Xe ô tô hyundai excel toàn tập hyundai excel - P7

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GENERAL 2 CLUTCH 6 CLUTCH CONTROL 10

GENERAL

SPECIFICATIONS

Clutch operating method

Clutch disc

Type

Facing diameter

(Outside x Inside)

Clutch cover assembly

Type

Setting load N (lb.)

Mounting bolt circle dia.

Cable type

Single dry disc

184 mm x 127 mm (7.24 in x 5.00 in.)

Diaphragm spring strap drive type 3.234 N (727.5 lb.)

222 mm (8.74 in.)

SERVICE STANDARD

Standard value

Clutch pedal height

Clutch pedal free play

Clutch pedal stroke

Clearance between adjusting nut and cable holder

Limit

Clutch disc

Revet sink

187-192 mm (7.4-7.6 in.) 20-30 mm (0.8-1.2 in.)

145 mm (5.7 in.) 5-6 mm (0.20-0.24 in.) 0.3 mm (0.012 in.)

Transmission to engine bolts 43-53 430-540 32-39 Starter motor mounting bolts 30-34 300-350 22-25 Clutch to flywheel 15-21 150-210 11-15

4 1 - 2

SPECIAL TOOLS

Tool

(Number and name)

09411-11000

Clutch disc guide

09414-11100

Lock pin installer

09414-11000

Lock pin extractor

Illustration Use

Centering flywheel and clutch disc

1) Driving out the spring pin of the clutch shaft

2) Driving out of spring pin of the shift fork

Driving in the spring pin of the shift fork

41-3

TROUBLESHOOTING

Symptom

Clutch chatter

Clutch slipping

Difficult gear shifting

Clutch noisy

Clutch operation

erratic or rough

Probable cause Worn or damaged disc assembly Oil or grease on disc facings

Weak or broken disc damper springs Broken or loose engine mounts Insufficient pedal free play Burned, worn or oil-socked Weak or broken pressure spring Excessive pedal free play Worn or damaged disc assembly Clutch disc splines sticking

Clutch cable sticks Clutch cable broken or loose Clutch pedal bushing damaged Worn release bearing

Worn disc assembly Worn diaphragm spring Insufficient lubrication on clutch pedal pivot

Remedy Replace disc assembly Replace disc assembly and correct cause of contamination

Replace disc assembly Replace or tighten mounts Adjust clutch pedal free play Replace disc assembly and correct cause of contamination

Replace cover assembly Adjust clutch pedal free play Replace clutch assembly Remove disc assembly and unstick splines or replace disc

Replace parts Repair or replace parts Replace parts

Replace release bearing Replace disc assembly Replace disc assembly Lubricate

4 1 - 4

CLUTCH PEDAL INSPECTION AND ADJUSTMENT

1 Turn the adjusting bolt so that the distance from the toe board to

the clutch pedal will be the standard.

Clutch pedal height (distance between the toe board and the

clutch pedal) A

[Standard value] 187-192 mm (7.4-7.6 in.)

2 Lightly pull the clutch outer cable and adjust the clearance

between adjusting nut and holder to the standard value by

turning the adjusting nut.

Clearance between adjusting nut and holder

[Standard value] 5-6 mm (0.20-0.25 in.)

3 Check to ensure that the pedal free play is the standard and that

the pedal stroke, until the clutch is disengaged, is the standard.

Pedal free play B 20-30 mm (0.8-1.2 in.)

Clutch pedal stroke C 145 mm (5.7 in.)

4 If the clutch pedal stroke is more than the standard value,

defective clutch assembly is suspected Repair the clutch

assembly.

41-5

CLUTCH

COMPONENTS

4 1 - 6

REMOVAL

1 Remove the transmission See “Manual Transmission”, for

detailed procedure.

2 Insert Special Tool, Clutch Disc Guide (09411-11000), in center

spline to prevent dropping of clutch disc.

3 Diagonally loosen bolts which attach clutch cover to flywheel.

Back off bolts in succession, one or two turns at a time, to avoid

bending cover flange.

CAUTION

DO NOT clean clutch disc or release bearing with cleaning

solvent.

4 Remove return clip, then remove release bearing.

5 Remove spring pins from clutch release fork and shaft, with

Special Tool (09414-11000) or a 4.8 mm (3/16 in.) punch Do not

reuse spring pins.

6 Remove clutch release shaft and then remove release fork,

packings and return spring.

CLEANING AND INSPECTION

1 Clean clutch dust from clutch housing with vacuum brush or

shop towel Do not use compressed air Inspect for oil leakage

through engine rear main bearing oil seal and transmission

front oil seal If leakage is noted, it should be corrected at this

time.

2 Friction face of pressure plate should be have a uniform

appear-ance throughout entire disc contact area If there is evidence of

heavy contact on one portion of wear circle and a very light

contact 180 degrees from that portion, pressure plate may be

improperly mounted or sprung.

3 Friction face of flywheel should also be free from excessive

discoloration, burned areas, small cracks, deep grooves, or

ridges.

The disc assembly should be handle without touching facings.

Replace if facings show evidence of grease or oil soakage, or

wear to within less than 0.3 mm (0.09 2 in.) of the rivet heads.

The hub springs and splines on transmission input shaft should

be a snug fit without signs of excessive wear.

Metallic portions of disc assembly should be dry and clean and

show no evidence of having been hot Each of the arched

springs between facings should be unbroken and all rivets

should be tight.

5 Wipe friction surface of pressure plate with a suitable solvent.

4 1 - 7

6 Using a straight edge, check pressure plate for flatness The

pressure plate friction area should be flat within 0.5 mm (0.020

in.) and free from discoloration, burned area, checks, grooves or

ridges.

7 Visually inspect the cover outer mounting flange for flatness It

should be free of nicks, burrs, dents or other damage.

8 The three dowels on the flywheel should be tight and

undam-aged The cover stamping should be a snug fit on the dowels.

9 If the clutch assembly does not meet these requirements, it

should be replaced.

INSTALLATION

1 Prior to installing release shaft, apply multipurpose grease.

2 Insert release shaft and install packings, return spring and

release shaft and install packings, return spring and release

fork.

3 Apply grease to release bearing contact surfaces of release fork.

4 Align lock pin holes of release fork and release shaft and drive in

two spring pins, using a stuitable punch When spring pins are

installed, make sure that spring pin slot direction is at right

angles to center line of control shaft.

CAUTION

DO NOT reuse spring pins.

5 Apply grease into groove of release bearing and then install

release bearing to front bearing retainer of transmission.

6 Install return clip to release bearing and fork.

7 Clean the surfaces of flywheel and pressure plate thoroughly

with fine sandpaper or crocus cloth, and make certain that all oil

or grease has been removed Apply grease

41-8

8 Apply and rub a small amount of multipurpose grease to the

clutch disc spline and input shaft spline.

9 Use Special Tool, Clutch Disc Guide (09411-11000) install

clutch disc assembly to flywheel When installing clutch disc,

be sure that surface having manufacturers stamped mark is on

pressure plate side.

10 Install clutch cover assembly onto flywheel and install six (6)

bolts through clutch cover into flywheel.

11 Diagonally tighten bolts to 15-21 Nm (150-210 kg.cm, 11-15

Ib.ft) Screw in bolts, one or two turns at a time, in

succes-sion, to avoid bending cover flange.

12 Remove centering tool.

13 Install transmission See “Manual Transmission”.

14 Adjust clutch free play.

41-9

CLUTCH CONTROL

CLUTCH CONTROL

COMPONENTS

REMOVAL

Clutch Cable

1 Loosen the cable adjusting nut.

2 Remove the cotter pin from the clutch control lever and discon-nect the clutch cable from the holder.

3 Disconnect the cable from the clutch pedal, and remove the toward the engine compartment.

Clutch Pedal

1 Loosen the adjusting nut, and then disconnect the clutch cable from the pedal.

2 Remove the pedal shaft tightening nut and the clutch pedal with the bushing attached.

4 1 - 1 0

CLUTCH CONTROL

INSPECTION

1 Check the dust boot for damage.

2 Check the cable movement for roughness.

3 Check the outer cable for damage.

4 Check the clutch cable hardware condition at both ends of cable

of connections.

5 Check the pedal shaft and bushing for wear.

6 Check the clutch pedal for bend or torsion.

INSTALLATION

1 Apply grease to the pedal shaft, bushings, and cable fitting area

of the clutch pedal arm.

2 Tighten pedal mounting nut to the specified torque.

Clutch pedal mounting nut

16-24 Nm (160-240 kg.cm, 12-17 Ib.ft)

3 Adjust the clutch pedal as described under “SERVICE

ADJUST-MENT PROCEDURE” of this section.

41-11