General Information

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 cylind-
9 ~ 14 0.9 ~ 1.4 6.5 ~ 10.1
er (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 r-
CASMOLY L9508 As required
elease fork
Inner surface of clutch release bearing CASMOLY L9508 As required
Inner surface of clutch release cylinder and outer circumfe-
Brake fluid DOT 3 or DOT 4 As required
rence of piston and cup
Inner surface of clutch disc spline CASMOLY L9508 As required
Inner surface of clutch master cylinder and outer circumfer-
Brake fluid DOT 3 or DOT 4 As required
ence 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 rod CASMOLY L9508 As required
Input shaft spline CASMOLY L9508 As required

SPECIAL SERVICE TOOLS

Tool (Number and name) Illustration Use
09411-11000 Installation of the clutch disc.
Clutch disc guide
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 dri- Hardened clutch disc facing, or oil on surface Replace
ving
Damaged pressure plate or flywheel Replace
Weak or broken pressure spring Replace
Difficult gear shifting (gear noise d- Excessive pedal free play Adjust
uring shifting)
Hydraulic system fluid leaks, air trapping or cl- Repair or replace parts
ogging
Unusual wear or corrosion of the clutch disc s- Replace
pline
Excessive vibration (distortion) of the clutch di-
Replace
sc
Clutch noi- When the clutch is not Insufficient play of the clutch pedal Adjust
sy used
Excessive wear of the clutch disc facing Replace
A noise is heard after Unusual wear and/ or damage of the release b- Replace
the clutch is disengag- earing
ed
A noise is heard when Insufficient grease on the sliding surface of the Repair
the clutch is disengag- bearing sleeve
ed
Repair
Improperly installed clutch assembly or bearing

A noise is heard when Damaged pilot bushing Replace

the car suddenly rolled
up with the clutch part-
ially engaged
Hard pedal effort Insufficient lubrication of the clutch pedal Repair
Insufficient lubrication of the spline part of clut- Repair
ch disc
Insufficient lubrication of the clutch release lev- Repair
er 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 or Inspect the clutch disc
lining broken
Spline on the input shaft or clutch disc dirty or Repair as necessary
burned
Faulty of the clutch pressure plate Replace the clutch cover
 Trouble symptom Suspect area Remedy (See page)
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
SERVICE ADJUSTMENT PROCEDURE 3. If the clutch pedal free play is not within the standard
CLUTCH PEDAL INSPECTION AND value range, turn and adjust the nut.
ADJUSTMENT Clutch cable free play (C) : 3~4mm (0.12~0.16in)
[GASOLINE]
1. Measure the clutch pedal height.
Standard value (A) : 180.3mm ( 7.10in)

AOHE004A

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
AOHE002A
disengaged, are within the standard value ranges.
2. Measure the clutch pedal free play.
Standard value (D) : 33mm (1.30in)
Standard value (B) : 15~20mm (0.5 8~ 0.78in)

AOHE005A
AOHE003A
[DIESEL] 2) Turn the push rod to agree with the standard
1. Measure the clutch pedal height (from the face of the value and then secure the push rod with the lock
pedal pad to the floorboard) and the clutch pedal nut.
clevis pin play (measured at the face of the pedal CAUTION
pad.) When adjusting the clutch pedal height or the
Standard value clutch pedal play, be careful not to push the
(A) : 6~13mm (0.24~0.51in) push rod toward the master cylinder.
(B) : 209.6mm (8.25in) 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)
CAUTION
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.
SEDCH7008L

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.
NOTICE
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.
SPACH8023L

2. Depress the clutch pedal slowly until all air is

expelled.
3. Hold the clutch pedal down until the bleeder is
retightened.

SPACH8015L
4. Refill the clutch master cylinder with the specified
fluid.
CAUTION
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.

EOKD006A
Clutch Cover And Disc
COMPONENTS (1)

SPACH8016L
COMPONENTS (2)

SPACH8017L
REMOVAL 6. Remove the clutch release fork after removing the
[GASOLINE] return clip.
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.
NOTICE
Do not clean the clutch disc or release bearing with
cleaning solvent.

AOHE013A

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.

SPACH8009L

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

fork.

SPACH8002L

3. Loosen the bolts in succession, one or two turns at a

time, to avoid bending the cover.
NOTICE
Do not clean the clutch disc or the release bearing
with cleaning solvent.
AOHE012A

5. Remove the return clip and the clutch release

assembly.
INSTALLATION 4. Install the return clip to the release bearing and
[GASOLINE] tighten the reamer bolt (A).
1. Apply multipurpose grease to release fork assembly.
CAUTION
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

AOHE012A

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.
LOHE005A

3. Install the release bearing and release fork to clutch Grease : CASMOLY L9508
housing. CAUTION
Do not apply more grease than necessary. Too
much grease could cause clutch slip or judder.

AOHE013A
8. Install the clutch disc to flywheel using special tool [DIESEL]
(09411-11000). 1. Apply multipurpose grease to the spline of the disc.
Grease: CASMOLY L 9508

CAUTION
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).

LOHE007A

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) EOKD011A

11.Install the transaxle assembly to the engine 2. Temporarily install the clutch disc assembly to the
12.Adjust the clutch pedal free play. flywheel using the special tool (09411-11000).

SPACH8004L
3. Tighten the bolts one or two steps at a time in a star Clutch disc
pattern. 1. Check the clutch facing for loose rivets, uneven
TORQUE : contact, deterioration due to seizure, adhesion of oil,
15~22Nm (1.5~2.2 kgf.m, 10.9~16.0 lb-ft) 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.

SPACH8018L

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
EOKD010A
Clutch cover assembly
3. Check for the torsion spring play and damage and if
1. Check the diaphragm spring end for wear and
defective, replace the clutch disc.
uneven height.
4. Clean the splines on the input shaft and install the
2. Check the pressure plate surface for wear, cracks
clutch disc.
and color change.
If the disc does not slide smoothly or if play is
3. Check the rivets for looseness and replace the clutch
excessive, replace the clutch disc and/or the input
cover assembly if necessary.
shaft.
Clutch release bearing
CAUTION
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 Master Cylinder
COMPONENTS

SPACH8020L
REMOVAL 5. Remove the clutch pedal mounting nut.
1. Drain the brake fluid through the bleeding plug (A).

SPACH8021L

SPACH8006L 6. Disconnect the push rod from the master cylinder by

2. Remove the flexible hose (A) connected to brake removing the snap pin (A) and washer-bolt (B).
reserve tank from the master cylinder.

SPACH8001L

SPACH8007L 7. Remove the screws mounting the master cylinder to

3. Disconnect the clutch tube (B) from the master the clutch pedal assembly.
cylinder and remove the mounting nut (C).
4. Disconnect the ignition lock switch connector from
the clutch pedal assembly.
INSTALLATION 5. Install the clutch pedal mounting nut (A).
1. Apply the specified grease to the clutch pedal and TORQUE :
bushings. 9~14Nm (0.9~1.4kgf.m, 6.5~10.1Ib-ft)
Chassis grease: SAE J310a, NLGI No.1

SPACH8021L

AOJF221A 6. Adjust the clutch pedal within the standard value,

2. Install the screws or nut mounting the master cylinder then secure by tightening the lock nut.
to the clutch pedal assembly. Standard value
3. Apply the specified grease to the snap pin(A) and Free play(A) : 6~13mm (0.24~0.51in)
washer. Height(B) : 209.6mm (8.25in)
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).

SEDCH7008L

SPACH8001L
7. Connect the flexible hose (A) of the brake reserve INSPECTION
tank to the master cylinder. 1. Check the inside of the cylinder body for rust, pitting
or scoring.
2. Check the piston cup for wear or distortion.
3. Check the piston for rust, pitting or scoring.
4. Check to make sure the clutch line tube is not
clogged or restricted in any way.
5. Measure the master cylinder inside diameter and the
piston outside diameter with a cylinder gauge
micrometer.
NOTICE
Measure the inside diameter of the master cylinder
at three places (bottom, middle, and top) in a
perpendicular direction.
6. If the master cylinder-to-piston clearance exceeds the
SPACH8007L
limit, replace the master cylinder and/or piston
8. Connect the clutch tube (B) to the master cylinder. assembly.
9. Refill the brake fluid. Limit : 0.15 mm (0.006 in)
10.Bleed the air in the clutch system.(refer to Bleeding in
Serive Adjustment Procedure) REASSEMBLY
1. Apply the specified fluid to the inner surface of the
DISASSEMBLY master cylinder body and to the entire periphery of
1. Remove the piston stop ring. the piston assembly.
2. Pull out the push rod and piston assembly.
Specified fluid: Brake fluid DOT 3 or DOT 4
3. Remove the reserve tank band, reserve tank cap,
2. Install the piston assembly.
and reserve tank.
3. Install the piston snap ring.
NOTICE
4. Install the push rod assembly.
1. Use care not to damage the master cylinder body
and piston assembly.
2. Do not disassemble the piston assembly.
Clutch Pedal
COMPONENTS (1)

SPACH8024L
COMPONENTS (2)

SPACH8019L
REMOVAL 4. Remove the clutch pedal assembly.
[GASOLINE]
1. Remove the clutch cable bracket (A) from the
transaxle assembly.

SPACH8011L

[DIESEL]
1. Disconnect the push rod from the master cylinder by
SPACH8008L removing the snap pin (A) and washer-bolt (B).
2. Seperate the clutch cable (B) from the clutch lever.
3. Remove the mounting nuts.

SPACH8001L

2. Remove the screws or nut mounting the master

SPACH8010L cylinder to the clutch pedal assembly.
INSTALLATION 4. Connect the push rod to the clutch pedal by installing
[GASOLINE] the snap pin (A) and washer-bolt (B).
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
SPACH8001L

AOJF221A

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
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.

LOJF012A

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)

LOJF002B
Clutch Release Cylinder
COMPONENTS

SPACH8022L
REMOVAL TORQUE :
1. Drain the brake fluid through the bleed plug (A). 15~22Nm (1.5~2.2kgf.m, 11~16lb-ft)

SPACH8006L SPACH8023L

2. Disconnect the clutch tube (A). 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.

SPACH8023L

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

LOGF006B

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