Removing
Remove gearbox.
Loosen the fixing screws (1) (6 pcs.) clutch pressure plate in turn 1-1.5 turns in one pass until the pressure plate is released. To prevent the flywheel from turning when unscrewing the bolts, fix it with a rod or a screwdriver.
Attention: If the bolts are loosened immediately, the diaphragm spring and guide pins may be damaged (2) between pressure plate and flywheel.
Finally, completely unscrew the bolts. О Remove the clutch pressure and driven plates.
Attention: The discs must not fall when removed, otherwise jerking and difficult engagement of the clutch may occur after installation.
Clean the flywheel with a cloth soaked in gasoline.
Examination
Check clutch pressure plate for burn marks and deep scratches and replace if necessary.
Check diaphragm spring for damage (arrows).
Check spring connections between pressure plate and cover for cracks, rivet fastening and tight fit. Replace disc with damaged or loose rivets.
Check the working surface of the pressure plate for scratches, burn marks and wear. Discs that have concavities up to 0.3 mm deep can be used further. Checking is done using a ruler and flat probes.
Check the flywheel for signs of overheating and gouges.
Treat the clutch pressure plate and flywheel with the finest sandpaper.
An oily or damaged driven disc must be replaced.
Measure the thickness of the clutch disc wear lining using a vernier caliper. The distance to the rivet heads must be at least 0.3 mm. Otherwise, you need to replace the driven disk. The same applies to damaged pads.
In the workshop, you can check the clutch disc for runout. Lateral runout should not exceed 0.25 mm.
Attention: This check is only necessary if the old driven disc is to be installed, and before that there were defects in the operation of the clutch.
Check the release bearing in the gearbox housing. There should be no visible signs of deformation on it. Rotate the bearing by hand. He shouldn't eat. If the bearing makes noise when the clutch is disengaged, then it also needs to be replaced.
Installation
Attention: Before installing a new clutch, remove the protective varnish from the working surface of the pressure plate with a solvent, and also wipe the flywheel.
Check the three dowel pins on the flywheel for tightness.
Approximately center the driven plate in the middle of the pressure plate. However, it is better to do this with a special rod or an old gearbox input shaft.
In specialized workshops, a special device is used. If the driven plate is not centered, it will not be possible to insert the gearbox input shaft later.
Install the pressure plate with the centered driven plate onto the corresponding dowel pins on the flywheel.
Insert the clutch pressure plate mounting bolts and screw them in by hand, and then tighten them crosswise 1-1.5 turns until the pressure plate is attracted.
Attention: Make sure that the pressure plate is evenly and without distortions attracted to the flywheel when tightening the bolts. The tightening torque for the bolts is 30 Nm.
Pull out the centering rod.
If used, remove flywheel locking tool.
Clean gearbox input shaft splines and lightly lubricate them with molybdenum based grease. Do not use too much grease, otherwise it will be squeezed out onto the clutch surfaces, causing the clutch to slip.
Install gearbox.