Contents: Checking the pedal height ↓ Checking the pedal free play…↓ Checking the pedal free play (with…↓ Adjusting the pedal free play and…↓ Determining the Clutch Release Moment ↓ Checking the operation of the clutch…↓
Checking the pedal height
1. Measure the height from the clutch pedal to the floor surface of the passenger compartment.
Pedal height "A" - 161 mm
2. If necessary, adjust the height of the clutch pedal at point "B". Loosen the lock nut and, by turning the lock bolt, achieve the desired height of the pedal. Tighten the lock nut.
Note: After adjusting the pedal height, check and adjust the pedal free play and push rod stroke.
Checking the pedal free play (without amplifier)
1. Press the pedal until it starts to resist movement. Measure the free travel of the pedal. Free travel of the pedal "C" - 13 - 23 mm
2. If the pedal free play exceeds the permissible value, adjust it at point "E" by changing the length of the push rod.
Caution: Do not press the push rod into the master cylinder, the value "D" of the free play of the push rod before the start of the master cylinder should be within 1 - 5 mm (on top of the clutch pedal).
Checking the pedal free play (with amplifier)
1. Press the pedal until it starts to resist movement. Measure the free travel of the pedal. Free travel of the pedal "C" - 15 - 30 mm
2. Check the stroke of the pusher.
a) Turn off the engine and press the clutch pedal several times until there is no vacuum left in the booster.
b) Press the clutch pedal with a slight force until the resistance to pedal movement begins to increase, then measure the stroke of the push rod on the top of the pedal.
Pusher stroke "D" - 5 - 9 mm
Note: The pushrod stroke corresponds to the pedal stroke as long as the booster piston provides movement of the check valve.
Adjusting the pedal free play and push rod stroke
Note: For booster models, disconnect the vacuum line from the clutch booster before adjusting.
1. At point "E", loosen the lock nut and rotate the push rod until the pedal free play and push rod travel values become equal to the standard value.
2. Tighten the lock nut.
3. Check the pedal height.
Determining the Clutch Release Moment
1. Apply the parking brake lever and place chocks under the vehicle wheels.
2. Start the engine at idle speed.
3. Without pressing the clutch pedal, slowly move the gear shift lever to the reverse position until you feel the noise of the gears contacting.
4. Gradually depress the clutch pedal and measure the pedal travel from the point where the gear noise disappears (switch-off point) to the end point of the pedal's full travel.
Pedal travel: 25mm or more
5. If the clutch pedal travel differs from the specified value, perform the following operations:
- a) Check the pedal height.
- b) Check the pedal free play
- c) Bleed the clutch hydraulic drive.
- d) Check the condition of the clutch housing cover.
Checking the operation of the clutch booster
Note: If the amplifier is not sealed, the amplifier must be repaired before testing.
1. Operational check.
a) Turn off the engine and press the clutch pedal several times
b) Set the pedal to the middle position. Start the engine. If the pedal moves slightly downwards, the booster is working properly. If there is no change, the booster is faulty.
2. Checking the tightness of the amplifier,
a) With the engine off, press the clutch pedal several times. Start the engine. Press the clutch pedal and make sure that the resistance to pedal movement is less than with the engine off.
b) Run the engine for a few minutes to create sufficient vacuum in the booster, then turn off the engine. Press the clutch pedal and make sure that the resistance to pedal movement is equal with the engine running and with the engine stopped
Note: If necessary, check the operation of the clutch booster check valve.