Installation Procedure:

1

2

1

3

FE03-0209b

1.

Install  clutch  master  cylinder  and  tighten  clutch  master
cylinder retaining nuts (1).

Torque: 23 Nm (Metric) 17.0 lb-ft (US English)

2.

Install  piston  rod  U-shaped  clip  to  the  clutch  master
cylinder piston rod, and tighten the clutch master cylinder
piston rod and the piston rod U-shaped locking nut (20.

Torque: 11 Nm (Metric) 8.1 lb-ft (US English)

3.

Install connecting pin (3) between the clutch pedal and the
piston rod U-shaped clip, lock the pin (3).

2

1

FE03-0210b

4.

Connect the clutch master cylinder metal connector 1.

Torque: 10 Nm (Metric) 7.4 lb-ft (US English)

5.

Install the master cylinder oil inlet hoses, tighten the steel
clamp (2).

Torque: 14 Nm (Metric) 10.3 lb-ft (US English)

6.

Bleed air.

7.

Adjust the clutch pedal.

8.

Install Instrument panel lower left shield panel.

9.

Fill the clutch / brake fluid to the MAX (maximum) mark.

10. Connect the battery negative cable.

3.2.6.3 Hydraulic Clutch Bleeding

Note

Brake  fluid  is  corrosive  and  it  will  damage  electrical
connectors  and  paint.  Use  a  suitable  container  and
fender  cover  to  prevent  exposure  to  brake  fluid.  Use
cotton cloth to wipe spilled fluid.
It  is  prohibited  to  refill  brake  fluid  to  the  clutch  master
cylinder  brake  fluid  reservoir,  because  the  used  brake
fluid may be mixed with the air, impurities and moisture.

Transmission / Drive Axle

Clutch System

3-19

FE03-0211b

1.

During  the  hydraulic  system  bleeding,  make  sure  the
clutch  /  brake  fluid  level  is  between  reservoir  minimum
(MIN) and maximum (MAX) marker.

FE03-0212b

2.

Connect one end of the vinyl plastic hose to the bleeder
nipple, the other end to a half full brake fluid container.

3.

Slowly press the clutch pedal several times.

4.

Release the bleeder nipple screws, until the fluid begins
to flow, and then tighten the bleeder nipple screws.

5.

Repeat  step  3  until  bubbles  no  longer  appear  in  brake
fluid.

6.

Fill brake fluid to the maximum (MAX) marker level.

3-20

Clutch System

Transmission / Drive Axle

3.2.6.4 Clutch Pedal Free Travel Adjustment

FE03-0213b

1.

Measure clutch pedal travel. Press the clutch pedal to the
end. Measure the distance between the start position and
the end position.

2.

Adjust the clutch pedal travel. Release the locking nut and
rotate  the  bolt.  Clutch  pedal  travel  should  be  more
than128  mm  (5.0  in).  Tighten  the  lock  nut  after
adjustment.

FE03-0214b

3.

Determine the clutch pedal free travel, with a hand gently
press the clutch pedal and determine the distance while
there is a resistance feel.

4.

Adjust the clutch pedal free travel. Release the lock nut
and turn. Clutch pedal free travel should be between 6 and
12 mm (0.2-0.5 in)Tighten the lock nut after adjustment.

Transmission / Drive Axle

Clutch System

3-21

3.2.6.5 Clutch Assembly Replacement

Removal Procedure:

Warning!

Refer to "Battery Disconnection Warning" in "Warnings
and Notices".

FE03-0215b

1.

Disconnect  the  battery  negative  cable.  Refer  to

2.11.8.1

 

Battery Disconnection

.

2.

Lift the vehicle.

3.

Remove the engine bottom shield. Refer to 

12.10.1.7

 

Left

and Right Engine Bottom Shield Replacement

.

4.

Remove  the  transmission  assembly.  Refer  to

3.3.8.3

 

Transmission Assembly Replacement

.

5.

Remove clutch bolts, the clutch pressure plate and clutch
driven plate.

Installation Procedure:

FE03-0216b

1.

Apply grease on the clutch plate spline.

2.

With a special tool GL301-017, align the clutch pressure
plate and drive plate with the flywheel.

3.

Install pressure plate bolts and tighten.

Torque: 25 Nm (Metric) 18.5 lb-ft (US English)

Note

Install bolts in diagonal order.

4.

Remove the special tool GL301-017.

5.

Install the transmission assembly.

6.

Install the engine bottom shield.

7.

Lower the vehicle.

8.

Connect the battery negative cable.

3.2.6.6 Clutch Pilot Bearing Replacement

Removal Procedure:

Warning!

Refer to "Battery Disconnection Warning" in "Warnings
and Notices".

3-22

Clutch System

Transmission / Drive Axle