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05-3

1. SPECIFICATION
Description
Operating type
Clutch cover

Clutch pedal

Clutch disc

Specification
Hydraulic type

Type

Diaphragm spring strap

Adjusting type

SATIC (Self Adjusting Technology with

Integrated Cassette) type

Type

Suspended type

Max. operating travel

135 3 mm

Pedal free play (Longitudinal)

7.1 3 mm

Pedal free play (Transverse)

3 mm

Type

Dry type single diaphragm (Rigid type)

Diameter of facing

Outer: 250 1 mm
Inner:160 0.8 mm

Thickness of disc

Free: 8.7 0.3 mm

When loaded: 8.0 0.2 (at 7,800 N)

Numbers of disc

Weight

1.18 kg

Flywheel type

DMF (Dual Mass Flywheel)

Setting load of clutch cover assembly

At least 7,800 N

Clutch master cylinder Operating travel

30 mm

Inner diameter

17.46 mm

Concentric slave
cylinder

Maximum operating travel

12.55 mm

Operating pressure

Maximum 50 bar

Clutch oil

Standard

DOT 3 or DOT 4

Capacity

As required

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2. TIGHTENING TORQUE
Description

Tightening torque

Amount

Upper (17 mm)

85.0 to 100 Nm

Front (14 mm)

54.0 Nm + 20

Rear (14 mm)

51.3 to 56.7 Nm

Lower (14 mm)

56.0 to 62.0 Nm

Pressure plate assembly bolt (Hexagon 6 mm)

21.0 to 27.0 Nm

Concentric slave cylinder bolt (Hexagon 5 mm)

10 to 16 Nm

Concentric slave cylinder oil pipe nut

24.5 to 28.4 Nm

Remove the nut if it is

necessary. (Once
removed, apply the
Loctite on the thread
before installation.)

Master cylinder nut (12 mm)

7.8 to 17.6 Nm

Master cylinder oil pipe nut (10 mm)

14.7 to 17.6 Nm

Master cylinder push rod lock nut

8.8 to 13.7 Nm

Clutch oil chamber screw and bolt (10 mm)

3.9 to 7.8 Nm

Clutch housing bolt

Oil pipe nut (10 mm)

14.7 to 17.6 Nm

Clutch pedal mounting nut (12 mm)

7.8 to 17.6 Nm

Stopper bolt

16 to 22 Nm

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05-5

1. OVERVIEW
The hydraulic clutch transmits the force required to operate the clutch pedal to the concentric slave
cylinder fitted to the clutch housing as a hydraulic pressure.
(The hydraulic pressure is transmitted in the following order: Clutch pedal - Clutch master cylinder Clutch pipe - Clutch damper - Clutch pipe and hose - Concentric slave cylinder - Pressure plate Flywheel.)
If a driver depress the clutch pedal, the hydraulic pressure is generated in the master cylinder. It is
transmitted to the concentric slave cylinder through the pipe, resulting in the cylinder being forced out. At
this time, the clutch disc is forced against the cylinder by pushing the cover. This, in turn, remove the
flywheel from the pressure plate. As a consequence, the power from the engine will be cut off and the
gear change can be carried out.

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2. SATIC (SELF ADJUSTING TECHNOLOGY WITH

INTEGRATED CASSETTE)
1) System Description
Function
On the conventional clutch, the pedal force tends
to increase in proportion to the degree of disc
run-out. However, the SATIC clutch has the
adjusting function which activates the cassette
system inserted to the clutch cover to maintain a
constant pedal force and clearance when the
disc runs out. (Unlike SAT type, SATIC type
does not need SST for clutch cover removal.)

Operation
Diaphragm spring rotates the adjusting
equipment as clutch disc is wearing and so,
pressure plate is pushed to clutch disc side at the
amount of wear.
Disc wear (Free play) Diaphragm spring
(1) Adjusting equipment (2, 3) Pressure
plate (4)

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05-7

2) Overview
Driving elements
The driving elements consist of two flat surfaces machined to a smooth finish.
One of these is the rear face of the engine flywheel and the other is the clutch pressure plate. The clutch
pressure plate is fitted into a clutch steel cover, which is bolted to the flywheel.
Driven elements
The driven element is the clutch disc with a splined hub which is free to slide lengthwise along the splines
of the input shaft.
The driving and driven elements are held in contact by spring pressure. This pressure is exerted by a
diaphragm spring in the clutch cover pressure plate assembly.
Operating Elements
The clutch "release" system consists of the clutch pedal and clutch release cylinder.
This system directly releases the clutch by using hydraulic pressure while the conventional clutch system
releases the clutch by using release lever and release fork. This system provides higher efficiency than
conventional clutch system, and its durability is superior.
- Clutch master cylinder (mounted on clutch pedal)
- Concentric slave cylinder pipe (mounted inside of transmission)

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3) Layout
Clutch disc

Clutch cover assembly

Clutch setting jig

Dual mass flywheel (DMF)

Concentric slave cylinder

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05-9

3. DUAL MASS FLYWHEEL (DMF)

The dual mass flywheel (DMF) is of having a mass divided into two halves.
While one mass is connected to the engine crankshaft, which is affected by the mass moment of inertia
of the engine, the other mass is affected by one of the transmission.
The divided dual masses are connected to the coil spring and damping system internally.
The DMF has the following benefits:
-

Reducing fuel consumption by lowering engine speed

Reducing rattling noise and vehicle vibration in all driving ranges
Reducing synchronization wear
Facilitating gear change
Protecting power train parts by preventing excessive load from being delivered

1. Primary flywheel
2. Secondary flywheel
3. Arc damper spring
4. Torque limiter
5. Ring gear