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G2M0235
3) Upon completion of adjustment, securely lock spherical
nut with lock nut.
Install return spring on lever (Models without hill holder
only).
NOTE:
Hook the long hook side of the return spring with the lever
(Models without hill holder only).
G2M0236
4) Depress clutch pedal to assure there is no abnormality
in the clutch system.
G2M0970
2. HYDRAULIC APPLICATION TYPE
Bleed air from oil line with the help of a co-worker.
1) Fit one end of a vinyl tube into the air bleeder of clutch
damper and put the other end into a clutch fluid container.
G2M0971
2) Slowly depress the clutch pedal and keep it depressed.
Then open the air bleeder to discharge air together with the
fluid.
Release the air bleeder for 1 or 2 seconds. Next, with the
bleeder closed, slowly release the clutch pedal.
3) Repeat these steps until there are no more air bubbles
in the vinyl tube.
CAUTION:
Cover bleeder with waste cloth when loosening it, to
prevent clutch fluid from being splashed over sur-
rounding parts.
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2-10SERVICE PROCEDURE
2. On-Car Service
Page 570 of 3342
G2M0972
4) Tighten air bleeder.
Tightening torque:
T: 18±3 N⋅m (1.8±0.3 kg-m, 13.0±2.2 ft-lb)
B2M1178A
5) Remove air chamber.
6) Repeat steps 1) through 3) using air bleeder on oper-
ating cylinder.
B2M1179A
7) Tighten air bleeder.
Tightening torque:
T: 18±3 N⋅m (1.8±0.3 kg-m, 13.0±2.2 ft-lb)
8) After depressing the clutch pedal, make sure that there
are no leaks evident in the entire system.
9) After bleeding air from system, ensure that clutch oper-
ates properly.
B2M0633A
3. Release Bearing and Lever
A: REMOVAL
1. MECHANICAL APPLICATION TYPE
1) Remove release lever return spring
1(Models without
hill holder only).
2) Remove the two clips
2from clutch release lever3
and remove release bearing6.
CAUTION:
Be careful not to deform clips.
3) Remove release lever seal
4.
8
2-10SERVICE PROCEDURE
2. On-Car Service - 3. Release Bearing and Lever
Page 571 of 3342
G2M0972
4) Tighten air bleeder.
Tightening torque:
T: 18±3 N⋅m (1.8±0.3 kg-m, 13.0±2.2 ft-lb)
B2M1178A
5) Remove air chamber.
6) Repeat steps 1) through 3) using air bleeder on oper-
ating cylinder.
B2M1179A
7) Tighten air bleeder.
Tightening torque:
T: 18±3 N⋅m (1.8±0.3 kg-m, 13.0±2.2 ft-lb)
8) After depressing the clutch pedal, make sure that there
are no leaks evident in the entire system.
9) After bleeding air from system, ensure that clutch oper-
ates properly.
B2M0633A
3. Release Bearing and Lever
A: REMOVAL
1. MECHANICAL APPLICATION TYPE
1) Remove release lever return spring
1(Models without
hill holder only).
2) Remove the two clips
2from clutch release lever3
and remove release bearing6.
CAUTION:
Be careful not to deform clips.
3) Remove release lever seal
4.
8
2-10SERVICE PROCEDURE
2. On-Car Service - 3. Release Bearing and Lever
Page 572 of 3342
B2M0174A
4) Remove release lever retainer spring from release lever
pivot with a screwdriver by accessing it through clutch
housing release lever hole. Then remove release lever.
B2M1257A
2. HYDRAULIC APPLICATION TYPE
1) Remove transmission assembly from vehicle body.
2) Remove operating cylinder
1.
3) Remove the two clips
2from clutch release lever3
and remove release bearing6.
CAUTION:
Be careful not to deform clips.
4) Remove release lever seal
4.
B2M1258A
5) Remove release lever retainer spring from release lever
pivot with a screwdriver by accessing it through clutch
housing release lever hole. Then remove release lever.
9
2-10SERVICE PROCEDURE
3. Release Bearing and Lever
Page 573 of 3342

B2M0173A
B: INSPECTION
1. RELEASE BEARING
CAUTION:
Since this bearing is grease sealed and is of a nonlu-
brication type, do not wash with gasoline or any sol-
vent when servicing the clutch.
1) Check the bearing for smooth movement by applying
force in the radial direction.
Radial direction stroke:
FWD; Approx.
1.0 mm (0.039 in)
AWD; Approx.
1.4 mm (0.055 in)
G2M0240
2) Check the bearing for smooth rotation by applying pres-
sure in the thrust direction.
3) Check wear and damage of bearing case surface con-
tacting with lever.
G2M0241
2. RELEASE LEVER
Check lever pivot portion and the point of contact with
release bearing case for wear.
C: INSTALLATION
CAUTION:
Before or during assembling, lubricate the following
points with a light coat of grease.
Inner groove of release bearing
Contact surface of lever and pivot
Contact surface of lever and bearing
Transmission main shaft spline (Use grease contain-
ing molybdenum disulphide.)
10
2-10SERVICE PROCEDURE
3. Release Bearing and Lever
Page 574 of 3342

B2M0633A
1. MECHANICAL APPLICATION TYPE
1) While pushing release lever
3to pivot and twisting it to
both sides, fit retainer spring
5onto the constricted portion
of pivot.
NOTE:
Confirm that retainer spring is securely fitted by observing
it through the main case hole.
2) Install release bearing
6and fasten it with two clips2.
3) Install release lever seal
4.
G2M0235
4) After remounting engine and transmission on body,
make adjustment of the clutch release lever end play.
CAUTION:
Take care not to twist the cable during adjustment.
5) Install release lever return spring (Models without hill
holder only).
NOTE:
Hook up the return spring to right side hole of the release
lever.
B2M1257C
2. HYDRAULIC APPLICATION TYPE
1) While pushing release lever
1to pivot and twisting it to
both sides, fit retainer spring
2onto the constricted portion
of pivot.
NOTE:
Apply grease (SUNLIGHT 2: P/N 003602010) to contact
point of release lever and operating cylinder.
Confirm that retainer spring is securely fitted by observ-
ing it through the main case hole.
2) Install release bearing
3and fasten it with two clips4.
3) Install release lever seal
5.
4) Install operating cylinder
6.
Tightening torque:
T: 37±3 N⋅m (3.8±0.3 kg-m, 27.5±2.2 ft-lb)
11
2-10SERVICE PROCEDURE
3. Release Bearing and Lever
Page 575 of 3342
5) After remounting engine and transmission on body;
6) Bleed air from oil line with the help of a co-worker.
G2M0242
4. Clutch Disc and Cover
A: REMOVAL
1) Install ST on flywheel.
ST 498497100 CRANKSHAFT STOPPER
2) Remove clutch cover and clutch disc.
CAUTION:
Take care not to allow oil on the clutch disc facing.
Do not disassemble either clutch cover or clutch
disc.
G2M0243
3) Remove flywheel.
B2M0328
B: INSPECTION
1. CLUTCH DISC
1) Facing wear
Measure the depth of rivet head from the surface of facing.
Replace if facings are worn locally or worn down to less
than the specified value.
Depth of rivet head:
Standard value
1.3—1.9 mm (0.051—0.075 in)
Limit of sinking
0.3 mm (0.012 in)
CAUTION:
Do not wash clutch disc with any cleaning fluid.
12
2-10SERVICE PROCEDURE
3. Release Bearing and Lever - 4. Clutch Disc and Cover
Page 576 of 3342
5) After remounting engine and transmission on body;
6) Bleed air from oil line with the help of a co-worker.
G2M0242
4. Clutch Disc and Cover
A: REMOVAL
1) Install ST on flywheel.
ST 498497100 CRANKSHAFT STOPPER
2) Remove clutch cover and clutch disc.
CAUTION:
Take care not to allow oil on the clutch disc facing.
Do not disassemble either clutch cover or clutch
disc.
G2M0243
3) Remove flywheel.
B2M0328
B: INSPECTION
1. CLUTCH DISC
1) Facing wear
Measure the depth of rivet head from the surface of facing.
Replace if facings are worn locally or worn down to less
than the specified value.
Depth of rivet head:
Standard value
1.3—1.9 mm (0.051—0.075 in)
Limit of sinking
0.3 mm (0.012 in)
CAUTION:
Do not wash clutch disc with any cleaning fluid.
12
2-10SERVICE PROCEDURE
3. Release Bearing and Lever - 4. Clutch Disc and Cover