REPAIR MAINTENANCE OPERATION OF MOTOR VEHICLES
Kia Clarus (1995 issue)

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Kia
	Clarus
		Maintenance
		Engines FE DOHC and DOHC T8
		Greasing system
		Cooling
		The power supply system and release
		Fuel system
		Ignition system
		Coupling
			Technical data
			Check the fluid level
			Adjust the clutch pedal
			The clutch pedal
			Bleeding the hydraulic clutch
			Clutch Master Cylinder
			Repair of the clutch master cylinder
			Clutch slave cylinder
			Repair of the working cylinder of coupling
			Clutch disc
			Troubleshooting
		Manual transmission
		ACP G4A-EL
		AKP 50-40 LE
		Axes and power shafts
		Steering
		Wheels and tires
		Suspension
		Body
		The air conditioning system
		Electrical equipment
		Brakes
		Electric schemes

Clutch disc

Clutch

1 - clutch slave cylinder;
2 - Transmission;
3 - Case;
4 - clutch;

5 - clutch fork;
6 - a casing of coupling with a press disk;
7 - the clutch plate;
8 - flywheel.

Withdrawal

PERFORMANCE ORDER

1. Remove the slave cylinder connected to a hydraulic tube.
2. Remove the gearbox.
3. Remove the cover clutch fork.
4. Remove the clutch.
	5. Establish special tool OK590 111 001 for blocking of a flywheel from turning the mandrel and OK130 160 010 for centering the clutch.
6. Gradually loosen the bolts diagonally clutch assembly, turning each bolt 1 turn up until not stop the action of the diaphragm spring, and bolts can be unscrewed by hand. Remove the clutch cover with the pressure plate and clutch disc.
	7. If necessary, a special tool OK401 111 012 remove the central bearing.
A warning It is desirable to remove the flywheel and check the back sealing ring of the crankshaft for leaks. If necessary, replace the O-ring.
	8. The indicator of hour type measure palpation of a flywheel. If the runout exceeds the limit, replace the flywheel. Heartbeat: 0.2 mm
	9. Establish special tool OK590 111 001 for blocking of a flywheel from turning, remove the six screws and remove flywheel.

Check

Check of the central bearing

PERFORMANCE ORDER

Thumb turn the bearing with the application of maximum force in the axial direction. If the bearing is turned hardly, replace it.

Check the flywheel

PERFORMANCE ORDER

	1. Check the condition of the friction surface of the flywheel for cracks, metal penetration and surface wear. The following slight generation or burning should be removed with sandpaper.
2. Check the condition of the teeth of the flywheel for wear, and mowing. If necessary, replace the flywheel.

Checking release bearing

A warning

Clutch sealed and should not be washed in a solvent.

PERFORMANCE ORDER

	1. Check the release bearing which should rotate easily, smoothly and quietly and it should no longer play. The working surface of the bearing influencing a press spring should be smooth, without cracks, local corrosion or development.
2. Defective clutch can be determined without removing it from the car, which is necessary when the engine is running, press the clutch pedal. If the clutch pedal is pressed, an additional noise, means clutch is faulty and must be replaced.

Check of a casing of coupling with a press disk

PERFORMANCE ORDER

1. Check the pressure plate for cracks, metal penetration and surface wear.
	2. Check the diaphragm spring in contact with the release bearing for wear and cracks. In the presence of defects, replace the clutch cover with the pressure plate.

Check clutch

PERFORMANCE ORDER

	1. Check the clutch facings and at presence with them of traces of oil or mechanical damages replace a coupling disk.
2. Check the riveted joints friction linings to the disc clutch. In the presence of defects, replace the clutch disc.
	3. Check the protrusion of the friction linings over heads of rivets. If the protrusion is less than acceptable, replace the clutch disc. The protrusion: 0.3 mm
	4. Insert a disc clutch on the mandrel in the centers and the indicator of hour type measure its palpation. If palpation above admissible, replace a coupling disk. Heartbeat: 0.7 mm

Setting

PERFORMANCE ORDER

	1. A hammer and tubular mandrel set the central bearing. The outer diameter of the bearing - 35 mm.
2. Clean the threads of the mounting bolts of the flywheel of the hermetic rests. Before screwing bolts put on a carving of bolts fresh hermetic.
3. Establish a flywheel and special adaptation OK590 111 001 prevent it from turning.
	4. In certain sequence tighten bolts of a flywheel. Torque: 96-103 N ??? m
5. Clean the spline on the clutch and apply a thin layer of grease on the basis of molybdenum disulphide.
A warning Lubricate splines on the clutch disc and install it on the flywheel. Then remove the excess grease from the end surface of the disc slots or drive shaft transmission.
	6. Install the drive coupling and center its special mandrel OK130 160 010.
7. Install the clutch cover with a press disk on directing pins of a flywheel.
	8. Gradually, in diagonal sequence and in a certain order, tighten the flywheel bolts. Torque: 17,65-26,48 N ??? m