Kia Clarus/Credos

1995-2001 of release

Repair and car operation



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





2.16. Block of cylinders

GENERAL INFORMATION

Block of cylinders of the FE DOHC engine

1–basket of coupling (M/t), basic plate (And/t);
2–the conducted disk of coupling (M/t) conducting a disk (And/t);
3–flywheel (M/t), plate (And/t);
4–transitional plate;
5–oil pallet;
6–maslopriyemnik;
7–rigidity element;
8–back cover;
9–water pump;
10-a forward cover with the oil pump;
11-oil spray.

Block of cylinders of the DOHC T8 engine

1–basket of coupling (M/t), basic plate (And/t);
2–the conducted disk of coupling (M/t) conducting a disk (And/t);
3–flywheel (M/t), plate (And/t);
4–transitional plate;
5–oil pallet;
6–maslopriyemnik;
7–rigidity element;
8–back cover;
9–water pump;
10-a forward cover with the oil pump;
11-oil spray.

Cranked shaft, pistons and rods

1–rod cover;
2–loose leaf of the shatunny bearing;
3–the piston with a rod;
4–piston rings;
5–cover of the radical bearing;
6–cranked shaft;
7–needle bearing of primary shaft of a transmission;
8–loose leaf of the radical bearing;
9–block of cylinders.

The description of dismantling and assembly of the block of cylinders on the engine from which auxiliary details, a gear belt, pulleys of camshafts and a head of cylinders previously are removed is provided.

PERFORMANCE ORDER
1. Establish special tools for a centering of a disk of coupling and flywheel blocking from a provorachivaniye.
Gradually, on a diagonal, weaken bolts of fastening of a casing of a press disk of coupling until it will be terminated a diafragmenny spring, then turn out bolts manually.
Remove a casing of a press disk of coupling and a coupling disk.
2. Turn out bolts and remove a flywheel.
3. Turn out bolts and remove a transitional plate.
4. Turn out bolts of fastening of the oil pallet. An edge of the flat screw-driver inserted between the oil pallet and an element of rigidity of the block of cylinders, separate the oil pallet from the block of cylinders.

Prevention

Do not insert a screw-driver between the block of cylinders and the oil pallet as it can damage interfaced surfaces.

Separating the oil pallet by means of the lever, do not bend it.

Clearing the pallet of hermetic, do not damage and do not scratch a privalochny surface.


5. Remove the oil pallet.
6. Unscrew bolts and remove a maslopriyemnik.
7. Unscrew bolts and remove a back cover from the block of cylinders.
8. Unscrew bolts and remove the water pump.
9. Unscrew bolts and remove a forward cover with the oil pump from the block of cylinders.
10. Unscrew a bolt and remove an oil spray.
11. Check lack of a step and a deposit in the top part of each cylinder.

Prevention

If to make removal of pistons, without having cleaned a step in the top part of the cylinder, it can lead to damage of piston rings and pistons.


12. Using the special tool, remove a step in the top part of cylinders.
13. Turn a cranked shaft of the engine so that pistons of the first and fourth cylinders were established in the bottom dead point.
14. Mark covers of rods and rods according to cylinder number in which they are established.
15. Note rods and covers of rods so that at installation they occupied the correct situation and the direction. At the wrong installation of rods supply of greasing in shatunny loose leaves that will lead to their fast damage will be broken.
16. Turn a cranked shaft of the engine so that pistons of the second and third cylinders were established in the bottom dead point and similarly mark rods and covers of rods.
17. Unscrew nuts of fastening of a cover of a rod and in easy blows of a plastic hammer bring down a cover.
18. Before removal of a rod clear the loose leaf, a rod and a shatunny neck and carry out the following measurements:

– lateral gap of a rod;
– oil gap of a shatunny neck.
19. For protection of necks of a cranked shaft dress on bolts of fastening of covers of rods pieces of a rubber or plastic tube.
20. Wooden whetstone or the hammer handle вытолкните the piston with a rod from the cylinder.
21. Repeat these operations on other cylinders.
22. Mark pistons according to numbers of cylinders in which they were established.
23. Before removal of covers of the radical bearing clear bearings, radical necks and covers, then make the following measurements:

– axial люфт cranked shaft;
– oil gap of a radical neck.
24. The special adaptation ОК410 111 012 remove from an end face of a cranked shaft the needle bearing.
25. Special пассатижами unclench piston rings and remove them from the piston.
26. Establish the piston horizontally and check smoothness of moving of a rod.
27. Moving a rod, check absence люфта and jammings.
28. If the rod moves with jammings, check an opening for a piston finger in the piston and a rod on absence of deformation.
29. Remove lock rings from end faces of a piston finger.
30. The special adaptation ОК710 110 010 and a hammer beat out a piston finger.
31. Turn out bolts of fastening of covers of radical bearings.
32. Remove covers of radical bearings.
33. Remove a cranked shaft.
34. Remove loose leaves of radical bearings from the block of cylinders and covers of radical bearings.

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.

Prevention

Be careful not to damage a surface of a friction of details from an aluminum alloy (such, as a head of the block of cylinders or pistons).



Check of the block of cylinders


PERFORMANCE ORDER
1. Check the block of cylinders on absence of the following damages:

– local damages or leak;
– cracks;
– developments 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. Measure diameters of cylinders in the opposite directions, in three planes on height of cylinders.

Diameter of the cylinder:
The nominal: 86,000–86,019
Repair +0,25 mm: 86,250–86,269
Repair +0,50 mm: 86,500–86,519
5. For definition of a konusnost of the cylinder measure diameter of the cylinder in the top, average and bottom parts.

Maximum permissible konusnost: 0,019 mm
Ovality: 0,019 mm
6. If the difference between measurements of the X-th and Y exceeds the most admissible ovality, chisel the cylinder till next increased size.

Prevention

Diameter of the cylinder should correspond to the increased diameter of the piston, and it belongs to all cylinders.


7. If in the top part of a wall of the cylinder there is a non-uniform wear, remove roughnesses with a shaber.

Check of pistons


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 at an angle 90 ° to a piston finger at distance of 18 mm in the FE DOHC engine and at distance of 21 mm in DOHC TV engine from bottom edge of a maslosjemny ring.

Diameter of the piston
FE DOHC

Nominal 85,944–85,964 mm
1st repair (+0,25) 86,194–86,214 mm
2nd repair (+0,50) 86,444–86,464 mm

T8 DOHC
Nominal 80,954–80,972 mm
1st repair (+0,25) 81,204–81,222 mm
2nd repair (+0,50) 81,454–81,472 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.

Gap:
FE DOHC: 0,049–0,062 mm
FE DOHC: 0,039–0,053 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.

Prevention

At replacement of the piston it is also necessary to replace piston rings.



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.

Gap between a piston ring and a flute in the piston:
Top kompressionny ring:
FE DOHC: 0,03–0,07 mm
Т8 DOHC: 0,04–0,08 mm
Second kompressionny ring: 0,03–0,07 mm
The most admissible: 0,15 mm
2. If the gap exceeds maximum permissible value, replace the piston.
3. Check piston rings on absence of damages, wear or breakage. If necessary, replace piston rings.
4. Measure a gap in the lock of piston rings, having manually inserted a piston ring into the engine cylinder. The bottom of the piston push a piston ring in the lower part of the cylinder.
5. By Shchup measure a gap in the lock of a piston ring.

Gap in locks of piston rings:
Top kompressionny ring: 0,15–0,30 mm
Second kompressionny ring:
FE DOHC: 0,20–0,35 mm
Т8 DOHC: 0,30–0,45 mm
Maslosjemnoye ring: 0,20–0,70 mm
Maximum permissible gap: 1,0 mm

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: 21,988–21,998 mm
2. Measure diameter of each piston finger, in two opposite directions, four planes.

Diameter:
FE DOHC: 21,987–21,993 mm
Т8 DOHC: 19,987–19,993 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: from–0,005 to 0,011 mm

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

Rod check


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

Diameter: 22,003–22,014 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: 0,010–0,027 mm

3. Check each rod on bend or twisting existence. If necessary repair or replace a rod.

Allowed bend: 0,075 mm on длине50 mm
Allowed twisting: 0,180 mm on length of 50 mm

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. Check lubricant openings of a cranked shaft on lack of a contamination.
2. Establish a cranked shaft on V-shaped supports.
3. 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.

The most admissible palpation:
FE DOHC: 0,03 mm
Т8 DOHC: 0,025 mm

4. By a micrometer measure diameters of necks of a cranked shaft in two opposite directions.

Radical neck
Diameter:
FE DOHC: 59,937–59,955 mm
Т8 DOHC: 54,938–54,956 mm
Ovality: 0,05 mm

Shatunny neck
Diameter:
FE DOHC: 50,940–50,955 mm
Т8 DOHC: 44,940–44,958 mm
Ovality: 0,05 mm
5. In the presence of development or ovality перешлифуйте a cranked shaft. Repolishing of necks of a cranked shaft carry out only till next repair size.

Bearings of the reduced size:
on 0,25 mm
on 0,50 mm
on 0,75 mm

Prevention

Do not grind a surface galtel.



Diameters of necks of radical bearings of a cranked shaft

Size of the bearing
FE DOHC
T8 DOHC
1st repair size (+0,25 mm) No. 1, 2, 4, 5
59,693–59,711
55,188–55,206
No. 3
59,687–59,705
55,188–55,206
2nd repair size (+0,50 mm) No. 1, 2, 4, 5
59,443–59,461
55,438–55,456
No. 3
59,437–59,455
55,438–55,456
3rd repair size: (+0,75 mm) No. 1, 2, 4, 5
59,193–59,211
55,688–55,706
No. 3
59,187–59,205
55,688–55,706

Diameters of necks of shatunny bearings of a cranked shaft


Size of the bearing
FE DOHC
T8 DOHC
1st repair size (+0,25 mm)
50,690–50,705
45,190–45,208
2nd repair size (+0,50 mm)
50,440–50,445
45,440–45,458
3rd repair size: (+0,75 mm)
50,190–50,205
45,690–45,708

Verification of shatunny and radical loose leaves


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

Check of sprays for cooling of pistons


PERFORMANCE ORDER
1. Check, whether the channel of an oil nozzle is hammered.
2. Check, whether jams the return ball valve.

Assembly


PERFORMANCE ORDER
1. Before assembly clear all details of the engine.
2. Before assembly of details apply a thin film pure engine oil on all surfaces of sliding.
3. Replace radical and shatunny loose leaves even if they have insignificant damages or wear. At installation it is necessary to use only new laying.
4. Establish a spring lock ring in a piston flute.
5. Combine a label on the lower part of a rod with well-aimed "F" on the piston.
6. Establish the piston in a rod and the special adaptation ОК710 110 010 insert a piston finger via the piston and a rod before fixing by its already established lock ring. Check, that relative position of the piston and a rod was same, as well as before dismantling.
7. Establish the second spring lock ring of a piston finger in a flute on the other side of the piston.
8. Hold the piston vertically and check freedom of moving of a rod.
9. Establish three parts of a maslosjemny ring on the piston:

– grease with pure engine oil a dilator of a maslosjemny ring both the top and bottom parts of a ring;
– establish a dilator of a maslosjemny ring on the piston so that the ends of a dilator were directed up;
– establish the lower part of a maslosjemny ring on the piston. The ring can be established by any party up;
– establish the top part of a maslosjemny ring on the piston. The ring can be established by any party up;

Prevention

The top and bottom parts of a maslosjemny ring are interchangeable.


10. Check that the dilator of a maslosjemny ring divides the top and bottom parts of a maslosjemny ring and is freely turned on the piston.
11. To Passatizhami for a release of piston rings establish on the piston the 2nd kompressionny ring.
12. To Passatizhami for a release of piston rings establish on the piston the 1st kompressionny ring.
13. Put enough of pure engine oil on the second and top piston rings.
14. Arrange locks of piston rings as is shown in drawing.

Prevention

At installation of piston rings of a label of "R" should be directed up.


15. Clear radical and shatunny necks of a cranked shaft of greasing, and lubricant openings blow the compressed air.
16. Establish loose leaves of radical bearings on the block of cylinders of the engine.
17. Establish a cranked shaft on loose leaves of radical bearings in the block of cylinders.
18. Establish the remained loose leaves of radical bearings in covers of radical bearings of a cranked shaft.
19. Arrange pieces of a plastic measuring core of Plastigage on necks of radical bearings of a cranked shaft.
20. According to marking establish covers of radical bearings.
21. In a certain sequence in 2–3 stages tighten bolts of fastening of covers of radical bearings of a cranked shaft in the following order:

Inhaling moment:
FE DOHC: 82–88 N • m
Т8 DOHC:

and. tighten bolts the moment of an inhaling of 39,2 N • m;
b. in sequence, return to a tightening, weaken bolts;
page tighten bolts the moment of an inhaling of 19,6 N • m;
d. tighten bolts on a corner 90 °;
е. tighten bolts on a corner 60 °

Prevention

Do not turn a cranked shaft of the engine at measurement of a gap of radical bearings of a cranked shaft.


22. Turn out bolts and remove covers of radical bearings of a cranked shaft. By a measuring template measure width of the deformed plastic core of Plastigage and define gap size.
23. If the gap exceeds maximum permissible value, перешлифуйте necks of a cranked shaft and use repair loose leaves of the increased size.

Oil gap
No. 1, 2, 4, 5: 0,025–0,043 mm
No. 3: 0,031–0,049 mm

Maximum permissible gap: 0,08 mm

24. Remove a cranked shaft from the block of cylinders and remove the deformed plastic core of Plastigage from necks of a cranked shaft and loose leaves of radical bearings.
25. Apply a thin film engine oil on loose leaves of radical bearings in the block of cylinders and establish a cranked shaft on loose leaves.
26. Apply a thin film engine oil on radical necks of a cranked shaft and loose leaves in covers of radical bearings.
27. According to marking <-establish covers of radical bearings of a cranked shaft.
28. In a certain sequence in 2–3 stages tighten bolts of fastening of covers of radical bearings of a cranked shaft in the following order:

Inhaling moment:
FE DOHC: 82–88 N • m
Т8 DOHC:
and. tighten bolts the moment of an inhaling of 39,2 N • m;
b. in sequence, return to a tightening, weaken bolts;
page tighten bolts the moment of an inhaling of 19,6 N • m;
d. tighten bolts on a corner 90 °;
е. tighten bolts on a corner 60 °

29. Turn a cranked shaft and check that it rotates easily and smoothly.
30. Establish a measuring tip of the indicator of hour type on a forward end face of a cranked shaft.
31. Move a cranked shaft along an axis against the stop and establish a scale of the indicator of hour type on a zero.
32. Move a cranked shaft along an axis to other party against the stop and read values axial люфта on an indicator scale.
Engine
Thickness, mm
FE DOHC
Т8 DOHC
Axial люфт
0,08–0,18
0,08–0,282
Maximum permissible value
0,30
33. If axial люфт exceeds admissible values, it is necessary to replace persistent half rings of a cranked shaft.

Thickness of persistent half rings, mm


Persistent half ring
Thickness, mm
FE DOHC
Т8 DOHC
The nominal
2,0–2,05
2,50–2,55
The 1st repair (+0,25)
2,125–2,175
2,625–2,675
The 2nd repair (+0,50)
2,240–2,290
2,750–2,80
The 3rd repair (+0,75)
2,365–2,415
2,875–2,925

Prevention

Persistent half rings with bigger thickness can be used only in the central radical bearings.


34. Grease with engine oil an external lateral surface of the needle bearing of primary shaft of a transmission.
35. A pipe piece (external diameter of 30-34 mm), established on an external ring of the bearing, evenly press the bearing in a cranked shaft.
36. Grease the bearing with greasing.
37. Establish the shatunny loose leaf in a rod.
38. For protection of a neck of a cranked shaft against damage dress on bolts of fastening of covers of rods pieces of a rubber or plastic tube.
39. Check correctness of an arrangement of locks of piston rings on the piston.
40. Establish the piston with piston rings over the first cylinder, thus F label on the piston should be directed to a forward part of the block of cylinders.
41. Turn a cranked shaft in such situation that the shatunny neck of a cranked shaft of the 1st cylinder was in the bottom dead point.
42. The special adaptation compress piston rings on the piston.
43. The handle of a hammer press the piston into the cylinder so that the bottom head of a rod was established on a neck of a cranked shaft.
44. Establish the shatunny loose leaf in a rod cover.
45. Arrange pieces of a plastic measuring core of Plastigage on necks of shatunny bearings of a cranked shaft.
46. According to marking establish covers of rods and fix them nuts.

Inhaling moments:
FE DOHC: 69–73,0 N • m
Т8 DOHC: 47–50 N • m

47. Turn out nuts and uncover a rod.
48. By a measuring template measure width of the deformed plastic core of Plastigage and define gap size. Remove the deformed plastic core of Plastigage from necks of a cranked shaft and loose leaves of shatunny bearings.

Nominal gap in a rod the bearing:
FE DOHC: 0,027–0,067 mm
Т8 DOHC: 0,02–0,05 mm

Maximum permissible gap: 0,10 mm
49. If the gap exceeds maximum permissible value, перешлифуйте necks of a cranked shaft and use repair loose leaves of the increased size.

Prevention

Establishing a rod cover, combine adjusting labels on a cover and a rod.


50. Check a lateral gap of each rod without a cover.

Nominal lateral gap of a rod: 0,110–0,262 mm

Maximum permissible gap: 0,30 mm
51. If the lateral gap of a rod exceeds maximum permissible value, replace a rod and a rod cover.
52. Apply a thin film engine oil on a shatunny neck of a cranked shaft and the shatunny loose leaf in a rod cover.
53. Establish a cover of a rod and fix nuts.

Inhaling moments:
FE DOHC: 69–73,0 N • m
Т8 DOHC: 47–50 N • m

54. Apply a thin film engine oil on a back cover, oil consolidation and a flange of oil consolidation.
55. Press oil consolidation in a back cover.
56. Establish a back cover with new laying and fix it bolts.

Inhaling moment: 8–12 N • m
57. Cut off the part of laying supporting limits of the block of cylinders, towards the oil pallet.

Prevention

Do not scratch privalochny surfaces of the block of cylinders and a back cover.


58. Establish a transitional plate and fix it bolts.

Inhaling moment: 19–30 N • m
59. Apply a thin film pure engine oil on a working edge of a forward oil sealing ring of a cranked shaft and a nest of the oil pump.
60. Press oil consolidation of the oil pump in a forward cover.
61. Grease a working edge of oil consolidation.
62. Remove dirt or other substances from privalochny surfaces of a forward cover and the block of cylinders.
63. Put a continuous strip of silicone hermetic on a privalochny surface of a forward cover.

Prevention

Do not allow hermetic hit to the oil canal.


64. Establish on a forward cover a new sealing ring.
65. Establish a forward cover on the block of cylinders and fix it bolts.

Inhaling moment:
А: 19–25 N • m
В: 37–52 N • m

66. Remove the hermetic squeezed out outside.
67. Establish oil sprays.

Inhaling moment: 12–18 N • m

Prevention

Sprays of oil of cylinders No. 1, 3 in a form differ from sprays of oil of cylinders No. 2, 4.


68. Remove dirt or other substances from a privalochny surface of an element of rigidity.
69. Put a continuous strip of silicone hermetic (TORAY SH780M or LOCTITE ULTRA BLUE 587 type) on a rigidity element on internal edges of openings for bolts and with overlapping of the ends of a strip.
70. Establish an element of rigidity and fix it bolts.

Inhaling moment: 7–12 N • m
71. Establish the mesh oil filter with new laying and fix it bolts.

Inhaling moment: 8–12 N • m
72. Put a continuous strip of silicone hermetic (TORAY SH780M or LOCTITE ULTRA BLUE 587 type) on a rigidity element on internal edges of openings for bolts and with overlapping of the ends of a strip.
73. Establish the oil pallet and fix it bolts.

Inhaling moment: 7–12 N • m

Prevention

Discrepancy of edge of the oil pallet and edge of the block of cylinders should not exceed 1,5 mm.


74. Clear a carving of bolts of fastening of a flywheel and an opening under bolts of the remains of old hermetic. If it is impossible to remove hermetic from a carving of bolts, replace them.
75. Put on a carving of reused bolts a thin layer of hermetic.
76. Establish a flywheel or a drive plate on a cranked shaft and fix bolts.

Inhaling moment: 96–103 N • m
77. On cars with an automatic transmission establish a transitional plate, a leading disk and a basic plate and a dinamometrichesky key tighten bolts.
78. Establish a disk of coupling and a casing of coupling with a press disk.
79. Establish an opravka aligning a disk of coupling, and in some stages tighten bolts of fastening of a casing of coupling with a press disk.

Inhaling moment: 22–32 N • m

80. Remove dirt, greasing and other substances from a privalochny surface of the water pump.
81. Establish the water pump and fix it bolts.

Inhaling moment: 19–25 N • m