Clutch System

GENERAL
SPECIFICATIO NS................................................. CH-2
LUBRICAN TS......................................................... CH-3
SPECIAL TO O LS................................................... CH-3
TROUBLESHOOTING.......................................... CH-4

CLUTCH SYSTEM
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CLUTCH CONTROL
SERVICE ADJUSTM ENT PR O C EDU R E......CH-6
CLUTCH CORVER AND DISC
COM PONENTS.................................................. CH-8
REM OVAL........................................................... CH-9
IN S P E C T IO N ..................................................... CH-9
INSTALLATION.................................................. CH-10
CLUTCH MASTER CYLINDER
COM PONENTS.................................................. CH-12
D ISASSEM BLY.................................................. CH-13
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IN S P E C T IO N ..................................................... CH-13
R EASSEM BLY................................................... CH-13
CLUTCH PEDAL
COM PONENTS.................................................. CH-14
R EM O VAL...........................................................CH-15
IN S P E C T IO N ..................................................... CH-15
INSTALLATION.................................................. CH-15
CLUTCH RELEASE CYLINDER
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COM PONENTS.................................................. CH-16

R EM O VAL...........................................................CH-17
INSTALLATION.................................................. CH-17
D ISASSEM BLY.................................................. CH-17
IN S P E C T IO N ..................................................... CH-18
R EASSEM BLY................................................... CH-18
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CH -2 CLUTCH SYSTEM

GENERAL
SPECIFICATIONS E374E2C2

Clutch operating method Hydraulic type

Clutch disc
- Type Single dry with diaphragm.
- Facing diameter (Outside x Inside) mm (in.) 215 x 145 (8.5 x 5.7)
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Clutch cover assembly
- Type Diaphragm spring strap
Clutch release cylinder 2.0L : 19.05 (0.76)
* I.D. mm (in.) 2.7L : 20.64 (0.82)
Clutch master cylinder
* I.D. mm (in.) 15.87(0.62)

* I.D. : Inside Diameter

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SERVICE STANDARD

Clutch pedal free play 6-13 mm (0.24-0.52 in.)

Clutch pedal height 166.9 mm (6.676 in.)
Clutch pedal stroke 2.0L : 145 mm (5.7 in.)
2.7L : 152 mm (6.1 in.)
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Lim it
Clutch disc rivet sink 1.1 mm (0.044 in.)
Diaphragm spring end height difference 0.5 mm (0.02 in.)
Clutch release cylinder clearance to piston 0.15 mm (0.006 in.)
Clutch master cylinder clearance to piston 0.15 mm (0.006 in.)
unit of measure : mm (inch)

TIGHTENING TORQUE
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Item Nm kgf.cm Ibf.ft

Clutch pedal to pedal support member 19-28 190-280 14-20
(Clutch pedal bracket)
Clutch pedal support member to master cylinder 8-10 80-100 6 -7
Clutch tube flare nut 13-17 130-170 9-13
Clutch tube bracket 4 -6 40-60 3 -4
Reservoir band 13-17 130-170 9-13
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Clutch release cylinder 15-22 150-220 11-16

Clutch release cylinder union bolt 20-25 200-250 15-18
Clutch cover assem bly
Single mass flywheel 15-22 150-220 11-16
Dual mass flywheel 20-27 200-270 14-19
GENERAL CH -3
LUBRICANTS EADFD948

Items Specified lubricants Quantity

Contact surface of release bearing and CASMOLY L 9508 As required
fulcrum of clutch release fork
Inner surface of clutch release bearing CASMOLY L 9508 As required
Inner surface of clutch release cylinder and outer Brake fluid DOT 3 or DOT 4 As required
circumference o f piston and cup
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Inner surface of clutch disc spline CASMOLY L 9508 As required
Inner surface of clutch master cylinder and outer Brake fluid DOT 3 or DOT 4 As required
circumference of piston assembly
Clutch master cylinder push rod, clevis Wheel bearing grease SAE J310a, As required
pin and washer NLGI No.2
Clutch pedal shaft and bushings SAE J310a, Chassis grease, NLGI-No.1 As required
Contact portion of release fork to release CASMOLY L 9508 As required
cylinder push rod
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Input shaft spline CASMOLY L 9508 As required

Clutch release fork shaft contact portion & bushings CASMOLY L 9508 About Ig.

SPECIAL TOOLS ECEBFE57

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CH -4 CLUTCH SYSTEM
TROUBLESHOOTING EF93CCD2

Symptom Probable cause Remedy

Clutch slipping Insufficient clutch pedal free play Adjust
• Car will not respond to
Clogged hydraulic system Correct or replace parts
engine speed during
acceleration Excessive wear of clutch disc facing Replace
• Insufficient vehicle Hardened clutch disc facing, or oil on surface Replace
speed
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• Lack of power during Damaged pressure plate or flywheel Replace
uphill driving Weak or broken pressure spring Replace
Difficult gear shifting (gear Excessive pedal free play Adjust
noise during shifting)
Hydraulic system fluid leaks, air trapping or clogging Repair or replace parts
Unusual wear or corrosion of clutch disc spline Replace
Excessive vibration (distortion) of clutch disc Replace
Clutch When clutch is Insufficient play of clutch pedal Adjust
noisy not used
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Excessive wear of clutch disc facing Replace
A noise is heard Unusual wear and/or damage of release bearing Replace
after clutch is
disengaged
A noise is heard Insuffcient grease on the sliding surface of bearing sleeve Repair
when clutch is
disengaged Improperly installed clutch assembly or bearing Repair
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A noise is heard Damaged pilot bushing Replace

when car is
suddenly rolled
with clutch partially
engaged
Difficult to depress clutch Insufficient lubrication of clutch pedal Repair
pedal
Insufficient lubrication of the clutch disc spline Repair
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Insufficient lubrication of the clutch release lever shaft Repair

Insufficient lubrication of front bearing retainer Repair
Difficult to shift gear or Excessive clutch pedal free play excessive Adjust pedal free play
cannot shift at all
Clutch release cylinder faulty Repair release cylinder
Clutch disc out of true, runout is excessive or lining broken Inspect clutch disc
Spline on input shaft or clutch disc dirty or burred Repair as necessary
Clutch pressure plate faulty Replace clutch cover
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Clutch slips Clutch pedal free play insufficient Adjust pedal free play
Clogged hydraulic system Repair or replace parts
Clutch disc lining oily or worn out Inspect clutch disc
Pressure plate faulty Replace clutch cover
Release fork binding Inspect release fork
GENERAL CH -5

Symptom Probable cause Remedy

Clutch grabs/chatters Clutch disc lining oily or worn out Inspect clutch disc
Pressure plate faulty Replace clutch cover
Clutch diaphragm spring bent Replace clutch cover
Worn or broken torsion spring Replace clutch disc
Engine mounts loose Repair as necessary
Clutch noisy Damaged clutch pedal bushing Replace clutch pedal
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bushing
Loose part inside housing Repair as necessary
Replace release
Release bearing worn or dirty
bearing
Release fork or linkage sticks Repair as necessary
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CH -6 CLUTCH SYSTEM

CLUTCH SYSTEM / l \ CAUTION

When adjusting the clutch pedal height o r the
CLUTCH CONTROL clutch pedal clevis pin play, be careful not to
push the push rod towardthe master cylinder.

SERVICE ADJUSTMENT 3. After completing the adjustments, check that the

PROCEDURE EDF0A1DB clutch pedal free play (measured at the face of the
pedal pad) is within the standard value ranges.
CLUTCH PEDAL INSPECTION AND ADJUSTMENT
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Standard value:
1. Measure the clutch pedal height (from the face of the (B) 6-13 mm (0.24-0.52 in.)
pedal pad to the floorboard) and the clutch pedal cle­ (C) 50 mm (1.5 in.)
vis pin play (measured at the face of the pedal pad).

Standard value: (A) 166.9 mm 4. If the clutch pedal free play, and the distance between
the clutch pedal and the floor board when the clutch is
disengaged, do not meet with the standard values, it
Clutch pedal height (A)
may be the result of either air in the hydraulic system
or a faulty clutch master cylinder. Bleed the air or dis­
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assemble and inspect the master cylinder or clutch.

The distance between the

Clutch pedal free play clutch pedal and the
floor board
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EOOB007A

2. If the clutch pedal clevis pin free-play is not within the

standard value range, adjust as follows:
• Turn and adjust the bolt, then secure by tighten­
EODA007A
ing the lock nut.
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EODA006B

( u j NOTE
After the adjustment, tighten the bolt until it reaches
the pedal stopper, and then tighten the lock nut.
• Turn the push rod to agree with the standard
value and then secure the push rod with the lock
nut.
CLUTCH SYSTEM CH -7
BLEEDING

Whenever the clutch tube, the clutch hose, and/or the

clutch master cylinder have been removed, or if the clutch
pedal is spongy, bleed the system.

,/^ i CAUTION
Use the specified fluid. Avoid mixing different
brands o f fluid.
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Specified fluid: SAE J1703 (DOT 3 or DOT 4)

1. Loosen the bleeder screw at the clutch release cylin­

der.

2. Push the clutch pedal down slowly until all Is expelled.

3. Hold the clutch pedal down until the bleeder Is retight­

ened.
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4. Refill the clutch master cylinder with the specified
fluid.

, / j \ CAUTION
The rapidly-repeated operation o f the clutch pedal
in B-C range may cause the release cylinder's
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position to be forcedout from the release cylinder
body during air bleeding, Repress the dutch
pedal after it returns to the "A" point completely.
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EODA007C
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CH -8 CLUTCH SYSTEM

CLUTCH COVER AND DISC

COMPONENTS E837BFE6

e <— 1
<6M/T> i
------ 2
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® < -— 3
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1
2
<5M/T> I
(S)< -3
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------ 5
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10.8-15.9(150-220,14.7-21.6)

5.9~7.8(6.~80,4.3~5.8)
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10.8-15.9(150-220,14.7-21.6)
TORQUE: Nm(kgf.cm, Ibf.ft)

1. Nut 7. Bolt
2. Spring washer 8. Release bearing sleeve
3. Plain washer 9. Clutch release bearing
4. Release folk shaft lever 10. Clutch cover assembly
5. Bushing 11. Clutch disc assembly
6. Clutch release folk shaft
E O O F 502A
CLUTCH SYSTEM CH -9
REMOVAL EB605EE5 INSPECTION E3EE7280

1. Drain the clutch fluid and transaxle gear oil. CLUTCH COVER ASSEMBLY

2. Remove the transaxle assembly. 1. Check the diaphragm spring end for wear and uneven
height.
3. Insert the special tool (09411-25000) in the clutch disc Replace if wear is evident or height difference ex­
to prevent the disc from falling. ceeds the limit.

4. Loosen the bolts that attach the clutch cover to the Lim it: 0.3 mm (0.012 in.)
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flywheel in a star pattern.

5. Loosen the bolts in succession, one or two turns at a 2. Check the pressure plate surface for wear, cracks and
time, to avoid bending the cover flange. color change.

3. Check the rivets for looseness and replace the clutch

A CAUTION cover assembly if necessary.
DO NOT clean the clutch disc or release bearing
CLUTCH DISC
with cleaning solvent
1. Check the clutch facing for loose rivets, uneven con­
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tact, deterioration due to seizure, adhesion of oil, or
grease, and replace the clutch disc if defective.

2. Measure the rivet sink and replace the clutch disc if it

is out of specification

Lim it: 1.1 mm (0.044 in.)

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EODA018A

3. Check for torsion spring play and damage and if de­

fective, replace the clutch disc.

4. Clean the splines on the input shaft and install the

clutch disc.
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If the disc does not slide smoothly or if play is exces­

sive, replace the clutch disc and/or the input shaft.
CH -10 CLUTCH SYSTEM
CLUTCH RELEASE BEARING INSTALLATION EEEAAC8F

A CAUTION 1. Apply multipurpose grease to the release bearing

contact surfaces and the release cylinder contact
The release bearing Is packed with grease. Do not surface of the clutch release fork assembly.
use cleaning solvent or oil.

1. Check the bearing for seizure, damage or abnormal CAUTION

noise. Also check the diaphragm spring contacting When installing the clutch, apply grease to each
points for wear. part, but be careful not to apply excessive grease.
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It can cause clutchsllppage and judder.
2. Replace the bearing if the release fork contacting
points are worn abnormally.

CLUTCH RELEASE FORK

If there is abnormal wear at the point of contact with the

bearing, replace the release fork assembly.
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2. Apply multipurpose grease into the groove of the re­

lease bearing.
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Grease: CASMOLY L9508

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Apply grease

EODA019A
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CLUTCH SYSTEM CH -11
3. Apply multipurpose grease to the clutch release lever 8. Tighten the bolts by one or two turns at a time, in
fulcrum contact surface of the clutch release fork as­ succession, to avoid bending the cover flange.
sembly. If a special tool is not available, tighten the bolt tem­
porarily and then torque to specification in diagonal
Grease: CASMOLY L9508 torquing sequence indicated below.
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EOOE1QOA
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TIGHTENING TORQUE
4. Clean the surfaces of the flywheel and pressure plate
Single mass flywheel:
thoroughly with fine sandpaper or crocus cloth, and
15-22 N m (150-220 kgfcm, 11-16 Ibfft)
make certain that all oil or grease has been removed.
Dual mass flywheel:
5. Apply a small amount of multipurpose grease to the 20-27 N m (200-270 kgf cm, 14-19 Ibf ft)
clutch disc splines and input shaft splines.
9. Remove the special tool.
Grease: CASMOLY L9508
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10. Install the transaxle. (Refer to GROUP - Manual

Transaxle Assembly)
/ i \ CAUTION
11. Adjust the clutch pedal free-play. (See CH-6)
Do not apply more grease than necessary. Too
much grease could cause clutch slip or judder.

6. Using the special tool (09411-25000), install the

clutch disc to the flywheel. When installing the clutch
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disc, be sure that the surface having the manufac­

tures stamp is towards the pressure plate side.

7. Install the the clutch cover assembly onto the flywheel

and install the six (6) bolts through the clutch cover
into the flywheel.
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EODA120A
CH -12 CLUTCH SYSTEM

CLUTCH MASTER CYLINDER

COMPONENTS EAC2D9FE
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TORQUE: Nm(kgf.cm, Ibf.ft)

1. Reservoir cam assembly 8. Clutch master cylinder assembly

2. Bolt 9. Sealer
3. Reservoir mounting bracket 10. Plain washer
4. Clutch master cylinder reservoir 11. Split pin
5. Clutch tube clip 12. Hose clip
6. Reservoir hose 13. Clutch tube
7. Nut 14. Clutch tube bracket
EOOF504A
CLUTCH SYSTEM CH -13
DISASSEMBLY E4E69E0D REASSEMBLY ED731BA1

1. Remove the reservoir band, reservoir tank and reser­ 1. Apply the specified fluid to the inner surface of the
voir cap. cylinder body and to the outside of the piston assem­
bly.
2. Remove the piston stop ring.
Specified fluid: BRAKE FLUID DOT 3 or DOT 4
3. Pull out the push rod and piston assembly.

2. Install the piston assembly.

(U J w o t e
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Be careful not to damage the master cylinder body 3. Install the piston stop ring.
and piston assembly.
4. Install the push rod assembly.

INSPECTION E98DC4AA

1. Check the inside of the cylinder body for rust, pitting

or scoring.

2. Check the piston cup for wear or distortion.

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3. Check the piston for rust, pitting or scoring.

4. Check the clutch tube line for obstructions.

5. Measure the clutch master cylinder inside diameter

with a cylinder gauge and the piston outside diameter
EODA014B
with a micrometer.
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5. Install the reservoir band, reservoir tank and reservoir

(Uj) NOTE cap.
Measure the inside diameter o f the clutch master
cylinder in three places (bottom, middle, and top), in
perpendicular directions.

6. If the clutch master cylinder-to-piston clearance ex­

ceeds the limit, replace the master cylinder and/or pis­
ton assembly.
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Lim it: 0.15 mm (0.006 in.)

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EODA014A
CH -14 CLUTCH SYSTEM

CLUTCH PEDAL

COMPONENTS EFB A 3914

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1. Clutch pedal bracket 7. Nut

2. Stop lamp switch assembly 8. Clutch pedal bush
3. Bolt 9. Spring washer
4. Turn over spring 10. Rubber stopper
5. Bush 11. Clutch pedal
6. Clutch pedal pasition switch assenbly 12. pedal pad
EOOF508A
CLUTCH SYSTEM CH -15
REMOVAL E2D C 6E23 INSTALLATION E8641C37

1. Remove the cotter pin, washer and clevis pin. 1. Installation is the reverse of removal.

2. Remove the clutch pedal mounting bolt. 2. Apply multi-purpose grease to the bushings.

INSPECTION ECDB823F

1. Check the clutch pedal shaft and bushing for wear.

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2. Check the clutch pedal for bending or distortion.

3. Check the return spring for damage or deterioration.

4. Check the clutch pedal pad for damage or wear.

IGNITION LOCK SWITCH INSPECTION

Check for continuity between terminals. EODA009B

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— ^ " T e r m in a l
1 2
3. Apply multi-purpose grease to the clevis pin and
C o n d itio n ^ ~—
washer.
P ushed
4. Install the push rod to the clutch pedal.
F re e

EODA009A 5. Adjust the clutch pedal clevis pin play.

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EOOB059C EOOF519A
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CH -16 CLUTCH SYSTEM

CLUTCH RELEASE CYLINDER

COMPONENTS E135E9C4
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1. Clevis pin 7. Clutch release cylinder plate valve

2. Split pin 8. Clutch release cylinder gasket
3. Push rad 9. Union bolt
4. Return spring 10. Clutch hose assembly
5. Bleeder screw 11. Clutch release cylinder assenbly
6. Valve spring
EOOF511A
CLUTCH SYSTEM CH -17
REMOVAL ED6907D3 DISASSEMBLY EFBC496B

1. Disconnect the clutch tube. 1. Remove the clutch hose, valve plate, spring, push rod
and boot.
2. Remove the clutch release cylinder mounting bolt.
2. Remove any dirt from the piston bore opening of the
release cylinder.
INSTALLATION EAE95458

3. Remove the piston from the release cylinder using

1. Coat the clevis pin with the specified grease. compressed air.
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Specified grease: CASMOLY L9508
/ j \ CAUTION
1. Cover the release cylinder with rags to pre­
vent the piston from popping out and causing
injury.
2. Apply compressed air slowly to prevent the
fluid from splashing in your eyes or on your
skin.
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EOOF512A

2. Install the clutch release cylinder, and the clutch tube.

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EODA016A
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EO D A011A
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CH -18 CLUTCH SYSTEM
INSPECTION E85E24ED REASSEMBLY E3CEEE7A

1. Check the clutch release cylinder lor fluid leakage. 1. Apply specified brake fluid to the release cylinder bore
and the outer surface of the piston and piston cup, and
2. Check the clutch release cylinder boots for damage. push the piston cup assembly into the cylinder.

3. Check the release cylinder bore for rust and damage. Use the specified fluid:
Brake fluid DOT 3 or DOT 4
4. Measure the release cylinder bore at three locations
(bottom, middle and top) with a cylinder gauge and
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replace the release cylinder assembly if the bore-to- 2. Install the valve plate, push rod and boot.
piston clearance exceeds the limit.

Limit: 0.15 mm (0.006 in.)

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Cylinder gauge

EODA016B
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