CLUTCH UNIT REMOVAL/INSTALLATION [J65M-R]

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1.  Remove in the order indicated in the table.

2.  Install in the reverse order of removal.

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1	Manual transaxle (See MANUAL TRANSAXLE REMOVAL/INSTALLATION [J65M-R].)
2	Clutch release cylinder component (See CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION [J65M-R].)
3	Clutch cover (See Clutch Cover and Disc Removal Note.) (See Clutch Cover and Disc Installation Note.)
4	Clutch disc (See Clutch Cover and Disc Removal Note.) (See Clutch Cover and Disc Installation Note.)
5	Flywheel (See Flywheel Removal Note.) (See Flywheel Installation Note.) (See FLYWHEEL INSPECTION [J65M-R, A26M-R].)

Clutch Cover and Disc Removal Note

Caution

•  When removing a clutch with wear compensation, note the following regarding the readjustment mechanism.

―  When replacing components, always replace as a complete set.

―  If the old cover assembly is reused, it must be reinstalled together with its original clutch disc.

―  If the clutch cover is removed without releasing the stopper, the adjustment function may become inoperable. In this case, the clutch cover and disc must be replaced with new parts.

1.  Unscrew the stop to loosen.

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•  Verify the position of the stop.

―  There is only one.

―  It is located on the pitch circle of cover installation bolts between the bolt mount and the dowel pin, wedged between the cover and the flywheel.

―  The head of the guide bolt sticks out approx. 3 mm {0.12 in} from the housing.

2.  Install the SST.

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3.  Loosen the clutch cover installation bolts opposite each other in increments (approx. 5 passes).

Caution

•  Check that the stop loosens and slides down to the block in the housing.

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•  If necessary, push the guide bolt toward the flywheel.

4.  Remove the clutch cover and disc.

Flywheel Removal Note

1.  Hold the flywheel using the SST.

2.  Remove the bolts evenly and gradually in a crisscross pattern.

Caution

•  Do not reuse the flywheel installation bolts.

3.  Remove the flywheel.

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4.  Inspect for oil leakage from the crankshaft rear oil seal.

•  If there is any malfunction, replace the crankshaft rear oil seal.

(See REAR OIL SEAL REPLACEMENT [MZ-CD 1.6 (Y6)].)

Flywheel Installation Note

Caution

•  Clean the crankshaft threads before tightening the bolts.The threads may be damaged if the bolts are tightened with any old sealant remaining.

1.  Clean the crankshaft thread holes before installing the new flywheel installation bolts.

2.  Install the flywheel to the crankshaft.

3.  Hand‐tighten the new flywheel installation bolts.

4.  Install the SST to the flywheel.

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5.  Gradually tighten the flywheel installation bolts in a crisscross pattern.

Clutch Cover and Disc Installation Note

1.  Using the SST, center the clutch disc on the clutch cover.

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2.  Using the SST, install the clutch disc and clutch cover.

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3.  Tighten the new clutch cover installation bolts finger tight and then by two turns at a time in the sequence shown to the specified torque.

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4.  Remove the SSTs.