Clutch: Service and Repair
CLUTCH UNIT REMOVAL/INSTALLATION [C66M-R]
1. Remove the battery cover. Removal and Replacement
2. Disconnect the negative battery cable. Removal and Replacement
3. Remove the aerodynamic under cover No.2 and the splash shield as a single unit. Aerodynamic Under Cover No. 2 Removal/Installation Splash Shield Removal/Installation
4. Drain the manual transaxle oil. Manual Transaxle Oil Replacement [C66M-R]
5. Disconnect and/or remove the following parts in the engine compartment.
a. Remove the battery component. (ex: battery, battery tray and PCM component) Removal and Replacement
b. Remove the air cleaner component. (ex: air cleaner, air hose) Service and Repair
c. Disconnect the control cable from MTX. Service and Repair
d. Disconnect the connectors and GND wiring harness from the MTX.
e. Remove the brackets from MTX.
6. Disconnect and/or remove the following parts related to the suspension and axle.
a. Remove the front tires. Procedures
b. Disconnect the clip securing the brake hose from the shock absorber. Brake Hose (Rear) Removal/Installation
c. Disconnect the ABS wheel-speed sensors from the steering knuckles. Antilock Braking System (ABS)
d. Disconnect the tie-rod end ball joints from the steering knuckles. Service and Repair
e. Disconnect the stabilizer control links (upper side) from the shock absorbers. Front Suspension - Stabilizer Control Link Inspection
f. Disconnect the front lower arms from the steering knuckles. Service and Repair
g. Disconnect the drive shaft (LH) from the MTX. Drive Shaft Removal/Installation
h. Disconnect the drive shaft (RH) from the joint shaft. Drive Shaft Removal/Installation
i. Remove the joint shaft. Joint Shaft Disassembly
7. Disconnect and/or remove the following parts from the underside of the vehicle.
a. Remove the hanger rubber from the exhaust manifold.
b. Disconnect the clutch release cylinder from MTX. Service and Repair
c. Remove the starter. Removal and Replacement
8. Install the SST using the following procedure.
CAUTION:
- Refer to the SST instruction manual for the basic handing procedure.
a. Remove the windshield wiper arm and blade. Windshield Wiper Arm And Blade Removal/Installation
b. Remove the front fender molding. Cowl Grille Removal/Installation
c. Remove the cowl grille. Cowl Grille Removal/Installation
d. Remove the cowl panel. Cowl Panel Removal/Installation
e. Protect the windshield using tape.
f. Replace the hood stay to the position shown in the figure.
NOTE:
- The hood opening angle is increased by placing the hood stay to the position shown in the figure. A space for installing the SST can be secured by increasing the hood opening angle.
i. Disconnect the washer tank and set it aside.
ii. Tilt the hood stay in the direction of the arrow shown in the figure.
iii. Pull out the hood stay in the direction of the arrow shown in the figure.
iv. Rotate the hood stay at the pivot fulcrum shown in the figure.
v. Remove the hood stay.
vi. Install the hood stay as shown in the figure.
CAUTION:
- If the hood stay is not hooked to the hood hole, the hood may fall down. Lightly shake the hood to verify that the hood stay is hooked securely.
g. To enable to install the SST, disconnect the clip shown in the figure and set the wiring harness aside.
h. Install the SST using part number 99794 1025 or an M10x1.25, length 25 mm {0.98 in} bolt as shown in the figure.
Engine front side
Tightening torque
- 38-51 Nm {3.9-5.2 kgf-m, 29-37 ft-lbf}
Engine rear side
Tightening torque
- 38-51 Nm {3.9-5.2 kgf-m, 29-37 ft-lbf}
i. Align the bolt of the shock absorber (RH) shown in the figure with the rear shaft hole for the right side of the SST.
j. Align the bolt of the shock absorber (LH) shown in the figure with the rear shaft hole for the left side of the SST.
k. Install one front foot No.2 to each of the left and right front shafts of the SST, and then align the holes of the SST front shafts with the bolt on the left and right side of each front side frame.
l. Install the SST (49 L017 5A0) to the SST (49 C017 5A0) as shown in the figure.
m. Install the SST (49 L017 5A0) to the SST (49 UN30 3050) with the hook of the SST (49 L017 5A0) facing outward.
CAUTION:
- Install the SST (49 L017 5A0) so that it does not interfere with parts such as the fuel pipe. If the SST (49 L017 5A0) interferes, parts such as the fuel pipe could be damaged.
n. Adjust the height of the left and right side bars so that they are leveled, then tighten each part of the SST.
o. Apply tension to the chain to secure the engine.
9. Remove the MTX. Manual Transaxle Removal/Installation
10. Remove in the order indicated in the table.
11. Install in the reverse order of removal.
12. Add the specified amount of specified transaxle oil. Manual Transaxle Oil Replacement [C66M-R]
Clutch Cover and Disc Removal Note
1. Hold the clutch unit using the SST.
2. Loosen each bolt one turn at a time in a crisscross pattern until spring tension is released.
3. Remove the clutch cover and disc.
Pilot Bearing Removal Note
NOTE:
- The pilot bearing does not need to be removed unless you are replacing it.
1. Use the SST to remove the pilot bearing.
Flywheel Removal Note
1. Hold the flywheel using the SST.
2. Remove the lock bolts, and remove the plate and the flywheel.
3. Inspect for oil leakage from the crankshaft rear oil seal.
- If there is any malfunction, replace the crankshaft rear oil seal. Service and Repair
Flywheel Installation Note
1. Clean the crankshaft thread holes.
2. Install the flywheel and the plate to the crankshaft, and temporarily tighten a new lock bolts.
3. Hold the flywheel using the SST.
4. Tighten the lock bolts completely in the order shown in the figure.
Tightening torque
- 108-116 Nm {11.1-11.8 kgf-m, 80-85 ft-lbf}
Pilot Bearing Installation Note
1. Install new pilot bearing to the specified position using the following tools.
Tool
- Snap-on brand millimeter size bushing driver set (A160M) adapter A160M7 (20-22 mm)
- Use the adapter with the 20 mm side of the A160M7 (20-22 mm) facing the pilot bearing side.
Substitution tool
- Outer diameter: 21 mm {0.83 in}
- Inner diameter: 19 mm {0.75 in}
Standard position
- Distance A of pilot bearing from crankshaft end: 1.5-2.5 mm {0.060-0.098 in}
Clutch Disc and Cover Installation Note
1. Hold the clutch disc position using the SST.
2. Hold the clutch unit using the SST.
3. Tighten the bolts in Min. 2 stages.
a. Temporarily tighten the bolts in the order shown in the figure.
b. Tighten the bolts completely in the order shown in the figure and install the clutch disc and cover.
Tightening torque
- 25-33 Nm {2.6-3.3 kgf-m, 19-24 ft-lbf}
4. Remove the SSTs.