KIA RIO

Since 2000 of release

Repair and car operation



Kia Rio
+ 1.1. Short acquaintance to the car
+ 2. Engines A3E, А5D
+ 3. Greasing system
+ 4. Cooling system
+ 5. Fuel system
+ 6. Ignition system
+ 7. Coupling
- 8. A transmission
   - 8.1. A mechanical transmission
      8.1.1. Specifications
      8.1.2. Check of level of oil
      8.1.3. Oil replacement
      8.1.4. Replacement of an oil sealing ring
      8.1.5. Removal and transmission installation
      8.1.6. Dismantling, check and transmission assemblage
      8.1.7. Carter couplings and components картера transmissions
      8.1.8. A primary shaft of a transmission
      8.1.9. A secondary shaft of a transmission
      8.1.10. A choice of adjusting linings
      8.1.11. Differential
      8.1.12. The gear change mechanism
   + 8.2. Automatic transmission F4E–K
+ 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







8.1.5. Removal and transmission installation
THE GENERAL DATA

Mechanical transmission

1 – заборник fresh air;
2 – the air filter in gathering;
3 – the holder of the storage battery;
4 – the storage battery;
5 – a support of the storage battery;
6 – an arm of the storage battery;
7 – a coupling cable;
8 – a wire of connection with "weight";
9 – a tip of steering draught;
10 – the bottom lever of a forward suspension bracket;
11 – draught;
12 – the right power shaft;
13 – the left power shaft;
14 – a protective plate of the engine;
15 – draught of a choice of transfers;
16 – draught of a gear change;
17 – a starter;
18 – a transmission;
19 – a support of the power unit №2;
20 – a support of the power unit №1;
21 – a stabilizer earring;
22 – the stabilizer of cross-section stability.

Removal

PERFORMANCE ORDER
1. Disconnect first of all a wire from the negative plug of the storage battery, then from the positive.
2. Remove a broad tank of system of cooling for access to an arm of the storage battery.
3. Remove the holder of the storage battery, the storage battery and a support of the storage battery.
4. Remove заборник fresh air and the air filter in gathering.
5. Disconnect a socket of the switch of light of a backing.
6. Disconnect a socket of the gauge of speed of the car, located on the right side of a transmission.
7. Turn out one bolt and disconnect a wire of connection with "weight".
8. Disconnect a socket of the gauge of an angle of rotation of a cranked shaft.
9. After removal of a squeezing clutch lever take a coupling cable aside.

10. Turn out the top bolt of fastening of a starter.

11. Turn out three bolts of fastening картера couplings.
12. Special adaptation OK201 170 AA0 support the engine so that the engine weight was perceived by the adaptation.
13. Lift the car and fix on support.
14. Remove both lobbies of a wheel.
15. Turn out screws and remove both mudguards.
16. Turn out two bolts and four nuts and remove a plate of protection of the engine.
17. Establish the pallet under a stopper plum of oil from a transmission.
18. Turn out a stopper plum of oil and merge oil from a transmission.
19. Disconnect from a transmission draught of a choice of transfers and draught of a gear change.
20. Turn out two bolts of fastening of a support №1 power units.
21. Turn out three bolts of fastening of a support №2 power units.
22. Turn out nuts of fastening of forward longitudinal draughts.
23. Remove the stabilizer and earrings of the stabilizer of cross-section stability.
24. Remove шплинты and turn out nuts of fastening of tips of steering bent for to rotary fists.
25. Special adaptation OK670 321 019 disconnect the left and right tips of steering draughts from rotary fists.
26. Turn out coupling bolts of fastening of pins of hinges to rotary fists from two parties of the car.
27. Mount wring out the bottom levers downwards and separate pins of hinges from rotary fists from two parties of the car.

The prevention

Do not damage a protective cover of the hinge of the bottom lever of a forward suspension bracket.


28. Insert mount between an internal SHRUS of a power shaft and a transmission and easy blow on mount take a power shaft from a transmission.

The prevention

At extraction of a power shaft from a transmission at once do not apply the big efforts, and made efforts increase gradually.

For an exception of damage of an external SHRUS of a power shaft a steel wire tie up a power shaft.


29. Turn out the bottom bolt of fastening of a starter and remove a starter.
30. Turn out three bottom bolts of fastening картера couplings, then support a transmission a jack and turn out the last two bolts of fastening картера couplings.
31. Being careful separate a transmission from the engine and slowly lower it under the car.


Installation

PERFORMANCE ORDER
1. On a jack lift a transmission and establish it under the car.
2. Slowly lifting and moving to the engine establish a transmission into place. Fix a transmission on the engine five bolts screwed through картер of coupling.

The inhaling moment:
The top bolts 1, 2, 3, 4 (4ЕА): 64–89 Nm
The bottom bolts 5, 6, 7, 8, 9 (5ЕА): 37–52 Nm

3. Lower a jack.
4. Remove plastic заглушки OK201 270 014 from a transmission.
5. Establish a starter and screw the bottom bolt of fastening of a starter.
6. Establish a lock ring on the internal end of a power shaft.
7. A push, insert a power shaft into a transmission, thus a cut of a lock ring should settle down from above.

8. Establish pins of spherical hinges of the left and right bottom levers in rotary fists and fix their coupling bolts.

The inhaling moment: 54–68 Nm

9. Establish pins of spherical hinges of the left and right tips of steering draughts in rotary fists and fix their nuts.

The inhaling moment: 30–44 Nm

10. Шплинтами fix nuts from отворачивания.

11. Establish the left and right earrings of the stabilizer and fix them.

The inhaling moment: 42–60 Nm

12. Establish longitudinal draughts and fix their nuts.

The inhaling moment: 118–147 Nm

13. Establish a support №2 power units and fix its bolts and nuts.

The inhaling moment:
Bolt: 43–54 Nm
Nut: 67–93 Nm

14. Establish a support №1 power units.

The inhaling moment: 43–54 Nm

15. Connect draught of a gear change and draught of a choice of transfers.
16. Screw a stopper oil plum in a transmission.
17. Establish a plate of protection of the engine and fix its bolts and nuts.

The inhaling moment:
Bolt and nut of fastening of a plate: 47–66 Nm
Nuts of fastening of support №1 and №2: 37–57 Nm

18. Establish both mudguards and fix their screws.
19. Establish forward wheels.

The inhaling moment: 88–118 Nm

20. Lower the car.
21. Remove special adaptation OK201 170 AA0, supporting the engine.
22. Screw three bolts of fastening картера couplings to the block of cylinders of the engine.

The inhaling moment: 89–116 Nm

23. Screw two top bolts of fastening of a starter.

The inhaling moment: 37–52 Nm

24. Establish squeezing the lever.
25. Connect a socket of the gauge of an angle of rotation of a cranked shaft.
26. Connect a wire of connection with "weight" and fix its bolt.
27. Connect a socket of the gauge of speed of the car.
28. Connect a socket of the switch of a lantern of a backing.
29. Establish the case of the air filter.
30. Connect a socket of the gauge of temperature of air arriving in the engine.
31. Connect a socket of the gauge of a measuring instrument of the expense of air.
32. Establish заборник fresh air and fix its bolt and a nut.
33. Connect first of all a wire to the positive plug of the storage battery, then to the negative.
34. Fill in oil in a transmission.
35. Conduct road tests of the car and check up levels of liquids.