General Information
Specifications
Item Specification
Clutch operation method Hydraulic type
Clutch disc
Type Single dry with diaphragm
Facing diameter (outside x inside)mm (in) • Gasoline 1.4 / 1.6 : Ø215 × Ø145 (Ø8.5 × Ø5.7)
• Gasoline 2.0 : Ø225 × Ø150 (Ø8.9 × Ø5.9)
• Diesel 1.6 / 2.0 : Ø240 × Ø155 (Ø9.4 × Ø6.1)
Clutch cover assembly
Type Diaphragm spring strap
Clutch release cylinder [M5CF only]
* I.D. mm (in) 20.64 (0.81)
Clutch master cylinder
* I.D. mm(in) 15.87 (0.62)
* I.D: Inside diameter
Service Standard
Standard value
Clutch disc thickness [When free] Diesel 1.6 : 8.7 ± 0.3 mm (0.343 ± 0.012 in)
Diesel 2.0 : 8.5 ± 0.3 mm (0.334 ± 0.012 in)
Clutch pedal height [Without carpet] Gasoline : 8.55 ± 0.3 mm (0.335 ±0.012 in)
Clutch pedal free play 182.8 mm (7.19 in)
Clutch pedal stroke 6 ~ 13 mm (0.24 ~ 0.51 in)
Gasoline : 140 ± 3mm (5.5 ± 0.12 in)
Diesel : 150 ± 3mm (5.9 ± 0.12 in)
Limit
Clutch disc rivet depth Gasoline 1.4 / 1.6 : 1.4 mm (0.055 in)
Gasoline 2.0 : 1.2 mm (0.047 in)
Diesel 1.6 : 1.3 mm (0.051 in)
Diesel 2.0 : 1.0 mm (0.0394 in)
Diaphragm spring end height difference Diesel 1.6 / Gasoline : 0.5 mm (0.02 in)
Diesel 2.0 : 0.8 mm (0.0315 in)
Clutch master cylinder clearance to piston 0.15 mm (0.006 in)
Tightening Torques
Item N.m kgf.m lb-ft
Clutch pedal to pedal support member
17 ~ 26 1.7 ~ 2.6 12.3~ 18.8
(Clutch pedal bracket)
Clutch pedal support member to master cylinder 6~8 0.6 ~ 0.8 4.3 ~ 5.8
Clutch tube flare nut 13 ~ 17 1.3 ~ 1.7 9.4 ~ 12.4
Clutch tube bracket 8~ 10 0.8 ~ 1.0 5.8 ~ 7.24
Clutch release cylinder 15 ~ 22 1.5 ~ 2.2 10.9 ~ 16.0
Clutch release cylinder union bolt 25 ~ 35 2.5 ~ 3.5 18.1 ~ 25.5
Gasoline(6ea) 15 ~ 22 1.5 ~ 2.2 10.9 ~ 16.0
Clutch cover assembly Disesel 1.6(9ea) 12 ~ 15 1.2 ~ 1.5 8.7 ~ 10.9
Disesel 2.0(6ea) 25 ~ 36 2.5 ~ 3.6 18.1 ~ 26.0
Ignition lock switch nut 8 ~ 10 0.8 ~ 1.0 5.8 ~ 7.3
Lubricants
Items Specified lubricants Quantity
Contact surface of release bearing and fulcrum of clutch r-
CASMOLY L9508 As required
elease fork
Inner surface of clutch release bearing CASMOLY L9508 As required
Inner surface of clutch release cylinder and outer circumfe-
Brake fluid DOT 3 or DOT 4 As required
rence of piston and cup
Inner surface of clutch disc spline CASMOLY L9508 As required
Inner surface of clutch master cylinder and outer circumfer-
Brake fluid DOT 3 or DOT 4 As required
ence of piston assembly
Wheel bearing grease SAE J310,
Clutch master cylinder push rod, clevis pin and washer As required
NLGI No.2V
Chassis grease SAE J310a, NLGI
Clutch pedal shaft and bushings As required
No.1
Contact portion of release fork to release cylinder push rod CASMOLY L9508 As required
Input shaft spline CASMOLY L9508 As required
Special Service Tools
Tool (Number and name) Illustration Use
09411-11000 Installation of the clutch disc.
Clutch disc guide
Troubleshooting
Trouble symptom Suspect area Remedy (See page)
Clutch slipping Insufficient pedal free play Adjust
• Car will not respond to engine
Clogged hydraulic system Correct or replace parts
speed during acceleration
• Insufficient vehicle speed Excessive wear of clutch disc facing Replace
• Lack of power during uphill dri- Hardened clutch disc facing, or oil on surface Replace
ving
Damaged pressure plate or flywheel Replace
Weak or broken pressure spring Replace
Difficult gear shifting (gear noise d- Excessive pedal free play Adjust
uring shifting)
Hydraulic system fluid leaks, air trapping or cl- Repair or replace parts
ogging
Unusual wear or corrosion of the clutch disc s- Replace
pline
Excessive vibration (distortion) of the clutch di-
Replace
sc
Clutch noi- When the clutch is not Insufficient play of the clutch pedal Adjust
sy used
Excessive wear of the clutch disc facing Replace
A noise is heard after Unusual wear and/ or damage of the release b- Replace
the clutch is disengag- earing
ed
A noise is heard when Insufficient grease on the sliding surface of the Repair
the clutch is disengag- bearing sleeve
ed
Repair
Improperly installed clutch assembly or bearing
A noise is heard when Damaged pilot bushing Replace
the car suddenly rolled
up with the clutch part-
ially engaged
Hard pedal effort Insufficient lubrication of the clutch pedal Repair
Insufficient lubrication of the spline part of clut- Repair
ch disc
Insufficient lubrication of the clutch release lev- Repair
er shaft
Hard to shift or will not shift Excessive clutch pedal free play Adjust the pedal free play
Faulty of the clutch release cylinder Repair the release cylinder
Clutch disc out of place, runout is excessive or Inspect the clutch disc
lining broken
Spline on the input shaft or clutch disc dirty or Repair as necessary
burned
Faulty of the clutch pressure plate Replace the clutch cover
Trouble symptom Suspect area Remedy (See page)
Clutch slips Insufficient clutch pedal free play Adjust the pedal free play
Clogged of the hydraulic system Repair or replace parts
Clutch disc lining oily or worn out Inspect the clutch disc
Faulty pressure plate Replace the clutch cover
Binding of the release fork Inspect the release fork
Clutch grabs/chatters Clutch disc lining oily or worn out Inspect the clutch disc
Faulty the pressure plate Replace the clutch cover
Bent clutch diaphragm spring Replace the clutch cover
Worn or broken torsion spring Replace the clutch disc
Engine mounts loose Repair as necessary
Clutch noisy Damaged the clutch 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
Clutch System
Description
Self Adjusting Clutch(S.A.C.) Cover
• As a clutch disc facing is worn away according to its
durability, a cover weight is increasing and a clutch
pedal pressure can be more needed.
• To make up for this defect, the self adjusting clutch
system makes the requsted pedal pressure
minimized so that makes the maintenance cycle
longer.
SEDCH7001L
Concentric Slave Cylinder-C.S.C.
It improves working efficiency and lowers the number
and the weight of part by unifing clutch release control
parts(clutch release bearing ~ clutch release cylinder) in
a manual transaxle.
Operation 2. If the clutch pedal freeplay and height is not within
the standard value range, adjust as follows:
Concentric Slave Cylinder-C.S.C
1) Turn and adjust the bolt within the standard
When the clutch pedal is pressed, oil pressure is
value, then secure by tightening the lock nut.
transmitted along the arrow directions shown below and
that moves the clutch slave cylinder and the diaphragm NOTICE
spring of the clutch cover. If the clutch pedal height is lower than the
standard value, loosen the bolt and adjust the
push rod.
After adjustment, tighten the bolt so that the
clearance with pedal stopper becomes
0.5mm(0.02 in) to 1.0mm (0.04 in) and secure
with lock nut.
KORE001B
Service Adjustment Procedure
Clutch Pedal Inspection And Adjustment
1. Measure the clutch pedal height (from the face of the
pedal pad to the floorboard) and the clutch pedal
clevis pin play (measured at the face of the pedal
LOJF003A
pad.)
2) Turn the push rod to agree with the standard
Standard value
value and then secure the push rod with the lock
(A) : 6 ~ 13 mm (0.24~0.51 in)
nut.
(B) : 182.8 mm (7.19 in)
CAUTION
When adjusting the clutch pedal height or the
clutch pedal play, be careful not to push the
push rod toward the master cylinder.
3. 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 may be the result of either air in the hydraulic
system or a faulty clutch master cylinder. Bleed the
air or disassemble and inspect the master cylinder or
clutch.
SEDCH7008L
Bleeding 4. Refill the clutch master cylinder with the specified
fluid.
CAUTION
Use the specified fluid. Avoid mixing different CAUTION
brands of fluid. The rapidly-repeated operation of the clutch
Specified fluid: SAE J1703 (DOT 3 or DOT 4) pedal in B-C range may disrupt the release
cylinder's position. During the bleeding
[M5CF] operation, press the clutch pedal to the floor
1. Loosen the bleeder screw(A) at the clutch release after it returns to the "A" point.
cylinder.
EOKD006A
SLDCH7002D
2. Depress the clutch pedal slowly until all air is
expelled.
3. Hold the clutch pedal down until the bleeder is
retightened.
[M6GF2]
Concentric Slave Cylinder Air Bleeding Procedure
1. After disconnecting a cap from the concentric slave
cylinder air bleeder, insert a vinyl hose in the plug.
2. Loosening the plug screw, press and release the
clutch pedal about 10 times.
NOTICE
Hold the air bleeder body not to rotate with a
spanner(A). The holding is needed when the plug
loosened or tightened.
3. Tighten the plug during the clutch pedal pressed.
Afterwards, raise the pedal with a hand.
Tightening torque :
25~29N.m (2.5~2.9Kgf.m, 18~21lb-ft)
4. After pressing the clutch pedal 3 times more, loosen
the plug and retighten it with the pedal pressed.
Raise it again, then.
5. Repeat the step 4 two or three times. (until there is
no bubble in the fluid)
KORE001C
CAUTION
1. Do not clamp the pipe of a concentric slave
cylinder.
2. Be careful not to damage O-rings.
Clutch Cover And Dinode
Components
SEDCH7002L
Removal Installation
1. Remove the transaxle assembly. (Refer to Manual 1. Apply multipurpose grease to the spline of the disc.
transaxle's removal in MT group)
Grease: CASMOLY L 9508
2. Insert the special tool (09411-11000) in the clutch
disc to prevent the disc from shifting. CAUTION
When installing the clutch, apply grease to each
part, but be careful not to apply excessive
grease.
It can cause clutch slippage and vibration
(shudder).
SHDCH6003D
3. Loosen the bolts(Gasoline : 6ea, Diesel 1.6 : 9ea,
Diesel 2.0 : 6ea) which attach the clutch cover to the
flywheel in a star pattern. Loosen the bolts in
succession, one or two turns at a time, to avoid
EOKD011A
bending the cover.
2. Temporarily install the clutch disc assembly to the
NOTICE
flywheel using the special tool (09411-11000).
Do not clean the clutch disc or the release bearing
with cleaning solvent.
SHDCH6003D
3. Tighten the bolts one or two steps at a time in a star
pattern.
[GASOLINE] Inspection
Tightening torque : Clutch cover assembly
15 ~ 22 Nm (1.5 ~ 2.2 kgf.m, 10.9 ~ 16.0 lb-ft) 1. Check the diaphragm spring end for wear and
uneven height.
2. Check the pressure plate surface for wear, cracks
and color change.
3. Check the rivets for looseness and replace the clutch
cover assembly if necessary.
Clutch disc
1. Check the clutch facing for loose rivets, uneven
contact, deterioration due to seizure, adhesion of oil,
or grease, and replace the clutch disc if defective.
2. Measure the thickness of the disc when free.
Standard value
Clutch disc thickness(A)[when free]
Clutch disc rivet depth(B)
KKNF002E : refer to 'SERVICE STANDARD' in GENERAL section.
[DIESEL 1.6]
Tightening torque :
12 ~ 15 Nm (1.2 ~ 1.5 kgf.m, 8.7 ~ 10.9 lb-ft)
EOKD010A
3. Check for the torsion spring play and damage and if
defective, replace the clutch disc.
SHDCH6006L 4. Clean the splines on the input shaft and install the
[DIESEL 2.0] clutch disc.
If the disc does not slide smoothly or if play is
Tightening torque :
excessive, replace the clutch disc and/or the input
25 ~ 36 Nm (2.5 ~ 3.6 kgf.m, 18.1 ~ 26.0 lb-ft)
shaft.
4. Remove the clutch disc guide (09411-11000).
5. Install the transaxle assembly to the engine. (Refer to
Manual transaxle's installation in MT group)
Clutch release bearing
CAUTION
The release bearing is packed with grease. Do not
use cleaning solvent or oil.
Standard grease : CASMOLY L9508
1. Check the bearing for seizure, damage or abnormal
noise. Also check the diaphragm spring contacting
points for wear.
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.
Clutch Master Cylinder
Components
SHDCH6002L
Removal [RHD]
1. Drain the brake fluid through the bleeding plug (A).
SHDCH6007L
SEDCH7009L 3. Disconnect the clutch tube (B) from the master
2. Remove the flexible hose (A) connected to brake cylinder.
reserve tank from the master cylinder. 4. Disconnect the two ignition lock switch connectors.
[LHD] 5. Remove the clutch pedal mounting nuts(A-2ea) and
the bracket mounting nut.
[LHD]
SHDCH6010D
SEDCH7005L
[RHD] 7. Remove the screws mounting the master cylinder to
the clutch pedal assembly.
Installation
1. Apply the specified grease to the clutch pedal and
bushings.
Chassis grease: SAE J310a, NLGI No.1
SEDCH7006L
6. Disconnect the push rod from the master cylinder by
removing the snap pin (A) and washer (B).
[LHD]
AOJF221A
2. Install the screws or nut mounting the master cylinder
to the clutch pedal assembly.
3. Apply the specified grease to the snap pin(A) and
washer.
Wheel bearing grease: SAE J310, NLGI No.2
SHDCH6011L
[RHD]
SHDCH6012L
4. Connect the push rod to the clutch pedal by installing 5. Install the clutch pedal mounting nuts (A-2ea).
the snap pin (A) and washer (B).
Tightening torque :
[LHD] 17 ~ 26Nm (1.7 ~ 2.6kgf.m, 12.3 ~ 18.8Ib-ft)
[LHD]
SHDCH6011L
[RHD] SEDCH7005L
[RHD]
SHDCH6012L
SEDCH7006L
6. Adjust the clutch pedal within the standard value, 7. Connect the flexible hose of the brake reserve tank to
then secure by tightening the lock nut. the master cylinder.
Standard value [LHD]
Free play (A)
6~13mm (0.24~0.51 in)
Height (B)
182.8mm (7.19 in)
SHDCH6010D
[RHD]
SEDCH7008L
SHDCH6007L
8. Connect the clutch tube(B) to the master cylinder.
9. Refill the brake fluid.
10.Bleed the air in the clutch system.(refer to Bleeding in
Serive Adjustment Procedure)
Disassembly
1. Remove the piston stop ring.
2. Pull out the push rod and piston assembly.
3. Remove the reserve tank band, reserve tank cap,
and reserve tank.
NOTICE
1. Use care not to damage the master cylinder body
and piston assembly.
2. Do not disassemble the piston assembly.
Inspection
1. Check the inside of the cylinder body for rust, pitting
or scoring.
2. Check the piston cup for wear or distortion.
3. Check the piston for rust, pitting or scoring.
4. Check to make sure the clutch line tube is not
clogged or restricted in any way.
5. Measure the master cylinder inside diameter and the
piston outside diameter with a cylinder gauge
micrometer.
NOTICE
Measure the inside diameter of the master cylinder
at three places (bottom, middle, and top) in a
perpendicular direction.
6. If the master cylinder-to-piston clearance exceeds the
limit, replace the master cylinder and/or piston
assembly.
Limit : 0.15 mm (0.006 in)
Reassembly
1. Apply the specified fluid to the inner surface of the
master cylinder body (A) and to the entire periphery
of the piston assembly (B).
Specified fluid: Brake fluid DOT 3 or DOT 4
2. Install the piston assembly.
3. Install the piston snap ring.
4. Install the push rod assembly.
Clutch Pedal
Components (1)
SEDCH7003L
Components (2)
SEDCH7004L
Removal [RHD]
1. Drain the brake fluid through the bleeding plug (A).
SHDCH6007L
SLDCH7002D 3. Disconnect the clutch tube (B) from the master
2. Remove the flexible hose (A) connected to brake cylinder.
reserve tank from the master cylinder. 4. Disconnect the two ignition lock switch connectors.
[LHD] 5. Remove the clutch pedal mounting nuts(A-2ea) and
the bracket mounting nut.
[LHD]
SHDCH6010D
SEDCH7005L
[RHD] 7. Remove the screws or nut mounting the master
cylinder to the clutch pedal assembly.
Installation
1. Apply the specified grease to the clutch pedal and
bushings.
Chassis grease: SAE J310a, NLGI No.1
SEDCH7006L
6. Disconnect the push rod from the master cylinder by
removing the snap pin (A) and washer (B).
[LHD]
AOJF221A
2. Install the screws or nut mounting the master cylinder
to the clutch pedal assembly.
3. Apply the specified grease to the snap pin(A) and
washer.
Wheel bearing grease: SAE J310, NLGI No.2
4. Connect the push rod to the clutch pedal by installing
the snap pin (A) and washer (B).
[LHD]
SHDCH6011L
[RHD]
SHDCH6011L
SHDCH6012L
[RHD] [RHD]
SHDCH6012L SEDCH7006L
5. Install the clutch pedal mounting nuts (A-2ea). 6. Adjust the clutch pedal within the standard value,
then secure by tightening the lock nut.
Tightening torque :
17 ~ 26Nm (1.7 ~ 2.6kgf.m, 12.3 ~ 18.8Ib-ft) Standard value
Free play (A)
[LHD]
6~13mm (0.24~0.51 in)
Height (B)
182.8mm (7.19 in)
SEDCH7005L
SEDCH7008L
7. Connect the flexible hose of the brake reserve tank to Inspection
the master cylinder. 1. Check the pedal shaft and bushing for wear.
[LHD] 2. Check the clutch pedal for bending or torsion.
3. Check the return spring for damage or deterioration.
4. Check the pedal pad for damage or wear.
Ignition lock switch inspection
Remove the ignition lock switch and check for continuity
between the terminals. If the continuity is not as
specified, replace the switch.
SHDCH6010D LOJF012A
[RHD] Standard value
Full stroke(A) : 12.0 ± 0.3mm (0.472 ± 0.012 in.)
ON-OFF point (B) : 2.0 ± 0.3mm (0.078 ± 0.012 in)
SHDCH6007L
8. Connect the clutch tube(B) to the master cylinder.
9. Refill the brake fluid. LOJF002B
10.Bleed the air in the clutch system.(refer to Bleeding in
Serive Adjustment Procedure)
Clutch Release Cylinder
Components
SEDCH7007L
Removal Installation
1. Drain the brake fluid through the bleed plug(A). 1. Coat the clutch clevis push rod specified grease.
Specified grease: CASMOLY L9508
SLDCH7002D
2. Disconnect the clutch tube(A). LOGF006B
2. Install the release cylinder mounting nuts(B-2ea).
Tightening torque :
15 ~ 22Nm (150 ~220 kgf.cm, 11 ~ 16 lb-ft)
SEDCH7010L
3. Remove the two clutch release cylinder mounting
nuts(B-2ea).
SEDCH7010L
3. Install the clutch tube(A).
4. Refill the brake fluid.
5. Bleed the air in the clutch system.
(refer to Bleeding in Service Adjustment Procedure)
Inspection
1. Check the release cylinder bore for rust and damage.
2. Measure the release cylinder bore at three locations
(bottom, middle, and top) with a cylinder gauge and
replace the release cylinder assembly if the
bore-to-piston clearance exceeds the limit.
Limit clearance to piston: 0.25mm (0.0098 in)
EOKD024A
Reassembly
1. Apply specified brake fluid to the release cylinder
bore and the outer surface of the piston and piston
cup, and push the piston cup assembly into the
cylinder.
Specified fluid: Brake fluid DOT 3 or DOT 4
EOKD025A 2. Install the valve plate(A), Spring(B), push rod(C) and
3. Check the clutch release cylinder for fluid leakage. boot(D).
4. Check the clutch release cylinder boots for damage.
Disassembly
1. Remove the clutch hose, valve plate, spring, push
rod, and boot.
2. Remove any dirt from the piston bore opening of the
release cylinder.
3. Remove the piston from the release cylinder using
compressed air.
CAUTION
• Use rags to prevent the piston from popping
out and causing injury.
• Apply compressed air slowly. Keep the fluid
from splashing in your eyes or on your skin. LOJF003B
