Clutch Disc - 1.6L

WARNING: This page is about a different car, the 2007 Chrysler PT Cruiser. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Release Bearing & Lever

Courtesy of CHRYSLER LLC

1 - RELEASE BEARING

2 - LEVER

WARNING: DaimlerChrysler does not manufacture any vehicles or replacement parts that contain asbestos. Aftermarket products may or may not contain asbestos. Refer to aftermarket product packaging for product information. Whether the product contains asbestos or not, dust and dirt can accumulate on manual clutch parts during normal use. Follow practices prescribed by appropriate regulations for the handling, processing and disposing of dust and debris

Inspect clutch release bearing (1) and lever (2) for excessive wear and replace as necessary. See Fig 1.

Fig 2: Identifying Flywheel & Crankshaft Flange

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1 - FLYWHEEL

2 - BOLT (8)

3 - CRANKSHAFT FLANGE

Clean the surfaces of the flywheel (1) and pressure plate to make certain that all oil, grease and rust have been removed. See Fig 2.
Verify the crankshaft mounting flange is free of debris, oil, grease, etc. Position the flywheel (1) onto the engine crankshaft.

Install and torque the flywheel-to-crankshaft bolts (2) to 95 N.m (70 ft. lbs.).

Fig 3: Clutch Disc & Pressure Plate

Courtesy of CHRYSLER LLC

1 - FLYWHEEL

2 - CLUTCH DISC

3 - PRESSURE PLATE

4 - BOLT (6)

Apply a very light coating of grease to the splines in the clutch disc hub.
Position the clutch disc (2) to the flywheel. Make sure the side marked "FLYWHEEL SIDE" faces the flywheel (1). See Fig 3.

Install the clutch pressure plate (3) to the flywheel (1) and clutch disc (2). Finger tighten the six pressure plate-to-flywheel bolts (4).

Fig 4: Identifying Flywheel, Clutch Pressure Plate & Clutch Alignment Tool

Courtesy of CHRYSLER LLC

1 - FLYWHEEL

2 - PRESSURE PLATE

3 - CLUTCH DISC ALIGNMENT TOOL

Use Clutch Alignment Tool 6724 (3) to position the clutch disc to the center of the flywheel (1). See Fig 4.

Fig 5: Clutch Disc & Pressure Plate

Courtesy of CHRYSLER LLC

1 - FLYWHEEL

2 - CLUTCH DISC

3 - PRESSURE PLATE

4 - BOLT (6)

Tighten pressure plate bolts (4) evenly and in rotation a few threads at a time. See Fig 5. The bolts must be tightened evenly and to specified torque to avoid distorting the pressure plate. .
Using a "criss-cross" pattern, torque the pressure plate-to-flywheel bolts to 28 N.m (250 in. lbs.). Remove the clutch disc alignment tool.
Apply light coat of Mopar® High Temperature Bearing Grease or equivalent to clutch disc hub and splines of transmission input shaft.
CAUTION: Do not over lubricate shaft splines. This will result in grease contamination of disc.
Install transaxle. Refer to INSTALLATION .