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2. Remove CSC bolts and the CSC from clutch housing.
INSTALLATION 1. Install CSC to clutch housing and then tighten bolts to specification. Refer to MT-59, " Disassembly and
Assembly " .
CAUTION:
• Do not reuse CSC.
• Do not insert and operate CSC because piston an d stopper of CSC components may fall off.
2. Install transaxle assembly. Refer to EM-88, " Removal and Installation " (HR16DE models),
EM-195," Removal and Installation " (MR18DE models).
3. Bleed the air from the clutch hydraulic system. Refer to CL-8, " Air Bleeding Procedure " .
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.
2. Remove the air cleaner and air duct. Refer to EM-26, " Removal and Installation " (HR16DE models),
EM-139, " Removal and Installation " (MR18DE models).
3. Use one of the following methods to remove hose from clutch master cylinder. • Drain clutch fluid from reservoir tank and remove hose.
• Remove hose from clutch master cylinder. Immediat ely plug hose and reservoir tank to prevent clutch
fluid from dripping.
CAUTION:
Do not spill clutch fluid onto painted surfaces. If it spills, wi pe up immediately and wash the
affected area with water.
4. Remove clutch tube lock pin from clutch master cylinder.
5. Remove clutch tube lock pin at clutch housing.
6. Remove clutch tube lock pins (2) from clutch damper (3).
7. Remove clutch tube (1) from clutch damper (3).
8. Remove clutch damper (3) from bracket (4).
INSTALLATION
Installation is in the reverse order of removal.
• Make sure that all tubes are fu lly installed into connectors.
• Make sure that all connector lock pins are fully installed.
• After installation, bleed the air from the clutch hydraulic system. Refer to CL-8, " Air Bleeding Procedure " .
1. Clutch tube 2. Clutch tube lock pin 3. CSC
4. Clutch damper 5. Clutch master cylinder 6. Clutch pedal WCIA0597E
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CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
Removal and Installation INFOID:0000000004305174
COMPONENTS
CAUTION:
• Never reuse CSC (Concentric Slave Cylinder). B ecause CSC slides back to the original position
every time when removing transaxle assembly. At th is timing, dust on the sliding parts may damage
a seal of CSC and may cause clut ch fliud leakage. Refer to CL-12, " Removal and Installation " .
• Never bring any grease to the clutch disc faci ng, pressure plate surface and flywheel surface.
• When installing, be careful that grease applied to input shaft does not adhere to clutch disc.
• Never clean clutch disc using solvent.
REMOVAL 1. Remove transaxle assembly from the vehicle. Refer to MT-16, " Removal and Installation " (RS5F91R
models), MT-58, " Removal and Installation " (RS6F94R models).
2. Loosen clutch cover bolts evenly. Then remove clutch cover and clutch disc.
INSPECTION AND ADJUSTMENT AFTER REMOVAL
Clutch Disc • Measure clutch disc runout and spline backlash. If either measure- ment exceeds the specificat ion, replace clutch disc.
• Check clutch disc for burns, discoloration or oil or grease leakage. Replace if necessary.
1. Flywheel 2. Clutch disc 3. Clutch cover
4. Input shaft A. First step (MR18DE engine models) B. First step (HR16DE engine models)
C. Final step Apply lithium-based grease including molybdenum disulphide Clutch Disc " .
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Inspection "
(HR16DE models),
EM-216, " Inspection After Disassembly "
(MR18DE models).
CAUTION:
Measure flywheel outer face (not on knock pin and clutch cover
mounting hole).
INSTALLATION
1. Clean clutch disc and input shaft splines to remove grease and dust caused by abrasion.
2. Apply recommended grease to clutch disc and input shaft splines. CAUTION:
Be sure to apply grease to the points specified. Ot herwise, noise, poor disengagement, or damage
to the clutch may result. Excessive grease may cause sl ip or shudder. If it adheres to CSC seal, it
will cause clutch fluid l eakage. Wipe off excess grease.
Clutch facing wear : Refer to
CL-18, " Clutch Disc " .
Clutch
Cover " .
Tool number A : ST20050240 ( — )
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3. Install clutch disc using suitable clutch aligner (A).
• B: HR16DE
• C: MR18DE
4. Install clutch cover. Pre-tighten clutch cover bolts.
5. Tighten clutch cover bolts evenly in two steps in the order shown.
6. Install transaxle assembly. Refer to MT-58, " Removal and Instal-
lation " .
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Clearance (A) between clutch pedal and ASCD switch threaded
end while clutch pedal is fully released (if equipped). 0.74 - 1.96 mm (0.0291 - 0.0772 in)
Clearance (C) between clutch pedal and clutch interlock switch
threaded end while clutch pedal is fully depressed. 0.74 - 1.96 mm (0.0291 - 0.0772 in)Engine type HR16DE MR18DE
Model 200 225
Facing size (outer dia. × inner dia. × thickness) 200 mm x 140 mm x 3.1 mm (7.87 in x
5.51 in x 0.122 in) 225 mm
× 160 mm × 3.2 mm (8.86 in ×
6.30 in × 0.126 in)
Thickness of disc assembly with load 7.1 - 7.5 mm (0.280 - 0.295 in) with 4,658
N (475 kg, 1,047 lb) 7.2 - 7.6 mm (0.283 - 0.299 in) with
5,394 N (550 kg, 1,213 lb)
Runout limit/diameter of the area to be measured 1.0 mm (0.039 in) / 190 mm (7.48 in) dia 1.0 mm (0.039 in) / 215 mm (8.46 in)
dia.
Maximum spline backlash (at outer edge of disc) 0.8 mm (0.031 in) 0.9 mm (0.035 in)
Wear limit of facing (depth to the rivet head) 0.3 mm (0.012 in) 0.3 mm (0.012 in) Engine type HR16DE MR18DE
Set-load 4,658 N (475.1 kg, 1,047.1 lb) 5,394 N (550 kg, 1,213 lb)
Diaphragm spring lever height 29 - 31 mm (1.14 - 1.22 in) 20 - 22 mm (0.79 - 0.87 in)
Uneven limit of diaphragm spring toe height 0.7 mm (0.028 in) or less 0.7 mm (0.028 in) or less
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CONTENTS
ENGINE COOLING SYSTEM
HR16DE
PRECAUTION ....... ........................................
3
PRECAUTIONS .............................................. .....3
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ............................................................. ......
3
Precaution Necessary fo r Steering Wheel Rota-
tion After Battery Disconnect ............................... ......
3
Precaution for Liquid Gasket ............................... ......4
PREPARATION .... ........................................5
PREPARATION .............................................. .....5
Special Service Tool ........................................... ......5
Commercial Service Tool .................................... ......5
SYMPTOM DIAGNOSIS ..... ..........................7
OVERHEATING CAUSE ANALYSIS ............. .....7
Troubleshooting Chart ..... ..........................................7
FUNCTION DIAGNOSIS .. .............................9
DESCRIPTION ............................................... .....9
Engine Cooling System ....................................... ......9
Engine Cooling System Schematic ..................... ....10
ON-VEHICLE MAINTENA NCE ....................11
ENGINE COOLANT ....................................... ....11
Inspection ............................................................ ....11
Changing Engine Coolant ................................... ....11
RADIATOR ..................................................... ....14
Checking Radiator Cap ....................................... ....14
Checking Radiator ............................................... ....14
ON-VEHICLE REPAIR .... .............................16
RADIATOR ..................................................... ....16 Component ..........................................................
....16
Removal and Installation ..................................... ....16
COOLING FAN .................................................. 18
Component (Models with A/C) ............................. ....18
Component (Models without A/C) ........................ ....18
Removal and Installation ..................................... ....19
WATER PUMP .................................................. 20
Exploded View ..................................................... ....20
Removal and Installation ..................................... ....20
Inspection ............................................................ ....21
THERMOSTAT .................................................. 22
Exploded View ..................................................... ....22
Removal and Installation ..................................... ....22
Inspection ............................................................ ....23
WATER OUTLET .............................................. 24
Exploded View ..................................................... ....24
Removal and Installation ..................................... ....24
Inspection ............................................................ ....25
DISASSEMBLY AND AS SEMBLY ..............26
COOLING FAN .................................................. 26
Disassembly and Assembly ................................. ....26
SERVICE DATA AND SPECIFICATIONS
(SDS) ............... .............................................
27
SERVICE DATA AND SPECIFICATIONS
(SDS) ................................................................. 27
Periodical Maintenance Specification .................. ....27
Radiator ............................................................... ....27
Thermostat .......................................................... ....27
MR18DE
SERVICE INFORMATION .. .........................28
PRECAUTIONS ................................................. 28
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