Kia Rio: Clutch System

Kia Rio 2017-2023 YB Service Manual / Clutch System

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	As required
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

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

Repair procedures Removal 1. Release the residual pressure in fuel line. (Refer to Fuel Delivery System - "Release Residual Pressure in Fuel Line") When removing the fuel pump relay, a Diagnostic Trouble Code (DTC) may occur.

Clutch Cover And Disc❯

Components and components location Components 1. Clutch release fork 2. Clutch cover assembly 3. Clutch disk assembly 4.

Other information:

Kia Rio 2017-2023 YB Service Manual: Smart Key Diagnostic

Repair procedures Inspection Self Diagnosis With Scan Tool It will be able to diagnose defects of SMART KEY system with KDS/GDS quickly. KDS/GDS can operates actuator forcefully, input/output value monitoring and self diagnosis. The following three features will be major problem in SMART KEY system.

Kia Rio 2017-2023 YB Service Manual: Evaporator Temperature Sensor

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