Kia Picanto JA: Clutch System

Kia Picanto (JA) 2017-{YEAR} Service & Repair Manual / Clutch System

Specifications

Items		Specifications
Clutch operation method		Kappa 1.0 MPI / FFV, Kappa 1.2 MPI : Cable type
Clutch operation method		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	As required
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

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.

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