Procee'd Clutch System

2014 > G 1.
6 TGDI > Clutch System > General Information > Specifications English
SPECIFICATIONS
Items Specifications
Clutch operation method Hydraulic type
Clutch cover Type Diaphragm spring strap
Type Single dry with diaphragm
Gasoline: Ø210 × Ø145mm
Clutch disc Type Facing diameter (Ø8.2677 × Ø5.7087 in.)
(Outer × inner) Diesel: Ø235 × Ø155mm
(Ø9.2520 × Ø6.1024 in.)
Clutch release cylinder inner diameter 20.64 mm (0.8126 in.)
Clutch master cylinder inner diameter 15.87 mm (0.6248 in.)
Clutch disc thickness [When free] 8.3 ± 0.3 mm (0.3268 ± 0.0118 in.)
Clutch disc rivet depth 1.1 mm (0.0433 in.)
Service Standard
Item Specification
Clutch disc rivet depth 0.3 mm (0.0118 in.)
Tightening Torques
Item N.m kgf.m lbft

Clutch pedal mounting nut 16.7 ~ 25.5 1.7 ~ 2.6 12.3 ~ 18.8
Clutch release cylinder mounting bolt 14.7 ~ 21.6 1.5 ~ 2.2 10.8 ~ 15.9
Clutch release cylinder union bolt 24.5 ~ 34.3 2.5 ~ 3.5 18.1 ~ 25.3
Clutch release cylinder bleed plug 6.8 ~ 9.8 0.7 ~ 1.0 5.0 ~ 7.2
Clutch cover mounting bolt (Gasoline) 14.7 ~ 21.6 1.5 ~ 2.2 10.8 ~ 15.9
Clutch cover mounting bolt (Diesel) 11.8 ~ 14.7 1.2 ~ 1.5 8.7 ~ 10.8
LUBRICANTS
Items Specified lubricants Quantity

Clutch release cylinder assembly Brake fluid DOT 3 or DOT 4
As required
Clutch pedal shaft and bushings Chassis grease SAE J310a, NLGI No.1
Input shaft spline 0.2 g
Release bearing & Fork 0.3 ~ 0.5 g
CASMOLY L9508
Release Fork & Fulcrum 0.5 ~ 1.0 g
Release cylinder & Fork 0.4 ~ 0.8 g
Clutch release bearing and Clutch housing CASMOLY L9508 0.5~1.0 g
English
2014 > G 1.6 TGDI > Clutch System > General Information > Special Service Tools English
SPECIAL SERVICE TOOLS
Tools
Illustration Use
(Number and Name)
094111P000 Installation of the clutch disc.
Clutch disc guide
2014 > G 1.6 TGDI > Clutch System > Clutch System > Clutch Cover And Disc > Components andEnglish
Components Location
COMPONENTS
1. Clutch release fork 3. Clutch disk assembly
2. Clutch cover assembly 4. Clutch release bearing
2014 > G 1.6 TGDI > Clutch System > Clutch System > Clutch Cover And Disc > Repair procedures
English
REMOVAL
1. Remove the transaxle assembly.
G 1.6 MPI (Refer to Manual Transaxle System " Manual Transaxle")
D 1.6 TCIU2 (Refer to Manual Transaxle System " Manual Transaxle")
G 1.6 GDI (Refer to Manual Transaxle System " Manual Transaxle")
G 1.6 TGDI (Refer to Manual Transaxle System " Manual Transaxle")
2. Remove the clutch cover bolts. Be careful not to be bent or twist bolts. Loosen bolts in diagonal directions.
INSPECTION
1. Inspect diaphragm spring wear which is in contact with a concentric slave cylinder bearing.
2. Check the clutch cover and disc surface for wear or cracks.
3. Check the clutch disc lining for slipping or oil marks.
4. Measure the depth from a clutch lining surface to a rivet. If the measured value is less than the specification below, replace
it.
Standard value
Clutch disc rivet depth (A): 0.3 mm (0.0118 in.)
INSTALLATION
English
If reinstalling used cover, the cover should be installed with its clutch disc as a set.
1. Apply grease on a disc spline part and transaxle input shaft spline part as required.
Specified grease: CASMOLY L9508
Amount: 0.2 g

Possible problems when not following
• When not applying: Excessive wear of splines and bad clutch operation can occur.
• When excessively applying: Grease can be scattered by centrifugal force which can conaminate the clutch disc.
This can cause a loss of friction force causing a slip.
2. The 'T/M SIDE' marked surface should face the transaxle.

Possible problems when the disc is installed in the opposite direction.
• Transaxle shift error or a strange sound can occur due to clutch separation.
3. Install the clutch disc and the cover with SST (A: 094111P000).
4. Install the clutch cover bolts. Not to be bent or twisted, Tighten them in diagonal directions.
Tightening torque:
Gasoline : 14.7 ~ 21.6 N.m (1.5 ~ 2.2 kgf.m, 10.8 ~ 15.9 lbft)
Diesel : 11.8 ~ 14.7 N.m (1.2 ~ 1.5 kgf.m, 8.7 ~ 10.8 lbft)

• Loosely tighten every clutch cover bolts, then torque to specifications in a diagonal direction. This can prevent
twisting, vibration of the cover, and the lifting of the pressure plate.
• Install the all the components with the specified torques. If not, the clutch torque transaxle may have concerns
or the mounting bolt can loosen.
5. Install the transaxle assembly.
2014 > G 1.6 TGDI > Clutch System > Clutch System > Clutch Switch > Description and Operation
English
DESCRIPTION
Clutch switch is connected to clutch pedal and transmits clutch operating state to ECM.
When clutch pedal is depressed during driving, engine load changes from loaded to none loaded condition. However, ECM regards
vehicle to be loaded becuase VSS signal is still inputted to it. therefore, ECM controls none loaded engine with the condition suitable for
loaded engine.
Accordingly, optimum fuel injection control is not performed then, RPM becomes unstable and smoke is produced.
Clutch operation is detected through clutch switch signal. This signal enables ECM to cope with instant change of load condition.
Besides, clutch switch signal is used to detect engaged gear with vehicle speed and engine speed.
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2014 > G 1.6 MPI
2014 > G 1.6 TGDI 2014 > G 1.6 TGDI > Clutch System > Clutch System > Clutch Switch > Specifications
General Information
Engine Mechanical System
SPECIFICATIONS
Engine Electrical System
Emission Control System Item Specifications
Engine Control / Fuel System
Working voltage DC 12V
Clutch System
14.7 ± 2.9N
General Information Operating force
(1.5 ± 0.3kg, 3.3 ± 0.7lb)
Specifications
Voltage drop 0.4V
Special Service Tools
40°C ~ 80°C
Clutch System Working temperature
(40°F ~ 176°F)
Clutch Cover And Disc
Components and Components Location
Repair procedures
Clutch Switch
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Description and Operation
Specifications
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Repair procedures
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Ignition Lock Switch
Clutch Pedal Clear Submit
Clutch Master Cylinder
Clutch Release Cylinder
Clutch Release Fork and Clutch Release Bearing
Concentric Slave Cylinder Assembly
Manual Transaxle System
Driveshaft and axle
Knowledge Feedback
2014 > G 1.6 TGDI > Clutch System > Clutch System > Clutch Switch > Repair procedures English
INSPECTION
Signal Circuit Inspection
1. Check clutch switch pullup voltage
(1) IG KEY "OFF", ENGINE "OFF".
(2) Disconnect clutch switch connector.
(3) IG KEY "ON".
(4) Measure the voltage between signal terminal of clutch switch harness connector and chassis ground.
Specification : 11.5V ~ 13.0V
2. Check open in clutch switch signal circuit
(2) Disconnect clutch switch connector and ECM connector.
(3) Check continuity between signal terminal of clutch switch harness connector and ECM harness connector.
Specification : Continuity ( below 1.0Ω )
Ground Circuit inspection
1. IG KEY "OFF", ENGINE "OFF".
2. Disconnect clutch switch connector.
3. Check continuity between clutch switch connector terminal 1 and chassis ground.
Component Inspection
1. Remove the clutch switch.
2. Push the clutch switch in the direction of the arrow to make sure that continuity is cut off.

Condition Clutch Pedal pressed Clutch Pedal Released

Switch Operation ON (below 1.0Ω ) OFF ( Infinite Ω )
English
REMOVAL
1. Turn ignition switch OFF and disconnect the negative () battery cable.
2. Disconnect clutch switch connector (A).
3. Remove the clutch switch (B) by loosening a nut (A).
INSTALLATION
1. Install in the reverse order of removal.
2. Adjust the clutch switch.
(1) Adjust the gab by rotating the adjust nut (A) to satisfy the standard gap range.
Standard gap range:
0.5 ~ 1.0 mm (0.0197 ~ 0.0394 in.)
(2) Tighten the nut (B) with the specified torque.
Tightening torque:
7.8 ~ 9.8 N (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lbft)
2014 > G 1.6 TGDI > Clutch System > Clutch System > Ignition Lock Switch > Description and Operation
English
DESCRIPTION
• Ignition lock switch is mounted on the clutch pedal.
• Ignition lock switch is operated when you press the clutch pedal.
2014 > G 1.6 TGDI > Clutch System > Clutch System > Ignition Lock Switch > Specifications English
SPECIFICATIONS
Item Specifications
Working voltage DC 12V
14.7 ± 2.9N
Operating force
(1.5 ± 0.3kg, 3.3 ± 0.7lb)
40°C ~ 80°C
Working temperature
(40°F ~ 176°F)
2014 > G 1.6 TGDI > Clutch System > Clutch System > Ignition Lock Switch > Repair proceduresEnglish
INSPECTION
Signal Circuit Inspection
1. Check ignition lock switch pullup voltage
(2) Disconnect ignition lock switch connector.
(3) IG KEY "ON".
(4) Measure the voltage between signal terminal of ignition lock switch harness connector and chassis ground.
Specification : 11.5V ~ 13.0V
2. Check open in ignition lock switch signal circuit
(2) Disconnect ignition lock switch connector and ECM connector.
(3) Check continuity between signal terminal of lock switch signal harness connector and ECM harness connector.
Ground Circuit inspection
1. IG KEY "OFF", ENGINE "OFF".
2. Disconnect ignition lock switch connector.
3. Check continuity between lock switch signal connector terminal 1 and chassis ground.
Component Inspection
1. Remove the ignition lock switch.
2. Push the ignition lock switch in the direction of the arrow to make sure that continuity between terminals. (refer to the table
below)
Standard value :
Full stroke (A): 12.0 ± 0.3mm (0.4724 ± 0.0118 in.)
ONOFF point (B): 2.0 mm(0.0787 in.)

Condition Clutch Pedal pressed Clutch Pedal Released
English
Switch Operation ON (below 1.0Ω ) OFF ( Infinite Ω )
REMOVAL
1. Turn ignition switch OFF and disconnect the negative () battery cable.
2. Disconnect ignition lock switch connector (A).
3. Remove the ignition lock switch by loosening a nut (A).
INSTALLATION
2. Adjust the ignition switch.
(1) In state of full stroke, adjust the gab by rotating the adjust nut (A) to satisfy the standard gap range.
Standard gap range :
Gasoline : 3 ~ 4 mm (0.1181 ~ 0.1575 in.)
Diesel : 1 ~ 2 mm (0.0394 ~ 0.0787 in.)
(2) Tighten the nut (B) with the specified torque.
Tightening torque:
7.8 ~ 9.8 N (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lbft)
2014 > G 1.6 TGDI > Clutch System > Clutch System > Clutch Pedal > Components and Components
English
Location
COMPONENTS
1. Master cylinder 3. Clutch switch
2. Ignition lock switch 4. Pedal pad
2014 > G 1.6 TGDI > Clutch System > Clutch System > Clutch Pedal > Repair procedures English
REMOVAL
1. Remove the battery and battery tray.
G 1.6 MPI (Refer to Engine Electrical System "Battery")
D 1.6 TCIU2 (Refer to Engine Electrical System "Battery")
G 1.6 GDI (Refer to Engine Electrical System "Battery")
G 1.6 TGDI (Refer to Engine Electrical System "Battery")
2. Remove the ECM.
G 1.6 MPI (Refer to Engine Control / Fuel System "Engine Control Module")
D 1.6 TCIU2 (Refer to Engine Control / Fuel System "Engine Control Module")
G 1.6 GDI (Refer to Engine Control / Fuel System "Engine Control Module")
G 1.6 TGDI (Refer to Engine Control / Fuel System "Engine Control Module")
3. The case of diesel vehicle, remove the fuel filter.
D 1.6 TCIU2 (Refer to Engine Control / Fuel System "Fuel Filter")
4. Disconnect the clutch tube (B) and reservoir hose (A) from the clutch master cylinder.

• Do not spill brake fluid on the vehicle; it may damage the paint if brake fluid does contact the paint, wash it off
immediately with water.
[Gasoline]
[Diesel]
English
5. Disconnect the ignition lock switch connector (A) and clutch switch connector (B) and EPB stroke sensor connector (C).
6. Remove the clutch pedal mounting nuts (D3ea).
Tightening torque :
(D) 16.7 ~ 25.5 N.m (1.7 ~ 2.6 kgf.m, 12.3 ~ 18.8 lbft)
7. Remove the clutch pedal and master cylinder together.
8. Remove the master cylinder from the clutch pedal.
(1) Separate the push rod (C) after remove the pin (A) and washer (B).
(2) Remove the master cylinder by rotating in a clockwise direction.
INSTALLATION
2. After be equipped, perform bleeding air procedure in clutch release cylinder after pouring the brake fluid.
(Refer to Clutch System "Clutch release cylinder")
2014 > G 1.6 TGDI > Clutch System > Clutch System > Clutch Master Cylinder > Components andEnglish
Components Location
COMPONENTS
1. Master cylinder 3. Clutch switch
2. Ignition lock switch 4. Pedal pad
2014 > G 1.6 TGDI > Clutch System > Clutch System > Clutch Master Cylinder > Repair procedures
English
REMOVAL
1. Separate the push rod (C) after remove the pin (A) and washer (B).
2. Remove the battery and battery tray.
G 1.6 GDI (Refer to Engine Electrical System "Battery")
G 1.6 TGDI (Refer to Engine Electrical System "Battery")
3. Remove the ECM.
G 1.6 GDI (Refer to Engine Control / Fuel System "Engine Control Module")
G 1.6 TGDI (Refer to Engine Control / Fuel System "Engine Control Module")
4. The case of diesel vehicle, remove the fuel filter.
5. Disconnect the clutch tube (B) and reservoir hose (A) from the clutch master cylinder.

[Gasoline]
English
[Diesel]
6. Remove the master cylinder (A) by rotating in a clockwise direction.
INSTALLATION
2. After be equipped, perform bleeding air procedure in clutch release cylinder after pouring the brake fluid.
(Refer to Clutch System "Clutch release cylinder")
2014 > G 1.6 TGDI > Clutch System > Clutch System > Clutch Release Cylinder > Components and
English
Components Location
COMPONENTS
1. Union bolt 7. Bleeder screw
2. Gasket 8. Release cylinder
3. Tube joint 9. Return spring
4. Clutch tube 10. Piston
5. Valve plate 11. Boot
6. Valve spring 12. Push rod
2014 > G 1.6 TGDI > Clutch System > Clutch System > Clutch Release Cylinder > Repair procedures
English
INSPECTION
1. Check the clutch release cylinder for fluid leakage.
2. Check the clutch release cylinder boot for damage.
REMOVAL
1. Drain the brake fluid through the bleed plug (A).

2. Remove the clutch release cylinder assembly (C) after removing the tube (B) and bolts (A2ea).
Tightening torque:
14.7 ~ 21.6 N.m (1.5 ~ 2.2 kgf.m,10.8 ~ 15.9 lbft)
INSTALLATION

Apply the specified grease to the pushrod end.
English
Quantity: 0.4 ~ 0.8 g
ADJUSTMENT
Clutch Release Cylinder Air Bleeding Procedure

• Use the specified fluid. Avoid mixing different brands of fluid.
1. After disconnecting a cap from the clutch release cylinder air bleeder, insert a vinyl hose in the plug.
2. Refill the clutch master cylinder with the specified fluid.
Specified fluid: SAE J1703 (DOT 3 or DOT 4)
3. Loosening the plug screw, press and release the clutch pedal about 10 times.
4. Tighten the plug (A) during the clutch pedal pressed. Afterwards, raise the pedal with a hand.
5. After pressing the clutch pedal 3 times more, loosen the plug (A) and retighten it with the pedal pressed. Raise it again,
then.
6. Repeat the step 4 two or three times.
(until there is no bubble in the fluid)
Tightening torque:
6.8 ~ 9.8 N.m (0.7 ~ 1.0 kgf.m, 5.0 ~ 7.2 lbft)
7. Refill the clutch master cylinder with the specified fluid.
2014 > G 1.6 TGDI > Clutch System > Clutch System > Clutch Release Fork and Clutch Release Bearing >
English
COMPONENTS
1. Clutch release fork 3. Clutch disk assembly
2. Clutch cover assembly 4. Clutch release bearing
2014 > G 1.6 TGDI > Clutch System > Clutch System > Clutch Release Fork and Clutch Release Bearing >
English
Repair procedures
REMOVAL
2. Remove the clutch release bearing (A).
3. Pull the clip (A).
4. Remove the clutch release fork (A).
5. Remove the boot (A).
English
INSPECTION
1. Check for damage to boot.
2. Check for deformation to clutch release fork.
3. Check for deformation to clutch release bearing.
INSTALLATION
1. Install the boot (A).
2. Install the clip to the clutch release fork.
3. Apply to grease in location A, B and C.
Location Quantity (g) Remarks

A 0.3 ~ 0.5 Release bearing & Fork
B 0.5 ~ 1.0 Release Fork & Fulcrum
C 0.4 ~ 0.8 Release cylinder & Fork
4. Apply the grease to the hole surface of the clutch release bearing all around.
Amount: 0.5 ~ 1.0 g
5. Install the clutch release fork (B), clutch release bearing (A).
6. Install the transaxle assembly.
2014 > G 1.6 TGDI > Clutch System > Clutch System > Concentric Slave Cylinder Assembly > English
COMPONENT
1. Concentric slave cylinder assembly 2. Manual transaxle
2014 > G 1.6 TGDI > Clutch System > Clutch System > Concentric Slave Cylinder Assembly > Repair
English
procedures
REMOVAL
2. Remove the concentric slave cylinder assembly from the transaxle case by removing bolts (A).
Tightening torque:
19.6 ~ 26.5 N.m (2.0 ~ 2.7 kgf.m, 14.5 ~ 19.5 lbft)
INSTALLATION

• Install the concentric slave cylinder bolts. Not to be bent or twisted, Tighten them in diagonal directions.
• When it is assembled, it must be free from invasive foreign matters and oil leakage.
1. Installation is in reverse order of removal.
2. Perform bleeding air procedure in concentric slave cylinder after pouring the brake fluid.
(Refer to Concentric Slave Cylinder Assembly "Adjustment")
ADJUSTMENT
Concentric Slave Cylinder Air Bleeding Procedure
1. After disconnecting a cap from the concentric slave cylinder air bleeder, insert a vinyl hose in the plug.
2. Refill the reservoir tank with the specified fluid.

Use the specified fluid. Avoid mixing different brands of fluid.
English
3. Pump the clutch pedal about 10 times.
4. Loosen the air bleed screw (A) at hold down the clutch pedal to allow air to escape from the clutch system. Then tighten
the air bleed screw.
5. Repeat the step 2 ~ 4 until there is no bubble in the fluid.

Procee'd Clutch System

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Item N.m kgf.m lbft

Items Specified lubricants Quantity

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Condition Clutch Pedal pressed Clutch Pedal Released

Location Quantity (g) Remarks

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2014 > G 1.

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Shop DTC Body Owner's System System

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Condition Clutch Pedal pressed Clutch Pedal Released

Location Quantity (g) Remarks

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Procee'd Clutch System

Procee'd Clutch System

Item N.m kgf.m lbft