1. Clutch master cylinder installation
1. RZ4E
1) Install the clutch master cylinder to the dash panel.
Tightening torque: 23 N・m { 2.3 kgf・m / 17 lb・ft }
2) Install the oil hose to the clutch master cylinder.
Legend
- Oil hose
- Clutch master cylinder
3) Connect the oil pipe to the clutch master cylinder.
Tightening torque: 20 N・m { 2.0 kgf・m / 15 lb・ft }
Legend
- Oil pipe
- Clutch master cylinder
2. 4JJ3
1) Install the clutch master cylinder to the dash panel.
Tightening torque: 23 N・m { 2.3 kgf・m / 17 lb・ft }
2) Install the oil hose to the clutch master cylinder.
Legend
- Oil hose
- Clutch master cylinder
3) Connect the oil pipe to the clutch master cylinder.
Tightening torque: 20 N・m { 2.0 kgf・m / 15 lb・ft }
Legend
- Oil pipe
- Clutch master cylinder
4) Connect the connector to the clutch master cylinder.
2. Clutch pedal installation
1) Apply BESCO chassis grease or equivalent to the assist spring between coils and rotation sliding section.
2) Install the plate bolt to the clutch pedal.
Tightening torque: 9.4 N・m { 1.0 kgf・m / 83 lb・in }
3) Install the clutch pedal nut to the dash panel.
Tightening torque: 21 N・m { 2.1 kgf・m / 15 lb・ft }
Legend
- Clutch pedal nut
- Plate bolt
4) Apply BESCO rubber grease or equivalent to the rotation sliding section of the clevis pin.
Standard: 1 g { 0.04 oz } Application amount
Legend
- Clevis (Master cylinder)
5) Install the clevis pin to the clutch pedal.
6) Install the pin to the clevis pin.
Legend
- Clevis pin
- Pin
7) Connect the harness connector to the clutch switch.
3. Clutch pedal inspection
1) Lightly press the clutch pedal with a hand to inspect that the play is within the standard value range.
Standard: 5.0 to 15.0 mm { 0.2 to 0.6 in }
Standard value
a: 5.0 to 15.0 mm { 0.2 to 0.6 in } Play
4. Clutch switch adjustment
1) Loosen the lock nut using a wrench.
2) Turn the clutch switch to adjust the clearance so that it is within the standard range.
Standard: 0.5 to 1.5 mm { 0.020 to 0.059 in } Clearance
3) After adjustment, tighten the lock nut.
Legend
- Clutch switch
- Lock nut
Standard value
a: 0.5 to 1.5 mm { 0.020 to 0.059 in } Clearance
5. Clutch fluid air bleed
1) Apply the parking brake.
Note
- Fully pull the parking brake lever.
2) Clean passages of clutch master cylinder, slave cylinder, piping, etc., using an air blower.
3) Add brake fluid up to the reservoir tank MAX level and wait 1 minute or more.
Note
- The clutch fluid reservoir tank is shared with the brake fluid reservoir tank.
- The fluid levels in the clutch fluid chamber and brake fluid chamber differ because of partitioning inside the reserve tank, and so the clutch fluid level needs to be checked on the clutch chamber side.
Caution
- Because brake fluid will decrease during the air bleeding process, take care to prevent the reservoir tank from becoming empty.
Legend
- Reservoir tank
- Clutch master cylinder
Legend
- MAX level
- MIN level
- Clutch fluid compartment
4) Connect the vinyl tube to the bleeder screw, and insert the other end into a container filled with brake fluid.
5) Depress the clutch pedal 3 times and hold it down.
Note
- Depress the clutch pedal at the rate of 60 mm/sec, and return the pedal at the rate of 40 mm/sec.
6) Loosen the bleeder screw 1/3 of a turn using a wrench to discharge the brake fluid.
7) Tighten the bleeder screw using a wrench.
Note
- Release the clutch pedal after tightening the bleeder screw.
8) Repeat the process from depressing the clutch pedal to opening/closing the bleeder screw at intervals of 2 seconds.
Caution
- Repeat the operation 30 times or more until all air is completely discharged.
RZ4E
4JJ3
6. Preliminary and post procedures
1. Post procedures
1) Connect the battery cable to the battery negative terminal.
2) Referring to the following, perform the setting of the front door power window switch with AUTO UP/AUTO DOWN function.
Refer to "9.Body, Cab, Accessories 9T.Glass, Windows, Mirrors front door power window switch setting".
3) Close the engine hood.