Kia Picanto JA Quiz
Clutch System

Clutch Cover and Disc

In this manual: Clutch System
General Information — 8Maintenance — 30Engine Mechanical System — 46Engine Electrical System — 14Emission Control System — 11Engine Control System/Fuel System — 46Clutch System — 12Manual Transmission — 10Drive Shaft and Axle — 8Suspension System — 15Steering — 9Restraints — 17Brake System — 22Body (Interior and Exterior) — 104Body Electrical System — 80Heating, Ventilation, and Air Conditioning — 17
13steps
~83min
4/5difficulty
1special tools
0102030405021.616N·mlb·ft
Tightening torque found on this page
Done 0 of 13

Components and Component 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 Disc 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 bend or twist the bolts. Loosen the bolts in a diagonal sequence.

Inspection

Clutch Cover Assembly

  1. Check the diaphragm spring tips for wear and uneven height.
  2. Check the pressure plate surface for wear, cracks, and discoloration.
  3. Check the rivets for looseness and replace the clutch cover if necessary.

Clutch Disc Assembly

  1. Check the clutch facing for loose rivets, uneven contact, and wear. Check for seizure or oil or grease contamination, and replace the clutch disc if faulty.
  2. Check the torsion spring for play and damage. If faulty, replace the clutch disc.
  3. Measure the depth from the clutch facing surface to the rivet head. If the measured value is less than the value specified below, replace the clutch disc.
    Clutch disc rivet depth (A) standard value: 0.3 mm (0.0118 in)

Installation

  1. If necessary, apply grease to the spline of the clutch disc and the spline of the transmission input shaft.

    Recommended grease: CASMOLY L9508. Quantity: 0.2 g

  2. When installing, pay attention to the direction of the clutch disc.
  3. Install the clutch disc and cover using SST (A: 09411-1P000).
  4. Install the clutch cover bolts. To prevent bending or twisting, tighten them in a diagonal sequence.

    Tightening torque: 14.7–22 N·m

  5. Install the transmission assembly. G 1.0 MPI KAPPA (See Manual Transaxle System - Manual Transaxle) G 1.0 T-GDI KAPPA (See Manual Transaxle System - Manual Transaxle) G 1.2 MPI KAPPA (See Manual Transaxle System - Manual Transaxle) F 1.0 KAPPA FFV (See Manual Transaxle System - Manual Transaxle)

Test yourself

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