CLUTCH - R + R

Operation 1810A20 · CLUTCH MECHANISM

1.9 JTS, 2.2 JTS

Removing

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

Op. 1076B72 INTERMEDIATE EXHAUST PIPE WITH HOSE SECTION - R+R

Op. 4410D10 FRONT SUSPENSION FRAME - R+R

Op. 5530B10 BATTERY - R+R

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

Op. 1072C43 EXHAUST MANIFOLD UPPER BULKHEAD R R

Op. 1072C42 EXHAUST MANIFOLD LOWER BULKHEAD 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 the pins (4a) are in contact with the 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. 1072C42 EXHAUST MANIFOLD LOWER BULKHEAD R R

Op. 1072C43 EXHAUST MANIFOLD UPPER BULKHEAD R R

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

Op. 5530B10 BATTERY - R+R

Op. 4410D10 FRONT SUSPENSION FRAME - R+R

Op. 1076B72 INTERMEDIATE EXHAUST PIPE WITH HOSE SECTION - R+R

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

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. 1076B72 INTERMEDIATE EXHAUST PIPE WITH HOSE SECTION - R+R

Op. 4410D10 FRONT SUSPENSION FRAME - R+R

Op. 5530B10 BATTERY - R+R

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

Op. 1084A16 OIL DIPSTICK PIPE - R.R

Op. 1048A50 TURBOCHARGER AIR INTAKE PIPE - R.R.

Op. 4410A80 DAMPER LOWER FORK - R R

(left and right sides).

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

1. Fit the flywheel lock.

2. With the centering tool (2a) 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 drip tray centering tool.

3. Remove the flywheel lock.

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

Op. 4410A80 DAMPER LOWER FORK - R R

(left and right sides).

Op. 1048A50 TURBOCHARGER AIR INTAKE PIPE - R.R.

Op. 1084A16 OIL DIPSTICK PIPE - R.R

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

Op. 5530B10 BATTERY - R+R

Op. 4410D10 FRONT SUSPENSION FRAME - R+R

Op. 1076B72 INTERMEDIATE EXHAUST PIPE WITH HOSE SECTION - R+R

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

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

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

Op. 0010T67 HYDRAULIC CLUTCH SYSTEM - BLEED AIR

- Remove the vehicle from the lift.

- Connect the negative battery terminal.

2.4 JTD 20V

- On this vehicle in order to remove-refit the clutch, the power unit must be removed-refitted.

Op. 1004B10 POWER UNIT WITH MANUAL GEARBOX - R.R

and then dismantled at the bench.

Op. 1004D10 POWER UNIT (MANUAL GEARBOX), REMOVED, DISMANTLE AND REASSEMBLE

The latter operation includes removal/refitting of the clutch.

3.2 JTS