Page 705 of 2898
Components Ð RHD Model with QG Engine ÐNJCL0041
SCL843-A
1. Clutch pedal bracket
2. Pedal stopper bolt
3. Bush
4. Clutch pedal
5. Bush
6. Clevis pin
7. Assist spring
8. Return spring
9. Bush
10. Stopper rubber11. Bush
12. Snap pin
13. Fulcrum pin
14. Clutch master cylinder
15. Nipple
16. Reservoir cap
17. Reservoir tank
18. Hose clamp
19. Hose
20. Washer21. Clutch disc
22. Clutch cover
23. Withdrawal lever
24. Spacer
25. Operating cylinder
26. Clutch hose
27. Clutch lever
28. Spring pin
29. Release bearing
30. Release bearing spring
CLUTCH SYSTEM
Components Ð RHD Model with QG Engine Ð
CL-5
Page 706 of 2898
Components Ð LHD Model with QG Engine ÐNJCL0048
SCL844
1. Clutch pedal bracket
2. Clevis pin
3. Bush
4. Snap pin
5. Pedal stopper bolt
6. Clutch pedal
7. Clutch master cylinder
8. Nipple9. Reservoir cap
10. Reservoir tank
11. Hose clamp
12. Hose
13. Washer
14. Clutch disc
15. Clutch cover
16. Withdrawal lever17. Spacer
18. Operating cylinder
19. Clutch hose
20. Clutch lever
21. Spring pin
22. Release bearing
23. Release bearing spring
CLUTCH SYSTEM
Components Ð LHD Model with QG Engine Ð
CL-6
Page 707 of 2898
Components Ð RHD Model with YD Engine ÐNJCL0005
SCL845-A
1. Clutch pedal bracket
2. Pedal stopper bolt
3. Bush
4. Clutch pedal
5. Bush
6. Clevis pin
7. Assist spring
8. Bush
9. Stopper rubber
10. Bush11. Snap pin
12. Fulcrum pin
13. Clutch master cylinder
14. Nipple
15. Reservoir cap
16. Reservoir tank
17. Hose clamp
18. Hose
19. Washer20. Air bleeder screw
21. Withdrawal lever
22. Operating cylinder
23. Clutch hose
24. Clutch disc
25. Clutch cover
26. Clutch hose connector
27. Release bearing
28. Washer
CLUTCH SYSTEM
Components Ð RHD Model with YD Engine Ð
CL-7
Page 708 of 2898
Components Ð LHD Model with YD Engine ÐNJCL0049
SCL846
1. Clutch pedal bracket
2. Clevis pin
3. Bush
4. Snap pin
5. Pedal stopper bolt
6. Clutch pedal
7. Clutch master cylinder
8. Nipple9. Reservoir cap
10. Reservoir tank
11. Hose clamp
12. Hose
13. Washer
14. Air bleeder screw
15. Withdrawal lever16. Operating cylinder
17. Clutch hose
18. Clutch disc
19. Clutch cover
20. Clutch hose connector
21. Release bearing
22. Washer
CLUTCH SYSTEM
Components Ð LHD Model with YD Engine Ð
CL-8
Page 709 of 2898

Inspection and AdjustmentNJCL0006CLUTCH PEDAL INSPECTIONNJCL0006S03Pedal StrokeNJCL0006S0301Check clutch pedal stroke by using a 1±meter rule to measure the
total pedal stroke. Place end of rule onto the middle of the clutch
pedal pad. Place a book/clipboard on the driver's seat to set a ref-
erence point, ensure the book/clipboard does not move during
pedal depression. Mark (A) the pedal fully up position on the rule.
Depress the clutch pedal and mark (B) the rule again next to the
reference point on the book/clipboard. Measure the distance
between the marks (A and B), this is the actual pedal stroke (S).
Check the specified pedal stroke in the table, adjust actual pedal
stroke if necessary (refer toªCLUTCH PEDAL ADJUSTMENTº).
NOTE:
+Do not use steering wheel as a reference point, angle gives
incorrect reading.
+Ensure there is no interference between the floor carpet and
clutch pedal when fully depressed.
NCL058
SCL702
Pedal Free PlayNJCL0006S0302Check pedal free play, if out of specification refer toªCLUTCH
PEDAL ADJUSTMENTº
+Push on the clutch pedal until resistance is felt, and check the
distance the pedal moves.
CLUTCH SYSTEM
Inspection and Adjustment
CL-9
Page 710 of 2898

CLUTCH PEDAL ADJUSTMENTNJCL0006S04Pedal StrokeNJCL0006S04011. Loosen the pedal stopper bolt completely (so there is no con-
tact between pedal and stopper bolt).
2. Adjust pedal stroke to the specified value with the master cyl-
inder push rod.
3. Adjust the pedal stopper bolt until it is just in contact with the
pedal, then tighten the lock nut.
4. Once stroke is set to specification, adjust clutch pedal free
play.
Pedal stroke ªSº.
Refer to ªSDSº, CL-24.
Pedal Free PlayNJCL0006S04021. Adjust pedal free play to the specified value with the master
cylinder push rod.
2. Tighten lock nut of the master cylinder push rod.
+Push on the clutch pedal until resistance is felt, and check the
distance the pedal moves.
Pedal free play ªAº.
Refer to ªSDSº, CL-24.
SCL838
SCL839
AIR BLEEDING PROCEDURENJCL0006S021. Bleed air from clutch operating cylinder according to the fol-
lowing procedure.
+Carefully monitor fluid level at master cylinder during
bleeding operation.
a. Top up reservoir with recommended brake fluid.
b. Connect a transparent vinyl tube to air bleeder valve.
c. Slowly depress the clutch pedal to its full stroke and release it
completely. Repeat this operation several times at 2 to 3 sec-
onds intervals.
d. Open the air bleeder with the clutch pedal fully depressed.
e. Close the air bleeder.
f. Release the clutch pedal and wait at least 5 seconds.
g. Repeat steps c through f mentioned above, then air bubbles
will no longer appear at the damper in the brake fluid.
Air bleeder valve tightening torque:
: 5.9 - 9.8 N´m (0.6 - 1.0 kg-m, 52 - 86 in-lb)
CLUTCH SYSTEM
Inspection and Adjustment (Cont'd)
CL-10
Page 711 of 2898
ComponentsNJCL0007
SCL840-A
SCL847-A
CLUTCH MASTER CYLINDER
Components
CL-11
Page 712 of 2898

RemovalNJCL00081. Drain brake fluid.
CAUTION:
Be careful not to splash brake fluid on painted areas; it may
cause paint damage. If brake fluid is splashed on painted
areas, wash it away with water immediately.
2. Remove clutch tube using a flare nut wrench.
3. Remove snap pin between clutch pedal and push rod, and
remove clevis pin.
4. Unscrew master cylinder assembly mounting nuts and remove
master cylinder assembly from vehicle.
InstallationNJCL00091. Connect clutch tube to master cylinder assembly, and hand-
tighten flare nut.
2. Install master cylinder assembly to vehicle, and tighten mount-
ing nuts to the specified torque.
: 11 - 14 N´m (1.1 - 1.5 kg-m,8-10ft-lb)
3. Tighten clutch tube flare nut using a flare nut torque wrench.
: 15 - 18 N´m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)
4. After installing clevis pin, install snap pin to connect clutch
pedal to push rod.
5. After finishing the operation, bleed air from clutch piping con-
nector and operating cylinder. (Refer to ªAir Bleeding
Procedureº, CL-10.)
SCL725
DisassemblyNJCL00101. Loosen push rod lock nut A to remove clevis and lock nut A.
2. Remove dust cover.
3. Remove stopper ring and stopper, and remove push rod from
cylinder body. During removal, keep push rod depressed, to
prevent piston inside master cylinder from popping out.
4. Remove piston assembly from cylinder body.
InspectionNJCL0011Check the following items, and replace if necessary.
+Rubbing surface of cylinder and piston, for uneven wear, rust
or damage
+Piston with piston cup, for wear or damage
+Return spring, for wear or damage
+Dust cover, for cracks, deformation or damage
+Reservoir, for deformation or damage
CLUTCH MASTER CYLINDER
Removal
CL-12