GENERAL CLUTCH COVER AND DISC

CLUTCH MASTER CYLINDER

CLUTCH SYSTEM CLUTCH PEDAL
CH -2 CLUTCH SYSTEM

GENERAL
SPECIFICATION E41BDFA7

Item SPECIFICATION
Engine type 2.0L 2.4L
Clutch operation Hydraulic type
Clutch disc Single dry with diaphragm
Clutch cover assembly General Diaphragm Spring Strap Self Adjusting Clutch

TIGHTENING TORQUE

Item Nm Kgf.cm lb-ft

Clutch cover (2.0L-6EA) 24.5~35.3 250~360 18.1~26.0
Clutch cover (2.4L-9EA) 11.8~14.7 120~150 8.7~10.8
Concentric slave cylinder 11.8~14.7 120~150 8.7~10.8
Stop lamp switch 7.8~9.8 80~100 5.8~7.2
Ignition lock switch 7.8~9.8 80~100 5.8~7.2
Air bleeding plug 24.5~28.4 250~290 18.1~21.0
Clutch pedal mounting 24.5~34.3 250~350 18.1~25.3

LUBRICANTS

Item Specified lubricants Quantity

Inner surface of clutch disc spline CASMOLY L9508 0.2 gr.
Clutch master cylinder tube RG 306 As required

SERVICE STANDARD

Item Standard value

Clutch pedal stroke 145mm (5.7inch)
Clutch pedal free play 13mm (0.51inch) or less
Distance between a mat and a clutch pedal 234.7mm (9.2401inch)
Depth from a clutch lining surface to a rivet 0.3mm (0.0118inch)
GENERAL CH -3

SPECIAL TOOLS K40B7BB0

Tool
Illustration Use
(Number and Name)
09411-11000 Installation of the clutch disc
Clutch disc guide

KORE001D
CH -4 CLUTCH SYSTEM

CLUTCH SYSTEM • To make up for this defect, the self adjusting clutch
system makes the requsted pedal pressure minimized
so that makes the maintenance cycle longer.
DESCRIPTION EC4E5C54 • Applied only in 2.4L gasoline engine vehicles.

SELF ADJUSTING CLUTCH(S.A.C.) COVER

• As a clutch disc facing is worn away according to its

durability, a cover weight is increasing and a clutch
pedal pressure can be more needed.

GENERAL CLUTCH COVER SELF ADJUSTING CLUTCH COVER

Coil spring

Adjusting ring

Cover
Cover

Sensor spring
Diaphragm spring

Diaphragm spring

In a general clutch cover, the diaphragm In a self adjusting clutch, the adjusting ring prevents
spring increases the weight to the disc the diaphragm spring from being raised to
in proportion to abrasion. the transmission side in spite of abrasion.

Applicable vehicle model: 2.0L Applicable vehicle model: 2.4L

EORE001A

CONCENTRIC SLAVE CYLINDER-C.S.C.

It improves working efficiency and lowers the number

and the weight of part by unifing clutch release control
parts(clutch release bearing ~ clutch release cylinder) in
a manual transaxle.

OPERATION E3DBBDB3

CONCENTRIC SLAVE CYLINDER-C.S.C

When the clutch pedal is pressed, oil pressure is trans-

mitted along the arrow directions shown below and that
moves the clutch slave cylinder and the diaphragm spring
of the clutch cover. KORE001B
CLUTCH SYSTEM CH -5

SERVICE ADJUSTMENT CONCENTRIC SLAVE CYLINDER AIR BLEEDING

PROCEDURE
PROCEDURE EFBFAD84
1. After disconnecting a cap from the concentric slave
STOP LAMP SWITCH
cylinder air bleeder, insert a vinyl hose in the plug.
1. Disconnect the 2P connector from the stop lamp
2. Loosening the plug screw, press and release the
switch.
clutch pedal about 10 times.
2. Remove the stop lamp switch.
NOTE
3. Check for continuity between the terminals according
Hold the air bleeder body not to rotate with a span-
to the table.
ner(A). The holding is needed when the plug loosened
or tightened.
Clutch pedal position Stop lamp switch Continuity
Released Pressed YES 3. Tighten the plug during the clutch pedal pressed. Af-
terwards, raise the pedal with a hand.
Pressed Released NO
TORQUE :
If the continuity is not as specified, replace the stop 24.5~28.4Nm (80~100Kgf.cm, 18.1~21.0lb-ft)
lamp switch.
If OK, install the stop lamp switch and adjust the pedal 4. After pressing the clutch pedal 3 times more, loosen
height. the plug and retighten it with the pedal pressed. Raise
it again, then.
TORQUE :
7.8~9.8Nm (80~100Kgf.cm, 5.8~7.2lb-ft) 5. Repeat the step 4 two or three times. (until there is
no bubble in the fluid)
IGNITION LOCK SWITCH

1. Disconnect 2P-connector from a ignition lock switch. A

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)

Ignition lock
Clutch pedal position Continuity
switch
Released Released NO
Pressed Pressed YES

If there is difference between what tested and the ta-

ble above, replace the ignition lock switch with a new
one.
If not, install the ignition lock switch and adjust the
clutch pedal. KORE001C

TORQUE : CAUTION
7.8~9.8Nm (80~100Kgf.cm, 5.8~7.2lb-ft)
1. Do not clamp the pipe of a concentric slave
cylinder.
2. Be careful not to damage O-rings.
CH -6 CLUTCH SYSTEM

CLUTCH PEDAL AND IGNITION LOCK SWITCH

NOTE
• Inspect a ignition lock switch.
• Remove the driver’s seat mat to adjust a clutch
pedal.
• No gap between a clutch master cylinder pistion
and push rod can cause clutch slip.

1. Loosen and draw out the bolt until it is off the pedal
surface.

2. Push and pull a clutch master cylinder push rod to

satisfy the specification below.

Specification:
Clutch pedal stroke - 145mm(5.7087inch)
Clutch pedal free play - 13mm(0.5118inch)
Clutch pedal distance - 234.7mm(9.2401inch)

3. With no pressure on a clutch pedal, tighten the bolt

until it contacts on the pedal.

4. Fix the bolt with a nut.

5. Press the clutch pedal to the seat ground.

6. Adjust the ignition lock switch position with the pedal

a little(3~5mm) raised.

7. Install the ignition lock switch firmly.

TORQUE:
7.8~9.8Nm (80~100Kgf.cm, 5.8~7.2lb-ft)
CLUTCH SYSTEM CH -7

CLUTCH COVER AND DISC

COMPONENTS E20BA2A5

4
24.5~35.3 (250~360, 18.1~26.0)-2.0L, 6EA
1 11.8~14.7 (120~150, 8.7~10.8)-2.4L, 9EA

TORQUE : Nm (kgf.cm, lb-ft)

1. Clutch disc 3. Manual transaxle

2. Clutch cover 4. Engine flywheel
EORE002A
CH -8 CLUTCH SYSTEM

INSPECTION E8A9C621

1. Inspect diaphragm spring wear which is in contact

with a concentric slave cylinder bearing.

KORE002I

2. Check the clutch cover and disc surface for wear or

crack.

3. Check the clutch disc lining for slipping or oil mark.

4. Measure the depth from a clutch lining surface to a

rivet. If the measured value is less than the specifica-
tion below, replace it.

Specification: 0.3mm(0.0118inch)

Rivet depth

EORE002J
CLUTCH SYSTEM CH -9

REPLACEMENT EAFB05D6 4. Using the SST(09411-11000), install a disc(A).

1. Remove a transaxle assembly (refer to ’MT’-group).

2. Remove the clutch cover bolts(A). Not to be bent or

twisted, loosen them in diagonal directions(the figures
below are on the base of 2.0L gasoline vehicles).

09411-11000

A KORE002D

CAUTION
KORE002B • On vehicles with 2.4L gasoline engines, re-
place a clutch cover and disc as a set.
3. Remove the clutch cover(A) and disc(B).
* Possible problems when not following the
caution
- When replacing only a disc, slip problem
can occur because of the initial clamp
load loss by the adjusting ring’s unusual
work.
A - When replacing only a disc, it can be dif-
ficult to cut power because the thickness
B
of the disc cannot be permitted.
- On vehicles with 2.4L gasoline engines
and self adjusting clutches, it is neces-
sary to replace a clutch cover and disc
together.

KORE002C
CH -10 CLUTCH SYSTEM

• Apply grease on a disc spline part and trans- the clutch disc. Loss of friction force can
mission input shaft spline part as required. cause a slip
→ How to do: apply grease(CASMOLY L9508)
0.2gr. on the transmission input shaft spline • The ’T/M SIDE’ marked surface should face
part. the transaxle.
→ If the surface face the opposite side, there
* Possible problems when not following can be an interference between a disc and a
- When not applying: Excessively wear of flywheel surface.
splines and bad clutch operation
- When excessively applying: Scattered
grease by centrifugal force conteminates

GENERAL CLUTCH SELF ADJUSTING CLUTCH

T/M SIDE
Mark

EORE002E
CLUTCH SYSTEM CH -11

5. Tighten the clutch cover. * Possible problems when not following

- When tightening the bolt completely at a time:
TORQUE: the clutch cover can be twisted and vibration
24.5~35.3Nm (250~360kgf.cm, 18.1~26.0lb-ft) can occur.
(2.0L-6EA) - On vehicles with 2.4L gasoline engines and
11.8~14.7Nm (120~150kgf.cm, 8.7~10.8lb-ft) self adjusting clutches, it is necessary to fol-
(2.4L-9EA) low this caution.
- Not following tightening torque: There can be
bad torque transmission in clutch and relax-
ation possibility of bolts.

KORE002G

CAUTION
When installing the clutch cover, tighten the bolts
in diagonal directions not to be bent or twisted.

<2.0L gasoline>

EORE002H
CH -12 CLUTCH SYSTEM

CLUTCH MASTER CYLINDER

COMPONENTS E6FA42CC

Apply grease(RG 306)

Apply grease

2
6
3

Apply grease

1. Body assembly 4. Hose clip

2. Piston & cup assembly 5. Washer
3. Push rod 6. Self-locking pin
EORE003A
CLUTCH SYSTEM CH -13

REMOVAL E0D1FDC6 3. Disconnect the hose from the cylinder by releasing

the clutch master cylinder clamp.
NOTE
4. Remove the clip(A) and disconnect the clutch tube(B).
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. Remove the brake fluid fron the clutch master cylinder

A
reservoir with a syringe.

2. Clamp the clutch master cylinder hose(A). If there is

no enough room for clamping, you can also clamp the
hose(B) from the brake master cylinder side.

B
KORE003D

5. Remove the pin and washer which connect the clutch

pedal with the clutch master cylinder.

6. After loosening the clutch master cylinder assembly

mounting bolts under the driver’s seat, remove the
A
clutch master cylinder. It can be helpful to do this step
after removing the clutch pedal mounting bracket.

KORE003B
INSTALLATION E5DE05DE

B
Installation is in the reverse order of removal.
After installation, bleed the clutch hydaulic system.

KORE003C
CH -14 CLUTCH SYSTEM

CLUTCH PEDAL

COMPONENTS EEFBE94E

8 2

24.5~34.3 (250~350, 18.1~25.3)

9
7.8~9.8 (80~100, 5.8~7.2)

TORQUE : Nm (Kgf.cm, lb-ft)

1. Clutch arm 6. Ignition lock switch

2. Clutch member 7. Clutch master cylinder assembly
3. Pedal pad 8. Sealer
4. Bush 9. Stopper
5. Turn over spring
EORE004A
CLUTCH SYSTEM CH -15

REPLACEMENT EBE33D7A

1. Remove a bolt and ignition lock switch.

2. Remove the lock pin and the pin which connects the
clutch master cylinder push rod with the clutch pedal.

3. Remove the mounting nuts from the clutch master

cylinder and the clutch pedal.

4. Remove the clutch pedal.

5. Tighten the mounting bolts to the clutch pedal and the

clutch master cylinder.

6. Apply grease to the pin connecting the clutch pedal

with the clutch master cylinder and install the pin and
a new lock pin in it.

7. Adjust the clutch pedal and the ignition lock switch.