Checking and adjusting the clutch pedal
1. Measure the height of the clutch pedal (from the side surface of the pedal pad to the floor) and stem pin play (when measured at the level of the side surface of the pedal pad).
Note:
Standard value:
- Full stroke (A): 150 - 155 mm.
- backlash (IN): 6-13 mm.
- Height (WITH): 167 mm.
2. If the pedal play and height are not correct, adjust them as follows:
(1) Set the required values by turning the adjusting bolt and tighten the lock nut.
Note:
- If the clutch pedal height is less than the required value, loosen the bolt and adjust the stem.
- After completing the adjustment, tighten the bolt so that the pedal stop gap is between 0.5 mm and 1.0 mm, and tighten the lock nut.
(2) Rotate the stem to the position corresponding to the above standard value, and then fix it with the lock nut.
Note: When adjusting clutch pedal height or play, be careful not to push the rod towards the master cylinder.
3. If the clutch pedal play and distance from the floor when the clutch is released is not correct, the cause may be air in the hydraulic system or a malfunction of the master cylinder. Bleed the system or disassemble the master cylinder or clutch for inspection.
Bleeding the hydraulic clutch system
In all cases, after removing and reinstalling the clutch release hose and pipe and/or master cylinder, or if the clutch pedal becomes stiff, bleed the system.
Attention.
Use the specified brand of brake fluid. Avoid mixing brake fluids of different brands.
Recommended Fluid: SAE J1703 (DOT3 or DOT4).
Removal of air from the concentric working cylinder
5 - speed manual transmission
1. Loosen fitting (IN) for bleeding the clutch slave cylinder (A).
2. Slowly depress the clutch pedal several times until all air is removed.
3. Keep the clutch pedal depressed until the bleeder screw is tight.
4. Fill the clutch master cylinder with the specified brand of fluid.
Attention. Rapidly re-depressing the clutch pedal between points B and C can change the position of the clutch slave cylinder. While bleeding, fully depress the clutch pedal after it returns to point A.
6 - speed manual transmission
1. Remove the slave cylinder bleeder cap and attach the vinyl hose.
2. Release the fitting and press the clutch pedal about ten times.
Note: Use a wrench to keep the fitting body from rotating (A). It is necessary to hold the body in the process of releasing or tightening.
3. Tighten fitting (IN) with the clutch pedal depressed. Then lift the pedal with your hand.
4. After depressing the pedal at least three times, release the fitting and then tighten it with the pedal depressed. Raise the pedal again.
5. Repeat step 4 two or three times (until air bubbles disappear from the liquid).
Note: Tightening torque: (IN) 7.0 - 9.8 Nm.
Attention.
1. Do not pinch the pipeline of the working cylinder.
2. Be careful not to damage the O-rings.
6. Add the recommended brake fluid to the expansion tank to the correct level.