Daewoo Matiz (2003 year). Manual — part 169
5C – 4 CLUTCH
DIAGNOSTIC INFORMATION AND PROCEDURES
GENERAL DIAGNOSIS
Condition
Probable Cause
Correction
Slipping Clutch
D
Improper clutch cable adjustment.
D
Adjust clutch cable.
D
Worn or oily contamination on clutch disc
surface.
D
Replace clutch disc.
D
Worn or oily contamination on pressure
plate, flywheel surface.
D
Replace pressure plate, flywheel.
D
Damaged or weakened diaphragm spring.
D
Replace pressure plate.
D
Rusted clutch cable.
D
Replace clutch cable.
Dragging Clutch
D
Improper clutch cable adjustment.
D
Adjust clutch cable.
D
Worn or weakened diaphragm spring.
D
Replace pressure plate.
D
Worn or rusted splines of input shaft or
clutch disc.
D
Replace input shaft or clutch disc.
D
Excessively wobbly clutch disc.
D
Replace clutch disc.
D
Worn clutch disc.
D
Replace clutch disc.
Fails to Release
D
Bent or damaged clutch disc.
D
Replace clutch disc.
D
Worn or rusted splines of input shaft or
clutch disc.
D
Replace input shaft or clutch disc.
D
Improper operation of clutch release shaft.
D
Replace clutch release shaft.
Pedal Stays on Floor
When Disengaged
D
Interfered clutch release bearing.
D
Lubricate and adjust clutch release
bearing.
D
Weakened diaphragm spring.
D
Replace pressure plate.
Clutch Vibration
D
Clutch facing with oily contamination.
D
Replace clutch disc.
D
Release bearing slides unsmoothly on input
shaft bearing retainer.
D
Lubricate retainer release bearing.
D
Wobbly clutch disc or poor facing contact.
D
Replace clutch disc.
D
Loose clutch disc rivets.
D
Replace clutch disc.
D
Weakened clutch disc torsion spring.
D
Replace clutch disc.
D
Distorted pressure plate or flywheel
surface.
D
Replace pressure plate or flywheel.
D
Weakened engine mounting or loosened
installing bolt or nut.
D
Retighten or replace mounting.
Clutch Noise
D
Worn or broken release bearing.
D
Replace release bearing.
D
Worn input shaft bearing.
D
Replace input shaft bearing.
D
Cracked clutch disc.
D
Replace clutch disc.
D
Pressure plate and diaphragm spring
rattling.
D
Replace pressure plate.
D
Improper clutch cable adjustment.
D
Adjust clutch cable.
Grabbing Clutch
D
Clutch disc facing with oily contamination.
D
Replace clutch disc.
D
Excessively worn on clutch disc facing.
D
Replace clutch disc.
D
Rivet head showing out of facing.
D
Replace clutch disc.
D
Weakened clutch torsion spring.
D
Replace clutch disc.
CLUTCH 5C – 5
CLUTCH PEDAL OPERATION
D103C301
Clutch pedal free travel
It is designed that there is no clutch pedal free travel.
Clutch pedal travel (A)
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
Pedal Travel
ÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
100–110 mm (3.9–4.3 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 ped-
al.
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁ
Clearance Between Pedal and Floor
just Before Clutch Connection
ÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁ
30–40 mm
(1.2–1.6 in.)
Caution: During inspection, take care on sudden
departure.
CLUTCH CABLE ADJUSTMENT
D103C302
If clutch connection / disconnection is operated un-
smoothly, adjust the clutch cable by adjusting clutch
cable adjust nut.
5C – 6 CLUTCH
INSTRUCTION REPAIR
ON–VEHICLE SERVICE
D13B5151
D103B516
PRESSURE PLATE, CLUTCH DISC
AND INPUT SHAFT BEARING
Tools Required
09917–58010
Input Shaft Bearing Remover
09924–17810
Flywheel Holder
09925–98210
Input Shaft Bearing Installer
DW110–021
Engine Fixture
DW210–010
Clutch Center Guide
Removal Procedure
1. Remove the transaxle from the vehicle. Refer to Sec-
tion 5B, Manual Transaxle.
2. Support the engine to normal position using the en-
gine fixture DW110–021.
Notice: The abnormal position of the engine may dam-
age to the related parts and interfere with them. You
must support the engine to normal position after remov-
ing the transaxle.
D13C5021
3. Remove the pressure plate and the clutch disc.
D
Fix the fly wheel using the fly wheel holder 09924–
17810.
D
Remove the pressure plate bolts (1).
D
Remove the pressure plate and the clutch disc (2).
CLUTCH 5C – 7
D13C5031
4. Remove the transaxle input shaft bearing using the
input shaft bearing remover 09917–58010, the fly-
wheel holder 09924–17810 and a spanner.
D13C5041
Inspection Procedure – 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).
D103C505
2. Clutch disc inspection
D
Measure rivet head depth from clutch disc surface
and replace if below limit.
Unit : mm (in.)
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁ
Standard
ÁÁÁÁÁÁ
ÁÁÁÁÁÁ
Limit
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
Rivet Head Depth
1.2 (0.047)
0.5 (0.02)
D
Replace the clutch disc if clutch disc surface is
contaminated or clutch disc rivets are loosen.
D103C506
3. Clutch disc runout in rotational direction inspection.
D
Measure runout in rotational direction and replace
if runout exceeds limit.
Unit : mm (in.)
ÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁ
Disc Runout Limit in Rotational
Direction (Periphery)
ÁÁÁÁÁÁ
ÁÁÁÁÁÁ
ÁÁÁÁÁÁ
0.7 (0.028)
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