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










2.9. Head of the block of cylinders

GENERAL INFORMATION

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

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

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

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

15-camshaft;
16-crackers;
17-plate of a spring of the valve;
18-valve spring;
19-laying;
20-maslootrazhatelny cap;
21-the directing plug of the valve;
22-pulley of a gear belt of a camshaft;
23-bolt, 49–61 N • m;
24-head of the block of cylinders;
25-laying of a head of the block of cylinders;
26-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 supply of fuel and a hose of cooling liquid.
5. Remove high-voltage wires from spark plugs. Removal of high-voltage wires carry out 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 the thermofilter and a final collector assembled.

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 a 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 laying 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 laying remains.

Prevention

Exclude hit of the remains of laying to canals for greasing and engine cylinders.


Check

PERFORMANCE ORDER
Check laying of a head of the block of cylinders on absence of leaks, spots from cooling liquid or прожогов laying 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, leakages of oil and cooling liquid. If necessary replace a head of the block of cylinders.
2. A metal ruler and shchupy in six directions check planeness of a head of the block of cylinders. If necessary перешлифуйте head of the block of cylinders.

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


Prevention

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

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


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

The maximum deviation from planeness:
A5D engine: 0,03 mm
A3E engine: 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 laying of a cover of a head of the block of cylinders.

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

5. If the height of a head of the block of cylinders differs from nominal rates, replace a head of the block of cylinders.

Prevention

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


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

Deviation from planeness: no more than 0,05 mm

7. If not planeness exceeds admissible limits, replace a head of the block of cylinders.

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

PERFORMANCE ORDER
1. Clear interfaced surfaces of a head of the block of cylinders of the laying remains.
2. Establish new laying on the block of cylinders of the engine. At installation of laying use hermetic. Do not use repeatedly laying of a head of the block of cylinders. Establish a head of the block of cylinders.
3. In a 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 of 49 N • m;
b. in sequence, return to a tightening, weaken bolts of fastening of a head of the block of cylinders;
c. repeatedly tighten bolts the moment of an inhaling of 25 N • m;
d. tighten bolts on 90 °.

Prevention

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

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

Two bolts (7 and 8) is 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 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 it bolts, having tightened them the demanded moment.

Inhaling moment: 4,9–8,8 N • m

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

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

Inhaling moment:
Bolts and nuts of fastening of inlet and final collectors: 15–20 N • m
The leveling tank to nuts and bolts of an inlet collector: 15–20 N • m

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 supply 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 the A3E engine

PERFORMANCE ORDER
1. Clear interfaced surfaces of a head of the block of cylinders of the laying remains.
2. Establish new laying on the block of cylinders of the engine. At installation of laying use hermetic. Do not use repeatedly laying of a head of the block of cylinders.
3. Establish a head of the block of cylinders.
4. In a 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 of 49 N • m;
b. in sequence, return to a tightening, weaken bolts of fastening of a head of the block of cylinders;
c. repeatedly tighten bolts the moment of an inhaling of 25 N • m;
d. tighten bolts on 90 °.