GENERAL DESCRIPTION DIAGNOSIS ON-VEHICLE SERVICE (Cute Pedal Haight (Clutch Pedal Fre0 Tavs (Chutch Fui Pipe and Hose (Chui Master Cylinder hid Inspection Disassembly and Assenby ‘Cuter Master Cyt: SECTION 7C1 CLUTCH CONTENTS ror 2 71-3 rer 4 yer 4 71-4 71-4 71-5 71-8 71-7 (Ctch Operating Gvinder UNIT REPAIR Clutch Cover, Clutch Die and Fyahoal = UNIT REPAIR TIGHTENING TORQUE ‘SPECIFICATIONS REQUIRED SERVICE MATERIALS SPECIAL TOOLS ror. 8 7e1-10 701-10 7e1-14 res 7e1-14 708-14GENERAL DESCRIPTION ‘Thecutchisa daphragr-sprogcutchota diy single «isciype. The daphragmspxing sofatapering-inger "ype. whichis sling n he cuter ameter part ris of tapered fingers pining inward 22, caring torsional ol sping, possioned on he tranerisien input chat wth an invelut pine ft The clutch coveris secured the fywhee! and ea ‘ies he Gaphragm spring in such a way thatthe pe- ripheral ecge pet of the sping pushes on he pres su plato against the fywheol (wit te dsc in bo: ‘wean) when the chuchrlaste bearings heck This tho engaged condition otha cteh. Depressing the clutch peda causes the release bea- ing to advance and pushes on he tps of te tapered ‘ings of he diaphvagm spring. When Ms happens, tne haphragm spring pulls the pressure pata away ‘tom the flywhoo, thereby iniruping the flow of «tivo tem yhoo! through clutch de to rane ion input shaftDIAGNOSIS Condition Possible Cause Conrcion “Sipping ‘sinpropar Gulch pedal es wave Bised a or eplace masior ‘ovinder. ‘2Worn oo elute cs facing, Fplace dis. (*Warpod cae, presoure pate or yao! Rope dao, toh cover or uface. fyaeet ‘*Woakored siaphragm spring. FRoplace cluch cover. ‘easter olnder piston or seal cup not returning. | Rept mastor cyngor Dragging clutch | eimproper clutch pedal reo rave, Blood airor replace masior find ‘*Wockened diaphragm sping, oF worn apring ip. | Replace clutch cover. ‘*Rusted input shaft splines. Labecate ‘*Damaged or wom spines of ransmission | Replace input shat. Input shat ‘eB xcossvely wobbly clutch cise Replace ase ‘ecuze acings broken or diy wih Replace ase ‘Flug leakage Repair oF opaco. Clutch vibration | © Glazed (glase-he) cach facings Repair or epace dee ‘ecuch facings diy wih ol Replace dc ‘*Ficlegse besnng sides unsmootny on Iput__ | Lubricate or replace input shaft bearing retro: shaft bearing retarer ‘eWobbly clutch iso, or poor facing contact. | Replace dic. ‘Weakened tsion springs in ctch doe. Replace dle ‘*ciuich dic rete loos. Replace die. “Distorted pressure pate or ywheel surface. | Replace ehtchcoverorfywheel ‘* Weakened or loosened engine mounting Retghten or replace mounting bot or nt Woiey clutch "Wor or brokanvelanse bearing plaoo roeace boarng ‘Input shat ont bearing worn down, Replace put shaft bearing ‘Excessive rate of hitch cee ub, Replace dc sOracked ohtch dec Replace disc. {Pressure plate and aphragm spring rating, | Replace cuic cover. “Grabbing clutch | @Chacn die fcings soaked wit al Replace ds. ‘*Chich cic facings excessively worn Replace des. ‘Rivet needs chowing out of facing Replace dee. ‘Weakened torsion springs. place dss.ON-VEHICLE SERVICE CLUTCH PEDAL HEIGHT Adu clutch pedal heght by loosening clove ack nut and tuning ush reas sewer, ‘Clutch pedal helght is normal if clutch pedal is about 201mm (0.79) higher than brake pedal. tor adjusting, tighten lock nuto species torque Tightening Torque | (@): 181m (18 kg, 18.0 1) CLUTCH PEDAL FREE TRAVEL Depress clutch pedal stop the moment uh esstanoeisftand measur clstance (clutch pedal ree rave). Freo travel should be nn fobowing specication, Pedal fee travel a": 18~25mm (06~ 1.4 In) REMOVAL, NOTE: ‘De not allow lu to get on painted sure. 1) Remove cust ance rom each int ofhese andpipetobe dis Connected and clean around resenor Ca. 2) Take out le wih syango or such 5} Disoonec i pipe trom Nose. NOTE: ‘Todisconnect pipe from hose, separate them by using are ‘nut wrench and spanner so a net to kink them: INSPECTION a CChack pipe ar nase for dent kink, eack, and cst. Replace Heveck results not satetactory. wean te , Reverse removal sequence noting following points. <2 +4) | Soria: ; aw ‘Tightening Torque (2): 16m (1.6 kom, 11.5 1) 7 D | nore: ‘For airbleeding of master oylinder alone, it mustbe removed from vehicle. (For procedures of removal and installation of master cyln- der assembly and alr bleeding, refer to CLUTCH MASTER CYLINDER ection) ‘#0 not alow fu to get on painted surtace. Do not alow pipe and hoes to contact hard ag ‘or other pats. ‘sInctall each clamp cocurely ‘Install E-ring securely as shown, ‘After instalation, check lutch pedal ree travel and blood: trom system. eck ful leakage, 1 Add fue close to AX evel of reservow. vole He CLUTCH MASTER CYLINDER REMOVAL 1) loan around reservoir cap and tke out fid with syringe ot such 2) Remove push rod cles pin. 9) Disconnect id pipe fam master eying. NOTE: ‘Do not allow fai to got on paintod eurtaoa 4) lemove master cya attaching nut and bolt 5} Remove master cylinder assembly and gasketINSTALLATION 1) To Bleed air rom master cylinder ise as shown figure and adic 8 Nore: ‘Aor bleeding air rom master oylinder, plug pipe hole init to prevent Mus trom sping out ofl pipe is connected. 2) Install mast: clinderassembly androw gasket tobody. attach tng bl ruts end push rod ee Note: Do not reuse gasket. 83) Torque attaching bot and nt to specication 4) Connect id pipe and torque fare nut to specication. Tightening Toraue (2) 181m (13 kom, 8 ay (©) 16m (18 kgm, 11.510) 5) Aoply grease to evs pin ar inatal it ““R*: Grease 99000-25010 6 Fill rsowtr wih spaciod brake fd and check ic lakage. 7) Ate insaiion, bled ar om eystom and check elutch pedal {roo travel, Roferto BRAKE section fo ai booding procedure. FLUID INSPECTION Fie evel shouldbe alvays between MIN and MAX dnes on rset- oir fd decreases qu, cneck or leakage, ropa leaky por, ‘fen, ancl acs Sud upto MAX leva. Note: ‘Brake fluid damages painted surace badly. Should itget on painted surface, remove It immediately and clean surface thoroughly. ‘*Donotuse shock absorber luldor anyother fui which con- ‘tains mineral ell Do not use container which has been used {or mineral ol or which i wet from water. Minera ol wil ‘cause ewoling and distortion of rubber pats In hydraulle ‘lutoh system and water wll mx with brake fui, lowering fluid boiling point. Keep all uid containers capped to pre- vent contamination. ‘ehfake sure not 10 use fluld whose container cap was frst ‘opened more than a year ago.DISASSEMBLY AND ASSEMBLY CLUTCH MASTER CYLINDER DISASSEMBLY 1) Remove boot and thon cep with piston pushed in 2) Remo push fod and blow compressed ir radualy into hole for ppe connection ta remove piston assem using care to proventit om jumping ot. INSPECTION Inspect all isassarled parts for wear or damage and replace pars nacessary. Note: ‘Wash dlsassomblod parts with broke tui, '*Donot reuse piston assembly and circlip Inspect yindor boc lr sootng or coreson Ite best to replace corteded cylinder. Corrosion can be dened as pis or excessive roughness, bore of eylindar with anything abrasive ie prohib- ted, as damage to cylinder bore may coeur nse cylinder in clean brake tid Shake excess rinsing ti rom ‘ylnder.Donot use acon to yey, in Kom eth cannot be kept away rom cyirder bore sues. ASSEMBLY Nore: Before installation, wash each patin specified brake fluld. 1) Apply brake fu toinsie of piston assembly and oyindr body. 2) lnsal peton aembly int ying. {3) Wit piston pushed down, insta cps shown, nd natal woo4) Tighten lock nto spected trav, ‘Tightoning Torque (@): 18m (1.8 kgm, 13.016) 5) Forlrstalaion of master eynder to vehicle refortoINSTALLA- TION described prowoush. CLUTCH OPERATING CYLINDER REMOVAL Note: Do not allow luc o get on painted surfaces 1) Clean around rsarvor cap a ake out Mad with syringe or auch, 2) Disconnect hid hose trom operating cylinder 8) Remove operating eyinderstaching bois and operating cyn- cer INSTALLATION 4) For al bleeding of maser cylinder alone, it must be removes trom vehicle Forprocedure of removal and instaaon efmastercynderas- emalyandairbeading, lero CLUTCH NASTER.CYLINDER. extn, 2) Reply smal aroun! of groste 10 rod. A": Grease 99000-25010 NOTE: Don't allow any grease to be on boot 2) Instat cuteh operating cylinder and torque attaching bots to spectiaton. 14) Connect lth fuchose an trque union ltt specication. Retin Tora 0 Nm (6.0 kg-m, 365 bt) Sesanmeaige, ws)5) Filrosorvo with speciod brake fld and check fr fd oak- a0 6) Bleed ir rom systom and check clutch pdel res travel Rafer 4 BRAKE section fr air bleeding procedure.erersge_ so Embrague Descripcion general constrecin oh omragu po nara) Series wero emus Sarg hanged wih the DEMO VERSION of CAD-KAS PDF Eat (htpilwww cadkas com) ‘ange wih She DEMO VERSION of CAD-KAS PDF-Ecthpiheww.cadkas om)202 emorague Ubicacién de los componentes Ubicacién dela mangueray l tubo del liquide de embrague Informacion y procedimientos de diagnéstico tema de embrague "de frenoa es entremadamerte perjadiclal parala| ‘renos en una superficie pintada, seque inmediatamente el iquido y imple la superficie pintada, ‘renes: ef la Seasin 4A en el manual correspondentEmbrague_5C3 Instrucciones de reparacion Extraccién e instalaci6n del ellindro maestro del embrague APRECAUCION ‘No permita que caiga liquide sobre superficies pintadas, Podria counar dafion en la superficie pintada. “+ No desmonte elciinaro maestro del embrague. Extraccign 1) Linpie arededor dea tapa del depésito del clin maestrodel embrague y extraiga el Iquide con una {ergs o algo semeiante 2) Separe a esis de fsibles principal 3) Desconecte, del grupo (1 del ctindro maestro, el tuto (2) ae liquid ya manguers (del dopo, 44) Quite Ia abrazadera (8) ys horquila(6) dels vals 5) Retire las tuersas de fact (3 del clindro maestro. 6) Desmonie el grupo del cindro maesto (1) la junta Instatacién, Paral stalin. invert el procedmiento de ‘Sesmoniaje teniendo en cuenta lo siguiente + Aplique orses ania horus (1) de Is vars empue. Ae: Grasa 99000-29100 (Grasa de siicona suzUKD, + Aprite al par especificado ls tueroas de flacén (2) dal clindro maesre. Par de apricte embrague ja}: 23 New (2,3kgt-m, 17,0 Ib) + Rellene el cepésio con el igido de frenos especticado y comprucbe sihay siguna fuga, ‘embrague y compruebs Ia carrera libre del pedal del smbrague. Conc ol prosedimianto de purga de fife en "Purge de aire del sistema de embrague:C4 Embrague Extraccién e instalacién del grupo del cilindro, de accionamiento del embrague 1) Linpie alrededor de la tapa del depisto del cindro imaeste del embrague y extraiga eiliquiso con una {ernga o algo semejate 2) Desmonte el conjunto dea transmision consutande “Desmantajey monte de! conjunie de a trenamision manual nis Secon SE 23) Afoje a tuerea abecinaéa (1) del tubo de liquito de ‘embrague de! grupo (2) de! ciindrode ‘scsionamient del embrague. 4) Retr, de a eaja elantera dela transmisién, ot ‘manguto (3) dela unta del tubo del ebrague ‘despues, ee el tubo () del iqudo de embrague. 5) Retire. dela caia delantera de a transmis, ol ‘grupo del cindro de accionanienta del embrague 1) Instale, en la caja élantera dela transmisién el ‘grupo (2) del tind de accionamiento del ‘Embrague. Aorete al par especificado los perros de rmontaie Par de apricte Perna de montaje del grupo del cilindra de {ccionamiento del embrague (a: 10 Nm (1,0 = eri 2) Gonecteprovsionalmerte etubo (4) de liquide de lembrague con el grup del eiindre de ‘scionamiento del embrague, 3) Monte frmemente el manguito (3) de a unta de ‘bo de embrague en Iacajadelatera de la \tansmsin y desoués, apie al par especifesdo la ‘uerca abosinada (1) dal tube de liquide de embrague. ‘Tueroa abocinads del tubo de liuido de i combrague (0): 46 Nem (16 kote, 4) Vuslva a montar¢ conjunto de la ranemicién ceonsuitando ‘Desmontae y montaje del conjunto de 5) Relene el depésto con el liquido de frenos cipeciicadayy comprucse shay siguna fuga 6) Purgue el aire del sistema y comprucbela carera ive det peal delembrague. Consultee! procedmien de purgade aie en ‘Purga de ire det Compruete si hay fugas de liquico de embrague, dafios ‘encuentra cualquier anomaia, eemplace el grupo del