Kit 4pz e Service Kit

Transmission Systems
KIT4P
Conversion kit
a b c Product focus valeoscope

998102 - VS - Transmission Systems - Clutch KIT4P - Product focus valeoscope - EN.indd 1 27/01/2016 17:53
Valeo clutches,
expertise & innovation
dedicated to customer
satisfaction
D.M.F./KIT4P
Adapted to your needs! Aftermarket
D.M.F. self-adjusting solutions
gg Designed for lasting performance
2 offers:
Improved driving comfort
KIT4P gg S.A.T. (O.E. solution for I.A.M.)
gg Economical & reliable

H.E.C. (I.A.M. solution)
3 main benefits:
g
Alternative solution to D.M.F.
Easy to fit! No need
Hydraulics
gg for a specialist tool
gg
All-in-one solution Economical solution
Quick & easy to install
Constant pedal effort = comfort!
Traditional Kits
gg One of the market’s best coverage rates
Best-in-class Valeo friction material
Table
of Contents
1. Disclaimer P3
2. Valeo, your Transmission P4
Systems Multi-Specialist
3. Valeo TechAssist P6
4. Why Conversion kit - KIT4P P7
5. KIT4P composition P8
5.1 Mechanical or semi-hydraulic clutch actuation P9
5.2 Full hydraulic clutch actuation P10
MORE ABOUT VALEO KIT4P? 6. KIT4P design: Long Travel Damper P11
6.1 Long Travel Damper technology P12
6.2 Long Travel Damper innovative characteristics P13
6.3 Long Travel Damper key benefits P13
6.4 Long Travel Damper evolution: High Angular P14
Displacement (H.A.D.) Technology
7. KIT4P Main advantages P15

7.1 A reliable solution P16
7.2 Increased clutch life P16
7.3 Efficient torque transfer P17
7.4 Comfortable solution P17
7.5 Non-wear flywheel & Service Kit P17
qr.valeodrive.com/998100/003097 7.6 Easy to fit P17
7.7 D.M.F. & KIT4P Comparison P18
8. KIT4P Technical support P19

8.1 Technical fitting instructions P19
8.1.1 After disassembling the gearbox from the engine P20
8.1.2 Fixing the flywheel to the crankshaft P20
8.1.3 Preparation of the clutch for fitment P21
8.1.4 Fitting the clutch P21
8.1.5 Re-assembling the gearbox P22
8.1.6 After the fitment – verify that the clutch P22
is functioning correctly
8.2 KIT4P box content P23
8.2.1 KIT4P product notice P23
8.2.2 KIT4P fitting notice P23
8.2.3 KIT4P sticker P24
8.2.4 KIT4P fitting bolts P24
9. F.A.Q. - Everything you need to know P26

about KIT4P
10. Conclusion P28
1
Foreword
Our Multi-Specialist expertise
is rooted in our genes.
As one of the leading automotive system designers Reliable because Valeo clutches are able to perform
and manufacturers, nothing is more natural for in the most hostile operating environments. Valeo
Valeo than to deliver 14 product lines for passenger aftermarket customers benefit from this Original
cars and 8 products lines for heavy-duty vehicles, Equipment (O.E.) expertise, rigor and quality.
serving all distribution channels from car makers’
networks to independent aftermarket and modern
The worldwide vehicle car parc consists of 69%
distribution, in more than 120 countries all over the
passenger cars and is growing by 3.9% per year.
world.
Every second passenger car or light commercial vehicle
which rolls off the assembly line is equipped with a
Valeo Transmission Systems’ mission is to be the sup-
D.M.F., and that share is still increasing. Consequently,
plier of choice for all powertrain architectures with
the share of vehicles in Europe equipped with a D.M.F.
innovative technologies developed for efficient and
is estimated to increase to 39% by 2018.
comfortable power transfer from the engine to the
transmission, whilst reducing fuel consumption.
In order to meet consumer needs, Valeo Service in-
troduced Valeo KIT4P and is now proud to present to
All Valeo clutches are manufactured to Valeo’s highest
you this technical handbook which will fully explain
quality standards, making Valeo products efficient
what KIT4P is, why it was developed and how it
and reliable and ensuring full customer satisfaction.
has been designed in order to optimize consumer
benefits. All fitting steps and related material will be
Efficient because Valeo’s expertise in research and
detailed, and the most frequently asked questions
development allows the reduction of clutch noise
will be addressed.
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
Whilst we endeavour to ensure that the information
included in this training documentation is correct,
we do not warrant its completeness or accuracy;
1 Disclaimer
(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
nor do we commit to ensuring that the material in excluded under applicable law.
the documentation is kept up to date.
The limitations and exclusions of liability set out in
To the maximum extent permitted by applicable this section and elsewhere in this disclaimer: (a) are
law, we exclude all representations, warranties and subject to the preceding paragraph; and (b) govern
conditions relating to this documentation and the all liabilities arising under the disclaimer or in rela-
use of this documentation (including, without limi- tion to the subject matter of this disclaimer, inclu-
tation, any warranties implied by law in respect to ding liabilities arising in contract, in tort (including
satisfactory quality, fitness for purpose and/or the negligence) and for breach of statutory duty.
use of reasonable care and skill).
To the extent that this documentation and this training
Nothing in this disclaimer will: (a) limit or exclude documentation are provided free of charge, we will
our or your liability for death or personal injury not be liable for any loss or damage of whatsoever
resulting from negligence; (b) limit or exclude our or nature.
your liability for fraud or fraudulent misrepresentation;
Valeo,
2
your Transmission
Systems
Multi-Specialist
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 CO2 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.
Valeoscope library
Technical handbooks
Air conditioning Lighting Systems
The A/C system From light to advanced
Thermal comfort loop
vision technologies
a b c Technical handbook valeoscope a b c Technical handbook valeoscope

998321 - VS - Air Conditioning Systems - The AC System - Technical handbook valeoscope - EN.indd 1 19/01/2016 15:19 130167 - VS - Lighting Systems - Lighting - Technical handbook valeoscope - EN.indd 1 19/01/2016 14:58
Air Conditioning Lighting Systems

Ref: 998321 Ref: 998542
Product focus
Transmission Systems Transmission Systems Transmission Systems Transmission Systems
Self Adjusting Technology (S.A.T.)
High Efficiency Clutch (H.E.C.) Clutch KIT4P Dual Mass
Hydraulics Flywheel
Conversion kit
a b c Product focus valeoscope a b c Product focus valeoscope a b c Product focus valeoscope a b c Product focus valeoscope
998121 - VS - Transmission Systems - Clutch HEC SAT - Porduct focus valeoscope - EN.indd 1 19/01/2016 15:05 998123 - VS - Transmission Systems - Clutch Hydraulics - Product focus valeoscope - EN.indd 1 19/01/2016 15:07 998102 - VS - Transmission Systems - Clutch KIT4P - Product focus valeoscope - EN.indd 1 19/01/2016 15:00 998120 - VS - Transmission Systems - Dual-Mass Flywheel DMF - Product focus valeoscope - EN.indd 1 19/01/2016 15:02
Transmission Systems Transmission Systems Transmission Systems Transmission Systems

Clutch HEC-SAT Clutch Hydraulics Clutch KIT4P Dual-Mass Flywheel DMF
Ref: 998121 Ref: 998123 Ref: 998102 Ref: 998120
Diag & Fit

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957100 - VS - Truck Braking Systems - Brake Pad Fault Assessment - Diag & Fit valeoscope - EN.indd 1 19/01/2016 14:59
Truck Brake Pad

Ref: 957100
3 valeo-techassist.com
You will benefit from Valeo TechAssist throughout
the entire workshop service process:
g Get product information: product data sheets provide

details in addition to the catalogue information.
g Find common failures: step-by-step failure

diagnosis guides about typical faults.
g Keep you updated about Valeo Service products:

full access to all Technical Service Bulletins.
g Find help when it is needed: answers to frequently

asked questions and contact to the Valeo Service
Valeo TechAssist is a web-based application, speci- technical hotline
fically developed for repair workshops, automotive
spare parts distributors and technical trainers. g Use Valeo workshop tools efficiently: retrieve
user manuals, service manuals and software
Valeo TechAssist is available at any time, and 10 updates on Valeo Service tools.
languages are implemented to date. Just connect
to the website www.valeo-techassist.com. g Learn about new technologies: online training
modules (e-learning) and self-study documents
Valeo TechAssist is not only a technical database, about most modern product technologies. In
but also a learning platform and a forum for infor- addition, you have access to some advanced
mation exchange. It covers passenger cars and features:
all Valeo product lines.
The information in Valeo TechAssist is structured in

g Add comments to any document: give personal
feedback to Valeo Service and contribute to a
four comprehensive domains: continuous service improvement.
1.Product documentation g Fill in your evaluation: provide feedback on your

satisfaction.
2.Technical assistance
g Write a fitting testimony: share your experience
with other users.
3.Workshop tools
4.Technical training
4 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.
5 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.
Rigid Flywheel Flywheel Fitting Bolts Clutch Disc Clutch Cover Clutch Cover
Fitting Bolts
Release
Bearing
5.1 Mechanical or semi-hydraulic
clutch actuation
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:
gg Rigid Flywheel
gg
Clutch Cover
Clutch Disc
g
Release Bearing
Fitting bolts
Semi-hydraulic clutch actuation (Clutch Master Cylinder & Clutch Release Cylinder)
5. KIT4P composition
5.2 Full hydraulic clutch actuation

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:
Full hydraulic clutch actuation (Clutch Master Cylinder & Concentric Slave Cylinder)
KIT4P without C.S.C. KIT4P with C.S.C.

ggRigid Flywheel ggRigid Flywheel
gg gg
Cover Cover
Disc Disc
g
Fitting bolts Concentric Slave Cylinder
Fitting bolts
10
6 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.
Rigid flywheel
Engine Gear box
Clutch kit
with L.T.D.
KIT4P
Filtration of engine acyclism in case of KIT4P
11
6. KIT4P design:
Long Travel Damper (L.T.D.)
The L.T.D. technology consists of a specific friction Current Valeo O.E. Long Travel Damper techno-
plate with a high damper capacity and a damper logy can be found in three product categories;
with very low stiffness for improved filtration SX, WX and High Angular Displacement Techno-
and transmission performance. This low angular logy (NX1…NX4). The design depends on the
stiffness coupled with the specifically matched maximum torque of the vehicle engine and on
flywheel inertia ensures the appropriate damping the diameter of the clutch. A majority of the
level as well as an extended life of the clutch kit. 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
12
WX type SX type HAD (NX1...NX4)
Key features
Sizes from 220 mm or with min Sizes from 228 mm or with min Sizes from 190 mm
155 mm inner diameter 170 mm inner diameter
Engine torque up to 360 Nm Engine torque up to 280 Nm Engine torque up to 360 Nm
Valeo O.E. technology since 1994 Valeo O.E. technology since 2000 Valeo O.E. technology since 2009
Innovative characteristics
Low main damper stiffness Compact design for low inertia Large anti-creeping cassette and
and robustness for life robustness for life
Long Travel pre-damper with 2 steps including one Long travel pre-damper with
Long travel pre-damper with anti-creeping device
anti-creeping step anti-creeping device
Main damper large single step and large Progressive torsional characteristics Progressive torsional characteristics
hysteresis value for dampening
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 Stiffness and hysteresis levels can be tuned Stiffness and hysteresis levels can be tuned
for each driving condition for each driving condition for each driving condition
6.2 Long Travel Damper 6.3 Long Travel Damper key

innovative characteristics: benefits:
gg Very low damper and pre-damper stiffness gg Improved acoustic comfort
Lower idle and creeping noise
gg
Pre-damper with two stages including
one anti-creeping stage gg Excellent capacity to filter engine torque oscillations
Improved driveline Noise, Vibrations, Harshness (N.V.H.)
Main damper with dual hysteresis device
Possibility of half stiffness in coast gg High reliability
g Possibility to add Bonded Tripod® technology
g
High price/performance ratio
Alternative to Dual Mass Flywheel (D.M.F.)
13
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.
14
7 KIT4P
Main advantages
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:
g Extremely reliable solution providing full

gearbox and engine protection
g Increased durability and clutch life thanks to low
wear and tear and better thermal resistance
g 100% torque transfer in all drive conditions pro-
viding an important safety factor
g Comfortable solution with high filtration of vi-
bration and noise to enhance driving pleasure
g Reduced labor and optimized serviceability
thanks to the Valeo Service Kit
g Easy to fit, same installation and fitting time as
D.M.F. and the associated clutch kit
15
7. KIT4P
Main advantages
7.1 A reliable solution 7.2 Increased clutch life

KIT4P includes a rigid flywheel. The inertia in com- The clutch facing within a KIT4P works at lower
bination with the cover assembly is calculated to temperatures compared to a D.M.F. version
have a good compensation on piston alternative (between 100ºC and 270ºC). KIT4P overall lifetime
forces to reduce engine acyclisms. The transmis- is improved as the friction wear decreases at
sion protection provides full engine and gearbox lower temperatures.
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.
Low and Medium Energy Tests - Facing Wear (200mm)
Facing Wear (mm^3/MJ)
F808 (21 tests) F810 DS (6 tests)

150
125
100
Low Energy Wear
75
50
25
0
0 50 100 150 200 250 300 350
Low and medium energy tests - Clutch facing wear Temperature (°C)
16
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 7.4 Comfortable solution
temperature range between 100ºC and 270ºC
KIT4P filters vibrations and noise for essential dri-
offers advantages in terms of a reduced friction
ving pleasure. The innovative long travel dam-
coefficient.
per aids driver comfort and comes close to the
damping performance characteristics of a D.M.F.
KIT4P may allow increased disengagement comfort
HILL START SIMULATION TEST reducing the pedal load due to greater stiffness
Friction coefficients versus pressure plate (200 mm) in the complete system, from diaphragm fingers
mass temperature for different facing materials to crankshaft.
Depending on the application, KIT4P technology
0,5
may allow increased clutch size. This increases
MINIMUM FRICTION COEFICIENT
0,45 the safety factor for torque transmission and

also reduces the release bearing load, conse-
0,4
quently reducing pedal load for clutch actuation.
0,35
0,3
VDA
7.5 Non-wear flywheel &
0,25
REQUIEREMENTS
JF840 Service Kit
I0146-‐01
0,2
F830DS The rigid flywheel does not require replacement
0,15
F820DS unless there is abnormal damage on the fric-
F810DS tion surface or the starter ring. When the second
0,1
50 100 150 200 250 300 350 400 450
clutch replacement is due, only the cover, the
TEMPERATURE ( ̊C) disc and the bearing need to be replaced. Valeo
offers a complete range of Service Kits for vehi-
cles equipped with KIT4P.
17
7. KIT4P
Main advantages
7.6 Easy to fit 7.7 D.M.F. and KIT4P comparison

KIT4P is a standard clutch replacement and does In order to meet customer requirements, Valeo
develops KIT4P also for vehicles equipped with
not require any specific tooling. The KIT4P packa-
a Valeo D.M.F. The diagram on this page shows
ging contains everything required for a proper and
a comparison between two Valeo products with
easy installation.
different technologies.
g Fitting time and procedure is the same as for
a standard clutch replacement
As you can see in the comparison below, Valeo
KIT4P (KIT4P 835071) ensures equivalent func-
g Bolts for both crankshaft and cover are inside
the box
tion and even provides improved characteristics
compared to the D.M.F. solution (Valeo D.M.F.
g Fitting tips and useful information on KIT4P is
inside the box
Module 836162), such as lower pedal load.
Function 836162 D.M.F. Module 835071 KIT4P Comment
ASPECT
ASSEMBLY & FITTING Bolts and fitting notice included for both
Engine torque is transferred at all drive

TORQUE TRANSMISSION speeds without any slippage
KIT4P pedal load is lower than the DMF version
DISENGAGE (102 Nm at new clutch and 132 Nm at used clutch)
START AND REENGAGE
No judder detected during start
COMFORT
SHIFTABILITY KIT4P dampen improved shiftability
HILL START &

THERMAL COMFORT
ACOUSTIC COMFORT Does not dampen noise at all engine speeds.
MECHANICAL
BALANCING
ENGINE FUNCTIONS
Rigid flywheel & Service Kit for the second
DURABILITY replacement
18
8 KIT4P
Technical support
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.
19
8. KIT4P
Technical support
8.1.1 After disassembling the

gearbox from the engine 1
g Check engine crankshaft seal and verify that
there is no oil contaminating the flywheel
g Check the condition of the gearbox input
shaft splines
g Block the flywheel in rotation before removal
of the flywheel bolts (1)
gg Check the gearbox input shaft seal
Check the clutch actuator (guiding tube
surface, clutch lever, receiver push rod or
concentric slave cylinder) (2)
8.1.2 Fixing the flywheel to the

crankshaft
gg Position the flywheel to the crankshaft centre
Tighten the bolts in star sequence to the specific
tightening torque and angle (3) 2
20
8.1.3 Preparation of the clutch
for fitment 4
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)
8.1.4 Fitting the clutch

gg Position the disc over the flywheel
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
g Tighten each screw slightly in a crosswise
sequence. The diaphragm fingers should
move as uniformly as possible. Repeat the
sequence three times
g Using a torque wrench, completely fasten
the screws (6) 5
g Mount the release bearing on the guide tube
and check if it slides correctly.
21
8. KIT4P
Technical support
8.1.5 Re-assembling the gearbox

7
gg Check condition of the block pins
Position the gearbox coaxially with the
engine crankshaft, support the gearbox
weight with appropriate tools
g Introduce the gearbox input shaft into the
disc hub ensuring that there is no shock
and avoiding excessive force (7)
g Make sure that the weight of the gearbox is
not supported by the disc only during assembly
g Check for full contact between gearbox and engine
block as well as correctly fitted centring pins.
g Attach gearbox to the engine block using
appropriate torque.
8.1.6 After the fitment – verify

that the clutch is functioning 8
correctly
g Disengage and reengage the clutch shifting
each ratio (8)
g Check that there is no abnormal noise during
engagement/disengagement
g Check that there is no abnormal noise at neutral
speed and while accelerating up to 4000 rpm
g Check that there is no abnormal clutch sliding
while driving
22
8.2 KIT4P box content
A KIT4P contains everything required for an
easy and efficient clutch replacement:
gg KIT4P product notice

KIT4P fitting notice
gg KIT4P sticker
Flywheel fitting bolts
gg Clutch cover fitting bolts
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
23
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.
24
KIT4P flywheel fitting bolt torques
KIT4P Service Kit No. of bolts KIT4P Service Kit No. of bolts
826317 826363 6 60 Nm + 90º 835047 828107 6 60 Nm + 90º

826551 828408 6 60 Nm + 90º 835048 828109 7 90 Nm
835000 826700 8 15 Nm + 30 Nm +75 Nm + 45º 835049 828409 10 60 Nm
835001 826701 8 60 Nm 835050 826875 6 60 Nm + 90º
835002 826702 7 60 Nm 835051 828137 8 110 Nm
835003 826855 8 75 Nm 835052 828376 8 85 Nm + 90º
835004 826703 8 105 Nm 835053 828377 8 85 Nm + 90º
835005 826856 6 60 Nm + 90º 835054 828381 8 25 Nm + 45º
835006 826704 6 60 Nm + 90º 835055 828378 8 110 Nm
835007 826857 8 60 Nm 835057 828372 8 15 Nm +30 Nm + 75 Nm + 45º
835008 826874 8 60 Nm 835058 828373 6 110 Nm
835009 826904 8 100 Nm 835059 828374 6 110 Nm
835010 826875 6 60 Nm + 90º 835060 828386 8 15 Nm + 30 Nm + 75 Nm + 45º
835011 826876 8 65 Nm + 35º 835061 828390 8 30 Nm + 45°
835012 826877 6 60 Nm + 90º 835062 828383 8 15 Nm + 30 Nm + 75 Nm + 45º
835013 826878 8 55-60 Nm + 50º 835063 828387 8 15 Nm + 30 Nm + 75 Nm + 45º
835014 826879 7 25 Nm + 50º 835064 828393 8 44 Nm
835015 826880 7 30 Nm + 90º 835065 828391 6 110 Nm
835017 826858 8 115 Nm 835066 828375 6 110 Nm
835019 826883 8 110 Nm 835068 828382 8 60 Nm
835020 826883 8 40 Nm + 48º 835069 828384 8 60 Nm
835022 826907 8 45 Nm + 90º 835070 828407 8 35 Nm + 45 º
835023 826908 7 130 Nm + 90º 835071 828392 6 60 Nm
835024 826909 8 90 Nm 835072 828403 8 44 Nm
835026 826911 6 60 Nm + 90º 835073 828411 8 44 Nm
835027 826912 8 60 Nm + 90º 835074 828437 8 85 Nm +30º+15º
835028 826913 8 75 Nm 835075 828438 8 85 Nm +30º+15º
835031 826916 8 105-120 Nm 835076 828439 8 44 Nm
835033 826905 7 60 Nm 835077 828440 7 65 Nm
835035 828002 6 55-60 Nm + 50º 835080 828443 10 45 Nm + 65º
835036 828385 8 85 Nm + 90º 835081 828444 10 45 Nm + 65º
835038 828093 8 110 Nm 835082 828445 8 121 Nm
835039 826875 10 60 Nm + 90º 835083 828446 6 130 Nm
835040 826856 6 60 Nm + 90º 835084 828447 6 130 Nm
835041 826856 6 60 Nm + 90º 835085 828464 8 120 Nm
835044 828099 8 110 Nm 835087 828484 8 115 Nm
835045 828100 8 60 Nm + 90º 835088 828486 10 45 Nm + 65º
835046 828101 8 60 Nm + 90º
25
Below you will find answers to common
questions on KIT4P. For your additional
questions which may not be listed here
9 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
please contact Valeo. lead to delays in parts supply particu-
larly important on L.C.Vs. and taxis.”
“How does the solid flywheel conver-
Inside each KIT4P box, Valeo provides a sticker
sion kit work to dampen vibration?” notice that will be attached to the engine. This
The KIT4P offers optimal flywheel inertia, which enables vehicles fitted with KIT4P to be identified
contributes significantly to the reduction of engine immediately during each service, well before any
vibrations. In addition to this, within a KIT4P the dismounting.
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- “I replaced the D.M.F. with a KIT4P.
per stiffness and increased inertia thanks to the rigid Should I buy another KIT4P for the
flywheel for reducing oscillation frequency. next clutch replacement?
The rigid flywheel inside KIT4P does not contain
“Is there a loss in power transmission wear components. Except for abnormal conditions
or slippage when KIT4P is fitted?” (cracks on surface, damaged starter ring...) the
No, there is no loss in power transmission at all. KIT4P clutch kit only needs to be replaced using Valeo Ser-
transmits 100% engine torque without any slippage. vice Kits. Service Kits are available for the complete
In the design phase, maximum engine torque over KIT4P product range.
the complete application range is considered inclu-
ding a safety factor. “Can KIT4P replace all D.M.F. applica-
tions?”
“If the flywheel weight changes, does No, current KIT4P technology is suitable for vehicles
it impact my starter?” with up to 360 Nm max engine torque. Diesel or
turbo engines above this max engine torque require
Change of the flywheel weight has no negative
D.M.F. within today’s kit technology.
impact on the starter.
26
“Is it normal that when fitting a KIT4P “Do you offer warranty when the KIT4P
the clutch pedal gets harder to ope- is used in light commercial vehicles or
rate?” taxis?”
Yes, KIT4P has the same warranty conditions as any
KIT4P is designed and produced according to the same regular product at Valeo for range of applications
acceptance criteria as an O.E. product. A KIT4P actually specified in Valeo catalogues. Valeo does not limit
the range of applications for vehicles with com-
reduces pedal load. However, noting such a difference
mercial usage.
directly after fitment is normal and simply due to the
difference between a used clutch and a new clutch.
“What are the examples of vehicles
“Do I need any specific tool to fit KIT4P?” using KIT4P technology in O.E.M.?”
Here are some examples:
No, KIT4P is a regular clutch replacement that does not
require any specific tooling. Valeo provides within the
g Ford Transit 2000-2006 2.4Tdi – Ford Turkey, after
initial D.M.F. problems on the first vehicles
KIT4P box some installation tips for garages and shares decided to use rigid flywheel in Turkey. Thus
technical fitting instructions on electronic catalogues Valeo KIT4P 835000 is O.E. in Turkey
and Valeo TechAssist. g 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
“Can I use the bolts of the D.M.F. for re- flywheel and a Valeo kit containing long travel
placing KIT4P?” damper
It is not adequate to use “old” bolts for installing the

g Peugeot Expert, Citroen Jumpy, Fiat Scudo 2.0Hdi
2011>-PSA has decided to launch this vehicle
new flywheel. This is why Valeo provides crankshaft with rigid flywheel and asked Valeo to supply the
fitting bolts inside every KIT4P box. clutch kit. Valeo’s new H.A.D. technology is used
KIT4P contains all items required for a complete repla- on this model instead of a D.M.F.
cement. g Renault Scenic 1.9dCi and Renault Megane
Fluence 1.5Dci also use H.A.D. technology in O.E.
Volkswagen 1.2TDi engines (Polo…)
“If KIT4P can replace D.M.F., why is it not
used by carmakers in O.E.?” gg Ford with new Ecoboost 1.3l engines (Ford
C-Max, Focus…) on which a D.M.F. solution is
The KIT4P technology is used in O.E. But since these technically not possible.
vehicles are already equipped with a rigid flywheel,
Valeo only supplies the clutch kit. “Why choose KIT4P?”
KIT4P is an I.A.M. solution for vehicles fitted with D.M.F.
originally. However technology used or components g A reliable solution, corresponding to the highest
O.E. standards
are original equipment. D.M.F. is a common application
for diesel or turbo engines with engine torques higher g Increased durability thanks to solid flywheel, low
wear and better thermal resistance
than 250 Nm. Thus, any diesel vehicle above this
engine torque is a potential D.M.F. application. If a rigid g 100% torque transfer providing an important
safety factor
flywheel is used in such vehicles, one could say that
the vehicle is already equipped with a KIT4P. However, g Comfortable solution with high filtration of vibration
and noise to enhance driving pleasure
since the flywheel has a low replacement rate, it is not
included in the module. This is why we sell only the g Avoids costly replacements due to known D.M.F.
problems on certain vehicles
clutch kit on the I.A.M. Car manufacturers are looking
for opportunities to increase efficiency. This includes
g Easy to fit, same installation and fitting time as
D.M.F. and associated kit.
the launch of new, low-consumption engines into the
market. We are likely to see this trend increase even
further in the near future.
27
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.
28
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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.
Valeo Service
70, rue Pleyel
Cedex 93285 - Saint Denis - France
Tel. : (+33)149 453 232
Fax : (+33)149 453 201
www.valeoservice.com Automotive technology, naturally

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Transmission Systems

a b c Product focus valeoscope

gg Economical & reliable

7. KIT4P Main advantages P15

8. KIT4P Technical support P19

9. F.A.Q. - Everything you need to know P26

In 2013, the Group generated sales of € 12.1

Valeo consists of 4 Business Groups: Powertrain

a b c Technical handbook valeoscope a b c Technical handbook valeoscope

Air Conditioning Lighting Systems

Transmission Systems Transmission Systems Transmission Systems Transmission Systems

Diag & Fit

hl n Diag & Fit valeoscope

Truck Brake Pad

g Get product information: product data sheets provide

g Find common failures: step-by-step failure

g Keep you updated about Valeo Service products:

g Find help when it is needed: answers to frequently

The information in Valeo TechAssist is structured in

1.Product documentation g Fill in your evaluation: provide feedback on your

Yet certain applications faced problems linked to the

In Europe, the story began in Spain with the first KIT4P

KIT4P has been in the spare parts market since

5.2 Full hydraulic clutch actuation

KIT4P without C.S.C. KIT4P with C.S.C.

The KIT4P is composed of a rigid flywheel with a

Engine Gear box

Filtration of engine acyclism in case of KIT4P

Multi spring pre-damper cassette

Main damper springs

Plate retaining stilts

Damper hysteresis washers

WX Long Travel Damper Disc combination

Engine torque up to 360 Nm Engine torque up to 280 Nm Engine torque up to 360 Nm

2 independent hysteresis levels 4 independent hysteresis levels 4 independent hysteresis levels

6.2 Long Travel Damper 6.3 Long Travel Damper key

6.4 Long Travel Damper

KIT4P is not only a cost-effective solution, but

g Extremely reliable solution providing full

7.1 A reliable solution 7.2 Increased clutch life

F808 (21 tests) F810 DS (6 tests)

KIT4P runs at optimized temperature boundaries,

The graph below shows the friction coefficient

0,45 the safety factor for torque transmission and

7.6 Easy to fit 7.7 D.M.F. and KIT4P comparison

Function 836162 D.M.F. Module 835071 KIT4P Comment

Engine torque is transferred at all drive

HILL START &

KIT4P is easy to fit on the vehicle. Assembly is

8.1.1 After disassembling the

8.1.2 Fixing the flywheel to the

8.1.4 Fitting the clutch

8.1.5 Re-assembling the gearbox

8.1.6 After the fitment – verify

gg KIT4P product notice

8.2.1 KIT4P product notice

8.2.2 KIT4P fitting notice

Provided within the box:

8.2.3 KIT4P sticker

Service Kit: once the KIT4P is installed in the

8.2.4 KIT4P fitting bolts

The flywheel bolts and clutch cover bolts are

826317 826363 6 60 Nm + 90º 835047 828107 6 60 Nm + 90º

It is not adequate to use “old” bolts for installing the