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REPAIR MAINTENANCE OPERATION OF MOTOR VEHICLES
Kia Rio (2000 release)

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Kia Rio
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Instructions
Engines A3E, A5D
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Compression Test
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The pistons and connecting rods
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The pistons and connecting rods



Piston and connecting rod

1 - piston ring;
2 - piston;
3 - the piston pin;
4 - the connecting rod;
5 - connecting rod bearings;
6 - a cover of a rod;
7 - a nut, 29-34 N ??? m

Withdrawal

Removal of pistons from rods should be carried out on the engine, which is removed from the cylinder head and oil pan. Check the steps and soot at the top of each cylinder.


A warning

If removal of pistons produce a step in removing the top of the cylinder, which may result in damage to the piston rings and pistons. Using a special tool, remove the notch at the top of the cylinder


PERFORMANCE ORDER
1. Label cover rods and cranks in accordance with the number of cylinders in which they are installed.

A warning

Note rods and covers of rods so that when you install them in the correct position and direction. Incorrect installation of rods will be disrupted supply of lubricant in the connecting rod bearings, causing rapid damage to them.


2. Turn the crankshaft of the engine so that the pistons of the second and third cylinders installed to the bottom dead center and similarly label the connecting rods and connecting rod cover.
3. Remove the nuts connecting rod cap and light blows a plastic hammer knock the cover.
4. Remove the connecting rod cap.

A warning

To protect the crankshaft journals put on bolts of covers of rods pieces of a rubber or plastic tube.


5 pieces of wood or hammer handle push the piston rod of the cylinder.
6. Repeat these steps on the remaining cylinders.
7. Label the pistons according to the number of cylinders in which they were established.
8. Special pliers unclench piston rings and remove them from the piston.
9. Install the piston vertically and check for smooth movement of the connecting rod.

10. By moving the rod, check the absence of backlash and binding.


A warning

Not widely swing the crank so it can enter into contact with the piston skirt and damage it, resulting in the need to replace the piston.


11. If the rod moves from jamming, check the hole for the piston pin and connecting rod in the piston in the absence of deformation.
12. Remove the retaining rings on the ends of the piston pin.
13. Tilt the piston and the piston pin let slip out of the piston. If you want to squeeze out the piston pin from the piston.
14. Remove the rod from the piston. When disassembling hold together the piston, connecting rod, piston pin and piston pin retaining rings.

Checking of piston rings

PERFORMANCE ORDER

1. Insert the new piston ring in the groove of the piston and probe measure the clearance between the piston ring and the wall of the groove.

Nominal backlash:
Engine A5D: 0,03-0,07 mm
Engine A3E: 0,04-0,08 mm
Maximum permissible backlash: 0,10 mm

2. If the clearance exceeds the limit, replace the piston.
3. Check the piston rings for damage or wear or breakage.
4. If necessary, replace the piston rings.
5. Measure the end gap of the piston rings, piston ring is manually inserted into the engine cylinder.
6. piston crown push the piston ring into the bottom of the cylinder.

7. The probe measure the end gap of the piston ring.

The gap piston ring

Piston ring
A3E
A5D
The first compression ring
0.20-0.35 mm
0.15-0.30 mm
The second compression ring
0,37-0,52 mm
0,40-0,55 mm
Scraper ring
0,20-0,70 mm
0,20-0,70 mm
Maximum permissible backlash
1.0 mm

Setting

PERFORMANCE ORDER
1. Establish the piston rod and insert into the piston pin through piston and connecting rod until it locks already installed locking ring.

A warning

Check that the relative position of the piston rod and was the same as before the disassembly.


2. Install the second snap ring of the piston pin in the groove on the other side of the piston.
3. Keep the piston vertically and check for freedom of movement of the connecting rod.
4. Install the three-part oil scraper ring on the piston:

- Lubricate with clean engine oil extender oil ring and the upper and lower part of the ring;
- Set the extender oil scraper ring on the piston so that the ends of the expander facing up;
- Install the lower part of the oil scraper ring on the piston. The ring may be installed either side up;
- Install the upper part of the oil scraper ring on the piston. The ring may be installed either side up.
5. Check that the oil ring expander divides the upper and lower oil ring rotates freely on the piston.
6. pliers for a release of piston rings establish on the piston 2nd compression ring.
7. pliers for a release of piston rings establish on the piston 1st compression ring.

A warning

Tags "R" or "Y" on the compression ring must be directed toward the top of the piston.


8. Place the piston rings as shown in Figures.
9. Install the connecting rod bearings into the connecting rod

10. To protect the crankshaft journals from damage put on bolts of covers of rods pieces of rubber or plastic tubing.

11. Establish the piston with the piston rings over the first cylinder, and the mark F on the piston must be pointing toward the front of the cylinder.
12. Rotate the crankshaft in a position to crank pins of the 1st cylinder is at bottom dead center.
13. The special adaptation compress piston rings on the piston.
14. hammer handle press the piston into the cylinder so that the bottom head of a rod was established on the crankshaft.
15. Install connecting rod bearings into the connecting rod cap.
16. Arrange pieces of plastic measuring rod Plastigauge on necks connecting rod bearings of the crankshaft.
17. In accordance with the marking establish covers of rods and fix their nuts.

Torque: 29-34 N ??? m


A warning

When installing the rods combine the labels put on the connecting rod and the connecting rod cap and correctly orient the rod relative to the cylinder block, as otherwise there will be disrupted supply of lubricant to the connecting rod bearings.

After all the pistons turn a crankshaft in a position that the pistons are located between the TDC and BDC, then install the cylinder head. This would eliminate the impact of pistons and valves, which can lead to deformation and damage to the engine valves.


18. Remove the nuts and remove the rod.

19. The measuring template measure width of deformed plastic core Plastigauge and define backlash size. Remove deformed plastic rod Plastigauge with the crankshaft journals and connecting rod bearing inserts.

Nominal clearance of connecting rod bearings: 0,026-0,054 mm
Maximum permissible backlash: 0,10 mm

20. If the backlash exceeds the limit, pereshlifuyte crankshaft journal and use repair loose leaves of the increased size.
21. Apply a thin coat of engine oil to the crank pin of the crankshaft and connecting rod bearings into the connecting rod cap.
22. Replace the cover and tighten the connecting rod nuts.

Torque: 29-34 N ??? m

23. The probe inserted between the connecting rod and the crankshaft, connecting rod, measure the backlash.

Nominal backlash rod: 0,110-0,262 mm
Maximum permissible backlash: 0,30 mm


A warning

Do not measure the gap between the rod cover and the crankshaft.


24. If the connecting rod side clearance exceeds the limit, replace the connecting rod and the connecting rod cap.




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