Kia Niro: Clutch System / Clutch Cover And Disc Repair procedures

Removal

1.	Remove the hybrid motor assembly. (Refer to Hybrid Motor System - "Hybrid Motor Assembly")

2.	Remove the clutch cover assembly and clutch disc after loosening the bolts.

Be careful not to be bent or twist bolts. Loosen bolts in diagonal directions.

Inspection

1.	Inspect diaphragm spring wear which is in contact with a concentric slave cylinder bearing.

2.	Check the clutch cover and disc surface for wear or cracks.

3.	Check the clutch disc lining for slipping or oil marks.

Measure the depth from a clutch lining surface to a rivet. If the measured value is less than the specification below, replace it.

Clutch disc depth (A): 6.4 ± 0.2 mm (0.2519 ± 0.0078 in.)

Clutch disc rivet depth (B): 0.3 mm (0.0118 in.)

Installation

•	If reinstalling used cover, the cover should be installed with its clutch disc as a set.

•	If you only replace a disk, the adjustment ring may malfunction, resulting in a slip due to the initial decrease of clamp load. (This is because the clutch cover is adjusted by as much as the amount of its wear.)

•	If you only replace a disk, the disk may exceed its acceptable thickness for assembly, making it difficult to block the driving force.

Apply grease on a disc spline part and hybrid motor input shaft spline part as required.

•	When not applying: Excessive wear of splines and bad clutch operation can occur.

•	When excessively applying: Grease can be scattered by centrifugal force which can contaminate the clutch disc. This can cause a loss of friction force causing a slip.

2.	The 'T/M SIDE' marked surface should face the transaxle.

3.	Install the clutch disc and the cover with SST (09411-1P000, 09411-G2100).

Install the clutch cover bolts.

•	Loosely tighten every clutch cover bolts, then torque to specifications in a diagonal direction. This can prevent twisting, vibration of the cover, and the lifting of the pressure plate.

•	Install the all the components with the specified torques. If not, the clutch torque transaxle may have concerns or the mounting bolt can loosen.

5.	Install the hybrid motor assembly. (Refer to Hybrid Motor System - "Hybrid Motor Assembly")

After replacing the concentric slave cylinder assembly, operate the followings in order using GDS / KDS equipment.

(1)	Engine clutch inspection line learning and diagnostic information.

(2)

Removal of air from engine clutch hydraulic pressure line

•	When using vacuum pressurized hydraulic fluid injection device, change maximum vacuum pressure to 2.5 torr and injection pressure to 2.3-2.5 bar.

•	If it is impossible to inject hydraulic fluid using the above condition, be sure to remove air from the hydraulic line of the engine clutch at a temperature between 0 - 40°C.

(3)	Engine clutch/motor resolver adaptation.

(4)	Stabilization of the engine clutch hardware transfer torque.

Components 1. Clutch disc 2. Clutch cover 3. Concentric slave cylinder 4. Hybrid motor assembly 5. Engine clutch actuator 6. Reservoir ...

Components 1. Clutch disc 2. Clutch cover 3. Concentric slave cylinder 4. Hybrid motor assembly 5. Engine clutch actuator 6. Reservoir ...

Kia Niro 2017 (DE HEV) Service Manual: High voltage shut-off procedures
High Voltage Shut-off Procedures • Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system. Failure t ...