Kia Carens: Clutch Pedal / Repair procedures

Kia Carens RP (2013-2018) Service Manual / Clutch System / Clutch Pedal / Repair procedures

Removal
1.
Remove the battery.
G 1.6 GDI (Refer to Engine Electrical System - "Battery")
G 2.0 GDI (Refer to Engine Electrical System - "Battery")
G 2.0 MPI (Refer to Engine Electrical System - "Battery")
D 1.7 LP (Refer to Engine Electrical System - "Battery")
D 1.7 HP (Refer to Engine Electrical System - "Battery")
2.
Remove the ECM.
G 1.6 GDI (Refer to Engine Control/Fuel System - "Engine Control Module")
G 2.0 GDI (Refer to Engine Control/Fuel System - "Engine Control Module")
G 2.0 MPI (Refer to Engine Control/Fuel System - "Engine Control Module")
D 1.7 LP (Refer to Engine Control/Fuel System - "Engine Control Module")
D 1.7 HP (Refer to Engine Control/Fuel System - "Engine Control Module")
3.
Remove the following items.
[Diesel 1.7 LP / HP]
(1)
Remove the fuel filter.
D 1.7 LP (Refer to Engine Control/Fuel System - "Fuel Filter")
D 1.7 HP (Refer to Engine Control/Fuel System - "Fuel Filter")
(2)
Remove the regulator (B) and reservoir hose (A) from the clutch master cylinder.
  
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.

[Gasoline 1.6 / 2.0]
(1)
Disconnect the clutch tube (B) and reservoir hose (A) from the clutch master cylinder.
  
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.

4.
Disconnect the clutch sensor connector. (Only Electronic Parking Brake)

5.
Remove the smart junction box.
(Refer to Body Electrical System - "Relay Box (Passenger Compartment)")
6.
Remove the clutch pedal.
(1)
Disconnect the ignition lock switch connector (A) and clutch switch connector (B).

(2)
Loosen the clutch pedal mounting nuts (A) and bolt (B).
Tightening torque:
16.7 ~ 25.5 N.m (1.7 ~ 2.6 kgf.m, 12.3 ~ 18.8 lb-ft)

(3)
Disconnect the wiring from the clutch pedal aseembly.
(4)
Remove the clutch pedal with master cylinder assembly.
7.
Remove the master cylinder from the clutch pedal.
(1)
Separate the push rod (C) after remove the pin (A) and washer (B).
(2)
Remove the master cylinder by rotating in a clockwise direction.

Installation
  
When installing, O-rings of clutch tube & regulator connector should be replaced with a new one.
1.
Install in the reverse order of removal.
2.
After be equipped, perform bleeding air procedure after pouring the brake fluid.
[Gasoline 1.6 / 2.0, Diesel 1.7 LP]
(Refer to Clutch System - "Clutch Release Cylinder")
[Diesel 1.7 HP]
(Refer to Clutch System - "Concentric Slave Cylinder Assembly")
Components and components location
Components 1. Clutch switch 2. Ignition lock switch 3. Clutch pedal assembly 4. Master cylinder assembly 5. Connector (Only diesel) 6. Regu ...

Clutch Master Cylinder
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