Kia Rio: Clutch System / Clutch Cover And Disc

Kia Rio 2017-2023 YB Service Manual / Clutch System / Clutch Cover And Disc

Components and components location

Components

1. Clutch release fork
2. Clutch cover assembly

3. Clutch disk assembly
4. Clutch release bearing

[Gasoline 1.2 only]

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

Repair procedures

Removal

Remove the transaxle assembly.

D 1.4 U2 TCI (Refer to Manual Transaxle System - "Manual Transaxle")

G 1.0 T-GDI (Refer to Manual Transaxle System - "Manual Transaxle")

G 1.2 MPI (Refer to Manual Transaxle System - "Manual Transaxle")

G 1.4 MPI (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. [Diesel 1.4]

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.

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.

Apply grease on the transaxle input shaft spline as required.

Specified grease: CASMOLY L9508

Amount: 0.2 g

•	Clean the transaxle input shaft spline and apply specified grease thin, evenly on it in the clockwise direction.

•	Clean the inside of release bearing and axle sleeve, apply specified grease thinly on inside of the bearing as clockwise direction.

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.

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

•	When installing the cover, remove the foreign of material of flywheel and pressure plate completely.

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

Install the clutch cover bolts. Not to be bent or twisted, Tighten them in diagonal directions

Tightening torque

Gasoline 1.0 T-GDI,1.25, 1.4 : 14.7 - 21.6 N·m (1.5 - 2.2 kgf·m, 10.8 - 15.9 lb·ft)

Diesel 1.4 : 11.8 - 14.7 N·m (1.2 - 1.5 kgf·m, 8.7 - 10.8 lb·ft)

•	Loosely tighten every clutch cover bolts, then torque to specifications in a diagonal direction. This can prevent twisting, vibration of the cover, and the lifting of the pressure plate.

•	Install the all the components with the specified torques. If not, the clutch torque transaxle may have concerns or the mounting bolt can loosen.

[Diesel 1.4]

Install the transaxle assembly.

D 1.4 U2 TCI (Refer to Manual Transaxle System - "Manual Transaxle")

G 1.0 T-GDI (Refer to Manual Transaxle System - "Manual Transaxle")

G 1.2 MPI (Refer to Manual Transaxle System - "Manual Transaxle")

G 1.4 MPI (Refer to Manual Transaxle System - "Manual Transaxle")

❮Clutch System

Specifications Specifications Items Specifications Clutch operation method Hydraulic type Clutch cover Type Diaphragm spring strap Clutch disc Type Type Single dry with diaphragm Facing diameter (Outer × inner) Gasoline 1.

Ignition Lock Switch❯

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

Other information:

Kia Rio 2017-2023 YB Service Manual: Overhead Console Lamp

Repair procedures Inspection 1. Remove the overhead console lamp assembly then check for continuity between terminals. If the continuity is not as specified, replace the map lamp switch. Removal 1.

Kia Rio 2017-2023 YB Service Manual: Power Windows