( TL19E1PE10411212211MAAT00 )

A/T Clutch Clearance Inspection

Special Tools Required
Clutch compressor attachment
07ZAE-PRP0100

1. Inspect the clutch piston, the discs, the plates, and the end-plate for wear and damage, and inspect the clutch wave-plate phase difference, if necessary.

1. Install the clutch piston in the clutch drum. Do not install the O-rings during inspection.

1. For R20A3 engine model 1st clutch: Install the waved spring (A) in the 1st clutch drum (B). Starting with the clutch wave-plate, alternately install the clutch wave-plates (C) (5) and the clutch discs (D) (5), then install the clutch end-plate (E) with the flat side toward the top disc.

1. For R20A3 engine model 2nd clutch: Install the waved spring (A) in the 2nd clutch drum (B). Install the 4.0 mm-thick plate (C) with the shear droop side (D) toward the inside of the drum, the clutch disc (E), and the 2.0 mm-thick clutch flat-plate (F). Starting with the clutch disc, alternately install the clutch discs (G) (4) and the wave-plates (H) (3), then install the clutch end-plate (I) with the flat side toward the top disc.

1. For R20A3 engine model 3rd clutch: Install the waved spring (A) in the 3rd clutch drum (B). Install the clutch flat-plate (C) (1), the clutch disc (D), and the clutch flat-plate (E). Starting with the clutch disc, alternately install the clutch discs (F) (4) and the wave-plates (G) (3), then install the clutch end-plate (H) with the flat side toward the top disc.

1. For K24Z3 engine model 1st clutch: Install the waved spring (A) in the 1st clutch drum (B). Install the clutch flat-plate (C) (1), then starting with the clutch disc, alternately install the clutch discs (D) (5) and the clutch wave-plates (E) (4). Install the clutch end-plate (F) with the flat side toward the top disc.

1. For K24Z3 engine model 2nd clutch: Install the waved spring (A) in the 2nd clutch drum (B). Install the clutch flat-plate (C) (1), then starting with the clutch disc, alternately install the clutch discs (D) (6) and the clutch wave-plates (E) (5). Install the clutch end-plate (F) with the flat side toward the top disc.

1. For K24Z3 engine model 3rd clutch: Install the waved spring (A) in the 3rd clutch drum (B). Install the clutch flat-plate (C) (1), then starting with the clutch disc, alternately install the clutch discs (D) (6) and the clutch wave-plates (E) (5). Install the clutch end-plate (F) with the flat side toward the top disc.

1. Install the waved spring (A) in the 4th clutch drum (B). Starting with the clutch wave-plate, alternately install the clutch wave-plates (C) (4) and the clutch discs (D) (4). Install the clutch end-plate (E) with the flat side toward the top disc.

1. Install the waved spring (A) in the 5th clutch drum (B). Starting with the clutch wave-plate, alternately install the clutch wave-plates (C) (4) and the clutch discs (D) (4). Install the clutch end-plate (E) with the flat side toward the top disc.

1. Install the snap ring using a screwdriver to secure the clutch end-plate.

1. Set a dial indicator (A) on the clutch end-plate (B).

1. Zero the dial indicator with the clutch end-plate lifted up to the snap ring (C).

1. Release the clutch end-plate to lower the clutch end-plate, then put the clutch compressor attachment on the clutch end-plate (A).

1. Press the clutch compressor attachment down with 147 N (15 kgf, 33 lbf) (B) using a force gauge, and read the dial indicator (C). The dial indicator reads the clearance (D) between the clutch end-plate and the top disc (E). Take measurements in at least three places, and use the average as the actual clearance.

   Clearance between Clutch End-Plate and Top Disc
   Service Limit
   R20A3 Engine Model:
   1st Clutch: | 1.28−1.48 mm (0.050−0.058 in.)
   2nd Clutch: | 0.88−1.08 mm (0.035−0.043 in.)
   3rd Clutch: | 0.93−1.13 mm (0.037−0.044 in.)
   4th Clutch: | 0.93−1.13 mm (0.037−0.044 in.)
   5th Clutch: | 0.93−1.13 mm (0.037−0.044 in.)
   K24Z3 Engine Model:
   1st Clutch: | 1.38−1.58 mm (0.054−0.062 in.)
   2nd Clutch: | 1.14−1.34 mm (0.045−0.053 in.)
   3rd Clutch: | 1.23−1.43 mm (0.048−0.056 in.)
   4th Clutch: | 0.93−1.13 mm (0.037−0.044 in.)
   5th Clutch: | 0.93−1.13 mm (0.037−0.044 in.)

1. If clutch clearance is out of the service limit, select a new clutch end-plate from the following tables.

R20A3 Engine Model 1ST, 2ND, and 3RD CLUTCH END-PLATES

Mark | Part Number | Thickness (t)
--- | --- | ---
1 | 22551-R00-003 | 2.6 mm (0.102 in.)
2 | 22552-R00-003 | 2.7 mm (0.106 in.)
3 | 22553-R00-003 | 2.8 mm (0.110 in.)
4 | 22554-R00-003 | 2.9 mm (0.114 in.)
5 | 22555-R00-003 | 3.0 mm (0.118 in.)
6 | 22556-R00-003 | 3.1 mm (0.122 in.)
7 | 22557-R00-003 | 3.2 mm (0.126 in.)
8 | 22558-R00-003 | 3.3 mm (0.130 in.)
9 | 22559-R00-003 | 3.4 mm (0.134 in.)

R20A3 Engine Model 4TH and 5TH CLUTCH END-PLATES

Mark | Part Number | Thickness (t)
--- | --- | ---
1 | 22581-R91-003 | 2.1 mm (0.083 in.)
2 | 22582-R91-003 | 2.2 mm (0.087 in.)
3 | 22583-R91-003 | 2.3 mm (0.091 in.)
4 | 22584-R91-003 | 2.4 mm (0.094 in.)
5 | 22585-R91-003 | 2.5 mm (0.098 in.)
6 | 22586-R91-003 | 2.6 mm (0.102 in.)
7 | 22587-R91-003 | 2.7 mm (0.106 in.)
8 | 22588-R91-003 | 2.8 mm (0.110 in.)
9 | 22589-R91-003 | 2.9 mm (0.114 in.)

K24Z3 Engine Model 1ST CLUTCH END-PLATES

Mark | Part Number | Thickness (t)
--- | --- | ---
1 | 22571-RZH-003 | 2.6 mm (0.102 in.)
2 | 22572-RZH-003 | 2.7 mm (0.106 in.)
3 | 22573-RZH-003 | 2.8 mm (0.110 in.)
4 | 22574-RZH-003 | 2.9 mm (0.114 in.)
5 | 22575-RZH-003 | 3.0 mm (0.118 in.)
6 | 22576-RZH-003 | 3.1 mm (0.122 in.)
7 | 22577-RZH-003 | 3.2 mm (0.126 in.)
8 | 22578-RZH-003 | 3.3 mm (0.130 in.)
9 | 22579-RZH-003 | 3.4 mm (0.134 in.)

K24Z3 Engine Model 2ND CLUTCH END-PLATES

Mark | Part Number | Thickness (t)
--- | --- | ---
10 | 22569-RZH-003 | 2.4 mm (0.094 in.)
11 | 22570-RZH-003 | 2.5 mm (0.098 in.)
1 | 22571-RZH-003 | 2.6 mm (0.102 in.)
2 | 22572-RZH-003 | 2.7 mm (0.106 in.)
3 | 22573-RZH-003 | 2.8 mm (0.110 in.)
4 | 22574-RZH-003 | 2.9 mm (0.114 in.)
5 | 22575-RZH-003 | 3.0 mm (0.118 in.)
6 | 22576-RZH-003 | 3.1 mm (0.122 in.)
7 | 22577-RZH-003 | 3.2 mm (0.126 in.)

K24Z3 Engine Model 3RD CLUTCH END-PLATES

Mark | Part Number | Thickness (t)
--- | --- | ---
1 | 22551-RZH-003 | 2.1 mm (0.083 in.)
2 | 22552-RZH-003 | 2.2 mm (0.087 in.)
3 | 22553-RZH-003 | 2.3 mm (0.091 in.)
4 | 22554-RZH-003 | 2.4 mm (0.094 in.)
5 | 22555-RZH-003 | 2.5 mm (0.098 in.)
6 | 22556-RZH-003 | 2.6 mm (0.102 in.)
7 | 22557-RZH-003 | 2.7 mm (0.106 in.)
8 | 22558-RZH-003 | 2.8 mm (0.110 in.)
9 | 22559-RZH-003 | 2.9 mm (0.114 in.)

K24Z3 Engine Model 4TH and 5TH CLUTCH END-PLATES

Mark | Part Number | Thickness (t)
--- | --- | ---
1 | 22581-R91-003 | 2.1 mm (0.083 in.)
2 | 22582-R91-003 | 2.2 mm (0.087 in.)
3 | 22583-R91-003 | 2.3 mm (0.091 in.)
4 | 22584-R91-003 | 2.4 mm (0.094 in.)
5 | 22585-R91-003 | 2.5 mm (0.098 in.)
6 | 22586-R91-003 | 2.6 mm (0.102 in.)
7 | 22587-R91-003 | 2.7 mm (0.106 in.)
8 | 22588-R91-003 | 2.8 mm (0.110 in.)
9 | 22589-R91-003 | 2.9 mm (0.114 in.)

1. Install a new clutch end-plate, and recheck the clearance. If the thickest clutch end-plate is installed, but the clearance is still over the service limit, replace the clutch discs and the plates.