Clutch Cover And Disc

Repair procedures

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] [Gasoline 2.0 MPI]

• 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.

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. The 'FLYWHELL SIDE' marked surface should face the flywheel.

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] [Gasoline 2.0 MPI]

Ignition Lock & Clutch Switch

Description and operation

Schematic diagrams

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

Repair procedures

Regulator

Components and components location

Repair procedures

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.

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.

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.

Clutch Tube

Components and components location

Repair procedures

3.	Pull the snap pin (A) and then separate the clutch tube (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.

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) • 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.

Clutch Master Cylinder

Components and components location

Repair procedures

Concentric Slave Cylinder Assembly

Repair procedures

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

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). (1) Pull the clip (A) and then moving the clutch hose (B) towards the arrow direction.

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)

1.

Open the Concentric Slave Cylinder (CSC)'s cap (A) and connect the hose (B) to the CSC's plug (C). 1) Open the cap (A). 2) Insert the hose (B) • 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.)

3.	Move about 5 mm(0.1969in.) until you feel the click. • 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.

4.	Fill the vehicle's reservoir tank with specified oil. • Use the specified fluid. Avoid mixing different brands of fluid. Specified fluid : DOT 4

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

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.

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. • 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. • 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.)