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VELOSTER(FS) > 2012 > G 1.6 GDI > Clutch System

Clutch System > General Information > Specifications

Specifications

Items Specifications
Clutch operation method Hydraulic type
Clutch cover Type Diaphragm spring strap
Type Single dry with diaphragm
Clutch disc Type
Faling diameter (Outer × inner) Ø210 × Ø145 (Ø8.2677 × Ø5.7087)
Clutch release cylinder inner diameter 20.64 mm (0.8126 in.)
Clutch master cylinder inner diameter 15.87 mm (0.6248 in.)

Service Standard

Item Specification
Clutch disc thickness [When free] 8.3 ± 0.3 mm (0.3268 ± 0.0118 in.)
Clutch pedal height [With carpet] 194.5 mm (7.6575 in.)
Clutch pedal free play 7 ~ 10 mm (0.2756 ~ 0.3937 in.)
Clutch pedal stroke 130 ± 0.3 mm (5.1181 ± 0.0118 in.)
Clutch disc rivet depth 1.1 mm (0.0433 in.)
Diaphragm spring end height difference 0.5 mm (0.0197 in.)
Clutch master cylinder clearance to piston 1.6 mm (0.0630 in.)

Tightening Torques

Item N.m kgf.m lb-ft

Clutch pedal mounting bolts & nuts 18.6 ~ 23.5 1.9 ~ 2.4 13.7 ~ 17.4
Clutch release cylinder installation nut 14.7 ~ 21.6 1.5 ~ 2.2 10.8 ~ 15.9
Clutch release cylinder union bolt 24.5 ~ 34.3 2.5 ~ 3.5 18.1 ~ 25.3
Clutch release cylinder bleed plug 6.8 ~ 9.8 0.7 ~ 1.0 9.2 ~ 13.3
Clutch cover mounting bolt 14.7 ~ 21.6 1.5 ~ 2.2 10.8 ~ 15.9

Lubricants

Items Specified lubricants Quantity

Input shaft spline CASMOLY L9508 0.2g
clutch release cylinder assembly Brake fluid DOT 3 or DOT
As required
Clutch pedal shaft and bushings Chassis grease SAE J310a, NLGI No.1

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Clutch System > General Information > Special Service Tools

Special Service Tools

Tool (Number and name) Illustration Use

09411-1P000 Installation of the clutch disc.
Clutch disc guide

Clutch System > Clutch System > Clutch Cover And Disc > Components and Components
Location
Components

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1. Clutch release fork 3. Clutch disk assembly

2. Clutch cover assembly 4. Clutch release bearing

Clutch System > Clutch System > Clutch Cover And Disc > Repair procedures
Removal
1. Remove the transaxle assembly.
(Refer to "Manual transaxle system" in MT group)
2. Remove the clutch cover bolts. Be careful not to be bent ortwist bolts. Loosen bolts in diagonal directions.

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Inspection
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 lining for slipping or oil marks.
4. Measure the depth from a clutch lining surface to a rivet. If the measured value is less than the specification below,
replace it.

Standard value
Clutch disc thickness(A)[when free] :
8.3 ± 0.3 mm (0.3268 ± 0.0118 in.)
Clutch disc rivet depth(B) : 1.1 mm (0.0433 in.)

Installation

If reinstalling used cover, the cover should be installed with its clutch disc as a set.

1. Replace a clutch cover and disc as a set.

• When replacing only a disc, a slip problem can occur because of the load loss due to uneven surface wear.
• When replacing only a disc, it can be difficult to cut power because the thickness of the disc won't permit it.

2. Apply grease on a disc spline part and transmission input shaft spline part as required.

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* Possible problems when not following

- 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.

3. The 'T/M SIDE' marked surface should face the transmission .

* Possible problems when the disc is installed in the opposite direction.

• There can be an interference between the concentric slave cylinder on the TM side and a engine flywheel
surface.
• Transaxle shift errror or a strangesound can occur due to clutch separation.

4. Install the clutch disc and the cover with SST(A : 09411-1P000).

5. Install the clutch cover bolts. Not to be bent or twisted, Tighten them in diagonal directions.

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Tightening torque:
14.7 ~ 21.6 N.m (1.5 ~ 2.2 kgf.m, 10.8 ~ 15.9 lb-ft)

• Loosely tighten every clutch cover bolts, then torque to specifications in a diagonal direction. This can prevent
twisting, vibration of the cover, and the lifting of the pressure plate.
• Install the all the components with the specified torques. If not, the clutch torque transmission may have
concerns or the mounting bolt can loosen.

6. Install the transaxle assembly.

(Refer to "Manual transaxle system" in MT group)

Clutch System > Clutch System > Clutch Master Cylinder > Components and Components
Location
Components

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1. Reverse hose 4. Clutch switch

2. Master cylinder 5. Clutch arm assembly
3. Ignition lock switch 6. Pedal pad

Clutch System > Clutch System > Clutch Master Cylinder > Repair procedures
Removal

• 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. Disconnect the push rod from the master cylinder by removing the snap pin (A) and washer (B).

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2. Remove the battery and ECM.

(Refer to "Manual transaxle system" in MT group)
3. Disconnect the clutch tube (B) and reservoir hose (A) from the clutch master cylinder.

4. Remove the clutch master cylinder assembly (A) by turning it clockwise.

Installation
1. Installation is the reverse of removal.

• Perform bleeding air procedure in clutch release cylinder after pouring the brake fluid.
(Refer to "clutch release cylinder" in CH group.)

Clutch System > Clutch System > Clutch Pedal > Components and Components Location

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Components

1. Reverse hose 4. Clutch switch

2. Master cylinder 5. Clutch arm assembly
3. Ignition lock switch 6. Pedal pad

Clutch System > Clutch System > Clutch Pedal > Repair procedures
Inspection
Clutch Pedal Inspection
1. Measure the clutch pedal height (from the face of the pedal pad to the floor board) and the clutch pedal clevis pin play
(measured at the face of the pedal pad.)

Standard value
Stroke (A): 130 ± 0.3 mm (5.1181 ± 0.0118 in.)
Free play (B): 7 ~ 10 mm (0.2756 ~ 0.3937 in.)
Height (C): 194.5 mm (7.6575 in.)

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Ignition Lock Switch Inspection

1. Disconnect 2P-connector from a ignition lock switch.
2. Disconnect the ignition lock switch. (if you can install a tester with the switch fixed, this step can be omissible)
3. Check for continuity between terminals. (refer to the table below)

• If there is difference between what tested and the table above, replace the ignition lock switch with a new one.

Pedal position Clutch switch Ignition lock switch

Released Pressed (Continuity) Released (Open)
Fully pressed Released (Open) Pressed (Continuity)

Standard value
Full stroke (A): 12.0 ± 0.3mm (0.4724 ± 0.0118 in.)
ON-OFF point (B): 2.0 ± 0.3mm (0.0787 ± 0.0118 in)

Removal

• 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.

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1. Remove the battery and ECM.

(Refer to "Manual transaxle system" in MT group)
2. Disconnect the clutch tube (B) and reservoir hose (A) from the clutch master cylinder.

3. Disconnect the push rod from the master cylinder by removing the snap pin (A) and washer (B).

4. Remove the clutch pedal mounting bolt (A) and nuts (B-2ea).

Tightening torque:
(A) 16.7 ~ 25.5 N.m (1.7 ~ 2.6 kgf.m, 12.3 ~ 18.8 lb-ft)
(B) 18.6 ~ 23.5 Nm (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft)

5. Disconnect the ignition lock switch connector (C) and clutch switch connector (B).

6. Remove the clutch pedal and the master cylinder assembly together.

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Installation
1. Installation is in reverse order of removal.

• Perform bleeding air procedure in clutch release cylinder after pouring the brake fluid.
(Refer to "clutch release cylinder" in CH group.)

Clutch System > Clutch System > Clutch Release Cylinder > Components and
Components Location
Components

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1. Union bolt 7. Bleeder screw

2. Gasket 8. Release cylinder
3. Tube joint 9. Return spring
4. Clutch tube 10. Piston
5. Valve plate 11. Boot
6. Valve spring 12. Push rod

Clutch System > Clutch System > Clutch Release Cylinder > Repair procedures
Removal
1. Drain the brake fluid through the bleed plug (A).

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2. Remove the clutch release cylinder assembly (C) after removing thd tube (B) and nuts (A-2ea).

Tightening torque:
14.7 ~ 21.6 N.m (1.5 ~ 2.2 kgf.m, 10.9 ~ 15.9 lb-ft)

Installation
1. Installation is the reverse of removal.

Coat the clutch clevis push rod specified grease.

Specified grease: CASMOLY L9508

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Adjustment
Clutch Release Cylinder Air Bleeding Procedure

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

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

1. After disconnecting a cap from the clutch release cylinder air bleeder, insert a vinyl hose in the plug.
2. Loosening the plug screw, press and release the clutch pedal about 10 times.
3. Tighten the plug (A) during the clutch pedal pressed. Afterwards, raise the pedal with a hand.
4. After pressing the clutch pedal 3 times more, loosen the plug (A) and retighten it with the pedal pressed. Raise it again,
then.
5. Repeat the step 4 two or three times. (until there is no bubble in the fluid)

Tightening torque:
6.8 ~ 9.8 N.m (0.7 ~ 1.0 kgf.m, 9.2 ~ 13.3 lb-ft)

6. Refill the clutch master cylinder with the specified fluid.

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