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







2.4. Pistons and rods
THE GENERAL DATA

The piston and rod

1 – a piston ring;
2 – the piston;
3 – a piston finger;
4 – a rod;
5 – шатунные loose leaves;
6 – a rod cover;
7 – a nut, 29–34 Nm

Removal

Removal of pistons from rods is necessary for spending on the engine from which the head of the block of cylinders and the oil pallet is removed. Check up absence of a step and a deposit in the top part of each cylinder.


The prevention

If to make removal of pistons without having cleaned a step in the top part of the cylinder, it can lead to damage of piston rings and pistons. Using the special tool remove a step in the top part of cylinders


PERFORMANCE ORDER
1. Mark covers of rods and rods according to cylinder number in which they are established.

The prevention

Note rods and covers of rods so that at installation they have occupied correct position and a direction. At wrong installation of rods greasing giving in шатунные loose leaves that will lead to their fast damage will be broken.


2. Turn a cranked shaft of the engine so that pistons of the second and third cylinders were established in the bottom dead point and similarly mark rods and covers of rods.
3. Turn away a nut of fastening of a cover of a rod and easy blows of a plastic hammer bring down a cover.
4. Uncover a rod.

The prevention

For protection of necks of a cranked shaft dress on bolts of fastening of covers of rods pieces of a rubber or plastic tube.


5. Wooden бруском or the hammer handle push out the piston with a rod from the cylinder.
6. Repeat these operations on other cylinders.
7. Mark pistons according to numbers of cylinders in which they have been established.
8. Special пассатижами unclench piston rings and remove them from the piston.
9. Establish the piston vertically and check up smoothness of moving of a rod.

10. Moving a rod, check up absence люфта and jammings.


The prevention

Do not shake a rod very widely as it can make contact with a skirt of the piston and damage it that will lead to necessity of replacement of the piston.


11. If the rod moves with jammings, check up an aperture for a piston finger in the piston and a rod on absence of deformation.
12. Remove lock rings from end faces of a piston finger.
13. Incline the piston and allow a piston finger to slip out the piston. If necessary squeeze out a piston finger from the piston.
14. Take a rod from the piston. At dismantling hold together the piston, a rod, a piston finger and lock rings of a piston finger.

Check of piston rings

PERFORMANCE ORDER

1. Insert a new piston ring into a flute of the piston and щупом measure a backlash between a piston ring and a flute wall.

Nominal backlash:
Engine A5D: 0,03–0,07 mm
Engine A3E: 0,04–0,08 mm
Maximum permissible backlash: 0,10 mm

2. If the backlash exceeds maximum permissible value, replace the piston.
3. Check up piston rings on absence of damages, deterioration or breakage.
4. If necessary replace piston rings.
5. Measure a backlash in the lock of piston rings, manually having inserted a piston ring into the engine cylinder.
6. The piston bottom push a piston ring in the bottom part of the cylinder.

7. Щупом measure a backlash in the lock of a piston ring.

Backlash in locks of piston rings

Piston ring
A3E
A5D
The first компрессионное a ring
0,20–0,35 mm
0,15–0,30 mm
The second компрессионное a ring
0,37–0,52 mm
0,40–0,55 mm
Maslosemnoe ring
0,20–0,70 mm
0,20–0,70 mm
Maximum permissible backlash
1,0 mm

Installation

PERFORMANCE ORDER
1. Establish the piston in a rod and insert a piston finger through the piston and a rod before fixing by its already established lock ring.

The prevention

Check up, that relative position of the piston and a rod was same, as well as before dismantling.


2. Establish the second spring lock ring of a piston finger in a flute on the other hand the piston.
3. Hold the piston vertically and check up freedom of moving of a rod.
4. Establish three parts маслосъемного rings on the piston:

      – Grease with pure engine oil a dilator маслосъемного rings both the top and bottom parts of a ring;
      – Establish a dilator маслосъемного rings on the piston so that the dilator ends have been directed upwards;
      – Establish the bottom part маслосъемного rings on the piston. The ring can be established any party upwards;
      – Establish the top part маслосъемного rings on the piston. The ring can be established any party upwards.
5. Check up that the dilator маслосъемного rings divides the top and bottom parts маслосъемного rings and is freely turned on the piston.
6. Пассатижами for a release of piston rings establish on the piston 2 компрессионное a ring.
7. Пассатижами for a release of piston rings establish on the piston 1 компрессионное a ring.

The prevention

Labels "R" or "Y" on компрессионных rings should be directed to the top part of the piston.


8. Arrange locks of piston rings as is shown in drawings.
9. Establish шатунный the loose leaf in a rod

10. For protection of a neck of a cranked shaft against damage dress on bolts of fastening of covers of rods pieces of a rubber or plastic tube.

11. Establish the piston with piston rings over the first cylinder, thus label F on the piston should be directed to a forward part of the block of cylinders.
12. Turn a cranked shaft in such position that шатунная the neck of a cranked shaft of 1st cylinder was in the bottom dead point.
13. The special adaptation compress piston rings on the piston.
14. The hammer handle press the piston into the cylinder so that the bottom head of a rod was established on a neck of a cranked shaft.
15. Establish шатунный the loose leaf in a rod cover.
16. Arrange pieces of plastic measuring core Plastigauge on necks шатунных bearings of a cranked shaft.
17. According to marks establish covers of rods and fix their nuts.

The inhaling moment: 29–34 Nm


The prevention

At installation of rods combine the labels put on a rod and a cover of a rod and it is correct сориентируйте a rod in relation to the block of cylinders, greasing giving to шатунным to loose leaves otherwise will be broken.

After installation of all pistons turn a cranked shaft in such position that pistons have settled down between ВМТ and НМТ, then establish a head of the block of cylinders. It will exclude impact of pistons and valves which can lead to deformation of valves and engine damage.


18. Turn out nuts and uncover a rod.

19. By a measuring template measure width of deformed plastic core Plastigauge and define backlash size. Remove deformed plastic core Plastigauge from necks of a cranked shaft and loose leaves шатунных bearings.

Nominal backlash in шатунном the bearing: 0,026–0,054 mm
Maximum permissible backlash: 0,10 mm

20. If the backlash exceeds maximum permissible value, перешлифуйте necks of a cranked shaft and use repair loose leaves of the increased size.
21. Apply a thin film engine oil on шатунную a neck of a cranked shaft and шатунный the loose leaf in a rod cover.
22. Establish a cover of a rod and fix nuts.

The inhaling moment: 29–34 Nm

23. Щупом, inserted between a rod and cranked shaft, measure a lateral backlash of a rod.

Nominal lateral backlash of a rod: 0,110–0,262 mm
Maximum permissible backlash: 0,30 mm


The prevention

Do not measure a backlash between a cover of a rod and cranked shaft.


24. If the lateral backlash of a rod exceeds maximum permissible value, replace a rod and a rod cover.