Warning: Please note that the dust generated by the wear of the friction disc linings may contain asbestos, which is harmful to health. Never blow off dust with compressed air and try not to inhale it. Do not use gasoline-based solvents to clean clutch components. Use only special cleaner or methanol.
Removing
1. Remove the transmission (see related section).
2. Mark the pressure plate assembly and flywheel with chalk or marker before removing the clutch.
3. Working in a diagonal sequence, evenly and gradually loosen the pressure plate bolts by turning them half a turn at a time, then unscrew the bolts by hand.
Warning: It is critical to loosen the pressure plate bolts evenly to avoid deforming the diaphragm spring. Models with solid flywheel (this is not possible for a compound flywheel) Opel dealers use a special tool to compress the diaphragm spring, then fix it in this state with special brackets (see illustration 6.3). Removing these brackets and installing them on the new pressure plate requires the use of a press.
4. Remove the pressure plate assembly and remove the friction plate, noting its orientation.
Inspection
Note: Due to the length and complexity of the removal and installation of clutch components, it is recommended to change the friction plate, pressure plate assembly and release bearing after each removal of the engine or transmission.
5. Remove the clutch assembly.
6. When cleaning clutch components see Warning, given at the beginning of this chapter.
7. Examine overlays of a frictional disk. If they are cracked, burned, worn or otherwise damaged, or contaminated with oil/grease (black shiny spots), the friction disc must be replaced.
8. If the pads are still serviceable, check the hub grooves for wear. Make sure damper springs are in good condition and securely attached, and that all rivets are in place. If not, replace friction disc.
9. If the friction lining is contaminated with oil, this may be due to leakage from the crankshaft oil seal, sump/cylinder block joint, or release cylinder assembly (through the transmission input shaft seal or O-ring). Replace crankshaft oil seal or sump gasket (see related section), before installing a new friction disc. The assembly of the release cylinder is described in Chapter 4 this section.
10. Inspect the pressure plate assembly for damage and signs of wear. Shake it to check for broken rivets and diaphragm spring retainers. Check that the plates holding the pressure plate to the clutch housing do not show signs of overheating (bright yellow or blue spots). If the diaphragm spring is worn or damaged, or if its pressure is weakened, replace the pressure plate.
11. Inspect the working surfaces of the pressure plate and flywheel; they must be clean, perfectly even and smooth. If one of the components is either discolored from overheating or cracked, it should be replaced. However, minor damage of this nature can sometimes be sanded off using sandpaper.
12. Make sure the release bearing rotates smoothly and easily, without noise or jerks. Also check its surface - it should be smooth and free from cracks, pitting and worn spots. If there is any doubt as to its condition, replace the bearing (see Chapter 4 of this section).
Installation
13. Make sure that the working surfaces of the flywheel and pressure plate are clean and smooth. Remove protective grease from new components with a solvent.
14. Install the friction disc with the spring hub facing the pressure plate (see illustration).
15. Establish assemblage of a pressure disk, having combined made during removal of a label. Insert the pressure plate bolts, but tighten them only by hand for now, so that the friction plate can still move.
16. The friction disc must be centered so that when the transmission is installed, its input shaft can pass through the disc hub.
17. To do this, insert a screwdriver or some kind of long rod through the friction disc into the recess in the end of the crankshaft and move the disc in the desired direction so that the crankshaft recess is exactly in the center of the disc hub. Alternatively, a special centering tool can be used (see illustration) or make a home-made tool from a metal or wooden pin, close in diameter to the recess in the crankshaft and having a thickening in contact with the hub of the friction disk, corresponding to the diameter of the disk hole.
18. After the friction plate is centered, tighten the pressure plate bolts evenly and in a diagonal sequence with the tightening torque specified specifications. When finished, remove the centering tool. Where necessary, remove the clamps from the pressure plate.
Warning: It is critical to tighten the pressure plate bolts evenly so as not to deform the diaphragm spring.
19. Install the transmission (see related section).
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