Page 1 2004 Kia Spectra 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder 2004 ENGINES 1.8L 4-Cylinder 2004 ENGINES 1.8L 4-Cylinder GENERAL SPECIAL SERVICE TOOLS Fig. 1: Service Tools (1 Of 3) domingo, 7 de febrero de 2021 08:29:49 a. m. domingo, 7 de febrero de 2021 08:29:59 a. m.
Page 2 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Courtesy of KIA MOTORS AMERICA, INC. Fig. 2: Service Tools (2 Of 3) Courtesy of KIA MOTORS AMERICA, INC. domingo, 7 de febrero de 2021 08:29:49 a. m. Page 2 © 2011 Mitchell Repair Information Company, LLC.
Page 3 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 3: Service Tools (3 Of 3) Courtesy of KIA MOTORS AMERICA, INC. TROUBLESHOOTING GUIDE ENGINE domingo, 7 de febrero de 2021 08:29:49 a. m. Page 3 © 2011 Mitchell Repair Information Company, LLC.
Page 4 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 4: Engine Troubleshooting Chart (1 Of 3) Courtesy of KIA MOTORS AMERICA, INC. domingo, 7 de febrero de 2021 08:29:49 a. m. Page 4 © 2011 Mitchell Repair Information Company, LLC.
Page 5 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 5: Engine Troubleshooting Chart (2 Of 3) Courtesy of KIA MOTORS AMERICA, INC. domingo, 7 de febrero de 2021 08:29:49 a. m. Page 5 © 2011 Mitchell Repair Information Company, LLC.
Page 6 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 6: Engine Troubleshooting Chart (3 Of 3) Courtesy of KIA MOTORS AMERICA, INC. TIMING BELT Fig. 7: Timing Belt Troubleshooting Chart domingo, 7 de febrero de 2021 08:29:49 a. m. Page 6...
Page 7: Engine Specifications
2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Courtesy of KIA MOTORS AMERICA, INC. ENGINE SPECIFICATIONS Engine Specifications Chart Item Engine model T8 DOHC Type Gasoline, 4 cycle Cylinder arrangement and number In line, 4 cylinders Combustion chamber Pentroof Valve system...
Page 8 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 8: Disconnecting Battery Cables Courtesy of KIA MOTORS AMERICA, INC. 2. Remove battery and battery tray. 3. Drain engine coolant. domingo, 7 de febrero de 2021 08:29:49 a. m. Page 8 © 2011 Mitchell Repair Information Company, LLC.
Page 9 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 9: Draining Engine Coolant Courtesy of KIA MOTORS AMERICA, INC. 4. Remove data link connector upward from mass airflow sensor bracket. 5. Disconnect intake air temperature sensor connector and mass air flow sensor connector.
Page 10 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 10: Removing Accelerator Cable And Cruise Control Cable If Equipped Courtesy of KIA MOTORS AMERICA, INC. 10. Remove air cleaner assembly. 11. Disconnect brake vacuum hose and purge control vacuum hose from dynamic chamber.
Page 11 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 11: Disconnecting Brake Vacuum Hose And Purge Control Vacuum Hose Courtesy of KIA MOTORS AMERICA, INC. 12. Remove upper and lower radiator hoses. 13. Disconnect fuel hose from fuel injector rail. WARNING: Keep open flames and sparks away from open fuel lines or a fire or explosion may result.
Page 12 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 12: Disconnecting Fuel Hose Courtesy of KIA MOTORS AMERICA, INC. 14. Remove heater hoses. domingo, 7 de febrero de 2021 08:29:49 a. m. Page 12 © 2011 Mitchell Repair Information Company, LLC.
Page 13 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 13: Removing Heater Hoses Courtesy of KIA MOTORS AMERICA, INC. 15. Disconnect IAC and throttle position sensor connectors. domingo, 7 de febrero de 2021 08:29:49 a. m. Page 13 © 2011 Mitchell Repair Information Company, LLC.
Page 14 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 14: Disconnecting IAC And Throttle Position Sensor Connectors Courtesy of KIA MOTORS AMERICA, INC. 16. Disconnect injector connectors. Fig. 15: Disconnecting Injector Connectors Courtesy of KIA MOTORS AMERICA, INC. domingo, 7 de febrero de 2021 08:29:49 a. m.
Page 15 17. Disconnect electric connectors, bracket and reinstall engine hanger. Tightening torque: 27.5~38.3 lb-ft (37.2~51.9 N.m, 3.8~5.3 kg-m) Fig. 16: Disconnecting Electric Connectors Courtesy of KIA MOTORS AMERICA, INC. 18. Disconnect B-terminal connector and S-terminal connector from starter. domingo, 7 de febrero de 2021 08:29:49 a. m.
Page 16 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 17: Disconnecting B-Terminal And S-terminal Connectors From Starter Courtesy of KIA MOTORS AMERICA, INC. 19. Disconnect generator B-terminal connector and connector C121 from generator. domingo, 7 de febrero de 2021 08:29:49 a. m.
Page 17 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 18: Disconnecting Generator B-Terminal And Connector C121 From Generator Courtesy of KIA MOTORS AMERICA, INC. 20. Disconnect engine ground strap. domingo, 7 de febrero de 2021 08:29:49 a. m. Page 17 © 2011 Mitchell Repair Information Company, LLC.
Page 18 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 19: Disconnecting Engine Ground Strap Courtesy of KIA MOTORS AMERICA, INC. 21. Remove RH & LH splash shield. domingo, 7 de febrero de 2021 08:29:49 a. m. Page 18 © 2011 Mitchell Repair Information Company, LLC.
Page 19 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 20: Removing RH & LH Splash Shield Courtesy of KIA MOTORS AMERICA, INC. 22. Remove exhaust manifold heat shield and three P/S pump bracket bolts. domingo, 7 de febrero de 2021 08:29:49 a. m.
Page 20 2004 ENGINES 1.8L 4-Cylinder Fig. 21: Removing Exhaust Manifold Heat Shield And P/S Pump Bracket Bolts Courtesy of KIA MOTORS AMERICA, INC. 23. Remove four A/C compressor bolts and five A/C compressor mounting bracket bolts. domingo, 7 de febrero de 2021 08:29:49 a. m.
Page 21 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 22: Removing A/C Compressor Mounting Bolts Courtesy of KIA MOTORS AMERICA, INC. 24. Disconnect ground strap from top of transaxle. domingo, 7 de febrero de 2021 08:29:49 a. m. Page 21 © 2011 Mitchell Repair Information Company, LLC.
Page 22 2004 ENGINES 1.8L 4-Cylinder Fig. 23: Disconnecting Ground Strap From Top Of Transaxle Courtesy of KIA MOTORS AMERICA, INC. 25. Remove three No. 4 engine mounting nuts and one bolt and remove No. 4 engine mount. 26. Disconnect input/turbine speed sensor connector (A/T).
Page 23 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 24: Disconnecting Input/Turbine Speed Sensor Connector (A/T) Courtesy of KIA MOTORS AMERICA, INC. 27. Disconnect back-up light switch connector (M/T). 28. Disconnect vehicle speed sensor connector. domingo, 7 de febrero de 2021 08:29:49 a. m.
Page 24 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 25: Disconnecting Vehicle Speed Sensor Connector Courtesy of KIA MOTORS AMERICA, INC. 29. Remove U-clip from selector cable to transaxle linkage (A/T). 30. Remove nut and washer from transaxle linkage (A/T). domingo, 7 de febrero de 2021 08:29:49 a. m.
Page 25 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 26: Removing Transaxle Linkage Courtesy of KIA MOTORS AMERICA, INC. 31. Remove manual transaxle linkage and extension bar (M/T). 32. Remove clutch release cylinder and pipe (M/T). domingo, 7 de febrero de 2021 08:29:49 a. m.
Page 26 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 27: Removing Clutch Release Cylinder And Pipe (M/T) Courtesy of KIA MOTORS AMERICA, INC. 33. Disconnect transaxle range switch connector (A/T). 34. Disconnect solenoid valve connector (A/T). 35. Disconnect two ATF cooler hoses (A/T).
Page 27 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 28: Disconnecting Two ATF Cooler Hoses (A/T) Courtesy of KIA MOTORS AMERICA, INC. 36. Remove both front wheels (four lug nuts each). 37. Disconnect front oxygen sensor connector. 38. Remove front exhaust pipe.
Page 28 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 29: Removing Front Exhaust Pipe Courtesy of KIA MOTORS AMERICA, INC. 39. Remove both right and left tie rod ends from steering knuckles by removing one cotter pin and one nut each.
Page 29 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 30: Separating Ball Joints From Control Arm Courtesy of KIA MOTORS AMERICA, INC. 43. Remove joint shaft support bracket from engine block (three bolts). 44. Gently pry both driveshafts from transaxle. domingo, 7 de febrero de 2021 08:29:49 a. m.
Page 30 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 31: Prying Both Driveshafts From Transaxle Courtesy of KIA MOTORS AMERICA, INC. 45. Support engine with engine hoist. domingo, 7 de febrero de 2021 08:29:49 a. m. Page 30 © 2011 Mitchell Repair Information Company, LLC.
Page 31 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 32: Supporting Engine With Engine Hoist Courtesy of KIA MOTORS AMERICA, INC. 46. Remove two nuts from No. 2 engine mount-to-mounting member. domingo, 7 de febrero de 2021 08:29:49 a. m. Page 31...
Page 32 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 33: Removing No. 2 Engine Mount-To-Mounting Member Courtesy of KIA MOTORS AMERICA, INC. 47. Remove one bolt from No. 3 engine mount. 48. Remove three No. 1 engine mount bolts. domingo, 7 de febrero de 2021 08:29:50 a. m.
Page 33: Installation
2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 34: Removing No. 1 Engine Mount Bolts Courtesy of KIA MOTORS AMERICA, INC. 49. Lift engine and transaxle out as a unit. INSTALLATION 1. Install engine and transaxle into engine compartment as a unit.
Page 34 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 35: Installing No. 1 Engine Mount Bolts Courtesy of KIA MOTORS AMERICA, INC. 3. Install No. 3 engine mount bolt. Tightening torque: 62.9~86 lb-ft (85.3~116.6 N.m, 8.7~11.9 kg-m) 4. Install two No. 2 engine mount nuts.
Page 35 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 36: Installing No. 2 Engine Mount Nuts Courtesy of KIA MOTORS AMERICA, INC. 5. Install No. 4 engine mount. domingo, 7 de febrero de 2021 08:29:50 a. m. Page 35 © 2011 Mitchell Repair Information Company, LLC.
Page 36 Nuts: 49~68 lb-ft (68~93 N.m, 6.8~9.5 kg-m) Bolt: 47~66 lb-ft (64~89 N.m, 6.5~9.1 kg-m) Fig. 37: Installing No. 4 Engine Mount Courtesy of KIA MOTORS AMERICA, INC. 6. Remove engine hoist. 7. Install new clips on driveshaft. 8. Push driveshaft and joint shaft into transaxle with opening of clips pointing upward.
Page 37 11. Install both right and left stabilizer control links. Tightening torque: 32~45 lb-ft (43~61 N.m, 4.4~6.2 kg-m) Fig. 38: Installing Both Right And Left Stabilizer Control Links Courtesy of KIA MOTORS AMERICA, INC. 12. Install front exhaust pipe. Tightening torque: A: 29.7~40.5 lb-ft (40.2~54.9 N.m, 4.1~5.6 kg-m)
Page 38 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 39: Installing Front Exhaust Pipe Courtesy of KIA MOTORS AMERICA, INC. 13. Connect two ATF cooler hoses (A/T). domingo, 7 de febrero de 2021 08:29:50 a. m. Page 38 © 2011 Mitchell Repair Information Company, LLC.
Page 39 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 40: Connecting Two ATF Cooler Hoses (A/T) Courtesy of KIA MOTORS AMERICA, INC. 14. Connect solenoid valve connector (A/T). 15. Connect auto transaxle range switch connector (A/T). 16. Install clutch release cylinder and pipe (M/T).
Page 40 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 41: Installing Clutch Release Cylinder And Pipe (M/T) Courtesy of KIA MOTORS AMERICA, INC. 17. Install extension bar and manual transaxle linkage (M/T). Extension bar tightening torque: 23~34 lb-ft (32~47 N.m) Manual transaxle linkage tightening torque: 12~17 lb-ft (16~23 N.m) 18.
Page 41 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 42: Installing Washer And Nut To Auto Transaxle Linkage (A/T) Courtesy of KIA MOTORS AMERICA, INC. 20. Connect back-up light switch connector (M/T). 21. Connect vehicle speed sensor connector (M/T). domingo, 7 de febrero de 2021 08:29:50 a. m.
Page 42 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 43: Connecting Vehicle Speed Sensor Connector (M/T) Courtesy of KIA MOTORS AMERICA, INC. 22. Connect input turbine speed sensor connector. domingo, 7 de febrero de 2021 08:29:50 a. m. Page 42 © 2011 Mitchell Repair Information Company, LLC.
Page 43 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 44: Connecting Input Turbine Speed Sensor Connector Courtesy of KIA MOTORS AMERICA, INC. 23. Connect ground strap to top of transaxle. domingo, 7 de febrero de 2021 08:29:50 a. m. Page 43...
Page 44 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 45: Connecting Ground Strap To Top Of Transaxle Courtesy of KIA MOTORS AMERICA, INC. 24. Install A/C compressor mounting bracket (five bolts) Tightening torque: Mounting bracket: Four (14 mm) bolts: 28~38 lb-ft (38~51 N.m, 3.9~5.2 kg-m) One (12 mm) bolt (oil pump side): 14~18 lb-ft (19~25 N.m, 1.9~25 kg-m)
Page 45 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 46: Installing A/C Compressor Mounting Bracket Courtesy of KIA MOTORS AMERICA, INC. Install three P/S pump bracket bolts. Tightening torque: 28~38 lb-ft (39~52 N.m, 3.9~5.3 kg-m) Install exhaust manifold heat shield. Tightening torque: 13.7~22.4 lb-ft (18.6~30.4 N.m, 1.9~3.1 kg-m) domingo, 7 de febrero de 2021 08:29:50 a.
Page 46 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 47: Installing Exhaust Manifold Heat Shield Courtesy of KIA MOTORS AMERICA, INC. Install RH & LH splash shield. Tightening torque: 10~12 lb-ft (13.5~16 N.m, 1.4~1.6 kg-m) domingo, 7 de febrero de 2021 08:29:50 a. m.
Page 47 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 48: Installing RH & LH Splash Shield Courtesy of KIA MOTORS AMERICA, INC. Install both front wheels. Tightening torque: 65~87 lb-ft (88~118 N.m, 9~12 kg-m) Connect engine ground strap. Tightening torque: A:28~38 lb-ft (38~51 N.m, 3.8~5.3 kg-m) B:5.8~8.7 lb-ft (7.8~11.8 N.m, 0.8~1.2 kg-m)
Page 48 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 49: Connecting Engine Ground Strap Courtesy of KIA MOTORS AMERICA, INC. Connect two generator connectors. (B-terminal connector and C121 to the generator) domingo, 7 de febrero de 2021 08:29:50 a. m. Page 48...
Page 49 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 50: Connecting Two Generator Connectors Courtesy of KIA MOTORS AMERICA, INC. Connect B-terminal and S-terminal connectors to the starter. domingo, 7 de febrero de 2021 08:29:50 a. m. Page 49 © 2011 Mitchell Repair Information Company, LLC.
Page 50 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 51: Connecting B-Terminal And S-Terminal Connectors To The Starter Courtesy of KIA MOTORS AMERICA, INC. Connect IAC and throttle position sensor connectors. domingo, 7 de febrero de 2021 08:29:50 a. m. Page 50...
Page 51 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 52: Connecting IAC And Throttle Position Sensor Connectors Courtesy of KIA MOTORS AMERICA, INC. Install connector bracket and connect electric connectors. Tightening torque: 27.5~38.3 lb-ft (37.2~51.9 N.m, 3.8~5.3 kg-m) domingo, 7 de febrero de 2021 08:29:50 a. m.
Page 52 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 53: Installing Connector Bracket And Connecting Electric Connectors Courtesy of KIA MOTORS AMERICA, INC. Connect injector connectors. domingo, 7 de febrero de 2021 08:29:50 a. m. Page 52 © 2011 Mitchell Repair Information Company, LLC.
Page 53 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 54: Connecting Injector Connectors Courtesy of KIA MOTORS AMERICA, INC. Connect heater hoses. domingo, 7 de febrero de 2021 08:29:50 a. m. Page 53 © 2011 Mitchell Repair Information Company, LLC.
Page 54 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 55: Connecting Heater Hoses Courtesy of KIA MOTORS AMERICA, INC. Connect fuel hose to injector rail. domingo, 7 de febrero de 2021 08:29:50 a. m. Page 54 © 2011 Mitchell Repair Information Company, LLC.
Page 55 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 56: Connecting Fuel Hose To Injector Rail Courtesy of KIA MOTORS AMERICA, INC. Connect upper and lower radiator hoses. domingo, 7 de febrero de 2021 08:29:50 a. m. Page 55 © 2011 Mitchell Repair Information Company, LLC.
Page 56 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 57: Connecting Upper And Lower Radiator Hoses Courtesy of KIA MOTORS AMERICA, INC. Connect brake vacuum hose and purge control vacuum hose to dynamic chamber. domingo, 7 de febrero de 2021 08:29:50 a. m.
Page 57 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 58: Connecting Brake Vacuum Hose And Purge Control Vacuum Hose Courtesy of KIA MOTORS AMERICA, INC. Install air cleaner assembly and connect air intake hose to throttle body. Install fresh air duct.
Page 58 2004 ENGINES 1.8L 4-Cylinder Fig. 59: Installing Air Cleaner Assembly And Connecting Air Intake Hose To Throttle Body Courtesy of KIA MOTORS AMERICA, INC. Install P/S and A/C belt. Turn adjustment screw until correct belt deflection is achieved. Tighten pivot bolt and mounting bolt.
Page 59 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 60: Installing P/S And A/C Belt Courtesy of KIA MOTORS AMERICA, INC. Install battery tray and battery. Tightening torque: 10~12 lb-ft (13.5~16 N.m, 1.4~1.6 kg-m) Fill engine coolant with specified type and amount.
Page 60 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 61: Illustrating Engine-To-Transaxle Disassembly Courtesy of KIA MOTORS AMERICA, INC. 1. Remove No. 2 engine mount. domingo, 7 de febrero de 2021 08:29:50 a. m. Page 60 © 2011 Mitchell Repair Information Company, LLC.
Page 61 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 62: Removing No. 2 Engine Mount Courtesy of KIA MOTORS AMERICA, INC. 2. Remove No. 3 engine mount and bracket. domingo, 7 de febrero de 2021 08:29:50 a. m. Page 61 © 2011 Mitchell Repair Information Company, LLC.
Page 62 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 63: Removing No. 3 Engine Mount And Bracket Courtesy of KIA MOTORS AMERICA, INC. domingo, 7 de febrero de 2021 08:29:50 a. m. Page 62 © 2011 Mitchell Repair Information Company, LLC.
Page 63 4. Remove eight transaxle mounting bolts and separate transaxle from engine. 5. Remove exhaust manifold and coolant bypass pipe. Fig. 64: Removing Exhaust Manifold And Coolant Bypass Pipe Courtesy of KIA MOTORS AMERICA, INC. 6. Install engine to Service Tool. domingo, 7 de febrero de 2021 08:29:50 a. m.
Page 64 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 65: Installing Engine To Service Tool Courtesy of KIA MOTORS AMERICA, INC. 7. Drain engine oil. 8. Remove front and rear engine hangers. 9. Remove generator by loosening adjusting bolt and removing mounting bolts and pivot bolt.
Page 65 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder domingo, 7 de febrero de 2021 08:29:50 a. m. Page 65 © 2011 Mitchell Repair Information Company, LLC.
Page 66 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 66: Removing Intake Manifold Support Bracket Courtesy of KIA MOTORS AMERICA, INC. 11. Remove intake manifold. Fig. 67: Removing Intake Manifold Courtesy of KIA MOTORS AMERICA, INC. 12. For timing belt removal, see TIMING SYSTEM.
Page 67 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 68: Cylinder Head Loosening Sequence Courtesy of KIA MOTORS AMERICA, INC. 14. Remove cylinder head by lifting it off from cylinder block. domingo, 7 de febrero de 2021 08:29:50 a. m. Page 67...
Page 68 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 69: Removing Cylinder Head Courtesy of KIA MOTORS AMERICA, INC. 15. For additional cylinder head removal and disassembly information, see CYLINDER HEAD ASSEMBLY. 16. Remove external engine components. domingo, 7 de febrero de 2021 08:29:50 a. m.
Page 69 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 70: Illustrating External Engine Components Courtesy of KIA MOTORS AMERICA, INC. 17. Install SST or equivalent. (Clutch disc centering tool and ring gear brake) 18. Loosen each bolt one turn at a time, in a crisscross pattern, until spring tension is released then remove clutch cover and disc.
Page 70 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 71: Removing Clutch Cover And Disc Courtesy of KIA MOTORS AMERICA, INC. 19. Remove pilot bearing with SST (Bearing puller) or equivalent if necessary. 20. Hold flywheel with SST (Ring gear brake) or equivalent.
Page 71 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 72: Removing Pilot Bearing Courtesy of KIA MOTORS AMERICA, INC. 21. Remove six bolts to remove flywheel. domingo, 7 de febrero de 2021 08:29:50 a. m. Page 71 © 2011 Mitchell Repair Information Company, LLC.
Page 72 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 73: Removing Flywheel Courtesy of KIA MOTORS AMERICA, INC. 22. Remove oil pan mounting bolts. domingo, 7 de febrero de 2021 08:29:50 a. m. Page 72 © 2011 Mitchell Repair Information Company, LLC.
Page 73 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 74: Removing Oil Pan Mounting Bolts Courtesy of KIA MOTORS AMERICA, INC. 23. Remove oil pan with a screwdriver or suitable tool as shown in figure. See Fig. 75. CAUTION: a. Do not force tools between cylinder block and oil pan as this may damage sealing surface.
Page 74 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 75: Removing Oil Pan With A Screwdriver Or Suitable Tool Courtesy of KIA MOTORS AMERICA, INC. 24. Remove oil strainer. domingo, 7 de febrero de 2021 08:29:50 a. m. Page 74 © 2011 Mitchell Repair Information Company, LLC.
Page 75 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 76: Removing Oil Strainer Courtesy of KIA MOTORS AMERICA, INC. 25. Remove timing belt pulley. domingo, 7 de febrero de 2021 08:29:50 a. m. Page 75 © 2011 Mitchell Repair Information Company, LLC.
Page 76 2004 ENGINES 1.8L 4-Cylinder Fig. 77: Remove Timing Belt Pulley Courtesy of KIA MOTORS AMERICA, INC. 26. Remove oil pump mounting bolt and oil pump. 27. Using a screwdriver covered by a rag, remove oil seal from pump cover side.
Page 77 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 78: Removing Oil Pump Mounting Bolt And Oil Pump Courtesy of KIA MOTORS AMERICA, INC. 28. Remove rear cover. domingo, 7 de febrero de 2021 08:29:50 a. m. Page 77 © 2011 Mitchell Repair Information Company, LLC.
Page 78 2004 ENGINES 1.8L 4-Cylinder Fig. 79: Removing Rear Cover Courtesy of KIA MOTORS AMERICA, INC. 29. Wrap a prying tool with a shop towel and slowly pry out rear oil seal. domingo, 7 de febrero de 2021 08:29:50 a. m.
Page 79 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 80: Prying Out Rear Oil Seal Courtesy of KIA MOTORS AMERICA, INC. 30. Remove water pump. domingo, 7 de febrero de 2021 08:29:50 a. m. Page 79 © 2011 Mitchell Repair Information Company, LLC.
Page 80 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 81: Removing Water Pump Courtesy of KIA MOTORS AMERICA, INC. 31. Remove oil filter and oil pressure switch. domingo, 7 de febrero de 2021 08:29:50 a. m. Page 80 © 2011 Mitchell Repair Information Company, LLC.
Page 81 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 82: Removing Oil Filter And Oil Pressure Switch Courtesy of KIA MOTORS AMERICA, INC. domingo, 7 de febrero de 2021 08:29:50 a. m. Page 81 © 2011 Mitchell Repair Information Company, LLC.
Page 82 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 83: Illustrating Engine Block Components Courtesy of KIA MOTORS AMERICA, INC. 32. Check top of each cylinder for ridges. NOTE: Failure to remove a ridge before removing piston will result in damaged ring-lands, cracked piston rings, or cracked piston.
Page 83 Fig. 84: Removing Cylinder Ridge Courtesy of KIA MOTORS AMERICA, INC. 34. Rotate engine block so that crankshaft is at Top Dead Center (TDC). 35. Rotate crankshaft so that No. 1 and No. 4 cylinders are at Bottom Dead Center (BDC).
Page 84 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder 39. Remove rod caps. NOTE: Cover connecting rod bolts to protect crankshaft journals. 40. Push connecting rod and piston as far up into cylinder as possible. Using a wooden dowel, tap gently on piston to release it from cylinder.
Page 85 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Courtesy of KIA MOTORS AMERICA, INC. 42. Mark tops of pistons with corresponding cylinder numbers they were removed from. 43. Using a piston ring expander, remove piston rings. Fig. 86: Removing Piston Rings Courtesy of KIA MOTORS AMERICA, INC.
Page 86 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 87: Measuring Connecting Rod Movement Courtesy of KIA MOTORS AMERICA, INC. 46. If connecting rod does not move freely, check piston pin bore and connecting rod for straightness and deformation. 47. Remove piston pin clip from ends of piston pin bore.
Page 87 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 88: Removing Connecting Rod From Piston Courtesy of KIA MOTORS AMERICA, INC. 50. Mark main bearing caps (front to back) including direction. NOTE: Each main bearing cap is matched to that particular journal. Installing a cap on wrong journal will cause an align bore problem that will require an expensive machine process to correct.
Page 88: Cylinder Block
2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 89: Main Bearing Cap Bolt Loosening Sequence Courtesy of KIA MOTORS AMERICA, INC. 52. Remove main bearing caps. 53. Grasp crankshaft and lift straight out. 54. Remove main bearings and thrust bearings from cylinder block saddles.
Page 89 Distortion: 0.006 in (0.15 mm) maximum Fig. 90: Checking Distortion Of Cylinder Head Mating Surface Courtesy of KIA MOTORS AMERICA, INC. 3. Repair block deck by surface grinding block, or in extreme cases replace cylinder block. Maximum resurface amount: 0.008 in (0.20 mm) domingo, 7 de febrero de 2021 08:29:51 a.
Page 90 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 91: Measuring Cylinder Block Distortion Courtesy of KIA MOTORS AMERICA, INC. 4. If deck is at or below this specification, replace cylinder block. NOTE: Before surfacing cylinder block, check deck height from center line of crankshaft to deck surface.
Page 91 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 92: Measuring Cylinder Bore With A Dial Bore Gauge Courtesy of KIA MOTORS AMERICA, INC. 6. Take cylinder measurements at top, center and bottom of cylinder to check for cylinder diameter, taper and out-of-round.
Page 92: Connecting Rod
2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 93: Measuring Cylinder Bore Taper Courtesy of KIA MOTORS AMERICA, INC. CONNECTING ROD 1. Check connecting rod bushing inside diameter. Inside diameter: 0.9055~0.9063 in (23.0~23.021 mm ) domingo, 7 de febrero de 2021 08:29:51 a. m.
Page 93 2004 ENGINES 1.8L 4-Cylinder Fig. 94: Measuring Connecting Rod Bushing Inside Diameter Courtesy of KIA MOTORS AMERICA, INC. 2. Subtract piston pin diameter from connecting rod bushing inside diameter to determine piston pin fit. Clearance: 0.0004~0.0010 in (0.010~0.027 mm ) 3.
Page 94 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 95: Checking Connecting Rod Straightness Courtesy of KIA MOTORS AMERICA, INC. 5. Replace connecting rods if necessary. NOTE: Connecting rods must always be replaced as an assembly. Rod cap, rod, bolts and nuts are a matched set.
Page 95 Check main and connecting rod bearings for peeling, scoring and other damage. Fig. 96: Checking Main And Connecting Rod Bearings For Damage Courtesy of KIA MOTORS AMERICA, INC. CRANKSHAFT 1. Check crankshaft bearing and crank pin journals for damage and scoring.
Page 96: Crankshaft Journal Diameter
2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 97: Measuring Crankshaft Run-Out Courtesy of KIA MOTORS AMERICA, INC. 5. Use a micrometer to measure crankshaft main bearing journals and crank pin journals at X and Y direction as shown in figure.
Page 97 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 98: Crankshaft Journal Diameter Chart Courtesy of KIA MOTORS AMERICA, INC. domingo, 7 de febrero de 2021 08:29:51 a. m. Page 97 © 2011 Mitchell Repair Information Company, LLC.
Page 98 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 99: Measuring Crankshaft Journal Diameter Courtesy of KIA MOTORS AMERICA, INC. 6. Grind crankshaft only if there is visible scoring, or if out-of-round is excessive. 7. Only grind crankshaft amount necessary to correct condition.
Page 99: Piston Assemblies
2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 100: Main Journal Diameter Undersize Chart Courtesy of KIA MOTORS AMERICA, INC. CRANK PIN JOURNAL DIAMETER UNDERSIZES: Fig. 101: Crank Pin Journal Diameter Undersize Chart Courtesy of KIA MOTORS AMERICA, INC. PISTON ASSEMBLIES PISTON COOLING JETS domingo, 7 de febrero de 2021 08:29:51 a.
Page 100 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder 1. Apply compressed air to each piston cooling jet valve at (A) and verify that air passes through piston cooling jet valve at (B). If air does not pass, replace piston cooling jet valve.
Page 101 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 102: Checking Piston Cooling Jet Nozzle For Clogs Courtesy of KIA MOTORS AMERICA, INC. PISTON NOTE: Replacing a piston also requires replacing piston rings. domingo, 7 de febrero de 2021 08:29:51 a. m.
Page 102: Piston Diameter
Fig. 103: Checking Circumference Of Piston For Damage, Scoring, Or Unusual Wear Patterns Courtesy of KIA MOTORS AMERICA, INC. 2. Check outside diameter of each piston at a 90° right angle to piston pin, 0.650 in. (16.5 mm) below oil ring land's lower edge.
Page 103 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 104: Piston Diameter Chart Courtesy of KIA MOTORS AMERICA, INC. NOTE: If piston is collapsed or bell mouthed, replace piston. domingo, 7 de febrero de 2021 08:29:51 a. m. Page 103 © 2011 Mitchell Repair Information Company, LLC.
Page 104: Piston Rings
2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 105: Measuring Piston Diameter Courtesy of KIA MOTORS AMERICA, INC. 3. Check piston-to-cylinder wall clearance by subtracting piston diameter from the largest cylinder wall diameter, at each cylinder. Clearance: 0.0015~0.0021 in (0.039~0.053 mm) Maximum: 0.006 in (0.15 mm )
Page 105 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 107: Piston Ring-To-Side Clearance Chart Courtesy of KIA MOTORS AMERICA, INC. domingo, 7 de febrero de 2021 08:29:51 a. m. Page 105 © 2011 Mitchell Repair Information Company, LLC.
Page 106 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 108: Measuring Piston Ring-To-Side Clearance Courtesy of KIA MOTORS AMERICA, INC. 2. If clearance exceeds the maximum, replace piston. 3. Inspect piston rings for damage, abnormal wear, or breakage. 4. Replace piston rings if necessary.
Page 107 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 109: Squaring Piston Ring In Cylinder Courtesy of KIA MOTORS AMERICA, INC. 7. Place a feeler gauge in end gap and check end gap clearance. END GAP CLEARANCE: domingo, 7 de febrero de 2021 08:29:51 a. m.
Page 108 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 110: Piston Ring End Gap Clearance Chart Courtesy of KIA MOTORS AMERICA, INC. domingo, 7 de febrero de 2021 08:29:51 a. m. Page 108 © 2011 Mitchell Repair Information Company, LLC.
Page 109: Piston Pin
2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 111: Measuring Piston Ring End Gap Clearance Courtesy of KIA MOTORS AMERICA, INC. 8. Replace piston ring if necessary. PISTON PIN 1. Measure each piston pin hole diameter at X and Y directions in four locations shown in figure.
Page 110 Diameter: 0.7872~0.7875 in (19.994~20.002 mm) Fig. 112: Measuring Each Piston Pin Hole Diameter Courtesy of KIA MOTORS AMERICA, INC. 2. Measure each piston pin diameter at X and Y direction at four locations shown in figure. Diameter: 0.7869~0.7871 in (19.987~19.993 mm) domingo, 7 de febrero de 2021 08:29:51 a.
Page 111 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 113: Measuring Piston Pin Diameter Courtesy of KIA MOTORS AMERICA, INC. 3. Subtract piston pin diameter from pin hole diameter to determine piston pin to piston clearance. Clearance: 0.00004~0.00006 in (0.001~0.015 mm) 4.
Page 112 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 114: Illustrating Engine Block Components Courtesy of KIA MOTORS AMERICA, INC. 1. Clean all parts before assembly. 2. Apply a coat of clean engine oil to all sliding and rotating parts before assembly.
Page 113 Verify that piston and rod are assembled in same direction as they were prior to disassembly. Fig. 115: Installing Connecting Rod Onto Piston Courtesy of KIA MOTORS AMERICA, INC. 6. Install second piston pin clip into clip grooves on opposite side of piston. domingo, 7 de febrero de 2021 08:29:51 a. m.
Page 114 2004 ENGINES 1.8L 4-Cylinder Fig. 116: Install Piston Pin Clip Courtesy of KIA MOTORS AMERICA, INC. 7. Hold piston upright and move connecting rod back and forth. Check that rod moves freely. 8. Install three piece oil ring onto piston.
Page 115 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 117: Installing Lower Oil Ring Onto Piston Courtesy of KIA MOTORS AMERICA, INC. 9. Check that oil ring expander separates upper and lower oil rings, and that oil ring assembly spins freely on piston.
Page 116 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 118: Illustrating Oil Ring Position Courtesy of KIA MOTORS AMERICA, INC. 10. Use a ring expander and install second ring. 11. Use a ring expander and install top ring. NOTE: Top ring and second ring should be installed with "R" mark facing up.
Page 117 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 119: Illustrating Top & Second Ring Position Courtesy of KIA MOTORS AMERICA, INC. 12. Align piston ring gaps as shown in figure. domingo, 7 de febrero de 2021 08:29:51 a. m. Page 117...
Page 118 2004 ENGINES 1.8L 4-Cylinder Fig. 120: Positioning Piston Ring Gaps Courtesy of KIA MOTORS AMERICA, INC. 13. Inspect journals and bearings for any foreign material. Clean crankshaft, oil holes and main bearing journals thoroughly, and dry components with compressed air.
Page 119 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 121: Installing Thrust Bearings Courtesy of KIA MOTORS AMERICA, INC. 16. Set crankshaft on installed bearings. 17. Install remaining main bearings into main bearing caps. 18. Position Plastigage on crankshaft journals. domingo, 7 de febrero de 2021 08:29:51 a. m.
Page 120 2004 ENGINES 1.8L 4-Cylinder Fig. 122: Positioning Plastigage On Crankshaft Journals Courtesy of KIA MOTORS AMERICA, INC. 19. Install main bearing caps along with lower main bearings according to cap number and mark. 20. Tighten main bearing cap bolts according to the following procedure: a.
Page 121 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 123: Main Bearing Cap Bolt Tightening Sequence Courtesy of KIA MOTORS AMERICA, INC. 21. Remove main bearing caps and check bearing clearance. NOTE: The widest point of Plastigage™ is the smallest clearance, and the narrowest point of Plastigage is the largest clearance.
Page 122 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 124: Measuring Main Bearing Clearance Courtesy of KIA MOTORS AMERICA, INC. 23. Lift crankshaft out of cylinder block and carefully remove Plastigage from main bearings and crankshaft journals. 24. Apply a light coat of engine oil on main bearings and install crankshaft by gently lowering it onto bearings.
Page 123 Rotate bolts another 60°(1/6 Turn) in order shown. Fig. 125: Main Bearing Cap Bolt Tightening Sequence Courtesy of KIA MOTORS AMERICA, INC. 28. Rotate crankshaft to ensure it does not bind. 29. Place a dial indicator against front of crankshaft and zero gauge.
Page 124 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 126: Measuring Crankshaft End Play Courtesy of KIA MOTORS AMERICA, INC. 32. If end play exceeds specification, grind crankshaft and install oversized thrust bearings, or replace crankshaft and thrust bearings. THRUST BEARING WIDTH domingo, 7 de febrero de 2021 08:29:51 a.
Page 125 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 127: Measuring Thrust Bearing Width Courtesy of KIA MOTORS AMERICA, INC. domingo, 7 de febrero de 2021 08:29:51 a. m. Page 125 © 2011 Mitchell Repair Information Company, LLC.
Page 126 2004 ENGINES 1.8L 4-Cylinder Fig. 128: Thrust Bearing Width Specification Chart Courtesy of KIA MOTORS AMERICA, INC. 33. Install a bearing into connecting rod. 34. Place rubber sleeves (rubber fuel line works well) on connecting rod bolts to protect crankshaft from damage.
Page 127 2004 ENGINES 1.8L 4-Cylinder Fig. 129: Illustrating Connecting Rod Bolt Protective Sleeves Courtesy of KIA MOTORS AMERICA, INC. 35. Check piston rings for correct end gap stagger. 36. Place piston (cylinder number one) with"F"mark facing front of engine block, then slip piston and connecting rod assembly into a piston ring compressor.
Page 128 2004 ENGINES 1.8L 4-Cylinder Fig. 130: Installing Piston And Connecting Rod Assembly Courtesy of KIA MOTORS AMERICA, INC. 39. Using butt end of a hammer, tap the top of piston into cylinder and continue tapping until connecting rod makes contact with crankshaft.
Page 129 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 131: Identifying Connecting Rod Mating Marks Courtesy of KIA MOTORS AMERICA, INC. 43. Loosen and remove connecting rod caps. 44. Check the connecting rod bearing clearance. Oil clearance: 0.0008-0.0019 in (0.020-0.05 mm) Maximum : 0.004 in (0.10 mm)
Page 130 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 132: Measuring Connecting Rod Bearing Clearance Courtesy of KIA MOTORS AMERICA, INC. 45. If oil clearance exceeds maximum oil clearance specification, grind the crankshaft and use undersized connecting rod bearings. 46. Apply a coat of clean engine oil to connecting rod bearing in connecting rod cap.
Page 131 2004 ENGINES 1.8L 4-Cylinder Fig. 133: Identifying Connecting Rod Side Clearance Measuring Location Courtesy of KIA MOTORS AMERICA, INC. 49. If side clearance exceeds maximum side clearance specification, replace connecting rod and cap. domingo, 7 de febrero de 2021 08:29:51 a. m.
Page 132 2004 ENGINES 1.8L 4-Cylinder Fig. 134: Identifying Engine Block External Components Courtesy of KIA MOTORS AMERICA, INC. 50. Apply a light coat of clean engine oil to rear oil seal. 51. Install rear oil seal into rear cover by hand.
Page 133 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 135: Installing Oil Seal Into Rear Cover Courtesy of KIA MOTORS AMERICA, INC. 53. Apply a coat of silicone sealer to rear cover. Thickness: 0.08 in (2 mm) 54. Install the rear cover.
Page 134 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 136: Removing Any Protruding Sealant Courtesy of KIA MOTORS AMERICA, INC. 56. Apply clean engine oil to new front oil seal and oil pump body. 57. Install front oil seal by hand.
Page 135 2004 ENGINES 1.8L 4-Cylinder Fig. 137: Installing Oil Seal Into Oil Pump Body Courtesy of KIA MOTORS AMERICA, INC. 59. Install a new O-ring seal. 60. Apply a bead of silicone sealant to oil pump body as shown in figure.
Page 136 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 138: Applying Silicone Sealant Courtesy of KIA MOTORS AMERICA, INC. 61. Install oil pump with six bolts. Tightening torque: 14-19 lb-ft (19-26 N.m, 1.9-2.6 kg-m) 62. Remove any sealant that protrudes from oil pump onto oil pan mounting surface.
Page 137 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 139: Installing Water Pump Courtesy of KIA MOTORS AMERICA, INC. 65. Install oil pressure switch. Tightening torque: 8.7-13.7 lb-ft (11.7-17.6 N.m, 1.2-1.8 kg-m) 66. Apply a small amount of engine oil to rubber seal of oil filter.
Page 138 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 140: Installing Oil Pressure Switch And Oil Filter Courtesy of KIA MOTORS AMERICA, INC. 68. Install oil strainer with a new gasket. Tightening torque: 5.8-8.7 lb-ft (7.8-11.8 N.m, 0.8-1.2 kg-m) domingo, 7 de febrero de 2021 08:29:51 a. m.
Page 139 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 141: Installing Oil Strainer Courtesy of KIA MOTORS AMERICA, INC. 69. Remove all foreign material from gasket surface. 70. Apply a continuous bead of silicone sealant to oil pan contact surfaces. NOTE: Install oil pan within five minutes of applying silicone sealer.
Page 140 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 142: Applying Silicone Sealant To Oil Pan Courtesy of KIA MOTORS AMERICA, INC. 71. Install oil pan and tighten oil pan bolts. Tightening torque: 5.8-8.0 lb-ft (7.8-10.8 N.m, 0.8-1.1 kg-m) domingo, 7 de febrero de 2021 08:29:51 a. m.
Page 141 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 143: Identifying Oil Pan Bolt Positions Courtesy of KIA MOTORS AMERICA, INC. 72. Clean thread sealant from flywheel bolts and bolt holes in crankshaft. NOTE: If thread sealant cannot be removed from bolt, replace flywheel bolt. If you are using new flywheel bolts, do not apply sealant: new bolts have sealant already applied to threads.
Page 142 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 144: Applying Sealant To Flywheel Bolts Courtesy of KIA MOTORS AMERICA, INC. 73. Install separator plate onto cylinder block. Tightening torque: 13.7-22.4 lb-ft (18.6-30.4 N.m, 1.9-3.1 kg-m) 74. Install flywheel (M/T) or drive plate/backing plate/adapter (A/T) assembly onto crankshaft.
Page 143 Tightening torque: 71-75.9 lb-ft (97-103 N.m, 9.8-10.5 kg-m) Fig. 145: Flywheel (M/T) Or Drive Plate/Backing Plate/Adapter (A/T) Bolt Tightening Sequence Courtesy of KIA MOTORS AMERICA, INC. 78. Install clutch disc and clutch cover (M/T). 79. Center the clutch disc with SST or equivalent and torque clutch cover bolts to specification (M/T).
Page 144 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 146: Installing Clutch Disc And Clutch Cover Courtesy of KIA MOTORS AMERICA, INC. 80. Remove locking tool. 81. Remove all foreign material from contact surface of cylinder head and cylinder block. 82. Place cylinder head gasket onto cylinder block and lower cylinder head onto cylinder block.
Page 145 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 147: Installing Cylinder Head Gasket Courtesy of KIA MOTORS AMERICA, INC. 83. For additional cylinder head installation information, see CYLINDER HEAD ASSEMBLY. 84. Install cylinder head bolts. 85. Tighten cylinder head bolts according to following procedure: a.
Page 146 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 148: Cylinder Head Bolt Tightening Sequence Courtesy of KIA MOTORS AMERICA, INC. 86. Install HLA's. See HYDRAULIC LASH ADJUSTER (HLA). 87. For camshaft sprocket and timing belt information, see TIMING SYSTEM. 88. Install new intake manifold gasket.
Page 147 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder domingo, 7 de febrero de 2021 08:29:52 a. m. Page 147 © 2011 Mitchell Repair Information Company, LLC.
Page 148 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 149: Installing Intake Manifold Bracket Courtesy of KIA MOTORS AMERICA, INC. 91. Install generator and generator mounting bolts and adjusting bolt. 92. Install generator belt and adjust it to specification. Generator drive belt deflection New: 0.31-0.35 in (8-9 mm)
Page 149 A: 28.2~34 lb-ft (38.2-46.1 N.m, 3.9-4.7 kg-m) B: 15.9~21 lb-ft (21.6-28.4 N.m, 2.2-2.9 kg-m) Fig. 151: Installing Exhaust Manifold Nuts Courtesy of KIA MOTORS AMERICA, INC. 97. Install No. 3 engine mount and bracket. Tightening torque: 54.1-75.9 lb-ft (73.5-102.9 N.m, 7.5-10.5 kg-m) domingo, 7 de febrero de 2021 08:29:52 a.
Page 150 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 152: Installing No. 3 Engine Mount And Bracket Courtesy of KIA MOTORS AMERICA, INC. domingo, 7 de febrero de 2021 08:29:52 a. m. Page 150 © 2011 Mitchell Repair Information Company, LLC.
Page 151 4 upper bolts (1,2,3,4): 65.8-86.1 lb-ft (89-116 N.m, 9.1-11.9 kg-m) 4 lower bolts (5,6,7,8): 27.5-38.3 lb-ft (37-52 N.m, 3.8-5.3 kg-m) Fig. 153: Installing Transaxle Mounting Bolts Courtesy of KIA MOTORS AMERICA, INC. 100. Install starter. Tightening torque: 27-38 lb-ft (37-52 N.m, 3.7~5.8 kg-m) domingo, 7 de febrero de 2021 08:29:52 a.
Page 152: Cylinder Head Removal & Installation
REMOVAL 1. Disconnect negative battery cable. Fig. 154: Disconnecting Negative Battery Cable Courtesy of KIA MOTORS AMERICA, INC. 2. Relieve fuel system pressure. See FUEL DELIVERY SYSTEM . 3. Drain engine coolant. domingo, 7 de febrero de 2021 08:29:52 a. m.
Page 153 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 155: Identifying Radiator Drain Plug Courtesy of KIA MOTORS AMERICA, INC. 4. Drain engine oil. domingo, 7 de febrero de 2021 08:29:52 a. m. Page 153 © 2011 Mitchell Repair Information Company, LLC.
Page 154 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 156: Identifying Engine Oil Drain Plug Courtesy of KIA MOTORS AMERICA, INC. 5. Remove PCV hose and ventilation hose. 6. Remove accelerator cable and auto cruise control cable if equipped. domingo, 7 de febrero de 2021 08:29:52 a. m.
Page 155 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 157: Removing Accelerator And Cruise Control Cable Courtesy of KIA MOTORS AMERICA, INC. 7. Remove air intake hose and fresh air duct. domingo, 7 de febrero de 2021 08:29:52 a. m. Page 155...
Page 156 2004 ENGINES 1.8L 4-Cylinder Fig. 158: Removing Air Intake Hose And Fresh Air Duct Courtesy of KIA MOTORS AMERICA, INC. 8. Disconnect brake vacuum hose and purge control vacuum hose at dynamic chamber. domingo, 7 de febrero de 2021 08:29:52 a. m.
Page 157 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 159: Disconnecting Brake Vacuum And Purge Control Vacuum Hose Courtesy of KIA MOTORS AMERICA, INC. 9. Remove upper radiator hose. domingo, 7 de febrero de 2021 08:29:52 a. m. Page 157 © 2011 Mitchell Repair Information Company, LLC.
Page 158 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 160: Removing Upper Radiator Hose Courtesy of KIA MOTORS AMERICA, INC. 10. Disconnect fuel hose from injector rail. WARNING: Keep open flames and sparks away from open fuel lines or a fire or explosion may result.
Page 159 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 161: Disconnecting Fuel Hose From Injector Rail Courtesy of KIA MOTORS AMERICA, INC. 11. Remove heater hoses. domingo, 7 de febrero de 2021 08:29:52 a. m. Page 159 © 2011 Mitchell Repair Information Company, LLC.
Page 160 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 162: Removing Heater Hoses Courtesy of KIA MOTORS AMERICA, INC. 12. Disconnect IAC and throttle position sensor connectors. domingo, 7 de febrero de 2021 08:29:52 a. m. Page 160 © 2011 Mitchell Repair Information Company, LLC.
Page 161 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 163: Disconnecting IAC And Throttle Position Sensor Connectors Courtesy of KIA MOTORS AMERICA, INC. 13. Disconnect injector connectors. Fig. 164: Disconnecting Injector Connectors Courtesy of KIA MOTORS AMERICA, INC. domingo, 7 de febrero de 2021 08:29:52 a. m.
Page 162 14. Disconnect electrical connectors, remove bracket and reinstall engine hanger. Tightening torque: 27.5~38.3 lb.ft (37.2~51.9 N.m, 3.8~5.3 kg.m) Fig. 165: Disconnecting Electrical Connectors, Removing Bracket And Reinstalling Engine Hanger Courtesy of KIA MOTORS AMERICA, INC. 15. Disconnect ground strap. domingo, 7 de febrero de 2021 08:29:52 a. m.
Page 163 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 166: Disconnecting Ground Strap Courtesy of KIA MOTORS AMERICA, INC. 16. Remove exhaust manifold heat shield. domingo, 7 de febrero de 2021 08:29:52 a. m. Page 163 © 2011 Mitchell Repair Information Company, LLC.
Page 164 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 167: Removing Exhaust Manifold Heat Shield Courtesy of KIA MOTORS AMERICA, INC. 17. Remove exhaust manifold pipe. domingo, 7 de febrero de 2021 08:29:52 a. m. Page 164 © 2011 Mitchell Repair Information Company, LLC.
Page 165 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 168: Removing Exhaust Manifold Pipe Courtesy of KIA MOTORS AMERICA, INC. 18. Remove coolant bypass pipe. domingo, 7 de febrero de 2021 08:29:52 a. m. Page 165 © 2011 Mitchell Repair Information Company, LLC.
Page 166 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 169: Removing Coolant Bypass Pipe Courtesy of KIA MOTORS AMERICA, INC. 19. Remove intake manifold support bracket. domingo, 7 de febrero de 2021 08:29:52 a. m. Page 166 © 2011 Mitchell Repair Information Company, LLC.
Page 167 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder domingo, 7 de febrero de 2021 08:29:52 a. m. Page 167 © 2011 Mitchell Repair Information Company, LLC.
Page 168: Installation
2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 170: Removing Intake Manifold Support Bracket Courtesy of KIA MOTORS AMERICA, INC. 20. For camshaft and HLA removal procedure, see HYDRAULIC LASH ADJUSTER (HLA). 21. For timing belt removal procedure, see TIMING SYSTEM.
Page 169 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 172: Installing New Cylinder Head Gasket Courtesy of KIA MOTORS AMERICA, INC. 2. Install cylinder head bolts. 3. Tighten cylinder head bolts according to following procedure: a. Tighten cylinder head bolts in order shown in figure. See Fig. 173.
Page 170 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 173: Cylinder Head Bolt Tightening Sequence Courtesy of KIA MOTORS AMERICA, INC. 4. For timing belt installation procedure, see TIMING SYSTEM. 5. For camshaft and HLA installation procedure, see HYDRAULIC LASH ADJUSTER (HLA).
Page 171 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder domingo, 7 de febrero de 2021 08:29:52 a. m. Page 171 © 2011 Mitchell Repair Information Company, LLC.
Page 172 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 174: Installing Intake Manifold Support Bracket Courtesy of KIA MOTORS AMERICA, INC. 7. Install coolant bypass pipe Tightening torque: 65.8~86 lb.ft (89.2~116.6 N.m, 9.1~11.9 kg.m) Fig. 175: Installing Coolant Bypass Pipe Courtesy of KIA MOTORS AMERICA, INC.
Page 173 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 176: Identifying Exhaust Manifold Nut Position Courtesy of KIA MOTORS AMERICA, INC. 9. Install exhaust manifold heat shield. Tightening torque: 13.7~22.4 lb.ft (18.6~30.3 N.m, 1.9~3.1 kg.m) domingo, 7 de febrero de 2021 08:29:52 a. m.
Page 174 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 177: Installing Exhaust Manifold Heat Shield Courtesy of KIA MOTORS AMERICA, INC. 10. Reconnect ground strap. domingo, 7 de febrero de 2021 08:29:52 a. m. Page 174 © 2011 Mitchell Repair Information Company, LLC.
Page 175 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 178: Reconnecting Ground Strap Courtesy of KIA MOTORS AMERICA, INC. 11. Install connector bracket and reconnect electrical connectors. Tightening torque (engine hanger bolt): 27.5~38.3 lb.ft (37.2~51.9 N.m, 3.8~5.3 kg.m) domingo, 7 de febrero de 2021 08:29:52 a. m.
Page 176 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 179: Installing Connector Bracket And Reconnecting Electrical Connectors Courtesy of KIA MOTORS AMERICA, INC. 12. Connect injector connectors. domingo, 7 de febrero de 2021 08:29:52 a. m. Page 176 © 2011 Mitchell Repair Information Company, LLC.
Page 177 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 180: Connecting Injector Connectors Courtesy of KIA MOTORS AMERICA, INC. 13. Connect IAC and throttle position sensor connectors. Fig. 181: Connecting IAC And Throttle Position Sensor Connectors Courtesy of KIA MOTORS AMERICA, INC.
Page 178 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder 14. Install heater hoses. Fig. 182: Installing Heater Hoses Courtesy of KIA MOTORS AMERICA, INC. 15. Connect fuel hose to fuel injector rail. domingo, 7 de febrero de 2021 08:29:52 a. m. Page 178...
Page 179 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 183: Connecting Fuel Hose To Fuel Injector Rail Courtesy of KIA MOTORS AMERICA, INC. 16. Install upper radiator hose. domingo, 7 de febrero de 2021 08:29:52 a. m. Page 179 © 2011 Mitchell Repair Information Company, LLC.
Page 180 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 184: Installing Upper Radiator Hose Courtesy of KIA MOTORS AMERICA, INC. 17. Connect brake vacuum hose and purge control vacuum hose. domingo, 7 de febrero de 2021 08:29:52 a. m. Page 180...
Page 181 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 185: Connecting Brake And Purge Control Vacuum Hoses Courtesy of KIA MOTORS AMERICA, INC. 18. Install air intake hose and fresh air duct. domingo, 7 de febrero de 2021 08:29:52 a. m.
Page 182 2004 ENGINES 1.8L 4-Cylinder Fig. 186: Installing Air Intake Hose And Fresh Air Duct Courtesy of KIA MOTORS AMERICA, INC. 19. Install accelerator cable and check cable deflection. If deflection is not correct, adjust by turning nut "A". Deflection: 0.04~0.12 in (1~3 mm) domingo, 7 de febrero de 2021 08:29:52 a.
Page 183 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 187: Installing Accelerator Cable Courtesy of KIA MOTORS AMERICA, INC. 20. Install cruise control cable if equipped. 21. Install PCV hose and ventilation hose. domingo, 7 de febrero de 2021 08:29:52 a. m.
Page 184 2004 ENGINES 1.8L 4-Cylinder Fig. 188: Installing PCV And Ventilation Hoses Courtesy of KIA MOTORS AMERICA, INC. 22. Fill engine with specified amount and type of engine oil. (Refer to LUBRICATION SYSTEM). 23. Fill engine with specified amount and type of coolant. (Refer to COOLING SYSTEM).
Page 185 2004 ENGINES 1.8L 4-Cylinder Fig. 189: Connecting Negative Battery Cable Courtesy of KIA MOTORS AMERICA, INC. 25. Start engine and check for oil and coolant leaks and HLA noise. 26. Operate engine until cooling fans cycle and check ignition timing (Refer to Ignition system).
Page 186 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 190: Removing Valve Spring From Cylinder Head Courtesy of KIA MOTORS AMERICA, INC. 4. Remove valve seals with SST or equivalent. domingo, 7 de febrero de 2021 08:29:52 a. m. Page 186...
Page 187: Cylinder Head
2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 191: Removing Valve Seals Courtesy of KIA MOTORS AMERICA, INC. 5. Repeat same procedure on all 16 valves. 6. Keep valves in correct order if they are to be reused. 7. Mark cylinder so that valves can be installed to their original positions.
Page 188 Distortion: 0.004 in (0.10 mm) Maximum Fig. 192: Measuring Cylinder Head Straightness Courtesy of KIA MOTORS AMERICA, INC. 4. If distortion exceeds specification, resurface or replace cylinder head. Only remove the amount of material required to achieve a flat surface.
Page 189 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 193: Checking Cylinder Head Height Courtesy of KIA MOTORS AMERICA, INC. 6. If cylinder head height is not within specification, replace cylinder head. NOTE: If cylinder head requires machining, remove intake and exhaust manifolds and check their mounting surfaces for straightness.
Page 190 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 194: Measuring Intake And Exhaust Manifold Mating Surface Distortion Courtesy of KIA MOTORS AMERICA, INC. 8. If distortion exceeds specification, resurface or replace cylinder head. Maximum material removal: 0.008 in (0.20 mm) 9.
Page 191 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 195: Checking Cylinder Block For Distortion Courtesy of KIA MOTORS AMERICA, INC. 10. If distortion exceeds specification, resurface block deck. Maximum material removal: 0.008 in (0.20 mm) CAMSHAFT 1. Set front and rear camshaft bearing journals on V-blocks.
Page 192 2004 ENGINES 1.8L 4-Cylinder Fig. 196: Measuring Camshaft Runout Courtesy of KIA MOTORS AMERICA, INC. 4. Check camshaft for uneven wear patterns, cracks, or damage. 5. Measure cam lobe heights at two points as shown in figure. See Fig. 197.
Page 193 2004 ENGINES 1.8L 4-Cylinder Fig. 197: Measuring Camshaft Lobe Height Courtesy of KIA MOTORS AMERICA, INC. 6. Check camshaft bearing journal diameter (X and Y directions) on both sides (A and B) of journal as shown in figure. See Fig. 198.
Page 194 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 198: Measuring Camshaft Bearing Journal Diameter Courtesy of KIA MOTORS AMERICA, INC. 7. Replace camshafts if necessary. 8. Measure camshaft journal oil clearance with HLAs removed. 9. Remove all foreign material and oil from journals and bearing surfaces.
Page 195 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 199: Camshaft Bearing Cap Bolt Tightening Sequence Courtesy of KIA MOTORS AMERICA, INC. 15. Loosen camshaft cap bolts in five or six steps in order shown in figure. 16. Remove camshaft caps.
Page 196 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 200: Camshaft Bearing Cap Removal Sequence Courtesy of KIA MOTORS AMERICA, INC. 17. Measure oil clearances. Oil clearance: 0.0014~0.0031 in (0.035~0.081 mm) Maximum: 0.006 in (0.15 mm) 18. If oil clearance exceeds specification, replace cylinder head.
Page 197 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 201: Measuring Camshaft Bearing Oil Clearance Courtesy of KIA MOTORS AMERICA, INC. 19. Install camshafts. 20. Place a dial indicator against end of camshaft. 21. Using a prying tool, move camshaft as far forward as possible.
Page 198: Valve Mechanism
2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 202: Measuring Camshaft End Play Courtesy of KIA MOTORS AMERICA, INC. VALVES VALVE MECHANISM 1. Inspect each valve for following: a. Damaged or bent valve stem b. Rough or damaged face c. Damaged or unevenly worn stem tip 2.
Page 199 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 203: Measuring Valve Margin Courtesy of KIA MOTORS AMERICA, INC. 3. Measure length of each valve. Length Intake: 4.052 in (102,92 mm) Exhaust: 3.993 in (101.42 mm) domingo, 7 de febrero de 2021 08:29:53 a. m.
Page 200 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 204: Measuring Valve Length Courtesy of KIA MOTORS AMERICA, INC. 4. Measure diameter of each valve stem. domingo, 7 de febrero de 2021 08:29:53 a. m. Page 200 © 2011 Mitchell Repair Information Company, LLC.
Page 201 Intake:0.2350~0.2356 in (5.970-5.985 mm) Exhaust: 0.2348-0.2354 in (5.965-5.980 mm) Fig. 205: Measuring Valve Diameter Courtesy of KIA MOTORS AMERICA, INC. 5. Measure inside diameter of each valve guide at points shown in figure. Diameter intake and exhaust valve guide: 0.2367-0.2374 in (6.01-6.03 mm) domingo, 7 de febrero de 2021 08:29:53 a.
Page 202 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 206: Measuring Valve Guide Inside Diameter Courtesy of KIA MOTORS AMERICA, INC. 6. Calculate valve stem-to-valve guide clearance. Subtract outer diameter of valve stem from inside diameter of respective valve guide. Clearance>...
Page 203 2004 ENGINES 1.8L 4-Cylinder Fig. 207: Calculating Valve Stem-To-Valve Guide Clearance Courtesy of KIA MOTORS AMERICA, INC. 7. If clearance exceeds specification, replace valve, and/or valve guide. 8. Measure protrusion height of each valve guide. Replace valve guide as needed.
Page 204 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 208: Measuring Valve Guide Protrusion Height Courtesy of KIA MOTORS AMERICA, INC. NOTE: Intake and exhaust valve guides are different. Be sure to use correct valve guide. domingo, 7 de febrero de 2021 08:29:53 a. m.
Page 205: Valve Seat
2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 209: Identifying Proper Valve Guides Courtesy of KIA MOTORS AMERICA, INC. VALVE SEAT domingo, 7 de febrero de 2021 08:29:53 a. m. Page 205 © 2011 Mitchell Repair Information Company, LLC.
Page 206 Cracks Fig. 210: Inspecting Valve Seat And Face Surface Courtesy of KIA MOTORS AMERICA, INC. 2. Resurface valve seats with a 45° valve seat cutter. Resurface valve faces as needed. domingo, 7 de febrero de 2021 08:29:53 a. m.
Page 207 2004 ENGINES 1.8L 4-Cylinder Fig. 211: Resurfacing Valve Seats Courtesy of KIA MOTORS AMERICA, INC. 3. Apply a coat of Dychem blue to valve face and valve seat and allow to dry. 4. Inspect valve seating by pressing valve against seat and rotating valve 360°.
Page 208 2004 ENGINES 1.8L 4-Cylinder Fig. 212: Measuring Seat Contact Width Courtesy of KIA MOTORS AMERICA, INC. 6. Check that valve seat contact area is at center of valve face. a. If valve seating position is too high, correct valve seat with a 63° valve seat cutter, and a 45° cutter.
Page 209 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 213: Checking Valve Seat Contact Area Courtesy of KIA MOTORS AMERICA, INC. 7. Complete seat-cutting process by lapping valve to seat using valve-lapping compound. 8. Inspect valve seat for sinking. NOTE: Clean valves thoroughly before reassembly, and insure that all traces of lapping compound have been removed.
Page 210 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 214: Measuring Valve Seat Position Courtesy of KIA MOTORS AMERICA, INC. 9. Check for valve sink by measuring protruding length (Dimension L) of valve stem to lower valve spring seat. domingo, 7 de febrero de 2021 08:29:53 a. m.
Page 211 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 215: Valve Sink Dimension Chart Courtesy of KIA MOTORS AMERICA, INC. domingo, 7 de febrero de 2021 08:29:53 a. m. Page 211 © 2011 Mitchell Repair Information Company, LLC.
Page 212: Valve Spring
2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 216: Measuring For Valve Sink Courtesy of KIA MOTORS AMERICA, INC. VALVE SPRING 1. Inspect each valve spring for cracks and damage. 2. Measure free length and out-of-square. Replace valve springs as needed.
Page 213 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 217: Measuring Valve Spring Free Length And Out-Of-Square Courtesy of KIA MOTORS AMERICA, INC. REASSEMBLY 1. Install valve, then slide valve seal over seal over valve stem and onto valve guide. 2. Install valves guide seal installer over valve seal.
Page 214 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 218: Installing Valve Guide Seal Installer Courtesy of KIA MOTORS AMERICA, INC. CAUTION: Using a hammer will damage valve seals. domingo, 7 de febrero de 2021 08:29:53 a. m. Page 214 © 2011 Mitchell Repair Information Company, LLC.
Page 215 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 219: Installing Valve Guide Seals Courtesy of KIA MOTORS AMERICA, INC. 3. Remove the valve guide seal installer. 4. Install lower spring seat on cylinder head. 5. Install HLA protector SST(K95A-1000-E) if available.
Page 216 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 220: Identifying Valve Spring Position Courtesy of KIA MOTORS AMERICA, INC. 7. Install upper spring seat and compress valve spring with SST or equivalent. domingo, 7 de febrero de 2021 08:29:53 a. m.
Page 217: Hydraulic Lash Adjuster (Hla)
2004 ENGINES 1.8L 4-Cylinder Fig. 221: Compressing Valve Spring Courtesy of KIA MOTORS AMERICA, INC. 8. Install valve locks and release SST or equivalent from valve spring. 9. Tap end of valve stem lightly two or three times with a plastic hammer to verify that valve locks are fully seated.
Page 218 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 222: Disconnecting Negative Battery Cable Courtesy of KIA MOTORS AMERICA, INC. 2. Remove center cover. domingo, 7 de febrero de 2021 08:29:53 a. m. Page 218 © 2011 Mitchell Repair Information Company, LLC.
Page 219 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 223: Removing Center Cover Courtesy of KIA MOTORS AMERICA, INC. 3. Remove ignition coils and high-tension cords. 4. Disconnect PCV hose and ventilation hose. domingo, 7 de febrero de 2021 08:29:53 a. m.
Page 220 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 224: Disconnecting PCV And Ventilation Hoses Courtesy of KIA MOTORS AMERICA, INC. 5. Remove timing belt. See TIMING SYSTEM. 6. Remove cylinder head cover. domingo, 7 de febrero de 2021 08:29:53 a. m.
Page 221 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 225: Removing Cylinder Head Cover Courtesy of KIA MOTORS AMERICA, INC. NOTE: Align camshaft and crankshaft timing belt alignment marks. domingo, 7 de febrero de 2021 08:29:53 a. m. Page 221 © 2011 Mitchell Repair Information Company, LLC.
Page 222 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 226: Aligning Camshaft And Crankshaft Timing Belt Alignment Marks Courtesy of KIA MOTORS AMERICA, INC. 7. Remove phase sensor. domingo, 7 de febrero de 2021 08:29:53 a. m. Page 222 © 2011 Mitchell Repair Information Company, LLC.
Page 223 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 227: Removing Phase Sensor Courtesy of KIA MOTORS AMERICA, INC. 8. Remove camshaft pulleys. domingo, 7 de febrero de 2021 08:29:53 a. m. Page 223 © 2011 Mitchell Repair Information Company, LLC.
Page 224 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 228: Removing Camshaft Pulleys Courtesy of KIA MOTORS AMERICA, INC. domingo, 7 de febrero de 2021 08:29:53 a. m. Page 224 © 2011 Mitchell Repair Information Company, LLC.
Page 225 9. Loosen camshaft bearing cap bolts in five or six steps in order shown in figure. Fig. 229: Camshaft Bearing Cap Bolt Removal Sequence Courtesy of KIA MOTORS AMERICA, INC. 10. Remove camshafts. 11. Mark HLA's to identify their original position if they will be reused.
Page 226 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 230: Identifying Hydraulic Lash Adjusters Courtesy of KIA MOTORS AMERICA, INC. 12. Remove HLA's from cylinder head. 13. Store HLA's upside-down in an oil-filled container. domingo, 7 de febrero de 2021 08:29:53 a. m.
Page 227 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 231: Storing HLA'S Courtesy of KIA MOTORS AMERICA, INC. INSPECTION 1. Check HLA face for wear or damage, and replace if necessary. 2. With HLA filled with engine oil, hold (A) and press down on (B) by hand. If (B) moves, replace HLA.
Page 228 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 232: Testing HLA Function Courtesy of KIA MOTORS AMERICA, INC. domingo, 7 de febrero de 2021 08:29:53 a. m. Page 228 © 2011 Mitchell Repair Information Company, LLC.
Page 229 3. Measure HLA bore diameters (X and Y directions) at two points (A and B) as shown in figure. Distortion: 1.1812~1.1820 in (30.000~30.025 mm) Fig. 233: Measuring HLA Bore Diameters Courtesy of KIA MOTORS AMERICA, INC. 4. Measure HLA diameters (X and Y directions) at two points (A and B) as shown in figure. See Fig. 234. Diameter: 1.1795~1.1801 in (29.959~29.975 mm)
Page 230: Installation
Clearance: 0.00099~0.00259 in (0.025~0.066 mm) Maximum: 0.0071 in (0.180 mm) Fig. 234: Measuring HLA Clearance Courtesy of KIA MOTORS AMERICA, INC. INSTALLATION 1. Apply a coat of clean engine oil to friction surfaces of HLA. domingo, 7 de febrero de 2021 08:29:53 a. m.
Page 231 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 235: Applying Oil To HLA Courtesy of KIA MOTORS AMERICA, INC. 2. Install HLA into cylinder head bore. NOTE: If HLA is being reused, install it in its original position. 3. Check that HLA moves smoothly in its bore.
Page 232 2004 ENGINES 1.8L 4-Cylinder Fig. 236: Camshaft Bearing Cap Bolt Tightening Sequence Courtesy of KIA MOTORS AMERICA, INC. 7. Apply a coat of clean engine oil to the lip of new camshaft seal. 8. Seat camshaft seal by hand and tap the seal in place until it is flush with the edge of camshaft bearing cap.
Page 233 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 237: Installing Camshaft Seal Courtesy of KIA MOTORS AMERICA, INC. 9. Install camshaft pulleys onto camshaft, aligning "I" mark with the intake camshaft dowel pin, and "E" mark with exhaust camshaft dowel pin.
Page 234 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 238: Installing Camshaft Pulleys Courtesy of KIA MOTORS AMERICA, INC. 10. Install phase sensor. domingo, 7 de febrero de 2021 08:29:53 a. m. Page 234 © 2011 Mitchell Repair Information Company, LLC.
Page 235 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 239: Installing Phase Sensor Courtesy of KIA MOTORS AMERICA, INC. 11. Install cylinder head cover. Tightening torque: 5.8~8.7 lb.ft (7.8~11.8 N.m, 0.8~1.2 kg.m) domingo, 7 de febrero de 2021 08:29:53 a. m.
Page 236 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 240: Installing Cylinder Head Cover Courtesy of KIA MOTORS AMERICA, INC. 12. Install timing belt. See TIMING SYSTEM. 13. Connect PCV hose and ventilation hose. 14. Install high tension cords and ignition coils.
Page 237 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 241: Installing High Tension Cords And Ignition Coils Courtesy of KIA MOTORS AMERICA, INC. 15. Install center cover. Tightening torque: 3.6~6.5 lb.ft (4.9~8.8 N.m, 0.5~0.9 kg.m) domingo, 7 de febrero de 2021 08:29:53 a. m.
Page 238 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 242: Installing Center Cover Courtesy of KIA MOTORS AMERICA, INC. 16. Connect negative battery cable. domingo, 7 de febrero de 2021 08:29:53 a. m. Page 238 © 2011 Mitchell Repair Information Company, LLC.
Page 239 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 243: Connecting Negative Battery Cable Courtesy of KIA MOTORS AMERICA, INC. OIL PAN REMOVAL 1. Disconnect negative battery cable. domingo, 7 de febrero de 2021 08:29:53 a. m. Page 239 © 2011 Mitchell Repair Information Company, LLC.
Page 240 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 244: Disconnecting Negative Battery Cable Courtesy of KIA MOTORS AMERICA, INC. 2. Drain engine oil. domingo, 7 de febrero de 2021 08:29:53 a. m. Page 240 © 2011 Mitchell Repair Information Company, LLC.
Page 241 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 245: Draining Engine Oil Courtesy of KIA MOTORS AMERICA, INC. 3. Remove LH and RH side splash shields. domingo, 7 de febrero de 2021 08:29:53 a. m. Page 241 © 2011 Mitchell Repair Information Company, LLC.
Page 242 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 246: Removing LH And RH Side Splash Shields Courtesy of KIA MOTORS AMERICA, INC. 4. Remove front exhaust pipe. domingo, 7 de febrero de 2021 08:29:53 a. m. Page 242 © 2011 Mitchell Repair Information Company, LLC.
Page 243 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 247: Removing Front Exhaust Pipe Courtesy of KIA MOTORS AMERICA, INC. 5. Remove oil pan mounting bolts. domingo, 7 de febrero de 2021 08:29:54 a. m. Page 243 © 2011 Mitchell Repair Information Company, LLC.
Page 244 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 248: Removing Oil Pan Mounting Bolts Courtesy of KIA MOTORS AMERICA, INC. 6. Remove oil pan with screwdriver or suitable tool as shown in figure. See Fig. 249. CAUTION: a. Do not force tools between cylinder block and oil pan because this may damage sealing surfaces.
Page 245 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 250: Removing Oil Strainer Courtesy of KIA MOTORS AMERICA, INC. INSTALLATION CAUTION: If oil pan is reused, remove all foreign material from sealing surfaces of cylinder block and oil pan. If bolts are reused, remove old sealant from bolt threads.
Page 246 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 251: Applying A Continuous Bead Of Silicone Sealant To Baffle Plate Courtesy of KIA MOTORS AMERICA, INC. 3. Install oil pan. Tightening torque: A, B, C, D: 5.8~8.0 lb-ft (7.8~10.8 N.m, 0.8~1.1 kg-m) E: 28~38 lb-ft (38~51 N.m, 3.8~5.3 kg-m)
Page 247 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 252: Illustrating Oil Pan Bolt Locations Courtesy of KIA MOTORS AMERICA, INC. 4. Install front exhaust pipe. Tightening torque: A : 29.7~40.5 lb-ft (40.2~54.9 N.m, 4.1~5.6 kg-m) B : 51~69 lb-ft (69~94 N.m, 6.9~9.4 kg-m) C : 15.2~20.2 lb-ft (20.6~27.4 N.m, 2.1~2.8 kg-m)
Page 248 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 253: Installing Front Exhaust Pipe Courtesy of KIA MOTORS AMERICA, INC. 5. Install LH and RH side splash shields. Tightening torque: 12~18 lb-ft (16~24 N.m, 1.6~2.4 kg-m) domingo, 7 de febrero de 2021 08:29:54 a. m.
Page 249 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 254: Installing LH And RH Side Splash Shields Courtesy of KIA MOTORS AMERICA, INC. 6. Fill with specified amount and type of engine oil. 7. Connect negative battery cable. domingo, 7 de febrero de 2021 08:29:54 a. m.
Page 250: Cooling System
2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 255: Connecting Negative Battery Cable Courtesy of KIA MOTORS AMERICA, INC. 8. Start engine and check for leaks. 9. Check oil level and add oil if necessary. COOLING SYSTEM TROUBLESHOOTING GUIDE domingo, 7 de febrero de 2021 08:29:54 a. m.
Page 251: Specification
2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 256: Cooling System Troubleshooting Guide Courtesy of KIA MOTORS AMERICA, INC. SPECIFICATION Fig. 257: Cooling System Specifications Courtesy of KIA MOTORS AMERICA, INC. domingo, 7 de febrero de 2021 08:29:54 a. m.
Page 252: Engine Coolant
2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 258: Cooling System Functional Diagram Courtesy of KIA MOTORS AMERICA, INC. ENGINE COOLANT INSPECTION WARNING: Never remove radiator cap while engine is hot. Wrap a thick cloth around radiator cap before removing.
Page 253 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 259: Measuring Coolant Level Courtesy of KIA MOTORS AMERICA, INC. COOLANT QUALITY 1. Verify that there is no build-up of rust or scale around radiator cap or radiator filler neck. 2. Verify that coolant is free of contaminants. Replace coolant if necessary.
Page 254 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 260: Verifying Coolant Quality Courtesy of KIA MOTORS AMERICA, INC. LEAKAGE 1. Connect a coolant system pressure tester to the radiator filler neck. 2. Apply 15 psi (103 kPa, 1.05 kg/cm ) pressure to the system.
Page 255: Engine Coolant Pump
2004 ENGINES 1.8L 4-Cylinder Fig. 261: Identifying Radiator Drain Plug Courtesy of KIA MOTORS AMERICA, INC. 2. Drain coolant into a suitable container. 3. Flush cooling system with water until all traces of color are gone; then let system drain completely.
Page 256 CAUTION: Do not disassemble water pump assembly. If a problem is found, replace assembly as a unit. 1. Disconnect negative battery cable. Fig. 262: Disconnecting Negative Battery Cable Courtesy of KIA MOTORS AMERICA, INC. 2. Drain engine coolant. domingo, 7 de febrero de 2021 08:29:54 a. m. Page 256...
Page 257 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 263: Identifying Radiator Drain Plug Courtesy of KIA MOTORS AMERICA, INC. 3. Remove timing belt. See TIMING SYSTEM. 4. Remove tensioner and idler. domingo, 7 de febrero de 2021 08:29:54 a. m.
Page 258 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 264: Removing Timing Belt Tensioners Courtesy of KIA MOTORS AMERICA, INC. 5. Remove water pump. domingo, 7 de febrero de 2021 08:29:54 a. m. Page 258 © 2011 Mitchell Repair Information Company, LLC.
Page 259: Installation
2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 265: Removing Water Pump Courtesy of KIA MOTORS AMERICA, INC. INSPECTION 1. Check water pump for cracks and damage. 2. Check for abnormal noise, bearing sticking or loose. 3. Replace water pump if necessary.
Page 260 3. Install water pump. Tightening torque: 14~19 lb-ft (19~26 N.m, 1.9~2.6 kg-m) Fig. 266: Installing Water Pump Courtesy of KIA MOTORS AMERICA, INC. 4. Install tensioner, idler and timing belt. See TIMING SYSTEM. 5. Fill engine coolant. 6. Connect negative battery cable.
Page 261 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 267: Connecting Negative Battery Cable Courtesy of KIA MOTORS AMERICA, INC. 7. Start engine and check for leaks. RADIATOR COMPONENT domingo, 7 de febrero de 2021 08:29:54 a. m. Page 261 © 2011 Mitchell Repair Information Company, LLC.
Page 262 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder domingo, 7 de febrero de 2021 08:29:54 a. m. Page 262 © 2011 Mitchell Repair Information Company, LLC.
Page 263 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 268: Identifying Radiator Courtesy of KIA MOTORS AMERICA, INC. REMOVAL 1. Disconnect negative battery cable. Fig. 269: Disconnecting Negative Battery Cable Courtesy of KIA MOTORS AMERICA, INC. 2. Drain engine coolant. domingo, 7 de febrero de 2021 08:29:54 a. m.
Page 264 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 270: Identifying Radiator Drain Plug Courtesy of KIA MOTORS AMERICA, INC. 3. Remove fresh air duct. domingo, 7 de febrero de 2021 08:29:54 a. m. Page 264 © 2011 Mitchell Repair Information Company, LLC.
Page 265 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 271: Removing Fresh Air Duct Courtesy of KIA MOTORS AMERICA, INC. 4. Disconnect upper radiator hose. 5. Disconnect cooling fan motor connector. 6. Disconnect condenser fan motor connector. 7. Disconnect coolant reservoir hose.
Page 266 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 272: Removing Radiator Brackets Courtesy of KIA MOTORS AMERICA, INC. 9. Disconnect Automatic Transaxle Fluid (ATF) inlet and outlet pipe. domingo, 7 de febrero de 2021 08:29:54 a. m. Page 266 © 2011 Mitchell Repair Information Company, LLC.
Page 267 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 273: Disconnecting Automatic Transaxle Fluid Inlet And Outlet Pipe Courtesy of KIA MOTORS AMERICA, INC. 10. Disconnect lower radiator hose. 11. Lift radiator assembly from engine compartment. 12. Remove cooling fan assembly and condenser fan assembly.
Page 268 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 274: Inspecting Radiator Courtesy of KIA MOTORS AMERICA, INC. 3. Check for damaged radiator inlet and outlet and hose connections. INSTALLATION 1. Install cooling fan assembly and condenser fan assembly. 2. Install radiator assembly into engine compartment.
Page 269 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 275: Connecting ATF Inlet And Outlet Pipes Courtesy of KIA MOTORS AMERICA, INC. 5. Install radiator brackets. 6. Connect coolant reservoir hose. 7. Connect condenser fan motor connector. 8. Connect cooling fan motor connector.
Page 270 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 276: Installing Fresh Air Duct Courtesy of KIA MOTORS AMERICA, INC. 11. Connect negative battery cable. domingo, 7 de febrero de 2021 08:29:54 a. m. Page 270 © 2011 Mitchell Repair Information Company, LLC.
Page 271 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 277: Connecting Negative Battery Cable Courtesy of KIA MOTORS AMERICA, INC. 12. Fill engine coolant. See ENGINE COOLANT. domingo, 7 de febrero de 2021 08:29:54 a. m. Page 271 © 2011 Mitchell Repair Information Company, LLC.
Page 272: Radiator Fan Motor
2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 278: Filling Engine Coolant Courtesy of KIA MOTORS AMERICA, INC. 13. Start engine and check for leaks. RADIATOR FAN MOTOR COMPONENT domingo, 7 de febrero de 2021 08:29:54 a. m. Page 272...
Page 273 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 279: Identifying Radiator Fan Motor Courtesy of KIA MOTORS AMERICA, INC. REMOVAL 1. Disconnect negative battery cable. domingo, 7 de febrero de 2021 08:29:54 a. m. Page 273 © 2011 Mitchell Repair Information Company, LLC.
Page 274 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 280: Disconnecting Negative Battery Cable Courtesy of KIA MOTORS AMERICA, INC. 2. Drain engine coolant. domingo, 7 de febrero de 2021 08:29:54 a. m. Page 274 © 2011 Mitchell Repair Information Company, LLC.
Page 275 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 281: Draining Engine Coolant Courtesy of KIA MOTORS AMERICA, INC. 3. Remove fresh air duct. domingo, 7 de febrero de 2021 08:29:54 a. m. Page 275 © 2011 Mitchell Repair Information Company, LLC.
Page 276 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 282: Removing Fresh Air Duct Courtesy of KIA MOTORS AMERICA, INC. 4. Disconnect cooling fan motor connector. 5. Remove upper radiator hose. domingo, 7 de febrero de 2021 08:29:54 a. m. Page 276...
Page 277 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 283: Removing Upper Radiator Hose Courtesy of KIA MOTORS AMERICA, INC. 6. Remove upper two radiator cowling bolts. 7. Remove lower two radiator cowling bolts. domingo, 7 de febrero de 2021 08:29:54 a. m.
Page 278 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 284: Removing Lower Radiator Cowling Bolts Courtesy of KIA MOTORS AMERICA, INC. 8. Lift radiator cowling from engine compartment. 9. Remove clip and fan. Remove three fan motor bolts and nuts. INSPECTION Check current as shown with an ammeter.
Page 279 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 285: Testing Fan Motor Courtesy of KIA MOTORS AMERICA, INC. INSTALLATION 1. Install fan motor and tighten three fan motor bolts and nuts. 2. Install fan and clip 3. Install radiator cowling to radiator.
Page 280 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 286: Installing And Tightening Lower Two Radiator Cowling Bolts Courtesy of KIA MOTORS AMERICA, INC. 6. Install upper radiator hose. domingo, 7 de febrero de 2021 08:29:54 a. m. Page 280 © 2011 Mitchell Repair Information Company, LLC.
Page 281 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 287: Installing Upper Radiator Hose Courtesy of KIA MOTORS AMERICA, INC. 7. Connect cooling fan motor connector. 8. Install fresh air duct and tighten bolt and nut. domingo, 7 de febrero de 2021 08:29:54 a. m.
Page 282 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 288: Installing Fresh Air Duct And Tightening Bolt And Nut Courtesy of KIA MOTORS AMERICA, INC. 9. Fill engine coolant See ENGINE COOLANT. 10. Connect negative battery cable. domingo, 7 de febrero de 2021 08:29:54 a. m.
Page 283: Radiator Cap Inspection
2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 289: Connecting Negative Battery Cable Courtesy of KIA MOTORS AMERICA, INC. 11. Start engine and check for leaks. RADIATOR CAP INSPECTION RADIATOR CAP VALVE 1. Remove foreign material from radiator cap valve and the valve seat.
Page 284 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 290: Testing Radiator Cap Valve Courtesy of KIA MOTORS AMERICA, INC. 3. Wait about 10 seconds. Verify that pressure has not decreased. 4. Replace radiator cap as necessary. NEGATIVE PRESSURE VALVE 1. Pull negative pressure valve to open it. Verify that it closes completely when released.
Page 285 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 291: Testing Radiator Cap Negative Pressure Valve Courtesy of KIA MOTORS AMERICA, INC. 3. Replace radiator cap as necessary. THERMOSTAT REMOVAL 1. Disconnect negative battery cable. domingo, 7 de febrero de 2021 08:29:54 a. m.
Page 286 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 292: Disconnecting Negative Battery Cable Courtesy of KIA MOTORS AMERICA, INC. 2. Drain engine coolant. domingo, 7 de febrero de 2021 08:29:54 a. m. Page 286 © 2011 Mitchell Repair Information Company, LLC.
Page 287 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 293: Draining Engine Coolant Courtesy of KIA MOTORS AMERICA, INC. 3. Remove bolt and nut of thermostat housing. domingo, 7 de febrero de 2021 08:29:54 a. m. Page 287 © 2011 Mitchell Repair Information Company, LLC.
Page 288 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 294: Removing Thermostat Housing Bolt and Nut Courtesy of KIA MOTORS AMERICA, INC. 4. Remove thermostat housing and thermostat. domingo, 7 de febrero de 2021 08:29:54 a. m. Page 288 © 2011 Mitchell Repair Information Company, LLC.
Page 289 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 295: Removing Thermostat Housing And Thermostat Courtesy of KIA MOTORS AMERICA, INC. INSPECTION 1. Visually check that thermostat is airtight. 2. Place thermostat and a thermometer in water. 3. Gradually heat water and check following.
Page 290 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 296: Testing Thermostat Operation Courtesy of KIA MOTORS AMERICA, INC. INSTALLATION 1. Install thermostat into cylinder head with jiggle pin positioned up. 2. Install new gasket. domingo, 7 de febrero de 2021 08:29:55 a. m.
Page 291 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 297: Installing Thermostat Into Cylinder Head Courtesy of KIA MOTORS AMERICA, INC. 3. Place thermostat housing and tighten bolt and nut. domingo, 7 de febrero de 2021 08:29:55 a. m. Page 291...
Page 292 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 298: Installing Thermostat Housing And Tightening Bolt And Nut Courtesy of KIA MOTORS AMERICA, INC. Tightening torque: 14~19 lb.ft (19~26 N.m, 1.9~2.6 kg.m) 4. Fill radiator with specified amount and type of engine coolant.
Page 293: Lubrication System
2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 299: Connecting Negative Battery Cable Courtesy of KIA MOTORS AMERICA, INC. 6. Start engine and check for leaks. LUBRICATION SYSTEM TROUBLESHOOTING GUIDE domingo, 7 de febrero de 2021 08:29:55 a. m. Page 293...
Page 294: General Description
2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 300: Lubrication System Troubleshooting Guide Courtesy of KIA MOTORS AMERICA, INC. SPECIFICATION Fig. 301: Lubrication System Specification Chart Courtesy of KIA MOTORS AMERICA, INC. GENERAL DESCRIPTION The engine lubrication system consists of an oil pan, oil pump, oil filter and various oil passages. A rotor-type oil pump is driven by crankshaft.
Page 295: Engine Oil
Fig. 302: Illustrating Lubrication Flow Courtesy of KIA MOTORS AMERICA, INC. ENGINE OIL INSPECTION 1. Be sure vehicle is on level ground.
Page 296 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder 5. Add or replace oil as necessary. Fig. 303: Checking Oil Level And Condition Courtesy of KIA MOTORS AMERICA, INC. REPLACEMENT domingo, 7 de febrero de 2021 08:29:55 a. m. Page 296 © 2011 Mitchell Repair Information Company, LLC.
Page 297 2. Remove oil filler cap and oil pan drain plug. Fig. 304: Identifying Engine Oil Drain Plug Courtesy of KIA MOTORS AMERICA, INC. 3. Allow oil to be fully drained. 4. Install drain plug with new gasket. Tightening torque: 22~30 lb.ft (29~41 N.m, 3.0~4.2 kg.m) 5.
Page 298: Oil Filter
3. Apply a small amount of clean engine oil to rubber seal of new filter. Fig. 305: Installing Oil Filter Courtesy of KIA MOTORS AMERICA, INC. 4. Install oil filter and turn it by hand until rubber seal contacts base.
Page 299: Oil Pressure Check
OIL PRESSURE CHECK 1. Disconnect and remove oil pressure switch. Fig. 306: Removing Oil Pressure Switch Courtesy of KIA MOTORS AMERICA, INC. 2. Install oil pressure gauge into oil pressure switch installation hole. domingo, 7 de febrero de 2021 08:29:55 a. m.
Page 300: Oil Pump
2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 307: Installing Oil Pressure Gauge Courtesy of KIA MOTORS AMERICA, INC. 3. Warm engine to normal operating temperature. 4. Run engine at 3,000 RPM, and note gauge readings. Oil pressure: 43~57 psi (294~392 kPa, 3.0~4.0 kg/cm2) 5.
Page 301 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder COMPONENT Fig. 308: Identifying Oil Pump Components Courtesy of KIA MOTORS AMERICA, INC. REMOVAL 1. Disconnect negative battery cable. domingo, 7 de febrero de 2021 08:29:55 a. m. Page 301 © 2011 Mitchell Repair Information Company, LLC.
Page 302 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 309: Disconnecting Negative Battery Cable Courtesy of KIA MOTORS AMERICA, INC. 2. Drain engine oil. domingo, 7 de febrero de 2021 08:29:55 a. m. Page 302 © 2011 Mitchell Repair Information Company, LLC.
Page 303 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 310: Draining Engine Oil Courtesy of KIA MOTORS AMERICA, INC. 3. Remove timing belt. See TIMING SYSTEM. 4. Remove oil pan and oil strainer. See OIL PAN. 5. Remove generator. See CHARGING SYSTEMS .
Page 304: Installation
2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 311: Removing Oil Pump Mounting Bolt Courtesy of KIA MOTORS AMERICA, INC. 10. Remove oil pump. INSTALLATION 1. Apply a continuous bead of silicone sealant to oil pump sealing surface. CAUTION: The oil pump must be installed no longer than 5 minutes after silicone sealant is applied.
Page 305 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 312: Applying Grease To A New O-Ring Courtesy of KIA MOTORS AMERICA, INC. 3. Install oil pump. Tightening torque: 14~19 lb.ft (19~26 N.m, 1.9~2.6 kg.m) 4. Install timing belt pulley and crankshaft pulley lock bolt.
Page 306 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 313: Installing Timing Belt Pulley And Crankshaft Pulley Lock Bolt Courtesy of KIA MOTORS AMERICA, INC. 5. Install A/C compressor bracket and A/C compressor. 6. Install generator. See CHARGING SYSTEMS . 7. Install oil strainer and oil pan. See OIL PAN.
Page 307 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 314: Connecting Negative Battery Cable Courtesy of KIA MOTORS AMERICA, INC. 11. Start engine and check for leaks. 12. Check oil level and add oil if necessary. DISASSEMBLY 1. Remove oil seal using a screwdriver covered by a rag to protect sealing surface from pump cover side.
Page 308 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 315: Removing Oil Seal Courtesy of KIA MOTORS AMERICA, INC. 2. Remove seven screws and remove pump cover. domingo, 7 de febrero de 2021 08:29:55 a. m. Page 308 © 2011 Mitchell Repair Information Company, LLC.
Page 309 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 316: Removing Oil Pump Cover Courtesy of KIA MOTORS AMERICA, INC. 3. Remove outer rotor and inner rotor. INSPECTION 1. Check the following and replace any faulty parts. Distorted or damaged oil pump body or cover.
Page 310 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 317: Measuring Side Clearance Courtesy of KIA MOTORS AMERICA, INC. 3. Measure tooth tip clearance. Clearance: 0.007 in (0.18 mm) Max. domingo, 7 de febrero de 2021 08:29:55 a. m. Page 310...
Page 311 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 318: Measuring Tooth Tip Clearance Courtesy of KIA MOTORS AMERICA, INC. 4. Measure outer rotor to pump body clearance. Clearance: 0.015 in (0.376 mm) Max. domingo, 7 de febrero de 2021 08:29:55 a. m.
Page 312 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 319: Measuring Outer Rotor To Pump Body Clearance Courtesy of KIA MOTORS AMERICA, INC. REASSEMBLY 1. Assemble outer rotor and inner rotor into oil pump body. domingo, 7 de febrero de 2021 08:29:55 a. m.
Page 313 2004 ENGINES 1.8L 4-Cylinder Fig. 320: Assembling Outer And Inner Rotor Into Oil Pump Body Courtesy of KIA MOTORS AMERICA, INC. 2. Apply thread locking compound to cover mounting screw threads. 3. Assemble oil pump cover to oil pump body.
Page 314 2004 ENGINES 1.8L 4-Cylinder Fig. 321: Installing Oil Pump Cover To Oil Pump Body Courtesy of KIA MOTORS AMERICA, INC. 4. Apply engine oil to outside of new oil seal and oil pump body. 5. Press oil seal into oil pump body.
Page 315: Front Oil Seal
2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 322: Pressing Oil Seal Into Oil Pump Body Courtesy of KIA MOTORS AMERICA, INC. FRONT OIL SEAL REMOVAL 1. Remove oil pump. See OIL PUMP. 2. Remove front oil seal. REPLACEMENT 1. Install oil seal. See OIL PUMP.
Page 316 Use a flywheel locking tool or equivalent when removing flywheel or drive plate. 3. Remove rear cover. Fig. 323: Removing Rear Cover Courtesy of KIA MOTORS AMERICA, INC. domingo, 7 de febrero de 2021 08:29:55 a. m. Page 316 © 2011 Mitchell Repair Information Company, LLC.
Page 317 2004 ENGINES 1.8L 4-Cylinder 4. Wrap a prying tool with a shop towel and slowly pry old seal out. Fig. 324: Prying Out Oil Seal Courtesy of KIA MOTORS AMERICA, INC. REPLACEMENT domingo, 7 de febrero de 2021 08:29:55 a. m.
Page 318 Protrusion: 0~0.02 in (0~0.5 mm) Fig. 325: Pressing Oil Seal Into Rear Cover Courtesy of KIA MOTORS AMERICA, INC. 3. Cut away silicon sealer that has been squeezed out from rear cover assembly toward oil pan mounting domingo, 7 de febrero de 2021 08:29:55 a. m.
Page 319 2004 ENGINES 1.8L 4-Cylinder surface. CAUTION: Do not scratch rear cover assembly. Fig. 326: Removing Excess Sealer Courtesy of KIA MOTORS AMERICA, INC. 4. Install rear cover. Tightening torque: A: 5.8~8.0 lb.ft (7.8~10.8 N.m, 0.8~1.1 kg.m) B: 29.7~40.5 lb.ft (40.2~54.9 N.m, 4.1~5.6 kg.m) domingo, 7 de febrero de 2021 08:29:55 a.
Page 320 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 327: Installing Rear Cover Courtesy of KIA MOTORS AMERICA, INC. 5. Install flywheel and manual transaxle, see Fig. 144. In case of A/T, install drive plate and automatic transaxle. 6. Connect negative battery cable.
Page 321: Intake And Exhaust System
2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 328: Connecting Negative Battery Cable Courtesy of KIA MOTORS AMERICA, INC. INTAKE AND EXHAUST SYSTEM TROUBLESHOOTING GUIDE EXHAUST SYSTEM domingo, 7 de febrero de 2021 08:29:55 a. m. Page 321 © 2011 Mitchell Repair Information Company, LLC.
Page 322 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 329: Exhaust System Troubleshooting Guide Courtesy of KIA MOTORS AMERICA, INC. GENERAL DESCRIPTION EXHAUST SYSTEM The principal parts that comprise the engine exhaust system are warm-up catalytic converter, the front exhaust pipe, the catalytic converter, the pre-silencer and the main silencer. Each component is joined with a gasket to prevent exhaust leaks.
Page 323 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 330: Illustrating Exhaust System (1 Of 2) Courtesy of KIA MOTORS AMERICA, INC. domingo, 7 de febrero de 2021 08:29:55 a. m. Page 323 © 2011 Mitchell Repair Information Company, LLC.
Page 324: Exhaust System Inspection
2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 331: Illustrating Exhaust System (2 Of 2) Courtesy of KIA MOTORS AMERICA, INC. EXHAUST SYSTEM INSPECTION WARNING: Leaking exhaust systems are potentially hazardous to a vehicle's passengers because carbon monoxide is poisonous.
Page 325 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder will not be effective. Listening for leaks will be more productive. 4. Inspect pre-silencer for leaks. Pipe joining catalytic converter and pre-silencer also has a heat shield. Listening for leaks is the best method.
Page 326: Installation
2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 332: Removing Splash Shield Courtesy of KIA MOTORS AMERICA, INC. 6. Remove three nuts that attach warm-up TWC converter to front exhaust pipe. Fig. 333: Removing Front Exhaust Pipe Nuts Courtesy of KIA MOTORS AMERICA, INC.
Page 327 2004 ENGINES 1.8L 4-Cylinder Tightening torque: 27.4~38.3 lb.ft (37.2~51.9 N.m, 3.8~5.3 kg.m) Fig. 334: Installing Front Exhaust Pipe Nuts Courtesy of KIA MOTORS AMERICA, INC. 6. Install splash shield. Tightening torque: 10~12 lb.ft (13.5~16 N.m, 1.4~1.6 kg.m) 7. Lower vehicle.
Page 328: Front Exhaust Pipe
2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder FRONT EXHAUST PIPE CAUTION: A hot exhaust system can produce a serious burn. REMOVAL 1. Remove three nuts that attach front exhaust pipe to warm-up TWC converter. 2. Remove two nuts at spring-loaded flange of front exhaust pipe.
Page 329 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 335: Removing Front Flange Nuts Courtesy of KIA MOTORS AMERICA, INC. 2. Remove two nuts from forward pre-silencer flange. 3. Remove one gasket. INSTALLATION 1. Clean mating surfaces as required. 2. Install one new gasket.
Page 330 2. Remove two supports from pre-silencer. 3. Remove two nuts at main-silencer flange. Fig. 336: Removing Silencer Flange Nuts Courtesy of KIA MOTORS AMERICA, INC. domingo, 7 de febrero de 2021 08:29:55 a. m. Page 330 © 2011 Mitchell Repair Information Company, LLC.
Page 331 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder 4. Remove two gaskets. INSTALLATION 1. Lubricate inside of two pre-silencer hangers with a silicone lubricant. 2. Clean mating surfaces as required. 3. Install two new gaskets on bolts. 4. Install two nuts at main-silencer flange.
Page 332 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 337: Removing Main-Silencer Supports Courtesy of KIA MOTORS AMERICA, INC. 3. Remove one gasket. INSTALLATION 1. Lubricate inside of three main-silencer hangers with a silicone lubricant. domingo, 7 de febrero de 2021 08:29:55 a. m.
Page 333 2. Disconnect mass air flow sensor connector. 3. Loosen clamp on outlet hose of air cleaner housing. Fig. 338: Loosening Air Cleaner Outlet Hose Clamp Courtesy of KIA MOTORS AMERICA, INC. domingo, 7 de febrero de 2021 08:29:55 a. m. Page 333...
Page 334: Timing System
2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder 4. Remove air intake hoses from air cleaner housing. 5. Remove bolts holding the top of air cleaner housing in place. 6. Remove top of air cleaner housing. 7. Remove air cleaner element.
Page 335 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 339: Identifying Timing Belt Components Courtesy of KIA MOTORS AMERICA, INC. REMOVAL 1. Disconnect negative battery cable. domingo, 7 de febrero de 2021 08:29:56 a. m. Page 335 © 2011 Mitchell Repair Information Company, LLC.
Page 336 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 340: Disconnecting Negative Battery Cable Courtesy of KIA MOTORS AMERICA, INC. 2. Loosen power steering lock bolts and nuts accordingly and remove tension from power steering (P/S) and/or air conditioning (A/C) compressor drive belt.
Page 337 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 341: Removing P/S And/Or A/C Drive Belt Courtesy of KIA MOTORS AMERICA, INC. 4. Loosen generator mounting bolts and adjusting bolt. 5. Remove generator bolts. domingo, 7 de febrero de 2021 08:29:56 a. m.
Page 338 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 342: Loosening Generator Mounting And Adjusting Bolts Courtesy of KIA MOTORS AMERICA, INC. 6. Remove water pump pulley. domingo, 7 de febrero de 2021 08:29:56 a. m. Page 338 © 2011 Mitchell Repair Information Company, LLC.
Page 339 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 343: Removing Water Pump Pulley Courtesy of KIA MOTORS AMERICA, INC. 7. Remove crankshaft pulley and timing belt guide plate. domingo, 7 de febrero de 2021 08:29:56 a. m. Page 339 © 2011 Mitchell Repair Information Company, LLC.
Page 340 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 344: Removing Crankshaft Pulley And Timing Belt Guide Plate Courtesy of KIA MOTORS AMERICA, INC. 8. Remove upper and lower timing belt covers. domingo, 7 de febrero de 2021 08:29:56 a. m.
Page 341 2004 ENGINES 1.8L 4-Cylinder Fig. 345: Removing Upper And Lower Timing Belt Covers Courtesy of KIA MOTORS AMERICA, INC. 9. Turn crankshaft so that timing mark on timing belt pulley is aligned with timing mark on engine. domingo, 7 de febrero de 2021 08:29:56 a. m.
Page 342 2004 ENGINES 1.8L 4-Cylinder Fig. 346: Aligning Timing Mark On Crankshaft Courtesy of KIA MOTORS AMERICA, INC. 10. Check that T mark on intake camshaft pulley is aligned with mark on cylinder head cover and "E" mark on exhaust camshaft pulley is aligned with mark on cylinder head cover.
Page 343 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 347: Aligning Camshaft Timing Marks Courtesy of KIA MOTORS AMERICA, INC. 11. Loosen tensioner pulley lock bolt. 12. Protect timing belt with a rag. 13. Remove tensioner pulley. domingo, 7 de febrero de 2021 08:29:56 a. m.
Page 344 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 348: Identifying Tensioner Pulley Lock Bolt Courtesy of KIA MOTORS AMERICA, INC. 14. Remove timing belt. NOTE: Mark the direction of timing belt rotation (on the timing belt) for proper reinstallation. INSPECTION NOTE: Never forcefully twist, turn inside out or bend timing belt.
Page 345 Fig. 349: Inspecting Timing Belt For Wear Courtesy of KIA MOTORS AMERICA, INC. 3. Bend timing belt into a "U" shape as shown in figure. Distance "A" must be at least 1.0 in (25 mm). domingo, 7 de febrero de 2021 08:29:56 a. m.
Page 346 2004 ENGINES 1.8L 4-Cylinder Fig. 350: Inspecting Timing Belt Condition Courtesy of KIA MOTORS AMERICA, INC. 4. Inspect both idler pulley and tensioner pulley for uneven wear and smooth bearing operation. domingo, 7 de febrero de 2021 08:29:56 a. m.
Page 347 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 351: Inspecting Timing Belt Tensioner Pulley Courtesy of KIA MOTORS AMERICA, INC. NOTE: Do not clean tensioner pulley or idler pulley with cleaning fluids. If needed, use a soft rag to wipe them clean. Avoid scratching tensioner pulley or idler pulley as it can affect integrity of timing belt.
Page 348 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 352: Measuring Tension Spring Free Length Courtesy of KIA MOTORS AMERICA, INC. 6. Inspect camshaft pulleys and timing belt pulley for broken teeth or damage. NOTE: Replace any component that shows damage, excessive wear, or that appears prone to a possible failure.
Page 349 Replace tensioner spring whenever timing belt is replaced. Fig. 353: Installing Tensioner Pulley Courtesy of KIA MOTORS AMERICA, INC. 2. Pull tensioner pulley to its furthest point and tighten lock bolt. 3. Check that timing mark on timing belt pulley is aligned with timing mark on engine.
Page 350 2004 ENGINES 1.8L 4-Cylinder Fig. 354: Aligning Crankshaft Timing Mark Courtesy of KIA MOTORS AMERICA, INC. 4. Check that "I" mark on intake camshaft pulley is aligned with mark on cylinder head cover and "E" mark on exhaust camshaft pulley is aligned with mark on cylinder head cover.
Page 351 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 355: Aligning Camshaft Timing Marks Courtesy of KIA MOTORS AMERICA, INC. NOTE: If existing timing belt is being reused, install belt in proper rotation direction marked prior to removal. domingo, 7 de febrero de 2021 08:29:56 a. m.
Page 352 2004 ENGINES 1.8L 4-Cylinder Fig. 356: Identifying Timing Belt Rotation Direction Courtesy of KIA MOTORS AMERICA, INC. 5. Install timing belt onto timing belt pulley first, then idler pulley, exhaust camshaft pulley, intake camshaft pulley, and tensioner pulley in that order.
Page 353 6. Check that there is no looseness in belt between idler pulley and exhaust camshaft pulley or between intake and exhaust camshaft pulleys. Fig. 357: Illustrating Proper Timing Belt Position Courtesy of KIA MOTORS AMERICA, INC. domingo, 7 de febrero de 2021 08:29:56 a. m. Page 353...
Page 354 9. Rotate crankshaft two full revolutions (clockwise only) and align timing mark on timing belt pulley with timing mark on engine block. Fig. 358: Identifying Engine Rotation Direction Courtesy of KIA MOTORS AMERICA, INC. domingo, 7 de febrero de 2021 08:29:56 a. m. Page 354...
Page 355 Fig. 359: Aligning Camshaft Timing Marks Courtesy of KIA MOTORS AMERICA, INC. 11. If they are not aligned, remove timing belt and start process from tensioner installation. 12. Measure timing belt deflection by applying moderate pressure midway between camshaft pulleys. If deflection is not correct, repeat from tensioner installation.
Page 356 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 360: Measuring Timing Belt Deflection Courtesy of KIA MOTORS AMERICA, INC. 13. Install lower and upper timing belt covers in that order. Tightening torque: 70~96 lb.ft (7.9~10.7 N.m, 0.8~1.1 kg.m) domingo, 7 de febrero de 2021 08:29:56 a. m.
Page 357 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 361: Installing Lower And Upper Timing Belt Covers Courtesy of KIA MOTORS AMERICA, INC. 14. Install timing belt guide plate and crankshaft pulley. domingo, 7 de febrero de 2021 08:29:56 a. m.
Page 358 2004 ENGINES 1.8L 4-Cylinder Tightening torque: 9.0~12.6 lb.ft (12.3~17.2 N.m, 1.3~1.8 kg.m) Fig. 362: Installing Timing Belt Guide Plate And Crankshaft Pulley Courtesy of KIA MOTORS AMERICA, INC. 15. Install water pump pulley. Tightening torque: 9.0~12.6 lb.ft (12.3~17.2 N.m, 1.3~1.8 kg.m) domingo, 7 de febrero de 2021 08:29:56 a.
Page 359 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 363: Installing Water Pump Pulley Courtesy of KIA MOTORS AMERICA, INC. 16. Install generator belt and adjust the tension. 17. Install P/S and/or A/C drive belt and adjust the tension. 18. Connect negative battery cable.
Page 360: Torque Specifications
2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 364: Connecting Negative Battery Cable Courtesy of KIA MOTORS AMERICA, INC. TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m) A/C Compressor Bracket Bolt 12-mm 14-18 (19-25) 14-mm 28-38 (38-51) A/C Compressor Mounting Bolt...
Page 361 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Cylinder Head Bolts Step 1 36 (49) Step 2 Loosen Bolts In Sequence Step 3 29 (39) Step 4 Plus Torque Angle 90 Degrees Step 5 Plus Torque Angle Additional 90 Degrees Engine Ground Strap-To-Engine Bolts...
Page 362 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Stabilizer Control Link Bolts 32-45 (43-61) Starter Bolt 27-38 (37-52) Tensioner Pulley Lock Bolt 28-38 (38-52) Thermostat Housing Bolt 14-19 (19-26) Water Pump Bolt 14-19 (19-26) INCH Lbs. (N.m) 97-124 (11-14) Camshaft Bearing Cap Bolts...
Page 363 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 365: Cylinder Head Bolt Tightening Sequence Courtesy of KIA MOTORS AMERICA, INC. domingo, 7 de febrero de 2021 08:29:56 a. m. Page 363 © 2011 Mitchell Repair Information Company, LLC.
Page 364 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 366: Illustrating Engine Mount No. 1 Courtesy of KIA MOTORS AMERICA, INC. domingo, 7 de febrero de 2021 08:29:56 a. m. Page 364 © 2011 Mitchell Repair Information Company, LLC.
Page 365 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 367: Illustrating Engine Mount No. 2 Courtesy of KIA MOTORS AMERICA, INC. domingo, 7 de febrero de 2021 08:29:56 a. m. Page 365 © 2011 Mitchell Repair Information Company, LLC.
Page 366 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 368: Illustrating Engine Mount No. 4 Courtesy of KIA MOTORS AMERICA, INC. domingo, 7 de febrero de 2021 08:29:56 a. m. Page 366 © 2011 Mitchell Repair Information Company, LLC.
Page 367 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 369: Main Bearing Cap Bolt Tightening Sequence Courtesy of KIA MOTORS AMERICA, INC. domingo, 7 de febrero de 2021 08:29:56 a. m. Page 367 © 2011 Mitchell Repair Information Company, LLC.
Page 368 2004 Kia Spectra 2004 ENGINES 1.8L 4-Cylinder Fig. 370: Camshaft Bearing Cap Bolt Removal/Installation Sequence Courtesy of KIA MOTORS AMERICA, INC. domingo, 7 de febrero de 2021 08:29:56 a. m. Page 368 © 2011 Mitchell Repair Information Company, LLC.

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