Kia Picanto (JA): Clutch System / Clutch Cover And Disc

Kia Picanto (JA) 2017-2025 Service & Repair Manual / Clutch System / Clutch System / Clutch Cover And Disc

Components and components location

Components
[Kappa 1.0 MPI / FFV, Kappa 1.2 MPI]

1. Clutch disc assembly
2. Clutch cover assembly
3. Clutch release bearing
4. Clutch release lever assembly
5. Return spring
6. Clutch release fork
7. Return clip

[Kappa 1.0 T-GDI]

1. Clutch release fork
2. Clutch cover assembly
3. Clutch disk assembly
4. Clutch release bearing

Repair procedures

Removal
1.
Remove the transaxle assembly.
G 1.0 MPI KAPPA (Refer to Manual Transaxle System - "Manual Transaxle")
G 1.0 T-GDI KAPPA (Refer to Manual Transaxle System - "Manual Transaxle")
G 1.2 MPI KAPPA (Refer to Manual Transaxle System - "Manual Transaxle")
F 1.0 KAPPA FFV (Refer to Manual Transaxle System - "Manual Transaxle")
2.
Remove the clutch cover bolts. Be careful not to be bent or twist bolts. Loosen bolts in diagonal directions.

Inspection
Clutch cover assembly
1.
Check the diaphragm spring end for wear and uneven height.
2.
Check the pressure plate surface for wear, cracks and color change.
3.
Check the rivets for looseness and replace the clutch cover assembly if necessary.
Clutch disc assembly
1.
Check the clutch facing for loose rivets, uneven contact, deterioration due to seizure, adhesion of oil, or grease, and replace the clutch disc if defective.
2.
Check for the torsion spring play and damage and if defective, replace the clutch disc.
3.
Measure the depth from a clutch lining surface to a rivet. If the measured value is less than the specification below, replace it.
Standard value
Clutch disc rivet depth (A): 0.3 mm (0.0118 in.)

Installation
   
If reinstalling used cover, the cover should be installed with its clutch disc as a set.
1.
Apply grease on a disc spline part and transaxle input shaft spline part as required.
Specified grease: CASMOLY L9508
Amount: 0.2 g
   
Possible problems when not following
•
When not applying: Excessive wear of splines and bad clutch operation can occur.
•
When excessively applying: Grease can be scattered by centrifugal force which can contaminate the clutch disc. This can cause a loss of friction force causing a slip.

2.
Make sure about the direction of the clutch disc when installing.

3.
Install the clutch disc and the cover with SST (A: 09411-1P000).

4.
Install the clutch cover bolts. Not to be bent or twisted, Tighten them in diagonal directions
Tightening torque :
14.7 - 21.6 N·m (1.5 - 2.2 kgf·m, 10.8 - 15.9 lb·ft)

5.
Install the transaxle assembly.
G 1.0 MPI KAPPA (Refer to Manual Transaxle System - "Manual Transaxle")
G 1.0 T-GDI KAPPA (Refer to Manual Transaxle System - "Manual Transaxle")
G 1.2 MPI KAPPA (Refer to Manual Transaxle System - "Manual Transaxle")
F 1.0 KAPPA FFV (Refer to Manual Transaxle System - "Manual Transaxle")

    Specifications Specifications Item Specifications Working voltage DC 12.5V Operating force Initial position : 0.

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