Repair Procedures: Installation

NOTE:

Check that the input shaft spline part (A) is sufficiently greased before installing the dual clutch assembly. If the input shaft spline part is not greased, apply the grease to 10 mm (0.3937 in.) on each spline end.
If an excessive amount of grease is applied, it may get scattered by centrifugal force, contaminating the clutch disc. This can lead to loss of friction force.
Specified Grease: Extreme pressure grease for vehicle

Quantity: 0.15 - 0.25 g

Fig 1: Checking Input Shaft Spline Part
Courtesy of KIA MOTORS AMERICA, INC.

If dual clutch assembly needs replacement, perform the clutch wear compensation Initialize.
1. Remove the fork cover (A).
  
  Fig 2: Removing Fork Cover
  Courtesy of KIA MOTORS AMERICA, INC.
2. Remove the clutch actuator assembly (A).
  
  Fig 3: Removing Clutch Actuator Assembly
  Courtesy of KIA MOTORS AMERICA, INC.
3. Perform the clutch wear compensation Initialize.
  (Refer to Dual Clutch Transmission Control System - "CLUTCH ACTUATOR ASSEMBLY ")
4. Install the clutch actuator assembly (A).
  Tightening Torque:
  
  19.6 - 26.5 N.m (2.0 - 2.7 kgf.m, 14.5 - 19.5 lb.ft)
  
  Fig 4: Installing Clutch Actuator Assembly
  Courtesy of KIA MOTORS AMERICA, INC.
5. Install the fork cover (A).
  Tightening Torque:
  
  3.9 - 5.9 N.m (0.4 - 0.6 kgf.m, 2.9 - 4.3 lb.ft)
  
  Fig 5: Installing Fork Cover
  Courtesy of KIA MOTORS AMERICA, INC.
Install the double clutch assembly (A) by using double clutch installer (09430-2A240).

Fig 6: Installing Double Clutch Assembly (1 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.

Fig 7: Installing Double Clutch Assembly (2 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.
Install the snap ring (A).

Fig 8: Installing Snap Ring
Courtesy of KIA MOTORS AMERICA, INC.
Install the spline hub (B) and the retaining ring (A).

Fig 9: Installing Spline Hub And Retaining Ring
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Check the installation condition of retaining ring after installing.

Fig 10: Checking Retaining Ring Installation Condition
Courtesy of KIA MOTORS AMERICA, INC.
Install the hybrid drive motor assembly to the DCT assembly.
(Refer to Hybrid Motor System - "HYBRID DRIVE MOTOR ASSEMBLY ")
Install the hybrid drive motor & dual clutch transmission assembly to the vehicle.
(Refer to DCT System - "DCT ")