Content .. 167 168 169 170 ..

Daewoo Matiz (2003 year). Manual - part 169

5C – 4 CLUTCH

DIAGNOSTIC INFORMATION AND PROCEDURES

GENERAL DIAGNOSIS

Condition

Probable Cause

Correction

Slipping Clutch

Improper clutch cable adjustment.

Adjust clutch cable.

Worn or oily contamination on clutch disc
surface.

Replace clutch disc.

Worn or oily contamination on pressure
plate, flywheel surface.

Replace pressure plate, flywheel.

Damaged or weakened diaphragm spring.

Replace pressure plate.

Rusted clutch cable.

Replace clutch cable.

Dragging Clutch

Improper clutch cable adjustment.

Adjust clutch cable.

Worn or weakened diaphragm spring.

Replace pressure plate.

Worn or rusted splines of input shaft or
clutch disc.

Replace input shaft or clutch disc.

Excessively wobbly clutch disc.

Replace clutch disc.

Worn clutch disc.

Replace clutch disc.

Fails to Release

Bent or damaged clutch disc.

Replace clutch disc.

Worn or rusted splines of input shaft or
clutch disc.

Replace input shaft or clutch disc.

Improper operation of clutch release shaft.

Replace clutch release shaft.

Pedal Stays on Floor
When Disengaged

Interfered clutch release bearing.

Lubricate and adjust clutch release
bearing.

Weakened diaphragm spring.

Replace pressure plate.

Clutch Vibration

Clutch facing with oily contamination.

Replace clutch disc.

Release bearing slides unsmoothly on input
shaft bearing retainer.

Lubricate retainer release bearing.

Wobbly clutch disc or poor facing contact.

Replace clutch disc.

Loose clutch disc rivets.

Replace clutch disc.

Weakened clutch disc torsion spring.

Replace clutch disc.

Distorted pressure plate or flywheel
surface.

Replace pressure plate or flywheel.

Weakened engine mounting or loosened
installing bolt or nut.

Retighten or replace mounting.

Clutch Noise

Worn or broken release bearing.

Replace release bearing.

Worn input shaft bearing.

Replace input shaft bearing.

Cracked clutch disc.

Replace clutch disc.

Pressure plate and diaphragm spring
rattling.

Replace pressure plate.

Improper clutch cable adjustment.

Adjust clutch cable.

Grabbing Clutch

Clutch disc facing with oily contamination.

Replace clutch disc.

Excessively worn on clutch disc facing.

Replace clutch disc.

Rivet head showing out of facing.

Replace clutch disc.

Weakened clutch torsion spring.

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

Pedal Travel

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

Clearance Between Pedal and Floor

just Before Clutch Connection

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.

Fix the fly wheel using the fly wheel holder 09924–
17810.

Remove the pressure plate bolts (1).

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 .

Check the weak and damaged diaphragm spring
(1).

Check the polluted face by the oil, grease (2).

D103C505

2. Clutch disc inspection

Measure rivet head depth from clutch disc surface
and replace if below limit.

Unit : mm (in.)

ÁÁÁÁÁÁÁ

ÁÁÁÁÁÁ

Standard

ÁÁÁÁÁÁ

Limit

ÁÁÁÁÁÁÁ

Rivet Head Depth

1.2 (0.047)

0.5 (0.02)

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.

Measure runout in rotational direction and replace
if runout exceeds limit.

Unit : mm (in.)

ÁÁÁÁÁÁÁÁÁÁÁÁ

Disc Runout Limit in Rotational

Direction (Periphery)

ÁÁÁÁÁÁ

0.7 (0.028)

Content .. 167 168 169 170 ..