CLUTCH UNIT REMOVAL/INSTALLATION [G66M-R]

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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.

1.  Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZR 1.8, MZR 2.0, MZR 2.5].)(See BATTERY REMOVAL/INSTALLATION [MZR 2.0 DISI].)

2.  Remove the following parts:

(1)  Battery and battery tray (MZR 2.0, MZR 2.5)(See BATTERY REMOVAL/INSTALLATION [MZR 1.8, MZR 2.0, MZR 2.5].)

(2)  Battery component (ex: battery, battery tray and PCM component)(MZR 2.0 DISI)(See BATTERY REMOVAL/INSTALLATION [MZR 2.0 DISI].)

(3)  Air cleaner component (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 1.8, MZR 2.0, MZR 2.5].)(See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 2.0 DISI].)

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

(5)  Splash shields (See SPLASH SHIELD REMOVAL/INSTALLATION.)

(6)  Plug hole plate (See PLUG HOLE PLATE REMOVAL/INSTALLATION [MZR 1.8, MZR 2.0, MZR 2.5].)(See PLUG HOLE PLATE REMOVAL/INSTALLATION [MZR 2.0 DISI].)

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

(8)  Aerodynamic under cover No.1 (See AERODYNAMIC UNDER COVER NO.1 REMOVAL/INSTALLATION.)

(9)  Tunnel member (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR 1.8, MZR 2.0, MZR 2.5].)(See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR 2.0 DISI].)

(10)  Floor under cover (left side)(See FLOOR UNDER COVER REMOVAL/INSTALLATION.)

3.  Disconnect the A/F sensor connector. (See AIR FUEL RATIO (A/F) SENSOR REMOVAL/INSTALLATION [MZR 1.8, MZR 2.0, MZR 2.5].)(See AIR FUEL RATIO (A/F) SENSOR REMOVAL/INSTALLATION [MZR 2.0 DISI].)

4.  Disconnect the HO2S connector. (See HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION [MZR 1.8, MZR 2.0, MZR 2.5].)(See HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION [MZR 2.0 DISI].)

5.  Remove the hanger on the TWC side as shown in the figure and set the hanger aside.

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6.  Remove the steering shaft cover. (See STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION [L.H.D.].)(See STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION [R.H.D.].)

7.  Remove the joint bolt for the steering shaft and disconnect the steering shaft from the steering gear and linkage side. (See STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION [L.H.D.].)(See STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION [R.H.D.].)

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

Warning

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

9.  Remove the manual transaxle. (See MANUAL TRANSAXLE REMOVAL/INSTALLATION [G66M-R].)

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].)

MZR 2.0, MZR 2.0 DISI

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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	Plate
8	Flywheel (See Flywheel Removal Note.) (See Flywheel Installation Note.)

MZR 2.5

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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	Plate
8	Flywheel (See Flywheel Removal Note.) (See Flywheel Installation Note.)

Clutch Cover and Disc Removal Note

Caution

•  When newly replacing the clutch disc or the clutch cover, always replace the clutch disc and the clutch cover at the same time.

•  Due to the automatic adjustment function of clutch cover, if the old cover assembly is reused, it must be installed 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.  Loosen the lock bolts uniformly in the order of the numbers shown in the figure and 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.  Temporarily tighten the lock bolts uniformly in the order of the numbers shown in the figure and install the flywheel.

6.  Tighten the lock bolts in three steps in the order shown in the figure.

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}) or substitution tool.

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2.  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 uniformly in the order of the numbers shown in the figure and install the clutch cover.