KIA RIO

Since 2000 of release

Repair and car operation



Remove the block of valves of management and completely clear it if coupling or a brake tape have burnt slightly or quality of a liquid in an automatic transmission has worsened.

Clearing



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
   - 8.2. Automatic transmission F4E–K
      8.2.1. Specifications
      8.2.2. Check of work and adjustment of position of the lever of the selector
      8.2.3. Testing of teamwork of an automatic transmission and the engine for the motionless car (stall test)
      8.2.4. Time lag testing (Lag test)
      8.2.5. Pressure check трансмиссионной liquids
      8.2.6. Check of level and liquid replacement in an automatic transmission
      8.2.7. Procedure of replacement of a liquid in the converter of an automatic transmission
      8.2.8. Leaks of a liquid from an automatic transmission
      8.2.9. Replacement of oil sealing rings
      8.2.10. Removal and installation of an automatic transmission
      8.2.11. Repair of an automatic transmission
      8.2.12. A radiator of cooling of a liquid of an automatic transmission
      8.2.13. The block of valves
      8.2.14. The case of regulating valves
      8.2.15. The oil pump
      8.2.16. Check of resistance of the gauge of frequency of rotation of an entrance shaft \of a turbine wheel
      8.2.17. Check of resistance of the gauge of speed
      8.2.18. The switch of operating modes of transmission O\D
      8.2.19. The switch of a range of a transmission
      8.2.20. The gauge of temperature of an automatic transmission
      8.2.21. Electromagnetic valves
      8.2.22. The linear electromagnetic valve
      8.2.23. The selector lever
      8.2.24. Repair of the lever of the selector
      8.2.25. Check of functioning of the mechanism of blocking of the lever of the selector
+ 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







8.2.11. Repair of an automatic transmission
THE GENERAL DATA

Automatic transmission

1 – the twisting moment converter;
2 – a shaft of the oil pump;
3 – a pipe of the index of level and oil pouring;
4 – the gauge of frequency of rotation of an entrance shaft / of a turbine wheel;
5 – the switch of a range of a transmission;
6 – an arm of a cable of the selector;
7 – an arm;
8 – the gauge of position of a cranked shaft;
9 – the gauge of speed and a gear wheel of a drive of a speedometer;
10 – an entrance pipe;
11 – a target pipe;
12 – the oil pallet;
13 – a lining to (replace);
14 – the case of the block of valves;
15 – the oil pump.

Automatic transmission

1 – a lock ring;
2 – coupling of a forward / backing;
3 – a small solar gear wheel and coupling №1;
4 – brake tapes 2-oj/4th transfers;
5 – анкерная a rack and a pin;
6 – a lock ring;
7 – coupling №2 and the planetary block;
8 – the holder of the servo-driver;
9 – the servo-driver piston;
10 – a piston rod;
11 – a lock ring;
12 – an internal gear wheel;
13 – coupling 3-ej/4th transfers.

Automatic transmission

1 – a turbine shaft;
2 – the exit case;
3 – nuts;
4 – a washer;
5 – a plate;
6 – a shaft;
7 – a bolt;
8 – the holder of the lever;
9 – the parking lever;
10 – the lock lever;
11 – a returnable spring;
12 – bolts;
13 – a modulator support;
14 – картер transmissions.

Automatic transmission

1 – differential;
2 – a cylindrical pin to (replace);
3 – the case of bearings;
4 – an intermediate gear wheel;
5 – a target gear wheel;
6 – a bearing cover;
7 – external rings of bearings to (replace);
8 – an adjusting lining to (replace);
9 – an oil sealing ring to (replace);
10 – sealing rings to (replace);
11 – картер the converter.

The general recommendations

Dismantling of an automatic transmission spend in a place protected from a dust, for an exception of pollution of details of a transmission.

At dismantling check a condition of details of a transmission on absence of deterioration and damages.

For division of parts картера use only plastic hammers.

Do not use rags at transmission dismantling: rags fibres can hammer in channels for a liquid.



Some details are similar against each other, therefore at dismantling arrange them so that not to mix them.
PERFORMANCE ORDER
1. Before dismantling clear an external surface of a transmission a cleaner or solvent.
2. Clear the removed details solvent and dry up compressed air. Clear all channels and apertures the compressed air and check up that in them there are no barriers.

The prevention

At clearing of details by the compressed air dress points.

Be careful not to spill a liquid at removal of the converter of a twisting moment.


Dismantling

PERFORMANCE ORDER
1. Remove the converter of a twisting moment from картера the converter.
2. Manually remove a shaft of the oil pump.
3. Remove a pipe of the index of level and oil pouring.
4. Remove the gauge of frequency of rotation of an entrance shaft / turbine.
5. Remove the switch of a range of a transmission.
6. Remove an arm of a cable of the selector.
7. Remove an arm.
8. Remove the gauge of position of a cranked shaft.
9. Remove the gauge of speed and a gear wheel of a drive of a speedometer.
10. Remove an entrance pipe.
11. Remove a target pipe.
12. Collect special adaptation OK130 990 007 with holder OK130 175 011A.

The prevention

Do not incline a transmission in one party in the course of dismantling as it can suddenly turn over and put a trauma.

Before переворачиванием transmissions remove the oil pallet. It guarantees that all extraneous inclusions and particles remain in the pallet.


13. Turn out nineteen bolts and remove the oil pallet.
Investigate all extraneous inclusions and the particles found in the pallet and on a magnet to define a condition of details of a transmission. Presence of particles of deterioration of coupling testifies to deterioration of a plate of a drive or brake tapes. Steel particles on a magnet testify to deterioration of bearings, gear wheels or drive plates. Presence of aluminium particles testifies to deterioration of plugs or картера transmissions.
In the presence of a considerable quantity of extraneous inclusions and particles, replace the converter of a twisting moment and carefully check up a condition of details of a transmission.
14. Remove a clip (one bolt).
15. Disconnect electromagnetic valves.
16. Turn out three bolts and remove the mesh filter.

17. Turn out bolts A, B and C and remove the arms shown in drawing.

Length of bolts (measured from the head basis):

And: 30 mm
In: 50 mm
With: 14 mm

18. Remove the case of the block of valves of management.
19. Remove a shaft and a plate:
      – ослабьте nuts also extend a shaft;
      – Turn out nuts, remove a washer and a plate.
20. Turn out a bolt and remove the holder of the lever of a parking.
21. Turn out two bolts of the holder of the lever of a parking.
22. Remove the lock lever and a returnable spring.
23. Remove a modulator support.
24. Turn out ten bolts and remove the oil pump.
25. Remove coupling of a forward / backing:

      – Remove a lock ring of a shaft of a turbine wheel;
      – Lift in gathering coupling of a forward / backing and remove it from a transmission.

26. Remove a small solar gear wheel and coupling №1.


The prevention

Use a piece of a wire for fastening of a brake tape so that it has not been damaged at вытягивании.


27. Remove brake tapes 2–4.
28. Remove a pin, thus support анкерную a rack.
29. Remove анкерную a rack.
30. Remove the servo-driver:

      – Compress the piston of the servo-driver and remove a lock ring;
      – Remove the holder of the servo-driver, the piston and a spring.

31. Remove unilateral coupling №2 and planetary assemblage:

      – Remove a lock ring;
      
– Remove unilateral coupling №2 together with planetary assemblage;
      – Remove a frictional plate.

32. Remove an internal gear wheel:

      – Remove a lock ring;
    
  – Remove an internal gear wheel from the exit case.

33. Remove the block of coupling 3–4:

      – Remove a sealing ring from a turbine shaft sideways the converter;
      – Deduce a turbine shaft to remove the block of coupling 3–4;
      
– Remove the block of coupling 3–4 of a turbine shaft.

34. Turn out bolts (from outside the converter – eight bolts and from outside картера transmissions – seven bolts) and remove картер transmissions, striking on it a plastic hammer.

35. Remove the case of an exit from a target gear wheel.

36. Remove differential.
37. Remove the case of bearings:

      – A hammer and round выколоткой beat out a cylindrical pin;
      – Turn out eleven bolts of fastening of the case of bearings;
      – Remove the case of bearings, striking on it a plastic hammer.
38. Remove the block of an intermediate gear wheel and knot of a target gear wheel, beating out them from outside the twisting moment converter.

39. Uncover bearings:

      – Turn out bolts of fastening of a cover of bearings;
      – Special adaptation OK130 175 011A remove the converter case;
      
– Squeeze out a cover of bearings from the converter case.


The prevention

Establish earlier removed external ring of the bearing during repeated assemblage to adjust a preliminary tightness of bearings.


40. Special adaptation OK130 170 012 remove an external ring of the bearing.

Assemblage


The prevention

If the plate of a drive or a brake tape are replaced new, before installation impregnate a new detail in a liquid for an automatic transmission during, at least two hours.

Before assemblage grease with a liquid for an automatic transmission all oil sealing rings rotating details, sealing rings of round section and mobile details.

All sealing rings of round section, oil sealing rings and linings should be replaced with the new.

At repeated assemblage use technical vaseline, but do not grease консистентной with greasing.

When it is necessary to replace the plug, replace a detail (knot) containing same plug.

After drawing of hermetic assemblage is necessary for making within 10 minutes and to sustain 30 minutes before filling with a liquid for an automatic transmission.


External diameter of bearings and surfaces качения


1
2, 6
3
4
5
7
Diameter of the bearing, mm
86,1
56,1
58,1
86,1
86,1
72,1
Diameter of a surface качения, mm
88,0
84,0

PERFORMANCE ORDER

1. Combine a cover of bearings with directing bolts and press it, as is shown in drawing.

The inhaling moment: 10,8–13,7 Nm

2. Tapping with a plastic hammer establish in gathering an intermediate gear wheel and a target gear wheel.
3. Establish the bearing case:

      – Establish the bearing case on a converter casing;
      – Combine deepening on intermediate to a shaft with a label on the bearing case;
      – A hammer and thin выколоткой establish a cylindrical pin;
      – Screw eleven bolts.

The inhaling moment: 19–25 Nm

4. Establish a parking stopper:

      – Establish a stopper of a parking and a shaft;
      – Establish a spring and a lock ring.
      – Manually move a shaft and be convinced that the parking stopper works.
5. Establish a support of the modulator and fix new bolts.

The inhaling moment: 15–17 Nm

6. Establish the lever of a clamp and a returnable spring.
7. Establish the parking lever.
8. Establish the holder of the lever and a bolt.

The inhaling moment: 7,9–10,7 Nm

9. Establish a plate and a shaft:

      – Establish a plate a washer and nuts;
      – Tighten nuts the demanded moment.

The inhaling moment: 42–54 Nm

10. Establish differential in a converter casing. Establish special adaptation OK201 270 014.
11. Establish a new oil sealing ring on the block of a target gear wheel.
12. Establish the exit case on a target gear wheel and establish a bearing ring on the exit case.

External diameter of the bearing: 72,1 mm

13. Apply a thin film silicone hermetic TB-1217B on interfaced surfaces of a casing of the converter and картера transmissions.
14. Establish new sealing rings on a converter casing.

The prevention

Check up that hermetic will not be squeezed out in channels for greasing at installation картера transmissions.




15. Fix картер transmissions to a converter casing.

The inhaling moment: 38–51 Nm

16. For support of a shaft of the turbine establish special adaptation OK201 190 019.

17. Establish a shaft of the turbine and the block of coupling 3–4:

      – Collect a shaft of the turbine and the block of coupling 3–4;
      – Check up that the axial bearing is established properly;
      – Establish a shaft of the turbine and the block of coupling 3–4 in картер transmissions as assemblage.

18. Establish an internal gear wheel:

      – Establish an internal gear wheel in the exit case;
      – Establish a spring lock ring.

19. Establish planetary assemblage:

      – Check up that the axial bearing and a surface качения the bearing are established properly;
      
– One hand keep a shaft of the turbine from проворачивания;
      – Establish planetary assemblage and a drum of coupling 3–4, turning it.

20. Establish brake tapes of the lowest transfers, transfers of a backing and a drive plate.

21. Establish a fastening plate.

22. Establish a spring lock ring.
23. To establish a frictional disk.

24. To establish unilateral coupling №2:

      – Hold unilateral coupling №2 horizontally;
      – Establish it, turning planetary assemblage counter-clockwise;
      – Establish a spring lock ring.
25. Establish анкерную a rack and a shaft.

The prevention

The lock of a brake tape 2–4 and анкерная a rack are held apart, as is shown in drawing.


26. Establish a brake tape 2–4 in картере transmissions so that the tape was completely free.

27. Establish a small solar gear wheel and unilateral coupling №1:

      – Check up that the axial bearing and a surface качения the bearing are established in correct position;
      – Turning, establish a small solar gear wheel and unilateral couplings №1.

28. Establish coupling of a forward / backing:

      – Check up that the axial bearing is established in correct position;
      – Turning, establish coupling of a forward / backing.


The prevention

The height of installation of coupling of a forward / backing in relation to a flange картера transmissions is various.

The maximum height: 0,9 mm


29. Establish a spring lock ring in deepening of a shaft of the turbine.

30. Measure a backlash between a flange and a bearing end face качения as follows:

      – Establish the bearing on coupling of a forward / backing;
      – Remove preliminary established surface качения and a lining;
      – Establish the thickest lining (2,2 mm) on the oil pump;
      – Establish the oil pump on coupling assemblage, without establishing a lining of the oil pump.


The prevention

At this stage do not establish a lining of the oil pump.


      – Measure a backlash And between картером transmissions and the oil pump;
      – According to the measured backlash choose a lining of a certain thickness;

Backlash And, mm
Thickness of a lining, mm
0,091–1,01
1,2
0,71–0,90
1,4
0,51–0,70
1,6
0,31–0,50
1,8
0,11–0,30
2,0
0–0,10
2,2

      – Remove the oil pump;
      – Establish a surface качения the bearing and a new lining on the oil pump;
      – Establish the oil pump on a transmission.

The inhaling moment: 19–25 Nm

31. Check up adjustment of brake tapes 2–4 as follows:

      – Establish the servo-driver piston on adaptation OK201 190 021;
      – Establish a sealing ring of round section on the holder of the servo-driver with adaptation OK201 190 021;
      – Grease a sealing ring of round section with a liquid for automatic transmissions and establish assemblage of a tape of the servo-driver with the adaptation in картер transmissions and fix a spring lock ring;

The prevention

Check up that brake tapes of 2-4 transfers are located opposite to a core of the piston of the servo-driver.


      – Establish a measuring tip of the indicator of hour type in an end face of a core of the piston;

      – Submit compressed air through the channel of giving of a liquid with the air nozzle, condensed by rubber and measure a core course;

Pressure of air: a maximum 392 кПа
Core course: 1,0–7,0 mm

      – If the core course does not correspond demanded, choose a corresponding core;

Length of a core of the piston mm: 95,0, 95,5, 96,0, 96,5, 97,0, 97,5, 98,0, 98,5, 99,0

      – Remove assemblage of a tape of the servo-driver with the adaptation.


The prevention

At removal do not damage a spring lock ring.


32. Establish the servo-driver in картер transmissions:

      – Establish a spring of the servo-driver and servo-driver assemblage.
      – Establish a spring lock ring.
      – Establish a brake tape 2–4 on a core of the servo-driver of the piston.

33. Combine the mechanical valve with a pin on a plate and establish the case of the regulating valve.

The inhaling moment: 7,9–10,7 Nm
Length of bolts (measured from the head basis):

And: 30 mm
In: 50 mm
With: 14 mm

34. Connect the electromagnetic valve and a socket of the gauge of temperature of a liquid in an automatic transmission.

35. Connect a socket of the electromagnetic valve.


The prevention

Establish magnets in the oil pallet in the places shown in drawing.


36. Establish a new lining and the oil pallet and fix its nineteen bolts.

The inhaling moment: 8,4–10,7 Nm

37. Establish an entrance and target pipe.
38. Establish the gauge of speed and the mechanism of a drive of a speedometer.
39. Establish the gauge of an angle of rotation of a cranked shaft.
40. Establish an arm.

41. Establish the switch of a range of a transmission:

      – Manually turn a shaft in position N;
      – Establish the switch of a range of a transmission;
      – Tighten bolts of fastening of the switch of a range of a transmission;

The inhaling moment: 7,9–10,7 Nm
      – Check up that position of the lever of the selector and the indicator of the chosen position coincide.

42. Remove a transmission from the special adaptation 130 990 007/OK130 175 011A.
43. Establish a new sealing ring and a pipe of the index of level and oil pouring.

The inhaling moment: 7,9–10,7 Nm

44. Establish the gauge of frequency of rotation of an entrance shaft / of a turbine wheel.

The inhaling moment: 7,9–10,7 Nm

45. Establish a shaft of the oil pump.
46. Establish a sealing ring on a turbine shaft.

47. Fill the converter with a liquid for automatic transmissions.

Type of a liquid for an automatic transmission: SK ATF SP–III or DIAMOND ATF SP–III


The prevention

At filling with a liquid hold the converter in vertical position. Do not pour a liquid.

If the converter is not established easily, do not apply to it the big efforts: establish carefully.

Do not damage a sealing ring of a shaft of a turbine wheel.


48. Establish the converter in a converter casing, turn it for combination of grooves.
49. Check up correctness of installation of the converter, measuring distance And between an end face of the converter and a flange картера transmissions.

Distance A: 13.6 mm