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Clutch
Overview Tightening torques Nm Bolt Pedal to the bracket ..... 25-35 Bolt of the master cylinder to pedal bracket ..... 17-26 Union nut fastening pipe ..... 13-17 Holder pipe ..... 4-6 Bolt working cylinder ..... 15-22 The hollow pipe bolt to the working cylinder ..... 25 Plate mounting bolts 15-22 ..... Nut master cylinder pushrod to the pedal ..... 9-14 Nut locking switch ignition ..... 8-10
Technical specifications Clutch Type | Hydraulic | Clutch plate | Dry, diaphragm | The outer / inner diameter of the clutch disc, mm | 215/145 | Clutch cover assembly with the pressure plate | With diaphragm compression spring | Inner diameter: working cylinder, mm master cylinder, mm |
20.64 15.57 |
Data for checks and adjustments Clutch Type | Hydraulic | Plate thickness (in free state) mm: Engines 1.3; 1.5 and 1.6 liters 1.1 liter engine |
8,5 + 0,3 8,0 + 0,3 | Free travel, mm | 6-13 | The height of the clutch pedal from the floor mm | 160.7 | The clutch pedal, mm | 140 | The clearance between the cylinder and the piston, mm | 0.15 | The gap between the master cylinder and the piston, mm | 0.15 |
Applied Lubricants Place of application | Name | The surface of the terminal with release bearing | CASMOLY L9508 | The inner surface of release bearing | CASMOLY L9508 | Mirror working cylinder, the outer surface of the piston and sleeve | Brake fluid DOT-3 or DOT-4 | Slots clutch plate | CASMOLY L9508 | Mirror master cylinder and the outer surface of the piston | Brake fluid DOT-3 or DOT-4 | The pusher of the main cylinder, the axis of the pusher and puck | Grease for wheel bearings SAE J310a, NLGI No.2 | The axis of the sleeve and the clutch pedal | SAE J310a, chassis grease, NLGI-No.1 | The contact surface with the clutch fork pusher of the working cylinder | CASMOLY L9508 |
Removing and installing clutch and drive
| Fig. 3.1. Ctseplenie and its drive: 1 - clutch fork; 2 - clutch; 3 - plate mounting bolts; 4 - clutch cover; 5 - clutch plate; 6 - pipeline clutch; 7 - an arm of the clutch pedal; 8 - the axis of the clutch pedal; 9 - the clutch pedal; 10 - Clutch master cylinder; 11 - the clutch slave cylinder; 12 - bleeder valve clutch slave cylinder
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Bleeding the clutch Pumping the clutch control should be carried out each time the removal of the connecting pipe, hose and / or the master cylinder, and in a case where the clutch pedal becomes "soft".
A WARNING Use only the specified hydraulic fluid brand. Do not mix different brands of liquid. Use fluid DOT-3 or DOT-4. |
| Fig. 3.2. Location bleeder clutch
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Loosen the bleed screw on the working cylinder (Fig. 3.2). Slowly push the stop on the clutch pedal until the until no leakage of fluid. Hold the pedal depressed, tighten the bleeder valve. Top up to the normal level in the reservoir fluid required mark.
Clutch master cylinder
| Fig. 3.3. Clutch master cylinder: 1 - body of the clutch master cylinder; 2 - the nut of the clutch master cylinder; 3 - the piston; 4 - a lock ring; 5 - plunger damper; 6 - axis pusher
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Clutch master cylinder is shown in Fig. 3.3. Withdrawal Drain the hydraulic fluid through the bleeder valve.
| Fig. 3.4. Nut clutch master cylinder
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Disconnect pipelines and hoses clutch.
| Fig. 3.5. Clip fastening pipe to gearbox
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Remove the clamp fastening of the pipeline to the gearbox (Fig. 3.5). Check the hoses and pipelines for corrosion, scoring and shells. Setting Attach the tubing to the working cylinder.
| Fig. 3.6. Flexible Hose clutch
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Install the master cylinder. Connect the pushrod to the clutch pedal. Bleed the hydraulic clutch. Dismantling Remove the retaining ring of the piston. Remove the pushrod assembly with the piston, thus take care not to damage the housing and the piston cylinder. Technical condition Check the cylinder bore for corrosion, scoring and shells. Check the cylinder sleeve for wear or misalignment. Inspect the piston for signs of corrosion, burrs shells go. Check the cleanliness of the pipeline. Check with the help of the inner diameter of the cylinder bore gauge with a micrometer and an outer diameter of the piston. If the clearance between the piston and the cylinder exceeds the maximum allowable size (0.15 mm), replace the master cylinder or the piston. Assembly Apply the working fluid DOT-3 and DOT-4 in the cylinder bore and the outer surface of the piston. Insert the piston into the cylinder. Install the retaining ring of the piston. Install the pusher. Attach a hose to the cylinder.
The clutch pedal
| Fig. 3.7. Clutch pedal arm and its mount: 1 - the switch of ignition interlock; 2 - pedal bracket; 3 - a bolt of fastening of an arm of a pedal; 4 - the pedal shaft; 5 - inner sleeve pedal; 6 - a returnable spring; 7 - outer sleeve pedal; 8 - inner sleeve pedal; 9 - spring washer; 10 - a nut axis of the pedal; 11 - emphasis pedal; 12 - the clutch pedal
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Clutch pedal arm and its mount are shown in Fig. 3.7. Withdrawal
| Fig. 3.8. Cotter pin axis of the clutch pedal pusher
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| Fig. 3.9. Nuts of fastening of the clutch pedal
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Technical condition Check the following: - Pedal axle and hub for wear; - The clutch pedal for the presence of bending and warping; - A return spring for damage or weakening; - Pedal pad for damage or wear;
| Fig. 3.10. Measuring the height of the clutch pedal from the floor
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- Pedal height above the floor of A (from the outer surface of the pedal pad to the floor) (Fig. 3.10). It should be 160.7 mm. If the pedal height above the floor is not correct, adjust it as follows.
A WARNING When adjusting the height of the pedal, make sure that the plunger is not shifted to the side of the master cylinder. |
1. Bolt adjust the pedal height, then tighten the lock nut.
A WARNING After the adjustment, tighten the bolt so that it touches the pedal stops, then tighten the lock nut. |
| Fig. 3.11. The height above the floor and the clutch pedal
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2. Rotate the pusher adjust its length to a new height pedal (Fig. 3.11), then fasten the pusher nut.
After adjustment, make sure that the clutch pedal free play (measured from the surface of the pedal pad) is in the range 6-13 mm (Fig. 3.12). If the clutch pedal free play is incorrect, then got in the air or hydraulic master cylinder is faulty. Bleed and check the hydraulic master cylinder or clutch.
| Fig. 3.13. Driving test the integrity of the electrical circuit between the contacts of the switch
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Check the ignition switch lock. Check the integrity of the electrical circuit between the contacts of the switch (Fig. 3.13). Setting
| Fig. 3.14. Places applying universal lubricant
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Apply universal grease to the places indicated by arrows in Fig. 3.14. Install the cotter pin axis of the clutch pedal.
Clutch cover and clutch disc
| Fig. 3.15. Clutch cover and clutch disc 1 - clutch fork; 2 - clutch; 3 - plate mounting bolts; 4 - clutch cover; 5 - Clutch Disc
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Clutch cover and clutch disc are shown in Fig. 3.15. Withdrawal Drain the clutch and the oil from the gearbox. Remove the gearbox (see. Subsection "Transmission"). Insert the mandrel into the hole 09411-25000 hub drive plate to prevent it from falling. Loosen crosswise Tightening the clutch cover to the flywheel.
| Fig. 3.16. The weakening of the pressure plate mounting bolts to a flywheel
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Bolts wrench turns, each time for one or two turns, to prevent warping of the flange cover (Fig. 3.16).
A WARNING Do not use solvents to clean the clutch disc and release bearing. |
Checking technical condition Clutch cover. Make sure the ends of the petals of the diaphragm spring for wear and the difference in height. Check the pressure plate surface for wear, cracks and discoloration. Check for loose rivets and, if necessary, replace the clutch cover. Slave drive. Check friction linings for loose rivets, uneven tracks fit, damage from tacking, adhesion of oil or grease. If necessary, replace the damaged clutch disc.
| Fig. 3.17. Check the thickness of the drive plate in the free (unloaded) state
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Check the thickness of the drive plate in the free state (Fig. 3.17). Check the spring drive for play and damage, if necessary replace the failed drive. Clean the splines on the input shaft of the gearbox and the clutch disc set. At the complicated moving disc on shaft splines or the presence of his excessive play, replace the clutch disc and / or the gearbox output shaft.
A WARNING The clutch laid grease. Do not use solvents to clean the bearing. |
Clutch. Check the clutch for binding, damage or noise. Check the point of contact with the diaphragm spring cage for wear. Replace worn bearing seats with a strong contact with the clutch fork. Clutch fork. Replace the plug with a strong clutch wear in contact with the release bearing. Setting Apply universal grease to the release fork in contact with the bearing and the clutch slave cylinder.
| Fig. 3.18. Place the universal application of grease on the clutch fork
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Apply universal grease to release bearing groove. Recommended grease - CASMOLY L9508. Apply universal grease CASMOLY L9508 on the release fork in contact with the axis of the release lever. Thoroughly clean the surface of the flywheel and pressure plate of fine-grained sandpaper and make sure no traces of them oil or grease. Apply a small amount of lubricant CASMOLY L9508 universal slots on the hub drive plate and the input shaft of a transmission.
A WARNING | Fig. 3.19. Bolts clutch slave cylinder
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When installing the clutch, do not apply too much grease on these Fig. 3.19 space, since it can lead to slippage and jerks during clutch operation. |
With mandrel 09411-25000 install the clutch disc on the flywheel side with the factory marked the pressure plate. Replace the flywheel clutch cover and replace the six bolts. Tighten bolts crosswise torque of 15-22 Nm. Tighten bolts alternately, each time for one or two turns, to prevent warping of the flange coupling casing. Remove the mandrel to center the clutch disc. Install gearbox (see. Subsection "Transmission"). Adjust the clutch clearance.
A WARNING Apply only the necessary amount of grease. Excess grease can cause slippage and jerks at the clutch. |
The clutch slave cylinder Withdrawal Disconnect from the slave cylinder connecting pipe.
| Fig. 3.20. Remove the piston from the cylinder
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Technical condition Check the slave cylinder for signs of fluid leakage. Check out the cover of the working cylinder for damage. Dismantling Disconnect from the cylinder a connecting hose, remove the valve plate, spring, pusher and cover. Carefully remove the dirt around the working cylinder bore for the piston. Remove the plunger from the cylinder with compressed air directed into the cylinder (Fig. 3.20).
A WARNING Previously working cylinder cover with a cloth, as the piston can fly at high speed and cause injury. |
Gradually increase the air pressure to prevent the release of the brake fluid and its hit in the eyes or on the skin. Technical condition Check the mirror of the working cylinder for corrosion or damage. Using bore gauge, check the inner diameter of the cylinder in three places (in the lower, middle and upper parts). If the clearance between the piston and the cylinder exceeds the legal limit, replace the slave cylinder. Maximum permissible backlash between the piston and the cylinder of 0.15 mm. Assembly Apply brake fluid desired mark on an inner surface of the working cylinder and an outer surface of the piston and the piston sleeve and the piston in the cylinder is set. Used fluid: Brake Fluid DOT-3 or DOT-4. Setting Install the valve plate, pusher and cover. Apply grease on the axle pusher CASMOLY L9508. Install the clutch slave cylinder and attach it to the pipeline.
| Fig. 3.21. Bolts clutch slave cylinder
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Useful information and advice Reasons slipping clutch or a part-time off by pressing the pedal Slipping the clutch is shown that under quite serviceable engine the car badly overcomes liftings, slowly dispersed. This may be caused by severe wear or lubricating with disks, reducing the elasticity of the springs, the lack of free running clutch pedal. Incomplete clutch causes difficulty and noise during gear changes and can lead to premature failure of synchronizers and accelerated wear of the teeth of a transmission. This failure is most often caused by pollution, a warp or deformation of disks, wrong adjustment of the position of levers off, too much free during the clutch pedal. It will be appreciated that the noise in the gearbox - is not always a consequence of the partial clutch. Noise can occur when wear or incorrect adjustment bearing wear or incorrect engagement of bevel gears. Strong knock in these locations indicates a serious problem that requires an immediate stop of the car and repair the unit. Reasons hindered shift or turns off Difficulty shifting gears or spontaneous off - the result of deterioration of locks and latches or drive shift mechanism. There without serious repair is necessary. To prevent such failure in the following ways: periodically carefully to check reliability of fastening of all units and power transmission components, to monitor the level of oil in the gearbox and in time to change it.
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