KIA RIO

since 2000 of release

Repair and car operation



Rio KIA
+ 1.1. Short acquaintance to the car
- 2. Engines A3E, A5D
   2.1. Specifications
   2.2. Compression check
   2.3. Camshafts
   2.4. Pistons and rods
   2.5. Cranked shaft
   2.6. Verification of shatunny and radical loose leaves
   2.7. Air filter (ACL)
   2.8. Accelerator cable
   2.9. 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. Gear belt
   2.14. System of production of the fulfilled gases
+ 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





2.3. Camshafts

GENERAL INFORMATION

DOHC engine camshafts

1–bolt, 37–52 N • m;
2–hairpin, 29–35 N • m;
3–bolt, 4,9–8,8 N • m;
4–cover of a head of the block of cylinders;
5–elements of a cover of a head of the block of cylinders;
6–laying of a cover of a head of the block of cylinders;
7–bolt, 11,2–14,2 N • m;
8–cover of camshafts;
9–bolt, 37–52 N • m;
10-camshafts;
11-hairpin, 7,8–12 N • m;
12-head of the block of cylinders;
13-hairpin, 7,8–12 N • m;
14-laying of a head of the block of cylinders

SOHC engine camshafts

1–bolt, 7,8–11 N • m;
2–bolt, 7,8–11 N • m;
3–bolt, 22–28 N • m;
4–bolt, 22–28 N • m;
5–cover of a head of the block of cylinders;
6–bolt, 4,9–8,8 N • m;
7–shaft of levers;
8–levers;
9–camshaft;
10-pulley of a gear belt of a camshaft;
11-bolt, 49–61 N • m;
12-head of the block of cylinders;
13-laying of a head of the block of cylinders

Removal
PERFORMANCE ORDER
1. Disconnect a wide hose and a hose of ventilation of a case.
2. Remove a pulley of the water pump and a pulley of a cranked shaft.
3. Remove a casing of a gear belt.
4. Weaken a bolt of fastening of a pulley of the mechanism of a tension of a gear belt, take a pulley aside and fix it in this situation.
5. Remove a gear belt from a camshaft pulley.
6. Turn out bolts and remove from the engine the central cover.
7. Remove the block of coils of ignition.
8. Turn out bolts and uncover heads of the block of cylinders.
9. Turn out a bolt and remove a camshaft pulley.

10. Uncover camshafts and a gear belt.

11. Remove a camshaft.
12. Remove hydraulic jacks of gaps of valves.

Check (A5D engine)

PERFORMANCE ORDER
1. Establish the first and last necks of a camshaft on V-shaped blocks.
2. Establish a measuring head of the indicator of hour type on an average neck of the bearing of a camshaft and establish an indicator scale on 0.
3. Turn a camshaft and measure its palpation.

Maximum permissible palpation of a camshaft: 0,03 mm

4. Check a camshaft on lack of non-uniform wear, cracks or damages.

5. In two points measure height of each cam of camshafts.

Height of cams of inlet and final camshafts:
The nominal – 42,870 mm
The minimum admissible – 42,868 mm

6. In two perpendicular directions and two planes measure diameter of each neck of camshafts.

Nominal diameter: 33,961–34,000 mm
Minimum admissible diameter: 26,910 mm
Maximum permissible ovality: 0,03 mm

7. If wear of cams or necks of bearings of camshafts exceeds maximum permissible value, replace camshafts.
8. Measure a gap in bearings of camshafts with remote hydraulic jacks of valves.
9. Clear of greasing of a neck of bearings of camshafts, bearings in a cover of camshafts and bearings in a head of the block of cylinders.

10. Establish camshafts on a head of the block of cylinders.

11. For measurement of a gap use the plastic calibrated round core of Plastigauge. The core of Plastigauge is compressed between the bearing and a camshaft neck. After removal of a cover of the bearing of a camshaft the deformed plastic core of Plastigauge is measured by a special template which is available in a set. Cut off slices of a plastic core and arrange them on camshaft necks.
12. After installation of plastic cores do not turn camshafts.
13. Establish a cover of camshafts.
14. Establish bolts of fastening of a cover of camshafts and tighten them in some stages.

Inhaling moment: 11,2–14,2 N • m

15. Turn out bolts of fastening of a cover of camshafts.
16. Uncover camshafts.
17. Measuring by a template width of the deformed plastic core, define gaps in camshaft bearings.

Nominal gap: 0,035–0,081 mm
Maximum permissible gap: 0,15 mm

18. If the gap exceeds maximum permissible value, replace a head of the block of cylinders.
19. Establish camshafts.
20. Establish a measuring tip of the indicator of hour type on a camshaft end face.
21. Move a camshaft along an axis against the stop to one party.
22. Establish an arrow of the indicator of hour type on 0.
23. Move a camshaft along an axis against the stop to other party.

24. Read indications on the indicator of hour type which shows size axial люфта a camshaft.

Nominal axial люфт: 0,067–0,137 mm
Maximum permissible gap: 0,147 mm

Check (A3E engine)

PERFORMANCE ORDER
1. Establish the first and last necks of a camshaft on V-shaped blocks.
2. Establish a measuring head of the indicator of hour type on an average neck of the bearing of a camshaft and establish an indicator scale on 0.
3. Turn a camshaft and measure its palpation.

Maximum permissible palpation of a camshaft: 0,03 mm

4. Check a camshaft on lack of non-uniform wear, cracks or damages.

5. In two points measure height of each cam of a camshaft.

Height of cams of a camshaft of inlet valves:
The nominal – 36,3422 mm
The minimum admissible – 36,3402 mm
Height of cams of a camshaft of final valves:
The nominal – 36,0752 mm
The minimum admissible – 36,0732 mm

6. In two perpendicular directions and two planes measure diameter of each neck of a camshaft.

1 and 3 necks of a camshaft: 43,440–43,460 mm
2 neck of a camshaft: 43,430–43,455 mm

Installation

PERFORMANCE ORDER
1. Establish hydraulic jacks of a gap of valves.
2. Grease camshafts with pure engine oil and establish them in a head of the block of cylinders.
3. Establish a cover of camshafts.
4. Establish bolts of fastening of a cover of camshafts and tighten them in some stages.

Inhaling moment: 11,2–14,2 N • m

5. Grease an external surface of sealing rings of camshafts with pure engine oil and the special tool 09221-21000 establish them against the stop in nests of a head of the block of cylinders.
6. Establish pulleys on camshafts and fix them bolts.
7. Check that the label of I camshafts on a pulley of inlet valves was combined with the index on a cover of a head of the block of cylinders and label Е on a pulley of a camshaft of final valves was combined with the index on a cover of a head of the block of cylinders.

Prevention

After combination of labels with indexes do not turn distributive and cranked shaft.


8. Establish a gear belt and adjust its tension.

9. Further installation is carried out to sequences, return to removal.