Kia Rio: Clutch System / Clutch Release Cylinder

Kia Rio 2017-2021 YB Service Manual / Clutch System / Clutch Release Cylinder

Components and components location
Components

1. Union bolt
2. Gasket
3. Tube joint
4. Clutch tube
5. Valve plate
6. Valve spring
7. Bleeder screw
8. Release cylinder
9. Return spring
10. Piston
11. Boot
12. Push rod

Repair procedures
Removal

[Gasoline 1.2]

1.

Drain the brake fluid through the bleed plug (A).

  

Do not spill brake fluid on the vehicle; it may damage the paint if brake fluid does contact the paint, wash it off immediately with water.

2.

Loosen the release cylinder bolts (A) and then clutch tube nut (B) after removing release cylinder assembly (C ).

[Gasoline 1.0 T-GDI, 1.4, Diesel 1.4]

1.

Drain the brake fluid through the bleed plug (A).

  

Do not spill brake fluid on the vehicle; it may damage the paint if brake fluid does contact the paint, wash it off immediately with water.

2.

Loosen the release cylinder bolts (A) and then clutch tube nut (B) after removing release cylinder assembly ©.

Installation
1.

Install in the reverse order of removal.

  

Apply the specified grease to the push rod end.

Specified grease: CASMOLY L9508

Quantity: 0.4 - 0.8 g

Inspection
1.

Check the clutch release cylinder for fluid leakage.

2.

Check the clutch release cylinder boot for damage.

Adjustment

Clutch Release Cylinder Air Bleeding Procedure

  

Use the specified fluid. Avoid mixing different brands of fluid.

1.

After disconnecting a cap from the clutch release cylinder air bleeder, insert a vinyl hose in the plug.

2.

Refill the clutch master cylinder with the specified fluid.

Specified fluid: SAE J1703 (DOT 3 or DOT 4)

3.

Loosening the plug screw, press and release the clutch pedal about 10 times.

4.

Tighten the plug (A) during the clutch pedal pressed. Afterwards, raise the pedal with a hand.

5.

After pressing the clutch pedal 3 times more, loosen the plug (A) and re-tighten it with the pedal pressed. Raise it again, then.

Tightening torque:

6.8 - 9.8 N·m (0.7 - 1.0 kgf·m, 5.0 - 7.2 lb·ft)

6.

Repeat the step 4 two or three times.

(until there is no bubble in the fluid)

[Gasoline 1.2]

[Gasoline 1.0 T-GDI, 1.4, Diesel 1.4]

7.

Refill the clutch master cylinder with the specified fluid.

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