M35c Clutch.pdf part of Daewoo Matiz 796cc (My 2003).part01.rar, Service Manual, Wiring Diagram - 16 Part File

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SECTION 5C

CLUTCH
CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise noted.

TABLE OF CONTENTS
Description and Operation . . . . . . . . . . . . . . . . . . Driving Members . . . . . . . . . . . . . . . . . . . . . . . . . . Driven Members . . . . . . . . . . . . . . . . . . . . . . . . . . Operating Members . . . . . . . . . . . . . . . . . . . . . . . Component Locator . . . . . . . . . . . . . . . . . . . . . . . . Clutch Components . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Information and Procedures . . . . . General Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . 5C-2 5C-2 5C-2 5C-2 5C-3 5C-3 5C-4 5C-4 Pressure Plate, Clutch Disc and Input Shaft Bearing . . . . . . . . . . . . . . . . . . . . . . . . 5C-6 Clutch Release Bearing, Shaft and Bushing . . . 5C-8 Clutch Release Arm . . . . . . . . . . . . . . . . . . . . . . 5C-10 Clutch Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-11 Clutch Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Specifications . . . . . . . . . . . . . . . . . . . . Fastener Tightening Specifications . . . . . . . . . . 5C-12 5C-13 5C-13 5C-13

Clutch Pedal Operation . . . . . . . . . . . . . . . . . . . . 5C-5 Clutch Cable Adjustment . . . . . . . . . . . . . . . . . . . 5C-5 Repair Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-6 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-6

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-14 Special Tools Table . . . . . . . . . . . . . . . . . . . . . . . 5C-14

DAEWOO M-150 BL2

5C ґ 2 CLUTCH

DESCRIPTION AND OPERATION
DRIVING MEMBERS
The driving members 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 pressure plate. The pressure plate is fitted into a steel cover, which is bolted to the flywheel. The driving and driven members are held in contact by spring pressure. This pressure is exerted by a diaphragm spring in the pressure plate assembly.

OPERATING MEMBERS
The clutch release system consists of the clutch pedal, the clutch release shaft, the clutch cable, the release arm and the release bearing. When pressure is applied to the clutch pedal, the clutch release shaft pushes against the release bearing by rotating. The bearing then pushes against the diaphragm spring in the pressure plate assembly, thereby releasing the clutch.

DRIVEN MEMBERS
The driven member is the clutch disc with a splined hub which is free to slide lengthwise along the splines of the input shaft, but which drives the input shaft through these same splines.

DAEWOO M-150 BL2

CLUTCH 5C ґ 3

COMPONENT LOCATOR
CLUTCH COMPONENTS

D13C4011

1 2 3 4 5 6

Clutch Disc Pressure Plate Release Bearing Release Shaft Release Shaft Bushing (No.1) Release Shaft Bushing (No.2)

7 8 9 10 11

Release Shaft Seal Release Arm Clutch Cable Adjusting Nut Clutch Cable Clutch Pedal

DAEWOO M-150 BL2

5C ґ 4 CLUTCH

DIAGNOSTIC INFORMATION AND PROCEDURES
GENERAL DIAGNOSIS
Condition Slipping Clutch Probable Cause D Improper clutch cable adjustment. D Worn or oily contamination on clutch disc surface. D Worn or oily contamination on pressure plate, flywheel surface. D Damaged or weakened diaphragm spring. D Rusted clutch cable. Dragging Clutch D Improper clutch cable adjustment. D Worn or weakened diaphragm spring. D Worn or rusted splines of input shaft or clutch disc. D Excessively wobbly clutch disc. D Worn clutch disc. Fails to Release D Bent or damaged clutch disc. D Worn or rusted splines of input shaft or clutch disc. D Improper operation of clutch release shaft. Pedal Stays on Floor When Disengaged Clutch Vibration D Interfered clutch release bearing. D Weakened diaphragm spring. D Clutch facing with oily contamination. D Release bearing slides unsmoothly on input shaft bearing retainer. D Wobbly clutch disc or poor facing contact. D Loose clutch disc rivets. D Weakened clutch disc torsion spring. D Distorted pressure plate or flywheel surface. D Weakened engine mounting or loosened installing bolt or nut. Clutch Noise D Worn or broken release bearing. D Worn input shaft bearing. D Cracked clutch disc. D Pressure plate and diaphragm spring rattling. D Improper clutch cable adjustment. Grabbing Clutch D Clutch disc facing with oily contamination. D Excessively worn on clutch disc facing. D Rivet head showing out of facing. D Weakened clutch torsion spring. Correction D Adjust clutch cable. D Replace clutch disc. D Replace pressure plate, flywheel. D Replace pressure plate. D Replace clutch cable. D Adjust clutch cable. D Replace pressure plate. D Replace input shaft or clutch disc. D Replace clutch disc. D Replace clutch disc. D Replace clutch disc. D Replace input shaft or clutch disc. D Replace clutch release shaft. D Lubricate and adjust clutch release bearing. D Replace pressure plate. D Replace clutch disc. D Lubricate retainer release bearing. D Replace clutch disc. D Replace clutch disc. D Replace clutch disc. D Replace pressure plate or flywheel. D Retighten or replace mounting. D Replace release bearing. D Replace input shaft bearing. D Replace clutch disc. D Replace pressure plate. D Adjust clutch cable. D Replace clutch disc. D Replace clutch disc. D Replace clutch disc. D Replace clutch disc.

DAEWOO M-150 BL2

CLUTCH 5C ґ 5

CLUTCH PEDAL OPERATION

CLUTCH CABLE ADJUSTMENT

D103C302

If clutch connection / disconnection is operated unsmoothly, adjust the clutch cable by adjusting clutch cable adjust nut.

D103C301

Clutch pedal free travel
It is designed that there is no clutch pedal free travel.

Clutch pedal travel (A)

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Pedal Travel 100ґ110 mm (3.9ґ4.3 in.)

Clearance between pedal and floor just before clutch connection (B)

After starting the engine, check if the clearance between pedal and floor is within specified range in condition of idling, lifting, parking brake and drawing out clutch pedal.

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Clearance Between Pedal and Floor just Before Clutch Connection 30ґ40 mm (1.2ґ1.6 in.) Caution: During inspection, take care on sudden departure.
DAEWOO M-150 BL2

5C ґ 6 CLUTCH

INSTRUCTION REPAIR ONґVEHICLE SERVICE
PRESSURE PLATE, CLUTCH DISC AND INPUT SHAFT BEARING
Tools Required
09917ґ58010 09924ґ17810 09925ґ98210 DW110ґ021 DW210ґ010 Input Shaft Bearing Remover Flywheel Holder Input Shaft Bearing Installer Engine Fixture Clutch Center Guide

Removal Procedure
D13B5151

1. Remove the transaxle from the vehicle. Refer to Section 5B, Manual Transaxle. 2. Support the engine to normal position using the engine fixture DW110ґ021. Notice: The abnormal position of the engine may damage to the related parts and interfere with them. You must support the engine to normal position after removing the transaxle.

D103B516

3. Remove the pressure plate and the clutch disc. D Fix the fly wheel using the fly wheel holder 09924ґ 17810. D Remove the pressure plate bolts (1). D Remove the pressure plate and the clutch disc (2).

D13C5021

DAEWOO M-150 BL2

CLUTCH 5C ґ 7
4. Remove the transaxle input shaft bearing using the input shaft bearing remover 09917ґ58010, the flywheel holder 09924ґ17810 and a spanner.

D13C5031

Inspection Procedure ґ Pressure Plate and Clutch Disc
1. Pressure plate inspection . D Check the weak and damaged diaphragm spring (1). D Check the polluted face by the oil, grease (2).

D13C5041

D103C505

D103C506

DAEWOO M-150 BL2

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D Replace the clutch disc if clutch disc surface is contaminated or clutch disc rivets are loosen. 3. Clutch disc runout in rotational direction inspection. D Measure runout in rotational direction and replace if runout exceeds limit. Unit : mm (in.)

2. Clutch disc inspection D Measure rivet head depth from clutch disc surface and replace if below limit. Unit : mm (in.) Standard Limit Rivet Head Depth 1.2 (0.047) 0.5 (0.02)

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Disc Runout Limit in Rotational Direction (Periphery) 0.7 (0.028)

5C ґ 8 CLUTCH Installation Procedure
1. Install in the reverse order of removal. 2. Install the input shaft bearing using the input shaft bearing installer 09925ґ98210 and the flywheel holder 09924ґ17810.

D13C5071

3. Install the pressure plate and the clutch disc. D Install the clutch disc. D Install the pressure plate (1). D Align the pressure plate and the clutch disc onto the flywheel using the clutch center guide DW210ґ010 and the flywheel holder 09924ґ17810. D Install the pressure plate bolts.

Tighten
Tighten the bolts to 18ґ28 NSm (13ґ21 lb-ft).

D13C508B

CLUTCH RELEASE BEARING, SHAFT AND BUSHING
Tools Required
09923ґ46040 09925ґ48220 09930ґ30102 09943ґ88211 Bushing Joint Pipe Bushing Remover/Installer Sliding Shaft Bushing, Bearing Installer

Removal Procedure
1. Remove the transaxle from the vehicle. Refer to Section 5B, Manual Transaxle. 2. Remove the release arm. Refer to "Clutch Release Arm" in this section. 3. Remove the release bearing. 4. Remove the release shaft and bushing. D Remove the bushing (No.2) and seal using the bushing remover 09925ґ48220 and hammer. D Remove the release shaft (1).

D103C509

D103C510

DAEWOO M-150 BL2

CLUTCH 5C ґ 9
D Insert the tap (M14X1.5) to the busing (No.1) (2).

D103C511

D Insert the bushing joint pipe 09923ґ46040 to the tab. D Connect the sliding shaft 09930ґ30102 to the end of the bushing joint pipe 09923ґ46040. D Remove the bushing (No.1) by pulling.

D13C512A

Inspection Procedure ґ Release Bearing and Shaft
1. Release bearing inspection D Check for noisy, worn and damaged release bearing. D Check for a grabbing rotation of release bearing. D Replace the release bearing if necessary.

D103C513

2. Release shaft inspection D Check for a warped shaft (1). D Check for a worn fork (2). D Replace the shaft if necessary.

D103C514

DAEWOO M-150 BL2

5C ґ 10 CLUTCH Installation Procedure
1. Install in the reverse order of removal. 2. Install the release shaft bushing (No.1) using the bushing joint pipe 09923ґ46040, bushing, bearing installer 09943ґ88211 and a hammer.

D103C515

3. Install the release shaft bushing (No.2) and seal using the bushing remover/installer 09925ґ48220 and a hammer.

D103C516

4. Install the release bearing. D Coat the spline of transaxle input shaft with multiґ purpose grease (1). D Coat the release bearing bore and the connecting of release shaft with multiґpurpose grease (2). D Install the release bearing.

D103C517

CLUTCH RELEASE ARM
Removal Procedure
1. Disconnect the clutch cable. D Remove the adjusting nut (1). D Disconnect the cable (2).

D103C518

DAEWOO M-150 BL2

CLUTCH 5C ґ 11
2. Remove the clutch release arm. D Remove the bolt and nut (1). D Remove the release arm (2).

D103C519

Installation Procedure
1. Install in the reverse order of removal. 2. Install the clutch release arm. D Install the clutch release arm matching to punched mark (1).

Tighten
Tighten the bolt and nut to 10ґ16 NSm (7.5ґ12 lb-ft). 3. Adjust the clutch cable. Refer to "Diagnosis" in this section.

D13C520A

CLUTCH CABLE
(LeftґHand Drive Shown, RightґHand Drive Similar) Removal Procedure
1. Disconnect the clutch cable from the transaxle. D Remove the adjusting nut (1). D Disconnect the cable from the wire clip (2). D Pull and remove the cable from the transaxle mount hole (3).
D103B506

2. Disconnect the clutch cable from the pedal. D Pull upward and disconnect the cable from the pedal hook (1).

D13C5211

DAEWOO M-150 BL2

5C ґ 12 CLUTCH
3. Remove the battery. Refer to Section 1E, Engine Electrical. 4. Remove the clutch cable. D Remove the nuts (1). D Remove the cable grommet (2). D Remove the cable from the pedal (3).

D103C522

Installation Procedure
1. Install the clutch cable. 2 Install the battery. 3. Connect the clutch cable to the pedal. 4. Connect the clutch cable to the transaxle. 5. Adjust the clutch cable. Refer to "Diagnosis" in this section.

D103C302

CLUTCH PEDAL
(LeftґHand Drive Shown, RightґHand Drive Similar) Removal Procedure
1. Disconnect the clutch cable. Refer to "Clutch Cable" in this section. 2. Remove the clutch pedal. D Release the pedal return spring. D Remove the nut (1). D Remove the clutch pedal (2). D Remove the bushing (3). D Remove the pedal return spring (4).

D103C524

Installation Procedure
1. Install the pedal return spring. 2. Install the bushings. 3. 4. 5. 6. Install the clutch pedal. Install the nut. Fix the pedal return spring. Connect the clutch cable.

7. Adjust the clutch cable. Refer to "Diagnosis" in this section.

D103C302

DAEWOO M-150 BL2

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Application Clutch Release Arm Bolt and Nut Pressure Plate Bolt Clutch Pedal Clutch Disc Clearance between pedal and floor just before clutch connection Pedal Travel Pedal Free Travel Disc Runout Limit in Rotational Direction Rivet Head Depth Thickness Inside Diameter Outside Diameter Type Application

DAEWOO M-150 BL2

FASTENER TIGHTENING SPECIFICATIONS

Description

GENERAL SPECIFICATIONS

SPECIFICATIONS

10 ґ 16 18 ґ 28 NSm ґ

mm (in.)

mm (in.)

mm (in.)

mm (in.)

mm (in.)

mm (in.)

mm (in.)

mm (in.)

Unit

Single Dry Plate

7.15 (0.281)

1.2 (0.047)

100 ґ 110 (3.9 ґ 4.3)

Standard

170 (6.7)

110 (4.3)

7.5 ґ 12 13 ґ 21 Lb-Ft 0 (0) ґ ґ

CLUTCH 5C ґ 13

0.7 (0.028)

0.5 (0.020)

30 ґ 40 (1.2 ґ 1.6)

Lb-In ґ ґ ґ ґ ґ ґ

Limit

ґ ґ

5C ґ 14 CLUTCH

SPECIAL TOOLS
SPECIAL TOOLS TABLE

09917ґ58010 Input Shaft Bearing Remover

09930ґ30102 Sliding Shaft

D103C101

D103C106

09923ґ46040 Bushing Joint Pipe

09943ґ88211 Bushing, Bearing Installer

D103C105

D103C107

09924ґ17810 Fly Wheel Holder

DW110ґ021 Engine Assembly Support Fixture

D102B116

D103B103

09925ґ48220 Bushing Remover/ Installer

DW210ґ010 Clutch Center Guide

D103C104

D103C103

09925ґ98210 Input Shaft Bearing Installer

D103C102

DAEWOO M-150 BL2