Kia Picanto: Clutch System / Clutch Cable

Kia Picanto JA 2017-2021 Service & Repair Manual / Clutch System / Clutch System / Clutch Cable

Components and components location
Components
[Kappa 1.0 MPI / FFV, Kappa 1.2 MPI]

1. Clutch pedal assembly
2. Clutch cable

Repair procedures
Removal
1.
Turn ignition switch OFF and disconnect the negative (-) battery cable.
2.
Loosen the clutch cable adjust nut (A) and then separate the clutch cable

3.
Loosen the bolts (A) and then remove the clutch cable bracket.
Tightening torque :
19.6 - 26.5 N·m (2.0 - 2.7 kg·m, 14.5 - 19.5 lb·ft)

4.
Loosen the bolt and then remove the clutch cable bracket from the battery tray.
Tightening torque :
7.8 - 11.8 N·m (0.8 - 1.2 kg·m, 5.8 - 8.7 lb·ft)

5.
Remove the clutch cable bracket by using the driver.

6.
Remove the battery.
G 1.0 MPI KAPPA (Refer to Engine Electrical System - "Battery")
G 1.2 MPI KAPPA (Refer to Engine Electrical System - "Battery")
F 1.0 KAPPA FFV (Refer to Engine Electrical System - "Battery")
7.
Remove the ECM.
G 1.0 MPI KAPPA (Refer to Engine Control / Fuel System - Engine Control Module (ECM)")
G 1.2 MPI KAPPA (Refer to Engine Control / Fuel System - Engine Control Module (ECM)")
F 1.0 KAPPA FFV (Refer to Engine Control / Fuel System - Engine Control Module (ECM)")
8.
Loosen the clutch cable bracket nut.

9.
Remove the crash pad lower panel.
(Refer to Body - "Crash Pad Lower Panel")
10.
Pushing the clutch pedal and then remove the clutch cable (A).

11.
Loosen the nuts (A) and then remove the clutch pedal.
Tightening torque :
9.8 - 14.7 N·m (1.0 - 1.5 kg·m, 7.2 - 10.8 lb·ft)

Installation
1.
Tighten the clutch cable bracket nut.

2.
Tighten the nuts (A) and then install the clutch cable and clutch pedal bracket.
Tightening torque :
9.8 - 14.7 N·m (1.0 - 1.5 kg·m, 7.2 - 10.8 lb·ft)

3.
Install the clutch cable (A).

   
Apply the grease to the clutch pedal hook (A).
Grease : Control cable type 0.1 - 1.0 g

4.
Insert the cable damper to the clutch bracket hole.

5.
Install the clutch cable bracket.
Tightening torque :
19.6 - 26.5 N·m (2.0 - 2.7 kg·m, 14.5 - 19.5 lb·ft)

6.
Install the cable end to the clutch release lever hook.

7.
Attach cable end to clutch release lever hook, by lifting clutch pedal in (A) direction.

8.
Tighten the adjust nut (A) up to (B) position.

   
Attach surface of adjust nut (A) to surface of cable shoe (B).

9.
operate the clutch pedal up to full stroke several time.

10.
Adjust the clutch pedal standard gap value.
Standard gap value : 25 - 35 mm (0.9843 - 1.378 in)

   
If the stroke is not proper, adjust again.
11.
Install the crash pad lower panel.
(Refer to Body - "Crash Pad Lower Panel")
12.
Install the ECM.
G 1.0 MPI KAPPA (Refer to Engine Control / Fuel System - Engine Control Module (ECM)")
G 1.2 MPI KAPPA (Refer to Engine Control / Fuel System - Engine Control Module (ECM)")
F 1.0 KAPPA FFV (Refer to Engine Control / Fuel System - Engine Control Module (ECM)")
13.
Install the battery.
G 1.0 MPI KAPPA (Refer to Engine Electrical System - "Battery")
G 1.2 MPI KAPPA (Refer to Engine Electrical System - "Battery")
F 1.0 KAPPA FFV (Refer to Engine Electrical System - "Battery")
Adjustment
1.
Tighten the adjust nut (A) up to (B) position.

   
Attach surface of adjust nut (A) to surface of cable shoe (B).

2.
Operate the clutch pedal up to full stroke several time.

3.
Adjust the clutch pedal standard gap value.
Standard gap value : 25 - 35 mm (0.9843 - 1.378 in)

   
If the stroke is not proper, adjust again.
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