1. Disconnect the negative battery cable. (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-G 2.5].)
2. Remove the manual transaxle. (See MANUAL TRANSAXLE REMOVAL/INSTALLATION [C66M-R].)
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.
5. Add the specified amount of specified manual transaxle oil. (See MANUAL TRANSAXLE OIL REPLACEMENT [C66M-R].)
| 1 | Boot |
| 2 | Clutch release fork |
| 3 | Clutch release collar |
| 4 | Pivot pin |
| 5 | Clutch cover |
| 6 | Clutch disc |
| 7 | Pilot bearing (See Pilot Bearing Removal Note.) |
| 8 | Dual-mass flywheel |
CAUTION:
When newly replacing the clutch cover or disc, always replace a new clutch cover or a disc at the same time.
Due to the automatic adjustment function of clutch cover, if old assembly is reused, it must be installed with its original clutch disc.
1. Install the SSTs (49 E011 1A0, 49 SE01 310A).
2. Loosen each bolt one turn at a time in a crisscross pattern until spring tension is released.
3. Remove the clutch cover and clutch disc.
NOTE:
The pilot bearing does not need to be removed unless you are replacing it.
1. Use the SST (49 1285 071) to remove the pilot bearing.
1. Lock the dual-mass flywheel against rotation using the SST (49 E011 1A0).
2. Loosen the lock bolts uniformly and gradually in the order shown in the figure, and remove them.
3. Remove the dual-mass flywheel.
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 [SKYACTIV-G 2.5].)
1. Clean the crankshaft thread holes.
2. Install the dual-mass flywheel to the crankshaft.
3. Lock the dual-mass flywheel against rotation using the SST (49 E011 1A0).
4. Temporarily tighten the new lock bolts.
5. Tighten the lock bolts uniformly and gradually in the order shown in the figure.
Tightening torque
152—160 N·m {15.5—16.3 kgf·m, 113—118 ft·lbf}
1. Install new pilot bearing to the specified position using the following tools.
Tool
Snap-on brand millimeter size bushing driver set (A160M) adapter A160M7 (20—22 mm)
Use the adapter with the 20 mm side of the A160M7 (20—22 mm) facing the pilot bearing side.
Substitution tool
Outer diameter: 21 mm {0.83 in}
Inner diameter: 19 mm {0.75 in}
Standard position
Distance A of pilot bearing from crankshaft end: 1.5—2.5 mm {0.060—0.098 in}
1. Clean the splines of the new clutch disc and the primary shaft with a brush.
2. Spread a thin layer of clutch grease on the splines.
3. Hold the clutch disc position using the SST (49 SE01 310A).
4. Install the new clutch cover while aligning the guide pins.
5. Install the SST (49 E011 1A0).
6. Tighten the bolts uniformly and gradually in the order shown in the figure.
Tightening torque
25—33 N·m {2.6—3.3 kgf·m, 19—24 ft·lbf}
7. Remove the SSTs (49 SE01 310A, 49 E011 1A0).