KIA RIO

Since 2000 of release

Repair and car operation



Kia Rio
+ 1.1. Short acquaintance to the car
- 2. Engines A3E, А5D
   2.1. Specifications
   2.2. Compression check
   2.3. Camshafts
   2.4. Pistons and rods
   2.5. A cranked shaft
   2.6. Check шатунных and radical loose leaves
   2.7. The air filter (ACL)
   2.8. An accelerator cable
   2.9. A head of the block of cylinders
   2.10. Check of valves
   2.11. Check of a saddle of the valve
   2.12. Check of a spring of the valve
   2.13. A gear belt
   2.14. System of release of the fulfilled gases
+ 3. Greasing system
+ 4. Cooling system
+ 5. Fuel system
+ 6. Ignition system
+ 7. Coupling
+ 8. A transmission
+ 9. Axes and power shafts
+ 10. A suspension bracket
+ 11. Wheels and tyres
+ 12. A steering
+ 13. Brake system
+ 14. A body
+ 15. Air central air
+ 16. The electric equipment







2.3. Camshafts
THE GENERAL DATA

Engine DOHC camshafts

1 – a bolt, 37–52 Nm;
2 – a hairpin, 29–35 Nm;
3 – a bolt, 4,9–8,8 Nm;
4 – a cover of a head of the block of cylinders;
5 – elements of a cover of a head of the block of cylinders;
6 – a lining of a cover of a head of the block of cylinders;
7 – a bolt, 11,2–14,2 Nm;
8 – a cover of camshafts;
9 – a bolt, 37–52 Nm;
10 – camshafts;
11 – a hairpin, 7,8–12 Nm;
12 – a head of the block of cylinders;
13 – a hairpin, 7,8–12 Nm;
14 – a lining of a head of the block of cylinders

Engine SOHC camshafts

1 – a bolt, 7,8–11 Nm;
2 – a bolt, 7,8–11 Nm;
3 – a bolt, 22–28 Nm;
4 – a bolt, 22–28 Nm;
5 – a cover of a head of the block of cylinders;
6 – a bolt, 4,9–8,8 Nm;
7 – a shaft of levers;
8 – levers;
9 – a camshaft;
10 – a pulley of a gear belt of a camshaft;
11 – a bolt, 49–61 Nm;
12 – a head of the block of cylinders;
13 – a lining of a head of the block of cylinders

Removal
PERFORMANCE ORDER
1. Disconnect a wide hose and a ventilation hose картера.
2. Remove a pulley of the water pump and a pulley of a cranked shaft.
3. Remove a casing of a gear belt.
4. Loosen the a bolt of fastening of a pulley of the mechanism of a tension of a gear belt, take a pulley aside and fix it in this position.
5. Remove a gear belt from a camshaft pulley.
6. Turn out bolts and remove from the engine the central cover.
7. Remove the block of coils of ignition.
8. Turn out bolts and uncover heads of the block of cylinders.
9. Turn out a bolt and remove a camshaft pulley.

10. Uncover camshafts and a gear belt.

11. Remove a camshaft.
12. Remove hydraulic jacks of backlashes of valves.

Check (engine A5D)

PERFORMANCE ORDER
1. Establish the first and last necks of a camshaft on V-shaped blocks.
2. Establish a measuring head of the indicator of hour type on an average neck of the bearing of a camshaft and establish an indicator scale on 0.
3. Turn a camshaft and measure its palpation.

Maximum permissible palpation of a camshaft: 0,03 mm

4. Check up a camshaft on absence of non-uniform deterioration, cracks or damages.

5. In two points measure height of each cam of camshafts.

Height of cams of inlet and final camshafts:
Nominal – 42,870 mm
Is minimum admissible – 42,868 mm

6. In two perpendicular directions and two planes measure diameter of each neck of camshafts.

Nominal diameter: 33,961–34,000 mm
Is minimum admissible diameter: 26,910 mm
Maximum permissible ovality: 0,03 mm

7. If deterioration of cams or necks of bearings of camshafts exceeds maximum permissible value, replace camshafts.
8. Measure a backlash in bearings of camshafts with remote hydraulic jacks of valves.
9. Clear of greasing of a neck of bearings of camshafts, bearings in a cover of camshafts and bearings in a head of the block of cylinders.

10. Establish camshafts on a head of the block of cylinders.

11. For backlash measurement use plastic calibrated round core Plastigauge. Core Plastigauge is compressed between the bearing and a camshaft neck. After removal of a cover of the bearing of a camshaft the deformed plastic core Plastigauge is measured by a special template which is available in the complete set. Cut off slices of a plastic core and arrange them on camshaft necks.
12. After installation of plastic cores do not turn camshafts.
13. Establish a cover of camshafts.
14. Establish bolts of fastening of a cover of camshafts and tighten them in some stages.

The inhaling moment: 11,2–14,2 Nm

15. Turn out bolts of fastening of a cover of camshafts.
16. Uncover camshafts.
17. Measuring by a template width of the deformed plastic core, define backlashes in camshaft bearings.

Nominal backlash: 0,035–0,081 mm
Maximum permissible backlash: 0,15 mm

18. If the backlash exceeds maximum permissible value, replace a head of the block of cylinders.
19. Establish camshafts.
20. Establish a measuring tip of the indicator of hour type on a camshaft end face.
21. Move a camshaft along an axis against the stop to one party.
22. Establish an arrow of the indicator of hour type on 0.
23. Move a camshaft along an axis against the stop to other party.

24. Read indications on the indicator of hour type which shows size axial люфта a camshaft.

Nominal axial люфт: 0,067–0,137 mm
Maximum permissible backlash: 0,147 mm

Check (engine A3E)

PERFORMANCE ORDER
1. Establish the first and last necks of a camshaft on V-shaped blocks.
2. Establish a measuring head of the indicator of hour type on an average neck of the bearing of a camshaft and establish an indicator scale on 0.
3. Turn a camshaft and measure its palpation.

Maximum permissible palpation of a camshaft: 0,03 mm

4. Check up a camshaft on absence of non-uniform deterioration, cracks or damages.

5. In two points measure height of each cam of a camshaft.

Height of cams of a camshaft of inlet valves:
Nominal – 36,3422 mm
Is minimum admissible – 36,3402 mm
Height of cams of a camshaft of final valves:
Nominal – 36,0752 mm
Is minimum admissible – 36,0732 mm

6. In two perpendicular directions and two planes measure diameter of each neck of a camshaft.

1 and 3 necks of a camshaft: 43,440–43,460 mm
2 neck of a camshaft: 43,430–43,455 mm

Installation

PERFORMANCE ORDER
1. Establish hydraulic jacks of a backlash of valves.
2. Grease camshafts with pure engine oil and establish them in a head of the block of cylinders.
3. Establish a cover of camshafts.
4. Establish bolts of fastening of a cover of camshafts and tighten them in some stages.

The inhaling moment: 11,2–14,2 Nm

5. Grease an external surface of sealing rings of camshafts with pure engine oil and the special tool 09221–21000 establish them against the stop in nests of a head of the block of cylinders.
6. Establish pulleys on camshafts and fix their bolts.
7. Check up that the label I on a pulley of a camshaft of inlet valves was combined with the index on a cover of a head of the block of cylinders and label Е on a pulley of a camshaft of final valves was combined with the index on a cover of a head of the block of cylinders.

The prevention

After combination of labels with indexes do not turn distributive and cranked shaft.


8. Establish a gear belt and adjust its tension.

9. The further installation is spent to sequences, return to removal.