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

2.4. Pistons and rods

GENERAL INFORMATION

Piston and rod

1–piston ring;
2–piston;
3–piston finger;
4–rod;

5–shatunny loose leaves;
6–rod cover;
7–nut, 29–34 N • m

Removal

Removal of pistons with rods is necessary for carrying out on the engine from which the head of the block of cylinders and the oil pallet is removed. Check lack of a step and a deposit in the top part of each cylinder.

Prevention

If to make removal of pistons without having cleaned a step in the top part of the cylinder, it can lead to damage of piston rings and pistons. Using the special tool remove a step in the top part of cylinders

PERFORMANCE ORDER

	1. Mark covers of rods and rods according to cylinder number in which they are established.
Prevention Note rods and covers of rods so that at installation they occupied the correct situation and the direction. At the wrong installation of rods supply of greasing in shatunny loose leaves that will lead to their fast damage will be broken.
2. Turn a cranked shaft of the engine so that pistons of the second and third cylinders were established in the bottom dead point and similarly mark rods and covers of rods.
3. Unscrew nuts of fastening of a cover of a rod and in easy blows of a plastic hammer bring down a cover.
4. Uncover a rod.
Prevention For protection of necks of a cranked shaft dress on bolts of fastening of covers of rods pieces of a rubber or plastic tube.
	5. Wooden whetstone or the hammer handle вытолкните the piston with a rod from the cylinder.
6. Repeat these operations on other cylinders.
7. Mark pistons according to numbers of cylinders in which they were established.
	8. Special пассатижами unclench piston rings and remove them from the piston.
	9. Establish the piston vertically and check smoothness of moving of a rod.
10. Moving a rod, check absence люфта and jammings.
Prevention Do not shake a rod very widely as it can make contact with a skirt of the piston and damage it that will result in need of replacement of the piston.
11. If the rod moves with jammings, check an opening for a piston finger in the piston and a rod on absence of deformation.
	12. Remove lock rings from end faces of a piston finger.
13. Incline the piston and allow a piston finger to slip out the piston. If necessary squeeze out a piston finger from the piston.
14. Take a rod from the piston. When dismantling hold together the piston, a rod, a piston finger and lock rings of a piston finger.

Check of piston rings

PERFORMANCE ORDER

	1. Insert a new piston ring into a flute of the piston and shchupy measure a gap between a piston ring and a flute wall. Nominal gap: A5D engine: 0,03–0,07 mm A3E engine: 0,04–0,08 mm Maximum permissible gap: 0,10 mm
2. If the gap exceeds maximum permissible value, replace the piston.
3. Check piston rings on absence of damages, wear or breakage.
4. If necessary replace piston rings.
5. Measure a gap in the lock of piston rings, having manually inserted a piston ring into the engine cylinder.
	6. The bottom of the piston push a piston ring in the lower part of the cylinder.
	7. By Shchup measure a gap in the lock of a piston ring.

Gap in locks of piston rings

Piston ring	A3E	A5D
First kompressionny ring	0,20–0,35 mm	0,15–0,30 mm
Second kompressionny ring	0,37–0,52 mm	0,40–0,55 mm
Maslosjemnoye ring	0,20–0,70 mm	0,20–0,70 mm
Maximum permissible gap	1,0 mm

Installation

PERFORMANCE ORDER

1. Establish the piston in a rod and insert a piston finger via the piston and a rod before fixing by its already established lock ring.
Prevention Check, that relative position of the piston and a rod was same, as well as before dismantling.
	2. Establish the second spring lock ring of a piston finger in a flute on the other side of the piston.
	3. Hold the piston vertically and check freedom of moving of a rod.
	4. Establish three parts of a maslosjemny ring on the piston: – grease with pure engine oil a dilator of a maslosjemny ring both the top and bottom parts of a ring; – establish a dilator of a maslosjemny ring on the piston so that the ends of a dilator were directed up; – establish the lower part of a maslosjemny ring on the piston. The ring can be established by any party up; – establish the top part of a maslosjemny ring on the piston. The ring can be established by any party up.
	5. Check that the dilator of a maslosjemny ring divides the top and bottom parts of a maslosjemny ring and is freely turned on the piston.
6. To Passatizhami for a release of piston rings establish on the piston the 2nd kompressionny ring.
7. To Passatizhami for a release of piston rings establish on the piston the 1st kompressionny ring.
Prevention "R" or "Y" labels on kompressionny rings should be directed to the top part of the piston.

8. Arrange locks of piston rings as is shown in drawings.
9. Establish the shatunny loose leaf in a rod
	10. For protection of a neck of a cranked shaft against damage dress on bolts of fastening of covers of rods pieces of a rubber or plastic tube.
11. Establish the piston with piston rings over the first cylinder, thus F label on the piston should be directed to a forward part of the block of cylinders.
12. Turn a cranked shaft in such situation that the shatunny neck of a cranked shaft of the 1st cylinder was in the bottom dead point.
	13. The special adaptation compress piston rings on the piston.
14. The handle of a hammer press the piston into the cylinder so that the bottom head of a rod was established on a neck of a cranked shaft.
15. Establish the shatunny loose leaf in a rod cover.
16. Arrange pieces of a plastic measuring core of Plastigauge on necks of shatunny bearings of a cranked shaft.
17. According to marking establish covers of rods and fix them nuts. Inhaling moment: 29–34 N • m
Prevention At installation of rods combine the labels put on a rod and a cover of a rod and it is correct сориентируйте a rod in relation to the block of cylinders, supply of greasing to shatunny loose leaves otherwise will be broken. After installation of all pistons turn a cranked shaft in such situation that pistons settled down between VMT and NMT, then establish a head of the block of cylinders. It will exclude impact of pistons and valves which can lead to deformation of valves and engine damage.
	18. Turn out nuts and uncover a rod.
19. By a measuring template measure width of the deformed plastic core of Plastigauge and define gap size. Remove the deformed plastic core of Plastigauge from necks of a cranked shaft and loose leaves of shatunny bearings. Nominal gap in a rod the bearing: 0,026–0,054 mm Maximum permissible gap: 0,10 mm
20. If the gap exceeds maximum permissible value, перешлифуйте necks of a cranked shaft and use repair loose leaves of the increased size.
	21. Apply a thin film engine oil on a shatunny neck of a cranked shaft and the shatunny loose leaf in a rod cover.
22. Establish a cover of a rod and fix nuts. Inhaling moment: 29–34 N • m
	23. Shchup inserted between a rod and cranked shaft, measure a lateral gap of a rod. Nominal lateral gap of a rod: 0,110–0,262 mm Maximum permissible gap: 0,30 mm
Prevention Do not measure a gap between a cover of a rod and cranked shaft.
24. If the lateral gap of a rod exceeds maximum permissible value, replace a rod and a rod cover.