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

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Kia
	Rio
		Instructions
		Engines A3E, A5D
			Technical data
			Compression Test
			Camshafts
			The pistons and connecting rods
			Crankshaft
			Checking the connecting rod and indigenous inserts
			Air filter (ACL)
			The accelerator cable
			Cylinder Head
			Check valves
			Check the valve seat
			Check the valve spring
			Toothed belt
			Exhaust
		Greasing system
		Cooling
		Fuel system
		Ignition system
		Coupling
		Transmission
		Axes and power shafts
		Suspension
		Wheels and tires
		Steering
		Brakes
		Body
		The air conditioning system
		Electrical equipment

printable version

Engines A3E, A5D

Sump

1 - a bolt, 7,8-11 N ??? m;
2 - oil pan;
3 - strainer;
4 - a bolt;
7.8 - 11 N ??? m;

5 - nut 37-52 N ??? m;
6 - a reception exhaust pipe and catalytic converter;
7 - a bolt, 37-52 N ??? m;
8 - a nut, 37-52 N ??? m

Elements of the engine compartment and the engine

1 - a bolt, 7,8-11 N ??? m;
2 - radiator fan;
3 - a nut,
7,8-11 N ??? m;
4 - fresh air intake;
5 - a bolt, 7,8-11 N ??? m;
6 - accelerator cable;

7 - clip the battery;
8 - battery;
9 - a support battery;
10 - an arm of the battery;
11 - a nut, 31,4-46,1 N ??? m;
12 - control cable

Stub, drive shaft and the catalytic converter

1 - a bolt, 37-52 N ??? m;
2 - nut 37-52 N ??? m;
3 - an arm;
4 - a reception exhaust pipe and catalytic converter;
5 - nut 53-64 N ??? m;

6 - drive shaft;
7 - the ball joint of the lower control arm front suspension;
8 - Ball rod end;
9 - knuckle

Supports power unit

1 - a rubber support ?„–2 power units;
2 - a bolt, 37-52 N ??? m;
3 - a bolt, 66-93 N ??? m;
4 - an arm of support of the power unit;
5 - a bolt, 37-49 N ??? m;
6 - rubber support ?„–3 power unit;
7 - a nut, 60-85 N ??? m;
8 - a rubber support ?„–1 power unit;

9 - a bolt, 66-93 N ??? m;
10 - a bolt, 43-54 N ??? m;
11 - a nut, 71-93 N ??? m;
12 - a nut, 37-52 N ??? m;
13 - the bottom bar;
14 - a nut, 37-52 N ??? m;
15 - a nut, 71-93 N ??? m

Transmission (2) and the engine (1)

Withdrawal

PERFORMANCE ORDER

1. Disconnect the battery
2. Remove the battery and battery support.
3. Drain the coolant from the cooling system.
4. Remove the intake of fresh air.
	5. Loosen the hose clamps and remove the upper and lower radiator hoses.
6. Disconnect the accelerator cable.
7. Disconnect the fuel hose from the fuel line.
A warning Do not smoke or use an open flame near the fuel system components, as this may cause an explosion.
8. Loosen the clamps and disconnect the hoses going to a heater
9. Disconnect a vacuum hose from the vacuum brake booster.
10. Disconnect electric sockets from fuel atomizers.
	11. Disconnect the electrical connectors from the engine.
12. On cars with automatic transmission, disconnect the control cable from the gearbox.
13. On cars with a manual gearbox, disconnect traction shift and select from the gearbox.
14. On cars with a manual gearbox, disconnect the phone from the clutch slave cylinder and remove clutch slave cylinder
15. On cars with automatic transmission disconnect switch electrical connector of the gear indicator.
16. On cars with automatic transmission, disconnect the electrical connector from the solenoid valve.
	17. On cars with automatic transmission, disconnect from the transmission cooler hose for transmission fluid.
	18. Disconnect hoses from the power steering pump.
	19. Disconnect electric sockets from in-contact and S-contact starter.
	20. Disconnect electric sockets from the B-contact connector generator.
21. Remove the four screws on the air conditioning compressor.
22. Remove both front wheels.
23. Remove a reception exhaust pipe and catalytic converter.
24. Remove the pins and remove the nuts tips of steering drafts in rotary fists.
25. Remove the bolts and nuts of the left and right lower arms to rotary fists
	26. Remove the two screws and nuts spring strut to the swivel.
27. pry pry internal hinges of power shafts from a transmission.
	28. Support the engine lifting mechanism.
	29. Remove the four nuts and four bolts securing the motor to the lower beam.
30. Remove the two screws on the upper arm of a support ?„–1 power unit.
31. Remove the two nuts securing the support ?„–2 power units.
32. Remove the four screws on the upper arm of a support ?„–2 power units.
33. Remove the two nuts securing the support of the power unit ?„–3.
34. Remove the engine together with a transmission from the car.

Setting

PERFORMANCE ORDER

1. Set the engine with the transmission in the engine compartment of the vehicle.
2. Screw the two nuts rubber support ?„–3 power unit. Torque: 60-85 N ??? m
3. Screw the bracket bolts support ?„–3 power unit and screw the nuts of the rubber mounts. Tightening torques: Nuts: 66-93 N ??? m Bolts: 37-52 N ??? m
	4. Replace the four screws and nuts of the engine to the lower beam. Tightening torques Nuts: 37-52 N ??? m Bolts: 71-93 N ??? m
5. Remove the lifting device, which supports the engine.
6. Install the new lock ring on the drive shafts.
7. Lightly tap, set the internal hinge of equal angular velocity drive shafts in the gearbox, with the cut of a lock ring should be directed upwards.
8. Install the lower part of the shock absorber on the knuckles and secure them with bolts and nuts.
9. Install the ball joint of the lower arm front suspension knuckles.
	10. Install the ball joint tips of steering drafts in rotary fists.
11. Establish a reception exhaust pipe and catalytic converter. Torque: 37-52 N ??? m
	12. Install the air conditioning compressor.
13. Connect the electrical connectors to the B-terminal connector of the generator
	14. Connect the electrical connectors to the B terminal and the S-contact starter.
15. Connect the hoses to the power steering pump.
16. On cars with automatic transmission, connect to a transmission cooler hose for transmission fluid.
	17. Connect the electrical connector to the solenoid valve.
	18. Connect the electrical connector to the switch gear position indicator.
19. Install the clutch slave cylinder and connect it to the phone. The inhaling moments: 18,6-25,5 N ??? m
20. Attach the traction control and gear selection. Tightening torques: Traction control: 37-52 N ??? m Link selection: 16-235 N ??? m
21. Secure the nut with the thrust washer automatic transmission. The inhaling moment: 31,4-46,1 N ??? m
	22. Connect the electrical connectors to the engine.
23. Connect the electrical connectors to the fuel injectors
24. Attach the vacuum hose to the brake servo.
25. Connect the hoses going to a heater.
	26. Connect the fuel hose to the fuel line.
27. Set the accelerator cable.
28. Install the upper and lower radiator hoses and fix their collars.
29. Install the intake of fresh air.
	30. Establish a support battery and battery. Torque: 13.5-16 N ??? m
31. Fill in cooling liquid in cooling system.
32. Connect the wires to the positive and negative terminals of the battery.
33. Check levels and, if necessary, add all liquids.
34. Start up the engine, check the operation and leaks of liquids.

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