2003-2008 Kia Cerato Spectra LD Service & Repair Manual

8/13/12 https://www.kiatechinfo.com/viewer/toc_print.asp?vehicletype=Passenger&mfrcode=KM&area=KM… 1/26 https://www.kiatechinfo.com/viewer/toc_print.asp?vehicletype=Passenger&mfrcode=KM&area=KM… SPECTRA(LD) > 2007 > G 2.0 DOHC > Clutch System Clutch System > General Information > Special Service Tools SPECIAL TOOLS Tool (Number and name) Illustration Use 0941125000 Clutch disc guide Installation of the clutch disc. Clutch System > General Information > Troubleshooting TROUBLESHOOTING Trouble symptom Suspect area Remedy (See page) Clutch slipping • Car will not respond to engine speed during acceleration • Insufficient vehicle speed • Lack of power during uphill driving Insufficient pedal free play Adjust Clogged hydraulic system Correct or replace parts Excessive wear of clutch disc facing Replace Hardened clutch disc facing, or oil on surface Replace Damaged pressure plate or flywheel Replace Weak or broken pressure spring Replace Difficult gear shifting (gear noise during shifting) Excessive pedal free play Adjust Hydraulic system fluid leaks, air trapping or clogging Repair or replace parts Unusual wear or corrosion of the clutch disc spline Replace Excessive vibration (distortion) of the clutch disc Replace Clutch noisy When the clutch is not used Insufficient play of the clutch pedal Adjust Excessive wear of the clutch disc facing Replace A noise is heard after the clutch is disengaged Unusual wear and/ or damage of the release bearing Replace A noise is heard when the clutch is disengaged Insufficient grease on the sliding surface of the bearing sleeve Repair Improperly installed clutch assembly or bearing Repair A noise is heard when the car suddenly rolled up with the clutch partially engaged Damaged pilot bushing Replace Hard pedal effort Insufficient lubrication of the clutch pedal Repair Insufficient lubrication of the spline part of clutch disc Repair Insufficient lubrication of the clutch release lever shaft Repair Insufficient lubrication of the front bearing retainer Repair

8/13/12 https://www.kiatechinfo.com/viewer/toc_print.asp?vehicletype=Passenger&mfrcode=KM&area=KM… 2/26 https://www.kiatechinfo.com/viewer/toc_print.asp?vehicletype=Passenger&mfrcode=KM&area=KM… Hard to shift or will not shift Excessive clutch pedal free play Adjust the pedal free play Faulty of the clutch release cylinder Repair the release cylinder Clutch disc out of place, runout is excessive or lining broken Inspect the clutch disc Spline on the input shaft or clutch disc dirty or burned Repair as necessary Faulty of the clutch pressure plate Replace the clutch cover Clutch slips Insufficient clutch pedal free play Adjust the pedal free play Clogged of the hydraulic system Repair or replace parts Clutch disc lining oily or worn out Inspect the clutch disc Faulty pressure plate Replace the clutch cover Binding of the release fork Inspect the release fork Clutch grabs/chatters Clutch disc lining oily or worn out Inspect the clutch disc Faulty the pressure plate Replace the clutch cover Bent clutch diaphragm spring Replace the clutch cover Worn or broken torsion spring Replace the clutch disc Engine mounts loose Repair as necessary Clutch noisy Damaged the clutch pedal bushing Replace the clutch pedal bushing Loose part inside housing Repair as necessary Worn or dirty release bearing Replace the replease bearing Sticking release fork or linkage Repair as necessary Clutch System > General Information > Specifications SPECIFICATIONS Clutch operation method Hydraulic type Clutch disc Type Single dry with diaphragm Facing diameter (outside x inside)mm (in.) 215 x 145 (8.5 x 5.7) Clutch cover assembly Type Diaphragm spring strap Clutch release cylinder * I.D. mm (in.) 20.64 (0.81) Clutch master cylinder * I.D. mm(in.) 15.87 (0.62) * I.D: Inside diameter SERVICE STANDARD Standard value Clutch disc thickness [When free] Clutch pedal height Clutch pedal free play Clutch pedal stroke 8.5 ± 0.3 mm (0.326 ~ 0.350 in.) 166.9 mm 6 ~ 13 mm (0.24 ~ 0.51 in.) 145 mm (5.7 in.) Limit Clutch disc rivet sink Diaphragm spring end height difference Clutch replease cylinder clearance to piston Clutch master cylinder clearance to piston 1.1 mm (0.044 in.) 0.5 mm (0.02 in.) 0.15 mm (0.006 in.) 0.15 mm (0.006 in.)

8/13/12 https://www.kiatechinfo.com/viewer/toc_print.asp?vehicletype=Passenger&mfrcode=KM&area=KM… 3/26 https://www.kiatechinfo.com/viewer/toc_print.asp?vehicletype=Passenger&mfrcode=KM&area=KM… TIGHTENING TORQUE Item Nm kg·cm lb·ft Clutch pedal to pedal support member (Clutch pedal bracket) 25 ~ 35 250 ~ 350 18 ~ 25 Clutch pedal support member to master cylinder 19 ~ 20 190 ~ 200 13 ~ 14 Clutch tube flare nut 12 ~ 16 120 ~ 160 9 ~ 12 Clutch tube bracket 12 ~ 15 120 ~ 150 9 ~ 11 Clutch release cylinder 15 ~ 22 150 ~ 220 11 ~ 16 Clutch release cylinder union bolt 25 ~ 35 250 ~ 350 18 ~ 25 Clutch cover assembly 15 ~ 22 150 ~ 220 10 ~ 16 Clutch reserve tank bracket bolt 12 ~ 16 120 ~ 160 9 ~ 12 Clutch reserve tank tube nut 12 ~ 16 120 ~ 160 9 ~ 12 Clutch release fork nut 27 ~ 40 270 ~ 400 20 ~ 29 Roll rod support bracket washer bolt 60 ~ 80 600 ~ 800 40 ~ 60 Release bearing washer bolt 6~8 60 ~ 80 4~6 Ignition lock switch nut 8 ~ 10 80 ~ 100 6~7 LUBRICANTS Items Specified lubricants Quantity Contact surface of release bearing and fulcrum of clutch release fork CASMOLY L 9508 As required Inner surface of clutch release bearing CASMOLY L 9508 As required Inner surface of clutch release cylinder and outer circumference of piston and cup Brake fluid DOT 3 or DOT 4 As required Inner surface of clutch disc spline CASMOLY L 9508 As required Inner surface of clutch master cylinder and outer circumference of piston assembly Brake fluid DOT 3 or DOT 4 As required Clutch master cylinder push rod, clevis pin and washer Wheel bearing grease SAE J310, NLGI No.2V As required Clutch pedal shaft and bushings Chassis grease SAE J310a, NLGI No.1 As required Contact portion of release fork to release cylinder push rod CASMOLY L 9508 As required Input shaft spline CASMOLY L 9508 As required Clutch System > Clutch System > Components and Components Location COMPONENTS

8/13/12 https://www.kiatechinfo.com/viewer/toc_print.asp?vehicletype=Passenger&mfrcode=KM&area=KM… 4/26 https://www.kiatechinfo.com/viewer/toc_print.asp?vehicletype=Passenger&mfrcode=KM&area=KM…

8/13/12 https://www.kiatechinfo.com/viewer/toc_print.asp?vehicletype=Passenger&mfrcode=KM&area=KM… 5/26 https://www.kiatechinfo.com/viewer/toc_print.asp?vehicletype=Passenger&mfrcode=KM&area=KM… COMPONENTS

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2003-2008 Kia Cerato Spectra LD Service & Repair Manual

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