Service Manual Kalos 2006 EMBRAGUE (TIPO HIDRÁULICO)

SECTION 5C1

CLUTCH (HYDRAULIC TYPE)

Precaución : Desconecte el cable negativo de la batería antes de desmontar o instalar cualquier unidad eléctrica o cuando una herramienta o equipo pueda entrar fácilmente en contacto con los terminales eléctricos expuestos. La desconexión de este cable ayudará a evitar lesiones personales y daños al vehículo. El encendido también debe estar en la posición LOCK, a menos que se indique lo contrario.

ESPECIFICACIONES

Fastener Tightening Specifications

Application	N•m	Lb-Ft	Lb-In
Clutch Master Cylinder Nuts	22	16	-
Clutch Pedal Shaft Nut	20	15	-
Pressure Plate-to-Flywheel Bolts	15	11	-
Release Cylinder Bolts	20	15	-

SPECIAL TOOLS

Special Tools Table

J-36547

Input Shaft Seal

Installer

J-42474

Clutch Arbor

DIAGNOSIS

Clutch Operation

Fails to Release

Checks	Action
DEFINICIÓN: Cuando se pisa el pedal hasta el suelo, la palanca de cambios no se mueve libremente para entrar y salir de la marcha atrás.
Check for a loose linkage.	Repair or replace loose linkage, if necessary.
Check for a damaged clutch disc.	Replace the damaged clutch disc.
Check for an improperly installed fork shaft.	Remove and properly reinstalled the fork shaft. Very lightly lubricate the fork fingers at the release bearing with wheel bearing grease.
Check for the clutch disc hub binding on the input shaft splines.	Repair or replace the clutch disc hub.
Check for a warped or bent clutch disc.	Replace the warped or bent clutch disc.

Slipping

Checks	Action
Check for the driver improperly operating the vehicle.	Correct the driver's operation of the vehicle as necessary.
Check for an oil-soaked clutch disc.	Correct the leak at its source and install a new clutch disc.
Check for a worn facing or facing torn from the disc.	Replace the worn disc with a new disc.
Check for a warped pressure plate or a warped flywheel.	Replace the warped pressure plate or the warped flywheel.
Check for a weak diaphragm spring.	Replace the pressure plate.
Check for a driven plate that is not seated.	Start the engine 30 to 40 times. Do not overheat the engine.
Check for a driven plate that is overheated.	Allow the driven plate to cool.

Grabbing (Chattering)

Checks	Action
Check for a burned or a glazed facing caused by oil on the facing.	Correct the leak at its source and install a new clutch disc.
Check for worn splines on the input shaft.	Replace the worn input shaft.
Check for a warped pressure plate or a warped flywheel.	Replace the warped pressure plate or the warped flywheel.
Check for a burned or smeared resin on the flywheel or the pressure plate.	Sand off the burned or smeared resin if it is superficial. Replace any burned or heat-checked parts.

Rattling (Transaxle Click)

Checks	Action
Check for weak retracting springs.	Replace the pressure plate.
Check for a loose release fork.	Remove and reinstall the release fork properly.
Check for oil in the driven plate bumper.	Correct the cause of the oil leak and replace the driven disc.
Check for a damaged driven plate damper spring.	Replace the driven disc.

Release Bearing Noise with Clutch Fully Engaged

Checks	Action
Check for the driver improperly operating the vehicle.	Correct the driver's operation of the vehicle as necessary.
Check for a binding release bearing.	Clean and re-lubricate the release bearing. Inspect the release bearing for burrs and nicks.
Check for an improperly installed release lever.	Remove and reinstall the release lever properly.
Check for a weak linkage return spring.	Replace the weak linkage return spring.

Noisy

Checks	Action
Check for a worn release bearing.	Replace the worn release bearing.
Check for a improperly installed release lever.	Remove and properly reinstall the fork shaft. Very lightly lubricate the fork fingers at the release bearing with wheel bearing grease.

Pedal Stays on Floor When Disengaged

Checks	Action
Check for binding in the linkage or the release bearing.	Lubricate and free-up the binding linkage or the release bearing.
Check for weak pressure plate springs.	Replace the pressure plate.

Hard Pedal Effort

Checks	Action
Check for binding in the linkage.	Lubricate and free-up the binding linkage.
Check for a worn driven plate.	Replace the worn driven plate.

COMPONENT LOCATOR

Hydraulic Clutch

Clutch Master Cylinder
Clutch Master Cylinder Gasket
Nut
Clutch Master Cylinder Pipe
Clutch Release Cylinder
Bolt
Bolt
Washer
Bolt
Clip
Reservoir Tank Hose

Clutch Pedal

Clutch Pedal Brace
Nut
Pedal Shaft
Bolt
E-Ring
Bushing
Pin
Nut
Clutch Pedal Buffer
Bushing
Turn Over Spring
Clutch Pedal
Clutch Pedal Pad
Clutch Pedal Buffer

MAINTENANCE AND REPAIR

ON-VEHICLE SERVICE

Clutch Pedal

Removal Procedure

Disconnect the negative battery cable.
Disconnect the return spring from the clutch pedal.
Remove the nut, the washer, and the pedal mounting shaft.

Remove the locking clip and push rod fixing pin.
Remove the push rod from the clutch pedal.
Remove the clutch pedal.

Installation Procedure

Install the clutch pedal.
Coat the push rod with multi-purpose grease.
Install the push rod to the clutch pedal.
Install the locking clip and push rod fixing pin.

Coat the pedal mounting shaft with multi-purpose grease.
Install the nut, the washer, and the pedal mounting shaft.

Tighten

Tighten the nut to 20 N•m (15 lb-ft).

Connect the return spring to the clutch pedal.
Connect the negative battery cable.

Clutch Pedal Adjustment (Hydraulic)

Adjustment Procedure

Determine the clutch pedal play. Depress the clutch pedal lightly with your hand and measure the distance when you feel resistance.

Adjust the clutch pedal play. Loosen the locknut and turn the pushrod. Clutch pedal play should measure 6 to 12 mm (0.2 to 0.5 inch). Tighten the locknut after adjustment.

Measure the clutch pedal travel. Press the clutch pedal all the way to the floor. Measure from the starting position to the ending position.
Adjust the clutch pedal travel. Loosen the locknut and turn the bolt. Clutch pedal travel should measure 125 to 130 mm (4.9 to 5.1 inches). Tighten the locknut after adjustment.

Clutch Release Point Adjustment (Hydraulic)

Adjustment Procedure

Apply the parking brake.
Run the engine at idle speed.
While you move the shift lever into the reverse position, depress the clutch pedal slowly and measure the distance between the point when gear noise is not heard and the point the clutch pedal is completely depressed. The distance should be 30 to 35 mm (1.2 to 1.4 inches).

If the distance is not within the specified value, check the following:

Clutch pedal height
Clutch pedal play
Air in the system
Clutch cover and disc pressure plate

Air Bleeding

Bleed the hydraulic system to remove the air which entered When the pipes were disconnected for repairs. The clutch/brake fluid in the clutch/brake reservoir must be maintained at the MIN level or higher during air bleeding.

Attach a vinyl hose to the bleeder plug. Place the other end of the vinyl tube in a glass container half-filled with brake fluid.
Slowly pump the clutch pedal several times.
While you press the clutch pedal, loosen the bleeder screw until the fluid starts to run out. Close the bleeder screw.
Repeat Step 3 until there are no air bubbles in the fluid.
Fill the reservoir with brake fluid up to the MAX level.

Pressure Plate and Clutch Disc

Removal Procedure

Disconnect the negative battery cable.
Remove the transaxle from the vehicle. Refer to Section 5B1, Five-Speed Manual Transaxle (D16).
Remove the pressure plate bolts and the pressure plate.

Important : Support the pressure plate when you remove the last bolt.

Remove the clutch disc from the flywheel.

Inspection Procedure – Clutch Disc

Visual Inspection

Inspect the worn or oily contamination on the clutch surface.
Inspect the damaged or weakened torsion spring.
Inspect the a warped or bent clutch disc. After inspection, replace new clutch disc, if necessary.

Clutch Disc Inspection

Measure the rivet head depth from the clutch disc surface.
Replace the clutch disc if the measured value is below the limit.
Rivet Head Depth (Limit) : 1.2 mm (0.047 in)

Clutch Disc Runout in Rotational Direction Inspection

Measure runout using the dial gauge.
If runout exceeds limit, replace the clutch disc.

Inspection Procedure – Pressure Plate

Check for a worn diaphragm spring finger.
Check for a worn or cracked pressure plate surface.
Check for the polluted face by the oil. After inspection, replace the pressure plate if necessary.

Installation Procedure

Coat the spline on the clutch disc with multi-purpose grease.
Align the pressure plate and the clutch disc onto the flywheel using the clutch arbor J-42474.
Install the pressure plate bolts.

Tighten

Tighten the bolts to 15 N•m (11 lb-ft).

Remove the clutch arbor J-42474.
Install the transaxle into the vehicle. Refer to Section 5B1, Five-Speed Manual Transaxle (D16).
Connect the negative battery cable.

Clutch Master Cylinder Assembly

Removal Procedure

Before disconnecting the reservoir tank hose, remove the clutch/brake fluid from the reservoir tank.

Remove the locking clip.
Remove the push rod fixing pin and push rod.

Disconnect the hose clamp on the master cylinder.
Disconnect the master cylinder hose.

Remove the master cylinder pipe.

Remove the clutch master cylinder nuts.
Remove the clutch master cylinder.

Installation Procedure

Install the clutch master cylinder and clutch master cylinder nuts.

Tighten

Tighten the clutch master cylinder nuts to 22 N•m (16 lb-ft).

Install the master cylinder pipe.

Connect the master cylinder hose.
Connect the hose clamp on the master cylinder.

Install the push rod fixing pin and push rod.
Install the locking clip.
Bleed the air. Refer to "Air Bleeding" in this section.
Adjust the clutch pedal. Refer to "Clutch Pedal Adjustment" in this section.
Fill the reservoir with clutch/brake fluid up to the MAX level.

Clutch Release Cylinder Assembly

Removal Procedure

Remove the bolt and disconnect the hose from the clutch release cylinder.

Remove the clutch release cylinder bolts and remove the release cylinder from the transaxle.

Installation Procedure

Connect the release cylinder to the transaxle and install the bolts.

Tighten

Tighten the release cylinder bolts to 20 N•m (15 lb-ft).

Connect the hose assembly to the cylinder body.
Apply grease where the pushrod connects to the release lever. Be careful not to stain the boot.
Bleed the air. Refer to "Air Bleeding" in this section.
Adjust the clutch pedal. Refer to "Clutch Pedal Adjustment (Hydraulic)" in this section.
Fill the reservoir with clutch/brake fluid up to the MAX level.

UNIT REPAIR

Clutch Master Cylinder

Disassembly Procedure

Remove the clutch master cylinder assembly from the vehicle. Refer to "Clutch Master Cylinder Assembly"in this section.
Remove the boot and disconnect the piston stop ring using ring pliers.

Remove the pushrod assembly and the piston assembly.
Inspect the clutch master cylinder wall and the piston for wear. Replace the piston if necessary.
Inspect the cup and the piston for wear. Fluid leaks will show wear on the cup and the piston. Replace the cup and the piston if necessary.
Inspect the pushrod for wear. Repair the pushrod if necessary.

Assembly Procedure

Apply clean fluid to the piston assembly cup and insert the piston assembly and the pushrod assembly into the master cylinder body.

Install the piston stop ring using ring pliers. Install the boot.
Install the clutch master cylinder assembly into the vehicle. Refer to "Clutch Master Cylinder Assembly"in this section.

Clutch Release Cylinder

Disassembly Procedure

Remove the clutch release cylinder assembly from the vehicle. Refer to "Clutch Release Cylinder Assembly" in this section.
Remove the bolts and brackets.

Remove the boot and the pushrod.

Compress the piston with a driver and remove the snap ring with snap ring pliers.
Remove the piston assembly.

Assembly Procedure

Apply clean clutch fluid to the piston and the cup.
Install the spring to the piston, and insert the assembly into the cylinder body.
Compress the piston with a driver, then install the snap ring with snap ring pliers.

Install the pushrod and the boot.

Install the brackets and the bolts.
Install the clutch release cylinder assembly. Refer to "Clutch Release Cylinder Assembly" in this section.

GENERAL DESCRIPTION AND SYSTEM OPERATION

Driving Members

The driving members consist of two flat surfaces machined to a smooth finish. One of these is the rear face of the engine flywheel and the other is the pressure plate. The pressure plate is fitted into a steel cover which is bolted to the flywheel.

Driven Members

The driven member is the clutch disc with a splined hub.The splined hub is free to slide lengthwise along the splines of the input shaft and drives the input shaft through these same splines.

The driving and driven members are held in contact by spring pressure. This pressure is exerted by a diaphragm spring in the pressure plate assembly.

Operating Members

The clutch release system consists of the clutch pedal, the clutch shaft, the fork, and the release bearing. When pressure is applied to the clutch pedal, the fork pivots on its shaft and the inner end pushes against the release bearing. The bearing then pushes against the release levers in the pressure plate assembly, thereby releasing the clutch.