TRANSMISSION/TRANSAXLE

SECTION CL CLUTCH
B

CL

E
CONTENTS
SERVICE INFORMATION ............................ 2 MODELS WITH YD ENGINE : Removal and In- F
stallation ..................................................................13
PRECAUTIONS ................................................... 2 MODELS WITH YD ENGINE : Disassembly and
Service Notice or Precaution ..................................... 2 Assembly .................................................................13 G
PREPARATION ................................................... 3 MODELS WITH VQ ENGINE .....................................14
Special Service Tool ................................................. 3 MODELS WITH VQ ENGINE : Component .............14
Commercial Service Tool .......................................... 3 MODELS WITH VQ ENGINE : Removal and In- H
stallation ..................................................................14
NOISE, VIBRATION AND HARSHNESS MODELS WITH VQ ENGINE : Disassembly and
(NVH) TROUBLESHOOTING ............................. 5 Assembly .................................................................14 I
NVH Troubleshooting Chart ...................................... 5
CLUTCH PIPING ............................................... 16
CLUTCH PEDAL ................................................. 6 Removal and Installation .........................................16
On Board Inspection ................................................. 6 J
Removal and Installation ........................................... 7 CLUTCH RELEASE MECHANISM ................... 17
Removal and Installation .........................................17
CLUTCH FLUID ................................................... 9
K
Air Bleeding Procedure ............................................. 9 CLUTCH DISC, CLUTCH COVER AND FLY-
WHEEL .............................................................. 20
CLUTCH MASTER CYLINDER ..........................10 Removal and Installation .........................................20
Component .............................................................. 10 L
Removal and Installation ......................................... 10 SERVICE DATA AND SPECIFICATIONS
Disassembly and Assembly .................................... 11 (SDS) ................................................................. 23
Clutch Control System .............................................23 M
OPERATING CYLINDER ...................................13 Clutch Master Cylinder ............................................23
MODELS WITH YD ENGINE ..................................... 13 Clutch Operating Cylinder .......................................23
MODELS WITH YD ENGINE : Component ............ 13 Clutch Disc ..............................................................23
N
Clutch Cover ............................................................23

CL-1
 PRECAUTIONS
< SERVICE INFORMATION >
SERVICE INFORMATION
PRECAUTIONS
Service Notice or Precaution INFOID:0000000005447936

• Recommended clutch fluid is brake fluid “DOT 3”. Refer to MA-25, "Fluids and Lubricants".
• Do not reuse drained clutch fluid.
• Be careful not to splash clutch fluid on painted areas.
• Use a flare nut wrench, when removing and installing clutch piping.
• Use new clutch fluid to clean or wash all parts of master cylinder
and operating cylinder.
• Do not use mineral oils such as gasoline or kerosene. It will cor-
rode the rubber parts of the hydraulic system.
WARNING:
After cleaning clutch disc, clean it with a dust collector. Do not
use compressed air.

SBR820BA

CL-2
 PREPARATION
< SERVICE INFORMATION >
PREPARATION
A
Special Service Tool INFOID:0000000005447937

B
Tool number
Description
Tool name
KV30101400 Installing release bearing
CL
Drift
a: 51 mm (2.01 in) dia.
b: 44 mm (1.73 in) dia.
D

ZZA0838D
E
ST20050240 Adjusting unevenness of diaphragm spring of
Diaphragm adjusting wrench clutch cover

G
ZZA0508D

KV30100100 Installing clutch disc

Clutch aligning bar H
a: 15.7 mm (0.618 in) dia.
b: 22.8 mm (0.898 in) dia.

ZZA1178D

J
Commercial Service Tool INFOID:0000000005447938

K
Tool name Description
Pin punch Removing and installing master cylinder
Tip diameter: 4.5 mm (0.177 in) dia. spring pin
L

ZZA0515D

CL-3
 PREPARATION
< SERVICE INFORMATION >
Tool name Description
GG94310000 Removing and installing clutch piping
Flare nut torque wrench
a: 10 mm (0.39 in)

S-NT406

Puller Removing release bearing

NT077

CL-4
 Symptom
Reference page

Clutch slips
Clutch noisy
Clutch pedal spongy
< SERVICE INFORMATION >

Clutch grabs/chatters
SUSPECTED PARTS (Possible cause)
NVH Troubleshooting Chart

Clutch does not disengage

CLUTCH PEDAL (Inspection and adjustment) CL-6

1
1
CLUTCH LINE (Air in line) CL-9

2
tion. If necessary, repair or replace these parts.

MASTER CYLINDER PISTON CUP (Damaged) CL-10

3
OPERATING CYLINDER PISTON CUP (Damaged) CL-14

4
ENGINE MOUNTING (Loose) EM-100 (VQ engine models), EM-244 (YD engine models)

CL-5
RELEASE BEARING (Worn, dirty or damaged) CL-17

1
CLUTCH DISC (Out of true)

5
CLUTCH DISC (Runout is excessive)

5
CLUTCH DISC (Lining broken)

5
CLUTCH DISC (Dirty or burned)

5
CLUTCH DISC (Oily)

2
2

5
CLUTCH DISC (Worn out) CL-20

2
2
CLUTCH DISC (Hardened)

2
CLUTCH DISC (Lack of spline grease)

5
DIAPHRAGM SPRING (Damaged)

3
6
DIAPHRAGM SPRING (Out of tip alignment)

6
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

PRESSURE PLATE (Distortion)

4
7
FLYWHEEL (Distortion) EM-119 (VQ engine models), EM-256 (YD engine models)

5
INFOID:0000000005447939

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

L
F

P
K
E
B
A

N
CL

H
D

O
G

M
 CLUTCH PEDAL
< SERVICE INFORMATION >
CLUTCH PEDAL
On Board Inspection INFOID:0000000005447940

HEIGHT INSPECTION
1. Make sure clutch pedal height H1 from upper surface of the dash
panel is within the specified range.

Pedal height H1
: 199 - 209 mm (7.83 - 8.23 in) (LHD)
: 190 - 199 mm (7.48 - 7.83 in) (RHD)

SCIA1256E

PLAY INSPECTION
• Press the clutch pedal by hand until certain resistance can be felt.
Using a scale, make sure the free play is within the specified
range.

Pedal free play

: 1-3 mm (0.04-0.12 in)

MAA0023D

CLEARANCE CHECK
1. Start the engine and let it idle.
2. Apply parking brake.
3. Depress the brake pedal.
4. Fully depress clutch pedal and shift to 1st gear.
5. Release clutch pedal gradually. Using a scale, check the clear-
ance between the clutch pedal and floor panel to see if it is
within the specified range.

Pedal height when the clutch disengages

: 117-130 mm (4.60-5.12 in) (LHD) MAA0024D

: 107-121 mm (4.21-4.76 in) (RHD)

NOTE:
Pedal height at clutch disengagement varies slightly from the clutch engagement point. Despite this, pedal
height at clutch engagement is commonly used for both cases in order to simplify the inspection.

CL-6
 CLUTCH PEDAL
< SERVICE INFORMATION >
Removal and Installation INFOID:0000000006059775

A
COMPONENTS
LHD models B

CL

G
E1DIA0059GB

1. Clutch pedal assembly 2. Clevis pin 3. Bushing

4. Stopper rubber 5. Pedal stopper bolt (Without ASCD) 6. ASCD clutch switch (With ASCD) H
7. Pedal pad 8. Stopper rubber 9. Snap pin
10. Bushing 11. Assist spring 12. I-key switch (if equipped)
I
: Apply lithium-based grease including molybdenum disulphide.
Refer to GI-9, "Component", for symbols not described on the above.

RHD models J

O
E1DIA0060GB

1. Clutch pedal assembly 2. Assist spring 3. Bushing

4. Clevis pin 5. Bushing 6. Stopper rubber
P
7. Pedal pad 8. Pedal stopper bolt (Without ASCD) 9. ASCD clutch switch (With ASCD)
10. Snap pin 11. I-key switch (if equipped)
: Apply lithium-based grease including molybdenum disulphide.
Refer to GI-9, "Component", for symbols not described on the above.

REMOVAL

CL-7
 CLUTCH PEDAL
< SERVICE INFORMATION >
1. Disconnect ASCD clutch switch harness connectors (if equipped). Disconnect I-key clutch switch harness
connector (if equipped).
2. Remove snap pin and clevis pin from clevis of clutch master cylinder.
3. Remove clutch pedal assembly mounting nuts and bolt, and then remove clutch pedal assembly from the
vehicle.
INSPECTION AFTER REMOVAL
• Check clutch pedal for bend, damage, or a cracked weld. If bend, damage, or a cracked weld is found,
replace clutch pedal.
• Check assist spring for settling. If settling is found, replace assist spring.
INSTALLATION
Installation is the reverse order of removal.
NOTE:
• Tighten pedal stopper bolt lock nut or ASCD clutch switch lock nut to the specified torque after installing
clutch pedal assembly in vehicle and adjusting the pedal free play.

Tightening torque: 13.3 N

I-key switch is push and twist type (if equipped). Install I-key switch
after pedal stopper lock nut or ASCD switch lock nut. After installa-
tion, clearance A between I-key switch (1) and pedal lever (2)
should be within the specified range.

Clearance A: 0.74 - 1.96 mm (0.03 - 0.08 in)

E1DIA0063ZZ

CL-8
 CLUTCH FLUID
< SERVICE INFORMATION >
CLUTCH FLUID
A
Air Bleeding Procedure INFOID:0000000005447942

NOTE: B
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.
CAUTION:
• Monitor clutch fluid level in reservoir tank to make sure it CL
does not empty.
• Keep painted surface on the body or other parts free of clutch
fluid. If it spills, wipe up immediately and wash the affected D
area with water.
• Bleed air for operating cylinder.
1. Fill reservoir tank with new clutch fluid. E
2. Connect a transparent vinyl hose to air bleeder valve.
3. Depress clutch pedal slowly and fully several times at an interval
of 2 to 3 seconds and hold it. F
PCIB1390E
4. With clutch pedal depressed, open air bleeder valve to release
air.
5. Close air bleeder valve. G
6. Release clutch pedal and wait for 5 seconds.
7. Repeat steps 3 to 6 until no bubbles can be observed in clutch fluid.
8. Tighten air bleeder valve to the specified torque. Refer to CL-14, "MODELS WITH VQ ENGINE : Compo- H
nent".

CL-9
 CLUTCH MASTER CYLINDER
< SERVICE INFORMATION >
CLUTCH MASTER CYLINDER
Component INFOID:0000000005447943

PCIB1388E

1. Nipple 2. Clamp 3. Hose

4. Cylinder body 5. Dust cover 6. Clevis
7. Clevis pin 8. Snap pin 9. Stopper ring
10. Stopper 11. Push rod 12. Piston assembly
13. Return spring 14. Seal 15. Spring pin

Removal and Installation INFOID:0000000005447944

REMOVAL
1. Using one of the following methods, remove hose from nipple.
• Drain clutch fluid from reservoir tank and then remove hose.
• Remove hose from nipple. Immediately plug hose and reservoir tank to prevent clutch fluid from drip-
ping.
CAUTION:
Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.
2. Remove clutch tube using a flare nut wrench.
3. Remove snap pin and clevis pin on clevis in passenger compartment to separate clutch pedal.
4. Remove master cylinder assembly mounting nuts, and then remove master cylinder assembly from the
vehicle.
INSTALLATION
1. Check position of clevis and push rod. If measurement is outside
the standard length, adjust position of clevis and push rod.

Length “L”
Models with VQ engine : 120.5 mm (4.74 in)
Except models with VQ : 121.0 mm (4.76 in)
engine
2. Connect clutch tube to master cylinder assembly and tempo-
rarily tighten flare nut.
SCIA5158E
3. Install master cylinder assembly and tighten mounting nuts to
the specified torque.

CL-10
 CLUTCH MASTER CYLINDER
< SERVICE INFORMATION >
4. Tighten clutch tube flare nut to the specified torque using a flare nut torque wrench. Refer to CL-16,
"Removal and Installation". A
5. Set clevis to clutch pedal and insert clevis pin.
CAUTION:
Apply recommended grease to clevis pin. B
6. Attach snap pin to clevis pin.
7. Install hose to nipple.
8. After completing this procedure, inspect and adjust for clutch pedal and then bleed the air from the clutch CL
hydraulic system. Refer to CL-6, "On Board Inspection" and CL-9, "Air Bleeding Procedure".
Disassembly and Assembly INFOID:0000000005447945
D
DISASSEMBLY
1. Remove spring pin using a pin punch.
E
2. Remove nipple and seal from cylinder body.
3. Loosen push rod lock nut then remove clevis and lock nut, if
necessary.
F
NOTE:
Clutch pedal height is controlled with position of clevis and push
rod.
4. Remove dust cover from cylinder body. G
5. Remove stopper ring and stopper. Remove push rod from cylin-
der body while holding it securely to prevent piston assembly PCIB0274E
popping out. H
CAUTION:
Restrain the push rod while doing this because there is a danger the piston assembly will fly out
of the cylinder body. I
6. Remove piston assembly and return spring.
INSPECTION AFTER DISASSEMBLY
Check for any of the conditions shown below. If any malfunction is found, replace the part concerned. J
• Damaged cylinder internal wall, foreign matter, wear, corrosion, or pinhole
• Damaged or deformed nipple or reservoir tank
• Settling of return spring K
• Cracked or deformed dust cover
ASSEMBLY
1. Apply rubber lubricant to the internal surface of cylinder body, the sliding surface of piston assembly, and L
piston cup of piston assembly.
2. Insert return spring and piston assembly to cylinder body.
3. Apply silicone grease to push rod and then install stopper. M
4. Install stopper ring while holding down push rod by hand to prevent piston assembly from popping out.
CAUTION:
Do not reuse stopper ring. N
5. Install dust cover to cylinder body.
6. Install seal and nipple to cylinder body.
CAUTION: O
Do not reuse seal.
7. Install spring pin using a pin punch.
8. Install clevis to push rod. P

CL-11
 CLUTCH MASTER CYLINDER
< SERVICE INFORMATION >
9. Check and adjust the positions of clevis and push rod. After
adjusting “L”, tighten lock nut to the specified torque. Refer to
CL-10, "Component".

Length “L”
Models with VQ engine : 120.5 mm (4.74 in)
Except models with VQ : 121.0 mm (4.76 in)
engine

SCIA5158E

CL-12
 OPERATING CYLINDER
< SERVICE INFORMATION >
OPERATING CYLINDER
A
MODELS WITH YD ENGINE
MODELS WITH YD ENGINE : Component INFOID:0000000006108603
B

CL

PCIB0863E

H
1. Air bleeder 2. Clutch hose 3. Union bolt
4. Copper washer 5. Cylinder body 6. Dust cover
7. Push rod 8. Piston 9. Piston cup
I
10. Piston spring

MODELS WITH YD ENGINE : Removal and Installation INFOID:0000000006108604

J
REMOVAL
1. Drain clutch fluid.
CAUTION: K
Do not spill clutch fluid onto painted surfaces. If it spills, wipe up immediately and wash the
affected area with water.
2. Remove clutch hose from operating cylinder. L
3. Remove operating cylinder mounting bolt and then remove operating cylinder from vehicle.
INSTALLATION M
To install, reverse the removal procedure, following the cautions below:
• Install hose with care so that it will not be bent or twisted.
• After completing the procedure, bleed clutch tube. Refer to CL-9, "Air Bleeding Procedure".
N
MODELS WITH YD ENGINE : Disassembly and Assembly INFOID:0000000006108605

DISASSEMBLY O
• Remove dust cover and push rod. Remove piston assembly and piston spring from inside cylinder body.
INSPECTION AFTER DISASSEMBLY
Check for any of the conditions shown below. If any malfunction is found, replace the part concerned. P
• Damage to cylinder inner surface or piston sliding surface. Foreign matter, wear, corrosion, or pin hole
• Settling of the spring
• Cracked or deformed dust cover
ASSEMBLY
1. Apply rubber lubricant to cylinder body inner surface and rubber grease to piston cup and piston. Insert
piston assembly and piston spring into cylinder body.

CL-13
 OPERATING CYLINDER
< SERVICE INFORMATION >
2. Apply rubber grease to dust cover and install push rod and dust cover.
MODELS WITH VQ ENGINE
MODELS WITH VQ ENGINE : Component INFOID:0000000005447946

PCIB1602E

1. Air bleeder valve 2. Copper washer 3. Clutch hose

4. Cylinder body 5. Dust cover 6. Push rod
7. Piston assembly 8. Piston cup 9. Piston spring

MODELS WITH VQ ENGINE : Removal and Installation INFOID:0000000005447947

REMOVAL
1. Drain clutch fluid.
CAUTION:
Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.
2. Remove clutch hose from operating cylinder assembly.
3. Remove operating cylinder assembly mounting bolts, and then remove operating cylinder assembly from
the vehicle.
INSTALLATION
Note the following, and install in the reverse order of removal.
• Install clutch hose with care so that it will not be bent or twisted.
• Tighten clutch hose to the specified torque.
CAUTION:
Do not reuse copper washer.
• After completing the procedure, bleed the air from the clutch hydraulic system. Refer to CL-9, "Air Bleeding
Procedure".
MODELS WITH VQ ENGINE : Disassembly and Assembly INFOID:0000000005447948

DISASSEMBLY
• Remove dust cover and push rod. Then remove piston, piston cup and piston spring from cylinder body.
INSPECTION AFTER DISASSEMBLY
Check for any of the conditions shown below. If any malfunction is found, replace the part concerned.
• Damage to cylinder internal surface or piston sliding surface. Foreign matter, wear, corrosion, or pinhole
• Settling of piston spring
• Cracked or deformed dust cover

CL-14
 OPERATING CYLINDER
< SERVICE INFORMATION >
ASSEMBLY
1. Apply rubber lubricant to cylinder body internal surface and rubber grease to piston cup and piston. Insert A
piston assembly and piston spring into cylinder body.
2. Apply rubber grease to dust cover and then install push rod and dust cover.
B

CL

CL-15
 CLUTCH PIPING
< SERVICE INFORMATION >
CLUTCH PIPING
Removal and Installation INFOID:0000000005447949

PCIB1799E

1. Clutch tube 2. Clutch orifice 3. Lock plate

4. Clutch hose 5. Operating cylinder 6. Master cylinder
7. Clutch pedal
Refer to GI-9, "Component", for the symbols in the figure.

Carefully observe the following steps during clutch tube removal and installation.
CAUTION:
Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.
• To fix clutch hose on bracket, position clutch hose clasp on the
emboss of bracket and drive lock plate vertically from above. Be
careful not to bend or twist clutch hose. Do not scratch or damage
clutch hose.
• Tighten clutch tube flare nut to the specified torque.
• Tighten clutch hose to the specified torque.
CAUTION:
Do not reuse copper washer.
• After installation, bleed the air from the clutch hydraulic system.
Refer to CL-9, "Air Bleeding Procedure".
PCIB0681E

CL-16
 CLUTCH RELEASE MECHANISM
< SERVICE INFORMATION >
CLUTCH RELEASE MECHANISM
A
Removal and Installation INFOID:0000000005447950

COMPONENTS B

CL

PCIB1615E
J
1. Holder spring 2. Release bearing sleeve 3. Release bearing
4. Snap spring 5. Dust cover 6. Withdrawal lever
K
REMOVAL
1. Remove manual transmission from the vehicle. Refer to MT-19, "Removal and Installation from Vehicle".
L
2. Remove release bearing sleeve assembly, holder spring and withdrawal lever from inside clutch housing.
3. Remove dust cover.
4. Remove snap spring from withdrawal lever. M
5. Remove release bearing from release bearing sleeve using a
puller.
N

P
CLA0013D

INSPECTION AFTER REMOVAL

CL-17
 CLUTCH RELEASE MECHANISM
< SERVICE INFORMATION >
• If release bearing is seized, damaged, not properly centered or
does not rotate smoothly, replace it.
• If contact surface of withdrawal lever is excessively worn, replace
it.
• If dust cover is cracked, replace it.

SCIA1660E

INSTALLATION
CAUTION:
• Be sure to apply grease to the points specified. Otherwise, noise, poor disengagement, or damage to
the clutch may result. Excessive grease may cause slip or judder. Wipe off any grease oozing from
the parts.
• Be careful not to bring any grease to the clutch disk facing, pressure plate surface and flywheel sur-
face.
1. Install release bearing to release bearing sleeve using the drift.

Tool number : KV30101400

CAUTION:
Press bearing inner race by pushing with the drift.

PCIB0275E

2. Following the instructions below, apply grease to the specified points.

PCIB1393E

CAUTION:
Wipe off any old grease, debris, or powdery residue left on the grease applying surfaces.
• Evenly apply approximately 1 mm (0.04 in) thick coating of recommended grease to withdrawal lever
and release bearing sliding surface.
• Apply recommended grease to withdrawal lever ball pin contact surface and inner slots of release bear-
ing sleeve. The grease surface should be level with the surrounding area.
• Apply a thin coat of recommended grease evenly to release bearing sleeve sliding surface of front
cover. Install release bearing sleeve assembly to front cover. Wipe off any excess grease that oozes
from the parts and then remove release bearing sleeve assembly.
3. To install, reverse the removal procedure, following the cautions below.
CAUTION:
• Before installing manual transmission to the vehicle, make sure that each sliding surface slides
smoothly by operating withdrawal lever.

CL-18
 CLUTCH RELEASE MECHANISM
< SERVICE INFORMATION >
• When assembling, make sure that both ends of snap
spring touch the end face of withdrawal lever. A
• Be careful with the orientation snap spring.

CL

SCIA6903E

CL-19
 CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
< SERVICE INFORMATION >
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
Removal and Installation INFOID:0000000005447951

COMPONENTS

PCIB1394E

1. Flywheel 2. Clutch disc 3. Clutch cover

CAUTION:
• Be careful not to bring any grease to the clutch disc facing, pressure plate surface and flywheel sur-
face.
• If the flywheel is removed, align the dowel pin with smallest hole of flywheel. Refer to EM-105, "Dis-
assembly and Assembly" (VQ engine models) or EM-249, "Disassembly and Assembly" (YD engine
models).
REMOVAL
1. Remove manual transmission from the vehicle. Refer to MT-19, "Removal and Installation from Vehicle".
2. Loosen clutch cover mounting bolts evenly. Then remove clutch cover and clutch disc.
INSPECTION AND ADJUSTMENT AFTER REMOVAL
Clutch Disc
• Measure circumferential runout relative to clutch disc center spline.
If it is outside the specification, replace clutch disc.

Runout limit/diameter of the area to be measured

: Refer to CL-23, "Clutch Disc".
• Measure backlash to clutch disc spline and main drive gear spline
at the circumference of clutch disc. If outside the specification,
replace clutch disc.

Maximum allowable spline backlash SCL221

: Refer to CL-23, "Clutch Disc".

CL-20
 CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
< SERVICE INFORMATION >
• Measure the depth “A” to clutch disc facing rivet heads using a cal-
ipers. If it exceeds the allowable wear limit, replace clutch disc. A

Facing wear limit (depth to the rivet head)

: Refer to CL-23, "Clutch Disc". B

CL

JPDIB0026ZZ

D
Clutch Cover
Check diaphragm spring lever claws for unevenness with the lever
still on the vehicle. If they exceed the tolerance, adjust lever height
using the diaphragm adjusting wrench. E

Tolerance for diaphragm spring lever unevenness

: Refer to CL-23, "Clutch Cover". F

Tool number : ST20050240

G
• Check clutch cover thrust ring for wear or breakage. If wear or
breakage is found, replace clutch cover assembly. PCIB0276E

NOTE:
• Worn thrust ring will generate a beating noise when tapped at the rivet with a hammer. H
• Broken thrust ring will make a clinking sound when cover is shaken up and down.
• If a trace of burn or discoloration is found on the clutch cover pressure plate to clutch disc contact surface,
repair the surface with sandpaper. If surface is damaged or distorted, replace the assembly. I
Flywheel Runout
Measure the runout at the flywheel clutch contact surface using a
dial indicator. If runout is outside the specification, replace flywheel. J
If a trace of burn or discoloration is found on the surface, repair it
with sandpaper.
K
Allowable flywheel runout
VQ engine models
: Refer to EM-119, "Inspection After Disassembly". L
YD engine models
: Refer to EM-256, "Inspection". PBIC2646E

M
CAUTION:
Measure it at flywheel outer face (not on knock pin and clutch cover mounting hole).
INSTALLATION N
1. Apply recommended grease to clutch disc and main drive gear splines.
CAUTION:
Be sure to apply grease to the points specified. Otherwise, noise, poor disengagement, or damage O
to the clutch may result. Excessive grease may cause slip or judder. Wipe off any grease oozing
from the parts.
2. Install clutch disc using the clutch aligning bar.
P

Tool number A: KV30100100

3. Install clutch cover. Pre-tighten clutch cover mounting bolts.
4. Tighten clutch cover mounting bolts evenly in two steps in the order shown in the figure. Refer to "COM-
PONENTS".

CL-21
 CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
< SERVICE INFORMATION >
• YD engine models
B: First step
C: Final step

PCIB1801E

• VQ engine models
B: First step
C: Final step
5. Install manual transmission. Refer to MT-19, "Removal and
Installation from Vehicle".

PCIB1800E

CL-22
 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE INFORMATION >
SERVICE DATA AND SPECIFICATIONS (SDS)
A
Clutch Control System INFOID:0000000005447952

B
Type of clutch control Hydraulic

Clutch Master Cylinder INFOID:0000000005447953

CL

Inner diameter 15.87 mm (5/8 in)

D
Clutch Operating Cylinder INFOID:0000000005447954

Inner diameter 19.05 mm (3/4 in) E

Clutch Disc INFOID:0000000006071291

F
Engine type VQ40DE YD25DDTi
Model 260 250
G
260 mm × 190 mm × 3.2 mm (10.24 275 mm × 180 mm × 3.2 mm (10.83
Facing size (outer dia. × inner dia. × thickness)
in × 7.48 in × 0.126 in) in × 7.09 in × 0.126 in)
Wear limit (depth to rivet head) 0.3 mm (0.012 in) H
1.0 mm (0.039 in) / 250 mm (9.84 1.0 mm (0.039 in) / 240 mm (9.45
Runout limit/diameter of the area to be measured
in) dia. in) dia.
Maximum backlash of spline (at outer disc edge) 1.0 mm (0.039 in) I
Clutch Cover INFOID:0000000006071292

J
Engine type VQ40DE YD25DDTi
Set-load 8,340 N (850 kg, 1,875 lb) 9,750 N (995 kg, 2,192 lb)
Diaphragm spring lever height 44.0 - 46.0 mm (1.732 - 1.811 in) 38.5 - 40.5 mm (1.516 - 1.594 in)
K

Uneven limit of diaphragm spring toe height 1.0 mm (0.039 in) or less

CL-23