Almera Tino V10 (2003 year). Manual — part 59
CLUTCH PEDAL
CL-5
[RS6F51R]
D
E
F
G
H
I
J
K
L
M
A
B
CL
CLUTCH PEDAL
PFP:46540
On-Vehicle Inspection and Adjustment
ECS00951
CLUTCH PEDAL STROKE INSPECTION
Check 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 reference 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. Mea-
sure 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 to
).
NOTE:
●
Do not use steering wheel as a reference point, angle gives incorrect reading.
●
Ensure there is no interference between the floor carped and clutch pedal when fully depressed.
CLUTCH PEDAL FREE PLAY INSPECTION
Check pedal free play, if out of specification refer to
.
●
Push on the clutch pedal until resistance is felt, and check the
distance the pedal moves.
CLUTCH PEDAL STROKE ADJUSTMENT
1.
Loosen the pedal stopper bolt completely (so there is on contact between pedal and stopper bolt).
2.
Adjust pedal stroke to the specified value with the master cylinder push rod.
NCL058
SCL702
CL-6
[RS6F51R]
CLUTCH PEDAL
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.
CLUTCH PEDAL FREE PLAY ADJUSTMENT
1.
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.
Removal and Installation
ECS00952
NOTE:
Install clutch pedal assembly and adjust the pedal height. Tighten stopper bolt to the specified torque.
Clutch pedal stroke “S”:
155 - 160 mm (6.10 - 6.30 in)
Pedal free play “A”:
1 - 3 mm (0.04 - 0.12 in)
MCIA0125E
MCIA0126E
1.
Clutch pedal assembly
2.
Clevis pin
3.
Bushing
4.
Snap pin
5.
Stopper bolt
6.
Clutch pedal
CLUTCH PEDAL
CL-7
[RS6F51R]
D
E
F
G
H
I
J
K
L
M
A
B
CL
INSPECTION AFTER REMOVAL
●
Check clutch pedal for bend, damage, or a cracked weld. If bend, damage, or a cracked weld is found,
replace the clutch pedal.
●
Check assist spring for settling. If settling is found, replace the assist spring.
CL-8
[RS6F51R]
CLUTCH FLUID
CLUTCH FLUID
PFP:00017
Air Bleeding Procedure
ECS00953
CAUTION:
●
Monitor fluid level in the reservoir to make sure it does not empty.
●
Do not spill clutch fluid onto painted surfaces. If it spills, wipe up immediately and wash the
affected area with water.
●
Bleed the operating cylinder.
1.
Fill the master cylinder reservoir tank with new clutch fluid.
2.
Connect a transparent vinyl hose to the air bleeder.
3.
Depress the clutch pedal slowly and fully a few times at an inter-
val of 2 to 3 seconds and hold it.
4.
With clutch pedal depressed, open air bleeder.
5.
Close air bleeder.
6.
Release clutch pedal and wait for 5 seconds.
7.
Repeat steps 3 to 6 until no bubbles can be observed in the
brake fluid.
Air bleeder
: 5.9 - 9.8 N·m (0.6 - 1.0 kg·m, 52 - 86 in·lb)
MCIA0127E
CLUTCH MASTER CYLINDER
CL-9
[RS6F51R]
D
E
F
G
H
I
J
K
L
M
A
B
CL
CLUTCH MASTER CYLINDER
PFP:30610
Removal and Installation
ECS00954
REMOVAL
1.
Using one of the following methods, remove hose from the nipple.
●
Drain clutch fluid from reservoir tank and remove hose.
●
Remove hose from the nipple. Immediately plug hose and reservoir tank to prevent clutch fluid from
dripping.
CAUTION:
Do not spill clutch fluid onto painted surfaces. If it spills, wipe up immediately and wash the
affected area with water.
2.
Using a flare nut wrench, remove clutch tube.
3.
Remove snap pin and clevis pin on clevis in passenger compartment to separate clutch pedal.
4.
First remove the mounting nuts on the master cylinder assembly, and then the master cylinder assembly
from the vehicle.
INSTALLATION
1.
Connect clutch tube to master cylinder assembly and temporarily tighten flare nut.
2.
Install master cylinder assembly and tighten mounting nut to the specified torque.
3.
Using a flare nut torque wrench, tighten clutch tube flare nut to the specified torque.
4.
Attach clevis of the clevis pin to the clutch pedal.
5.
Attach snap pin to the clevis pin.
6.
Install hose to the nipple.
7.
After completing this procedure, inspect and adjust pedal height and then bleed the clutch tube. Refer to
CL-5, "On-Vehicle Inspection and Adjustment"
,
CL-8, "Air Bleeding Procedure"
SCIA0324E
1.
Clevis pin
2.
Snap pin
3.
Clevis
4.
Lock nut
5.
Dust cover
6.
Stopper ring
7.
Stopper
8.
Push rod
9.
Piston assembly
10. Return spring
11.
Cylinder body
12. Seal
13. Spring pin
14. Nipple
15. Clamp
16. Hose
CL-10
[RS6F51R]
CLUTCH MASTER CYLINDER
Disassembly and Assembly
ECS00955
DISASSEMBLY
1.
Using a pin punch, remove spring pin, nipple and seal from the
cylinder body.
2.
Loosen push rod lock nut. Remove clevis and lock nut.
3.
Remove dust cover.
4.
Remove stopper ring and stopper. Remove push rod from cylin-
der body while holding it securely to reduce possibility of the pis-
ton popping out.
5.
Remove piston assembly and return spring.
INSPECTION AFTER DISASSEMBLY
Check for any of the conditions shown below. If any malfunction is found, replace the part concerned.
●
Damaged cylinder internal wall, foreign matter, wear, corrosion, or pinhole
●
Damaged or deformed nipple or reservoir tank
●
Settling of the spring
●
Cracked or deformed dust cover
ASSEMBLY
1.
Apply rubber lubricant to internal surface of the cylinder body, sliding surface of piston assembly, and the
piston cup. Insert piston assembly and return spring.
2.
Apply silicon grease to push rod and install stopper. Install stopper ring while holding down the push rod
by hand to prevent the piston assembly from popping out.
3.
Install dust cover.
4.
Install clevis to the push rod and tighten lock nut to the specified torque.
5.
Install seal and nipple to the cylinder body. Using a pin punch, install spring pin.
CLB0166D
OPERATING CYLINDER
CL-11
[RS6F51R]
D
E
F
G
H
I
J
K
L
M
A
B
CL
OPERATING CYLINDER
PFP:30620
Removal and Installation
ECS00956
REMOVAL
1.
Drain clutch fluid.
CAUTION:
Do not spill clutch fluid onto painted surfaces. If it spills, wipe up immediately and wash the
affected area with water.
2.
Remove clutch hose from the operating cylinder.
3.
Remove operating cylinder mounting bolt and remove operating cylinder.
INSTALLATION
Paying attention to the following items, install in the reverse order of removal.
●
Install hose with care so that it will not be bent or twisted.
●
After completing the procedure, bleed the clutch tube. Refer to
CL-8, "Air Bleeding Procedure"
.
Disassembly and Assembly
ECS00957
DISASSEMBLY
●
Remove dust cover and push rod. Remove piston, piston cup, and piston spring from inside the cylinder
body.
INSPECTION AFTER DISASSEMBLY
Check for any of the conditions shown below. If any malfunction is found, replace the part concerned.
●
Damage to cylinder inner surface or piston sliding surface. Foreign matter, wear, corrosion, or pinhole
●
Settling of the spring
MCIA0128E
1.
Cylinder body
2.
Piston spring
3.
Piston cup
4.
Piston
5.
Push rod
6.
Dust cover
7.
Air bleeder
8.
Union bolt
9.
Copper washer
10. Clutch hose
CL-12
[RS6F51R]
OPERATING CYLINDER
●
Cracked or deformed dust cover
ASSEMBLY
1.
Apply rubber lubricant to cylinder body inner surface and rubber grease to the piston cup and piston.
Insert piston assembly into the cylinder body.
2.
Apply rubber grease to dust cover and install push rod and dust cover.
CLUTCH PIPING
CL-13
[RS6F51R]
D
E
F
G
H
I
J
K
L
M
A
B
CL
CLUTCH PIPING
PFP:30650
Removal and Installation
ECS00958
Carefully observe the following steps during clutch tube removal and installation.
●
Do not spill clutch fluid onto painted surfaces. If it spills, wipe up immediately and wash the affected area
with water.
●
To fix clutch hose on the bracket, position hose clasp on the
bracket locating embossment and drive the lock plate vertically
from above. Be careful not to bend or twist the hose. Do not
scratch or damage the clutch hose.
●
Tighten clutch tube flare nut to the specified torque below:
●
Tighten clutch hose union bolt to the specified torque:
CAUTION:
Do not reuse the copper washer.
●
After installation, bleed the clutch tube. Refer to
CL-8, "Air Bleeding Procedure"
.
: 14.8 - 17.6 N·m (1.5 - 1.8 kg·m, 11 - 13 ft·lb)
: 16.7 - 19.6 N·m (1.7 - 2.0 kg·m, 13 - 14 ft·lb)
MCIA0129E
CL-14
[RS6F51R]
CLUTCH RELEASE MECHANISM
CLUTCH RELEASE MECHANISM
PFP:30502
Removal and Installation
ECS0095A
REMOVAL
1.
Remove manual transaxle from the vehicle. Refer to
.
2.
Remove release bearing, holder spring, and withdrawal lever from inside the clutch housing.
3.
Remove dust cover.
4.
Remove retainer spring from the withdrawal lever.
INSPECTION AFTER REMOVAL
●
If release bearing is seized, damaged, not properly centered or
does not rotate smoothly, replace it.
●
If contact surface of the withdrawal lever is excessively worn,
replace it.
●
If dust cover is cracked, replace it.
INSTALLATION
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. Wipe off any grease oozing
from the parts.
●
Be careful not to bring any grease into contact with the clutch disc facing, pressure plate surface,
or flywheel surface.
SCIA0328E
SCL733
CLUTCH RELEASE MECHANISM
CL-15
[RS6F51R]
D
E
F
G
H
I
J
K
L
M
A
B
CL
1.
Following the instructions below, apply grease to the specified points.
CAUTION:
Wipe off any old grease, debris, or powdery residue left on the grease applying surfaces.
●
Evenly apply a 1-mm thick coating of recommended grease to withdrawal lever and holder spring slid-
ing surface.
●
Apply recommended grease to withdrawal lever ball pin contact surface and inner slots of the release
bearing. The grease surface should be level with the surrounding area.
●
Apply a thin coat of recommended grease evenly to the release bearing sliding surface. Install release
bearing. Wipe off any excess grease that oozes from the parts and then remove release bearing.
2.
Install in the reverse order of the removal.
SCL815
CL-16
[RS6F51R]
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
PFP:30100
Removal and Installation
ECS0095B
CAUTION:
Be careful not to bring any grease into contact with the clutch disc facing, pressure plate surface, or
flywheel surface.
REMOVAL
1.
Remove manual transaxle from the vehicle. Refer to
.
2.
Loosen clutch cover mounting bolts evenly. Remove clutch cover and clutch disc.
INSPECTION AND ADJUSTMENT AFTER REMOVAL
Clutch Disc
●
Measure circumferential runout relative to the clutch disc center
spline. If it is outside the specification, replace the clutch disc.
●
Measure clutch disc spline and input shaft spline backlash at the
circumference of the disc. If outside the specification, replace.
●
Using calipers, measure the depth to the clutch disc facing rivet
heads. If it exceeds the allowable wear limit, replace the facing.
MCIA0130E
Runout limit/diameter of the area to be measured:
MODEL 240
1.0 mm (0.039 in) or less/230 mm
(9.06 in) dia.
Maximum allowable spline backlash:
MODEL 240
1.0 mm (0.039 in)
MCIA0131E
Facing wear limit (depth to the rivet head):
0.3 mm (0.012 in)
MCIA0132E
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL
CL-17
[RS6F51R]
D
E
F
G
H
I
J
K
L
M
A
B
CL
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 a diaphragm adjusting wrench (special service tool).
●
Check clutch cover thrust ring for wear or breakage. If wear or
breakage is found, replace clutch cover assembly.
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 the assembly.
Flywheel Runout
Using a dial gauge, measure runout at the flywheel clutch contact
surface. If runout is outside the specification, replace the flywheel. If
a trace of burn or discoloration is found on the surface, repair it with
sandpaper.
CAUTION:
Measure it at flywheel outer face (not on knock pin and clutch
cover mounting hole).
INSTALLATION
1.
Apply recommended grease to clutch disc and input shaft splines.
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. Wipe off any grease oozing
from the parts.
2.
Install clutch disc and clutch cover. Pre-tighten mounting bolts and install clutch aligning bar.
3.
Tighten clutch cover attaching bolts evenly in two steps in the
order shown in the figure.
4.
Install manual transaxle. Refer to
.
Tolerance for diaphragm spring lever unevenness:
MODEL 240
0.7 mm (0.028 in)
SCL466-C
Allowable flywheel runout:
AEM100
Engine type
Tool number
YD22DDTi
ST20630000
Tightening torque:
First step
: 9.9 - 19 N·m (1.0 - 2.0 kg·m, 7 - 14 ft·lb)
Final step
: 35 - 44 N·m (3.5 - 4.5 kg·m, 26 - 32 ft·lb)
MCIA0133E
CL-18
[RS6F51R]
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
PFP:00030
Clutch Control System
ECS0095C
Clutch Master Cylinder
ECS0095D
Unit: mm (in)
Clutch Operating Cylinder
ECS0095E
Unit: mm (in)
Clutch Disc
ECS0095F
Unit: mm (in)
Clutch Cover
ECS0095G
Unit: mm (in)
Clutch Pedal
ECS0095H
Unit: mm (in)
Type of clutch control
Hydraulic
Inner diameter
15.87 (5/8)
Inner diameter
19.05 (3/4)
Engine type
YD22DDTi
Model
240
Facing size (outer dia.
×
inner dia.
×
thickness)
240
×
170
×
3.5 (9.45
×
6.69
×
0.138)
Thickness of disc assembly with lord
7.5 - 8.1 (0.295 - 0.319) with 6,865 N (700.2 kg, 1543.3 lb)
Wear limit of facing surface to rivet head
0.3 (0.012)
Runout limit/diameter of the area to be measured
1.0 (0.039) or less/230 (9.06) dia.
Maximum allowable spline backlash
1.0 (0.039)
Engine type
YD22DDTi
Model
240
Full-load
6,867 N (700.4 kg, 1543.7 lb)
Diaphragm spring lever height
37.0 - 39.0 (1.457 - 1.535)
Uneven limit diaphragm spring toe height
0.7 (0.028)
Clutch pedal stroke “S”
155 - 160 (6.10 - 6.30)
Pedal free play “A”
1 - 3 (0.04 - 0.12)
CLUTCH
CONTENTS
RS5F70A, RS5F50A
PRECAUTIONS . . . . . . . . . . . . . . . ...2
Precautions . . . . . . . . . . . . . . . . ..2
PREPARATION . . . . . . . . . . . . . . . ...3
Special Service Tools . . . . . . . . . . . . ..3
Commercial Service Tools . . . . . . . . . . ...3
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING . . . . . . . . . . . . . .4
NVH Troubleshooting Chart. . . . . . . . . . .4
. . . . . . . . . . . . . . . . ...4
CLUTCH SYSTEM. . . . . . . . . . . . . . ...5
Components - RHD Model with QG Engine - . . . .5
Components - LHD Model with QG Engine -. . . ..6
Components - RHD Model with YD Engine -. . . ..7
Components - LHD Model with YD Engine - . . . ..8
Inspection and Adjustment . . . . . . . . . . ..9
. . . . . . . . ...9
. . . . . . . ...10
. . . . . . . . ..10
CLUTCH MASTER CYLINDER. . . . . . . . . . 11
Components. . . . . . . . . . . . . . . ... 11
Removal. . . . . . . . . . . . . . . . . .12
Installation. . . . . . . . . . . . . . . . ..12
Disassembly. . . . . . . . . . . . . . . ...12
Inspection. . . . . . . . . . . . . . . . ...12
Assembly . . . . . . . . . . . . . . . . ...13
OPERATING CYLINDER. . . . . . . . . . . ...14
Components. . . . . . . . . . . . . . . ...14
Removal. . . . . . . . . . . . . . . . . .14
Disassembly. . . . . . . . . . . . . . . ...14
Inspection. . . . . . . . . . . . . . . . ...14
Assembly . . . . . . . . . . . . . . . . ...15
Installation. . . . . . . . . . . . . . . . ..15
PIPING . . . . . . . . . . . . . . . . . . ...16
Removal. . . . . . . . . . . . . . . . . .16
Installation. . . . . . . . . . . . . . . . ..16
RS5F70A
CLUTCH RELEASE MECHANISM . . . . . . . ...17
Components. . . . . . . . . . . . . . . ...17
Removal. . . . . . . . . . . . . . . . . .17
Inspection. . . . . . . . . . . . . . . . ...17
Installation. . . . . . . . . . . . . . . . ..17
RS5F50A
CLUTCH RELEASE MECHANISM . . . . . . . ...20
Components. . . . . . . . . . . . . . . ...20
Removal. . . . . . . . . . . . . . . . . .20
Inspection. . . . . . . . . . . . . . . . ...20
Installation. . . . . . . . . . . . . . . . ..20
RS5F70A, RS5F50A
CLUTCH DISC, CLUTCH COVER AND
FLYWHEEL. . . . . . . . . . . . . . . . . 22
Components. . . . . . . . . . . . . . . ...22
Inspection and Adjustment . . . . . . . . . . 22
. . . . . . . . . . . . . . .22
. . . . . . . . . . . . . .23
. . . . . . . . . . . . . . . .23
Installation. . . . . . . . . . . . . . . . ..23
SERVICE DATA AND SPECIFICATIONS (SDS) . . .24
Clutch Control System. . . . . . . . . . . ...24
Clutch Master Cylinder . . . . . . . . . . . ..24
Clutch Operating Cylinder . . . . . . . . . . .24
Clutch Disc. . . . . . . . . . . . . . . . .24
Clutch Cover . . . . . . . . . . . . . . . ..24
Clutch Pedal . . . . . . . . . . . . . . . ..24
GI
MA
EM
LC
EC
FE
MT
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
SBR820BA
Precautions
I
Recommended fluid is brake fluid “DOT 4”. Refer to MA-20,
“Fluid and Lubricants”.
I
Never reuse drained brake fluid.
I
Be careful not to splash brake fluid on painted areas.
I
When removing and installing clutch piping, use Tool.
I
Use new brake fluid to clean or wash all parts of master
cylinder and operating cylinder.
I
Never use mineral oils such as gasoline or kerosene. It will
ruin the rubber parts of the hydraulic system.
WARNING:
After cleaning clutch disc, wipe it with a dust collector. Do not
use compressed air.
PRECAUTIONS
RS5F70A, RS5F50A
Precautions
CL-2
Нет комментариевНе стесняйтесь поделиться с нами вашим ценным мнением.
Текст