KIA RIO

since 2000 of release

Repair and car operation



Rio KIA
+ 1.1. Short acquaintance to the car
+ 2. Engines A3E, A5D
+ 3. Greasing system
+ 4. Cooling system
+ 5. Fuel system
+ 6. Ignition system
+ 7. Coupling
+ 8. Transmission
+ 9. Axes and power shafts
+ 10. Suspension bracket
+ 11. Wheels and tires
+ 12. Steering
+ 13. Brake system
+ 14. Body
+ 15. Air central air
- 16. Electric equipment
   16.1. Specifications
   16.2. Electric chains
   - 16.3. Generator
      16.3.1. Generator check
      16.3.2. Belt of a drive of the generator
      16.3.3. Removal, repair and generator installation
   + 16.4. Storage battery
   16.5. Starter
   16.6. Check at a provorachivaniye of a cranked shaft not the heated-up engine
   16.7. Check of an electric chain of the traction relay
   16.8. Check of the traction relay
   16.9. Check of brushes and shchetkoderzhatel
   16.10. Check of coils of a stator
   16.11. Rotor check
   16.12. Removal and starter installation
   16.13. Starter repair
   16.14. Multipurpose switch
   16.15. Sound signal
   16.16. The block of safety locks and the relay, established in car salon
   16.17. Check of the relay of the activator of the lock of a door
   16.18. Check of the switch of adjustment of provision of an external rear-view mirror
   16.19. Check of the activator of provision of an external rear-view mirror
   16.20. Check of the engine of a window regulator
   16.21. Check of a heater of back glass
   16.22. Repair of a current-carrying strip of a heater
   16.23. Engine of a screen wiper of a windscreen
   16.24. Stekloomyvateli
   16.25. Adjustment of light of headlights
   16.26. Adjustment of light of fog lights
   16.27. Safety cushions (SRS)
   16.28. Precautionary labels
   16.29. Safety cushion of the driver and spiral wire
   16.30. Safety cushion check
   16.31. Check of a spiral wire (spring)
   16.32. Safety cushion of the forward passenger
   + 16.33. Electric circuits





16.3.3. Removal, repair and generator installation

Removal

PERFORMANCE ORDER
1. Disconnect a wire from the negative plug of the storage battery.
2. Remove a protective cap from the generator plug B.
3. Turn out a nut of fastening of a wire to the generator plug B.
4. Remove a wire from the generator plug B.
5. Disconnect generator sockets.
6. Weaken a sharnirny bolt of B of fastening of the generator and an assembly bolt of A of the mechanism of a tension.
7. Rotating an adjusting bolt of C, weaken a tension of a belt of a drive of the generator.
8. Remove a drive belt from a generator pulley.
9. Turn out a bolt of fastening of the mechanism of a tension.

10. Turn out a sharnirny bolt of fastening of the generator.

11. Weaken a bolt of fastening of an adjusting arm and turn an arm.
12. Remove the generator from the engine.

Dismantling


Prevention

Establish on sponges of a vice soft protective overlays for an exception of damage of details of the generator.


PERFORMANCE ORDER
1. Fix the generator in a vice and turn out four screws of fastening of a back cover of the generator.
2. Palnik, capacity of 200 W heat up a back cover and remove it from the generator.

Prevention

If the back cover is not heated up, it is very difficult for removing in connection with very dense landing.


3. A screw-driver with a flat edge remove a forward cover of the generator together with a rotor.

Prevention

Be careful not to lose a lock spring which is located at the back bearing.

Establish on sponges of a vice soft protective overlays for an exception of damage of details of the generator.


4. Fix a rotor in a vice and unscrew a nut, then remove a pulley, a rotor and a forward cover.
5. If necessary, using a stripper, remove the forward bearing from a generator shaft.
6. A stripper remove the back bearing from a generator shaft.
7. Turn out a nut on the plug B and remove isolating plugs.
8. Turn out five screws and remove the rectifier and a shchetkoderzhatel.
9. Divide a back cover and a stator.

10. A soldering iron отпаяйте the rectifier and wires, then remove a tension regulator.


Prevention

Otpaivaniye see off during no more than 5 with, the tension regulator otherwise can be damaged.


11. Replace brushes. Otpayayte a wattled wire also remove a brush.

Rotor check

PERFORMANCE ORDER
1. By an ohmmeter measure resistance between contact rings. If resistance differs from demanded, replace a rotor.

Resistance: 3,5–4,5 Ohm

2. An ohmmeter check conductivity between a contact ring and a rotor anchor. In the presence of conductivity replace a rotor.
3. If the surface of a contact ring has a roughness or wear tracks, smooth out it an emery paper.

Stator check

PERFORMANCE ORDER
1. An ohmmeter check conductivity between wires of the coil of a stator.
2. In the absence of conductivity replace a stator.
3. An ohmmeter check conductivity between stator coils.
4. In the presence of conductivity replace a stator.

Check of the block of the rectifier

Negative (black)
Positive (red)
Conductivity
Е
Pn, Р1, Р2, Р3
0
B
Pn, Р1, Р2, Р3
X
T
Pn, Р1, Р2, Р3
X
Pn, Р1, Р2, Р3
Е
X
B
0
Pn, Р2, Р3
T
0
Pn
T
X

PERFORMANCE ORDER
1. An ohmmeter check conductivity between conclusions of each diode.
2. If necessary replace the rectifier block.

Check of bearings

PERFORMANCE ORDER
1. Check the bearing on smoothness of rotation, absence of jammings and noise at rotation, and also люфта.
2. In the presence of any defects replace the bearing.

Assembly

PERFORMANCE ORDER
1. Establish brushes and solder a wattled wire so that the line of limiting wear of a brush acted on 2–3 mm from the holder of brushes.
2. Solder a tension regulator to the rectifier and stator windings.

Prevention

The soldering carry out during no more than 5 with, the tension regulator otherwise can be damaged.


3. Collect a back cover and a stator.
4. Screw screws of fastening of the rectifier and a shchetkoderzhatel.

Inhaling moment: 2,0–5,4 N • m

5. Establish isolating plugs on the plug B and fix them a nut.
6. Establish the back bearing and fix a lock spring.

Prevention

Check that the groove is in a nest of the bearing flush with a bearing end face.


7. Establish the forward bearing of the generator. For installation of the bearing it is desirable to use a manual press with an opravka which diameter corresponds to diameter of an external ring of the bearing.
8. Fix a rotor in a vice, establish on it a forward cover and a pulley. Fix a pulley a nut.

Inhaling moment: 59–98 N • m

9. Establish a back cover of the generator and fix four screws.

Inhaling moment: 2,9–6,4 N • m

Installation

PERFORMANCE ORDER
1. Establish the generator on the engine.
2. Screw, but do not tighten a sharnirny bolt of fastening of the generator.
3. Turn an arm in a starting position.
4. Establish the tension mechanism on an arm.
5. Screw, but do not tighten a bolt of fastening of the mechanism of a tension.
6. Establish a belt of a drive of the generator on a generator pulley.

7. Rotating an adjusting bolt of C, adjust a tension of a belt of a drive of the generator.


Deflection of a belt of a drive of the generator
New 5,5–7,0 mm
6,0–7,0 mm which were in the use

8. Tighten a bolt of fastening of an overlay of an adjusting plate.

Inhaling moment: 19–26 N • m

9. Tighten a sharnirny bolt and a bolt of fastening of an arm.

Inhaling moment: 38–51 N • m

10. Connect to the generator sockets L and S.

11. Connect a wire to the generator plug B.
12. A nut fix a wire on the plug B.
13. Close the generator plug B a protective cap.
14. Establish an inlet air branch pipe and fix it a collar.
15. Establish a zabornik of fresh air.
16. Screw forward bolts of fastening of a zabornik of fresh air.
17. Connect a wire to the negative plug of the storage battery.

Prevention

Be convinced that wires of the storage battery are correctly connected.

Do not use high-voltage devices, such as мегомметра for check of resistance.

Remember that tension of the storage battery always moves to the plug B of the generator of an alternating current.

Do not connect to "weight" contact of L at operation of the engine.

Do not start up the engine while contacts of L and S are disconnected from the generator.