16-Clutch System

General Information
2007 > J2.9L DIESEL CRDI(VGT) >
SPECIAL TOOLS
Tool
Illustration Use
(Number and Name)
09411-43000 Installation of the clutch disc
Clutch disc guide
SPECIFICATION
Item SPECIFICATION
Engine type J2.9
Clutch operation Hydraulic type
Clutch disc Single dry with diaphragm
Clutch cover assembly Self Adjusting Clutch
TIGHTENING TORQUE
Item Nm Kgf.cm lb-ft

Clutch cover (6EA) 25~36 250~360 18.2~26.2
Clutch pedal bracket mounting 19~26 190~260 13.8~18.9
Regulator bolt 28~33 280~330 20.3~24
Connecting rod adjusting bolt 9~14 90~140 6.5~10.1
Clutch master cylinder mounting 12~16 120~160 8.7~11.6
5.8~7.27 or
Stopper bolt 8~10 or 14~20 80~100 or 140~200
10.1~14.5
Clutch pedal bolt/nut 25~34 250~340 18.1~24.7
SERVICE STANDARD
Item Standard value

Clutch pedal stroke 150mm (5.91in)
Clutch pedal free play 6~13mm (0.24~0.51in)
Clutch System
DESCRIPTION
SELF ADJUSTING CLUTCH(S.A.C.) COVER
a. 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.
b. To make up for this defect, the self adjusting clutch system makes the requsted pedal pressure minimized so that
makes the maintenance cycle longer.
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
CONCENTRIC SLAVE CYLINDER-C.S.C
When the clutch pedal is pressed, oil pressure is transmitted along the arrow directions shown below and that moves
the clutch slave cylinder and the diaphragm spring of the clutch cover.
Clutch Cover and Disc
COMPONENTS
REPLACEMENT
1. Remove a transaxle assembly (refer to 'MT'-group).
2. Remove the clutch cover bolts. Not to be bent or twisted, loosen them in diagonal directions.
3. Remove the clutch cover and disc.

4. Using the SST(09411-43000), install a clutch disc and cover.
a. Replace a clutch cover and disc as a set.

* Possible problems when not following the caution
a. When replacing only a disc, slip problem can occur because of the initial clamp load loss by the adjusting
ring's unusual work.
b. When replacing only a disc, it can be difficult to cut power because the thickness of the disc cannot be
permitted.
b. Apply grease on a disc spline part and transmission input shaft spline part as required.
* Possible problems when not following
a. When not applying: Excessively wear of splines and bad clutch operation
b. When excessively applying: Scattered grease by centrifugal force conteminates the clutch disc. Loss of friction
force can cause a slip
c. The 'T/M SIDE' marked surface should face the transaxle.
→ If the surface face the opposite side, there can be an interference between a disc and a flywheel surface.
5. Tighten the clutch cover.
TORQUE:
24.5~35.3Nm (250~360kgf.cm, 18.1~26.0lb-ft) (6EA)
When installing the clutch cover, tighten the bolts in diagonal directions not to be bent or twisted.
* Possible problems when not following

a. When tightening the bolt completely at a time: the clutch cover can be twisted and vibration can occur.
b. On vehicles with self adjusting clutches, it is necessary to follow this caution.
c. Not following tightening torque: There can be bad torque transmission in clutch and relaxation possibility of
bolts.
INSPECTION
1. Inspect diaphragm spring wear which is in contact with a concentric slave cylinder bearing.
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 specification below,
replace it.
Specification: 0.3mm(0.0118inch)
Clutch Master Cylinder
REMOVAL
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 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
from the brake master cylinder side.
3. Disconnect the hose(A) from the cylinder by releasing the clutch master cylinder clamp.
4. Remove the clutch master cylinder mounting bolts(A,B).

One is the engine room, the other near the clutch pedal assembly.
5. Remove the pin and washer which connect the clutch pedal with the clutch master cylinder.
6. Remove the clutch master cylinder. It can be helpful to do this step after removing the clutch pedal mounting
bracket.
INSTALLATION
Installation is in the reverse order of removal.
After installation, bleed the clutch hydaulic system.
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. Loosening the plug screw, press and release the clutch pedal about 10 times.
Hold the air bleeder body not to rotate with a spanner(A). The holding is needed when the plug loosened or
tightened.
3. Tighten the plug during the clutch pedal pressed. Afterwards, raise the pedal with a hand.
TORQUE :
25~29Nm (250~290Kgf.cm, 18.2~21.1lb-ft)
4. After pressing the clutch pedal 3 times more, loosen the plug and retighten it with the pedal pressed. Raise it
again, then.
5. Repeat the step 4 two or three times. (until there is no bubble in the fluid)
a. Do not clamp the pipe of a concentric slave cylinder.

b. Be careful not to damage O-rings.
Clutch Pedal
ADJUSTMENT PROCEDURE
IGNITION LOCK SWITCH
1. Disconnect 2P-connector from a ignition lock switch.
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)
Clutch pedal position Ignition lock switch Continuity
Released Released NO
Pressed Pressed YES
If there is difference between what tested and the table above, replace the ignition lock switch with a new one.
If not, install the ignition lock switch and adjust the clutch pedal.
TORQUE :
8~10Nm (80~100kgf.cm, 5.8~7.2lb-ft)
Clutch pedal and Ignition lock switch
a. Inspect a ignition lock switch.

b. Remove the driver's seat mat to adjust a clutch pedal.
c. 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(A) - 150mm(5.91in)
Clutch pedal free play(B) - 6~13mm(0.24~0.51in)
Clutch pedal distance - 234.7mm(9.24in)
3. With no pressure on a clutch pedal, tighten the bolt until it contacts on the pedal.
4. Fix the bolt with a nut.
TORQUE :
14~20Nm (140~200kgf.cm, 10.2~14.5lb-ft)
5. Press the clutch pedal to the seat ground.
6. Adjust the ignition lock switch position with the pedal a little(23~26mm) raised.
7. Install the ignition lock switch firmly.
TORQUE:
8~10Nm (80~100kgf.cm, 5.8~7.2lb-ft)
REPLACEMENT
a. Inspect the continuity of the ignition lock switch.

b. Remove the floor mat before adjusting the clutch pedal.
1. Remove the ignition lock switch.

2. Remove the snap pin and the clevis pin(A) connecting the clutch master cylinder push rod and the clutch pedal.
3. Remove the clutch master cylinder mounting nut(A,B) and the clutch pedal mounting nut(C).
4. Remove the clutch pedal.
5. Install a new one by tightening the bolts of the clutch pedal bracket and master cylinder .
TORQUE :
19~26 Nm(19~260 kgf.cm, 13.8~18.9 Ib-ft)(Clutch pedal bracket)
12~16 Nm(120~160 kgf.cm, 8.7~11.6 Ib-ft)(Clutch master cylinder)
6. Grease the clevis pin and insert it and the snap pin.
7. Adjust the clutch pedal and the ignition lock switch.

16-Clutch System

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General Information

2007 > J2.9L DIESEL CRDI(VGT) >

Item Nm Kgf.cm lb-ft

Item Standard value

CONCENTRIC SLAVE CYLINDER-C.S.C.

3. Remove the clutch cover and disc.

a. Replace a clutch cover and disc as a set.

* Possible problems when not following

4. Remove the clutch master cylinder mounting bolts(A,B).

CONCENTRIC SLAVE CYLINDER AIR BLEEDING PROCEDURE

a. Do not clamp the pipe of a concentric slave cylinder.

Clutch pedal and Ignition lock switch

a. Inspect a ignition lock switch.

a. Inspect the continuity of the ignition lock switch.

1. Remove the ignition lock switch.

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