Kia Carens. Manual - part 104

• Install pilot bearing flush with flywheel.
• Wipe off residual grease when assembling the release bearing to nose part of transmission primary

shaft.

• Wipe off residual grease when assembling the clutch disc to transmission primary shaft.

1. Install pilot bearing flush with a suitable tool.

Bearing outer diameter : 1.378 in (35 mm)

2. Wipe bolts and apply sealant to bolt threads.

3. Install flywheel and SST(0K590 111 001).

4. Tighten bolts in pattern shown below.

Tightening torque : 70.8~75.9lb-ft (96.1~103.0 N·m, 9.8~10.5 kg-m)

5. Clean clutch disc internal splines ; then apply a thin coat of molybdenum disulfide grease to the splines.

6. Hold clutch disc in position with SST(0K130 160 010).

7. Align dowel holes of clutch cover assembly with flywheel dowels.

8. Tighten bolts perpendicularly and gradually in pattern shown below.

Tightening torque : 13.0~19.5 lb-ft(17.6~26.5 N·m, 1.8~2.7 kg-m)

9. Install transaxle assembly.(Refer to section manual transaxle.)

Inspection

Release bearing

The clutch release bearing is sealed, and should not be washed in solvent.

1. Turn bearing while applying force in axial direction.

If bearing sticks or has excessive resistance, replace it.

Clutch cover

1. Inspect contact surface of pressure plate for scoring, cracks, and burning. Resurface or replace as

necessary.

2. Inspect release bearing contact surface (on the diaphragm spring fingers )for wear and cracks. if there is

wear or cracks on diaphragm fingers, replace clutch cover assembly.

Clutch disc

1. Inspect lining surface for burning oil contamination or other damage.

Replace clutch disc if it is burned, oil soaked or other damaged.

2. Inspect for loose clutch facing rivets and damaged torsional dampers.

Replace clutch disc if either is faulty.

3. Measure depth of lining from clutch face to head of a rivet with calipers. Replace clutch disc if thickness on

either side is less than minimum.

Thickness : 0.012 in (0.3 mm) minimum

4. Measure clutch disc runout with a dial indicator.

Replace clutch disc if runout is excessive.

Runout : 0.028 in (0.7 mm) maximum

Pilot bearing

1. Turn bearing while applying force in axial direction. If bearing sticks or has excessive resistance, replace it.

Flywheel

Minor scoring or burning should be reoved with remery cloth.

1. Inspect contact surface of flywheel for scoring, cracks, and burning ; resurface or replace as necessary.

2. Inspect starter ring gear teeth for wear or damage. If necessary, replace ring gear.

Inspection

Release bearing

The clutch release bearing is sealed, and should not be washed in solvent.

1. Turn bearing while applying force in axial direction.

If bearing sticks or has excessive resistance, replace it.

Clutch cover

1. Inspect contact surface of pressure plate for scoring, cracks, and burning. Resurface or replace as

necessary.

2. Inspect release bearing contact surface (on the diaphragm spring fingers )for wear and cracks. if there is

wear or cracks on diaphragm fingers, replace clutch cover assembly.

Clutch disc

1. Inspect lining surface for burning oil contamination or other damage.

Replace clutch disc if it is burned, oil soaked or other damaged.

2. Inspect for loose clutch facing rivets and damaged torsional dampers.

Replace clutch disc if either is faulty.

3. Measure depth of lining from clutch face to head of a rivet with calipers. Replace clutch disc if thickness on

either side is less than minimum.

Thickness : 0.012 in (0.3 mm) minimum

4. Measure clutch disc runout with a dial indicator.

Replace clutch disc if runout is excessive.

Runout : 0.028 in (0.7 mm) maximum

Pilot bearing

1. Turn bearing while applying force in axial direction. If bearing sticks or has excessive resistance, replace it.