Clutch cover Type Diaphragm spring strap. Clutch pedal Type Suspended type. Maximum operating travel

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Hugh Gaines
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1 SPECIFICATION Operating type Description Hydraulic type Specification Clutch cover Type Diaphragm spring strap Adjusting type Clutch pedal Type Suspended type Max. operating travel Pedal free play (Longitudinal) Pedal free play (Transverse) SATIC (Self Adjusting Technology with Integrated Cassette) type 135 ± 3 mm 7.1 ± 3 mm 3 mm Clutch disc Type Dry type single diaphragm (Rigid type) Diameter of facing Thickness of disc Numbers of disc 2 Weight Flywheel type Setting load of clutch cover assembly Clutch master cylinder Concentric slave cylinder Clutch oil Operating travel Inner diameter Maximum operating travel Operating pressure Outer: 250 ± 1 mm Inner:160 ± 0.8 mm Free: 8.7 ± 0.3 mm When loaded: 8.0 ± 0.2 (at 7,800 N) 1.18 kg DMF (Dual Mass Flywheel) At least 7,800 N 30 mm mm mm Maximum 50 bar Standard DOT 3 or DOT 4 Capacity As required

2 TIGHTENING TORQUE Description Tightening torque Amount Clutch housing bolt Upper (17 mm) 85.0 to 100 Nm 2 Front (14 mm) 54.0 Nm Rear (14 mm) 51.3 to 56.7 Nm 2 Lower (14 mm) 56.0 to 62.0 Nm 4 Pressure plate assembly bolt (Hexagon 6 mm) 21.0 to 27.0 Nm 6 Concentric slave cylinder bolt (Hexagon 5 mm) 10 to 16 Nm 3 Concentric slave cylinder oil pipe nut 24.5 to 28.4 Nm Remove the nut if it is necessary. (Once removed, apply the Loctite on the thread before installation.) Master cylinder nut (12 mm) Master cylinder oil pipe nut (10 mm) Master cylinder push rod lock nut Clutch oil chamber screw and bolt (10 mm) Oil pipe nut (10 mm) Clutch pedal mounting nut (12 mm) Stopper bolt 7.8 to 17.6 Nm 14.7 to 17.6 Nm 8.8 to 13.7 Nm 3.9 to 7.8 Nm 14.7 to 17.6 Nm 7.8 to 17.6 Nm 16 to 22 Nm

000000 045 1. OVERVIEW The hydraulic clutch transmits the force required to operate the clutch pedal to the concentric slave cylinder fitted to the clutch housing as a hydraulic pressure.

3 OVERVIEW The hydraulic clutch transmits the force required to operate the clutch pedal to the concentric slave cylinder fitted to the clutch housing as a hydraulic pressure. (The hydraulic pressure is transmitted in the following order: Clutch pedal Clutch master cylinder Clutch pipe Clutch damper Clutch pipe and hose Concentric slave cylinder Pressure plate Flywheel.) If a driver depress the clutch pedal, the hydraulic pressure is generated in the master cylinder. It is transmitted to the concentric slave cylinder through the pipe, resulting in the cylinder being forced out. At this time, the clutch disc is forced against the cylinder by pushing the cover. This, in turn, remove the flywheel from the pressure plate. As a consequence, the power from the engine will be cut off and the gear change can be carried out.

the pedal force tends to increase in proportion to the degree of disc runout.

to maintain a constant pedal force and clearance when the disc runs out.

4 SATIC (SELF ADJUSTING TECHNOLOGY WITH INTEGRATED CASSETTE) 1) System Description Function On the conventional clutch, the pedal force tends to increase in proportion to the degree of disc runout. However, the SATIC clutch has the adjusting function which activates the cassette system inserted to the clutch cover to maintain a constant pedal force and clearance when the disc runs out. (Unlike SAT type, SATIC type does not need SST for clutch cover removal.) Operation Diaphragm spring rotates the adjusting equipment as clutch disc is wearing and so, pressure plate is pushed to clutch disc side at the amount of wear. Disc wear (Free play) Diaphragm spring (1) Adjusting equipment (2, 3) Pressure plate (4)

5 ) Overview Driving elements The driving elements 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 clutch pressure plate. The clutch pressure plate is fitted into a clutch steel cover, which is bolted to the flywheel. Driven elements The driven element is the clutch disc with a splined hub which is free to slide lengthwise along the splines of the input shaft. The driving and driven elements are held in contact by spring pressure. This pressure is exerted by a diaphragm spring in the clutch cover pressure plate assembly. Operating Elements The clutch "release" system consists of the clutch pedal and clutch release cylinder. This system directly releases the clutch by using hydraulic pressure while the conventional clutch system releases the clutch by using release lever and release fork. This system provides higher efficiency than conventional clutch system, and its durability is superior. Clutch master cylinder (mounted on clutch pedal) Concentric slave cylinder pipe (mounted inside of transmission)

6 048 3) Layout Clutch disc Clutch cover assembly Clutch setting jig Dual mass flywheel (DMF) Concentric slave cylinder

000000 049 3. DUAL MASS FLYWHEEL (DMF) The dual mass flywheel (DMF) is of having a mass divided into two halves.

7 DUAL MASS FLYWHEEL (DMF) The dual mass flywheel (DMF) is of having a mass divided into two halves. While one mass is connected to the engine crankshaft, which is affected by the mass moment of inertia of the engine, the other mass is affected by one of the transmission. The divided dual masses are connected to the coil spring and damping system internally. The DMF has the following benefits: Reducing fuel consumption by lowering engine speed Reducing rattling noise and vehicle vibration in all driving ranges Reducing synchronization wear Facilitating gear change Protecting power train parts by preventing excessive load from being delivered 1. Primary flywheel 2. Secondary flywheel 3. Arc damper spring 4. Torque limiter 5. Ring gear

1. General GENERAL CL-2

1. General GENERAL CL-2 SYSTEM GENERAL 1. General The clutch is of a dry, single plate type with a diaphragm spring. The clutch is a push type clutch. When the pedal is depressed, the release bearing will press the center of