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Tips for CLUTCHES, CLUTCH KIT Clutch fitting instructions for 4PKit 835015 and how it is implemented | Valeo Service

Fitting Instruction for CLUTCHES, CLUTCH KIT, 835015 - Valeo Service

Clutch fitting instructions for 4PKit 835015

<h3>Iveco</h3>
			<ul><li>Daily (99&gt;2004) 2.3 TD</li>
			</ul>

Applications

<h3>Manipulation of the friction disc</h3>
				<ul><li>The friction disc is an essential part for the performance of the 4P clutch kit. It must be handled with particular care.</li>
					<li>To avoid any grease contamination of the facings, wear clean gloves and avoid as much as possible contact with the facings.</li>
					<li>The friction disc includes a complex damping system, which is very sensitive to shocks and pollution (grease, oil). Excessive grease applied at the hub splines will be distributed by centrifugal forces and could destroy the function of the system. Be careful at the greasing operations.</li>
					<li>Disc position printed in one of the faces.</li>
				</ul><h3>Manipulation of the clutch cover</h3>
				<ul><li>Most fragile parts of the clutch cover are the return straps. Avoid put it under pressure or hit the cover.</li>
				</ul>

Caution

<h3>After disassembling the gearbox from the engine</h3>
				<ol start="1"><li>Check engine crankshaft seal : Verify that there is not oil contaminating the flywheel. If an oil leack detected, after remove the flywheel, change the crankshaft seal.</li>
					<li>Check gearbox input shaft splines checking that there is not damaged or show excessive wear along the spline length.</li> 
					<li>Prevent the flywheel from rotating and remove the flywheel fixing bolts.</li> 
					<li>Check the gear box input shaft seal : Verify that there is not oil comming from the gear box. If an oil leak is present repair the gearbox by changing the input shaft seal.</li> 
					<li>Check the clutch release system:
						<ul><li>Check the guide tube surface: Checking there are no marks or excessive wear.</li>
						<li>Check the clutch fork: check for excessive wear at connecting and pivot points.</li>
						</ul></li>
					<li>Check that the push rod connected to the slave cylinder can move, sliding smoothly when it is pushed and it doesn’t leak oil.</li>
				</ol><img alt="835015-1.JPG" data-entity-type="file" data-entity-uuid="979ca526-dc49-4cbf-892a-01ae0a374fd7" src="https://api.techassist.valeoservice.systems/sites/default/files/node/fitting_instructions/assets/FI-CL-835015/FI-CL-835015__835015-1.jpg" /><h3>Prepare the clutch for assembly</h3>
				<ol start="7"><li>Apply a small quantity of grease in the hub splines at approximatly 5 mm of the hub extremity.</li>
					<li>Apply a small quantity of grease to the release bearing (internal diameter and contact area with the fork) and in the fulcrum fork.</li>
				</ol><img alt="835015-2.JPG" data-entity-type="file" data-entity-uuid="ebc86248-7521-4678-98eb-d7491ff32bed" src="https://api.techassist.valeoservice.systems/sites/default/files/node/fitting_instructions/assets/FI-CL-835015/FI-CL-835015__835015-2.jpg" /><h3>Fasten the flywheel</h3>
				<ol start="9"><li>Position carfully the new flywheel Valeo on the crankshaft center and tightenning the bolts (M12×1.25-6h,hexagonal head) with a progessive torque following a star sequence, taking care not to apply excessive torque. 
						<ul><li>Tigtenning torque: 30 Nm + apply a torque angle of 90º over each bolt.</li></ul></li>
				</ol><img alt="835015-3.JPG" data-entity-type="file" data-entity-uuid="c8b9c17c-c4f1-41c4-997a-e0d31ae67e0e" src="https://api.techassist.valeoservice.systems/sites/default/files/node/fitting_instructions/assets/FI-CL-835015/FI-CL-835015__835015-3.jpg" /><h3>Fasten the clutch and release bearing</h3>
				<ol start="10"><li>Position the driven plate in the flywheel using an alingment tool (see the photo).</li>
					<li>Fasten the cover assy centering it with the pins and hand thightening 3 screws at 120º and checking that the driven plate remains stable and well centered with the alingment tool.</li>
					<li>Carefully Tighten each bolt using a star-like sequence simular to that used for the flywheel. The diaphragm fingers have to move as uniform as possible to prevent distortion. 
						<ul><li>Repeat the complete sequence approximately 3 times.</li>
							<li>Use screws M8×1.25×15.5 with a internal hexagonal (Allen) head.</li>
						</ul></li>
					<li>Complete the installation apply a torque of 25Nm using a torque wrench following the previous sequence.</li>
					<li>Assemble the release bearing on the guide tube and check that it slides correctly.</li>
				</ol><img alt="835015-4.JPG" data-entity-type="file" data-entity-uuid="3603c2c7-ebec-48e9-99ed-8d8c9ff35b81" src="https://api.techassist.valeoservice.systems/sites/default/files/node/fitting_instructions/assets/FI-CL-835015/FI-CL-835015__835015-4.jpg" /><h3>Re-assemble the gearbox</h3>
				<ol start="15"><li>Check that the dowel pins are existing and that they are not damaged.</li> 
					<li>Position the gearbox in line with the engine crankshaft, supporting the gearbox weight with the appropriate tools.</li> 
					<li>Introduce the gearbox input shaft into the driven plate hub spline.</li>  
					<li>Take care that the input shaft is introduced without force onto the drive plate splines. If necessary rotate the crankshaft to make input shaft entry easier.
						<div class="simple">Avoid supporting the weight of the gearbox on the drive plate during the assembly.</div>
					</li> 
					<li>Check that the gearbox is in full contact with the engine block and that the centering pins are well fitted</li> 
					<li>Finally fasten the gearbox to the engine block tightening the screws with the appropriate torque.</li>
				</ol>

Fitting Instructions

<h3>After the assembly</h3>
			<ol><li>In order to prevent excessive clutch preload, smoothly push the clutch pedal by hand (with one or two fingers), to measure a free-play of 10 to 15 mm. In case of a self adjusting cable actuation system, check the wear compensation mechanism and replace it if necessary.</li>
				<li>Check the clutch functions.
					<ul><li>Disengage and reengage the clutch shifting each gear ratio (including reverse).</li>
						<li>Check that there is no abnormal noise when engaging and disengaging operation.</li>
						<li>In neutral raise the engine speed up to 4000 rpm and check that there is no abnormal vibration or noises.</li>
						<li>Check there is not abnormal clutch sliding in driving conditions.</li>
					</ul></li>
				<li>After fitting the 4P Kit, paste the provided sticker. At the next clutch replacement, only the Service Kit can be applied (friction disc + mechanism + release bearing).</li>
			</ol>

After The Assembly