CLUTCH SYSTEM

General Description
CLUTCH SYSTEM

1. General Description
A: SPECIFICATION
Model 2.5 L non-turbo 2.5 L Turbo
Transmission type 5MT
Type Push type
Clutch cover
Diaphragm set load N (kgf, lbf) 5,688 (580, 1,279) 7,850 (800, 1,764)
Facing material Woven (Non-asbestos)
230 × 155 × 3.5
Clutch cover side
O.D. × I.D. × thickness 225 × 150 × 3.5 (9.06 × 6.10 × 0.138)
mm (in) (8.86 × 5.9 × 0.138) 230 × 155 × 3.2
Flywheel side
(9.06 × 6.10 × 0.126)
Clutch disc Spline outer diameter mm (in) 25.2 (0.992), (Number of teeth: 24)
Clutch cover side 1.65 — 2.25 (0.065 — 0.089)
Depth of rivet head
Flywheel side 1.35 — 1.95 (0.053 — 0.077)
mm (in)
Limit of sinking 0.3 (0.012)
Deflection limit mm (in) 0.7 (0.028) at R = 110 (4.33)
Clutch release lever ratio 1.6
Release bearing Grease-packed self-aligning
Full stroke mm (in) 130 — 135 (5.12 — 5.31) 135 — 140 (5.31 — 5.51)
Clutch pedal
Free play mm (in) 4 — 11 (0.16 — 0.43)
Flywheel Type Flexible

B: COMPONENT
1. CLUTCH ASSEMBLY

(3) (1)

T2
(2)
(5)
T1
(4)

(12) (8)
(13)
(7)
(6) (5)

(10)
(9)
T1
T1

(11)

CL-00547

(1) Dust cover (7) Lever spring (Turbo model) (13) Flywheel
(2) Lever spring (Non-turbo model) (8) Pivot (Turbo model)
(3) Pivot (Non-turbo model) (9) Release lever (Turbo model) Tightening torque:N·m (kgf-m, ft-lb)
(4) Release lever (Non-turbo model) (10) Release bearing (Turbo model) T1: 16 (1.6, 11.8)
(5) Clip (Non-turbo model) (11) Clutch cover T2: 72 (7.3, 52.8)
(6) Release bearing (Non-turbo model) (12) Clutch disc

CL-2
 General Description
CLUTCH SYSTEM

2. CLUTCH PIPE AND HOSE

T3
(10)
(3) (7) (8)

(11)

T5 T1
(2)
(9)

T3
(1)

T1
T2

T3
T4
(2) T2

(3) (6)

(4)
(5)
T5
(12)

T1

CL-00554

(1) Operating cylinder (7) Master cylinder ASSY Tightening torque:N·m (kgf-m, ft-lb)
(Non-turbo model) (8) Clevis pin T1: 7.8 (0.8, 5.8)
(2) Washer (9) Snap pin T2: 15 (1.5, 11.1)
(3) Clutch hose (10) Lever T3: 18 (1.8, 13.3)
(4) Bracket (11) Pedal T4: 25 (2.5, 18.4)
(5) Clip (12) Operating cylinder (Turbo model) T5: 37 (3.8, 27.5)
(6) Clutch pipe

CL-3
 General Description
CLUTCH SYSTEM

3. MASTER CYLINDER

(1) (12) T2

(11)
(2)

(10)

(3)

(4) (9)

(8)

(13)

(5)

(7)
T1

(6) T3

CL-00559

(1) Reservoir cap (7) Gasket (13) Breather screw

(2) Reservoir tank (8) Return spring
(3) Oil seal (9) Piston Tightening torque:N·m (kgf-m, ft-lb)
(4) Straight pin (10) Push rod ASSY T1: 7.8 (0.8, 5.8)
(5) Master cylinder (11) Piston stop ring T2: 10 (1.0, 7.4)
(6) Clutch damper (12) Seat T3: 46.6 (4.8, 34.4)

CL-4
 General Description
CLUTCH SYSTEM

4. OPERATING CYLINDER
Non-turbo model

(6) T

(3)
(2)

(1)

(4) (5)

CL-00483

(1) Push rod (4) Piston spring Tightening torque:N·m (kgf-m, ft-lb)
(2) Boot (5) Operating cylinder T: 7.8 (0.8, 5.8)
(3) Piston (6) Breather screw

CL-5
 General Description
CLUTCH SYSTEM

Turbo model

(6)

(3)

(2)

(1)

(4) (5)

CL-00504

(1) Push rod (4) Piston spring Tightening torque:N·m (kgf-m, ft-lb)
(2) Boot (5) Operating cylinder T: 7.8 (0.8, 5.8)
(3) Piston (6) Breather screw

CL-6
 General Description
CLUTCH SYSTEM

5. CLUTCH PEDAL

(7)
(3)

(26)
(11)
T2 (25) (4)
T1

T2
(2)

(24)
T2

(23)
(11)
(22)
T1 (21)
(27) (2)
(20)
(1)

(1)
(19) (18)
(14)
(13) (14) (4)
(8)
(2)
(7)
(2)
(17)
(16) (7)
(15)
(12) (11)

(1) (5)
(6)

(9)
(10)
CL-00560

(1) Stopper (13) Assist rod A (23) Stop light switch

(2) Bushing (14) Clip (24) Pedal bracket
(3) Spring pin (15) Assist spring (25) Clutch master cylinder bracket
(4) Snap pin (16) Assist bushing (26) Lever
(5) Brake pedal pad (17) Assist rod B (27) Clutch switch (Starter interlock)
(6) Brake pedal (18) Spring S
(7) Clevis pin (19) Rod S Tightening torque:N·m (kgf-m, ft-lb)
(8) Brake pedal spring (20) Bushing S T1: 8 (0.8, 5.8)
(9) Clutch pedal pad (21) Clip T2: 18 (1.8, 13.3)
(10) Clutch pedal (22) Clutch switch
(11) Bushing C (Model with cruise control)
(12) Clutch clevis pin

CL-7
 General Description
CLUTCH SYSTEM

C: CAUTION • Be sure to tighten fasteners including bolts and

nuts to the specified torque.
• Wear appropriate work clothing, including a cap,
• Place shop jacks or rigid racks at the specified
protective goggles and protective shoes when per-
points.
forming any work.
• Remove contamination including dirt and corro- • Apply grease onto sliding or revolving surfaces
sion before removal, installation or disassembly. before installation.
• Before installing O-rings or snap rings, apply suf-
• Keep the disassembled parts in order and pro-
ficient amount of fluid to avoid damage and defor-
tect them from dust and dirt.
mation.
• Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re- • Before securing a part in a vise, place cushioning
moval, installation, disassembly and replacement. material such as wood blocks, aluminum plate or
cloth between the part and the vise.
• Vehicle components are extremely hot after driv-
• Keep fluids away from the vehicle body. If any
ing. Be wary of receiving burns from heated parts.
fluid contacts the vehicle body, immediately flush
• Use SUBARU genuine fluid, grease etc. or
the area with water.
equivalent. Do not mix fluid, grease, etc. of different
grades or manufacturers.
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
498497100 CRANKSHAFT Used for stopping rotation of the flywheel when
STOPPER loosening/tightening bolts, etc.

ST-498497100
499747100 CLUTCH DISC Used when installing the clutch disc to the
GUIDE flywheel.

ST-499747100

2. GENERAL TOOL
TOOL NAME REMARKS
Circuit tester Used for measuring resistance, voltage and ampere.
Dial gauge Used for measuring clutch disc run-out.
Depth gauge Used for measuring clutch disc wear.

CL-8
 Clutch Disc and Cover
CLUTCH SYSTEM

2. Clutch Disc and Cover 2) Install the clutch cover to the flywheel and tight-
en the bolts to the specified torque.
A: REMOVAL NOTE:
1) Remove the transmission assembly from vehicle • When installing the clutch cover to the fly wheel,
body. position the clutch cover so that the distance be-
<Ref. to 5MT-24, REMOVAL, Manual Transmis- tween unbalance marks ( paint marks) is at least
sion Assembly.> 120°. (The unbalance marks indicate the direc-
2) Attach the ST on the flywheel. tions of residual unbalance.)
ST 499747100 CLUTCH DISC GUIDE • Note the front and rear of the clutch disc when in-
(A)
stalling.
• Temporarily tighten the bolts by hand. Each bolt
should be tightened to the specified torque in a
crisscross order.
Tightening torque:
16 N·m (1.6 kgf-m, 11.8 ft-lb)

ST

CL-00011

(A) Clutch cover

3) Remove the clutch cover and clutch disc.

NOTE:
• Take care not to allow oil to touch the clutch disc
face. (A)
• Do not disassemble the clutch cover or clutch
disc.
B: INSTALLATION (3) (1)
1) Insert the ST into the clutch disc and attach to
the flywheel by inserting the ST end into pilot bear-
ing. (5)
NOTE: (6)
When installing the clutch disc, be careful to attach
in the correct direction. (2) (4) ST
CL-00013
ST 499747100 CLUTCH DISC GUIDE
(A) Unbalance mark (paint)

3) Remove the ST.

ST 499747100 CLUTCH DISC GUIDE
(A) 4) Install the transmission assembly.
ST <Ref. to 5MT-27, INSTALLATION, Manual Trans-
mission Assembly.>

CL-00208

(A) Flywheel side

CL-9
 Clutch Disc and Cover
CLUTCH SYSTEM

C: INSPECTION 4) Deflection on facing:

If deflection exceeds the specified value at the out-
1. CLUTCH DISC er circumference of the facing, replace the clutch
1) Facing wear: disc.
Measure the depth from the facing surface to the ST 499747100 CLUTCH DISC GUIDE
rivet head. Replace if the face is worn locally or Limit for deflection:
worn down to less than the specified value. 0.7 mm (0.028 in) at R = 110 mm (4.33 in)
Depth to rivet head:
Limit of sinking
0.3 mm (0.012 in) ST
NOTE:
Do not wash the clutch disc with any type of clean-
ing fluid.

CL-00016

5) If there is spline wear, loose rivets, failed torsion

springs, etc., replace the clutch disc.

CL-00014

2) Hardened facing
Replace the clutch disc.
3) Oil soakage on facing
Replace the clutch disc and inspect the transmis-
sion front oil seal, transmission case mating sur-
face, engine rear oil seal and other locations for oil CL-00017
leakage.
(A) Spline
(A)
(B) Rivet
(C) Torsion spring

CL-00015

(A) Clutch facing

CL-10
 Clutch Disc and Cover
CLUTCH SYSTEM

2. CLUTCH COVER
NOTE:
Visually check the following items without disas-
sembling, and replace or repair if defective.
1) Loose thrust rivet
2) Damaged or worn bearing contact area at the
center of diaphragm spring

(A)
(B)

CL-00018

(A) Thrust rivet

(B) Diaphragm spring

3) Damaged or worn disc contact surface of the

pressure plate
4) Loose strap plate installation area
5) Worn diaphragm sliding area

(A) (B)

CL-00176

(A) Pressure plate

(B) Strap plate

CL-11
 Flywheel
CLUTCH SYSTEM

3. Flywheel 2) Tighten the flywheel mounting bolts to the spec-

ified torque.
A: REMOVAL NOTE:
1) Remove the transmission assembly. Tighten the flywheel attachment bolts gradually.
<Ref. to 5MT-24, REMOVAL, Manual Transmission Each bolt should be tightened to the specified
Assembly.> torque in crisscross order.
2) Remove the clutch cover and clutch disc. <Ref.
Tightening torque:
to CL-9, REMOVAL, Clutch Disc and Cover.>
72 N·m (7.3 kgf-m, 53.1 ft-lb)
3) Using the ST, remove the flywheel.
ST 498497100 CRANKSHAFT STOPPER

(5) (1)
(7)
(3)

(4)
(8)
(2) (6)

CL-00021
(A)
ST
CL-00019 3) Install the clutch disc and cover. <Ref. to CL-9,
INSTALLATION, Clutch Disc and Cover.>
(A) Flywheel 4) Install the transmission assembly.
<Ref. to 5MT-27, INSTALLATION, Manual Trans-
B: INSTALLATION mission Assembly.>
1) Install the flywheel and ST. C: INSPECTION
ST 498497100 CRANKSHAFT STOPPER
CAUTION:
Because this bearing is grease-sealed and is a
non-lubrication type, do not wash with gasoline
or solvents.
1) If there is damage or defectiveness in the facing
sliding surface or ring gear, replace the flywheel.
(B)

ST
CL-00020

(A)
CL-00022

(A) Flywheel
(B) Ring gear

2) Smoothness of rotation
Rotate the ball bearing while applying pressure in
the thrust direction.
3) If noise or excessive play is noted, replace the
flywheel.

CL-12
 Release Bearing and Lever
CLUTCH SYSTEM

4. Release Bearing and Lever B: INSTALLATION

A: REMOVAL NOTE:
Apply the specified grease to lubricate the following
1) Remove the transmission assembly from vehicle points before installation.
body. • Contact surface of lever and pivot
<Ref. to 5MT-24, REMOVAL, Manual Transmission • Contact surface of lever and bearing
Assembly.>
• Transmission main shaft spline (Use grease con-
2) Remove the two clips from the release lever and taining molybdenum disulphide.)
remove the release bearing. (Non-turbo model) 1) Apply grease (KOPR-KOTE: Part No. 003603001)
CAUTION: to the contact point of the release lever and operating
Be careful not to deform the clips. cylinder.
3) Remove the release bearing from the release le- 2) While pushing the release lever to the pivot and
ver. (Turbo model) twisting it to both sides, fit the lever spring onto the
4) Remove the dust cover. raised portion of the pivot. (Non-turbo model)
(A)

(A)

(B)

CL-00023 CL-00026

(A) Release lever (A) Release lever

(B) Dust cover
NOTE:
5) Remove the lever spring from the pivot with a Observing from the main case hole, check that the
screwdriver by accessing it through the clutch lever spring is installed securely.
housing release lever hole. Then remove the re- 3) Hook the release bearing to the release lever,
lease lever. and fit the lever spring onto the raised portion of the
pivot, while pushing the release lever to the pivot
and twisting it to both sides. (Turbo model)
(B)
NOTE:
Observing from the main case hole, check that the
lever spring is installed securely.
4) Install the release bearing and fasten it with two
clips. (Non-turbo model)
5) Install the dust cover.
(A)

CL-00024

(A) Release lever

(B) Screwdriver (A)

(B)

CL-00023

(A) Release lever

(B) Dust cover

CL-13
 Release Bearing and Lever
CLUTCH SYSTEM

6) Check the bearing for smooth movement by op- 2. RELEASE LEVER

erating the release lever. Check the pivot portion of the lever and the contact
7) Install the transmission assembly. area with the release bearing case for wear.
<Ref. to 5MT-27, INSTALLATION, Manual Trans-
mission Assembly.> (A)

C: INSPECTION
1. RELEASE BEARING (B)
CAUTION:
Since this bearing is grease-sealed and is a (C)
non-lubrication type, do not wash with gasoline
or any other solvent when servicing the clutch.
1) Check the bearing for smooth movement by ap- CL-00034
plying force to the bearing in the radial direction.
(A) Release lever
Radial direction stroke:
(B) Pivot
Non-turbo model
(C) Release bearing
1.4 mm (0.055 in)
Turbo model
1.6 mm (0.063 in)

(A)

CL-00032

(A) Bearing case

2) While applying force to the bearing in the rota-

tional direction, check the bearing for smooth rota-
tion.

(A)

CL-00160

(A) Bearing case

3) Check for wear and damage at the bearing case

surface in contact with the lever.

CL-14
 Operating Cylinder
CLUTCH SYSTEM

5. Operating Cylinder B: INSTALLATION

A: REMOVAL NOTE:
The illustration below is suitable for every model.
NOTE: Perform the same procedures for the other models.
The illustration below is suitable for every model. 1) Install in the reverse order of removal.
Perform the same procedures for the other models.
1) Remove the air intake chamber. (Non-turbo model) NOTE:
<Ref. to IN(H4SO)-7, REMOVAL, Air Intake Cham- Before installing the operating cylinder, apply
ber.> grease (KOPR-KOTE: Part No. 003603001) to the
2) Remove the intercooler. (Turbo model) contact point of the release lever and operating cyl-
inder.
<Ref. to IN(H4DOTC)-11, REMOVAL, Intercool-
er.> Tightening torque:
3) Disconnect the clutch hose from the operating T1: 18 N·m (1.8 kgf-m, 13.3 ft-lb)
cylinder. T2: 37 N·m (3.8 kgf-m, 27.3 ft-lb)
CAUTION:
• Cover the hose joint to prevent the clutch flu- T1
id from flowing out.
• Do not loosen or remove the cap bolt. (Turbo
model) T2

(A)

T2
CL-00359
(B)
NOTE:
• Be sure to install the clutch hose with the mark
side facing upward.
• Be careful not to twist the clutch hose during in-
CL-00353 stallation.
(A) Clutch hose
(C)
(B) Operating cylinder
(A)
4) Remove the operating cylinder from the trans-
mission.

(B)
CL-00041

(A) Mark
(B) Clutch hose
(C) Operating cylinder

CL-00356 2) After bleeding air from the operating cylinder,

ensure that the clutch operates properly. <Ref. to
CL-21, Clutch Fluid Air Bleeding.>

CL-15
 Operating Cylinder
CLUTCH SYSTEM

C: DISASSEMBLY D: ASSEMBLY
NOTE: NOTE:
The illustration below is suitable for every model. • During assembly, apply hydraulic oil to all parts.
Perform the same procedures for the other models. • The illustration below is suitable for every model.
1) Remove the boots and push rod assembly. Perform the same procedures for the other models.
Recommended clutch fluid:
New FMVSS No. 116 DOT3 or DOT4 brake fluid
1) Install the piston spring to the piston.

CL-00457

2) Apply compressed air through clutch hose at-

taching port.
NOTE: CL-00459
Face the piston port down and place a piece of 2) Insert piston to the operating cylinder.
wood underneath to prevent the piston from pop- 3) Install push rod to the boot.
ping out. 4) Install boot and push rod to the operating cylin-
der.

CL-00458

3) Separate the piston and piston spring. CL-00457

E: INSPECTION
1) Check the operating cylinder for damage. If op-
erating cylinder is damaged, replace it.
2) Check the operating cylinder for fluid leakage or
damage on the boot. If any leakage or damage is
found, replace the operating cylinder.

CL-00459

CL-16
 Master Cylinder
CLUTCH SYSTEM

6. Master Cylinder B: INSTALLATION

1) Install the master cylinder to the vehicle body,
A: REMOVAL and connect the clutch pipe to the master cylinder.
1) Thoroughly drain the brake fluid from the reser-
voir tank. NOTE:
2) Remove the snap pin and clevis pin, and then Check that the pipe is routed properly.
separate the push rod of the master cylinder from Tightening torque:
clutch pedal. T1: 15 N·m (1.5 kgf-m, 11.1 ft-lb)
(A) T2: 18 N·m (1.8 kgf-m, 13.3 ft-lb)

(B)

(D)

(C)

T2
T1

CL-00042
CL-00561
(A) Clevis pin
(B) Snap pin 2) Connect the push rod of the master cylinder to
the clutch pedal, and install the clevis pin and snap
(C) Push rod
pin.
(D) Lock nut
NOTE:
3) Remove the air intake chamber. (Non-turbo mod- Apply grease to the clevis pin.
el) <Ref. to IN(H4SO)-7, REMOVAL, Air Intake
Chamber.> (A)

4) Remove the intercooler. (Turbo model) <Ref. to

IN(H4DOTC)-11, REMOVAL, Intercooler.> (B)
5) Remove the clutch pipe from the master cylin-
der.
6) Remove the master cylinder and reservoir tank (C)
as a unit.
CAUTION:
Be careful not to spill the brake fluid. Brake flu- CL-00045
id spilled on the vehicle body will harm the
paint surface; wash it off with water and wipe (A) Clevis pin
clean quickly if spilled. (B) Snap pin
(A)
(C) Push rod

3) After bleeding air from the clutch system, ensure

that the clutch operates properly.
(B) <Ref. to CL-21, Clutch Fluid Air Bleeding.>
4) Install the air intake chamber. (Non-turbo model)
<Ref. to IN(H4SO)-7, INSTALLATION, Air Intake
Chamber.>
5) Install the intercooler. (Turbo model) <Ref. to
IN(H4DOTC)-12, INSTALLATION, Intercooler.>
CL-00152

(A) Master cylinder

(B) Clutch pipe

CL-17
 Master Cylinder
CLUTCH SYSTEM

C: DISASSEMBLY D: ASSEMBLY
1) Remove the straight pin and reservoir tank. 1) Install the clutch damper.
Tightening torque:
46.6 N·m (4.8 kgf-m, 34.4 ft-lb)
2) Apply a coat of grease to the contact surfaces of
the push rod and piston before installation.
(A)
Grease:
SILICONE GREASE G-40M (Part No. 004404003)
(B)

CL-00562

(A) Reservoir tank

(B) Straight pin

2) Remove the oil seal.

(A)
CL-00564

3) Assemble in the reverse order of disassembly.

Tightening torque:
10 N·m (1.0 kgf-m, 7.4 ft-lb)
E: INSPECTION
(B)
If any damage, deformation, wear, swelling, rust or
other faults are found on the cylinder, piston, push
CL-00563
rod, reservoir tank, return spring, gasket, clutch
(A) Oil seal damper, seat or hose, replace the faulty part.
(B) Master cylinder (C)
(B)
3) Move the seat towards the rear. (A)
(G)
(A) (D)

(E)
(F)
CL-00565

(B) (A) Master cylinder body

(B) Return spring
CL-00513
(C) Piston
(A) Seat (D) Piston stop ring
(B) Master cylinder (E) Push rod ASSY
(F) Clutch damper
4) Remove the piston stop ring. (G) Seat
CAUTION:
When removing the piston stop ring, be careful
to prevent the rod, washer, piston and return
spring from coming out.
5) Remove the clutch damper.

CL-18
 Clutch Pipe and Hose
CLUTCH SYSTEM

7. Clutch Pipe and Hose B: INSTALLATION

Install in the reverse order of removal.
A: REMOVAL
1) Remove the air intake chamber and air intake NOTE:
duct. (Non-turbo model) <Ref. to IN(H4SO)-7, RE- • Bleed air from the clutch fluid. <Ref. to CL-21,
MOVAL, Air Intake Chamber.> <Ref. to IN(H4SO)- Clutch Fluid Air Bleeding.>
8, REMOVAL, Air Intake Duct.> • The illustration below is suitable for every model.
2) Remove the intercooler. (Turbo model) Perform the same procedures for the other models.
<Ref. to IN(H4DOTC)-11, REMOVAL, Intercooler.> Tightening torque:
3) Drain the clutch fluid. <Ref. to CL-20, Clutch Flu- T1: 15 N·m (1.5 kgf-m, 11.1 ft-lb)
id.> T2: 18 N·m (1.8 kgf-m, 13.3 ft-lb)
4) Disconnect the clutch pipe from the clutch hose T3: 25 N·m (2.5 kgf-m, 18.4 ft-lb)
and master cylinder.
5) Pull out the clamp, then disconnect the clutch
hose from the bracket.

(A)

T1

(B) T3 (A) T1

CL-00057
(C)
(A) Clamp (B)
(B) Clutch hose
T2
6) Remove the hose from operating cylinder.
7) Remove the bracket.

CL-00566

(A) Clutch pipe

(B) Clip
(C) Clutch hose

C: INSPECTION
Check pipes and hoses for cracks, breakage or
damage. Check joints for fluid leakage. If any
cracks, breakage, damage or leakage is found, re-
pair or replace the defective pipe or hose.

CL-19
 Clutch Fluid
CLUTCH SYSTEM

8. Clutch Fluid B: REPLACEMENT

A: INSPECTION CAUTION:
• Use new FMVSS No. 116 DOT3 or DOT4 brake
1) Park the vehicle on a level surface. fluid.
2) Inspect the fluid level using the scale on the out- • Cover the breather with cloth to prevent
side of the reservoir tank. If the level is below “MIN”, brake fluid from being splashed on surround-
add fluid to bring it up to “MAX”, and also inspect for ing parts when loosening the breather.
leakage. • Avoid mixing different brands of brake fluid
to prevent the quality of fluid from degrading.
(A)
• Be careful not to allow dirt or dust to enter the
reservoir tank.
(C) NOTE:
MA X • During bleeding operation, keep the clutch reser-
MIN
voir tank filled with brake fluid to prevent entry of
(B) air.
• Clutch pedal must be operated very slowly.
• Bleed air from the oil line with help of a co-work-
CL-00567 er.
(A) Reservoir tank
• The amount of brake fluid required is approxi-
mately 70 m2 (2.4 US fl oz, 2.5 Imp fl oz) for total
(B) MIN. level
clutch system.
(C) MAX. level
1) Remove the air intake chamber. (Non-turbo
model) <Ref. to IN(H4SO)-7, REMOVAL, Air Intake
Chamber.>
2) Remove the intercooler. (Turbo model) <Ref. to
IN(H4DOTC)-11, REMOVAL, Intercooler.>
3) Drain the brake fluid from the reservoir tank.
4) Refill the reservoir tank with recommended
brake fluid.
Recommended brake fluid:
New FMVSS No. 116 DOT3 or DOT4 brake fluid
5) If necessary, bleed air from the clutch fluid. <Ref.
to CL-21, Clutch Fluid Air Bleeding.>

CL-20
 Clutch Fluid Air Bleeding
CLUTCH SYSTEM

9. Clutch Fluid Air Bleeding 5) Repeat procedure 4), until there are no more air
bubbles in the vinyl tube.
A: PROCEDURE 6) Tighten the air breather.
NOTE: Tightening torque:
• Bleed air from the oil line with help of a co-work- T:7.8 N·m (0.8 kgf-m, 5.8 ft-lb)
er.
• The illustration below is suitable for every model.
Perform the same procedures for the other models.
1) Remove the air intake chamber. (Non-turbo
model) <Ref. to IN(H4SO)-7, REMOVAL, Air Intake
Chamber.>
2) Remove the intercooler. (Turbo model) <Ref. to
IN(H4DOTC)-11, REMOVAL, Intercooler.>
3) Fit one end of a vinyl tube into the air breather of T
the operating cylinder, and put the other end into a
CL-00358
brake fluid container.
7) After stepping on the clutch pedal, make sure
(A) that there are no leaks evident in the entire clutch
system.
8) After bleeding the air from clutch system, ensure
that the clutch operates properly.
9) Install the air intake chamber. (Non-turbo model)
<Ref. to IN(H4SO)-7, INSTALLATION, Air Intake
(B)
Chamber.>
10) Install the intercooler. (Turbo model) <Ref. to
IN(H4DOTC)-12, INSTALLATION, Intercooler.>
CL-00360

(A) Clutch hose

(B) Air breather

4) Slowly depress the clutch pedal and keep it de-

pressed. Then open the air breather to discharge
air together with the fluid.
Release the air breather for 1 or 2 seconds. Next,
with the breather closed, slowly release the clutch
pedal.
CAUTION:
Cover the breather with cloth to prevent brake
fluid from being splashed on surrounding parts
when loosening the breather.

(B)

(A)
CL-00357

(A) Operating cylinder

(B) Vinyl tube

CL-21
 Clutch Pedal
CLUTCH SYSTEM

10.Clutch Pedal B: INSTALLATION

1) Install in the reverse order of removal.
A: REMOVAL
1) Disconnect the ground cable from battery. CAUTION:
2) Remove the steering column. <Ref. to PS-16, Always use a new clevis pin.
REMOVAL, Tilt Steering Column.> 2) Adjust the clutch pedal after installation. <Ref. to
3) Disconnect the connector from the stop light CL-23, ADJUSTMENT, Clutch Pedal.>
switch and clutch switch. 3) Adjust the clutch switch (starter interlock). <Ref.
4) Remove the snap pins from clevis pins which se- to CL-27, ADJUSTMENT, Clutch Switch.>
cure the lever to the push rod and operating rod. C: DISASSEMBLY
5) Pull out the clevis pins which secures the lever to
1) Remove the clip, assist spring, rod and bushing.
the push rod and operating rod.

(D)
(A)
(D)
(A) (E)
(D) (C)
(C) (D)
(C) (B) (D)
(B) (E)
(C)
CL-00354
CL-00090
(A) Clip
(A) Operating rod
(B) Assist spring
(B) Push rod
(C) Assist rod
(C) Snap pin
(D) Bushing
(D) Clevis pin
(E) Clevis pin
6) Remove the air intake chamber. (Non-turbo mod-
el) <Ref. to IN(H4SO)-7, REMOVAL, Air Intake 2) Remove the spring pin and lever.
Chamber.> (A)
7) Remove the intercooler. (Turbo model)
<Ref. to IN(H4DOTC)-11, REMOVAL, Intercooler.>
8) Remove the nut which secures the clutch master
cylinder.

(B)

CL-00095

(A) Pin
(B) Lever

CL-00093

9) Remove the bolts and nuts which secure the

brake pedal and clutch pedal, and remove the ped-
al assembly.

CL-22
 Clutch Pedal
CLUTCH SYSTEM

3) Remove the clutch pedal and bushings. E: INSPECTION

(B) Move the clutch pedal pads in the lateral direction
with a force of approximately 10 N (1 kgf, 2 lbf) to
check that the clutch pedal deflection is within the
(B) service limit.
CAUTION:
If the play exceeds the service limit, replace the
bushing with a new part.
(A)
Deflection of the clutch pedal:
CL-00096 Service limit
5.0 mm (0.197 in) or less
(A) Clutch pedal
(B) Bushing

4) Remove the stopper, clip, O-ring and rod S, and

remove the spring and bushing S. (A) (B)

(B)
(A) CL-00098
(E)
(A) Clutch pedal
(B) Brake pedal

(D) (C) CL-00355 F: ADJUSTMENT

(A) Clip
1) Turn the lock nut until the full stroke of clutch
pedal becomes within the specification.
(B) Bushing S
(C) Spring S CAUTION:
(D) Rod S When adjusting the full stroke of clutch pedal,
(E) Stopper
do not turn the clutch switch.
NOTE:
5) Remove the stopper from the clutch pedal. If the lock nut cannot adjust the full stroke of clutch
6) Remove the clutch pedal pad. (Non-turbo model) pedal to the specified value, adjust it by turning the
master cylinder push rod.
D: ASSEMBLY
1) Install the stopper, etc., temporarily to the pedal Clutch pedal full stroke A:
bracket. 130 — 135 mm (5.12 — 5.31 in) (Non-turbo
2) Clean the clutch pedal and brake pedal bushing model)
holes, apply grease, and install the bushings. 135 — 140 mm (5.31 — 5.51 in) (Turbo model)
3) Align the holes of the pedal bracket, clutch pedal Tightening torque (Clutch switch lock nut):
and brake pedal, and install the brake pedal return T:8 N·m (0.8 kgf-m, 5.9 ft-lb)
spring, assist rod, spring and bushing.
NOTE:
Clean the inside of the bushings and apply grease
before installing the spacer.
T

A
CL-00225

CL-23
 Clutch Pedal
CLUTCH SYSTEM

2) If the full stroke is not within the specified range, 5) Turn the push rod to shorten until a clearance is
adjust it by loosening the clutch stopper nut (for gained on the stopper bolt side (for models without
models without cruise control) or clutch switch lock cruise control) or clutch switch side (for models with
nut (for models with cruise control). cruise control).
• Models without cruise control
Tightening torque:
8 N·m (0.8 kgf-m, 5.9 ft-lb)
3) Loosen the push rod lock nuts.
(A)

(B)

(B)
(D)

(A)
(C)
CL-00099

(A) Stopper
CL-00042
(B) Stopper bolt
(A) Clevis pin
• Models with cruise control
(B) Snap pin
(C) Push rod
(D) Push rod lock nut

4) Rotate the push rod to adjust.

(1) Make sure that the clutch pedal contacts the
stopper bolt side (for models without cruise con- (A)
trol) or clutch switch side (for models with cruise
control) when the pedal is released. (B)
(2) Make sure that the clutch pedal contacts the
clutch pedal bracket stopper when the clutch CL-00100
pedal is at the maximum stroke position.
(A) Clutch switch
(B) Stopper
(A)
6) Turn the push rod to lengthen until the clutch
pedal contacts the stopper bolt (for models without
(B)
cruise control) or clutch switch (for models with
cruise control).
(C) (F)
7) Turn further in the direction that will shorten the
(E) push rod (arrow direction shown in figure) by 270°.
(D)
CL-00080 (B)

(A) Clevis hole

(B) Push rod lock nut (A)
(C) In the shorter direction
(D) In the longer direction
(E) Push rod
(F) Clevis
CL-00101

(A) Accelerator pedal

(B) Clevis

8) Check that the clevis pin moves smoothly by

moving it in the left and right directions.

CL-24
 Clutch Pedal
CLUTCH SYSTEM

9) Tighten the push rod lock nut. 13) Push the release lever until the operating cylin-
der push rod retracts. Check that the clutch fluid
Tightening torque (Push rod lock nut):
level in the reservoir tank increases.
T:10 N·m (1.0 kgf-m, 7.4 ft-lb)
(A)
(2)
(1)
(B)

(C)

(3) CL-00227
CL-00226
(1) Push rod
(A) Clevis pin
(2) Release lever
(B) Snap pin
(3) Operating cylinder
(C) Push rod
14) If the clutch fluid level increases, hydraulic
10) Depress and release the clutch pedal two or
clutch play is correct.
three times to ensure that the clutch pedal and re-
15) If the clutch fluid level does not increase or
lease lever operate smoothly. If the clutch pedal
push rod does not retract, readjust the clutch pedal.
and release lever do not operate smoothly, bleed
air from the clutch hydraulic system. <Ref. to CL- 16) Check the fluid level using the scale on the out-
21, Clutch Fluid Air Bleeding.> side of the reservoir tank. If the level is below “MIN”,
fill fluid up to “MAX” level.
11) Measure the clutch pedal full stroke length
again to ensure that it is within specifications. If it is Recommended clutch fluid:
not within specifications, repeat adjustment proce- New FMVSS No. 116 DOT3 or DOT4 brake fluid
dures again from the beginning.
(A)
Clutch pedal full stroke:
130 — 135 mm (5.12 — 5.31 in) (Non-turbo
model)
(C)
135 — 140 mm (5.31 — 5.51 in) (Turbo model) MA X
12) Push the release lever until the operating cylin- MIN

der push rod retracts. Make sure that the clutch flu-
(B)
id level in the reservoir tank increases. If the clutch
fluid level increases, the hydraulic clutch is properly
adjusted; If the fluid level does not increase or the CL-00567
push rod does not retract, replace the master cylin-
der with a new part. <Ref. to CL-17, Master Cylin- (A) Reservoir tank
der.> (B) MIN. level
(C) MAX. level

(2)
(1)

(3) CL-00227

(1) Push rod

(2) Release lever
(3) Operating cylinder

CL-25
 Clutch Switch
CLUTCH SYSTEM

11.Clutch Switch 2. CLUTCH SWITCH

(STARTER INTERLOCK)
A: REMOVAL 1) Fully depress the clutch and hold it.
1) Disconnect the ground cable from battery. 2) Install the clutch pedal plate and clutch switch
2) Remove the instrument panel lower cover. so that the gap between them is 3 — 3.5 mm
3) Disconnect the connector of clutch switch. (0.12 — 0.14 in), and then tighten the lock nut.
4) Remove the clutch switches.
Tightening torque:
B: INSTALLATION 8 N·m (0.8 kgf-m, 5.9 ft-lb)
1. CLUTCH SWITCH (CRUISE CONTROL) (A) (C)
(B)
1) Move the clevis pin of push rod to left and right,
retain it at the position where it moves smoothly,
and measure the clutch pedal stroke.
Clutch pedal full stroke A:
130 — 135 mm (5.12 — 5.31 in) (Non-turbo
model)
135 — 140 mm (5.31 — 5.51 in) (Turbo model)
CL-00104
Tightening torque:
T:8 N·m (0.8 kgf-m, 5.9 ft-lb) (A) Plate
(B) Clutch switch
(C) 3 × 3.5 mm (0.12 × 0.14 in)

3) Connect the clutch switch connector.

T 4) Make sure that engine does not start with clutch
pedal not depressed.
5) Make sure that engine starts with clutch pedal
fully depressed.
A
CL-00225
C: INSPECTION
1) If the clutch switch (cruise control) does not op-
2) If the clutch pedal stroke is out of specification, erate properly (or if it does not stop at the specified
adjust the stroke. <Ref. to CL-23, ADJUSTMENT, position), replace it with a new part.
Clutch Pedal.>
3) Connect the clutch switch connector. Specified position L:
2 + 1.5 mm (0.079 + 0.059 in)

CL-00231

CL-26
 Clutch Switch
CLUTCH SYSTEM

2) Check the clutch switch for continuity. If the re- D: ADJUSTMENT

sistance is not at the standard value, replace the
1) Loosen the lock nut of clutch switch (starter in-
switch.
terlock).
(1) Disconnect the clutch switch connector.
(2) Measure the resistance between terminal 1
and 2 of the switch.
• Clutch switch (Cruise control)
(A)
Specified (B)
Condition Terminal No.
resistance
When clutch pedal is
No. 1 — No. 2 1 M: or more
depressed
When the clutch pedal
No. 1 — No. 2 Less than 1 :
is not depressed
CL-00105

(A) Lock nut

(B) Clutch switch (starter interlock)
2 1
2) Fully depress the clutch and hold it.
3) Adjust the gap of the clutch pedal plate and the
clutch switch to be 3 — 3.5 mm (0.12 — 0.14 in).
(A) (C)
(B)

CL-00084

• Clutch switch (starter interlock)

Specified
Condition Terminal No.
resistance
When clutch pedal is
No. 1 — No. 2 Less than 1 :
depressed
When the clutch pedal CL-00104
No. 1 — No. 2 1 M: or more
is not depressed
(A) Plate
(B) Clutch switch (starter interlock)
(C) 3 × 3.5 mm (0.12 × 0.14 in)
1
2 4) Tighten the lock nut.
Tightening torque:
8 N·m (0.8 kgf-m, 5.9 ft-lb)

CL-00102

3) Make sure that engine does not start with clutch

pedal not depressed. If the engine starts, adjust the
clutch switch and inspect the starter interlock cir-
cuit.
4) Make sure that engine starts with clutch pedal
fully depressed. If the engine does not start, adjust
the clutch switch and inspect the starter interlock
circuit.

CL-27
 General Diagnostic Table
CLUTCH SYSTEM

12.General Diagnostic Table

A: INSPECTION
1. CLUTCH
Symptom Possible cause Corrective action
1. Clutch slippage. (a) Oil on the clutch face Replace.
It is hard to perceive clutch slippage in (b) Worn clutch face Replace.
the early stage, but pay attention to the
(c) Deteriorated diaphragm spring Replace.
following symptoms.
• Engine speeds up when shifting. (d) Warped pressure plate or flywheel Correct or replace.
• High-speed driving is not possible; (e) Defective release bearing holder Correct or replace.
especially rapid acceleration is not possi-
ble and vehicle speed does not increase
in proportion to the increase in engine
speed.
• Power drops particularly when ascend-
ing a slope, and there is a burning smell
of the clutch plate.
• Method of testing: Park the vehicle and
fully apply the parking brake. Disengage
the clutch and shift the transmission gear
into the 1st. Gradually increase the
engine speed while gradually allowing the
clutch to engage. The clutch function is
satisfactory if the engine stalls. However,
the clutch is slipping if the vehicle does
not move forward and the engine does
not stall.
2. Clutch drags. (a) Worn or rusty clutch disc hub spline Replace the clutch disc.
As a symptom of this trouble, a harsh (b) Excessive deflection of clutch disc Correct or replace.
scratching noise occurs and control face
becomes difficult when shifting gears.
(c) Seized crankshaft pilot needle bearing Replace.
The symptom becomes more apparent
when shifting into the 1st gear. However, (d) Cracked clutch disc face Replace.
because most trouble of this sort is due to (e) Stuck clutch disc (smeared by oil or Replace.
a defective synchronization mechanism, water)
perform the following tests.
• Method of testing: <Ref. to CL-29,
DIAGNOSTIC DIAGRAM OF CLUTCH
DRAG, INSPECTION, General Diagnos-
tic Table.>
The problem is caused by insufficient dis-
engagement of the clutch if an abnormal
noise occurs during this test.
3. Clutch chatters. (a) Adhesion of oil on the clutch face Replace the clutch disc.
Clutch chattering is an unpleasant vibra- (b) Weak or broken damper spring Replace the clutch disc.
tion to the whole vehicle when the vehicle
(c) Poor contact of the disc surface or Replace the faulty clutch disc.
is just started with clutch partially
excessively worn disc
engaged.
(d) Warped pressure plate or flywheel Correct or replace.
(e) Loose disc rivets Replace the clutch disc.
(f) Loose engine mounting Retighten or replace mounting.
(g) Improper adjustment of the pitching Adjust.
stopper

CL-28
 General Diagnostic Table
CLUTCH SYSTEM

Symptom Possible cause Corrective action

4. Noisy clutch (a) Broken, worn or insufficiently lubri- Replace the release bearing.
Noise occurs when the clutch is disen- cated release bearing
gaged, engaged, or partially engaged. (b) Insufficient lubrication of the pilot Apply grease or replace the pilot bearing.
bearing
(c) Loose clutch disc hub Replace the clutch disc.
(d) Loose damper spring retainer Replace the clutch disc.
(e) Deteriorated or broken damper spring Replace the clutch disc.
5. Clutch grabs suddenly. (a) Grease or oil on facing Replace the clutch disc.
When starting the vehicle with the clutch (b) Deteriorated cushioning spring Replace the clutch disc.
partially engaged, the clutch engages
(c) Worn or rusted spline of clutch disc or Take off rust, apply grease or replace
suddenly and the vehicle jumps instead
main shaft clutch disc or main shaft.
of making a smooth start.
(d) Deteriorated or broken damper spring Replace the clutch disc.
(e) Loose engine mounting Retighten or replace mounting.
(f) Deteriorated diaphragm spring Replace.
2. CLUTCH PEDAL
Symptom Corrective action
Insufficient pedal play Adjust the free play of the pedal.
Insufficient clutch pedal free play Adjust the free play of the pedal.
Excessively worn and damaged pedal shaft and/or bushing Replace the bushing or shaft with a new part.

3. DIAGNOSTIC DIAGRAM OF CLUTCH DRAG

Step Check Yes No
1 CHECK GEAR NOISE. Is there any abnormal noise Go to step 2. Clutch is normal.
1) Start the engine. from the transmission gear?
2) Disengage the clutch and shift quickly from
neutral to reverse in idling condition.
2 CHECK GEAR NOISE. Is there any abnormal noise Go to step 3. Defective trans-
Disengage the clutch at idle and shift from neu- from the transmission gear? mission or exces-
tral to reverse within 0.5 — 1.0 seconds. sive clutch drag
torque. Inspect
pilot bearing,
clutch disc, trans-
mission and clutch
disc hub spline.
3 CHECK GEAR NOISE. Is there any abnormal noise Inadequate clutch Clutch and fly-
1) Disengage the clutch at idle and shift from from the transmission gear? disengage. Inspect wheel seizure.
neutral to reverse within 0.5 — 1.0 seconds. the clutch disc, Inspect the clutch
2) With the clutch disengaged, shift from neu- clutch cover, clutch disc and the spline
tral to reverse, reverse to neutral several times. release, and clutch of the clutch disc
pedal free play. hub.

CL-29
 General Diagnostic Table
CLUTCH SYSTEM

CL-30