Clutch System GENERAL ‘SPECIFICATIONS TROUBLESHOOTING SPECIAL TOOLS CLUTCH SYSTEM (CLUTCH COVER AND DISC ‘COMPONENTS INSPECTION. REPLACEMENT CLUTCH MASTER CYLINDER ‘COMPONENTS REMOVAL INSPECTION. CLUTCH PEDAL ‘COMPONENTS INSPECTION. REPLACEMENT ADJUSTMENT CLUTCH RELEASE CYLINDER ‘COMPONENTS REPLACEMENT cH cH cH cH-6 cH-7 cH? cH-10 cH-11 CHa cH 14 CH-15 CH-15 cH-16 cH-17 cH 18 a PeCH2 GENERAL SPECIFICATIONS | tccu: CLUTCH SYSTEM Clutch operation method Hydraulic type Clutch dise Type ‘Single dry with diaphragm (Clutch cover assembly Type Diaphragm spring strap SERVICE STANDARD ‘Standard value Clutch disc thickness [When free] Distance between inner pad and clutch pedal Clutch pedal free play 8.7 + 0.3 mm (0.3307 ~ 0.3543 in.) 252 + 2mm (9 84 ~ 10,00in,) 43:mm (0.51 in) or less Clutch replease cylinder clearance to piston Clutch master eylinder clearance to piston Clutch pedal stroke 150 mm (5.9 in) Limit Clutch dise rivet sink 0.3 mm (0.011 in.) Diaphragm spring end height difference 0.5 mm (0.02 in.) (0.15 mm (0.006 ‘n.) 0.15 mm (0.006 in.) TIGHTENING TORQUE item Nm kgfem Tbk Ignition tock switch a-10 {0 = 100 58-74 (Clutch pedal mounting 25 = 38 250 ~ 350 184 ~ 258 Glutch tube to atch oll chamber 3-17 130 ~ 170 96-125 ‘Glutch tube to clutch master eylinder 2-16 120 = 160 39-118 Clutch tube to clutch gose 130 ~ 170 96-125 Clutch release cylinder to clutch hose 250 ~ 350 184 = 25.8 Clutch olf chamber mounting o-8 60 ~ 80 44-59 Clutch release cylder Hedder screw 12 ~ 20 120 ~ 220 89-148 (Clutch cover B- 2 150 ~ 220 114 = 404 Clutch mounting ars “0-350 GER) 59-74GENERAL CH -3 LUBRICANTS Teme Specified lubricants auantay Contact surface of release bearing and Kier 7 Contact surace ofr CASMOLY L 9508 As requies Inner sace of auth release bearing CASNOLY L958 7s remuted Inne surface of ath release cylinder ard oer 7 circumference of piston and cup Brake fluid DOT S or DOT 4 As required Inner suiaoe of etch aise spin CASMOLY L508 oe Taner srace of dutch master eynder and aver . circumference of piston assembly Brake fluid DOT 3 or DOT 4 As required ‘Whee bearing grease SAE Citch master ejinder pushrod, cles pin and washer | Whee! Beating a fs requted Citoh pedal shat and bushings Chassis grease SAE 4510, As requies Contact porionaelese foro release oye pushrod | CASMOLY L 9608 fs eared Input sta spline CASMOLY L 9508 fs required TROUBLESHOOTING | cc0cssic Trouble symptom Suspect area Remedy ‘Gluteh slipping Insufficient pedal free play Replace + Carwill notrespond to engine ‘speed during acceleration Clogged hydraulle system Correct or replace parts + Insufficient vehiole speed | Excessive wear of clutch dise facing Replace + Lack of power during lardened clutch disc facing, or oll on surface | Replace carn ene Hardened clutch disc facing, or oll on surface | Repl Damaged pressure plate or flywheel Replace Weak or broken pressure spring Replace Difficult gear shiting (gear Excessive pedal free play Replace noise during shifting) trapping or clogging Hydraulic system fluid leaks, air Repair or replace parts, dutch dise ‘Unusual wear or corrosion of the Replace dlutch disc spline Excessive vibration (distortion) of the ReplacecH CLUTCH SYSTEM Trouble symptom ‘Suspect area Remedy Clutch | When the clutch is | Insufficient play of the clutch pedal Replace noisy | not used Excessive wear of the clutch dise facing Replace ‘Anoise Is heard | Unusual wear and! or damage of the Replace after the clutch is release bearing disengaged ‘A noise is heard | Insufficient grease on the sliding surface | Repair when the clutch is | of the bearing sleeve disengaged Improperly installed the clutch assembly | Repair cor bearing ‘Anoise is heard when | Damaged pilot bushing Replace the ear suddenly rolled up with the cluteh partially engaged Hard pedal effort Insufficient lubrication of the clutch pedal__| Repair Insufficient lubrication of the spline Repair part of clutch disc Insufficient lubrication of the clutch Repair release lever shaft Insufficient lubrication of the front bearing retainer Repair Hard to shift or will not shift Excessive clutch pedal free play Replace Faulty of the clutch release cylinder Repair the release cylinder Clutch disc out of place, runout is excessive or lining broken Inspect the clutch dise Spline on the Input shaft or clutch disc dirty or burred Repair as necessary Faulty of the clutch pressure plate Replace the clutch cover Clutch sips Tnsuffcient of the clutch pedal free play Replace Clogged of the hydraulic system Repair or replace parts Clutch disc lining olly or worn out Taspeat the olutch dise Fauily of the pressure plate Replace the clutch cover Binding of the release fork Inspect the release fork Clutch grabsichatters Clutch dise lining olly or worn out Inspect the clutch disc Faulty the pressure plate Replace the clich cover Bent the dutch diaphragm spring Replace the clutch cover ‘Worn or broken torsion spring Replace the clutch dise Loose the engine mounts Repair as necessary Clutch noisy Damaged the chiich pedal bushing Replace the clutch pedal bushing Loose part inside housing Repair as necessary Worn or dirty release bearing Replace the replease bearing Sticking release fork or linkage Repair as necessaryGENERAL CH-5 SPECIAL TOOLS | cxrscas Tool (Number and name) Use (09411-17000 Clutch dise guide Installation of the clutch disc.cHs CLUTCH SYSTEM CLUTCH SYSTEM CLUTCH COVER AND DISC COMPONENTS. cxcrces I< —otch Roioaso lover @<———assting Y @<—Packing ¢/ Clutch cover assembly Clutch cise TORQUE: Nm (kg-cm, lb-ft)CLUTCH SYSTEM cH-7 INSPECTION CLUTCH COVER ASSEMBLY 4. Check the diaphragm spring end for wear and uneven height. 2. Check the pressure plate surface for wear, cracks and ‘olor change. 3, Check the rivets for looseness and replace the clutch cover assembly if necessary, CLUTCH Disc 41. Check the clutch facing for loose rivets, uneven con- tact, deterioration due to seizure, adhesion of oll, or ‘grease, and replace the clutch disc if defective 2. Measure the thickness of the disc when free. 3. Check for the torsion spring play and damage and if defective, replace the clutch disc. 4, Clean the splines on the input shaft and install the clutch disc. Ifthe disc does not slide smoothly or if play is exces- sive, replace the clutch disc andlor the input shaft CLUTCH RELEASE BEARING &\ caution The release bearing is packed with grease. Do not use cleaning solvent or oll. 41. Check the bearing for seizure, damage or abnormal noise. Also check the diaphragm spring contacting points for wear. 2. Replace the bearing if: points are worn abnormally. release fork contacting CLUTCH RELEASE FORK If there is abnormal wear at the point of contact with the bearing, replace the release fork assembly REPLACEMENT 1. Remove the transaxle assembly(See ‘MT’ group - ‘Manual Transaxle’) 2. _Insertthe special tool (08411-11000) in the clutch disc to prevent the disc from falling.cH CLUTCH SYSTEM 3. Loosen the bolts which attach the clutch cover to the flywheel in a star pattern, Loosen the bolts in succes sion, one or two turns at atime, to avoid bending the cover flange. Do not clean the clutch disc or the release bearing with cleaning solvent. 6. Install the alutch disc assembly to the flywheel using the special tool (09411-11000), 7. Install the clutch cover assembly to the flywheel and temporarily tighten the bolts one or two steps at atime ina star pattern. Tightening torque roatsne Clutch cover bolt: 15 ~ 22 Nm (150-220 kgfem, 11~16 IbF ft) 4, Remove the release fork shaft and bushing. 5. Apply multipurpose grease to the spline ofthe disc. Grease: CASMOLY | 9508 0.2gr QA caution When installing the clutch, apply grease to each part, but be careful not to apply excessive grease. It can cause clutch slippage and judder.CLUTCH SYSTEM CH-9 8. Align the bearing (A) to the release fork (B) and then 10. Install the transaxle assembly to the engine. install it to the sleeve of the housing, &) caution t\ CAUTION IW the transaxle assembly Is Installed to the engine Apply multipurpose grease (CASMOLY L9508) to without performing this step, the release bear- the bearing sleeve, contact point of the release ing can be separated, as the release fork rotates, fork (B) and the bushing Inner surface (C). freely. 8. Install the release lever to the release fork,CH -10 CLUTCH SYSTEM CLUTCH MASTER CYLINDER COMPONENTS | sarc: Return spring Clutch master eytincer Master cylinder bodyCLUTCH SYSTEM CH-11 REMOVAL rroses 3. Disconnect the clutch tube (A) (master cylinder side). 1. Drain the clutch fluid through the bleed plug (A). coca 4. Remove the master cylinder mounting nuts. 2. Remove clutch master cylinder connecting rod (A), 5: Remove the clutch line clips (A) spit pin {cotter pin) (C) and washer (8). 6. Hold the nut on the clutch hose (B) and loosen the flare nut (C) on the clutch tube. 7. Remove the clutch tube.CH-12 CLUTCH SYSTEM 8 Disconnectthe clutch hose (A) (release cylinderside). 10. Temporarily tighten the flare nut by hand, then tighten itto the specified torque, being careful that the clutch hose does not become twisted, 1 Maa = oN 8. Connect the clutch tube (A) (release cylinder side). coKoo78 111. Install the clutch tube and clips (A). 412. Install the master eylinder.CLUTCH SYSTEM CH-13, 13. Apply the specified grease to the clevis pin and INSPECTION eaux a. check in insite fhe ender toy for st piting Wheel bearing grease: SAE J310a, NUGINO. 2 or scoring 2. Check the piston cup for wear or distortion 3. Check the piston for rust, piting or scoring, 4. Check the elutch tube line for clogged. 5. Measure the master cylinder inside diameter and the piston outside diameter with a cylinder gauge microm- eter, NOTE Measure the inside diameter of the master cylindor at three places (bottom, middle, and top) in a perpendic- ular direction 414, Install the push rod to the clutch pedal 418, Pour the clutch fluid into the clutch master cylinder. 16. Bleed the clutch system 6. ifthe master cylinder-to-piston clearance exceeds the limit, replace the master cylinder and/or piston assem bly. Limitz 0.18 mm (0,006 in)CH-14 CLUTCH SYSTEM CLUTCH PEDAL COMPONENTS sarees Clutch member assembly Ignition lock switch 0.81.0 Pedal bush Clutch pedal TORQUE: Nm (kgf-om, Ib-ft)CLUTCH SYSTEM CH-15, INSPECTION 4. Check the pedal shaft and bushing for wear. 2. Check the lutch pedal fr bending or trsion. 3. Check the return spring for damage or deteroration 4, Check the pedal pad for damage or wear IGNITION LOCK SWITCH INSPECTION Remove the ignition lock switeh and check for continuity between the terminals, Ifthe continulty Is not as specified, replace the switch. ——_Teiminal Condtion 1 2 Pushed ———o Free 120003 = f iz RETURING TEST OF CLUTCH PEDAL. Deformation of pedal pad must be MAX. Smm after repeat- Ing the test 20 times (sudden return from full stroke), REPLACEMENT 1. Remove the clutch master cylinder connecting rod (A), washer (B), and split pin (C). 2. Remove the clutch pedal mounting bolts, 3. Apply the specified grease to the clutch pedal and bushings. Chassis grease: SAE J310a, NLGI No.1 4. Install the clutch pedal mounting bolt ‘Apply ease eoCH-16 CLUTCH SYSTEM 5. Apply the specified grease to the dlevis pin and washer. Wheel bearing grease: SAE J310, NLGINo2 6. Install the push rod to the clutch pedal. ADJUSTMENT ccs:ccus (nore + Chock forthe ignition ck switch. in case often look system vehicle theres an axtiond switch «Bote adjusting, remove the divers floor seat ‘After loosening the ignition lock switch nut, move it back untl it has no contact with the clutch pedal arm,(in case of clutch lock system vehicle, repeat this step with its additonal ignition lock switch). 2. Check for the specification below. Clutch pedal stroke : 150 mm Clutch pedal free play: 13 mm or less Distance between the inner pad and clutch pedal : 250 ~ 254 mm 3. Fix the ignition switch whtn its signal is OFF pressing the pedal slowly (52 ~ 58 mm). Tighten the fixing nut with specification ORQUE (O.Nm (80 ~ 100 kgfem, 5.2 A Worf) 4, (Clutch lock system vehicle) Fix the additional ignition lock switch when its signal Is ON pressing the pedal slowly (117 ~ 123 mm). Tighten the fixing nut with specicationCLUTCH SYSTEM CH-17 CLUTCH RELEASE CYLINDER COMPONENTS = Gasket Clutch hose __ Bleeder screw _ Recease onder 4 Retum spring [eed ss SS Union bott Piston Cotter pinCH-18 CLUTCH SYSTEM REPLACEMENT | courses 1. Drain the fluid from the bledding ply(A). 2. Clamp the clutch hose between the dutch release cylinder and the clutch tube. 3. Remove the clutch release cylinder loosening the mounting bolt. 4. Install the new clutch release cylinder.