Clutch assembly.
1 - clutch disc, 2 - clutch cover, 3 - gearbox.
Withdrawal
1. Disconnect the gearbox from the engine (see chapter "Manual Transmission").
2. Remove the clutch release lever.
- A) Loosen the clutch release lever nut and remove the washer.
- b) Remove the pin and circlip from the clutch release slave cylinder.
- V) Remove the clutch release lever.
Note: It is not possible to remove the transmission assembly without following the steps above because the clutch cover, release bearing and release fork are fixed together.
3. Remove the clutch release slave cylinder (see section "Clutch release slave cylinder").
4. Remove release bearing.
- A) Rotate the release bearing in either direction to locate the snap ring lock.
- b) Insert the puller legs under the knurled washer and place them in the center of the circlip.
- V) Spread the ends of the circlip by pressing on the bearing as shown.
- G) While holding the ends of the circlip apart, pull on the release bearing and remove it.
- d) Install the special tool in the clutch disc to prevent it from falling.
- e) Loosen the bolts securing the clutch cover to the flywheel in a diagonal sequence in several passes. Loosen the mounting bolts no more than one or two turns at a time to avoid damage to the clutch cover.
Caution: Do not clean the clutch disc or release bearing with solvent.
- and) Remove the clutch release fork axle and bearing.
Examination
1. Check the clutch cover.
- A) Clean the clutch housing of dust with a vacuum cleaner or rags. Do not use compressed air for this purpose. Check for oil leaks from the engine crankshaft rear oil seal and transmission front oil seal. If there are leaks, make the necessary repairs.
- b) The friction surface of the pressure plate must be worn evenly. If any part of the disc surface is worn excessively, the pressure plate has not been installed correctly.
Note: Before checking, clean the friction surface of the pressure plate with a cleaning solvent.
- V) Check the flatness of the pressure plate surface with a square. If the surface roughness exceeds the allowable value, then replace the pressure plate.
- Limit value: 0.5 mm
- G) Check the ends of the petals of the diaphragm spring for wear and symmetry of the relative position. Replace the spring if there is significant wear or the difference in the relative position of the ends of the petals exceeds the maximum allowable value.
- Limit value: 0.5 mm
- d) Check the pressure plate surface for wear, cracks or discoloration.
- e) Check that the rivets securing the casing elements are not loose and, if necessary, replace the clutch casing assembly.
2. Check the flywheel.
- A) Check the friction surface of the flywheel for discoloration, minor damage, small cracks and wear.
- b) Check that the three flywheel pins are correctly installed.
3. Check the slave drive
- A) Check the friction surface of the clutch disc for loose rivets, uneven contact, deterioration due to scuffing, oil or grease contamination. Replace the driven disk if defective.
Note: Do not touch the clutch disc with dirty hands or gloves. Replace the clutch disc if its surface is contaminated with oil or grease.
- b) Measure the distance from the surface of the friction linings to the rivet heads of the clutch driven disk and replace the disk if the measured value is less than the maximum allowable value.
- Limit value: 0.3 mm
- V) Check the clutch disc splines and damper springs for excessive wear, play and damage. Replace disc if defective.
- G) Clean the transmission input shaft splines and install the clutch disc. If the clutch disc does not move smoothly or there is excessive play, replace the clutch disc and/or the transmission input shaft.
Diameter (outdoor / indoor) clutch disc lining:
- for models before 2001:
- with engines displacement:
- 2.0 L: 215/145 mm
- 2.4 l, 2.7 l: 225 / 150 mm
- for models since 2001: 225/150 mm
Clutch plate thickness (in a free state) along the circumference of the disc pads:
- for models before 2001:
- with engines displacement:
- 2.0L: 8.2-8.8mm
- 2.4L: 8.4-9.0mm
- for models since 2001: 8.3-8.9 mm
4. Check the release bearing for binding, damage or unusual noise when rotating. Also check the contact surface of the release bearing with the diaphragm spring for wear. Replace bearing if necessary.
Attention: the release bearing is filled with special grease. Do not flush the bearing with solvent or oil.
5. Check the clutch release fork.
If the contact surface of the clutch fork with the release bearing is excessively worn, replace the clutch fork assembly.
Installation
1. Apply grease to the clutch disc hub splines.
- Lubricant: CASMOLY L9508
Caution: Be careful not to over-lubricate each part when installing the clutch. Too much lubrication can cause the clutch to slip and the vehicle to jerk when the clutch is engaged at the beginning of a journey.
2. Using the special tool, install the clutch disc onto the flywheel.
3. Install the clutch cover assembly to the flywheel and temporarily tighten the mounting bolts in a diagonal sequence in several passes.
- Tightening torque: 15-22 Nm
4. Align the release bearing with the release fork and then install the assembly into the clutch housing bushing.
Caution: Apply multipurpose grease or the grease listed below to the bearing bush and bearing contact points with the clutch release fork.
- Lubricant: CASMOL Y L9508
5. Install the clutch release lever into the clutch release fork.
6. Install the transmission assembly to the engine.
7. Push the clutch release lever in the direction of the arrow. If a click is heard, the release bearing and clutch cover are aligned correctly. If the assembly does not lock into place, proceed from step "1" again. Clutch release lever moves 3°or less.
If the operating range of the lever is more than 3°, then the release bearing and clutch cover are not correctly aligned. Push the clutch release lever in the direction of the arrow again.