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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2.8. Engine dismantling

GENERAL INFORMATION


Head of the block of cylinders


1–forward cover of a camshaft;
2–camshaft;
3–hydraulic jack of gaps of valves;
4–bolt of fastening of a head of the block of cylinders;
5–head of the block of cylinders;
6–laying of a head of the block of cylinders;
7–crackers;
8–top nest of a spring;
9–valve spring;
10-bottom nest of a spring;
11-valve;
12-maslootrazhatelny cap;
13-the directing plug of the valve

Forward and back covers of the engine and oil pallet

1–press coupling disk assembled;
2–coupling disk;
3–flywheel;
4–plate;
5–oil pallet;
6–a maslopriyemny tube with the mesh filter;
7–back cover of the block of cylinders;
8–water pump;
9–oil pump;
10-oil spray

Cranked shaft, pistons and rods

1–rod cover;
2–shatunny loose leaves;
3–rod and piston;
4–piston rings;
5–cover of the radical bearing of a cranked shaft;
6–cranked shaft;
7–radical loose leaves;
8–block of cylinders

Dismantling

PERFORMANCE ORDER
1. Remove a support No. 2 of the power unit.
2. Remove a support No. 3 of the power unit and a support arm.
3. Turn out three bolts and remove a starter.
4. Turn out eight bolts and separate a transmission from the engine.
5. Turn out bolts and remove a bypass pipe of cooling liquid and a final collector.
6. Fix the engine at the repair stand.
7. Merge from the engine engine oil.
8. Remove lobbies and back eyes for engine lifting.
9. Weaken an adjusting bolt, turn out bolts and a sharnirny bolt and remove the generator.
10. Remove an arm of support of an inlet collector.

11. Turn out bolts and remove an inlet collector.
12. Remove hydraulic jacks of gaps of valves.
13. Store hydraulic jacks of gaps of valves in the overturned look in the container with engine oil.
14. 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.
15. The special adaptation ОК993 120 001 with a head ОК993 120 004 compress a spring of the valve and remove from a valve core crackers.
16. Slowly release the adaptation compressing a spring and remove a valve spring from a head of the block of cylinders.
17. Passatizhami ОК993 120 006 remove a maslootrazhatelny cap.
18. Repeat these operations on all 16 valves.
19. For storage of valves prepare the numbered plastic bags or containers.
20. Mark the valve in order that at assembly it was possible to establish them on the initial places.
21. Take the valve from a head of the block of cylinders.
22. Take the bottom nests of springs from a head of the block of cylinders.
23. Establish special tools for a centering of a disk of coupling and flywheel blocking from a provorachivaniye.
24. Gradually, on a diagonal, weaken bolts of fastening of a casing of a press disk of coupling until it will be terminated a diafragmenny spring, then turn out bolts manually.
25. Remove a casing of a press disk of coupling and a coupling disk.
26. Using the adaptation ОК401 111 012, remove the needle bearing.
27. Turn out eight bolts and remove a flywheel (on the BFD engine – six bolts).
28. Turn out bolts of fastening of the oil pallet.
29. An edge of a flat screw-driver separate the oil pallet from the block of cylinders.

Prevention

Do not insert a screw-driver between the block of cylinders and the oil pallet as it can damage interfaced surfaces.


30. Turn out two bolts and lift the receiver a maslopriyemnik with the mesh filter.

31. Remove a pulley of a drive of a gear belt from a cranked shaft.

 

32. Turn out bolts and remove the oil pump.
33. An edge of a flat screw-driver remove an oil sealing ring from a cover of the oil pump.
34. Turn out bolts and remove a back cover of the block of cylinders.
35. An edge of a flat screw-driver remove an oil sealing ring from a back cover of the block of cylinders.
36. Turn out bolts and remove the water pump.
37. Turn out the oil filter and the sensor of pressure of oil.

38. 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.



39. Using the special tool, remove a step in the top part of cylinders.
40. Turn a cranked shaft of the engine so that the piston of the first cylinder was established in the top dead point.
41. Turn a cranked shaft of the engine so that pistons of the first and fourth cylinders were established in the bottom dead point.
42. Mark covers of rods and rods according to cylinder number in which they are established.
43. 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.
44. 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.
45. Unscrew nuts of fastening of a cover of a rod and, in easy blows of a plastic hammer, bring down a cover.
46. For protection of necks of a cranked shaft, dress on bolts of fastening of covers of rods pieces of a rubber or plastic tube.
47. Wooden whetstone or the hammer handle, вытолкните the piston with a rod from the cylinder.
48. Repeat these operations on other cylinders.
49. Mark pistons according to numbers of cylinders in which they were established.
50. Special пассатижами unclench piston rings and remove them from the piston.
51. Establish the piston vertically and check smoothness of moving of a rod.
52. Moving a rod, check absence люфта and jammings.
53. If the rod moves with jammings, check an opening for a piston finger in the piston and a rod on absence of deformation.
54. Remove lock rings from end faces of a piston finger.
55. Incline the piston and allow a piston finger to slip out the piston. If necessary, squeeze out a piston finger from the piston.
56. Take a rod from the piston. When dismantling hold together the piston, a rod, a piston finger and lock rings of a piston finger.
57. Number covers of radical bearings and note their arrangement.
58. In a certain sequence, for 2–3 stages, weaken and turn out bolts of fastening of covers of radical bearings.
59. Remove covers of radical bearings.
60. Remove a cranked shaft.
61. Remove loose leaves of radical bearings from the block of cylinders and covers of radical bearings.

Assembly

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 11/6 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.