 July

SUSPECTED PARTS (Possible cause)

Clutch does not disengage

essary, repair or replace these parts.

CL-7 CLUTCH PEDAL (Inspection and adjustment)

EM-87 (HR12DE), EM-214 [HR15DE (TYPE 1*)],

*: Refer to EM-134, "How to Check Vehicle Type".

PRESSURE PLATE (Distortion)

EM-95 (HR12DE), EM-236 [HR15DE (TYPE 1*)],

Clutch pedal height : Refer to CL-31, "Clutch Pedal".

3. Replace clutch pedal if the height is outside the reference value.

Position of Clutch Interlock Switch (With Push-Button Ignition Switch System)

Revision: 2012 July CL-7 N17

Clearance “C” : Refer to CL-31, "Clutch Pedal".

Clearance “A” : Refer to CL-31, "Clutch Pedal".

Clearance “C” : Refer to CL-31, "Clutch Pedal".

the clutch pedal bracket.

Clearance “A” : Refer to CL-31, "Clutch Pedal".

Revision: 2012 July CL-8 N17

Revision: 2012 July CL-9 N17

Dimension “A” : 5 mm (0.20 in)

Dimension “A” : 5 mm (0.20 in)

Revision: 2012 July CL-10 N17

Air Bleeding INFOID:0000000006655968

Dimension “A” : 5 mm (0.20 in) N

Revision: 2012 July CL-11 N17

1. Clutch pedal 2. Pedal stopper rubber 3. Pedal pad

LHD : Removal and Installation INFOID:0000000006655970

INSPECTION AFTER REMOVAL

Revision: 2012 July CL-12 N17

1. Clutch pedal 2. Pedal stopper rubber 3. Pedal pad

Revision: 2012 July CL-13 N17

3. Remove master cylinder rod end from clutch pedal.

push-button ignition switch system)

INSPECTION AFTER REMOVAL

Revision: 2012 July CL-14 N17

Revision: 2012 July CL-15 N17

1. Reservoir hose 2. Master cylinder

LHD : Removal and Installation INFOID:0000000006655976

4. Remove battery bracket (1).

Revision: 2012 July CL-16 N17

Revision: 2012 July CL-17 N17

8. Install battery bracket (1).

9. Install bolts (A) and nut (B).

LHD : Inspection and Adjustment INFOID:0000000006655977

INSPECTION AFTER INSTALLATION

1. Reservoir hose 2. Master cylinder

RHD : Removal and Installation INFOID:0000000007697976