CLUTCH ACTUATOR (for C551A) INSTALLATION


  1. INSTALL CLUTCH STROKE SENSOR


    1. Apply MP grease to a new O-ring.

    2. Install the new O-ring onto the stroke sensor.

    3. A01373GE02
      Text in Illustration
      *a Sensor Arm (Actuator Side)
      *b Sensor Arm (Sensor Side)

      Set the stroke sensor so that the sensor side and the actuator side sensor arms are in the positions shown in the illustration.

    4. Turn the stroke sensor clockwise and fix it with the 2 screws.

      Torque:
      2.0 N*m  { 20 kgf*cm, 18 in.*lbf }

    5. Connect the clutch stroke sensor connector.

    6. Install the connector into the clamp bracket.

  2. CLUTCH POSITION ADJUSTMENT

    Note

    Perform the following procedure ((a) to(e)) to set a new clutch actuator in the clutch clamp position because it is not originally placed in that position.

    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 (1) 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. Connect the clutch stroke sensor connector and motor connector to the clutch actuator.

    2. Connect the battery negative terminal.

    3. Perform clutch position adjustment (clutch clamp position)


      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.

    4. Disconnect the battery negative terminal.

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

  3. INSTALL CLUTCH ACTUATOR ASSEMBLY


    1. A0137TV

      Apply grease to the clutch release lever.

    2. Set the clutch actuator to the transaxle and provisionally tighten the 3 bolts.

      Note

      Keep the clearance between the bolt head and actuator flange.

    3. A0138FTE02
      Text in Illustration
      *1 Clutch Release Lever

      Move the clutch actuator through the bolt hole in the direction indicated by the arrow in the illustration.

    4. Check that the clutch release lever moves smoothly in the direction indicated by the arrow in the illustration.

    5. Move the clutch actuator in the direction indicated by the arrow in the illustration until the clutch actuator rod end (rounded part) is fully inserted into the groove.

      A0135YQE02
      Text in Illustration
      *1 Rod - -
      *a There is no clearance between the clutch release lever and rod end. *b The rod end (rounded part) is not fully inserted into the groove in the clutch release lever.
      *c There is clearance between the clutch release lever and rod end. *d Rod End (Rounded Part)
      *e Clutch Release Lever (Groove) - -

      Note


      • Make sure that the clutch actuator rod end is fully inserted into the groove in the clutch release lever.

      • Make sure that the clutch actuator rod end comes into contact with the groove in the clutch release lever so that there is no clearance.

    6. A0136MIE01

      Tighten the 3 bolts by hand while holding the clutch actuator assembly.

      Note


      • Support the clutch actuator assembly until all the 3 bolts are tightened.

      • Make sure that the clutch actuator rod end is fully inserted into the groove in the clutch release lever.

      • Make sure that the clutch actuator rod end comes into contact with the groove in the clutch release lever so that there is no clearance.

    7. Tighten the 3 bolts to the specified torque in the order A, B, and C, as shown.

      Torque:
      17 N*m  { 173 kgf*cm, 13 ft.*lbf }
    8. A0136LI

      Connect the clutch stroke sensor connector and motor connector.

  4. INSTALL BATTERY CLAMP SUB-ASSEMBLY

    A0135TUE03

    1. Install the battery clamp sub-assembly with the 3 bolts.

      Torque:
      Bolt A
      7.4 N*m  { 75 kgf*cm, 65 in.*lbf }
      Bolt B
      17 N*m  { 175 kgf*cm, 13 ft.*lbf }

  5. INSTALL ENGINE ROOM RELAY BLOCK


    1. Engage the 3 wire harness clamps.

    2. A0138XKE01

      Engage the claw and install the engine room relay block.

    3. Install the 2 bolts.

      Torque:
      Bolt A
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }
      Bolt B
      8.4 N*m  { 85 kgf*cm, 74 in.*lbf }

  6. INSTALL BATTERY

    A0136B5E01
    Text in Illustration
    *a Identification line
    *b A-A
    *c B-B

    1. Install the battery onto the battery clamp sub-assembly, as shown in the illustration.

      Note


      • The identification line should be seen after installing the battery.

      • The battery clamp should be in contact with the battery after the installation.

    2. Install the battery clamp with the bolt.

      Torque:
      15 N*m  { 154 kgf*cm, 11 ft.*lbf }

    3. Connect the battery positive (+) terminal with the nut.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Torque:
    5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  8. INITIALIZATION OF MULTI-MODE MANUAL TRANSAXLE SYSTEM

    Click here

  9. LEARNING OF MULTI-MODE MANUAL TRANSAXLE SYSTEM

    Click here

  10. SYNCHRONIZATION POSITION CALIBRATION

    Click here