Valeoscope - Transmission Syst. Clutch KIT4P Conversion Kit

Transmission Systems

KIT4P Conversion kit

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Valeo clutches, expertise & innovation dedicated to customer satisfaction

D.M.F. g Designed for lasting performance g Improved driving comfort D.M.F./KIT4P Adapted to your needs! KIT4P g Economical & reliable g Alternative solution to D.M.F. Hydraulics g All-in-one solution g Quick & easy to install

Aftermarket self-adjusting solutions 2 offers: g S.A.T. (O.E. solution for I.A.M.) g H.E.C. (I.A.M. solution) 3 main benefits: g Easy to fit! No need for a specialist tool g Economical solution g Constant pedal effort = comfort!

Traditional Kits g One of the market’s best coverage rates g Best-in-class Valeo friction material

Table of Contents 1. Disclaimer 2. Valeo, your Transmission Systems Multi-Specialist 3. Valeo TechAssist 4. Why Conversion kit - KIT4P 5. KIT4P composition 5.1 Mechanical or semi-hydraulic clutch actuation 5.2 Full hydraulic clutch actuation 6. KIT4P design: Long Travel Damper 6.1 Long Travel Damper technology 6.2 Long Travel Damper innovative characteristics 6.3 Long Travel Damper key benefits 6.4 Long Travel Damper evolution: High Angular Displacement (H.A.D.) Technology 7. KIT4P Main advantages

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MORE ABOUT VALEO KIT4P?

7.1 A reliable solution 7.2 Increased clutch life 7.3 Efficient torque transfer 7.4 Comfortable solution 7.5 Non-wear flywheel & Service Kit 7.6 Easy to fit 7.7 D.M.F. & KIT4P Comparison

qr.valeodrive.com/998100/003097

8. KIT4P Technical support 8.1 Technical fitting instructions 8.1.1 After disassembling the gearbox from the engine

8.1.2 Fixing the flywheel to the crankshaft 8.1.3 Preparation of the clutch for fitment 8.1.4 Fitting the clutch 8.1.5 Re-assembling the gearbox 8.1.6 After the fitment – verify that the clutch is functioning correctly 8.2 KIT4P box content

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8.2.1 KIT4P product notice 8.2.2 KIT4P fitting notice 8.2.3 KIT4P sticker 8.2.4 KIT4P fitting bolts

9. F.A.Q. - Everything you need to know about KIT4P 10. Conclusion

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Foreword

Our Multi-Specialist expertise is rooted in our genes.

As one of the leading automotive system designers and manufacturers, nothing is more natural for Valeo than to deliver 14 product lines for passenger cars and 8 products lines for heavy-duty vehicles, serving all distribution channels from car makers’ networks to independent aftermarket and modern distribution, in more than 120 countries all over the world. Valeo Transmission Systems’ mission is to be the sup- plier of choice for all powertrain architectures with innovative technologies developed for efficient and comfortable power transfer from the engine to the transmission, whilst reducing fuel consumption. All Valeo clutches are manufactured to Valeo’s highest quality standards, making Valeo products efficient and reliable and ensuring full customer satisfaction. Efficient because Valeo’s expertise in research and development allows the reduction of clutch noise and vibrations along with enhanced driver comfort through better gear changes, giving consumers a smoother and more comfortable ride.

Valeo - from original equipment leadership to aftermarket excellence In order to meet consumer needs, Valeo Service in- troduced Valeo KIT4P and is now proud to present to you this technical handbook which will fully explain what KIT4P is, why it was developed and how it has been designed in order to optimize consumer benefits. All fitting steps and related material will be detailed, and the most frequently asked questions will be addressed. The worldwide vehicle car parc consists of 69% passenger cars and is growing by 3.9% per year. Every second passenger car or light commercial vehicle which rolls off the assembly line is equipped with a D.M.F., and that share is still increasing. Consequently, the share of vehicles in Europe equipped with a D.M.F. is estimated to increase to 39% by 2018. Reliable because Valeo clutches are able to perform in the most hostile operating environments. Valeo aftermarket customers benefit from this Original Equipment (O.E.) expertise, rigor and quality.

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Disclaimer

Whilst we endeavour to ensure that the information included in this training documentation is correct, we do not warrant its completeness or accuracy; nor do we commit to ensuring that the material in the documentation is kept up to date. To the maximum extent permitted by applicable law, we exclude all representations, warranties and conditions relating to this documentation and the use of this documentation (including, without limi- tation, any warranties implied by law in respect to satisfactory quality, fitness for purpose and/or the use of reasonable care and skill). Nothing in this disclaimer will: (a) limit or exclude our or your liability for death or personal injury resulting from negligence; (b) limit or exclude our or your liability for fraud or fraudulent misrepresentation;

(c) limit any of our or your liabilities in any way that is not permitted under applicable law; or (d) exclude any of our or your liabilities that may not be excluded under applicable law. The limitations and exclusions of liability set out in this section and elsewhere in this disclaimer: (a) are subject to the preceding paragraph; and (b) govern all liabilities arising under the disclaimer or in rela- tion to the subject matter of this disclaimer, inclu- ding liabilities arising in contract, in tort (including negligence) and for breach of statutory duty. To the extent that this documentation and this training documentation are provided free of charge, we will not be liable for any loss or damage of whatsoever nature.

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Valeo is an automotive supplier, partner to all automakers worldwide. As a technology company, Valeo proposes innovative products and systems that contribute to the reduction of CO 2 emissions and to the development of intuitive driving. In 2013, the Group generated sales of € 12.1 billion euros and invested over 10% of its original equipment sales in research and development. Valeo has 124 production sites, 16 Research centers, 35 Development centers and 12 distribution platforms, and employs 74,800 people in 29 countries throughout the world. Valeo consists of 4 Business Groups: Powertrain Systems, Thermal Systems, Comfort and Driving, Assistance Systems and Visibility Systems. Together, these 4 Business Groups comprise 16 Product Groups and supply both the Original Equipment (O.E.) market and the aftermarket. The Transmission Systems product portfolio is part of Valeo’s Powertrain Systems Business Group. Valeo, your Transmission Systems Multi-Specialist

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Valeoscope library

Technical handbooks

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The A/C system Thermal comfort loop

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KIT4P Conversion kit

Self Adjusting Technology (S.A.T.) High Efficiency Clutch (H.E.C.)

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998121 -VS -TransmissionSystems -ClutchHECSAT -Porduct focus valeoscope -EN.indd 1

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998123 -VS -TransmissionSystems -ClutchHydraulics -Product focus valeoscope -EN.indd 1

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Transmission Systems Clutch HEC-SAT Ref: 998121

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Transmission Systems Clutch KIT4P Ref: 998102

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valeo-techassist.com

You will benefit from Valeo TechAssist throughout the entire workshop service process:

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Get product information: product data sheets provide details in addition to the catalogue information.

Find common failures: step-by-step failure diagnosis guides about typical faults.

Keep you updated about Valeo Service products: full access to all Technical Service Bulletins. Find help when it is needed: answers to frequently asked questions and contact to the Valeo Service technical hotline Use Valeo workshop tools efficiently: retrieve user manuals, service manuals and software updates on Valeo Service tools. Learn about new technologies: online training modules (e-learning) and self-study documents about most modern product technologies. In addition, you have access to some advanced features: Add comments to any document: give personal feedback to Valeo Service and contribute to a continuous service improvement. Fill in your evaluation: provide feedback on your satisfaction. Write a fitting testimony: share your experience with other users.

Valeo TechAssist is a web-based application, speci- fically developed for repair workshops, automotive spare parts distributors and technical trainers. Valeo TechAssist is available at any time, and 10 languages are implemented to date. Just connect to the website www.valeo-techassist.com. Valeo TechAssist is not only a technical database, but also a learning platform and a forum for infor- mation exchange. It covers passenger cars and all Valeo product lines. The information in Valeo TechAssist is structured in four comprehensive domains:

1.Product documentation 2.Technical assistance 3.Workshop tools 4.Technical training

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Why Conversion kit - KIT4P? Today’s modern engines produce higher torques and can be driven at low engine speeds. The resulting higher maximum engine torque to be transmitted leads to increased vibration and noise. One of the key reasons why diesel cars and light commercial vehi- cles have become much quieter over recent years and less prone to rattling is the development of the Dual Mass Flywheel (D.M.F.) technology. Yet certain applications faced problems linked to the D.M.F. resulting in early flywheel and clutch repla- cement. D.M.F. manufacturers including Valeo have improved D.M.F. technology to reduce such problems. As an alternative offer to the spare parts market (I.A.M.), Valeo has also developed the KIT4P. In Europe, the story began in Spain with the first KIT4P for Volkswagen 1.9Tdi engines that were used on taxi models. The technical problem was poor heat dissi- pation and rapid wear. The affected customers were seeking a more reliable solution. For Valeo designing an alternative and efficient solution as KIT4P was obvious. KIT4P has been in the spare parts market since 2002 with high success and customer satisfac- tion. The rigid flywheel and clutch kit combination is designed for today’s high engine torques and capable of filtering the engine acyclisms. KIT4P ensures correct clutch functionality under all driving conditions, filters out the vibration and noise generated by the engine, and fully protects the engine and the gearbox. It is important to remember that Valeo is an increasin- gly important O.E. Dual Mass Flywheel supplier for several car makers. Valeo’s powertrain technology roadmap clearly identifies D.M.F. as a future solution for different powertrain structures. It is important to note that within technological constraints, both D.M.F. and rigid flywheel solutions are possible according to the car maker’s choice.

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KIT4P composition

KIT4P is composed of a rigid flywheel with no wear and a high-performance clutch kit. The rigid flywheel has its key timing slots machined and aligned correctly, which means that there is no risk of poor starting and running once fitted. The clutch kit within a KIT4P contains a long travel damper clutch disc which incorporates a high-tech pre-damper multi-cassette and “long-travel” dampers. The specific KIT4P composition can vary depending on clutch actuation.

Clutch Disc

Rigid Flywheel

Clutch Cover

Clutch Cover Fitting Bolts

Flywheel Fitting Bolts

Release Bearing

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Vehicles with mechanical (clutch cable) or semi- hydraulic (master & release cylinder) clutch actua- tors are equipped with a conventional type of me- chanical bearing. In this case, the KIT4P contains: 5.1 Mechanical or semi-hydraulic clutch actuation

g Rigid Flywheel g Clutch Cover g Clutch Disc g Release Bearing g Fitting bolts

Semi-hydraulic clutch actuation (Clutch Master Cylinder & Clutch Release Cylinder)

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5. KIT4P composition

Vehicles with full hydraulic clutch actuators are equip- ped with a concentric slave cylinder (C.S.C.). In this case, Valeo offers two product alternatives: 5.2 Full hydraulic clutch actuation

Full hydraulic clutch actuation (Clutch Master Cylinder & Concentric Slave Cylinder)

KIT4P without C.S.C. g Rigid Flywheel g Cover g Disc g Fitting bolts

KIT4P with C.S.C. g Rigid Flywheel g Cover g Disc g Concentric Slave Cylinder g Fitting bolts

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KIT4P design: Long Travel Damper (L.T.D.)

6.1 Long Travel Damper technology

The D.M.F. is designed to increase the mass moment of inertia of the transmission without increasing the mass to be shifted (flywheel weight) or, in other words, to equalize the iner- tia between gearbox and flywheel. The KIT4P is composed of a rigid flywheel with a significant moment of inertia used as a storage device for rotational energy. Thanks to Valeo’s Long Travel Damper technology, the dampening function can be transferred to the clutch disc. In certain cases, however, Valeo may use a stan- dard damper to comply with clutch requirements due to design and vehicle characteristics.

Engine

Gear box

Rigid flywheel Clutch kit with L.T.D. KIT4P

Filtration of engine acyclism in case of KIT4P

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6. KIT4P design: Long Travel Damper (L.T.D.)

The L.T.D. technology consists of a specific friction plate with a high damper capacity and a damper with very low stiffness for improved filtration and transmission performance. This low angular stiffness coupled with the specifically matched flywheel inertia ensures the appropriate damping level as well as an extended life of the clutch kit.

Current Valeo O.E. Long Travel Damper techno- logy can be found in three product categories; SX, WX and High Angular Displacement Techno- logy (NX1…NX4). The design depends on the maximum torque of the vehicle engine and on the diameter of the clutch. A majority of the KIT4P range features a WX damper. On certain applications such as Ford Transit, an SX damper is used. The H.A.D. technology is used only in O.E. currently. This will enable Valeo to develop further KIT4P versions for vehicles with higher torques on the I.A.M.

Multi spring pre-damper cassette with 2 stages

Main damper springs 2 or even 3 stages

Plate retaining stilts

Damper hysteresis washers

WX Long Travel Damper Disc combination

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SX type

HAD (NX1...NX4)

WX type

Key features

Sizes from 228 mm or with min 170 mm inner diameter

Sizes from 190 mm

Sizes from 220 mm or with min 155 mm inner diameter

Engine torque up to 280 Nm

Engine torque up to 360 Nm

Engine torque up to 360 Nm

Valeo O.E. technology since 2000

Valeo O.E. technology since 2009

Valeo O.E. technology since 1994

Innovative characteristics

Low main damper stiffness and robustness for life

Compact design for low inertia

Large anti-creeping cassette and robustness for life

Long Travel pre-damper with 2 steps including one anti-creeping step

Long travel pre-damper with anti-creeping device

Long travel pre-damper with anti-creeping device

Main damper large single step and large hysteresis value for dampening

Progressive torsional characteristics

Progressive torsional characteristics

1 stage in drive/one stage in coast

4 stages in drive and 4 stages in coast

4 stages in drive and 4 stages in coast

2 independent hysteresis levels

4 independent hysteresis levels

4 independent hysteresis levels

Stiffness and hysteresis levels can be tuned for each driving condition

Stiffness and hysteresis levels can be tuned for each driving condition

Stiffness and hysteresis levels can be tuned for each driving condition

6.2 Long Travel Damper innovative characteristics: g Very low damper and pre-damper stiffness g Pre-damper with two stages including one anti-creeping stage g Main damper with dual hysteresis device g Possibility of half stiffness in coast g Possibility to add Bonded Tripod ® technolog y

6.3 Long Travel Damper key benefits: g Improved acoustic comfort g Lower idle and creeping noise g Excellent capacity to filter engine torque oscillations g Improved drivelineNoise, Vibrations, Harshness (N.V.H.) g High reliability g High price/performance ratio g Alternative to Dual Mass Flywheel (D.M.F.)

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6. KIT4P design: Long Travel Damper (L.T.D.)

6.4 Long Travel Damper evolution: High Angular Displacement (H.A.D.) Technology

Car Manufacturers request high-performance products for increased engine torque with com- pact size. These expectations are now covered with the H.A.D. offer for diesel engines and pe- trol direct injection engines. Valeo High Angular Displacement (H.A.D.) is a further evolution of Valeo O.E. Long Travel Damper Technology. It is composed of a high- tech pre-damper multi-cassette that provides an optimized angular stiffness over the clutch disc. This O.E. technology enables car manufactu- rers to use a rigid flywheel instead of the Dual Mass Flywheel technology even at high engine torques (up to 270 Nm for passenger cars and 350 Nm for Light Commercial Vehicles) On the front cover of this brochure, you can see the H.A.D. clutch together with the rigid flywheel for Fiat Scudo, Citroën Jumpy and Peugeot Expert with 2.0HDi engine. This is not the only example, as H.A.D. is also available for the Renault Scénic 1.9D and the Renault Fluence 1.5dCi. The choice of clutch product depends on many factors such as performance, efficiency and reduction of ove- rall costs. Valeo’s R&D centres are capable of offering a solution that is perfectly matched to the car manufacturer’s requirements and the given technical limitations.

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KIT4P provides savings during the first clutch replacement as it uses a rigid flywheel. Fur- thermore, the rigid flywheel is very durable and does not need to be replaced. When the second clutch replacement is due, only the clutch kit itself needs to be replaced, not the flywheel. This enables cost savings for all future clutch replacements. KIT4P is not only a cost-effective solution, but also yields technical advantages in certain cases: KIT4P Main advantages Extremely reliable solution providing full gearbox and engine protection Increased durability and clutch life thanks to low wear and tear and better thermal resistance 100% torque transfer in all drive conditions pro- viding an important safety factor Comfortable solution with high filtration of vi- bration and noise to enhance driving pleasure Reduced labor and optimized serviceability thanks to the Valeo Service Kit Easy to fit, same installation and fitting time as D.M.F. and the associated clutch kit g g g g g g

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7. KIT4P Main advantages

7.1 A reliable solution KIT4P includes a rigid flywheel. The inertia in com- bination with the cover assembly is calculated to have a good compensation on piston alternative forces to reduce engine acyclisms. The transmis- sion protection provides full engine and gearbox safety.

The graphic below shows the wear ratio behavior of the two most popular facings used within the KIT4P range depending on the temperature and the thermal load of the clutch. 7.2 Increased clutch life The clutch facing within a KIT4P works at lower temperatures compared to a D.M.F. version (between 100ºC and 270ºC). KIT4P overall lifetime is improved as the friction wear decreases at lower temperatures.

Low and Medium Energy Tests - Facing Wear (200mm)

F810 DS (6 tests)

F808 (21 tests)

150

125

100

Low Energy Wear

Facing Wear (mm^3/MJ)

75

50

25

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0

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100

150

200

250

300

350

Temperature (°C)

Low and medium energy tests - Clutch facing wear

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7.3 Efficient torque transfer KIT4P ensures 100% torque transfer, and during the design phase, the maximum engine torque is considered. In addition, Kit4P efficiency is vali- dated via benchmark tests and vehicle trials. KIT4P runs at optimized temperature boundaries, thus keeping the facing’s friction coefficient in good value for increasing torque transfer capacity. The graph below shows the friction coefficient as a function of temperature for different facings used in KIT4P. It is once again visible that the temperature range between 100ºC and 270ºC offers advantages in terms of a reduced friction coefficient.

7.4 Comfortable solution KIT4P filters vibrations and noise for essential dri- ving pleasure. The innovative long travel dam- per aids driver comfort and comes close to the damping performance characteristics of a D.M.F. KIT4P may allow increased disengagement comfort reducing the pedal load due to greater stiffness in the complete system, from diaphragm fingers to crankshaft. Depending on the application, KIT4P technology may allow increased clutch size. This increases the safety factor for torque transmission and also reduces the release bearing load, conse- quently reducing pedal load for clutch actuation. 7.5 Non-wear flywheel & Service Kit The rigid flywheel does not require replacement unless there is abnormal damage on the fric- tion surface or the starter ring. When the second clutch replacement is due, only the cover, the disc and the bearing need to be replaced. Valeo offers a complete range of Service Kits for vehi- cles equipped with KIT4P.

HILL START SIMULATION TEST Friction coefficients versus pressure plate (200 mm) mass temperature for different facing materials

0,5

0,45

0,4

0,35

0,3

VDA REQUIEREMENTS JF840 I0146-­‐01

MINIMUM FRICTION COEFICIENT

0,25

0,2

F830DS F820DS F810DS

0,15

0,1

50

100

150

200

250

300

350

400

450

TEMPERATURE (̊ C)

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7. KIT4P Main advantages

7.6 Easy to fit KIT4P is a standard clutch replacement and does not require any specific tooling. The KIT4P packa- ging contains everything required for a proper and easy installation. g g g Fitting time and procedure is the same as for a standard clutch replacement Bolts for both crankshaft and cover are inside the box Fitting tips and useful information on KIT4P is inside the box

7.7 D.M.F. and KIT4P comparison In order to meet customer requirements, Valeo develops KIT4P also for vehicles equipped with a Valeo D.M.F. The diagram on this page shows a comparison between two Valeo products with different technologies. As you can see in the comparison below, Valeo KIT4P (KIT4P 835071) ensures equivalent func- tion and even provides improved characteristics compared to the D.M.F. solution (Valeo D.M.F. Module 836162), such as lower pedal load.

836162 D.M.F. Module 835071 KIT4P

Function

Comment

ASPECT

ASSEMBLY & FITTING

Bolts and fitting notice included for both Engine torque is transferred at all drive speeds without any slippage

TORQUE TRANSMISSION

KIT4P pedal load is lower than the DMF version (102 Nm at new clutch and 132 Nm at used clutch)

DISENGAGE

HILL START & THERMAL COMFORT START AND REENGAGE COMFORT SHIFTABILITY

No judder detected during start

KIT4P dampen improved shiftability

ACOUSTIC COMFORT

Does not dampen noise at all engine speeds.

MECHANICAL

BALANCING

ENGINE FUNCTIONS

Rigid flywheel & Service Kit for the second replacement

DURABILITY

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8.1 Technical Fitting Instructions KIT4P is easy to fit! Clutch Experts create technical fitting instructions that provide a step-by-step installation guide. These easy-to-follow instructions are prepared and verified by research and development sites during real vehicle trials. Results are verified through drive tests performed by specialists. Instructions are available in the Valeo Electronic Catalogue, on the Valeo TechAssist Website and via TecDoc ® . For detailed info on fitting instructions, please contact your Valeo representative for your region. KIT4P is easy to fit on the vehicle. Assembly is made in the conventional way and there is no need for a special tool. The assembly follows a normal, conventional sequence for flywheel and clutch assembly. KIT4P Technical support

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8. KIT4P Technical support

8.1.1 After disassembling the gearbox from the engine Check engine crankshaft seal and verify that there is no oil contaminating the flywheel Check the condition of the gearbox input shaft splines Block the flywheel in rotation before removal of the flywheel bolts (1) Check the gearbox input shaft seal Check the clutch actuator (guiding tube surface, clutch lever, receiver push rod or concentric slave cylinder) (2) g g g g g 8.1.2 Fixing the flywheel to the crankshaft Position the flywheel to the crankshaft centre Tighten the bolts in star sequence to the specific tightening torque and angle (3) g g

1

2

3

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8.1.3 Preparation of the clutch for fitment g Apply a small quantity of grease (4) in the hub splines, release bearing internal diameter and contact with lever, guide tube and clutch lever contact point (5) Position the cover, center it using the pins, tighten three screws by 120° and check that the disc remains stable and well-centered using the centring tool Tighten each screw slightly in a crosswise sequence. The diaphragm fingers should move as uniformly as possible. Repeat the sequence three times Using a torque wrench, completely fasten the screws (6) Mount the release bearing on the guide tube and check if it slides correctly. g g g g g 8.1.4 Fitting the clutch Position the disc over the flywheel

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8. KIT4P Technical support

8.1.5 Re-assembling the gearbox Check condition of the block pins Position the gearbox coaxially with the engine crankshaft, support the gearbox weight with appropriate tools Introduce the gearbox input shaft into the disc hub ensuring that there is no shock and avoiding excessive force (7) Make sure that the weight of the gearbox is not supported by the disc only during assembly Check for full contact between gearbox and engine block as well as correctly fitted centring pins. Attach gearbox to the engine block using appropriate torque. 8.1.6 After the fitment – verify that the clutch is functioning correctly Disengage and reengage the clutch shifting each ratio (8) Check that there is no abnormal noise during engagement/disengagement Check that there is no abnormal noise at neutral speed and while accelerating up to 4000 rpm Check that there is no abnormal clutch sliding while driving gg g g g g g g g g

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8.2 KIT4P box content

A KIT4P contains everything required for an easy and efficient clutch replacement: g KIT4P product notice g KIT4P fitting notice g KIT4P sticker g Flywheel fitting bolts g Clutch cover fitting bolts g Additional items as necessary (clutch lever…) 8.2.1 KIT4P product notice KIT4P product notice: explains product composi- tion and technology to the worldwide customers in 16 different languages. The objective is to reassure the product quality and the application compatibility.

8.2.2 KIT4P fitting notice KIT4P fitting notice: indicates tightening torque/ angle of the fixing bolts, position of the flywheel and provides essential fitting tips on the rigid flywheel for a perfect assembly.

Provided within the box: essential fitting instructions, tightening torques & position. Illustrated with photos in 6 main languages with Service Kit information

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8. KIT4P Technical support

8.2.3 KIT4P sticker The KIT4P sticker makes vehicles equipped with a KIT4P easily recognizable. Only the associated Service Kit must be purchased and replaced on the vehicle during second clutch replacement. This sticker must be put on the engine environ- ment once the KIT4P is mounted on the vehi- cle. It resists increased engine temperatures so there is no risk when applied to an appropriate part of the vehicle. Service Kit: once the KIT4P is installed in the vehicle, the rigid flywheel does not require replacement if not damaged. Thus, when the second clutch replacement is due, only the cover, the disc and the bearing need to be replaced. Valeo offers a complete range of Service Kits which feature this advantage and hence lead to reduced cost and labor starting from the second clutch replacement. 8.2.4 KIT4P fitting bolts During each KIT4P replacement, use the bolts supplied in the box and respect tightening infor- mation to avoid any warranty issues. The flywheel bolts and clutch cover bolts are always supplied in all KIT4P boxes. They are specifically designed for each application. Once tightened and used in operation, they should not be reused and must be replaced by new bolts provided in the box each time.

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KIT4P flywheel fitting bolt torques

KIT4P

KIT4P

Service Kit

No. of bolts

Service Kit

No. of bolts

60 Nm + 90º 60 Nm + 90º 15 Nm + 30 Nm +75 Nm + 45º

60 Nm + 90º 90 Nm 60 Nm 60 Nm + 90º 110 Nm

828107 828109 828409 826875 828137 828376 828377 828381 828378 828372 828373 828374 828386 828390 828383 828387 828393 828391 828375 828382 828384 828407 828392 828403 828411 828437 828438 828439 828440 828443 828444 828445 828446 828447 828464 828484 828486

6 7 10

6 6 8 8 7 8 8 6 6 8 8 8 6 8 6 8 7 7 8 8 8 8 7 8 6 8 8 8 7 6 8 8 10

826363 828408 826700 826701 826702 826855 826703 826856 826704 826857 826874 826904 826875 826876 826877 826878 826879 826880 826858 826883 826883 826907 826908 826909 826911 826912 826913 826916 826905 828002 828385 828093 826875 826856 826856 828099 828100 828101

835047 835048 835049 835050 835051 835052 835053 835054 835055 835057 835058 835059 835060 835061 835062 835063 835064 835065 835066 835068 835069 835070 835071 835072 835073 835074 835075 835076 835077 835080 835081 835082 835083 835084 835085 835087 835088

826317 826551 835000 835001 835002 835003 835004 835005 835006 835007 835008 835009 835010 835011 835012 835013 835014 835015 835017 835019 835020 835022 835023 835024 835026 835027 835028 835031 835033 835035 835036 835038 835039 835040 835041 835044 835045 835046

60 Nm 60 Nm 75 Nm 105 Nm

6 8 8 8 8 8 8 6 6 8 8 8 8 8 6 6 8 8 8 6 8 8 8 8 8 7

85 Nm + 90º 85 Nm + 90º 25 Nm + 45º 110 Nm 15 Nm +30 Nm + 75 Nm + 45º 110 Nm 110 Nm 15 Nm + 30 Nm + 75 Nm + 45º 30 Nm + 45° 15 Nm + 30 Nm + 75 Nm + 45º 15 Nm + 30 Nm + 75 Nm + 45º 44 Nm

60 Nm + 90º 60 Nm + 90º

60 Nm 60 Nm 100 Nm

60 Nm + 90º 65 Nm + 35º 60 Nm + 90º 55-60 Nm + 50º

25 Nm + 50º 30 Nm + 90º

110 Nm 110 Nm

115 Nm 110 Nm

60 Nm 60 Nm 35 Nm + 45 º

40 Nm + 48º 45 Nm + 90º 130 Nm + 90º 90 Nm 60 Nm + 90º 60 Nm + 90º 75 Nm 105-120 Nm 60 Nm 55-60 Nm + 50º 85 Nm + 90º 110 Nm

60 Nm 44 Nm 44 Nm

85 Nm +30º+15º 85 Nm +30º+15º

44 Nm 65 Nm

45 Nm + 65º 45 Nm + 65º 121 Nm 130 Nm 130 Nm 120 Nm 115 Nm 45 Nm + 65º

10 10 8 6 6 8 8 10

60 Nm + 90º 60 Nm + 90º 60 Nm + 90º 110 Nm 60 Nm + 90º 60 Nm + 90º

6 6 8 8 8

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9 Below you will find answers to common questions on KIT4P. For your additional questions which may not be listed here please contact Valeo. “How does the solid flywheel conver- sion kit work to dampen vibration?” The KIT4P offers optimal flywheel inertia, which contributes significantly to the reduction of engine vibrations. In addition to this, within a KIT4P the dampening function is transmitted to the clutch disc, which features Valeo long travel damper technology. The technology has a very low damper and pre-dam- per stiffness and increased inertia thanks to the rigid flywheel for reducing oscillation frequency. “Is there a loss in power transmission or slippage when KIT4P is fitted?” No, there is no loss in power transmission at all. KIT4P transmits 100% engine torque without any slippage. In the design phase, maximum engine torque over the complete application range is considered inclu- ding a safety factor. “If the flywheel weight changes, does it impact my starter?” Change of the flywheel weight has no negative impact on the starter.

F.A.Q. - Everything you need to know about KIT4P Once a KIT4P has been fitted, parts can only be identified after the old clutch has been removed. This can lead to delays in parts supply particu- larly important on L.C.Vs. and taxis.” Inside each KIT4P box, Valeo provides a sticker notice that will be attached to the engine. This enables vehicles fitted with KIT4P to be identified immediately during each service, well before any dismounting. “I replaced the D.M.F. with a KIT4P. Should I buy another KIT4P for the next clutch replacement? The rigid flywheel inside KIT4P does not contain wear components. Except for abnormal conditions (cracks on surface, damaged starter ring...) the clutch kit only needs to be replaced using Valeo Ser- vice Kits. Service Kits are available for the complete KIT4P product range. “Can KIT4P replace all D.M.F. applica- tions?” No, current KIT4P technology is suitable for vehicles with up to 360 Nm max engine torque. Diesel or turbo engines above this max engine torque require D.M.F. within today’s kit technology.

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“Do you offerwarrantywhen the KIT4P is used in light commercial vehicles or taxis?” Yes, KIT4P has the same warranty conditions as any regular product at Valeo for range of applications specified in Valeo catalogues. Valeo does not limit the range of applications for vehicles with com- mercial usage. “What are the examples of vehicles using KIT4P technology in O.E.M.?” Here are some examples: Ford Transit 2000-2006 2.4Tdi – Ford Turkey, after initial D.M.F. problems on the first vehicles decided to use rigid flywheel in Turkey. Thus Valeo KIT4P 835000 is O.E. in Turkey Hyundai Santa Fe. - 2.0/2.4 l models had been produced with a D.M.F. + Kit application until 2003. After 2003, Hyundai decided to use a rigid flywheel and a Valeo kit containing long travel damper Peugeot Expert, Citroen Jumpy, Fiat Scudo 2.0Hdi 2011>-PSA has decided to launch this vehicle with rigid flywheel and asked Valeo to supply the clutch kit. Valeo’s new H.A.D. technology is used on this model instead of a D.M.F. Renault Scenic 1.9dCi and Renault Megane Fluence 1.5Dci also use H.A.D. technology in O.E. Volkswagen 1.2TDi engines (Polo…) Ford with new Ecoboost 1.3l engines (Ford C-Max, Focus…) on which a D.M.F. solution is technically not possible. “Why choose KIT4P?” A reliable solution, corresponding to the highest O.E. standards Increased durability thanks to solid flywheel, low wear and better thermal resistance 100% torque transfer providing an important safety factor Comfortable solution with high filtration of vibration and noise to enhance driving pleasure Avoids costly replacements due to known D.M.F. problems on certain vehicles Easy to fit, same installation and fitting time as D.M.F. and associated kit. g g g g g g gg g g g g

“Is it normal that when fitting a KIT4P the clutch pedal gets harder to ope- rate?” KIT4P is designed and produced according to the same acceptance criteria as an O.E. product. A KIT4P actually reduces pedal load. However, noting such a difference directly after fitment is normal and simply due to the difference between a used clutch and a new clutch. “Do I need any specific tool to fit KIT4P?” No, KIT4P is a regular clutch replacement that does not require any specific tooling. Valeo provides within the KIT4P box some installation tips for garages and shares technical fitting instructions on electronic catalogues and Valeo TechAssist. “Can I use the bolts of the D.M.F. for re- placing KIT4P?” It is not adequate to use “old” bolts for installing the new flywheel. This is why Valeo provides crankshaft fitting bolts inside every KIT4P box. KIT4P contains all items required for a complete repla- cement. “If KIT4P can replace D.M.F., why is it not used by carmakers in O.E.?” The KIT4P technology is used in O.E. But since these vehicles are already equipped with a rigid flywheel, Valeo only supplies the clutch kit. KIT4P is an I.A.M. solution for vehicles fitted with D.M.F. originally. However technology used or components are original equipment. D.M.F. is a common application for diesel or turbo engines with engine torques higher than 250 Nm. Thus, any diesel vehicle above this engine torque is a potential D.M.F. application. If a rigid flywheel is used in such vehicles, one could say that the vehicle is already equipped with a KIT4P. However, since the flywheel has a low replacement rate, it is not included in the module. This is why we sell only the clutch kit on the I.A.M. Car manufacturers are looking for opportunities to increase efficiency. This includes the launch of new, low-consumption engines into the market. We are likely to see this trend increase even further in the near future.

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10

Conclusion

Valeo expertise is dedicated to both O.E. and I.A.M. products with performances matching their O.E. counterparts.. Over the course of 10 years Valeo KIT4P technology has evolved alongside the technical further development of engines and powertrain structures. Valeo KITP4P is a great alternative to D.M.F. solutions with key benefits ranging from technical advantages such as reliability, increased clutch life, efficient torque transfer, non-wear flywheel to comfort, easy fitment and cost saving. Valeo supports the installation with fitting instructions and notices included in the box, on TecDoc ® on the Valeo TechAssist website. On our website www.valeoservice.com, you will find all information you might need in order to find the part number you are looking for and to fit it in the vehicle.

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Tech’Care Delivering Technical Expertise A range of technical and support services from your multi-specialist T e c h n i c a l T r a i n i n g W o r k s h o p t o o l s Training on all product lines For passenger cars and commercial vehicles Theoretical session and practical exercises Elearning on Valeo-Techassist.com ClimFill ® - air conditioning station Regloscope TM - Headlight beam adjustment Fastfill ® - vacuum coolant re-filling Brake Fluid Tester - DOT boiling point tester Professional tools for diagnosis and maintenance A complete catalogue of technical training modules

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V a l e o t e c h n i c a l s u p p o r t Assistance on FAQ’s Fitting instructions Technical Hotline valeo-techassist.com Technical Bulletins Trouble shooting guidelines

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CONTACT YOUR VALEO TECHNICAL PROMOTER FOR A DEMO !

Valeo, your Multi-Specialist partner.

Today, every second car which rolls off the assembly line is fitted with a D.M.F. and this equipment rate is still increasing. In order to meet consumer needs, Valeo introduced the Clutch Conversion kit - KIT4P , manufactured under Valeo’s highest quality standards, an efficient and reliable alternative solution ensuring full customer satisfaction. Efficient because Valeo’s expertise inresearch and development allows the reduction of clutch noise and vibrations, along with enhanced driver comfort through better gear changes, giving consumers a smoother and comfortable ride. Reliable because Valeo clutches are able to perform in the most hostile operating environments. Valeo’s Aftermarket customers benefit from this Original Equipment expertise, rigor and quality. Valeo is now proud to present you this technical handbook which will fully explain what Valeo Clutch KIT4P is, why it was developed and how it has been designed in order to maximize consumer benefits. All fitting steps and related material will be detailed as well as the most frequently asked questions.

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