Removal and installation - all models
1. If the engine/transmission unit is not removed from the vehicle, the clutch release mechanism can only be accessed after removing the transmission.
2. Installation is described in Section 6.
Disassembly and assembly - 1.6 liter models
3. Remove the two spring clips, release the release fork, and move the release bearing away from the guide sleeve. Unfasten the spring clamps from the bearing tongues.
4. Rotate the release shaft, knock the fork pin out with a hammer and a thin bit (see fig. 5.13).
Pic. 5.13. Knocking out the release fork fastening keys - 1.6 liter models
5. Remove the release lever and shaft, fork and return spring.6 The oil seal of the rotary sleeve is installed in the clutch housing in the release shaft. The bushing can be removed using a bearing puller. Install the new bushing into the housing.
7. When installing, lightly coat the release shaft with molybdenum grease and insert it into the housing (photo). Place the return spring on the shaft with its straight end against the wall of the clutch housing, and place the release fork.
13.7. Lubricate the running surfaces of the clutch release shaft bearing - 1.6 liter models
8. Insert the shaft completely into the lower bearing, then rotate the shaft to align the release fork holes with the seats on the shaft and insert the fork into place, sliding it onto the pins. Install the return spring as shown in Fig. 5.13.
9. Fasten the spring clamps on the release bearing tongues (photo).
13.9. Install the spring clips onto the release bearing tongues - 1.6 liter models
10. Place the release bearing on the guide sleeve until the spring clamps snap into place at the end of the fork.
Disassembly and assembly - all other models
11. Pull off the rubber dust cap on the clutch housing and from the release fork. Remove the retainer spring.
12. Move the release fork upwards from the clutch housing until the spring clamps of the release bearing are unfastened from the ends of the fork. Remove the release bearing and fork. Note the position of the spring clamps before unfastening them from the release bearing tongues.
Pic. 5.12. View of the clutch release mechanism - 1.6 liter models
13. Assembly is carried out in reverse order. Check the correct location of the spring clamps and snap them onto the release bearing tongues.
14. Check that the retaining spring is in place on the release fork, insert the fork into the cutout in the clutch housing from the inside and fit the release bearing to the fork. Install the bearing on the guide sleeve.
Pic. 5.14. View of the clutch release mechanism - 1.8 and 2.0 liter models
15. Install the retainer springs. Install the rubber dust cap.