CL-2

CLUTCH CLUTCH PEDAL

Push Rod Play Adjust Point

CLUTCH PEDAL
CL09S-01

INSPECTION
1. CHECK THAT PEDAL HEIGHT IS CORRECT Pedal height from dash panel: 134.3 - 144.3 mm (5.287 - 5.681 in.) 2. IF NECESSARY, ADJUST PEDAL HEIGHT Loosen the lock nut and turn the stopper bolt until the height is correct. Tighten the lock nut.

Pedal Height Adjust Point

Pedal Height Push Rod Play

D07734

3. (a)

(b)
Pedal Free Play
CL0102

4. (a) (b) (c) 5. (a) (b) (c)

CHECK THAT PEDAL FREE PLAY AND PUSH ROD PLAY ARE CORRECT Push in on the pedal until the beginning of clutch resistance is felt. Pedal free play: 5.0 - 15.0 mm (0.197 - 0.591 in.) Gently push on the pedal until the resistance begins to increase a little. Push rod play at pedal top: 1.0 - 5.0 mm (0.039 - 0.197 in.) IF NECESSARY, ADJUST PEDAL FREE PLAY AND PUSH ROD PLAY Loosen the lock nut and turn the push rod until the free play and push rod play are correct. Tighten the lock nut. After adjusting the pedal free play, check the pedal height. CHECK CLUTCH RELEASE POINT Pull the parking brake lever and install wheel stopper. Start the engine and idle the engine. Without depressing the clutch pedal, slowly shift the shift lever into reverse position until the gears contact.

2002 ECHO (RM884U)

Author :

Date :

866

CL-3
CLUTCH CLUTCH PEDAL

(d)

25 mm (0.98 in.) or more Release Point

Full Stroke End Position

CL0512

Gradually depress the clutch pedal and measure the stroke distance from where the gear noise stops (release point) up to the full stroke end position. Standard distance: 25 mm (0.98 in.) or more (From pedal stroke end position to release point) If the distance is not as specified, perform the following operation. S Check pedal height. S Check push rod play and pedal free play. S Bleed clutch line. S Check clutch cover and disc.

6. (a)

CHECK CLUTCH START SYSTEM Check that the engine does not start when the clutch pedal is released. (b) Check that the engine starts when the clutch pedal is fully depressed. If necessary, replace the clutch start switch.

Clutch Start Switch

D07735

7. INSPECT CLUTCH START SWITCH CONTINUITY Check the continuity between terminals when the switch is ON and OFF.
Switch position ON (pushed) OFF (free) Condition Continuity No continuity

8 0.5 mm (0.31 0.020 in.)

2002 ECHO (RM884U)

Q08667

Author :

Date :

867

CL-14
CLUTCH CLUTCH UNIT

CLUTCH UNIT
CL09N-01

COMPONENTS
1st 49 (500, 36) 2nd Turn 90

19 (195, 14)

Release Bearing x6 Clip Release Fork Flywheel Clutch Disc Clutch Cover Release Fork Support
37 (375, 27)

Nm (kgfcm, ftlbf) : Specified torque z Non-reusable part Clutch spline grease Release hub grease Boot
D07716

2002 ECHO (RM884U)

Author :

Date :

878

CL-16
CLUTCH CLUTCH UNIT
CL09P-01

INSPECTION
1. INSPECT CLUTCH DISC FOR WEAR OR DAMAGE Using vernier calipers, measure the rivet head depth. Minimum rivet depth: 0.3 mm (0.012 in.) If necessary, replace the clutch disc.

Q01057

2. INSPECT CLUTCH DISC RUNOUT Using a dial indicator, check the disc runout. Maximum runout: 0.8 mm (0.031 in.) If necessary, replace the clutch disc runout.

Q06033

3. INSPECT FLYWHEEL RUNOUT Using a dial indicator, check the flywheel runout. Maximum runout: 0.1 mm (0.004 in.) If necessary, replace the flywheel. Torque: 1st: 49 Nm (500 kgfcm, 36 ftlbf) 2nd: Turn 90
D00203

B A

4. INSPECT DIAPHRAGM SPRING FOR WEAR Using vernier calipers, measure the diaphragm spring for depth and width of wear. Maximum: A (Depth): 0.5 mm (0.020 in.) B (Width): 6.0 mm (0.236 in.) If necessary, replace the clutch cover.
Z10408

5. INSPECT RELEASE BEARING Turn the bearing by hand while applying force in the axial direction. HINT: The bearing is permanently lubricated and requires no cleaning or lubrication. If necessary, replace the release bearing.
Q01060

2002 ECHO (RM884U)

Author :

Date :

880

CL-17
CLUTCH CLUTCH UNIT
CL09Q-01

SST

INSTALLATION
1.
Flywheel Side

(a)

INSTALL CLUTCH DISC AND CLUTCH COVER ON FLYWHEEL Insert SST in the clutch disc, then insert them in the flywheel. SST 09301-00210

HINT: Take care not to insert clutch disc in the wrong direction.
D07710

SST 3 6

(b) (c)

Align the matchmarks on the clutch cover and flywheel. Following the procedures shown in the illustration, tighten the 6 bolts in the order starting the bolt locating near the knock pin on the top. Torque: 19 Nm (195 kgfcm, 14 ftlbf)

HINT:
4 2 Matchmarks

D00204

SST

D00205

Q05807

Following the order in the illustration, tighten the bolts at a time evenly. S Move SST up and down, right and left lightly, after checking that the disc is in the center, tighten the bolts. 2. CHECK DIAPHRAGM SPRING TIP ALIGNMENT Using a dial indicator with roller instrument, check the diaphragm spring tip alignment. Maximum non-alignment: 0.5 mm (0.020 in.) If alignment is not as specified, using SST, adjust the diaphragm spring tip alignment. SST 09333-00013 3. INSTALL BOOT AND RELEASE FORK SUPPORT TO TRANSAXLE Torque: 37 Nm (375 kgfcm, 27 ftlbf) 4. APPLY RELEASE HUB GREASE Apply release hub grease to the release fork and hub contact, release fork and push rod contact and release fork pivot points. Sealant: Part No. 08887-01806, RELEASE HUB GREASE or equivalent 5. APPLY CLUTCH SPRING GREASE Apply clutch spline grease to the input shaft spline. Sealant: Part No. 08887-01706, CLUTCH SPLINE GREASE or equivalent 6. INSTALL RELEASE BEARING AND FORK TO TRANSAXLE Install the bearing to the release fork, and then install them to the transaxle. 7. INSTALL TRANSAXLE TO ENGINE (See page MX-8 )

2002 ECHO (RM884U)

Author :

Date :

881

CL-15
CLUTCH CLUTCH UNIT
CL09O-01

REMOVAL
1. REMOVE TRANSAXLE FROM ENGINE (See page MX-4 ) 2. REMOVE CLUTCH COVER AND DISC (a) Align the matchmark on the clutch cover with the one on the flywheel. (b) Loosen each set bolt one turn at a time until spring tension is released. (c) Remove the set bolts, and pull off the clutch cover with the clutch disc. NOTICE: Do not drop the clutch disc.

Matchmarks
D00202

3.

REMOVE RELEASE BEARING AND FORK FROM TRANSAXLE Remove the release bearing with the fork together and then separate them. 4. REMOVE RELEASE FORK SUPPORT AND BOOT

Q01056

2002 ECHO (RM884U)

Author :

Date :

879

CL-4
CLUTCH CLUTCH MASTER CYLINDER

CLUTCH MASTER CYLINDER

CL088-03

COMPONENTS
Inlet Union Return Spring Reservoir Hose z Grommet Piston Clip Slotted Spring Pin Clevis Lock Nut Washer Clip Boot

Push Rod Spring

12 (120, 9)

Clevis Pin

Snap Ring

Master Cylinder Body

Clutch Line
15 (155, 11)

Nm (kgfcm, ftlbf) : Specified torque z Non-reusable part Lithium soap base glycol grease

D07746

2002 ECHO (RM884U)

Author :

Date :

868

CL-6
CLUTCH CLUTCH MASTER CYLINDER
CL08A-02

DISASSEMBLY
1. (a) (b) 2. (a)
D07747

(b) 3. (a) (b) 4.

REMOVE INLET UNION Using a pin punch (3 mm) and hammer, drive out the slotted spring pin. Remove the inlet union and grommet. REMOVE CLEVIS AND BOOT Loosen the lock nut to remove the clevis and remove the lock nut. Remove the boot. REMOVE PUSH ROD While pushing the push rod, using snap ring pliers, remove the snap ring. Remove the push rod and washer. REMOVE PISTON WITH SPRING

D05851

2002 ECHO (RM884U)

Author :

Date :

870

CL-8
CLUTCH CLUTCH MASTER CYLINDER
CL08C-03

INSTALLATION
1. INSTALL MASTER CYLINDER Install the master cylinder to the body with the 2 nuts. Torque: 12 Nm (120 kgfcm, 9 ftlbf) 2. INSTALL CLEVIS PIN, CLIP AND RETURN SPRING (a) Install the clevis pin. (b) Using needle-nose pliers, install the clip. (c) Using needle-nose pliers, install the return spring.

SST

D07754

3. CONNECT CLUTCH LINE TO MASTER CYLINDER Using SST, connect the clutch line. SST 09023-00100 Torque: 15 Nm (155 kgfcm, 11 ftlbf) 4. CONNECT RESERVOIR HOSE TO MASTER CYLINDER Connect the reservoir hose to the inlet union and using pliers, install the clip. 5. w/ ABS: INSTALL ABS ACTUATOR (See page BR-37 ) 6. FILL RESERVOIR WITH BRAKE FLUID AND BLEED CLUTCH SYSTEM 7. CHECK FOR LEAKS 8. ADJUST CLUTCH PEDAL (See page CL-2 ) 9. FILL BRAKE FLUID UP TO MAX. LINE ON RESERVOIR 10. INSTALL FILLER CAP TO RESERVOIR

2002 ECHO (RM884U)

Author :

Date :

872

CL-7
CLUTCH CLUTCH MASTER CYLINDER
CL08B-02

REASSEMBLY
1. 2. 3. (a) (b)
Z08053

(c) 4.

COAT PARTS WITH LITHIUM SOAP BASE GLYCOL GREASE, AS SHOWN INSERT PISTON WITH SPRING INTO CYLINDER INSTALL PUSH ROD AND BOOT Install the washer to the push rod. Push the push rod to the piston, using snap ring pliers, install the snap ring. Install the boot. TEMPORARILY INSTALL LOCK NUT AND CLEVIS

5. (a) (b)

INSTALL INLET UNION Install the inlet union and a new grommet. Using a pin punch (3 mm) and hammer, drive in the slotted spring pin.

Protrusion 1.5 - 3.5 mm (0.059 - 0.138 in.) D07732

2002 ECHO (RM884U)

Author :

Date :

871

CL-5
CLUTCH CLUTCH MASTER CYLINDER
CL089-03

REMOVAL
1. REMOVE FILLER CAP FROM RESERVOIR 2. DRAW OUT BRAKE FLUID WITH SYRINGE NOTICE: Do not let brake fluid remain on a painted surface. Wash it off immediately. 3. w/ ABS: REMOVE ABS ACTUATOR (See page BR-36 ) 4. DISCONNECT RESERVOIR HOSE FROM MASTER CYLINDER Using pliers, slide the clip toward the reservoir and disconnect the reservoir hose. Use a container to catch the fluid.

5.

SST

D07754

DISCONNECT CLUTCH LINE FROM MASTER CYLINDER Using SST, disconnect the line. Use a container to catch the fluid. SST 09023-00100 6. REMOVE RETURN SPRING, CLIP AND CLEVIS PIN (a) Using needle-nose pliers, remove the return spring. (b) Using needle-nose pliers, remove the clip. (c) Remove the clevis pin. 7. REMOVE MASTER CYLINDER Remove the 2 nuts and master cylinder from the body.

D02320

2002 ECHO (RM884U)

Author :

Date :

869

CL-9
CLUTCH CLUTCH RELEASE CYLINDER

CLUTCH RELEASE CYLINDER

CL02U-05

COMPONENTS

Union Bolt
24.5 (250, 18)

z Gasket Union Bleeder Plug

8.4 (85, 74 in.lbf)

Clutch Line
15 (155, 11)

Spring Piston Push Rod Boot

12 (120, 9)

Release Cylinder Body

Nm (kgfcm, ftlbf) : Specified torque zNon-reusable part Lithium soap base glycol grease
D00198

2002 ECHO (RM884U)

Author :

Date :

873

CL-1 1
CLUTCH CLUTCH RELEASE CYLINDER
CL02W-03

DISASSEMBLY
1. REMOVE BLEEDER PLUG 2. REMOVE UNION BOLT, 2 GASKETS AND UNION 3. PULL OUT BOOT WITH PUSH ROD 4. REMOVE PISTON WITH SPRING Using compressed air, remove the piston with the spring from the cylinder. NOTICE: S Blowing off the air may cause the pistons jump-out. When removing the piston, hold it with your hand using a waste cloth. S Take care not to splash brake fluid when air-blowing.

D00200

2002 ECHO (RM884U)

Author :

Date :

875

CL-13
CLUTCH CLUTCH RELEASE CYLINDER
CL07E-02

INSTALLATION
1. INSTALL RELEASE CYLINDER WITH 2 BOLTS Torque: 12 Nm (120 kgfcm, 9 ftlbf)

SST

2. CONNECT CLUTCH LINE Using SST, connect the clutch line. SST 09023-00100 Torque: 15 Nm (155 kgfcm, 11 ftlbf) 3. FILL CLUTCH RESERVOIR WITH BRAKE FLUID AND BLEED CLUTCH SYSTEM 4. CHECK FOR LEAKS
D08255

2002 ECHO (RM884U)

Author :

Date :

877

CL-12
CLUTCH CLUTCH RELEASE CYLINDER
CL02X-03

REASSEMBLY
1. 2. 3. 4. COAT PISTON WITH LITHIUM SOAP BASE GLYCOL GREASE, AS SHOWN INSTALL PISTON WITH SPRING INTO CYLINDER INSTALL BOOT WITH PUSH ROD TO CYLINDER INSTALL UNION AND 2 NEW GASKETS WITH UNION BOLT Torque: 24.5 Nm (250 kgfcm, 18 ftlbf) INSTALL BLEEDER PLUG Torque: 8.4 Nm (85 kgfcm, 74 in.lbf)

CL0672

5.

2002 ECHO (RM884U)

Author :

Date :

876

CL-10
CLUTCH CLUTCH RELEASE CYLINDER
CL02V-03

SST

REMOVAL
1. (a) (b) 2. DISCONNECT CLUTCH LINE Using SST, disconnect the clutch line. SST 09023-00100 Use a container to catch the fluid. REMOVE 2 BOLTS AND PULL OUT RELEASE CYLINDER

D08255

2002 ECHO (RM884U)

Author :

Date :

874

CL-1
CLUTCH TROUBLESHOOTING

TROUBLESHOOTING
CL02N-06

PROBLEM SYMPTOMS TABLE

Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts.
Symptom Suspect Area 12.Engine mounting (Loosen) 13.Clutch disc (Runout is excessive) 14.Clutch disc (Oily) 15.Clutch disc (Worn out) 16.Clutch disc torsion rubber (Damaged) 17.Clutch disc (Glazed) 18.Diaphragm spring (Out of tip alignment) 1. Clutch line (Air in line) 2. Master cylinder cu cup (Damaged) 3. Release cylinder cup (Damaged) 1. Release bearing (Worn, 1 (Worn dirty, dirty or damaged) 2 Clutch 2. Cl h disc di torsion i rubber bb (Damaged) (D d) 1. 2. 3. 4. 5. 6. Clutch pedal edal (Free play lay out of adjustment) Clutch disc (Oily) Clutch disc (Worn out) Diaphragm Dia hragm s spring ring (Damaged) Pressure plate late (Distortion) Flywheel (Distortion) See page CL-14 CL-14 CL-14 CL-14 CL 14 CL-14 CL 14 CL-14 CL-4 CL 4 CL-9 CL-14 CL 14 CL 14 CL-14 CL-2 CL-14 CL-14 CL 14 CL-14 CL 14 CL-14 CL 14 CL-2 CL 4 CL-4 CL 9 CL-9 CL 14 CL-14 CL 14 CL-14 CL 14 CL-14 CL 14 CL-14 CL CL-14 CL-14 CL-14 CL-14 CL-14

Clutch grabs/chatters

Clutch pedal edal spongy s ongy

Clutch noisy

Cl t h slips Clutch li

Cl t h does Clutch d not t disengage di

1. Clutch pedal (Free play out of adjustment) 1 2 Clutch line (Air in line) 2. 3 Master cylinder cup (Damaged) 3. 4 Release cylinder cup (Damaged) 4. 5 Clutch disc (out of true) 5. 6 Clutch 6. Cl tch disc (R (Runout no t is e excessive) cessi e) 7 Clutch 7. Cl t h disc di (Lining (Li i broken) b k ) 8 Clutch 8. Cl t h di disc (Di (Dirty t or b burned) d) 9. Clutch Cl h disc di (Oil (Oily) ) 10.Clutch disc (Lack of spline grease) 11.Diaphragm g spring g( (Damaged) g ) 12.Diaphragm g spring g (Out ( of tip alignment) g ) 13.Pressure plate (Distortion)

2002 ECHO (RM884U)

Author :

Date :

865