CLUTCH UNIT REMOVAL/INSTALLATION [J65M-R]

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Caution
•  When newly replacing the clutch cover or the clutch disc, replace the clutch cover and the clutch disc as a set.

1.  Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)

2.  Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)

3.  Remove the following parts:

(1)  Battery, battery tray (See BATTERY REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)
(2)  Air cleaner component (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)
(3)  Inter cooler pipe bracket (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)
(4)  Catalytic converter bracket (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)
(5)  Front tires (See GENERAL PROCEDURES (SUSPENSION).)
(6)  Splash shield (See SPLASH SHIELD REMOVAL/INSTALLATION.)
(7)  Aerodynamic under cover No.2 (See AERODYNAMIC UNDER COVER NO.2 REMOVAL/INSTALLATION.)

4.  Cut off the vacuum chamber installation bolt and set the vacuum chamber aside so that it does not interfere with the servicing.

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5.  Remove the starter.

6.  Drain the transaxle oil into a suitable container. (See TRANSAXLE OIL REPLACEMENT [J65M-R].)

7.  Remove the manual transaxle. (See MANUAL TRANSAXLE REMOVAL/INSTALLATION [J65M-R].)

8.  Remove in the order indicated in the table.

9.  Install in the reverse order of removal.

10.  Add the specified amount of specified transaxle oil. (See TRANSAXLE OIL REPLACEMENT [J65M-R].)

11.  Perform the clutch fluid line air bleeding. (See CLUTCH FLUID AIR BLEEDING/REPLACEMENT.)

Note
•  If the transaxle is overhauled and installed to the vehicle, perform the "INSPECTION AFTER TRANSAXLE INSTALLATION" and verify that there is no abnormality. (See INSPECTION AFTER TRANSAXLE INSTALLATION [J65M-R].)
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1
Clutch release cylinder component
(See CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION [J65M-R].)
2
Clutch cover
(See Clutch Cover and Disc Removal Note.)
(See Clutch Cover and Disc Installation Note.)
3
Clutch disc
(See Clutch Cover and Disc Removal Note.)
(See Clutch Cover and Disc Installation Note.)
4
Flywheel
(See Flywheel Removal Note.)
(See Flywheel Installation Note.)
(See FLYWHEEL INSPECTION [J65M-R].)


Clutch Cover and Disc Removal Note

Caution
•  When removing a clutch with wear compensation, note the following regarding the readjustment mechanism.
―  When replacing components, always replace as a complete set.
―  If the old cover assembly is reused, it must be reinstalled together with its original clutch disc.
―  If the clutch cover is removed without releasing the stopper, the adjustment function may become inoperable. In this case, the clutch cover and disc must be replaced with new parts.

1.  Lock the flywheel using the SST.

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•  Rotate the crankshaft until the special tool aligns with one of the slots in the flywheel.

2.  Unscrew the stop to loosen.

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•  Verify the position of the stop.
―  There is only one.
―  It is located on the pitch circle of cover installation bolts between the bolt mount and the dowel pin, wedged between the cover and the flywheel.
―  The head of the guide bolt sticks out approx. 3 mm {0.12 in} from the housing.

3.  Loosen the clutch cover installation bolts opposite each other in increments (approx. 5 passes).

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Caution
•  Check that the stop loosens and slides down to the block in the housing.
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•  If necessary, push the guide bolt toward the flywheel.

4.  Remove the clutch cover and disc.


Flywheel Removal Note

1.  Lock the flywheel using the SST.

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•  Rotate the crankshaft until the special tool aligns with one of the slots in the flywheel.

2.  Remove the bolts evenly and gradually in a crisscross pattern.

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Caution
•  Do not reuse the flywheel installation bolts.

3.  Remove the flywheel.

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

•  If there is any malfunction, replace the crankshaft rear oil seal.


Flywheel Installation Note

Caution
•  Clean the crankshaft threads before tightening the bolts.The threads may be damaged if the bolts are tightened with any old sealant remaining.

1.  Clean the crankshaft thread holes before installing the new flywheel installation bolts.

2.  Install the flywheel to the crankshaft.

3.  Hand‐tighten the new flywheel installation bolts.

4.  Lock the flywheel using the SST.

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•  Rotate the crankshaft until the special tool aligns with one of the slots in the flywheel.

5.  Gradually tighten the flywheel installation bolts in a crisscross pattern.

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Tightening torque
30 N·m {3.1 kgf·m, 22 ft·lbf}+ 90°

Clutch Cover and Disc Installation Note

1.  Lock the flywheel using the SST.

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•  Rotate the crankshaft until the special tool aligns with one of the slots in the flywheel.

2.  Using the SST, center the clutch disc on the clutch cover.

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3.  Install the clutch cover and clutch disc to the flywheel with the SST installed.

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4.  Tighten the new clutch cover installation bolts finger tight and then by two turns at a time in the sequence shown to the specified torque.

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Tightening torque
29 N·m {3.0 kgf·m, 21 ft·lbf}

5.  Remove the SSTs.