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F1 CLUTCH

CLUTCH SYSTEM----------------------------- F1 - 1
BASIC CHECK AND ADJUSTMENT--- F1 - 1
CLUTCH PEDAL ------------------------------- F1 - 2
REMOVAL AND INSTALLATION(RHD VEHI-
CLE)--------------------------------------------- F1 - 2
REMOVAL AND INSTALLATION(LHD VEHI-
CLE)--------------------------------------------- F1 - 5
CLUTCH CABLE ------------------------------- F1 - 8
REMOVAL AND INSTALLATION-------- F1 - 8
CLUTCH ---------------------------------------- F1 - 13
REMOVAL AND INSTALLATION ------ F1 - 13

F1
F1–1
1 CLUTCH SYSTEM
1-1 BASIC CHECK AND ADJUSTMENT
1-1-1 CHECK OF CLUTCH PEDAL HEIGHT A

1.Check the height from the dash panel to the center of the
pedal at the right side.
SPECIFIED VALUE: Height of clutch pedal
149.9-154.9mm(RHD)
149.1-154.1mm(LHD) dash panel
CAUTION T11K5503ET10

• There is no need of adjusting the pedal height.

• The height cannot be adjusted by means of the bolt at
the section A.
1-1-2 ADJUSTMENT OF CLUTCH PEDAR FREE TRAVEL
1.Move the clutch release lever by your left hand and stop it Clutch outer cable
at a position where it comes in contact lightly with the
Adjusting screw
diaphragm spring of the clutch cover.
(The arrow mark in the figure shows the direction in which Vibration isolating rubber
the release lever is moved.)
2.Pull up the clutch outer cable by your right hand and hold
it at a position where there is no slack of the inner cable. Inner cable
Then, release your left hand.
3.Screw in the adjusting screw by your left hand, until it
comes in contact with the rotation stopper protrusion of
the vibration preventive rubber.
At this time, if the rotation stopper protrusion is not aligned
with the groove position of the adjusting screw, perform Clutch release lever Cable end
C11K5002ET16
the alignment by backing off the adjusting screw.
4.Release your hand under a condition where the groove
position of the adjusting screw is aligned with the rotation
stopper protrusion.
5.Ensure that the free travel of the clutch pedal conforms to
the specified value.
(When carrying out the operations above, the operations
to be performed by your right hand can be performed by
your left hand and vice versa.)
SPECIFIED VALUE: Free travel of clutch pedal
10 to 25 mm
(Upper surface of pedal pad)
1-1-3 CHECK OF DISTANCE TO THE FLOOR WHEN THE
CLUTCH IS DISENGAGED
1.Check and adjust the clutch pedal height.
2.Check and adjust the free travel of the clutch pedal.
3.With the engine idling, pull the parking brake lever fully. Then, move the shift lever to the 1st gear posi-
tion and slowly release the pedal. Check the distance between the pedal at a moment immediately
before the clutch is engaged and the position when the clutch pedal is depressed fully to the floor.
SPECIFIED VALUE: 20 mm or more (Reserve travel)
 F1–2
2 CLUTCH PEDAL
2-1 REMOVAL AND INSTALLATION(RHD VEHICLES)
2-1-1 ARTICLES TO BE PREPARED
Instrument
Torque wrench

Lubricant,adhesive,others
MP grease

2-1-2 OPERATION BEFORE REMOVAL

1.Remove the instrument panel finish lower panel.
Refer to Page I2-23.

2-1-3 REMOVAL AND INSTALLATION PROCEDURES

(1) Components

~a

f
g

T:18.2&3.4 {185&35}
d
h

T11K5519S33

k: MP grease
~:Non - reusable parts
Unit: N;m{kgf;cm}
F1–3
(2) Removal and installation procedures
1 a Clip 6 f Bush
2 b Cable Ay, clutch release i 7 g Cushion
3 c Shaft, pedal 8 h Pad, clutch pedal
4 d Pedal S/A, clutch
5 e Spring, torsion

2-1-4 INSPECTION
Check each of the following parts. Replace any faulty part.

Wear

Damage

Wear
Damage

Damage,wear
Damage,wear

T11K5520ES33
 F1–4
2-1-5 POINTS OF INSTALLATION
(1) Cushion
1.Apply soap water to the tip end of the cushion. Then,
install it to the clutch pedal subassembly.

Apply soap water.

L11K5006ET10

2-1-6 OPERATION AFTER INSTALLATION

1.Check the clutch pedal height and adjust the free play.
Refer to Page F1-1.

2.Install the instrument panel finish lower panel.

Refer to Page I2-23.
F1–5
2-2 REMOVAL AND INSTALLATION
2-2-1 ARTICLES TO BE PREPARED
Instrument
Torque wrench

Lubricant,adhesive,others
MP grease

2-2-2 OPERATION BEFORE REMOVAL

1.Remove the instrument panel finish lower panel.
Refer to Page I2-23.

2-2-3 REMOVAL AND INSTALLATION PROCEDURES

(1) Components

~a

b
c
f
d

f
e
T:18.2&3.4 {185&35}

T11K5521S33

k: MP grease
~:Non - reusable parts
Unit: N;m{kgf;cm}
 F1–6
(2) Removal and installation procedures
1 a Clip 6 f Bush
2 b Cable Ay, clutch release i 7 g Cushion
3 c Shaft, pedal 8 h Pad, clutch pedal
4 d Pedal S/A, clutch
5 e Spring, torsion

2-2-4 INSPECTION
Check each of the following parts. Replace any faulty part.

Wear

Wear
Damage

Damage

Damage,wear

Damage,wear

T11K5522ES33
F1–7
2-2-5 POINTS OF INSTALLATION
(1) Cushion
1.Apply soap water to the tip end of the cushion. Then,
install it to the clutch pedal subassembly.

Apply soap water.

L11K5006ET10

2-2-6 OPERATION AFTER INSTALLATION

1.Check the clutch pedal height and adjust the free play.
Refer to Page F1-1.

2.Install the instrument panel finish lower panel.

Refer to Page I2-23.
 F1–8
3 CLUTCH CABLE
3-1 REMOVAL AND INSTALLATION
3-1-1 ARTICLES TO BE PREPARED
Instrument
Torque wrench

Lubricant,adhesive,others
MP grease,Rope

3-1-2 OPERATION BEFORE REMOVAL

1.Remove the instrument panel finish lower panel S/A.
Refer to Page I2-23.

3-1-3 REMOVAL AND INSTALLATION PROCEDURES

(1) Components

T:5.4&1.5 {55&15}

~b

T11K5517S25

k: MP grease
~:Non - reusable parts
Unit: N;m{kgf;cm}
(2) Removal and installation procedures
j i 1 a Bracket, clutch release cable No.1
2 b Clip
j i 3 c Cable Ay, clutch release
F1–9
3-1-4 POINTS OF REMOVAL
(1) Bracket, clutch cable, No.1
1.Remove the bracket.
(1) Loosen the adjusting nut of the clutch release cable Adjusting nut
assembly.
(2) While pulling up the clutch release lever subassembly
by your hand, take out the clutch release cable
bracket No.1 from the clutch release lever sub-
assembly.

Clutch release lever S/A

M21K5006ET16

(3) Route the cable at the cutout section of the clutch

release cable bracket No.1. Then, remove the clutch 2

release cable bracket No.1 by raising it 90 degrees. 1

C11K5007T10
(2) Cable Ay, clutch release
1.Loosen the play adjusting nut of the clutch release cable
assembly fully to the position indicated in the figure on the
right. Then, while pulling the clutch release cable assem-
bly by the cord, push it into the vehicle interior.
CAUTION
• This cord will be used when the clutch release cable
assembly is installed. Hence, leave this cord routed
from the engine compartment side to the vehicle interi-
M21K5007T10
or side.
• Be sure to use a cord of about 2 m in length.
 F1–10
3-1-5 INSPECTION
1.Check the following items. Replace any faulty part.
(1) Push and pull the inner cable of the clutch release cable assembly. At this time, ensure that there
is no abnormal resistance and binding.
(2) Check each part of the clutch release cable assembly for scores, deformation, wear and cracks.

Deformation

Damage, wear
Wear

M21K5008ES16

(3) Clutch release cable bracket No.1 for damage and

wear.

Damage, wear

L11K5013ET10
F1–11
3-1-6 POINTS OF INSTALLATION
(1) Cable Ay, clutch release
1.Install the cable Ay.
CAUTION
• Utmost care must be exercised so that the inner cable
may not be bent.
(1) Fully loosen the play adjusting nut of the clutch release
cable assembly.
(2) Apply the cord, that was used at the time of the
removal, to the play adjusting nut.
(3) Pull the cord from the engine compartment side. Also,
push the clutch release cable from the vehicle interi- T11K5502T10

or side at the same time, thus pulling out the tip end
to the engine compartment side.
CAUTION
• There is the possibility that the inner cable is bent if
the cord is pulled strongly. Be very careful not to pull
the cord strongly.
(4) Set the play adjusting nut of the clutch release cable
assembly to the position indicated in the figure on the
right. While pulling by means of the cord, pull the
play adjusting nut to the engine compartment side.
NOTE
• If any difficulty is encountered in passing the adjusting
nut through the dash panel, adjust the angle of the nut
by inserting a fine rod into the nut, as indicated in the
figure on the right.

N11K5029T10
 F1–12
(2) Bracket, clutch cable, No.1
1.Install the bracket. 1
(1) Connect the cable by routing it at the cutout section of 2
the clutch release cable bracket No.1. Then, tilt the
cable 90 degrees.

C11K5008T10

(2) Lightly pull the clutch release lever S/A by hand, until
it is brought into contact with the clutch cover. Then,
apply the bracket to the clutch release lever S/A.
(3) Tighten the adjusting nut to adjust the play. Adjusting nut
Refer to Page F1-1.

CAUTION
• Be very careful not to damage the grommet section.

Clutch release lever S/A

M21K5006ET16

3-1-7 OPERATION AFTER INSTALLATION

1.Install the instrument panel finish lower panel S/A.
Refer to Page I2-23.
F1–13
4 CLUTCH
4-1 REMOVAL AND INSTALLATION
4-1-1 ARTICLES TO BE PREPARED
SST
Shape Part No. Part name

09210-87701-000 Holder,fly wheel

09301-87703-000 Tool,clutch guide

09302-87701-000 Gauge,clutch diaphragm spring height No.4

09333-00013-000
Aligner,clutch diaphragm spring
(09301-00012-000)

Instrument
Dial gauge,Vernier calipers,Thickness gauge,Torque wrench

Lubricant,adhesive,others
MP grease,EP grease,Clutch grease

4-1-2 OPERATION BEFORE REMOVAL

1.Remove the manual transaxle assembly from the vehicle.
Refer to Page F2-2.
 F1–14
4-1-3 REMOVAL AND INSTALLATION PROCEDURES
(1) Components

(Inner periphery and outer periphery)

f

T:18.1&3.4 {185&35} e
a (Sliding section with
B the "g" parts) c
g
b

f ~
(Hub section) (Entire periphery of
T:34.3&4.9 {350&50}
diameter section)
(Inner periphery and outer periphery)

T11K5504ES33

l:MP grease
m:EP grease
k:Clutch grease
~:Non - reusable parts
Unit:N;m{kgf;cm}
(2) Removal and installation procedures
j i 1 a Cover Ay, clutch 6 f Bush
i 2 b Disc Ay, clutch 7 g Hub Ay, clutch release bearing
3 c Yoke, clutch release lever
4 d Lever S/A, clutch release
5 e Spring, torsion
F1–15
4-1-4 POINTS OF REMOVAL
(1) Cover Ay, clutch, and disk Ay, clutch
SST
1.Prevent the ring gear from turning, using the SST. Under
this condition, remove the clutch cover assembly and
clutch disc assembly.
SST: 09210-87701-000

T04K6024T10

4-1-5 INSPECTION
1.Check the following items. Replace any faulty part.
(1) Flywheel and pressure plate surface of clutch cover
assembly for streak, cracks and discoloration.

L11K5019T10

(2) Clean the flywheel surface. Then, check the runout.

ALLOWABLE LIMIT: 0.10mm

T04K6025T10

(3) Pressure plate (Diaphragm spring finger section) of

clutch cover assembly for wear, rust formation and
breakage

L11K5021T10

(4) Clutch disc assembly for wear and runout

ALLOWABLE LIMIT: Wear limit
0.3mm(Sagging of rivet)
Lateral runout limit
1.0mm

J04K6006T10
 F1–16
CAUTION
• The measurement of the lateral runout should be car- Clutch disc
ried out under a condition where the clutch disc
assembly is assembled with a new input shaft.

L11K5023ET10

(5) When the sliding section (the contact surface with the
clutch cover) of the clutch release bearing hub sub-
assembly is turned, and when pressure is applied to
push the sliding section in the turning direction,
ensure that there is no abnormal resistance nor bind-
ing.

L11K5024T10

(6) Check the clutch release bearing hub subassembly for

damage and wear. Also, check the clip contact sur- Clip contact surface
face and sliding section of the housing for damage
and wear.

Damage, wear
L11K5025ET10

4-1-6 POINTS OF INSTALLATION Apply grease

(1) Disc Ay, clutch
1.Install the clutch disc Ay.
(1) Thinly apply clutch grease to the hub inside (the spline
section) of the clutch disc assembly.
CAUTION
• As regards the grease applying direction, grease
should be applied from the clutch cover side. Be sure
to apply grease as thinly as possible so that the exces- T11K5501ET10

sive grease may not ooze out to the flywheel side.

LUBRICANT: Clutch grease
(2) Install the clutch disc assembly to the flywheel by cen-
tering it, using the SST. SST
SST: 09301-87703-000

Engine side

T04K6026ET10
F1–17
(2) Cover Ay, clutch
1.Install the cover Ay while aligning it with the knock pin of 6 SST
SST
the flywheel S/A. 1 5
2.Using the SST, prevent the flywheel S/A from turning.
SST: 09210-87701-000
3.Temporarily tighten the bolts in the sequence of 1 and 5. 4
4.Temporarily tighten the bolts in the sequence of 3, 1, 5, 2

2, 6 and 4. 3
5.Check the diaphragm spring section for unevenness in T04K6027T10
height, using the SST.
SST: 09302-87701-000 SST

ALLOWABLE LIMIT: 0.6mm

M21K5015T10
6.If the above check has revealed that the unevenness
exceeds the limit, correct the unevenness in height, using
the SST.
SST
SST: 09333-00013-000

M21K5016T10
4-1-7 OPERATION AFTER INSTALLATION
1.Install the manual transaxle Ay.
Refer to Page F2-2.

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