Clutch System

General Information

Clutch System
 2010 > G 1.0 SOHC >

SPECIFICATIONS
Item Specification
Gasoline : Cable type
Clutch operation method
Diesel : Hydraulic type
Clutch disc
Type Single dry with diaphragm
Facing diameter (outside x inside)mm (in) • Gasoline : Ø181.5 ! Ø122 (Ø7.1 ! Ø4.8)
• Diesel : Ø215 ! Ø148 (Ø8.5 ! Ø5.8)
Clutch cover assembly
Type Diaphragm spring strap
Clutch release cylinder [Diesel only]
* I.D. mm (in) 20.64 (0.81)
Clutch master cylinder [Diesel only]
* I.D. mm(in) 15.87 (0.62)

* I.D: Inside diameter

SERVICE STANDARD

Standard value
Clutch disc thickness [When free] Gasoline : 7.9 ± 0.3 mm (0.311 ±0.012 in)
Diesel : 8.55 ± 0.3 mm (0.337 ± 0.012 in)
Clutch pedal height [Without carpet] Gasoline : 180.3 mm (7.09 in)
Diesel : 209.6 mm (8.25 in)
Clutch pedal free play 6 ~ 13 mm (0.24 ~ 0.51 in)
Clutch pedal stroke Gasoline : 145 ± 3mm (5.7 ± 0.12 in)
Diesel : 145 ± 3mm (5.7 ± 0.12 in)
Limit
Clutch disc rivet depth Gasoline : 1.1 mm (0.043 in)
Diesel : 1.4 mm (0.055 in)

TIGHTENING TORQUE

Item Nm kgf.m lb-ft

Clutch pedal to pedal support member
17 ~ 26 1.7 ~ 2.6 12.3~ 18.8
(Clutch pedal bracket)
Clutch pedal support member to master
9 ~ 14 0.9 ~ 1.4 6.5 ~ 10.1
cylinder (Diesel)
Clutch tube flare nut (Diesel) 13 ~ 17 1.3 ~ 1.7 9.4 ~ 12.4
Clutch tube bracket (Diesel) 9 ~ 14 0.9 ~ 1.4 6.5 ~ 10.1
Clutch release cylinder (Diesel) 15 ~ 22 1.5 ~ 2.2 10.9 ~ 16.0
Clutch release cylinder union bolt (Diesel) 25 ~ 35 2.5 ~ 3.5 18.1 ~ 25.5
Clutch cover assembly (6ea) 15 ~ 22 1.5 ~ 2.2 10.9 ~ 16.0
Ignition lock switch nut (Diesel) 8 ~ 10 0.8 ~ 1.0 5.8 ~ 7.3

LUBRICANTS
Items Specified lubricants Quantity
Contact surface of release bearing and fulcrum of clutch
Contact surface of release bearing and fulcrum of clutch
CASMOLY L9508 As required
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 J310,
Clutch master cylinder push rod, clevis pin and washer As required
NLGI No.2V
Chassis grease SAE J310a, NLGI
Clutch pedal shaft and bushings As required
No.1
Contact portion of release fork to release cylinder push
CASMOLY L9508 As required
rod
Input shaft spline CASMOLY L9508 As required
 2010 > G 1.0 SOHC >

SPECIAL SERVICE TOOLS

Tool (Number and name) Illustration Use
09411-11000 Installation of the clutch disc.
Clutch disc guide
 2010 > G 1.0 SOHC >

TROUBLESHOOTING
Trouble symptom Suspect area Remedy (See page)
Clutch slipping Insufficient pedal free play Adjust
• Car will not respond to engine Clogged hydraulic system Correct or replace parts
speed during acceleration
• Insufficient vehicle speed Excessive wear of clutch disc facing Replace
• Lack of power during uphill Hardened clutch disc facing, or oil on surface Replace
driving Damaged pressure plate or flywheel Replace
Weak or broken pressure spring Replace
Difficult gear shifting (gear noise Excessive pedal free play Adjust
during shifting)
Hydraulic system fluid leaks, air trapping or Repair or replace parts
clogging
Unusual wear or corrosion of the clutch disc Replace
spline
Excessive vibration (distortion) of the clutch
Replace
disc
Clutch When the clutch is not Insufficient play of the clutch pedal Adjust
noisy used
Excessive wear of the clutch disc facing Replace
A noise is heard after Unusual wear and/ or damage of the release Replace
the clutch is bearing
disengaged
A noise is heard when Insufficient grease on the sliding surface of Repair
the clutch is the bearing sleeve
disengaged
Improperly installed clutch assembly or Repair
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 part of Repair
clutch disc
Insufficient lubrication of the clutch release Repair
lever shaft
Hard to shift or will not shift Excessive clutch pedal free play Adjust the pedal free play
Faulty of the clutch release cylinder Repair the release cylinder
Clutch disc out of place, runout is excessive Inspect the clutch disc
or lining broken
Spline on the input shaft or clutch disc dirty Repair as necessary
or burned
Faulty of the clutch pressure plate Replace the clutch cover
Clutch slips Insufficient clutch pedal free play Adjust the pedal free play
Clogged of the hydraulic system Repair or replace parts
 Clutch disc lining oily or worn out Inspect the clutch disc
Faulty pressure plate Replace the clutch cover
Binding of the release fork Inspect the release fork
Clutch grabs/chatters Clutch disc lining oily or worn out Inspect the clutch disc
Faulty the pressure plate Replace the clutch cover
Bent clutch diaphragm spring Replace the clutch cover
Worn or broken torsion spring Replace the clutch disc
Engine mounts loose Repair as necessary
Clutch noisy Damaged the clutch pedal bushing Replace the clutch pedal bushing
Loose part inside housing Repair as necessary
Worn or dirty release bearing Replace the replease bearing
Sticking release fork or linkage Repair as necessary
 Clutch System

Clutch System

Clutch System
 2010 > G 1.0 SOHC >

SERVICE ADJUSTMENT PROCEDURE

CLUTCH PEDAL INSPECTION AND ADJUSTMENT
[GASOLINE]
1. Measure the clutch pedal height.

Standard value (A) : 180.3mm ( 7.10in)

2. Measure the clutch pedal free play.

Standard value (B) : 15~20mm (0.5 8~ 0.78in)

3. If the clutch pedal free play is not within the standard value range, turn and adjust the nut.

Clutch cable free play (C) : 3~4mm (0.12~0.16in)

4. After completing the adjustments, check that the distance between the clutch pedal (the face of the pedal pad) and
the toe board when the clutch is disengaged, are within the standard value ranges.
 Standard value (D) : 33mm (1.30in)

[DIESEL]
1. Measure the clutch pedal height (from the face of the pedal pad to the floorboard) and the clutch pedal clevis pin
play (measured at the face of the pedal pad.)

Standard value
(A) : 6~13mm (0.24~0.51in)
(B) : 209.6mm (8.25in)

2. If the clutch pedal freeplay and height is not within the standard value range, adjust as follows:
(1) Turn and adjust the bolt within the standard value, then secure by tightening the lock nut.

If the clutch pedal height is lower than the standard value, loosen the bolt and adjust the push rod.
After adjustment, tighten the bolt so that the clearance with pedal stopper is within the standard value
(A)(0.8~1.0mm, 0.031~0.039in) and secure with lock nut.

(2) Turn the push rod to agree with the standard value and then secure the push rod with the lock nut.
 When adjusting the clutch pedal height or the clutch pedal play, be careful not to push the push rod toward
the master cylinder.

3. 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 system or a
faulty clutch master cylinder. Bleed the air or disassemble and inspect the master cylinder or clutch.

BLEEDING (Diesel only)

Use the specified fluid. Avoid mixing different brands of fluid.

Specified fluid: SAE J1703 (DOT 3 or DOT 4)

1. Loosen the bleeder screw(A) at the clutch release cylinder.

2. Depress the clutch pedal slowly until all air is expelled.

3. Hold the clutch pedal down until the bleeder is retightened.
4. Refill the clutch master cylinder with the specified fluid.

The rapidly-repeated operation of the clutch pedal 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" point.
 Clutch System

Clutch System - Clutch Cover and Dinode

Clutch System
2010 > G 1.0 SOHC >

COMPONENTS (1)

COMPONENTS (2)
 2010 > G 1.0 SOHC >

REMOVAL
[GASOLINE]
1. Remove the transaxle assembly. (Refer to Manual transaxle's removal in MT group)
2. Insert the special tool (09411-11000) in the clutch disc to prevent the disc from falling.
3. Loosen the bolts in succession, one or two turns at a time in a star pattern, to avoid bending the cover flange.

Do not clean the clutch disc or release bearing with cleaning solvent.

4. Remove the reamer bolt (A) from the clutch release fork.

5. Remove the return clip and the clutch release assembly.

6. Remove the clutch release fork after removing the return clip.

7. Remove the clutch release shaft and return spring.

[DIESEL]
1. Remove the transaxle assembly. (Refer to Manual transaxle's removal in MT group)
2. Insert the special tool (09411-11000) in the clutch disc to prevent the disc from shifting.

3. Loosen the bolts in succession, one or two turns at a time, to avoid bending the cover.

Do not clean the clutch disc or the release bearing with cleaning solvent.

INSTALLATION
[GASOLINE]
1. Apply multipurpose grease to release fork assembly.

When installing the clutch, apply grease to each part, but be careful not to apply excessive grease; it can
cause clutch slippage and judder.

2. Apply multipurpose grease into the groove of the release bearing.

Grease : CASMOLY L9508

3. Install the release bearing and release fork to clutch housing.

4. Install the return clip to the release bearing and tighten the reamer bolt (A).

5. Apply multipurpose grease to clutch release bearing contact surface of the clutch release fork assembly.

Grease : CASMOLY L9508

6. Clean the surfaces of the flywheel and pressure plate throughly with fine sandpaper or crocus cloth, and make
certain that all oil or grease has been removed.
7. Apply a small amount of multipurpose grease to the clutch disc splines and input shaft splines.

Grease : CASMOLY L9508

Do not apply more grease than necessary. Too much grease could cause clutch slip or judder.

8. Install the clutch disc to flywheel using special tool (09411-11000).

9. Install the clutch cover assembly to the flywheel and temporarily tighten the bolts one or two steps at a time in a
star pattern.
10. Remove the special tool(09411-11000)
11. Install the transaxle assembly to the engine
12. Adjust the clutch pedal free play.

[DIESEL]
1. Apply multipurpose grease to the spline of the disc.

Grease: CASMOLY L 9508

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

2. Temporarily install the clutch disc assembly to the flywheel using the special tool (09411-11000).
3. Tighten the bolts one or two steps at a time in a star pattern.

TORQUE :
15~22Nm (1.5~2.2 kgf.m, 10.9~16.0 lb-ft)

4. Remove the clutch disc guide (09411-11000).

5. Install the transaxle assembly to the engine. (Refer to Manual transaxle's installation in MT group)

INSPECTION
Clutch cover assembly
1. Check the diaphragm spring end for wear and uneven height.
2. Check the pressure plate surface for wear, cracks and color change.
3. Check the rivets for looseness and replace the clutch cover assembly if necessary.

Clutch disc
1. Check the clutch facing for loose rivets, uneven contact, 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
Clutch disc thickness(A)[when free]
Clutch disc rivet depth(B)
: refer to 'SERVICE STANDARD' in GENERAL section.
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 excessive, replace the clutch disc and/or the input shaft.

Clutch release bearing

The release bearing is packed with grease. Do not use cleaning solvent or oil.

Standard grease : CASMOLY L9508

1. Check the bearing for seizure, damage or abnormal noise. Also check the diaphragm spring contacting points for
wear.
2. Replace the bearing if the release fork contacting points are worn abnormally.

Clutch release fork

If there is abnormal wear at the point of contact with the bearing, replace the release fork assembly.
 Clutch System

Clutch System - Clutch Master Cylinder

Clutch System
2010 > G 1.0 SOHC >

COMPONENTS
2010 > G 1.0 SOHC >

COMPONENTS
 Clutch System

Clutch System - Clutch Pedal

Clutch System
2010 > G 1.0 SOHC >

COMPONENTS (1)

COMPONENTS (2)
 2010 > G 1.0 SOHC >

REMOVAL
[GASOLINE]
1. Remove the clutch cable bracket (A) from the transaxle assembly.

2. Seperate the clutch cable (B) from the clutch lever.

3. Remove the mounting nuts.

4. Remove the clutch pedal assembly.

[DIESEL]
1. Disconnect the push rod from the master cylinder by removing the snap pin (A) and washer-bolt (B).
2. Remove the screws or nut mounting the master cylinder to the clutch pedal assembly.

INSTALLATION
[GASOLINE]
1. Installation is reverse of removal.
2. Apply multi-purpose grease to the bushings.

Standard grease :
Multi-purpose grease SAE J310, NLGI No.3

3. Adjust the clutch pedal height and pedal free play after installing.

Clutch pedal height : 180.3mm (7.10in)

Clutch pedal free play :15 ~ 20mm (0.58 ~ 0.78in)

[DIESEL]
1. Apply the specified grease to the clutch pedal and bushings.

Chassis grease: SAE J310a, NLGI No.1

2. Install the screws or nut mounting the master cylinder to the clutch pedal assembly.
3. Apply the specified grease to the snap pin(A) and washer.

Wheel bearing grease: SAE J310, NLGI No.2

4. Connect the push rod to the clutch pedal by installing the snap pin (A) and washer-bolt (B).
 INSPECTION
1. Check the pedal shaft and bushing for wear.
2. Check the clutch pedal for bending or torsion.
3. Check the return spring for damage or deterioration.
4. Check the pedal pad for damage or wear.

Ignition lock switch (DIESEL ONLY)

Remove the ignition lock switch and check for continuity between the terminals. If the continuity is not as specified,
replace the switch.

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)
 Clutch System

Clutch System - Clutch Release Cylinder

Clutch System
2010 > G 1.0 SOHC >

COMPONENTS
 2010 > G 1.0 SOHC >

REMOVAL
1. Drain the brake fluid through the bleed plug (A).

2. Disconnect the clutch tube (A).

3. Remove the two clutch release cylinder mounting nuts (B-2ea).

INSTALLATION
1. Coat the clutch clevis push rod specified grease.

Specified grease: CASMOLY L9508

2. Install the release cylinder mounting nuts (B-2ea).

TORQUE :
15~22Nm (1.5~2.2kgf.m, 11~16lb-ft)
3. Install the clutch tube (A).
4. Refill the brake fluid.
5. Bleed the air in the clutch system.
(refer to Bleeding in Service Adjustment Procedure)

INSPECTION
1. Check the release cylinder bore for rust and damage.
2. Check the clutch release cylinder for fluid leakage.
3. Check the clutch release cylinder boots for damage.