A/T Clutch Clearance Inspection
Special Tools Required

Clutch compressor attachment
 07ZAE-PRP0100
  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.