CLUTCH UNIT REMOVAL/INSTALLATION [A26M-R (MZR-CD 2.2)]

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Caution

•  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.

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

1.  Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZR-CD 2.2].)

2.  Remove the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [MZR-CD 2.2].)

3.  Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [MZR-CD 2.2].)

4.  Remove the following parts:

(1)  Air cleaner and air inlet hose (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2].)

(2)  Battery and battery tray (See BATTERY REMOVAL/INSTALLATION [MZR-CD 2.2].)

(3)  Air inlet pipe and turbocharger air outlet pipe No.2 (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2].)

(4)  EGR cooler and EGR cooler bypass valve component (See EGR COOLER REMOVAL/INSTALLATION [MZR-CD 2.2].)

(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.)

(8)  Front pipe bracket No.1 (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2].)

5.  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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6.  Remove the front pipe bracket No.2. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2].)

7.  Remove the front auto leveling sensor. (See AUTO LEVELING SENSOR REMOVAL/INSTALLATION.)

8.  Drain the transaxle oil into a suitable container. (See TRANSAXLE OIL REPLACEMENT [A26M-R].)

9.  Remove the manual transaxle. (See MANUAL TRANSAXLE REMOVAL/INSTALLATION [A26M-R (MZR-CD 2.2)].)

10.  Remove in the order indicated in the table.

11.  Install in the reverse order of removal.

12.  Add the specified amount of specified transaxle oil. (See TRANSAXLE OIL REPLACEMENT [A26M-R].)

13.  Warm up the engine and transaxle, inspect for oil leakage, and inspect the transaxle operation.

Warning

•  Improperly jacking a transaxle is dangerous. It can slip off the jack and may cause serious injury.

Note

•  If the transaxle is overhauled and installed to the vehicle, perform the 'INSPECTION AFTER TRANSAXLE OVERHAUL' and verify that there is no abnormality. (See INSPECTION AFTER TRANSAXLE INSTALLATION [A26M-R].)

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1	Boot
2	Clutch release collar
3	Clutch release fork
4	Clutch cover (See Clutch Cover and Disc Removal Note.) (See Clutch Cover Installation Note.)
5	Clutch disc (See Clutch Cover and Disc Removal Note.) (See Clutch Disc Installation Note.)
6	Pilot bearing (See Pilot Bearing Removal Note.) (See Pilot Bearing Installation Note.)
7	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 of clutch cover, if the old assembly is reused, it must be reinstalled together with its original clutch disc.

1.  Install the SSTs.

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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 bolts evenly and gradually in a crisscross pattern.

3.  Remove the flywheel.

Flywheel Installation Note

1.  Clean the crankshaft thread holes.

2.  Install the flywheel to the crankshaft.

3.  Hand-tighten the new flywheel lock bolts.

4.  Install the SST to the flywheel.

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

Pilot Bearing Installation Note

1.  Use the SSTs to install the pilot bearing.

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2.  As shown in the figure, press-fit the pilot bearing to the position which is 4.0—5.0 mm {0.16—0.19 in} from the crankshaft end.

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Clutch Disc Installation Note

1.  Clean the splines of the clutch disc and the main drive gear with a brush.

2.  Spread a thin layer of clutch grease on the splines.

3.  Hold the clutch disc position using the SST.

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Clutch Cover Installation Note

1.  Install the SSTs.

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2.  Tighten the bolts in Min. 2 stages.

3.  Tighten partially with a crisscross pattern.

4.  Fully tighten to specified torque with a crisscross pattern.