Kia Picanto: Clutch System

Kia Picanto JA 2017-2024 Service & Repair Manual / Clutch System

Specifications
Specifications
Items
Specifications
Clutch operation method
Kappa 1.0 MPI / FFV, Kappa 1.2 MPI : Cable type
Kappa 1.0 T-GDI : Hydraulic type
Clutch cover
Type
Diaphragm spring strap
Clutch disc Type
Type
Single dry with diaphragm
Facing diameter
(Outer × inner)
Kappa 1.0 MPI / FFV : Ø180 ± 1 × Ø125 + 1 mm
( Ø7.0866±0.0394 × Ø4.9213+0.0394 in)
Kappa 1.0 T-GDI : Ø225 ± 1 × Ø155 + 0.8 mm
( Ø8.8583±0.0394 × Ø6.1024+0.0315 in.)
Kappa 1.2 MPI : Ø190 ± 1 × Ø130 + 0.8 mm
( Ø7.4803 ± 0.0394 × Ø5.1181+0.0394 in)
Clutch disc thickness [When free]
Kappa 1.0 MPI / FFV, Kappa 1.0 T-GDI :
Ø8.1 ± 0.3 mm (0.3189 ± 0.0118 in.)
Kappa 1.2 MPI :
Ø7.9 ± 0.3 mm (0.3110 ± 0.0118 in.)
1.1 mm (0.0433 in.)

Service Standard
Item
Specification
Clutch disc rivet depth
0.3 mm (0.0118 in.)

Tightening Torques
Item
N·m
kgf·m
lb·ft
Clutch pedal mounting nut
9.8 - 14.7
1.0 - 1.5
7.2 - 10.8
Ignition lock & clutch switch mounting bolt
2.0 - 3.9
0.2 - 0.4
1.4 - 2.9
Clutch cover mounting bolt
14.7 - 21.6
1.5 - 2.2
10.8 - 15.9
Clutch tube bracket mounting bolt
9.8 - 14.7
1.0 - 1.5
7.2 - 10.8
Clutch release cylinder bleed plug
(Kappa 1.0 T-GDI only)
6.8 - 9.8
0.7 - 1.0
5.0 - 7.2
Clutch release cylinder mounting bolt
(Kappa 1.0 T-GDI only)
14.7 - 21.6
1.5 - 2.2
10.8 - 15.9

Lubricants
Items
 Specified lubricants
 Quantity
Clutch release cylinder assembly
Brake fluid DOT 3 or DOT 4
 As required
Clutch pedal shaft and bushings
Chassis grease SAE J310a, NLGI No.1
Input shaft spline
CASMOLY L9508
0.2 g
Release bearing & Fork
0.3 - 0.5 g
Release Fork & Fulcrum
0.5 - 1.0 g
Release Cylinder & Fork
0.4 - 0.8 g
Clutch Release Bearing & Clutch Housing
0.5 - 1.0 g

Special service tools
Special Service Tools
Tool Name / Number
Illustration
Description
Clutch disc guide
09411-1P000

Installation of the clutch disc.

Troubleshooting
Troubleshooting
Symptom
Suspected Area
Remedy 
Clutch grabs/chatters
Engine mounting (Loose)
Tighten the engine mounting.
Clutch disc assembly (Excessive runout)
Inspect the clutch disc.
Clutch disc assembly (Oily)
Inspect the clutch disc.
Clutch disc assembly (Worn out)
Replace the clutch disc.
Clutch disc torsion spring (Damaged)
Replace the clutch disc.
Clutch disc assembly (Glazed)
Inspect the clutch disc.
Diaphragm spring (Out of alignment)
Replace the clutch disc.
Clutch pedal spongy
Master cylinder (Damaged)
Replace the master cylinder.
Clutch noisy
Clutch release bearing assembly (Worn, dirty or damaged)
Repair or replace to release bearing.
Clutch slips
Clutch disc assembly (Oily)
Inspect the clutch disc.
Clutch disc assembly (Worn out)
Replace the clutch disc.
Diaphragm spring (Damaged)
Replace the clutch disc.
Pressure plate (Distorted)
Replace the clutch disc.
Flywheel (Distorted)
Replace the flywheel.
Clutch does not disengage
Master cylinder (Damaged)
Replace the master cylinder.
Clutch disc assembly (Out of line)
Replace the clutch disc.
Clutch disc assembly (Excessive runout)
Replace the clutch disc.
Clutch disc assembly (Lining broken)
Replace the clutch disc.
Clutch disc assembly (Dirty or burned)
Repair or replace to release bearing.
Clutch disc assembly (Oily)
Inspect the clutch disc.
Clutch disc assembly (Lack of spline grease)
Apply the grease to spline.

High Pressure Fuel Pump
Specifications Specification Items Specification High Pressure Fuel Line bar 20  - 200 MPa 2 - 20 kgf/cm² 20.4 - 203.9 psi ...

Clutch System
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