Kia Rio: Installation
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1. |
Dowel pin of crankshaft setted about 3° with vertical center line.
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2. |
Align the TDC marks (A) of the CVVT sprockets with the upper sureface
of the cylinder head to make No.1 cylinder be positioned at TDC.
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3. |
Install the new O-rings (A).
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4. |
Install the timing chain guide (A) and the timing chain (B).
Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
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When installing a timing chain, align the timing marks
on the sprockets with paint marks of the chain.
Order : Crankshaft sprocket → Timing chain guide → Intake
CVVT sprocket → Exhaust CVVT sprocket.
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5. |
Install the chain tensioner arm (A).
Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
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6. |
Install the hydraulic tensioner (A) and remove the pin (B).
Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
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Recheck the top dead center (TDC) marks on the crankshaft
and camshaft.
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7. |
Install the timing chain cover.
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(1) |
Before installing, remove the hardened sealant from the
cylinder block and ladder frame surface.
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(2) |
Apply the liquid gasket(TB 1217H or LOCTITE 5900H) on
the surface between the cylinder head and the cylinder block.
Width :
3 ~ 5mm (0.1181~0.1969in.)
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(3) |
Apply the liquid gasket, THREE BOND 1282B or THREE BOND
1216E on the water pump contact parts (A) of the timing chain
cover and THREE BOND 1217H or LOCTITE 5900H on the rest parts
(B). Reassemble the cover within 5 minutes.
Width :
3.5 ~ 4.5 mm (0.1378 ~ 0.1772 in.)
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Remove oil or dust on the surface surely.
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(4) |
Align the dowel pin of the cylinder block and the holes
of the oil pump.
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(5) |
Tighten the bolts to install the timing chain cover (A).
Tightening torque :
M8 bolts :
18.6 ~ 23.5 N.m (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4
lb-ft)
M6 bolts :
9.8 ~ 11.8 Nm (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
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After the installation, do not crank engine or
apply pressure on the cover for half an hour.
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8. |
Using the SST(09455-21200), reassemble the timing chain cover
oil seal.
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9. |
Install the crankshaft pulley (A).
Tightening torque :
11T : 127.5 ~ 137.3 N.m (13.0 ~ 14.0 kgf.m, 94.0 ~ 101.3
lb-ft)
12T : 46.1 ~ 52.0 N.m (4.7 ~ 5.3 kgf.m, 34.0 ~ 38.3 lb-ft)
+ 38 ~ 42°
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There are two methods to hold the ring gear when installing
or removing the crankshaft damper pulley.
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Install the SST (09231-2B100) to hold the ring
gear after removing the starter.
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Install the SST (09231-3D100) to hold the ring
gear after removing the dust cover.
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| 1. |
Remove the bracket (A).
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| 2. |
Remove the dust cover (A) and unfasten the transaxle
mounting bolt (B).
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| 3. |
Adjust the length of the holder nuts (A) so that
the front plate of the holder (B) puts in the ring gear
(C) teeth.
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| 4. |
Adjust the angle of the links (D), and fasten
the bolt 70mm(2.7559in) in the original mounted hole.
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| 5. |
Tighten the bolts and nuts of the holder and links
securely.
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When installing the pulley, the groove on the pulley should
be positioned outside.
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10. |
Install the water pump (A) with a gasket.
Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
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11. |
Install the water pump pulley (A) and the drive belt idler (B).
Tightening torque :
A: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
B: 42.2 ~ 53.9 N.m (4.3 ~ 5.5 kgf.m, 31.1 ~ 39.8 lb-ft)
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Tighten the bolts diagonally.
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12. |
Install the engine support bracket (A).
Tightening torque :
29.4 ~ 41.2 N.m (3.0 ~ 4.2 kgf.m, 21.7 ~ 30.4 lb-ft)
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13. |
Install the alternator bracket (B).
Tightening torque :
19.6 ~ 26.5 N.m (2.0 ~ 2.7 kgf.m, 14.5 ~ 19.5 lb-ft)
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14. |
Install the engine mounting support bracket (B) and then connect
the ground line (A).
Tightening torque
Ground line bolt :
10.8 ~ 13.7 N.m (1.1 ~ 1.4 kgf.m, 8.0 ~ 10.1 lb-ft)
Nut (C) :
63.7 ~ 83.4 N.m (6.5 ~ 8.5 kgf.m, 47.0 ~ 61.5 lb-ft)
Bolt (D) and nuts (E) :
49.0 ~ 63.7 N.m (5.0 ~ 6.5 kgf.m, 36.2 ~ 47.0 lb-ft)
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15. |
Install the alternator (A).
Tightening torque :
M8 bolt :
19.6 ~ 26.5 N.m (2.0 ~ 2.7 kgf.m, 14.5 ~ 19.5 lb-ft)
M10 bolt :
29.4 ~ 41.2 N.m (3.0 ~ 4.2 kgf.m, 21.7 ~ 30.4 lb-ft)
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16. |
Install the drive belt (A).
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17. |
Adjust tension by tightening the alternator tension adjust bolt
(A).(Refer to Charging system in EE Group).
Tension
[With OAD]
New belt :637.4 ~ 735.5N (65 ~ 75kg, 143.3 ~ 165.3lb)
Used belt :490.3 ~ 588.4N (50 ~ 60kg, 110.2 ~ 132.3lb)
[Without OAD]
New belt: 882.6 ~ 980.7N (90 ~ 100kg, 198.4 ~ 220.5lb)
Used belt: 637.4 ~ 735.5N (65 ~ 75kg, 143.3 ~ 165.3lb)
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18. |
Before installing the cylinder head cover, remove oil, dust or
hardened sealant from the timing chain cover and the cylinder head upper
surface.
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19. |
After applying the liquid gasket, THREE BOND 1217H or LOCTITE
5900H on the cylinder head cover, reassemble the cover within five minutes.
Width : 2.0 ~ 2.5mm(0.0787~0.0984in.)
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20. |
Install the OCV (Oil Control Valve) adapter (A).
Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
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Keep the OCV adapter clean.
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Make sure the O-rings on the front bearing cap
are installed.
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21. |
Install the cylinder head cover (A) with a new gasket (B).
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Do not reuse the disassembled gasket.
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22. |
Tighten the cylinder head cover bolts with the order and steps.
Tightening torque :
1st step: 3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)
2nd step: 7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb-ft)
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23. |
Install the exhaust OCV (Oil Control Valve) (A).
Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
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24. |
Install the ignition coils (A).
Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
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25. |
Install the high pressure fuel pump (A) and the roller tappet
(B). (Refer to FL group)
Tightening torque :
12.7 ~ 14.7N.m (1.3 ~ 1.5kgf.m, 9.4 ~ 10.8lb-ft)
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Before installing the high pressure fuel pump, position
the roller tappet in the lowest position (BDC) by rotating the
crankshaft. Otherwise the installation bolts may be broken because
of tension of the pump spring.
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Do not use already used bolt again.
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When tightening the installation bolts of the high pressure
fuel pump, tighten in turn the bolts in small step (0.5 turns)
after tightening them with hand-screwed torque.
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Note that internal damage may occur when the component
is dropped. In this case, use it after inspecting.
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Apply engine oil to the O-ring (A) of the high pressure
fuel pump, the roller tappet (B), and the protrusion (C). Also
apply engine oil to the groove where the protrusion is installed.
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26. |
Install the high pressure pipe (A). (Refer to FL group)
Tightening torque :
25.5 ~ 31.4N.m (2.6 ~ 3.2kgf.m, 18.8 ~ 23.1lb-ft)
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Do not reuse the high pressure pipe.
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27. |
Install the vacuum pipe assembly (A).
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
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28. |
Connect the fuel hose (A) and the PCSV (Purge control solenoid
valve) hose (B).
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29. |
Connect the oxygen sensor connectors (A) and the condenser connector
(B).
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30. |
Connect the FPCV (Fuel pressure control valve) connector (A),
the intake CMPS (Camshaft position sensor) connector (B) and the exhaust
CMPS (Camshaft position sensor) connector (C).
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31. |
Connect the ignition coil connectors (A), the injector extension
connector (B), the VIS (Variable intake system) connector (C) and the
PCSV (Purge control solenoid valve) connector (D).
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32. |
Connect the intake OCV (Oil control valve) connector (A) and the
exhaust OCV (Oil control valve) connector (B).
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33. |
Connect the A/C compressor switch connector (A), the alternator
connector (B) and the cable from the alternator “B” terminal (C).
Tightening torque :
9.8 ~ 14.7N.m (1.0 ~ 1.5kgf.m, 7.2 ~ 10.8lb-ft)
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34. |
Install the under covers (A).
Tightening torque :
6.9 ~ 10.8 N.m (0.7 ~ 1.1 kgf.m, 5.1 ~ 8.0 lb-ft)
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35. |
Install the RH front wheel.
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36. |
Install the air cleaner assembly.
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(1) |
Install the air cleaner assembly (D) and then connect
the air intake hose (C).
Tightening torque :
Hose clamp bolt :
2.9 ~ 4.9N.m (0.3 ~ 0.5kgf.m, 2.2 ~ 3.6lb-ft)
Air cleaner assembly bolts :
7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
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(2) |
Connect the breather hose (B).
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(3) |
Install the air duct (A) .
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Install the air intake hose while the plate of
the hose clamp must be in line with the stopper of the
hose.
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Install the air intake hose while the groove of
hose must be matched to the protrusion of the throttle
body.
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37. |
Connect the battery negative terminal (A).
Tightening torque :
Without battery sensor :
7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
With battery sensor :
4.0 ~ 6.0N.m (0.4 ~ 0.6kgf.m, 3.0 ~ 4.4lb-ft)
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38. |
Install the engine cover.
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Make sure the engine cover is installed before driving.
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Sprockets, Hydraulic Tensioner, Chain
Guide, Tensioner Arm
1.
Check the CVVT sprocket, crankshaft sprocket teeth for abnormal
wear, cracks or damage. Repla ...
Inspection