Xe ô tô hyundai excel toàn tập hyundai excel - P7

Tài liệu xe ô tô hyundai excel toàn tập hyundai excel

CLUTCH Return To Main Table of Contents GENERAL CLUTCH CLUTCH CONTROL 10 GENERAL GENERAL SPECIFICATIONS Clutch operating method Clutch disc Cable type Type Facing diameter (Outside x Inside) Clutch cover assembly Single dry disc 184 mm x 127 mm (7.24 in x 5.00 in.) Type Setting load N (lb.) Mounting bolt circle dia 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 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.) Limit Clutch disc Revet sink 0.3 mm (0.012 in.) TIGHTENING TORQUE Transmission to engine bolts Starter motor mounting bolts Clutch to flywheel 41-2 Nm kg.cm 43-53 30-34 15-21 430-540 300-350 150-210 lb.ft 32-39 22-25 11-15 GENERAL SPECIAL TOOLS Tool (Number and name) Illustration Use 09411-11000 Clutch disc guide Centering flywheel and clutch disc 09414-11100 Lock pin installer 1) Driving out the spring pin of the clutch shaft 2) Driving out of spring pin of the shift fork 09414-11000 Lock pin extractor Driving in the spring pin of the shift fork 41-3 GENERAL TROUBLESHOOTING Clutch chatter Clutch slipping Difficult gear shifting Clutch noisy Clutch operation erratic or rough 41-4 Remedy Probable cause Symptom Worn or damaged disc assembly Replace disc assembly Oil or grease on disc facings Replace disc assembly and correct cause of contamination Weak or broken disc damper springs Replace disc assembly Broken or loose engine mounts Replace or tighten mounts Insufficient pedal free play Adjust clutch pedal free play Burned, worn or oil-socked Replace disc assembly and correct cause of contamination Weak or broken pressure spring Replace cover assembly Excessive pedal free play Adjust clutch pedal free play Worn or damaged disc assembly Replace clutch assembly Clutch disc splines sticking Remove disc assembly and unstick splines or replace disc Clutch cable sticks Replace parts Clutch cable broken or loose Repair or replace parts Clutch pedal bushing damaged Replace parts Worn release bearing Replace release bearing Worn disc assembly Replace disc assembly Worn diaphragm spring Replace disc assembly Insufficient lubrication on clutch Lubricate pedal pivot GENERAL CLUTCH PEDAL INSPECTION AND ADJUSTMENT 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.) 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.) 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.) If the clutch pedal stroke is more than the standard value, defective clutch assembly is suspected Repair the clutch assembly 41-5 CLUTCH CLUTCH COMPONENTS 41-6 CLUTCH REMOVAL Remove the transmission See “Manual Transmission”, for detailed procedure Insert Special Tool, Clutch Disc Guide (09411-11000), in center spline to prevent dropping of clutch disc 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 Remove return clip, then remove release bearing 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 Remove clutch release shaft and then remove release fork, packings and return spring CLEANING AND INSPECTION 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 Friction face of pressure plate should be have a uniform appearance 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 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 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 Wipe friction surface of pressure plate with a suitable solvent 41-7 CLUTCH 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 Visually inspect the cover outer mounting flange for flatness It should be free of nicks, burrs, dents or other damage The three dowels on the flywheel should be tight and undamaged The cover stamping should be a snug fit on the dowels If the clutch assembly does not meet these requirements, it should be replaced INSTALLATION Prior to installing release shaft, apply multipurpose grease Insert release shaft and install packings, return spring and release shaft and install packings, return spring and release fork Apply grease to release bearing contact surfaces of release fork 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 Apply grease into groove of release bearing and then install release bearing to front bearing retainer of transmission Install return clip to release bearing and fork 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 41-8 Apply grease CLUTCH Apply and rub a small amount of multipurpose grease to the clutch disc spline and input shaft spline 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 succession, 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 Loosen the cable adjusting nut Remove the cotter pin from the clutch control lever and disconnect the clutch cable from the holder Disconnect the cable from the clutch pedal, and remove the toward the engine compartment Clutch Pedal Loosen the adjusting nut, and then disconnect the clutch cable from the pedal Remove the pedal shaft tightening nut and the clutch pedal with the bushing attached 41-10 CLUTCH CONTROL INSPECTION Check the dust boot for damage Check the cable movement for roughness Check the outer cable for damage Check the clutch cable hardware condition at both ends of cable of connections Check the pedal shaft and bushing for wear Check the clutch pedal for bend or torsion INSTALLATION Apply grease to the pedal shaft, bushings, and cable fitting area of the clutch pedal arm Tighten pedal mounting nut to the specified torque Clutch pedal mounting nut 16-24 Nm (160-240 kg.cm, 12-17 Ib.ft) Adjust the clutch pedal as described under “SERVICE ADJUSTMENT PROCEDURE” of this section 41-11 ... bolts Clutch to flywheel 4 1-2 Nm kg.cm 4 3-5 3 3 0-3 4 1 5-2 1 43 0-5 40 30 0-3 50 15 0-2 10 lb.ft 3 2-3 9 2 2-2 5 1 1-1 5 GENERAL SPECIAL TOOLS Tool (Number and name) Illustration Use 0941 1-1 1000 Clutch disc guide... stroke Clearance between adjusting nut and cable holder 18 7-1 92 mm (7. 4-7 .6 in.) 2 0-3 0 mm (0. 8-1 .2 in.) 145 mm (5.7 in.) 5-6 mm (0.2 0-0 .24 in.) Limit Clutch disc Revet sink 0.3 mm (0.012 in.)... 1 6-2 4 Nm (16 0-2 40 kg.cm, 1 2-1 7 Ib.ft) Adjust the clutch pedal as described under “SERVICE ADJUSTMENT PROCEDURE” of this section 4 1-1 1