Application	N•m	Lb-Ft	Lb-In
Clutch Master Cylinder Nuts	22	16	-
Clutch Pedal Shaft Nut	18	13	-
Pressure Plate-to-Flywheel Bolts	15	11	-
Release Cylinder Bolts	20	15	-

J-42474 Clutch Arbor

Checks	Action
DEFINITION: When the pedal is pressed to the floor, the shift lever does not move freely in and out of reverse gear.
Check for a loose linkage.	Repair or replace loose linkage, if necessary.
Check for a damaged clutch disc.	Replace the damaged clutch disc.
Check for an improperly installed fork shaft.	Remove and properly reinstalled the fork shaft. Very lightly lubricate the fork fingers at the release bearing with wheel bearing grease.
Check for the clutch disc hub binding on the input shaft splines.	Repair or replace the clutch disc hub.
Check for a warped or bent clutch disc.	Replace the warped or bent clutch disc.

Checks	Action
Check for the driver improperly operating the vehicle.	Correct the driver's operation of the vehicle as necessary.
Check for an oil-soaked clutch disc.	Correct the leak at its source and install a new clutch disc.
Check for a worn facing or facing torn from the disc.	Replace the worn disc with a new disc.
Check for a warped pressure plate or a warped flywheel.	Replace the warped pressure plate or the warped flywheel.
Check for a weak diaphragm spring.	Replace the pressure plate.
Check for a driven plate that is not seated.	Start the engine 30 to 40 times. Do not overheat the engine.
Check for a driven plate that is overheated.	Allow the driven plate to cool.

Checks	Action
Check for a burned or a glazed facing caused by oil on the facing.	Correct the leak at its source and install a new clutch disc.
Check for worn splines on the input shaft.	Replace the worn input shaft.
Check for a warped pressure plate or a warped flywheel.	Replace the warped pressure plate or the warped flywheel.
Check for a burned or smeared resin on the flywheel or the pressure plate.	Sand off the burned or smeared resin if it is superficial. Replace any burned or heat-checked parts.

Checks	Action
Check for weak retracting springs.	Replace the pressure plate.
Check for a loose release fork.	Remove and reinstall the release fork properly.
Check for oil in the driven plate bumper.	Correct the cause of the oil leak and replace the driven disc.
Check for a damaged driven plate damper spring.	Replace the driven disc.

Checks	Action
Check for the driver improperly operating the vehicle.	Correct the driver's operation of the vehicle as necessary.
Check for a binding release bearing.	Clean and re-lubricate the release bearing. Inspect the release bearing for burrs and nicks.
Check for an improperly installed release lever.	Remove and reinstall the release lever properly.
Check for a weak linkage return spring.	Replace the weak linkage return spring.

Checks	Action
Check for a worn release bearing.	Replace the worn release bearing.
Check for a improperly installed release lever.	Remove and properly reinstall the fork shaft. Very lightly lubricate the fork fingers at the release bearing with wheel bearing grease.

Checks	Action
Check for binding in the linkage or the release bearing.	Lubricate and free-up the binding linkage or the release bearing.
Check for weak pressure plate springs.	Replace the pressure plate.

Checks	Action
Check for binding in the linkage.	Lubricate and free-up the binding linkage.
Check for a worn driven plate.	Replace the worn driven plate.

1. Clutch Master Cylinder
2. Clutch Master Cylinder Gasket
3. Nut
4. Clutch Master Cylinder Pipe
5. Clutch Release Cylinder
6. Bolt
7. Bolt
8. Washer
9. Bolt
10. Clip
11. Reservoir Tank Hose

1. Clutch Pedal Brace
2. Pedal Shaft
3. E-Ring
4. Bushing
5. Pin
6. Nut
7. Bushing
8. Turn Over Spring
9. Clutch Pedal
10. Clutch Pedal Pad
11. Clutch Pedal Buffer

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1. Disconnect the negative battery cable.
2. Disconnect the return spring from the clutch pedal.
3. Remove the nut, the washer, and the pedal mounting shaft.



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4. Remove the locking clip and push rod fixing pin.
5. Remove the push rod from the clutch pedal.
6. Remove the clutch pedal.

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1. Install the clutch pedal.
2. Coat the push rod with multi-purpose grease.
3. Install the push rod to the clutch pedal.
4. Install the locking clip and push rod fixing pin.



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5. Coat the pedal mounting shaft with multi-purpose grease.
6. Install the nut, the washer, and the pedal mounting shaft.
Tighten
Tighten the nut to 18 N•m (13 lb-ft).


7. Connect the return spring to the clutch pedal.
8. Connect the negative battery cable.

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Bleed the hydraulic system to remove the air which entered When the pipes were disconnected for repairs. The clutch/brake fluid in the clutch/brake reservoir must be maintained at the MIN level or higher during air bleeding.
1. Attach a vinyl hose to the bleeder plug. Place the other end of the vinyl tube in a glass container half-filled with brake fluid.
2. Slowly pump the clutch pedal several times.
3. While you press the clutch pedal, loosen the bleeder screw until the fluid starts to run out. Close the bleeder screw.
4. Repeat Step 3 until there are no air bubbles in the fluid.
5. Fill the reservoir with brake fluid up to the MAX level.

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1. Disconnect the negative battery cable.
2. Remove the transaxle from the vehicle. Refer to Section 5B1, Five-Speed Manual Transaxle (D16).
3. Remove the pressure plate bolts and the pressure plate.
Important : Support the pressure plate when you remove the last bolt.



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4. Remove the clutch disc from the flywheel.

1. Visual Inspection
• Inspect the worn or oily contamination on the clutch surface.
• Inspect the damaged or weakened torsion spring.
• Inspect the a warped or bent clutch disc. After inspection, replace new clutch disc, if necessary.



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2. Clutch Disc Inspection
• Measure the rivet head depth from the clutch disc surface.
• Replace the clutch disc if the measured value is below the limit.
• Rivet Head Depth (Limit) : 1.2 mm (0.047 in)



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3. Clutch Disc Runout in Rotational Direction Inspection
• Measure runout using the dial gauge.
• If runout exceeds limit, replace the clutch disc.

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1. Check for a worn diaphragm spring finger.
2. Check for a worn or cracked pressure plate surface.
3. Check for the polluted face by the oil. After inspection, replace the pressure plate if necessary.

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1. Coat the spline on the clutch disc with multi-purpose grease.
2. Align the pressure plate and the clutch disc onto the flywheel using the clutch arbor J-42474.
3. Install the pressure plate bolts.
Tighten
Tighten the bolts to 15 N•m (11 lb-ft).


4. Remove the clutch arbor J-42474.
5. Install the transaxle into the vehicle. Refer to Section 5B1, Five-Speed Manual Transaxle (D16).
6. Connect the negative battery cable.

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Before disconnecting the reservoir tank hose, remove the clutch/brake fluid from the reservoir tank.
1. Remove the locking clip.
2. Remove the push rod fixing pin and push rod.



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3. Disconnect the hose clamp on the master cylinder.
4. Disconnect the master cylinder hose.



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5. Remove the master cylinder pipe.



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6. Remove the clutch master cylinder nuts.
7. Remove the clutch master cylinder.

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1. Install the clutch master cylinder and clutch master cylinder nuts.
Tighten
Tighten the clutch master cylinder nuts to 22 N•m (16 lb-ft).




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2. Install the master cylinder pipe.



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3. Connect the master cylinder hose.
4. Connect the hose clamp on the master cylinder.



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5. Install the push rod fixing pin and push rod.
6. Install the locking clip.
7. Bleed the air. Refer to "Air Bleeding" in this section.
8. Fill the reservoir with clutch/brake fluid up to the MAX level.

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1. Remove the bolt and disconnect the hose from the clutch release cylinder.



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2. Remove the clutch release cylinder bolts and remove the release cylinder from the transaxle.

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1. Connect the release cylinder to the transaxle and install the bolts.
Tighten
Tighten the release cylinder bolts to 20 N•m (15 lb-ft).




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2. Connect the hose assembly to the cylinder body.
3. Apply grease where the pushrod connects to the release lever. Be careful not to stain the boot.
4. Bleed the air. Refer to "Air Bleeding" in this section.
5. Fill the reservoir with clutch/brake fluid up to the MAX level.

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1. Remove the clutch master cylinder assembly from the vehicle. Refer to "Clutch Master Cylinder Assembly" in this section.
2. Remove the boot and disconnect the piston stop ring using ring pliers.



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3. Remove the pushrod assembly and the piston assembly.
4. Inspect the clutch master cylinder wall and the piston for wear. Replace the piston if necessary.
5. Inspect the cup and the piston for wear. Fluid leaks will show wear on the cup and the piston. Replace the cup and the piston if necessary.
6. Inspect the pushrod for wear. Repair the pushrod if necessary.

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1. Apply clean fluid to the piston assembly cup and insert the piston assembly and the pushrod assembly into the master cylinder body.



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2. Install the piston stop ring using ring pliers. Install the boot.
3. Install the clutch master cylinder assembly into the vehicle. Refer to "Clutch Master Cylinder Assembly" in this section.

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1. Remove the clutch release cylinder assembly from the vehicle. Refer to "Clutch Release Cylinder Assembly" in this section.
2. Remove the bolts and brackets.



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3. Remove the boot and the pushrod.



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4. Compress the piston with a driver and remove the snap ring with snap ring pliers.
5. Remove the piston assembly.

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1. Apply clean clutch fluid to the piston and the cup.
2. Install the spring to the piston, and insert the assembly into the cylinder body.
3. Compress the piston with a driver, then install the snap ring with snap ring pliers.



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4. Install the pushrod and the boot.



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5. Install the brackets and the bolts.
6. Install the clutch release cylinder assembly. Refer to "Clutch Release Cylinder Assembly" in this section.