Clutch: Workshop Manual

WORKSHOP MANUAL
N Series
CLUTCH
FREE CLUTCH SYSTEM
SECTION 7
No.LGFCS-WE-0111
Clutch Free System 7C2-1
Section 7C2
Clutch Free System (CFS)

CONTENTS
Introduction .........................................................................7C2-2
Overview of Clutch Free System (CFS) .........................7C2-2
System Components ......................................................7C2-6
Clutch Free ON/OFF Lamp,
CHECK lamp, Operation Buzzer, Alarm Buzzer.........7C2-15
Clutch Free System Hydraulic Piping Air Vent Procedure.....7C2-16
Clutch Free System Initial Adjusting (Learning) Procedure ...7C2-18
Troubleshooting for Learning Process..........................7C2-22
Detecting and Warning for Worn Clutch .......................7C2-23
Clutch Wear Follow-up Control Mechanism .................7C2-25
Clutch Free Half-Disengaged Clutch Position Fine Adjusting Procedure ....7C2-26
HSA Release Point Position Fine Adjusting Method Procedure ......7C2-27
Self Diagnosis...............................................................7C2-28
Trouble Code Indication ...............................................7C2-29
Diagnosis with THCH2 .................................................7C2-30
Connection of TECH2...................................................7C2-31
Cautions for Failure Diagnosis .....................................7C2-34
Failure Diagnosis ..............................................................7C2-36
Failure Diagnosis Flow .................................................7C2-36
Circuit Diagram (Clutch Free System)..........................7C2-37
Circuit Diagram (Voice Alarm System) .........................7C2-39
Parts Layout Diagram...................................................7C2-40
Connector List ..............................................................7C2-41
Clutch Free Component Terminal Allotment ................7C2-44
Inspection of CFS Control Unit Terminal ......................7C2-47
Failure Diagnosis Based on Trouble Codes .................7C2-51
Failure Diagnosis Based on Vehicle Condition.............7C2-92
On-Vehicle Service .........................................................7C2-116
CFS Control Unit ........................................................7C2-116
Actuator ASM .............................................................7C2-117
Clutch Stroke Sensor ASM.........................................7C2-119
Transmission Shift and Select Sensor...........................7C2-122
Transmission Rotation Sensor ...................................7C2-125
Clutch Hydraulic Switch..............................................7C2-125
Neutral Switch ............................................................7C2-126
Shift Knob Switch .......................................................7C2-126
Removal and Installation of Change Lever ASM........7C2-127
Clutch Pedal Switch....................................................7C2-128
Accelerator Position Sensor (APS).............................7C2-129
Idle Switch ..................................................................7C2-129
Clutch Free Switch .....................................................7C2-130
HSA RESET Switch....................................................7C2-130
HSA/CFS ADJUST Switch .........................................7C2-131
Speed Sensor.............................................................7C2-131
HSA Valve ..................................................................7C2-132
HSA OFF Switch ........................................................7C2-133
Unapplied Parking Brake Voice Alarm Unit ................7C2-134
Door Switch ................................................................7C2-136
Parking Brake Switch .................................................7C2-136
Stop Lamp Switch.......................................................7C2-137
Diode Box ...................................................................7C2-138
Unit Repair......................................................................7C2-139
Clutch Free Actuator ASM..........................................7C2-139
Cylinder ASM..............................................................7C2-141
Change Lever ASM ....................................................7C2-143
Introduction
Overview of Clutch Free System (CFS)
Clutch Free System (CFS) is an image drive system with which the driver
can shift the gears without stepping on the clutch pedal to start or stop the
vehicle, or change its speed, operating only the accelerator pedal and brake
pedal.
• CFS realizes the merits of manual transmission vehicles such as high
fuel cost performance, positive effect of engine brake, effect of exhaust
brake and so on.
• By linking the control with the Hill Start Aid (HSA), starting the
vehicle on a slope or other situation was improved more than in manual
vehicles.
• The driver can select any desired gear speed when traveling as in
manual transmission vehicles.
Usually, he/she can drive the vehicle operating only the accelerator and
brake pedals but, when delicate clutch operation is required, the Clutch
Free System can be turned ON (Clutch Free switch operation) to drive
the vehicle as a manual clutch vehicle (3 pedals). If the system fails, the
vehicle can be driven by operating the clutch manually.
• Such a function is also provided that the optimum half-disengaged
clutch position is detected according to the progress of wear of the
clutch disk. Clutch disk wear detection function provides more
efficient inspections and services.
Clutch Free System ON Function

When the Clutch Free ON is selected and the shift lever is shifted to the
start speed, the shift knob switch incorporated in the shift knob detects the
shifted position, the pump is immediately started with the Clutch Free
actuator to increase the hydraulic and the clutch is disengaged. Then, by
stepping on the accelerator pedal, the half-disengaged clutch position is
determined according to the accelerator opening so that the vehicle starts
moving. Then, the clutch is fully engaged and the vehicle start step is
completed. The clutch is disengaged and engaged by shifting the gears to
higher or lower speed. For deceleration, as the vehicle speed reduces, the
clutch is automatically disengaged and the vehicle can stop.
The half-disengaged clutch position is determined by feed-back control
from the accelerator opening, engine rpm, transmission rotation, shifted
gear speed and other signals. The Clutch Free control unit controls the
clutch condition depending on various traveling situations.
Clutch Free OFF Function

By selecting the Clutch Free OFF, the Clutch Free System stops
functioning so that the vehicle can be driven by ordinary manual clutch
mode. This function is used when driver's skillful clutch operation is
required.
HSA (Hill Start Aid) Function

HSA is a system to hold the braking force even when the driver takes away
his foot from the brake pedal and release the braking force automatically
when the vehicle is started. The HSA valve provided midway on the brake
piping is controlled with the Clutch Free control unit to keep or release the
brake fluid pressure.
Other Functions
Both the Clutch Free System and HSA have various alarm functions and
self diagnosis function.
Control of Clutch Free System

1. ON/OFF switching of Clutch Free System
The Clutch Free System can be changed over between ON and OFF
with the Clutch Free switch. Watching the Clutch Free ON/OFF
lamp, turn the switch ON or OFF as required. The switch can be
turned ON or OFF only when the conditions below are met. If not,
the switch cannot be changed over. If the switch cannot be changed
over, the Clutch Free ON/OFF lamp blinks.
Clutch Free ON/OFF switching conditions

When vehicle is at a stop: The change lever is at the neutral position
and the clutch pedal is not stepped on.
When vehicle is traveling: The clutch pedal is not stepped on or the
clutch is engaged.
2. Turning ON the Clutch Free System

Before starting the engine
1. Turn ON the starter switch. Make sure that the Clutch Free
ON/OFF lamp and the Clutch Free CHECK lamp in the meter
panel blink for about 2 seconds. (Lamp check)
2. Then, check that the Clutch Free ON lamp lights up. If the Clutch
Free OFF lamp lights up, select the Clutch Free ON of the Clutch
Free switch and then check that the Clutch Free ON lamp lights
up.
Starting the vehicle

1. Check that the change lever is at the neutral position and start the
engine.
2. Without stepping on the clutch pedal, shift the change lever to the
start gear (second speed, first speed, reverse) position. The clutch
linked with the change lever is automatically disengaged, the
gears are engaged, and the vehicle is ready to start.
3. Release the parking brake, step on the accelerator pedal gradually
to start the vehicle. As the accelerator pedal is stepped little by
little, the clutch is automatically engaged.
Changing the speed

1. Without stepping on the clutch pedal, shift the change lever from
the current position to the desired gear position.
2. The clutch linked with the change lever is automatically
disengaged. When the change lever shifting is completed, the
clutch is automatically engaged. The speed can be changed by the
same procedure for shifting up and down.
Stopping the vehicle

1. Keeping the change lever at any gear position, step on the brake
pedal without stepping on the clutch pedal to reduce the vehicle
speed. When the vehicle speed reduces enough, the clutch is
automatically disengaged and the vehicle stops.
3. Operation with the Clutch Free OFF

When the Clutch Free is OFF, the clutch pedal should be stepped on
as usual.
1. Turn OFF the Clutch Free switch. Make sure that the Clutch Free
OFF lamp in the meter panel lights up.
2. Step on the clutch pedal as required in normal operation.
ABS
Parking brake switch ECU
HSA RESET HSA OFF switch PTO actuation
switch switch
Door switch
ABS actuation signal

HSA/CFS ADJUST Clutch free switch
switch (ON/OFF)
Shift knob switch Meters

Clutch Free ON/OFF lamp
Clutch Free CHECK lamp
HSA OFF lamp
HSA lamp (indicating operation/warning)
HSA valve
Clutch Free
Exhaust brake
System (CFS)
cut signal Engine control
control unit
module (ECM)
Accelerator
Brake Engine rpm
opening
switch
Accelerator Clutch Free actuator ASM
position sensor
Hydraulic
Engine pump
control Motor
module Hydraulic
switch Solenoid valve
(ECM))
Accelerator idle
switch Select stroke Cylinder ASM
sensor
Master cylinder
Shift stroke Neutral

sensor switch
Speed sensor
Engine
Clutch pedal
T/M rotation sensor switch
Clutch pedal
Engine
revolution sensor Transmission
Clutch stroke sensor

Slave
cylinder
Overview of HSA
HSA (Hill Start Aid) is a system to help the vehicle start on a slope. Even
if the driver takes away his/her foot from the brake pedal when stopping
the vehicle, the braking force is kept, while the braking force is
automatically released when the vehicle is started.
The HSA valve provided midway on the piping between the master
cylinder and wheel cylinder is activated by the CFS control unit to keep or
release the brake fluid pressure. A warning function and self diagnosis
function are also provided so that the CFS control unit gives an alarm to
the driver when the door is opened while keeping the HSA active, HSA has
worked for too long, or the HSA holding pressure reduces.
Front right wheel cylinder Rear right wheel cylinder

Servo unit master cylinder
HSA
valve
For front
wheel
For
rear wheel
CFS
control
unit
Front left wheel cylinder Rear left wheel cylinder
Controlling HSA
When the following conditions are met, the HSA is activated.
1. Gear is at the neutral position.
2. Brake pedal is stepped on.
3. Parking brake is released.
4. The vehicle stops.
When either one of the following conditions is met, the HSA is released.
1. Gear is at any position other than Neutral and more than half of the
clutch is engaged.
2. Parking brake is applied.
3. HSA OFF switch is pushed.
4. Starter switch is changed over to the ACC or OFF position.
System Components
Meters

ON: Clutch Free ON
OFF: Manual clutch mode
HSA OFF lamp

HSA lamp (operation/alarm indication)
HSA/OFF switch
- +
クラッチ
フリー
クラッチ IDLING
フリー STOP
TRIP A
ODO B
Clutch Free switch
S F
L HSA/CFS A
O ADJUST S
W T
HSA RESET switch
HSA/CFS ADJUST switch

Parts Layout Diagram
HSA lamp (active/alarm indication)
Clutch Free ON/OFF lamp HSA OFF switch

Clutch Free switch (ON/OFF)
Shift knob switch
Not applied parking brake

voice alarm unit
Clutch Free System

control unit
Diagnosis connector
Emergency connector
Clutch pedal switch
HSA RESET switch Accelerator position sensor

Stop lamp switch Accelerator idle switch
Door switch
Parking brake switch

Diagnosis connector (black), 16 poles Accelerator position sensor (APS)
CFS diagnosis connector (orange), 3 poles Accelerator idle switch
Emergency connector (white), 2 poles
Clutch Free switch (ON/OFF)
HSA OFF switch
HSA RESET switch Shift stroke sensor
Unapplied parking brake voice alarm unit Select stroke sensor
HSA lamp (Operation/Alarm indication) Neutral switch

HSA OFF lamp
Clutch Free ON/OFF lamp Speed sensor
Door switch
Clutch Free System

control unit
HSA valve
Clutch pedal
switch
Clutch Free actuator

(provided at wheel base)
Clutch
hydraulic Clutch hydraulic switch
switch
Door switch
Transmission rotation sensor
Shift knob switch Clutch stroke sensor
180
(installed to clutch housing)
Stop lamp switch
00/07/19
250
51671A
(installed behind the mad cover)
Work
C 0 7 L
Clutch Free control unit

The Clutch Free System and HSA are controlled according to signals from
each switch and sensor. Alarm buzzer is incorporated.
C部
B 部
A 部
MADE IN JAPAN
D部
826LY00008

This actuator receives signals from the Clutch Free control unit and
disengages or engages the clutch. The pump is actuated to generate
hydraulic pressure to disengage the clutch, open the solenoid valve and
releases the hydraulic pressure and engages the clutch. A middle cylinder
is incorporated to change over the Clutch Free ON and OFF smoothly. A
hydraulic oil reserve tank is provided.
203LY00001
Shift knob switch

This switch detects the shift knob operating power and shift operation start
timing. The clutch is disengaged quickly according to the shift up signal
or shift down signal.
235LY00005
Clutch stroke sensor

This sensor detects the clutch stroke. It detects the clutch position linked
Sensor with the clutch shift fork and clutch disc wear condition.
Transmission shift and select sensor

This sensor detects the transmission gear position. It changes the control
map depending on gears or detects the gear shift completion. Mounted
ahead of the transmission quadrant box.
230LY00002

Input rotations of the transmission gear, which rotates at the ratio of 1:1
with the clutch disc, is detected. Mounted to the transmission case side.
230LX003
Engine revolution sensor

1
Detects the engine rpm. Signal enters the Clutch Free control unit through
the engine control module (ECM). Signal is used jointly with the
tachometer.
2
(Earth)
Accelerator position sensor

Stepping stroke of the accelerator pedal is detected. The driver's intention
to accelerate or decelerate is guessed from this signal and clutch
engagement is controlled accordingly.
The signal is converted to PWM signal by the engine control module
(ECM) and enters the Clutch Free control unit.
3 2 1
101LX002
Accelerator idle switch

The accelerator idle switch is mounted to the accelerator control link ASM
same as the accelerator position sensor. By using the accelerator idle
switch, the idle position is accurately detected.
NO The signal is used jointly with the engine control module (ECM).
C NO
101LX007
Clutch hydraulic switch

The clutch hydraulic switch is mounted to the middle cylinder of the
Clutch Free actuator. It detects the clutch stroke position where the
hydraulic pressure becomes a certain level as the standard to compensate
or cause to follow up the Clutch Free clutch torque point (half-disengaged
clutch position) and HSA release point to the progress of wear of the clutch
disc.
203LX002
HSA valve
The HSA valve is provided midway of the piping of the brake master
cylinder and wheel cylinder and driven by the output of the Clutch Free
control unit (ON/OFF).
350LX001
Clutch Free ON/OFF switch

When this switch is fully pushed in, the Clutch Free is turned OFF so that
the manual clutch can be operated.
Clutch
Free
HSA OFF switch

When this switch is fully pushed in, the HSA is released.
(At this time, the HSA OFF lamp lights up.)
Clutch
Free

Used to adjust the half-disengaged clutch position of the Clutch Free
System. Also used to adjust finely the clutch pedal position to release the
HSA brake force holding. Used for the initial adjustment also.
S F By using this switch while the HSA is working, the HSA can be adjusted
L A
O
HSA/CFS
ADJUST S and by using it with the Clutch Free ON and HSA OFF, the Clutch Free
W T
system can be adjusted.
825LX012
HSA RESET switch

Used for initial learning of the Clutch Free or HSA.
HSA
RESET
825LX013

Indicates whether the Clutch Free System is working or manual clutch
should be used.
Clutch F
Free
Clutch
Free
2
1 X1000r/m
E
H
0
IDLIN
C STO

Indicates existence of some trouble in the system or trouble codes, or
alarms wear of the clutch disc.
F
2
1 X1000r
E
H
0
IDL
C ST
821LY00017
HSA lamp (operation or alarm indication)

Lights up when the HSA operates and goes out when the HSA is not
working. Blinks when alarm is issued and blinks or lights up in the event
of failure. Used for failure diagnosis also.
821LY00018
HSA OFF lamp

When the HSA OFF switch is pushed and the HSA is released, the HSA
OFF lamp lights up.
821LY00019
Unapplied parking brake voice alarm unit

This unit is mounted behind the HSA RESET switch on the right below the
instrument panel. When the parking brake lever is not pulled even though
required, it gives an alarm in voice. When the following conditions are
met while the parking brake lever is not pulled, chime sounds and then the
voice, "pull the parking brake" are repeated three times.
1. When the door is opened with the start switch ON and the gear at the
neutral position.
2. When the starter switch is changed over from ON to ACC or OFF.
In either case, the alarm stops when the parking brake lever is pulled. In
826LY00017
the above case of 1, when the door is closed or the gear is shifted to any
position other than neutral, the alarm stops.
In cold districts, when the vehicle is parked with some gear engaged, the
voice alarm sounds since the above 2 conditions are met but it is not a
trouble.
Diagnosis connector
The diagnosis connector is used when the trouble code is inspected or
deleted, at the time of execution of learning control, or oil supply to
hydraulic pipes.
By short-circuiting the terminal 11 and 4 or 5, those functions are
activated.
While the terminals are short-circuited, the Clutch Free CHECK lamp
1 2 3 4 5 6 7 8 blinks indicating that condition.
9 10 11 12 13 14 15 16
By connecting the diagnosis tool TECH2, data communication in the
control unit becomes possible.
826LX019
When learning the clutch torque point, by short-circuiting the terminal 6
and 4 or 5, the diagnosis connector of the engine control system can be
short-circuited.
Emergency connector
This is a connector to operate the starter motor irrespective of the gear
position at an emergency.
Caution
Never use the emergency connector except for emergency. After
use, be sure to remove the short-circuit connector.
1 2
826LX020
Overview of Clutch Free System (CFS) control functions

In addition to the normal control, the Clutch Free Control Unit
incorporates vehicle adjustment/service control functions.
● : Usual control (user mode)
O : Adjustment/service control (dealer mode)
Note: When using the dealer mode, short-circuit the diagnosis connecter terminal
(11 and 4 or 5).
CFS
Control item Summary of control
OFF ON
1 Manual mode control ● Controls to maintain the manual clutch operation
2 Gear position detection control ● ● Controls to detect the shift gear positionbased on the moving distance of the shift lever.
3 Actuator control ● Increases or decreases the pressure of the actuator.
In the Clutch Free mode, disengages or engages the clutch
4 Start control ●
from the zero start to half-disengaged clutch.
In the Clutch Free mode, controls the clutch disengagement
5 Speed change control ●
and engagement at the time of shifting up and down.
6 Clutch control ● Determines the clutch disengagement or engagement speed and other methods.
7 Exhaust brake control ● ● Sends exhaust brake operation signal to the exhaust brake control unit.
8 Clutch wear detection control ● ● Detects the progress of wear of the clutch.
9 Starter inhibit control ● ● Limits the starter operation when gear is engaged.
10 Gear parking control ● Enables parking with some gear engaged in the Clutch Free mode.
11 HSA control ● ● Controls operation of HSA
12 Clutch Free torque point wear follow-up learning Controls so that the half-disengaged clutch stroke position varies
● ●
control depending on the clutch wear extent.
13 Clutch drag learning control ● Controls learning of clutch's full disengagement position
14 Clutch's fully engaged position learning position ● Controls learning of clutch's fully connected position
Controls to change the half-disengaged clutch stroke position
15 HSA release point wear follow-up control ● ●
to release HSA according to the clutch wear
16 Buzzer control ● ● Controls output of alarm sound or input acceptance sound, etc.
17 Indicator lamp control ● ● Controls the lighting of the indicator lamp
18 Clutch Free ON/OFF switching control ● ● Controls to change over the Clutch Free and manual operation.
19 PTO operation control ● Warn operation of PTO with CPS ON.
20 Self diagnosis control ● ● Controls to detect troubles and back up.
21 CFS clutch torque point position adjusting control ● Controls to adjust the half-disengaged stroke position as required.
22 HSA clutch release point position adjustment control ● ● Controls to adjust the half-disengaged clutch position as required to release the HSA
Controls to learn the relation between the shift lever position
23 Select shift & neutral position learning control O
and stroke sensor output.
Controls to learn the half-disengaged clutch stroke position and HSA
24 CFS clutch torque point position learning control O
release point.
25 New clutch initial position learning control O O Control to memorize the clutch thickness when a new clutch is installed.
26 Clutch Free self diagnosis code indication control O Controls to indicate Clutch Free trouble code
27 HSA self diagnosis code indication control ● Controls to display HSA trouble codes
28 Self diagnosis code erasion control O O Controls to delete trouble codes
Controls to activate the actuator in the event of serviceof the hydraulic
29 Actuator oil supply control at maintenance O
unit to vent the air.
Controls so that the diagnosis connector terminal (11 and 4 or 5)
30 Diagnosis connector short-circuit alarm control O O
is short-circuited.
31 Warning of non-learning O O Controls to inform the initial learning has not been made.
32 Diagnosis tool communication (TECH2) ● ● Data communication to diagnosis tool in control unit.
Clutch Free ON/OFF lamp, CHECK lamp,

operation buzzer, alarm buzzer
In the following cases, condition of the Clutch Free System can be known
from the Clutch Free ON/OFF lamp, CHECK lamp, operation buzzer, and
alarm buzzer.
Clutch Free Clutch Free Operation Warning
Contents ON/OFF lamp Remedy
Check lamp buzzer buzzer
When the vehicle stops with some Beeps Return the shift lever to the
gear which does not serve for the ON lights up. - - repeatedly. neutral position and shift to
start of the vehicle engaged. the starting gear.
When the driver opens the door Beeps Return the gear to the
-
and leaves the vehicle with some ON lights up. repeatedly. neutral position.
-
gear engaged.
When the clutch pedal is stepped Beeps Take away the foot from
- repeatedly. the clutch pedal.
on with the Clutch Free ON. ON lights up.
Step on the accelerator
Half-disengaged clutch is kept at - - Beeps pedal and start or stop the
ON lights up.
that position for a long time. repeatedly. vehicle.
Vehicle is driven with the Release the parking brake

ON lights up. - - or stop the vehicle.
parking brake applied.
Warning
ON
When the clutch disc approaches ON or OFF only when the Inspect or replace the clutch
the service limit. lights up.
( vehicle stops with
some gear engaged
) - - disc with new one.
Meet the change over

When Clutch Free ON/OFF Either ON or OFF conditions or return the
change over has not been - - - Clutch Free switch to the
blinks.
completed. original position.
Turn OFF the PTO or
return the gear to the
When PTO is turned ON while - - Beeps neutral position and turn
ON or OFF blinks
the Clutch Free is ON. repeatedly. OFF the Clutch Free
switch.
Stop the vehicle safely and
Failure of Clutch Free system. ON or OFF blinks Blinks. - Beep change over the Clutch Free
to OFF.
Clutch Free ON ON lights up - - - -

Operation indication
Clutch Free OFF OFF lights up - - - -
When the Clutch Free ON/OFF Lighting ON or OFF Short

- beep - -
switch is operated. is changed over.
When HSA/CFS ADJUST Short
ON lights up - beep - -
switch is operated.
Clutch Free System Hydraulic Piping

Air Vent Procedure (Dealer Mode)
The hydraulic piping of the Clutch Free System branches at the Clutch
Free actuator, unlike the usual manual clutch vehicles. Air in the hydraulic
piping should be discharged in the order of 1, 2 and 3 as shown in the
drawing below.
1 Actuator
Secondary piston
2 Between cylinder ASM and actuator Middle port
3 Between master cylinder and actuator Primary piston
Clutch master cylinder
Clutch slave cylinder

Actuator
Reserve
tank
3
Hydraulic switch 1
M
Intermediate cylinder Solenoid Relief

Hydraulic valve valve
Check pump
valve Motor
In the maintenance operation, supply oil making use of the actuator oiling
control always by two people; driver and some person near the actuator.
Note: Care should be taken not to drop foreign substances into the reserve
tank.
1 Oil supply into and air discharge from actuator

Fill up the actuator with oil.
1 Supply oil into the actuator reserve tank.

2 Pull up the parking brake lever with the starter switch OFF. Turn OFF the Clutch Free switch, move the change lever to the neutral
position and short-circuit the diagnosis connecter terminal 11 and 4 or 5.
3 Turn ON the starter switch (but do not start the engine.)
4 Stepping on the brake pedal and accelerator pedal at the same time, operate the HSA RESET switch.
(Short beep sound indicates the oil supply mode is entered.)
Until following steps are completed, the brake and accelerator pedals should be kept stepped.
(If either the brake or accelerator pedal is released, the air vent software stops functioning.)
5 When the Clutch Free ON and OFF lamps blink alternately, the air vent software becomes standby.
6 By pushing the FAST of the HSA/CFS ADJUST switch, "beep" sounds indicating that the motor rotates for 0.5 seconds. When the
sound stops, release the switch.
7 Keep pushing the SLOW of the HSA/CFS ADJUST switch until the "beep" sound stops. The valve opens for 10 seconds, the oil
returns, and then the valve automatically closes.
8 Air comes up into the actuator reserve tank.
9 Repeat the above steps 6 and 7 until no air is discharged (standard frequency is 10 to 20 times.)
10 When no air comes out any more, the procedure is completed.
2 Oil supply and air discharge between the cylinder ASM and
slave cylinder
Next, fill the slave cylinder with oil making use of the actuator force.
1 Replenish the oil to the actuator reserve tank.
2 Pull up the parking brake lever with the starter switch OFF. Short-circuit the diagnosis connector terminal 11 and 4 or 5 with the
Clutch Free switch OFF and the change lever at the neutral position.
3 Turn ON the starter switch (but do not start the engine.)
4 Stepping on the brake pedal and accelerator pedal at the same time, operate the HSA RESET switch.
(Short beep sound indicates the oil supply mode is entered.)
Until following steps are completed, the brake and accelerator pedals should be kept stepped.
(If either the brake or accelerator pedal is released, the air vent software stops functioning.)
5 When the Clutch Free ON and OFF lamps blink alternately, the air vent software becomes standby.
6 By pushing the FAST of the HSA/CFS ADJUST switch, "beep" sounds indicating that the motor rotates for 0.5 seconds. When the
sound stops, release the switch.
7 Open the breather of the slave cylinder.
8 Close the breather of the slave cylinder.
9 Keep pushing the SLOW of the HSA/CFS ADJUST switch until the "beep" sound stops. The valve opens for 10 seconds, the oil
returns, and then the valve automatically closes.
10 Repeat the above steps 2 through 5 until no air comes out of the breather of the slave cylinder (standard frequency is 10 to 20 times.)
11 When no air comes out any more, the procedure is completed. Turn OFF the starter switch and reset the short circuit of the diagnosis
connector.
3 Oil supply and air vent between master cylinder and actuator
cylinder ASM
Finally, step on the clutch pedal on the master cylinder side and fill
the piping with oil.
1 Replenish the master cylinder reserve tank with oil.
2 Step on the clutch pedal and feed the oil (following steps are the same as usual air vent procedure).
3 Open the actuator cylinder ASM breather
4 Close the actuator cylinder ASM breather
5 Repeat the above steps 2 through 4 until no air comes out of the actuator cylinder ASM breather.
6 If no air comes out any more, this procedure is completed.
Clutch Free System Initial Adjusting (Learning)

Procedure (Dealer Mode)
Clutch Free hydraulic control is based on the half-disengaged clutch stroke
position and gear stroke position. Therefore, the initial basic conditions
should be memorized in the control unit. Follow the steps below for this
purpose. (Note 2)
The initial adjustment (learning) can be performed independently if
required. In this case, perform the procedures in the order of numbers from
the smallest one. After completion of learning, check that the Clutch Free
/ HSA operation is correct.
O : Learning is required - : Learning is not required
Learning item
Repair 1. 2. 3.
Parts replaced/repaired Learning of gear shift Learning of Learning of
item
and Clutch Free use start position
select stroke clutch torque point of new clutch disc
Clutch disc
- O O
Repair of (new)
clutch Clutch cover, release bearing,

- O -
shift fork, etc.
Repair of Engine, flywheel,

- O -
engine flywheel housing, etc.
Transmission ASM,
Repair of
quadrant box, external lever, -
transmission
O O
clutch housing, etc.
Repair of clutch Slave cylinder, master cylinder,

- - -
hydraulic system clutch pipe, etc.
Transmission shift
O - -
select sensor ASM
Repair of Clutch stroke sensor ASM,

- O -
clutch free parts link, bracket
Actuator ASM - - -
Replacement of
Control unit (new) O O - Note 1
control unit
Note 1:
New control unit stores data corresponding to new clutch and requires no learning.
When using a used control unit, learning is required.
Note 2:
After completing learning, erase the trouble code and conduct a trial run to make sure the proper operation of the system.
(Refer to "Test run of failed Clutch Free vehicle" of Cautions for Failure Diagnosis.)
1. Leaning of gear shift and select stroke

Have the system learn the shift and select stroke of gear control lever.
1 Short-circuit the diagnosis connector terminal 11 and 4 or 5, and select ON of the parking brake switch and OFF of the Clutch Free switch.
Turn ON the starter switch and wait for about 2 seconds until the lamp check is completed.
2
(Do not start the engine and do not step on the accelerator at this time.)
3 By turning the HSA RESET switch, beep sound starts and learning mode is entered.
Move the shift lever in the select (lateral) direction once each to the reverse side, 5th speed side, and 6th speed side in this order in full
4 select stroke, stopping the lever at each position for more than 1 second.
By this operation, either the 5th or 6th speed transmission is automatically judged and select stroke is learned.
Step on the clutch pedal and move the shift lever to each gear position keeping the shift lever at the full stroke position for 1 second.
By this operation, the shift stroke is automatically learned.

5
After completion of shifting to all gear positions, return the shift lever to the neutral position.
If the beep sound stops, learning has succeeded. If the sound does not stop, learning has failed. In such a case, repeat the above
steps 3 and 4. (Note 1)
(When learning has completed) Turn OFF the starter switch and return the diagnosis connector to the original position finally.
6
(When moving to the next learning procedure) Go to the next learning procedure at that condition.
When performing multiple learning procedures continuously,

"turning the starter switch OFF" and "returning the diagnosis
connector to the original position" are not required after completion
of each learning process. Keeping the diagnosis connector terminal
short-circuited, learning can be continued.
Note 1: • To discontinue the learning procedure, step on the

accelerator pedal or return the diagnosis connector to
the original position.
• After the beep sound stops, turn the starter switch OFF
more than 3 seconds later.
2. Learning of Clutch Free System clutch torque point position

Have the system learn the initial clutch torque transmission point
position which is the basic position of half-engaged clutch when the
vehicle starts using the Clutch Free function.
Short-circuit the diagnosis connector terminal 11 and 4 or 5 and start the engine (whenever starting the engine, warm it up, turn OFF
1
the AC and warm-up SW OFF, before starting the engine.)
2 Wait until the engine idling speed becomes stable at about 575rpm. Note 2
3 Check that the Clutch Free System is turned ON (HSA SW may be at OFF or ON).
4 Pull up the parking brake lever fully to apply the brake.
Step on the brake pedal fully to apply the brake. (Keep the brake pedal stepped until the learning process is completed to avoid the
5
vehicle from moving.)
Check that the gear is at the neutral position and operate the reset SW to enter the learning mode (the Clutch Free ON lamp starts
6
blinking and beep starts).
Without stepping on the clutch pedal, move the shift lever to the 2nd gear position, and then automatic learning is started. The clutch is
automatically half-engaged and torque transmission point is detected. (Since the clutch is automatically half-engaged, brake pedal
7
should be fully stepped. If the vehicle starts to move, learning process is automatically discontinued.)
The torque transmission point learning process is always repeated twice until the clutch becomes in half-engaged condition.
The Clutch Free ON lamp stops blinking and the beep sound stops as well.
8
(Keep the brake stepped fully until the beep sound stops, which indicates completion of the automatic learning process.)
If the engine speed decreases by 30 - 50rpm and the beep sound stops, the learning process has succeeded (Clutch Free ON lamp
lights up).
If both the Clutch Free ON lamp and OFF lamps blink (indicating incomplete learning process), the learning process has failed. In this
9
case, start from the step 6 again until the learning process succeeds as described above.
*If learning does not succeed even after the required steps are repeated, turn OFF the engine with the key and start from the step 1
(start the engine) again.
10 Return the gear to the neutral position and return the brake pedal to the original position.
11 Keep the gear at the neutral position and keep the engine idling for 15 seconds until the drag learning is completed (count the Clutch
Free CHECK lamp blinking frequency to about 15 times).
(When learning is completed) Turn OFF the ignition key, wait for about 5 seconds, and return the CFS diagnosis connector to the
12
original position finally.
(When moving to the next learning process) Go to the next learning process at this condition.
Note 2: The diagnosis connector of the engine needs not be

short-circuited when carrying out the Clutch Free
clutch torque point position learning process.
If torque learning process is not correctly finished after repeating

some times, it is possible to have the system learn the torque point by
the following procedure.
Short-circuit the diagnosis connector terminal 11 and 4 or 5 and check that the engine was started.
1
(Whenever starting the engine, warm it up, turn OFF the AC and warm up SW OFF, before starting the engine.)
2 Wait until the engine idling speed becomes stable at about 575rpm.
3 Turn OFF the Clutch Free SW (to enter the MT mode).
4 Pull the parking brake lever, step on the brake pedal fully, and step on the clutch pedal to disengage the clutch.
5 Move the shift lever to the 2nd gear position.
By pushing the reset SW, beep sound starts and learning mode is entered.
6
(Clutch Free OFF lamp lights up and ON lamp starts blinking.)
7 Return the clutch pedal gradually to engage the clutch little by little.
When the clutch is half-engaged and the engine speed has reduced by 30 - 50rpm, push the HSA/CFS ADJUST switch (either SLOW
8
or FAST). Then the leaning value is read and the beep sound stops. (The Clutch Free ON lamp goes out.)
9 Step on the clutch pedal and return the gear to the neutral position.
(When the learning process is completed) Turn OFF the IGN switch, wait for 5 seconds, and return the diagnosis connector of CFS to
10 the original position finally.
3. Learning of new clutch disc use start position

• To issue a clutch wear alarm, have the system learn the reference
position of a new clutch.
• Perform this process only when replacing the clutch with new
one.
1 Short-circuit the diagnosis connector terminal 11 and 4 or 5 and move the shift lever to the neutral position.
Turn ON the IGN switch and wait for 2 seconds until the lamp check is completed (do not start the engine and do not step the
2
accelerator pedal).
Step on the brake SW more than 5 times within 3 seconds after completion of the lamp check (this returns the wear distance counter in
3
the control unit to zero).
4 When the buzzer sounds 3 times, acceptance of learning is completed.
(When the learning process has completed) After turning OFF the IGN switch, wait for 5 seconds, and return the diagnosis connector
5
to the original position finally.
Note: The wear counter can be reset only to zero. Therefore,

when replacing the CFS or reusing a (used) clutch, it is
required to use the TECH2 and write the current wear
value to the control unit. (See the TECH2 Operation
Manual for the operation of the TECH2.) If such a value
is not written here, wear condition will not be correctly
warned.
7C2-22 Clutch Free System
Troubleshooting for learning process

If the learning process cannot be correctly performed or completed, check
the cause and correct following the procedure below.
"Clutch torque point position learning" is impossible.
Condition Correction
Automatic learning is not started by pushing • Turn OFF the starter switch once and short-circuit the diagnosis connector
the reset SW. again.
• After short-circuit the diagnosis connector, turn the starter switch ON and
perform the learning process again.
• Check that the clutch sensor is normal.
When some gear is engaged, the motor • Push the reset SW immediately and start the "torque point position learning"
keeps rotating. process.
• If the motor does not stop, move the shift lever to the neutral position and turn
OFF the CFS switch.
• Perform the "torque point position learning" process again.
Before learning process is completed, the • Check if the idling rotation is not steady.
clutch is not half-engaged and the process is • Check that the learning start requirements are met.
completed at this condition.
After the reset switch is pushed and learning • Check the clutch stroke sensor installing direction (180 degrees reversed).
process is started, the clutch is engaged too • Check the arrangement of the connector pins of the clutch stroke sensor.
tightly, the engine stops and learning is not
properly completed.
After completion of the learning process, the • Check if the door is closed.
buzzer beeps.
The clutch sensor has failed. If the clutch stroke sensor circuit has failed, "torque point position reset" and
"torque point position learning" processes cannot be performed. In such a case,
• Disconnect the wiring harness and check for short circuit.
• Check for disconnected connector and improper fitting.
• Replace the sensor.
Gear shift and select stroke cannot be learned.
Condition Correction
After selecting gears one by one and • Check if the sensor arm is installed properly.
returning the shift lever to the neutral • Check the clutch stroke sensor installing direction (180 degrees reversed).
position, the learning mode is not • Check the connector pin arrangement of the clutch stroke sensor.
completed. • Perform the "shift and select stroke learning" process again.
• If the stroke learning is not completed after repeating 3 times, replace the sensor.
• To disconnect or complete the learning, step on the accelerator pedal or open the
diagnosis connector and turn OFF the starter switch.
Learning mode is not started by pushing • Check that the learning start requirements are met.
the reset switch. • Check the shift and select stroke sensor circuit for failure.
The shift and select stroke sensor has If the shift/select stroke sensor circuit has failed, the "gear shift and select stroke
failed. learning" process cannot be performed.
• Check for disconnected wiring harness or short circuit.
• Check for disconnected connector or improper fitting.
• Replace the sensor.
Detecting and Warning for Worn Clutch

• When the clutch disk has worn and approached the service limit, the
Clutch Free CHECK lamp lights up and gives a warning to the driver.
Deviation of the shift fork position of used clutch (which has been
remarkably worn out) from a new clutch shift fork position as the zero
wear reference point (wear amount) is detected. When the total wear
amount exceeds the set value, an alarm is given.
• When the alarm is indicated, check the clutch disk immediately.
• When the clutch disc is replaced with new one, have the system learn the
shift fork position of the new clutch, reset the wear amount to zero and
memorize it in ECU.
• When the ECU is replaced or the clutch disc is replaced with some used
one, change the wear amount to the value of the used one using TECH2.
Refer to TECH2 Operation Procedure for details.
• Alarm servers only as one criterion.
<Indication of vehicle condition and alarm>
1. Engine is running.
2. Move the gear shift lever to some gear
The clutch disc has reached the service limit.
position.
3. Vehicle stops.
4. Clutch Free CHECK lamp lights up and keeps
ON.
Cautions: • Warning is only one index for the necessity of

inspection and does not indicate exact clutch
replacement timing.
• While the vehicle is running or gear is at the neutral
position, no alarm is indicated.
• If the wear amount is not reset to zero or written into
the memory, no correct indication is presented.
<Reset the clutch wear to zero (method of learning the new clutch position after the clutch is replaced)>
→Refer to page 7C2-21 for details.
1. Short-circuit the diagnosis connector and move the shift lever to the neutral position.
2. Turn ON the IGN switch and wait for 2 seconds until valve check is completed (do not start the engine and
do not step on the accelerator pedal).
3. Within 3 seconds after completion of the valve check, take away the foot from the brake switch and turn it
ON and OFF more than 5 times.
4. If the buzzer beeps 3 times, the learning process has been accepted (wear amount has been reset to zero).
• The wear counter is reset always to zero. Therefore,

when replacing the ECU or installing a used clutch,
current wear value should be entered using TECH2.
(How to use TECH2 is described separately.) When
no value is entered, correct wear amount warning is
not given.
<Rewriting the clutch wear amount to a value other than zero>

→Refer to the TECH2 operation procedure for details.
Summary of ECU replacement procedure:
1. Memorize the clutch wear value recorded in the current ECU using the TECH2.
2. Replace the ECU and have the system learn the clutch torque point position.
3. Enter the clutch wear value which was memorized above to the new ECU using TECH2.
Procedure to replace the clutch disc with used one:
1. Measure the facing thickness of the clutch disc to be installed and record the result.
2. Replace the clutch disc and have the system learn the clutch torque point position.
3. Write the facing thickness value which was memorized above to ECU using the TECH2.
Visual check of clutch disc wear

Slave cylinder • Wear of the clutch disc (approximate value) can be known from the
projection of the push rod beyond the housing end of the slave cylinder.
• Remove the boot and measure the distance from the cylinder end to the
push rod end (engage the clutch during this process).
When clutch disc is new: About 45mm

When clutch disc has fully worn out: About 28mm
Measured length
Clutch Wear Follow-up Control Mechanism

• As the clutch disc wear progresses, the clutch torque point position (half-
engaged position) moves gradually toward the clutch contact side. This
movement is automatically compensated by the function of the clutch
wear follow-up control. Wear is compensated.
• The hydraulic switch is turned ON when the clutch is disengaged and
OFF when the clutch is engaged. Positional relation between the clutch
torque point position (half-engaged clutch position) and the hydraulic
switch ON/OFF point of the Clutch Free System is constant irrespective
of wear of the clutch disc. Making use of this characteristic, by moving
the clutch torque point position (half-engaged position) by the amount
corresponding to the deviation of the position where the hydraulic switch
is turned OFF, constant clutch engagement feeling can be maintained
following up the wear of the clutch disc.
• Similarly, for the release point of HSA, constant release feeling can be
maintained following up the wear of the clutch disc.
High pressure
ON
Clutch hydraulic switch
OFF
Cylinder ASM
Hydraulic pump
When clutch has worn away

High
Clutch hydraulic pressure
HSA released
ON When clutch is new
Hydraulic switch
Half-engaged clutch position
Low OFF
Constant
Clutch engagement Clutch disengaged
Constant
Clutch stroke
Clutch Free Half-Engaged Clutch Position Fine

Adjustment Procedure (User Mode)
Half-engaged clutch position of the Clutch Free System can be adjusted
with a step of ±2 from the initial adjustment (standard) position. Adjust
this position in the following cases.
1. When starting the vehicle, clutch engagement is too hard or slippery
2. When starting the vehicle, clutch engaging timing is not as desired.
Adjusting procedure
1. While the engine is running, turn the Clutch Free switch ON, pull the
parking brake lever, and set the change lever to the neutral position.
2. Push the HSA OFF switch to release the HSA. (HSA OFF lamp lights
up.)
Clutch Free switch

HSA OFF switch
クラッチ IDLING
フリー STOP
3. Push the FAST or SLOW side of the HSA/CFS ADJUST switch

(HSA/Clutch Free System adjusting switch).
Select a desired position from 5 steps in total (standard value ±2
steps).
4. By keeping the ADJUST switch pushed, the buzzer beeps twice
indicating the adjustment of one step has completed. To adjust
S F
L
O
W
HSA/CFS A
ADJUST S
T another step, take away the hand once from the ADJUST switch and
press the ADJUST switch again. The buzzer beeps twice again
indicating the adjustment of another step has completed. If the
HSA / CFS ADJUST switch adjustment of more than ±2 steps is made, the beep sound continues
indicating the upper or lower limit of adjustment has been reached.
Note: The half-engaged clutch position can be adjusted only by

keeping the ADJUST switch pressed until the buzzer beeps
twice. When adjusting, be sure to keep the ADJUST switch
pressed.
HSA Release Point Position Fine Adjustment

Procedure (User Mode)
HSA release point position can be adjusted as required. Adjust it in the
following cases:
1. When starting the vehicle, dragging brake is felt.
2. When starting the vehicle on a slope, the vehicle is apt to fall back.
Adjusting procedure
1. While the engine is running, pull the parking brake lever and set the
change lever to the neutral position.
2. The HSA OFF switch should not have been selected.
(HSA OFF lamp is extinguished.)
3. Step on the brake pedal and pull down the parking brake lever.
4. Check that the HSA operation lamp lights up and set the change lever
Clutch Free switch to any position other than the neutral
(e.g. 2nd gear position).
HSA OFF switch
5. Push the FAST or SLOW side of the HSA/CFS ADJUST switch
(HSA/Clutch Free System adjustment switch) .
If the brake release is slow and dragging brake is felt when starting
クラッチ IDLING
the vehicle, push the FAST side and, when the brake is released
フリー STOP
quickly and the vehicle is apt to fall back on a slope, push the SLOW
side.
6. When the ADJUST switch is pushed, the buzzer beeps once
indicating the adjustment of the first step has completed. To adjust
another step, take away the hand once from the ADJUST switch and
push it again. The release position is adjusted by the number of times
that the switch was pushed.
7. Start the vehicle and, if the feeling is not as desired, repeat the steps from
3.
S F
L
O
W
HSA/CFS A
ADJUST S
T 8. Adjustable range is as listed below.
Adjustable range
HSA / CFS ADJUST switch Adjust with the
±2 steps from the standard position
Clutch Free ON
Adjust with the

About ±10 steps from the standard position
Clutch Free OFF
Such a function is available that the HSA release timing is automatically

adjusted according to the driving condition only when the Clutch Free
System is ON. In order to maximize the effect of this function, adjustable
range with the Clutch Free ON is limited to ±2 steps.
Caution
Whenever the ADJUST switch is pushed, beep sounds. Each
time when the switch is pushed, the adjustment advances so that
the brake is released at a higher or lower position.
Frequency to push
1 - 2 times Fine adjustment by FAST or SLOW
2 - 3 times When dragging brake is felt: FAST
When the vehicle falls back on a slope: SLOW
3 - 5 times When the brake is dragging: FAST
When the vehicle falls back on a slope: SLOW
Self Diagnosis
If any trouble occurs in the Clutch Free System, self diagnosis takes place
in the following procedure. The trouble is indicated by the blinking Clutch
Free CHECK lamp or HSA lamp and buzzer. Buzzer which sounds while
the lamp is blinking indicates current failure and blinking lamp without
buzzer indicates past failure.
Clutch Free related trouble codes and HSA related ones can be separately
indicated and identified.
Clutch Free trouble code identification method

1 Pull the parking brake lever, turn the starter switch ON, and short circuit the diagnosis connector terminal 11 and 4 or 5.
2 Select the Clutch Free ON and HSA OFF.
3 Keep to push the FAST or SLOW side of the HSA/CFS ADJUST switch.
4 While keeping to push the switch, a trouble code is indicated by the Clutch Free CHECK lamp.
HSA trouble code identification method

1 Pull the parking brake lever, turn the starter switch ON and short circuit the diagnosis connecter terminal 11 and 4 or 5.
2 Reset the HSA OFF and select the Clutch Free OFF.
3 Keep to push the FAST or SLOW side of the HSA/CFS ADJUST switch.
4 While keeping to push, a trouble code is indicated by the HSA lamp.
Trouble code erasing method

1 With the starter switch OFF, short circuit the diagnosis connector terminal 11 and 4 or 5.
2 Turn the starter switch ON and wait for 2 seconds until the lamp check is completed (do not start the engine and do not step on the accelerator step.)
3 Within 3 seconds after completion of the lamp check, open the diagnosis connector terminal.
Trouble Code Indication

Indication of Clutch Free trouble codes and HSA trouble codes
Clutch Free trouble codes are indicated by the blinking Clutch Free
CHECK lamp or HSA lamp. If the buzzer sounds at this time, it shows a
current failure and if not, it shows a past failure.
Indication of trouble code 32
CHECK lamp
Tens digits <3> Unit digits <2>
ON
OFF
3.2 (sec.) 0.4 0.4 0.4 0.4 0.4 1.2 0.4 0.4 0.4 3.2 2nd time
Example of trouble code indication
When normal 01 01 01 01 01 01 01
3.2 (sec.) 3.2 3.2

In case of trouble 01 01 01 31 31 31 32 32 32 01 01 01 31 31
(31 and 32)
3.2 (sec.) 3.2 3.2 3.2
Caution:
Each code is indicated repeatedly 3 times. When there is no other
code, the initial code is indicated 3 times again.
When there are more than 2 codes: Code 14 <current failure>/code 21

<past failure>
Lamp 14 14 14 21 21 21
Buzzer beeps beeps beeps
Diagnosis with TECH2

With the Clutch Free System, troubleshooting can be performed for the
electrical system using the failure diagnosis unit TECH2.
When the Clutch Free CHECK lamp or HSA lamp blinks, or when some
electrical trouble of the Clutch Free system is anticipated, check the
trouble code using the TECH2.
• Write all the codes indicated with TECH2 and check if the code of the
trouble has appeared intermittently.
• Clear the codes.
• Run the vehicle and reproduce the failure.
• Check the trouble code again using the TECH2.
• If no code is indicated by a test drive, that failure is a trouble occurring
intermittently. In such a case, refer to the section, "Troubles occurring
intermittently", of "Cautions for failure diagnosis".
• If some code is indicated, diagnosis is made referring to "Failure
diagnosis based on trouble codes".
Connection of TECH2
TECH2 diagnosis unit is a tool effective to diagnose electrical failures of
the Clutch Free or HSA system and check the system. Though any failure
diagnosis is possible without the TECH2, the TECH2 facilitates the
diagnosis remarkably.
The TECH2 is a portable, small-size, light-weight tester. By connecting it
to the diagnosis connector provided on the vehicle, it communicates with
the Clutch Free control unit of the vehicle to diagnose and test various
failures.
1. Composition of TECH2 unit
• TECH2 kit No.7000086
• TECH2 scan tool unit (No.7000057) and DLC cable (No.3000095)
901RW176
• SAE 16/19 adaptor (No.3000098) (1), PCMCIA card

1
(No.3000117) (2) and battery power cable (No.3000097) (3)
2
3
F07LX010
2. Connection of TECH2
Always observe the instructions in the TECH2 User Guide.
• Check that the ignition is OFF.
• Insert the ISUZU99 system PCMCIA card (1) into the TECH2 (4).
• Connect the SAE 16/19 adaptor (2) to the DLC cable (3).
• Connect the DLC cable (3) to the TECH2 (4).
• Connect the SAE 16/19 adaptor (2) to the diagnosis connector of
1 2 3 4 5 6 7 8 the vehicle.
9 10 11 12 13 14 15 16
• Connect the power plug (3) of the DLC cable directly to the
battery with the battery power cable (5).
826LX019
Cautions:
• When installing or removing the PCMCIA card, check that no
power is being supplied to the TECH2.
• As the working voltage of TECH2 is 12V, communication
between the control unit and TECH2 is conducted with the
voltage of 12V ON or OFF. Therefore, on a vehicle equipped with
a battery of 24V, when power is supplied to the TECH2, power of
12V should be supplied using a battery power cable.
If power of 24V is supplied by mistake from the cigar lighter to the
TECH2, internal circuit of the control unit may be destroyed.
2
3
- +
+ -
• Turn ON the ignition key on the vehicle and push the "PWR" key of the
TECH2.
• Check the display screen of TECH2.
Push ENTER to continue.

Operating Procedure
Car identification
Select either one of followings.
Car type
(UB) Bighorn
(UE) Wizard, Mu
Push ENTER to continue.
(N＊) ELF,NKR,NPR
(1) Push the "ENTER" key. (4) Select "( N*)ELF,

NKR, NPR."
Main menu System selection menu

(N*)ELF, NKR, NPR
F0 : Diagnosis
F1 : List of capture data F0 : Power Train
F2 : Tool option F1 : Chars
F3 : Download/upload help
F2 : Body
(2) Select "F0: Diagnosis".
(5) Select "F0: Power Train".
Car identification
Select either one of followings. Car Identification
Select either one of followings.
MY
Powertrain
※ ※※※※ 4.6L 4HG1
Clutch Free System/HSA
Others
※ ※※※※
(3) Select "Year model". (6) Select "Clutch Free System
/HSA" unit to diagnose.
By selecting the test vehicle powertrain, "Clutch Free System/HSA",

"Powertrain" application menu screen is displayed.
Select desired application and continue operation.
Refer to "TACH2 Manual" for detailed procedure and other information.

Cautions for Failure Diagnosis

When replacing the control unit
The control unit main body fails very rarely. In most cases, failure of the
control unit is a secondary failure due to a trouble of the wiring harness,
sensor, or switches (particularly short circuit) or intermittent fault due to
incorrect contact which are misconceived to be a failure though they are
corrected by replacing the control unit. Therefore, before replacing the
control unit, connecting points of controllers, extra electric load due to
short circuit or other reasons should be checked.
Troubles occurring intermittently

Intermittent troubles are attributable to temporarily imperfect contact or
the like of wiring harness or connectors in most cases. In the event of such
a trouble, check the related circuit in the following procedure.
1. Check that the connector is connected with the correct object and the
connector terminal is fully inserted.
2. Check the terminal for deformation or damage. If any, correct and
connect properly.
3. Some damage like disconnected wire may have occurred in the wiring
harness. When checking the wiring harness, shake it gently caking
care not to damage it.
Test run of a vehicle with faulty Clutch Free System

If the Clutch Free CHECK lamp or HSA lamp has blinked even once in the
past, the failed point can be specified by the failure diagnosis based on
the trouble code. In the event where such a failure has occurred that the
driver can detect only as an abnormal condition of the vehicle, carry out a
test run to reproduce the trouble and perform the failure diagnosis based
on the vehicle conditions following the procedure below.
1. Start the engine and check that lamp check takes place for the Clutch
Free ON/OFF lamp, Clutch Free CHECK lamp and HSA lamp (lamps
light up for about 2 seconds), then the Clutch Free CHECK lamp goes
out, Clutch Free ON/OFF lamp returns to the selected condition, and
the HSA lamp indicates the operating condition. (If the Clutch Free
CHECK lamp or HSA lamp starts blinking, read the trouble code and
specify the position of failure.)
2. While the vehicle is at a stop, change over the Clutch Free switch ON,
OFF and ON again and check that it indicates the condition correctly.
If "in change-over process" is indicated at this time, set the
transmission to the neutral position and engage the clutch to complete
the change-over process.
3. Without pushing the HSA OFF switch, press on the brake pedal,
release the parking brake and check that the HSA lamp lights up.
Then push the HSA OFF switch and check that the HSA lamp goes
out and the HSA OFF lamp lights up.
4. Start the vehicle slowly in the Clutch Free OFF mode, shift the gear
in the order of 1st, 2nd, 3rd, 4th, 5th and 6th gear, accelerate the
vehicle to more than 60 km/h pressing on the accelerator pedal a little
more than usual, and keep that vehicle speed for several seconds.
Then shift down the gear in the order of 6th, 5th, 4th, 3rd, 2nd and 1st
gear, apply the brake and stop the vehicle completely. Repeat this
pattern twice each with the exhaust brake ON and OFF.
5. Start the vehicle slowly in the Clutch Free ON mode, shift up the gear
in the order of the 1st, 2nd, 3rd, 4th, 5th and 6th gear, accelerate the
vehicle to more than 60 km/h stepping on the accelerator pedal a little
more than usual, and keep the vehicle speed for several seconds.
Then, shift down the vehicle speed in the order of the 6th, 5th, 4th,
3rd, 2nd and 1st gear, apply the brake and stop the vehicle completely.
Repeat this pattern twice each with the exhaust brake ON and OFF.
6. Start and stop the vehicle with the Clutch Free switch ON and HSA
ON, at the reverse, 1st and 2nd gear positions more than twice each.
Then, start and stop the vehicle with the Clutch Free switch ON and
HSA OFF, at the reverse, 1st and 2nd gear positions more than twice
each.
If the Clutch Free CHECK lamp or HSA lamp starts blinking during the
test run, check for the trouble code. If some other abnormal condition
occurs, check the situation properly according to the failure diagnosis
procedure. When the condition cannot be confirmed, reproduce the
trouble as far as possible.
Check after completion of repair

Unless the trouble code is erased or the starter switch is turned OFF, the
control unit may continuously blink the Clutch Free CHECK lamp or HSA
lamp even after the failure is repaired. After completion of repair, turn the
starter switch OFF, erase the trouble code, start the engine, perform the
items 1 through 6 of "Clutch Free failed vehicle test run" and check that
the Clutch Free CHECK lamp or HSA lamp does not blink.
Failure Diagnosis
Failure Diagnosis Flow
Complaint from client
Diagnosis through interview to the client
After turning ON the starter switch, check the Clutch Free CHECK lamp and
around it, switches, HSA lamp, and switch indications and operation.
Normal Abnormal
Clutch Free CHECK lamp/HSA lamp blinking
Blinking Not blinking

Specifying the position of failure based on trouble code
(self diagnosis)
No trouble code indicated Trouble code indicated
Specifying the position of failure based on vehicle conditions
Test run
Repair of failure
Normal Abnormal
Erasion of trouble code
Lamp blinking Functional trouble, indication trouble

Check of Clutch Free CHECK lamp and HSA lamp indication
Lamp blinking Functional trouble, indication trouble

Test run
Normal
Completion
Circuit Diagram (Clutch Free System)
Starter switch
Note:
OFF
Connector No. Wire diameter, color
KEY ACC
2L 8W/B 3W/L B
2
H5
No.20 0.5LG
3
50A ON 3B/Y 0.5B/O 2
B67
Terminal No.
8W
8W/B
No.19
10A
15A
ST
3B/Y
/B
Male terminal Female terminal
3B/W
4 B67
0.5B/O
0.5B/O
0.5B/O
ECM
40A
50A
ACL
No.16
15A
C
No.22
10A
+
Neutral switch
Battery
3W/G
0.5B/Y
0.85B/O
0.5LG
J50
J50
B258
B259
–
H7
20
0.5B/W
Clutch switch
7
2
10
0.85B/Y
2
0.5B/O 0.5W/L
0.5B/G
H5
19
B260
B89
B89
+
Battery
No.1
10A
HSA
0.5LG 0.5LG M/V1
20
–
0.5LG
6
4
0.5LG/R 0.5LG/R
1.25W/G
3Y/B
0.3B/R
5
H5
0.5B/G
12
21
30
2
0.5LG/B 0.5LG/B
0.5B/L 0.3B/L
2
H4
B258
H5
J155
J155
M/V2
H46
4
X27
X16
3
3
Emergency relay
0.5B/W
Starter cut relay

Starter relay
1.25W/G
0.5B/G
4
5
5
X27
X16
0.5B/O
E
X21
0.5B
0.5B
0.3B/Y
5
X21
0.5B
0.5B
0.3B/Y 0.3B/Y
7
Emergency
connector
H46
T/M rotation
0.5Y 0.5Y
2 12
2
0.5W/G
sensor
2 B269
B
0.5BR 0.5BR
1
CFS relay
J139
11 B258 3
0.5R/Y 0.5R/Y
3
10
4
H46
3Y/R
2 X24
3 X24
1.25Y/R 1.25Y/R
1
4
H17
10
16
0.5R 0.5R
1
CFS control unit
ATC motor
Select stroke
10
1.25Y/R 1.25Y/B
6
17
sensor
3Y/R 0.5W 0.5W
2 J136
2
5
1 J136
M
15
1.25Y/R 1.25Y
17
18
6
0.5B 0.5B
3
3
Joint5
J141
22
14
1.25Y/R 1.25Y/G
solenoid valve
9
Actuator
3B/W
clutch
0.5Y/R
1
2
J137
J137
0.5GR 0.5GR
4
19
11
0.5R 0.5R
3
H46
Shift stroke
12
sensor
0.5W 0.5W
7
2
5
1.25B/W 1.25B/W
7
1 15
4
16
13
0.5B 0.5B
1
1.25B/W 1.25B/Y
Joint6
8 15
3 10
J142
1.25B/W 1.25B/R
6 22
14
16 B257
1.25B/W 1.25B/W
9
18
19
0.5R 0.5R
1
Clutch stroke
20
0.5W 0.5W
5
sensor
HSA/CFS ADJUST
14
21
switch 0.5B 0.5G

3
0.3GR/B
1
J140
H46
0.5B/O 0.5B/O
3 B106
0.5B/G
2 B106
A
11
0.3GR/R 0.5W/O
9
ECM(B286-4)
0.5B/O HSA RESET

switch 0.5L/R
6
ECM(B286-15)
0.3GR/L
4
0.5B/O
3
B259
B105
B105
Clutch pressure
switch Diode
box
15
14
0.3SB
2
0.5B/O 0.5SB 0.5V/W

8
PTO lamp
9 X33
5
8 B258
(meter B52-11)
J138
J138
H17
H46
0.85B/Y
Hour meter
7
(meter B52-4)
0.5B/G 0.3B/G
X33
7 B260
ECM(B286-17)
0.5LG
HSA/CFS switch
Note:
0.85B/Y
12
1
5
0.3B/O 0.3LG Connector No. Wire diameter, color
B260
H12
0.3W/B
6
2
0.3B 0.3LG/R Front combination 3
lamp (left) Terminal No.
3B
Male terminal Female terminal

1.25B 0.3B 0.3B
4
3B 1.25B 0.85B
0.5LG
0.5B
8 B318
1
Idle switch
0.5B/O
7 B318
connector
Joint
B172
14 B260
Meter 0.5W/R
1 B75
2 B75
Clutch Free ON
A
3
6 0.3W/V
9
0.5B/Y 0.5W/R
ECM(B286-10)
4 B53
Clutch Free OFF

0.3Y
8 B53
3
0.5LG/L
2 B258
ECM(B286-6)
CHECK lamp Diode
13
18 B51
10
0.5B/Y 0.3Y/G
3
0.5G/O
ECM(B286-20)
1.25B
0.5G
2 X31
6 B260
1 X31
0.5L/B
ECM(B286-19)
HSA
20
0.3BR/W
4 B258
0.5LG
Meter(B52-8)
0.5LG
1 B259
0.5LG
HSA OFF ECM(B287-10)
19
0.3LG/B
6
0.3G/W 0.5G/W Stop lamp relay
8 B260
(X26-4)
H5
Parking brake Diode box
13 X33
12 X33
16 B260
2 B66
1 B66
0.3W/B 0.5W/B 0.3W/B
3 B51
Fuse
No.8 10A
CFS control unit

Stop lamp switch
17 B52
0.5Y/G 0.3Y/G 3
I/F
Parking brake
H12
3
switch
1 N6
0.3W/B
Door switch (left)

11 B259
1 N7
3 H3
0.5GR 0.3GR
0.5GR X33
2
0.5GR/B 0.5GR/R 1.25GR/R

1 N2
1 X33
4 X33
Room lamp
H12
Diode box
B268
connector
Joint
Door switch (right)

0.5B
0.85B
Shift knob switch

1
0.3V 0.3V
5
0.5B
9
4 B259 13
0.3B
2 N12
13
0.3R/B 0.3R/B
2
7 H12
3 N12
0.5B 0.85B
7
E
10
0.85B
6
11
12
0.5B
5
0.85B
3B
12
0.5B
B
0.5B/L
2 B257 4
ECM(B286-16)
EXH-B CUT
9 B260
0.5B
0.3B/W
B260
9 10 11 12 13 14 15 16
1
2 3
13 B259
0.5B
4 5
0.5B/L
0.3LB
0.5GR/W
connector(B79)
Diagnosis
ECM(B286-9)
6 7
0.5B
0.5LB
8
0.5B/L
9
0.5B
H12
Circuit Diagram (Voice Alarm Unit)
Starter switch
OFF
ACC
KEY 50A B67 B67
B ON 3B/Y
+
2 ST 3
Ð
ECM
50A
3B/Y
+
No.19 No.20
0.5B/Y 0.85B/Y 15A 10A
Ð
18 B51
0.85B/Y
3W/G
Parking brake
lamp (meter)
0.5B/O
Tail relay
3 B51
0.5B/Y
2 H7
0.5W/B
3W/G
13 X33 2 J50
Room lamp
3G
Diode box
Neutral
switch
No.1 No.10
10A 10A
12 X33 1 J50
0.5B/O
0.5B/G
0.5GR/B
1.25W/G
0.5LG/R
0.5W/B
3 H12
1 X33
15 H4
0.3W/B
Diode box
0.5B/O
0.5B/G
0.3W/B
1 N6 1 B31
Parking brake
Idle stop
switch
switch
4 2 X33
0.5LG/R
0.3W/G
0.5B/O
4 B31
0.5GR/R
0.5W/G
0.5GR
0.5B/G
CFS control unit(B259-11)
H12
4 9 8 2 1 7 6 B147
B147
0.3GR
Unapplied parking brake voice alarm unit
1.25GR/R
4 B147 3
3 H3
0.5G
0.5GR
0.3B
Door switch (right)
Door switch (left)
1 N2 1 N7
ECM(B268-5)
0.3B
9
3B 1.25B
6
B172
Joint
connector
B107 X31, X33 diode
HSA OFF switch relay box ASM (No.1)
B245 X16 Starter cut relay
CFS switch
B106 HSA/CFS ADJUST switch

J142 Shift
B79 Starter stroke sensor
Diagnosis connector B51 switch
B269 Meter
Emergency connector
B75 B52
Idle switch Meter
J50 Neutral J141 Select
B147 B53 switch stroke sensor
Parking brake Meter
warning unit B67
B105
HSA RESET switch H14
H72
B257,B258,B259,B260
CFS control unit
Battery
B89 H80 J136 ATC motor <Around engine>
Clutch switch H81 J137 Actuator
H82 Clutch solenoid valve
H-17 H-4
H-46 H-5 J138 Clutch pressure switch
H-6
Fusible link
Parts Layout Diagram
H-7
X21 Starter relay
H-8 H14
X24 CFS relay
N12
X26 Stop lamp relay H72
Shift knob connector
X27 Emergency relay
J155
HSA valve E98 Tacho sensor
Relay box ASM
B286,B287,
B172 Joint connector Fuse & relay
B288,B289 J139 T/M rotation sensor
ECM box ASM
B268 Joint connector J140 Clutch stroke sensor
Connector List
No. Connector face No. Connector face
B31 B106
1
1 2 3
2
4 5 6
3
B51 B147
1 2 3 4
1 2 3 4 5 6 7 8 5 6 7 8 9
9 1011121314 151617181920
B52 B172
1 2 3 4 5 6 7 8 9 10 11
1 2 3 4 5 6 7 8
12 13 14 15 16 17 18 19 20 21 22
9 10 11 12 13 14 15 16 17 18 19 20
B53 B257
1 2 3 4 5 6 7 8
1 2 3 4
9 10 11 12 13 14 15 16
5 6 7 8 9 10 1112
B66 B258
1 2 3 4 5 6
1 2 7 8 9 10 11 12
B67 B259
1 2 3 4 5 6 7 8 9 10
2 1
1 2 4 3
11 12 13 14 15 16 17 18 19 20
3 4
B75 B260
1 2 3 4 5 6 7 8
1 2 9 10 11 12 13 14 15 16
B79 B268
1 2 3 4 5 6 7 8
1 2 3 4 5
9 10 11 12 13 14 15 16
6 7 8 9 10 11 12
B89 B269
1
1 2 2 1
2
B105 B286
1 2 1 2 3 4 5 6 7 8 9 10 11
3 4 5 6 12 13 14 15 16 17 18 19 20 21 22
Connector List
B287 H46
1 2 3 4 5 6 6 5 4 3 2 1
1 2 3 4 5 6 14 13 12 11 10 9 8 7
7 8 9 10 11 12 13 14
7 8 9 10 11 12 15 16 17 18 19 20 21 22
22 21 20 19 18 17 16 15
B288 J50
1 2 3 4 5 6 7 8
2 1
1 2
9 10 11 12 13 14 15 16
B289 J136
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
1 2
B318 J137
1 2 3 4
5 6 7 8 1 2 2 1
H3 J138
1 2 3
3 2 1
4 5 6 2 1
6 5 4 1 2
H4 J139
9 8 7 6 5 4 3 2 1
1 2 3 4 5 6 7 8 9 2 1
20 19 18 17 16 15 14 13 12 11 10 1 2
10 1112 13 14 15 16 17 1819 20
H5 J140
1 2 3 4 5 6 6 5 4 3 2 1
7 8 9 10 11 12 12 11 10 9 8 7 1 2 3
13 14 15 16 17 18 18 17 16 15 14 13
19 20 21 22 23 24 24 23 22 21 20 19
25 26 27 28 29 30 30 29 28 27 26 25
31 32 33 34 35 36 37 38 39 40 40 39 38 37 36 35 34 33 32 31
H6 J141
1 2 H-6 2 1
H7
H8
1 2 H-7 2 1
3 2 1
1 2 3 4 4 3 2 1
5 6 7 8 8 7 6 5
9 10 11 12 13 13 12 11 10 9
H-8
14 15 16 17 18 18 17 16 15 14
H12 J142
6 5 4 3 2 1
1 2 3 4 5 6
7 8 9 10 11 12 13 14 1413 12 11 10 9 8 7 1 2 3
H17 J155
1 2 3 4 5 6 6 5 4 3 2 1
7 8 9 10 11 12 13 14 14 13 12 11 10 9 8 7 1 2 2 1
22 21 20 19 18 17 16 15 3 4 4 3
15 16 17 18 19 20 21 22
Connector List
N2
N6
2 1
N7
N12
1 2 3
X16
1
3 4 5
X21
2 3
4 5
X24
2 3
4 5
X27
1
3 4 5
X31
1 2 3
X33
1 2 3 4 5 6
7 8 9 10 11 12 13 14
Clutch Free Component Terminal Allotment

<Control unit>
8 7 6 5 4 3 2 1 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9 12 11 10 9 8 7 20 19 18 17 16 15 14 13 12 11 16 15 14 13 12 11 10 9
A 16-pin B 12-pin C 20-pin D 16-pin
Connector A : B257
Terminal No. Name of signal Terminal No. Name of signal
1 Actuator clutch solenoid valve 1 9
2 ABS input signal 10
3 CFS power source 11 CFS GND3
4 CFS GND2 12 CFS GND4
5 Actuator motor power source 2 13 CFS GND1
6 Actuator motor power source 1 14 Actuator motor power source 3
7 Actuator motor earth 1 15 Actuator motor earth 3
8 Actuator motor earth 2 16 Actuator motor earth 4
Connector B: B258
1 HSA OFF switch 7 IG switch
2 Exhaust brake cut 8 PTO switch
3 CFS OFF lamp 9 CFS ON lamp
4 HSA lamp 10 CFS CHECK lamp
5 Start cut relay 11 CFS relay
6 HSA M/V1 12 HSA M/V2
Connector C: B259
1 Engine rotation sensor 11 Door switch
2 T/M rotation sensor (SIG) 12 T/M rotation sensor (GND)
3 Vehicle speed sensor (SIG) 13 Vehicle speed sensor (GND)
4 Sensor GND 14 Clutch stroke sensor (GND)
5 Clutch stroke sensor (SIG) 15
6 Accelerator position sensor (APS) 16 Shift stroke sensor (GND)
7 Shift stroke sensor (SIG) 17 Select stroke sensor (GND)
8 Select stroke sensor (SIG) 18 Clutch stroke sensor (5V)
9 Torque cut 19 Shift stroke sensor (5V)
10 Select stroke sensor (5V) 20 IG switch
Connector D: B260
1 Checker 9 Diagnosis tool (TECH2)
2 HSA/CFS ADJUST switch (FAST) 10 Clutch pedal switch
3 HSA RESET switch 11 HSA/CFS ADJUST switch (SLOW)
4 CFS diagnosis switch 12 CFS switch
5 Shift knob switch (2,4,6,R) 13 Shift knob switch (1,3,5)
6 Idle up 14 Idle switch
7 Neutral switch 15 Clutch hydraulic switch
8 Brake switch 16 Parking brake switch
<Actuator ASM>
Motor connector: J136 (male type)

Terminal No.
1 Power terminal
2 1
2 GND terminal
Solenoid valve connector: J137 (male type)
Terminal No.
1 GND terminal of solenoid valve 1

2 1
2 Power terminal of solenoid valve 1
Pressure switch connector: J138 (male type)

Terminal No.
1 Control unit side terminal
2 1
2 Power terminal
<Shift and select stroke sensor ASM>
Shift stroke sensor connector: J142 (male type)
Terminal No.
1 GND terminal
3 2 1
2 Signal terminal
3 Power terminal
Select stroke sensor connector: J141 (female type)

Terminal No.
1 Power terminal
1 2 3 2 Signal terminal
3 GND terminal
Clutch stroke sensor connector: J140 (male type)
Terminal No.
1 Power terminal
3 2 1 2 Signal terminal
3 Sensor GND terminal
Transmission rotation sensor connector: J139 (male type)
Terminal No.
1 Sensor GND terminal

2 1
2 Signal terminal
Shift knob switch connector: N12 (male type)
Terminal No.
1 24R direction shift signal terminal

3 2 1
2 GND terminal
3 135 direction shift signal terminal

Inspection of CFS Control Unit Terminal

• If any trouble is detected by the self diagnosis function, or in the event
of troubles which are not detected by the self diagnosis, inspect the
input and output signals of the control unit and electrical parts around
the control unit to check for normal condition of sensors and switches
equipped on the vehicle.
These inspections allow to determine whether the trouble is attributable
to the control unit or peripheral electrical parts or wiring.
• Usually, unless otherwise specified, connectors on the wiring harness
side (vehicle side) are used for the continuity (resistance) check and
voltage check.
• Continuity (resistance) check is made with the starter switch OFF, and
the voltage check is made with the control unit connector connected, by
turning the starter switch ON.
Inspection with the signal check board

Using the signal check board enables to inspect the control unit connector
terminal easily without damaging the control unit connector terminal with
the tester rod, or the like.
Special tools
Signal check board: 5-8840-0612-0
Adaptor code and
guide plate: 5-8840-2632-0
F07LX004
Guide plate
A-1 A-2 A-3 A-4 A-5 A-6 A-7 A-8

NKR, NPR
equipped with
A-9 A-10 A-11 A-12 A-13 A-14 A-15 A-16 Clutch Free System
B-1 B-2 B-3 B-4 B-5 B-6 B-7 B-8 B-9 B-10 B-11 B-12
C-1 C-2 C-3 C-4 C-5 C-6 C-7 C-8 C-9 C-10 C-11 C-12
C-13 C-14 C-15 C-16 C-17 C-18 C-19 C-20
D-1 D-2 D-3 D-4 D-5 D-6 D-7 D-8 D-9 D-10 D-11 D-12
D-13 D-14 D-15 D-16

8 7 6 5 4 3 2 1 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9 12 11 10 9 8 7 20 19 18 17 16 15 14 13 12 11 16 15 14 13 12 11 10 9
A 16-pin B 12-pin C 20-pin D 16-pin
Connector A: B257
NO Name of signal Remarks NO Name of signal Remarks
1 Actuator clutch solenoid valve 1 A-1 9 A-19
2 ABS input signal A-2 10 A-10
3 CFS power source A-3 11 CFS GND3 A-11
4 CFS GND2 A-4 12 CFS GND4 A-12
5 Actuator motor power source 2 A-5 13 CFS GND1 A-13
6 Actuator motor power source 1 A-6 14 Actuator motor power source 3 A-14
7 Actuator motor earth 1 A-7 15 Actuator motor earth 3 A-15
8 Actuator motor earth 2 A-8 16 Actuator motor earth 4 A-16
Connector B: B258
1 HSA OFF switch B-1 7 IG switch B-7
2 Exhaust brake cut B-2 8 PTO SWITCH B-9
3 CFS OFF lamp B-3 9 CFS ON lamp B-10
4 HSA lamp B-4 10 CFS CHECK lamp B-11
5 Start cut relay B-5 11 CFS relay B-12
6 HSA M/V1 B-6 12 HSA M/V2 B-13
Connector C: B259
1 Engine rotation sensor C-1 11 Door switch C-11
2 T/M rotation sensor (SIG) C-2 12 T/M rotation sensor (GND) C-12
3 Vehicle speed sensor (SIG) C-3 13 Vehicle speed sensor (GND) C-13
4 Sensor GND C-4 14 Clutch stroke sensor (GND) C-14
5 Clutch stroke sensor (SIG) C-5 15 C-15
6 Acceleration position sensor (APS) C-6 16 Shift stroke sensor (GND) C-16
7 Shift stroke sensor (SIG) C-7 17 Select stroke sensor (GND) C-17
8 Select stroke sensor (SIG) C-8 18 Clutch stroke sensor (5V) C-18
9 Torque cut C-9 19 Shift stroke sensor (5V) C-19
10 Select stroke sensor (5V) C-10 20 IG switch C-20
Connector D: B260
1 D-1 9 Diagnosis tool (TECH2) D-9
2 HSA/CFS ADJUST switch (FAST) D-2 10 Clutch pedal switch D-10
3 HSA RESET switch D-3 11 HSA/CFS ADJUST switch (SLOW) D-11
4 CFS diagnosis switch D-4 12 CFS switch D-12
5 Shift knob switch (2,4,6,R) D-5 13 Shift knob switch (1,3,5) D-13
6 Idle up D-6 14 Idle switch D-14
7 Neutral switch D-7 15 Clutch hydraulic switch D-15
8 Brake switch D-8 16 Parking brake switch D-16
Note: No. in the column of "Remarks" indicates the terminal No. shown on the guide plate
of the signal check board.
CFS control unit connector terminal inspection list
Inspection circuit Inspection terminal No. *1 Tester range Standard value Remarks
Clutch Free actuator B257-3 - B257-1

½ 6-20½
solenoid valve 1 circuit (A-3) (A-1)
B257-6 - B257-7
Actuator motor circuit ½ 0.1-10½
(A-6) (A-7)
CFS control unit B257-3 (+) - B257-13 (-)

DCV Approx. 24V
power source circuit (A-3) (A-13)
Clutch Free switch B260-12 (+) - B257-13 (-) 0V Switch ON

DCV
ON/OFF circuit (D-12) (A-13) Approx. 24V Switch OFF
B258-1 (+) - B257-13 (-) Approx. 24V Switch OFF
HSA OFF switch DCV
(B-1) (A-13) 0V Switch ON
B258-2 (+) - B257-13 (-) Approx. 24V With clutch engaged
Exhaust brake cut output circuit DCV
(B-2) (A-13) 0V With clutch disengaged
B258-3 (+) - B257-13 (-) Approx. 24V With lamp OFF
Clutch Free OFF lamp circuit DCV
(B-3) (A-13) 0V With lamp ON
Clutch Free ON lamp circuit DCV
Clutch Free CHECK B258-10 (+) - B257-13 (-) Approx. 24V With lamp OFF
DCV
lamp circuit (B-10) (A-13) 0V With lamp ON
HSA operation lamp circuit DCV
B258-1 (+) - B258-5 (-) Approx. 24V Gear: Any position other than neutral
Starter cut circuit DCV
(B-1) (B-5) 0V Gear: At neutral position
B258-7 (+) - B257-13 (-)
DCV Approx. 24V
(B-7) (A-13)
Ignition power source circuit
B259-20(+) - B257-13 (-)
DCV Approx. 24V
(C-20) (A-13)
B258-6 - B258-1
HSA valve 1 circuit ½ 40-70½ Push the HSA OFF SW.
(B-6) (B-1)
B258-12 - B258-1
HSA valve 2 circuit ½ 40-70½ Push the HSA OFF SW.
(B-12) (B-1)
B258-11 (+) - B257-13 (-)

DCV Approx. 24V Battery voltage
(B-11) (A-13)
Clutch Free relay circuit
B257-3 (+) - B257-13 (-)
DCV Approx. 24V At IGN ON
(A-3) (A-13)
B259-1 - B259-4 Oscilloscope

Engine rotation sensor circuit *2
(C-1) (C-4) waveform
Transmission rotation B259-2 - B259-12

½ Approx. 1-2.5k½ At engine speed of 600rpm, 315Hz
sensor circuit (C-2) (C-12)
B259-3 (+) - B259-13 (-)

Vehicle sensor circuit DCV Approx. 2V or 14V
(C-3) (C-13)
B259-18 (+) - B259-14 (-)

DCV 4.5V or more
Clutch stroke sensor (C-18) (C-14)
circuit B259-5 (+) - B259-14 (-)

DCV 0.1-4.8V Operate the clutch pedal.
(C-5) (C-14)
4.4-4.6V At idling
Accelerator opening B259-6 - B259-4 Measure with
sensor circuit (C-6) (C-4) ( analog voltmeter)
0.4-0.6V At WOT
*1: No. in ( ) indicates the display terminal No. of the guide plate of signal check board
*2: Oscilloscope waveform
At idling 21-25ms At 2000rpm 7.4-7.6ms
24V 24V
0V 0V
Inspection circuit Inspection terminal No. *1 Tester range Standard value Standard value
B259-19 (+) - B259-16 (-) Approx. 4.5V

DCV or more
(C-19) (C-16)
Shift stroke sensor circuit
B259-7 (+) - B259-16 (-) 2nd speed position: 0.15-1.5V
DCV 0.1-4.8V
(C-7) (C-16) 3rd speed position: 3.5-4.8V
B259-10 (+) - B259-17 (-) Approx. 4.5V
(C-10) (C-17) DCV
or more
Select stroke sensor circuit
B259-8 (+) - B259-17 (-)
(C-8) (C-17) DCV 0.1-4.8V
B259-11 (+) - B257-13 (-) 0V Door open *2
Door switch circuit (C-11) (A-13) DCV Approx. 24V Door closed *2
B260-3 (+) - B257-13 (-) 0V Switch OFF
HSA RESET switch circuit DCV
(D-3) (A-13) Approx. 24V Switch ON
B260-2 (+) - B257-13 (-)
(D-2) (A-13) DCV 0V Switch OFF
B260-11(+) - B257-13 (-)
(D-11) (A-13) DCV 0V Switch OFF
HSA/CFS ADJUST switch circuit
B260-2 (+) - B257-13 (-)
(D-2) (A-13) DCV Approx. 24V Switch ON ("FAST" side)
B260-11 (+) - B257-13 (-)
(D-11) (A-13) DCV Approx. 24V Switch ON ("SLOW" side)
Continuity
Shift knob switch circuit B260-13 - B257-13 not indicated
(1,3,5th) Ω
(D-13) (A-13) Continuity Push the knob toward
indicated the 1st, 3rd and 5th gear side
Continuity
Shift knob switch circuit B260-5 - B257-13 not indicated
Ω
(R,2,4,6th) (D-5) (A-13) Continuity Push the knob toward
indicated the R, 2nd, 4th, 6th gear side
B260-6 (+) - B257-13 (-)
Idle up input circuit (D-6) (A-13) DCV Approx. 24V A/C compressor ON
B260-7 (+) - B257-13 (-) 0V Gear in
Neutral switch circuit (D-7) (A-13) DCV
Approx. 24V Gear: Neutral
B260-8 (+) - B257-13 (-) 0V Release the brake pedal.
Brake switch circuit DCV
(D-8) (A-13) Approx. 24V Step the brake pedal.
B260-10 (+) - B257-13 (-) 0V Step the clutch pedal.
Clutch switch circuit DCV
(D-10) (A-13) Approx. 24V Release the clutch pedal.
B260-14 (+) - B257-13 (-) Approx. 24V Accelerator WOT
Idle switch circuit (D-14) (A-13) DCV
0V Accelerator idle
B260-15 (+) - B257-13 (-) 0V Release the clutch pedal.
Parking brake switch circuit DCV
(D-15) (A-13) Approx. 24V Step the clutch pedal.
Actuator hydraulic B260-16 (+) - B257-13 (-) 0V Pull the parking brake lever
DCV
switch circuit (D-16) (A-13) Approx. 24V Return the parking brake lever
B258-8 (+) - B257-13 (-) 0V PTO switch ON
PTO switch (B-8) (A-13) DCV
Approx. 24V PTO switch OFF
B260-4 (+) - B257-13 (-) 0V Self diagnosis start switch ON
Self diagnosis start switch circuit DCV
(D-4) A-13) Approx. 8-24V Self diagnosis start switch OFF
*1: No. in ( ) indicates terminal No. of the guide plate of the signal check board.
*2: Keep the room lamp switch with the door.
Failure Diagnosis Based on Trouble Codes

Failure diagnosis based on trouble codes memorized by the self diagnosis function of the system.
Trouble code list
Trouble code
Failure condition
CFS HSA
06 - Transmission neutral switch signal error
08 08 Clutch stroke sensor signal error
11 - Transmission rotation sensor signal error
13 - Accelerator pedal idle switch or accelerator position sensor (APS) signal error
14 - Clutch actuator solenoid valve 1 signal error
16 - Incorrect gear control lever select stroke learning value
17 - Incorrect actuator hydraulic switch learning value
19 19 HSA/CFS ADJUST switch signal error
21 - Acceleration position sensor (APS) signal error
23 - Faulty control unit power system
- 25 Vehicle speed sensor output signal error
31 - Gear control select stroke sensor signal error
32 - Gear control shift stroke sensor signal error
33 33 Faulty control unit
34 - Shift knob switch circuit GND short circuit
35 - Shift knob switch circuit disconnected wire
37 - Actuator motor error, continuous operation
41 - Engine rotation sensor signal error
86 86 Actuator hydraulic switch signal error
- 91 HSA valve signal error
Trouble code Failure conditions
CFS : 06 HSA : - Transmission neutral switch signal error
• Faulty neutral switch

• Disconnected wire or short circuit of neutral switch wiring harness
• Faulty transmission neutral switch groove
Major causes of failure
• Incorrect dimension of neutral switch installing bearing surface
• Improper learning process for gear shift and select stroke
• Faulty shift stroke sensor
Alarm lamp Clutch Free CHECK lamp blinking
Alarm buzzer Not working
Control after detection of trouble CFS shift stroke sensor substituted for neutral switch signal.
Starter motor does not rotate.
Conditions on vehicle when trouble occurs
When the vehicle starts, HSA is not released or HSA does not work.
H4
Neutral switch B260 0.3 Black/green 0.5 Black/green 0.5 Black/green J50 J50 0.5 Black/yellow
signal input 7 1 2
0.5 Black/green 15
Neutral switch No.19
ECM(B286-17) 15A
B258 0.5 Black/orange No.20 3 Black/yellow
Ignition power 7
10A
input B259 0.5 Black/orange
20 Starter
switch
(B67-3)
CFS control unit
CFS : 06 HSA : - Transmission neutral switch signal error
Standard value
Gear neutral: Continuity indicated.
Is the fuse normal? Gear in (other than neutral)
: No continuity
Yes No
• Turn OFF the IGN and remove the control unit. Replace the fuse.
• Remove the control unit connector, and check the
continuity between the wiring harness connector terminal
B260-7 and B258-7 or B259-20.
Is the result a standard value?
Yes No
Check the continuity between the neutral

Is the trouble code (CFS) 32 of the shift
switch terminal J50-1 and J50-2.
stroke sensor recorded?
Yes No Yes No
Is the gear shift and Repair the wiring harness Replace the neutral
Repair the trouble code
select stroke learning between the control unit switch or repair the
(CFS) 32.
completed normally? and neutral switch. transmission control box.
Yes No
Trouble occurring Have the system learn the

intermittently gear shift and select.
CFS : 08 HSA : 08 Clutch stroke sensor signal error
• Failed clutch stroke sensor

• Disconnected wire or short circuit of wiring between the clutch stroke sensor and control
unit
• Improper clutch stroke sensor and link fixing position, deformation of bracket
• Improper learning process of Clutch Free clutch torque point position
• Failed clutch pressure plate, release bearing, or clutch shift fork
CFS - Clutch Free CHECK lamp blinking.
Alarm lamp
HSA - HSA lamp blinks only when the HSA is ON.
CFS - Operates only when the Clutch Free is ON or HSA is ON.
Alarm buzzer
HSA - Operates only when the HSA is operating.
CFS - Keep the clutch position and stop the Clutch Free system control.
Control after detection of trouble
HSA - Not works.
Clutch Free does not work. The vehicle starts with the Clutch Free ON and speed-change
feeling gets worse.
HSA does not work.
Clutch stroke sensor B259 0.5 Red H46 0.5 Red J140
power source (VCC) 18 19 1
Clutch stroke 0.5 White 0.5 White

sensor input (SIG) 5 20 2
Clutch stroke 0.5 Black 0.5 Green

sensor earth (GND) 14 21 3
0.5 Black 9
Sensor earth (GND) 4 B268
3 0.5 Black 0.5 Black/green
Joint
14 Clutch stroke sensor
connector
B260 0.3 Black/green 0.5 Black/green H4 0.5 Black/green J50 J50 Fuse
Neutral switch input
7 15 1 2 (No.19 15A)
CFS control unit ECM (B286-17)

CFS : 08 HSA : 08 Clutch stroke sensor signal error
Standard value
¥ Connect the TECH2, turn the IGN ON and read the voltage of the "Clutch
Clutch stroke sensor signal: 0.1-4.8V
stroke sensor signal".
¥ Does the voltage change within the standard range of values when the clutch
pedal is pressed and relieved?
(Instead of connecting the TECH2, following procedure is permitted: connect
the signal check board between the control unit and vehicle side wiring
harness. Turn ON the IGN and measure the voltage between the terminal
B259-5 and B259-14.
Yes No
Check the clutch stroke sensor for Remove the control unit connector (B259)
loosened fixing, dislocation, or deformation and sensor connector (J140) and check
of bracket or link. the continuity of the vehicle wiring
Is there any trouble? harness for correctness.
there any trouble?
Vcc : B259-18/J140-1
SIG : B259-5/J140-2
Yes No GND : B259-14/J140-3
Yes No
Repair the looseness, Was the Clutch Free clutch
dislocation, or torque point position
deformation of the learning successfully
bracket or link. completed?
Replace the sensor. Repair the wiring harness.
Yes No
Trouble occurring Perform learning of clutch

intermittently. torque point position.
CFS : 11 HSA : - Transmission rotation sensor signal error
• Failed transmission rotation sensor

• Disconnected wire or short circuit of wiring harness between control unit and rotation
Major causes of failure sensor
• Complete wear of clutch disk
• Faulty transmission gear, improper dimension of installing bearing surface
Alarm buzzer Works only when the Clutch Free is ON or HSA is ON.
Controls when T/M=0rpm. After MT switching, Clutch Free is turned OFF by CFS relay.
(Clutch position held)
Conditions on vehicle when trouble occurs When the vehicle starts in the Clutch Free mode, the clutch is felt to be slippery.
Transmission rotation B259 0.5 Yellow H46 0.5 Yellow J139

sensor input 2 8 2
(SIG)
Transmission rotation
sensor earth 0.5 Brown 0.5 Brown
12 9 1
(GND)
0.5 Black 0.5 Black 0.5 Black/green
Earth
4 9 1 10
B268
CFS control unit Joint Transmission
connector rotation sensor
CFS : 11 HSA : - Transmission rotation sensor signal error
Standard value
¥ Turn OFF the IGN and remove the control unit. Resistance value: 1-2.5 k½
¥ Remove the control unit connector and install the signal When engine speed is 600rpm:
check board to the wiring harness connector. Pulse 315Hz, Vpp>6V
¥ Measure the resistance value between the terminal B259-2 (Reference) V average > 3V
and B259-12.
Is a standard value indicated?
Yes No
Measure the resistance value between the

Are the clutch stroke sensor trouble code
terminal J139-1 and J139-2 of the single
(CFS) 08 and the engine rotation sensor
unit of the transmission rotation sensor.
trouble code (CFS) 41 recorded?
Yes No Yes No
¥ Connect the signal check Repair the wiring harness Replace the
Repair based on the
board to the control uni between the control unit transmission rotation
trouble code 08 and 41.
¥ Start the engine. and rotation sensor. sensor.
¥ Increase the engine
¥ speed to 600rpm, set the
gear to the neutral posi-
tion and engage the clutch
and check for the pulse
waveform between the
terminal B259-2 and
B259-12.
Is a standard value indica-
ted?
Yes No
Faulty transmission
HSA the clutch disc been excessive rotation sensor gap,
fully worn away? ( damaged gear )
Repair the transmission.
Yes No
Trouble occurring
Replace the clutch disc.
intermittently.

Accelerator pedal idle switch or
CFS : 13 HSA : -
accelerator position sensor (APS) signal error
• Faulty idle switch

• Disconnected wire or short circuit of wiring harness between the control unit and idle
switch
• Improper adjustment of idle switch
• Faulty ECM or APS
• Disconnected wire or short circuit between ECM and APS
Control is continued by replacing the engine rotation with the idle switch signal but after
being changed to Clutch Free OFF, the Clutch Free System control is discontinued.
Conditions on vehicle when trouble occurs Feeling when the vehicle starts in the Clutch Free mode gets worse.
B288 0.5 Yellow/red B280

3 3
Acceleration position B259 0.5 Blue/red B286 0.5 Green/orange
sensor signal
input 6 15 11 2
0.5 White/red 0.5 Yellow/black
10 6 1
0.5 0.5
Idle switch B260 White/red B75 B75 Black
signal input 14 Engine control Acceleration
1 2 position sensor
module (ECM)
Idle switch (APS)
B257 0.85 Black

Earth
13
B259 0.5 Black
Sensor earth
4
CFS control unit


Accelerator pedal idle switch or
CFS : 13 HSA : -
accelerator position sensor (APS) signal error
Standard value
• Turn OFF the IGN and remove the control unit. Continuity
• Remove the control unit connector and install the signal Accelerator pedal free (idle):
check board to the wiring harness connector. Continuity indicated.
• Check for continuity between the terminal B 260-14 and Accelerator pedal pressed (accelerator ON):
earth terminal B257-13. No continuity indicated
ECM output
When changing over the idle switch ON to OFF
0.41-0.71V
Yes No
• Connect the signal check board to the

Check the continuity on the idle switch
control unit.
connector.
• Turn ON the IGN.
• Change over the idle switch from ON to
OFF and check the ECM output at the
terminal B259-6 and sensor earth B259-4.
Yes No Yes No
Check the trouble code 21 Check the continuity of a

Correct the idle switch Repair the wiring harness
accelerator position sensor single unit of idle switch.
installing position. between the control unit
signal for abnormality. Is the result as follows?
and idle switch.
With the switch pushed:
Continuity indicated.
With the switch free:
No continuity indicated.
Yes No
Correct the idle

switch installing Replace the idle switch.
CFS : 14 HSA : - Clutch actuator solenoid valve 1 signal error
• Faulty actuator solenoid valve 1

• Disconnected wire or short circuit of wiring harness of actuator solenoid valve 1
• Leakage or insufficient air bleeding from hydraulic piping
Major causes of failure • Faulty clutch stroke sensor
• Unsuccessful learning of Clutch Free clutch torque point position learning
• Faulty clutch pressure plate, release bearing or shift fork
Alarm lamp Clutch Free CHECK lamp blinking.
Alarm buzzer Works only when the Clutch Free is ON or HSA ON.
Control after detection of trouble Clutch position is held and the Clutch Free System control is discontinued.
Conditions on vehicle when trouble occurs Clutch Free System does not work.
B260 0.5 White/ blue B89 B89 0.5 Black/orange No.16

Clutch switch 0.85 Black/orange
signal input 10 2 1
15Ａ
Clutch switch
Ignition B258 No.20 3 Black/yellow

0.5 Black/orange Starter
power input 7 switch
10Ａ
Actuator B257 H46 J137 J137 0.5 Yellow/red

0.5 Gray 0.5 Gray
solenoid valve 1
1 4 1 2
signal input
Actuator solenoid valve
1.25 Yellow/red H17 1.25 Yellow/red 2

Actuator power input Joint 5
3 1 4
5
3 Yellow/red
CFS control unit
Actuator motor
(B136-1)
CFS : 14 HSA : - Clutch actuator solenoid valve 1 signal error
Standard value
Is the clutch stroke sensor normal? Actuator solenoid valve 1 resistance value
6-20Ω
Clutch switch continuity
With the clutch pedal depressed:
Yes No No continuity indicated

With the clutch pedal released:
Continuity indicated.
¥ Turn OFF the IGN and remove the control unit.

Inspect the clutch stroke
¥ Remove the control unit connector and measure the
sensor
resistance value between the wiring harness connector
(trouble code 08)
terminal B257-3 and B257-1.
Yes No
Check the continuity between the wiring Measure the resistance between actuator
harness connector terminal B260-10 and connector terminal J137-1 and J137-2.
B258-7 of the clutch pedal switch. Is a standard value indicated?
Yes No Yes No
Isn't a leak in the clutch Check for continuity on the

Repair the wiring harness Repair the solenoid valve 1
hydraulic piping and HSA clutch pedal switch
between the control unit Faulty actuator.
the air bleeding been connector.
and actuator.
properly completed? Is the result a standard
value?
Yes No
Check for continuity of a

Repair the wiring harness single unit of clutch pedal
between the control unit switch.
and clutch pedal switch. Is the result a standard
value?
Yes No Yes No
Has the learning of the

Repair the piping. Adjust the clutch pedal Replace the clutch pedal
Clutch Free clutch torque
Discharge the air. switch installing position. switch.
point position been
successfully completed?
Yes No
Perform the learning of

Trouble occurring
intermittently.
point position.
CFS : 16 HSA : - Incorrect gear control lever select stroke learning value
• Improper learning process of gear shift and select stroke

• Faulty select stroke sensor

Control after detection of trouble Clutch position is held and the Clutch Free System control is discontinued.
Conditions on vehicle when trouble occurs Clutch Free does not work.
H46 J141
Select stroke sensor B259 0.5 Red 0.5 Red
Select stroke 0.5 White 0.5 White

Select stroke 0.5 Black 0.5 Black

0.5 Black 0.5 Black 0.5 Black/green Select stroke sensor

Earth 4 9 1 10
B268
CFS control unit Joint connector
CFS : 16 HSA : - Incorrect gear control lever select stroke learning value
Standard value
¥ Connect the TECH2, turn ON the IGN and read the voltage of "Select stroke
Clutch stroke sensor signal:
sensor signal".
01-4.8V
¥ When the gear control lever is pulled fully in the left or right direction, is the
voltage changed within the standard values?
(Instead of connecting the TECH2, the following procedure is permissible:
connect the signal check board between the control unit and vehicle side wiring
harness. Turn ON the IGN and measure the voltage between the terminal
B259-8 and B259-17).
Yes No
Perform learning of gear shift and

Check the trouble code 31 (select
select stroke.
stroke sensor).
Is the learning value becomes correct?
Yes No
Complete Replace the control unit.

CFS : 17 HSA : - Incorrect actuator hydraulic switch learning value
• Improper learning process for Clutch Free clutch torque point position
• Leak and insufficient air bleeding from hydraulic piping
• Faulty clutch stroke sensor

Control after detection of trouble Clutch position is held and Clutch Free System control is discontinued.
CFS : 17 HSA : - Incorrect actuator hydraulic switch learning value
Has sufficient quantity of oil been

supplied to and air discharged from the
clutch hydraulic piping?
Yes No
Are the clutch stroke sensor trouble code Supply oil and air
(CFS) 08 and hydraulic switch trouble code bleeding.
(CFS) 86 recorded?
Yes No
When the Clutch Free is

Check the trouble code
OFF, can the vehicle be
(CFS) 08 and (CFS) 86.
started with the 2nd gear?
Yes No
When the Clutch Free is HSA the clutch disc

ON, can the vehicle be fully worn out?
started with the 2nd gear?
Yes No Yes No
Erase the trouble code Perform the clutch Perform the clutch
and perform a test run. torque point position Replace the clutch disc. torque point position
Is the trouble code 17 learning. learning.
recorded?
Yes No
Trouble occurring
Replace the control unit.
intermittently.
CFS : 19 HSA : 19 HSA/CFS ADJUST switch signal error
• Faulty HSA/CFS ADJUST switch

• Short circuit of HSA/CFS ADJUST switch wiring harness
CFS - Clutch Free CHECK lamp blinking.

Alarm lamp
Alarm buzzer CFS - Works only when the Clutch Free is ON or HSA is ON.
CFS - Usual control
HSA - Not works.
HSA does not work and HSA release point gets out of position.
Feeling when the vehicle starts in the Clutch Free mode is changed.
Adjust switch B260 0.3 Gray/black B106

signal input 2 1
(FAST) B106 0.5 Black/orange
3
Adjust switch 0.3 Gray/red
signal input 11 2
(SLOW) 0.5 Black/
HSA/CFS
orange
ADJUST switch
Ignition
B258 0.5 Black/orange 0.5 Black/orange
power input
7
No.20
CFS control unit 10A
Starter switch
(B67-3)
CFS : 19 HSA : 19 HSA/CFS ADJUST switch signal error
Standard value
• Turn OFF the IGN and remove the control unit. Continuity
• Remove the control unit connector and check for continuity sually: No continuity
between the wiring harness connector terminal B260-2 and When switch is operated:
B258-7 (FAST side) and between B260-11 and B258-7 Continuity indicated (operation side only)
(SLOW side).
Is continuity indicated in both positions when operating the
switch ?
Yes No
Check for continuity between the connector

terminal B106-1 and B106-3 (FAST side) Trouble occurring intermittently.
and between B106-2 and B106-3 (SLOW
side) for a single unit of HSA/CFS ADJUST
switch.
When operating the switch, is continuity
indicated at both positions?
Yes No
Repair the wiring harness between the

Replace the HSA/CFS ADJUST switch.
control unit and HSA/CFS ADJUST switch.
CFS : 21 HSA : - Accelerator position sensor (APS) signal error
• Faulty accelerator position sensor (APS)

• Disconnected wire or short circuit of APS wiring harness
Major causes of failure • APS getting out of fixed position
• Improperly adjusted pedal stopper
• Faulty ECM
Alarm buzzer Works only CFS is ON or HSA is ON.
APS signal is replaced with idle SW signal and control is continued but, after the Clutch
Free is changed to OFF, CFS control is discontinued.
Conditions on vehicle when trouble occurs After the vehicle is started in the Clutch Free mode, the feeling gets worse.
B288 0.5 Yellow/red B280

3 3
Accelerator position B259 0.5 Blue/red B286 0.5 Black/orange

sensor signal input 6 15 11 2
1.25 Black 0.5 Yellow/black

11 6 1
0.5 Black
Sensor earth
4 Accelerator position
Engine control
module (ECM) sensor (APS)
CFS control unit

CFS : 21 HSA : - Accelerator position sensor (APS) signal error
Standard value
• Turn OFF the IGN and remove the control unit connector. Accelerator position sensor output
• Install the signal check board between the control unit and (voltage)
connector. Power source voltage : 5V
• Turn OFF the engine and turn ON the IGN. Idling : 4.4 - 4.6V
• Measure the voltage between the terminal B259-6 and B259-4. Full throttle : 0.4 - 0.6V
Is the measured value a standard value?
Note: Measure the voltage value
with analog voltmeter.
Yes No
• Turn OFF the engine and turn ON

• Depress the accelerator pedal fully. the IGN.
Is a standard voltage value • Measure the voltage between the
ECM connector terminal B286-15
and earth terminal B286-11.
Is a standard voltage value
No
indicated?
Yes
Yes No
Trouble occurring intermittently.

• Depress the accelerator pedal fully.
Is a standard voltage indicated?
No
Yes
Faulty wiring harness between the • Remove the APS wiring harness
control unit and ECM or Faulty connector.
control unit • Measure the supply power voltage
between the connector terminal B280-1
and B280-3.
Is a voltage of 5V indicated?
Yes No
Check the APS connector and if Check the wiring harness between
there is no trouble, replace the APS. APS and ECM and if there is no
trouble, replace the ECM.
CFS : 23 HSA : - Faulty control unit power source system
• Dropped battery voltage

• Fuse blown
• Faulty CFS relay
• Faulty CFS relay wiring harness
Alarm lamp Clutch Free CHECK lamp blinks.
CFS relay B258 0.5 Red/yellow H46 0.5 Red/yellow X24 X24 0.5 White/green 1.25 White/green H4 1.25 White/green
signal input 11 3 5 4 4 No.1
10A
B257 1.25Yellow/red H17 1.25 Yellow/red 3 Yellow/red 3 Yellow/black
CFS
3 1 4 8 3 2
power source 4 H7
CFS relay 3 White/
green
Joint connector
B268 ACL ECM 50Ａ
0.85 Black 0.85 Black
Earth
13
7 5 40Ａ
CFS control unit
Battery
CFS : 23 HSA : - Faulty control unit power source system
Standard value
Battery power source voltage:

Is the battery power source voltage a standard value? Approx. 24V (with IGN ON)
Yes No
• Turn OFF the IGN and remove the control unit.

• Install the signal check board to the wiring harness Check the battery.
connector.
• Check for the voltage between the terminal B258-11 and
B257-13.
Is a voltage detected?
Yes No
Is the CFS relay normal? Is the fuse (10A and 50A) normal?
Yes No Yes No
Is the fuse (40A) normal? Replace the CFS relay. Is the CFS relay normal? Replace the fuse.
Yes No Yes No
• Connect the signal

Repair the wiring harness
check board to the Replace the fuse (40A). Replace the CFS relay.
between the control unit
control unit.
and CFS relay.
• Turn ON the IGN.
• Measure the voltage
between the terminal
B257-3 and B257-13.
Is a standard value
indicated?
Yes No
Is the image reproduced? Repair the wiring harness.
Yes No
Trouble occurring
Replace the control unit. intermittently.
CFS : - HSA : 25 Vehicle speed sensor output signal error
• Faulty vehicle speed sensor

• Disconnected wire or short circuit of vehicle speed sensor wiring harness
• Faulty speed meter gear
Alarm lamp HSA lamp blinks only when HSA is ON.

Alarm buzzer Not works.
Control after detection of trouble CFS - Controls as usual.
HSA - Not works.
Conditions on vehicle when trouble occurs HSA does not work.
Meter Starter switch
(B52-17) (B67-3)
No.19
J32
0.5 Black/yellow
1
15A
Vehicle H5
B259 0.3 Yellow/green 0.5 Yellow/green 0.5 Yellow/green
speed sensor
3 25 3
signal input
0.5 Black/blue
32 2
0.5 Black/blue
Earth
13
Vehicle speed sensor
CFS control unit

CFS : - HSA : 25 Vehicle speed sensor output signal error
Standard value
Output signal
Does the speed meter operate correctly
14±2V
according to the vehicle speed?
2±1V
Yes No
¥ Turn OFF the IGN and remove the control Check the following components according
unit. to the instructions on the speed meter?
¥ Install a signal check board between the ¥ Speed sensor
control unit and connector. ¥ Speed meter
¥ Turn ON the IGN and start the engine. ¥ Wiring harness
¥ Measure the voltage between the ¥ Speed meter gear
terminal B259-3 and earth B259-13 while
moving the vehicle very slowly.
Is a standard output voltage indicated?
Yes No
Trouble occurring intermittently Check and repair the wiring harness.

CFS : 31 HSA : - Gear control select stroke sensor signal error
• Faulty select stroke sensor

• Disconnected wire or short circuit of select stroke sensor wiring harness.
• Select stroke sensor gets out of fixing position, deformed bracket, work link pin
• Unsuccessful Clutch Free select stroke learning
Control after detection of trouble Control with backup map.
Conditions on vehicle when trouble occurs Slippery clutch is felt when the vehicle starts in the Clutch Free mode.
H46 J141
Select stroke sensor B259 0.5 Red 0.5 Red
Select stroke 0.5 White 0.5 White

Select stroke 0.5 Black 0.5 Black

0.5 Black 0.5 Black 0.5 Black/green Select stroke sensor

Earth 4 9 1 10
B268
CFS control unit Joint connector
CFS : 31 HSA : - Gear control select stroke sensor signal error
Standard value
¥ Connect the TECH2, turn ON the IGN, and read the "Select stroke sensor Select stroke sensor signal:
signal" voltage. 0.1-4.8V
¥ When the gear control lever is moved fully in the right and left directions, does
the voltage change within the range of standard values?
(Instead of connecting the TECH2, the following procedure is allowable:
Connect the signal check board between the control unit and vehicle side
wiring harness. Turn ON the IGN and measure the voltage between the
terminal B259-8 and B259-17.)
Yes No
Check the select stroke sensor for Remove the control unit connector (B259)
loosened fixing, getting out of position, and sensor connector (J141) and check that
or deformation of the bracket or link. continuity of the vehicle wiring harness is
Is there any abnormality? correct.
Is there any abnormality?
Vcc : B259-10/J141-1
SIG : B259-8/J141-2
GND : B259-17/J141-3
Yes No Yes No
Correct loosened fixing, Trouble occurring Replace the sensor. Repair the wiring harness.
getting out of position, intermittently
deformation of the
bracket or link.
CFS : 32 HSA : - Gear control shift stroke sensor signal error

• Disconnected wire or short circuit of shift stroke sensor wiring harness
Major causes of failure • Fixing point of shift stroke sensor getting out of position, deformed bracket, worn link pin
• Unsuccessful learning of Clutch Free shift stroke

Alarm buzzer Works only the Clutch Free is ON or HSA is ON.
Shift stroke sensor B259 0.5 Red H46 0.5 Red J142
Shift stroke 0.5 White 0.5 White

Shift stroke 0.5 Black 0.5 Black

0.5 Black 0.5 Black 0.5 Black/blue Shift stroke sensor

Earth 4 14
B268
CFS control unit Joint
connector
CFS : 32 HSA : - Gear control shift stroke sensor signal error
Standard value
¥ Connect the TEC2, turn ON the IGN, and read the "Shift stroke sensor signal" Shift stroke sensor signal:
voltage. 0.1-4.8V
¥ When the gear control lever is moved fully to the 2nd, 4th and 6th gear side,
and then fully to the 1st, 3rd and 5th gear side, does the voltage change within
the standard values?
(Instead of connecting the TEC2, the following procedure is allowed:
Connect the signal check board between the control unit and vehicle side wir-
ing harness. Turn ON the IGN and measure the voltage between the terminal
B259-7 and B259-16.)
Yes No
Check the shift stroke sensor for Remove the control unit connector (B259)
loosened fixing, getting out of position, and sensor connector (J142) and check if
or deformation of the bracket or link. the continuity of the vehicle wiring harness
Is there any abnormality? is normal.
Is there any abnormality?
Vcc : B259-19/J142-3
SIG : B259-7/J142-2
GND : B259-16/J142-1
Yes No Yes No
Correct the loosened Trouble occurring Repair the wiring

Replace the sensor.
fixing, getting out of intermittently harness.
position, or deformation
of the bracket or link.
CFS : 33 HSA : 33 Faulty control unit
Faulty control unit
CFS - Clutch Free CHECK lamp blinks.

Alarm lamp
HSA - HSA lamp blinks.
CFS - Works only when the Clutch Free is ON.
Alarm buzzer
HSA - Works only when HSA is ON.
CFS - Clutch position is held and Clutch Free System control is discontinued.
HSA - Not works.
Conditions on vehicle when trouble occurs CFS and HSA do not work.
Turn ON the IGN. Is the trouble

reproduced?
Yes No
• Erase the trouble code and

Replace the control unit. perform a test run.
Is the trouble reproduced?
Yes No
Replace the control unit. Trouble occurring intermittently.

MEMO
CFS : 34 HSA : - Shift knob switch circuit GND short circuit
• Faulty shift knob switch

• Shift knob switch wiring harness GND short circuit

Control after detection of trouble Usually, Clutch Free control is continued but the Clutch Free control is disconnected after
the Clutch Free is turned OFF.
Conditions on vehicle when trouble occurs Clutch is not engaged when gear is shifted to either the front side (2nd, 4th, 6th, Rev.) or
rear side (1st, 3rd, 5th).
Shift knob switch B260 0.3 Red/black H12 0.3 Red/black N12
signal input 13 7 3
(1,3,5) N12 0.3 Black 0.5 Black H12
2 9
Shift knob switch 0.3 Bluish violet 0.3 Bluish violet
signal input 5 1 1
(2,4,6,R)
Shift knob switch
B257 0.85 Black 0.85 Black 3 Black

CFS GND 1
13 7 5
B268
Joint
connector
CFS control unit
CFS : 34 HSA : - Shift knob switch circuit GND short circuit
Standard value
• Turn OFF the IGN and remove the control unit. Switch: Usually opened.
• Remove the control unit connector and check for continuity Closed when shifting.
between the wiring harness and connector terminal B260-13 Switch operating load:
and B257-13, and between the terminal B260-5 and B257-13. 12.7N (1.3kgf) - 24.5N (2.5kgf)
Is continuity indicated without operating the switch?
Yes No
Check for continuity of the independent shift

knob switch between the terminal N12-1 and Check for operating load of the
N12-2 and between the terminal N12-3 and shift knob switch.
N12-2. Is the load a standard value?
Is continuity indicated without operating the
switch?
Yes No Yes No
Repair the GND short

circuit of the wiring Trouble occurring Replace the shift knob
Replace the shift knob
harness between the intermittently switch.
switch.
control unit and shift knob
switch.
CFS : 35 HSA : - Disconnected wire of shift knob switch circuit
• Faulty shift knob switch

• Disconnected wire of shift knob switch wiring harness

Control after detection of trouble Normal control
Conditions on vehicle when trouble occurs Gears cannot be shifted to either the front side (2nd, 4th, 6th, Rev.) or rear side (1st, 3rd,
5th). After shifting gears several times, the trouble recurs.
Shift knob switch B260 0.3 Red/black H12 0.3 Red/black N12
signal input 13 7 3
(1,3,5) N12 0.3 Black 0.5 Black H12
2 9
Shift knob switch 0.3 Bluish violet 0.3 Bluish violet
signal input 5 1 1
(2,4,6,R)
Shift knob switch
B257 0.85 Black 0.85 Black 3 Black

CFS GND 1
13 7 5
B268
Joint
connector
CFS control unit
CFS : 35 HSA : - Disconnected wire of shift knob switch circuit
Standard value
Is the shift stroke sensor normal? Switch: Usually opened.

Closed when shifting gears.
Switch operating load:
12.7N (1.3kgf) - 24.5N (2.5kgf)
No
Yes
• Turn OFF the IGN and remove the control unit.

Check the shift stroke
• Remove the control unit connector. Check for continuity
sensor
between the wiring harness connector terminal B260-5
(trouble code 32)
and B257-13 pushing the shift knob switch against the
front side (2nd, 4th, 6th, Rev.) or between the wiring
harness connector terminal B260-13 and B257-13
pushing the shift knob switch against the rear side (1st,
3rd, 5th) respectively.
Is continuity indicated?
Yes No
• For the separate shift knob switch, check for

Check for operating load of the shift knob continuity between the terminal N12-1 and
switch. N12-2 pushing the shift knob switch to the
Is the load a standard value? front side (2nd, 4th, 6th, Rev.) and between
the terminal N12-3 and N12-2 pushing the
shift knob switch against the rear side (1st,
3rd, 5th) respectively.
Is continuity indicated?
Yes No Yes No

Trouble occurring Replace the shift knob between the control unit Replace the shift knob
intermittently switch. and shift knob switch. switch.
CFS : 37 HSA : - Trouble in actuator motor; continuous operation
• Faulty actuator motor

• Disconnected wire or short circuit of actuator motor wiring harness
Major causes of failure • Leakage or insufficient air bleeding from hydraulic piping
• Faulty clutch stroke sensor
• Unsuccessful learning of Clutch Free clutch torque point position
Control after detection of trouble Hold the clutch position and discontinue the Clutch Free System control.
Clutch Free does not work. After gears are shifted, abnormal sound is generated from the
actuator for several seconds and the trouble recurs.
CFS relay
3 Yellow/red
Actuator motor B257 1.25 Yellow H17 1.25 Yellow/red 3 Yellow/red J136
power source 6 15 3 5 1
Joint 5
M
Actuator 1.15 Black/White H46 1.25 Black/White 3 Black/White
motor earth 7 1 4 5 2
Joint 6
Actuator motor
CFS control unit

CFS : 37 HSA : - Trouble in actuator motor; continuous operation
Standard value
Is the clutch stroke sensor normal? Actuator motor

resistance value = 0.1-10½
Note: Since the actuator motor

No
Yes resistance value is low, be sure to
adjust the zero point before the
measurement.
¥ Turn OFF the IGN and remove the control unit.

Check the clutch stroke
¥ Remove the control unit connector and measure the
sensor.
resistance value between the wiring harness connector
(Trouble code 08)
terminal B257-6 and B257-7.
Is a standard value is indicated?
Yes No
¥ Apply voltage of 24V to the terminal J136-1 ¥ Measure the resistance value between the
and J136-2 of the independent actuator terminal J136-1 and J136-2 of the
motor. independent actuator motor.
Does the motor rotate? Is a standard value indicated?
Yes No Yes No
Is there leakage from

Check and repair the Replace the actuator
the hydraulic piping, or
between the control unit
actuator motor. motor.
is the air bleeding not
and actuator motor.
enough?
Yes No
Has the learning of the

Repair the piping or Clutch Free clutch torque
discharge the air. point position been
successfully completed?
Yes No
Perform learning of
Replace the control unit. Clutch Free clutch
torque point position.
CFS : 41 HSA : - Engine revolution sensor signal error
• Faulty engine revolution sensor

• Disconnected wire or short circuit of the engine revolution sensor wiring harness
Major causes of failure • Full wear of clutch disc
• Improperly installed engine revolution sensor
• Disconnected wire or short circuit of the wiring harness between the control unit and ECM
• Faulty ECM
Alarm buzzer Works only the Clutch Free is ON or HSA is ON.
Control after detection of trouble Controls at the engine speed of 0 rpm (for the Rev. 1st and 2nd gear only).
Conditions on vehicle when trouble occurs When starting the vehicle in the Clutch Free system, the clutch is slippery.
Meter
(B52-8)
0.5 0.5 0.5
B287 H4 H72 E98
Blue Blue/red Blue/red
0.5 12 10 13 1
Light
B259 B287
Engine revolution green
sensor signal 10 0.5 0.5 0.5
1
Green Blue/white Blue/white
6 1 H14 10 2
1.25 black B286
11 2 13
Engine control module Engine revolution sensor

(ECM)
Clutch stroke sensor 0.5 Red H46 0.5 Red J140


sensor signal (SIG)
5 20 2
Clutch stroke
0.5 Green 0.5 Green
sensor earth (GND)
14 21 3
Earth (GND) 0.5 Black 0.85 Black

4 9 5
B268 3 Black
Joint
connector
CFS control unit Clutch stroke sensor
CFS : 41 HSA : - Engine revolution sensor signal error
Standard value
Oscilloscope waveform
21 - 25ms
¥ Turn OFF the IGN and remove the control unit. At idling 24V
¥ Install the signal check board between the control unit and 0V
connector.
¥ Turn ON the IGN and start the engine.
7.4 - 7.6ms
¥ Measure the pulse between the terminal B259-1 and earth At 2000rpm 24V
terminal B259-4.
0V
Yes No
¥ Measure the pulse between the ECM

terminal B287-10 and earth terminal
HSA the clutch disc fully worn out?
B286-11.
Yes No Yes No
Isn't a clutch stroke sensor Faulty wiring harness Measure the signal
signal error trouble code between the control unit between the ECM terminal
(CFS) 08 recorded? and ECM or Faulty control B287-12 and B287-6.
unit Is a standard value
indicated? Refer to the
engine repair manual.
Yes No Yes No
Check the clutch stroke Faulty wiring harness

Trouble
断続的に発生するoccurring sensor signal error trouble between ECM and engine
Faulty ECM
intermittently
トラブル code (CFS) 08. revolution sensor or faulty
engine revolution sensor
CFS : 86 HSA : 86 Actuator hydraulic switch signal error
• Faulty actuator hydraulic switch

• Disconnected wire or short circuit of the actuator hydraulic switch wiring harness
Major causes of failure • Insufficient air bleeding or oil leakage from hydraulic piping
• "Torque point position learning" has not been performed or has not been correctly
completed.
CFS - Clutch Free CHECK lamp blinks.
Alarm lamp
Alarm buzzer Does not work.
CFS - Control is continued with the value learned immediately before the failure was
Control after detection of trouble detected.
HSA - Normal control
Failure recurs after clutch is engaged for 10 minutes or clutch is disengaged for 5 minutes
continuously.
Clutch pressure B260 0.3 Sky blue H46 0.5 Sky blue J138 J138 0.5 Black/orange H17 No.20
Starter
switch input 15 5 1 2 14 switch
10A
Clutch pressure (B67-3)
switch
Ignition power B258 0.5 Black/orange

source input 7
CFS control unit

CFS : 86 HSA : 86 Actuator hydraulic switch signal error
Standard value
With pedal depressed:
Is the play of the clutch pedal proper? Switch ON (battery voltage)

With pedal released:
Switch OFF (0V)
Yes No
¥ Connect the TECH2, turn OFF the CFS, turn ON the IGN
Adjust the clutch pedal
and read the ON/OFF value? of the "Clutch hydraulic switch
play.
signal".
¥ Is the switch turned ON when the pedal is depressed and
turned OFF when the foot is removed from the pedal?
(Instead of connecting the TECH2, following procedure is
permitted:
Connect the signal check board between the control unit and
vehicle side wiring harness. Turn ON the IGN and measure
the voltage between the terminal B260-15 and B258-7.)
Yes No
Check for continuity between the terminal

HSA the air bleeding of the hydraulic J138-1 and J138-2 of a single unit of
piping been properly completed? actuator hydraulic switch.
Yes No Yes No
Has the Clutch Free

clutch torque point Replace the actuator
Air bleeding. Repair the wiring harness.
position learning been hydraulic switch.
correctly completed?
Yes No
Perform learning of the

Trouble occurring
intermittently
point position learning.
Note: If the "Torque point position learning" was discontinued midway or has not been performed, clutch
disengaged condition (= hydraulic switch ON) may be maintained. If this condition is left, the
trouble code 86 may be recorded. It is solved by performing the "Torque point position learning".
CFS : - HSA : 91 HSA valve signal error
• Faulty HSA valve

• Disconnected wire or short circuit of the HSA valve wiring harness
Alarm lamp HSA lamp blinks only when the HSA is ON.
Alarm buzzer Works only when HSA is ON.
Control after detection of trouble HSA control does not work.
Conditions on vehicle when trouble occurs HSA does not work.
HSA M/V1
B258 0.5 Light green/red H5 0.5Light green/red J155 J155
HSA M/V1 input
6 20 3 4
0.5
Light green
0.5 Light green/black 0.5 Light green/black
HSA M/V2 input
12 21 1 2
M/V2
19 H5
0.5 Light green
HSA OFF switch
input 1
0.5
Light green
B318
Fuse 0.5 Black/orange B318 7
No.20 10A 8
B257 0.85黒 Meter HSA 0.3 Light green/black
Earth OFF lamp
13 (B51-19) 4
3
Front 0.3 Light green/red 0.3 Black
combination 6 2
lamp
CFS control unit HSA OFF switch

CFS : - HSA : 91 HSA valve signal error
Standard value
• Turn OFF the IGN and remove the control unit. Resistance value = 40 - 70Ω
• Install the signal check board to the wiring harness Voltage:
connector. With the HSA OFF switch ON ( ):
• Turn OFF the HSA. (Push the HSA OFF switch.) 20V or more
• Measure the resistance value between the wiring harness With HSA OFF switch OFF ( ):
connector terminal B258-6 and B258-1 and between B258- 0V
12 and B258-1.
Does the resistance value indicate a standard value?
Yes No
• Connect the signal check board to the Measure the independent resistance of the
control unit. solenoid valve.
• Turn ON the IGN. Between J155-3 and 155-4
• Turn ON and OFF the HSA OFF switch. Between J155-1 and J155-2
• Measure the voltage between the terminal Does each resistance value indicate a standard
B258-6 and B257-13 and between B258- value?
12 and B257-13.
Does the voltage value indicate a
standard value?
Yes No Yes No
Trouble occurring Repair the wiring harness Repair the wiring Replace or repair the
intermittently. or the HSA OFF switch. harness. HSA valve
Failure Diagnosis Based on Vehicle Conditions

If the CHECK lamp or HSA lamp indicates no system fault, failure diagnosis should be based on the diagnosis based on
questions and answers with a client or test run to distinguish the defect and perform failure diagnosis.
A. Condition related with Clutch Free
Chart Failure condition Major cause

• Disconnected wire of valve of the Clutch Free
When ON or OFF is selected with the Clutch Free switch, the
A1 ON/OFF lamp
Clutch Free ON or OFF lamp does not light up.
• Failed control unit
When ON is selected with the Clutch Free switch, the Clutch Free • Failed Clutch Free switch
A2
control is not performed. • System is suspended because of failure diagnosis.
When OFF is selected with the Clutch Free switch, the Clutch • Failed Clutch Free switch
A3
Free control works not to permit the manual clutch operation. • Clutch Free ON is being changed over to OFF.
When gear shift is attempted with the Clutch Free ON, the clutch • Failed shift knob switch
A4
is not disengaged and the gear is not engaged, or not • System is suspended because of failure diagnosis
disengaged.
• Failed shift knob switch
A5 When starting the vehicle is attempted with the Clutch Free ON, • Failed or improperly adjusted idle switch
the clutch is not engaged or the vehicle cannot be start. • System is being suspended because of failure diagnosis
• PTO signal error
When the manual clutch is operated with the Clutch Free OFF • Insufficiently depressed clutch pedal
A6 and starting of the vehicle is attempted, the clutch is not engaged
and the vehicle cannot be started.
When the starter switch is turned ON, the starter motor does not • Failed neutral switch
A7
rotate.
• Insufficient exhaust brake cut output
Exhaust brake does not work or is kept applied even under
A8 • Failed control unit
conditions to be released.
• Failed engine control system
• HSA/CFS adjust switch operated on the outside of
the adjustment range.
• Failed door switch
• Failed parking brake switch
Alarm buzzer (beeping repeatedly or once) sounds often or does
A9 • Failed clutch pedal switch
not sound when requirements are met.
• Failed PTO switch
• Worn clutch disc
• Unsuccessful learning of gear shift and select stroke
• System suspended because of failure diagnosis
• Unsuccessful learning of Clutch Free clutch torque
Clutch engaging feeling gets worse when the clutch is half-
A10 point position
engaged or the feeling is not as desired.
• Failed diagnosis connector
• When the starter switch is turned ON, the Clutch Free CHECK
lamp constantly blinks.
A11 • Unsuccessful learning of clutch position where use
• Only when the vehicle stops with the gear engaged, the Clutch
of a new clutch disc is started.
Free CHECK lamp lights up.
• System in suspension because of failure diagnosis
B. Condition related with HSA
Chart Failure condition Major cause

• Parking brake signal error
• HSA does not work.
B1 • Brake lamp signal error
• HSA lamp does not light up (HSA does not work).
• Faulty control unit
B2 HSA cannot be released by pushing the HSA OFF switch. • Faulty HSA OFF switch
• Faulty neutral switch
B3 HSA cannot be released by vehicle starting procedure.
• Improper release point adjustment
B4 HSA cannot be released by pulling the parking brake lever. • Parking brake signal error
• Failed HSA lamp bulb.
B5 HSA lamp does not light up (HSA works)
• Failed control unit.
B6 HSA lamp does not extinguish (HSA is released) • Failed control unit.
When HSA is working, the alarm buzzer does not sound even
B7 • Failed door switch.
when the door is opened.
At the time of self diagnosis, the HSA lamp blinks abnormally but
B8 • Failed parking brake switch
no trouble code is output.
At the time of self diagnosis, the alarm buzzer continues to sound • Alarm sounds for a long time.
B9
(trouble code cannot be output). • Alarm to indicate start is actuated.
Chart A1: When ON or OFF is selected with the Clutch Free switch, the Clutch Free ON or OFF lamp does
not light up.
HSA the initial learning No

been completed? Perform the initial learning.
Yes
This is not a trouble.

Isn't the ON and OFF
No Meet the change-over
of the Clutch Free
requirements.
System being changed over?
• Gear at the neutral position.
• Clutch pedal released.
Yes
Function has stopped due to

Has the Clutch Free CHECK No failed system.
lamp been extinguished? Check for the trouble code
and perform the inspection
based on the trouble code.
Yes
When the starter switch is

turned ON, do the Clutch No Are the fuse No.1, No.19 and No Replace
Free ON and OFF lamps light No.20 normal? the fuse.
up for 2 seconds?
Yes
Yes
Are the Clutch Free ON and No Replace

Is the Clutch Free switch
Replace OFF lamp bulbs normal? the bulb.
normal? No
the Clutch Free
The Clutch Free switch
switch. Yes
should be turned OFF
by pushing it in.

Yes
No
Is the fuse No.20 normal? Replace the fuse.
Yes
Turn OFF the starter

switch once, and turn it Trouble occurring
ON again 10 seconds intermittently
later. Does the condition No
continue?
Yes

Chart A2: When ON is selected with the Clutch Free switch, the Clutch Free control is not performed.
HSA the initial learning No Perform the learning

been completed? process.
Yes
Does the ON lamp light Clutch Free SW related

up when the Clutch Free No trouble can be
switch is turned ON? supposed. Check as
Does the OFF lamp light shown in Chart A1.
up when the switch is
turned OFF (pushed)?
Yes
Has the Clutch Free Function is in suspension

CHECK lamp been No due to system failure.
extinguished? Isn't there Check the trouble code and
trouble code recorded? perform inspections based
on the trouble code.
Yes

turned ON, can the gear be No Check according to the
shifted to the running gear chart A4.
speed without stepping the
clutch pedal?
Yes
Turn OFF the starter switch

once and turn it ON again No Trouble occurring
10 seconds later. Does the intermittently
condition continue?
Yes

Chart A3: When OFF is selected with the Clutch Free switch, the Clutch Free control works not to permit the
manual clutch operation.

Yes
Have the requirements for This is not a trouble.

changing over the Clutch No Meet the following requirement
Free ON and OFF been for change over.
met? Gear: Neutral
Clutch pedal: Released.
Yes
Does the OFF lamp light up Clutch Free switch related

No
when the Clutch Free switch failure can be supposed.
is turned OFF (pushed)? Check as described in A1.
Yes

once and then turn it ON No
Trouble occurring intermittently
again 10 seconds later.
Does the condition continue?
Yes

Chart A4: When gear shift is attempted with the Clutch Free ON, the clutch is not disengaged and the gear is
not engaged or not disengaged

Yes
Has the Clutch Free CHECK Check for the "Function is in

lamp been extinguished? No suspension due to system
Isn't a trouble code failure" trouble code and
recorded? check based on the trouble
code.
Yes
Clutch Free switch related

When the Clutch Free switch No trouble:
is turned ON, does the ON Perform the check according
lamp light up? to the chart A1.
Yes
Does the condition occur

No Was the oil supplied to the No
only when the starter switch Supply oil and discharge
hydraulic tube and air
is turned ON, and the engine the air.
discharged properly from it?
is stopped?
Yes Yes
Not a trouble. Is the hydraulic piping Correct the piping correction

From the starter switch ON to connected correctly, does no No
and oil leakage, check for the
start of engine, only the oil leak, and is the oil level in oil level in the reserve tank.
change lever is operated and the reserve tank proper?
the clutch is not disengaged.
Yes

turned OFF and the clutch is No Turn OFF the starter switch
operated manually, does the once and turn it ON again 10
same condition occur? seconds later. Does the
No
same condition continue?
Yes
Check the transmission or

clutch mechanism. Yes
Trouble occurring intermittently Replace the control unit.

Chart A5: When starting the vehicle is attempted with the Clutch Free ON, the clutch is not engaged or the
vehicle cannot be started.
HSA the initial learning

No Perform the learning
Yes
Function is suspended
Has the Clutch Free
because of system
CHECK lamp been
No failure. Check for a
extinguished, isn't a
trouble code and inspect
trouble code recorded?
according to the trouble
Yes code.
Is the HSA release point No Adjust the HSA release
proper? point.
Yes
Is the accelerator Check the accelerator

No
position sensor signal position sensor.
normal? (Trouble code 21)
Yes
Is the accelerator idle
switch normal? No
Check the idle switch
Idle: close
Accelerator: open
Yes
Is the shift knob switch No Check the shift knob

normal? switch.
Yes
Is the PTO signal No

Repair the PTO switch.
normal?
Yes
Is the Clutch Free switch No Check the Clutch Free

normal? switch.
Yes
Can the vehicle start by Is the hydraulic piping

operating the clutch No Hasn't the clutch disc No No
fully worn away? crushed or closed by
manually when the some other reason?
Clutch Free is OFF?
Yes Yes
Yes
Replace the clutch. Repair the piping.
No
Is the actuator normal? Check the actuator.
Yes

switch once and turn it
ON again 10 seconds
later. Does the condition No Trouble occurring
continue? intermittently
Yes
Replace the control unit

Chart A6: When the manual clutch is operated with the Clutch Free OFF and the starting of the vehicle is
attempted, the clutch is not engaged and the vehicle cannot be started.
Yes
Isn't the ASA/CFS adjust
No Stop operating the adjust

switch pushed beyond
switch.
the adjusting range?
Yes
Has the Clutch Free No Turn OFF the Clutch
switch been turned OFF? Free switch.
Yes
Meet the change-over

Isn't the Clutch Free
No requirements.
ON/OFF lamp indicating
Gear: Neutral
change-over (blinking)?
Clutch pedal: Released
Yes
Is the Clutch Free switch Clutch Free switch related

No
OFF and does the OFF failure can be supposed.
lamp light up? Check as described in A1.
Yes
Depress the clutch pedal
fully with the gear at the Has the Clutch Free Check for the trouble
No No
neutral position and then CHECK lamp been code and inspect
release it. Is the problem extinguished? Isn't a according to the trouble
solved? trouble code recorded? code.
Yes Yes
Trouble which occurs when
the function is stopped with Hasn't the clutch disc No

the clutch disengaged. In been fully worn away?
such a case, be sure to
depress the clutch pedal fully
once. Yes
Is the hydraulic pipe normal

No
Repair the hydraulic pipe.
without closing by crush or
some other reason?
Yes
Does the actuator work

No
normally when the Clutch Replace the actuator.
Free System is ON?
Yes

No
switch once and then turn

Trouble occurring
it ON again 10 seconds
intermittently
later. Does the condition
continue?
Yes

Chart A7: When the starter switch is turned ON, the starter motor does not rotate.
Is the battery voltage No

Check the battery.
normal?
Yes
Not a trouble. When the

Is the gear shift at the No gear is not at the neutral
neutral position? position, the starter
motor does not rotate.
Shift the gear to the
neutral position.
Yes
Has the initial learning No

Perform the learning.
been completed?
Yes

CHECK lamp been No because of system failure.
extinguished? Isn't a Check for the trouble code
trouble code recorded? and inspect according to the
trouble code.
Yes
Is the neutral of the

transmission normal? No Check the neutral
Neutral: Close switch.
Other: Open
Yes
Is the starter motor No Repair the starter

power circuit normal? motor power circuit.
Yes
When the control unit is

removed and the gear is at No Check the neutral relay
the neutral position, does and circuit.
the starter rotate?
Yes
When the control unit is

installed, and the gear is at No
the neutral position, does Replace the control unit.
the starter rotate?
Yes
Trouble occurring
intermittently
Chart A8: Exhaust brake does not work, or is kept applied even under conditions to be released.
Is the engine control No Check the engine control

module (ECM) normal? module (ECM).
Yes
Has the initial learning No

been completed?
Yes

CHECK lamp been No because of system failure.
extinguished? Isn't a Check the trouble code and
trouble code recorded? inspect according to the
trouble code.
Yes
Is the clutch pedal switch No Correct the clutch pedal

normal? switch.
Yes
Is the accelerator idle No

Correct the idle switch.
switch normal?
Yes
• Install the single check

board between the control
unit and wiring harness.
• Is the voltage between the
terminal B258-2 and B257-
13 as follows? No
With the clutch engaged:
Voltage of power source
With the clutch disengaged:
Approx. 0V
Yes
Is there continuity between

the Clutch Free control unit No
terminal B258-2 and ECM Repair the wiring harness.
terminal B286-6?
Yes

once and turn it ON again 10
seconds later. Does the No Trouble occurring
condition continue? intermittently
Yes

Chart A9: Alarm buzzer (beeping repeatedly or once) sounds often or does not sound when requirement are
met.
Has the initial learning been No

completed?
Yes
Isn't the HSA/CFS adjust
switch pushed beyond the

Yes Stop operating the adjust
switch.
adjusting range?
No
Has the Clutch Free CHECK This buzzer indicates that the
lamp been extinguished? No function is in suspension
Isn't a trouble code because of system failure.
recorded? Check for the trouble code
and inspect according to the
trouble code.
Yes
Is the door switch normal?

Erroneous alarm for gear
No
Door closed: Open
engagement and door open.
Door opened: Close

Repair the door switch.
Yes
Is the parking brake switch

Erroneous alarm for dragging
normal? No
parking brake. Repair the
Brake applied: Close

parking brake switch.
Brake released: Open
Yes
Is the clutch pedal switch When the Clutch Free is ON,
normal? No alarm for foot placed on the
With pedal depressed: Open pedal. Repair the clutch pedal
No pedal: Close switch.
Yes
Is the PTO signal normal?
Repair the PTO SW.

Voltage between B258-8 (+)
No
Repair the PTO lamp.
and B257-13 (-)
Repair the PTO.

PTO ON: 0V
PTO OFF: Approx. 24V
Yes
Erroneous alarm for half-

No
Are the trouble code CFS11, No
Is the clutch disc normal? engaged clutch for a long time.
31, and 32 recorded?
Yes Yes
When the Clutch Free is ON, Turn OFF the starter switch
erroneous alarm for the start once and turn it ON again 10 No

with high-speed gear seconds later.
engaged. Inspect according Does the condition continue?
to the trouble code.
Yes

Chart A10: Clutch engaging feeling gets worse when the clutch is half-engaged or the feeling is not as desired.
Has the initial learning been No

completed?
Yes
Has the Clutch Free CHECK Check the trouble code for
lamp been extinguished? feeling got worse because of

No
Isn't a trouble code system failure and perform
recorded? inspection according to
trouble codes.
Yes
After the HSA/CFS ADJUST Deviation of half-engaged
switch is adjusted to SLOW No

clutch point which can be
or FAST, does the feeling improved by adjustment.
remain the same condition? Can be used as it is.
Yes
Perform learning of the Clutch

Deviated half-engaged
No
Free clutch torque point
clutch point. Can be used
position. After that, does the

as it is.
feeling remain the same?
Yes
Change over to Clutch Free Are the clutch pedal, master cylinder,
OFF and start the vehicle by No slave cylinder, clutch shift fork, release No
Repair the left components.
operating the clutch manually. bearing, clutch cover and the clutch disk
Is the feeling improved? normal?
Yes
Repeat starting the vehicle

Clutch wear follow-up function
with the Clutch Free ON and
No worked and the condition was
with the 2nd gear, traveling
improved. The vehicle can
and stopping 10 times. Does
travel at this condition.
the feeling remain the same?
Yes
Hasn't some foreign

No
substance been entered the Repair or replace the actuator.
actuator circuit?
Yes
Yes
No
Repair or replace the actuator.
Is the actuator cylinder ASM normal?
Yes
once and turn it ON again 10
seconds later and travel the
car. Does the condition

No
remain the same?
Yes

Chart A11: • When the starter switch is turned ON, the Clutch Free CHECK lamp constantly blinks.
• Clutch Free CHECK lamp lights up only when the vehicle stops with the gear engaged.
Has the initial learning been No Perform the learning.

completed?
Yes Yes
When the starter switch is

turned ON, the Clutch Free No The Clutch Free CHECK lamp
CHECK lamp blinks Reset the short circuit of the lights up only when the vehicle No Replace the clutch disc.
constantly. CFS diagnosis connector. stops with gear engaged.
Is the diagnosis connector Isn't there any trouble such as
terminal No.11 open? wear in the clutch disc?
Yes Yes
Is the wiring harness of the When installing a new clutch
diagnosis connector terminal No Replace the clutch disc with
No.11 normal? No continuity Repair the wiring harness. disk, is learning of use start No new one and perform
is indicated between the position of new clutch disc learning of use start position.
terminal B260-4 and B257-13. performed?
Yes Yes
Isn't a trouble code No Follow the inspection Aren't the trouble code CFS08 No Follow the inspection
recorded? procedure specified and 86 recorded? procedure specified
Yes Yes
Turn OFF the starter switch Isn't abnormal wear observed

once and then turn it ON No Trouble occurring intermittently at the contact point of the No
clutch shift fork, release Replace the left parts.
again 10 seconds later. Does
the condition continue? bearing and clutch cover.
Yes
Yes
Replace the control unit Replace the clutch disc with

new one and perform the
learning procedure for the use
start position.
TECH2 B260 0.3 Sky blue

communication 9
0.5 Black 0.5 Sky blue
Self diagnosis start 0.3 Black/white 1 2 3 4 5 6 7 8

switch signal input 4 9 10 11 12 13 14 15 16
Emergency
connector (B269)
B257 0.85 Black Diagnosis
Earth connector(B79)
13
1 2
0.3 Black
CFS control unit
0.3 Black/yellow
Starter relay (X21-5)
Chart B1: • HSA does not work.

• HSA lamp does not light up (HSA does not work).
Doesn't the HSA lamp light up?
Yes No
Is the fuse No.20 normal? Check the HSA valve and piping and correct or replace.
Yes No
Is the battery voltage (20V or more) applied

After correcting short circuit of the circuit and parts
between the CFS control unit connector terminal
(clutch hydraulic switch, HSA valve, etc.) connected to
B258-7 and body earth B257-13?
the fuse No.20.
(Remove the connector when checking.)
Yes No
Is the resistance between the CFS control unit Repair the disconnected wire between the fuse
connector terminal B259-4 and body earth B257- No.20 and B258-7.
13 less than 5½?
Yes No
Correct the disconnected wire between the B257-13

While the parking brake is not applied, is the and earth terminal (in front of the left frame) or Faulty
battery voltage (20V or more) applied between the earth.
CFS control unit connector terminal B260-16 and
body earth B257-13?
Yes No
Is the continuity (resistance value) of the parking

Is the fuse No.8 normal? brake switch normal? (Refer to the section, "Parking
brake switch "of "On-Vehicle Services "below.)
A
Yes No
Replace the CFS Correct or replace the

control unit. parking brake switch.
Yes No
Is continuity indicated between the terminals on the Check the stop lamp system circuit for short circuit,
switch side of the stop lamp switch when the brake correct, and then repair the fuse.
pedal is depressed and not indicated when the brake
pedal is returned?
Yes No
Is the battery voltage (20V or more) applied between Correct or replace the stop lamp switch.
the stop lamp switch connector terminal B66-1 and
body earth?
Yes No
Correct the disconnected wire between the fuse No.8

Connect the stop lamp switch connector. Is the and B66-1 (stop lamp switch).
battery voltage (20V or more) applied between the
CFS control unit connector terminal B260-8 of the CFS
control unit and body earth B257-13?
Yes No
Correct the disconnected wire between the B66-2 and

Replace the CFS control unit.
B260-8.
Starter switch
(B67-3)
B258 0.5 Black/orange No.20

IGN switch input
7 10A
Stop lamp relay
(X26-4)
No.19
0.3 0.5 15A
B260 Green/white Green/yellow B66 B66 No.8 Main
Stop lamp B+ 0.85
switch input 8 2 1 10A 100A Black/yellow
Stop lamp switch
1 B172
N6 Joint
3 connector
1 Parking
3 H12 0.3 brake
Parking brake B260 0.3 White/black X33 X33 White/black B51 0.5
switch input Black/yellow
16 12 13 3 B51
Diode box HSA 18
B258 0.3 Brown/white
HSA lamp input
4 20
B257 0.85 Black
Earth Meter
13
CFS control unit

Chart B2: HSA cannot be released by pushing the HSA OFF switch.
Is the continuity of the HSA OFF switch normal?

(Refer to the section of on-vehicle service, "HSA OFF switch" below.)
Yes No
Replace the HSA valve.

Replace the HSA OFF switch.
(Refer to the section of on-vehicle service, "HSA valve" below.)
HSA M/V1
B258 0.5 Light green/red H5 0.5Light green/red J155 J155
HSA M/V1 input
6 20 3 4
0.5
Light green
0.5 Light green/black 0.5 Light green/black
HSA M/V2 input
12 21 1 2
M/V2
19 H5
0.5 Light green
HSA OFF switch
input 1
0.5
Light green
B318
Fuse 0.5 Black/orange B318 7
No.20 10A 8
B257 0.85黒 Meter HSA 0.3 Light green/black
Earth OFF lamp
13 (B51-19) 4
3
Front 0.3 Light green/red 0.3 Black
combination 6 2
lamp
CFS control unit HSA OFF switch

Chart B3: HSA cannot be released by vehicle starting procedure.
Is the continuity of the neutral switch (resistance value)

normal?
(Check the trouble code "06".)
Yes No
Correct or replace the neutral switch.

Is the installation of the clutch stroke sensor normal?
(Refer to the section, "Neutral switch", of "On-Vehicle
(Check the trouble code "08".)
Services" below.)
Yes No
Is the resistance value between the terminals of the

clutch stroke sensor within the standard value? After installation, make the initial adjustment.
(Remove the connector when checking.) (Refer to the section, "Clutch Free half-engaged clutch
(Refer to the section, "Clutch stroke sensor ASM", of position adjusting method", of "Over view" this Chapter.)
"On-Vehicle Services".)
Yes No
Replace the CFS control unit. Replace the clutch stroke sensor.
Clutch stroke sensor B259 0.5 Red H46 0.5 Red J140

Clutch stroke 0.5 Black 0.5 Green

0.5 Black 9
Sensor earth (GND) 4 B268
3 0.5 Black 0.5 Black/green
Joint
14 Clutch stroke sensor
connector
B260 0.3 Black/green 0.5 Black/green H4 0.5 Black/green J50 J50 Fuse
Neutral switch input
7 15 1 2 (No.19 15A)
CFS control unit ECM (B286-17)

Chart B4: HSA cannot be released by pulling the parking brake lever.
Is the continuity (resistance value) of the parking brake

switch normal?
(Refer to the section, "Parking brake switch", of "On-
Vehicle Services" below.)
Yes No
Is the battery voltage (20V or more) applied between Correct or replace the parking brake switch.
the parking brake switch connector terminal N6-1 and
body earth B257-13?
Yes No
Is the battery voltage (20V or more) applied between Correct improper connection or disconnected
the CFS control unit connector terminal B260-16 and wire of the connector between B51-3 (meter) and
body earth B257-13? N6-1.
Yes No
Replace the CFS control unit. Correct the disconnected wire between
B51-3 (meter) and B260-16.
Parking brake
switch
0.3 H12 0.3
White/black White/black N6
3 1
Starter switch
(B67-3)
0.3 0.3 0.5 0.85

B260 White/black X33 X33 White/black B51 B51 Black/yellow Black/yellow No.19
Parking brake
switch input 16 12 13 3 18 3 1 15A
Diode box B172
B257 0.85 Black Joint connector
Earth
13 Parking brake
lamp (meter)
CFS control unit

Chart B5: HSA lamp does not light up. (HSA works.)
Does the meter function normally?
Yes No
Is the HSA lamp normal? Is the fuse No.19 normal?
Yes No Yes No
Replace the bulb. Correct the disconnected Replace the fuse.

wire between the fuse
No.19 and B51-18 (meter).
Is the battery voltage (20V or more) applied between

the connector terminal B258-4 of the CFS control unit
and body earth B257-13?
Yes No
Correct the disconnected wire between the terminal

B51-20 (meter) and B258-4.
B258 0.3 Brown/block B51 B51 0.5 Black/yellow 0.85 Black/yellow No.19 Starter
HSA lamp input earth switch
4 20 18 3 1 15A (B67-3)
B172
Earth
13 HSA LAMP
(meter)
CFS control unit

Chart B6: HSA lamp does not go out. (HSA is released.)
Does the HSA lamp go out when the CFS control

unit connector is removed?
Yes No
Correct the earth short circuit between the terminal

B51-20 (meter) and B258-4 (control unit).
B258 0.3 Brown/block B51 B51 0.5 Black/yellow 0.85 Black/yellow No.19 Starter
HSA lamp input earth switch
4 20 18 3 1 15A (B67-3)
B172
Earth
13 HSA LAMP
(meter)
CFS control unit

Chart B7: When HSA is working the alarm buzzer does not sound even when the door is opened.
Is the continuity (resistance value) of the diode box

normal?
Yes No
When the door is opened, is the voltage below 3V

applied between the CFS control unit connector Replace the diode box.
terminal B259-11 and body earth B257-13? When the
door is closed, is the battery voltage (20V or more)
applied?
(Connect the connector when checking.)
Yes No
Is the continuity (resistance value) of the door switch

Replace the CFS control unit. normal?
(Refer to the section, "Door switch", of "On-Vehicle
Services" below.)
Yes No
Check the
disconnected wire of Correct or replace the
the door switch and door switch.
improper connection of
the connector.
B259 0.3 Gray H3 0.5 Gray N7

Door switch input 11
3 1
Door switch (left)
2 X33
X33 X33 0.5 Gray/red H12 1.25 Gray/red N2
Room lamp
1 4 1
4
Diode box Door switch (right)
B257 0.85 Black
Earth
13
CFS control unit

Chart B8: At the time of self diagnosis, the HSA lamp blinks abnormally but no trouble code is output.
Does the parking brake lamp (meter) light up when the

parking brake lever is pulled?
Yes No
Is the continuity (resistance value) of the parking

Replace the CFS control unit. brake switch normal? (Refer to the section, "Parking
brake switch", of "On-Vehicle Services".)
Yes No
Correct the improper

connection or Correct or replace the
disconnected wire parking brake switch.
between the terminal
B51-3 (meter) and N6-1.
Parking brake
switch
0.3 H12 0.3
White/black White/black N6
3 1
Starter switch
(B67-3)
0.3 0.3 0.5 0.85

B260 White/black X33 X33 White/black B51 B51 Black/yellow Black/yellow No.19
Parking brake
switch input 16 12 13 3 18 3 1 15A
Diode box B172
Earth
13 Parking brake
lamp (meter)
CFS control unit

Chart B9: At the time of self diagnosis, the alarm buzzer continues to sound (trouble code cannot be output).
Chart B8: Refer to the section, "At the time of self diagnosis, the HSA lamp blinks showing a trouble but no
trouble code is output."
HSA alarm lamp has blinked or the alarm buzzer has sounded so far (they are normal now).
HSA lamp (alarm) has blinked before.
When the backup fuse No.1 was pulled out, the It is because the control unit was reset. It is not
HSA lamp blinked. a trouble.
*1
Yes *1: The HSA lamp blinked
When the starter switch was turned ON, gear was Not a trouble.
engaged, and the clutch was engaged and the when the engine stopped
engine stopped, the HSA lamp blinked. By when the vehicle was to
Check for the start or when the vehicle
returning the gear to the neutral position and then
No trouble code 25. stopped with some gear
the vehicle starts, does the HSA lamp go out?
engaged. This is not a
trouble.
*2
HSA lamp blinked when the HSA release point
Adjust properly according to
position adjustment value was extremely
the adjustment procedure.
deviated or when the clutch play adjustment
could not be done. *2: When pushing the HSA release adjusting switch fully to
the FAST or SLOW side while keeping the HSA
ADJUST switch pushed, the HSA lamp blinks.
If operation is continued at this condition, fall back of
the vehicle or dragging brake may be caused. Adjust
properly at this stage.
When HSA is operated continuously for 7 to 8

Long alarm is not a trouble.
minutes, the HSA lamp blinked.
When the vehicle moves while the HSA is

working, the HSA lamp blinked. (When the
Alarm showing start of vehicle is not a trouble.
vehicle is started with the brake dragging or
when the vehicle gets back because the brake
pedal was depressed insufficiently, the HSA
lamp blinked.)
*3
When "FAST" or "SLOW" of the ADJUST Though diagnosis was made for the ADJUST
switch while the vehicle is running, the HSA switch trouble (trouble code 19), this is not a
lamp blinked. trouble.
By turning OFF the ADJUST switch, the
diagnosis is discontinued and the HSA
lamp goes out.
*3: Operating the ADJUST switch while the vehicle is

traveling should be avoided since it interferes with
the driving operation.
HSA alarm buzzer has sounded in the past.
The alarm buzzer sounded when the HSA was

Alarm for long time operation is not a trouble.
operated continuously for 7 to 8 minutes.
When the vehicle moved while the HSA was

operating, alarm buzzer sounded. (When the The alarm warning start of the vehicle is not a
vehicle started dragging the brake or when the trouble.
vehicle got back because the brake pedal was
not fully pressed on, the lamp blinked.)
When the starter switch is turned ON with the

The buzzer sounds because the control unit
backup fuse No.1 removed (blown out), buzzer
was reset and is not a trouble.
sounds.
(NKR Vehicle)
On-Vehicle Services
CFS Control Unit
Removal
1. Cover
2. CFS control unit
Remove the meter.
Clutch Free System
control unit • Remove the 4 connectors.
• Remove the 3 fixing nuts.
3. Bracket
Installation
Install the parts in the reverse order of removal.
C部
B 部
A 部
MADE IN JAPAN
D部
826LY00008
Actuator ASM
Removal
Mad cover positioned in the rear Positioned in the wheel base

：Wiring harness connector
：Clutch pipe
1. Battery cable
Remove the battery cable (-).
2. Wiring harness connectors.
Remove the 3 wiring harness connectors.
3. Clutch pipes.
Remove the 2 clutch pipes.
Mad cover positioned in the rear Positioned in the wheel base
2 screws
：Bracket fixing bolt

Mad cover positioned in the rear 4. Actuator ASM with bracket

Remove the bolt fixing the bracket.
5. Actuator ASM
Remove the 3 fixing bolts.
Positioned in the wheel base
Installation
1. Actuator ASM
Install the bracket to the actuator ASM with 3 bolts.
Tightening torque: 52 N-m {5.3 kg-m}

2. Actuator ASM with bracket
Install the actuator ASM with bracket in position with a bolt or bolt
and nut.

3. Clutch pipe

4. Wiring harness connector
5. Battery cable
Clutch Stroke Sensor ASM

• Two types of sensors are available; the one with fixing arm having longer
Transmission rotation
hole and the other with fixing arm having round hole.
sensor connector
Removal
1. Connector
Clip Remove 2 connectors and 2 clips.
2. Clutch stroke sensor ASM
Remove 2 bolts on the sensor side installing the clutch stroke sensor
ASM to the clutch housing and one bolt fixing to the shift fork side.
3. Link rod
4. Bracket
Remove the fixing bolt.
5. Sensor
Clutch shift arm
Inspection
<In case of round hole type>
Connect 5V to the sensor terminal 1 (CLT.VCC) and connect the terminal
Clip
Transmission rotation 2 (CLT.GND) to GND.
sensor wiring harness Record the voltage between the terminal 2 (CLT.SIG) and 3 (CLT.GND)
turning the sensor arm.
If the voltage does not change in the range of approximately 0.1 - 4.8V,
replace.
<In case of longer hole type>

• Measure the resistance value between the sensor terminal 1 (CLT.VCC)
and 3 (CLT.GND1) and check that it is in the range of about 0.5 to 2.7
kΩ.
• Turn the sensor arm from the stopper position fully clockwise and fully
counterclockwise and check that the resistance value between the sensor
terminal 2 (CLT.SIG) and 3 (CLT.GND) changes in the range of about
0.1 to 3kΩ. If the above conditions are not met, replace.
Adjustment of link rod

Adjust the distance from center to center of the ball joints to 85.5-
86.5mm and fix with the lock nuts (2 positions).
Longer hole type Round hole type
Tightening torque: 9N-m {0.9 kg-m}
Installation and adjustment

1. Install the sensor facing the marking on the sensor fixing arm side
and lock projection of the connector rearward of the vehicle with 2
bolts.

1. Measure the sensor resistance value between the sensor terminal 2
(CLT.SIG) and 3 (CLT GND) under the condition below and
determine the aimed adjusting value when fixing the sensor itself to
9500
the bracket.
The average resistance value of those obtained by turning the sensor
Marking arm fully clockwise and that when turning it fully counterclockwise
shall be the target value.
Connector lock projection
Install the sensor with 2 bracket bolts so that the above target value
is obtained when the sensor arm hole and sensor fixing bracket bolt
hole are aligned.

Connector
3
2
Bolt 1
Sensor
Sensor arm hole
2. Link rod
3. Clutch stroke sensor ASM

Install to the clutch housing with 2 fixing bolts.
Coat one of 3 fixing bolts on the shift fork side with LOCTITE 242 at
85.5 - 86.5mm 90°
the end of the threaded part before tightening.
230LY00012
Where the arrow marks are aligned, fix with 2 bolts so that R is the
targeted adjusting value.
R2 measurement
R1 measurement
Measurement/calculation method (longer hole type only):
Resistance value Decision of target

Sensor arm position
measurement result adjusting value R for this sensor
Position turned fully clockwise R1 [Ω]
R = (R1+R2)÷2 ±25[Ω]
Position turned fully counterclockwise R2 [Ω]
• Decide the "clockwise" and "counterclockwise" directions viewed from the sensor arm side.
Example:

Sensor arm position
Position turned fully clockwise R1 = 1212 [Ω] R = (1212+250)÷2 ±25[Ω]
Position turned fully counterclockwise R2 = 250 [Ω] R = 731 ±25[Ω]
Aligning the sensor arm hole and fixing bolt (position shown in above figure), install the sensor to the bracket with 2
bolts so that the target adjusting value R[Ω] is obtained.
Note: The adjusting hole of φ6.2mm is not used.
Transmission Shift and Select Sensor

Shift stroke sensor
• Two types of sensors are available, the one with fixing arm having
Select stroke sensor longer hole and round type.
Removal
1. Connectors (2)
2. Remove the shift and select stroke sensor ASM together with the
bracket.
3. Remove the shift and select stroke sensors.
Counter
Inspection
clockwise <In case of round hole type>
Connect 5V to the shift sensor terminal 3 (SFT.VCC) and terminal 3
(SFT.GND) to GND.
Record the voltage between the terminal 2 (SFT.GIG) and 1 (SFT.GND)
rotating the sensor arm.
Connect 5V to the select sensor terminal 1 (SEL.VCC) and terminal 1
Clockwise
(SEL.GND) to GND. Record the voltage between the terminal 2
(SEL.SIG) and 3 (SEL.GND) rotating the sensor arm.
If the voltage does not change in the range of about 0.1 and 4.8V, replace
the sensor.

• Measure the resistance value between the shift sensor terminal 3
(SFT.VCC) and 1 (SFT.GND) and the resistance value between the
select sensor terminal 1 (SEL.VCC) and 3 (SEL.GND) and check that
the resistance values are within the range from about 0.5 to 2.7kΩ.
• Turning the sensor arm fully clockwise from the stopper position and
then fully counterclockwise and check that the resistance values
between the shift sensor terminal 2 (SFT.SIG) and 1 (SFT.GND) and
between the select sensor terminal 2 (SEL.SIG) and 3 (SEL.GND) are
Longer hole type Round hole type within the range of about 0.1 to 3kΩ. If the above conditions are not
met, replace the sensor.
Installation and adjustment

Identification marking <In case of longer hole type>
1. Measure the shift sensor resistance value between the shift sensor
Identification
marking terminal 1 (SFT.GND) and 2 (SFT.SIG) and the select sensor
resistance value between the select sensor terminal 3 (SEL.GND)
and 2 (SEL.SIG) under the following condition to determine the
target adjusting value when fixing a single unit of sensor to the
bracket.
The average value of the resistance values when the sensor arm is
turned fully clockwise and counterclockwise shall be the target
value.
Connector lock

1. Install the sensor to the bracket with 2 bolts so that the marking on
the sensor fixing arm side and connector lock projection can be seen
from the rear of the vehicle.
2. Shift and select stroke sensor ASM

Apply the sensor arm and transmission pin sliding parts with vesco
chassis grease and install them.
9500
Marking
Connector lock projection
3 2 1 1 2 3
5V SIG GND 5V SIG GND

Shift stroke Select stroke
sensor terminal sensor terminal
Measurement/calculation method (longer hole type only):
Resistance value Decision of target adjusting value,

Sensor arm position
measurement result R_SFT and R_SEL for this sensor
Shift Position turned fully clockwise R1 [Ω]
R_SFT ＝(R1+R2)÷2 ±25[Ω]
sensor Position turned fully counterclockwise R2 [Ω]
Select Position turned fully clockwise R3 [Ω]
R_SEL ＝(R3+R4)÷2 ±25[Ω]
sensor Position turned fully counterclockwise R4 [Ω]
• Decide the "clockwise" and "counterclockwise" directions viewed from the sensor arm side (for both the shift
sensor and select sensor).
Counter
clockwise
Shift stroke sensor
Select stroke sensor Clockwise
Example:

Sensor arm position
Shift Position turned fully clockwise R1 = 1109 [Ω] R_SFT = (1109+155)÷2 ±25[Ω]
sensor Position turned fully counterclockwise R2 = 155 [Ω] R_SFT = 632 ±25[Ω]
Select Position turned fully clockwise R3 = 1085 [Ω] R_SEL = (1085+172)÷2 ±25[Ω]
sensor Position turned fully counterclockwise R4 = 172 [Ω] R_SEL = 629 ±25[Ω]
Where the sensor arm hole and bracket adjusting hole are aligned, install the sensor to the bracket with 2 bolts so
that the target adjusting value R_SFT[Ω] and R_SEL[Ω is obtained above can be obtained.
Transmission Rotation Sensor

Removal
1. Connector
2. Transmission rotation sensor
Inspection
• Replace the wiring harness, connector and seal if damaged.
• Measure the resistance between terminals and replace the terminal if the
resistance between 1 and 2 is out of range from 1.5 to 2.1kΩ.
Installation
1. Transmission rotation sensor
Coat the sensor threaded part with Three Bond 1215 and install.
Tightening torque: 29 N-m {3 kg-m}

2 1
2. Connector
Clutch Hydraulic Switch

Removal
1. Actuator ASM
Refer to the section of actuator ASM removal.
2. Clutch hydraulic switch
Inspection
• Replace the wiring harness, connector and seal if damaged.
Clutch hydraulic switch • Check for continuity between the connector terminals with the clutch
pedal fully stepped on and released. Continuity should be indicated when
stepped and should not indicated when released. If not, replace the
switch.
Installation
2 1 Coat the clutch hydraulic switch with LOCTITE PSD-575 avoiding
to block the oil pressure sensing hole at the end of the sensor and
install.
Tightening torque: 9 N-m {0.9kg-m}
2. Actuator ASM
Refer to the section of actuator installation.
Neutral Switch
Removal
1. Connector
2. Neutral switch
1. Neutral
switch Inspection
Connector • Inspect the wiring harness, connector and seal and replace if damaged.
(gray) • Pushing the end of the switch, check for continuity between connector
terminals. Replace the switch if it is not such that continuity is indicated
when not pushed and continuity is not indicated when pushed.
Installation
1. Neutral switch
Coat the switch threaded part with Three Bond 1141 and install.
2 1 Push Tightening torque: 34 N-m {3.5 kg-m}
2. Connector
Shift Knob Switch

Removal
1. Gear control cover
Untighten the screw and clip and remove the cover.
2. Boot
Lift the cover and turn the inside of the boot out.
3. Connector
Remove the connector leading from the change lever.
Inspection
• Measure the switch operating load and replace the switch if the load is
out of the range from 12.7 to 24.5N (1.3-2.5kg) (measure at a point 15mm
below the knob end).
• Check the wiring harness and connector and replace if damaged.
• Check the continuity between terminals. If continuity is not indicated
between 1 and 2 when the knob is pulled down to the "R, 2, 4, 6" side and
3 2 1 between 2 and 3 when pulled down to "1, 3, 5" side, replace.
• Refer to the section of the removal and installation of change lever ASM
of the onboard services and disassemble and reassemble of the change
lever ASM of the unit service, for replacement of the switch (change
lever subassembly with switch).
Installation
1. Connector
2. Boot
2 3 0 L X 0 1 0
Removal and Installation of Change Lever ASM
3
Shift cable
Removal order
1. Change lever knob
3. Shift & select cable
3 4. Change lever ASM
Select cable
Installation order
Removal
• Drive out the pin and remove the change lever knob.
• Untighten the screw and clip and remove the cover.
• Separate the cable from the change lever.
• Remove the clip fixing the cable.
4. Change lever ASM
• Remove the connector on the right below the change lever ASM.
• Remove the parking brake from the bracket and put it aside,
untighten the bracket fixing bolt and fixing nut, and remove them
together with the bracket.
Installation
4. Change lever ASM
• Connect the connector.
• After tightening the shift cable fixing nut with specified torque,
adjust. For the adjusting procedure, refer to "Adjustment of gear
control".

• Drive in the pin and fix the change lever knob.
Clutch Pedal Switch

Inspection
• Continuity should be indicated when the driver takes away the foot from
the pedal and not indicated when stepping on the pedal. If not, replace
the switch.
Adjustment
• Adjust so that the pin of the clutch pedal switch projects 0.5 to 1.0mm
203LX006 when the driver takes away the foot from the pedal.
1
2
Accelerator Position Sensor (APS)

Return cable
Inspection and adjustment
Idle switch B Measure the voltage between terminals.
A 1. Apply voltage of 5±0.01V on the terminal (3).

APS connector
2. Measure the output voltage of the terminal (2) and earth terminal (1).
Specified voltage
3 2 1 Idling: 0.3-0.6V (with accelerator SW ON)
Accelerator SW operating position: 0.41-0.71V (with accelerator
SW OFF)
Idle switch connector
WOT: 4.07-4.67V
3. If the measurement value is out of the range of the specified voltage,
untighten the APS fixing bolt and adjust moving the APS sideways.
4. After adjusting, fix with the APS fixing bolt.
Accelerator
position sensor
Idle Switch
Inspection
• Continuity should be indicated when the accelerator is idle and should
not be indicated when the accelerator is opened. If not, replace.
Adjustment
For adjusting the play of the return cable components at the part A in the
above figure, provide a gap of 1.2-2.0mm at the idle switch joint point on
the stopper, tighten with the nut B and check the OFF of the switch.
Clutch Free Switch

Removal
1. Meter cluster
HS
O F FA
2. Connector
3. Clutch Free switch
IDLING
STOP • Remove the Clutch Free switch pushing the claw of the switch from
the rear side of the instrument panel.
825LY00013
Inspection
Check for continuity between switch terminals.
4 3 2 1
8 7 6 5
Terminal No.
HSA OFF Clutch Free

SW SW Connected to
OFF ON OFF ON
8 IGN
7 ECU(HSA)
4 Lamp (meter)
Installation
3 Earth
Install parts in the reverse order of removal.
5 Earth
1 ECU (Clutch Free)
6 Lighting
2 Earth
HSA RESET Switch

Connector Removal
1. Unapplied parking brake voice alarm unit
2. USA RESET switch
Unapplied parking brake
voice alarm unit 3. Connector
HSA RESET
switch
Inspection
2 1
6 5 4 3
Terminal
SW No. 4 6
position
O N
OFF
Installation
Install parts in the reverse order of removal.
HSA/CFS ADJUST Switch

Removal
1. Connector
2. HSA/CFS ADJUST switch
• Remove the switch pushing the claw from the rear side of the
instrument panel.
Claw
Claw
Inspection
Terminal
No. 1 2 3
SW
position
1
FAST
2
3 OFF
SLOW Installation
1. Protector Speed Sensor

Removal
1. Protector
2. Connector
3. Speed sensor
3. Speed sensor 2. Connector
Inspection
1. Connect a resistance of 390Ω ±5%, 2W, between the speed sensor
connector terminal 1 and battery (+) terminal and connect the
terminal 2 to the battery (-) terminal.
3 2 1
Caution
Never connect the (+) terminal of the battery to the connector terminal 3.
Speed sensor may be failed.
390Ω±5%,2W 2. Turning the speed sensor shaft gently, measure the voltage between
the terminal 3 and 2 using a digital tester.
Repeat measurement 8 times at the voltage of 2V±1V and 14V

+1
- 2 V while the shaft turns once.
If a trouble is noticed in the inspection, replace the sensor with new

– +
one.
Battery Installation
3. Speed sensor
Tightening torque: 24.5 N-m {2.5 kg-m}
2. Connector
1. Protector
For rear For front

wheel
HSA Valve
wheel
HSA valve
Removal
1. Connector
2. Brake pipe
3. HSA valve
• Remove 2 fixing bolts.
Installation
3. HSA valve
• Tighten 2 fixing bolts.
2. Brake pipe
1. Connector
Cautions
• After connecting the pipe, check for dust or other foreign
substances.
• Connect the pipe correctly.
• After completion of installation, be sure to vent the air from the
brake completely.
• Use new and specified brake fluid.
HSA OFF Switch

Removal
1. Meter cluster
HS
O F FA
2. Connector
3. HSA OFF switch
IDLING
STOP • Remove the switch pushing the claw from the rear of the instrument
panel.
825LY00013
Inspection
Check for continuity between the switch terminals.
4 3 2 1
8 7 6 5
Terminal No.
HSA OFF Clutch Free

SW SW Connected to
OFF ON OFF ON Installation
8 IGN Install the parts in the reverse order of removal.
7 ECU(HSA)
4 Lamp (meter)
3 Earth
5 Earth
1 ECU (Clutch Free)
6 Lighting
2 Earth
1. Unapplied parking
Unapplied Parking Brake Voice Alarm Unit
brake voice Bracket
alarm unit Removal
1. Unapplied parking brake voice alarm unit
• Pushing up the claw, push the unit in the arrow mark direction and
remove from the bracket.
2. Connector
Claw
Installation
Inspection
In case of malfunction of the unapplied parking brake voice alarm unit, or
when it does not function at all, remove the connector of the vice alarm unit
and check as described below using the connector on the wiring harness
side.
When the inspection results are different from normal values, correct
referring to the list on the next page.
Terminal Terminal Connected to

Connected to
No. No.
1 2 3 4
5 6 7 8 9 1 Neutral switch 6 Starter switch
2 Parking brake switch 7 Idling stop SW
3 Idling stop output 8 Head lamp SW
4 Earth 9 Battery
5 Door switch
Terminal Connected Inspection Normal

Inspection condition Correction
No. to item value
Gear at "neutral" and starter switch "ON" About 24V A
1 1 - Earth Voltage Gear at "other than neutral" 0V B
Starter switch "OFF" 0V C
Parking brake lever "pulled" 0V D
2 2 - Earth Voltage
Parking brake lever "returned" About 24V E
4 4 - Earth Continuity - Indicated F
Right door "Open" 0V G
5
5 - Earth Voltage Left door "Open" 0V H
*Note
Both doors "Closed" About 24V I
Starter switch "ON" About 24V J
6 6 - Earth Voltage
Starter switch "OFF" 0V K
9 9 - Earth Voltage - About 24V L
Caution
If the voice alarm unit functions incorrectly when the operating conditions are not met, possibility of failed door
switch system is high.
*Note: Link the room lamp switch with the door.
Connection of voice alarm trouble
Faulty part Cause Correction
When the gear is shifted to the neutral,

A Neutral switch Correct or replace the switch.
A the switch contact point is not closed.
Wiring Disconnected wire Correct the disconnected wire.
When the gear is shifted to other than neutral,

Neutral switch Correct or replace the switch.
B the switch contact point is kept closed.
Wiring Incorrect wiring Correct the incorrect wiring.
C Wiring Incorrect wiring Correct the incorrect wiring.
D Parking brake switch Even though the parking brake is pulled, Correct or replace the parking brake switch.
the switch contact point is not closed.
Even though the parking brake lever is returned, Correct or replace the parking brake switch.
E Parking brake switch
the switch contact point is kept closed.
Wiring Short circuited wiring Correct the short circuit of the wiring.
F Wiring Disconnected wire or improper earth Correct the disconnected wire or improper earth.
Door switch contact point is not closed Correct or replace the door switch.
G Door switch
when the door is opened.
H Wiring Disconnected wire Correct the disconnected wire.
Door switch contact point is closed

Door switch Correct or replace the door switch.
I when the door is closed.
Wiring Short circuited wiring Correct the short circuit o the wiring.
Fuse Melted fuse No.20 Replace the fuse No.20.

J
K Wiring Incorrect wiring Correct the incorrect wiring.
Fuse Melted fuse No.1 Replace the fuse No.1

L
Door Switch
Removal
Slide 1. Door switch
• Pushing the slide of the door, remove the fixing screw.
• Remove the connector.
Screw
Inspection
Slide in this direction Moving the slide, check for continuity between the terminal and body.
Terminal – Leave Push
Terminal +
Connector
No. N-2 N-7
Switch Terminal
No. 1 Body
operation
Leave
Push
Installation
Parking Brake Switch

Removal
1. Parking brake rear cover
• Remove 2 clips.
2. Parking brake switch
• Remove 1 fixing screw.
• Remove the connector.
311LX001
Parking brake lever

Inspection
1. Parking brake switch
Parking brake Disconnect the connector.
switch 2. Between the switch terminal and body earth
Connect a circuit tester and check for continuity.
3. HSA OFF switch
With parking brake lever pulled: Continuity indicated.
With parking brake lever returned: No continuity indicated.
If the inspection result shows some trouble, correct or replace the

switch with new one.
Installation
Stop Lamp Switch

Removal
1. Stop lamp switch
• Disconnect the connector of the stop lamp switch.
• Untighten the lock nut.
1.Stop lamp switch • Remove the switch from the bracket turning the switch body.
Lock nut
Brake pedal
0.5-1.0mm Removal
Lock nut 1. Stop lamp switch
• Screw in the stop lamp switch until the end of the screwed part
touches the brake pedal.
Caution
Do not push the pedal with the switch end.
Brake pedal
• When the switch end touched the brake pedal, return the switch until
1. Stop lamp switch
the gap between the pedal and screwed part is 0.5 - 1.0mm and
tighten the lock nut.
Diode Box
Removal
1. Instrument panel
Refer to the "Cab repair manual".
2. Diode box
Inspection
Check for continuity between terminals.
Installation
1 2 3 4 5 6
7 8 9 10 11 12 13 14
Terminal No.
Connector No.
1 2 4 7 8 9
X33
Unit Repair
Clutch Free Actuator ASM
1
1
8
7
6 9
Disassembling order
1. Wiring harness connector and
clip
2. Bracket
3. Cylinder ASM
4. Motor ASM
5. Tank ASM
6. Pump ASM
7. Oldam's coupling
8. Body ASM
1 9. Solenoid coil
3 Reassembling order
Reassemble the parts in the reverse
order of disassembly.
Disassembly
Discharge the clutch oil from the oil tank.
1. Wiring harness connector and clip

• Remove the wiring harness connectors and clip fixing the wiring
harness from the bracket.
Connectors
(1) For motor
(2) For clutch hydraulic switch
(3) For solenoid valve
2. Bracket
3. Cylinder ASM
4. Motor ASM
5. Tank ASM
6. Pump ASM
7. Oldam's coupling
8. Body ASM
9. Solenoid coil
Inspection
• Oldam's coupling
Replace if worn away or damaged remarkably.
• Valve body ASM
Wash the hydraulic circuit if clogged with foreign substances.
Replace if damaged or deformed.
• Solenoid coil
Replace if the resistance value is out of range from 6 to 20Ω.
When operating the solenoid valve continuously, set up the cooking
time as listed below.
Working voltage Continuous operating time Cooling time

24V 30 sec. or less 5 min. or more
12V 5 min. or less 5 min. or more
• Motor ASM
If the resistance value is out of the range from 0.1 to 10Ω, and the
motor does not rotate when load of 12V is applied, replace the motor.
Rotate the motor under 24V within 5 seconds and cool it for more
than 3 minutes after operating.
• O-ring and other rubber parts
Replace if damaged, worn, broken or deformed.
• Filter
Remove dust or other foreign substances, if any.
• Diaphragm
Replace if the rubber is damaged.
Assembly
1. Solenoid coil
2. Body ASM
3. Oldam's coupling
4. Pump ASM
• Install with fixing bolts.
5. Tank ASM
• Install with fixing screws.
6. Motor ASM
• Coat the Oldam's coupling with grease and install it between the
body ASM and motor ASM.
• Install the motor ASM with fixing bolts.
7. Cylinder ASM
• Install the cylinder ASM with fixing bolts.
8. Bracket
9. Wiring harness connector and clip
• Install the wiring harness connector to the bracket and fix the wiring
harness with the fixing clip.
• After installing the wiring harness to the vehicle, supply clutch oil
and discharge the air.
Cylinder ASM
Disassembling order
1. Bleeder
2. Snap ring
6 3. Cylinder end nut
4 4. Cylinder end cap and O-ring
5. Return spring and retainer
3
6. Secondary piston ASM
2 7. Primary piston ASM
8. Cylinder
5
9. Hydraulic switch
Reassembling order
Reassemble the parts in the reverse
order of disassembly.
Removal
1. Bleeder
2. Snap ring
3. Cylinder end nut
4. Cylinder end cap and O-ring
7. Primary piston ASM
8. Cylinder
9. Hydraulic switch
Inspection
• O-ring, cup and other rubber parts
Replace if damaged, worn, broken or deformed.
• Cylinder
Replace if the inside is damaged.
• Return spring
Replace if the working load is below 5kg (when set length L =
36mm).
Installation
• PSD575 preventing the hydraulic sensing hole from being blocked
and install.
2. Cylinder
3. Primary piston ASM
Coat the cup lip with brake oil or rubber grease and install.
Coat the cup lip with brake oil or rubber grease and install.
6. Cylinder end cap and O-ring
Fit the O-ring into the groove and insert the cap.
7. Cylinder end nut
8. Snap ring
9. Bleeder

Change Lever ASM
4
1
6
8
5
9
2
3
Disassembling order
1. Band clip
10 2. Plate
3. Ball seat
4. Change lever sub ASM with switch
5. E-ring
6. Select lever
7. Spring
8. Stopper
10 9. Ball
10. Cushion rubber and distance piece
11 11. Bracket ASM
Reassembling order
Reassemble the parts in the reverse order of
disassembly.
Inspection
• Check the working load of the shift knob switch.
1, 3, 5 side
2, 4, R side Working load: 12.7 - 24.5 [N]
(Measure at a point 15mm below the knob
end.)
3 2 1 • Check the switch operation.

If not working as listed below, replace.
Terminal No. 1 2 3
1, 3, 5 side O O
Neutral
2, 4, R side O O
Disassembly
1. Band clip
Remove band clips at 4 positions shown by the arrow mark, fixing
the wiring harness.
2. Plate
3. Ball seat
Remove the bolt fixing the plate, pull out the plate together with the
change lever from the bracket ASM, and remove the ball seat.
4. Change lever sub ASM with switch
5. E-ring
6. Select lever
7. Spring
8. Stopper
F07LY00002
9. Ball
Remove the ball from the select lever.
11. Bracket ASM
Assembly
1. Bracket ASM
3. Ball
Coat the ball spherical surface and hole with grease and install the
ball to the select lever.
4. Stopper
Spring
5. Spring
Boss
6. Select lever
Coat the portions of the spring and select lever shown by the arrow
marks with grease. Insert the spring into the boss of the select lever,
hitch the spring spreading its edge to the pin of the select lever and
Pin install the spring to the select lever.
7. E-ring
Installing the change lever sub ASM with switch to the ball of the
Select lever select lever assembled with the spring, install the select lever to the
shaft of the bracket ASM. Fit the E-ring.
Expand here. 8. Change lever sub ASM with switch
9. Plate
10. Ball seat
Coat the ball of the change lever sub ASM with switch, fit the plate
and install the ball seat.
Install the change lever sub ASM with switch, plat and ball seat to
the bracket ASM and fix the plate with the bolt.

11. Band clip

Fix the wiring harness to the change lever ASM at the portions
shown by the arrow marks with band clips.
F07LY00002
MEMO
LGFCS-WE-0111
You are requested to order this manual using the

manual number that is shown above.
This manual is applicable for vehicles in all countries

except USA.
All rights reserved. This manual may not be

reproduced in whole or in part, without the
permission in writing of ISUZU MOTORS LIMITED.
Issued by
ISUZU MOTORS LIMITED
INTERNATIONAL SERVICE DEPARTMENT
Tokyo, Japan
First edition Nov., 2001

WORKSHOP MANUAL
N Series
CLUTCH
FREE CLUTCH SYSTEM
SECTION 7
No.LGFCS-WE-0111

Clutch: Workshop Manual

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WORKSHOP MANUAL

Clutch Free System (CFS)

Clutch Free System ON Function

Clutch Free OFF Function

HSA (Hill Start Aid) Function

Control of Clutch Free System

Clutch Free ON/OFF switching conditions

2. Turning ON the Clutch Free System

Starting the vehicle

Changing the speed

Stopping the vehicle

3. Operation with the Clutch Free OFF

ABS actuation signal

Shift knob switch Meters

Shift stroke Neutral

Clutch stroke sensor

Front right wheel cylinder Rear right wheel cylinder

Front left wheel cylinder Rear left wheel cylinder

Clutch Free ON/OFF lamp

HSA OFF lamp

Clutch Free switch

HSA RESET switch

HSA/CFS ADJUST switch

Parts Layout Diagram

HSA lamp (active/alarm indication)

Clutch Free ON/OFF lamp HSA OFF switch

Clutch Free switch (ON/OFF)

Shift knob switch

Not applied parking brake

HSA/CFS ADJUST switch

Clutch Free System

Clutch pedal switch

HSA RESET switch Accelerator position sensor

Parking brake switch

HSA lamp (Operation/Alarm indication) Neutral switch

Clutch Free System

Clutch Free actuator

Clutch Free control unit

Clutch Free actuator

Shift knob switch

Clutch stroke sensor

Transmission shift and select sensor

Transmission rotation sensor

Engine revolution sensor

Accelerator position sensor

Accelerator idle switch

Clutch hydraulic switch

Clutch Free ON/OFF switch

HSA OFF switch

HSA/CFS ADJUST switch

HSA RESET switch

Clutch Free ON/OFF lamp

Clutch Free CHECK lamp

HSA lamp (operation or alarm indication)

HSA OFF lamp

Unapplied parking brake voice alarm unit

Overview of Clutch Free System (CFS) control functions

Clutch Free ON/OFF lamp, CHECK lamp,

Vehicle is driven with the Release the parking brake

Meet the change over

Clutch Free ON ON lights up - - - -

Clutch Free OFF OFF lights up - - - -