Valeo Transmission Systems Clutch KIT4P Conversion Kit valeoscope product focus 998102

Transmission Systems
valeoscope
KIT4PConversion kit
Product focusa b c
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
Aftermarket
self-adjusting solutions
2 offers:
gS.A.T. (O.E. solution for I.A.M.)
gH.E.C. (I.A.M. solution)
3 main benefits:
gEasy to fit! No need
for a specialist tool
gEconomical solution
gConstant pedal effort = comfort!
D.M.F.
gDesigned for lasting performance
gImproved driving comfort
D.M.F./KIT4P
Adapted to your needs!
Traditional Kits
gOne of the market’s best coverage rates
gBest-in-class Valeo friction material
KIT4P
gEconomical & reliable
gAlternative solution to D.M.F.
Hydraulics
gAll-in-one solution
gQuick & easy to install

1
Table
of Contents
P3
P4
P6
P7
P8
P9
P10
P11
P12
P13
P13
P14
P15
P16
P16
P17
P17
P17
P17
P18
P19
P19
P20
P20
P21
P21
P22
P22
P23
P23
P23
P24
P24
P26
P28
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
MORE ABOUT VALEO KIT4P?
qr.valeodrive.com/998100/003097
9. F.A.Q. - Everything you need to know
about KIT4P
10. Conclusion
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
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
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
8.2.1 KIT4P product notice
8.2.2 KIT4P fitting notice
8.2.3 KIT4P sticker
8.2.4 KIT4P fitting bolts

Foreword
2
Valeo - from original
equipment leadership
to aftermarket excellence
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.
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.
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.
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.

Disclaimer
3
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).
(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.
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;
1

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.
Valeo,
your Transmission
Systems
Multi-Specialist2
4

5
Technical handbooks
Product focus
Diag & Fit
Valeoscope library
Air conditioning
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Dual Mass
Flywheel
Product focusa b c
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Dual-Mass Flywheel DMF
Ref: 998120

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:
valeo-techassist.com3
1.Product documentation
2.Technical assistance
3.Workshop tools
4.Technical training
6
You will benefit from Valeo TechAssist throughout
the entire workshop service process:
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.
g
g
g
g
g
g
g
g
g

Why Conversion kit
- KIT4P?4Today’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.
7

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.
5KIT4P composition
Clutch Disc Clutch Cover
Release
Bearing
Clutch Cover
Fitting Bolts
Flywheel Fitting BoltsRigid Flywheel
8

9
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:
Semi-hydraulic clutch actuation (Clutch Master Cylinder & Clutch Release Cylinder)
gRigid Flywheel
gClutch Cover
gClutch Disc
gRelease Bearing
gFitting bolts
5.1 Mechanical or semi-hydraulic
clutch actuation

KIT4P with C.S.C.
gRigid Flywheel
gCover
gDisc
gConcentric Slave Cylinder
gFitting bolts
Full hydraulic clutch actuation (Clutch Master Cylinder & Concentric Slave Cylinder)
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:
10
5. KIT4P composition
KIT4P without C.S.C.
gRigid Flywheel
gCover
gDisc
gFitting bolts
5.2 Full hydraulic clutch actuation

11
66.1 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.
KIT4P design:
Long Travel Damper
(L.T.D.)
Filtration of engine acyclism in case of KIT4P
Gear boxEngine
Rigidflywheel
Clutch kit
with L.T.D.
KIT4P

12
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.
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.
WX Long Travel Damper Disc combination
Multi spring pre-damper cassette
with 2 stages
Main damper springs
2 or even 3 stages
Damper hysteresis washers
Plate retaining stilts
6. KIT4P design:
Long Travel Damper (L.T.D.)

13
innovative characteristics:
gVery low damper and pre-damper stiffness
gPre-damper with two stages including
one anti-creeping stage
gMain damper with dual hysteresis device
gPossibility of half stiffness in coast
gPossibility to add Bonded Tripod®
technology
6.3 Long Travel Damper key
benefits:
gImproved acoustic comfort
gLower idle and creeping noise
gExcellent capacity to filter engine torque oscillations
gImproveddrivelineNoise,Vibrations,Harshness(N.V.H.)
gHigh reliability
gHigh price/performance ratio
gAlternative to Dual Mass Flywheel (D.M.F.)
WX type SX type HAD (NX1...NX4)
Innovative characteristics
Sizes from 220 mm or with min
155 mm inner diameter
Engine torque up to 360 Nm
Valeo O.E. technology since 1994
Sizes from 228 mm or with min
170 mm inner diameter
Sizes from 190 mm
Key features
Low main damper stiffness
and robustness for life
Long Travel pre-damper with 2 steps including one
anti-creeping step
Main damper large single step and large
hysteresis value for dampening
1 stage in drive/one stage in coast
2 independent hysteresis levels
Stiffness and hysteresis levels can be tuned
for each driving condition
Compact design for low inertia
Long travel pre-damper with
anti-creeping device
Progressive torsional characteristics
4 stages in drive and 4 stages in coast
Large anti-creeping cassette and
robustness for life
Long travel pre-damper with anti-creeping device
Progressive torsional characteristics
4 stages in drive and 4 stages in coast

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

15
7KIT4P 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

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.
0
25
50
75
100
125
150
50 100 150 200 250 300 350
FacingWear(mm^3/MJ)
F808 (21 tests) F810 DS (6 tests)
Low and Medium Energy Tests - Facing Wear (200mm)
Temperature (°C)
Low Energy Wear
0
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.
7. KIT4P
Main advantages
16
Low and medium energy tests - Clutch facing wear

17
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.
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.
0,1

0,15

0,2

0,25

0,3

0,35

0,4

0,45

0,5

50
100
150
200
250
300
350
400
450

MINIMUM
FRICTION
COEFICIENT

TEMPERATURE
(

̊C)

VDA

REQUIEREMENTS

JF840

I0146-‐01

F830DS

F820DS

F810DS

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

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.
ASPECT
ASSEMBLY & FITTING
TORQUE TRANSMISSION
DISENGAGE
Comment
HILL START &
THERMAL COMFORT
START AND REENGAGE
COMFORT
SHIFTABILITY
ACOUSTIC COMFORT
MECHANICAL
BALANCING
ENGINE FUNCTIONS
DURABILITY
Bolts and fitting notice included for both
Engine torque is transferred at all drive
speeds without any slippage
KIT4P pedal load is lower than the DMF version
(102 Nm at new clutch and 132 Nm at used clutch)
No judder detected during start
KIT4P dampen improved shiftability
Does not dampen noise at all engine speeds.
Rigid flywheel & Service Kit for the second
replacement
Function 836162 D.M.F. Module 835071 KIT4P
18
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

19
88.1 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

8.1.1 After disassembling the
gearbox from the engine
8.1.2 Fixing the flywheel to the
crankshaft
8. KIT4P
Technical support
20
1
3
2
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
gg
Position the flywheel to the crankshaft centre
Tighten the bolts in star sequence to the specific
tightening torque and angle (3)
gg

21
8.1.3 Preparation of the clutch
for fitment 4
5
6
gApply 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
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
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.
gg
g
g
g

8. KIT4P
Technical support
22
7
8
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

23
8.2 KIT4P box content
A KIT4P contains everything required for an
easy and efficient clutch replacement:
gKIT4P product notice
gKIT4P fitting notice
gKIT4P sticker
gFlywheel fitting bolts
gClutch cover fitting bolts
gAdditional items as necessary (clutch lever…)
Provided within the box:
essential fitting instructions,
tightening torques & position.
Illustrated with photos
in 6 main languages
with Service Kit information
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.
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.

8.2.3 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.
8. KIT4P
Technical support
24

25
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
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
6
6
8
8
7
8
8
6
6
8
8
8
6
8
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8
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7
8
8
8
8
7
8
6
8
8
8
7
6
8
8
10
6
6
8
8
8
60 Nm + 90º
60 Nm + 90º
15 Nm + 30 Nm +75 Nm + 45º
60 Nm
60 Nm
75 Nm
105 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
115 Nm
110 Nm
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 + 90º
60 Nm + 90º
60 Nm + 90º
110 Nm
60 Nm + 90º
60 Nm + 90º
835047
835048
835049
835050
835051
835052
835053
835054
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835057
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828107
828109
828409
826875
828137
828376
828377
828381
828378
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828373
828374
828386
828390
828383
828387
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828375
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828384
828407
828392
828403
828411
828437
828438
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828440
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828444
828445
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828447
828464
828484
828486
6
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10
6
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8
8
8
8
8
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6
8
8
8
8
8
6
6
8
8
8
6
8
8
8
8
8
7
10
10
8
6
6
8
8
10
60 Nm + 90º
90 Nm
60 Nm
60 Nm + 90º
110 Nm
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
110 Nm
110 Nm
60 Nm
60 Nm
35 Nm + 45 º
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
KIT4P Service Kit KIT4P Service Kit
KIT4P flywheel fitting bolt torques
No. of boltsNo. of bolts

9Below 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
26
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.

27
“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 anyspecific 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.
“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

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.
Conclusion10
28

Tech’Care
Delivering Technical Expertise
A range of technical and support services from your multi-specialist
Techn
ical Training
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chnical support Technical Pro
m
oters
Workshop
tools
Training on all product lines
For passenger cars
and commercial vehicles
Theoretical session and practical exercises
Elearning on Valeo-Techassist.com
A complete catalogue of
technical training modules
ClimFill®
- air conditioning station
RegloscopeTM
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adjustment
Fastfill®
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Brake Fluid Tester - DOT boiling point tester
Professional tools for
diagnosis and maintenance
Multi-Specialist approach
for workshops
Product demonstrations
Tools demonstrations
Technical Trainings
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Technical Hotline
CONTACT YOUR VALEO TECHNICAL
PROMOTER FOR A DEMO !

Valeo, your
Multi-Specialist
partner.
©2016-ValeoServiceSASaucapitalde12900000euros-RCSBobignyn°306486408•©Designandprintwww.advence.frRef:998102-v2
Créditsphotos:www.pension-complete.com;Enjoy:);ChristianSchryve-Compiègne;1000&1Images;ETAI;Advence
Automotive technology, naturally
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.
www.valeoservice.com
Valeo Service
70, rue Pleyel
Cedex 93285 - Saint Denis - France
Tel. : (+33)149 453 232
Fax : (+33)149 453 201

Valeo Transmission Systems Clutch KIT4P Conversion Kit valeoscope product focus 998102

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