For 1990-2009 cars

### Removal Procedure

#### Tools Required

• | J 34860 Clutch Alignment Arbor

• | J 35271 Flywheel Holder

• | J 7872 Magnetic Base Indicator Set

• | J 26900-5 Vernier Caliper

1. Remove the manual transaxle assembly from the vehicle. Refer to Transmission Replacement in Manual Transmission.
2. Install J 35271 in order to hold the flywheel (3) stationary.
3. Install J 34860 in order to support the clutch disc during removal.
4. Slowly and evenly loosen the 6 cover bolts (2) from the clutch pressure plate until the tension of the spring is completely released.
5. Remove the 6 cover bolts, and remove the pressure plate from the flywheel.

Important: Do not use solvents, mineral spirits, or other cleaning agents that contain alcohol on the clutch disc (1). Solvents on the clutch disc causes slipping and premature clutch wear.

6. Remove the clutch disc and J 34860 from the flywheel.
7. Remove the J 35271 from the flywheel.
8. Use J 7872 in order to measure the flywheel.

Important: Before removal, index the flywheel (1) in relation to the crankshaft with a china marker in order to verify correct installation. Engine imbalance and/or transaxle imbalance results if the flywheel is not installed in the position from which the flywheel was removed.

9. Use J 7872 a flywheel wrench in order to slowly turn the flywheel (1). Use the in order to measure the flywheel for runout. Resurface or replace the flywheel if the flywheel runout exceeds 0.1 mm (0.004 in).
10. If the flywheel needs resurfacing, remove the flywheel bolts and the flywheel from the crankshaft. Observe the flywheel position on the crankshaft.
11. Clean the flywheel (2) and the mating surfaces between the clutch pressure plate and the clutch disc (1,3).
12. Clean the clutch disc (1) using a clean dry cloth.
13. Inspect the flywheel (2) and the clutch pressure plate (3) for the following conditions:

• | Cracks

• | Heat checking

• | Grooves

• | Excessive wear

• | Pressure plate spring levers that are bent or broken

• | A weak diaphragm spring or a damaged diaphragm spring

Notice: If any of the following conditions exist, do not attempt to disassemble or repair the clutch pressure plate. If the flywheel or the clutch pressure plate appears excessively worn, replace the flywheel and/or clutch pressure plate as necessary.

14. Inspect the clutch pilot bearing for smooth rotation. Replace the clutch pilot bearing if the clutch pilot bearing does not spin freely. Refer to Clutch Pilot Bearing Replacement .
15. Inspect the clutch disc for the following conditions:

• | Cracks

• | Excessive wear

• | Damaged torsional springs or weak torsional springs

16. Use J 26900-5 in order to measure the clutch disc (1) wear. Measure the depth of each rivet head depression (2).

Measurement

• | 1.2 mm (0.05 in) for the 1.0-liter engine

• | 1.5 mm (0.06 in) for the 1.3-liter engine

17. Replace the clutch disc if the clutch rivet depth is less than 0.5 mm (0.02 in).
18. Use J 7872 in order to measure the clutch disc (1) for runout. Place the clutch disc between the 2 horizontal arbors. Slowly turn the clutch disc while measuring runout. Replace the clutch disc if the clutch disc runout exceeds 0.8 mm (0.031 in).

### Installation Procedure

#### Tools Required

• | J 34860 Clutch Alignment Arbor

• | J 35271 Flywheel Holder

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

1. If you removed the flywheel, install the flywheel (1) to the crankshaft in the same position (3) from which the flywheel was removed. Secure the flywheel with the six flywheel bolts (2).

Tighten

• | Tighten the flywheel bolts for the 1.0-liter engine to 61 N·m (45 lb ft).

• | Tighten the flywheel bolts for the 1.3-liter engine to 78 N·m (57 lb ft).

2. Use J 35271 in order to hold the flywheel stationary.
3. Install the clutch disc to the flywheel with the torsion springs offset toward the transaxle. Use the J 34860 in order to center the clutch disc, and hold the clutch disc in place on the flywheel.
4. Install the clutch pressure plate to the flywheel. Install the 6 cover bolts in order to retain the flywheel.

Tighten
Tighten the cover bolts to 23 N·m (17 lb ft).

5. Remove the J 35271 and the J 34860 .
6. Lubricate the transaxle input shaft splines (2) and the clutch release bearing with a thin coat of GM P/N 1051344 or of an equivalent lubricant.
7. Lubricate the clutch pilot bearing (1) with a thin coat of the GM P/N 1051344 or of an equivalent wheel-bearing lubricant.
8. Install the manual transaxle assembly into the vehicle. Refer to Transmission Replacement in Manual Transmission.
9. Adjust the clutch pedal free travel. Tighten or loosen the clutch cable adjustment nut (5) until the clutch pedal free travel is within specifications. Refer to Clutch Pedal Free Travel Adjustment .