Kia Sephia/Shuma/Spectra

since 1995 of release

Repair and car operation



KIA of Sefia / Noise/range
- 2. Engine
   2.1. Specifications
   2.2. Gear belt
   2.3. Hydraulic jacks of gaps of valves
   2.4. Head of the block of cylinders
   2.5. Forward oil sealing ring
   2.6. Back oil sealing ring
   2.7. Removal and engine installation
   2.8. Engine dismantling
   2.9. Engine check
   2.10. Engine assembly
+ 3. Greasing system
+ 4. Cooling system
+ 5. Power supply system and release
+ 6. Fuel system
+ 7. Ignition system
+ 8. Coupling
+ 9. Mechanical transmission
+ 10. Automatic transmission
+ 11. Axes and power shafts
+ 12. Steering
+ 13. Wheels and tires
+ 14. Brake system
+ 15. Suspension bracket
+ 16. Body
+ 17. Central air
+ 18. Electric equipment


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2.10. Engine Cборка

PERFORMANCE ORDER
1. Before assembly clear all details of the engine.
2. Before assembly of details apply a thin film pure engine oil on all surfaces of sliding.
3. Replace radical and shatunny loose leaves even if they have insignificant damages or wear. At installation it is necessary to use only new laying.
4. Establish a spring lock ring in a piston flute.
5. 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. Check, that relative position of the piston and a rod was same, as well as before dismantling.
6. Establish the second spring lock ring of a piston finger in a flute on the other side of the piston.
7. Hold the piston vertically and check freedom of moving of a rod.
8. 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;
9. 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.
10. To Passatizhami for a release of piston rings establish on the piston the 2nd kompressionny ring.
11. To Passatizhami for a release of piston rings establish on the piston the 1st kompressionny ring.
12. Arrange locks of piston rings as is shown in drawing.
13. Clear radical and shatunny necks of a cranked shaft of greasing, and lubricant openings blow the compressed air.
14. Establish loose leaves of radical bearings on the block of cylinders of the engine.
15. Establish persistent half rings of a cranked shaft.
16. Establish a cranked shaft on loose leaves of radical bearings in the block of cylinders.
17. Establish the remained loose leaves of radical bearings in covers of radical bearings of a cranked shaft.

18. Arrange pieces of a plastic measuring core of Plastigage on necks of radical bearings of a cranked shaft.
19. According to marking establish covers of radical bearings.

20. In a certain sequence tighten bolts of fastening of covers of radical bearings of a cranked shaft in the following order:
TED: and. tighten bolts the moment of an inhaling of 39,2 N • m;
b. in sequence, return to a tightening, weaken bolts;
page tighten bolts the moment of an inhaling of 19,6 N • m;
d. tighten bolts on a corner 90 °;
е. tighten bolts on a corner 60 °;
BFD: tighten bolts the moment of an inhaling of 54-59 N • m.

Prevention

Do not turn a cranked shaft of the engine at measurement of a gap of radical bearings of a cranked shaft.


21. Turn out bolts and remove covers of radical bearings of a cranked shaft. By a measuring template measure width of the deformed plastic core of Plastigage and define gap size.

22. If the gap exceeds maximum permissible value, перешлифуйте necks of a cranked shaft and use repair loose leaves of the increased size.

Gap in radical bearings of a cranked shaft:
TED: 0,024–0,042 mm
BFD: 0,018–0,036

23. Remove a cranked shaft from the block of cylinders and remove the deformed plastic core of Plastigage from necks of a cranked shaft and loose leaves of radical bearings.
24. Apply a thin film engine oil on loose leaves of radical bearings in the block of cylinders and establish a cranked shaft on loose leaves.
25. Apply a thin film engine oil on radical necks of a cranked shaft and loose leaves in covers of radical bearings.
26. According to marking establish covers of radical bearings of a cranked shaft.
27. In a certain sequence tighten bolts of fastening of covers of radical bearings of a cranked shaft in the following order:
TED: and. tighten bolts the moment of an inhaling of 39,2 N • m;
b. in sequence, return to a tightening, weaken bolts;
page tighten bolts the moment of an inhaling of 19,6 N • m;
d. tighten bolts on a corner 90 °;
е. tighten bolts on a corner 60 °;
BFD: tighten bolts the moment of an inhaling of 54-59 N • m.
28. Turn a cranked shaft and check that it rotates easily and smoothly.
29. Establish a measuring tip of the indicator of hour type on a forward end face of a cranked shaft.
30. Move a cranked shaft along an axis against the stop and establish a scale of the indicator of hour type on a zero.
31. Move a cranked shaft along an axis to other party against the stop and read values axial люфта on an indicator scale.

Axial люфт cranked shaft: 0,080–0,282 mm.

32. If axial люфт exceeds admissible values, it is necessary to replace persistent half rings of a cranked shaft.
33. Establish the shatunny loose leaf in a rod.
34. 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.
35. Check correctness of an arrangement of locks of piston rings on the piston.
36. 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.
37. 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.
38. The special adaptation compress piston rings on the piston.
39. 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.
40. Establish the shatunny loose leaf in a rod cover.
41. Arrange pieces of a plastic measuring core of Plastigage on necks of shatunny bearings of a cranked shaft.
42. According to marking establish covers of rods and fix them nuts.

Inhaling moments:
TED: 47–50 N • m
BFD: 64–69 N • m

43. Turn out nuts and uncover a rod.
44. By a measuring template measure width of the deformed plastic core of Plastigage and define gap size. Remove the deformed plastic core of Plastigage from necks of a cranked shaft and loose leaves of shatunny bearings.

Nominal gap in a rod the bearing:
TED: 0,20–0,05 mm
BFD: 0,028–0,068 mm
Maximum permissible gap: 0,10 mm

45. If the gap exceeds maximum permissible value, перешлифуйте necks of a cranked shaft and use repair loose leaves of the increased size.
46. Apply a thin film engine oil on a shatunny neck of a cranked shaft and the shatunny loose leaf in a rod cover.
47. Establish a cover of a rod and fix nuts.

Inhaling moments:
TED: 47–50 N • m
BFD: 64–69 N • m

48. 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

49. If the lateral gap of a rod exceeds maximum permissible value, replace a rod and a rod cover.
50. Apply a thin film pure engine oil on an external surface and a working edge of a back oil sealing ring of a cranked shaft.
51. Manually establish a sealing ring in a back cover of the block of cylinders.
52. Special the adaptation press a sealing ring into a back cover so that the end face of a ring was flush with a cover or acted from it no more than on 0,5 mm.
53. Put a layer of silicone hermetic in thickness of 2 mm on an interfaced surface of a back cover.
54. Establish a back cover and fix bolts.

Inhaling moments: 7,8–10,8 N • m

55. Remove the hermetic which has been squeezed out at installation of a back cover on an interfaced surface of the oil pallet.
56. Apply a thin film pure engine oil on a working edge of a forward oil sealing ring of a cranked shaft and a nest of the oil pump.
57. Manually establish a forward sealing ring of a cranked shaft.
58. Special the adaptation press a sealing ring into the case of the oil pump so that the end face of a ring acted on 0,5–1,0 mm from the case of the oil pump.
59. Establish a new sealing ring of round section.
60. Put a layer of silicone hermetic in diameter of 1-2 mm on an interfaced surface of the case of the oil pump, as is shown in drawing.
61. Establish the oil pump and fix 6 bolts.

Inhaling moments: 19–26 N • m

62. Remove the hermetic which has been squeezed out at installation of the oil pump on an interfaced surface of the oil pallet.
63. Clear an interfaced surface of the water pump.

64. Establish the water pump with new laying and fix bolts.

Inhaling moments: 19–26 N • m

65. Screw the sensor of pressure of oil.

Inhaling moments: 11,7–17,6 N • m

66. Grease with a thin layer of fresh engine oil a sealing ring of the new oil filter.
67. Screw the oil filter before contact of a sealing ring of the oil filter with the block of cylinders, then tighten the filter on 1–1/6 turns.
68. Establish a maslozabornik with the mesh filter and new laying and fix bolts.

Inhaling moments: 7,8–11,8 N • m

69. Clear interfaced surfaces of the oil pallet and the block of cylinders.
70. Put a continuous layer of silicone hermetic on an interfaced surface of the oil pallet

71. Establish the oil pallet and fix bolts.

Inhaling moments: 7,8–10,8 N • m

72. Clear a carving of bolts of fastening of a flywheel and an opening under bolts of the remains of old hermetic. If it is impossible to remove hermetic from a carving of bolts, replace them.
73. Establish a transitional plate on the block of cylinders and fix bolts.

Inhaling moments:
TED: 18,6–30,4 N • m
BFD: 7,8–11,0 N • m

74. Establish a flywheel or a drive plate on a cranked shaft.
75. Put on a carving of reused bolts a thin layer of hermetic.
76. The special tool block a flywheel from a provorachivaniye.
77. In a certain sequence, in two or three stages tighten bolts of fastening of a flywheel.

Inhaling moments: 97–103 N • m

78. Establish a disk of coupling and a casing of coupling with a press disk.
79. Establish an opravka aligning a disk of coupling and, in some stages, in a certain sequence tighten bolts of fastening of a casing of coupling with a press disk.

Inhaling moments:
TED: 22–32 N • m
BFD: 18–26 N • m

80. Remove the tool blocking a flywheel from a provorachivaniye and an opravka, aligning a coupling disk.

81. Establish the valve and on a core of the valve establish a maslootrazhatelny cap.
82. The special adaptation press a maslootrazhatelny cap into place.

Prevention

Maslootrazhatelnye caps of inlet and final valves are various. Maslootrazhatelnye caps of final valves have 4 teeth.


83. Remove the adaptation for a press fitting of a maslootrazhatelny cap.
84. Establish the bottom nest of a spring on a head of the block of cylinders.
85. At existence, establish protection of the hydraulic jack of a gap of valves.
86. Establish a valve spring so that rounds with a small step (In) were directed to a head of the block of cylinders.
87. Establish the top nest of a spring and the special adaptation, compress a spring.
88. Establish crackers and remove the special adaptation for spring compression.
89. With a plastic hammer several times strike on an end face of a core of the valve in order that crackers were established on the places.
90. At existence, remove protection of the hydraulic jack of a gap of valves.
91. Similarly establish the others of the valve.
92. Establish laying and a head of the block of cylinders on the block of cylinders.
93. Establish bolts of fastening of a head of the block of cylinders.
94. In a certain sequence tighten bolts of fastening of a head of the block of cylinders in the following order:
TED: and. tighten bolts the moment of an inhaling of 49 N • m;
b. in sequence, return to a tightening, weaken bolts;
page tighten bolts the inhaling moment 39,2Н • m;
d. tighten bolts on a corner 90 °;
е. tighten bolts on a corner 90 °;
BFD: tighten bolts the moment of an inhaling of 76-81 N • m.
95. Establish hydraulic jacks of a gap of valves.
96. Establish new laying of an inlet collector.
97. Establish an inlet collector and fix bolts.

Inhaling moments: 17,6–25,5 N • m

98. Establish an arm of an inlet collector and fix bolts.

Inhaling moments:
TED: (А) 15,7–22,5 N • m
(В) 36,3–53,9 N • m
BFD: 31,4–46,1 N • m

99. Establish the generator and fix it assembly bolts and an adjusting bolt.
100. Establish a belt of a drive of the generator and adjust its tension.

Deflection of a belt of a drive of the generator:
New belt: 8–9 mm
Belt which was in use: 9–10 mm

101. Tighten all bolts of fastening of the generator the demanded moments.

Inhaling moments:
Assembly bolts: 37–52 N • m
Adjusting bolt: 19–26 N • m

102. Establish forward and back eyes for engine lifting.
103. The load-lifting mechanism remove the engine from the stand.

104. Establish a final collector and a bypass pipe of cooling liquid and fix them bolts.

Inhaling moments: (А) 38,2–46,1 N • m

105. Establish the engine a support No. 3 and an arm and fix them bolts.

Inhaling moments: 73,5–102,9 N • m

106. Establish the engine a support No. 2 and fix bolts.

Inhaling moments: 37,2–51,9 N • m

107. Establish a transmission and fix 8 bolts.

Inhaling moments:
4 top bolts (1, 2, 3, 4) 89–116 N • m
4 bottom bolts (5, 6, 7, 8) 37–52 N • m

108. Establish a starter and fix bolts.

Inhaling moments: 37–52 N • m

109. Fill in in the engine engine oil.