TRSSS & DRV ST UT TTS RUT... 2 RUTS... 2 recaution for Supplemental Restraint System (SRS) "R " and "ST T R-T- SR"...2 recaution for rocedure without owl Top over...2 Service otice or recautions for lutch...2 RRT... 4 RRT... 4 Special Service Tools...4 ommercial Service Tools...4 SYT DSS... 5 S, VRT D RSSS (V) TRUST... 5 V Troubleshooting hart...5 RD T... 6 UT D... 6 nspection and djustment...6 UT UD... 8 nspection...8 Draining...8 Refilling...9 ir leeding...10 RV D STT...11 UT D...11 xploded View...11 Removal and nstallation...11 nspection and djustment...12 UT STR YDR...13 xploded View...13 Removal and nstallation...13 nspection and djustment...14 UT...15 xploded View...15 ydraulic ayout...15 Removal and nstallation...15 nspection and djustment...16 UT RV D STT...17 S (TR SV YDR)...17 xploded View...17 Removal and nstallation...17 nspection and djustment...17 UT DS D UT VR...18 xploded View...18 Removal and nstallation...18 nspection...19 SRV DT D STS (SDS)...21 SRV DT D STS (SDS)...21 eneral Specifications...21 lutch edal...21 lutch Disc...21 lutch over...21-1
< RUT > RUT RUTS RUTS recaution for Supplemental Restraint System (SRS) "R " and "ST T R-TSR" D:0000000007576601 The Supplemental Restraint System such as R and ST T R-TSR, used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted. nformation necessary to service the system safely is included in the SRS R and ST T of this Service anual. WR: lways observe the following items for preventing accidental activation. To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision that would result in air bag inflation, all maintenance must be performed by an authorized SS/T dealer. mproper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. or removal of Spiral able and ir ag odule, see SRS R. ever use electrical test equipment on any circuit related to the SRS unless instructed to in this Service anual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors. RUTS W US WR TS (R R TR) D RS WR: lways observe the following items for preventing accidental activation. When working near the ir ag Diagnosis Sensor Unit or other ir ag System sensors with the ignition or engine running, never use air or electric power tools or strike near the sensor(s) with a hammer. eavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing serious injury. When using air or electric power tools or hammers, always switch the ignition, disconnect the battery, and wait at least 3 minutes before performing any service. recaution for rocedure without owl Top over When performing the procedure after removing cowl top cover, cover the lower end of windshield with urethane, etc to prevent damage to windshield. D:0000000007576602 Service otice or recautions for lutch 3706 D:0000000007576603 WR: fter cleaning clutch disc, wipe it with a dust collector. ever use compressed air. lutch fluid use refer to -10, "luids and ubricants". ever reuse drained clutch fluid. eep painted surface on the body or other parts free of clutch fluid. f it spills, wipe up immediately and wash the affected area with water. -2
< RUT > RUTS ever use mineral oils such as gasoline or kerosene. t will ruin the rubber parts of the hydraulic system. ever reuse S (oncentric Slave ylinder). ecause S slides back to the original position every time when removing transaxle assembly. t this timing, dust on the sliding parts may damage a seal of S and may cause clutch fluid leakage. Refer to -17, "Removal and nstallation". ever disassemble clutch master cylinder and S. -3
< RRT > RRT RRT Special Service Tools RRT D:0000000007576604 The actual shapes of ent-oore tools may differ from those of special service tools illustrated here. Tool number (ent-oore o.) Tool name ST20050240 ( - ) Diaphragm adjusting wrench Description djusting unevenness of diaphragm spring lever ZZ0508D ommercial Service Tools D:0000000007576605 Tool name lutch aligner Description nstalling clutch disc 0404-4
S, VRT D RSSS (V) TRUST < SYT DSS > SYT DSS S, VRT D RSSS (V) TRUST V Troubleshooting hart D:0000000007576606 Use the chart below to find the cause of the symptom. The numbers indicate the order of the inspection. f necessary, repair or replace these parts. SUSTD RTS (ossible cause) Reference Symptom UT D (nspection and adjustment) -6 UT (ir in line) -10 UT (oose) -59 S (oncentric Slave ylinder) (Worn, dirty or damaged) -17 UT DS (ut of true) lutch grabs/chatters 1 2 2 2 2 2 lutch pedal spongy 1 2 lutch noisy 1 lutch slips 1 2 2 3 4 5 lutch does not disengage 1 2 3 3 3 3 3 3 3 4 4 5 UT DS (Runout is excessive) UT DS (ining broken) UT DS (Dirty or burned) UT DS (ily) UT DS (Worn out) -18 UT DS (ardened) UT DS (ack of spline grease) DR SR (Damaged) DR SR (ut of tip alignment) RSSUR T (Distortion) YW (Distortion) -119-5
< RD T > RD T UT D nspection and djustment UT D D:0000000007576607 ST The eight of lutch edal 1. Turn the floor carpet. 2. heck that the clutch pedal height 1 from the dash lower panel (1) is within the reference value. lutch pedal height : Refer to -21, "lutch edal". 1 3. Replace clutch pedal if the height is outside the reference value. 0065ZZ lutch edal eight When Disengaging The lutch 1. Securely engage the parking brake. 2. Turn the floor carpet. 3. Start the engine and run at idle. 4. ully depress clutch pedal and shift to the 1st gear. Securely depress the brake pedal with shifter lever in 1st gear. 5. radually release the clutch pedal and check that the clutch pedal height 2 from the dash lower panel (1) is within the reference value with a scale immediately before the clutch is engaged. lutch pedal height at clutch disengagement 2 : Refer to -21, "lutch edal". T: lthough the clutch pedal height differs according to whether the clutch gets disengaged or engaged, clutch-engaged case is regarded as clutch-disengaged case for easier inspection. 6. Replace clutch pedal if the height is outside the reference value. lutch edal lay 1. ush the pedal pad by hand until a resistance can be felt and check that the play on the upper surface of the pedal pad is within the reference value. 0068ZZ lutch pedal play : Refer to -21, "lutch edal". 2. Replace clutch pedal if the play is outside the reference value. 0121ZZ osition of lutch nterlock Switch -6
< RD T > UT D heck that the clearance between the thread end of clutch interlock switch (1) and stopper rubber (2) is within the specified value while clutch pedal is fully depressed. learance : Refer to -21, "lutch edal". osition of lutch edal osition Switch (With SD or With ush-utton gnition Switch System) heck that the clearance between the thread end of clutch pedal position switch (1) and clutch pedal (2) is within the specified value while clutch pedal is fully released. D0164ZZ learance : Refer to -21, "lutch edal". D0165ZZ DUSTT osition of lutch nterlock Switch 1. Disconnect the clutch interlock switch connector. 2. oosen the clutch interlock switch 45 degrees counterclockwise. 3. With the clutch pedal fully depressed, press into the clutch interlock switch (1) until it reaches the stopper rubber (2) and turn the switch clockwise by 45 degrees to secure it. The clearance show in the figure must be within the specified value. learance T: ully depressed clutch pedal means a clutch pedal condition that the clutch pedal lever contacts the pedal stopper rubber. osition of lutch edal osition Switch (With SD or With ush-utton gnition Switch System) 1. Disconnect the clutch pedal position switch connector. 2. oosen the clutch pedal position switch 45 degrees counterclockwise. 3. ress-fit the clutch pedal position switch (1) until the clutch pedal position switch hits the clutch pedal (2) 45 degrees clockwise while pulling the pedal pad slightly. The clearance show in the figure must be within the specified value. learance : Refer to -21, "lutch edal". : Refer to -21, "lutch edal". D0164ZZ D0165ZZ -7
< RD T > UT UD nspection UT UD D:0000000007576608 UD heck clutch line for cracks, deterioration or other damage. Replace any damaged parts. heck for fluid leakage by fully depressing clutch pedal while engine is running. f leakage occurs around joints, reinstall the joints or, if necessary, replace damaged parts. UD V heck that the fluid level in the reservoir tank is within the specified range (X lines). Visually check for any clutch fluid leakage around the reservoir tank. heck the clutch system for any leakage if the fluid level is extremely low (lower than ). Draining 0007ZZ D:0000000007576609 eep painted surface on the body or other parts free of clutch fluid. f it spills, wipe up immediately and wash the affected area with water. 1. onnect a transparent vinyl hose to air bleeder of bleeding connector (1). D0166ZZ 2. ress the lock pin (1) into the bleeding connector (2), and maintain the position. D0041ZZ -8
< RD T > UT UD 3. Slide bleeding connector (1) in the direction of the arrow as shown in the figure. 4. Depress clutch pedal to gradually discharge clutch fluid. Since the inside of clutch tube is under hydraulic pressure, hold the tube to prevent it from getting disconnected. Refilling 2 : lutch housing Dimension : 10 mm (0.39 in) D0042ZZ D:0000000007576610 eep painted surface on the body or other parts free of clutch fluid. f it spills, wipe up immediately and wash the affected area with water. 1. heck that there is no foreign material in reservoir tank, and then fill with new clutch fluid. ever reuse drained clutch fluid. 2. onnect a transparent vinyl hose to air bleeder of bleeding connector (1). 3. ress the lock pin (1) into the bleeding connector (2), and maintain the position. D0166ZZ D0041ZZ 4. Slide bleeding connector (1) in the direction of the arrow as shown in the figure. 2 : lutch housing Dimension : 10 mm (0.39 in) 5. Slowly depress clutch pedal to the full stroke position, and then release the pedal. Since the inside of clutch tube is under hydraulic pressure, hold the tube to prevent it from getting disconnected. 6. Repeat step 5 at intervals of 2 or 3 seconds until new clutch fluid is discharged. onitor clutch fluid level in reservoir tank so as not to empty the tank. D0042ZZ -9
< RD T > UT UD 7. Return clutch tube and lock pin in their original positions while clutch pedal is depressed. 8. erform the air bleeding. Refer to -10, "ir leeding". ir leeding D:0000000007576611 onitor clutch fluid level in reservoir tank so as not to empty the tank. eep painted surface on the body or other parts free of clutch fluid. f it spills, wipe up immediately and wash the affected area with water. T: 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. 1. ill reservoir tank with new clutch fluid. ever reuse drained clutch fluid. 2. onnect a transparent vinyl hose to air bleeder of bleeding connector (1). 3. Depress and release the clutch pedal slowly and fully 15 times at an interval of 2 to 3 seconds and release the clutch pedal. D0166ZZ 4. ress the lock pin (1) into the bleeding connector (2), and maintain the position. Since the inside of clutch tube is under hydraulic pressure, hold the tube to prevent it from getting disconnected. D0041ZZ 5. Slide bleeding connector (1) in the direction of the arrow as shown in the figure. 2 : lutch housing Dimension : 10 mm (0.39 in) 6. Depress the clutch pedal soon and hold it, and then bleed the air from the piping. Since the inside of clutch tube is under hydraulic pressure, D0042ZZ hold the tube to prevent it from getting disconnected. 7. Return clutch tube and lock pin in their original positions. 8. Release clutch pedal and wait for 5 seconds. 9. Repeat steps 3 to 8 until no bubbles are observed in the clutch fluid. 10. heck that the fluid level in the reservoir tank is within the specified range after air bleeding. Refer to - 8, "nspection". -10
< RV D STT > UT D RV D STT UT D xploded View D:0000000007576612 D0161 1. lutch pedal 2. Stopper rubber 3. lip 4. lutch interlock switch 5. lutch pedal position switch * 6. edal pad 7. edal stopper rubber *: With SD or with push-button ignition switch system Removal and nstallation RV : m (kg-m, ft-lb) D:0000000007576613 1. Remove instrument lower panel. Refer to -12, "Removal and nstallation". 2. Disconnect clutch pedal position switch connector. (With SD or with push-button ignition switch system) 3. Disconnect clutch interlock switch connector. 4. Disconnect clip of harness from clutch pedal. (With SD or with push-button ignition switch system) -11
< RV D STT > UT D 5. Remove master cylinder rod end from clutch pedal. 6. Remove clutch pedal position switch and clip from clutch pedal. (With SD or with push-button ignition switch system) 7. Remove clutch interlock switch and clip from clutch pedal. 8. Remove clutch pedal from the vehicle. 9. Remove pedal pad from clutch pedal. 10. Remove stopper rubber and pedal stopper rubber from clutch pedal, using a suitable remover. 1491 STT ote the following, and install in the reverse order of removal. ress master cylinder rod end into clutch pedal until it stops. nspection and djustment D:0000000007576614 ST TR RV heck clutch pedal for bend, damage, or a cracked weld. f bend, damage, or a cracked weld is found, replace clutch pedal. heck stopper rubber and pedal stopper rubber. f damage or deformation is found, replace stopper rubber and pedal stopper rubber. heck pedal pad. f wear or damage is found, replace pedal pad. ST TR STT heck the clutch pedal height, clutch pedal height at clutch disengagement, and clutch pedal play. Refer to -6, "nspection and djustment". heck the clutch interlock switch position. Refer to -6, "nspection and djustment". heck the clutch pedal position switch position. (With SD or with push-button ignition switch system) Refer to -6, "nspection and djustment". DUSTT TR STT djust the clutch interlock switch position. Refer to -6, "nspection and djustment". djust the clutch pedal position switch position. (With SD or with push-button ignition switch system) Refer to -6, "nspection and djustment". -12
< RV D STT > UT STR YDR xploded View UT STR YDR D:0000000007576615 1. Reservoir hose 2. Reservoir tank 3. aster cylinder Removal and nstallation D0162ZZ D:0000000007576616 RV eep painted surface on the body or other parts free of clutch fluid. f it spills, wipe up immediately and wash the affected area with water. ever disassemble clutch master cylinder. 1. Drain clutch fluid. Refer to -8, "Draining". 2. Remove air cleaner case. Refer to -25, "Removal and nstallation". 3. Remove reservoir hose from reservoir tank and master cylinder. 4. Remove master cylinder rod end ( ) from clutch pedal. 5. ull up the lock pin (1) from connector of master cylinder (2) and separate clutch tube (3). 6. Rotate master cylinder clockwise by 45 degrees, and then remove master cylinder from the vehicle. 1491-13 D0167ZZ
UT STR YDR < RV D STT > STT eep painted surface on the body or other parts free of clutch fluid. f it spills, wipe up immediately and wash the affected area with water. 1. Tilt master cylinder clockwise by 45 degrees () and insert it to the mounting hole. Rotate counterclockwise and secure it. t this time, nipple (1) is upward of the vehicle. : ounting condition 2. nstall master cylinder rod end to clutch pedal. ress master cylinder rod end into clutch pedal until it stops. 3. nstall reservoir hose to reservoir tank and master cylinder. Set reservoir hose with painted mark facing upward. 4. ress down the lock pin into connector of master cylinder until it stops. 5. nstall clutch tube into connector of master cylinder until it stops. 6. or the next step and after, install in the reverse order of removal. nspection and djustment D0114ZZ D:0000000007576617 ST TR STT heck the fluid leakage and the fluid level. Refer to -8, "nspection". heck the clutch pedal height, clutch pedal height at clutch disengagement, and clutch pedal play. Refer to -6, "nspection and djustment". heck the clutch interlock switch position. Refer to -6, "nspection and djustment". heck the clutch pedal position switch position. (With SD or with push-button ignition switch system) Refer to -6, "nspection and djustment". DUSTT TR STT djust the clutch interlock switch position. Refer to -6, "nspection and djustment". djust the clutch pedal position switch position. (With SD or with push-button ignition switch system) Refer to -6, "nspection and djustment". erform the air bleeding. Refer to -10, "ir leeding". -14
< RV D STT > UT xploded View UT D:0000000007576618 D0184ZZ 1. S (oncentric Slave ylinder) 2. lutch tube 3. lutch damper 4. racket 5. aster cylinder ydraulic ayout D:0000000007576619 1499 1. lutch tube 2. ock pin 3. S (oncentric Slave ylinder) 4. lutch damper 5. aster cylinder 6. lutch pedal Removal and nstallation D:0000000007576620 eep painted surface on the body or other parts free of clutch fluid. f it spills, wipe up immediately and wash the affected area with water. RV ote the following, and refer to -15, "xploded View" for removal procedure. Drain clutch fluid. Refer to -8, "Draining". -15
< RV D STT > UT ress the lock pin into the bleeding connector of the S, and then remove clutch tube from S. ull the lock pins from the connectors of the clutch damper until the pins stop, and then remove clutch tubes from clutch damper. ull the lock pin from the connector of the clutch master cylinder until the pin stop, and then remove clutch tube from clutch master cylinder. STT ote the following, and refer to -15, "xploded View" for installation procedure. ever damage clutch tube. nsert each clutch tube into the S bleeding connector, the clutch damper connector, and the clutch master cylinder connector until it contacts the end of each connector. nstall each lock pin into the clutch damper connector and the clutch master cylinder connector until it contacts the end of each connector. nspection and djustment D:0000000007576621 ST TR RV heck the clutch tube for cracks and damage. f the clutch tube has cracks or damage, replace it with a new one. heck the -ring of the clutch tube for cracks and damage. f the -ring of the clutch tube has cracks or damage, replace clutch tube with a new one. heck the clutch damper for cracks and damage. f the clutch damper has cracks or damage, replace it with a new one. ST TR STT heck the fluid leakage and the fluid level. Refer to -8, "nspection". heck the clutch pedal height, clutch pedal height at clutch disengagement, and clutch pedal play. Refer to -6, "nspection and djustment". DUSTT TR STT erform the air bleeding. Refer to -10, "ir leeding". -16
< UT RV D STT > S (TR SV YDR) UT RV D STT S (TR SV YDR) xploded View D:0000000007576622 1. Transaxle assembly 2. S (oncentric Slave ylinder) : lways replace after every disassembly. : m (kg-m, ft-lb) Removal and nstallation D:0000000007576623 ever reuse S (oncentric Slave ylinder). ecause S slides back to the original position every time when removing transaxle assembly. t this timing, dust on the sliding parts may damage a seal of S and may cause clutch fluid leakage. ever disassemble S. eep painted surface on the body or other parts free of clutch fluid. f it spills, wipe up immediately and wash the affected area with water. RV 1. Remove transaxle assembly. Refer to T-25, "Removal and nstallation". 2. Remove S from clutch housing. STT 1. nstall S to clutch housing, and then tighten S mounting bolts to the specified torque. ever reuse S. ever insert and operate S because piston and stopper of S components may fall off. 2. or the next step and after, install in the reverse order of removal. nspection and djustment D0040 D:0000000007576624 ST TR STT heck the fluid leakage and the fluid level. Refer to -8, "nspection". DUSTT TR STT erform the air bleeding. Refer to -10, "ir leeding". -17
UT DS D UT VR < UT RV D STT > UT DS D UT VR xploded View D:0000000007576625 D0049 1. lywheel 2. lutch disc 3. lutch cover 4. nput shaft. irst step. inal step : m (kg-m, ft-lb) : pply lithium-based grease including molybdenum disulphide. Removal and nstallation D:0000000007576626 ever reuse S (oncentric Slave ylinder). ecause S slides back to the original position every time when removing transaxle assembly. t this timing, dust on the sliding parts may damage a seal of S and may cause clutch fluid leakage. Refer to -17, "Removal and nstallation". ever bring any grease to the clutch disc facing, pressure plate surface and flywheel surface. ever clean clutch disc using solvent. RV 1. Remove transaxle assembly. Refer to T-25, "Removal and nstallation". 2. Remove clutch cover mounting bolts while holding clutch cover. ever drop clutch disc. 3. Remove clutch cover and clutch disc. ever drop clutch disc. STT 1. lean clutch disc and input shaft splines to remove grease and powder arisen from abrasion. -18
< UT RV D STT > UT DS D UT VR 2. pply recommended grease to clutch disc (1) and input shaft (2) splines (). e sure to apply grease to the points specified. therwise, noise, poor disengagement, or damage to the clutch may result. xcessive grease may cause slip or judder. nd if it adheres to seal of S, it cause clutch fluid leakage. Wipe out excess grease. Wipe out any grease oozing from the parts. 3. nstall clutch disc, using a clutch aligner () [ommercial service tool]. 4. nstall clutch cover, and then temporarily tighten clutch cover mounting bolts. 5. Tighten clutch cover mounting bolts to the specified torque evenly in two steps in the numerical order as shown in the figure. 6. or the next step and after, install in the reverse order of removal. nspection ST TR RV lutch Disc easure circumferential runout relative to clutch disc center spline. f it is outside the specification, replace clutch disc. Runout limit/diameter of the area to be measured easure backlash to clutch disc spline and main drive gear spline at the circumference of clutch disc. f it is outside the specification, replace clutch disc. aximum allowable spline backlash (at outer edge of disc) : Refer to -21, "lutch Disc". : Refer to -21, "lutch Disc". easure the depth to clutch disc facing rivet heads, using a calipers. f it exceeds the allowable wear limit, replace clutch disc. D0239ZZ 1503 D:0000000007576627 S221 acing wear limit (depth to the rivet head) : Refer to -21, "lutch Disc". D0026ZZ lutch over heck clutch cover thrust ring for wear or breakage. f wear or breakage is found, replace clutch cover. T: Worn thrust ring will generate a beating noise when tapped at the rivet with a hammer. roken thrust ring will make a clinking sound when cover is shaken up and down. f a trace of burn or discoloration is found on the clutch cover pressure plate to clutch disc contact surface, repair the surface with sandpaper. f surface is damaged or distorted, replace clutch cover. -19
UT DS D UT VR < UT RV D STT > ST TR STT lutch over heck diaphragm spring lever claws for unevenness with the lever still on the vehicle. f they exceed the tolerance, adjust lever height, using the diaphragm adjusting wrench () [SST: ST20050240 ( - )]. Tolerance for diaphragm spring lever unevenness : Refer to -21, "lutch over". D0160ZZ -20
SRV DT D STS (SDS) < SRV DT D STS (SDS) SRV DT D STS (SDS) SRV DT D STS (SDS) eneral Specifications D:0000000007576628 Unit: mm (in) ngine type Transaxle type Type of clutch control lutch disc acing size (uter dia. nner dia. Thickness) Recommended clutch fluid lutch edal R16DDT RS694R ydraulic 230 155 3.2 (9.06 6.10 0.126) Refer to -10, "luids and ubricants". D:0000000007576629 ngine type Transaxle type R16DDT RS694R lutch pedal height 169.7 179.7 (6.68 7.07) lutch pedal height at clutch disengagement 80 (3.15) or more lutch pedal play [ooseness at clutch pedal pin] learance between stopper rubber and clutch interlock switch threaded end while clutch pedal is fully depressed. 2 8 (0.08 0.31) [0 1.3 (0 0.051)] 0.74 1.96 (0.0291 0.0772) learance between clutch pedal and clutch pedal position switch threaded end while clutch pedal is fully released. * 0.74 1.96 (0.0291 0.0772) Unit: mm (in) *: With SD or with push-button ignition switch system lutch Disc ngine type R16DDT Transaxle type RS694R Runout limit/diameter of the area to be measured 1.0 (0.039) / 220 (8.66) dia. aximum allowable spline backlash (at outer edge of disc) 0.9 (0.035) acing wear limit (depth to the rivet head) 0.35 (0.0138) lutch over D:0000000007576630 Unit: mm (in) D:0000000007576631 ngine type Transaxle type Tolerance for diaphragm spring lever unevenness R16DDT RS694R 0.7 (0.028) or less Unit: mm (in) -21