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GENESIS COUPEaBK) > 2013 > G 3.8 GDI > Clutch System

Clutch System > General Information > Specifications

Specifications
Items Spectification
Gasoline 3.8
Engine type Gasoline 2.0 TCI
MPI/GDI
Transmission type M6VR2 M6VR2
Clutch operation method Hydraulic type
Type Single dry with diaphragm
Clutch
disc Facing diameter Ø240 × 155
aoutside x inside)mm ain) aØ9.44 × 6.10)
Clutch cover assembly Diaphragm spring strap
Clutch master cylinder
15.87 a0.6248)
* I.D. mm ain)

* I.D: Inside diameter

Service Standard
Items Standard value
Clutch pedal height [Without
196.7mm a7.75in)
carpet]
Clutch pedal free play 6 ~ 13mm a0.24 ~ 0.51in)
Clutch disc thickness [When free] 8.4 ± 0.3mm a0.33 ± 0.012in)
Clutch pedal stroke 130.7mm a5.14in)
Clutch disc rivet sink 0.3mm a0.012in)
Diaphragm spring end height
0.5mm a0.019in)
difference
Clutch master cylinder clearance to
0.15mm a0.006in)
piston

Tightening Torques
Items kgf.m lb-ft
Clutch pedal assembly 13 ~ 16 1.3 ~ 1.6 9.4 ~ 11.6
Clutch pedal Ignition lock switch
8 ~ 10 0.8 ~ 1.0 5.8 ~ 7.2
nut
Clutch disc cover assembly 25 ~ 36 2.5 ~ 3.6 18.1~ 26.0

Lubricants

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Items Specified lubricants Quantity
Inner surface of clutch disc spline CASMOLY L9508 As required
Inner surface of clutch master cylinder and outer
Brake fluid DOT 3 or DOT 4 As required
circumference of piston assembly
Wheel bearing grease SAE J310,
Clutch master cylinder push rod, clevis pin and washer As required
NLGI No.2V
Chassis grease SAE J310a, NLGI
Clutch pedal shaft and bushings As required
No.1

Clutch System > General Information > Special Service Tools

Special Service Tools
Tool aNumber and name) Illustration Use
09411-1P000 Installation of the clutch disc.
Clutch disc guide

Clutch System > General Information > Troubleshooting

Troubleshooting
Trouble symptom Suspect area Remedy
Clutch slipping Insufficient pedal free play Adjust
• Car will not respond to engine speed during Clogged hydraulic system Correct or replace
acceleration parts
• Insufficient vehicle speed
Excessive wear of clutch disc Replace
• Lack of power during uphill driving
facing
Hardened clutch disc facing, or oil Replace
on surface
Damaged pressure plate or Replace
flywheel
Weak or broken pressure spring Replace
Difficult gear shifting agear noise during shifting) Excessive pedal free play Adjust
Hydraulic system fluid leaks, air Repair or replace
trapping or clogging parts
Unusual wear or corrosion of the Replace
clutch disc spline
Excessive vibration adistortion) of Replace
the clutch disc
Clutch When the clutch is not used Insufficient play of the clutch pedal Adjust
noisy
Excessive wear of the clutch disc Replace
facing
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A noise is heard when the clutch is Insufficient grease on the sliding Repair
disengaged surface of the bearing sleeve
Improperly installed clutch Repair
assembly
A noise is heard when the car suddenly rolled Damaged pilot bushing Replace
up with the clutch partially engaged
Hard pedal effort Insufficient lubrication of the clutch Repair
pedal
Insufficient lubrication of the spline Repair
part of clutch disc
Hard to shift or will not shift Excessive clutch pedal free play Adjust the pedal free
play
Clutch disc out of place, runout is Inspect the clutch
excessive or lining broken disc
Spline on the input shaft or clutch Repair as necessary
disc dirty or burned
Faulty of the clutch pressure plate Replace the clutch
cover
Clutch slips Insufficient clutch pedal free play Adjust the pedal free
play
Clogged of the hydraulic system Repair or replace
parts
Clutch disc lining oily or worn out Inspect the clutch
disc
Faulty pressure plate Replace the clutch
cover
Clutch grabs/chatters Clutch disc lining oily or worn out Inspect the clutch
disc
Faulty the pressure plate Replace the clutch
cover
Bent clutch diaphragm spring Replace the clutch
cover
Worn or broken torsion spring Replace the clutch
disc
Engine mounts loose Repair as necessary
Clutch noisy Damaged the clutch pedal bushing Replace the clutch
pedal bushing
Loose part inside housing Repair as necessary

Clutch System > Clutch System > Repair procedures

Service Adjustment Procedure
Clutch Pedal Inspection And Adjustment

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1. Measure the clutch pedal height afrom the face of the pedal pad to the floorboard) and the clutch pedal clevis pin
play ameasured at the face of the pedal pad.)

Standard value
aA) : 6 ~ 13mm a0.24 ~ 0.51in)
aB) : 196.9mm a7.75in)

2. If the clutch pedal freeplay and height is not within the standard value range, adjust as follows:

Clutch System > Clutch System > Clutch Cover And Disc > Repair procedures
Removal
1. Remove the transmission assembly.
aRefer to Manual transmission removal in MT group)
2. Insert the special tool a09411-1P000) in the clutch disc to prevent the disc from shifting.

3. Loosen the boltsa6ea) which attach the clutch cover to the flywheel in a star pattern.
Loosen the bolts in succession, one or two turns at a time, to avoid bending the cover.

Do not clean the clutch disc or the release bearing with cleaning solvent.

Inspection
Clutch Disc Cover Assembly
1. Check the diaphragm spring end for wear and uneven height.
2. Check the pressure plate surface for wear, cracks and color change.
3. Check the rivets for looseness and replace the clutch cover assembly if necessary.
Clutch Disc
1. Check the clutch facing for loose rivets, uneven contact, deterioration due to seizure, adhesion of oil, or grease,
and replace the clutch disc if defective.
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2. Measure the thickness of the disc when free.

Standard value
Clutch disc thickness aA) [when free] :
8.4 ± 0.3mm [0.33 ±0.012in]
Limit :
Clutch disc rivet depth aB) : 0.3mm [0.012in]

3. Check for the torsion spring play and damage and if defective, replace the clutch disc.
4. Clean the splines on the input shaft and install the clutch disc.
If the disc does not slide smoothly or if play is excessive, replace the clutch disc and/or the input shaft.
Clutch Release Bearing

The release bearing is packed with grease. Do not use cleaning solvent or oil.

Standard grease : CASMOLY L9508

1. Check the bearing for seizure, damage or abnormal noise. Also check the diaphragm spring contacting points for
wear.
2. Replace the bearing if the release fork contacting points are worn abnormally.
Clutch Release Fork
If there is abnormal wear at the point of contact with the bearing, replace the release fork assembly.

Installation
1. Apply multipurpose grease to the spline of the disc.

Grease : CASMOLY L 9508

When installing the clutch, apply grease to each part, but be careful not to apply excessive
grease.
It can cause clutch slippage and vibration ajudder).

2. Install the clutch disc assembly to the flywheel using the special tool a09411-1P000).
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3. Install the clutch cover assembly to the flywheel and temporarily tighten the bolts one or two steps at a time in a
star pattern.

Tightening torque :
Clutch disc cover bolt :
25 ~ 36Nm a2.5 ~ 3.6kgf.m, 18.1 ~ 26.0lb-ft)

4. Remove the clutch disc guide a09411-1P000).

5. Install the transmission assembly to the engine. aRefer to Manual transmission installation in MT group)

Clutch System > Clutch System > Clutch Master Cylinder > Components and Components Location
Components

1. Clutch pedal assembly

2. Clutch master cylinder 3. Clutch fluid hose
assembly

Clutch System > Clutch System > Clutch Master Cylinder > Repair procedures
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Removal
1. Remove the flexible hose aA) from the brake reserve tank.

2. After pulling out a clip, disconnect the clutch tube aB) from the master cylinder.
3. Disconnect the ignition lock switch connector aA).

4. Remove the push rod from the clutch pedal by removing the snap pin aA) and washer aB).

5. Remove the clutch pedal mounting nut aC-3ea).

6. Remove the clutch pedal bracket mounting nut aA-2ea).

7. Remove the clutch master cylinder from the clutch pedal assembly by rotating the clutch master cylinder 45 degree
counter clockwise.

Inspection
1. Check the inside of the cylinder body for rust, pitting or scoring.
2. Check the piston cup for wear or distortion.
3. Check the piston for rust, pitting or scoring.
4. Check to make sure the clutch line tube is not clogged or restricted in any way.
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5. Measure the master cylinder inside diameter and the piston outside diameter with a cylinder gauge micrometer.

Measure the inside diameter of the master cylinder at three places abottom, middle, and top) in a
perpendicular direction.
6. If the master cylinder-to-piston clearance exceeds the limit, replace the master cylinder and/or piston assembly.

Limit : 0.15 mm a0.006 in)

Installation
1. Install the clutch master cylinder to the clutch pedal assembly by rotating the clutch master cylinder 45 degree
clockwise.
2. Install the clutch pedal bracket mounting nut aA-2ea).

Tightening torque :
13 ~ 16 N.m a1.3 ~ 1.6 kgf.m, 9.4 ~ 11.6 lb-ft)

3. Install the clutch pedal mounting nut aC-3ea).

Tightening torque :
13 ~ 16 N.m a1.3 ~ 1.6 kgf.m, 9.4 ~ 11.6 lb-ft)

4. Install the push rod to the clutch pedal by installing the snap pin aA) and washer aB).

Wheel bearing grease : SAE J310, NLGI No.2

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5. Connect the ignition lock switch connector aA).

6. Install the flexible hose aA) to the brake reserve tank.

7. Connect the clutch tube aB) to the master cylinder and insert a clip.
8. Refill the brake fluid.
9. Bleed the air in the clutch system.
aRefer to bleeding in service adjustment procedure)

Clutch System > Clutch System > Clutch Pedal > Components and Components Location
Components

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1. Clutch pedal assembly
2. Clutch master cylinder 3. Clutch fluid hose
assembly

Clutch System > Clutch System > Clutch Pedal > Repair procedures
Removal
1. Remove the flexible hose aA) from the brake reserve tank.

2. After pulling out a clip, disconnect the clutch tube aB) from the master cylinder.
3. Disconnect the ignition lock switch connector aA).

4. Remove the push rod from the clutch pedal by removing the snap pin aA) and washer aB).

5. Remove the clutch pedal mounting nut aC-3ea).

6. Remove the clutch pedal bracket mounting nut aA-2ea).
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7. Remove the clutch master cylinder from the clutch pedal assembly by rotating the clutch master cylinder 45 degree
counter clockwise.

Inspection
Clutch Pedal Assembly
1. Check the pedal shaft and bushing for wear.
2. Check the clutch pedal for bending or torsion.
3. Check the return spring for damage or deterioration.
4. Check the pedal pad for damage or wear.
Ignition lock switch inspection
Remove the ignition lock switch and check for continuity between the terminals. If the continuity is not as specified,
replace the switch.

Standard value
Full strokeaA) : 12.0 ± 0.3mm a0.472 ± 0.012 in.)
ON-OFF point aB) : 2.0 ± 0.3mm a0.078 ± 0.012 in)

Installation
1. Install the clutch master cylinder to the clutch pedal assembly by rotating the clutch master cylinder 45 degree
clockwise.
2. Install the clutch pedal bracket mounting nut aA-2ea).

Tightening torque :
13 ~ 16 N.m a1.3 ~ 1.6 kgf.m, 9.4 ~ 11.6 lb-ft)

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3. Install the clutch pedal mounting nut aC-3ea).

Tightening torque :
13 ~ 16 N.m a1.3 ~ 1.6 kgf.m, 9.4 ~ 11.6 lb-ft)

4. Install the push rod to the clutch pedal by installing the snap pin aA) and washer aB).

Wheel bearing grease : SAE J310, NLGI No.2

5. Connect the ignition lock switch connector aA).

6. Install the flexible hose aA) to the brake reserve tank.

7. Connect the clutch tube aB) to the master cylinder and insert a clip.
8. Refill the brake fluid.
9. Bleed the air in the clutch system.
aRefer to bleeding in service adjustment procedure)

Clutch System > Clutch System > Concentric Slave Cylinder Assembly > Components and Components
Location
Components
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1. C.S.C aConcentric Slave 2. Manual transaxle case

Cylinder) assembly

Clutch System > Clutch System > Concentric Slave Cylinder Assembly > Repair procedures
Removal
1. Remove the transaxle assembly.
aRefer to Manual transaxle removal in MT group)
2. Remove the C.S.C assembly aB) from the transaxle case by removing bolts aA-3ea).

Installation
1. Install the C.S.C assembly aB) to the transaxle case by installing bolts aA-3ea).

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2. Install the transaxle assembly.
aRefer to Manual transaxle installation in MT group)
3. Bleed the air in the C.S.C system.
aRefer to C.S.C Adjustment Procedure)

C.S.C Adjustment Procedure

C.S.CaConcentric Slave Cylinder) Air Bleeding
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.

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.

Tightening torque :
8 ~ 10 Nm a0.8 ~ 1.0 kgf.m, 2.8 ~ 7.2 lb-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. auntil there is no bubble in the fluid)