Kia clutch. How to change clutch on kia rio

17.06.2019

Miscellaneous

For cars KIA Rio equipped with a manual transmission, install a dry single-plate clutch with a central diaphragm spring.

The clutch is located between the engine and gearbox and is designed to disconnect and connect the flywheel located on crankshaft engine, and input shaft gearboxes.

Clutch car KIA Rio consists of a driven (friction) plate, a clutch cover with a pressure plate and a diaphragm spring, as well as a clutch release mechanism.

Fig.1. KIA Rio clutch: 1- clutch cover with pressure plate; 2- diaphragm spring; 3- driven disk; 4- flywheel.

pressure plate mounted in a steel stamped casing 1 (Fig. 1.), Attached with six bolts to the flywheel 4 of the engine. The driven disk 3 is mounted on the splines of the input shaft of the gearbox and is clamped by a diaphragm spring 2 between the flywheel and the pressure disk.

Bearing 2 (Fig. 2) of the clutch release is mounted on the guide sleeve 3, pressed into the clutch housing 1, and moves along the sleeve with the fork 4, which in turn drives the clutch release hydraulic slave cylinder.

Fig.2. Clutch Release Mechanism: 1- clutch housing; 2- clutch release bearing; 3- guide sleeve of the clutch release bearing; 4- clutch release fork.

Hydraulic drive clutch release includes the following:

Clutch release master cylinder installed in engine compartment on the gear board;

The working cylinder located on the gearbox housing;

A pipeline consisting of…

... from the tube ...

... and an intermediate hose connecting master cylinder with a working cylinder;

Clutch pedal, the bracket of which is attached to the body.

The pedal is returned to its original position by a spring.

The master cylinder is connected by a hose to a reservoir mounted on the brake master cylinder (the reservoir is common to both master cylinders). The hydraulic clutch release uses brake fluid. Adjustment of a drive of deenergizing of coupling in operation is provided.

USEFUL TIPS:

In order for the clutch to serve for a long time and without fail, do not constantly keep your foot on the clutch pedal. This bad habit is acquired while learning to drive in driving schools for fear of not having time to turn off the clutch while the car is stopped. In addition to the rapid fatigue of the foot, which is all the time above the pedal, the clutch is, although slightly, but squeezed out, while the driven disk slips and wears out. In addition, despite the fact that the clutch release bearing is designed to operate in constant rotation mode, when the pedal is slightly depressed, it is under increased load, and its life is reduced. For the same reason, it is not recommended to keep the clutch off for a long time (for example, in traffic jams). If you do not have to move immediately, it is better to put the gearbox in neutral and release the pedal.

Clutch slip can be easily determined by the tachometer. If, while driving, with a sharp press on the accelerator pedal, the speed rises sharply, and then drops a little and the car starts to accelerate, the clutch needs to be repaired.

Possible clutch malfunctions, their causes and solutions

Cause of malfunction	Remedy
Incomplete clutch disengagement (clutch "leads")
Reduced clutch pedal travel	Adjust clutch release actuator
Warping of the driven disk (end runout more than 0.5 mm)	Replace the disk with a new one
Irregularities on the surfaces of the friction linings of the driven disk	Replace driven disk
Loose rivets or broken disc friction linings	Replace driven disk
Jamming of the hub of the driven disk on the splines of the input shaft of the gearbox	Clean the splines, coat with LSTs-15 grease. If jamming is caused by crushing or worn splines, then replace the input shaft or driven disk.
Air in the hydraulic clutch release system	Bleed the system
Fluid leakage from the master or slave cylinder of the clutch release actuator	Replace Master or Slave Cylinder
Loosening the compression spring fastening rivets	Replace clutch cover with pressure plate assembly
Skewed or warped pressure plate
Incomplete engagement of the clutch (clutch slips)
Increased wear or burning of the friction linings of the driven disk	Replace driven disk
	Thoroughly rinse the oiled surfaces with white spirit, eliminate the causes of oiling the disc
Damaged or stuck clutch release actuator	Troubleshoot causing jams
Jerks during clutch operation
Jamming of the hub of the driven disk on the splines of the input shaft	Clean the splines, lubricate with LSTs-15 grease. If jamming is caused by crushing or worn splines, replace the input shaft or driven disk if necessary.
Breakage or reduction of elasticity of springs of a damper of a conducted disk	Replace driven disc assembly
Lubrication of the friction linings of the driven disk, flywheel and pressure disk surfaces	Thoroughly rinse the oiled surfaces with white spirit, eliminate the cause of oiling the disc
Seizure in the clutch release mechanism	Replace deformed parts. Eliminate causes of jamming
Increased wear of the friction linings of the driven disk	Replace driven disk
Loosening the rivets of the friction linings of the driven disk
Surface damage or buckling of the pressure plate
increased noise when disengaging the clutch
Worn, damaged or leaking lubricant from the clutch release bearing	Replace bearing
Increased noise when engaging the clutch
Breakage of the plates connecting the pressure plate to the casing	Replace clutch cover with pressure plate assembly

Troubleshooting table

The table shows the most common causes that occur when the clutch is not fully engaged and disengaged (“leads” or slips), jerks during clutch operation, as well as when increased noise appears after it is engaged and disengaged.

Cause of malfunction	Elimination method
Clutch pedal full travel reduced	Adjust pedal release drive
The runout of the driven disk exceeds 0.5 mm	Replace with a new one
Weakening of rivets or sinking of their heads less than 0.3 mm
Scratches and bumps on the friction linings of the driven disc
The presence of air in the hydraulic clutch release	Bleed the system
Clutch release master/slave fluid leak	Replace problem cylinder
Jamming of the hub of the driven disk on the splines of the gearbox input shaft	Clean the splines and lubricate with LSC-15. If the splines are crushed or worn, replace the input shaft or the driven disk
Loosening the compression spring fastening rivets	Replace clutch cover with pressure plate assembly
Warped or warped pressure plate	Replace clutch cover with pressure plate assembly
Traces of heavy wear or burning of the friction linings of the driven disk	Replace with a new one
Lubrication of the friction linings of the driven disk	Check the gearbox input shaft seal. If necessary, replace
Damaged or stuck clutch release actuator	Eliminate the causes of the malfunction
Weakening or breakage of the damper springs of the driven disk	Replace with new assembly
Worn, damaged or leaking lubricant from the clutch release bearing	Replace with a new one
Pressure plate surface damage	Replace shroud and disc assembly
Breakage of the plates connecting the pressure plate to the casing	Replace shroud and disc assembly

Clutch inspection and replacement process

In order to disassemble, inspect for malfunctions, and replace the clutch without visiting a car service, you will need an assistant and up to 6-7 hours of free time. The whole procedure can be carried out in garage conditions. It is necessary to have a "pit" or lifting mechanisms.

Required tool

Keys with a set of heads;
screwdrivers;
spare structural parts of the clutch;
gearbox input shaft oil seal;
dye;
calipers;
molybdenum grease;
gloves.

Dismantling and replacing the clutch on the Kia Rio

Let's take a closer look at some of the manipulations with the clutch mechanism indicated in the tables above.

To gain access to the clutch, the first step is to dismantle the gearbox.

To keep the pressure plate balanced during reassembly, if its replacement is not required, it is better to mark with paint its previous position relative to the flywheel and casing. In that case, the correct reverse installation won't be difficult.

In order to disconnect the pressure and driven discs from the flywheel, you need to unscrew the six bolts that hold the structure together.

To prevent the flywheel from turning, you can insert a screwdriver between the teeth.

It is better to unscrew the bolts gradually: two turns per bolt with the transition in a circle from one to another.

During the removal process, support the driven disk from falling.

Now, it is necessary to conduct a thorough visual inspection of the various clutch elements.

Inspect the driven disc and friction lining surface for cracks and general wear.

Check rivets. Drowning of their heads is not allowed less than 0.3 mm, while the weakening of rivet joints should not be felt. Confirmation of any of these signs is a direct road to replacement.

Pay attention to oil smudges on the surface of the friction linings. If traces are noticed, it is necessary to check the gearbox input shaft oil seal and, if necessary, replace it.

Now, check the damper springs of the driven disc. To do this, try to manually move them in the sockets of the hub. If the springs are weakened or completely broken, replace it.

In addition, check the driven disk for "beating". With a "beat" value of more than 0.5 mm, replacement is also necessary.

The friction surfaces of the pressure plate and flywheel should be inspected. They must be replaced if deep scratches, risks, signs of overheating and heavy wear have been found.

The diaphragm spring must also be free of any cracks and deformations. The places where the spring petals come into contact with the clutch release bearing may have wear of no more than 0.8 mm.

Deformations and changes in the geometry of the casing and disc connecting links, as well as cracks and wear marks on the pressure spring support rings are not allowed.

When inspection and measurements have been made, and parts unsuitable for further operation have been replaced with new ones, assembly can be carried out. However, first of all, it is necessary to evaluate the ease of movement of the driven disk along the splines of the gearbox input shaft. In case of jamming, its causes should be identified and eliminated.

Then, apply molybdenum grease to the splines of the driven disc hub.

During the installation of the node, first you need to install the slave disk, using a mandrel for this. Install the casing, matching the marks left by the paint.

Do not forget that the protruding part of the driven disk hub "looks" towards the casing diaphragm spring.

It remains only to tighten the bolts. Tighten them evenly, one turn each. Tightening is desirable to carry out in a circle, alternating diametrically opposite each other bolts.

Now you can remove the mandrel, reinstall the gearbox and check the operation of the clutch.

Video about replacing the clutch on the Kia Rio

Unfortunately, there is no high-quality Russian-language video review of the replacement, therefore, you can familiarize yourself with the English version in two parts.

There are more and more new cars on the market today. Everyone can choose a car to their taste, regardless of age and social status. Often the choice falls on the Kia Rio with automatic transmission. Usually, buyers choose a modification with an automatic rather than a manual transmission. The point here is rather that it is carried out less often than restoration work on the "mechanics" of the same machine.

Mechanism

On all cars, like on, there is a clutch necessary to connect the gearbox to the engine and transmit rotation to the box. Despite the simplicity of the device, it is subject to wear, so it is sometimes necessary to repair the clutch on the Kia Rio. In fact, the system implies several mechanisms and devices that form one unit, called the "clutch".

To determine exactly what the problem is, you need to monitor the car and listen to each unusual sound. Not only noises speak about a breakdown, but also the behavior of the machine. For example, if while pressing the pedal it fluctuates, then you need to look at the disk. But there are a number of sounds that allow you to determine the breakdown yourself. It is important to listen not to the rustles and taps themselves, but to remember the moment of their occurrence. If the noise is heard when you press the pedal, then the release bearing has become unusable. Helps fix the problem simple replacement. And the sounds that are heard high speed, signal problems in the system mounts. All other noises are due to the clutch disc. Replacing the clutch will help to cope with such a scourge.

Mechanism adjustment

After installing new parts, we proceed to the next stage - debugging the clutch. There is nothing complicated here, because you do not need any specific knowledge and tools. The operation will require only a few wrenches to tighten the bolts and a ruler to measure the distance.

Let's see how to adjust kia clutch Rio 3. First you need to check how much the pedal is idling. By all standards, the stroke should be from 6 to 13 millimeters. To check this indicator, you will need to depress the pedal until resistance begins. The next step is to measure the distance from the bottom of the car to the extreme point of the pedal position.

It should be equal to 14 centimeters, otherwise adjustment will be required. This is necessary because a lower setting may cause the pedal to stop working properly, and a higher setting will make it impossible to determine some indicators.

After measurements, we proceed to the adjustment process itself. It consists in the need to loosen the nuts and adjust the sensor, showing all changes in the pedal. If, after setting up, nothing happened or it is impossible, then you will need to replace the entire unit.

Removal and installation

As soon as you are convinced of the need to replace the device, you should prepare for the repair. I would like to note right away that the process itself is not so complicated, but it will take a lot of time.

Please note: this procedure cannot be done alone, because at some stages of work you will need the help of a second person.

You will also need to lift the car. For this purpose, an automatic lift or pit is used. A lift is better, as it provides full access to all components of the car and allows you to replace other parts.

First of all, to carry out the work, you will need to remove the box responsible for turning on the gear and accelerating the machine. Then you need to separate the flywheel from the disk. At this stage, you will need to remove the bolts and ensure immobility. After removing the disc will be very simple due to the absence of interference.

The penultimate stage involves mounting a new disk on seat. This is where centering is required. To do this, you need to install a disk with a friction lining on the input shaft of the gearbox, and then fix it yourself. The last stage is the installation of the removed parts in place.

The principle of operation of the clutch car Kia Rio

Principle of operation: the basket together with the drive disc is rigidly fixed to the flywheel crankshaft. The disk can move relative to the basket, but it is spring loaded. A driven disk is placed between the drive disk and the flywheel. Friction linings are fixed on this disc, which significantly increase friction. A hub is located in the center of the driven disk. The hub accepts the drive shaft of the gearbox, and the spline connection provides a secure but movable connection - the disc can move along the shaft, but the rotation will be transmitted constantly.

When it is necessary to transfer rotation from the engine to the gearbox, the clutch is released. In this position, the drive disc, due to the pressure of the springs, presses the driven disc against the flywheel. The presence of friction linings provides a significant friction force, the driven disk does not slip relative to the drive disk and flywheel. And since the driven disk is connected to the gearbox shaft spline connection, then rotation is transferred.

To disconnect the gearbox from the engine, the driver presses the clutch pedal. With the help of a drive, it acts on the release bearing, which, moving, begins to put pressure on the release levers, as a result of which the drive disk moves inside the basket, overcoming the force of the springs. It stops pressing the driven disk to the flywheel, due to which the rotation transmission stops, which makes it possible to shift the gear to the gearbox.

The clutch also helps to get you off to a smooth start. When the pedal is gradually released, the drive disc gradually increases the pressure on the driven disc. With a small effort, the driven disk begins to take rotation, but due to insufficient preload, it slips. As the clutch pedal is released and the driven disc is compressed, it takes on more and more rotation, and slippage decreases.

Types and frequency of maintenance of the clutch car Kia Rio

With the planned technical inspection(after 15,000 km of run) it is necessary to check the tightness of the drive, the integrity of the return springs of the clutch pedal and the clutch release fork shaft lever, check the fluid level in the reservoir of the clutch master cylinder, add fluid if necessary.

For every 30 thousand kilometers or after two years, change the fluid in the clutch hydraulic system

For every 60 thousand km of run, adjust free play drive master cylinder piston pusher and free travel of the clutch release shaft lever and lubricate the bearings of the clutch release clutch and the clutch release shaft.

The technology for performing operations to repair the clutch of a Kia Rio car with the replacement of a driven disk

The reasons for replacing the clutch disc are the following symptoms:

Warping of the driven disk (end runout more than 0.5 mm);

Irregularities on the surfaces of the friction linings of the driven disk;

Weakening of the rivets or breakage of the friction linings of the driven disk;

Increased wear or burning of the friction linings of the driven disk;

Breakage or decrease in the elasticity of the springs of the damper of the driven disk;

Increased wear of the friction linings of the driven disk.

Table 1. Routing performance of operations to repair the clutch of a Kia Rio car with the replacement of the driven disk

	Conducted work (operations)	Photos of ongoing work (operations)	Used tool and accessories

1. Preparatory operations to remove the gearbox
	1. Remove the fixing pin of the cable end from the hole located in the axis of the gear lever.
	Remove the washer from the shift lever shaft.
	Remove the end of the cable from the shaft of the gear lever.
	Remove the end of the cable from the shaft of the gear selector lever.
	Remove the ends of the cable sheaths from the sockets located in the bracket mounted on the gearbox. After that, shift the control cables with the gearbox to the side.
	Remove the transmission control cable mounting bracket from the vehicle.	Flag ratchet. (GOST 22402-77) Extension. (GOST 24800-03) Socket head 19mm. (GOST 25604-83)
	Press the spring retaining element of the speed sensor wiring harness block (1) and the crankshaft position sensor (2), and then disconnect the block from the sensor electrical connector.
	Unscrew and remove fixing bolt tip of the "mass" wire.	Open end wrench 14mm. (GOST 2839-80)
	Loosen and remove the pipe fixing bolt hydraulic drive clutch release to the gearbox housing.	Flag ratchet. (GOST 22402-77) Extension. (GOST 24800-03) Socket head 17mm. (GOST 25604-83)
	Unscrew and remove the two threaded fasteners of the hydraulic clutch release cylinder.	Flag ratchet. (GOST 22402-77) Extension. (GOST 24800-03) Socket head 19mm. (GOST 25604-83)
	Press the locking element of the control wire block, and then disconnect the block from the output of the starter traction relay.
	Remove the end of the power wire from the starter terminal bolt.
	Unscrew and remove the fixing bolt of the wire harness holder, then move the holder with wires to the side.	Flag ratchet. (GOST 22402-77) Extension. (GOST 24800-03) Socket head 12mm. (GOST 25604-83)
	Unscrew and remove the two starter mounting bolts located on the side of the clutch housing. Dismantle the starter.	Flag ratchet. (GOST 22402-77) Extension. (GOST 24800-03) Socket head 21mm. (GOST 25604-83)
2. Dismantling the gearbox and clutch basket
	Remove gear oil from mechanical box gear shifting.	Flag ratchet. (GOST 22402-77) Extension. (GOST 24800-03) Socket head 17mm. (GOST 25604-83)
	Dismantle the drives of the front wheels of the car.	Socket set. (GOST 25604-83) CV joint puller (GOST 40005-99) A set of socket and open-end wrenches. (GOST 2839-80)
	Support the gearbox and engine with secure and firm supports.
	Unscrew and remove the three mounting bolts of the gearbox to the suspension support bracket power unit.	Flag ratchet. (GOST 22402-77) Extension. (GOST 24800-03) Socket head 21mm. (GOST 25604-83)
	Loosen and remove the two upper gearbox mounting bolts.	Flag ratchet. (GOST 22402-77) Extension. (GOST 24800-03) Socket head 19mm. (GOST 25604-83)
	Unscrew and remove the nut of the mounting bolt of the rear suspension support of the power unit to the bracket located on the power unit. In the process of unscrewing the nut, fix the fixing bolt from turning. Remove the mounting bolt from the holes located in the bracket and in back support power unit suspensions.	Flag ratchet. (GOST 22402-77) Socket wrench 21mm. (GOST 2839-80) Extension. (GOST 24800-03) Socket head 19mm. (GOST 25604-83)
	Unscrew and remove the two mounting bolts of the rear suspension bracket of the power unit to the transverse beam of the front suspension of the vehicle.	Socket wrench 20mm. (GOST 2839-80)
	Remove the rear suspension support of the power unit from the vehicle.
	Loosen and remove the five lower gearbox mounting bolts.	Flag ratchet. (GOST 22402-77) Extension. (GOST 24800-03) Socket head 20mm. (GOST 25604-83)
	Remove support from under gearbox. In the process of extracting the supports from under the box, maintain the gearbox. Move the gearbox back until its input shaft is removed from the hub of the clutch disc. Dismantle the gearbox. When installing the pressure plate, mark the relative position of the pressure plate housing and the flywheel and maintain balance.
	Loosen and remove the six mounting bolts of the clutch pressure plate housing to the flywheel, at the same time hold the flywheel from turning using a large screwdriver or mounting spatula. Loosen the bolts evenly, each bolt two turns of the wrench.	Flag ratchet. (GOST 22402-77) Extension. (GOST 24800-03) Socket head 19mm. (GOST 25604-83)
	Separate the clutch pressure and driven plates from the flywheel, holding the driven plate so that it does not fall.
3. Troubleshooting the driven disk.
	Inspect the clutch disc. Cracks and other damages on elements of a conducted disk are not supposed. The thickness of the driven disk in a compressed state with a force of 3700 N (377 kgf) should be in the range of 7.4-8.0 mm.	Caliper ШЦ-1 (GOST 166-89)
	Check the friction surfaces of the flywheel and the clutch pressure plate for congestion, deep scratches and risks. Replace damaged parts.
4. Assembly.
	Using a mandrel, install the driven disk, and then install the pressure plate casing, aligning the marks made during the dismantling process. After that, screw in the bolts securing the clutch pressure plate cover to the flywheel.	Mandrel for centering the clutch disc.
	Tighten the fastening bolts of the clutch pressure plate casing to the flywheel in the specified sequence, one turn of the wrench per approach for each bolt until the tightening torque is 18 N * m.	Wrench torque scale (GOST 25603-83 Extension. (GOST 24800-03) Socket head 19mm. (GOST 25604-83)
	Remove the centering mandrel, and then install the gearbox in reverse order. Then check that the clutch is working properly. Fill the gearbox with transmission SAE oil 80W 90.

One of the key systems in a car is the clutch. As in any other car, this device transmissions on Kio Rio are subject to wear over time, various breakdowns may occur that require intervention.

The clutch is that part of the transmission, the main purpose of which is to transfer the rotation of the engine to the gearbox. Roughly speaking, this is a system that provides communication between the engine and gearbox. In addition, thanks to the use of the clutch pedal, it is possible to stop the transmission of torque when needed.

Nothing lasts forever, and therefore the clutch on the car may break or, for some reason, work incorrectly. There are typical problems that everyone can identify and fix on their own. For example, if you hear a strange sound when using the pedal, there may be a problem with release bearing. This is resolved by replacing it. In addition, the reason extraneous noise may be broken work friction disc. If noises occur when changing speed, then the fastenings of the system parts may be worn out.

If, when using the pedal, you feel vibrations, then you need to pay attention to the disk and its condition. In general, pay attention to your car and fix problems in time.

Clutch adjustment

In some situations, clutch adjustment is considered justified on Kia Rio 2012. If, as a result of the inspection, any problems were identified, then it is necessary to find out their causes, and then proceed to direct adjustment. Almost everyone can do it, because no special equipment or special skills are not required. All that is required for this is a ruler and a pair of keys for 14.

So, clutch adjustment on Rio occurs according to the following scheme:

That's all, the adjustment is finished. If it is impossible to carry out the adjustment, or it does not give the desired results, then the entire system must be replaced with a Kia Rio 2012.

How to replace the clutch?

So, replacing the clutch is a fairly simple process, although it takes time. Design Kia car Rio 2012 allows you to make such repairs yourself, and it will take approximately 5 hours. Next, we will analyze in detail what and how to do and in what sequence.

I would like to note right away that it will not work to replace the clutch alone - at some stages you cannot do without an assistant. There are several ways to make a replacement:

Raise the car on a lift;
Perform work in the pit.

The first option is simpler, as it gives easier access to various nodes. However, not everyone has the opportunity to do this, so everything can be done in the garage where your Kia Rio 2012 is stored.

So, clutch replacement includes the following steps:

Preparatory work. It is necessary to dismantle the working cylinder, cardan shaft and a support, a starter, as well as a gearshift lever.
Removing the sensor activation of movement back and speedometer cable.
Dismantling the gearbox, which will allow access to all units.
Separation of the flywheel from the clutch disc. To do this, remove the mounting bolts, while ensuring immobility. Thus, removing the disk will not be a problem, since all fasteners are removed.
Installing a new clutch. As part of this step, you will need to center the disk itself. This can be done by installing the friction disc on the input shaft, fasten the roller to the crankshaft. After that, the clutch disc itself is mounted on the Kia Rio 2012.
Installation of all car parts removed at the preparatory stage.

Finally, I would like to say that in the movement of the pedal, the clutch system takes only a few centimeters, and therefore there is no need to press it to the floor. In order to check the correct operation of the new clutch on the Kia Rio 2012, you need to start the engine, while putting the car on a flat surface. Next, you need to press the pedal and release it very slowly, without pressing the accelerator pedal. If the engine speed starts to change, it means that everything is working correctly.