Clutch control removal (MVL)

1. Component views

Clutch control (RZ4E)

Part name

  1. Oil pipe
  2. Connector
  3. Oil hose
  4. Clutch master cylinder
  5. Nut
  6. Plate
  7. Plate bolt
  8. Assist spring bushing
  9. Assist spring
  10. Fulcrum pin
  11. Fulcrum pin nut
  12. Clutch pedal nut
  13. Clutch pedal bracket
  14. Clutch switch
  15. Assist spring bushing
  16. Fulcrum pin busing
  17. Clevis pin
  18. Pin
  19. Clutch pedal
  20. Clutch pedal rubber
  21. Oil hose bracket
  22. Bolt
  23. Oil hose
  24. Oil pipe
  25. Slave cylinder
  26. Bolt
  27. Eyebolt
  28. Damper cylinder
  29. Nut

Tightening torque

2: 20 N・m { 2.0 kgf・m / 15 lb・ft }

5: 23 N・m { 2.3 kgf・m / 17 lb・ft }

7: 9.4 N・m { 1.0 kgf・m / 83 lb・in }

11: 32 N・m { 3.3 kgf・m / 24 lb・ft }

12: 21 N・m { 2.1 kgf・m / 15 lb・ft }

22: 25 N・m { 2.5 kgf・m / 18 lb・ft }

24: 20 N・m { 2.0 kgf・m / 15 lb・ft }

26: 43 N・m { 4.4 kgf・m / 32 lb・ft }

27: 34 N・m { 3.5 kgf・m / 25 lb・ft }

29: 8 N・m { 0.8 kgf・m / 71 lb・in }

Clutch control (4JJ3 except dual mass flywheel specifications)

Part name

  1. Oil pipe
  2. Connector
  3. Oil hose
  4. Clutch master cylinder
  5. Nut
  6. Plate
  7. Plate bolt
  8. Assist spring bushing
  9. Assist spring
  10. Fulcrum pin
  11. Fulcrum pin nut
  12. Clutch pedal nut
  13. Clutch pedal bracket
  14. Clutch switch
  15. Assist spring bushing
  16. Fulcrum pin busing
  17. Clevis pin
  18. Pin
  19. Clutch pedal
  20. Clutch pedal rubber
  21. Oil hose bracket
  22. Bolt
  23. Oil hose
  24. Orifice
  25. Oil pipe
  26. Slave cylinder
  27. Bolt
  28. Eyebolt
  29. Damper cylinder
  30. Nut

Tightening torque

2: 20 N・m { 2.0 kgf・m / 15 lb・ft }

5: 23 N・m { 2.3 kgf・m / 17 lb・ft }

7: 9.4 N・m { 1.0 kgf・m / 83 lb・in }

11: 32 N・m { 3.3 kgf・m / 24 lb・ft }

12: 21 N・m { 2.1 kgf・m / 15 lb・ft }

22: 25 N・m { 2.5 kgf・m / 18 lb・ft }

25: 20 N・m { 2.0 kgf・m / 15 lb・ft }

27: 43 N・m { 4.4 kgf・m / 32 lb・ft }

28: 34 N・m { 3.5 kgf・m / 25 lb・ft }

30: 8 N・m { 0.8 kgf・m / 71 lb・in }

Clutch control (4JJ3 dual mass flywheel specifications)

Part name

  1. Oil pipe
  2. Connector
  3. Oil hose
  4. Clutch master cylinder
  5. Nut
  6. Plate
  7. Plate bolt
  8. Assist spring bushing
  9. Assist spring
  10. Fulcrum pin
  11. Fulcrum pin nut
  12. Clutch pedal nut
  13. Clutch pedal bracket
  14. Clutch switch
  15. Assist spring bushing
  16. Fulcrum pin busing
  17. Clevis pin
  18. Pin
  19. Clutch pedal
  20. Clutch pedal rubber
  21. Oil hose bracket
  22. Bolt
  23. Oil hose
  24. Orifice
  25. Oil pipe
  26. Slave cylinder
  27. Bolt
  28. Eyebolt
  29. Damper
  30. Gasket
  31. Damper cylinder
  32. Nut

Tightening torque

2: 20 N・m { 2.0 kgf・m / 15 lb・ft }

5: 23 N・m { 2.3 kgf・m / 17 lb・ft }

7: 9.4 N・m { 1.0 kgf・m / 83 lb・in }

11: 32 N・m { 3.3 kgf・m / 24 lb・ft }

12: 21 N・m { 2.1 kgf・m / 15 lb・ft }

22: 25 N・m { 2.5 kgf・m / 18 lb・ft }

25: 20 N・m { 2.0 kgf・m / 15 lb・ft }

27: 43 N・m { 4.4 kgf・m / 32 lb・ft }

28: 34 N・m { 3.5 kgf・m / 25 lb・ft }

29: 20 N・m { 2.0 kgf・m / 15 lb・ft }

32: 8 N・m { 0.8 kgf・m / 71 lb・in }

2. Preliminary and post procedures

1. Preliminary procedures

1) Open the engine hood.

2) Disconnect the battery cable from the battery negative terminal.

Caution

  • After turning OFF the ignition switch (power mode for models with passive entry and start system), do not disconnect the battery cable within 3 minutes.
  • If the battery cable is disconnected within 3 minutes, the vehicle electronic control system may malfunction.
  • If the battery cable is disconnected, perform the setting of the front door power window switch with AUTO UP/AUTO DOWN function after connecting the battery negative terminal.

3. Clutch pedal removal

1) Disconnect the harness connector from the clutch switch.

2) Remove the pin from the clevis pin.

3) Remove the clevis pin from the clutch pedal.

Legend

  1. Clevis pin
  2. Pin

4) Remove the plate bolt from the clutch pedal.

5) Remove the clutch pedal nut from the dash panel.

Legend

  1. Clutch pedal nut
  2. Plate bolt

4. Clutch master cylinder removal

1. RZ4E

1) Remove the oil pipe from the clutch master cylinder.

Legend

  1. Oil pipe
  2. Clutch master cylinder

2) Remove the oil hose from the clutch master cylinder.

Legend

  1. Oil hose
  2. Clutch master cylinder

3) Remove the clutch master cylinder from the dash panel.

2. 4JJ3

1) Disconnect the connector from the clutch master cylinder.

2) Remove the oil pipe from the clutch master cylinder.

Legend

  1. Oil pipe
  2. Clutch master cylinder

3) Remove the oil hose from the clutch master cylinder.

Legend

  1. Oil hose
  2. Clutch master cylinder

4) Remove the clutch master cylinder from the dash panel.

5. Slave cylinder removal

1. RZ4E

1) Remove the bushing from the oil hose bracket.

Legend

  1. Oil hose bracket
  2. Bushing

2) Remove the oil hose from the oil pipe connector.

Note

  • Pull out the clip to remove.

Legend

  1. Clip

Legend

  1. Oil pipe connector
  2. Oil hose

3) Remove the oil pipe and band clip from the transmission.

Legend

  1. Oil pipe
  2. Band clip

4) Remove the oil pipe from the slave cylinder.

Legend

  1. Slave cylinder
  2. Oil pipe

5) Remove the slave cylinder from the transmission.

Legend

  1. Slave cylinder
  2. Transmission

6) Remove the oil hose from the damper cylinder.

7) Remove the oil pipe from the damper cylinder.

Legend

  1. Oil pipe
  2. Damper cylinder
  3. Oil hose

8) Remove the damper cylinder from the tire house panel.

2. 4JJ3 (Except dual mass flywheel specifications)

1) Remove the bushing from the oil hose bracket.

Legend

  1. Oil hose bracket
  2. Bushing

2) Remove the oil hose from the orifice.

Note

  • Pull out the clip to remove.

Legend

  1. Clip

Legend

  1. Oil hose
  2. Orifice

3) Remove the orifice from the oil pipe connector.

Note

  • Pull out the clip to remove.

Legend

  1. Clip

Legend

  1. Oil pipe connector
  2. Orifice

4) Remove the oil pipe and band clip from the transmission.

Legend

  1. Oil pipe
  2. Band clip

5) Remove the oil pipe from the slave cylinder.

Legend

  1. Slave cylinder
  2. Oil pipe

6) Remove the slave cylinder from the transmission.

Legend

  1. Transmission
  2. Slave cylinder

7) Remove the oil hose from the damper cylinder.

8) Remove the oil pipe from the damper cylinder.

Legend

  1. Oil pipe
  2. Damper cylinder
  3. Oil hose

9) Remove the damper cylinder from the tire house panel.

3. 4JJ3 (Dual mass flywheel specifications)

1) Remove the bushing from the oil hose bracket.

Legend

  1. Oil hose bracket
  2. Bushing

2) Remove the oil hose from the orifice.

Note

  • Pull out the clip to remove.

Legend

  1. Clip

Legend

  1. Oil hose
  2. Orifice

3) Remove the orifice from the oil pipe connector.

Note

  • Pull out the clip to remove.

Legend

  1. Clip

Legend

  1. Oil pipe connector
  2. Orifice

4) Remove the oil pipe and band clip from the transmission.

Legend

  1. Oil pipe
  2. Band clip

5) Remove the oil pipe from the slave cylinder.

Legend

  1. Slave cylinder
  2. Oil pipe

6) Remove the slave cylinder from the transmission.

Legend

  1. Transmission
  2. Slave cylinder

7) Remove the oil hose from the damper cylinder.

8) Remove the oil pipe from the damper.

9) Remove the damper from the damper cylinder.

Legend

  1. Oil pipe
  2. Damper
  3. Gasket
  4. Damper cylinder
  5. Oil hose

10) Remove the damper cylinder from the tire house panel.

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