Page 697 of 2898
Measurement PointsNJBT0026S0102
SBT009A
BODY (ALIGNMENT)
Alignment (Cont'd)
BT-79
Page 698 of 2898
UNDERBODYNJBT0026S02MeasurementNJBT0026S0201
SBT010AA
BODY (ALIGNMENT)
Alignment (Cont'd)
BT-80
Page 699 of 2898
Measurement PointsNJBT0026S0202
SBT011AA
BODY (ALIGNMENT)
Alignment (Cont'd)
BT-81
Page 700 of 2898
BODY (ALIGNMENT)
Alignment (Cont'd)
BT-82
Page 701 of 2898

CLUTCH
SECTION
CL
CONTENTS
PRECAUTIONS...............................................................2
Precautions ..................................................................2
PREPARATION...............................................................3
Special Service Tools ..................................................3
Commercial Service Tools ...........................................3
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING.....................................................4
NVH Troubleshooting Chart.........................................4
CLUTCH...................................................................4
CLUTCH SYSTEM...........................................................5
Components - RHD Model with QG Engine - .............5
Components - LHD Model with QG Engine -..............6
Components - RHD Model with YD Engine -..............7
Components - LHD Model with YD Engine - ..............8
Inspection and Adjustment ..........................................9
CLUTCH PEDAL INSPECTION...................................9
CLUTCH PEDAL ADJUSTMENT...............................10
AIR BLEEDING PROCEDURE..................................10
CLUTCH MASTER CYLINDER..................................... 11
Components............................................................... 11
Removal .....................................................................12
Installation ..................................................................12
Disassembly...............................................................12
Inspection...................................................................12
Assembly ...................................................................13
OPERATING CYLINDER...............................................14
Components...............................................................14
Removal .....................................................................14
Disassembly...............................................................14
Inspection...................................................................14
Assembly ...................................................................15
Installation ..................................................................15
PIPING...........................................................................16
Removal .....................................................................16Installation ..................................................................16
RS5F30A, RS5F70A
CLUTCH RELEASE MECHANISM...............................17
Components...............................................................17
Removal .....................................................................17
Inspection...................................................................17
Installation ..................................................................17
RS5F50A
CLUTCH RELEASE MECHANISM...............................20
Components...............................................................20
Removal .....................................................................20
Inspection...................................................................20
Installation ..................................................................20
CLUTCH DISC, CLUTCH COVER AND
FLYWHEEL....................................................................22
Components...............................................................22
Inspection and Adjustment ........................................22
CLUTCH DISC.........................................................22
CLUTCH COVER.....................................................23
FLYWHEEL.............................................................23
Installation ..................................................................23
SERVICE DATA AND SPECIFICATIONS (SDS).........24
Clutch Control System ...............................................24
Clutch Master Cylinder ..............................................24
Clutch Operating Cylinder .........................................24
Clutch Disc.................................................................24
Clutch Cover ..............................................................24
Clutch Pedal ..............................................................24
Page 702 of 2898
SBR820BA
PrecautionsNJCL0001+Recommended fluid is brake fluid ªDOT 4º. Refer to
MA-16, ªFluid and Lubricantsº.
+Never reuse drained brake fluid.
+Be careful not to splash brake fluid on painted areas.
+When removing and installing clutch piping, use Tool.
+Use new brake fluid to clean or wash all parts of master
cylinder and operating cylinder.
+Never use mineral oils such as gasoline or kerosene. It will
ruin the rubber parts of the hydraulic system.
WARNING:
After cleaning clutch disc, wipe it with a dust collector. Do not
use compressed air.
PRECAUTIONS
Precautions
CL-2
Page 703 of 2898
Special Service ToolsNJCL0002
Tool number
Tool nameDescription
GG94310000
Flare nut torque wrench
NT406
Removing and installing clutch piping
a: 10 mm (0.39 in)
KV30101600 (New)
KV30101000 (Former)
Clutch aligning bar
NT645
Installing clutch cover and clutch disc
(F30A and F70A)
a: 15.9 mm (0.626 in) dia.
b: 17.9 mm (0.705 in) dia.
c: 40 mm (1.57 in)
ST20630000
Clutch aligning bar
NT405
Installing clutch cover and clutch disc
(F50A)
a: 15.8 mm (0.622 in) dia.
b: 22.9 mm (0.902 in) dia.
c: 45.0 mm (1.772 in)
ST20050240
Diaphragm spring adjust-
ing wrench
NT404
Adjusting unevenness of diaphragm spring of
clutch cover
a: 150 mm (5.91 in)
b: 25 mm (0.98 in)
KV32101000
Pin punch
NT410
Removing and installing spring pin
a: 4 mm (0.16 in) dia.
Commercial Service ToolsNJCL0003
Tool name Description
1 Flare nut crowfoot
2 Torque wrench
NT360
Removing and installing clutch piping
a: 10 mm (0.39 in)
PREPARATION
Special Service Tools
CL-3
Page 704 of 2898

NJCL0004
NVH Troubleshooting ChartNJCL0004S01Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-
tion. If necessary, repair or replace these parts.
CLUTCHNJCL0004S0101
Reference pageCL-10
CL-10
CL-11
CL-14
Refer to EM-137, ªRemoval and Installationº (QG engine model) and
EM-137, ªRemoval and Installationº (YD engine model).
CL-17 (RS5F30A, RS5F70A), CL-20 (RS5F50A)
CL-22
CL-22
CL-22
CL-22
CL-22
CL-22
CL-22
CL-22
CL-23
CL-23
CL-23
CL-23
SUSPECTED PARTS
(Possible cause)
CLUTCH PEDAL (Free play out of adjustment)
CLUTCH LINE (Air in line)
MASTER CYLINDER PISTON CUP (Damaged)
OPERATING CYLINDER PISTON CUP (Damaged)
ENGINE MOUNTING (Loose)
RELEASE BEARING (Worn, dirty or damaged)
CLUTCH DISC (Out of true)
CLUTCH DISC (Runout is excessive)
CLUTCH DISC (Lining broken)
CLUTCH DISC (Dirty or burned)
CLUTCH DISC (Oily)
CLUTCH DISC (Worn out)
CLUTCH DISC (Hardened)
CLUTCH DISC (Lack of spline grease)
DIAPHRAGM SPRING (Damaged)
DIAPHRAGM SPRING (Out of tip alignment)
PRESSURE PLATE (Distortion)
FLYWHEEL (Distortion)
SymptomClutch grabs/chatters 1 2 2 2 2 2
Clutch pedal spongy 1 2 2
Clutch noisy 1
Clutch slips 1 2 2 3 4 5
Clutch does not disen-
gage1234 55555 5667
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart
CL-4