2004 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX
Contents
1. T CL 00300 1 Dust cover 6 Clutch release bearing Tightening torque N m kgf m ft lb 2 Retainer spring 7 Clutch cover T1 16 1 6 11 8 3 Pivot 8 Clutch disc T2 72 7 3 52 8 4 Clutch release lever 9 Flywheel 5 Clip CL 4 General Description CLUTCH SYSTEM e 2 5 L SOHC MODEL CL 00301 1 Dust cover 6 Release bearing Tightening torque N m kgf m ft lb 2 Retainer spring 7 Clutch cover T1 16 1 6 11 8 3 Pivot 8 Clutch disc T2 72 7 3 52 8 4 Release lever 9 Dual mass flywheel 5 Clip CL 5 General Description CLUTCH SYSTEM DOHC TURBO MODEL CL 00302 1 Dust cover 5 Clutch release bearing Tightening torque N m kgf m ft lb 2 Clutch release lever 6 Clutch cover T1 16 1 6 11 8 3 Clutch release lever shaft 7 Clutch disc T2 44 4 5 32 5 4 Plug 8 Flywheel T3 72 7 3 52 8 Except for STi model 75 7 4 55 3 STi model CL 6 General Description CLUTCH SYSTEM 2 CLUTCH PIPE AND HOSE LHD SOHC MODEL CL 00107 1 Operating cylinder 6 Pipe Tightening torque N m kgf m ft lb 2 Washer 7 Master cylinder ASSY T1 8 0 8 5 8 3 Clutch hose 8 Clevis pin T2 15 1 5 10 82. _ _ B T 7 cL 00092 A PHV cable B Clamp 8 Disconnect the clutch cable from release lever 1 6 L model 9 Remove the clutch pedal and bracket as a unit CL 00126 A Clutch pedal bracket B Clutch pedal CL 41 Clutch Pedal CLUTCH SYSTEM 10 Depress the clutch pedal then disconnect the clutch cable from clutch pedal 1 6 L model B INSTALLATION 1 Install in the reverse order of removal CAUTION e If the cable clamp is damaged replace it with a new one e Never fail to cover the outer cable end with boot e Be careful not to kink the accelerator cable e Always use new clevis pins 2 Adjust the clutch pedal after installation lt Ref to CL 45 ADJUSTMENT Clutch Pedal gt C DISASSEMBLY 1 LHD MODEL e Except for 1 6 L MODEL 1 Remove the clips assist spring rod and bush ing CL 00094 A Clip B Assist spring C Assist rod D Bushing E Clevis pin 2 Remove the spring pin and lever CL 00095 3 Remove the clutch pedal and bushings CL 00096 A Clutch pedal B Bushing 4 Remove the stopper clip O ring rod S and then remove the spring and bushing S CL 00217 Clip O ring Bushing S Spring S Rod S Stopper 5 Remove the stoppers from clutch pedal 6 Remove the clutch pedal pad Non turbo mod el CL 42 Clutch Pedal CLUTCH SY
3. A Clamp B Clutch hose 5 Remove the hose from operating cylinder 6 Remove the bracket 2 RHD DOHC TURBO MODEL 1 Remove the intercooler lt Ref to IN H4DOTC 10 REMOVAL Intercooler gt 2 Drain the clutch fluid lt Ref to CL 37 Clutch Flu id gt CLUTCH SYSTEM 3 Remove the clutch pipe from the master cylin der connector and clutch hose CL 00053 A Clutch pipe B Clip C Connector D Clutch hose 4 Pull out the clamp then remove the clutch hose from bracket A Clamp B Clutch hose 5 Remove the connector 6 Remove the bracket B INSTALLATION 1 EXCEPT FOR RHD DOHC TURBO MOD EL Install in the reverse order of removal CL 35 Clutch Pipe and Hose CLUTCH SYSTEM NOTE Tightening torque Bleed the clutch fluid lt Ref to CL 38 Clutch Fluid T1 7 5 N m 0 76 kgf m 5 53 ft lb Air Bleeding gt T2 8 N m 0 8 kgf m 5 8 ft lb Tightening torque 19 15 N m 1 5 kgf m 10 8 ft lb T4 18 N m 1 8 kgf m 13 0 ft lb T1 15 N m 1 5 kgf m 10 8 ft lb T5 25 N m 2 5 kgf m 18 1 ft lb T2 18 N m 1 8 kgf m 13 0 ft lb SE T3 25 N m 2 5 kgf m 18 1 ft lb CL 00061 NOS a A Clutch pipe A Clutch pipe LHD model Ga B Clip C Clutch hose C INSPECTION D Clutch pipe RHD mode
4. 4 Bracket 9 Snap pin T3 18 1 8 13 0 5 Clip 10 Lever T4 37 3 8 27 5 CL 7 General Description CLUTCH SYSTEM RHD SOHC MODEL a Ze ce b AE Fis x ee CL 00003 1 Operating cylinder 7 Master cylinder ASSY Tightening torque N m kgf m ft lb 2 Washer 8 Clevis pin T1 8 0 8 5 8 3 Clutch hose 9 Snap pin T2 15 1 5 10 8 4 Bracket 10 Pedal T3 18 1 8 13 0 5 Clip 11 Clamp T4 25 2 5 18 1 6 Clutch pipe 12 Bracket T5 37 3 8 27 5 CL 8 General Description CLUTCH SYSTEM LHD DOHC TURBO MODEL n S gt Ts T5 T4 CL 00203 1 Operating cylinder Except for STi 6 Pipe Tightening torque N m kgf m ft lb model 7 Master cylinder ASSY T1 8 0 8 5 8 2 Washer 8 Clevis pin T2 15 1 5 10 8 3 Clutch hose 9 Snap pin T3 18 1 8 13 0 4 Bracket 10 Lever T4 37 3 8 27 5 5 Clip 11 Operating cylinder STi model T5 41 4 2 30 2 CL 9 General Description CLUTCH SYSTEM RHD DOHC TURBO MODEL CL 00204 1 Operating cylinder Except for STi 8 Snap pin Tightening torque N m kgf m ft lb model 9 Pedal T1 7 5 0 76 5 53 2 Washer 10 Clamp T2 8 0 8 5 8 3 C
5. CL 45 Clutch Pedal CLUTCH SYSTEM 3 Depress and release the clutch pedal two to three times to ensure that clutch pedal and release fork operates smoothly If the clutch pedal and re lease fork do not operate smoothly bleed air from the clutch hydraulic system lt Ref to CL 38 Clutch Fluid Air Bleeding gt 4 Measure the clutch pedal full stroke length again to ensure that it is within specifications If it is not repeat adjustment procedures again from the be ginning Specified clutch pedal full stroke 130 135 mm 5 12 5 31 in 5 Move the clevis pin to the left and then to the right It should move without resistance while it is rattling If resistance is felt repeat adjustment pro cedures again from the beginning 6 Push the release lever until operating cylinder push rod retracts Ensure that clutch fluid level in reservoir tank increases If the clutch fluid level in creases hydraulic the clutch is properly adjusted if fluid level does not increase or push rod does not retract replace the master cylinder with a new one lt Ref to CL 31 Master Cylinder gt CL 00227 1 Push rod 2 Release lever 3 Operating cylinder 7 Push the release lever until operating cylinder push rod retracts Check that the clutch fluid level in reservoir tank increases CL 00227 1 Push rod 2 Release lever 3 Operating cylinder 8 If the clutch fluid level increases
6. mission Assembly gt 2 Remove the clutch release lever from transmis sion 3 Put the clutch release bearing in engine side 4 Remove the clutch release bearing from the clutch cover using flat type screwdriver CL 00025 A Clutch release bearing B INSTALLATION 1 EXCEPT FOR DOHC TURBO MODEL NOTE Before or during assembling lubricate the following points with a light coat of grease e Contact surface of lever and pivot e Contact surface of lever and bearing e Transmission main shaft spline Use grease con taining molybdenum disulphide 1 While pushing the release lever to pivot and twisting it to both sides fit the retainer spring onto the constricted portion of pivot NOTE e Apply grease SUNLIGHT 2 Part No 003602010 to the contact point of release lever and operating cylinder e Confirm that the retainer spring is securely fitted by observing it through the main case hole CL 00026 A Release lever 2 Install the release bearing and fasten it with two clips CL 26 Release Bearing and Lever CLUTCH SYSTEM 3 Install the dust cover e Shaft SUNLIGHT 2 Part No 003602010 SC CN CL 00023 A Release lever B Dust cover 4 Install the transmission assembly lt Ref to 5MT 41 INSTALLATION Manual Trans D YWA Le mission Assembly gt eft B 2 D
7. 5 INSTAL LATION Air Cleaner Case gt and lt Ref to IN H4SO 6 INSTALLATION Air Intake Duct gt 5 Install the intercooler Turbo model lt Ref to IN H4DOTC 10 INSTALLATION Intercooler gt CL 31 Master Cylinder CLUTCH SYSTEM C DISASSEMBLY 5 Remove the clutch damper 1 EXCEPT FOR RHD DOHC TURBO MOD 2 RHD DOHC TURBO MODEL EL 1 Remove the hose 1 Remove the straight pin and reservoir tank CL 00046 A Reservoir tank B Straight pin 2 Remove the oil seal CL 00050 A Reservoir tank B Bracket CL 00047 3 Remove the straight pin and adapter A Oil seal B B Master cylinder S nr 3 Move the cylinder boot backward Ph EF CL 00051 A Straight pin B Adapter CL 00048 A Cylinder boot B Master cylinder 4 Remove the stop ring CAUTION Be careful when removing the snap ring to pre vent the rod washer piston and return spring from flying out CL 32 Master Cylinder 4 Remove the oil seal CL 00052 5 Move the cylinder boot backward CL 00048 A Cylinder boot B Master cylinder 6 Remove the stop ring CAUTION Be careful when removing the snap ring to pre vent the rod washer piston and return spring from flying out 7 Remove the air bleeder D ASSEMBLY 1 EXCEPT FOR RHD DOHC TURBO MOD EL 1 Install the clutch damper Tightening t
8. Clutch drags As a symptom of this trouble a harsh scratching noise develops and control becomes quite difficult when shifting gears The symptom becomes more apparent when shifting into the first gear However because much trouble of this sort is due to defective synchronization mechanism carry out the test as described after e Method of testing Pet to CL 50 CLUTCH INSPECTION General Diag nostic Table gt It may be judged as insufficient disen gagement of clutch if any noise occurs during this test a Worn or rusty clutch disc hub spline Replace the clutch disc b Excessive deflection of clutch disc facing Correct or replace c Seized crankshaft pilot needle bearing Replace d Cracked clutch disc facing Replace e Stuck clutch disc smeared by oil or water Replace 3 Clutch chatters Clutch chattering is an unpleasant vibra tion to the whole body when the vehicle is just started with clutch partially engaged a Adhesion of oil on the facing Replace the clutch disc b Weak or broken torsion spring Replace the clutch disc c Defective facing contact or excessive disc wear Replace the defective clutch disc Correct or replace Ss d Warped pressure plate or flywheel e Loose disc rivets Replace the clutch disc f Loose engine mounting Retighten or replace the mounting g Improper adjustment of pitching st
9. L AND 2 5 L MODEL CL 00111 1 Stopper 9 Assist bushing 17 Spacer 2 Clutch pedal pad 10 Assist rod B 18 Bushing 3 Clutch pedal 11 Spring A 19 Clutch pedal bracket 4 Bushing 12 RodS 5 Clutch clevis pin 13 Bushing B Tightening torque N m kgf m ft lb 6 Assist rod A 14 O ring T1 8 0 8 5 8 7 Clip 15 Clip T2 18 1 8 13 0 8 Assist spring 16 Clutch switch With cruise control 73 30 3 1 22 4 CL 16 General Description CLUTCH SYSTEM RHD 1 6 L MODEL CL 00206 1 Stopper 7 Clutch cable clamp Tightening torque N m kgf m ft lb 2 Bushing 8 Spacer T1 5 9 0 6 4 3 3 Clutch pedal bracket 9 Bracket T2 8 0 8 5 8 4 Clutch pedal pad 10 Adjust bolt T3 18 1 8 13 0 5 Clutch pedal 11 Spring T4 29 3 0 21 7 6 Clutch cable CL 17 General Description CLUTCH SYSTEM C CAUTION e Wear working clothing including a cap protec tive goggles and protective shoes during operation e Remove contamination including dirt and corro sion before removal installation or disassembly e Keep the disassembled parts in order and pro tect them from dust or dirt e Before removal installation or disassembly be sure to clarify the failure Avoid unnecessary re moval installation disassembly and replaceme
10. REMARKS Circuit Tester Used for measuring resistance voltage and ampere Dial Gauge CL 19 Used for measuring clutch disk run out Clutch Disc and Cover CLUTCH SYSTEM 2 Clutch Disc and Cover A REMOVAL 1 2 5 L MODEL 1 Remove the transmission assembly from vehicle body lt Ref to 5MT 38 REMOVAL Manual Trans mission Assembly gt 2 Insert the ST on flywheel ST 499747100 CLUTCH DISC GUIDE CL 00112 A Double mass flywheel 3 Remove the clutch cover and clutch disc NOTE e Take care not to allow oil on the clutch disc fac ing e Do not disassemble either the clutch cover or clutch disc e Put matching marks to the flywheel and clutch cover before removing the clutch cover CL 00113 2 EXCEPT FOR 2 5 L MODEL 1 Remove the transmission assembly from vehicle body lt Ref to 5MT 38 REMOVAL Manual Trans mission Assembly gt 2 Install the ST on flywheel ST 499747100 CRANKSHAFT STOPPER CL 00011 A Clutch cover 3 Remove the clutch cover and clutch disc NOTE e Take care not to allow oil on the clutch disc fac ing e Do not disassemble either the clutch cover or clutch disc B INSTALLATION 1 2 5 L MODEL 1 Insert the ST into clutch disc and install them on the flywheel by inserting the ST end into pilot bear ing NOTE When installing the clutch disc
11. air cleaner case and intake duct lt Ref to IN H4SO 5 REMOVAL Air Cleaner Case gt and lt Ref to IN H4SO 6 REMOVAL Air Intake Duct gt 3 Disconnect the clutch cable from release lever 4 Remove the instrument panel lower cover 5 Disconnect the operating rod of brake pedal 6 Remove the electrical connectors for stop light switch etc CL 40 Clutch Pedal 7 Remove the bolts and nuts which secure brake and clutch pedals and remove pedal bracket and clutch cable as a unit CL 00215 A Clutch pedal B Brake pedal 8 Depress the clutch pedal then disconnect the clutch cable from clutch pedal 2 RHD MODEL 1 Disconnect the ground cable from battery 2 Disconnect the connector from clutch Model with cruise control 3 Remove the instrument panel lower cover 4 Remove the snap pin and clevis pin that join push rod and clutch pedal Except for 1 6 L model 5 Remove the master cylinder mounting nuts Ex cept for 1 6 L model A Master cylinder CLUTCH SYSTEM 6 Remove the PHV adjusting nut and lock nut Model with hill holder Be A ros O A Adjusting nut B Lock nut C PHV 7 Remove the cable clamp and disconnect the PHV cable from PHV Model with hill holder CAUTION Carefully protect the boot and inner cable from damage when disconnecting the PHV cable
12. be careful to its di rection ST 499747100 CLUTCH DISC GUIDE A 4 CL 00208 A Flywheel side 2 Install the clutch cover on flywheel and tighten the bolts to specified torque NOTE e Align matching marks when reassemble es Note the front and rear of the clutch disc when in stalling e Tighten the clutch cover installing bolts gradual ly Each bolt should be tightened to the specified torque in a crisscross fashion CL 20 Clutch Disc and Cover Tightening torque 16 N m 1 6 kgf m 11 8 ft lb CL 00113 3 Remove the ST ST 499747100 CLUTCH DISC GUIDE 2 EXCEPT FOR 2 5 L MODEL 1 Insert the ST into clutch disc and install them on the flywheel by inserting the ST end into pilot bear ing NOTE When installing the clutch disc be careful to its di rection ST 499747100 CLUTCH DISC GUIDE A Flywheel side 2 Install the clutch cover on flywheel and tighten the bolts to specified torque NOTE e When installing the clutch cover on flywheel po sition the clutch cover so that there is a gap of 120 or more between unbalance marks on the fly wheel and clutch cover unbalance marks indi cate the directions of residual unbalance Note the front and rear of the clutch disc when in stalling e Temporarily tighten
13. hydraulic clutch play is correct 9 If the clutch fluid level does not increase or push rod does not retract clutch pedal must be readjust ed 10 Check the fluid level on the outside of the res ervoir tank If the level is below MIN add clutch fluid to bring it up to MAX Recommended clutch fluid FMVSS No 116 fresh DOT 3 or DOT 4 brake fluid CL 00214 A Max level B Min level C Reservoir tank CL 46 Clutch Pedal CLUTCH SYSTEM e 1 6 L MODEL 1 Disconnect the ground cable from battery 2 Remove the air cleaner case and intake duct lt Ref to IN H4SO 5 REMOVAL Air Cleaner Case gt and lt Ref to IN H4S0 6 REMOVAL Air Intake Duct gt 3 Remove the release lever return spring from le ver 4 Loosen the lock nut 5 Adjust the spherical nut of the lever end so that the play and full stroke is within the specified value center of spherical nut CAUTION Take care not to twist the cable during adjust ment Play 3 4 mm 0 12 0 16 in Full stroke 24 26 mm 0 94 1 02 in A Play B Full stroke 6 Upon completion of adjustment securely lock the spherical nut with lock nut Tightening torque 5 9 N m 0 60 kgf m 4 3 ft lb CL 00229 A Lock nut B Spherical nut C Clutch release lever 7 Install the return spring on lever NOTE Hook the long hook side of the return
14. properly 15 Install the intercooler lt Ref to IN H4DOTC 10 INSTALLATION Intercooler gt CL 39 Clutch Pedal CLUTCH SYSTEM 10 Clutch Pedal A REMOVAL 1 LHD MODEL e Except for 1 6 L MODEL 1 Remove the steering column lt Ref to PS 26 REMOVAL Tilt Steering Column gt 2 Disconnect the connectors from stop light and clutch switches 3 Remove the snap pins which secure lever to push rod and operating rod 4 Remove the clevis pins which secure lever to push rod and operating rod CL 00090 gt Operating rod Push rod C Snap pin Clevis pin is 5 Remove the air cleaner case and intake duct lt Ref to IN H4SO 5 REMOVAL Air Cleaner Case gt and lt Ref to IN H4SO 6 REMOVAL Air Intake Duct gt 6 Remove the PHV adjusting nut and lock nut Model with hill holder A Adjusting nut B Lock nut C PHV 7 Remove the cable clamp and disconnect the PHV cable from PHV Model with hill holder CAUTION Carefully protect the boot and inner cable from damage when disconnecting the PHV cable _ B T 7 cxr ov092 A PHV cable B Clamp 8 Remove the nut which secures clutch master cylinder CL 00093 9 Remove the bolts and nuts which secure brake and clutch pedals and remove the pedal assembly e 1 6 L MODEL 1 Disconnect the ground cable from battery 2 Remove the
15. spring with the lever 8 Depress the clutch pedal to assure there is no abnormality in the clutch system 9 Install the air cleaner case and intake duct lt Ref to IN H4SO 5 INSTALLATION Air Cleaner Case gt and lt Ref to IN H4SO 6 INSTALLATION Air Intake Duct gt CL 47 Clutch Cable CLUTCH SYSTEM 11 Clutch Cable A REMOVAL 1 Disconnect the ground cable from battery 2 Remove the air cleaner case and intake duct lt Ref to IN H4SO 5 REMOVAL Air Cleaner Case gt and lt Ref to IN H4SO 6 REMOVAL Air Intake Duct gt 3 Disconnect the clutch cable from release lever 4 Depress the clutch pedal to the floor 5 Remove the clutch cable clamp from pedal bracket CL 00230 A Clamp B Clutch cable 6 Remove the clutch cable from body B INSTALLATION 1 Clean the clutch pedal fitting hole and apply grease Connect the clutch cable to body 2 Fit the clutch pedal to pedal bolt and connect the clutch cable to bracket with clamp 3 Connect the clutch cable end to pedal end 4 Connect the clutch cable to release lever 5 Install the grommet to toe board 6 Adjust the cable after installation lt Ref to CL 45 ADJUSTMENT Clutch Pedal gt 7 Install the air cleaner case and intake duct lt Ref to IN H4SO 5 INSTALLATION Air Cleaner Case gt and lt Ref to IN H4SO 6 INSTALLATION Air Intake Duct gt C INSPECTION Check the removed cable and replace if d
16. the bolts by hand Each bolt should be tightened to the specified torque in a crisscross fashion CLUTCH SYSTEM Tightening torque 16 N m 1 6 kgf m 11 8 ft lb A Unbalance marks Paint 3 Remove the ST ST 499747100 CLUTCH DISC GUIDE 4 Install the transmission assembly lt Ref to 5MT 41 INSTALLATION Manual Transmission Assem bly gt C INSPECTION 1 CLUTCH DISC 1 Facing wear Measure the depth of rivet head from the surface of facing Replace if facings are worn locally or worn down to less than the specified value Depth of rivet head Limit of sinking 0 3 mm 0 012 in NOTE Do not wash the clutch disc with any cleaning fluid CL 21 Clutch Disc and Cover CLUTCH SYSTEM e 2 5 L MODEL e Except for 2 5 L MODEL CL 00015 A Clutch facing 4 Deflection on facing If deflection exceeds the specified value at the out er circumference of facing repair or replace ST 499747100 CLUTCH DISC GUIDE Limit for deflection 1 6 L model 0 8 mm 0 031 in at R 107 mm 4 21 in 2 0 L model CL 00014 0 8 mm 0 031 in at R 110 mm 4 33 in 2 5 L model 2 Hardened faing 1 0 mm 0 039 in at R 110 mm 4 33 in Correct by using emery paper or replace 2 5 L MODEL 3 Oil soakage on facing i Replace the clutch disc and inspect the transmis sion front oil seal transmission case mating sur fa
17. wear and damage of the bearing case surface contacting with lever 2 RELEASE LEVER 1 Check the lever pivot portion and the point of contact with release bearing case for wear at WT CL 00034 A Clutch release lever B Pivot C Clutch release bearing CL 28 Operating Cylinder 5 Operating Cylinder A REMOVAL 1 Remove the air cleaner case and air intake duct Non turbo model lt Ref to IN H4SO 5 REMOV AL Air Cleaner Case gt and lt Ref to IN H4SO 6 REMOVAL Air Intake Duct gt 2 Remove the intercooler Turbo model lt Ref to IN H4DOTC 10 REMOVAL Intercooler gt 3 Remove the clutch hose from operating cylinder CAUTION Cover the hose joint to prevent clutch fluid from flowing out e NON TURBO MODEL CL 00035 A Clutch hose B Operating cylinder e DOHC TURBO MODEL 5MT S S KA B A CAY A Ye A Clutch hose B Operating cylinder CLUTCH SYSTEM e DOHC TURBO MODEL 6MT l 4 CL 00209 A Clutch hose B Operating cylinder 4 Remove the operating cylinder from transmis sion e NON TURBO MODEL ___ CL 00037 e DOHC TURBO MODEL 5MT RA CA Ses Ge A Gi A Operating cylinder CL 29 Operating Cylinder CLUTCH SYSTEM e DOHC TURBO MODEL 6MT LD Q N Be CL 00210 A Operating cylinder B INS
18. 2004 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX TRANSMISSION SECTION CONTROL SYSTEMS cs AUTOMATIC TRANSMISSION 4AT AUTOMATIC TRANSMISSION PUNCHES DIAGNOSTICS MANUAL TRANSMISSION AND 5MT DIFFERENTIAL This service manual has been prepared to provide SUBARU service personnel MANUAL TRANSMISSION AND GMT With the necessary information and data DIFFERENTIAL for the correct maintenance and repair of SUBARU vehicles MANUAL TRANSMISSION AND ACIER This manual includes the procedures DIFFERENTIAL DIAGNOSTICS for maintenance disassembling reas sembling inspection and adjustment of CLUTCH SYSTEM CL components and diagnostics for guid ance of experienced mechanics Please peruse and utilize this manual fully to ensure complete repair work for satisfying our customers by keeping their vehicle in optimum condition When replacement of parts during repair work is needed be sure to use SUBARU genuine parts All information illustration and specifi cations contained in this manual are based on the latest product information available at the time of publication approval FUJI HEAVY INDUSTRIES LTD G1870GE4 i CLUTCH SYSTEM O OAN Oe BS wesch sech sesch sesch SE General Descriptions eee gen ee EEN 2 Clute Disc tee EE 20 ENEE SSSR ee Sn eege eege 24 Release Bearing and Lever 26 RI Ri Le E Master Cylinder seen Eelere Zeg Age ie Clutch Pipe and Hose EE TE Fluid EE Clutch Fluid Air E
19. 8 1 8 13 3 7 Reservoir tank bracket 14 Cylinder boot CL 13 General Description CLUTCH SYSTEM 4 CLUTCH PEDAL e LHD 2 0 L MODEL CL 00110 1 Stopper 12 Clutch clevis pin 23 Pedal bracket 2 Bushing 13 Assist rod A 24 Clutch master cylinder bracket 3 Spring pin 14 Clip 25 Lever 4 Snap pin 15 Assist spring 26 Adjust bolt 5 Brake pedal pad 16 Assist bushing 27 Clutch switch With cruise control 6 Brake pedal 17 Assist rod B 7 Clevis pin 18 Spring A Tightening torque N m kgf m ft Ib 8 Brake pedal spring 19 Rod T1 8 0 8 5 8 9 Clutch pedal pad 20 Bushing B T2 18 1 8 13 0 10 Clutch pedal 21 Clip 11 Bushing C 22 Stop light switch CL 14 General Description CLUTCH SYSTEM LHD 1 6 L MODEL CL 00205 1 Stopper 9 Clutch pedal pad Tightening torque N m kgf m ft lb 2 Bushing 10 Clutch pedal T1 5 9 0 60 4 3 3 Clutch pedal bracket 11 Clutch cable T2 8 0 8 5 8 4 Snap pin 12 Clutch cable clamp T3 18 1 8 13 0 5 Brake pedal pad 13 Clip T4 29 3 0 21 7 6 Brake pedal 14 Spring assist 7 Clevis pin 15 Stop light switch 8 Spring 16 Adjust bolt CL 15 General Description CLUTCH SYSTEM e RHD 2 0
20. Cover gt 3 Using the ST remove the flywheel ST 498497100 CRANKSHAFT STOPPER d Lei ST CL 00019 A Flywheel B INSTALLATION 1 2 5 L MODEL 1 Install the flywheel and ST ST 498497100 CRANKSHAFT STOPPER CL 00122 2 Tighten the flywheel attaching bolts to the spec ified torque ST 499057000 NOTE Tighten the flywheel installing bolts gradually Each bolt should be tightened to the specified torque in a crisscross fashion TORX PLUS Tightening torque 72 N m 7 3 kgf m 52 8 ft lb CL 00123 3 Install the clutch disc and cover lt Ref to CL 20 2 5 L MODEL INSTALLATION Clutch Disc and Cover gt 4 Install the transmission assembly lt Ref to 5MT 41 INSTALLATION Manual Transmission Assem bly gt CL 24 Flywheel 2 EXCEPT FOR 2 5 L MODEL 1 Install the flywheel and ST ST 498497100 CRANKSHAFT STOPPER gt CL 00020 2 Tighten the flywheel attaching bolts to the spec ified torque NOTE Tighten the flywheel installing bolts gradually Each bolt should be tightened to the specified torque ina crisscross fashion Tightening torque 72 N m 7 3 kgf m 52 8 ft lb ELON a 0150 E R G 250 o SS Ge RT 3 Install the clutch disc and cover lt Ref to CL 21 EXCEPT FOR 2 5 L MODEL INSTALLATION Clutch Disc and Cover gt 4 Install the transmission assembl
21. OHC TURBO MODEL 1 Install the release bearing on transmission 2 Insert the release fork into release bearing tab CL 00304 oe A NC lt ve A Spline FX2200 B Shaft SUNLIGHT 2 RU 10 XR B an Ce EN LI LG 4 Insert the release fork shaft into release fork ERAN P HERE NOTE ZA Le Sp Make sure the cutout portion of release fork shaft AA y he lee tact Lf W Ze b contacts spring pin B CL 00028 A C a A Release fork B Release bearing 7 3 Apply grease to the specified points e Spline FX2200 Part No 000040901 CL 00030 A Release fork B Release shaft C Spring pin 5 Tighten the plug CL 27 Release Bearing and Lever CLUTCH SYSTEM Tightening torque 44 N m 4 5 kgf m 32 5 ft lb 6 Install the transmission assembly lt Ref to 5MT 41 INSTALLATION Manual Transmission Assem bly gt C INSPECTION 1 RELEASE BEARING NOTE Since this bearing is grease sealed and is of a non lubrication type do not wash with gasoline or any solvent when servicing the clutch 1 Check the bearing for smooth movement by ap plying force in the radial direction Radial direction stroke 1 4 mm 0 055 in CL 00032 A Bearing case 2 Check the bearing for smooth rotation by apply ing pressure in the thrust direction CL 00160 A Bearing case 3 Check
22. STEM e 1 6 L MODEL 1 Remove the clip and then remove the spring as sist and spring A Spring assist B Spring 2 Remove the clutch pedal and brake pedal CL 00219 3 Remove the bushing stopper and clutch pedal pad A Si a al T D id B A Oe CL 00220 A Bushing B Stopper C Clutch pedal pad 4 Remove the adjuster bolt 2 RHD MODEL e Except for 1 6 L MODEL 1 Remove the clutch switch Model with cruise control 2 Remove the clip then pull out the clevis pin CL 00127 A Clevis pin 3 Remove the assist rod spring and bushing 4 Remove the clutch pedal from clutch pedal bracket CL 00128 A Clutch pedal bracket B Clutch pedal 5 Remove the following parts B to H from clutch pedal bracket A as shown in the figure CL 00129 KS m ee ee g et ee Clutch pedal bracket Bushing C Clip O ring Bushing S Spring S Rod S Bushing ZIOAMoOOD CL 43 Clutch Pedal CLUTCH SYSTEM 6 Remove the spacer bushing and pedal pad from 3 Remove the spacer bushing stopper and clutch clutch pedal pedal pad Se CL 00130 CL 00306 A Spacer A Spacer B Bushing B Bushing C Bushing C Stopper D Pedal pad D Clutch pedal pad E Clutch pedal F Bushing C ge bolt and stopper e 1 6 L MODEL i 1 Remove the spri
23. TALLATION 1 Install in the reverse order of removal NOTE Before installing the operating cylinder apply grease SUNLIGHT 2 Part No 003602010 to con tact point of the release lever and operating cylin der e NON TURBO MODEL Tightening torque T1 18 N m 1 8 kgf m 13 0 ft lb T2 37 N m 3 8 kgf m 27 5 ft lb CL 00039 e DOHC TURBO MODEL 5MT Tightening torque T1 18 N m 1 8 kgf m 13 0 ft lb T2 37 N m 3 8 kgf m 27 5 ft lb Wd e DOHC TURBO MODEL 6MT Tightening torque T1 18 N m 1 8 kgf m 13 0 ft lb T2 41 N m 4 2 kgf m 30 2 ft lb T1 CL 00211 NOTE e Be sure to install the clutch hose with the mark side facing upward e Be careful not to twist the clutch hose during in stallation CL 00041 A Marking B Clutch hose C Operating cylinder 2 After bleeding air from the operating cylinder ensure that clutch operates properly lt Ref to CL 38 Clutch Fluid Air Bleeding gt C INSPECTION 1 Check the operating cylinder for damage If op erating cylinder is damaged replace it 2 Check the operating cylinder for fluid leakage or damage on boot If any leakage or damage is found replace the operating cylinder CL 30 Master Cylinder 6 Master Cylinder A REMOVAL 1 Thoroughly drain the brake fluid from reservoir tank 2 Rem
24. a Le E Clutch Peach Gege geteilt Clits hi ee EE Clutch Zar Gagn deeg gen Seed enee dE General Diagnostic Table General Description CLUTCH SYSTEM 1 General Description A SPECIFICATIONS Model 1 6L 2 0 L NON TURBO 2 0L TURBO 2 5L Type Push type Pull type Push type Diaphragm set load kgf Ib 450 992 800 1 764 550 1 213 Facing material Woven Non asbestos 230 x 150 x 3 5 228 6 x 155 x 6 6 Clutch disc O D x I D x thickness mm in 225 x 150 x 3 5 8 86 x 5 91 x 0 138 9 06 x 5 91 x 9 00 x 6 10 x 0 138 0 260 Spline O D mm in 25 2 0 992 No of teeth 24 Clutch release lever ratio 1 6 1 7 1 6 Release bearing Grease packed self aligning Full stroke mm in 130 135 5 12 5 31 SINGH padal Free play mn in 10e 0 39 0 79 24 26 Release 0 94 1 02 lever Play at release lever 3 4 center mm in 0 12 0 16 Clutch cover 4 11 0 16 0 43 Stroke mm in 13 3 14 7 0 524 0 579 Flywheel side 1 35 1 95 0 053 0 077 Standard 1 3 1 9 0 051 0 075 Clutch cover side 1 65 2 25 0 065 0 089 0 3 0 012 1 3 1 9 Depth of rivet head 0 051 0 075 Chuichdise ES Limit of sinking 0 8 0 031 at R 107 4 21 1 0 0 039 at Limit for deflection mm in R 110 4 33 0 8 0 031 at R 110 4 33 Model 2 0 L TURBO STi Type Pull type Di
25. amaged rusty or malfunctioning 1 Check for smooth operation of the cable 2 Check the inner cable for damage and rust 3 Check the outer cable for damage bends and cracks 4 Check the boot for damage cracks and deterio ration CL 48 Clutch Switch CLUTCH SYSTEM 12 Clutch Switch Terminals Specified resistance When clutch pedal depressed A REMOVAL 1 2 Less than 1 92 1 Disconnect the ground cable from battery 2 Disconnect the connector from clutch switch i When clutch pedal not depressed 3 Remove the clutch switch 1 2 More than 1 MQ B INSTALLATION Clutch switch 1 Move the clevis pin of the push rod right and left ps and hold where it moves smoothly then measure stroke of clutch pedal Terminals Specified resistance Specified clutch pedal full stroke A PIRE 130 135 mm 5 12 5 31 in Tightening torque T 8 N m 0 8 kgf m 5 8 ft Ib CL 00084 Ka CL 00225 2 If the clutch pedal stroke is out of specification adjust the stroke lt Ref to CL 45 ADJUSTMENT Clutch Pedal gt 3 Connect clutch switch connector C INSPECTION 1 If the clutch switch does not operate properly or if it does not stop at the specified position replace with a new one Specified position L 2157 mm 0 079 9 959 in L kg He CL 00231 2 Check the clutch switch c
26. aphragm set load kgf Ib 930 2 050 Facing material Woven Non asbestos Flywheel side 240 x 160 x 3 2 9 45 x 6 30 x 0 126 Clutch cover side 240 x 160 x 3 5 9 45 x 6 30 x 0 138 Spline O D mm in 25 2 0 992 No of teeth 24 Clutch release lever ratio 1 7 Release bearing Grease packed self aligning Full stroke mm in 130 135 5 12 5 31 Free play mm in 3 13 0 12 0 51 mm in Clutch cover Clutch disc O D x I D x thickness mm in Clutch pedal Stroke in 13 3 14 7 0 524 0 579 Play at release lever center Release lever mm in Standard Flywheel side 1 35 1 95 0 053 0 077 Depth of rivet head Clutch cover side 1 65 2 25 0 065 0 089 Clutch disc mm in Limit of sinking Limit for deflection mm in 0 8 0 031 at R 110 4 33 I D Inner diameter O D Outer diameter 0 3 0 012 CL 2 General Description CLUTCH SYSTEM B COMPONENT 1 CLUTCH ASSEMBLY e 1 6 L SOHC MODEL CL 00299 1 Dust cover 7 Clip Tightening torque N m kgf m ft lb __ 2 Clutch cable bracket 8 Clutch release bearing T 16 1 6 11 8 3 Retainer spring 9 Clutch cover 4 Pivot 10 Clutch disk 5 Clutch release lever 11 Flywheel 6 Return spring 12 Clutch return spring bracket CL 3 General Description CLUTCH SYSTEM e 2 0 L SOHC MODEL
27. ce engine rear oil seal and other points for oil ST leakage S e 2 5 L MODEL LL A Wi ES e Except for 2 5 L MODEL CL 00117 A Clutch facing CL 00016 5 Worn spline loose rivets and torsion spring fail ure Replace defective parts CL 22 Clutch Disc and Cover CLUTCH SYSTEM e 2 5 L MODEL e Except for 2 5 L MODEL CL 00018 A Thrust rivet B Diaphragm spring CL 00017 A Spline B Rivet C Torsion spring 2 CLUTCH COVER NOTE Visually check for the following items without disas sembling and replace or repair if defective 1 Loose thrust rivet 2 Damaged or worn bearing contact area at center of diaphragm spring e 2 5 L MODEL CL 00120 CL 23 Flywheel CLUTCH SYSTEM 3 Flywheel A REMOVAL 1 2 5 L MODEL 1 Remove the transmission assembly lt Ref to 5MT 38 REMOVAL Manual Transmission As sembly gt 2 Remove the clutch cover and clutch disc lt Ref to CL 20 REMOVAL Clutch Disc and Cover gt 3 Remove the flywheel using ST1 and ST2 ST1 498497100 CRANKSHAFT STOPPER ST2 499057000 TORX PLUS CL 00121 A Flywheel 2 EXCEPT FOR 2 5 L MODEL 1 Remove the transmission assembly lt Ref to 5MT 38 REMOVAL Manual Transmission As sembly gt 2 Remove the clutch cover and clutch disc lt Ref to CL 20 REMOVAL Clutch Disc and
28. ing torque T 8 N m 0 8 kgf m 5 8 ft lb CL 00067 6 Remove the operating cylinder NOTE Do not remove the clutch hose Fw S 7 Fix the piston with clamp to avoid the piston from jumping out CL 00069 8 Fit one end of a vinyl tube into the air bleeder of operating cylinder and put the other end into a brake fluid container 9 Slowly depress the clutch pedal and keep it de pressed Then open the air bleeder to discharge air together with the fluid Release the air bleeder for 1 or 2 seconds Next with the bleeder closed slowly release the clutch pedal CLUTCH SYSTEM NOTE Set the air breather screw part higher than tip of op erating cylinder when performing this procedure CL 00070 A Operating cylinder B Vinyl tube 10 Repeat these steps until there are no more air bubbles in the vinyl tube CAUTION Cover the bleeder with waste cloth when loos ening it to prevent brake fluid from being splashed over surrounding parts 11 Tighten the air bleeder Tightening torque 8 N m 0 8 kgf m 5 8 ft lb 12 Install the operating cylinder Tightening torque 37 N m 3 8 kgf m 27 5 ft lb Ey w XX Ga 13 After depressing the clutch pedal make sure that there are no leaks evident in the entire system 14 After bleeding air from the system ensure that clutch operates
29. l Check the pipes and hoses for cracks breakage or damage Check the joints for fluid leakage If any 2 RHD DOHC TURBO MODEL cracks breakage damage or leakage is found re Install in the reverse order of removal pair or replace the applicable pipe or hose NOTE Bleed the clutch fluid lt Ref to CL 38 Clutch Fluid Air Bleeding gt CL 36 Clutch Fluid CLUTCH SYSTEM 8 Clutch Fluid A INSPECTION 1 Park the vehicle on a level surface 2 Inspect the fluid level using scale on the outside of the reservoir tank If the level is below MIN add fluid to bring it up to MAX and also inspect for leakage A Max level B Min level C Reservoir tank B REPLACEMENT CAUTION e The FMVSS No 116 fresh DOT3 or 4 brake fluid must be used e Cover the bleeder with waste cloth when loosening it to prevent brake fluid from being splashed over surrounding parts e Avoid mixing different brands of brake fluid to prevent degrading the quality of the fluid e Be careful not to allow dirt or dust to get into the reservoir tank NOTE e During bleeding operation keep the clutch reser voir tank filled with brake fluid to eliminate entry of air e Clutch pedal operating must be very slow e For convenience and safety it is advisable to have two men working es The amount of brake fluid required is approx 70 m Q 2 4 US fl oz 2 5 Imp fl oz for total clutch sys tem 1 Remove
30. lutch hose 11 Clutch pipe T3 15 1 5 10 8 4 Bracket 12 Bracket T4 18 1 8 13 0 5 Clip 13 Operating cylinder STi model T5 25 2 5 18 1 6 Master cylinder ASSY T6 37 3 8 27 5 7 Clevis pin T7 41 4 2 30 2 CL 10 General Description CLUTCH SYSTEM 3 MASTER CYLINDER e SOHC MODEL CL 00005 1 Reservoir cap 7 Gasket Tightening torque N m kgf m ft lb 2 Reservoir tank 8 Return spring T1 10 1 0 7 3 Oil seal 9 Piston T2 46 6 4 75 34 4 4 Straight pin 10 Push rod 5 Master cylinder 11 Piston stop ring 6 Clutch damper 12 Cylinder boot CL 11 General Description CLUTCH SYSTEM LHD DOHC TURBO MODEL CL 00109 1 Reservoir cap 7 Gasket Tightening torque N m kgf m ft lb 2 Reservoir tank 8 Return spring T1 10 1 0 7 3 Oil seal 9 Piston T2 46 6 4 75 34 4 4 Straight pin 10 Push rod 5 Master cylinder 11 Piston stop ring 6 Clutch damper 12 Cylinder boot CL 12 General Description CLUTCH SYSTEM RHD DOHC TURBO MODEL CL 00303 1 Reservoir cap 8 Oil seal 15 Bleeder screw 2 Reservoir tank 9 Master cylinder 3 Washer 10 Return spring Tightening torque N m kgf m ft lb 4 Straight pin 11 Piston T1 8 0 8 5 8 5 Clip 12 Push rod T2 10 1 0 7 6 Hose 13 Piston stop ring T3 1
31. ng and bushing 1 LHD MODEL 1 Attach the stopper etc to pedal bracket tempo rarily 2 Clean inside of bores of clutch pedal and brake pedal apply grease and set bushings into bores 3 Align bores of pedal bracket clutch pedal and brake pedal attach the brake pedal return spring assist rods spring and bushing Except for 1 6 L model NOTE Clean up inside of bushings and apply grease be fore installing the spacer 4 Align the bores of pedal bracket clutch pedal and brake pedal then attach the brake pedal bushings spring and clutch cable 1 6 L model 2 Remove the clutch pedal 5 Install the hill holder cable to clutch pedal Mod el with hill holder 2 RHD MODEL 1 Clean and apply grease to the hole of sliding portion between clutch pedal and bushing 2 Install the pad stopper spacer and bushings to clutch pedal NOTE Clean up inside of bushings and apply grease be fore installing the spacer 3 Install the rod S spring S bushing S O ring clip bushing clutch switch and bushing C to clutch pedal bracket Except for 1 6 L model 4 Install the pedal assembly stopper adjust rod clutch cable bushings and spring to clutch pedal bracket CL 00221 A Bushing B Spring CL 00222 CL 44 Clutch Pedal CLUTCH SYSTEM 5 Install the clutch pedal to pedal bracket Tightening torque T 29 N m 3 0 kgf m 21 7 ft lb CL 00224 6 I
32. nstall the assist rod bushing and assist spring to clutch pedal and pedal bracket 7 Install the PHV cable to clutch pedal Model with hill holder E INSPECTION 1 CLUTCH PEDAL Move the clutch pedal pads in the lateral direction with a force of approximately 10 N 1 kgf 2 Ib to ensure pedal play is in specified range CAUTION If excessive movement is noted replace the bushings with new ones Play of clutch pedal Service limit 5 0 mm 0 197 in or less CL 00098 A Clutch pedal B Brake pedal F ADJUSTMENT 1 CLUTCH PEDAL e Except for 1 6 L MODEL 1 Turn the lock nuts until clutch pedal full stroke length is within specifications CAUTION Do not attempt to turn the clutch switch to ad just clutch pedal full stroke length NOTE If lock nuts cannot adjust the clutch pedal full stroke length to specifications turn the master cylinder push rod to adjust it Specified clutch pedal full stroke A 130 135 mm 5 12 5 31 in Tightening torque Clutch switch lock nut T 8 N m 0 8 kgf m 5 8 ft lb CL 00225 2 Turn the master cylinder push rod so that clevis pin moves to the left and then to the right Clevis pin must move without resistance while it is rattling Tightening torque Push rod lock nut T 10 N m 1 0 kgf m 7 ft lb CL 00226 A Clevis pin B Snap pin C Push rod
33. nt Be careful not to burn your hands because each part on the vehicle is hot after running e Use Subaru genuine fluid grease etc or the equivalent Do not mix fluid grease etc with that of another grade or from other manufacturers D PREPARATION TOOL 1 SPECIAL TOOLS ILLUSTRATION TOOL NUMBER DESCRIPTION e Be sure to tighten fasteners including bolts and nuts to the specified torque e Place shop jacks or rigid racks at the specified points e Apply grease onto sliding or revolution surfaces before installation e Before installing O rings or snap rings apply suf ficient amount of fluid to avoid damage and defor mation e Before securing a part on a vise place cushion ing material such as wood blocks aluminum plate or shop cloth between the part and the vise e Keep fluid away from the vehicle body If any flu id contacts the vehicle body immediately flush the area with water REMARKS 498497100 ST 498497100 CRANKSHAFT STOPPER Used for stopping rotation of flywheel when loos ening tightening bolt etc 499747100 ST 499747100 CLUTCH DISC GUIDE Used when installing clutch disc to flywheel CL 18 ILLUSTRATION General Description TOOL NUMBER DESCRIPTION CLUTCH SYSTEM REMARKS ST 499057000 499057000 2 GENERAL PURPOSE TOOLS TOOL NAME TORX PLUS e Used for removing flywheel Dual mass fly wheel type e For 2 5 L model
34. ontinuity If continuity is not as specified replace the switch 1 Disconnect the clutch switch connector 2 Measure the resistance between 1 and 2 of switch terminal CL 49 CLUTCH SYSTEM General Diagnostic Table 13 General Diagnostic Table A INSPECTION 1 CLUTCH Symptom Possible cause Corrective 1 Clutch slippage It is hard to perceive clutch slippage in the early stage but pay attention to the following symptoms e Engine speed up when shifting e High speed driving is impossible espe cially rapid acceleration impossible and vehicle speed does not increase in pro portion to an increase in engine speed e Power falls particularly when ascend ing a slope and there is a smell of burn ing of the clutch facing e Method of testing Put the vehicle in stationary condition with parking brake fully applied Disengage the clutch and shift the transmission gear into the first Gradually allow the clutch to engage while gradually increasing the engine speed The clutch function is satisfactory if the engine stalls However the clutch is slipping if the vehicle does not start off and the engine does not stall a Clutch facing smeared by oil Replace b Worn clutch facing Replace Replace d Distorted pressure plate or flywheel Correct or replace b c Deteriorated diaphragm spring d e e Defective release bearing holder Correct or replace 2
35. op per Adjustment 4 Noisy clutch Examine whether the noise is generated when the clutch is disengaged engaged or partially engaged a Broken worn or unlubricated release bearing Replace the release bearing b Insufficient lubrication of pilot bearing Apply grease c Loose clutch disc hub Replace the clutch disc Replace the clutch disc d Loose torsion spring retainer e Deteriorated or broken torsion spring CL 50 Replace the clutch disc Symptom General Diagnostic Table Possible cause CLUTCH SYSTEM Corrective 5 Clutch grabs When starting the vehicle with the clutch partially engaged the clutch engages suddenly and the vehicle jumps instead of making a smooth start 2 CLUTCH PEDAL Trouble a Grease or oil on facing Replace the clutch disc Replace the clutch disc b Deteriorated cushioning spring c Worn or rusted spline of clutch disc or Take off rust apply grease or replace the clutch disc or main shaft d Deteriorated or broken torsion spring Replace the clutch disc main shaft Retighten or replace the mounting e Loose engine mounting f Deteriorated diaphragm spring Replace Corrective action Insufficient pedal play Adjust pedal play Clutch pedal free play insufficient Adjust pedal free play Excessively worn and damaged pedal shaf
36. orque 46 6 N m 4 75 kgf m 34 4 ft lb 2 Apply a coat of grease to the contacting surfaces of the push rod and piston before installation CLUTCH SYSTEM Grease SILICONE GREASE G40M Part No 004404003 CL 00054 3 To assemble the master cylinder reverse the sequence of disassembly procedure Tightening torque 10 N m 1 0 kgf m 7 ft lb 2 RHD DOHC TURBO MODEL 1 Apply a coat of grease to the contacting surfaces of the push rod and piston before installation Grease SILICONE GREASE G40M Part No 004404003 Ke CL 00055 2 Assemble in the reverse order of disassemble CL 33 Master Cylinder CLUTCH SYSTEM E INSPECTION If any damage deformation wear swelling rust or other faults are found on the cylinder piston push rod fluid reservoir return spring gasket clutch damper cylinder boot and hose replace the faulty part CL 00056 Master cylinder body Return spring Piston D Stop ring Rod ASSY Clutch damper Cylinder boot CL 34 Clutch Pipe and Hose 7 Clutch Pipe and Hose A REMOVAL 1 EXCEPT FOR RHD DOHC TURBO MOD EL 1 Remove the air cleaner case and air intake duct 2 Drain the clutch fluid lt Ref to CL 37 Clutch Flu id gt 3 Remove the clutch pipe from the clutch hose and master cylinder 4 Pull out the clamp then remove the clutch hose from bracket
37. ove the snap pin clevis pin and separate the push rod of master cylinder from clutch pedal CL 00042 A Clevis pin B Snap pin C Push rod D Lock nut 3 Remove the air cleaner case and air intake duct Non turbo model lt Ref to IN H4SO 5 REMOV AL Air Cleaner Case gt and Pei to IN H4SO 6 REMOVAL Air Intake Duct gt 4 Remove the intercooler Turbo model lt Ref to IN H4DOTC 10 REMOVAL Intercooler gt 5 Remove the clutch pipe from master cylinder 6 Remove the master cylinder with reservoir tank CAUTION Be extremely careful not to spill brake fluid Brake fluid spilt on the vehicle body will harm the paint surface wipe it off quickly if spilt CLUTCH SYSTEM B INSTALLATION 1 Install the master cylinder to body and install the clutch pipe to master cylinder NOTE Check that the pipe is routed properly Tightening torque T1 15 N m 1 5 kgf m 10 8 ft lb T2 18 N m 1 8 kgf m 13 0 ft lb CL 00213 2 Connect the push rod of master cylinder to clutch pedal and install the clevis pin and snap pin NOTE Apply grease to the clevis pin CL 00045 A Clevis pin B Snap pin C Push rod 3 After bleeding air from the system ensure that clutch operates properly lt Ref to CL 38 Clutch Fluid Air Bleeding gt 4 Install the air cleaner case and air intake duct Non turbo model lt Ref to IN H4SO
38. steps until there are no more air bubbles in the vinyl tube CAUTION Cover the bleeder with waste cloth when loos ening it to prevent brake fluid from being splashed over surrounding parts 5 Tighten the air bleeder Tightening torque T 8 N m 0 8 kgf m 5 8 ft lb _ CL 00065 6 After depressing the clutch pedal make sure that there are no leaks evident in the entire system 7 After bleeding air from the system ensure that clutch operates properly 2 TURBO MODEL NOTE Bleed air from the oil line with help of a co worker 1 Remove the intercooler lt Ref to IN H4DOTC 10 REMOVAL Intercooler gt 2 Fit one end of a vinyl tube into the air bleeder of master cylinder and put the air bleeder of other end into a brake fluid container RHD DOHC turbo model 3 Slowly depress the clutch pedal and keep it de pressed Then open the air bleeder to discharge air together with the fluid Release the air bleeder for 1 or 2 seconds Next with the bleeder closed slowly release the clutch pedal RHD DOHC turbo model CL 00066 A Vinyl tube 4 Repeat these steps until there are no more air bubbles in the vinyl tube RHD DOHC turbo mod el CAUTION Cover the bleeder with waste cloth when loos ening to prevent brake fluid from being splashed over surrounding parts CL 38 Clutch Fluid Air Bleeding 5 Tighten the air bleeder RHD DOHC turbo mod el Tighten
39. t and or bushing 3 DIAGNOSTIC DIAGRAM OF CLUTCH DRAG Step Check Replace the bushing and or shaft with a new one Yes No CHECK GEAR NOISE 1 Start the engine 2 Disengage the clutch and shift quickly from neutral to reverse in idling condition Is there any abnormal noise from the transmission gear Go to step 2 Clutch is normal CHECK GEAR NOISE Is there any abnormal noise Disengage the clutch at idle and shift from neu from the transmission gear tral to reverse within 0 5 1 0 seconds Defective trans mission or exces sive clutch drag torque Inspect the pilot bearing clutch disc transmission and clutch disc hub spline Go to step 3 CHECK GEAR NOISE Is there any abnormal noise Defect in clutch Clutch and fly 1 Disengage the clutch at idle and shift from neutral to reverse within 0 5 1 0 seconds 2 With the clutch disengaged shift from N to R R to N several times from the transmission gear disengaging Inspect the clutch disc clutch cover clutch release and wheel seizure Inspect the clutch disc spline of clutch disc hub CL 51 clutch pedal free play General Diagnostic Table CLUTCH SYSTEM CL 52
40. the air cleaner case and air duct 2 Either jack up the vehicle and place a safety stand under it or lift up the vehicle 3 Draw out the brake fluid from reservoir tank with syringe 4 Refill the reservoir tank with recommended brake fluid Recommended brake fluid FMVSS No 116 fresh DOTS3 or 4 brake fluid 5 Drain fluid in the same method as air bleeding 6 Refill the brake fluid before reservoir tank be comes empty and drain contaminated fluid again 7 Repeat the above procedure until the contami nated fluid is completely drained CL 37 Clutch Fluid Air Bleeding CLUTCH SYSTEM 9 Clutch Fluid Air Bleeding A PROCEDURE 1 NON TURBO MODEL NOTE Bleed air from the oil line with help of a co worker 1 Remove the air cleaner case and air intake duct lt Ref to IN H4SO 5 REMOVAL Air Cleaner Case gt and lt Ref to IN H4SO 6 REMOVAL Air Intake Duct gt 2 Fit one end of a vinyl tube into the air bleeder of operating cylinder and put the other end into a brake fluid container A Clutch hose B Air bleeder 3 Slowly depress the clutch pedal and keep it de pressed Then open the air bleeder to discharge air together with the fluid Release the air bleeder for 1 or 2 seconds Next with the bleeder closed slowly release the clutch pedal KE ep RES 2OSNT EX gt Es A por WC elle eg CL 00064 A Operating cylinder B Vinyl tube 4 Repeat these
41. y lt Ref to 5MT 41 INSTALLATION Manual Transmission Assem bly gt C INSPECTION CAUTION Since this bearing is grease sealed and is of a non lubrication type do not wash with gasoline or any solvent 1 Damage of facing and ring gear If defective replace the flywheel CLUTCH SYSTEM e 2 5L MODEL CL 00124 A Flywheel B Ring gear e Except for 2 5 L MODEL CL 00022 A Flywheel B Ring gear 2 Smoothness of rotation Rotate the ball bearing applying pressure in thrust direction 3 If noise or excessive play is noted replace the flywheel CL 25 Release Bearing and Lever CLUTCH SYSTEM 4 Release Bearing and Lever A REMOVAL 1 EXCEPT FOR DOHC TURBO MODEL 1 Remove the transmission assembly from vehicle body lt Ref to 5MT 38 REMOVAL Manual Transmis sion Assembly gt 2 Remove the two clips from clutch release lever and remove the release bearing CAUTION Be careful not to deform clips 3 Remove the dust cover CL 00023 A Clutch release lever B Dust cover 4 Remove the release lever retainer spring from release lever pivot with a screwdriver by accessing it through clutch housing release lever hole Then remove the release lever CL 00024 A Clutch release lever B Screwdriver 2 DOHC TURBO MODEL 1 Remove the transmission assembly from vehicle body lt Ref to 5MT 38 REMOVAL Manual Trans
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