CLUTCH - R + R

Operation 1810A20 · CLUTCH MECHANISM

2.2

Removing

Op. 4450B12 FRONT WHEELS (TWO) - R+R

Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R.

Op. 7055B91 RIGHT FRONT WHEEL ARCH LINER - R.R.

Op. 7055B90 LEFT FRONT WHEEL ARCH LINER - R.R.

Op. 1080B95 REAR LAMBDA SENSOR TO CATALYTIC CONVERTER - R.R

Op. 1076B18 RIGID SECTION OF EXHAUST PIPE BETWEEN CATALYTIC CONVERTER AND SILENCER - R + R

Op. 7055A43 CENTRE FRONT GRILLE - R.R.

Op. 4410D10 FRONT SUSPENSION FRAME - R+R

Op. 5530B10 BATTERY - R+R

Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R

Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R.

Op. 2110A10 MANUAL GEARBOX AND DIFFERENTIAL - R + R

1. Fit the flywheel lock.

2. Unscrew the three bolts spaced at 120° securing the clutch cradle.

3. Fit the locating pin (3a) and the remaining part of tool (3b), tightening bolts (3c) into the sockets of the bolts removed previously.

4. Turn the tool handwheel until pins (4a) are in contact with disc (4b).

5. Undo the remaining bolts securing the clutch cradle.

6. Undo the tool handwheel to discharge the clutch mechanism diaphragm spring.

- Remove the tool.

7. Remove the clutch tray.

- Remove the clutch plate.

Refitting

1. Fit the tool locating pin into the crankshaft.

2. Refit the clutch mechanism in position.

It is not possible to replace the cltuch plate on its own. Instead the clutch plate/cradle assembly must be replaced.

When fitting the clutch plate the correct position is shown by the words "engine side" and "gearbox side".

Handle the clutch plate carefully. Do not touch the surfaces of the friction linings with your hands.

Clean any anti-corrosion protection or detergents from the friction surface of the clutch tray.

3. Fit the remaining part of tool (3a) for fitting the clutch device and tighten bolts (3b).

4. Turn the tool handwheel until pins (4a) are in contact with disc (4b).

5. Hand tighten the three free retaining bolts until the clutch device is packed together.

6. Undo the tool handwheel to discharge the clutch mechanism diaphragm spring.

- Remove the tool.

- Tighten the remaining clutch fixing bolts by hand.

- Gradually tighten the bolts fixing the clutch diagonally until the recommended torque is reached.

7. Remove the flywheel lock.

Op. 2110A10 MANUAL GEARBOX AND DIFFERENTIAL - R + R

Op. 7055B54 UNDER ENGINE PROTECTION/GUARD - R.R.

Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R

Op. 5530B10 BATTERY - R+R

Op. 4410D10 FRONT SUSPENSION FRAME - R+R

Op. 7055A43 CENTRE FRONT GRILLE - R.R.

Op. 1076B18 RIGID SECTION OF EXHAUST PIPE BETWEEN CATALYTIC CONVERTER AND SILENCER - R + R

Op. 1080B95 REAR LAMBDA SENSOR TO CATALYTIC CONVERTER - R.R

Op. 7055B90 LEFT FRONT WHEEL ARCH LINER - R.R.

Op. 7055B91 RIGHT FRONT WHEEL ARCH LINER - R.R.

Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R.

Op. 4450B12 FRONT WHEELS (TWO) - R+R

Op. 0010T64 BRAKE AND/OR CLUTCH FLUID CHECK LEVEL AND TOP UP AS NECESSARY

Op. 0010T67 HYDRAULIC CLUTCH SYSTEM - BLEED AIR

Op. 0010T41 MANUAL GEARBOX OIL CHECK LEVEL AND TOP UP IF NECESSARY

1.9 JTD 8v, 1.9 JTD 16v

Removing

- Position the vehicle on a lift.

- Make sure that the ignition key is in the OFF position, then disconnect the battery terminal (-).

Op. 4450B12 FRONT WHEELS (TWO) - R+R

Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R.

Op. 7055B91 RIGHT FRONT WHEEL ARCH LINER - R.R.

Op. 7055B90 LEFT FRONT WHEEL ARCH LINER - R.R.

Op. 1080B95 REAR LAMBDA SENSOR TO CATALYTIC CONVERTER - R.R

Op. 1076B18 RIGID SECTION OF EXHAUST PIPE BETWEEN CATALYTIC CONVERTER AND SILENCER - R + R

Op. 7055A43 CENTRE FRONT GRILLE - R.R.

Op. 4410D10 FRONT SUSPENSION FRAME - R+R

Op. 5520B10 STARTER MOTOR - R+R

Op. 2110A10 MANUAL GEARBOX AND DIFFERENTIAL - R + R

1. Fit the flywheel lock.

2. With the centering tool (2) fitted, undo the bolts (2b) and remove the clutch drip tray (2c).

- Remove the clutch plate.

Refitting

1. Place the clutch plate and the clutch tray (1a) in their housing using the tool (1b) for centering.

2. Tighten the new bolts securing the clutch tray to the recommended torque.

- Remove the clutch plate and clutch tray centering tool.

3. Remove the flywheel lock.

Op. 2110A10 MANUAL GEARBOX AND DIFFERENTIAL - R + R

Op. 5520B10 STARTER MOTOR - R+R

Op. 4410D10 FRONT SUSPENSION FRAME - R+R

Op. 7055A43 CENTRE FRONT GRILLE - R.R.

Op. 1076B18 RIGID SECTION OF EXHAUST PIPE BETWEEN CATALYTIC CONVERTER AND SILENCER - R + R

Op. 1080B95 REAR LAMBDA SENSOR TO CATALYTIC CONVERTER - R.R

Op. 7055B90 LEFT FRONT WHEEL ARCH LINER - R.R.

Op. 7055B91 RIGHT FRONT WHEEL ARCH LINER - R.R.

Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R.

Op. 4450B12 FRONT WHEELS (TWO) - R+R

Op. 0010T64 BRAKE AND/OR CLUTCH FLUID CHECK LEVEL AND TOP UP AS NECESSARY

Op. 0010T67 HYDRAULIC CLUTCH SYSTEM - BLEED AIR

Op. 0010T41 MANUAL GEARBOX OIL CHECK LEVEL AND TOP UP IF NECESSARY

- Connect the negative battery terminal.

- Remove the vehicle from the lift.

1.8

Removing

Op. 7040D30 ENGINE BAY FRONT BEAM COVER - R R

Op. 4450B12 FRONT WHEELS (TWO) - R+R

Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R.

Op. 1080B95 REAR LAMBDA SENSOR TO CATALYTIC CONVERTER - R.R

Op. 1076B18 RIGID SECTION OF EXHAUST PIPE BETWEEN CATALYTIC CONVERTER AND SILENCER - R + R

Op. 4410D10 FRONT SUSPENSION FRAME - R+R

Op. 5530B10 BATTERY - R+R

Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R

Op. 2110A10 MANUAL GEARBOX AND DIFFERENTIAL - R + R

1. Diagonally undo the bolts securing the clutch mechanism to the flywheel and remove it.

- Remove the clutch plate.

Refitting

- Refit the clutch plate in position.

- Place the clutch mechanism in position using a suitable centering tool and tighten the bolts fixing it to the engine flywheel diagonally to the recommended torque.

Op. 2110A10 MANUAL GEARBOX AND DIFFERENTIAL - R + R

Op. 5530B52 BATTERY SUPPORT/DRIP TRAY - R.R

Op. 5530B10 BATTERY - R+R

Op. 4410D10 FRONT SUSPENSION FRAME - R+R

Op. 1076B18 RIGID SECTION OF EXHAUST PIPE BETWEEN CATALYTIC CONVERTER AND SILENCER - R + R

Op. 1080B95 REAR LAMBDA SENSOR TO CATALYTIC CONVERTER - R.R

Op. 7055B66 ENGINE COMPARTMENT DUST COVER IN RIGHT FRONT WHEEL ARCH - R.R.

Op. 4450B12 FRONT WHEELS (TWO) - R+R

Op. 7040D30 ENGINE BAY FRONT BEAM COVER - R R