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TRANSMISSION/TRANSAXLE SECTION CL CLUTCH A B CL D E CONTENTS SERVICE INFORMATION OPERATING CYLINDER 10 PRECAUTIONS Component 10 Removal and Installation 10 Service Notice or Precaution PREPARATION Special Service Tool Commercial Service Tool CLUTCH PIPING 11 CLUTCH RELEASE MECHANISM 13 CLUTCH MASTER CYLINDER H Removal and Installation 13 CLUTCH DISC, CLUTCH COVER AND FLYWHEEL 16 I Removal and Installation 16 CLUTCH FLUID Air Bleeding Procedure G Removal and Installation 11 CLUTCH PEDAL On-Vehicle Inspection and Adjustment Removal and Installation F SERVICE DATA AND SPECIFICATIONS (SDS) 18 Component Removal and Installation Disassembly and Assembly Clutch Control System .18 Clutch Master Cylinder 18 Clutch Operating Cylinder .18 Clutch Disc 18 Clutch Cover 18 J K L M N O P Revision: 2007 September CL-1 D40 PRECAUTIONS < SERVICE INFORMATION > SERVICE INFORMATION PRECAUTIONS Service Notice or Precaution INFOID:0000000002978305 • • • • Recommended clutch fluid is brake fluid “DOT 3” Refer to MA-12, "Fluids and Lubricants" Do not reuse drained clutch fluid Be careful not to splash clutch fluid on painted areas Use a flare nut torque wrench [Commercial service tool], when removing and installing clutch piping • Use new clutch fluid to clean or wash all parts of master cylinder and operating cylinder • Do not use mineral oils such as gasoline or kerosene It will corrode the rubber parts of the hydraulic system WARNING: After cleaning clutch disc, wipe it with a dust collector Do not use compressed air PCIB0272E Revision: 2007 September CL-2 D40 PREPARATION < SERVICE INFORMATION > PREPARATION A Special Service Tool INFOID:0000000002978306 B Tool number Tool name Description Installing release bearing KV30101400 Drift a: 51 mm (2.01 in) dia b: 44 mm (1.73 in) dia CL D ZZA0838D ST20050240 Diaphragm adjusting wrench E Adjusting unevenness of diaphragm spring of clutch cover F G ZZA0508D Commercial Service Tool INFOID:0000000002978307 Tool name Description Pin punch Tip diameter: 4.5 mm (0.177 in) dia Removing and installing master cylinder spring pin H I J K ZZA0515D Installing clutch disc Clutch aligner 1: Center shaft 2: Attachment 3: Guide L M PCIB0017E Flare nut torque wrench a: 10 mm (0.39 in) Removing and installing clutch piping N O S-NT406 Revision: 2007 September CL-3 P D40 PREPARATION < SERVICE INFORMATION > Tool name Description Flare nut torque wrench a: 14 mm (0.55 in) Removing and installing clutch piping (For YD engine of LHD models) S-NT406 Puller Removing release bearing NT077 Revision: 2007 September CL-4 D40 CLUTCH PEDAL < SERVICE INFORMATION > CLUTCH PEDAL A On-Vehicle Inspection and Adjustment a b c d a b a b INFOID:0000000002978308 Make sure that clevis pin floats freely in the bore of clutch pedal B It should not be bound by clevis or clutch pedal If clevis pin is not free, make sure that pedal stopper bolt (without ASCD) or ASCD clutch switch (with ASCD) is not applying CL pressure to clutch pedal causing clevis pin to bind To adjust, loosen lock nut and turn pedal stopper bolt (without ASCD) or ASCD clutch switch (with ASCD) D Tighten lock nut Make sure that clevis pin floats in the bore of clutch pedal It should not be bound by clutch pedal E PCIB0907E If clevis pin is still not free, remove clevis pin and check for deformation or damage Replace clevis pin if necessary Leave the pin removed for step Check clutch pedal stroke for free range of movement F With clevis pin removed, manually move clutch pedal up and down to determine if it moves freely If any sticking is found, replace related parts (clutch pedal, assist spring, bushing etc.) Re-assemble clutch pedal and again make sure that clevis pin floats freely in the bore of clutch pedal G Check clutch hydraulic and system components (clutch master cylinder, clutch operating cylinder, clutch withdrawal lever, clutch release bearing, etc.) for sticking or binding If any sticking or binding is found, repair or replace related parts as necessary H If hydraulic system repair was necessary, bleed the clutch hydraulic system Refer to CL-7, "Air Bleeding Procedure" NOTE: I Do not use a vacuum assist or any other type of power bleeder on this system Use of a vacuum assist or power bleeder will not purge all the air from the system Removal and Installation INFOID:0000000002978309 J COMPONENTS K LHD models L M N O P PCIB2041E Clutch pedal assembly Clevis pin Bushing Stopper rubber Pedal stopper bolt (Without ASCD) ASCD clutch switch (With ASCD) Pedal pad Stopper rubber Snap pin 10 Bushing Revision: 2007 September 11 Assist spring CL-5 D40 CLUTCH PEDAL < SERVICE INFORMATION > : Apply lithium-based grease including molybdenum disulphide Refer to GI-7, "Component" for symbols not described on the above RHD models PCIB2042E Clutch pedal assembly Assist spring Bushing Clevis pin Bushing Stopper rubber Pedal pad Pedal stopper bolt (Without ASCD) ASCD clutch switch (With ASCD) 10 Stopper rubber 11 Snap pin : Apply lithium-based grease including molybdenum disulphide Refer to GI-7, "Component" for symbols not described on the above INSTALLATION When installing clutch pedal, refer to the following NOTE: Tighten pedal stopper bolt lock nut (without ASCD) or ASCD clutch switch lock nut (with ASCD) to the specified torque after installing clutch pedal assembly in vehicle and adjusting the pedal free play Revision: 2007 September CL-6 D40 CLUTCH FLUID < SERVICE INFORMATION > CLUTCH FLUID A Air Bleeding Procedure INFOID:0000000002978310 NOTE: B Do not use a vacuum assist or any other type of power bleeder on this system Use of a vacuum assist or power bleeder will not purge all the air from the system CAUTION: CL • Monitor clutch fluid level in reservoir tank to make sure it does not empty • Keep painted surface on the body or other parts free of clutch fluid If it spills, wipe up immediately and wash the affected area with water • Bleed air for clutch connector first, and then for operating cylinder D (For YD engine of LHD models) Fill reservoir tank with new clutch fluid Connect a transparent vinyl hose to air bleeder valve E Depress clutch pedal slowly and fully several times at an interval of to seconds and hold it With clutch pedal depressed, open air bleeder valve to release air F Close air bleeder valve Release clutch pedal and wait for seconds Repeat steps to until no bubbles can be observed in clutch PCIB1797E G fluid Tighten air bleeder valve to the specified torque Refer to CL-11, "Removal and Installation" and CL-10, "Removal and Installation" H I J PCIB1390E K L M N O P Revision: 2007 September CL-7 D40 CLUTCH MASTER CYLINDER < SERVICE INFORMATION > CLUTCH MASTER CYLINDER Component INFOID:0000000002978311 PCIB1388E Nipple Clamp Hose Cylinder body Dust cover Clevis Clevis pin Snap pin Stopper ring 10 Stopper 11 Push rod 13 Return spring 14 Seal Removal and Installation 12 Piston assembly 15 Spring pin INFOID:0000000002978312 REMOVAL Refer to the figure for clutch master cylinder removal procedure CAUTION: Keep painted surface on the body or other parts free of clutch fluid If it spills, wipe up immediately and wash the affected area with water INSTALLATION Note the following, and install in the reverse order of removal • Check the positions of clevis and push rod If measurement is outside the standard length, adjust the positions of clevis and push rod Length “L” 5M/T models LHD models : 119.0 - 120.0 mm (4.69 - 4.72 in) RHD models : 109.5 - 110.5 mm (4.31 - 4.35 in) 6M/T models QR25DE engine models LHD models : 119.0 - 120.0 mm (4.69 - 4.72 in) YD25DDTi engine models LHD models : 121.0 - 122.0 mm (4.76 - 4.80 in) RHD models : 111.3 - 112.3 mm (4.38 - 4.42 in) Revision: 2007 September CL-8 SCIA5158E D40 CLUTCH MASTER CYLINDER < SERVICE INFORMATION > Disassembly and Assembly INFOID:0000000002978313 A DISASSEMBLY • Loosen push rod lock nut then remove clevis and lock nut, if necessary B NOTE: Clutch pedal height is controlled with position of clevis and push rod • Remove stopper ring and stopper Remove push rod from cylinder body while holding it securely to prevent piston assembly popping out CL CAUTION: Restrain the push rod while doing this because there is a danger the piston assembly will fly out of the cylinder body D ASSEMBLY • Apply rubber lubricant to the internal surface of cylinder body, the sliding surface of piston assembly, and piston cup of piston assembly CAUTION: Restrain the push rod while doing this because there is a danger the piston assembly will fly out of the cylinder body • Check and adjust the positions of clevis and push rod After adjusting “L”, tighten lock nut to the specified torque Refer to CL-8, "Component" Length “L” 5M/T models LHD models : 119.0 - 120.0 mm (4.69 - 4.72 in) RHD models : 109.5 - 110.5 mm (4.31 - 4.35 in) 6M/T models QR25DE engine models LHD models : 119.0 - 120.0 mm (4.69 - 4.72 in) YD25DDTi engine models LHD models : 121.0 - 122.0 mm (4.76 - 4.80 in) RHD models : 111.3 - 112.3 mm (4.38 - 4.42 in) E F G H SCIA5158E I J K L M N O P Revision: 2007 September CL-9 D40 OPERATING CYLINDER < SERVICE INFORMATION > OPERATING CYLINDER Component INFOID:0000000002978314 PCIB1897E Dust cover Push rod Piston assembly Piston cup Piston spring Air bleeder valve Clutch hose Copper washer Cylinder body R: Apply rubber grease r: Apply rubber lubricant Refer to GI-7, "Component" for symbols not described on the above Removal and Installation INFOID:0000000002978315 REMOVAL Refer to the figure for operating cylinder removal procedure CAUTION: Keep painted surface on the body or other parts free of clutch fluid If it spills, wipe up immediately and wash the affected area with water Revision: 2007 September CL-10 D40 TROUBLE DIAGNOSIS [ABS] < SERVICE INFORMATION > TROUBLE DIAGNOSIS Component Parts Location INFOID:0000000002978778 SFIA3401E Revision: 2007 September BRC-6 D40 TROUBLE DIAGNOSIS [ABS] < SERVICE INFORMATION > Schematic INFOID:0000000002978779 A B C D E BRC G H I J K L M N O P TFWB0178E Revision: 2007 September BRC-7 D40 TROUBLE DIAGNOSIS [ABS] < SERVICE INFORMATION > Wiring Diagram - ABS - INFOID:0000000002978780 TFWB0179E Revision: 2007 September BRC-8 D40 TROUBLE DIAGNOSIS [ABS] < SERVICE INFORMATION > A B C D E BRC G H I J K L M N O TFWB0180E P Revision: 2007 September BRC-9 D40 TROUBLE DIAGNOSIS [ABS] < SERVICE INFORMATION > TFWB0181E Revision: 2007 September BRC-10 D40 TROUBLE DIAGNOSIS [ABS] < SERVICE INFORMATION > A B C D E BRC G H I J K L M N O JPFWC0005GB P Revision: 2007 September BRC-11 D40 TROUBLE DIAGNOSIS [ABS] < SERVICE INFORMATION > JPFWC0006GB Control Unit Input/Output Signal Standard INFOID:0000000003111204 REFERENCE VALUE FROM CONSULT-III CAUTION: The display shows ABS actuator and electric unit (control unit) calculation data, so a normal value might be displayed even in the event the output circuit (harness) is open or short-circuited Revision: 2007 September BRC-12 D40 TROUBLE DIAGNOSIS [ABS] < SERVICE INFORMATION > Data monitor Monitor item FR LH SENSOR FR RH SENSOR RR LH SENSOR RR RH SENSOR Display content Condition Wheel speed STOP LAMP SW Brake pedal operation BATTERY VOLT Battery voltage supplied to the ABS actuator and electric unit (control unit) FR RH IN SOL FR RH OUT SOL FR LH IN SOL FR LH OUT SOL REAR IN SOL REAR OUT SOL MOTOR RELAY ACTUATOR RLY Operation status of all solenoid valve Motor and motor relay operation status Actuator relay operation status ABS WARN LAMP ABS warning lamp status EBD WARN LAMP Brake warning lamp status EBD SIGNAL EBD operation ABS SIGNAL ABS operation EBD FAIL SIG ABS FAIL SIG System error signal status CRANKING SIG CRANKING status A Reference value in normal operation Vehicle stopped [km/h (MPH)] B Vehicle running (Note) Nearly matches the speedometer display (± 10 %or less) C Brake pedal depressed On Brake pedal not depressed Off D Ignition switch ON 10 – 16 V Actuator (solenoid valve) is active (“Active Test ”with CONSULT-III) or actuator relay is inactive (in fail-safe mode) On When the actuator (solenoid valve) is not active and actuator relay is active (ignition switch ON) Off When the motor relay and motor are operating On When the motor relay and motor are not operating Off When the actuator relay is operating On When the actuator relay is not operating Off When ABS warning lamp is ON On When ABS warning lamp is OFF Off Brake warning lamp ON On Brake warning lamp OFF Off EBD active On EBD not active Off ABS active On ABS not active Off Malfunctions condition (When system is malfunctioning) Off Cranking On Not cranking Off E BRC G H I J K L M N Note: Confirm tire pressure is normal CONSULT-III Function INFOID:0000000002978781 O CONSULT-III MAIN FUNCTION CONSULT-III can display each self-diagnostic item using the diagnostic test modes shown following Diagnostic test mode SELF-DIAG RESULTS Self-diagnostic results can be read and erased quickly DATA MONITOR Input/Output data in the ABS actuator and electric unit (control unit) can be read CAN DIAG SUPPORT MNTR The results of transmit/receive diagnosis of communication can be read Revision: 2007 September P Function BRC-13 D40 TROUBLE DIAGNOSIS [ABS] < SERVICE INFORMATION > Diagnostic test mode Function ACTIVE TEST Diagnostic Test Mode in which CONSULT-III drives some actuators apart from the ABS actuator and electric unit (control unit) and also shifts some parameters in a specified range FUNCTION TEST Performed by CONSULT-III instead of a technician to determine whether each system is “OK” or “NG” ECU PART NUMBER ABS actuator and electric unit (control unit) part number can be read Self-Diagnosis INFOID:0000000002978782 Display Item List Self-diagnostic item Malfunction detecting condition Check system RR RH SENSOR-1 [C1101] (Note 1) Circuit of rear RH wheel sensor is open, shorted or sensor power voltage is unusual RR LH SENSOR-1 [C1102] (Note 1) Circuit of rear LH wheel sensor is open, shorted or sensor power voltage is unusual FR RH SENSOR-1 [C1103] (Note 1) Circuit of front RH wheel sensor is open, shorted or sensor power voltage is unusual FR LH SENSOR-1 [C1104] (Note 1) Circuit of front LH wheel sensor is open, shorted or sensor power voltage is unusual RR RH SENSOR-2 [C1105] (Note 1) When the distance between the wheel sensor and sensor rotor is too large and the sensor pulse cannot be recognized by the control unit RR LH SENSOR-2 [C1106] (Note 1) When the distance between the wheel sensor and sensor rotor is too large and the sensor pulse cannot be recognized by the control unit FR RH SENSOR-2 [C1107] (Note 1) When the distance between the wheel sensor and sensor rotor is too large and the sensor pulse cannot be recognized by the control unit FR LH SENSOR-2 [C1108] (Note 1) When the distance between the wheel sensor and sensor rotor is too large and the sensor pulse cannot be recognized by the control unit BATTERY VOLTAGE [ABNORMAL] [C1109] ABS actuator and electric unit (control unit) power voltage is too low • Check battery voltage CONTROLLER FAILURE [C1110] Internal malfunction of ABS actuator and electric unit (control unit) • Replace ABS actuator and electric unit (control unit) PUMP MOTOR [C1111] ABS SENSOR [ABNORMAL SIGNAL] [C1115] (Note 1) Revision: 2007 September During actuator motor operation with ON, when actuator motor turns OFF or when control line for actuator motor relay is open During actuator motor operation with OFF, when actuator motor turns ON or when control line for relay is shorted to ground Wheel sensor input is malfunction BRC-14 • Check tire • Check sensor and sensor rotor • Check ABS actuator and electric unit (control unit) • Check wheel sensor circuit • Check ABS actuator and electric unit (control unit) • Check tire • Check sensor and sensor rotor • Check ABS actuator and electric unit (control unit) • Check wheel sensor circuit D40 TROUBLE DIAGNOSIS [ABS] < SERVICE INFORMATION > Self-diagnostic item Malfunction detecting condition Check system FR LH IN ABS SOL [C1120] When the control unit detects an error in the front LH inlet solenoid circuit FR LH OUT ABS SOL [C1121] When the control unit detects an error in the front LH outlet solenoid circuit FR RH IN ABS SOL [C1122] When the control unit detects an error in the front RH inlet solenoid circuit FR RH OUT ABS SOL [C1123] When the control unit detects an error in the front RH outlet solenoid circuit ACTUATOR RLY [C1140] When the control unit detects an error in the actuator relay circuit REAR IN ABS SOL [C1190] When the control unit detects an error in the rear inlet solenoid circuit REAR OUT ABS SOL [C1191] When the control unit detects an error in the rear outlet solenoid circuit A B • Check ABS actuator and electric unit (control unit) C D E CAN COMM CIRCUIT [U1000] (Note 2) • Check ABS actuator and electric unit (control unit) • Check CAN communication line When ABS actuator and electric unit (control unit) is not transmitting or receiving CAN communication signal for seconds or more Note 1: After completing repairs of shorted sensor circuit, when ignition switch is turned ON, ABS warning lamp turns on Make sure that ABS warning lamp turns off while driving vehicle at 10 km/h (6 MPH) or more for approximately minute according to self-diagnosis procedure In addition, if wheel sensor is displayed for wheels, check wheel sensor circuit and also check control unit power voltage Note 2: When errors are detected in several systems, including CAN communication system [U1000], troubleshoot CAN communication circuit Data Monitor INFOID:0000000003111205 BRC G H I DISPLAY ITEM LIST ×: Applicable Monitor item (Unit) SELECT MONITOR ITEM : Optional item Remarks ECU INPUT SIGNALS MAIN SIGNALS FR LH SENSOR [km/h (MPH)] × × FR RH SENSOR [km/h (MPH)] × × RR LH SENSOR [km/h (MPH)] × × RR RH SENSOR [km/h (MPH)] × × STOP LAMP SW (On/Off) × × Stop lamp switch signal status × Battery voltage supplied to the ABS actuator and electric unit (control unit) BATTERY VOLT (V) K L Wheel speed × J M N O P Revision: 2007 September BRC-15 D40 TROUBLE DIAGNOSIS [ABS] < SERVICE INFORMATION > Monitor item (Unit) SELECT MONITOR ITEM ECU INPUT SIGNALS Remarks MAIN SIGNALS FR RH IN SOL (On/Off) × FR RH OUT SOL (On/Off) × FR LH IN SOL (On/Off) × FR LH OUT SOL (On/Off) × RR RH IN SOL (On/Off) × RR RH OUT SOL (On/Off) × RR LH IN SOL (On/Off) × RR LH OUT SOL (On/Off) × MOTOR RELAY (On/Off) × Motor and motor relay operation ACTUATOR RLY (On/Off) × Actuator relay operation ABS WARN LAMP (On/Off) × ABS warning lamp status Operation status of each solenoid valve EBD WARN LAMP (On/Off) Brake warning lamp status EBD SIGNAL (On/Off) EBD operation ABS SIGNAL (On/Off) ABS operation EBD FAIL SIG (On/Off) EBD fail-safe signal ABS FAIL SIG (On/Off) ABS fail-safe signal CRANKING SIG (On/Off) Cranking signal Active Test INFOID:0000000002978784 TEST ITEM Solenoid valve NOTE: The example shown is for front right wheel The procedure for the other wheels is the same as given below • For ABS solenoid valve, touch “UP”, “KEEP”, and “DOWN” on the display screen Make sure solenoid valve operates as shown in solenoid valve operation chart Solenoid Valve Operation Chart Operation ABS solenoid valve UP KEEP DOWN FR RH IN SOL OFF ON ON FR RH OUT SOL OFF OFF ON* *: ON for to seconds after the touch, and then OFF ABS Motor Revision: 2007 September BRC-16 D40 TROUBLE DIAGNOSIS [ABS] < SERVICE INFORMATION > Touch “ON” and “OFF” on the screen Make sure ABS motor relay and actuator relay operates as shown in table below Operation ON OFF MOTOR RELAY ON OFF ACTUATOR RLY ON ON A B Symptom Chart INFOID:0000000002978785 C If ABS warning lamp turn ON, perform self-diagnosis D Symptom Check item Brake force distribution Excessive ABS function operation frequency E Looseness of front and rear axle Wheel sensor and sensor rotor system Brake pedal stroke Unexpected pedal reaction Make sure the braking force is sufficient when the ABS is not operating The braking distance is long Check stopping distance when the ABS in not operating ABS function does not operate (Note 1) Wheel sensor Pedal vibration or ABS operation sound occurs (Note 2) Wheel sensor G H CAN communication line ABS warning lamp indication is not normal BRC ABS actuator and electric unit (control unit) Combination meter I Note 1: ABS does not operate when speed is 10 km/h (6 MPH) or lower Note 2: Under the following conditions, ABS is activated and vibration is felt when brake pedal is lightly depressed (just place a foot on it) However, this is normal • When shifting gears J • When driving on slippery road • During cornering at high speed K • When passing over dumps or grooves [at approximately 50 mm (1.97 in) or more] • When pulling away just after starting engine [at approximately 10 km/h (6 MPH) or more] Component Inspection INFOID:0000000002978786 L WHEEL SENSOR Wheel sensor can not be inspected with circuit tester M BRAKE FLUID LEVEL SWITCH Turn ignition switch OFF Disconnect brake fluid level switch connector Check continuity between brake fluid level switch connector terminal and Brake fluid level switch 1–2 Condition N O Continuity When brake fluid is full in the reservoir tank No When brake fluid is empty in the reservoir tank Yes P SFIA2966E If NG, replace brake fluid level switch STOP LAMP SWITCH Turn ignition switch OFF Revision: 2007 September BRC-17 D40 TROUBLE DIAGNOSIS < SERVICE INFORMATION > Disconnect stop lamp switch connector Check continuity between stop lamp switch connector terminal and Stop lamp switch 1–2 Condition [ABS] Continuity Release stop lamp switch (When brake pedal is depressed.) No Push stop lamp switch (When brake pedal is released.) Yes If NG, replace stop lamp switch PARKING BRAKE SWITCH Turn ignition switch OFF Disconnect parking brake switch harness connector Operate parking brake and check continuity between parking brake switch harness connector terminal and ground Parking brake switch – ground Condition Continuity When parking brake operated No When parking brake released Yes If NG, replace parking brake switch Revision: 2007 September BRC-18 D40 WHEEL SENSOR [ABS] < SERVICE INFORMATION > WHEEL SENSOR A Removal and Installation INFOID:0000000002978787 B C D E BRC G H I J K L SFIA3402E Front wheel sensor (LH) Rear wheel sensor (RH) A Front B Rear M : Front CAUTION: Wheel sensor can not be separate from axle parts N O P Revision: 2007 September BRC-19 D40 ACTUATOR AND ELECTRIC UNIT (ASSEMBLY) [ABS] < SERVICE INFORMATION > ACTUATOR AND ELECTRIC UNIT (ASSEMBLY) Removal and Installation INFOID:0000000002978788 SFIA3403E To rear From master cylinder secondary side To front left From master cylinder primary side To front right ABS actuator and electric unit (control unit) Harness connector Refer to GI-7, "Component" for symbol marks in the figure CAUTION: • Before servicing, disconnect battery cables • To remove brake tube, use flare nut wrench to prevent flare nuts and brake tube from being damaged To install, use flare nut torque wrench • Do not apply excessive impact to ABS actuator and electric unit (control unit), such as dropping it • Do not remove and install actuator by holding harness • After work is completed, bleed air from brake tube and hose Refer to BR-8, "Bleeding Brake System" Revision: 2007 September BRC-20 D40