Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-
tion. If necessary, repair or replace these parts.

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

CL-3

< SYMPTOM DIAGNOSIS >

Reference

2DDT),

(R9M),

(K9K),

(MR 2WD),

(MR 4WD)

(R9M)

,(K9K),

2DDT)

(HRA2DDT),

(R9M),

(K9K),

(MR20DDT)

EM-179

EM-459

(R9M),

EM-102

(HR

2DDT),

(K9K), (MR20DDT)

(RS6F95R),

F94R),

(RS6F52A)

SUSPECTED PARTS (Possible
cause)

CLUTCH P

DAL (Inspect

n an

d a

tme

)

CLUTCH LINE (A

ir in line)

ENGINE MOUN

TING (Loose)

CSC (Concentric Slave Cy

linder) (Bearing

rn)

CSC (Concentric Slave

lin

r) (flu

)

STER

CYLINDER,

DAMPER, OR PIPE (Fluid leak)

CLUTCH DISC (Runou

t i

ssi

)

CLUTCH DISC (Lining

broken)

CLUTCH DI

SC (Li

dirt

or b

, L

ini

Oily

, L

ini

worn

CLUTCH DI

SC (Cus

t wa

fla

tte

CLUTCH DISC (Lack of

line

rea

)

CLUTCH DISC (Hub

lin

rn)

CLUTCH DI

SC (Dam

r worn

r co

ate

oil

reas

)

APHRAGM SPRI

G (Dam

or we

ake

)

DIAPHRAGM

SPRING (Ou

t o

f ti

p a

lig

PRESSURE PLA

(Di

rti

PRESSURE

PLA

E DRI

VE STRA

PS (Distorted or

broken)

YWHE

EL (Di

torti

on)

DUAL M

ASS

YWHEE

(Da

dam

ged

r worn

)

TRANSAXLE (W

orn)

Symptom

Clutch grabs/judders

Clutch chatters/rattles

Clutch pedal spongy

Clutch noisy (whine/rum-
ble)

Clutch slips

Clutch drags/does not
disengage

CL-4

< PRECAUTION >

PRECAUTIONS

PRECAUTION

PRECAUTIONS

Precaution for Procedure without Cowl Top Cover

INFOID:0000000010497459

When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc to prevent damage to
windshield.

Service Notice or Precautions for Clutch

INFOID:0000000010288554

CAUTION:

• Recommended clutch fluid is brake fluid “DOT 4”. Refer to

MA-59, "Fluids and Lubricants"

• Never reuse drained clutch fluid.
• Never splash clutch fluid on painted areas.
• Never use mineral oils such as gasoline or kerosene. It will ruin the rubber parts of the hydraulic sys-

tem.

• If transaxle assembly is removed from the vehicle, always replace CSC (Concentric Slave Cylinder).

Return CSC insert to original position to remove transaxle assembly. Dust on clutch disc sliding
parts may damage seal of CSC and may cause clutch fluid leakage.

• Never disassemble master cylinder and CSC.

WARNING:

After cleaning clutch disc, wipe it with a dust collector. Never use compressed air.

Precautions for Removing Battery Terminal

INFOID:0000000010508556

• With the adoption of Auto ACC function, ACC power is automatically supplied by operating the intelligent key

or remote keyless entry or by opening/closing the driver side door. In addition, ACC power is supplied even
after the ignition switch is turned to the OFF position, i.e. ACC power is supplied for a certain fixed time.

• When disconnecting the 12V battery terminal, turn off the ACC

power before disconnecting the 12V battery terminal, observing
“How to disconnect 12V battery terminal” described below.
NOTE:
Some ECUs operate for a certain fixed time even after ignition
switch is turned OFF and ignition power supply is stopped. If the
battery terminal is disconnected before ECU stops, accidental DTC
detection or ECU data damage may occur.

• For vehicles with the 2-batteries, be sure to connect the main bat-

tery and the sub battery before turning ON the ignition switch.
NOTE:
If the ignition switch is turned ON with any one of the terminals of
main battery and sub battery disconnected, then DTC may be detected.

• After installing the 12V battery, always check "Self Diagnosis Result" of all ECUs and erase DTC.

NOTE:
The removal of 12V battery may cause a DTC detection error.

HOW TO DISCONNECT 12V BATTERY TERMINAL

Disconnect 12V battery terminal according to Instruction 1 or Instruction 2 described below.
For vehicles parked by ignition switch OFF, refer to Instruction 2.

INSTRUCTION 1

Open the hood.

PIIB3706J

SEF289H

PRECAUTIONS

CL-5

< PRECAUTION >

Turn key switch to the OFF position with the driver side door opened.

Get out of the vehicle and close the driver side door.

Wait at least 3 minutes. For vehicle with the engine listed below, remove the battery terminal after a lapse
of the specified time.

CAUTION:

While waiting, never operate the vehicle such as locking, opening, and closing doors. Violation of
this caution results in the activation of ACC power supply according to the Auto ACC function.

Remove 12V battery terminal.

CAUTION:

After installing 12V battery, always check self-diagnosis results of all ECUs and erase DTC.

INSTRUCTION 2 (FOR VEHICLES PARKED BY IGNITION SWITCH OFF)

Unlock the door with intelligent key or remote keyless entry.
NOTE:
At this moment, ACC power is supplied.

Open the driver side door.

Open the hood.

Close the driver side door.

Wait at least 3 minutes.

CAUTION:

While waiting, never operate the vehicle such as locking, opening, and closing doors. Violation of
this caution results in the activation of ACC power supply according to the Auto ACC function.

Remove 12V battery terminal.

CAUTION:

After installing 12V battery, always check self-diagnosis results of all ECUs and erase DTC.

D4D engine

: 20 minutes

K9K engine

: 4 minutes

M9R engine

: 4 minutes

R9M engine

: 4 minutes

V9X engine

: 4 minutes

CL-6

< PREPARATION >

PREPARATION

PREPARATION

Special Service Tools

INFOID:0000000010288555

Commercial Service Tools

INFOID:0000000010288556

Tool number
Tool name

Description

ST20050240
Diaphragm adjusting wrench

Adjusting unevenness of diaphragm spring of
clutch cover

—
Emb.1761
Kit for clutch cover removal and instal-
lation

Holding the clutch cover.
Assembly of three bolts, three spacers, and
three nuts.

—
Emb.1604
Clutch compression tool

Rearming the clutch cover compensation sys-
tem.

—
Mot.1431
Flywheel locking tool

Locking the flywheel.

ZZA0508D

E1BIA0775ZZ

E1BIA0778ZZ

JMAIA0431ZZ

Tool name

Description

Clutch aligner
1: Center shaft
2: Attachment
3: Guide

Installing clutch disc

SAC tool (Self Adjusting Clutch)

Installing clutch cover on R9M engine

PCIB0017E

CLUTCH PEDAL

CL-7

< PERIODIC MAINTENANCE >

PERIODIC MAINTENANCE

CLUTCH PEDAL

Inspection and Adjustment

INFOID:0000000010288557

INSPECTION

Check to see if the master cylinder rod end moves freely. It
should not be bound by the clutch pedal.
• If the rod end does not move freely, remove the rod end and

check for deformation or damage on the rod end. Leave the
rod end removed for step 2.

Check the clutch pedal stroke for free range of movement.

With the master cylinder rod end removed, manually move the
clutch pedal up and down to determine if it moves freely.

If any sticking is noted, replace the clutch pedal assembly.
Reverify that the master cylinder rod end moves freely.

Inspect the ASCD clutch switch position and Interlock clutch
switch position

If the rod end does not move freely, check that the ASCD clutch switch and Interlock clucth switch are not
applying pressure to the clutch pedal causing the rod end to bind. To adjust, disconnect the ASCD clutch
switch electrical connector and turn the ASCD clutch switch.

Connect the ASCD clutch switch and Interlock clutch switch electrical connector.

Check the clutch hydraulic system components (master cylinder assembly, CSC) for sticking or binding.

If any sticking or binding is noted, repair or replace the related parts as necessary.

If any hydraulic system repair is necessary, bleed the clutch hydraulic system. Refer to

CL-8, "Air Bleeding

Procedure"

NOTE:
Do not use a vacuum assist or any other type of power bleeder on this system. Use of a vacuum assist or
power bleeder will not purge all of the air from the system.

ADJUSTMENT

Adjust ASCD clutch switch (1) position and Interlock clutch switch
(2) position so that clearance between clutch pedal and thread end
of ASCD clutch switch and Interlock clutch switch, with clutch pedal
fully released, is within specification “A” or "B".

PCIB1491E

Clearance “A”

: Refer to

CL-31, "Clutch Pedal"

Clearance “B”

: Refer to

CL-31, "Clutch Pedal"

E1DIA0228ZZ

CL-8

< PERIODIC MAINTENANCE >

CLUTCH FLUID

CLUTCH FLUID

Inspection

INFOID:0000000010288558

CLUTCH FLUID LEVEL

• Check that the fluid level in the reservoir tank is within the specified

range (MAX – MIN lines).

• Visually check for any clutch fluid leakage around the reservoir

tank.

• Check the clutch system for any leakage if the fluid level is

extremely low (lower than MIN).

Air Bleeding Procedure

INFOID:0000000010288559

NOTE:
Do not use a vacuum assist or any other type of power bleeder on this system. Use of a vacuum assist or
power bleeder will not purge all the air from the system.

CAUTION:

• Monitor clutch fluid level in reservoir tank to make sure it does not empty.
• Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately

and wash the affected area with water.

• Bleed the air of bleeding connector (1).

Fill reservoir tank with new clutch fluid.

Connect a transparent vinyl hose to air bleeder of bleeding con-
nector.

“Depress” and “release” the clutch pedal slowly and fully 15
times at an interval of 2 to 3 seconds and release the clutch
pedal.

Push the lock pin (1) of the bleeding connector (2), and maintain
the position.

CAUTION:

Hold it to prevent releasing clutch tube from bleeding con-
nector when fluid pressure is applied in the tube.

JPFIA0007ZZ

PCIB1494E

JPDIB0041ZZ

CLUTCH FLUID

CL-9

< PERIODIC MAINTENANCE >

Slide clutch tube (1) in the direction of the arrow as shown in the
figure.

•

Depress the clutch pedal soon and hold it, and then bleed the air
from the piping.

CAUTION:

Hold it to prevent releasing clutch tube from bleeding con-
nector when fluid pressure is applied in the tube.

Return clutch tube and lock pin to their original positions.

Release clutch pedal and wait for 5 seconds.

Repeat steps 3 to 8 until no bubbles are observed in the clutch fluid.

: Clutch housing

Dimension “A”

: 10 mm (0.39 in)

JPDIB0042ZZ

CL-10

< REMOVAL AND INSTALLATION >

CLUTCH PEDAL

REMOVAL AND INSTALLATION

CLUTCH PEDAL

Exploded View

INFOID:0000000010288560

Removal and Installation

INFOID:0000000010288561

REMOVAL

Remove front kicking plate inner and dash side finisher. Refer to

INT-18, "Removal and Installation"

Remove lower instrument panel, driver side. Refer to

IP-13, "Removal and Installation"

Disconnect ASCD clutch switch and Interlock clutch switch harness connector and then disconnect clip of
harness from clutch pedal assembly.

Disconnect clutch stroke sensor harness connector.

Remove clutch stroke sensor. Refer to

CL-10, "Removal and Installation"

Clutch pedal

Interlock clutch switch

Clip

Spring

Cluctch switch (ASCD Cancel
Switch)

Nuts

Stroke sensor

Refer to

GI-4, "Components"

for the symbols in the figure.

E1DIA0227GB

CLUTCH PEDAL

CL-11

< REMOVAL AND INSTALLATION >

Remove master cylinder rod end from clutch pedal assembly.

Remove clutch pedal assembly.

INSTALLATION

Install in the reverse order of removal.

CLUTCH STROKE SENSOR INSTALLATION

Inserted the part (1) of the clutch stroke (2) into the hole and
slide it as shown on the figure.

Push the part (2) in the direction (B) to the hole deeply.
Turn the part (1) in counterclockwise until the part in completely
fixed.
Push the part (5) on the direction (C) to cover the cluch pedal
rod (4).

Inspection

INFOID:0000000010288562

INSPECTION AFTER REMOVAL

Check clutch pedal for bend, damage, or a cracked weld. If bend, damage, or a cracked weld is found, replace
clutch pedal assembly.

PCIB1491E

E1DIA0240ZZ

E1DIA0241ZZ

CL-12

< REMOVAL AND INSTALLATION >

CLUTCH MASTER CYLINDER

CLUTCH MASTER CYLINDER

Exploded View

INFOID:0000000010288563

Removal and Installation

INFOID:0000000010288564

REMOVAL

CAUTION:

• Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately

and wash the affected area with water.

• Never disassemble master cylinder.
1.

Remove the air cleaner case and air duct (inlet) or air ducts. Refer to

EM-23, "Removal and Installation"

(HRA2DDT),

EM-380, "Removal and Installation"

(R9M),

EM-279, "Removal and Installation"

(K9K),

(MR20DD)

EM-147, "Removal and Installation"

. (For LHD)

Remove cowl top assembly. Refer to

EXT-29, "Removal and Installation"

Remove engine room insulator. (for RHD).

Drain clutch fluid in reservoir tank assembly and then remove hose.

Remove master cylinder rod end from clutch pedal assembly.

Reservoir tank assembly

Hose

Master cylinder assembly

JPDIB0035ZZ

PCIB1491E

CLUTCH MASTER CYLINDER

CL-13

< REMOVAL AND INSTALLATION >

Remove lock pin (1) from connector of master cylinder (2) and
separate clutch tube (3).

Rotate master cylinder assembly clockwise by 45

and then

remove master cylinder assembly from the vehicle.

INSTALLATION

CAUTION:

Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.

Tilt master cylinder assembly clockwise by 45

and insert it to

the mounting hole. Rotate counterclockwise and secure it. At
this time, nipple is upward of the vehicle.

Install master cylinder rod end to clutch pedal assembly.

Install hose to reservoir tank assembly and master cylinder
assembly.

CAUTION:

Set hose with painted mark facing upward.

Install clutch tube (1) into connector of master cylinder assembly
(2) until it stops.

Install lock pin (3) into connector of master cylinder assembly
until it stops.

Fill new clutch fluid according to the following.

Fill reservoir tank assembly with new clutch fluid.

Connect a transparent vinyl hose to air bleeder of bleeding con-
nector.

Push the lock pin (1) of the bleeding connector (2).
• RS6F94R, RS6F95R and RS6F52A

Slide clutch tube (1) in the direction of the arrow as shown in the figure.

PCIB1497E

SCIA1286E

PCIB1500E

JPDIB0041ZZ

CL-14

< REMOVAL AND INSTALLATION >

CLUTCH MASTER CYLINDER

• RS6F94R, RS6F95R and RS6F52A

Depress clutch pedal slowly to full stroke and then release it.
Repeat this until new clutch fluid comes out.

CAUTION:

• Hold it to prevent releasing clutch tube from bleeding

connector when fluid pressure is applied in the tube.

• Monitor clutch fluid level in reservoir tank to make sure it

does not empty.

Place clutch tube (1) and lock pin back into position with clutch pedal depressed.

Bleed the air from the clutch hydraulic system. Refer to

CL-8, "Air Bleeding Procedure"

After completing this procedure, inspect for clutch pedal. Refer to

CL-7, "Inspection and Adjustment"

Install engine room insulator. (For RHD)

Install cowl top assembly. Refer to

EXT-29, "Removal and Installation"

. (For RHD with R9M)

10. Install the air cleaner case and air duct (inlet) or air ducts. Refer to

EM-380, "Removal and Installation"

(R9M),

EM-23, "Removal and Installation"

(HRA2DDT),

EM-279, "Removal and Installation"

(K9K),

EM-

147, "Removal and Installation"

(MR20DD). (For LHD)

: Clutch housing

Dimension “A”

: 10 mm (0.39 in)

JPDIB0042ZZ

CLUTCH PIPING

CL-15

< REMOVAL AND INSTALLATION >

CLUTCH PIPING

Exploded View

INFOID:0000000010288565

RS6F94R RS6F95R

RS6F52A

JPDIB0050ZZ

CSC (Concentric Slave Cylinder)

Clutch tube

Bracket

Clutch damper

Master cylinder assembly

JPDIB0054GB

CSC (Concentric Slave Cylinder)

Clutch tube

Bracket

Clutch damper

Master cylinder assembly

Refer to

GI-4, "Components"

for the symbols in the figure.

CL-16

< REMOVAL AND INSTALLATION >

CLUTCH PIPING

Hydraulic Layout

INFOID:0000000010288566

Removal and Installation

INFOID:0000000010288567

CAUTION:

Keep painted surface on the body or other parts free of clutch fluid. If it spills, wipe up immediately
and wash the affected area with water.

REMOVAL

Refer to the figure for removal procedure.

INSTALLATION

Refer to the figure for installation procedure.
• When installing clutch tube to connector of CSC, connector of clutch damper and connector of master cylin-

der, push it as far as it goes.

• When installing lock pin to connector of CSC, connector of clutch damper and connector of master cylinder,

push it as far as it goes.

• After installation, bleed the air from the clutch hydraulic system. Refer to

CL-8, "Air Bleeding Procedure"

CAUTION:

Never scratch or damage clutch hose.

Clutch tube

Lock pin

CSC (Concentric Slave Cylinder)

Clutch damper

Master cylinder assembly

Clutch pedal assembly

PCIB1499E

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