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General Information (Engine Mechanical System): Diagnosis Kia Rio II рестайлинг

Mechanical 20 illustrations ~895 words

COMPRESSION PRESSURE INSPECTION

Note. If the there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure.

Scheme 1

Scheme 1: COMPRESSION PRESSURE INSPECTION
Scheme 1: COMPRESSION PRESSURE INSPECTION

Scheme 2

Scheme 2
Scheme 2
  1. Warm up and stop engine. Allow the engine to warm up to normal operating temperature.
  2. Disconnect the ignition coil connectors and the spark plug cables. (Refer to «IGNITION SYSTEM»(ref-378908-S06466731442010113000000) )
  3. Remove the spark plugs. Using a 16mm plug wrench, remove the 4 spark plugs.
  4. Check the cylinder compression pressure. Insert a compression gauge into the spark plug hole. Fully open the throttle. While cranking the engine, measure the compression pressure. NOTE: Always use a fully charged battery to obtain engine speed of 250rpm or more. Repeat step 1 ) through 3 ) for each cylinder. NOTE: This measurement must be done in as short a time as possible. Compression pressure (1.6 CVVT) Standard : 1,422kPa (14.5kg/cm 2 , 206psi) (250~400 rpm) Minimum : 1,275kPa (13.0kg/cm 2 , 185psi) Difference between each cylinder : 98kPa (1.0kg/cm 2 , 14psi) or less If the cylinder compression in 1 or more cylinders is low, pour a small amount of engine oil into the cylinder through the spark plug hole and repeat step 1 ) through 3 ) for cylinders with low compression. If adding oil helps the compression, it is likely that the piston rings and/or cylinder bore are worn or damaged. If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket.
  5. Reinstall the spark plugs.
  6. Connect the ignition coil connectors and the spark plug cables. (Refer to «IGNITION SYSTEM»(ref-378908-S06466731442010113000000) )

Scheme 3

Scheme 3: TIMING BELT TENSION ADJUSTMENT
Scheme 3: TIMING BELT TENSION ADJUSTMENT

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Scheme 20
  1. Remove the engine cover (A).
  2. Remove the RH front wheel.
  3. Remove the bolts (B) and RH side cover (A).
  4. Loosen the water pump pulley bolts.
  5. Remove the alternator drive belt (A). (Refer to «ALTERNATOR»(ref-378909-S40507630572010113000000) )
  6. Remove the air conditioner compressor drive belt (B). (Refer to «COMPRESSOR»(ref-378984-S23871841592010113000000) )
  7. Remove the power steering pump drive belt (C). (Refer to «HYDRAULIC POWER STEERING SYSTEM»(ref-378946) )
  8. Remove the water pump pulley.
  9. Remove the 4 bolts (B) and timing belt upper cover (A).
  10. Turn the crankshaft pulley, and align its groove with timing mark "T" of the timing belt cover. Check that the timing mark of camshaft sprocket (A) is aligned with the timing mark of cylinder head cover. (No. 1 cylinder compression TDC position)
  11. Remove the crankshaft pulley (A).
  12. Remove the 4 bolts (B) and timing belt lower cover (A).
  13. Move the tensioner pulley (C) in the direction of the arrow shown after loosen the mounting bolt (A, B). And temporarily tighten mounting bolt (A, B).
  14. Adjust the timing belt tension. After inspecting the timing belt, replace it if necessary. Loosen the tensioner pulley mounting bolt and apply tension to the timing belt. After checking the alignment between each sprocket and each timing belt tooth, tighten the mounting bolt (A) and (B) one by one. Tightening torque : 19.6 ~ 26.5N.m (2.0 ~ 2.7kgf.m, 14.5 ~ 19.5lb-ft) Then recheck the belt tension. Verify that when the tensioner and the tension side of the timing belt are pushed in horizontally with a moderate force [approx. 49N (11lb)], the timing belt cog end is approx. 1/2 of the tensioner mounting bolt head radius (across flats) away from the bolt head center. Timing belt tension measuring procedure (by a sonic tension gauge) Rotate crankshaft in clockwise direction to set 1st piston on top dead center (TDC) and rotate crankshaft in counterclockwise to 90° then measure the belt tension in the middle of tension side span (in arrow direction of above illustration) by free vibration method. CAUTION: Avoid rotating the crankshaft in a counter clock wise direction. Engine damage could occur. Conversion equation of frequency into tension : T = (4/9.8) x S 2 x M x W x f 2 /100000000 S: Measured belt span (mm) M: Unit weight of belt (gf/cm 2 ) W: Belt width (mm) f: Transverse natural frequency of belt (Hz) Timing Belt Specifications TIMING BELT SPECIFICATIONS Item Specifications S (mm) 249.6 M (gf/cm 2 ) 0.4543 W (mm) 22 f (Hz) 70.4 ~ 87.9 T (kgf) 16 ± 3.5
  15. Turn the crankshaft two turns in the operating direction (clockwise) and realign the crankshaft sprocket and camshaft sprocket timing mark.
  16. Install the timing belt lower cover (A) with bolts (B). Tightening torque : 7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
  17. Install the crankshaft pulley (A). Tightening torque : 137.3 ~ 147.1N.m (14.0 ~ 15.0kgf.m, 101.3 ~ 108.5lb-ft)
  18. Install the timing belt upper cover (A) with bolts (B). Tightening torque : 7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
  19. Install the water pump pulley.
  20. Install the power steering pump drive belt (C). (Refer to «HYDRAULIC POWER STEERING SYSTEM»(ref-378946) )
  21. Install the air conditioner compressor drive belt (B). (Refer to «COMPRESSOR»(ref-378984-S23871841592010113000000) )
  22. Install the alternator drive belt (A). (Refer to «ALTERNATOR»(ref-378909-S40507630572010113000000) )
  23. Install the RH side cover (A) with bolts (B)
  24. Install the RH front wheel. Tightening torque : 88.3 ~ 107.9N.m (9 ~ 11kgf.m, 65.1 ~ 79.6lb-ft)
  25. Install the engine cover (A) with bolts. Tightening torque : 3.9 ~ 5.9N.m (0.4 ~ 0.6kgf.m, 2.9 ~ 4.3lb-ft)

TROUBLESHOOTING

SymptomSuspect areaRemedy
Engine misfire with abnormal internal lower engine noises.Loose or improperly installed engine flywheel.Repair or replace the flywheel as required.
Worn piston rings. (Oil consumption may or may not cause the engine to misfire.)Inspect the cylinder for a loss of compression. Repair or replace as required.
Worn crankshaft thrust bearings.Replace the crankshaft and bearings as required.
Engine misfire with abnormal valve train noise.Stuck valves. (Carbon buildup on the valve stem can cause the valve not to close properly.)Repair or replace as required.
Excessive worn or mis-aligned timing chain.Replace the timing chain and sprocket as required.
Worn camshaft lobes.Replace the camshaft and valve lifters.
Engine misfire with coolant consumption.Faulty cylinder head gasket and/or cracking or other damage to the cylinder head and engine block cooling system. Coolant consumption may or may not cause the engine to overheat.Inspect the cylinder head and engine block for damage to the coolant passages and/or a faulty head gasket. Repair or replace as required.
Engine misfire with excessive oil consumption.Worn valves, valve guides and/or valve stem oil seals.Repair or replace as required.
Worn piston rings. (Oil consumption may or may not cause the engine to misfire)Inspection the cylinder for a loss of compression. Repair or replace as required.
Engine noise on startup, but only lasting a few seconds.Incorrect oil viscosity.Drain the oil. Install the correct viscosity oil.
Worn crankshaft thrust bearing.Inspect the thrust bearing and crankshaft. Repair or replace as required.
Upper engine noise, regardless of engine speed.Low oil pressure.Repair or replace as required.
Broken valve spring.Replace the valve spring.
Worn or dirty valve lifters.Replace the valve lifters.
Stretched or broken timing chain and/or damaged sprocket teeth.Replace the timing chain and sprockets.
Worn timing chain tensioner, if applicable.Replace the timing chain tensioner as required.
Worn camshaft lobes.Inspect the camshaft lobes. Replace the camshaft and valve lifters as required.
Worn valve guides or valve stems.Inspect the valves and valve guides, then repair as required.
Stuck valves. (Carbon on the valve stem or valve seat may cause the valve to stay open.)Inspect the valves and valve guides, then repair as required.
Lower engine noise, regardless of engine speed.Low oil pressure.Repair or replace damaged components as required.
Loose or damaged flywheel.Repair or replace the flywheel.
Damaged oil pan, contacting the oil pump screen.Inspect the oil pan. Inspect the oil pump screen. Repair or replace as required.
Oil pump screen loose, damaged or restricted.Inspect the oil pump screen. Repair or replace as required.
Excessive piston-to-cylinder bore clearance.Inspect the piston and cylinder bore. Repair as required.
Excessive piston pin-to-bore clearance.Inspect the piston, piston pin and the connecting rod. Repair or replace as required.
Excessive connecting rod bearing clearance.Inspect the following components and repair as required. The connecting rod bearings. The connecting rods. The crankshaft. The crankshaft journal.
Excessive crankshaft bearing clearance.Inspect the following components and repair as required. The crankshaft bearings. The crankshaft journals.
Incorrect piston, piston pin and connecting rod installation.Verify the piston pins and connecting rods are installed correctly. Repair as required.
Engine noise under load.Low oil pressure.Repair or replace as required.
Excessive connecting rod bearing clearance.Inspect the following components and repair as required. The connecting rod bearings. The connecting rods. The crankshaft.
Excessive crankshaft bearing clearance.Inspect the following components and repair as required. The crankshaft bearings. The crankshaft journals. The cylinder block crankshaft bearing bore.
Engine will not crank. (crankshaft will not rotate)Hydraulically locked cylinder. Coolant/antifreeze in cylinder. Oil in cylinder. Fuel in cylinder.Remove spark plugs and check for fluid. Inspect for broken head gasket. Inspect for cracked engine block or cylinder head. Inspect for a sticking fuel injector and/or leaking fuel regulator.
Broken timing chain and/or timing chain gears.Inspect timing chain and gears. Repair as required.
Foreign material in cylinder. Broken valve. Piston material. Foreign material.Inspect cylinder for damaged components and/or foreign materials. Repair or replace as required.
Seized crankshaft or connecting rod bearings.Inspect crankshaft and connecting rod bearing. Repair or replace as required.
Bent or broken connecting rod.Inspect connecting rods. Repair or replace as required.
Broken crankshaft.Inspect crankshaft. Repair or replace as required.

TROUBLESHOOTING CHART

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