CLUTCH ACTUATOR (for C551A) REMOVAL


  1. PRECAUTION

    Note

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work Click here.

  2. CLUTCH POSITION ADJUSTMENT

    Tech Tips


    • The multi-mode manual transmission system has a load controlled clutch cover (adjustment system). The pressure plate moves depending on the wear quantity of the clutch disc lining.

    • When removing or installing any parts related to the multi-mode manual transmission system, move the clutch actuator to the clutch clamp position. This is for normal operation of the load controlled clutch cover (adjustment system).

    • If the clutch position adjustment operation input fails, perform the operation again from step (a) more than 15 seconds after turning the ignition switch to OFF.

    Note

    Do not depress the brake pedal while performing the clamp position adjustment using an intelligent tester.


    1. Prepare the vehicle:


      • Stop the vehicle.

      • Shift the lever into the N position.

      • Turn the ignition switch to OFF.

      • Apply the parking brake.

    2. A0136XRE03
      Text in Illustration
      *1 Intelligent Tester
      *2 DLC3

      Connect the intelligent tester to the DLC3.

    3. Turn the ignition switch to ON.

    4. Turn the intelligent tester ON.

    5. Select the following menu items: Powertrain / Multi-Mode M/T / Utility / Parts Exchange.

    6. A0138HGE02
      Text in Illustration
      *a Next

      Read the information.

    7. Press the Next key.

    8. A0137DME02
      Text in Illustration
      *a Next

      Read the information.

    9. After checking the vehicle condition, press the Next key.

    10. A0137ZCE02
      Text in Illustration
      *a Next

      Read the information.

    11. Press the Next key.

    12. A0136G3E02
      Text in Illustration
      *a Next

      Read the information.

    13. Press the Next key.

    14. A0136P3E02
      Text in Illustration
      *a Next
      *b Step 1 Clutch Position Adjustment

      On the Multi-Mode M/T / Utility screen, select Step 1 Clutch Position Adjustment (Clamp Position Adjustment).

    15. Press the Next key.

    16. A0135VVE02
      Text in Illustration
      *a Next

      Read the information.

    17. Press the Next key.

    18. Complete Clutch Position Adjustment.

    19. Turn the intelligent tester OFF.

    20. Turn the ignition switch to OFF.

    21. Replace the malfunctioning parts.

      Tech Tips

      Perform [Initialization and Learning] after repairing the multi-mode manual transmission control system Click here.

  3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  4. REMOVE BATTERY


    1. Loosen the nut and disconnect the battery positive (+) terminal.

    2. A0136L6

      Remove the bolt and the battery clamp.

    3. Remove the battery.

  5. SEPARATE ENGINE ROOM RELAY BLOCK

    A0138XK

    1. Remove the 2 bolts.

    2. Disengage the claw and separate the engine room relay block.

    3. A0138NO

      Disengage the 3 wire harness clamps.

    4. A0136C9

      Provisionally set the engine room relay block to the hood support rod.

  6. REMOVE BATTERY CLAMP SUB-ASSEMBLY


    1. A0135TU

      Remove the 3 bolts and the battery clamp sub-assembly.

  7. REMOVE CLUTCH ACTUATOR ASSEMBLY

    A0136LI

    1. Disconnect the clutch stroke sensor connector and motor connector.

      Note

      Do not forcibly pull the connector as this may damage the wire harness.

    2. A0136MI

      Remove the 3 bolts and clutch actuator assembly.

      Note


      • Loosen the bolts slowly, and be careful not to get your fingers caught as the clutch actuator assembly moves due to the reaction force from the clutch cover.

      • Do not drop the removed clutch actuator assembly or subject it to any impacts.

  8. REMOVE CLUTCH STROKE SENSOR

    A0137PV

    1. Remove the 2 screws and the stroke sensor from the clutch actuator.

    2. Remove the O-ring.