CLUTCH UNIT REMOVAL/INSTALLATION [G66M-R]

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1.  Remove the battery cover. (See BATTERY INSPECTION [MZR 2.0, MZR 2.5].)(See BATTERY REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

2.  Disconnect the negative battery cable. (See BATTERY INSPECTION [MZR 2.0, MZR 2.5].)(See BATTERY REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

3.  Remove the battery component. (ex: battery, battery tray and PCM component) (MZR 2.0, MZR 2.5)(See BATTERY INSPECTION [MZR 2.0, MZR 2.5].)

4.  Remove the battery and battery tray. (MZR 2.0 DISI i-stop)(See BATTERY REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

5.  Remove the air cleaner component. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 2.0, MZR 2.5].)(See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

6.  Remove the exhaust manifold insulator installation bolts and set the exhaust manifold insulator aside.

7.  Remove the following parts:

(1)  Exhaust manifold bracket

(2)  Front tires (See GENERAL PROCEDURES (SUSPENSION).)

(3)  Splash shield (See SPLASH SHIELD REMOVAL/INSTALLATION.)

(4)  Aerodynamic under cover No.2 (See AERODYNAMIC UNDER COVER NO.2 REMOVAL/INSTALLATION.)

(5)  Starter (See STARTER REMOVAL/INSTALLATION [MZR 2.0, MZR 2.5].)(See STARTER REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

8.  Drain the transaxle oil into a suitable container. (See TRANSAXLE OIL REPLACEMENT [G66M-R].)

9.  Remove the manual transaxle.(See MANUAL TRANSAXLE REMOVAL/INSTALLATION [G66M-R (EXCEPT MZR 2.0 DISI i-stop)].)(See MANUAL TRANSAXLE REMOVAL/INSTALLATION [G66M-R (MZR 2.0 DISI i-stop)].)

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 [G66M-R].)

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 [G66M-R].)

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1	Clutch release collar (See CLUTCH RELEASE COLLAR INSPECTION [G66M-R].)
2	Boot
3	Clutch release fork (See Clutch Release Fork Removal Note.)
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 Release Fork Removal Note

1.  Remove the fork supporter before disassembling the clutch release fork.

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Clutch Cover and Disc Removal Note

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.

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4.  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 [MZR 2.0, MZR 2.5].)

Flywheel Installation Note

1.  Install the flywheel to the crankshaft.

2.  Clean the crankshaft thread holes before installing the new lock bolts.

3.  Hand-tighten the 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.  Install the pilot bearing using the Snap-on brand millimeter size bushing driver set (A160M) adapter A160M7 (20—22 mm).

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Caution

•  Use the adapter with the 20 mm side of the A160M7 (20—22 mm) facing the pilot bearing side.

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.  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.

(1)  Tighten partially with a crisscross pattern.

(2)  Fully tighten to specified torque with a crisscross pattern.