Kia Rio: Clutch System

Kia Rio 2017-2020 YB Service Manual / 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 1.4 : Ø200 ± 1 × Ø130 + 0.8 mm
( Ø7.8740±0.0394 × Ø5.1181+0.0315 in.)
Gasoline 1.0 T-GDI : Ø225 ± 1 × Ø155 + 0.8 mm
( Ø8.8583±0.0394 × Ø6.1024+0.0315 in.)
Gasoline 1.25 : Ø225 ± 1 × Ø130 + 0.8 mm
( Ø7.4803±0.0394 × Ø5.1181+0.0315 in.)
Diesel 1.4 : Ø235 ± 1 × Ø155 + 0.8 mm
( Ø9.2520±0.0394 × Ø6.1024+0.0315 in.)

Clutch disc thickness [When free]
Gasoline 1.0 T-GDI / 1.4 : Ø8.1 ± 0.3 mm (0.3189 ± 0.0118 in.)
Diesel 1.4 : Ø8.3 ± 0.3 mm (0.3268 ± 0.0118 in.)
Gasoline 1.25 : Ø7.9 ± 0.3 mm (0.3110 ± 0.0118 in.)
Clutch disc rivet depth
1.1 mm (0.0433 in.)

Service Standard

Item
Specification
Clutch disc rivet depth
0.3 mm (0.0118 in.)

Tightening Torques

Item
N·m
kgf·m
lb·ft
Clutch pedal mounting nut
16.7 - 25.5
1.7 - 2.6
12.3 - 18.8
Ignition lock & clutch switch mounting bolt
2.0 - 3.9
0.2 - 0.4
1.4 - 2.9
Clutch release cylinder bleed plug
6.8 - 9.8
0.7 - 1.0
5.0 - 7.2
Clutch cover mounting bolt
(Gasoline 1.0 T-GDI, 1.25, 1.4)
14.7 - 21.6
1.5 - 2.2
10.8 - 15.9
Clutch cover mounting bolt
(Diesel 1.4)
11.8 ~ 14.7
1.2 ~ 1.5
8.7 - 10.8
Clutch release cylinder mounting bolt
14.7 - 21.6
1.5 - 2.2
10.8 - 15.9

Lubricants

Items
 Specified lubricants
 Quantity
Clutch release cylinder assembly
Brake fluid DOT 3 or DOT 4
 As required
Clutch pedal shaft and bushings
Chassis grease SAE J310a, NLGI No.1
Input shaft spline
CASMOLY L9508
0.2 g
Release bearing & Fork
0.3 - 0.5 g
Release Fork & Fulcrum
0.5 - 1.0 g
Release Cylinder & Fork
0.4 - 0.8 g
Clutch Release Bearing & Clutch Housing
0.5 - 1.0 g

Special service tools
Special Service Tools

Tool Name / Number
Illustration
Description
Clutch disc guide
09411-1P000

Installation of the clutch disc.

Troubleshooting
Troubleshooting

Symptom
Suspected Area
Remedy 
Clutch grabs/chatters
Engine mounting (Loose)
Tighten the engine mounting.
Clutch disc assembly (Excessive runout)
Inspect the clutch disc.
Clutch disc assembly (Oily)
Inspect the clutch disc.
Clutch disc assembly (Worn out)
Replace the clutch disc.
Clutch disc torsion spring (Damaged)
Replace the clutch disc.
Clutch disc assembly (Glazed)
Inspect the clutch disc.
Diaphragm spring (Out of alignment)
Replace the clutch disc.
Clutch pedal spongy
Clutch line (Air in line)
Perform the air bleeding.
Master cylinder (Damaged)
Replace the master cylinder.
Release cylinder (Damaged)
Replace the release cylinder.
Clutch noisy
Clutch release bearing assembly (Worn, dirty or damaged)
Repair or replace to release bearing.
Clutch slips
Clutch disc assembly (Oily)
Inspect the clutch disc.
Clutch disc assembly (Worn out)
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 line (Air in line)
Perform the air bleeding.
Master cylinder (Damaged)
Replace the master cylinder.
Release cylinder (Damaged)
Replace the release cylinder.
Clutch disc assembly (Out of line)
Replace the clutch disc.
Clutch disc assembly (Excessive runout)
Replace the clutch disc.
Clutch disc assembly (Lining broken)
Replace the clutch disc.
Clutch disc assembly (Dirty or burned)
Repair or replace to release bearing.
Clutch disc assembly (Oily)
Inspect the clutch disc.
Clutch disc assembly (Lack of spline grease)
Apply the grease to spline.

Delivery Pipe
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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 ...

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