The clutch mechanism consists of a pressure and driven disc (see illustration 7.1). A hydraulic clutch drive is used, consisting of a master and slave cylinder, pipelines, a clutch pedal and a clutch release mechanism.
7.1 Clutch Mechanism Components 1. 2-mass flywheel; 2. Bolt, subject to replacement; 3. Slave disk; 4. Pressure disc; 5. Bolt, 22 Nm; 6. Needle bearing
The pressure plate is bolted to the flywheel, which is connected to the engine crankshaft. Between the pressure plate and the flywheel is a driven disk, which is pressed against the flywheel by the release bearing of the slave cylinder. The driven disk is connected to the primary shaft of the manual transmission via a splined connection.
When the clutch pedal is depressed, the brake fluid from the common reservoir is transferred under pressure through the clutch master cylinder to the slave cylinder. The release bearing of the slave cylinder acts on the pressure plate. In this case, the driven plate is moved away from the flywheel and the power connection between the engine and the manual transmission is interrupted. In the released state, the pressure spring presses the bearing against the diaphragm spring of the pressure plate. This reduces wear on the clutch pressure bearing, since it does not accelerate to the engine speed when engaged. No adjustment of the clutch drive is required.
Each time the clutch is engaged and disengaged, the friction linings of the driven disk wear out as a result of the force applied. The driven disk is a wearing part, but its average service life is quite long and depends mainly on the engine load and driving style. Wear of the diaphragm petals of the pressure disk is allowed up to half their thickness.
7.2a. Clutch release mechanism1. Slave cylinder; 2. Self-locking bolt for mounting cylinder 1, 23 Nm, subject to replacement; 3. Pipeline bracket; 4. Actuating rod; 5. Thrust bearing; 6. Self-locking bolt, 25 Nm, subject to replacement; 7. Leaf spring; 8. Clutch release lever; 9. Bolts, 3 pcs., 15 Nm; 10. Guide bushing; 11. Input shaft seal of the manual transmission; 12. Intermediate piece; 13. Manual transmission
7.2b. Clutch pedal and master cylinder assembly 1. Pedal bracket; 2. Pedal axle; 3. Retainer; 4. Bolt, 25 Nm; 5. Brake pedal; 6. Clutch pedal position sensor F36, must be replaced after removal; 7. Axle mounting bolt 2.5 Nm; 8. Clutch pedal; 9, 10. Retainer; 11. Bolt, 20 Nm; 12. Clutch master cylinder; 13. Eccentric spring, black side facing the pedal; 14. Clutch pedal sensor for engine start permission (uS models only), subject to replacement; 15. Bolt for fastening the brake master cylinder to the bracket, 25 Nm
7.2c. Clutch hydraulic drive parts 1. Brake fluid reservoir; 2. Liquid supply hose to cylinder 7; 3. Assembling hoses and tubes; 4. Compaction; 5. Bracket; 6. Clutch pedal; 7. Clutch master cylinder; 8. Bolt, 20 Nm; 9. Retainer; 10. Manual transmission; 11. Clutch slave cylinder; 12. Bleed valve, 4.5 Nm; 13. Dust cover; 14. Retainer; 15. Assembly bracket 3; 16. Self-locking cylinder mounting bolt 7, 25 Nm; 17. Retainer; 18. Compaction; 19. Tank mounting bolt 1
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