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







2.9. A head of the block of cylinders
THE GENERAL DATA

Head of the block of cylinders of engine DOHC (A5D)

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

Head of the block of cylinders of engine SOHC (A3E)

1 – a bolt, 7,8–11 Nm;
2 – a bolt, 19–25 Nm;
3 – a thermostat cover;
4 – the thermostat;
5 – a bolt, 19–25 Nm;
6 – a bolt, 22–28 Nm;
7 – the hydraulic jack of backlashes of valves;
8 – a bolt, 22–28 Nm;
9 – a cover of a head of the block of cylinders;
10 – a bolt, 4,9–8,8 Nm;
11 – a shaft of levers;
12 – levers;
13 – levers;
14 – a shaft of levers;

15 – a camshaft;
16 – crackers;
17 – a plate of a spring of the valve;
18 – a valve spring;
19 – a lining;
20 – маслоотражательный a cap;
21 – the directing plug of the valve;
22 – a pulley of a gear belt of a camshaft;
23 – a bolt, 49–61 Nm;
24 – a head of the block of cylinders;
25 – a lining of a head of the block of cylinders;
26 – the valve

Removal

PERFORMANCE ORDER
1. Merge cooling liquid from system of cooling and disconnect the top hose of a radiator.
2. Remove the wide hose located between the air filter and the main cover.
3. Remove an air inlet branch pipe.
4. Remove a vacuum hose, a hose of giving of fuel and a hose of a cooling liquid.
5. Remove high-voltage wires from spark plugs. Removal of high-voltage wires spend for candle tips, instead of for wires.
6. Remove the ignition coil.
7. Remove the oil pump of the amplifier of a steering and an arm.
8. Remove an inlet collector.
9. Remove a thermofilter and a final collector in gathering.

10. Remove a pulley of the water pump and a pulley of a cranked shaft.

11. Remove a casing of a gear belt.
12. Remove a pulley of the tension mechanism of a gear belt.
13. Remove a gear belt.
14. Uncover heads of the block of cylinders and a cover of camshafts.
15. In certain sequence, for 2–3 stages turn out bolts of fastening of a head of the block of cylinders. Remove a head of the block of cylinders and a lining of a head of the block of cylinders.
16. Clear interfaced surfaces of a head of the block of cylinders and the block of cylinders of the lining rests.

The prevention

Exclude hit of the rests of a lining in channels for greasing and engine cylinders.


Check

PERFORMANCE ORDER
Check up a lining of a head of the block of cylinders on absence of leaks, stains from a cooling liquid or прожогов linings between cylinders.

Check of a head of the block of cylinders

PERFORMANCE ORDER
1. Examine a head of the block of cylinders on absence of damages, cracks, leaks of oil and cooling liquid. If necessary replace a head of the block of cylinders.
2. A metal ruler and щупом in six directions check up planeness of a head of the block of cylinders. If necessary перешлифуйте a head of the block of cylinders.

The maximum deviation from planeness:
Engine A5D: 0,03 mm
Engine A3E: 0,05 mm


The prevention

Before installation of a head of the block of cylinders check up following elements and if necessary execute repair or replace a head:

      – A condition and depth of installation of saddles of valves;
      – Damage of interfaced surfaces of inlet and final collectors;
      – Backlashes in bearings and axial люфт camshafts.


3. By a metal ruler and щупом in two directions measure planeness of interfaced surfaces of collectors.

The maximum deviation from planeness:
Engine A5D: 0,03 mm
Engine A3E: 0,05 mm

4. Measure height of a head of the block of cylinders from the basis of a head of the block of cylinders to a surface of installation of a lining of a cover of a head of the block of cylinders.

Height:
Engine A5D: 127,8–128,0 mm
Engine A3E: 107,4–107,6 mm

5. If the height of a head of the block of cylinders differs from rating values, replace a head of the block of cylinders.

The prevention

If it is necessary to make machining of a head of the block of cylinders, preliminary remove inlet and final collectors and check up planeness of interfaced surfaces of collectors.


6. By a metal ruler and щупом in two directions measure planeness of interfaced surfaces of collectors.

Deviation from planeness: no more than 0,05 mm

7. If неплоскостность exceeds admissible limits, replace a head of the block of cylinders.

Installation of a head of the block of cylinders of engine A5D

PERFORMANCE ORDER
1. Clear interfaced surfaces of a head of the block of cylinders of the lining rests.
2. Establish a new lining on the block of cylinders of the engine. At lining installation use hermetic. Do not use repeatedly a lining of a head of the block of cylinders. Establish a head of the block of cylinders.
3. In certain sequence tighten bolts of fastening of a head of the block of cylinders in some stages:

And. Tighten bolts the moment of an inhaling 49 Nm;
b. In sequence, return to a tightening, ослабьте bolts of fastening of a head of the block of cylinders;
c. Repeatedly tighten bolts the moment of an inhaling 25 Nm;
d. Tighten bolts on 90 .

The prevention

Do not turn a cranked shaft of the engine at the removed gear belt.

Before installation be convinced that pistons are located between ВМТ and НМТ. It will exclude impact of pistons and valves which can lead to deformation of valves and engine damage.

Two bolts (7 and 8) are shorter than other bolts. Do not establish these bolts in other positions.

For fastening of a head of the block of cylinders it is necessary to use new bolts.


4. Establish a pulley of the mechanism of a tension of a gear belt.
5. Establish a gear belt on a camshaft pulley, be thus convinced that all adjusting grids are combined with indexes.
6. Check up combination of adjusting labels of all pulleys of a gear belt.
7. Establish a cover of a head of the block of cylinders and fix its bolts, having tightened their demanded moment.

The inhaling moment: 4,9–8,8 Nm

8. Establish a casing of a gear belt.
9. Establish a new lining of an inlet collector and an inlet collector. Fix an inlet collector bolts, having tightened their demanded moment.
10. Establish a new lining of a final collector and a final collector. Fix a final collector nuts, having tightened their demanded moment.

11. Establish the levelling tank and tighten boats and nuts the demanded moment.

The inhaling moment:
Bolts and nuts of fastening of inlet and final collectors: 15–20 Nm
The levelling tank to nuts and bolts of an inlet collector: 15–20 Nm

12. Establish the oil pump of the amplifier of a steering and an arm.
13. Establish the ignition coil.
14. Establish an air inlet branch pipe.
15. Connect a vacuum hose, a hose of giving of fuel and a hose of system of cooling.
16. Establish a wide hose between the air filter and the main cover.

Installation of a head of the block of cylinders of engine A3E

PERFORMANCE ORDER
1. Clear interfaced surfaces of a head of the block of cylinders of the lining rests.
2. Establish a new lining on the block of cylinders of the engine. At lining installation use hermetic. Do not use repeatedly a lining of a head of the block of cylinders.
3. Establish a head of the block of cylinders.
4. In certain sequence tighten bolts of fastening of a head of the block of cylinders in some stages:

And. Tighten bolts the moment of an inhaling 49 Nm;
b. In sequence, return to a tightening, ослабьте bolts of fastening of a head of the block of cylinders;
c. Repeatedly tighten bolts the moment of an inhaling 25 Nm;
d. Tighten bolts on 90 .