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
   - 8.1. 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 assembly
      8.1.7. Case of coupling and components of a case of a transmission
      8.1.8. Primary shaft of a transmission
      8.1.9. Secondary shaft of a transmission
      8.1.10. Choice of adjusting laying
      8.1.11. Differential
      8.1.12. Gear shifting mechanism
   + 8.2. Automatic transmission of F4E-K
+ 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







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8.1.5. Removal and transmission installation

GENERAL INFORMATION

Mechanical transmission

1–zabornik of fresh air;
2–air filter assembled;
3–holder of the storage battery;
4–storage battery;
5–support of the storage battery;
6–arm of the storage battery;
7–coupling cable;
8–wire of connection with "weight";
9–tip of steering draft;
10-bottom lever of a forward suspension bracket;
11-draft;
12-right power shaft;
13-left power shaft;
14-protective plate of the engine;
15-draft of a choice of transfers;
16-draft of gear shifting;
17-starter;
18-transmission;
19-support of the power unit No. 2;
20-support of the power unit No. 1;
21-stabilizer earring;
22-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 a zabornik of fresh air and the air filter assembled.
5. Disconnect the socket of the switch of light of a backing.
6. Disconnect the socket of the sensor 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 the socket of the sensor 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 of a case of coupling.
12. The special AA0 adaptation OK201 170 support the engine so that the weight of the engine 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 oil plum from a transmission.
18. Turn out a stopper plum of oil and merge oil from a transmission.
19. Disconnect from a transmission draft of a choice of transfers and draft of gear shifting.
20. Turn out two bolts of fastening of a support of No. of 1 power unit.
21. Turn out three bolts of fastening of a support No. 2 of the power unit.
22. Turn out nuts of fastening of forward longitudinal drafts.
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. The special adaptation ОК670 321 019 disconnect the left and right tips of steering drafts 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 down and separate pins of hinges from rotary fists from two parties of the car.

Prevention

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


28. Insert mount between the internal CV JOINT of a power shaft and a transmission and easy blow on mount take a power shaft from a transmission.

Prevention

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

For an exception of damage of the external CV JOINT 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 of a case of coupling, then support a transmission a jack and turn out the last two bolts of fastening of a case of coupling.
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 a case of coupling.

Inhaling moment:
Top bolts 1, 2, 3, 4 (4EA): 64–89 N • m
Bottom bolts 5, 6, 7, 8, 9 (5EA): 37–52 N • m

3. Lower a jack.
4. Remove plastic caps 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 them coupling bolts.

Inhaling moment: 54–68 N • m

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

Inhaling moment: 30–44 N • m

10. Shplintami fix nuts from an otvorachivaniye.

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

Inhaling moment: 42–60 N • m

12. Establish longitudinal drafts and fix them nuts.

Inhaling moment: 118–147 N • m

13. Establish a support No. 2 of the power unit and fix it bolts and nuts.

Inhaling moment:
Bolt: 43–54 N • m
Nut: 67–93 N • m

14. Establish a support of No. of 1 power unit.

Inhaling moment: 43–54 N • m

15. Connect draft of gear shifting and draft 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 it bolts and nuts.

Inhaling moment:
Bolt and nut of fastening of a plate: 47–66 N • m
Nuts of fastening of support No. 1 and No. 2: 37–57 N • m

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

Inhaling moment: 88–118 N • m

20. Lower the car.
21. Remove the special AA0 adaptation OK201 170 supporting the engine.
22. Screw three bolts of fastening of a case of coupling to the block of cylinders of the engine.

Inhaling moment: 89–116 N • m

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

Inhaling moment: 37–52 N • m

24. Establish squeezing the lever.
25. Connect the socket of the sensor of an angle of rotation of a cranked shaft.
26. Connect a wire of connection with "weight" and fix it a bolt.
27. Connect the socket of the sensor of speed of the car.
28. Connect the socket of the switch of a lamp of a backing.
29. Establish the case of the air filter.
30. Connect the socket of the sensor of temperature of air arriving in the engine.
31. Connect the socket of the sensor of a measuring instrument of a consumption of air.
32. Establish a zabornik of fresh air and fix it a 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. Carry out road tests of the car and check levels of liquids.