Component Tests and General Diagnostics

Clutch Pedal Inspection

Cylinder Push Rod Play "a"
1) Press clutch pedal (1) gradually with finger, stop it when slight increase of resistance is felt and measure how much pedal has moved (push rod play) as represented by "a" as shown.

Push rod play
"a": 1 - 3 mm (0.04 - 0.11 in.)

2) If "a" is not within specification, replace master cylinder (3) or pedal arm (2).

Clutch Pedal Free Travel "b"
1) Depress clutch pedal (1), stop it when clutch resistance is felt, and measure how much pedal has moved (clutch pedal free travel) as represented by "b" in the figure.

Clutch pedal free travel "b"
: 5 - 15 mm (0.20 - 0.59 in.)

2) If "b" is not within specification, check pedal arm (2) and master cylinder (3) and replace defective part.

Clutch Release Margin "c"
1) Apply parking brake and block wheels.
2) Start engine and keep engine at idle with neutral gear position.
3) Without clutch pedal (1) depressed, slightly push the shift lever to reverse position until transaxle emits gear rattling noise. Do not shift the lever to reverse position.
4) While gear rattling noise is being emitted, slowly depress clutch pedal (1). Stop at the position where the gear rattling noise stops (release point).

NOTE:
Listen to gear rattling noise in the engine room and determine when noise changes.

5) Measure distance between release point (4) and full stroke point (5) on clutch pedal (1) which is shown by "c" in figure.

Clutch release margin
"c": 25 - 55 mm (0.99 - 2.16 in.)

6) If "c" is not within specification, it is possible that air is trapped in this system. If suspected so, bleed air referring to Air Bleeding of Clutch System. Upon completion of above inspection, start engine and check clutch for proper operation.