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Clutch System

Specifications
Items Specifications
Clutch operation method Hydraulic type
Clutch cover Type Diaphragm spring strap
Type Single dry with diaphragm
Facing diameter
Ø235 × Ø155 mm (Ø9.2520 × Ø6.1024 in.)
(Outer × inner)
Clutch disc Gasoline 1.6 T-GDI : 8.65 ± 0.3 mm (0.3406 ± 0.0118 in.)
Thickness [When free]
Gasoline 1.8 / 2.0 : 8.3 ± 0.3 mm (0.3268 ± 0.0118 in.)
Gasoline 1.8 / 2.0 : 1.0 mm (0.0394 in.)
Rivet depth
Gasoline 1.6 T-GDI : 1.1 mm (0.0433 in.)

Service Standard

Item Specification
Clutch disc rivet depth 0.3 mm (0.0118 in.)

Tightening Torques

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Item N.m kgf.m lb-ft
Clutch pedal mounting nut & bolt 18.6 ~ 23.5 1.9 ~ 2.4 13.7 ~ 17.4
Clutch switch mounting nut 7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2
Ignition lock switch mounting nut 7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2
Concentric slave cylinder assembly mounting bolt 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5
Clutch release cylinder mounting bolt 14.7 ~ 21.6 1.5 ~ 2.2 10.8 ~ 15.9
Clutch release cylinder bleed plug 6.8 ~ 9.8 0.7 ~ 1.0 5.0 ~ 7.2
Clutch cover mounting bolt (Gasoline 1.6 T-GDI) 24.5 ~ 35.3 2.5 ~ 3.6 18.1 ~ 26.0
Clutch cover mounting bolt (Gasoline 1.8 / 2.0) 11.8 ~ 14.7 1.2 ~ 1.5 8.7 ~ 10.8

Lubricants
Items Specified lubricants Quantity
Clutch release cylinder assembly Brake fluid DOT 3 or DOT 4 As required
Input shaft spline 0.2 g
Release bearing & Fork 0.3 ~ 0.5 g
Release Fork & Fulcrum CASMOLY L9508 0.5 ~ 1.0 g
Release cylinder & Fork 0.4 ~ 0.8 g
Clutch release bearing and Clutch housing 0.5~1.0 g

Clutch System

Special Service Tools

Tool Name / Number Illustration Description
09411-1P000
Clutch disc guide

Used for holding clutch disc when installing

Clutch System

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Components

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1. Clutch cover assembly 2. Clutch disc assembly

Clutch System

Removal
1. Remove the transaxle assembly.
(Refer to Manual Transaxle System - " Manual Transaxle")
2. Remove the clutch cover bolts. Be careful not to be bent or twist bolts. Loosen bolts in diagonal directions.

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Inspection
1. Inspect diaphragm spring wear which is in contact with a clutch release bearing.
2. Check the clutch cover and disc surface for wear or cracks.
3. Check the clutch disc facing for slipping or oil marks.
4. Measure the depth from a clutch facing surface to a rivet. If the measured value is less than the specification below, replace it.
Clutch disc rivet depth (A) :
0.3 mm (0.0118 in.)

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Installation

Clutch cover and disc should be replaced as a set.

1. Apply grease on a disc spline part and transaxle input shaft spline part as required.

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 by centrifugal force which can contaminate the clutch disc. This can
cause a loss of friction force causing a slip.
2. Install the clutch disc and the cover by using the SST (09411-1P000).

• When installing the cover, remove the foreign of material of flywheel and pressure plate completely.
• Make sure about the direction of the clutch disk when installing.

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

• Transaxle shift error or a strange sound can occur due to clutch separation.

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3. Tighten the clutch cover bolts.
Tightening torque
Gasoline 1.6 T-GDI : 24.5 ~ 35.3 N.m(2.5 ~ 3.6 kgf.m, 18.1 ~ 26.0 lb-ft)
Gasoline 1.8 / 2.0 : 11.8 ~ 14.7 N.m (1.2 ~ 1.5 kgf.m, 8.7 ~ 10.8 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 transaxle may have concerns or the
mounting bolt can loosen.

4. Install the transaxle assembly.

(Refer to Manual Transaxle System - "Manual Transaxle")
Clutch System

Description
• Component location :Clutch switch is connected to top of the clutch pedal assembly.

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• Function
1. Clutch operation is detected through clutch switch signal. This signal enables ECM to cope with instant change of load condition.
2. Clutch switch signal is used to detect engaged gear with vehicle speed and engine speed.
Clutch System

Specifications
Item Specifications
Working voltage DC 12V

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9.8 ± 2.9N
Operating force
(1.0 ± 0.3kg, 7.2 ± 0.7lb)
Voltage drop -0.4V
-40°C ~ 80°C
Working temperature
(-40°F ~ 176°F)

Clutch System

Inspection
Component Inspection
1. Remove the clutch switch.
(Refer to Clutch Switch - "Removal")
2. Push the clutch switch in the direction of the arrow to make sure that continuity is cut off.

Condition Clutch Pedal pressed Clutch Pedal Released

Switch Operation ON (below 1.0Ω ) OFF ( Infinite Ω )

Removal
1. Turn ignition switch OFF and disconnect the negative (-) battery cable.

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2. Remove the smart junction box

(Refer to Body Electrical System - "Relay Box (Passenger Compartment)")
3. Disconnect clutch switch connector (A).

4. Remove the clutch switch (B) by loosening a nut (A).

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Installation
1. Install in the reverse order of removal.
2. Adjust the clutch switch.
(1) Adjust the gab by rotating the adjust nut (A) to satisfy the standard gap range.
Standard gap range:
0.5 ~ 1.0 mm (0.0197 ~ 0.0394 in.)
(2) Tighten the nut (B) with the specified torque.
Tightening torque:
7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb-ft)

Clutch System

Description

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• Component location :Ignition lock switch is connected to clutch pedal assembly.

• Function
1. Start is possible only when press down the clutch pedal.
2. Ignition lock switch can be prevent to unintended departure when start the engine into the any range of the shift lever.
Clutch System

Specifications

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Item Specifications
Working voltage DC 12V
9.8 ± 2.9N
Operating force
(1.0 ± 0.3kg, 7.2 ± 0.7lb)
-40°C ~ 80°C
Working temperature
(-40°F ~ 176°F)

Clutch System

Inspection
Component Inspection
1. Remove the ignition lock switch.
2. Push the ignition lock switch in the direction of the arrow to make sure that continuity between terminals. (refer to the table below)
Standard value :
Full stroke (A): 12.0 ± 0.3mm (0.4724 ± 0.0118 in.)
ON-OFF point (B): 2.0 mm (0.0787 in.)

Condition Clutch Pedal pressed Clutch Pedal Released

Switch Operation ON (below 1.0Ω ) OFF ( Infinite Ω )

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Removal
1. Turn ignition switch OFF and disconnect the negative (-) battery cable.
2. Remove the smart junction box.
(Refer to Body Electrical System - "Relay Box (Passenger Compartment)")
3. Disconnect the ignition lock switch connector (A).

4. Remove the ignition lock switch by loosening a nut (A).

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Installation
1. Install in the reverse order of removal.
2. Adjust the ignition lock switch.
(1) In state of full stroke, adjust the gab by rotating the adjust nut (A) to satisfy the standard gap range.
Standard gap range :
3 ~ 4 mm (0.1181 ~ 0.1575 in.)
(2) Tighten the nut (B) with the specified torque.
Tightening torque:
7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb-ft)

Clutch System

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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

Removal
1. Remove the battery.
(Refer to Engine Electrical System - "Battery")
2. Remove the ECM.
(Refer to Engine Control/Fuel System - "Engine Control Module")
3. Disconnect the clutch regulator (B) and reservoir hose (A) from the clutch master cylinder.

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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4. Remove the clutch pedal.

(1) Disconnect the ignition lock switch connector (A) and clutch switch connector (B).
(2) Loosen the clutch pedal mounting nuts (C) and bolt (D).
Tightening torque:
18.6 ~ 23.5 N.m (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft)

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(3) Disconnect the wiring from the clutch pedal aseembly.
(4) Remove the clutch pedal with master cylinder assembly.
5. Remove the master cylinder from the clutch pedal.
(1) Separate the push rod (C) after remove the pin (A) and washer (B).
(2) Remove the master cylinder by rotating in a clockwise direction.

Installation
1. Install in the reverse order of removal.
2. After be equipped, perform bleeding air procedure in clutch release cylinder after pouring the brake fluid.
(Refer to Clutch System - "Clutch release cylinder")
Clutch System

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

Removal
1. Separate the push rod (C) after remove the pin (A) and washer (B).

2. Remove the battery.

(Refer to Engine Electrical System - "Battery")

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3. Remove the ECM.

(Refer to Engine Control/Fuel System - "Engine Control Module (ECM)")
4. Disconnect the clutch regulator (B) and reservoir hose (A) from the clutch master cylinder.

• 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.

5. Remove the master cylinder (A) by rotating in a clockwise direction.

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Installation
1. Install in the reverse order of removal.
2. After be equipped, perform bleeding air procedure in clutch release cylinder after pouring the brake fluid.
(Refer to Clutch System - "Clutch release cylinder")
Clutch System

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

Inspection
1. Check the clutch release cylinder for fluid leakage.
2. Check the clutch release cylinder boot for damage.

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

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• 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.

2. Remove the clutch release cylinder assembly (C) after removing the tube (B) and bolts (A-2ea).
Tightening torque:
14.7 ~ 21.6 N.m (1.5 ~ 2.2 kgf.m,10.8 ~ 15.9 lb-ft)

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Installation
1. Install in the reverse order of removal.

Apply the specified grease to the push rod end.

Specified grease:CASMOLY L9508
Quantity:0.4 ~ 0.8 g

Adjustment
Clutch Release Cylinder Air Bleeding Procedure

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

1. After disconnecting a cap from the clutch release cylinder air bleeder, insert a vinyl hose in the plug.
2. Refill the clutch master cylinder with the specified fluid.
Specified fluid:SAE J1703 (DOT 3 or DOT 4)
3. Loosening the plug screw, press and release the clutch pedal about 10 times.
4. Tighten the plug (A) during the clutch pedal pressed. Afterwards, raise the pedal with a hand.
5. After pressing the clutch pedal 3 times more, loosen the plug (A) and re-tighten it with the pedal pressed. Raise it again, then.
6. 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, 5.0 ~ 7.2 lb-ft)

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7. Refill the clutch master cylinder with the specified fluid.
Specified fluid:SAE J1703 (DOT 3 or DOT 4)
Clutch System

Components

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1. Clutch release fork 3. Clutch disk assembly
2. Clutch cover assembly 4. Clutch release bearing

Clutch System

Removal
1. Remove the transaxle assembly.
(Refer to Manual Transaxle System - " Manual Transaxle")
2. Remove the clutch release bearing (A).

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3. Pull the clip (A).

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4. Remove the clutch release fork (A).

5. Remove the boot (A).

Inspection
1. Check for damage to boot.
2. Check for deformation to clutch release fork.

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3. Check for deformation to clutch release bearing.

Installation
1. Install the boot (A).

2. Install the clip to the clutch release fork.

3. Apply to grease in location A, B and C.
Location Quantity (g) Remarks
A 0.3 ~ 0.5 Release bearing & Fork

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B 0.5 ~ 1.0 Release Fork & Fulcrum
C 0.4 ~ 0.8 Release cylinder & Fork

4. Apply the grease to the hole surface of the clutch release bearing all around.
Specified grease :CASMOLY L9508
Amount :0.5 ~ 1.0 g

5. Install the clutch release fork (B), clutch release bearing (A).

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6. Install the transaxle assembly.

(Refer to Manual Transaxle System - " Manual Transaxle")
Clutch System

Component

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1. Concentric slave cylinder assembly 2. Manual transaxle

Clutch System

Removal

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1. Remove the transaxle assembly.

(Refer to Manual Transaxle System - " Manual Transaxle")
2. Remove the concentric slave cylinder assembly from the transaxle case by removing bolts (A).
Tightening torque:
19.6 ~ 26.5 N.m (2.0 ~ 2.7 kgf.m, 14.5 ~ 19.5 lb-ft)

Installation

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• Install the concentric slave cylinder bolts. Not to be bent or twisted, Tighten them in diagonal directions.
• When it is assembled, it must be free from invasive foreign matters and oil leakage.
1. Installation is in reverse order of removal.
2. Perform bleeding air procedure in concentric slave cylinder after pouring the brake fluid.
(Refer to Concentric Slave Cylinder Assembly - "Adjustment")

Adjustment
Concentric Slave Cylinder Air Bleeding Procedure
1. After disconnecting a cap from the concentric slave cylinder air bleeder, insert a vinyl hose in the plug.
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)
3. Pump the clutch pedal about 10 times.
4. Loosen the air bleed screw (A) at hold down the clutch pedal to allow air to escape from the clutch system. Then tighten the air
bleed screw.

5. Repeat the step 2 ~ 4 until there is no bubble in the fluid.

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