TROUBLESHOOTING
Contents
1. Author Date 1780 CL 2 Pedal Height Adjust Point Push Rod Play and Freeplay Adjust Point PUSH Rod Play NA i fos mm 981 ie Release Point oY A Soe Full LN U S End Position CLUTCH CLUTCH PEDAL CLUTCH PEDAL INSPECTION 1 CHECK THAT PEDAL HEIGHT IS CORRECT Pedal height from asphalt sheet 1MZ FE 161 8 171 8 mm 6 370 6 764 in 55 156 8 166 8 mm 6 173 6 567 in 2 IF NECESSARY ADJUST PEDAL HEIGHT Loosen the lock nut and turn the stopper bolt until the height is correct Tighten the lock nut 3 CHECK THAT PEDAL FREEPLAY AND PUSH ROD PLAY ARE CORRECT Push in on the pedal until the beginning of clutch resistance is felt Pedal freeplay 5 0 15 0 mm 0 197 0 591 in Gently push the pedal until the resistance begins to increase a little Push rod play at pedal top 1 0 5 0 mm 0 039 0 197 in CL035 01 4 IF NECESSARY ADJUST PEDAL FREEPLAY AND PUSH ROD PLAY a Loosen the lock nut and turn the push rod until the free play and push rod play are correct b Tighten the lock nut c After adjusting the pedal freeplay check the pedal height d Connect the air duct and install the lower finish panel 5 INSPECT CLUTCH RELEASE POINT Pull the parking brake lever and install wheel stopper Start the engine and idle the engine c Without depressing the clutch pedal slowly shift the shift l2. 39 400 29 21 210 15 15 155 11 N m kgf cm ft Ibf Specified torque CL03G 01 w Cruise Control System T Cruise Control 5 5 Battery 13 130 9 13 130 9 Clutch Accumulator Bracket Author Date 1793 CL 15 CLUTCH CLUTCH ACCUMULATOR 1MZ FE REMOVAL 1 e Sg CLO3H 01 w Cruise Control System REMOVE CRUISE CONTROL ACTUATOR Remove the battery Remove the 3 bolts and cruise control actuator with bracket Torque 13 N m 130 kgf cm 9 ft Ibf REMOVE STARTER Remove the nut and disconnect the connectors Remove the 2 bolt and clamp Torque 39 N m 400 kgf cm 29 ft Ibf REMOVE CLUTCH ACCUMULATOR WITH BRACKET Using SST disconnect the clutch lines from the clutch ac cumulator Torque 15 N m 155 kgf cm 11 ft Ibf SST 09023 00100 Remove the 2 bolts and nut Torque Bolt 21 N m 210 kgf cm 15 ft Ibf Nut 27 N m 270 kgf cm 20 ft Ibf Author Date 1794 CL 16 CLUTCH CLUTCH ACCUMULATOR 1MZ FE INSTALLATION Installation is in the reverse order of removal See page CL 15 Author Date 1795 CL 17 CLUTCH CLUTCH UNIT CLUTCH UNIT COMPONENTS CL03J 01 5S FE Release Fork Flywheel 19 195 14 39 400 29 Release Bearing and Hub Release Fork 47 480 35 Clutch Cover
3. COMPONENTS 12 120 9 Clutch Line 15 155 11 Release Cylinder Body Bleeder Plug 8 4 85 74 in Ibf m kgf cm ft Ibf Spring Push Rod Specified torque Author Date CL 9 CLO3B 01 1788 CL 10 CLUTCH CLUTCH RELEASE CYLINDER REMOVAL 1 DISCONNECT CLUTCH LINE Using SST disconnect the line Use a container to catch the fluid SST 09023 00100 Torque 15 N m 155 kgf cm 11 ft Ibf 2 REMOVE 2 BOLTS AND PULL OUT RELEASE CYL INDER Torque 12 N m 120 kgf cm 9 ft Ibf CL03C 01 Author Date 1789 CL 11 CLUTCH CLUTCH RELEASE CYLINDER DISASSEMBLY 1 REMOVE BLEEDER PLUG 2 PULL OUT BOOT WITH PUSH ROD 3 REMOVE PISTON Blow compressed air into the release cylinder and remove the piston with spring Author Date 1790 CL 12 CLUTCH CLUTCH RELEASE CYLINDER REASSEMBLY 1 2 3 CLO3E 01 COAT PISTON WITH LITHIUM SOAP BASE GLYCOL GREASE AS SHOWN INSTALL PISTON WITH SPRING INTO CYLINDER INSTALL BOOT WITH PUSH ROD TO CYLINDER INSTALL BLEEDER PLUG Torque 8 4 N m 85 kgf cm 74 in Ibf Author Date 1791 CL 13 CLUTCH CLUTCH RELEASE CYLINDER INSTALLATION Installation is in the reverse order of removal See page CL 10 HINT After installation bleed clutch system Author Date 1792 CL 14 CLUTCH CLUTCH ACCUMULATOR 1MZ FE CLUTCH ACCUMULATOR 1MZ FE COMPONENTS Starter
4. Clutch Disc N m kgf cm ft Ibf Specified torque Author Date 1796 CLUTCH CLUTCH UNIT REMOVAL 1 CLO3K 01 REMOVE TRANSAXLE FROM ENGINE See page E153 MX 4 S51 MX 4 2 REMOVE CLUTCH COVER AND DISC a Place matchmarks on the flywheel and clutch cover b Loosen each set bolt one turn at a time until spring tension is released c Remove the set bolts and pull off the clutch cover with the clutch disc NOTICE Do not drop the clutch disc REMOVE RELEASE BEARING AND FORK FROM TRANSAXLE Remove the release bearing together with the fork and then separate them Remove the boot Author Date 1797 CL 19 CLUTCH CLUTCH UNIT INSPECTION 1 INSPECT CLUTCH DISC FOR WEAR OR DAMAGE Using calipers measure the rivet head depth Minimum rivet depth 0 3 mm 0 012 in If necessary replace the clutch disc CLO3L 01 2 INSPECT CLUTCH DISC RUNOUT Using a dial indicator check the disc runout Maximum runout 0 8 mm 0 031 in If necessary replace the clutch disc 3 INSPECT FLYWHEEL RUNOUT Using a dial indicator check the flywheel runout Maximum runout 0 1 mm 0 004 in If necessary replace the flywheel 4 INSPECT DIAPHRAGM SPRING FOR WEAR Using calipers measure the diaphragm spring for depth and width of wear Maximum Depth A 0 6 mm 0 024 in Width B 5 0 mm 0 197 in If necessary replace the clutch cover Author Date 1798 CL 20 CLUTC
5. CLUTCH MASTER CYLINDER REMOVAL 1 DRAW OUT FLUID WITH SYRINGE 2 DISCONNECT CLUTCH LINE Using SST disconnect the clutch line Use a container to catch the fluid SST 09023 00100 Torque 15 N m 155 kgf cm 11 ft Ibf 3 REMOVE CLIP AND CLEVIS PIN 4 REMOVE 2 MOUNTING NUTS AND PULL OUT MAS TER CYLINDER Torque 12 N m 120 kgf cm 9 ft Ibf CL037 01 Author Date 1784 CL 6 CLUTCH CLUTCH MASTER CYLINDER DISASSEMBLY 1 REMOVE RESERVOIR TANK a Using a pin punch and hammer drive out the slotted spring pin b Remove the reservoir tank and grommet CL038 01 2 REMOVE PUSH ROD Pull back the boot and using snap ring pliers remove the snap ring 3 REMOVE PISTON Author Date 1785 7 Protrusion 1 5 3 5mm 0 059 0 138 in Q10081 CL 7 CLUTCH CLUTCH MASTER CYLINDER REASSEMBLY 1 COAT PARTS WITH LITHIUM SOAP BASE GLYCOL GREASE AS SHOWN 2 INSERT PISTON INTO CYLINDER 3 INSTALL PUSH ROD ASSEMBLY WITH SNAP RING CL039 01 INSTALL RESERVOIR TANK Install the reservoir tank and a new grommet Using a pin punch and hammer drive in the slotted spring pin Ss Author Date 1786 CL 8 CLUTCH CLUTCH MASTER CYLINDER CLO3A 01 INSTALLATION Installation is in the reverse order of removal See page CL 5 HINT After installation bleed system and adjust clutch pedal See page CL 2 Author Date 1787 CLUTCH CLUTCH RELEASE CYLINDER CLUTCH RELEASE CYLINDER
6. CLUTCH TROUBLESHOOTING PROBLEM SYMPTOMS TABLE CL 1 TROUBLESHOOTING CL034 01 Use the table below to help you find the cause of the problem The numbers indicate the priority of the likely cause of the problem Check each part in order If necessary replace these parts Clutch grabs chatters Clutch pedal spongy Clutch noisy Clutch slips Clutch does not disengage 1 Engine mounting Loosen 2 Clutch disc Runout is excessive 3 Clutch disc Cily 4 Clutch disc Worn out 5 Clutch disc torsion rubber Damaged 6 Clutch disc Glazed 7 Diaphragm spring Out of tip alignment 1 Clutch line Air in line 2 Master cylinder cup Damaged 3 Release cylinder cup Damaged CL 4 GL 8 CL 19 CL 17 1 Release bearing Worn dirty or damaged 2 Clutch disc torsion rubber Damaged 1 Clutch pedal Freeplay out of adjustment 2 Clutch disc Oily 3 Clutch disc Worn out 4 Diaphragm spring Damaged 5 Pressure plate Distortion 6 Flywheel Distortion 1 Clutch pedal Freeplay out of adjustment 2 Clutch line Air in line 3 Master cylinder cup Damaged 4 Release cylinder cup Damaged 5 Clutch disc out of true 6 Clutch disc Runout is excessive 7 Clutch disc Lining broken 8 Clutch disc Dirty or burned 9 Clutch disc Cily 10 Clutch disc Lack of spline grease 11 Diaphragm spring Damaged 12 Diaphragm spring Out of tip alignment 13 Pressure plate Distortion
7. H CLUTCH UNIT 5 INSPECT RELEASE BEARING Turn the bearing by hand while applying force in the axial direc tion HINT The bearing is permanently lubricated and requires no cleaning or lubrication If necessary replace the bearing Author Date 1799 Flywheel Side Matchmarks RA CL 21 CLUTCH CLUTCHUNIT CLO3M 02 INSTALLATION 1 INSTALL CLUTCH DISC AND CLUTCH COVER FLYWHEEL 1 2 Insert SST in the clutch disc and then set them SST 09301 00220 b 55 Insert SST in the clutch disc and then set them SST 09301 00210 c Align the matchmarks on the clutch cover and flywheel d Torque the bolts on the clutch cover in the order shown Torque 19 N m 195 kgf cm 14 ft Ibf HINT Temporarily tighten the No 3 bolt 2 CHECK DIAPHRAGM SPRING TIP ALIGNMENT Using a dial indicator with roller instrument check the dia phragm spring tip alignment Maximum non alignment 0 5 mm 0 020 in If alignment is not as specified using SST adjust the dia phragm spring tip alignment SST 09333 00013 Author Date 1800 CL 22 1MZ FE Engine CLUTCH CLUTCH UNIT 3 APPLY MOLYBDENUM DISULPHIDE LITHIUM BASE GREASE NLGI NO 2 a Apply release hub grease to these parts Release fork and hub contact point Release fork and push rod contact point Release fork pivot point b Apply clutch spline grease Clutch disc spline HINT Recommended greas
8. e part number 08887 01706 100 g 4 INSTALL RELEASE BEARING AND FORK TO TRANS AXLE Install the bearing to the release fork and then install them to the transaxle 5 INSTALL TRANSAXLE TO ENGINE See page E153 MX 9 S51 MX 8 Author Date 1801
9. ever into reverse position until the gears contact d Gradually depress the clutch pedal and measure the stroke distance from the point the gear noise stops re lease point up to the full stroke end position Standard distance 25 mm 0 98 in or more From pedal stroke end position to release point If the distance not as specified do the following operation Inspect pedal height Inspect push rod play and pedal freeplay Bleed the clutch line Inspect the clutch cover and disc D o 9 9 Author Date 1781 CL 3 CLUTCH CLUTCH PEDAL 6 CHECK CLUTCH START SYSTEM a Check that the engine does not start when the clutch ped al is released b Check that the engine starts when the clutch pedal is fully depressed If necessary replace the clutch start switch 7 INSPECT CONTINUITY OF CLUTCH START SWITCH Check the continuity between terminals when the switch is ON and OFF ON pushed OFF free No continuity Author Date 1782 CL 4 CLUTCH CLUTCH MASTER CYLINDER CLUTCH MASTER CYLINDER COMPONENTS omen Filler Cap Float Boot Clevis Pin Slotted Spring Pin Washer T Body p Piston ore Grommet __ Lock Nut Clutch Line 15 155 11 prs Snap Ring Push Rod JL 3 Spring 12 120 9 Non reusable part N m kgf cm ft lbf Specified torque Author Date 1783 CL 5 CLUTCH
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