REPAIR MAINTENANCE OPERATION OF MOTOR VEHICLES
Kia Rio (2000 release)

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Kia
	Rio
		Instructions
		Engines A3E, A5D
		Greasing system
		Cooling
		Fuel system
		Ignition system
		Coupling
		Transmission
			Manual Transmission
			Automatic transmission F4E-K
				Technical data
				Check of work and adjustment of position of the selector lever
				Testing of teamwork of an automatic transmission and the engine for the motionless car (stall test)
				Testing time delay (Lag test)
				Check the transmission fluid pressure
				Check of level and liquid replacement in an automatic transmission
				The procedure for replacing the liquid in the converter of an automatic transmission
				Leaks of a liquid from an automatic transmission
				Replacement of oil sealing rings
				Removing and installing automatic transmission
				Repair of an automatic transmission
				Radiator cooling automatic transmission fluid
				Valve block
				The case of regulating valves
				Oil pump
				Check the resistance of the sensor, input speed of the turbine wheel
				Check resistance of speed sensor
				Mode switch transmission OD
				Switch range gearbox
				The temperature sensor of an automatic transmission
				Solenoid valves
				The linear solenoid valve
				Lever
				Repair of the selector lever
				Check the mechanism selector lever lock
		Axes and power shafts
		Suspension
		Wheels and tires
		Steering
		Brakes
		Body
		The air conditioning system
		Electrical equipment

Remove the control valve and clean it completely, if the clutch or brake band scorched or worse quality of a liquid in an automatic transmission.

Cleaning

printable version

Repair of an automatic transmission

Automatic transmission

1 - torque converter;
2 - oil pump shaft;
3 - tube level indicator and oil filling;
4 - the gauge of frequency of rotation of the input shaft / turbine wheel;
5 - the switch of a range of transmission;
6 - an arm of a cable of the selector;
7 - an arm;
8 - the crankshaft position sensor;

9 - speed sensor and speedometer drive gear;
10 - inlet pipe;
11 - outlet pipe;
12 - oil pan;
13 - a lining to (replace);
14 - the case of the valve block;
15 - oil pump.

Automatic transmission

1 - a lock ring;
2 - clutch forward / reverse;
3 - Small sun gear and the clutch ?��1;
4 - brake bands 2nd / 4th transfers;
5 - anchor desk and a pin;
6 - a lock ring;
7 - coupling ?��2 and planetary unit;

8 - the holder of the actuator;
9 - piston actuator;
10 - the piston rod;
11 - a lock ring;
12 - internal gear;
13 - clutch 3rd / 4th gear.

Automatic transmission

1 - the turbine shaft;
2 - the output;
3 - a nut;
4 - washer;
5 - a plate;
6 - shaft;
7 - a bolt;

8 - the holder of the lever;
9 - the lever of parking;
10 - the locking lever;
11 - a returnable spring;
12 - bolts;
13 - support of the modulator;
14 - the gearbox housing.

Automatic transmission

1 - differential;
2 - cylindrical pin (replace);
3 - the bearing housing;
4 - an intermediate gear;
5 - output gear;
6 - a cover of the bearing;

7 - outer bearing rings (replace);
8 - shim (substitute);
9 - an oil sealing ring to (replace);
10 - O-rings (replace);
11 - converter housing.

General recommendations

Dismantling of an automatic transmission spend in a place protected from dust, dirt in order to avoid transmission parts.

At dismantling check the condition of details of a transmission for wear and damage.

For the separation of the crankcase, use only plastic hammers.

Do not use rags at transmission dismantling: rags fibers can hammer fluid passages.

Some of the details are similar to each other, therefore at dismantling arrange them in such a way so as not to confuse them.

PERFORMANCE ORDER

1. Before disassembly, clean the outer surface of the transmission a cleaner or solvent.

2. Clear the removed details solvent and dry with compressed air. Clean all the channels and holes with compressed air and check that they have no barriers.

A warning

When cleaning with compressed air parts wear glasses.

Be careful not to spill liquid when removing the torque converter.

Dismantling

PERFORMANCE ORDER

	1. Remove the torque converter housing of the transducer.
	2. Manually remove the oil pump shaft.
3. Remove the dipstick tube and the oil filling.
4. Remove the speed sensor input shaft / turbine.
5. Remove the switch range gearbox.
6. Remove selector cable bracket.
7. Remove the bracket.
8. Remove the crankshaft position sensor.
9. Remove the speed sensor and speedometer drive gear.
10. Remove the inlet pipe.
11. Remove the outlet pipe.
	12. Collect the special adaptation OK130 990 007 with holder OK130 175 011A.
A warning Do not tilt transmission in one direction in the process of dismantling, as it can suddenly tip over and cause injury. Before turning over the gearbox, remove the oil pan. This ensures that all debris and particles remain in the pan.
	13. Remove the nineteen bolts and remove oil pan. Explore all debris and particles are found in the sump, and a magnet to determine the condition of components of a transmission. The presence of wear particles testifies to deterioration of the clutch plate drive or brake bands. Steel particles on the magnet indicate deterioration of the bearings, gears or the drive plate. The presence of aluminum particles indicates wear sleeves or gearbox housing. In the presence of large amounts of foreign substances and particles, replace the torque converter and carefully check each part of the transmission.
14. Remove the clip (one bolt).
	15. Remove the solenoid valves.
16. Remove the three screws and remove the strainer.
	17. Remove the screws A, B and C, and remove the brackets shown in the figure. The length of the bolts (measured from the base of the head): A: 30 mm B: 50 mm C: 14 mm
18. Remove the valve block controls.
19. Remove the shaft and the plate: - Loosen the nuts and pull out the shaft; - Remove the nut, remove the washer and plate.
	20. Remove the bolt and remove the holder lever parking.
	21. Remove the two screws of the parking lever.
	22. Remove the locking lever and return spring.
23. Remove the caliper modulator.
	24. Remove the ten bolts and remove the oil pump.

25. Remove the clutch forward / reverse: - Remove the retaining ring shaft of the turbine wheel; - Lift the assembly clutch forward / reverse lever and remove it from the gear box.
26. Remove small sun gear and the clutch ?��1.
A warning Use a length of wire for attaching a brake tape so that it is not damaged when pulling.
	27. Remove the brake tape 2-4.
	28. Remove the pin, thus support the anchor rack.
	29. Remove the rack anchor.
	30. Remove the servo drive: - Squeeze the servo piston and remove the retaining ring; - Remove the holder of the servo piston and spring.
31. Remove the one-way clutch ?��2 and planetary assembly: - Remove the retaining ring; - Remove the one-way clutch ?��2 with the planetary assembly; - Remove the friction plate.


32. Remove the internal gear: - Remove the retaining ring; - Remove the gear of the outlet housing.

33. Remove the 3-4 clutch: - Remove the sealing ring from the shaft of the turbine side transducer; - Output shaft of the turbine in order to remove the clutch unit 3-4; - Remove the coupling from the turbine shaft 3-4.
	34. Remove the bolts (from the transducer - and eight bolts from the gearbox - seven screws) and remove the gearbox housing by hitting it with a plastic hammer.
	35. Remove the output from the output gear.
	36. Remove the differential.
	37. Remove the bearings: - Round knockout hammer and beat out a cylindrical pin; - Remove the eleven bolts bearing housings; - Remove the bearing by hitting it with a plastic hammer.
	38. Remove the idler gear and the output node, knocking them from the torque converter.
	39. Remove the bearings: - Remove the cover bolts of bearings; - Special adaptation OK130 175 011A remove the transmitter housing; - Squeeze the cover bearing the body of the transducer.
A warning Install previously removed the outer ring of the bearing during reassembly to adjust the bearing preload.

40. Special adaptation OK130 170 012 remove the bearing outer race.

Assembly

A warning

If the plate drive or brake tape is replaced by a new, pre-installation of a new item soak in the liquid for an automatic transmission for at least two hours.

Before assemblage grease liquid for an automatic transmission all oil seals, rotating parts, O-rings and moving parts.

All O-rings, oil seals and gaskets must be replaced.

When reassembling, use petroleum jelly, but do not grease the.

When you need to replace the plug, replace the item (node) contains the same hub.

After applying sealant assembly must be made within 10 minutes and let stand 30 minutes before filling liquid for an automatic transmission.

The outer diameter of the bearing and rolling surfaces

	1	2, 6	3	4	5	7
The diameter of the bearing, mm	86.1	56.1	58.1	86.1	86.1	72.1
The diameter of the rolling surface, mm	88.0	-	-	-	84.0	-

PERFORMANCE ORDER

1. Align the cover bearing the guide bolts and press it as shown in the figure.

The inhaling moment: 10,8-13,7 N ??? m

2. Tapping with a plastic hammer, set assembly intermediate gear and output gear.

3. Install bearing housing:

- Install the bearing housing on the housing converter;
- Align the groove on the intermediate shaft with the mark on the bearing housing;
- A hammer and a thin knockout install cylindrical pin;
- Eleven screw bolts.

Torque: 19-25 N ??? m

4. Set the parking stopper:

- Set the parking stopper and the shaft;
- Establish a spring and a retaining ring.
- Manually move the shaft and make sure the parking stop working.

5. Establish a support modulator and fix new bolts.

Torque: 15-17 N ??? m

6. Set the release lever and return spring.

7. Set the parking lever.

8. Attach the lever and bolt.

The inhaling moment: 7,9-10,7 N ??? m

9. Install the plate and shaft:

- Set the plate washer and nut;
- Tighten the nut torque.

Torque: 42-54 N ??? m

10. Install the differential into the housing of the converter. Establish special adaptation OK201 270 014.

11. Establish a new oil sealing ring on the block output gear.

12. Establish the case of the output to the output gear and install the bearing race in the housing outlet.

The outer diameter of the bearing: 72.1 mm

13. Apply a thin coat of silicone sealant TB-1217B on interfaced surfaces of the converter housing and transmission housing.

14. Install new O-ring on the cover of the inverter.

A warning

Make sure that the sealant will be forced into the channels for lubrication when installing the gearbox.

15. Secure the gearbox housing to the housing of the converter.

Torque: 38-51 N ??? m

16. To support the turbine shaft, set the special adaptation OK201 190 019.

17. Install the turbine shaft and the block of coupling 3-4:

- Assemble the turbine shaft and the block of coupling 3-4;
- Check that the axial bearing is installed properly;
- Install the turbine shaft and the clutch unit 3-4 in the gearbox housing as an assembly.

18. Install the inner gear:

- Establish an internal gear in the housing outlet;
- Install the snap ring.

19. Establish planetary assemblage:

- Check that the axial surface of the bearing and the bearing installed properly;
- With one hand hold the turbine shaft from turning;
- Establish a planetary assembly and 3-4 clutch drum by turning it.

20. Install the brake tape of the lower gears, reverse gear and drive plate.

21. Install the mounting plate.

22. Install the snap ring.

23. Install the friction disk.

24. Install one-way clutch ?��2:

- Keep the one-way clutch ?��2 horizontally;
- Install it, turning the planetary assembly counterclockwise;
- Install the snap ring.

25. Place the rack and the anchor shaft.

A warning

Castle 2-4 brake band and the anchor desk bursting, as shown in the figure.

26. Install the brake band 2-4 in the gearbox so that the tape was completely free.

27. Install the small sun gear and one-way clutch ?��1:

- Check that the axial surface of the bearing and the bearing mounted in the correct position;
- Turning, set small sun gear and one-way clutch ?��1.

28. Install clutch forward / reverse:

- Check that the axial bearing is installed in the correct position;
- Rotating, set the clutch forward / reverse.

A warning

Installation height clutch forward / reverse with respect to the flange of the gearbox is different.

Maximum height: 0.9 mm

29. Install the snap ring in the groove of the turbine shaft.

30. Measure the clearance between the flange and the end of the rolling bearing follows:

- Set the bearing on the clutch forward / reverse;
- Remove the preset rolling surface and a lining;
- Establish the thickest gasket (2.2 mm) on the oil pump;
- Install the oil pump assembly clutch without installing a lining of the oil pump.

A warning

At this point, do not install the lining of the oil pump.

- Measure the clearance A between the gearbox housing and oil pump;
- In accordance with the measured gap select lining of a certain thickness;

A clearance, mm
Strip Thickness, mm
0,091-1,01
12
0,71-0,90
14
0,51-0,70
16
0,31-0,50
18
0,11-0,30
20
0-0,10
2.2

- Remove the oil pump;
- Set the rolling surface of the bearing and a new gasket on the oil pump;
- Establish the oil pump on the gearbox.

Torque: 19-25 N ??? m

31. Check the adjustment of the brake bands 2-4 as follows:

- Set the servo piston in the adaptation OK201 190 021;
- Install the O-ring on the holder with servo adaptation OK201 190 021;
- Lubricate the O-ring fluid for automatic transmissions and install the assembly tapes with servo device in the gearbox housing and secure with snap ring;

A warning

Check that the brake tape 2-4 gear located opposite the piston rod actuator.

- Establish a measuring tip of a dial indicator to the end of the piston rod;

- The compressed air through the fluid supply channel with an air nozzle, sealing rubber and measure the progress bar;

Air pressure: max 392 kPa
Progress bar: 1.0-7.0 mm

- If the progress bar is not correct, select the appropriate rod;

The length of the piston rod in mm: 95.0, 95.5, 96.0, 96.5, 97.0, 97.5, 98.0, 98.5, 99.0

- Remove the tape actuator assembly with the device.

A warning

When removing do not damage the snap ring.

32. Install the actuator on the gearbox housing:

- Install the spring and the servo actuator assembly.
- Install the snap ring.
- Set the brake band 2-4 in the servo piston rod.

33. Align the mechanical valve with the pin on the plate and set the control valve body.

The inhaling moment: 7,9-10,7 N ??? m
The length of the bolts (measured from the base of the head):
A: 30 mm
B: 50 mm
C: 14 mm

34. Connect the solenoid valve and temperature sensor connector fluid in an automatic transmission.

35. Connect the solenoid valve.

A warning

Install the magnets in the oil pan in the areas shown in the figure.

36. Install a new gasket and the oil pallet and fix its nineteen bolts.

The inhaling moment: 8,4-10,7 N ??? m

37. Install the inlet and outlet pipe.

38. Install the speed sensor and the speedometer driven gear.

39. Install the steering angle sensor of the crankshaft.

40. Install the bracket.

41. Set the range of a transmission:

- Manually turn the shaft in position N;
- Set the range of a transmission;
- Tighten the range selector gearbox;

The inhaling moment: 7,9-10,7 N ??? m
- Check that the position of the selector lever and the indicator chosen position coincide.

42. Remove the gearbox with special adaptation 130,990,007 / OK130 175 011A.

43. Establish a new sealing ring and pipe gauge and oil filling.

The inhaling moment: 7,9-10,7 N ??? m

44. Install the speed sensor input shaft / turbine wheel.

The inhaling moment: 7,9-10,7 N ??? m

45. Install the oil pump shaft.

46. Install the O-ring on the shaft of the turbine.

47. Fill the fluid converter automatic transmission.

Type of liquid for an automatic transmission: SK ATF SP-III or DIAMOND ATF SP-III

A warning

When filling liquid keep the unit vertically. Do not pour liquid.

If the converter is not installed easily, do not apply to his great efforts, install carefully.

Do not damage the O-ring of the shaft of the turbine wheel.

48. Install the drive converter housing, turn it to align the grooves.

49. Check the correct installation of the transmitter, measuring the distance A between the end of the converter and the gearbox flange.

Distance A: 13.6 mm

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