Engine Overhaul: Overhaul Kia Rio II

DISASSEMBLY

Note. Identify HLA (Hydraulic Lash Adjuster), valves, valve springs as they are removed so that each item can be reinstalled in its original position.

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1. Remove the HLAs (A).
2. Remove the valves. Using the SST (09222 - 28000, 09222 - 28100), compress the valve spring and remove the retainer lock. 1.6 CVVT Remove the spring retainer. Remove the valve spring. Remove the valve. Using a needle-nose pliers, remove the oil seal. Using a magnetic finger, remove the spring seat.

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1. Inspect for flatness. Using a precision straight edge and feeler gauge, measure the surface the contacting the cylinder block and the manifolds for warpage. Flatness of cylinder head gasket surface Standard: Less than 0.03mm (0.0012in) Limit: 0.05mm (0.0020in) Flatness of manifold mating surface Standard: Less than 0.15mm (0.0059in) Limit: 0.20mm (0.0079in)
2. Inspect for cracks. Check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracked, replace the cylinder head.

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1. Inspect the valve stems and valve guides. Using a caliper gauge, measure the inner diameter of valve guide. Valve guide inner diameter : 6.000~6.015mm (0.2362~0.2368in) Using a micrometer, measure the outer diameter of valve stem. Valve stem outer diameter Intake: 5.965~5.980mm (0.2348~0.2354in) Exhaust: 5.950~5.965mm (0.2343 - 0.2348in) Subtract the valve stem outer diameter measurement from the valve guide inner diameter measurement. Valve stem-to-guide clearance Standard Intake: 0.02~0.05mm (0.0008~0.0020in) Exhaust: 0.035~0.065mm (0.0014~0.0026in) Limit Intake: 0.10mm (0.0039in) Exhaust: 0.15mm (0.0059in) If the clearance is greater than maximum, replace the valve and valve guide.
2. Inspect the valves. Check the valve is ground to the correct valve face angle. Check the surface of valve for wear. If the valve face is worn, replace the valve. Check the valve head margin thickness. If the margin thickness is less than minimum, replace the valve. Margin Standard Intake: 1.1mm (0.0433in) Exhaust: 1.3mm (0.0512in) Limit Intake: 0.8mm (0.0315in) Exhaust: 1.0mm (0.0394in) Check the surface of valve stem tip for wear. If the valve stem tip is worn, replace the valve.
3. Inspect the valve seats. Check the valve seat for evidence of overheating and improper contact with the valve face. Replace the seat if necessary. Before reconditioning the seat, check the valve guide for wear. If the valve guide is worn, replace it, then recondition the seat. Recondition the valve seat with a valve seat grinder or cutter. The valve seat contact width should be within specifications and centered on the valve face.
4. Inspect the valve springs. Using a steel square, measure the out-of-square of valve spring. Using a vernier calipers, measure the free length of valve spring. Valve spring Standard Free height: 44mm (1.7323in) Load: 21.6±1.1kg/35.0mm (47.6±2.4lb/1.3780in) 45.1 ±2.2kg/27.2mm (99.4±4.9lb/1.0709in) Out of square: Less than 1.5° Limit Out of square: 3° If the loads is not as specified, replace the valve spring.

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1. Inspect the cam lobes. Using a micrometer, measure the cam lobe height. Cam height Intake: 43.7492~43.9492mm (1.72241~1.73028in) Exhaust: 44.1494~44.3494mm (1.73816~1.74604in) If the cam lobe height is less than specified, replace the camshaft.
2. Inspect the camshaft journal clearance. Clean the bearing caps and camshaft journals. Place the camshafts on the cylinder head. Lay a strip of plastigage across each of the camshaft journal. Install the bearing caps and tighten the bolts with specified torque. (Refer to «INSTALLATION»(ref-270970-S39272941762007110800000) ) CAUTION: Do not turn the camshaft. Remove the bearing caps. Measure the plastigage at its widest point. Bearing oil clearance Standard: 0.020~0.061mm (0.0008~0.0024in) Limit: 0.1mm ( 0.0039in) If the oil clearance is greater than specified, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set. Completely remove the plastigage. Remove the camshafts.
3. Inspect the camshaft end play. Install the camshafts. (Refer to «INSTALLATION»(ref-270970-S39272941762007110800000) ) Using a dial indicator, measure the end play while moving the camshaft back and forth. Camshaft end play Standard: 0.1~0.2mm (0.0039~0.0079in) 1.6 CVVT If the end play is greater than specified, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set. Remove the camshafts.

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1. Inspect the CVVT (Continuous Variable Valve Timing) assembly. Check that the CVVT (Continuous Variable Valve Timing) assembly will not turn. Apply vinyl tape to all the parts except the one indicated by the arrow in the illustration. Wrap tape around the tip of the air gun and apply air of approx. 98kpa (1 kg/cm 2 , 14psi) to the port of the camshaft. Perform this order to release the lock pin for the maximum delay angle locking.) NOTE: Wrap around it with a shop rag and the likes, because the oil splashes. Under the condition of 3), turn the CVVT assembly to the advance angle side with your hand. Depending on the air pressure, the CVVT assembly will turn to the advance side. If air is leaking from the port and air pressure cannot be maintained, the locking pin will not release. Except the position where the lock pin meets at the maximum delay angle, let the CVVT assembly turn back and forth and check the movable range and that there is no disturbance. Standard: Movable smoothly in the range about 20° Turn the CVVT assembly with your hand and lock it at the maximum delay angle position.

REASSEMBLY

Note. Thoroughly clean all parts to be assembled. Before installing the parts, apply fresh engine oil to all sliding and rotating surface. Replace oil seals with new ones.

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1. Install the valves. Install the spring seats. Using the SST (09222 - 22001), push in a new oil seal. NOTE: Do not reuse old valve stem oil seals. Incorrect installation of the seal could result in oil leakage past the valve guides. 1.6 CVVT Install the valve, valve spring and spring retainer. NOTE: Place the valve springs so that the side coated with enamel faces toward the valve spring retainer and then installs the retainer. Using the SST (09222 - 28000, 09222 - 28100), compress the spring and install the retainer locks. After installing the valves, ensure that the retainer locks are correctly in place before releasing the valve spring compressor. 1.6 CVVT Lightly tap the end of each valve stem two or three times with the wooden handle of a hammer to ensure proper seating of the valve and retainer lock. 1.6 CVVT
2. Install the HLA (Hydraulic Lash Adjusters. Check that the HLA rotates smoothly by hand.

Note. Thoroughly clean all parts to assembled. Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces. Replace all gaskets, O-rings and oil seals with new parts.

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1. Assemble the piston and connecting rod. Use a hydraulic press for installation The piston front mark and the connecting rod front mark must face the timing belt side of the engine.
2. Install the piston rings. Install the oil ring expander and 2 side rails by hand. Using a piston ring expander, install the 2 compression rings with the code mark facing upward. Position the piston rings so that the ring ends are as shown.
3. Install the connecting rod bearings. Align the bearing (A) claw with the groove of the connecting rod or connecting rod cap (B). Install the bearings (A) in the connecting rod and connecting rod cap (B).
4. Install the crankshaft main bearings. NOTE: Upper bearings have an oil groove of oil holes; Lower bearings do not. Align the bearing claw with the claw groove of the cylinder block, push in the 4 upper bearings (A). Align the bearing claw with the claw groove of the main bearing cap, and push in the 5 lower bearings.
5. Install the center bearing. Install the center bearing (A) under the No.3 journal position of the cylinder block with the oil grooves facing outward.
6. Place the crankshaft on the cylinder block.
7. Place the main bearing caps on the cylinder block.
8. Install the main bearing cap bolts. NOTE: The main bearing cap bolts are tightened in 2 progressive steps. If any of the bearing cap bolts in broken or deformed, replace it. Apply a light coat of engine oil on the threads and under the bearing cap bolts. Install and uniformly tighten the 10 bearing cap bolts (A), in several passes, in the sequence shown. Tightening torque : 53.9~58.8N.m (5.5~6.0kgf.m, 39.8~43.4lb-ft) Check that the crankshaft turns smoothly.
9. Check the crankshaft end play. (Refer to «CRANKSHAFT MAIN BEARING SELECTION TABLE»(ref-270970-S23982504322007110800000) )
10. Install the piston and connecting rod assemblies. NOTE: Before installing the piston, apply a coat of engine oil to the ring grooves and cylinder bores. Remove the connecting rod caps, and slip short sections of rubber hose over the threaded ends of the connecting rod bolts Install the ring compressor, check that the rings are securely in place, then position the piston in the cylinder, and tap it in using the wooden handle of a hammer. Stop after the ring compressor pops free, and check the connecting rod-to-crank journal alignment before pushing the piston into place. Apply engine oil to the bolt threads, install the rod caps with bearings, and tighten the nuts. Tightening torque : 31.4~34.3N.m (3.2~3.5kgf.m, 23.1~25.3lb-ft) NOTE: Maintain downward force on the ring compressor to prevent the rings from expending before entering the cylinder bore.
11. Install the rear oil seal case. Using a razor blade and gasket scraper, remove all the old packing material from the gasket surfaces. NOTE: Check that the mating surfaces are clean and dry before applying liquid gasket. Apply liquid gasket as an even bead, centered between the edges of the mating surface. Liquid gasket: MS 721-40A or equivalent Install the rear oil seal case (A) with 5 bolts (B). Tightening torque : 9.8~11.8N.m (1.0~1.2kgf.m, 7.2~8.7lb-ft)
12. Install the rear oil seal. Apply engine oil to a new oil seal lip. Using the SST (09231-21000) and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge.
13. Install the front case. (Refer to «INSTALLATION»(ref-270970-S39634559802007110800000) )
14. Install the oil screen. Install a new gasket (B) and oil screen (A) with 2 bolts (C). Tightening torque : 14.7~21.6N.m (1.5~2.2kgf.m, 10.8~15.9lb-ft)
15. Install the oil pan. Using a razor blade and gasket scraper, remove all the old packing material from the gasket surfaces. NOTE: Check that the mating surfaces are clean and dry before applying liquid gasket. Apply liquid gasket as an even bead, centered between the edges of the mating surface. Liquid gasket: MS 721-40A or equivalent NOTE: To prevent leakage of oil, apply liquid gasket to the inner threads of the bolt holes. D not install the parts if five minutes or more have elapsed since applying the liquid gasket. Instead, reapply liquid gasket after removing the residue. After assembly, wait at least 30 minutes before filling the engine with oil. Install the oil pan (A) with the bolts. Uniformly tighten the bolts in several passes. Tightening torque : 9.8~11.8N.m (1.0~1.2kgf.m, 7.2~8.7lb-ft)
16. Install the water pump. (Refer to «INSTALLATION»(ref-270970-S15799935752007110800000) )
17. Install the oil pressure switch. Apply adhesive to 2 or 3 threads. Adhesive: MS 721-39 (B) or equivalent. Install the oil pressure switch (A). Tightening torque : 14.7~21.6N.m (1.5~2.2kgf.m, 10.8~15.9lb-ft)
18. Install the knock sensor (A). Tightening torque : 16.7~26.5N.m (1.7~2.7kgf.m, 12.3~19.5lb-ft)
19. Install the oil level gauge tube (A). Install a new O-ring on the oil level gauge tube. Apply engine oil on the O-ring. Install the oil level gauge tube (A) with the bolt. Tightening torque : 11.8~14.7N.m (1.2~1.5kgf.m, 8.7~10.8lb-ft)
20. Install the cylinder head. (Refer to «INSTALLATION»(ref-270970-S39272941762007110800000) )
21. Install the timing belt. (Refer to «INSTALLATION»(ref-270970-S19627895942007110800000) )
22. Remove the engine stand.
23. A/T:install the drive plate. Tightening torque : 117.7~127.5N.m (12.0~13.0kgf.m, 86.8~94.0lb-ft)
24. M/T:install the fly wheel. Tightening torque : 117.7~127.5N.m (12.0~13.0kgf.m, 86.8~94.0lb-ft)

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