Clutch
Clutch
I. Overview
(I) Structure Summary
Architectural Overview
Clutch assembly is located between the engine and gearbox, the clutch pressure plate is fixed to the
rear plane of the flywheel by a bolt assembly. Clutch disc and gearbox are connected by a spline input
shaft which can slide axially, and transmit torque to the surrounding. During driving, according to the
depressing or releasing the clutch pedal to temporary separate and gradually engage the engine and
gearbox to cut off or pass the input power from the engine to the transmission.
Clutch system includes the following components:
• Active parts: clutch pressure plate assembly clutch pressure plate assembly is bolted to the flywheel.
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• Follower: Clutch disc Clutch disc and gearbox are connected by a spline input shaft. Active parts and
the follower are kept in contact by spring pressure. This pressure is exerted by a diaphragm spring
pressure inside plate assembly.
• Operating parts: clutch control system includes a clutch pedal, master cylinder, tubing, cylinder,
separation fork and bearing, when depress the clutch pedal, through hydraulic pressure, master cylinder
pushes cylinder, separation fork, through bearing pushes diaphragm spring separation claw, release the
pressure plate, to disengage the clutch
Clutch 21
Clutch
Clutch control system
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1. Clutch pedal assembly
2. Clutch hard pipe assembly -I
3. Clutch bracket -I
4. Clutch master cylinder and the inlet pipe assembly
5. Clutch cylinder assembly
Clutch 22
Clutch
Structure chart of clutch pressure plate and driven disc
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1. Clutch cover and pressure plate assembly
2. Clutch driven disc
3. Hexagon head bolt and spring washer assemblies
(II) Maintenance parameters
Maintenance parameters
No Item Parameters
1 clutch pedal free travel 6~20mm
grease
No Item Grease model
1 cylinder Kunlun II low temperature grease
kingpin
(III) Torque parameters
No Item Torque（N·m） Remark
1 clutch pedal fixing bolt 20~28
2 clutch pedal fixing nut 20~28
3 oil pipe mounting bracket 8~12
4 exhaust bolt 20~28
5 clutch pressure plate mounting bolts 20~28
Clutch 23
Clutch
(IV) Maintenance precaution
Precautions
• The recommended clutch hydraulic oil is brake fluid "DOT 4".
• Do not reuse drained clutch hydraulic oil.
• Be careful not to spill clutch hydraulic oil on the body paint.
• Do not use gasoline or kerosene and other mineral oils; otherwise it will corrode the rubber parts of the
hydraulic system.
• Do not disassemble master cylinder and hydraulic release bearing.
△ WARNING Use vacuum cleaner to clean clutch plate, but not with compressed air.
Inspection Points
△ CAUTION Do not use a vacuum pump or any other type of evacuation power plant to operate the
system. Check the fluid level of the clutch hydraulic oil; make sure that the level is normal. Do not let
the clutch hydraulic oil fall on the body paint or other components. If the clutch hydraulic oil spilled on
the body paint or other parts, immediately wipe clean with a dry cloth.
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(V) Special tools
No Tool Tool Dimensions Description
1 Flywheel stopper Fixed flywheel
II. Fault diagnosis
(I) Common fault diagnosis
Clutch assembly and clutch control system performance diagnosis should be performed by an
experienced driver or a skilled vehicle maintenance technician.
The following (failure) diagnosis involves common problems and possible causes. After appropriate
diagnosis, make adjustments according to the respective solutions in service manual diagnostic table and
corresponding to the appropriate section in each of the specific program, replace the parts as required.
During vehicle maintenance, clutch pressure plate and clutch disc cannot be repaired, if any one of
them is broken, replace the entire assembly.
If the clutch driven plate rivets polished or clutch disc polluted by oil or grease dirt, then it cannot be
used. If you need to replace a part, use well qualified new parts to replace it. The table below will help
diagnose the causes under the following conditions leads to emergence of a clutch system: not separation,
separation incomplete; the engagement incomplete, slip, noise and jitter
The number in the diagnosis table does not mean order of examination, there is no precedence
relations among the various possible causes.
(II) Diagnosis table
No Failure Failure cause analysis Solution Remark
performance
clutch lever deformation replace the deformation part Refers to
Clutch 24
Clutch
1 Unable to diaphragm spring deformation replace the deformation part clutch
separate unable to
diaphragm spring support ring replace the broken part
separate
broken
clutch pedal spring break and fatigue replace the worn and broken part
flowchart
clutch driven disc and flywheel or adjusting clutch system
clutch pressure plate or bonding
clutch driven disc deformation replace deformation, wear,
2 Unable to when it turns it will swing cracks and exceeding standard Refers to the
incomplete size parts unable to
separate incomplete
clutch driven disc broken Replace clutch driven disc separate
clutch driven disc input does not spline clutch disc not work well flowchart
match with the gearbox shaft input, with the gearbox input shaft
or the input surface is worn spline, to replace the clutch disc,
if any necessary, replace the
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gearbox input shaft
clutch partly adhesive flywheel or replace the non-qualified parts
clutch pressure plate or bite
flywheel / clutch pressure plate /
clutch disc exceeds standard size replace the non-qualified parts
clutch pedal and the clutch control adjust clutch system, remove
system drawing mechanical failure unnecessary gap, eliminate
or improper adjustment mechanical failure and reinstall
improper assembly parts
clutch driven disc stained by oil or Clean up the oil or grease dirt Refers to the
3 Unable to grease dirt disc broken
clutch driven replace the deformation worn and unable to
incomplete incomplete
no clutch pedal free travel broken
properlypart
adjust clutch pedal free
connect connect
diaphragm spring / clutch pressure travel 程clutch disc or clutch
replace flowchart
plate / clutch lever/ Clutch disc assembly problem
splines deformed or damaged
Clutch pedal and the clutch control adjust clutch system, remove
system drawing mechanical failure unnecessary gap, eliminate
or improper adjustment mechanical failure and reinstall
improper assembly parts
clutch plate wear replace driven disc Refers to
Clutch 25
Clutch
4 Slipping Clutch contaminated by oil or grease clean the grease or replace driven clutch
disc slippage
flowchart
Clutch engagement is not complete The same with "incomplete
separation" and "engaging
incomplete" solutions
Flywheel / clutch pressure plate /
clutch plate thickness exceeds a Replace non-qualified parts
predetermined size
improper driving leads to clutch Turn off the engine, cool the
housing over heating temperature in the clutch(if
overheated) and operate further
diagnosis
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Improper installation reinstall
Improper clutch driven disc Install requested clutch driven
5 noise disc
Improper balancing If any part has improper
balancing, replace the whole Refers to
cutch clutch noise
flowchart
adjusting clutch brush
Clutch thrust bearing failure and reinstall improper
assembly of parts
Clutch disc torsion damping spring replace deformation, wear and
damaged tear parts
Clutch damper spring does not meet Replace the driven disc
Jitter the specifications
6
Clutch driven disc does not meet Replace the driven disc
specifications
Clutch pollution by oil or grease Replace the driven disc
Clutch 26
Clutch
(III) Fault diagnosis flowchart
Clutch unable to separate flowchart
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Clutch 27
Clutch
Unable to incomplete separate flowchart
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Clutch 28
Clutch
Unable to complete connect flow chart
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Clutch 29
Clutch
Clutch slippage flowchart
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Clutch 30
Clutch
Clutch noise flowchart
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Clutch 31
Clutch
III Clutch pedal
(I) Remove
1. Open the engine hatch,
2. Disconnect the negative battery cable,
3. Drain the clutch hydraulic oil refers to clutch hydraulic oil,
4. Remove the lower driver's side fender body refers to the lower driver's side fender body
5. Remove the driver's airbag assembly refers to driver's airbag assembly
6. Remove the steering assembly refers to steering assembly See
7. Remove the steering column on the shell package; under the steering column cladding refers to the
steering column cladding
8. Remove the clock spring refers to clock spring
9. Remove the combination switch refers to combination Switch
10. Removing burglar alarm induction coil refers to induction coil
11. Remove ignition lock assembly refers to the ignition lock assembly
12. Remove the steering column assembly refers to the steering column assembly
13. Removing the clutch pedal
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1). Disconnect clutch wire harness connector.
2). Remove the clamp connected clutch pedal and
the clutch master cylinder, disassembly latch,
disengage the connection of clutch pedal and
clutch master cylinder.
3). Remove the two bolts connecting upper part
of clutch pedal and body.
Clutch 32
Clutch
4). Remove the two fixing nuts connecting clutch
pedal and the lower part of the body.
5). Remove the clutch pedal.
(II) Check
1. Check the clutch pedal after demolition
1) Check if the clutch pedal is distorted, damaged,
cracked or appears weld.
2). If occurs, please replace the clutch pedal assembly
(III) Installation
1. Install the clutch pedal
1). Place the clutch pedal to the mounting position.
2). Install two nuts connecting he clutch pedal and
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the lower part of the body.
Tightening torque 20~28N·m
3). Install two bolts connecting the clutch pedal and
the upper portion of the body. Tightening torque 20 ~
28N • m
4). Install lock pin, install the clamp connecting
clutch pedal and the clutch master cylinder.
△ Note Before installation, coat low grease Kunlun II
to the outer surface of the front pin。
Clutch 33
Clutch
5) Connect clutch harness connector.
2. Adjust the clutch pedal free travel
3. Install the steering column assembly
4. Install the ignition lock assembly
5. Install anti-theft induction coil
6. Install the combination switch
7. Install the clock spring
8. Install the lower steering column cladding, under
the steering column cladding
9. Install the steering wheel assembly
10. Install the driver's airbag assembly
11. Install the lower driver side fender body
12. Fill the clutch hydraulic oil
13. Connect the negative battery cable
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14. Close the engine hatch
IV. Clutch pedal stroke
1. Measure clutch pedal free travel
1). gently press the clutch pedal by hand to determine
when the pedal drop resistance, measure clutch pedal
free travel by scale.
Free travel: 6 ~ 20mm
△ Attention if the clutch pedal free travel is not in
specified region, then it must be the clutch hydraulic
circuit with air or clutch master cylinder is faulty.
Exhaust the systems, check the master cylinder or
dismantle the clutch.
2. Adjust the clutch pedal travel
1) Loosen the lock nut and turn the bolt, adjust the
clutch pedal travel. After adjusting, tighten the
lock nut.
Tightening torque 20 ~ 28N • m
△ Attention when adjust the height of the clutch
pedal, do not push the lever to the clutch master
cylinder.
V. Clutch hydraulic oil
1. Drain the clutch hydraulic oil
1) Open the brake fluid filler cap.
2) Place drip pan.
3). Empty brake fluid
4) Install the brake fluid filler cap.
Clutch 34
Clutch
△ Note cover the painted surface with a rag or cloth to
prevent adhesive of brake fluid.
2. Fill clutch hydraulic oil
1). Depress the brake pedal several times until the
complete elimination of the vacuum booster pressure.
2) Open the brake fluid filler cap.
3) Fill brake fluid.
△ NOTE Open the front tank cover, clean, only allowed to
store brake fluid in a sealed container.
3. Clutch system exhaust
△ Note after installing the clutch line, clutch master
cylinders, clutch assembly and clutch cylinder, if found
pedal weak, exhaust the system
1) Loosen the clutch working cylinder exhaust bolts。
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2) Slowly depress the clutch pedal until the air is
completely discharged.
3).) fully depress the pedal and hold, tighten the exhaust
bolts.
4) Supply clutch hydraulic system with hydraulic oil.
△ Note always keep the liquid level in the tank between
MIN and MAX
5) Repeat steps 1-4 until clutch hydraulic oil discharged
from the system is clean and with no air bubbles.
4. Check whether the clutch is working properly
1) Start the engine; depress the clutch pedal, carefully
hang in reverse gear after 2s. If there is big noise during
gear selection, fully depress the clutch pedal five times to
exhaust the system.
2) After waiting for about 30s and then check the work
situation of the clutch. If there is still big noise, repeat the
above step
VI. Clutch switch assembly
(I) Remove
1. Open the engine hatch
2. Disconnect the negative battery cable
Clutch 35
Clutch
3. Remove the lower driver's side fender body refers to the lower driver's side fender body
4. Remove the clutch switch assembly
1). Disconnect the clutch switch harness connector.
2). Remove the buckle connecting the clutch pedal with
clutch switch harness, disconnect the clutch switch and
pedal.
3) Removing the clutch switch fixed nut.
4) Remove the clutch switch.
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(II) Installation
1. Install the clutch switch assembly
1). Place clutch switch assembly to the mounting
position.
2) Tighten the clutch switch fixing nut.
3) Install the knuckle connecting clutch switch and
clutch pedal
4) Connect the clutch switch harness connector.
2. Install the lower driver side fender body
3. Connect the negative battery cable
4. Close the engine hatch
VII Clutch master cylinders and inlet pipe assembly
(I) Remove
1. Open the engine hatch
Clutch 36
Clutch
2. Drain clutch hydraulic oil, refers to clutch hydraulic oil
3. Remove the inlet pipe assembly
1). Remove the clip, disengage inlet pipe assembly
and brake master cylinder.
2). Remove the clip, disengage inlet pipe assembly and
clutch master cylinder.
3) Remove the inlet pipe assembly.
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4. Remove the clutch master cylinder
1). Removing the clip, disengage inlet pipe assembly
and clutch master cylinder.
2) Remove the flare nut and disengage the clutch
hard pipe assembly - I and clutch master cylinder.
Clutch 37
Clutch
3). Remove the clamp connecting the clutch pedal and
clutch master cylinders, remove the latch, disengage the
clutch pedal and the clutch master cylinder.
4) Remove the two fixing nuts connecting clutch master
cylinder and clutch pedal body.
5) Remove the clutch master cylinder.
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(II) Installation
1. Install the clutch master cylinder
1). Place the clutch master cylinder to the installation
location.
2) Install the two fixing nuts connecting clutch master
cylinder and clutch pedal body.
Tighten torque 20 ~ 28N • m
3) Install the lock pin, install clamp connecting clutch
pedal and the clutch master cylinder.
△ Note Coat low temperature grease Kunlun II on the
outer surface of the front pin.
4). Install nut connecting the clutch hard pipe assembly
- Ⅰ and clutch master cylinder.
Tightening torque 16 ~ 18N • m
Clutch 38
Clutch
5). Install clamps to connecting clutch master
cylinder inlet pipe assembly and the clutch master
cylinder.
2. Install the inlet pipe assembly
1). Install clamp to connect inlet pipe assembly and
brake master cylinder.
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2) Install clamp to connect inlet pipe assembly clutch
master cylinder.
3. Fill the clutch hydraulic oil refers to clutch
hydraulic oil
4. Drain clutch system refers to the clutch hydraulic oil
5. Close the engine hatch
VIII Clutch cylinder and the inlet pipe assembly
(I) Remove
1. Open the engine hatch
2. Drain clutch hydraulic oil refers to clutch hydraulic oil
3. Remove the clutch inlet pipe assembly
Clutch 39
Clutch
1) Remove connection nut between the clutch inlet
pipe and the clutch hard tube assembly
2). Remove the fixing nut connecting clutch inlet pipe
and clutch working cylinder.
3). Disengage clutch inlet pipe assembly
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4. Remove clutch cylinder
1). Remove bolts connecting the clutch inlet pipe and
the clutch cylinder.
2). Remove the latch and rivets connecting the clutch
cylinder and separation fork.
Clutch 40
Clutch
3) Remove the two fixing bolts connecting the clutch
cylinder and the gearbox.
4) Remove the clutch cylinder.
(II) Installation
1. Install clutch cylinder
1). Connect the latch and rivets to the clutch cylinder
and separation fork
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2). Install fixing bolts connecting the clutch inlet pipe
and the clutch cylinder
3). Install two fixing bolts to connect the clutch
cylinder and the gearbox.
Tightening torque 14.7 ~ 21.6N • m
Clutch 41
Clutch
2. Install the clutch inlet pipe assembly
1) Install the fixing bolts to connect the clutch inlet
pipe and the clutch cylinder.
2) Install the connection nut between the clutch inlet
pipe and the clutch hard tube assembly - Ⅰ.
Tightening torque 16 ~ 18N • m
3. Fill the clutch hydraulic oil refers to clutch hydraulic
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oil
4. Drain clutch system refers to the clutch hydraulic oil
5. Close the engine hatch
IX Clutch hard pipe assembly
(I) Remove
1. Open the engine hatch
2. Drain clutch hydraulic oil refers to the clutch
hydraulic oil
3. Remove clutch hard tube assembly
1) Remove the connection nut between the clutch inlet
pipe and the clutch hard tube assembly
2) Remove the pipe nut and the connection between the
clutch hard pipe assembly and clutch master cylinder.
3) Remove the clutch hard tube assembly
Clutch 42
Clutch
(II). Installation
1. Install the clutch hard tube assembly
1) Install oil pipe nuts and remove the connection
between clutch hard pipe assembly - Ⅰ and clutch master
cylinder.
Tightening torque 16 ~ 18N • m
2) Install the connection nut between the clutch inlet
pipe and the clutch hard tube assembly - Ⅰ
Tightening torque 20 ~ 28N • m
2. Fill the clutch hydraulic oil refers to clutch hydraulic
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oil
3. Drain clutch system refers to clutch hydraulic oil
4. Close the engine hatch
X Clutch cover and pressure plate assembly, clutch driven disc
(I) Remove
1. Remove the transmission assembly refers to gearbox assembly
2. Remove the clutch cover and pressure plate assembly,
clutch driven disc
1). Remove the clutch cover and pressure plate assembly,
6 fixed bolts connecting clutch driven disc and the engine
.
(II) Installation
1. Install the clutch cover and pressure plate assembly,
clutch driven disc
1) Clean the clutch friction plate and the input shaft
keyway to remove grease and wear metals crumbs.
2) Apply grease to the input shaft keyway.
Grease: SAE J310
△ Note ensure that the grease is applied in the
predetermined position, if not may lead to clutch noise,
separation bad or damage. Too much oil can lead to slip
or jitter.
3) Install the clutch cover.
4) Use the special tool to install clutch plates and the
Clutch 43
Clutch
clutch pressure plate.
5) As shown in Figure through 1-2-3-4-5-6 sequence
tighten the clutch fixing bolts successively and evenly.
Tightening torque 20 ~ 28N • m
△ Note tighten each bolt 1 to 2 laps in turn progressively.
2. Install the transmission assembly
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Clutch 44
