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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2.9. Engine check

PERFORMANCE ORDER
1. Clear all components of the engine.
2. Remove from the block of cylinders of the engine the remains of laying, hermetic, dirt, oil, lubricant and other alien materials.

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.

Maximum repolishing: 0,1 mm

3. If not planeness exceeds admissible limits, replace or перешлифуйте a head of the block of cylinders.
Replace or repair a head of the block of cylinders in the presence of the following defects:
      Ц the burned-through saddles of valves;
      Ц damage of an interfaced surface for installation of inlet and final collectors;
      Ц damage of nests for installation of oil sealing rings of camshafts.
4. Measure height of a head of the block of cylinders from the bottom surface of a head to a surface of installation of laying of a cover of a head of the block of cylinders.

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

Height:
TED: 133,9Ц134,1 mm
BFD: 133,8Ц134,0 mm

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

Deviation from planeness: no more than 0,20 mm

7. If not planeness exceeds admissible limits, replace a head of the block of cylinders.
8. A metal ruler and shchupy in six directions check planeness of an interfaced surface of the block of cylinders.

Deviation from planeness: no more than 0,20 mm

Check of valves

PERFORMANCE ORDER
1. Examine each valve on detection of the following defects:
      Ц damages or deformation of a core of the valve;
      Ц damages of a plate of the valve;
      Ц damages or non-uniform wear of an end face of a core of the valve.
2. If necessary, repair or replace the valve.

Height of an edge of the valve:
TED: 1,2 mm
BFD: 1,0 mm

3. Measure length of each valve.

Length of the valve:
Inlet valve:
TED: 10,2,92 mm
BFD: 105,29 mm
Final valve:
TED: 101,42 mm
BFD: 105,39 mm

4. A micrometer, in several places on height, measure diameter of a core of the valve.

Diameter of the valve:
Inlet valve: 5,970Ц5,985 mm
Final valve: 5,965Ц5,980

5. Nutromer, in several places, measure internal diameter of directing plugs of valves.

Internal diameter of directing inlet and final valves: 6,01Ц6,03 mm

6. Calculate a gap between the directing plug and a valve core. For this purpose subtract external diameter of a core of the valve from internal diameter of the corresponding directing plug of the valve.

Gap:
Inlet valve:
TED: 0,050Ц0,060 mm
BFD: 0,040Ц0,045 mm
Final valve:
TED: 0,030Ц0,065 mm
BFD: 0,045Ц0,050 mm
Maximum permissible value: 0,020 mm

7. If the gap exceeds maximum permissible value, replace the valve and / or directing plug of the valve.
8. Measure height of a vystupaniye of each plug of the valve. If necessary, replace directing plug of the valve.

Inlet valve A:
TED: 13,7Ц14,3 mm
BFD: 16,8Ц17,4 mm
Final valve:
TED: 16,7Ц17,3 mm
BFD: 18,1Ц18,7 mm


Prevention

Directing plugs of inlet and final valves are various.


Check of a saddle of the valve

PERFORMANCE ORDER
1. Check a working surface and facets of a saddle of the valve on lack of the following defects:
      Ц roughness;
      Ц burn-out;
      Ц dot corrosion;
      Ц cracks.
2. The special cutting tool at an angle 45 ∞ restore a working edge of a saddle of the valve.
3. Put special structure of dark blue color on a working facet of the valve and the valve and let's dry to structure.
4. Establish the valve in a valve saddle, press and turn on 360 ∞. If the dark blue structure is not completely removed from a working facet of the valve, replace the valve. If the dark blue structure is not completely removed from a working facet of a saddle of the valve, repeatedly process a valve saddle.

5. Measure width of a working facet of the valve.

Width:
TED: 1,98Ц2,69 mm
BFD: 0,8Ц1,4 mm

6. Check depth of an arrangement of a working surface of a saddle of the valve, measuring it in the center of a facet of the valve. If the valve established in a saddle of the valve is located too highly, process a valve saddle development with a corner 63 ∞, then development with a corner 45 ∞. If the valve established in a saddle of the valve is located too low, process a valve saddle development with a corner 0 ∞, then development with a corner 45 ∞.
7. Using a special abrasive powder, grind in the valve and a saddle of valves.
8. Clear the valve and a saddle of valves of the remains of an abrasive powder.

9. Establish the valve in a head of the block of cylinders and measure a vystupaniye (size L) of a core of the valve in relation to an installation site of the lower part of a spring of the valve.

Check of a spring of the valve

PERFORMANCE ORDER
1. Examine each spring of the valve on lack of cracks and damages.
2. Measure length of a spring in a free condition. Establish a spring on a flat horizontal surface and measure a deviation of the top part of a spring from the vertical plane.

Length of a spring in a free condition:
TED: 46,7 mm
BFD: 45,6 mm
Maximum permissible deviation of a spring from the vertical plane:
TED: 1,63 mm
BFD: 1,59 mm

Camshaft check

1. Establish the first and last necks of a camshaft on V-shaped blocks.
2. Establish a measuring head of the indicator of hour type on an average neck of the bearing of a camshaft and establish an indicator scale on 0.

3. Turn a camshaft and measure its palpation.

Maximum permissible palpation of a camshaft: 0,03 mm

4. Check a camshaft on lack of non-uniform wear, cracks or damages.
5. In two points measure height of each cam of a camshaft.

Height of cams of a camshaft of inlet valves:
TED: 41,6949 mm
BFD: 40,888 mm
Height of cams of a camshaft of final valves:
TED: 42,2369мм
BFD: 40,688 mm

6. In two perpendicular directions measure diameter of each neck of a camshaft.

Nominal diameter:
TED: 26,940Ц26,965 mm
BFD: 25,940Ц25,965 mm
Minimum admissible diameter:
TED: 26,910 mm
Maximum permissible ovality: 0,05 mm

7. If wear of necks of bearings of a camshaft exceeds maximum permissible value, replace a camshaft.

8. Measure a gap in bearings of camshafts with remote hydraulic jacks of valves.

9. Clear of greasing of a neck of bearings of camshafts, a cover of bearings and bearings in a head of the block of cylinders.
10. Establish camshafts on a head of the block of cylinders.
11. For measurement of a gap use the plastic calibrated round core of Plastigage. The core of Plastigage is compressed between the bearing and a camshaft neck. After removal of a cover of the bearing of the camshaft, the deformed plastic core of Plastigage is measured by a special template which is available in a set. Cut off slices of a plastic core and arrange them on camshaft necks
12. After installation of a plastic core do not turn a camshaft.
13. According to marking, establish covers of bearings of camshafts.

14. Establish bolts of fastening of covers of bearings and tighten them for 5Ц6 stages.

Inhaling moment: 11,3Ц14,2 N Х m


15. In a certain sequence for 5Ц6 stages turn out bolts of fastening of covers of bearings of camshafts.
16. Remove covers of bearings of camshafts.

17. Measuring by a template width of the deformed plastic core, define gaps in camshaft bearings.

Nominal gap: 0,035Ц0,081 mm
Maximum permissible gap: 0,15 mm

18. If the gap exceeds maximum permissible value, replace a head of the block of cylinders.
19. Establish camshafts in a head of the block of cylinders.
20. Establish a measuring tip of the indicator of hour type on a camshaft end face.
21. Move a camshaft along an axis against the stop to one party.
22. Establish an arrow of the indicator of hour type on 0.
23. Move a camshaft along an axis against the stop to other party.

24. Read indications on the indicator of hour type which shows size axial люфта a camshaft.

Nominal axial люфт: 0,08Ц0,10 mm
Maximum permissible gap: 0,20 mm

Check of hydraulic jacks of gaps of valves

PERFORMANCE ORDER
1. Check the face of hydraulic jacks of gaps of valves on lack of wear or damages and, if necessary, replace them.
2. Fill hydraulic jacks of gaps of valves with pure engine oil and compress them from two parties. If the hydraulic jack of gaps of valves is compressed, replace it. Never try to restore or repair the hydraulic jack of gaps of valves.
3. In the opposite directions, measure diameters of cylinders for hydraulic jacks of gaps of valves.

Diameter: 30,000Ц30,025 mm

4. In the opposite directions, at two levels, measure diameters of hydraulic jacks of gaps of valves.

Diameter: 29,959Ц29,975 mm

5. Calculate a gap between cylinders of the hydraulic jack of gaps of valves and the hydraulic jack. If the gap exceeds maximum permissible, replace the hydraulic jack of gaps of valves and / or a head of the block of cylinders.

Nominal gap: 0,025Ц0,066 mm
Maximum permissible gap: 0,180 mm

Check of blocks of cylinders

PERFORMANCE ORDER
1. Check the block of cylinders on absence of the following damages:
      Ц local damages or leaks;
      Ц cracks;
      Ц development of cylinders.
2. A metal ruler and shchupy in six directions check planeness of an interfaced surface of the block of cylinders.

Deviation from planeness: 0,15 mm

3. If not planeness exceeds admissible limits, перешлифуйте the block of cylinders.

The most admissible repolishing: 0,20 mm.

4. If repolishing of the block of cylinders, on big size is necessary, replace the block of cylinders.

Prevention

Before repolishing of the block of cylinders measure height of the block of cylinders from an axis of a cranked shaft to the top interfaced surface.


5. Measure diameters of cylinders in the opposite directions, in three planes on height of cylinders.

Diameter of the cylinder:
The nominal:
TED: 81,006Ц81,019 mm
BFD: 78,006Ц78,019 mm
Repair +0,25 mm:
TED: 81,256Ц81,269 mm
BFD: 78,256Ц78,269 mm
Repair +0,50 mm:
TED: 81,506Ц81,519 mm

BFD: 78,506Ц78,519 mm

6. For definition of a konusnost of the cylinder, measure diameter of the cylinder in the top, average and bottom parts.

Maximum permissible konusnost:
TED: 0,019 mm
BFD: 0,15 mm
Ovality: 0,019 mm

Check of sprays for cooling of pistons

7. Submitting the compressed air to an opening And a spray, check that air leaves V.Esli's opening air does not pass, replace a spray.

Pressure of air: 245,3Ц301,4 kPas

8. Check a tip of a spray of oil on absence of pollution of internal channels. If necessary, replace a spray tip.

Check of pistons


Prevention

At piston replacement, it is also necessary to replace piston rings.


PERFORMANCE ORDER
1. Check an external surface of the piston on absence of damages, development or non-uniform wear. If necessary, replace the piston.
2. Measure external diameter of each piston a sort by a corner 90 ∞ to a piston finger, at distance of 21,5 mm in the TED engine and at distance of 17,6 mm in the BFD engine from bottom edge of a maslosjemny ring.

Diameter of the TED piston
Nominal 80,9540Ц80,9720, mm
The 1st repair (+0,25) 81,204Ц81,222, mm
The 2nd repair (+0,50) 81,454Ц81,472, mm
BFD
Nominal 77,954Ц77,974, mm
The 1st repair (+0,25) 78,204Ц78,224, mm
The 2nd repair (+0,50) 78,454Ц78,474, mm
3. Calculate a gap between the piston and a cylinder wall, subtracting diameter of the piston from the greatest diameter of the cylinder, in each cylinder.

Nominal gap:
TED: 0,040Ц0,053 mm
BFD: 0,032Ц0,065 mm
Maximum permissible gap: 0,15 mm

4. If the gap exceeds maximum permissible value, replace pistons for the bigger repair size and chisel cylinders.

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. A gap between a piston ring and a flute in the piston,

1st kompressionny ring of TED: 0,04Ц0,08, BFD: 0,030Ц0,065
Maximum permissible gap Ц 0,15
2nd kompressionny ring of TED: 0,03Ц0,070, BFD:030Ц0,065
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:
First kompressionny ring: 0,15Ц0,30 mm
Second kompressionny ring: 0,30Ц0,45 mm
Maslosjemnoye ring: 0,20Ц0,70 mm
Maximum permissible gap: 1,0 mm

8. If the gap exceeds maximum permissible value, replace piston rings.

Check of piston fingers

PERFORMANCE ORDER


1. Measure diameters of openings for a piston finger in the piston, in two opposite directions, four planes.

Diameter:
TED: 19,994Ц20,002 mm
BFD: 19,998Ц20,000 mm

2. Measure diameter of each piston finger, in two opposite directions, four planes.

Diameter:
TED: 19,987Ц19,993 mm
BFD: 19,974Ц19,980 mm

3. Define a gap of a piston finger in the piston, subtracting diameter of a piston finger from diameter of an opening for a piston finger.

Gap:
TED: 0,001Ц0,015 mm
BFD: 0,008Ц0,026 mm

4. If the gap exceeds nominal rate, replace the piston and a piston finger.

Check of rods

PERFORMANCE ORDER


1. Measure internal diameter of a head of a rod.

Internal diameter of a head of a rod:
TED: 20,003Ц20,013 mm
BFD: 19,943Ц19,961 mm

2. Define a gap of a piston finger in a rod, subtracting diameter of a piston finger from diameter of an opening of a head of a rod.

Gap:
TED: 0,010Ц0,027 mm
BFD: 0,013Ц0,037 mm

3. If the gap exceeds nominal rate, replace the plug in the top head of a rod.

4. Check a bend of each rod.
5. If necessary, replace rods. Replacement of a rod carry out together with a rod cover.

Check of a cranked shaft

PERFORMANCE ORDER
1. Check necks of radical and shatunny bearings of a cranked shaft on lack of wear and development.
2. Check lubricant openings of a cranked shaft on lack of a contamination.
3. Establish the first and last necks of radical bearings of a cranked shaft on V-shaped blocks.

4. Establish a measuring head of the indicator of hour type on an average neck of the bearing of a cranked shaft and establish an indicator scale on 0. Turn a cranked shaft and measure its palpation. If palpation exceeds nominal palpation, replace a cranked shaft.

Palpation: 0,04 mm

5. By a micrometer measure diameters of necks of a cranked shaft in two opposite directions.
6. In the presence of development or ovality, перешлифуйте a cranked shaft.
7. Repolishing of necks of a cranked shaft carry out only till next repair size.
8. If a cranked shaft перешлифован for the repair size of +0,50 mm, carry out shaft heat treatment for increase in its durability.

Diameters of necks of radical bearings of a cranked shaft:
1st repair size (+0,25 mm):
TED: 54,688Ц54,706
BFD: 49,688Ц49,706
2nd repair size (+0,50 mm):
TED: 54,438Ц54,456
BFD: 49,438Ц49,456
3rd repair size: (+0,75 mm):
TED: 54,188Ц54,206
BFD: 49,188Ц49,206
Diameters of necks of shatunny bearings of a cranked shaft:
1st repair size (+0,25 mm):
TED: 44,690Ц44,708
BFD: 39,960Ц39,706
2nd repair size (+0,50 mm):
TED: 44,440Ц44,458
BFD: 39,440Ц39,456
3rd repair size (+0,75 mm):
TED: 44,190Ц44,208
BFD: 39,190Ц39,206

Verification of shatunny and radical loose leaves
PERFORMANCE ORDER

Check shatunny and radical loose leaves on absence of local corrosion, development and other damages. If necessary, replace loose leaves.

Check of a gear belt


Prevention

Strongly do not bend a gear belt and do not change the direction of its rotation. Do not allow oil and lubricant to contact with a gear belt as it will lead to its destruction.


PERFORMANCE ORDER
1. Replace a gear belt if it is polluted by oil or lubricant.
2. Check a gear belt on absence of damages, wear, stratification, cracks on teeths and in the basis of teeths, and also on defects at end faces and a reverse side of a belt.
In the presence of defects, replace a gear belt.

The mechanism of a tension of a gear belt and directing roller


Prevention

Do not purge a roller of the mechanism of a tension or a directing roller of a gear belt with use of clearing liquids. Grinding of rollers by pure soft rags is allowed. Do not scratch working surfaces of rollers as it will result in premature wear of a gear belt.


PERFORMANCE ORDER
Check a roller of the mechanism of a tension and directing roller on smoothness of rotation and absence of noise at rotation. If necessary, replace a roller of the mechanism of a tension or directing roller.

Spring of the mechanism of a tension

PERFORMANCE ORDER
Measure length of a spring of the mechanism of a tension in a free condition. If the length of a spring differs from nominal rate, replace it.

Length of a spring in a free condition
TED: 35.6 mm
BFD: 59,5 mm

Ўкифы camshafts


Prevention

Do not purge pulleys with use of clearing liquids. If necessary, use for their cleaning pure soft rags. Do not scratch working surfaces of pulleys as it will result in premature wear of a gear belt.


PERFORMANCE ORDER
Check teeths of pulleys on lack of wear and damages. If necessary, replace pulleys.