Components
COMPONENTS
ILLUSTRATION
Installation
INSTALLATION
PROCEDURE
1. INSTALL CLUTCH MASTER CYLINDER ASSEMBLY
(a) Install the clutch master cylinder assembly to the clutch pedal support with the 2 bolts.
Torque:
12 N·m {120 kgf·cm, 9 ft·lbf}
(b) Install the clutch start switch to the clutch pedal support with the nut.
Torque:
16 N·m {160 kgf·cm, 12 ft·lbf}
(c) Using a union nut wrench, connect the clutch master cylinder to 2 way tube to the clutch master cylinder assembly.
Torque:
Specified tightening torque :
15 N·m {155 kgf·cm, 11 ft·lbf}
HINT:
(d) Connect the clutch reservoir tube to the clutch master cylinder assembly.
2. INSTALL CLUTCH PEDAL WITH CLUTCH MASTER CYLINDER
(a) Install the clutch pedal with clutch master cylinder to the vehicle body with the bolt and 2 nuts.
Torque:
for Bolt :
18 N·m {184 kgf·cm, 13 ft·lbf}
for Nut :
14 N·m {145 kgf·cm, 10 ft·lbf}
(b) Connect the clutch switch connector.
(c) Connect the clutch start switch connector.
3. CONNECT CLUTCH MASTER CYLINDER TO FLEXIBLE HOSE TUBE
(a) Using a union nut wrench, connect the clutch master cylinder to flexible hose tube to the clutch pedal support way.
Torque:
Specified tightening torque :
15 N·m {155 kgf·cm, 11 ft·lbf}
HINT:
4. CONNECT CLUTCH RESERVOIR TUBE
(a) Connect the clutch reservoir tube.
5. INSTALL DRIVER SIDE JUNCTION BLOCK
(See page )
6. FILL RESERVOIR WITH BRAKE FLUID
7. BLEED BRAKE LINE (for Vacuum Brake Booster)
8. BLEED CLUTCH LINE
9. INSPECT FOR CLUTCH FLUID LEAK
10. CHECK FLUID LEVEL IN RESERVOIR
11. INSPECT AND ADJUST CLUTCH PEDAL
Removal
REMOVAL
PROCEDURE
1. DRAIN CLUTCH FLUID
2. REMOVE DRIVER SIDE JUNCTION BLOCK
(See page )
3. DISCONNECT CLUTCH RESERVOIR TUBE
(a) Disconnect the clutch reservoir tube. HINT: Use a container to collect the fluid. |
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4. DISCONNECT CLUTCH MASTER CYLINDER TO FLEXIBLE HOSE TUBE
(a) Using a union nut wrench, disconnect the clutch master cylinder to flexible hose tube from the clutch pedal support way. HINT: Use a container to collect the fluid. |
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5. REMOVE CLUTCH PEDAL WITH CLUTCH MASTER CYLINDER
(a) Disconnect the clutch start switch connector.
(b) Disconnect the clutch switch connector.
(c) Remove the bolt, 2 nuts and clutch pedal with clutch master cylinder from the vehicle body. |
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6. REMOVE CLUTCH MASTER CYLINDER ASSEMBLY
(a) Disconnect the clutch reservoir tube from the clutch master cylinder assembly.
(b) Using a union nut wrench, disconnect the clutch master cylinder to 2 way tube from the clutch master cylinder assembly. |
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(c) Remove the nut and clutch start switch from the clutch pedal support. |
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(d) Remove the 2 bolts and clutch master cylinder assembly from the clutch pedal support. |
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Disassembly
DISASSEMBLY
PROCEDURE
1. REMOVE BRAKE ACTUATOR BRACKET NO. 1
(a) Using a hexagon wrench (5 mm), remove the screw and brake actuator bracket
No. 1.
(b) Using a screwdriver, remove the fluid level warning switch connector.
2. REMOVE BRAKE M ...
Do-it-yourself service precautions
If you perform maintenance yourself, be sure to follow the correct procedures
as given in these sections.
CAUTION
The engine compartment contains many mechanisms and fluids that may move suddenly,
become hot, or become electrically energized. To avoid death or serious injury observe
the ...
Disassembly
DISASSEMBLY
PROCEDURE
1. INSPECT 3RD GEAR THRUST CLEARANCE
(a) Using a dial indicator, measure the 3rd gear thrust clearance.
Standard clearance:
0.200 to 0.490 mm (0.0079 to 0.0192 in.)
If the clearance is outside the specification, replace the 3rd gear,
thrust washer, c ...