REPAIR MAINTENANCE OPERATION OF MOTOR VEHICLES
Kia Sephia / Shuma (1995 release)

general info. full specifications. diagnostics. hints. tips. tricks

Home

Kia
	Sephia / Shuma
		Maintenance
		Engine
			Technical data
			Toothed belt
			Hydraulic jacks of backlashes of valves
			Cylinder Head
			Front oil seal ring
			Rear oil seal ring
			Removing and installing engine
			Disassembly of the engine
			Check Engine
			Build Engine
		Greasing system
		Cooling
		The power supply system and release
		Fuel system
		Ignition system
		Coupling
		Manual transmission
		Automatic Transmission
		Axes and power shafts
		Steering
		Wheels and tires
		Brakes
		Suspension
		Body
		The air conditioning system
		Electrical equipment

printable version

Disassembly of the engine

Cylinder Head

1 - the front cover of a camshaft;
2 - camshaft;
3 - hydraulic jacks of backlashes of valves;
4 - bolt cylinder head;
5 - cylinder head;
6 - cylinder head gasket;
7 - crackers;

8 - the upper spring seat;
9 - a spring valve;
10 - lower spring seat;
11 - the valve;
12 - valve stem seal;
13 - Valve Guides

The front and rear engine cover and oil pan

1 - clutch pressure plate assembly;
2 - disc clutch;
3 - flywheel;
4 - the plate;
5 - the oil pan;

6 - oil receiving tube with a strainer;
7 - the back cover of the cylinder;
8 - the water pump;
9 - the oil pump;
10 - a spray oil

Crankshaft, pistons and connecting rods

1 - a cover of a rod;
2 - connecting rod bearings;
3 - the connecting rod and the piston;
4 - piston rings;

5 - a cover of the crankshaft bearing;
6 - the crankshaft;
7 - radical loose leaves;
8 - cylinder block

Dismantling

PERFORMANCE ORDER

	1. Remove a support ?��2 power units.
	2. Remove the support of the power unit ?��3 and support arm.
3. Remove the three screws and remove the starter.
4. Remove the eight screws and separate the transmission from the engine.
5. Remove the screws and remove the coolant bypass pipe and exhaust manifold.
	6. Fix the engine on repair stand.
7. Drain the engine oil from the engine.
8. Remove the front and rear lifting eyes of the engine.
9. Loosen the adjusting bolt, remove the bolts and pivot bolt, and remove the generator.
	10. Remove the intake manifold support bracket.
	11. Remove the screws and remove the inlet manifold.
12. Remove the hydraulic jacks of backlashes of valves.
	13. Keep hydraulic jacks of backlashes of valves upside down in the container with engine oil.
	14. In certain sequence for 2-3 stages turn out bolts of the cylinder head. Remove the cylinder head and cylinder head gasket.
	15. Special adaptation OK993 120 001 head OK993 120 004 compress a spring valve and remove the valve stem with crackers.
16. Slowly release the tool, compress the spring and remove the spring of the valve from the cylinder head.
	17. Pliers OK993 120 006 remove the valve stem seal.
18. Repeat these steps on all 16 valves.
19. To prepare the storage valves numbered plastic bags or containers.
20. Mark the valve to the assembly they can be set to their initial location.
21. Remove the valve from the cylinder head.
22. Remove the lower spring seat of the cylinder head.
23. Install special tools to center the clutch disc and the flywheel from turning block.
	24. Gradually, diagonal, loosen the mounting bolts of a press disk of coupling, as long as the action does not stop the diaphragm spring, and then remove the screws by hand.
25. Remove the cover pressure plate and clutch disc clutch.
	26. Using the adaptation OK401 111 012, remove the needle bearing.
	27. Remove the eight bolts and remove a flywheel (the engine BFD - six bolts).
	28. Remove the oil pan mounting bolts.
29. An edge of a flathead screwdriver to separate the oil pan from the engine block.
A warning Do not insert a screwdriver between the cylinder block and oil pan, as this can damage the mating surfaces.
	30. Remove the two screws and remove the oil receiver pipe strainer.
	31. Remove the toothed belt pulley with the crankshaft.
	32. Remove the screws and remove the oil pump.
	33. An edge of a flathead screwdriver to remove the oil sealing ring of the oil pump cover.
	34. Remove the screws and remove the back cover of the cylinder.
	35. An edge of a flathead screwdriver to remove the oil sealing ring of the back cover of the cylinder.
	36. Remove the screws and remove water pump.
	37. Remove the oil filter and oil pressure gauge.
38. Check the steps and soot at the top of each cylinder.
A warning If produce lifting piston without removing the step at the top of the cylinder, which may result in damage to the piston rings and pistons.
	39. Using a special tool to remove the step at the top of the cylinder.
40. The cranked shaft motor so that the piston of the first cylinder established at TDC.
41. Turn the engine crankshaft so that the pistons of the first and fourth cylinders installed to the bottom dead center.
42. Mark the cover rods and cranks in accordance with the number of cylinders in which they are installed.
43. Note the connecting 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.
44. Turn the engine crankshaft so that the pistons of the second and third cylinders installed to the bottom dead center and, similarly, the connecting rods and label the cover rods.
45. Remove the nuts and the connecting rod cap, easy blows of a plastic hammer, knock the lid.
46. To protect the crankshaft journals, put on bolts of covers of rods pieces of a rubber or plastic tube.
	47 pieces of wood or hammer handle, push the piston rod of the cylinder.
48. Repeat these steps on the remaining cylinders.
49. Mark the pistons according to the number of cylinders in which they were established.
	50. Special pliers unclench piston rings and remove them from the piston.
51. Establish the piston vertically and check for smooth movement of the connecting rod.
	52. By moving the rod, check the absence of backlash and binding.
53. If the rod moves from jamming, check the hole for the piston pin and connecting rod in the piston in the absence of deformation.
54. Remove the retaining rings on the ends of the piston pin.
	55. Tilt the piston and the piston pin let slip out of the piston. If necessary, squeeze out the piston pin from the piston.
56. Remove the rod from the piston. When disassembling hold together the piston, connecting rod, piston pin and piston pin retaining rings.
57. Number the crankshaft bearing caps and mark their location.
	58. In sequence, phase 2-3, loosen and remove the bolts main bearing caps.
59. Remove the crankshaft bearing caps.
60. Remove the crankshaft.
61. Remove the main bearing shells from the cylinder block and main bearing caps.

Assembly

PERFORMANCE ORDER

1. Before assembly, clean all parts of the engine.
2. Before assembling the parts, apply a thin coat of clean engine oil to all sliding surfaces.
3. Replace the main and connecting rod bearings, even if they have minor damage or wear. When installing, use only new gaskets.
4. Install the snap ring in the groove of the piston.
	5. Install the piston into the connecting rod and insert the piston pin through piston and connecting rod until it locks already installed locking ring. Check that the relative position of the piston rod and was the same as before the disassembly.
	6. Set the second snap ring of the piston pin in the groove on the other side of the piston.
7. Keep the piston vertically and check for freedom of movement of the connecting rod.
	8. Install the three parts 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;
	9. Check that the expander oil ring separates the top and bottom of the oil ring rotates freely on the piston.
10. pliers for a release of piston rings establish on the piston 2nd compression ring.
	11. pliers for a release of piston rings establish on the piston 1st compression ring.
	12. Place the piston rings as shown.
13. Clean the indigenous and crank pins of grease and lubrication holes blow compressed air.
14. Install main bearing shells on the engine block.
	15. Establish persistent half rings of a cranked shaft.
16. Install the crankshaft main bearing shells in the cylinder block.
17. Install the remaining main bearing shells in main bearing caps of the crankshaft.
	18. Arrange pieces of plastic measuring rod Plastigage on the necks of the crankshaft bearing.
19. In accordance with the marking install main bearing caps.
	20. In certain sequence tighten bolts of covers of radical bearings of the crankshaft in the following order: TED: a. tighten the bolts tightening torque 39.2 N ??? m; b. in the reverse order tightening the bolts to loosen; from. tighten the bolts tightening torque 19.6 N ??? m; d. tighten screws at an angle of 90 ?�; e. tighten bolts on a corner 60 ?�; BFD: tighten the bolts tightening torque 54-59 N ??? m.
A warning Do not turn the crankshaft when measuring the gap crankshaft bearing.
21. Remove the bolts and remove the crankshaft bearing caps of the crankshaft. The measuring template measure width of deformed plastic core Plastigage and define backlash size.
	22. If the backlash exceeds the limit, pereshlifuyte crankshaft journal and use repair loose leaves of the increased size. The gap in the crankshaft bearing: TED: 0,024-0,042 mm BFD: 0,018-0,036
23. Remove the crankshaft to the cylinder and remove the deformed plastic core Plastigage with the crankshaft journals and main bearing shells.
24. Apply a thin coat of engine oil to the main bearing shells in the cylinder block and install the crankshaft inserts.
25. Apply a thin coat of engine oil to the crankshaft main journals and loose leaves in covers of radical bearings.
26. In accordance with the marking install main bearing caps of the crankshaft.
	27. In certain sequence tighten bolts of covers of radical bearings of the crankshaft in the following order: TED: a. tighten the bolts tightening torque 39.2 N ??? m; b. in the reverse order tightening the bolts to loosen; from. tighten the bolts tightening torque 19.6 N ??? m; d. tighten screws at an angle of 90 ?�; e. tighten bolts on a corner 60 ?�; BFD: tighten the bolts tightening torque 54-59 N ??? m.
28. Turn a cranked shaft and check that it rotates easily and smoothly.
29. Establish a measuring tip of a dial indicator on the front end of the crankshaft.
30. Move the crankshaft axis to stop and set the scale of dial gauge to zero.
	31. Move the crankshaft axis to the other side to stop and read the values of axial clearance on the scale indicator. Crankshaft end play: 0,080-0,282 mm.
	32. If the axial play exceeds the allowable value, replace persistent half rings of a cranked shaft.
33. Install connecting rod bearings into the connecting rod.
	34. To protect the crankshaft journals from damage, put on bolts of covers of rods pieces of rubber or plastic tubing.
35. Check the location of the piston rings on the piston.
36. Set the piston with the piston rings on the first cylinder, and the mark F in the piston should be directed to the front of the cylinder block.
37. Rotate the crankshaft in a position to crank pins of the 1st cylinder is at bottom dead center.
	38. The special adaptation compress piston rings on the piston.
39. hammer handle press the piston into the cylinder so that the bottom head of a rod was established on the crankshaft.
40. Install connecting rod bearings into the connecting rod cap.
41. Arrange pieces of plastic measuring rod Plastigage on necks connecting rod bearings of the crankshaft.
	42. In accordance with the marking establish covers of rods and fix their nuts. Tightening torques: TED: 47-50 N ??? m BFD: 64-69 N ??? m
43. Remove the nuts and remove the rod.
	44. The measuring template measure width of deformed plastic core Plastigage and define backlash size. Remove deformed plastic core Plastigage with the crankshaft journals and connecting rod bearing inserts. Nominal clearance of connecting rod bearings: TED: 0,20-0,05 mm BFD: 0,028-0,068 mm Maximum permissible backlash: 0,10 mm
45. If the backlash exceeds the limit, pereshlifuyte crankshaft journal and use repair loose leaves of the increased size.
46. Apply a thin coat of engine oil to the crank pin of the crankshaft and connecting rod bearings into the connecting rod cap.
47. Replace the cover and tighten the connecting rod nuts. Tightening torques: TED: 47-50 N ??? m BFD: 64-69 N ??? m
	48. 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
49. If the connecting rod side clearance exceeds the limit, replace the connecting rod and the connecting rod cap.
50. Apply a thin coat of clean engine oil to the outer surface of the lip and rear oil seal ring of the crankshaft.
51. Manually install the O-ring in the back cover of the cylinder.
	52. Special adaptation push the O-ring in the back cover so that the end of the ring is flush with the lid or spoke of it no more than 0.5 mm.
53. Apply a layer of silicone sealant thickness of 2 mm on an interfaced surface of the back cover.
54. Replace the back cover and fix bolts. The inhaling moments: 7,8-10,8 N ??? m
	55. Remove sealant squeezed when installing the rear cover on an interfaced surface of the oil pan.
56. Apply a thin coat of clean engine oil to the lip of the front oil seal ring of the crankshaft and oil pump jack.
57. Manually set the front crankshaft sealing ring.
	58. Special adaptation push the sealing ring in the oil pump housing so that the end of the ring performed at 0.5-1.0 mm from the oil pump.
59. Install new O-ring.
	60. Apply a layer of silicone sealant with a diameter of 1-2 mm on an interfaced surface of the oil pump body, as shown in the figure.
61. Install the oil pump and tighten 6 bolts. Tightening torque: 19-26 N ??? m
62. Remove sealant squeezed during the installation of the oil pump to the oil pan mating surface.
63. Clean the mating surface of the water pump.
	64. Install the water pump with a new lining and fix bolts. Tightening torque: 19-26 N ??? m
65. Replace the oil pressure sensor. The inhaling moments: 11,7-17,6 N ??? m
66. Apply a thin layer of fresh engine oil sealing ring of the new oil filter.
	67. Replace the oil filter to a contact of the O-ring of the oil filter to the engine block, then tighten the filter to 11/6 turns.
	68. Install maslozabornik strainer and a new lining and fix bolts. Tightening torques: 7.8-11.8 N ??? m
69. Clear interfaced surfaces of the oil pan and the engine block.
	70. Apply a continuous layer of silicone sealant to the mating surface of the oil pan
	71. Install the oil pan and tighten the bolts. The inhaling moments: 7,8-10,8 N ??? m
72. Clean the threads of the flywheel mounting bolts and bolt holes from the remnants of the old sealant. If the sealant can not be removed from the thread bolts, replace them.
73. Install the adapter plate on the block of cylinders and fix bolts. Tightening torques: TED: 18,6-30,4 N ??? m BFD: 7,8-11,0 N ??? m
74. Install the flywheel or the drive plate to the crankshaft.
75. Put on a carving of bolts reusable thin layer of sealant.
76. The special tool, lock the flywheel from turning.
	77. In certain sequence, in two or three stages tighten bolts of fastening of a flywheel. Tightening torques: 97-103 N ??? m
78. Install the clutch disc and clutch cover with pressure plate.
	79. Install the mandrel, centering clutch disc and a few steps in a certain sequence tighten bolts of fastening of a casing of coupling with a press disk. Tightening torques: TED: 22-32 N ??? m BFD: 18-26 N ??? m
80. Remove the tool that blocks the flywheel from turning and the mandrel, centering clutch disc.
	81. Install the valve stem and valve stem seal set.
	82. Special adaptation press-fit valve stem cap.
A warning Valve stem seals inlet and exhaust valves are different. Valve stem seals exhaust valves have 4 teeth.
83. Remove tool for fitting valve stem seals.
84. Install the lower spring seat in the cylinder head.
85. If available, set the protection of the hydraulic valve clearance compensator.
	86. Set the valve spring so that the coils with fine pitch (B) were sent to the cylinder head.
	87. Install the upper spring seat and the special adaptation, compress a spring.
88. Place the biscuits and remove special tool for spring.
89. Plastic hammer several times, hit the end of the valve stem to crackers established in its place.
90. If present, remove the protection of the hydraulic valve clearance compensator.
91. Similarly establish other valves.
92. Install the gasket and the cylinder head to the engine block.
93. Install the mounting bolts of the cylinder head.
	94. In certain sequence tighten bolts of the cylinder head in the following order: TED: a. tighten the bolts tightening torque 49 N ??? m; b. ?? ???????�?�???????�?�?�?�?????????�??, ???�???�?�?????? ?�?�?�?????????�??????, ?????�?�?�???�?� ?�???�?�?�; from. ?�?�?�???????�?� ?�???�?�?� ???????�???�???? ?�?�?�???�???? 39,2???????; d. ???????�???????�?� ?�???�?�?� ???� ???????� 90?�; ?�. ???????�???????�?� ?�???�?�?� ???� ???????� 90?�; BFD: tighten the bolts tightening torque 76-81 N ??? m.
95. ?????�?�?????????�?� ?????????�???�???�?�???????� ?????????�?????�?�?????� ?�?�?�?????� ???�?�???�??????.
96. Install the new intake manifold gasket.
97. Install the intake manifold and fix bolts. The inhaling moments: 17,6-25,5 N ??? m
	98. Establish an arm of an inlet collector and fix bolts. Tightening torques: TED: (A) 15,7-22,5 N ??? m (V) 36,3-53,9 N ??? m BFD: 31,4-46,1 N ??? m
99. Set the generator and fasten the mounting bolts and adjusting bolt.
100. Install the alternator drive belt and adjust its tension. Deflection of a belt drive of the generator: New belt: 8-9 mm The belt which was in the use: 9-10 mm
101. Tighten all screws generator demanded moment. Tightening torques: Mounting bolts: 37-52 N ??? m Adjusting bolt: 19-26 N ??? m
102. Set the front and rear lifting eyes of the engine.
103. The lifting mechanisms remove the engine from the stand.
	104. Install exhaust manifold and coolant bypass pipe and fix their bolts. Tightening torques: (A) 38,2-46,1 N ??? m
105. Install engine support ?��3 and bracket and secure them with screws. Tightening torques: 73,5-102,9 N ??? m
106. Install engine support ?��2 and fix bolts. The inhaling moments: 37,2-51,9 N ??? m
	107. Install the gearbox and tighten 8 bolts. Tightening torques: 4 upper screws (1, 2, 3, 4), 89-116 N ??? m 4 bottom screws (5, 6, 7, 8) 37-52 N ??? m
108. Install the starter and fix bolts. Tightening torque: 37-52 N ??? m
109. Fill the engine with engine oil.

« previos page
Removing and installing engine

next page »
Check Engine