CLUTCH

C TRANSMISSION/TRANSAXLE

SECTION CL CLUTCH
B

CL

E
CONTENTS
APPLICATION NOTICE .............................................. 2 CLUTCH MASTER CYLINDER ................................ 10 F
How to Check Vehicle Type ..................................... 2 Removal and Installation ........................................ 10
PRECAUTIONS .......................................................... 3 REMOVAL ........................................................... 10
Caution ..................................................................... 3 INSTALLATION ................................................... 10 G
PREPARATION ........................................................... 4 CSC (CONCENTRIC SLAVE CYLINDER) ................ 11
Special Service Tools ............................................... 4 Removal and Installation ........................................ 11
NOISE, VIBRATION AND HARSHNESS (NVH) REMOVAL ........................................................... 11
H
TROUBLESHOOTING ................................................ 5 INSPECTION ...................................................... 11
NVH Troubleshooting Chart ..................................... 5 INSTALLATION ................................................... 11
CLUTCH ................................................................ 5 CLUTCH DISC, CLUTCH COVER AND FLYWHEEL... 12
CLUTCH PEDAL ........................................................ 6 Removal and Installation ........................................ 12 I
On Board Inspection ................................................ 6 REMOVAL ........................................................... 13
HEIGHT INSPECTION .......................................... 6 INSPECTION AND ADJUSTMENT AFTER
PLAY INSPECTION .............................................. 6 REMOVAL (CR ENGINE) .................................... 13 J
CLEARANCE CHECK ........................................... 7 INSPECTION AND ADJUSTMENT AFTER
Removal and Installation .......................................... 7 REMOVAL (K9K ENGINE) .................................. 14
REMOVAL ............................................................. 7 INSTALLATION ................................................... 14
K
INSPECTION AFTER REMOVAL ......................... 7 SERVICE DATA AND SPECIFICATIONS (SDS) ...... 16
INSTALLATION ..................................................... 8 Clutch Pedal ........................................................... 16
CLUTCH FLUID .......................................................... 9 Clutch Disc ............................................................. 16
Air Bleeding Procedure ............................................ 9 Clutch Cover ........................................................... 16 L
Clutch Control System ............................................ 16
Clutch Master Cylinder ........................................... 16
M

CL-1
 APPLICATION NOTICE

APPLICATION NOTICE PFP:00000

How to Check Vehicle Type ECS00HJ5

Confirm K9K engine type with Model written on identification plate (refer to GI-44, "IDENTIFICATION INFOR-
MATION" ),then refer to service information in CL section.
Vehicle type Engine type
xTKxxxxK12Vxx Euro3 48kW
xTKxxxxK12Yxx Euro3 60kW
xTKxxxxK12Txx Euro4 50kW
xTKxxxxK12Uxx Euro4 63kW

CL-2
 PRECAUTIONS

PRECAUTIONS PFP:00001
A
Caution ECS008JC

● Recommended fluid is brake fluid “DOT 3” or "DOT 4". Refer to MA-35, "Fluids and Lubricants".
● Never reuse drained brake fluid. B
● Be careful not to splash brake fluid on painted areas.
● Use new brake fluid to clean or wash all parts of master cylinder and concentric slave cylinder.
● Never use mineral oils such as gasoline or kerosene. It will ruin the rubber parts of the hydraulic CL
system.
● If manual transaxle is removed from the vehicle, always replace CSC (concentric slave cylinder).
CSC insert is returned to original position to remove transaxle. Dust on clutch disc sliding parts D
may damage CSC seal and may cause fluid leak.
● Do not disassemble master cylinder and CSC.
WARNING: E
After cleaning clutch disc, wipe it with a dust collector. Do not use compressed air.

CL-3
 PREPARATION

PREPARATION PFP:00002

Special Service Tools ECS008JD

Tool number Description

(Renault tool number)
Tool name

ST20050240 Inspecting diaphragm spring of

Diaphragm spring adjusting wrench clutch cover

ZZA0508D

EM07020000 Installing clutch cover and disc

Clutch aligner

PCIB0017E

KV30101000 Installing clutch disc

Clutch aligner
a:15.9mm(0.626in)dia
b:19.8mm(0.780in)dia

ZZA1178D

CL-4
 CLUTCH

Symptom
Reference page

Clutch slips
Clutch noisy
Clutch pedal spongy
Clutch grabs/chatters
SUSPECTED PARTS (Possible cause)
NVH Troubleshooting Chart

Clutch does not disengage

CLUTCH PEDAL (Free play out of adjustment) CL-6.

1
1
CLUTCH LINE (Air in line) CL-9.

2
1
tion. If necessary, repair or replace these parts.

MASTER CYLINDER PISTON CUP (Damaged) CL-10.

3
2
ENGINE MOUNTING (Loose) EM-70 .

CL-5
RELEASE BEARING (Worn, dirty or damaged) CL-11

1
CLUTCH DISC (Out of true) CL-12.

4
CLUTCH DISC (Runout is excessive) CL-12.

4
2
CLUTCH DISC (Lining broken) CL-12.

4
CLUTCH DISC (Dirty or burned) CL-12.

4
CLUTCH DISC (Oily) CL-12.

4
2
2

CLUTCH DISC (Worn out) CL-12.

2
2

CLUTCH DISC (Hardened) CL-12

2

4 CLUTCH DISC (Lack of spline grease) CL-12

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

DIAPHRAGM SPRING (Damaged) CL-13.

5
3

DIAPHRAGM SPRING (Out of tip alignment) CL-13.

5
2
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

PRESSURE PLATE (Distortion) CL-13.

6
4

FLYWHEEL (Distortion) CL-12

5
PFP:00003

ECS008SM

Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-

L
F

K
E
B
A

CL

H
D

M
 CLUTCH PEDAL

CLUTCH PEDAL PFP:46540

On Board Inspection ECS00H8J

HEIGHT INSPECTION
1. Make sure clutch pedal height H1 from upper surface of the
dash panel is within the specified range.
Pedal height H1
: 160 - 169 mm (6.30 - 6.65 in) (LHD with CR engine)
(LHD K9K Euro3 48kW)
(LHD with HR engine)
: 164 - 174 mm (6.46 - 6.85 in) (RHD with CR engine)
(RHD K9K Euro3 48kW)
: 170 - 180 mm (6.69 - 7.09 in) (LHD K9K Euro3 60kW)
(LHD K9K Euro4
50/63kW)
: 175 - 185 mm (6.89 - 7.23 in) (RHD K9K Euro3 60kW)
(RHD K9K Euro4
50/63kW)
(RHD with HR engine)
2. If pedal height H1 is outside the specification, replace pedal
assembly.
3. Make sure free play A at pedal pad top surface and pedal height
SCIA1256E
H2 when clutch is disengaged are within the ranges specified
below.
A: Pedal free play at the pedal pad
: 0.5 mm (0.02 in)
Pedal height H2 when clutch is disengaged
: 100 mm (3.94 in) or more (CR engine)
4. If free play A at pedal pad top surface and pedal height H2 when clutch is disengaged are outside the
specification, replace clutch pedal assembly.
PLAY INSPECTION
● Press the clutch pedal by hand until certain resistance can be
felt. Using a scale, Make sure the free play is within the specified
range.
Pedal free play
: 0.5 mm (0.02 in)

MAA0023D

CL-6
 CLUTCH PEDAL

CLEARANCE CHECK
1. Start the engine and let it idle. A
2. Apply parking brake.
3. Depress the brake pedal.
B
4. Fully depress clutch pedal and shift to 1st gear.
5. Release clutch pedal gradually. Using a scale, check the clear-
ance between the clutch pedal and floor panel to see if it is
within the specified range. CL
Pedal height when the clutch disengages
: 100 mm (3.94 in) or more (CR engine) D
MAA0024D

NOTE:
Pedal height at clutch disengagement varies slightly from the clutch engagement point. Despite this, pedal
height at clutch engagement is commonly used for both cases in order to simplify the inspection. E
Removal and Installation ECS008JF

REMOVAL
1. Remove instrument panel under tray. Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" . F
2. Unlock master cylinder rod end and separate master cylinder
from clutch pedal.
3. Remove clutch switch harness clamp from pedal bracket. G
4. Disconnect clutch switch connector.

I
SCIA1284E

5. Remove nuts (3), and remove clutch pedal assembly. J

SCIA1260E

INSPECTION AFTER REMOVAL

● Check clutch pedal for bend, damage, and a cracked weld. If bend, damage, or a cracked weld is found,
replace clutch pedal assembly.

CL-7
 CLUTCH PEDAL

INSTALLATION
● Install in the reverse order of removal.

CL-8
 CLUTCH FLUID

CLUTCH FLUID PFP:00017

A
Air Bleeding Procedure ECS008JG

CAUTION:
● Monitor fluid level in the reservoir tank to make sure it does not empty. B
● Do not spill brake fluid onto painted surfaces. If it spills, wipe up immediately and wash the
affected area with water.
● Bleed the bleeding connector. CL
1. Fill the master cylinder reservoir tank with new brake fluid.
2. Remove rubber cap and connect a transparent vinyl hose to air
bleeder of bleeding connector. D

SCIA1261E

G
3. Lift tube side lock pin of bleeding connector up one step.
CAUTION:
Do not remove lock pin. H
4. “Depress” and “release” the clutch pedal slowly and fully 15
times at an interval of 2 to 3 seconds and hold it.
CAUTION: I
Hold it to prevent releasing tube from bleeding connector
when fluid pressure is applied in the tube.
J
SCIA1262E

5. Slide tube 5 mm (0.20 in) to the direction shown by the arrow K

and drain clutch fluid.
6. Return tube to its original position.
7. Release clutch pedal and wait for 5 seconds. L
8. Repeat steps 4 to 7 until no bubbles can be observed in the
brake fluid.
M

SCIA1263E

CL-9
 CLUTCH MASTER CYLINDER

CLUTCH MASTER CYLINDER PFP:30610

Removal and Installation ECS008JH

REMOVAL
1. Drain brake fluid from reservoir tank and remove hose from the nipple.
CAUTION:
Do not spill brake fluid onto painted surfaces. If it spills, wipe up immediately and wash the
affected area with water.
2. Unlock master cylinder rod end in the passenger room and sep-
arate master cylinder from clutch pedal.

SCIA1284E

3. Remove lock pin from master cylinder and separate clutch tube.
4. Rotate master cylinder clockwise by 45° and remove from the
vehicle.

SCIA1285E

INSTALLATION
1. Tilt master cylinder clockwise by 45° and insert to the mounting
hole. Rotate counter clockwise and secure it. At this time, nipple
is upward of the vehicle.
2. After finishing work, perform clutch pedal height inspection and
clutch piping air bleeding.
● Refer to CL-6, "On Board Inspection" ,CL-9, "Air Bleeding
Procedure"

SCIA1286E

CL-10
 CSC (CONCENTRIC SLAVE CYLINDER)

CSC (CONCENTRIC SLAVE CYLINDER) PFP:30500

A
Removal and Installation ECS00CW5

CAUTION:
● Do not spill brake fluid onto painted surfaces. B
If it spills, wipe up immediately and wash the affected area with water.
● If manual transaxle is removed from the vehicle, always replace CSC (concentric slave cylinder).
CSC insert is returned to original position to remove transaxle. Dust on clutch disc sliding parts CL
may damage CSC seal and may cause brake fluid leak.
REMOVAL
1. Remove manual transaxle. Refer to MT-7, "REMOVAL AND INSTALLATION" (JH3) or MT-37, D
"REMOVAL AND INSTALLATION" (JR5).
2. Remove bolts and CSC from manual transaxle.
E

MCIA0172E

INSPECTION K
NOTE:
● Cannot disassemble CSC and release bearing because they are integral parts. Replace them as an
assembly. L
Inspect for the following, and replace parts if necessary.
● CSC: damage, foreign material, wear or pinholes on the cylinder outer surface.
● Release bearing: damage, incorrect rotation direction, or has poor aligning function, and dust seal is M
deformed or cracked.
INSTALLATION
1. Install new CSC to manual transaxle. Tighten to the specified torque.
Tightening torque
: 21 N·m (2.15 kg-m, 15.5 ft- lb)
CAUTION:
Do not insert and operate CSC because piston and stopper of CSC components may fall off.
2. Install manual transaxle to the vehicle. Refer to MT-7, "REMOVAL AND INSTALLATION" (JH3) or MT-37,
"REMOVAL AND INSTALLATION" (JR5).
3. Bleed air from the clutch piping. Refer to CL-9, "Air Bleeding Procedure" .

CL-11
 CLUTCH DISC, CLUTCH COVER AND FLYWHEEL

CLUTCH DISC, CLUTCH COVER AND FLYWHEEL PFP:30100

Removal and Installation ECS008JJ

CAUTION:
● If manual transaxle is removed from the vehicle, always replace CSC (concentric slave cylinder).
CSC insert is returned to original position to remove transaxle. Dust on clutch disc sliding parts
may damage CSC seal and may cause brake fluid leak.
● Be careful not to bring any grease into contact with the clutch disc facing, pressure plate surface,
or flywheel surface.
Petrol Engine

SCIA1268E

Diesel Engine

YCL032

CL-12
 CLUTCH DISC, CLUTCH COVER AND FLYWHEEL

REMOVAL
1. Remove manual transaxle from the vehicle. Refer to MT-7, "REMOVAL AND INSTALLATION" (JH3) or A
MT-37, "REMOVAL AND INSTALLATION" (JR5).
2. Loosen clutch cover mounting bolts evenly. Remove clutch cover and clutch disc.
B
INSPECTION AND ADJUSTMENT AFTER REMOVAL (CR ENGINE)
Clutch Disc
● Measure circumferential runout relative to the clutch disc center CL
spline. If it is outside the specification, replace the clutch disc.
Runout limit/diameter of the area to be measured:
CR12 engine :1.0mm (0.039 in) or less/170 D
(6.69 in) mm dia.
CR14 engine :1.0mm (0.039 in) or less/180
(7.08 in) mm dia. E
HR engine :1.0mm (0.039 in) or less/190
(7.48 in) mm dia.
SCIA1270E
F

● Using calipers, measure the depth to the clutch disc facing rivet
heads. If it exceeds the allowable wear limit, replace the clutch
disc. G

Facing wear limit (depth to the rivet head)

: 0.3 mm (0.012 in) H

SCL229

Clutch Cover J
Check diaphragm spring lever claws for unevenness with the lever
still on the vehicle. If they exceed the tolerance, adjust lever height
using a diaphragm adjusting wrench (SST). K
Tolerance for diaphragm spring lever unevenness
CR engine : 0.7 mm (0.028 in)
L
HR engine : 0.7 mm (0.028 in)
K9K Euro4 50/63kW : 0.8 mm (0.031 in)
● Check clutch cover thrust ring for wear or breakage. If wear or M
breakage is found, replace clutch cover assembly.
CLA0069D
NOTE:
● Worn thrust ring will generate a beating noise when tapped at the rivet with a hammer.

● Broken thrust ring will make a clinking sound when cover is shaken up and down.

● If a trace of burn or discoloration is found on the clutch cover pressure plate to clutch disc contact surface,
repair the surface with sandpaper. If surface is damaged or distorted, replace the assembly.

CL-13
 CLUTCH DISC, CLUTCH COVER AND FLYWHEEL

Flywheel Runout
Using a dial gauge, measure runout at the flywheel clutch contact
surface. If runout is outside the specification, replace the flywheel. If
a trace of burn or discoloration is found on the surface, repair it with
sandpaper.
Flywheel surface runout
: EM-93, "FLYWHEEL RUNOUT" .
CAUTION:
Measure it at flywheel outer face (not on knock pin and clutch
cover mounting hole).
PCIB0016E

INSPECTION AND ADJUSTMENT AFTER REMOVAL (K9K ENGINE)

Clutch Disc
● The hubs of the clutch discs are nickle plated to improve their
sliding performance.
● Clean the splines of the clutch shaft and install the assembly
without lubricant.
● Degrease the friction face of the flywheel.
● Install the clutch disc (offset (A) from the hub on the flywheel
side).
CAUTION:
Reworking on the clutch face is not permitted.
YCL034

Flywheel Runout
Replace the flywheel if it has been damaged.
INSTALLATION
1. Clean input shaft spline by removing grease and dust from wear.
2. Apply recommended Grease to clutch disk and input shaft spline.
NOTE:
Applied amount of grease is 0.4 g. Film pressure is 1 mm (0.04 in) or less.
3. Insert clutch disc to input shaft. Wipe off any grease oozing from the parts.
CAUTION:
● Excessive grease may cause slip or judder. And if it adheres to CSC seal, it cause clutch fluid
leak. Wipe off excess grease.
● If grease is not applied, it may cause noise, poor disengagement, or damage to the clutch. Be
sure to apply grease.
4. Install clutch disc and clutch cover. Pre-tighten mounting bolts
and install a clutch aligner (SST).
Tool number A: EM07020000(CR,K9K engine)
A: KV30101000(HR engine)
5. Tighten clutch cover attaching bolts evenly in two steps in the
order shown in the figure.
Tightening torque(CR engine)
First
: 9.9 - 19 N·m (1.0 - 2.0 kg-m, 8 - 14 ft-lb)
step PCIB1503E

Final : 22 - 29 N·m (2.2 - 3.0 kg-m, 17 - 21 ft-lb)

step
Tightening torque(HR engine)

CL-14
 CLUTCH DISC, CLUTCH COVER AND FLYWHEEL

First
: 19 N·m (2.0 kg-m, 14 ft-lb) A
step
Final : 22 - 29 N·m (2.2 - 3.0 kg-m, 17 - 21 ft-lb)
step
B
Tighten clutch cover attaching bolts order shown in the figure. (K9K engine)
6. Install manual transaxle. Refer to MT-7, "REMOVAL AND INSTALLATION" (JH3) or MT-37, "REMOVAL
AND INSTALLATION" (JR5). CL

CL-15
 SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030

Clutch Pedal ECS00H8K

Unit mm (in)
K9K Euro3 K9K Euro4
Engine type CR HR
48kW 60kW 50/63kW
160 - 169 160 - 169 170 - 180 170 - 180 160 - 169
LHD models
(6.30 - 6.65) (6.30 - 6.65) (6.69 - 7.09) (6.69 - 7.09) (6.30 - 6.65)
Pedal height
164 - 174 164 - 174 175 - 185 175 - 185 175 - 185
RHD models
(6.46 - 6.85) (6.46 - 6.85) (6.89 - 7.23) (6.89 - 7.23) (6.89 - 7.23)
100 (3.94)
Pedal height at clutch disengagement —
or more
Pedal free play 0.5 (0.02)

Clutch Disc ECS008JL

Unit: mm (in)
K9K Euro3 K9K Euro4
Engine type CR12 CR14 HR
48/60kW 50/63kW
Size 180 (7.09) dia. 190 (7.48) dia. 215 (8.46) dia. 216 (8.50) dia. 200 (7.87) dia.
Wear limit (depth to rivet head) 0.3 (0.012) — 0.3 (0.012)
Wearing thickness of facing — 1 (0.039) —
1.0 (0.039) 1.0 (0.039) 1.0 (0.039)
Runout limit/diameter of the area
or less / 170 or less / 180 — or less / 190
to be measured
(6.69) dia. (7.08) dia. (7.48) dia.
Thickness of disc assy with load 6.8 - 7.2
— —
(new) (0.27 - 0.28)

Clutch Cover ECS008JM

Unit: mm (in)
Engine type CR K9K Euro3 48/60kW K9K Euro4 50/63kW HR
Size 190 (7.48) dia. — 216 (8.50) dia. 215 (8.46) dia.
32.0 - 34.0 29.0 - 31.0
Diaphragm spring lever height — —
(1. 26 - 1.34) (1.14 - 1.22)
Uneven limit diaphragm spring
0.7 (0.028) or less — 0.8 (0.031) or less 0.7 (0.028) or less
toe height

Clutch Control System ECS008SO

Type of clutch control Hydraulic

Clutch Master Cylinder ECS008SP

Unit: mm (in)
Inner diameter 15.87 (5/8)

CL-16