Contents: Checking and adjusting the clutch…⇓ Bleeding the hydraulic clutch system ⇓ Removal air from a concentric…⇓
Checking and adjusting the clutch pedal
1. Measure the clutch pedal height (from the side surface of the pedal pad to the floor) and the piston rod pin play (when measured at the level of the side surface of the pedal pad).
Note:
Default value:
- Full stroke (A): 150 - 155 mm.
- Backlash (B): 6-13 mm.
- Height (C): 167 mm.
2. If the pedal play and height are not as required, 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 rod.
- After completing the adjustment, tighten the bolt so that the clearance to the pedal stop is between 0.5 mm and 1.0 mm, and tighten the lock nut.
(2) Rotate the rod to set it to the position corresponding to the standard value given above, and then fix it with the lock nut.
Note: When adjusting the clutch pedal height or play, be careful not to push the piston rod toward the master cylinder.
3. If the clutch pedal play and the distance from the pedal to the floor when the clutch is released do not meet the requirements, the cause may be air in the hydraulic system or a faulty 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 line and/or master cylinder, and if the clutch pedal becomes stiff, bleed the air from 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 air from a concentric working cylinder
5-speed manual transmission
1. Loosen the nipple (B) to bleed the clutch slave cylinder (A).
2. Slowly press the clutch pedal several times until all air is removed.
3. Keep the clutch pedal depressed until the bleed screw is tightened.
4. Fill the clutch master cylinder with the specified grade of fluid.
Caution: Rapidly pressing the clutch pedal again between points B and C may change the position of the clutch slave cylinder. While bleeding, depress the clutch pedal fully after it returns to point A.
6-speed manual transmission
1. Remove the cap from the slave cylinder bleed nipple and install the vinyl hose.
2. Release the nipple and press the clutch pedal approximately ten times.
Note: Hold the nipple body from turning with a wrench (A). It is necessary to hold the body while loosening or tightening.
3. Tighten the nipple (B) with the clutch pedal depressed. Then lift the pedal by hand.
4. After pressing the pedal at least three times, release the nipple and then tighten it while pressing the pedal. Raise the pedal again.
5. Repeat step 4 two or three times (until there are no more air bubbles in the liquid).
Note: Tightening torque: (B) 7.0 - 9.8 Nm.
Attention.
1. Do not pinch the slave cylinder line.
2. Do not damage the sealing rings.
6. Add the recommended brake fluid to the expansion tank to the required level.