C TRANSMISSION/TRANSAXLE

B
SECTION
CLUTCH CL

E
CONTENTS
QG18DE CLUTCH DISC .................................................... 17 F
CLUTCH COVER ................................................ 18
PRECAUTIONS .......................................................... 3 FLYWHEEL ......................................................... 18
Precautions .............................................................. 3 Installation .............................................................. 18 G
PREPARATION ........................................................... 4 SERVICE DATA AND SPECIFICATIONS (SDS) ...... 19
Special Service Tools ............................................... 4 Clutch Control System ............................................ 19
Commercial Service Tools ........................................ 4 Clutch Master Cylinder ........................................... 19
NOISE, VIBRATION, AND HARSHNESS (NVH) H
Clutch Operating Cylinder ...................................... 19
TROUBLESHOOTING ................................................ 5 Clutch Disc ............................................................. 19
NVH Troubleshooting Chart ..................................... 5 Clutch Cover ........................................................... 19
CLUTCH SYSTEM ...................................................... 6 Clutch Pedal ........................................................... 19 I
Components ............................................................. 6
Inspection and Adjustment ....................................... 7
ADJUSTING CLUTCH PEDAL ............................. 7
QR25DE
J
BLEEDING PROCEDURE .................................... 7 PRECAUTIONS ........................................................ 20
CLUTCH MASTER CYLINDER .................................. 9 Precautions ............................................................. 20
Components ............................................................. 9 PREPARATION ......................................................... 21
Removal ................................................................... 9 K
Special Service Tools ............................................. 21
Installation ................................................................ 9 Commercial Service Tools ...................................... 21
Disassembly ........................................................... 10 NOISE, VIBRATION, AND HARSHNESS (NVH)
Inspection ............................................................... 10 TROUBLESHOOTING .............................................. 22 L
Assembly ................................................................ 10 NVH Troubleshooting Chart ................................... 22
OPERATING CYLINDER ...........................................11 CLUTCH SYSTEM .................................................... 23
Components ............................................................11 Components ........................................................... 23 M
Removal ..................................................................11 Inspection and Adjustment ..................................... 24
Disassembly ............................................................11 ADJUSTING CLUTCH PEDAL ............................ 24
Inspection ................................................................11 BLEEDING PROCEDURE .................................. 24
Assembly .................................................................11 CLUTCH MASTER CYLINDER ................................ 26
Installation .............................................................. 12 Components ........................................................... 26
PIPING ...................................................................... 13 Removal ................................................................. 26
Removal ................................................................. 13 Installation .............................................................. 26
Installation .............................................................. 13 Disassembly ........................................................... 27
CLUTCH RELEASE MECHANISM .......................... 14 Inspection ............................................................... 27
Components ........................................................... 14 Assembly ................................................................ 27
Removal ................................................................. 14 OPERATING CYLINDER .......................................... 28
Inspection ............................................................... 14 Components ........................................................... 28
Installation .............................................................. 14 Removal ................................................................. 28
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL... 17 Disassembly ........................................................... 28
Components ........................................................... 17 Inspection ............................................................... 28
Removal ................................................................. 17
Inspection and Adjustment ..................................... 17

CL-1
 Assembly ................................................................ 28 Inspection and Adjustment ......................................33
Installation ............................................................... 29 CLUTCH DISC .....................................................33
PIPING ....................................................................... 30 CLUTCH COVER .................................................34
Removal ................................................................. 30 FLYWHEEL ..........................................................34
Installation ............................................................... 30 Installation ...............................................................34
CLUTCH RELEASE MECHANISM ........................... 31 SERVICE DATA AND SPECIFICATIONS (SDS) ......35
Components ........................................................... 31 Clutch Control System ............................................35
Removal ................................................................. 31 Clutch Master Cylinder ............................................35
Inspection After Removal ....................................... 31 Clutch Operating Cylinder .......................................35
Installation ............................................................... 31 Clutch Disc ..............................................................35
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL... 33 Clutch Cover ...........................................................35
Components ........................................................... 33 Clutch Pedal ............................................................35
Removal ................................................................. 33

CL-2
 PRECAUTIONS
[QG18DE]
PRECAUTIONS PFP:00001
A
Precautions ECS00489

● Recommended fluid is brake fluid “DOT 3”.

● Do not reuse drained brake fluid. B
● Be careful not to splash brake fluid on painted areas; it may
cause paint damage. If brake fluid is splashed on painted
areas, wash it away with water immediately. CL
● Use flare nut wrench when removing or installing clutch
hydraulic tubes.
● Use new brake fluid to clean or wash all parts of master cyl- D
inder and operating cylinder.
● Never use mineral oils such as gasoline or kerosene. It will SBR686C
ruin the rubber parts of the hydraulic system. E
WARNING:
After cleaning clutch disc, wipe it with a dust collector. Do not use compressed air.
F

CL-3
 PREPARATION
[QG18DE]
PREPARATION PFP:00002

Special Service Tools ECS0048A

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number
(Kent-Moore No.) Description
Tool name
KV30101600 (New) Installing clutch cover and clutch disc
KV30101000 (Former) a: 15.9 mm (0.626 in) dia.
(J-33213) b: 17.9 mm (0.705 in) dia.
Clutch aligning bar c: 40 mm (1.57 in)

NT641

ST20050240 Adjusting unevenness of diaphragm spring of

( — ) clutch cover
Diaphragm spring adjusting wrench a: 150 mm (5.91 in)
b: 25 mm (0.98 in)

S-NT404

KV32101000 Removing and installing spring pin

(J-25689-A) a: 4 mm (0.16 in) dia.
Pin punch

S-NT410

Commercial Service Tools ECS0048B

Tool name Description

1. Flare nut crowfoot Removing and installing clutch piping
2. Torque wrench a: 10 mm (0.39 in)

S-NT360

CL-4
 Symptom
Reference page

Clutch slips
Clutch noisy
Clutch pedal spongy
Clutch grabs/chatters
SUSPECTED PARTS (Possible cause)

Clutch does not disengage

NVH Troubleshooting Chart

CLUTCH PEDAL (Inspection and adjustment) CL-7

1
1
CLUTCH LINE (Air in line) CL-7

2
1
MASTER CYLINDER PISTON CUP (Damaged) CL-9

3
2
OPERATING CYLINDER PISTON CUP (Damaged) CL-11

4
2
ENGINE MOUNTING (Loose) EM-54, "Removal and Installation"

CL-5
RELEASE BEARING (Worn, dirty or damaged) CL-14

1
CLUTCH DISC (Out of true)

5
Check each part in order. If necessary, repair or replace these parts.

CLUTCH DISC (Runout is excessive)

5
2
CLUTCH DISC (Lining broken)

5
CLUTCH DISC (Dirty or burned) CL-17

5
CLUTCH DISC (Oily)

5
2
2
CLUTCH DISC (Worn out)

2
2
CLUTCH DISC (Hardened)
2
CLUTCH DISC (Lack of spline grease) CL-17

5
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING

DIAPHRAGM SPRING (Damaged)

6
3 DIAPHRAGM SPRING (Out of tip alignment) CL-18
6
2
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING

7 CLUTCH COVER (Distortion)

4

FLYWHEEL (Distortion) CL-18

5
[QG18DE]
PFP:00003

ECS0048C

Use the chart below to help you find the cause of the symptom. The numbers indicate the order of inspection.

L
F

K
E
B
A

CL

H
D

M
 CLUTCH SYSTEM
[QG18DE]
CLUTCH SYSTEM PFP:30502

Components ECS0048D

WCL005

1. Clutch pedal bracket 2. ASCD clutch switch (if equipped) 3. Clutch interlock switch
4. Clutch pedal 5. Clutch master cylinder 6. Nipple
7. Clutch damper (not serviceable) 8. Clevis 9. Hose clamp
10. Reservoir hose 11. Reservoir tank 12. Reservoir cap
13. Clutch disc 14. Clutch cover 15. Withdrawal lever
16. Clutch lever 17. Spring pin 18. Release bearing
19. Operating cylinder 20. Clutch hose 21. Spacer
22. Release bearing spring 23. Clutch tube

CL-6
 CLUTCH SYSTEM
[QG18DE]
Inspection and Adjustment ECS0048E

ADJUSTING CLUTCH PEDAL A

1. Check to see if the clutch pedal clevis pin floats freely in the bore
of the clutch pedal. It should not be bound by the clevis or clutch
pedal. B
a. If the pin is not free, check that the ASCD switch or pedal stop-
per bolt is not applying pressure to the clutch pedal causing the
pin to bind. To adjust, loosen the ASCD switch or pedal stopper CL
bolt lock nut and turn the ASCD switch or pedal stopper bolt.
b. Tighten the lock nut.
c. Verify that the clutch pedal clevis pin floats freely in the bore of D
the clutch pedal. It should not be bound by the clevis or clutch
pedal.
d. If the pin is still not free, remove the pin and check for deforma-
E
tion or damage. Replace the pin if necessary. Leave the pin
removed for step 2.
2. Check the clutch pedal stroke for free range of movement.
F
a. With the clutch pedal clevis pin removed, manually move the
pedal up and down to determine if it moves freely.
b. If any sticking is noted, replace the related parts (clutch pedal,
pedal bracket, assist spring, bushing, etc.). Reassemble the G
pedal and re-verify that the clevis pin floats freely in the bore of
the pedal.
WCIA0146E
H
3. Adjust the clearance “C” while fully depressing the clutch pedal
(with the clutch interlock switch) as shown.
I
Clearance "C" : 0.1 - 1.0 mm (0.004 - 0.039 in)
4. Check the clutch hydraulic system components (clutch master
cylinder, clutch operating cylinder, Clutch withdrawal lever, J
clutch release bearing, etc.) for sticking or binding.
a. If any sticking or binding is noted, repair or replace the related
parts as necessary. K
b. If any hydraulic system repair was necessary, bleed the clutch
hydraulic system. Refer to CL-7, "BLEEDING PROCEDURE" .
NOTE: L
Do not use a vacuum assist or any other type of power bleeder
on this system. Use of a vacuum assist or power bleeder will not
purge all of the air from the system.
M

SCL800

BLEEDING PROCEDURE
CAUTION:
Carefully monitor fluid level at master cylinder during bleeding operation.
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.
1. Top off reservoir with recommended brake fluid.

CL-7
 CLUTCH SYSTEM
[QG18DE]
CAUTION:
Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is
splashed on painted areas, wash it away with water immediately.
2. Connect a transparent vinyl tube to air bleeder valve to drain the
fluid into a clean container.
3. Slowly depress the clutch pedal to its full stroke and release it
completely. Repeat this operation several times at 2 to 3 sec-
onds intervals.
4. Open the air bleeder valve with the clutch pedal fully depressed.

WCIA0018E

5. Close the air bleeder valve.

Air bleeder valve tightening torque : 5.9 - 9.8 N·m (0.6 - 1.0 kg-m, 52 - 87 in-lb)
6. Release the clutch pedal and wait at least 5 seconds.
7. Repeat steps 1 through 6 above until air bubbles no longer appear at the air bleeder valve in the brake
fluid.

CL-8
 CLUTCH MASTER CYLINDER
[QG18DE]
CLUTCH MASTER CYLINDER PFP:30610
A
Components ECS0048F

CL

G
WCIA0137E

1. Master cylinder body 2. Return spring 3. Piston assembly seals

4. Push rod 5. Stopper 6. Stopper ring H
7. Dust cover 8. Clevis 9. Hose clamps
10. Reservoir hose 11. Reservoir cap 12. Reservoir tank
13. Bracket 14. Clutch damper (not serviceable) 15. Clutch tube I
16. Seal 17. Pin 18. Nipple

Removal ECS0048G
J
1. Drain brake fluid from clutch system.
CAUTION:
Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is
K
splashed on painted areas, wash it away with water immediately.
2. Remove clutch tube flare nut using a flare nut wrench.
3. Remove reservoir hose. L
4. Remove the snap pin from the clevis pin and remove the clutch pedal from the clevis.
5. Unscrew master cylinder nuts and reservoir tank bracket nuts to remove master cylinder from the vehicle.
Installation ECS0048H
M
1. Install the reservoir hose.
2. Connect clutch tube to master cylinder, and hand-tighten the flare nut.
3. Install the master cylinder to the cowl, and tighten the master cylinder nuts to the specified torque.
Master cylinder nuts : 10.8 - 14.6 N·m (1.1 - 1.4 kg-m, 8 - 10 ft-lb)
4. Tighten reservoir tank bracket nuts to the specified torque.
Reservoir tank bracket nuts : 2.9 - 5.9 N·m (0.29 - 0.60 kg-m, 26 - 52 in-lb)
5. Tighten clutch tube flare nut using a flare nut torque wrench to the specified torque.
Clutch flare tube nut : 15 - 18 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)
6. After installing the clevis pin, install the snap pin to connect the clutch pedal to the push rod.
7. After finishing the operation, bleed the air from the clutch piping. Refer to CL-7, "BLEEDING PROCE-
DURE" .

CL-9
 CLUTCH MASTER CYLINDER
[QG18DE]
Disassembly ECS0048I

1. Loosen push rod lock nut "A" to remove clevis and lock nut "A".
2. Remove dust cover.
3. Remove stopper ring and stopper, and remove push rod from
cylinder body. During removal, keep push rod depressed, to pre-
vent piston inside master cylinder from popping out.
4. Remove piston assembly from cylinder body.
5. Remove return spring.
6. Remove pin using pin punch, then remove nipple and seal.

SCL725

Inspection ECS0048J

Inspect for the following, and replace parts if necessary.

● Damage, wear, rust, and pinholes on the cylinder inner wall
● Damage and deformation of the reservoir tank
● Weak spring
● Crack or deformation of the dust cover
Assembly ECS0048K

1. Install the return spring.

2. Apply rubber lubricant to the sliding part of piston assembly, and insert piston assembly into cylinder body.
3. After installing stopper to push rod, install stopper ring while keeping piston assembly depressed by hand,
so that piston assembly will not pop out.
CAUTION:
Stopper ring cannot be reused. Always use a new stopper ring for assembly.
4. Apply silicone grease, and install dust cover.
5. Install clevis to push rod, and tighten lock nut "A" to the specified torque.
Lock nut "A" : 7.8 - 11.8 N·m (0.8 - 1.2 kg-m, 69 - 104 in-lb)
6. Install seal and nipple to cylinder body, and install pin using a pin punch.

CL-10
 OPERATING CYLINDER
[QG18DE]
OPERATING CYLINDER PFP:30620
A
Components ECS0048L

CL

G
WCIA0138E

1. Cylinder body 2. Piston spring 3. Piston cup

4. Piston 5. Push rod 6. Dust cover H
7. Air bleeder 8. Spacer 9. Union bolt
10. Copper washer 11. Clutch hose

Removal ECS0048M
I

1. Drain brake fluid from clutch system.

CAUTION: J
Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is
splashed on painted areas, wash it away with water immediately.
2. Remove union bolt and clutch hose from operating cylinder.
K
3. Remove operating cylinder mounting bolts, and remove cylinder
from vehicle.
L

WCL009

Disassembly ECS0048N

Remove dust cover, and remove piston assembly from cylinder body.
Inspection ECS0048O

Inspect for the following, and replace parts if necessary.

● Damage, foreign material, wear, rust, and pinholes on the cylinder inner surface, piston, and sliding part of
piston cup
● Weak spring
● Crack or deformation of dust cover
Assembly ECS0048P

1. Apply rubber lubricant to the overall inside surface of the cylinder body. Also, apply rubber grease to the
piston.
CL-11
 OPERATING CYLINDER
[QG18DE]
2. Install the piston assembly into the cylinder body. Make sure tapered piston spring is installed correctly.
3. Install dust cover.
Installation ECS0048Q

Install the components in the reverse order of removal. Follow the operations described below.
CAUTION:
● Install the hose without twisting it.
● The copper washer of the union bolt should not be reused. Always use a new copper washer for
installation.
● After finishing the operation, bleed air from the clutch piping. Refer to CL-7, "BLEEDING PROCE-
DURE" .

CL-12
 PIPING
[QG18DE]
PIPING PFP:00000
A
Removal ECS0048R

1. Remove air cleaner and air duct.

2. Drain brake fluid from clutch system. B
CAUTION:
Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is
splashed on painted areas, wash it away with water immediately. CL
3. Remove flare nut from cylinder body using a flare nut wrench.
4. Remove clutch hose from operating cylinder.
5. Remove clutch hose and clutch tube from bracket by removing lock plate. D

Installation ECS0048S

1. When installing clutch hose to bracket, face lock plate in the cor- E
rect direction as shown to secure clutch hose.
CAUTION:
Install clutch hose without twisting or bending it.
F
2. Tighten flare nut to the specified torque, using a flare nut
wrench.
Flare nut : 15 - 18 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb) G
CAUTION:
Be careful not to damage flare nut and clutch tube.
3. Install clutch hose to operating cylinder, and tighten the clutch SCL730 H
hose bolt to the specified torque.
Clutch hose bolt : 17 - 19 N·m (1.7 - 2.0 kg-m, 13 - 14 ft-lb)
I
4. Bleed air from the clutch piping. Refer to CL-7, "BLEEDING PROCEDURE" .
5. Install air cleaner and air duct.
J

CL-13
 CLUTCH RELEASE MECHANISM
[QG18DE]
CLUTCH RELEASE MECHANISM PFP:30502

Components ECS0048T

SCL819

Removal ECS0048U

1. Remove manual transaxle from vehicle. Refer to MT-16,

"Removal and Installation" for RS5F70A, MT-80, "Removal and
Installation" for RS5F51A, or MT-139, "Removal and Installa-
tion" for RS6F51H.
2. Move withdrawal lever enough to remove release bearing and
release bearing spring, and remove release bearing from clutch
lever.
3. Support clutch lever claws with an appropriate wood block, align
retaining pin with A in the figure, and drive out spring pins using
a pin punch.
4. Pull out withdrawal lever and remove clutch lever from clutch WCL018

housing.
Inspection ECS0048V

● Replace the release bearing if it is seized, damaged, faulty in

rotation direction, or has poor aligning function.
● Replace the withdrawal lever if its contact surface is worn abnor-
mally.
● Replace the clutch lever if its contact surface is worn abnormally.

SCL733

Installation ECS0048W

CAUTION:
● Be sure to apply grease to the clutch components. Otherwise, abnormal noise, poor clutch disen-
gagement, or clutch damage may occur. Wipe the excess grease off completely, because it may
cause the clutch components to slip and shudder.
● Keep the clutch disc facing, pressure plate, and flywheel free of oil and grease.

CL-14
 CLUTCH RELEASE MECHANISM
[QG18DE]
● Clean old grease and abrasive materials off the grease
application area. A
● Apply approximately 1 mm (0.04 in) thick clutch sleeve
grease evenly on the sliding part of the clutch lever and the
release bearing spring. B
● Apply just enough clutch sleeve grease to fill up the release
bearing inner groove.
● Apply the clutch grease to the clutch disc and the input CL
shaft spline. Install the clutch disc to the input shaft,
remove the excess grease around the shaft, and remove the
clutch disc.
D
● Lightly and evenly apply the clutch sleeve grease on the
sliding part of the release bearing, install the release bear-
ing, remove the excess grease around the bearing, and
remove the release bearing. E

G
SCL821

1. Assemble clutch lever to clutch housing, and insert withdrawal H

lever.
2. Support clutch lever claws with an appropriate wood block, and
install new spring pins using a pin punch.
I
CAUTION:
Spring pins cannot be reused.
J

WCL015
K
3. Install release bearing springs to release bearing as shown in
the figure.
L

SCL736

4. Operate withdrawal lever manually, press clutch spring from

both sides, and install release bearing to clutch lever securely.
5. Make sure a click is heard when release bearing spring is
pressed from both sides.

SCL823

CL-15
 CLUTCH RELEASE MECHANISM
[QG18DE]
6. Make sure all parts operate smoothly when operating withdrawal
lever.
7. Install manual transaxle. Refer to MT-16, "Removal and Installa-
tion" for RS5F70A, MT-80, "Removal and Installation" for
RS5F51A, or MT-139, "Removal and Installation" for RS6F51H.
CAUTION:
Remove any excess grease with a shop towel.

SCL738

CL-16
 CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
[QG18DE]
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL PFP:30100
A
Components ECS0048X

CL

LCL049
G
NOTE:
The following operations are with manual transaxle removed from vehicle.
H
Removal ECS006S4

1. Evenly loosen the clutch cover bolts, then remove the clutch cover and clutch disc.
I
Inspection and Adjustment ECS0048Y

CLUTCH DISC
J
● Check clutch disc for wear of facing.
Wear limit of facing surface to rivet head : 0.3 mm
(0.012 in)
K

M
LCIA0109E

● Check clutch disc for backlash of spline and runout of facing.

Maximum backlash of spline : 0.9 mm (0.035 in)
(at outer edge of disc)
Runout limit : 1.0 mm (0.039 in)
Distance of runout check point : 102.5 mm (4.04 in)
(from hub center)
● Check clutch disc for burns, discoloration or oil or grease leak-
age. Replace if necessary.
LCIA0108E

CL-17
 CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
[QG18DE]
CLUTCH COVER
Check clutch cover installed on vehicle for unevenness of diaphragm
spring toe height.
Uneven limit : 0.88 mm (0.0346 in)
If out of limit, adjust the height with Tool.

WCL016

FLYWHEEL
● Check contact surface of flywheel for slight burns or discolora-
tion. Clean flywheel with emery paper.
● Check flywheel runout.
Maximum allowable runout : Refer to EM-68, "FLY-
WHEEL RUNOUT" .

SCL349

Installation ECS0048Z

1. Insert Tool into clutch disc hub when installing clutch cover and
disc.
CAUTION:
Be careful not to allow grease to contaminate clutch facing.
2. Tighten the clutch cover bolts in numerical order in 2 steps to
specification.
First step : 10 - 20 N·m (1.0 - 2.0 kg-m, 7 - 14 ft-lb)
Final step : 22 - 29 N·m (2.2 - 3.0 kg-m, 16 - 22 ft-lb)

WCL017

CL-18
 SERVICE DATA AND SPECIFICATIONS (SDS)
[QG18DE]
SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030
A
Clutch Control System ECS00490

Type of clutch control Hydraulic

B
Clutch Master Cylinder ECS00491

Unit: mm (in)
Inner diameter 15.87 (5/8) CL
Clutch Operating Cylinder ECS00492

Unit: mm (in)
D
Inner diameter 19.05 (3/4)

Clutch Disc ECS00493

Unit: mm (in) E
Engine model QG18DE
Model 215
F
Facing size (Outer dia. × inner dia. × thickness) 215 × 145 × 3.5 (8.46 × 5.71 × 0.138)
Thickness of disc assembly 7.7 - 8.3 (0.303 - 0.327)
With load with 4,900 N (499.8 kg, 1,101.5 lb)
G
Wear limit of facing surface to rivet head 0.3 (0.012)
Runout limit of facing 1.0 (0.039)
Distance of runout check point (from the hub center) 102.5 (4.04) H
Maximum backlash of spline
0.9 (0.035)
(at outer edge disc)
I
Clutch Cover ECS00494

Unit: mm (in)
Engine model QG18DE
J
Model 215
Full-load 4,900 N (499.8 kg, 1,101.5 lb)
Uneven limit of diaphragm spring toe height 0.88 (0.0346) K

Clutch Pedal ECS00495

Unit: mm (in) L
Clearance “C” between pedal stopper rubber and clutch interlock
0.1 - 1.0 (0.004 - 0.039)
switch threaded end while clutch pedal is fully depressed.
M

CL-19
 PRECAUTIONS
[QR25DE]
PRECAUTIONS PFP:00001

Precautions ECS00496

● Recommended fluid is brake fluid “DOT 3”.

● Do not reuse drained brake fluid.
● Be careful not to splash brake fluid on painted areas; it may
cause paint damage. If brake fluid is splashed on painted
areas, wash it away with water immediately.
● Use flare nut wrench when removing or installing clutch
hydraulic tubes.
● Use new brake fluid to clean or wash all parts of master cyl-
inder and operating cylinder.
● Never use mineral oils such as gasoline or kerosene. It will SBR686C
ruin the rubber parts of the hydraulic system.
WARNING:
After cleaning clutch disc, wipe it with a dust collector. Do not use compressed air.

CL-20
 PREPARATION
[QR25DE]
PREPARATION PFP:00002
A
Special Service Tools ECS00497

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number
B
(Kent-Moore No.) Description
Tool name
ST20630000 Installing clutch cover and clutch disc
(J-26366) a: 15.8 mm (0.622 in) dia. CL
Clutch aligning bar b: 22.9 mm (0.902 in) dia.
c: 45.0 mm (1.772 in)

NT405

ST20050240 Adjusting unevenness of diaphragm spring of E

( — ) clutch cover
Diaphragm spring adjusting wrench a: 150 mm (5.91 in)
b: 25 mm (0.98 in)
F

S-NT404
G
KV32101000 Removing and installing spring pin
(J-25689-A) a: 4 mm (0.16 in) dia.
Pin punch
H

S-NT410 I

Commercial Service Tools ECS00498

Tool name Description J

1. Flare nut crowfoot Removing and installing clutch piping
2. Torque wrench a: 10 mm (0.39 in)
K

L
S-NT360

CL-21
 Check each part in order. If necessary, repair or replace these parts.
Use the chart below to help you find the cause of the symptom. The numbers indicate the order of inspection.
NVH Troubleshooting Chart
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
Symptom

SUSPECTED PARTS (Possible cause)

Reference page

NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING

Clutch does not disengage
Clutch slips
Clutch noisy
Clutch pedal spongy
Clutch grabs/chatters
CLUTCH PEDAL (Inspection and adjustment) CL-24

1
1
2 CLUTCH LINE (Air in line) CL-24

1
MASTER CYLINDER PISTON CUP (Damaged) CL-26
3

2
CL-22

OPERATING CYLINDER PISTON CUP (Damaged) CL-28

4

2
ENGINE MOUNTING (Loose) EM-54, "Removal and Installation"
1
RELEASE BEARING (Worn, dirty or damaged) CL-31
1

CLUTCH DISC (Out of true)

5

CLUTCH DISC (Runout is excessive)

5

CLUTCH DISC (Lining broken)

5

CLUTCH DISC (Dirty or burned) CL-33

5

CLUTCH DISC (Oily)

5
2

CLUTCH DISC (Worn out)

2

CLUTCH DISC (Hardened)

2

CLUTCH DISC (Lack of spline grease) CL-33

5

DIAPHRAGM SPRING (Damaged)

6
3

[QR25DE]
DIAPHRAGM SPRING (Out of tip alignment) CL-34
6

PFP:00003
CLUTCH COVER (Distortion)
7
4

ECS00499
FLYWHEEL (Distortion) CL-34
5
 CLUTCH SYSTEM
[QR25DE]
CLUTCH SYSTEM PFP:30502
A
Components ECS0049A

CL

WCIA0139E

1. Reservoir cap 2. Hose clamp 3. Reservoir tank

4. Reservoir hose 5. Clutch tube 6. Nipple
7. Clutch master cylinder 8. Clevis 9. Clutch pedal bracket
10. Clutch interlock switch 11. ASCD clutch switch (if equipped) 12. Clutch pedal
13. Clutch cover 14. Withdrawal lever 15. Spacer
16. Clutch lever 17. Spring pin 18. Release bearing spring
19. Release bearing 20. Clutch hose 21. Operating cylinder
22. Clutch disc

CL-23
 CLUTCH SYSTEM
[QR25DE]
Inspection and Adjustment ECS0049B

ADJUSTING CLUTCH PEDAL

1. Check to see if the clutch pedal clevis pin floats freely in the bore
of the clutch pedal. It should not be bound by the clevis or clutch
pedal.
a. If the pin is not free, check that the ASCD switch or pedal stop-
per bolt is not applying pressure to the clutch pedal causing the
pin to bind. To adjust, loosen the ASCD switch or pedal stopper
bolt lock nut and turn the ASCD switch or pedal stopper bolt.
b. Tighten the lock nut.
c. Verify that the clutch pedal clevis pin floats freely in the bore of
the clutch pedal. It should not be bound by the clevis or clutch
pedal.
d. If the pin is still not free, remove the pin and check for deforma-
tion or damage. Replace the pin if necessary. Leave the pin
removed for step 2.
2. Check the clutch pedal stroke for free range of movement.
a. With the clutch pedal clevis pin removed, manually move the
pedal up and down to determine if it moves freely.
b. If any sticking is noted, replace the related parts (clutch pedal,
pedal bracket, assist spring, bushing, etc.). Reassemble the
pedal and re-verify that the clevis pin floats freely in the bore of
the pedal.
WCIA0146E

3. Adjust the clearance “C” while fully depressing the clutch pedal
(with the clutch interlock switch) as shown.
Clearance "C" : 0.1 - 1.0 mm (0.004 - 0.039 in)
4. Check the clutch hydraulic system components (clutch master
cylinder, clutch operating cylinder, Clutch withdrawal lever,
clutch release bearing, etc.) for sticking or binding.
a. If any sticking or binding is noted, repair or replace the related
parts as necessary.
b. If any hydraulic system repair was necessary, bleed the clutch
hydraulic system. Refer to CL-24, "BLEEDING PROCEDURE" .
NOTE:
Do not use a vacuum assist or any other type of power bleeder
on this system. Use of a vacuum assist or power bleeder will not
purge all of the air from the system.

SCL800

BLEEDING PROCEDURE
CAUTION:
Carefully monitor fluid level at master cylinder during bleeding operation.
NOTE:
Do not use a vacuum assist or any other type of bleeder on this system. Use of a vacuum assist or power
bleeder will not purge all the air from the system.
1. Top off reservoir with recommended brake fluid.

CL-24
 CLUTCH SYSTEM
[QR25DE]
CAUTION:
Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is A
splashed on painted areas, wash it away with water immediately.
2. Connect a transparent vinyl tube to air bleeder valve.
3. Slowly depress the clutch pedal to its full stroke and release it B
completely. Repeat this operation several times at 2 to 3 sec-
onds intervals.
4. Open the air bleeder valve with the clutch pedal fully depressed. CL

WCIA0018E

E
5. Close the air bleeder valve.
Air bleeder valve tightening torque : 5.9 - 9.8 N·m (0.6 - 1.0 kg-m, 52 - 87 in-lb)
F
6. Release the clutch pedal and wait at least 5 seconds.
7. Repeat steps 1 through 6 above until air bubbles no longer appear in the brake fluid.
G

CL-25
 CLUTCH MASTER CYLINDER
[QR25DE]
CLUTCH MASTER CYLINDER PFP:30610

Components ECS0049C

WCIA0140E

1. Bracket 2. Reservoir cap 3. Reservoir tank

4. Hose clamps 5. Reservoir hose 6. Nipple
7. Piston assembly seals 8. Push rod 9. Stopper ring
10. Stopper 11. Dust cover 12. Clevis
13. Return spring 14. Pin 15. Seal
16. Master cylinder body 17. Clutch tube

Removal ECS0049D

1. Drain brake fluid from clutch system.

CAUTION:
Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is
splashed on painted areas, wash it away with water immediately.
2. Remove clutch tube flare nut using a flare nut wrench.
3. Remove reservoir hose.
4. Remove the snap pin from the clevis pin and remove the clutch pedal from the clevis.
5. Unscrew master cylinder nuts and reservoir tank bracket nuts to remove master cylinder from the vehicle.
Installation ECS0049E

1. Install reservoir hose.

2. Connect clutch tube to master cylinder, and hand-tighten flare nut.
3. Install master cylinder to cowl, and tighten master cylinder nuts to the specified torque.
Master cylinder nuts : 10.8 - 14.6 N·m (1.1 - 1.4 kg-m, 8 - 10 ft-lb)
4. Tighten reservoir tank bracket nuts to the specified torque.
Reservoir tank bracket nuts : 2.9 - 5.9 N·m (0.29 - 0.60 kg-m, 26 - 52 in-lb)
5. Tighten clutch tube flare nut using a flare nut torque wrench to the specified torque.
Clutch tube flare nut : 15 - 18 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)
6. After installing clevis pin, install snap pin to connect clutch pedal to push rod.
7. After finishing the operation, bleed air from clutch piping. Refer to CL-24, "BLEEDING PROCEDURE" .

CL-26
 CLUTCH MASTER CYLINDER
[QR25DE]
Disassembly ECS0049F

A
1. Loosen push rod lock nut "A" to remove clevis and lock nut "A".
2. Remove dust cover.
3. Remove stopper ring and stopper, and remove push rod from
B
cylinder body. During removal, keep push rod depressed, to pre-
vent piston inside master cylinder from popping out.
4. Remove piston assembly from cylinder body.
CL
5. Remove return spring.
6. Remove pin using pin punch, then remove nipple and seal.
D
SCL725

Inspection ECS0049G

Inspect for the following, and replace parts if necessary. E

● Damage, wear, rust, and pinholes on the cylinder inner wall
● Damage and deformation of the reservoir tank
F
● Weak spring
● Crack or deformation of the dust cover
Assembly ECS0049H G
1. Install spring.
2. Apply rubber lubricant to the sliding part of piston assembly, and insert piston assembly into cylinder body.
H
3. After installing stopper to push rod, install stopper ring while keeping piston assembly depressed by hand,
so that piston assembly will not pop out.
CAUTION:
Stopper ring cannot be reused. Always use a new stopper ring for assembly. I
4. Apply silicone grease, and install dust cover.
5. Install clevis to push rod, and tighten lock nut "A" to the specified torque.
J
Lock nut "A" : 7.8 - 11.8 N·m (0.8 - 1.2 kg-m, 69 - 104 in-lb)
6. Install seal and nipple to cylinder body, and install pin using a pin punch.
K

CL-27
 OPERATING CYLINDER
[QR25DE]
OPERATING CYLINDER PFP:30620

Components ECS0049I

WCIA0141E

1. Cylinder body 2. Piston spring 3. Piston cup

4. Piston 5. Push rod 6. Dust cover
7. Air bleeder 8. Union bolt 9. Copper washer
10. Clutch hose

Removal ECS0049J

1. Drain brake fluid from clutch system.

CAUTION:
Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is
splashed on painted areas, wash it away with water immediately.
2. Remove union bolt and clutch hose from operating cylinder.
3. Remove operating cylinder mounting bolts, and remove cylinder
from vehicle.

LCIA0029E

Disassembly ECS0049K

Remove dust cover, and remove piston assembly from cylinder body.
Inspection ECS0049L

Inspect for the following, and replace parts if necessary.

● Damage, foreign material, wear, rust, and pinholes on the cylinder inner surface, piston, and sliding part of
piston cup
● Weak spring
● Crack or deformation of dust cover
Assembly ECS0049M

1. Apply rubber lubricant to the overall inside surface of the cylinder body. Also, apply rubber grease to the
piston.
CL-28
 OPERATING CYLINDER
[QR25DE]
2. Install the piston assembly into the cylinder body. Make sure tapered piston spring is installed correctly.
3. Apply rubber grease, and install dust cover. A

Installation ECS0049N

Install the components in the reverse order of removal. Follow the operations described below. B
CAUTION:
● Install the hose without twisting it.
● The copper washer of the union bolt should not be reused. Always use a new copper washer for CL
installation.
● After finishing the operation, bleed air from the clutch piping. Refer to CL-24, "BLEEDING PROCE-
DURE" . D

CL-29
 PIPING
[QR25DE]
PIPING PFP:00000

Removal ECS0049O

1. Remove air cleaner and air duct.

2. Drain brake fluid from clutch system.
CAUTION:
Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is
splashed on painted areas, wash it away with water immediately.
3. Remove flare nut from cylinder body using a flare nut wrench.
4. Remove clutch hose from operating cylinder.
5. Remove clutch hose and clutch tube from bracket by removing lock plate.
Installation ECS0049P

1. When installing clutch hose to bracket, face lock plate in the cor-
rect direction as shown to secure clutch hose.
CAUTION:
Install clutch hose without twisting or bending it.
2. Tighten flare nut to the specified torque, using a flare nut
wrench.
Flare nut : 15 - 18 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)
CAUTION:
Be careful not to damage flare nut and clutch tube.
3. Install clutch hose to operating cylinder, and tighten the clutch SCL730

hose bolt to the specified torque.

Clutch hose bolt : 17 - 19 N·m (1.7 - 2.0 kg-m, 13 - 14 ft-lb)
4. Bleed air from the clutch piping. Refer to CL-24, "BLEEDING PROCEDURE" .
5. Install air cleaner and air duct.

CL-30
 CLUTCH RELEASE MECHANISM
[QR25DE]
CLUTCH RELEASE MECHANISM PFP:30502
A
Components ECS0049Q

CL

LCIA0030E
G

Removal ECS0049R

1. Remove manual transaxle from vehicle. Refer to MT-16, "Removal and Installation" . H
2. Move withdrawal lever enough to remove release bearing, and remove release bearing from clutch lever.
3. Remove withdrawal lever retainer spring.
4. Pull out withdrawal lever and remove dust cover. I

Inspection After Removal ECS0049S

● Replace the release bearing if it is seized, damaged, faulty in J

rotation direction, or has poor aligning function.
● Replace the withdrawal lever if its contact surface is worn abnor-
mally. K
● Replace the dust seal if its deformed or cracked.

SCL733
M

Installation ECS0049T

Installation is in the reverse order of removal.

● Clean old grease and abrasive materials off the grease application area.

SCL815

CL-31
 CLUTCH RELEASE MECHANISM
[QR25DE]
● Apply approximately 1 mm (0.04 in) thick of clutch sleeve grease to withdrawal lever and holder spring
friction surfaces.
● Apply a coat of clutch sleeve grease to the grooves on contact surfaces of the withdrawal lever ball pin
and inner surface of release bearing; make sure grease is flush with grooves.
● Apply a thin coat of clutch sleeve grease to release bearing frictional surface. After grease application,
install release bearing. Wipe off excess grease forced out during bearing installation.

CL-32
 CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
[QR25DE]
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL PFP:30100
A
Components ECS0049U

CL

G
WCIA0142E

1. Flywheel 2. Clutch disc 3. Washer

4. Main drive shaft 5. Clutch cover H
NOTE:
The following operations are with manual transaxle removed from vehicle.
I
Removal ECS006S5

1. Evenly loosen the clutch cover bolts, then remove the clutch cover and clutch disc.
Inspection and Adjustment ECS0049V J
CLUTCH DISC

● Check clutch disc for wear of facing. K

Wear limit of facing surface to rivet head : 0.3 mm
(0.012 in)
L

LCIA0109E

● Check clutch disc for backlash of spline and runout of facing.

Maximum backlash of spline : 0.9 mm (0.035 in)
(at outer edge of disc)
Runout limit : 1.0 mm (0.039 in)
Distance of runout check point : 115.0 mm (4.53 in)
(from hub center)
● Check clutch disc for burns, discoloration or oil or grease leak-
age. Replace if necessary.
LCIA0108E

CL-33
 CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
[QR25DE]
CLUTCH COVER
Check clutch cover installed on vehicle for unevenness of diaphragm
spring toe height.
Uneven limit : 0.7 mm (0.028 in)
If out of limit, adjust the height with Tool.

WCL016

FLYWHEEL
● Check contact surface of flywheel for slight burns or discolora-
tion. Clean flywheel with emery paper.
● Check flywheel runout.
Maximum allowable runout : Refer to EM-165, "MOVE-
MENT AMOUNT OF FLY-
WHEEL (M/T MODEL)" .

SCL349

Installation ECS0049W

1. Insert Tool into clutch disc hub when installing clutch cover and
disc.
CAUTION:
Be careful not to allow grease to contaminate clutch facing.
2. Tighten bolts in numerical order by 2 steps.
First step : 10 - 20 N·m (1.0 - 2.0 kg-m, 7 - 14 ft-lb)
Final step : 35 - 44 N·m (3.5 - 4.5 kg-m, 26 - 32 ft-lb)

SCL600-C

CL-34
 SERVICE DATA AND SPECIFICATIONS (SDS)
[QR25DE]
SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030
A
Clutch Control System ECS0049X

Type of clutch control Hydraulic

B
Clutch Master Cylinder ECS0049Y

Unit: mm (in)
Inner diameter 15.87 (5/8) CL
Clutch Operating Cylinder ECS0049Z

Unit: mm (in)
D
Inner diameter 19.05 (3/4)

Clutch Disc ECS004A0

Unit: mm (in) E
Engine model QR25DE
Model 240
F
Facing size (Outer dia. × inner dia. × thickness) 240 × 160 × 3.5 (9.45 × 6.30 × 0.138)
Thickness of disc assembly 7.8 - 8.4 (0.307 - 0.331)
With load with 5,884 N (600 kg, 1,322 lb)
G
Wear limit of facing surface to rivet head 0.3 (0.012)
Runout limit of facing 1.0 (0.039)
Distance of runout check point (from the hub center) 115.0 (4.53) H
Maximum backlash of spline
0.9 (0.035)
(at outer edge disc)
I
Clutch Cover ECS004A1

Unit: mm (in)
Engine model QR25DE
J
Model 240
Full-load 5,884 N (600 kg, 1,322 lb)
Uneven limit of diaphragm spring toe height 0.7 (0.028) K

Clutch Pedal ECS004A2

Unit: mm (in) L
Clearance “C” between pedal stopper rubber and clutch interlock
0.1 - 1.0 (0.004 - 0.039)
switch threaded end while clutch pedal is fully depressed.
M

CL-35
SERVICE DATA AND SPECIFICATIONS (SDS)
[QR25DE]

CL-36