Kia Picanto: Clutch System

Items		Specifications
Clutch Operating Method		Kappa 1.0 MPI / FFV, Kappa 1.2 MPI: Cable Type
Clutch Operating Method		Kappa 1.0 T-GDI: Hydraulic Type
Clutch Cover	Type	Diaphragm Spring Strap
Clutch Disc Type	Type	Single Dry 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 [Free State]		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 Torque

Item	N·m	kgf·m	lbf·ft
Clutch Pedal Mounting Nut	9,8 - 14,7	1,0 - 1,5	7,2 - 10,8
Ignition Switch and 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 Slave Cylinder Bleeder Plug (Kappa 1.0 T-GDI only)	6,8 - 9,8	0,7 - 1,0	5,0 - 7,2
Clutch Slave 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	DOT 3 or DOT 4 brake fluid	As required
Clutch pedal shaft and bushing	Chassis grease SAE J310a, NLGI No. 1	As required
Input shaft spline	CASMOLIA L9508	0.2 g
Release Bearing and Fork		0.3 - 0.5 g
Release Fork and Pivot Point		0.5 - 1.0 g
Release Cylinder and Fork		0.4 - 0.8 g
Clutch Release Bearing and Clutch Housing		0.5 - 1.0 g

Tool Name/Number	Illustration	Description
Clutch Disc Guide 09411-1P000		Clutch disc installation

Symptom	Suspected Area	Remedy
Clutch grabs / chatters	Engine Mounting (Loose)	Tighten the engine mount.
	Clutch Disc Assembly (Excessive Runout)	Inspect the clutch disc.
	Clutch Disc Assembly (Oily)	Inspect the clutch disc.
	Clutch Disc Assembly (Worn)	Replace the clutch disc.
	Clutch disc torsion spring (damaged)	Replace the clutch disc.
	Clutch Disc Assembly (Glazed)	Inspect the clutch disc.
	Diaphragm Spring (Misalignment)	Replace the clutch disc.
Clutch Pedal Spongy	Clutch master cylinder (damaged)	Replace the clutch master cylinder.
Clutch noisy	Clutch Release Bearing Assembly (Worn, Contaminated or Damaged)	Repair or replace the clutch release bearing.
Clutch slips	Clutch Disc Assembly (Oily)	Inspect the clutch disc.
	Clutch Disc Assembly (Worn)	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	Clutch master cylinder (damaged)	Replace the clutch master cylinder.
	Clutch Disc Assembly (Out of Line)	Replace the clutch disc.
	Clutch Disc Assembly (Excessive Runout)	Replace the clutch disc.
	Clutch Disc Assembly (Broken Facing)	Replace the clutch disc.
	Clutch disc assembly (dirty or burnt)	Repair or replace the clutch release bearing.
	Clutch Disc Assembly (Oily)	Inspect the clutch disc.
	Clutch Disc Assembly (Lack of Spline Lubrication)	Apply grease to the splines.

Clutch System