Question about 2004 Kia Rio

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Wanting to replace the clutch because it is slipping.

I need to replace the clutch, and am unable to find a diagram to guide me through it

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  • Richard Scordino May 11, 2010

    Chiltons and Haynes sell an inexpensive manual $20 that should give you some help. Avaliable at most larger parts stores.

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  • Master
  • 1,959 Answers

Hope this helps. Best of luck to you!
Greg

Removal & Installation

  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Disconnect the negative battery cable.
  3. Remove the transaxle.
  4. Gradually loosen the clutch pressure plate bolts, in a crisscross pattern. Support the pressure plate and remove the bolts. Remove the pressure plate and clutch disc.
  5. Inspect the pilot bearing. If it is worn or damaged and does not turn easily by hand, remove it using a puller/slide hammer.
  6. Check the flywheel surface for scoring, cracks or burning and machine or replace, as necessary.
  7. Install a flywheel holder to keep the flywheel from turning. Loosen the flywheel bolts evenly and gradually in a crisscross pattern. Remove the flywheel.
  8. Inspect the clutch release bearing for wear. Replace it if it sticks or does not turn easily.
  9. Inspect the release fork for wear or damage and replace as necessary.
To install: wanting to replace the clutch because it is slippi - 7923kg32.gif Structural view of the hydraulic clutch system
7923kg33.gif Exploded view of the clutch assembly
wanting to replace the clutch because it is slippi - 7923kg34.gif to Enlarge
Flywheel tightening sequence
7923kg35.gif Pressure plate tightening sequence

  1. Lubricate the release fork fingers and pivot with molybdenum grease and install in the release fork boot.
  2. Install the clutch release bearing on the release fork.
  3. Install a new pilot bearing in the flywheel, if removed.
  4. Be sure the flywheel mounting surface and the crankshaft or eccentric shaft mounting surfaces are clean. Remove any old sealant from the flywheel bolt hole threads and the flywheel bolts.
  5. Install the flywheel.
  6. Apply sealant to the flywheel bolt threads and install them hand-tight. Install the flywheel holding tool. Tighten the bolts, in a crisscross pattern, to 71–76 ft. lbs. (96–103 Nm).
  7. Apply a small amount of molybdenum grease to the clutch disc splines and install the clutch disc on the flywheel, spring side toward the transaxle. Install a suitable alignment tool in the pilot bearing to position the clutch disc.
  8. Install the clutch pressure plate, aligning the dowel holes with the flywheel dowels.
  9. Install the pressure plate bolts and gradually tighten, in a crisscross pattern to 20 ft. lbs. (26 Nm). Remove the alignment tool.
  10. Install the transaxle.

Posted on May 20, 2009

  • Greg Margossian
    Greg Margossian May 20, 2009

    Here are the missing pics.







  • Greg Margossian
    Greg Margossian May 29, 2009

    Kindly rate the solution I provided should you find it answered your question. Thanks very much and good luck.

    Greg

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