Kia Picanto (JA): Clutch System / Clutch Release Cylinder

Kia Picanto (JA) 2017-2025 Service & Repair Manual / Clutch System / Clutch System / Clutch Release Cylinder

Repair procedures

Removal
[Kappa 1.0 T-GDI]
1.
Remove the engine room under cover.
G 1.0 T-GDI KAPPA (Refer to Engine Mechanical System - "Engine Room Under Cover")
2.
Drain the brake fluid through the bleed plug (A).
   
Do not spill brake fluid on the vehicle; it may damage the paint if brake fluid does contact the paint, wash it off immediately with water.

3.
Loosen the release cylinder bolts (A) and then clutch tube nut (B) after removing release cylinder assembly (C).
Tightening torque:
14.7 - 21.6 N·m (1.5 - 2.2 kgf·m, 10.8 - 15.9 lb·ft)

Installation
1.
Install in the reverse order of removal.
   
Apply the specified grease to the push rod end.
Specified grease: CASMOLY L9508
Quantity: 0.4 - 0.8 g

Inspection
1.
Check the clutch release cylinder for fluid leakage.
2.
Check the clutch release cylinder boot for damage.
Adjustment
Clutch Release Cylinder Air Bleeding Procedure
   
Use the specified fluid. Avoid mixing different brands of fluid.
1.
After disconnecting a cap from the clutch release cylinder air bleeder, insert a vinyl hose in the plug.
2.
Refill the clutch master cylinder with the specified fluid.
Specified fluid : SAE J1703 (DOT 3 or DOT 4)
3.
Loosening the plug screw, press and release the clutch pedal about 10 times.
4.
Tighten the plug (A) during the clutch pedal pressed. Afterwards, raise the pedal with a hand.
5.
After pressing the clutch pedal 3 times more, loosen the plug (A) and re-tighten it with the pedal pressed. Raise it again, then.
Tightening torque:
6.8 - 9.8 N·m (0.7 - 1.0 kgf·m, 5.0 - 7.2 lb·ft)
6.
Repeat the step 4 two or three times.
(until there is no bubble in the fluid)

7.
Refill the clutch master cylinder with the specified fluid.

    Components and components location Components [Kappa 1.0 T-GDI] 1. Clutch pedal assembly 2. Ignition lock and clutch switch 3. Master cylinder 4.

    Components and components location Components [Kappa 1.0 MPI / FFV, Kappa 1.2 MPI] 1. Clutch disc assembly 2. Clutch cover assembly 3. Clutch release bearing 4.

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