SECTION 5C
CLUTCH
Caution : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.
SPECIFICATIONS
Fastener Tightening Specifications
Application | N•m | Lb-Ft | Lb-In |
Pedal Mounting Shaft Nut | 18 | 13 | - |
Clutch Master Cylinder Nuts | 23 | 17 | - |
Concentric Slave Cylinder Retaining Bolts | 8~12 | - | 71~106 |
Concentric Slave Cylinder-to-Clutch Oil Pipe Screw | 16 | 12 | - |
Pressure Plate-to-Flywheel Bolts (FAM II 2.4D) | 15 | 11 | - |
Pressure Plate-to-Flywheel Bolts (2.0S DIESEL or HFV6 3.2L) | 28 | 21 | - |
DIAGNOSIS
Clutch Operation
Intermittent Clutch Operation
Checks | Action |
Check for the driver improperly operating the vehicle. | Correct the driver’s operation of the vehicle as necessary. |
Check for the insufficient oil or the leak at oil pressure line. | Repair the leak or add the oil. |
Check for a warped or worn clutch disc. | Replace the clutch disc (FAM II 2.4D). Replace new pressure plate and new clutch disc (2.0S DIESEL or HFV6 3.2L). |
Check for worn splines on the input shaft. | Repair or Replace the splines on the input shaft. |
Check for a weak diaphragm spring. | Replace the pressure plate (FAM II 2.4D). Replace new pressure plate and new clutch disc (2.0S DIESEL or HFV6 3.2L). |
Clutch Slipping
Checks | Action |
Check for a stuck concentric slave cylinder. | Replace the concentric slave cylinder. |
Check for improper return of clutch oil. | Perform the air bleeding. |
Check for a worn clutch disc or oil contamination. | Replace the clutch disc (FAM II 2.4D). Replace new pressure plate and new clutch disc (2.0S DIESEL or HFV6 3.2L). |
Check for a warped pressure plate. | Replace the pressure plate (FAM II 2.4D). Replace new pressure plate and new clutch disc (2.0S DIESEL or HFV6 3.2L). |
Clutch Vibration
Checks | Action |
Check for a contaminated or warped flywheel. | Repair or replace the flywheel. |
Check for a weak diaphragm spring. | Replace the pressure plate (FAM II 2.4D). Replace new pressure plate and new clutch disc (2.0S DIESEL or HFV6 3.2L). |
Check for a oily contamination of clutch disc. | Replace the clutch disc (FAM II 2.4D). Replace new pressure plate and new clutch disc (2.0S DIESEL or HFV6 3.2L). |
Check for worn splines on the input shaft. | Replace the splines on the input shaft. |
Hard Pedal Effort
Checks | Action |
Check for bad lubrication of clutch pedal shaft. | Apply the grease or repair it. |
Check for a clogged pipe. | Inspect or replace the clogged pipe. |
Check for a stuck concentric slave cylinder. | Replace the concentric slave cylinder. |
Noise in Clutch Pedal
Checks | Action |
Check for insufficient lubrication of clutch pedal bushing. | Lubricate the clutch pedal bushing. |
Check for interference of clutch pedal return spring. | Remove and reinstall the clutch pedal return spring. |
COMPONENT LOCATOR
Hydraulic Clutch Components
- Clutch Pedal
- E- Ring
- Bushing
- Clutch Pedal Position Switch
- Clutch Padal Brace
- Pedal Shaft
- Nut
- Return Spring
- Clutch Master Cylinder
- Nut
- Clutch Master Cylinder
- Nut
- Clip
- Reservoir Hose
- Clutch Actuator Cylinder Pipe Assembly
- Pin
- Concentric Slave Cylinder Pipe
- Concentric Slave Cylinder
- Bolt
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
Clutch Pedal
Removal Procedure
- Disconnect the negative battery cable.
- Remove the nut and the pedal mounting shaft.
- Disconnect the return spring from the mount brace.
- Remove the E-ring from the clutch pedal.
- Remove the push rod from the clutch pedal.
- Remove the clutch pedal.
Installation Procedure
- Install the clutch pedal.
- Coat the push rod with multi-purpose grease.
- Install the push rod to the clutch pedal.
- Install the E-ring to the clutch pedal.
- Coat the pedal mounting shaft with multi-purpose grease.
- Connect the return spring to the mount brace.
- Install the nut and the pedal mounting shaft.
Tighten
Tighten the pedal mounting shaft nut to 18 N•m (13 lb-ft).
- Connect the negative battery cable.
Clutch Pedal Position Switch
Removal Procedure
- Disconnect the negative battery cable.
- Disconnect the switch connector.
- Remove the clutch pedal position switch.
Installation Procedure
- Install the clutch pedal position switch.
- Connect the swich connector.
- Connect the negative battery cable.
Air Bleeding
Bleed the hydraulic system to remove the air which enteredwhen the pipes were disconnected for repairs. The clutch fluid in the clutch reservoir must be maintained at the MIN level or higher during air bleeding.
- Attach a vinyl hose to the bleeder plug. Place the other end of the vinyl tube in a glass container half-filled with clutch fluid.
- Slowly pump the clutch pedal several times.
- While you press the clutch pedal, loosen the bleeder screw until the fluid starts to run out. Close the bleeder screw.
- Repeat Step 3 until there are no air bubbles in the fluid.
- Fill the reservoir with clutch fluid up to the proper level.
Pressure Plate and Clutch Disc (FAM II 2.4D)
Removal Procedure
- Disconnect the negative battery cable.
- Remove the transaxle from the vehicle. Refer to Section 5B, Five-Speed Manual Transaxle.
- Remove the pressure plate bolts and the pressure plate.
Important : Support the pressure plate when you remove the last bolt.
- Remove the clutch disc from the flywheel.
Inspection Procedure – Clutch Disc
- Visual Inspection
- Inspect the worn or oily contamination on the clutch surface.
- Inspect the damaged or weakened torsion spring.
- Inspect the a warped or bent clutch disc. After inspection, replace the clutch disc, if necessary.
- Clutch Disc Inspection
- Measure the rivet head depth from the clutch disc surface.
- Replace the clutch disc if the measured value is below the limit.
- Rivet Head Depth (Limit) : 1.1 mm (0.043 in)
Inspection Procedure – Pressure Plate
- Check for a worn diaphragm spring finger.
- Check for a worn or cracked pressure plate surface.
- Check for the polluted face by the oil. After inspection, replace the pressure plate if necessary.
Installation Procedure
- Coat the spline on the clutch disc with multi-purpose grease.
- Align the pressure plate and the clutch disc onto the flywheel using a suitable tool.
- Install the pressure plate bolts.
Tighten
Tighten the bolts to 15 N•m (11 lb-ft).
- Install the transaxle into the vehicle. Refer to Section 5B, Five-Speed Manual Transaxle.
- Connect the negative battery cable.
Pressure Plate and Clutch Disc (2.0S DIESEL or HFV6 3.2L)
Removal Procedure
- Disconnect the negative battery cable.
- Remove the transaxle from the vehicle. Refer to Section 5B, Five-Speed Manual Transaxle.
- Remove the pressure plate bolts and the pressure plate.
Important : Support the pressure plate when you remove the last bolt.
- Remove the clutch disc from the flywheel.
Inspection Procedure – Clutch Disc
- Visual Inspection
- Inspect the worn or oily contamination on the clutch surface.
- Inspect the damaged or weakened torsion spring.
- Inspect the a warped or bent clutch disc. After inspection, replace new pressure plate and new clutch disc, if necessary.
- Clutch Disc Inspection
- Measure the rivet head depth from the clutch disc surface.
- Replace new pressure plate and new clutch disc if the measured value is below the limit.
- Rivet Head Depth (Limit) : 1.2 mm (0.047 in)
Inspection Procedure – Pressure Plate
- Check for a worn diaphragm spring finger.
- Check for a worn or cracked pressure plate surface.
- Check for the polluted face by the oil. After inspection, replace new pressure plate and new clutch disc if necessary.
Installation Procedure
- Coat the spline on the clutch disc with multi-purpose grease.
- Align the pressure plate and the clutch disc onto the flywheel using a suitable tool.
Important : When replacing the pressure plate or the clutch disc, Replace both the pressure plate and the clutch disc with new ones.
- Install the pressure plate bolts.
Tighten
Tighten the bolts to 28 N•m (21 lb-ft).
- Install the transaxle into the vehicle. Refer to Section 5B, Five-Speed Manual Transaxle.
- Connect the negative battery cable.
Clutch Master Cylinder Assembly
Removal Procedure
Before disconnecting the reservoir tank hose, remove the clutch fluid from the reservoir tank.
- Remove the locking clip from the clutch pedal.
- Remove the push rod from the clutch pedal.
- Disconnect the hose clamp on the master cylinder.
- Disconnect the master cylinder hose.
- Remove the master cylinder pipe.
- Remove the clutch master cylinder nuts.
- Remove the clutch master cylinder.
Installation Procedure
- Install the clutch master cylinder and clutch master cylinder nuts.
Tighten
Tighten the clutch master cylinder nuts to 23 N•m (17 lb-ft).
- Connect the pipe to the master cylinder.
- Connect the master cylinder hose.
- Connect the hose clamp on the master cylinder.
- Install the push rod to the clutch pedal.
- Install the locking clip to the clutch pedal.
- Bleed the air. Refer to "Air Bleeding" in this section.
- Fill the reservoir with clutch fluid up to the proper level.
Concentric Slave Cylinder
Removal Procedure
- Remove the transaxle from the vehicle. Refer to Section 5B, Five-Speed Manual Transaxle.
- Remove the concentric slave cylinder retaining bolts.
- Disconnect the concentric slave cylinder pipe from the concentric slave cylinder.
Important : When removing the bushing, Make sure not to remove it with excessive force.
- Remove the bushing from the concentric slave cylinder pipe.
- Remove the concentric slave cylinder pipe.
- Remove the O-ring and the concentric slave cylinder.
Installation Procedure
- Install the O-ring and concentric slave cylinder.
- After installing the pipe screw provisionally, tighten the concentric slave cylinder retaining bolts.
Tighten
Tighten the concentric slave cylinder retaining bolts to 8~12 N•m (71~106 lb-in).
- Tighten the pipe screw.
Tighten
Tighten the pipe screw to 16 N•m (12 lb-ft).
- Install the bushing to the concentric slave cylinder pipe.
- Install the transaxle into the vehicle. Refer to Section 5B, Five-Speed Manual Transaxle.
UNIT REPAIR
Clutch Master Cylinder
Disassembly Procedure
- Remove the clutch master cylinder assembly from the vehicle. Refer to "Clutch Master Cylinder Assembly" in this section.
- Remove the boot and disconnect the piston stop ring using ring pliers.
- Remove the pushrod assembly and the piston assembly.
Assembly Procedure
- Apply clean fluid to the piston assembly cup and insert the piston assembly and the pushrod assembly into the master cylinder body.
- Install the piston stop ring using ring pliers. Install the boot.
- Install the clutch master cylinder assembly into the vehicle. Refer to "Clutch Master Cylinder Assembly" in this section.
GENERAL DESCRIPTION AND SYSTEM OPERATION
Driving Members
The driving members consist of two flat surfaces machined to a smooth finish. One of these is the rear face of the engine flywheel and the other is the pressure plate. The pressure plate is fitted into a steel cover which is bolted to the flywheel.
Driven Members
The driven member is the clutch disc with a splined hub. The splined hub is free to slide lengthwise along the splines of the input shaft and drives the input shaft through these same splines.
The driving and driven members are held in contact by spring pressure. This pressure is exerted by a diaphragm spring in the pressure plate assembly.
Operating members
The clutch release system consists of the clutch pedal, the clutch master cylinder, and concentric slave cylinder.
Unlike the former system to release the clutch by the release lever and release fork, the concentric slave cylinder type makes the concentric slave cylinder directly perform the clutch release by the generated pressure through the clutch pedal operation.
