Clutch Cover And Disc: Installation

Apply multipurpose grease to the spline of disc. Grease: CASMOLY L 9508
CAUTION: When installing the clutch, apply grease to each part, but be careful not to apply excessive grease. It can cause clutch slippage and shudder.

Fig 1: Applying Multipurpose Grease To The Spline
Courtesy of KIA MOTORS AMERICA, INC.
Install the clutch disc assembly to the flywheel using special tool (09411-11000).
Install the clutch cover assembly to the flywheel and temporarily tighten the bolts one or two steps at a time in a star pattern.
Tightening torque clutch cover bolt: 2.4L/2.7L - 20-27 Nm (200-270 kg.m, 15-20 lb.ft)

Fig 2: Clutch Cover Bolt Tightening Sequence
Courtesy of KIA MOTORS AMERICA, INC.
Align the bearing to the release fork and then install it to the sleeve of housing.
CAUTION: Apply multipurpose grease (CASMOLY L9508) to the grease home of bearing sleeve and contact point of release fork.

Fig 3: Installing The Bearing To The Release Fork
Courtesy of KIA MOTORS AMERICA, INC.
Install the release lever to the release fork.
CAUTION: If transaxle assembly is installed to engine without doing this step, release bearing can be separated according as the release fork rotates free.

Fig 4: Installing The Release Lever To The Release Fork
Courtesy of KIA MOTORS AMERICA, INC.
Install the transaxle assembly to the engine.
After finishing step 6, pushing the release lever to the arrow mark until it clicks. Ensure that the release bearing and clutch cover are aligned correctly.
1. Release lever operating range: 3° or less
If the range is over 3° this is a symptom that the release bearing and clutch cover are not aligned correctly. So, push the release lever to the arrow mark one more time.

Fig 5: Measuring Release Lever Operating Range
Courtesy of KIA MOTORS AMERICA, INC.