CLUTCH UNIT REMOVAL/INSTALLATION [L3 Turbo]

CLUTCH UNIT REMOVAL/INSTALLATION [L3 Turbo]SM2445432

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Warning

• Fuel vapor is hazardous. It can very easily ignite, causing death, serious injury, or damage. Always keep sparks and flames away from fuel.

• Fuel line spills and leakage from the pressurized fuel system are dangerous. Fuel can easily ignite and cause serious injury or death and damage. Fuel can also irritate skin and eyes. To prevent this, always perform the Fuel Line Safety Procedure. (See BEFORE SERVICE PRECAUTION [L3 Turbo].)

• Secure the steering wheel using tape or a cable to prevent the steering shaft from rotating after disconnecting the steering shaft. If the steering wheel rotates after the steering shaft and the steering gear and linkage are disconnected, the internal parts of the clock spring could be damaged.

1.Remove the battery and battery tray. (See BATTERY REMOVAL/INSTALLATION [L3 Turbo].)

2.Remove the charge air cooler duct. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [L3 Turbo].)

3.Remove the air cleaner and fresh air duct component. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [L3 Turbo].)

4.Remove the front wheel and tire. (See GENERAL PROCEDURES (SUSPENSION).)

5.Remove the under cover, splash shield and mudguard.

6.Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [L3 Turbo].)

7.Drain the transaxle oil into a suitable container. (See TRANSAXLE OIL REPLACEMENT [A26MX-R].)

8.Remove the drive belt. (See DRIVE BELT REMOVAL/INSTALLATION [L3 Turbo].)

9.Disconnect the heater hose. (See A/C UNIT REMOVAL/INSTALLATION [FULL-AUTO AIR CONDITIONER].)

10.Disconnect the radiator hose. (See RADIATOR REMOVAL/INSTALLATION [L3 Turbo].)

11.Disconnect the brake vacuum hose. (See VACUUM HOSE REMOVAL/INSTALLATION.)

12.Disconnect the fuel hose and vacuum hose. (See QUICK RELEASE CONNECTOR (FUEL SYSTEM) REMOVAL/INSTALLATION [L3 Turbo].)

13.Disconnect the shift cable from the transaxle side. (See SHIFT MECHANISM REMOVAL/INSTALLATION [A26MX-R].)

14.Set the clutch release cylinder out of the way. (See CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION [L3 Turbo].)

15.Disconnect the wiring harnesses. (See PCM REMOVAL/INSTALLATION [L3 Turbo].)

16.Remove the propeller shaft. (See PROPELLER SHAFT REMOVAL/INSTALLATION.)

17.Remove the front pipe and HO2S. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [L3 Turbo].)

18.Disconnect the front drive shaft (RH) from the joint shaft side. (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION [L3 Turbo].)

19.Disconnect the front drive shaft (LH) from the transaxle side. (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION [L3 Turbo].)

Note

• Position and secure the A/C compressor out of the way with rope.

20.Remove the A/C compressor with the pipes still connected. (See A/C COMPRESSOR REMOVAL/INSTALLATION [FULL-AUTO AIR CONDITIONER].) (See A/C COMPRESSOR REMOVAL/INSTALLATION [MANUAL AIR CONDITIONER].)

21.Remove the engine. (See ENGINE REMOVAL/INSTALLATION [L3 Turbo].)

22.Remove the starter. (See STARTER REMOVAL/INSTALLATION [L3 Turbo].)

23.Remove the generator duct. (See GENERATOR REMOVAL/INSTALLATION [L3 Turbo].)

24.Remove the A/F sensor. (See AIR FUEL RATIO (A/F) SENSOR REMOVAL/INSTALLATION [L3 Turbo].)

25.Remove the exhaust manifold insulator (Upper). (See EXHAUST SYSTEM REMOVAL/INSTALLATION [L3 Turbo].)

26.Remove the exhaust manifold insulator (Lower). (See EXHAUST SYSTEM REMOVAL/INSTALLATION [L3 Turbo].)

27.Remove the WU-TWC insulator. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [L3 Turbo].)

28.Remove the WU-TWC bracket. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [L3 Turbo].)

29.Remove the WU-TWC. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [L3 Turbo].)

30.Remove the transfer. (See TRANSFER REMOVAL/INSTALLATION [A26MX-R (L3 Turbo)].)

31.Remove the manual transaxle. (See MANUAL TRANSAXLE REMOVAL/INSTALLATION [A26MX-R (L3 Turbo)].)

32.Remove in the order indicated in the figure.

33.Install in the reverse order of removal.

34.Start the engine, and inspect and adjust the following:

• Air bleeding (See CLUTCH FLUID AIR BLEEDING/REPLACEMENT.)

• Bleed the air from the cooling system. (See ENGINE COOLANT REPLACEMENT [L3 Turbo].)

• Runout and contact on pulley and belt

• Leakage of engine oil, engine coolant, transaxle oil.

• Ignition timing, idle speed and idle mixture (CO and HC)

• Engine accessories operation

35.Perform a road test and verify that there is no abnormal vibration or noise.

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1	Clutch release cylinder
2	Manual transaxle (See MANUAL TRANSAXLE REMOVAL/INSTALLATION [A26MX-R (L3 Turbo)])
3	Boot
4	Clutch release collar
5	Clutch release fork
6	Clutch cover (See Clutch Cover and Disc Removal Note) (See Clutch Cover Installation Note)
7	Clutch disc (See Clutch Cover and Disc Removal Note) (See Clutch Disc Installation Note)
8	Pilot bearing (See Pilot Bearing Removal Note.) (See Pilot Bearing Installation Note.)
9	Flywheel (See Flywheel Removal Note) (See Flywheel Installation Note)

Clutch Cover and Disc Removal Note

Caution

• When replacing components, always replace as a complete set.

• Due to the automatic adjustment function of clutch cover, if the old cover assembly is reused, it must be reinstalled together with its original clutch disc.

1.Install the SSTs.

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.

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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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Pilot Bearing Installation Note

1.Install the pilot bearing using the corresponding 20 mm {0.79 in} side of a Snap-on brand millimeter size bushing driver set A160M adapter A160M7 (20—22 mm {0.79—0.86 in}).