Juke F15 (2012 year). Service Repair Manual — part 54
CL-16
< REMOVAL AND INSTALLATION >
CLUTCH PEDAL
REMOVAL AND INSTALLATION
CLUTCH PEDAL
LHD
LHD : Exploded View
INFOID:0000000006404923
LHD : Removal and Installation
INFOID:0000000006404924
REMOVAL
1.
Remove instrument lower panel LH. (MR16DDT) Refer to
IP-13, "Removal and Installation"
2.
Disconnect clutch pedal position switch connector. (With ASCD or with push-button ignition switch sys-
tem)
3.
Disconnect clutch interlock switch connector. (With push-button ignition switch system)
4.
Disconnect clip of harness from clutch pedal. (With ASCD or with push-button ignition switch system)
1.
Clutch pedal
2.
Stopper rubber
3.
Clip
4.
Clutch interlock switch
*1
5.
Clutch pedal position switch
*2
6.
Pedal pad
7.
Pedal stopper rubber
*1 : With push-button ignition switch system
*2 : With ASCD or with push-button ignition switch system
: N·m (kg-m, ft-lb)
JPDIB0161GB
CLUTCH PEDAL
CL-17
< REMOVAL AND INSTALLATION >
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5.
Remove master cylinder rod end from clutch pedal.
6.
Remove clutch pedal position switch and clip from clutch pedal.
(With ASCD or with push-button ignition switch system)
7.
Remove clutch interlock switch and clip from clutch pedal. (With
push-button ignition switch system)
8.
Remove clutch pedal from the vehicle.
9.
Remove pedal pad from clutch pedal.
10. Remove stopper rubber and pedal stopper rubber from clutch
pedal, using a suitable remover.
INSTALLATION
Note the following, and install in the reverse order of removal.
CAUTION:
Press master cylinder rod end into clutch pedal until it stops.
LHD : Inspection and Adjustment
INFOID:0000000006404925
INSPECTION AFTER REMOVAL
• Check clutch pedal for bend, damage, or a cracked weld. If bend, damage, or a cracked weld is found,
replace clutch pedal.
• Check stopper rubber and pedal stopper rubber. If damage or deformation is found, replace stopper rubber
and pedal stopper rubber.
• Check pedal pad. If wear or damage is found, replace pedal pad.
INSPECTION AFTER INSTALLATION
• Check the clutch pedal height, clutch pedal height at clutch disengagement, and clutch pedal play. Refer to
CL-7, "Inspection and Adjustment"
• Check the clutch interlock switch position. (With push-button ignition switch system) Refer to
.
• Check the clutch pedal position switch position. (With ASCD or with push-button ignition switch system)
CL-7, "Inspection and Adjustment"
.
ADJUSTMENT AFTER INSTALLATION
• Adjust the clutch interlock switch position. (With push-button ignition switch system) Refer to
.
• Adjust the clutch pedal position switch position. (With ASCD or with push-button ignition switch system)
CL-7, "Inspection and Adjustment"
.
RHD
PCIB1491E
CL-18
< REMOVAL AND INSTALLATION >
CLUTCH PEDAL
RHD : Exploded View
INFOID:0000000006404926
RHD : Removal and Installation
INFOID:0000000006404927
REMOVAL
1.
Disconnect clutch pedal position switch connector. (With ASCD or with push-button ignition switch sys-
tem)
2.
Disconnect clutch interlock switch connector. (With push-button ignition switch system)
3.
Disconnect clip of harness from clutch pedal. (With ASCD or with push-button ignition switch system)
4.
Remove master cylinder rod end from clutch pedal.
5.
Remove clutch pedal position switch and clip from clutch pedal.
(With ASCD or with push-button ignition switch system)
6.
Remove clutch interlock switch and clip from clutch pedal. (With
push-button ignition switch system)
7.
Remove clutch pedal from the vehicle.
8.
Remove pedal pad from clutch pedal.
9.
Remove pedal stopper rubber from clutch pedal, using a suit-
able remover.
INSTALLATION
Note the following, and install in the reverse order of removal.
CAUTION:
1.
Clutch pedal
2.
Clutch interlock switch
*1
3.
Clip
4.
Clutch pedal position switch
*2
5.
Pedal pad
6.
Pedal stopper rubber
*1 : With push-button ignition switch system
*2 : With ASCD or with push-button ignition switch system
: N·m (kg-m, ft-lb)
JPDIB0237GB
PCIB1491E
CLUTCH PEDAL
CL-19
< REMOVAL AND INSTALLATION >
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Press master cylinder rod end into clutch pedal until it stops.
RHD : Inspection and Adjustment
INFOID:0000000006413956
INSPECTION AFTER REMOVAL
• Check clutch pedal for bend, damage, or a cracked weld. If bend, damage, or a cracked weld is found,
replace clutch pedal.
• Check pedal stopper rubber. If damage or deformation is found, replace pedal stopper rubber.
• Check pedal pad. If wear or damage is found, replace pedal pad.
INSPECTION AFTER INSTALLATION
• Check the clutch pedal height, clutch pedal height at clutch disengagement, and clutch pedal play. Refer to
CL-7, "Inspection and Adjustment"
• Check the clutch interlock switch position. (With push-button ignition switch system) Refer to
.
• Check the clutch pedal position switch position. (With ASCD or with push-button ignition switch system)
CL-7, "Inspection and Adjustment"
.
ADJUSTMENT AFTER INSTALLATION
• Adjust the clutch interlock switch position. (With push-button ignition switch system) Refer to
.
• Adjust the clutch pedal position switch position. (With ASCD or with push-button ignition switch system)
CL-7, "Inspection and Adjustment"
.
CL-20
< REMOVAL AND INSTALLATION >
CLUTCH MASTER CYLINDER
CLUTCH MASTER CYLINDER
LHD
LHD : Exploded View
INFOID:0000000006404929
LHD : Removal and Installation
INFOID:0000000006404930
REMOVAL
CAUTION:
• Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.
• Never disassemble clutch master cylinder.
1.
Drain clutch fluid. Refer to
(RS6F94R).
2.
Remove air cleaner case. Refer to
EM-26, "Removal and Installation"
(HR16DE), or
EM-280, "Removal and Installation"
(K9K).
3.
Remove reservoir hose from reservoir tank and master cylinder.
4.
Remove master cylinder rod end (
) from clutch pedal.
1.
Reservoir hose
2.
Reservoir tank
3.
Master cylinder
JPDIB0162ZZ
PCIB1491E
CLUTCH MASTER CYLINDER
CL-21
< REMOVAL AND INSTALLATION >
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5.
Pull up the lock pin (1) from connector of master cylinder (2) and
separate clutch tube (3).
6.
Rotate master cylinder clockwise by 45 degrees, and then
remove master cylinder from the vehicle.
INSTALLATION
CAUTION:
Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.
1.
Tilt master cylinder clockwise by 45 degrees (A) and insert it to
the mounting hole. Rotate counterclockwise and secure it. At
this time, nipple (1) is upward of the vehicle.
2.
Install master cylinder rod end to clutch pedal.
CAUTION:
Press master cylinder rod end into clutch pedal until it
stops.
3.
Install reservoir hose to reservoir tank and master cylinder.
CAUTION:
Set reservoir hose with painted mark facing upward.
4.
Press down the lock pin into connector of master cylinder until it stops.
5.
Install clutch tube into connector of master cylinder until it stops.
6.
For the next step and after, install in the reverse order of removal.
LHD : Inspection and Adjustment
INFOID:0000000006404931
INSPECTION AFTER INSTALLATION
• Check the fluid leakage and the fluid level. Refer to
(RS5F92R) or
(RS6F94R).
• Check the clutch pedal height, clutch pedal height at clutch disengagement, and clutch pedal play. Refer to
CL-7, "Inspection and Adjustment"
• Check the clutch interlock switch position. (With push-button ignition switch system) Refer to
.
• Check the clutch pedal position switch position. (With ASCD or with push-button ignition switch system)
CL-7, "Inspection and Adjustment"
.
ADJUSTMENT AFTER INSTALLATION
• Adjust the clutch interlock switch position. (With push-button ignition switch system) Refer to
.
• Adjust the clutch pedal position switch position. (With ASCD or with push-button ignition switch system)
CL-7, "Inspection and Adjustment"
.
• Perform the air bleeding. Refer to
CL-12, "RS5F92R : Air Bleeding"
(RS6F94R).
RHD
JPDIB0167ZZ
B
: Mounting condition
JPDIB0114ZZ
CL-22
< REMOVAL AND INSTALLATION >
CLUTCH MASTER CYLINDER
RHD : Exploded View
INFOID:0000000006404932
RHD : Removal and Installation
INFOID:0000000006404933
REMOVAL
CAUTION:
• Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.
• Never disassemble clutch master cylinder.
1.
Drain clutch fluid. Refer to
(RS6F94R).
2.
Move the fuel feed tube and the fuel return hose aside not to interfere with work. (K9K)
3.
Remove reservoir hose from reservoir tank and master cylinder.
4.
Remove master cylinder rod end (
) from clutch pedal.
5.
Remove the engine room insulator.
6.
Remove the cowl top extension. Refer to
.
7.
Pull up the lock pin (1) from connector of master cylinder (2) and
separate clutch tube (3).
8.
Rotate master cylinder clockwise by 45 degrees, and then
remove master cylinder from the vehicle.
INSTALLATION
CAUTION:
1.
Reservoir tank
2.
Reservoir hose
3.
Master cylinder
JPDIB0185ZZ
PCIB1491E
JPDIB0169ZZ
CLUTCH MASTER CYLINDER
CL-23
< REMOVAL AND INSTALLATION >
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Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.
1.
Tilt master cylinder clockwise by 45 degrees (A) and insert it to
the mounting hole. Rotate counterclockwise and secure it. At
this time, nipple (1) is upward of the vehicle.
2.
Install master cylinder rod end to clutch pedal.
CAUTION:
Press master cylinder rod end into clutch pedal until it
stops.
3.
Install reservoir hose to reservoir tank and master cylinder.
4.
Press down the lock pin into connector of master cylinder until it
stops.
5.
Install clutch tube into connector of master cylinder until it stops.
6.
Install the fuel feed tube and the fuel return hose. (K9K)
7.
Fill with clutch fluid. Refer to
(RS5F92R) or
(RS6F94R).
8.
Install the engine room insulator.
9.
Install the cowl top extension. Refer to
EXT-20, "Removal and Installation"
.
RHD : Inspection and Adjustment
INFOID:0000000006413957
INSPECTION AFTER INSTALLATION
• Check the fluid leakage and the fluid level. Refer to
(RS5F92R) or
(RS6F94R).
• Check the clutch pedal height, clutch pedal height at clutch disengagement, and clutch pedal play. Refer to
CL-7, "Inspection and Adjustment"
• Check the clutch interlock switch position. (With push-button ignition switch system) Refer to
.
• Check the clutch pedal position switch position. (With ASCD or with push-button ignition switch system)
CL-7, "Inspection and Adjustment"
.
ADJUSTMENT AFTER INSTALLATION
• Adjust the clutch interlock switch position. (With push-button ignition switch system) Refer to
.
• Adjust the clutch pedal position switch position. (With ASCD or with push-button ignition switch system)
CL-7, "Inspection and Adjustment"
.
• Perform the air bleeding. Refer to
CL-12, "RS5F92R : Air Bleeding"
(RS6F94R).
B
: Mounting condition
JPDIB0114ZZ
CL-24
< REMOVAL AND INSTALLATION >
CLUTCH PIPING
CLUTCH PIPING
Exploded View
INFOID:0000000006404935
RS5F92R
JPDIB0181ZZ
1.
CSC (Concentric Slave Cylinder)
2.
Clutch tube
3.
Clutch damper
4.
Bracket
5.
Master cylinder
CLUTCH PIPING
CL-25
< REMOVAL AND INSTALLATION >
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RS6F94R
Hydraulic Layout
INFOID:0000000006404936
Removal and Installation
INFOID:0000000006404937
CAUTION:
Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.
REMOVAL
Note the following, and refer to
• Drain clutch fluid. Refer to
(RS5F92R) or
(RS6F94R).
• Press the lock pin into the bleeding connector of the CSC, and then remove clutch tube from CSC.
• Pull the lock pins from the connectors of the clutch damper until the pins stop, and then remove clutch tubes
from clutch damper.
JPDIB0184ZZ
1.
CSC (Concentric Slave Cylinder)
2.
Clutch tube
3.
Clutch damper
4.
Bracket
5.
Master cylinder
1.
Clutch tube
2.
Lock pin
3.
CSC (Concentric Slave Cylinder)
4.
Clutch damper
5.
Master cylinder
6.
Clutch pedal
PCIB1499E
CL-26
< REMOVAL AND INSTALLATION >
CLUTCH PIPING
• Pull the lock pin from the connector of the clutch master cylinder until the pin stop, and then remove clutch
tube from clutch master cylinder.
INSTALLATION
Note the following, and refer to
for installation procedure.
CAUTION:
Never damage clutch tube.
• Insert each clutch tube into the CSC bleeding connector, the clutch damper connector, and the clutch master
cylinder connector until it contacts the end of each connector.
• Install each lock pin into the clutch damper connector and the clutch master cylinder connector until it con-
tacts the end of each connector.
Inspection and Adjustment
INFOID:0000000006404938
INSPECTION AFTER REMOVAL
• Check the clutch tube for cracks and damage. If the clutch tube has cracks or damage, replace it with a new
one.
• Check the O-ring of the clutch tube for cracks and damage. If the O-ring of the clutch tube has cracks or
damage, replace clutch tube with a new one.
• Check the clutch damper for cracks and damage. If the clutch damper has cracks or damage, replace it with
a new one.
INSPECTION AFTER INSTALLATION
• Check the fluid leakage and the fluid level. Refer to
(RS5F92R) or
• Check the clutch pedal height, clutch pedal height at clutch disengagement, and clutch pedal play. Refer to
CL-7, "Inspection and Adjustment"
ADJUSTMENT AFTER INSTALLATION
Perform the air bleeding. Refer to
CL-12, "RS5F92R : Air Bleeding"
(RS5F92R) or
(RS6F94R).
CSC (CONCENTRIC SLAVE CYLINDER)
CL-27
< UNIT REMOVAL AND INSTALLATION >
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UNIT REMOVAL AND INSTALLATION
CSC (CONCENTRIC SLAVE CYLINDER)
Exploded View
INFOID:0000000006404943
Removal and Installation
INFOID:0000000006404944
CAUTION:
• Never reuse CSC (Concentric Slave Cylinder). Because CSC slides back to the original position
every time when removing transaxle assembly. At this timing, dust on the sliding parts may damage
a seal of CSC and may cause clutch fluid leakage.
• Never disassemble CSC.
• Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.
REMOVAL
1.
Remove transaxle assembly. Refer to
TM-30, "Removal and Installation"
"MR16DDT : Removal and Installation"
(RS6F94R with MR16DDT),
TM-86, "K9K : Removal and Installa-
2.
Remove CSC from clutch housing.
INSTALLATION
1.
Install CSC to clutch housing, and then tighten CSC mounting bolts to the specified torque.
CAUTION:
• Never reuse CSC.
• Never insert and operate CSC because piston and stopper of CSC components may fall off.
2.
For the next step and after, install in the reverse order of removal.
Inspection and Adjustment
INFOID:0000000006404945
INSPECTION AFTER INSTALLATION
Check the fluid leakage and the fluid level. Refer to
(RS5F92R) or
(RS6F94R).
ADJUSTMENT AFTER INSTALLATION
1.
Transaxle assembly
2.
CSC (Concentric Slave Cylinder)
: Always replace after every disassembly.
: N·m (kg-m, ft-lb)
JPDIB0040GB
CL-28
< UNIT REMOVAL AND INSTALLATION >
CSC (CONCENTRIC SLAVE CYLINDER)
Perform the air bleeding. Refer to
CL-12, "RS5F92R : Air Bleeding"
(RS5F92R) or
(RS6F94R).
CLUTCH DISC AND CLUTCH COVER
CL-29
< UNIT REMOVAL AND INSTALLATION >
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CLUTCH DISC AND CLUTCH COVER
EXCEPT FOR K9K
EXCEPT FOR K9K : Exploded View
INFOID:0000000006404946
HR16DE
MR16DDT
JPDIB0148GB
1.
Flywheel
2.
Clutch disc
3.
Clutch cover
4.
Input shaft
A.
First step
B.
Final step
: N·m (kg-m, ft-lb)
: Apply lithium-based grease including molybdenum disulphide.
JPDIB0049GB
1.
Flywheel
2.
Clutch disc
3.
Clutch cover
4.
Input shaft
A.
First step
B.
Final step
: N·m (kg-m, ft-lb)
: Apply lithium-based grease including molybdenum disulphide.
CL-30
< UNIT REMOVAL AND INSTALLATION >
CLUTCH DISC AND CLUTCH COVER
EXCEPT FOR K9K : Removal and Installation
INFOID:0000000006404947
CAUTION:
• Never reuse CSC (Concentric Slave Cylinder). Because CSC slides back to the original position
every time when removing transaxle assembly. At this timing, dust on the sliding parts may damage
a seal of CSC and may cause clutch fluid leakage. Refer to
CL-27, "Removal and Installation"
• Never bring any grease to the clutch disc facing, pressure plate surface and flywheel surface.
• Never clean clutch disc using solvent.
REMOVAL
1.
Remove transaxle assembly. Refer to
TM-30, "Removal and Installation"
"MR16DDT : Removal and Installation"
(RS6F94R).
2.
Remove clutch cover mounting bolts while holding clutch cover.
CAUTION:
Never drop clutch disc.
3.
Remove clutch cover and clutch disc.
CAUTION:
Never drop clutch disc.
INSTALLATION
1.
Clean clutch disc and input shaft splines to remove grease and powder arisen from abrasion.
2.
Apply recommended grease to clutch disc (1) and input shaft (2)
splines (A).
CAUTION:
Be sure to apply grease to the points specified. Otherwise,
noise, poor disengagement, or damage to the clutch may
result. Excessive grease may cause slip or judder. And if it
adheres to seal of CSC, it cause clutch fluid leakage. Wipe
out excess grease. Wipe out any grease oozing from the
parts.
3.
Install clutch disc, using a clutch aligner (A) [Commercial service
tool].
4.
Install clutch cover, and then temporarily tighten clutch cover
mounting bolts.
5.
Tighten clutch cover mounting bolts to the specified torque
evenly in two steps in the numerical order as shown in the fig-
ure.
6.
For the next step and after, install in the reverse order of
removal.
EXCEPT FOR K9K : Inspection
INFOID:0000000006404948
INSPECTION AFTER REMOVAL
Clutch Disc
JPDIB0239ZZ
PCIB1503E
CLUTCH DISC AND CLUTCH COVER
CL-31
< UNIT REMOVAL AND INSTALLATION >
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• Measure circumferential runout relative to clutch disc center spline.
If it is outside the specification, replace clutch disc.
• Measure backlash to clutch disc spline and main drive gear spline
at the circumference of clutch disc. If it is outside the specification,
replace clutch disc.
• Measure the depth “A” to clutch disc facing rivet heads, using a
calipers. If it exceeds the allowable wear limit, replace clutch disc.
Clutch Cover
• Check clutch cover thrust ring for wear or breakage. If wear or breakage is found, replace clutch cover.
NOTE:
• Worn thrust ring will generate a beating noise when tapped at the rivet with a hammer.
• Broken thrust ring will make a clinking sound when cover is shaken up and down.
• If a trace of burn or discoloration is found on the clutch cover pressure plate to clutch disc contact surface,
repair the surface with sandpaper. If surface is damaged or distorted, replace clutch cover.
INSPECTION AFTER INSTALLATION
Clutch Cover
Check diaphragm spring lever claws for unevenness with the lever
still on the vehicle. If they exceed the tolerance, adjust lever height,
using the diaphragm adjusting wrench (A) [SST: ST20050240].
K9K
Runout limit/diameter of the area
to be measured
: Refer to
Maximum allowable spline back-
lash (at outer edge of disc)
: Refer to
Facing wear limit (depth to the
rivet head) “A”
: Refer to
SCL221
JPDIB0026ZZ
Tolerance for diaphragm spring
lever unevenness
: Refer to
JPDIB0160ZZ
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