Clutch Cover And Disc
Repair procedures
1. | Remove the manual transaxle assembly. (Refer to Manual Transaxle System - "Manual Transaxle") |
2. | Remove the clutch cover assembly after loosening the bolts. •
| Be careful not to be bent or twist bolts. Loosen bolts in diagonal directions. |
|
[Gasoline 1.6 MPI / Gasoline 1.6 T-GDI] ![](images/books/3027/sadmt60010d_n.gif)
[Gasoline 2.0 MPI] ![](images/books/3027/sqxch00002i.gif)
|
1. | Inspect diaphragm spring wear which is in contact with a concentric slave cylinder bearing. |
2. | Check the clutch cover and disc surface for wear or cracks. |
3. | Check the clutch disc facing for slipping or oil marks. |
4. | Measure the depth from a clutch facing surface to a rivet. If the measured value is less than the specification below, replace it.
Engine
| Item
| Specification
| ALL
| Clutch disc rivet depth (A)
| 0.3 mm (0.0118 in.)
|
![](images/books/3027/sbcch10234l.gif)
|
•
| If reinstalling used cover, the cover should be installed with its clutch disc as a set. |
|
1. | Apply grease on a disc spline part and transaxle input shaft spline part as required. Specified grease : CASMOLY L9508 Amount : 0.1 - 0.2g |
•
| When not applying: Excessive wear of splines and bad clutch operation can occur. |
•
| When excessively applying: Grease can be scattered bycentrifugal force which can conteminate the clutch disc. This can cause a loss of friction force causing a slip. |
|
![](images/books/3027/eokd011a_n.gif)
|
2. | Before installing the clutch disc, check the “TM SIDE” and “FLYWHEEL SIDE” marked on the clutch disc, and install it with the clutch cover using a special tool (09411-1P000). Possible problems when the disc is installed in the opposite direction. •
| There can be an interference between the concentric slave cylinder on the transaxle side and a engine flywheel surface. |
•
| Transaxle shift error or a strange sound can occur due to clutch separation. |
•
| The concentric slave cylinder can break. If it does, the concentric slave cylinder should be replaced new one. |
|
The 'T/M SIDE' marked surface should face the transaxle. |
![](images/books/3027/sadch60000d_n.gif)
The 'FLYWHELL SIDE' marked surface should face the flywheel. |
![](images/books/3027/srpch3005l_n.gif)
|
3. | Install the clutch disc and the cover with SST (A: 09411-1P000). ![](images/books/3027/sadch60001d_n.gif)
|
4. | Install the clutch cover mounting bolts. Tightening torque : 19.6 - 26.5 N·m (2.0 - 2.7 kgf.m, 14.5 - 19.5 lb-ft) [Gasoline 1.6 MPI] 24.5 - 18.1 N·m (2.5 - 3.5 kgf.m, 34.3 - 25.3 lb-ft) [Gasoline 1.6 T-GDI] 11.8 - 14.7 N.m (1.2 - 1.5 kgf.m, 8.7 - 10.8 lb-ft) [Gasoline 2.0 MPI] |
•
| Install the all the components with the specified torques. If not, the clutch torque transaxle may have concerns or the mounting bolt can loosen. |
•
| When installing the clutch cover assembly, check the below fastening order for each number of bolts and tighten the bolts loosely. Then, fasten the bolts to their proper tightening torque. This can prevent twisting and vibration of the cover, and the lifting of the pressure plate. ㅡ Fastening order for each number of bolts for installing the clutch cover assembly [Gasoline 1.6 MPI / Gasoline 1.6 T-GDI] ![](images/books/3027/sadmt60010d_n.gif)
[Gasoline 2.0 MPI] ![](images/books/3027/sqxch00002i.gif)
|
|
|
5. | Remove the clutch disc guide SST (No.: 09411-1P000). ![](images/books/3027/sadch60001d_n.gif)
|
6. | Install the transaxle assembly. (Refer to Manual Transaxle System - "Manual Transaxle") |
Ignition Lock & Clutch Switch
Description and operation
–
| Clutch operation is detected through clutch switch signal. This signal enables ECM to cope with instant change of load condition. |
–
| Clutch switch signal is used to detect engaged gear with vehicle speed and engine speed. |
Schematic diagrams
Connector and Pin Function |
![](images/books/3027/scnch10160d.gif)
Terminal
|
Description
|
1
| IG1
|
2
| Clutch switch
|
3
| Ignition lock switch
|
4
| Battery +
|
5
| PWM signal
|
6
| Ground
|
Repair procedures
•
| The ignition lock & clutch switch replaces the clutch master cylinder in one piece with the clutch master cylinder. (Refer to Clutch System - "Clutch Master Cylinder") |
|
Clutch Pedal
Components and components location
![](images/books/3027/scnch10200l.gif)
1. Clutch pedal arm 2. Clip 3. Push rod pin
| 4. Clutch pedal assembly 5. Clutch master cylinder 6. Clip
|
Repair procedures
1. | Remove the air cleaner assembly and air duct. (Refer to Engine Mechnical System - "Air Cleaner") |
2. | Remove the battery and battery tray. (Refer to Engine Electrical System - "Battery") |
3. | Pull the snap pin (A) and then separate the clutch regulator (B). [Gasoline 1.6 MPI / Gasoline 2.0 MPI] ![](images/books/3027/scnch10161d.gif)
[Gasoline 1.6 T-GDI] ![](images/books/3027/scnch10162d.gif)
|
4. | Disconnect the ignition lock & clutch switch connector (A). ![](images/books/3027/scnch10002d.gif)
|
5. | Loosen the nuts (A) and then removing the clutch pedal. Tightening torque : 16.7 - 25.5 N.m (1.7 - 2.6 kgf.m, 12.3 - 18.8 Ib-ft) |
![](images/books/3027/scnch10156d.gif)
|
1. | To install, reverse the removal procedures. |
2. | Perform bleeding air procedure in concentric slave cylinder after pouring the brake fluid. (Refer to Clutch System - "Concentric Slave Cylinder Assembly") |
Regulator
Components and components location
Components and Components Location |
[Gasoline 1.6 MPI / Gasoline 2.0 MPI] |
![](images/books/3027/scnch10163d.gif)
1. Clutch pedal arm 2. Clutch pedal assembly 3. Reservoir hose
| 4. Regulator 5. Cluch tube 6. Clutch hose
|
![](images/books/3027/scnch10164d.gif)
1. Clutch pedal arm 2. Clutch pedal assembly 3. Reservoir hose
| 4. Regulator 5. Cluch tube 6. Clutch hose
|
Repair procedures
1. | Remove the air duct and air cleaner assembly. (Refer to Engine Mechanical System - "Air Cleaner") |
2. | Remove the battery and battery tray. (Refer to Engine Electrical System - "Battery") |
3. | Pull the snap pins (A) and then removing the regulator (B). [Gasoline 1.6 MPI / Gasoline 2.0 MPI] •
| Do not spill brake fluid on the vehicle it may damage the paint if brake fluid does contact the paint, wash it off immediately with water. |
|
![](images/books/3027/scnch10170d.gif)
|
4. | Pull the snap pin (B) after separate the clutch tube (A) and Remove the regulator (C). [Gasoline 1.6 T-GDI] •
| Do not spill brake fluid on the vehicle it may damage the paint if brake fluid does contact the paint, wash it off immediately with water. |
|
![](images/books/3027/scnch10169d.gif)
|
1. | To install, reverse the removal procedures. •
| Be careful not to enter dust, foreign matters, etc in regulator. |
•
| When installing, apply grease on a O-ring part of regulator connector. |
•
| Replace the O-ring with new when install the clutch regulator. |
|
|
2. | After be equipped, perform bleeding air procedure in concentric slave cylinder after pouring the brake fluid. (Refer to Clutch System - "Concentric Slave Cyilnder Assembly") |
1. | Check the clutch tube for fluid leakage. |
2. | Check the clutch tube for strain and damage. |
Clutch Tube
Components and components location
Components and Components Location |
[Gasoline 1.6 MPI / Gasoline 2.0 MPI] |
![](images/books/3027/scnch10163d.gif)
1. Clutch pedal arm 2. Clutch pedal assembly 3. Reservoir hose
| 4. Regulator 5. Cluch tube 6. Clutch hose
|
![](images/books/3027/scnch10164d.gif)
1. Clutch pedal arm 2. Clutch pedal assembly 3. Reservoir hose
| 4. Regulator 5. Cluch tube 6. Clutch hose
|
Repair procedures
1. | Remove the air cleaner and air duct. (Refer to Engine Mechanical System - "Air Cleaner") |
2. | Remove the battery and battery tray. (Refer to Engine Electrical System - "Battery") |
3. | Pull the snap pin (A) and then separate the clutch tube (B). [Gasoline 1.6 MPI / Gasoline 2.0 MPI] ![](images/books/3027/scnch10166d.gif)
•
| Do not spill brake fluid on the vehicle it may damage the paint if brake fluid does contact the paint, wash it off immediately with water. |
|
|
4. | Loosen the flare nut and then separate the clutch tube (A). [Gasoline 1.6 T-GDI] Tightening torque: 12.7 - 16.7 N.m (1.3 - 1.7 kgf.m, 9.4 - 12.3 Ib-ft) |
![](images/books/3027/scnch10165d.gif)
•
| Do not spill brake fluid on the vehicle it may damage the paint if brake fluid does contact the paint, wash it off immediately with water. |
|
|
5. | Remove the snap pin (A) and then separate the clutch hose & tube (B). [Gasoline 1.6 MPI] ![](images/books/3027/sbcmt11207l.gif)
[Gasoline 1.6 T-GDI] ![](images/books/3027/scnch10171d.gif)
[Gasoline 2.0 MPI] ![](images/books/3027/stlch90004l_n.gif)
|
6. | Remove the clutch hose & tube from the vehicle. |
1. | To install, reverse the removal procedures. |
2. | Perform bleeding air procedure in concecntric slave cylinder after pouring the brake fluid (Refer to Clutch System - "Concentric Slave Cylinder Assembly") |
Clutch Master Cylinder
Components and components location
![](images/books/3027/scnch10200l.gif)
1. Clutch pedal arm 2. Clip 3. Push rod pin
| 4. Clutch pedal assembly 5. Clutch master cylinder 6. Clip
|
Repair procedures
1. | Remove the clutch pedal. (Refer to Clutch System - "Clutch Pedal") |
2. | Remove the clip (A). ![](images/books/3027/scnch10152d.gif)
|
3. | Remove the push rod pin (A) by pushing it in the “F” direction. ![](images/books/3027/scnch10159d.gif)
|
4. | Loosen the bolts (A) and then removing the clutch master cylinder (B). ![](images/books/3027/scnch10154d.gif)
![](images/books/3027/scnch10155d.gif)
|
1. | To install, reverse the removal procedures. |
2. | Perform bleeding air procedure in concecntric slave cylinder after pouring the brake fluid. (Refer to Clutch System - "Concentric Slave Cylinder Assembly") |
Concentric Slave Cylinder Assembly
Repair procedures
1. | Remove the manual transaxle assembly. (Refer to Manual Transaxle System - "Manual Transaxle") |
2. | Loosen the bolts and then removing the concentric slave cylinder assembly (A) from the clutch housing. [Gasoline 1.6 MPI] Tightening torque : 19.6 - 26.5 N.m (2.0 - 2.7 kgf.m, 14.2 - 19.5 lb-ft) |
![](images/books/3027/sadch90004c_n.gif)
![](images/books/3027/sadch90005c_n.gif)
|
3. | Loosen the bolts and then removing the concentric slave cylinder assembly (A) from the clutch housing. [Gasoline 1.6 T-GDI] Tightening torque : 19.6 - 26.5 N.m (2.0 - 2.7 kgf.m, 14.2 - 19.5 lb-ft) |
![](images/books/3027/spdmt12235e.gif)
![](images/books/3027/scnch10168d.gif)
|
4. | Remove the concentric slave cylinder assembly (B) from the transaxle case by removing bolts (A). [Gasoline 2.0 MPI] Tightening torque : 19.6 - 26.5 N.m (2.0 - 2.7 kgf.m, 14.2 - 19.5 lb-ft) |
![](images/books/3027/stlch90002l_n.gif)
![](images/books/3027/stlch90003l_n.gif)
|
1. | To install, reverse the removal procedures. •
| Install the concentric slave cylinder bolts. Not to be bent or twisted, Tighten them in diagonal directions. |
•
| Cup, Inner surface of body and outer surface of tube guide must be free from flaws. |
•
| When it is assembled, it must be free from invasive foreign matters and oil leakage. |
|
•
| When it is installed, assembly oil must be applied adequately to inner surface of body and outer surface of tube guide. Specified fluid : KLUBER 9R1007 |
|
|
|
2. | Perform bleeding air procedure in concecntric slave cylinder after pouring the brake fluid. (Refer to Concentric Slave Cylinder Assembly - "Adjustment") |
Air Bleeding Procedure [Gasoline 1.6 MPI] |
1. | Turn ignition switch OFF and disconnect the negative (-) battery cable. |
2. | Remove the air cleaner assembly and air duct. (Refer to Engine Mechanical System - "Air Cleaner") |
3. | Open the concentric slave cylinder air bleed cap (A). ![](images/books/3027/sbcch10249l.gif)
|
4. | Connect the vinyl hose to the air bleeder plug (A). ![](images/books/3027/sbcch10250l.gif)
|
5. | Pull the clip and then moving the clutch hose towards the arrow direction. •
| When the quick connector is completely removed, foreign matter inflow and O-ring damage occur, so be sure to remove only one clip (A). |
•
| Never pull out the clip (B). ![](images/books/3027/sbich10321i.gif)
|
|
(1) | Pull the clip (A) and then moving the clutch hose (B) towards the arrow direction. ![](images/books/3027/sbcch10251l.gif)
|
|
Air Bleeding Procedure [Gasoline 1.6 T-GDI]
1. | After disconnecting a cap from the concentric slave cylinder air bleeder, insert a vinyl hose in the plug. |
2. | Refill the reservoir tank with the specified fluid. •
| Use the specified fluid. Avoid mixing different brands of fluid. Specified fluid : SAE J1703 (DOT 3 or DOT 4) |
|
|
|
3. | Pump the clutch pedal about 10 times. |
4. | Loosen the air bleed screw (A) at hold down the clutch pedal to allow air to escape from the clutch system. Then tighten the air bleed screw. ![](images/books/3027/sadch70105d_n.gif)
|
5. | Repeat the step 2 - 4 until there is no bubble in the fluid. |
Air Bleeding Procedure [Gasoline 2.0 MPI]
1. | Open the Concentric Slave Cylinder (CSC)'s cap (A) and connect the hose (B) to the CSC's plug (C). ![](images/books/3027/spdch8n036e_n.gif)
•
| Be careful not to let any foreign material from getting inside or contaminate the CSC plug. (It may cause oil leakage due to damage on the hydraulic system while driving.) |
|
|
2. | Pull the connector (B) towards the arrow direction while pressing the CSC's double clip (A). |
3. | Move about 5 mm(0.1969in.) until you feel the click. ![](images/books/3027/spdch8n037e.gif)
•
| Do not pull the double clip (A) upward. (Clip can be damaged and the clutch pedal may not operate due to oil leakage.) ※ If the double clip is wrongly operated replace the CSC. ![](images/books/3027/spdch8n038e_n.gif)
|
|
|
4. | Fill the vehicle's reservoir tank with specified oil. •
| Use the specified fluid. Avoid mixing different brands of fluid. |
|
|
5. | Repeatedly depress the clutch pedal (A) to the full position until the bubble is not discharged from the hose. (Fill the reservoir tank with the oil if necessary.) •
| Pedal Position ![](images/books/3027/spdch8n039e_n.gif)
![](images/books/3027/spdch8n040e_n.gif)
|
|
|
6. | When the air bleeding is completed, maintain the clutch pedal (A) in full position and push the connector (B) until you hear the "click" sound and restore to the initial position. ![](images/books/3027/spdch8n041e.gif)
|
7. | For little air bleeding of Concentric Slave Cylinder (CSC)-Clutch Master Cylinder(CMC) area, maintain the clutch pedal (A) in freeplay position and push the double clip (B), In this case, the connector (C) is moved about 5 mm(0.1969in.) towards the arrow direction. •
| The connector will not move if the pedal is depressed beyond the freeplay position. |
|
![](images/books/3027/spdch8n042e.gif)
|
8. | Check for bubble by depressing the clutch pedal from the freeplay to the full position. ![](images/books/3027/spdch8n043e.gif)
|
9. | When the air bleeding is completed, maintain the clutch pedal (A) in full position and push the connector (B) until you hear the "click" sound and restore to the initial position. ![](images/books/3027/spdch8n041e.gif)
•
| If any bubble is detected during operation no. 8, repeat operations from 7 to 9. |
|
|
10. | Remove the hose and close the cap (A) if there is no bubble. ![](images/books/3027/spdch8n044e_n.gif)
•
| Be careful not to let any foreign material from getting inside or contaminate the CSC plug. (It may cause oil leakage due to damage on the hydraulic system while driving.) |
|
|
Special Service Tools
Tool (Number and name)
Illustration
Use
09411-1P000Clutch disc guideInstallation of the clutch dis ...