Kia Forte BD Quiz
Clutch System

Clutch Cover and Disc

In this manual: Clutch System
General Information — 8Maintenance — 32Engine Mechanical System — 47Engine Electrical System — 17Emission Control System — 10Engine Control System/Fuel System — 32Clutch System — 11Manual Transmission — 11DCT (Dual Clutch Transmission) System — 16Drive Shaft and Axle — 8Suspension System — 26Steering — 9Restraints — 11Brake System — 27Body (Interior and Exterior) — 119Body Electrical System — 98Heating, Ventilation, and Air Conditioning — 27
11steps
~71min
4/5difficulty
1special tools
02040608010035.326N·mlb·ft
Tightening torque found on this page
Done 0 of 11

Components and Component Location

Components

[Gasoline 1.6 / Diesel 1.6 / Gasoline 1.6 T-GDI]

1. Manual Transaxle Assembly
2. Clutch Cover Assembly		 3. Clutch Disc Assembly

[Gasoline 2.0]

1. Manual Transaxle Assembly
2. Clutch Release Fork
3. Clutch Housing Assembly		 4. Clutch Disc Assembly
5. Clutch Release Bearing

Repair Procedures

Removal

  1. Remove the manual transaxle assembly.

    G 1.6 MPI (Refer to Manual Transmission System - "Manual Transmission")

    G 2.0 MPI (Refer to Manual Transmission System - "Manual Transmission")

    D 1.6 TCI-NEW-U (Refer to Manual Transmission System - "Manual Transmission")

    G 1.6 T-GDI GAMMA (Refer to Manual Transmission System - "Manual Transmission")

  2. Remove the clutch cover assembly after loosening the bolts.

    [Gasoline 1.6]

    [Gasoline 2.0 / Diesel 1.6 / Gasoline 1.6 T-GDI]

Inspection

  1. Check the wear of the diaphragm spring, which contacts the clutch release bearing.

  2. Check the clutch cover and disc surface for wear or cracks.

  3. Check the clutch disc surface for slipping or oil stains.

  4. Measure the depth from the clutch facing surface to the rivet. If the measured value is less than the specification below, replace the clutch disc.

    Standard Value

    Clutch disc thickness (A) [free state]: 8.3 ± 0.3 mm (0.3268 ± 0.0118 in.)

    Clutch disc rivet depth (B): 1.1 mm (0.0433 in.)

Installation

  1. Apply grease to the spline of the clutch disc and the spline of the transmission input shaft as required.

    Recommended grease: CASMOLY L9508. Quantity: 0.1 - 0.3 g

  2. Install the clutch disc and cover using the special service tool (09411-1P000).

    Gasoline 2.0 / Diesel 1.6 / Gasoline 1.6 T-GDI: The surface marked "FLYWHEEL SIDE" must face the flywheel.

  3. Install the clutch cover bolts.

    Tightening Torque

    Gasoline 1.6: 24.5 - 35 N·m

    Gasoline 2.0 / Diesel 1.6 / Gasoline 1.6 T-GDI: 11.8 - 14.7 N·m

  4. Remove the clutch disc guide special service tool (09411-1P000).

  5. Install the manual transaxle assembly.

    G 1.6 MPI (Refer to Manual Transmission System - "Manual Transmission")

    G 2.0 MPI (Refer to Manual Transmission System - "Manual Transmission")

    D 1.6 TCI-NEW-U (Refer to Manual Transmission System - "Manual Transmission")

    G 1.6 T-GDI GAMMA (Refer to Manual Transmission System - "Manual Transmission")

Test yourself

A quick Kia Forte BD quiz: every answer comes with an explanation and a link to the manual page.