Clutch: Service and Repair
Clutch Pressure and Driven Plate Replacement (1.4L LUV)
Special Tools
* DT-6263 - Remover / Installer
* DT-6263-27 - Clutch Center Guide
* EN-652 - Flywheel Holder
For equivalent tools, refer to Special Tools Tools and Equipment.
Removal Procedure
Note:
* To prevent damage to the spring fangs of pressure plate use DT-6263 - remover / installer to remove and install clutch pressure plate.
* Note the different lengths of the brackets for attaching DT-6263 - remover / installer to lower engine block.
1. Remove the transmission. Refer to Transmission Replacement Service and Repair.
2. Install the EN-652 - holder (1) to the engine block.
3. Attach the DT-6263 - remover / installer (1) in conjunction with the DT-6263-1 - brace to the engine block.
4. Install the 4 bolts (arrows) to the engine block, but do not tighten yet.
5. Attach the DT-6263-27 - guide to the DT-6263-30 - drift (4).
6. Fasten the DT-6263 - remover / installer.
1. Align the DT-6263-30 - centering drift (2) in conjunction with the clutch center guide through the DT-6263 - remover / installer into the clutch driven plate and crankshaft center (arrow).
2. Tighten the knurled wheel (1).
3. Tighten the bolt (3).
4. Tighten the 4 bolts installing the DT-6263 - remover / installer to the engine block.
7. Preload the clutch springs, using the DT-6263 - remover / installer.
1. Turn the threaded rod (1) until it rests against the spring tangs of the clutch pressure plate.
2. Measure the distance a.
Note: Do NOT turn further than necessary to gain free movement of the clutch disc.
3. Turn the threaded rod clockwise until the distance a is extended by approximate 8 mm (0.31 in).
4. Check for free movement of the clutch disc.
Note: Ascertain if bolt was assembled with thread lock agent.
8. Remove and DISCARD the 6 clutch pressure plate bolts (1).
9. Release the DT-6263 - remover / installer (2).
1. Turn the threaded rod (1) of the DT-6263 - remover / installer counterclockwise to the stop.
2. Remove the DT-6263-30 - centering drift (3) in conjunction with the clutch center guide (arrow).
10. Remove the clutch pressure plate (1) and the driven plate (2).
Note: Clutch pressure plate and driven plate contaminated by foreign bodies (oil, cleaning agent etc.) have to be replaced. Check clutch driven plate for damage and friction rust in the hub profile and replace if necessary. Do not clean clutch pressure plate and driven plate with a high pressure cleaner or component washing machine.
11. Inspect the clutch pressure plate and the driven plate (1) and replace, if necessary.
Inspect for:
* Excessive wear
* Burned friction surface
* Oil on friction surface
* Damaged spline hub
* Damaged springs
Note: The clutch driven plate has to be replaced if the lining projection is less than 0.5 mm (0.020 in) (arrows).
12. Inspect the projection of lining at the clutch lining rivets.
13. Slide the clutch pressure plate onto the transmission input shaft and check for easy movement.
Installation Procedure
1. Install the bushing (1) to the crankshaft. The bushing stays in the crankshaft. For the correct bushing refer to the electronic parts catalog.
2. Re-cut the 6 clutch pressure plate bolt threads.
Note: The clutch drive plate must be installed so that the German lettering "Getriebe-seite" (means Gearbox-side) on the plate is orientated towards the transmission.
3. Install the clutch driven plate (3) and the clutch pressure plate (2).
Center the clutch driven plate, using the DT-6263-30 - centering drift (1) in conjunction with the clutch center guide.
Note: Do NOT turn further than necessary.
4. Preload the clutch springs, using the DT-6263 - remover / installer (2).
Turn the threaded rod (1) clockwise until the pressure plate contacts the flywheel (arrows).
Caution: Refer to Fastener Caution Fastener Caution.
Note: In the case that the clutch pressure plate bolts where assembled with thread lock agent: Service may offer bolts that are not microencapsulated. If this is the case apply thread lock agent to the bolt. If fastener is microencapsulated, install NEW clutch pressure plate bolts. DO NOT reuse the old bolt.
5. Install the 6 NEW clutch pressure plate bolts (1). For the correct bolts refer to the electronic parts catalog.
6. Tighten the clutch pressure plate bolts to 28 Nm (21 lb ft).
7. Remove the DT-6263 - remover / installer (2) from the engine block.
1. Turn the threaded rod (1) of the DT-6263 - remover / installer counterclockwise to the stop.
2. Remove the DT-6263-30 - centering drift (3) in conjunction with the clutch center guide (arrow).
3. Remove the 4 bolts installing the DT-6263 - remover / installer to the engine block.
8. Remove the EN-652 - holder (1) from the engine block.
9. Install the transmission. Refer to Transmission Replacement Service and Repair.