Clutch: Service and Repair
Clutch Disc and CoverREMOVAL
1) Remove the transmission assembly from the vehicle body.
2) Attach the ST on the flywheel.
ST 499747100 CRANKSHAFT STOPPER
3) Remove the clutch cover and clutch disc.
NOTE:
^ Take care not to allow oil to touch the clutch disc face.
^ Do not disassemble the clutch cover or clutch disc.
^ Be sure to mark alignment marks on the flywheel and clutch cover before removing the clutch cover.
INSTALLATION
1) Insert the ST into the clutch disc and attach to the flywheel by inserting the ST end into pilot bearing.
NOTE: When installing the clutch disc, be careful to attach in the correct direction.
ST 499747100 CLUTCH DISC GUIDE
2) Install the clutch cover to the flywheel, and tighten the bolts to the specified torque.
NOTE:
^ When installing the clutch cover to the flywheel, position the clutch cover in order to make the gap between unbalance marks (paint mark) of flywheel and clutch cover 120° or more. (The unbalance marks - indicate the directions of residual unbalance.)
^ Note the font and rear of the clutch disc when installing.
^ Temporarily tighten the bolts by hand. Each bolt should be tightened to the specified torque in a crisscross order.
Tightening torque: 16 N-m (1.6 kgf-m, 11.6 ft-lb)
3) Remove the ST.
ST 499747100 CLUTCH DISC GUIDE
4) Install the transmission assembly.
INSPECTION
CLUTCH DISC
1) Facing wear
Measure the depth of the rivet head from the surface of facing. Replace if the facings are worn locally or worn down to less than the specified value.
Depth of rivet head:
Limit of sinking 0.3 mm (0.012 in)
NOTE: Do not wash the clutch disc with any cleaning fluid.
2) Hardened facing
Correct by using emery paper, or replace.
3) Oil soakage on facing
Replace the clutch disc and inspect transmission front oil seal, transmission case mating surface, engine rear oil seal and other points for oil leakage.
4) Facing runout
If runout exceeds the specified value at the outer circumference of facing, repair or replace.
ST 499747100 CLUTCH DISC GUIDE
Limit of runout:
Non-turbo model 0.7 mm (0.028 in) at R = 107.5 mm (4.23 in)
2.0 L Turbo model 0.7 mm (0.028 in) at R = 110 mm (4.33 in)
5) Replace parts that have problems such as worn splines, loose rivets and torsion spring failure.
CLUTCH COVER
NOTE: Visually check the following items without disassembling, and replace or repair if there is a problem.
1) Loose thrust rivet
2) Damaged or worn bearing contact area at the center of diaphragm spring
