CLUTCH UNIT REMOVAL/INSTALLATION [C66M-R, C66MX-R]

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1.  Disconnect the negative battery cable. (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-G 2.0, SKYACTIV-G 2.5].) (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-G 2.0, SKYACTIV-G 2.5 (WITHOUT i-stop)].)

2.  Remove the manual transaxle. (See MANUAL TRANSAXLE REMOVAL/INSTALLATION [C66M-R].) (See MANUAL TRANSAXLE REMOVAL/INSTALLATION [C66MX-R].)

3.  Remove in the order indicated in the table.

4.  Install in the reverse order of removal.

5.  Add the specified amount of specified manual transaxle oil. (See MANUAL TRANSAXLE OIL REPLACEMENT [C66M-R, C66MX-R].)

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1
Boot
2
Clutch release fork
3
Clutch release collar
4
Pivot pin
5
Clutch cover
(See Clutch Cover and Disc Removal Note.)
(See Clutch Disc and Cover Installation Note.)
6
Clutch disc
(See Clutch Cover and Disc Removal Note.)
(See Clutch Disc and Cover Installation Note.)
7
Pilot bearing
(See Pilot Bearing Removal Note.)
(See Pilot Bearing Installation Note.)
8
Plate
9
Flywheel
(See Flywheel Removal Note.)
(See Flywheel Installation Note.)


Clutch Cover and Disc Removal Note

1.  Hold the clutch unit using the SST.

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2.  Loosen each bolt one turn at a time in a crisscross pattern until spring tension is released.

3.  Remove the clutch cover and disc.


Pilot Bearing Removal Note

Note
•  The pilot bearing does not need to be removed unless you are replacing it.

1.  Use the SST to remove the pilot bearing.

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Flywheel Removal Note

1.  Hold the flywheel using the SST.

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2.  Remove the lock bolts, and remove the plate and the flywheel.

3.  Inspect for oil leakage from the crankshaft rear oil seal.

•  If there is any malfunction, replace the crankshaft rear oil seal. (See REAR OIL SEAL REPLACEMENT [SKYACTIV-G 2.0, SKYACTIV-G 2.5].)


Flywheel Installation Note

1.  Degrease and clean the flywheel.

2.  Clean the crankshaft thread holes.

3.  Install the flywheel and the plate to the crankshaft, and temporarily tighten a new lock bolts.

4.  Hold the flywheel using the SST.

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5.  Tighten the lock bolts completely in the order shown in the figure in the following 3 steps.

Tightening torque
Step 1: 46—54 N·m {4.7—5.5 kgf·m, 34—39 ft·lbf}
Step 2: 76—84 N·m {7.8—8.5 kgf·m, 57—61 ft·lbf}
Step 3: 108—116 N·m {11.1—11.8 kgf·m, 80—85 ft·lbf}


Pilot Bearing Installation Note

1.  Install new pilot bearing to the specified position using the following tools.

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Tool
Snap-on brand millimeter size bushing driver set (A160M) adapter A160M7 (20—22 mm)
•  Use the adapter with the 20 mm side of the A160M7 (20—22 mm) facing the pilot bearing side.
Substitution tool
Outer diameter: 21 mm {0.83 in}
Inner diameter: 19 mm {0.75 in}
Standard position
Distance A of pilot bearing from crankshaft end: 1.5—2.5 mm {0.060—0.098 in}
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Clutch Disc and Cover Installation Note

Caution
•  Do not apply grease to the spline end (transaxle side). If excessive grease is applied, clutch-slip may occur.

1.  Apply grease to the spline (engine side) of the clutch disc.

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2.  Insert the clutch disc into the primary shaft and wipe off the excess grease protruding from the spline.

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3.  Slide the clutch disc three times in the directions of the arrows shown in the figure to engage to grease.

4.  Remove the clutch disc from the primary shaft and wipe off the excess grease protruding from the spline.

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5.  Verify that grease has been lightly applied to the clutch disc and the spline of the primary shaft.

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6.  Hold the clutch disc position using the SST.

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7.  Hold the clutch unit using the SST.

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8.  Tighten the bolts in Min. 2 stages.

(1)  Temporarily tighten the bolts in the order shown in the figure.
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(2)  Tighten the bolts completely in the order shown in the figure and install the clutch disc and cover.
Tightening torque
25—33 N·m {2.6—3.3 kgf·m, 19—24 ft·lbf}

9.  Remove the SSTs.