Almera Tino V10 (2003 year). Manual

Special Service Tools

NLCL0002

Tool number
Tool name

Description

GG94310000
Flare nut torque wrench

NT406

Removing and installing clutch piping
a: 10 mm (0.39 in)

KV30101600 (New)
KV30101000 (Former)
Clutch aligning bar

NT645

Installing clutch cover and clutch disc
(F70A)
a: 15.9 mm (0.626 in) dia.
b: 17.9 mm (0.705 in) dia.
c: 40 mm (1.57 in)

ST20630000
Clutch aligning bar

NT405

Installing clutch cover and clutch disc
(F50A)
a: 15.8 mm (0.622 in) dia.
b: 22.9 mm (0.902 in) dia.
c: 45.0 mm (1.772 in)

ST20050240
Diaphragm spring adjust-
ing wrench

NT404

Adjusting unevenness of diaphragm spring of
clutch cover
a: 150 mm (5.91 in)
b: 25 mm (0.98 in)

KV32101000
Pin punch

NT410

Removing and installing spring pin
a: 4 mm (0.16 in) dia.

Commercial Service Tools

NLCL0003

Tool name

Description

1 Flare nut crowfoot
2 Torque wrench

NT360

Removing and installing clutch piping
a: 10 mm (0.39 in)

IDX

PREPARATION

RS5F70A, RS5F50A

Special Service Tools

CL-3

NLCL0004

NVH

roubleshooting

Chart

NLCL0004S01

Use

the

chart

below

to
help

you

find

the

cause

of
the

symptom.

The

numbers

indicate

the

order

of
the

inspec-

tion.

necessary

repair

or
replace

these

parts.

CLUTCH

NLCL0004S0101

Reference

page

CL-10

CL-11

CL-14

Refer to EM-70, “Removal and Installation” (QG engine model) and

EM-197, “Removal and Installation” (YD engine model).

CL-17 (RS5F70A), CL-20 (RS5F50A)

CL-22

CL-23

SUSPECTED

(Possible

cause)

CLUTCH PEDAL (Free play out of adjustment)

CLUTCH LINE (Air in line)

MASTER CYLINDER PISTON CUP (Damaged)

OPERATING CYLINDER PISTON CUP (Damaged)

ENGINE MOUNTING (Loose)

RELEASE BEARING (Worn, dirty or damaged)

CLUTCH DISC (Out of true)

CLUTCH DISC (Runout is excessive)

CLUTCH DISC (Lining broken)

CLUTCH DISC (Dirty or burned)

CLUTCH DISC (Oily)

CLUTCH DISC (Worn out)

CLUTCH DISC (Hardened)

CLUTCH DISC (Lack of spline grease)

DIAPHRAGM SPRING (Damaged)

DIAPHRAGM SPRING (Out of tip alignment)

PRESSURE PLATE (Distortion)

FLYWHEEL (Distortion)

Symptom

Clutch

grabs/chatters

Clutch

pedal

spongy

Clutch

noisy

Clutch

slips

Clutch

does

not

disen-

gage

1234

55555

5667

NOISE,

IBRATION

AND

HARSHNESS

(NVH)

ROUBLESHOOTING

RS5F70A,

RS5F50A

NVH

roubleshooting

Chart

CL-4

Components — RHD Model with QG Engine —

NLCL0041

YCL038

Clutch pedal bracket

Pedal stopper bolt

Clutch pedal

Clevis pin

Bushing

Snap pin

Clutch master cylinder

Nipple

Reservoir cap

10. Reservoir tank
11. Hose clamp
12. Hose
13. Filter
14. Clutch disc
15. Clutch cover
16. Withdrawal lever

17. Spacer
18. Operating cylinder
19. Clutch hose
20. Clutch lever
21. Spring pin
22. Release bearing
23. Release bearing spring

IDX

CLUTCH SYSTEM

RS5F70A, RS5F50A

Components — RHD Model with QG Engine —

CL-5

Components — LHD Model with QG Engine —

NLCL0048

NCL047

Clutch pedal bracket

Clevis pin

Bushing

Snap pin

Pedal stopper bolt

Clutch pedal

Clutch master cylinder

Nipple

Reservoir cap

10. Reservoir tank
11. Hose clamp
12. Hose
13. Filter
14. Clutch disc
15. Clutch cover
16. Withdrawal lever

17. Spacer
18. Operating cylinder
19. Clutch hose
20. Clutch lever
21. Spring pin
22. Release bearing
23. Release bearing spring

CLUTCH SYSTEM

RS5F70A, RS5F50A

Components — LHD Model with QG Engine —

CL-6

Components — RHD Model with YD Engine —

NLCL0005

YCL039

Clutch pedal bracket

Pedal stopper bolt

Clutch pedal

Clevis pin

Bushing

Snap pin

Clutch master cylinder

Nipple

Reservoir cap

10. Reservoir tank
11. Hose clamp
12. Hose
13. Filter
14. Air bleeder screw
15. Withdrawal lever

16. Operating cylinder
17. Clutch hose
18. Clutch disc
19. Clutch cover
20. Clutch hose connector
21. Release bearing
22. Washer

IDX

CLUTCH SYSTEM

RS5F70A, RS5F50A

Components — RHD Model with YD Engine —

CL-7

Components — LHD Model with YD Engine —

NLCL0049

NCL049

Clutch pedal bracket

Clevis pin

Bushing

Snap pin

Pedal stopper bolt

Clutch pedal

Clutch master cylinder

Nipple

Reservoir cap

10. Reservoir tank
11. Hose clamp
12. Hose
13. Filter
14. Air bleeder screw
15. Withdrawal lever

16. Operating cylinder
17. Clutch hose
18. Clutch disc
19. Clutch cover
20. Clutch hose connector
21. Release bearing
22. Washer

CLUTCH SYSTEM

RS5F70A, RS5F50A

Components — LHD Model with YD Engine —

CL-8

Inspection and Adjustment

NLCL0006

CLUTCH PEDAL INSPECTION

NLCL0006S04

Pedal Stroke

NLCL0006S0401

Check clutch pedal stroke by using a 1–meter rule to measure the
total pedal stroke. Place end of rule onto the middle of the clutch
pedal pad. Place a book/clipboard on the driver’s seat to set a ref-
erence point, ensure the book/clipboard does not move during
pedal depression. Mark (A) the pedal fully up position on the rule.
Depress the clutch pedal and mark (B) the rule again next to the
reference point on the book/clipboard. Measure the distance
between the marks (A and B), this is the actual pedal stroke (S).
Check the specified pedal stroke in the table, adjust actual pedal
stroke if necessary (refer to “CLUTCH PEDAL ADJUSTMENT”).
NOTE:

Do not use steering wheel as a reference point, angle gives
incorrect reading.

Ensure there is no interference between the floor carpet and
clutch pedal when fully depressed.

NCL058

SCL702

Pedal Free Play

NLCL0006S0402

Check pedal free play, if out of specification refer to “CLUTCH
PEDAL ADJUSTMENT”

Push on the clutch pedal until resistance is felt, and check the
distance the pedal moves.

IDX

CLUTCH SYSTEM

RS5F70A, RS5F50A

Inspection and Adjustment

CL-9

CLUTCH PEDAL ADJUSTMENT

NLCL0006S01

Pedal Stroke

NLCL0006S0101

Loosen the pedal stopper bolt completely (so there is no con-
tact between pedal and stopper bolt).

Adjust pedal stroke to the specified value with the master cyl-
inder push rod.

Adjust the pedal stopper bolt until it is just in contact with the
pedal, then tighten the lock nut.

Once stroke is set to specification, adjust clutch pedal free
play.

Pedal stroke “S”.
Refer to “SDS”, CL-24.

Pedal Free Play

NLCL0006S0102

Adjust pedal free play to the specified value with the master
cylinder push rod.

Tighten lock nut of the master cylinder push rod.

Push on the clutch pedal until resistance is felt, and check the
distance the pedal moves.

Pedal free play “A”.
Refer to “SDS”, CL-24.

SCL838

SCL839

AIR BLEEDING PROCEDURE

NLCL0006S02

Bleed air from clutch operating cylinder according to the fol-
lowing procedure.

Carefully monitor fluid level at reservoir during bleeding
operation.

Top up reservoir with recommended brake fluid.

Connect a transparent vinyl tube to air bleeder valve.

Slowly depress the clutch pedal to its full stroke and release it
completely. Repeat this operation several times at 2 to 3 sec-
onds intervals.

Open the air bleeder with the clutch pedal fully depressed.

Close the air bleeder.

Release the clutch pedal and wait at least 5 seconds.

Repeat steps c through f mentioned above, until clear brake
fluid comes out of air bleeder valve.

Air bleeder valve tightening torque:

: 5.9 - 9.8 N·m (0.6 - 1.0 kg-m, 52 - 86 in-lb)

CLUTCH SYSTEM

RS5F70A, RS5F50A

Inspection and Adjustment (Cont’d)

CL-10

Removal

NLCL0008

Drain brake fluid.

CAUTION:

Be careful not to splash brake fluid on painted areas; it may
cause paint damage. If brake fluid is splashed on painted
areas, wash it away with water immediately.
2.

Remove clutch tube using a flare nut wrench.

Remove snap pin between clutch pedal and push rod, and
remove clevis pin.

Unscrew master cylinder assembly mounting nuts and remove
master cylinder assembly from vehicle.

Installation

NLCL0009

Connect clutch tube to master cylinder assembly, and hand-
tighten flare nut.

Install master cylinder assembly to vehicle, and tighten mount-
ing nuts to the specified torque.

: 13 - 16 N·m (1.3 - 1.6 kg-m, 10 - 12 ft-lb)

Tighten clutch tube flare nut using a flare nut torque wrench.

: 15 - 18 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)

After installing clevis pin, install snap pin to connect clutch
pedal to push rod.

After finishing the operation, bleed air from clutch piping con-
nector and operating cylinder. (Refer to “Air Bleeding
Procedure”, CL-10.)

SCL725

Disassembly

NLCL0010

Loosen push rod lock nut A to remove clevis and lock nut A.

Remove dust cover.

Remove stopper ring and stopper, and remove push rod from
cylinder body. During removal, keep push rod depressed, to
prevent piston inside master cylinder from popping out.

Remove piston assembly from cylinder body.

Inspection

NLCL0011

Check the following items, and replace if necessary.

Rubbing surface of cylinder and piston, for uneven wear, rust
or damage

Piston with piston cup, for wear or damage

Return spring, for wear or damage

Dust cover, for cracks, deformation or damage

Reservoir, for deformation or damage

CLUTCH MASTER CYLINDER

RS5F70A, RS5F50A

Removal

CL-12

Assembly

NLCL0012

Apply rubber lubricant to the sliding part of piston assembly,
and insert piston assembly.

After installing stopper to push rod, install stopper ring while
keeping piston assembly depressed by hand, so that piston
assembly will not pop out.

CAUTION:

Stopper ring cannot be reused. Always use a new stopper ring
for assembly.
3.

Install dust cover.

Install clevis to push rod, and tighten lock nut A to the speci-
fied torque.

: 8 - 10 N·m (0.8 - 1.1 kg-m, 70 - 95 in-lb)

Install spring pin using a pin punch.

IDX

CLUTCH MASTER CYLINDER

RS5F70A, RS5F50A

Assembly

CL-13

Components

NLCL0019

YCL001

Removal

NLCL0020

Drain brake fluid.

CAUTION:

Be careful not to splash brake fluid on painted areas; it may
cause paint damage. If brake fluid is splashed on painted
areas, wash it away with water immediately.
2.

Remove union bolt and clutch hose from operating cylinder.

Remove operating cylinder mounting bolts, and remove cylin-
der from vehicle.

Disassembly

NLCL0021

Remove dust cover, and remove piston assembly from cylinder
body.

Inspection

NLCL0022

Inspect for following, and replace parts if necessary.

Damage, foreign material, wear, rust, and pinholes on the cyl-
inder inner surface, piston, and sliding part of piston cup

Weak spring

Crack and deformation of dust cover

OPERATING CYLINDER

RS5F70A, RS5F50A

Components

CL-14

Assembly

NLCL0023

Apply recommended rubber grease to piston cup and piston,
and insert piston assembly.

Install dust cover.

Installation

NLCL0024

Install the components in the reverse order of removal. Adhere to
the operations described below.

CAUTION:

Install the hose without twisting it.

The copper washer of the union bolt should not be reused.
Always use a new copper washer for installation.

After finishing the operation, bleed air from the clutch
piping connector and operating cylinder. Refer to “Air
Bleeding Procedure”, CL-10.

IDX

OPERATING CYLINDER

RS5F70A, RS5F50A

Assembly

CL-15

SCL729

Removal

NLCL0042

Remove fuel filter mounting bracket.

Remove air cleaner and air duct.

Drain brake fluid.

CAUTION:

Be careful not to splash brake fluid on painted areas; it may
cause paint damage. If brake fluid is splashed on painted
areas, wash it away with water immediately.
4.

Remove flare nut using a flare nut wrench.

Remove clutch hose and clutch tube.

SCL730

Installation

NLCL0043

When installing clutch hose to bracket, face lock plate in the
correct direction as shown to secure clutch hose.

CAUTION:

Install clutch hose without twisting or bending it.
2.

Tighten flare nut to the specified torque, using a flare nut
wrench.

: 15 - 18 N·m (1.5 - 1.8 kg-m, 11 - 13 ft-lb)

CAUTION:

Be careful not to damage flare nut and clutch tube.
3.

Install clutch hose to operating cylinder, and tighten mounting
bolts to the specified torque.

: 17 - 19 N·m (1.7 - 2.0 kg-m, 13 - 14 ft-lb)

After finishing the operation, bleed air from the clutch piping.
Refer to “Air Bleeding Procedure”, CL-10.

PIPING

RS5F70A, RS5F50A

Removal

CL-16

Components

NLCL0044

SCL819

SCL820

Removal

NLCL0045

Remove manual transaxle from vehicle. Refer to MT-19,
“Removal”.

Move withdrawal lever enough to remove release bearing, and
remove release bearing from clutch lever.

Support clutch lever claws with an appropriate wood block,
align retaining pin with A in the figure, and drive out spring pin
using a pin punch.

Pull out withdrawal lever and remove clutch lever.

SCL733

Inspection

NLCL0046

Replace the release bearing if it is seized, damaged, faulty in
rotation direction, or has poor aligning function.

Replace the withdrawal lever if its contact surface is worn
abnormally.

Replace the clutch lever if its contact surface is worn abnor-
mally.

Replace the dust seal if it is deformed or cracked.

Installation

NLCL0047

CAUTION:

Be sure to apply grease to the clutch components.
Otherwise, abnormal noise, poor clutch disengagement,
or clutch damage may occur. Wipe the excess grease off
completely, because it may cause the clutch components
to slip and shudder.

Keep the clutch disc facing, pressure plate, and flywheel
free of oil and grease.

IDX

CLUTCH RELEASE MECHANISM

RS5F70A

Components

CL-17

YCL002

Clean old grease and abrasive materials off the grease
application area.

Apply approximately 1 mm (0.04 in)-thick clutch sleeve
grease evenly on the sliding part of the clutch lever and
the release bearing spring.

Apply just enough clutch sleeve grease to fill up the
release bearing inner groove.

Apply the clutch grease to the clutch disc and the input
shaft spline. Install the clutch disc to the input shaft,
remove the excess grease around the shaft, and remove
the clutch disc.

Lightly and evenly apply the clutch sleeve grease on the
sliding part of the release bearing, install the release
bearing, remove the excess grease around the bearing,
and remove the release bearing.

SCL822

Assemble clutch lever to clutch housing, and insert withdrawal
lever.

Support clutch lever claws with an appropriate wood block, and
install a new spring pin using a pin punch.

CAUTION:

Spring pin cannot be reused.

SCL736

Install release bearing spring to release bearing as shown in
the figure.

SCL823

Operate withdrawal lever manually, press clutch spring from
both sides, and install release bearing to clutch lever securely.

Make sure a click is heard when release bearing spring is
pressed from both sides.

CLUTCH RELEASE MECHANISM

RS5F70A

Installation (Cont’d)

CL-18

Almera Tino V10 (2003 year). Manual - part 60