Removal, inspection and installation of clutch components (Opel Corsa C)

Caution: Remember that dust generated during wear of the clutch slave disk friction linings may contain asbestos, which is harmful to health. Do not blow off dust with compressed air and try not to inhale it. Do not use petroleum-based solvents to wipe clutch components - use only special brake cleaners or pure methyl alcohol. Place used rags in a hermetically sealed container.

Removal

1. To gain access to the clutch assembly, it is necessary to first remove the gearbox (see Part B).

Note: If the engine was not removed from the vehicle, it is recommended to additionally support it with a jack or install special stands under it.

If you plan to reuse the same clutch basket, mark its position on the flywheel (in the absence of factory marks).

2. Install the special device KM-6263 (see accompanying illustration), tighten the mounting and adjusting bolts by hand. Be careful - the lower mounting bolts of the device must be attached to the engine block, and in no case to the oil pan.





3. To center the clutch on the F13 and F17 manual transmissions of all modifications, use the KM-6263-21 attachment, and on the F23 manual transmission, use the KM-6263-20 attachment. Insert the centering rod (see accompanying illustration) with the appropriate attachment through the shaft hole with the pressing mandrel into the central journal of the engine crankshaft, center the KM-6263 device and tighten the bolts using the tool.



4. Screw in (clockwise) shaft with the release mandrel until the latter comes into contact with the working edges of the diaphragm spring petals. Continue screwing the shaft in until it stops - the mandrel will compress the spring and separate the clutch discs.

5. Lock the flywheel from turning (see Chapter 2, Section 5), unscrew the 6 bolts securing the clutch to the engine flywheel in a diagonal order.

6. Smoothly turning inside out (counterclockwise) shaft with the release mandrel, completely release the diaphragm spring. Holding the basket, remove the centering rod and remove the clutch assembly - use the help of an assistant if necessary.



7. After completing the procedure, remove the KM-6263 device from the engine block.

Examination

8. Most often, the malfunction of the clutch is associated with wear of the friction linings of the driven disk. However, it is necessary to carefully examine the condition of all other components of the assembly.

9. Examine the working surface of the flywheel for cracks, traces of overheating, grooves and other damage - replace the flywheel if necessary (see Chapter 2). Also check the condition and evaluate the flatness of the mating surface of the clutch pressure plate (see accompanying illustration).



10. Assess the degree of wear of the friction linings of the driven clutch disc. The surface of the linings should rise above the rivet heads by at least 1.6 mm. Make sure that all rivets are tightly seated, check the torsion springs/dampers for cracks, signs of deformation and other mechanical damage (see accompanying illustration). Oiling of friction linings most often occurs due to failure of the crankshaft oil seal, damage to the integrity of the oil pan gasket, the sealing element of the actuator cylinder assembly, or the oil seal of the primary shaft of the manual transmission - replace the damaged components.





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11. It is advisable to replace the release bearing together with the driven disk (see Section 3). If the driven disk is OK, check the condition of the release bearing - the bearing should rotate smoothly, without signs of jamming. The mating surfaces should be absolutely smooth and undamaged, without cracks, burrs or dents. If you are not sure of the bearing condition, replace the slave cylinder assembly (see Section 3).

12. Assess the condition of the machined surfaces and petals of the diaphragm spring of the pressure plate (see accompanying illustrations). If defects are detected, replace the basket assembly. Light polishing traces can be removed with fine-grained sandpaper. A restored clutch assembly can always be purchased on an exchange basis through Opel branded service stations.

Installation

13. Make sure that the mating surfaces of the flywheel and clutch discs are absolutely clean and dry; if necessary, wipe the working surfaces with solvent.

14. Install the friction disc with the protruding part of the hub away from the flywheel. The disc is usually marked at the factory indicating which side it should be installed towards the flywheel.

15. Install the clutch basket - if you are installing an old basket, make sure that the alignment marks made during dismantling are correct. Screw in the basket mounting bolts and tighten them only by hand for now to ensure that the driven disk can be centered without any obstacles.



16. Install the KM-6263 device, insert the centering rod.

Note: Alignment is necessary so that when installing the gearbox, its input shaft passes through the splines in the disc and enters the guide sleeve in the crankshaft journal.

17. Using a pressing mandrel, completely unload the clutch discs (see above) and, in several steps, in a diagonal order, evenly tighten the basket mounting bolts to the required force. Remove the centering rod and remove the device.

18. Install the gearbox in place.