Page 2529 of 3573

7C±20CLUTCH
2. Adjust clutch padel adjusting bolt by backing it out
half a turn, and measure the clearance ()
between the clutch pedal arm and the adjusting
bolt.
203RW010
Legend
(9) Bracket
(10) Clutch Pedal Adjusting Bolt
(11) Lock Nut
(12) Clutch Pedal Arm
3. Lock the lock nut.
Clutch Switch and Clutch Pedal Clearance ()
0.5 mm ± 1.5 mm (0.020 in ± 0.059 in)
5. After adjusting the clutch pedal height, push the
clutch pedal by hand rightly to check the clutch pedal
free play (4) to within specification.
Pedal Free Play (4)
5 mm ± 15 mm (0.20 in ± 0.59 in)
203RW004
6. Clutch pedal engagement height inspection:
1. Operate the parking brake lever and block the
wheels.
2. Start the engine, fully step on the clutch pedal,
and move the shift lever to 1st position.
3. With the engine idling, release the clutch pedal
slowly and measure its stroke just prior to its
clutching position.
Clutch Pedal Engagement Height (14)
MIN. 30 mm (1.18 in)
7. If the measured value exceeds the specified limit,
check the following points. Repair if necessary:
Hydraulic circuit for fluid leakage or air in circuit.
Clutch disc warped.
Diaphragm spring weakened or tip of fingers worn.
Driven plate sticking on sprines.
Release bearing worn or damaged.
Master cylinder and slave cylinder worn.
203RW007
Legend
(3) Floor Panel
(14) Clutch Pedal Engagement Height
Page 2530 of 3573

CLUTCH7C±21
Torque Specifications
Master cylinder to dash panel
Torque: 16 N´m (1.6 kg´m/12 lb ft)
Clutch pedal to dash panel
Torque: 21 N´m (2.1 kg´m/15 lb ft)
Master cylinder push rod to yoke
Torque: 17 N´m (1.7 kg´m/12 lb ft)
Clutch pipe to master cylinder
Torque: 20 N´m (2.0 kg´m/14 lb ft)
Clutch pipe to flex, hose
Torque:
M 10: 16 N´m (1.6 kg´m/12 lb ft)
M 12: 20 N´m (2.0 kg´m/14 lb ft)
Slave cylinder to case
Torque: 43 N´m (4.4 kg´m/32 lb ft)
Slave cylinder bleeder screw
Torque: 8 N´m (0.8 kg´m/69 lb in)
Flexible hose to slave cylinder
Torque: 20 N´m (2.0 kg´m/14 lb ft)
Clutch pipe to damper cylinder
Torque: 12 N´m (1.2 kg´m/104 lb in)
Damper cylinder bleeder screw
Torque: 8 N´m (0.8 kg´m/69 lb in)
Bleeding
1. Check the level of clutch fluid in the reservoir and
replenish if necessary.
Bleeding the damper cylinder (except V6 LHD
model).
2. Remove the rubber cap from the bleeder screw and
wipe clean the bleeder screw. Connect a vinyl tube to
the bleeder screw and insert the other end of the vinyl
tube into a transparent container.
3. Pump the clutch pedal repeatedly and hold it
depressed.
203RS005
4. Loosen the bleeder screw to release clutch fluid with
air bubbles into the container, then tighten the bleeder
screw immediately.5. Release the clutch pedal carefully. Repeat the above
operation until air bubbles disappear from the clutch
fluid being pumped out into the container. During the
bleeding operation, keep the clutch fluid reservoir
filled to the specified level. Reinstall the rubber cap.
Bleeding the slave cylinder
6. Repeat step 2 through 5 for bleeding the slave
cylinder.
206RW003
Legend
(1) Slave Cylinder
(2) Bleeder Screw
(3) Vinyl Tube
Page 2531 of 3573
7C±22CLUTCH
Master Cylinder
Disassembled View
208RW016
Legend
(1) Master Cylinder Assembly
(2) Gasket(3) Damper Cylinder Assembly
(4) Nut
(5) Push Rod Damper
Page 2532 of 3573
CLUTCH7C±23
Disassembly
(4JX1)
1. Remove damper cylinder assembly and gasket.
2. Remove push rod damper.
NOTE: T h e m a s t e r cylinder assembly cannot be
disassembled because of point±staked rod stopper.
Inspection and Repair
Clean and inspect the removed parts.
Make necessary parts replacement if any abnormalities
such as wear, oil leaks or other damage are found through
inspection.
Reassembly
To reassemble, follow the disassembly steps in the
reverse order, noting the following points:
1.Push rod set length
RHD: 117.5 mm (4.626 in)
LHD: 119 mm (4.685 in)
2.Push rod nut torque
17 N´m (1.7 kg´m/12 Ib ft)
3.Damper cylinder torque
47 N´m (4.8 kg´m/35 Ib ft)
Page 2533 of 3573
7C±24CLUTCH
Slave Cylinder
Disassembled View
206RW004
Legend
(1) Cylinder Body
(2) Spring(3) Piston and Piston Cup
(4) Boot
(5) Push Rod
Disassembly
1. Remove boot.
2. Remove push rod.
3. Remove piston and piston cup.
4. Remove spring.
Inspection and Repair
Make the necessary adjustments, repairs, and part
replacements if excessive wear or damage is discovered
during inspection.
Cylinder Body
206RS003
1. Clean the cylinder body.
2. Check the fluid return port for restrictions and clean it
if necessary.
Page 2534 of 3573
CLUTCH7C±25
Piston and Piston Cup
1. Visually inspect the disassembled piston and piston
cup for excessive wear and damage.
2. Replace the inner parts with new parts shown in the
illustration.
206RS004
3. Measure the clearance between slave cylinder wall
and piston.
4. If the measured value exceeds the specified limit, the
slave cylinder assembly must be replaced.
Standard: 0.07 mm (0.0028 in)
Limit: 0.15 mm (0.0059 in)
206RS005
Reassembly
To reassemble, follow the disassembly steps in the
reverse order, noting the following points:
1. Before installing the parts, apply a thin coat of rubber
grease.
2. Install cup in groove in piston with the lip turned to the
front of cylinder. Use care so as not to scratch the
cylinder.
206RS006
Page 2535 of 3573
7C±26CLUTCH
Damper Cylinder
Disassembled View
205RW005
Legend
(1) Cylinder Body
(2) Spring
(3) Piston Assembly(4) Spacer
(5) Damper Rubber
(6) Cover and Gasket
Disassembly
1. Remove cover and gasket.
2. Remove damper rubber.
3. Remove spacer.
4. Remove piston assembly.
5. Remove spring.
Inspection and Repair
Check damper rubber and piston cup for cracks,
deformation or damage.
Replace the damper cylinder assembly if necessary.
Reassembly
To assemble, follow the disassembly steps in the reverse
order.
Page 2536 of 3573
CLUTCH7C±27
Main Data and Specifications
General Specifications
TypeDry single plate type with diaphragm spring
Size275 mm (10.83 in)
Pressure plate Outside diameter332 mm (13.07 in)
Pressure plate Clamping force7208 N (1621 lb)
Pressure plate Spring finger height49.9 ± 51.9 mm (1.965 ± 2.043 in)
Driven plate Outside diameter x inside diameter275y180 mm (10.83y6.69 in)
Thickness Clutch disengaged8.8 mm (0.346 in)
Thickness Clutch engaged8.3 mm (0.327 in)
Total friction area 339y2cm(52y2in)
Clutch control type Hydraulic
Clutch pedal free play 5 ± 15 mm (0.20 ± 0.59 in)
Clutch pedal heightLHD: 217 ± 227 mm (8.543 ± 8.937 in)
RHD:
(6VE1) 238.5 mm ± 248.5 mm (9.390 in ± 9.783 in)
(4JX1) 231 mm ± 241 mm (9.094 in ± 9.488 in)
Clutch pedal stroke 152.5 ± 162.5 mm (6.004 ± 6.398 in)
4JX1, RHD: 145 ± 155mm (5.709 ± 6.102 in)
Torque Specifications
E07RW053