Clutch System

GENERAL CLUTCH MASTER CYLINDER

CLUTCH PEDAL
CLUTCH SYSTEM CLUTCH RELEASE CYLINDER
CLUTCH COVER AND DISC
CH -2 CLUTCH SYSTEM

GENERAL
SPECIFICATIONS EC53B64D

Engine type G4EE(1.4)/G4ED(1.6)

Clutch operation method
Hydraulic type
Clutch disc
Single dry with diaphragm
Type
Facing diameter (outside x inside)mm (in.) 215 x 145 (8.5 x 5.7)
Clutch cover assembly
Type Diaphragm spring strap
Clutch release cylinder
* 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]
Clutch pedal height[without carpet]
Clutch pedal free play
Clutch pedal stroke
Limit
Clutch disc rivet sink
Diaphragm spring end height difference
Clutch replease cylinder clearance to piston
Clutch master cylinder clearance to piston
8.2 ~ 8.8 mm (0.322 ~ 0.346 in.)
LHD : 163.9 mm (6.45 in.)
RHD : 174.5 mm (6.87 in.)
LHD/ RHD : 6 ~ 13 mm (0.24 ~ 0.51 in.)
LHD/ RHD : 145 mm (5.7 in.)
1.1 mm (0.043 in.)
0.5 mm (0.02 in.)
0.15 mm (0.006 in.)
0.15 mm (0.006 in.)

TIGHTENING TORQUE

Item Nm kgf.cm lb-ft

Clutch pedal to pedal support member
25 ~ 35 250 ~ 350 18 ~ 25
(Clutch pedal bracket)
Clutch pedal support member to master cylinder 19 ~ 20 190 ~ 200 13 ~ 14
Clutch tube flare nut 13 ~ 17 130 ~ 170 10 ~ 13
Clutch tube bracket 15 ~ 22 150 ~ 220 11 ~ 16
Clutch release cylinder 15 ~ 22 150 ~ 220 11 ~ 16
Clutch release cylinder union bolt 25 ~ 40 250 ~ 400 18 ~ 29
Clutch cover assembly 12 ~ 22 120 ~ 220 9 ~ 16
Ignition lock switch nut 8 ~ 10 80 ~ 100 6 ~ 7
Clutch release lever fulcrum 55 ~ 60 550 ~ 600 40 ~ 43
Master cylinder cap screw 2 ~ 3 20 ~ 30 1.4 ~ 2.2
Master cylinder push rod nut 9 ~ 14 90 ~ 140 6.5 ~ 10
Master cylinder nut 9 ~ 14 90 ~ 140 6.5 ~ 10
GENERAL CH -3

LUBRICANTS

Items Specified lubricants Quantity

Contact surface of release bearing and fulcrum
CASMOLY L9508 As required
of clutch release fork
Inner surface of clutch release bearing CASMOLY L9508 As required
Inner surface of clutch release cylinder and outer
Brake fluid DOT 3 or DOT 4 As required
circumference of piston and cup
Inner surface of clutch disc spline CASMOLY L9508 As required
Inner surface of clutch master cylinder and outer
Brake fluid DOT 3 or DOT 4 As required
circumference of piston assembly
Wheel bearing grease SAE
Clutch master cylinder push rod, clevis pin and washer As required
J310, NLGI No.2V
Chassis grease SAE J310a,
Clutch pedal shaft and bushings As required
NLGI No.1
Contact portion of release fork to release
CASMOLY L9508 As required
cylinder push rod
Input shaft spline CASMOLY L9508 As required

SPECIAL TOOLS E13BAED1

Tool (Number and name) Illustration Use

09411-25000 Installation of the clutch disc.
Clutch disc guide

EOKD001A
CH -4 CLUTCH SYSTEM

TROUBLESHOOTING EDFF450F

Trouble symptom Suspect area Remedy (See page)

Clutch slipping Insufficient pedal free play Adjust
• Car will not respond to engine speed
Correct or replace
during acceleration Clogged hydraulic system
parts
• Insufficient vehicle speed
• Lack of power during uphill driving Excessive wear of clutch disc facing Replace
Hardened clutch disc facing, or oil on surface Replace
Damaged pressure plate or flywheel Replace
Weak or broken pressure spring Replace
Difficult gear shifting (gear noise during shifting) Excessive pedal free play Adjust
Hydraulic system fluid leaks, air Repair or replace
trapping or clogging parts
Unusual wear or corrosion of the Replace
clutch disc spline
Excessive vibration (distortion) of
Replace
the clutch disc
Clutch noisy When the clutch is not used Insufficient play of the clutch pedal Adjust
Excessive wear of the clutch disc facing Replace
A noise is heard after the Unusual wear and/ or damage of Replace
clutch is disengaged the release bearing
A noise is heard when the Insufficient grease on the sliding surface Repair
clutch is disengaged of the bearing sleeve
Improperly installed clutch assembly Repair
or bearing
A noise is heard when Damaged pilot bushing Replace
the car suddenly rolled up
with the clutch 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
Repair
bearing retainer
Hard to shift or will not shift Adjust the pedal
Excessive clutch pedal free play
free play
Repair the release
Faulty of the clutch release cylinder
cylinder
Clutch disc out of place, runout is Inspect the clutch disc
excessive or lining broken
Spline on the input shaft or clutch Repair as necessary
disc dirty or burned
Replace the clutch
Faulty of the clutch pressure plate
cover
GENERAL CH -5

Trouble symptom Suspect area Remedy (See page)

Clutch slips Adjust the pedal
Insufficient clutch pedal free play
free play
Repair or replace
Clogged of the hydraulic system
parts
Clutch disc lining oily or worn out Inspect the clutch disc
Replace the clutch
Faulty pressure plate
cover
Inspect the release
Binding of the release fork
fork
Clutch grabs/chatters Clutch disc lining oily or worn out Inspect the clutch disc
Replace the clutch
Faulty the pressure plate
cover
Replace the clutch
Bent clutch diaphragm spring
cover
Replace the clutch
Worn or broken torsion spring
disc
Engine mounts loose Repair as necessary
Clutch noisy Replace the clutch
Damaged the clutch pedal bushing
pedal bushing
Loose part inside housing Repair as necessary
Replace the replease
Worn or dirty release bearing
bearing
Sticking release fork or linkage Repair as necessary
CH -6 CLUTCH SYSTEM

CLUTCH SYSTEM
COMPONENTS (1) EF192322

[LHD]

15-22(150-220, 11-16)
7
6

12-15(120-150, 9-11)

8
5

13-17(130-170, 10-13) 10

A
4

13-17(130-170, 10-13)

TORQUE : Nm(kgf.cm, Ib-ft)

1. Clutch pedal 6. Bolt

2. Master cylinder 7. Clutch release fork
3. Reserve hose 8. Clutch cover
4. Clutch tube 9. Clutch disc
5. Clutch release cylinder 10. Clutch release bearing
LOJF001C
CLUTCH SYSTEM CH -7

COMPONENTS (2)

[RHD]

12-15(120-150, 9-11)

10

15-22(150-220, 11-16)
7

11

6
5

13-17(130-170, 10-13)
4 3
2

TORQUE : Nm(kgf.cm, Ib-ft)

1. Clutch pedal 7. Bolt

2. Master cylinder 8. Clutch release fork
3. Reserve hose 9. Clutch cover
4. Clutch tube 10. Clutch disc
5. Reservior tank 11. Clutch release bearing
6. Clutch release cylinder
LOJF015A
CH -8 CLUTCH SYSTEM

SERVICE ADJUSTMENT 2) Turn the push rod to agree with the standard
value and then secure the push rod with the lock
PROCEDURE E54C0944
nut.
CLUTCH PEDAL INSPECTION AND ADJUSTMENT
CAUTION
1. Measure the clutch pedal height (from the face of the
When adjusting the clutch pedal height or the
pedal pad to the floorboard) and the clutch pedal cle-
clutch pedal clevis pin play, be careful not to
vis pin play (measured at the face of the pedal pad.)
push the push rod toward the master cylinder.
Standard value
(A) LHD/ RHD : 1 ~ 3 mm (0.04~0.11 in.)
(B) LHD : 163.9 mm (6.45 in.)
RHD : 174.9 mm (6.87 in.)

Clutch pedal clevis pin and pedal height

0.5-1.0mm
(0.02-0.04 in)

B
LOJF003A

3. After completing the adjustments, check that the

clutch pedal free play (measured at the face of the
pedal pad) is within the standard value ranges.
LOJF001A
Standard value
2. If the clutch pedal clevis pin freeplay and height is not LHD/RHD : (C) 6~13 mm (0.24~0.51 in.)
within the standard value range, adjust as follows:
Clutch pedal
1) Turn and adjust the bolt within the standard value,
then secure by tightening the lock nut.

NOTE
If the clutch pedal height is lower than the standard
C
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.

LOJF012B

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 may be the result of either air in the hydraulic sys-
tem or a faulty the clutch master cylinder. Bleed the
air or disassemble and inspect the master cylinder or
clutch.
CLUTCH SYSTEM CH -9

BLEEDING 2. Pump the clutch pedal slowly until all air is expelled.

Whenever the clutch tube, the clutch hose, and/or the 3. Hold the clutch pedal down until the bleeder is retight-
clutch master cylinder have been removed, or if the clutch ened.
pedal is spongy, bleed the system.
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 pedal
Specified fluid: SAE J1703 (DOT 3 or DOT 4) in B-C range may disrupt the release cylinder’s
position. During the bleeding operation, press the
clutch pedal to the floor after it returns to the "A"
1. Loosen the bleeder screw(B) at the clutch release point.
cylinder(A).

A
C B

EOKD006A
LOJF004B
CH -10 CLUTCH SYSTEM

CLUTCH COVER AND DISC

COMPONENTS EB4E6FEE

12~22 (120~220, 9~16)

1

TORQUE: Nm (kgf.cm, lb-ft)

1. Clutch release fork 3. Clutch disc

2. Clutch disc cover 4. Clutch release bearing
LOJF005A
CLUTCH SYSTEM CH -11

REMOVAL ED7846C5 5. Remove the shift fork boot(A).

1. To remove the transaxle assembly, first drain the

clutch fluid and transaxle gear oil, then remove the
air cleaner joint and the mounting bracket etc.

2. Remove the transaxle assembly, after removing each

bolt which connects the transaxle assembly and en-
gine.

3. Loosen the bolts attached to the release cylinder and

remove the release cylinder.
A
4. Remove the clutch release fork(A) and bearing(B).

NOTE
• It is impossible to remove the transaxle assembly LOGF003C

without performing this step because the clutch

cover assembly, release bearing and release fork
are held together.
• To reduce rattling noise from the gear, a new dual
mass flywheel has been used. Due to the appli-
cation of the dual mass flywheel, the clutch as-
sembly has also been changed. When replac-
ing the flywheel with the dual mass flywheel, the
clutch disc and cover should be replaced with the
new parts at the same time.
6. Insert the special tool (09411-25000) in the clutch disc
to prevent the disc from shifting.
7. 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 a time, to avoid bending the
cover.
NOTE
Do not clean the clutch disc or the release bearing
with cleaning solvent.

B
A

LOGF003B
CH -12 CLUTCH SYSTEM

INSPECTION EEA83F69 CLUTCH RELEASE BEARING

CLUTCH COVER ASSEMBLY CAUTION

1. Check the diaphragm spring end for wear and uneven The release bearing is packed with grease. Do not
height. use cleaning solvent or oil.

2. Check the pressure plate surface for wear, cracks and Standard grease : CASMOLY L9508
color change.

3. Check the rivets for looseness and replace the clutch B

cover assembly if necessary.

CLUTCH DISC
A
C
1. Check the clutch facing for loose rivets, uneven con-
tact, 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
A: Clutch release bearing
Clutch disc thickness(A)[when free] : B: Clutch release cylinder
8.5 ± 0.3mm[0.33 ±0.012in.] C: Clutch release fork
Limit LOJF007A
Clutch disc rivet depth(B) : 0.3mm[0.012 in.]
1. Check the bearing for seizure, damage or abnormal
noise. Also check the diaphragm spring contacting
points for wear.

B 2. Replace the bearing if the release fork contacting

points are worn abnormally.
A
CLUTCH RELEASE FORK

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

bearing, replace the release fork assembly.

EOKD010A

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.
If the disc does not slide smoothly or if play is exces-
sive, replace the clutch disc and/or the input shaft.
CLUTCH SYSTEM CH -13

INSTALLATION EFC615DC

1. Apply multipurpose grease to the spline of the disc.

Grease: CASMOLY L 9508

CAUTION
When installing the clutch, apply grease to each
part, but be careful not to apply excessive grease. A
It can cause clutch slippage and vibration (shud-
der).

LOGF003E

5. Install the release bearing(A) and shift fork(B).

EOKD011A

2. Install the clutch disc assembly to the flywheel using

A
the special tool (09411-25000).
B
3. Install the clutch cover assembly to the flywheel and LOGF003F
temporarily tighten the bolts one or two steps at a time
in a star pattern. 6. Install the release cylinder(A) to the transaxle

TORQUE TORQUE
Clutch cover bolt : Release cylinder bolt :
12 ~ 22 Nm (120 ~ 220 kgf.cm, 9 ~ 16 lb-ft) 15 ~ 22 Nm (150 ~ 220 kgf.cm, 11 ~ 16 lb-ft)

3 1

6 5

2 4

LOJF008A LOJF004B

4. Install the clutch release fork boot(A). 7. Install the transaxle assembly to the engine.
CH -14 CLUTCH SYSTEM

CLUTCH MASTER CYLINDER

COMPONENTS ECAC355B

1
3

13-17(130~170, 10~13)
19-20(190~200, 13~14)

TORQUE: Nm (kgf.cm, lb-ft)

1. Return spring 3. Damper & Push rod

2. Clutch master cylinder 4. Clevis pin
LOJF009A
CLUTCH SYSTEM CH -15

REMOVAL E56B05FD 4. Remove the flexible hose connected to brake reserve

tank.
1. Drain the clutch fluid through the bleed plug (A).

LOJF011A

LOJF004A
5. Remove the master cylinder mounting nut (A).
2. Remove clevis pin (A), split pin (cotter pin) (C) and
washer (B).

A A

AOJF301A

LOJF010A

3. Disconnect the clutch tube (A) (master cylinder side).

AOJF200A
CH -16 CLUTCH SYSTEM

DISASSEMBLY EBDCBD55 INSPECTION E54BC349

1. Remove the piston stop ring. 1. Check the inside of the cylinder body for rust, pitting
or scoring.
2. Pull out the push rod and piston assembly.
2. Check the piston cup for wear or distortion.
3. Remove the reserve tank band, reserve tank cap, and
reserve tank. 3. Check the piston for rust, pitting or scoring.

NOTE 4. Check to make sure the clutch line tube is not clogged
or restricted in any way.
1. Use care not to damage the master cylinder body
and piston assembly. 5. Measure the master cylinder inside diameter and the
2. Do not disassemble the piston assembly. piston outside diameter with a cylinder gauge microm-
eter.

NOTE
Measure the inside diameter of the master cylinder at
three places (bottom, middle, and top) in a perpendic-
ular direction.

EOKD019A

EOKD100A

6. If the master cylinder-to-piston clearance exceeds the

limit, replace the master cylinder and/or piston assem-
bly.

Limit : 0.15 mm (0.006 in.)

CLUTCH SYSTEM CH -17

REASSEMBLY E6E9E4B3 2. Apply specified grease to the clevis pin(A) and

washer(B).
1. Apply the specified fluid to the inner surface of the
master cylinder body (A) and to the entire periphery Grease : SAE J310 NLGI NO.2
of the piston assembly (B).

Specified fluid: Brake fluid DOT 3 or DOT 4

C
2. Install the piston assembly.

3. Install the piston snap ring.

4. Install the push rod assembly.

A A

LOJF010A

3. Connect the push rod(A) to the clutch pedal.

B

LOGF004D

INSTALLATION EB167F18

1. Install the master cylinder(A).

A
TORQUE :
9~14Nm(90-140 kgf.cm, 6.5-10 Ib-ft)

AOJF202A

4. Connect the flexible hose of the brake reserve tank to

the master cylinder.

5. Pour the brake fluid.

6. Connect the clutch tube to the master cylinder.

A TORQUE :
13~17Nm(130-170 kgf.cm, 10-13 Ib-ft)

AOJF301A 7. Bleed the clutch system.

CH -18 CLUTCH SYSTEM

CLUTCH PEDAL

COMPONENTS (1) EB0F1E60

[LHD]
25~35(250~350, 18~25) 13
11
9
15
21

19
8 8~10(80~100, 6~7)
10 7
20 17
18

12
22
3
26
25 23

16

6
24
5
4

14
2

TORQUE: Nm (kgf.cm, lb-ft)

1. Clutch arm 10. Bolt 19. Bolt

2. Pedal plate 11. Cowl bracket 20. Nut
3. Pipe 12. Stopper bracket 21. Ignition lock switch
4. Bracket 13. Nut 22. Switch nut
5. Pedal stopper 14. Pedal pad 23. Bush
6. Arm bracket 15. Bolt 24. Brake pedal stopper
7. Plate 16. Bush 25. Bush
8. Clutch member 17. Spring washeer 26. Return spring
9. Switch bracket 18. Nut
LOJF001B
CLUTCH SYSTEM CH -19

COMPONENTS (2)

[RHD]
13

19
11
20
10
9

8 18

15 17

22

7 21

12
25
5
16
3
23
26 24
6 4

14

1. Clutch arm 10. Bolt 19. Bolt

2. Pedal plate 11. Cowl bracket 20. Nut
3. Pipe 12. Stopper bracket 21. Ignition lock switch
4. Bracket 13. Nut 22. Switch nut
5. Pedal stopper 14. Pedal pad 23. Bush
6. Arm bracket 15. Bolt 24. Brake pedal stopper
7. Plate 16. Bush 25. Bush
8. Clutch member 17. Spring washeer 26. Return spring
9. Switch bracket 18. Nut
LOJF016A
CH -20 CLUTCH SYSTEM

REMOVAL E9794D18 INSPECTION E40DC8B5

1. Remove the cotter pin (A), washer (B), and clevis pin 1. Check the pedal shaft and bushing for wear.
(C).
2. Check the clutch pedal for bending or torsion.

3. Check the return spring for damage or deterioration.

C
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,
A
replace the switch.
B

Terminal
Condition 1 2

Pushed(ON)
LOJF010A
Free(OFF)

2. Remove the clutch pedal mounting bolts(A) and

nuts(B).
LOJF012A

A
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.)

A
B

AOJF220A

LOJF002B
CLUTCH SYSTEM CH -21

INSTALLATION EF31349B 3. Apply the specified grease to the clevis pin and
washer.
1. Apply the specified grease to the clutch pedal and
bushings. Wheel bearing grease: SAE J310, NLGI No.2

Chassis grease: SAE J310a, NLGI No.1

LOJF010A

AOJF221A 4. Install the push rod to the clutch pedal.

2. Install the clutch pedal mounting bolts(A) and nuts(B). 5. Adjust the clutch pedal within the standard value, then
secure by tightening the lock nut.
TORQUE :
25~35 Nm(250~350 kgf.cm, 18~25 Ib-ft) Standard value
Free play (A)
A LHD/RHD : 6~13mm (0.24~0.51 in.)
Height (B)
LHD : 163.9 mm (6.45 in.)
RHD : 174.5 mm (6.87 in.)

Clutch pedal clevis pin and pedal height

B A

B
AOJF220A

LOJF001A
CH -22 CLUTCH SYSTEM

CLUTCH RELEASE CYLINDER

COMPONENTS EFF04CCC

10

11
6 12
5
3
4

2
1

25~35 (250~350, 18~25)

TORQUE: Nm (kgf.cm, lb-ft)

1. Union bolt 7. Bleeder screw

2. Gasket 8. Release cylinder
3. Tube joint 9. Return spring
4. Clutch tube 10. Piston
5. Valve plate 11. Boot
6. Valve spring 12. Push rod
LOGF006A
CLUTCH SYSTEM CH -23

REMOVAL E8901260 INSPECTION EB3A79B4

1. Disconnect the clutch tube(A). 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: 0.15 mm (0.006 in.)

LOJF013A

2. Remove the clutch release cylinder mounting bolt.

DISASSEMBLY EB5C6C24

1. Remove the clutch hose, valve plate, spring, push rod,

and boot. EOKD025A

2. Remove any dirt from the piston bore opening of the 3. Check the clutch release cylinder for fluid leakage.
release cylinder.
4. Check the clutch release cylinder boots for damage.
3. Remove the piston from the release cylinder using
compressed air.
REASSEMBLY EA0325E8

CAUTION
1. Apply specified brake fluid to the release cylinder bore
• Use rags to prevent the piston from popping and the outer surface of the piston and piston cup, and
out and causing injury. push the piston cup assembly into the cylinder.
• Apply compressed air slowly. Keep the fluid
from splashing in your eyes or on your skin. Specified fluid: Brake fluid DOT 3 or DOT 4

2. Install the valve plate(A), Spring(B), push rod(C) and

boot(D).

D
A B
C

EOKD024A

LOJF003B
CH -24 CLUTCH SYSTEM

INSTALLATION E281A68D 3. Install the clutch tube(A).

1. Coat the clevis push rod specified grease.

Specified grease: CASMOLY L9508

LOJF013A

LOGF006B

2. Install the release cylinder(A) to the transaxle.

TORQUE :
15 ~ 22Nm(150 ~ 220kgf.cm, 11~16 Ib-ft)

LOJF004B