KIA Klarus
1.1. Periodicity of maintenance
- 2. FE DOHC engines and Т8 DOHC
2.1. Specifications
2.2. Engine description
2.3. A filtering element of the air filter
2.4. Spark plugs
2.5. Oil in an engine case
2.6. Level of cooling liquid
2.7. Driving belt
2.8. High-voltage wires
2.9. Hydraulic jacks of a gap of valves
2.10. Check of a corner of an advancing of ignition
2.11. Compression
2.12. Removal and engine installation
2.13. Removal and installation from the engine of auxiliary elements
2.14. Removal and installation of a gear belt and pulleys
2.15. Head of cylinders
2.16. Block of cylinders
2.17. Search and elimination of malfunctions
+ 3. Greasing system
+ 4. Cooling system
+ 5. Power supply system and release
+ 6. Fuel system
+ 7. Ignition system
+ 8. Coupling
+ 9. Mechanical transmission
+ 10. АКП G4A–EL
+ 11. АКП 50–40 LE
+ 12. Axes and power shafts
+ 13. Steering
+ 14. Wheels and tires
+ 15. Suspension bracket
+ 16. Body
+ 17. Central air
+ 18. Electric equipment
+ 19. Brake system
+ 20. Electric circuits
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1–cover of a head of cylinders;
2–sealing plate;
3–camshaft cover;
4–camshaft;
5–hydrojack of a thermal gap of the valve;
6–bolt of fastening of a head of cylinders;
7–head of cylinders;
8–laying of a head of cylinders; | 9–crackers;
10-top nest of a spring;
11-external spring of the valve;
12-internal spring of the valve;
13-bottom nest of a spring;
14-valve;
15-maslootrazhatelny cap;
16-sensor of an angle of rotation (Т8 DOHC). |
Removal and dismantling
The description of removal and installation of a head of cylinders on the engine from which auxiliary details, a gear belt and pulleys of camshafts previously are removed is provided.
| PERFORMANCE ORDER |
| 1. Unscrew bolts and uncover heads of cylinders. | | 2. Unscrew bolts and remove a sealing plate (FE DOHC). | | 3. Unscrew bolts and remove covers of bearings of camshafts. |
| 4. Before removal of a camshaft clear bearings and necks, and also carry out the following checks:
– measure axial люфт a camshaft;
– measure an oil gap of a neck of a camshaft. | | 5. Remove hydraulic jacks of gaps of valves. Store hydraulic jacks of gaps of valves in the overturned look in the container with engine oil. Mark each hydraulic jack to establish it on that place, from where it was removed. | | 6. In a certain sequence, for 2–3 stages turn out bolts of fastening of a head of the block of cylinders. | | 7. Remove a head of the block of cylinders. | | 8. Remove laying of a head of the block of cylinders. | |
| 9. 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. |
| 10. Slowly release the adaptation compressing a spring, and remove the top nest of a spring of the valve from a head of the block of cylinders. | | 11. Remove external and internal springs of the valve and the bottom nest of the valve. | | 12. Take the valve from a head of the block of cylinders. For storage of valves prepare the numbered plastic bags or containers. Mark the valve in order that at assembly it was possible to establish them on the initial places. |
| 13. Passatizhami remove a maslootrazhatelny cap. | | 14. Repeat these operations on all valves. | | 15. Turn out bolts and remove the sensor of an angle of rotation (Т8 DOHC). | |
Check
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.
Allowed not planeness: 0,15 mm | |
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3. 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 cylinders.
The allowed height of a head:
FE DOHC: 133,95–134,05 mm
Т8 DOHC: 133,8–134,0 mm
Maximum permissible thickness of a soshlifovanny layer: 0,20 mm |
Prevention Before polishing execute the following checks and, if necessary, replace a head of cylinders:
– deepening of a saddle of the valve;
– existence of damages on the privalochny planes of collectors;
– a gap in bearings of camshafts and their axial люфт.
| | 4. By a metal ruler and shchupy in two directions measure planeness of interfaced surfaces of collectors. Deviation from planeness:
FE DOHC: 0,15 mm
Т8 DOHC: 0,20 mm | | 5. If not planeness exceeds admissible limits, прошлифуйте a surface or replace a head of the block of cylinders. | |
Check of valves
| PERFORMANCE ORDER |
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| 1. Examine each valve on detection of the following defects:
– damages or deformations of a core of the valve;
– damages of a plate of the valve;
– damage or non-uniform wear of an end face of a core of the valve. | | 2. If necessary, repair or replace the valve. | |
3. Measure height of an edge of a plate of the valve. If necessary, replace the valve. Height of an edge of a plate of the valve:
the inlet: 0,85 mm
the final: 0,9 mm | | 4. Measure length of each valve. Length of the valve:
Inlet valve:
FE DOHC: 103,18 mm
Т8 DOHC: 102,92 mm
Final valve:
FE DOHC: 103,94 mm
Т8 DOHC: 101,42 mm | | 5. By a micrometer in several places on height measure diameter of a core of the valve.
Diameter of a core of the valve:
Inlet valve: 5,970–5,985 mm
Final valve: 5,965–5,980 | | 6. By Nutromer in several places measure internal diameter of directing plugs of valves. Internal diameter of directing inlet and final valves: 6,01–6,03 mm | | 7. 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:
the inlet: 0,025–0,060 mm
the final: 0,030–0,065 mm
Maximum permissible value: 0,020 mm | | 8. If the gap exceeds maximum permissible value, replace the valve and / or directing plug of the valve. |
| 9. Measure height of a vystupaniye of each plug of the valve. If necessary, replace directing plug of the valve.
Inlet valve A: 11,4–11,9 mm |
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Prevention
Pay attention that directing inlet and final valves differ in a form.
| | 10. Gradually heat up a head of the block of cylinders in water to temperature near 90°С. |
| 11. By means of the adaptation ОК201 120 001 выпрессуйте directing the valve from outside, the opposite chamber of combustion. | | 12. Gradually heat up a head of the block of cylinders in water to temperature near 90°С. |
| 13. By means of the adaptation ОК201 120 001 press directing the valve from outside, the opposite chamber of combustion until she will not act over a block head on size recommended above. | |
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:
– roughnesses;
– burn-outs;
– dot corrosion;
– cracks. | | 2. The special cutting tool at an angle 45 ° restore a working edge of a saddle of the valve and/or a valve facet. | | 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: 1,2–1,6 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 60 °, 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 35 ° (for the inlet valve) or 15 ° (for final), then development with a corner 45 °. | |
7. Using a special abrasive powder, grind in the valve and a saddle of valves. Clear the valve and a saddle of valves of the remains of an abrasive powder. |
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| 8. Check zaglubleny saddles of the valve. Establish the valve in a head of the block of cylinders and measure a vystupaniye (size L) of a core of the valve.
Size L: 36,8 mm | | If L is in the limits given below, the valve can be used. Size L:
The inlet: 36,37–37,27 mm
The final: 36,36–37,26 mm If L is in the limits specified below, for adjustment it is necessary to establish laying between a plate of a spring and a head of the block of cylinders. Size L:
The inlet: 37,27–37,97 mm
The final: 37,26–37,96 mm
If more given below the size, it is necessary to replace with L a block head. Size L:
The inlet: 37,97 mm
The final: 37,96 mm | |
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:
The external: 39,1 mm
The minimum admissible: 38,7 mm
The internal: 38,0 mm
The minimum admissible: 37,7 mm
Maximum permissible deviation of a spring from the vertical plane:
The external: 1,36 mm
The internal: 1,33 mm | |
Camshaft check
| PERFORMANCE ORDER |
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| 1. Establish the first and last necks of a camshaft on V-shaped supports. 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. Turn a camshaft and measure its palpation. Maximum permissible palpation of a camshaft: 0,03 mm |
| 2. Check a camshaft on lack of non-uniform wear, cracks or damages. | |
| 3. In two points measure height of each cam of a camshaft. Height of cams of a camshaft: 45,052 mm
Minimum admissible height of cams of a camshaft: 44,852 mm | | 4. In two perpendicular directions measure diameter of each neck of a camshaft. Nominal diameter: 29,940–29,956 mm
Maximum permissible ovality: 0,05 mm | | 5. Measure a gap in bearings of camshafts. | | 6. Clear of greasing of a neck of bearings of camshafts, a cover of bearings and bearings in a head of the block of cylinders. | | 7. Establish camshafts on a head of the block of cylinders. |
| 8. 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 a 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. After installation of a plastic core do not turn a camshaft. | | 9. According to marking establish covers of bearings of camshafts. |
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| 10. Screw bolts of fastening of covers of bearings and in a certain sequence tighten them the demanded moment. Inhaling moment: 18–26 N • m | | 11. In a certain sequence turn out bolts and remove covers of bearings of camshafts. | | 12. Measuring by a template width of the deformed plastic core, define gaps in camshaft bearings. Nominal gap: 0,035–0,085 mm
Maximum permissible gap: 0,15 mm | | 13. If the gap exceeds maximum permissible value, replace a head of the block of cylinders. |
| 14. Establish camshafts in a head of the block of cylinders. Establish a measuring tip of the indicator of hour type on a camshaft end face. Move a camshaft along an axis against the stop to one party. | | 15. Establish an arrow of the indicator of hour type on 0. Move a camshaft along an axis against the stop to other party. Read indications on the indicator of hour type which shows size axial люфта a camshaft. Nominal axial люфт: 0,08–0,10 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. Compress the hydraulic jack two fingers. If the hydraulic jack of gaps of valves is compressed, replace it. |
Prevention Never try to restore or repair the hydraulic jack of gaps of valves.
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Assembly and installation
| PERFORMANCE ORDER |
| 1. Put engine oil on an internal part of a new maslootrazhatelny cap of the valve. | | 2. Establish a maslootrazhatelny cap of the valve on directing plug of the valve by means of the special adaptation ОК201 120 005. | |
3. Establish the bottom plate of the valve. | | 4. Establish the valve. | |
| 5. Establish springs of the valve and the top plate of the valve. | | 6. Establish a valve spring so that rounds with a small step (In) were directed to a head of the block of cylinders. | | 7. Establish the top nest of a spring and the special adaptation compress a spring. |
| 8. Establish crackers and remove the special adaptation for spring compression. | | 9. 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. | |
10. Repeat these operations on all valves. | | 11. Apply a thin film engine oil on a lateral surface of hydraulic jacks of gaps of valves. | | 12. Establish hydraulic jacks on those places, from where they were removed. | | 13. Check, whether there is no free moving of hydraulic jacks. |
| 14. Carefully remove from the top part of the block of cylinders all pollution and oil. | | 15. Establish new laying of a head of cylinders. | | 16. Establish a head of cylinders. | | 17. Put engine oil on carvings of bolts and a surface of saddles. | |
Prevention Be convinced that bolts of a head of cylinders of one type – (And) or (In). Do not use bolts of different types alternately.
| | 18. In a certain sequence tighten bolts of fastening of a head of the block of cylinders in the following order. FE DOHC: 80–86 N • m
Т8 DOHC:
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 °. | | 19. Put enough of engine oil on necks and bearings of camshafts. | | 20. Establish camshafts so that the adjusting pin settled down precisely above. | | 21. Put enough of pure engine oil on contours of cams and a neck of camshafts. | | 22. Put silicone hermetic on privalochny surfaces of forward covers of camshafts. | | 23. Establish covers of camshafts according to their numbers and a marking. |
| 24. In a certain sequence for 2–3 stages tighten bolts of fastening of covers of camshafts.
Inhaling moment: 17,6–26,5 N • m |
| 25. Establish a sealing plate and fix it bolts. Inhaling moment: 7,8–11,8 N • m | | 26. Put silicone hermetic on lobbies and a back cover of camshafts. |
| 27. Establish a cover of a head of cylinders and fix it bolts. Inhaling moment: 3,9–5,9 N • m | | 28. Remove dirt and greasing from a surface of the case of the sensor of an angle of rotation. | | 29. Establish the sensor of an angle of rotation with a new sealing ring and fix it bolts. |
Prevention
Do not use repeatedly sealing ring.
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