Reassembly: Removal & Installation Kia Spectra I рестайлинг 2

INSTALLATION

Note. Thoroughly clean all parts to be assembled. Always use a new cylinder head and manifold gasket. The cylinder head gasket is a metal gasket. Take care not to bend it. Rotate the crankshaft, set the No. 1 piston at TDC.

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1. Install the cylinder head gasket (A) on the cylinder block. NOTE: Be careful of the installation direction.
2. Place the cylinder head onto the block carefully in order to prevent damaging the gasket. If the gasket is damaged, fluid leakage could occur.
3. Install the cylinder head bolts. Apply a light coat if engine oil on the threads and under the heads of the cylinder head bolts. Using 8 mm and 10 mm hexagon wrench, install and tighten the 10 cylinder head bolts and plate washers, in several passes, in the sequence shown. Tightening torque: M10: 22.6~26.5 N-m (2.3~2.7 kg-m, 16.6~19.5 lb-ft)+60°~65° + 60°~65° M12: 27.5~31.4 N-m (2.8~3.2 kg-m, 20.3~23.1 lb-ft)+60°~65° + 60°~65°
4. Install the OCV (Oil Control Valve) filter (A). Tightening torque : 40.2 ~ 50.0 N-m (4.1 ~ 5.1 kg-m, 29.7 ~ 36.9 lb-ft)
5. Install the OCV (Oil Control Valve) (A). Tightening torque: 9.8 ~ 11.8 N-m (1.0 ~ 1.2 kg-m, 7.2 ~ 8.7 lb-ft) CAUTION: Do not reuse the OCV (Oil Control Valve) when dropped. Keep the OCV clean. Do not hold the OCV (Oil Control Valve) sleeve during servicing. When the OCV is installed on the engine, be careful not to rotate the engine while holding the yoke.
6. Install the camshafts. Align the camshaft timing chain with the intake timing chain sprocket and exhaust timing chain sprocket as shown. Install the camshaft (A) and bearing caps (B). Tightening torque: 13.7 ~ 14.7 N-m (1.4 ~ 1.5 kg-m, 10.1 ~ 10.8 lb-ft) Install the timing chain auto tensioner (A). Tightening torque: 7.8 ~ 9.8 N-m (0.8 ~ 1.0 kg-m, 5.8 ~ 7.2 lb-ft) Remove the auto tensioner stopper pin (B).
7. Check and adjust valve clearance. See «VALVE CLEARANCE INSPECTION & ADJUSTMENT»(ref-272903-S31381886592007112900000) .
8. Using the Service Tool (09221 - 21000), install the camshaft bearing oil seal.
9. Install the camshaft sprocket.
10. Install the cylinder head cover. Install the cylinder head cover gasket (A) in the groove of the cylinder head cover (B). Apply liquid gasket to the head cover gasket at the corners of the recess. NOTE: Use liquid gasket, loctite No. 5999. Check that the mating surfaces are clean and dry before applying liquid gasket. After assembly, wait at least 30 minutes before filling the engine with oil. Install the cylinder head cover (A) with the 12 bolts (B). Uniformly tighten the bolts in several passes. Tightening torque: 7.8 ~ 9.8 N-m (0.8 ~ 1.0 kg-m, 5.8 ~ 7.2 lb-ft)
11. Install the PCV (Positive Crankcase Ventilation) hose.
12. Install the timing belt. See «TIMING BELT»(ref-272903-S21027696902007112900000) .
13. Install the intake manifold. See «INTAKE AND EXHAUST SYSTEM»(ref-272903-S03757669002007112900000) .
14. Install the exhaust manifold. See «INTAKE AND EXHAUST SYSTEM»(ref-272903-S03757669002007112900000) .
15. Install the spark plug cables.
16. Install the power steering pump bracket (A) and bolts (B, C). Tightening torque: Bolt (B) : 34.3 ~ 49.0 N-m (3.5~ 5.0 kg-m, 25.3 ~ 36.2 lb-ft) Bolt (C): 11.8~ 14.7 N-m (1.2~ 1.5 kg-m, 8.7 ~ 10.8 lb-ft)
17. Install the power steering pump. See «CHECKING POWER STEERING BELT TENSION»(ref-272906-S09346315552007112900000) .
18. Install the accelerator cable.
19. Install the brake booster hose (C).
20. Connect the hose (B) of the PCSV (Purge Control Solenoid Valve) side.
21. Connect the fuel inlet hose (A) of the delivery pipe side.
22. Install the engine wire harness connectors and wire harness clamps to the cylinder head and the intake manifold. Connect the PCSV (Purge Control Solenoid Valve) connector (A). Connect the front heated oxygen sensor connector (A). Connect the CKP (Crankshaft Position Sensor) connector (B). Connect the oil pressure switch connector (C). Connect the air conditioner compressor switch connector (F). Connect the ground cables (D, E) to intake manifold and vehicle's body. Connect the knock sensor connector (C) Connect the fuel injector connectors (B) Connect the CMP (Camshaft position sensor) connector (A). Connect the ISA (Idle Speed Actuator) connector (B). Connect the TPS (Throttle Position Sensor) connector (A). Connect the ignition coil connector (D). Connect the ECT (Engine Coolant Temperature Sensor) connector (C). Connect the oil temperature sensor connector (B). Connect the OCV (Oil Control Valve) connector (A).
23. Install the heater hose (A).
24. Install the upper radiator hose (A) and lower radiator hose (B).
25. Install the intake air hose and air cleaner assembly. Install the air cleaner lower cover (A) and bolts (B). Tightening torque: 7.8 ~ 9.8 N-m (0.8 ~ 1.0 kg-m, 5.8 ~ 7.2 lb-ft) Install the air cleaner element. Install the intake air hose (D) and air cleaner upper cover (C). Install the breather hose (B) to intake air hose (D). Connect the AFS (Air Flow Sensor) connector (A).
26. Install the engine cover. Tightening torque: 3.9 ~ 5.9 N-m (0.4 ~ 0.6 kg-m, 2.9 ~ 4.3 lb-ft)
27. Install the heat shield (B) and connect the battery terminals (A) to the battery.
28. Fill with engine coolant.
29. Start the engine and check for leaks.
30. Recheck engine coolant level and oil level.

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REMOVAL

Note. Mark all wiring and hoses to avoid wrong connections.

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1. Disconnect the battery terminals (A) and remove the heat shield (B).
2. Remove the battery and battery tray.
3. Remove the engine cover.
4. Drain the engine coolant. Remove the radiator cap to speed draining.
5. Remove the intake air hose and air cleaner assembly. Disconnect the AFS (Air Flow Sensor) connector (A). Disconnect the breather hose (B) from intake air hose (D). Remove the intake air hose (D) and air cleaner upper cover (C). Remove the air cleaner element. Remove the bolts (B) and air cleaner lower cover (A).
6. Remove the upper radiator hose (A) and lower radiator hose (B).
7. Remove the ATF (Automatic transaxle fluid) cooler hose (A).
8. Remove the radiator. See «COOLING SYSTEM»(ref-272903-S17879332322007112900000) .
9. Remove the heater hose (A).
10. Remove the accelerator cable (A).
11. Remove the engine wire harness connectors and wire harness clamps from the cylinder head and the intake manifold. Disconnect the OCV (Oil Control Valve) connector (A). Disconnect the oil temperature sensor connector (B). Disconnect the ECT (Engine Coolant Temperature) sensor connector (C). Disconnect the ignition coil connector (D). Disconnect the TPS (Throttle Position Sensor) connector (A). Disconnect the ISA (Idle Speed Actuator) connector (B). Disconnect the CMP (Camshaft Position Sensor) connector (A). Disconnect the four fuel injector connectors (B). Disconnect the knock sensor connector (C). Disconnect the ground cables (D, E) from the intake manifold and vehicle's body. Disconnect the air conditioner compressor switch (F). Disconnect the front heated oxygen sensor connector (A). Disconnect the CKP (Crankshaft Position Sensor) connector (B). Disconnect the oil pressure switch connector (C). Disconnect the PCSV (Purge Control Solenoid Valve) connector (A).
12. Remove the transaxle wire harness connectors and control cable from transaxle (A/T). Disconnect the transaxle range switch connector (A). Disconnect the solenoid valve connector (B). Disconnect the input shaft speed sensor connector (C). Disconnect the output shaft speed sensor connector (D). Disconnect the vehicle speed sensor connector (A). Remove the transaxle ground cable (A). Remove the control cable nut (A) from transaxle range switch. Remove the control cable.
13. Disconnect the fuel inlet hose (A) of the delivery pipe side.
14. Disconnect the hose (B) of the PCSV (Purge Control Solenoid Valve) side.
15. Remove the brake booster vacuum hose (C).
16. Remove the power steering pump drive belt.
17. Remove the power steering pump and use a wire to secure the pump to the vehicle so that it is out of the way.
18. Remove the front wheel (RH, LH).
19. Remove the bolts (B) and RH side cover (A).
20. Remove the air conditioner compressor drive belt.
21. Remove the air conditioner compressor and fix the compressor to vehicle with a wire.
22. Remove the rear oxygen sensor connector (A) and clamp.
23. Disconnect the starter motor connector (B) and terminal (C).
24. Remove the mounting clip of the starter cable.
25. Remove the alternator connector (A) and terminal (B).
26. Remove the front muffler (A). Tightening torque: Nut (B) : 39.2 ~ 58.8 N-m (4.0~ 6.0 kg-m, 28.9 ~ 43.4 lb-ft) Bolt (C) : 29.4 ~ 39.2 N-m (3.0 ~ 4.0 kg-m, 21.7 ~ 28.9 lb-ft)
27. Remove the drive shaft.
28. Remove the front roll stopper. Tightening torque: 49.0 ~ 63.7 N-m (5.0 ~ 6.5 kg-m, 36.2 ~ 47.0 lb-ft)
29. Remove the rear roll stopper. Tightening torque: 49.0 ~ 63.7 N-m (5.0 ~ 6.5 kg-m, 36.2 ~ 47. 0 lb-ft)
30. Install the engine hanger lift to the engine and transaxle assembly.
31. Remove the bolt (B), nuts (C, D) and engine mounting support bracket (A). Tightening torque: Nut (D) : 68.6 ~ 93.2 N-m (7.0~ 9.5 kg-m, 50.6 ~ 68.7 lb-ft) Bolt (B), Nut (C) : 49.0~63.7 N-m (5.0~6.5 kg-m, 36.2~47.0 lb-ft)
32. Remove the transaxle mounting bracket. Tightening torque: Bolt (A,C) : 39.2 ~ 49.0 N-m (4.0~ 5.0 kg-m, 28.9 ~ 36.2 lb-ft) Nut (B) : 88.3 ~ 107.9 N-m (9.0 ~ 11.0 kg-m, 65.1 ~ 79.6 lb-ft)
33. Using engine hanger lift, remove the engine and transaxle assembly from vehicle. CAUTION: When removing the engine and transaxle assembly, be careful not to damage any surrounding parts or body components.

Installation is in the reverse order of removal.

Perform the following

1. Adjust the shift cable.
2. Adjust the throttle cable.
3. Refill the engine with engine oil.
4. Refill the transaxle with fluid.
5. Refill the radiator and reservoir tank with engine coolant.
6. Place the heater control knob on "HOT" position.
7. Bleed air from the cooling system Start engine and let it run until it warms up. (until the radiator fan operates 3 or 4 times.) Turn Off the engine. Check the level in the radiator, add coolant if needed. This will allow trapped air to be removed from the cooling system. Put the radiator cap on tightly, then run the engine again and check for leaks.
8. Clean the battery posts and cable terminals with sandpaper assemble them, then apply grease to prevent corrosion.
9. Inspect for fuel leakage. NOTE: After assemble the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump runs for approximately two seconds and fuel line pressurizes.
10. Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.

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1. M/T : Remove the fly wheel.
2. A/T : Remove the drive plate.
3. Install the engine block onto an engine stand for disassembly.
4. Remove the timing belt. See «REMOVAL»(ref-272903-S09714956372007112900000) .
5. Remove the cylinder head. See «REMOVAL»(ref-272903-S27766104682007112900000) .
6. Remove the oil level gauge tube (A).
7. Remove the knock sensor (A).
8. Remove the oil pressure switch (A).
9. Remove the water pump.
10. Remove the oil pan (A).
11. Remove the oil screen. Remove the 2 bolts (C), oil screen (A) and gasket (B).
12. Check the connecting rod end play.
13. Remove the connecting rod caps and check oil clearance.
14. Remove the piston and connecting rod assemblies. Using a ridge reamer, remove all the carbon from the top of the cylinder. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block. NOTE: Keep the bearings, connecting rod and cap together. Arrange the piston and connecting rod assemblies in the correct order.
15. Remove the front case.
16. Remove the rear oil seal case. Remove the 5 bolts (B) and rear oil seal case (A).
17. Remove the crankshaft bearing cap and check oil clearance.
18. Check the crankshaft end play.
19. Lift the crankshaft (A) out of the engine, being careful not to damage journals. NOTE: Arrange the main bearings and thrust bearings in the correct order.
20. Check fit between piston and piston pin. Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and pin as a set.
21. Remove the piston rings. Using a piston ring expander, remove the 2 compression rings. Remove the 2 side rails and oil ring by hand. NOTE: Arrange the piston rings in the correct order only.
22. Remove the connecting rod from the piston. Using a press, remove the piston pin from piston. (Press-in load: 350 ~ 1,350 kg (772~2,976 lb.))

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1. Check the connecting rod end play. Using feeler gauge, measure the end play while moving the connecting rod back and forth. End play Standard : 0.1 ~ 0.25 mm (0.0039 ~ 0.0098 in) Maximum : 0.4 mm (0.0157 in) If out-of-tolerance, install a new connecting rod. If still out-of-tolerance, replace the crankshaft.
2. Check the connecting rod bearing oil clearance. Check that the match marks on the connecting rod and cap are aligned to ensure correct reassembly. Remove the 2 connecting rod cap nuts. Remove the connecting rod cap and lower bearing. Clean the crankshaft pin journal and bearing. Place a plastigage across the crankshaft pin journal. Reinstall the lower bearing and cap, and tighten the nuts. Tightening torque: 49.0 ~ 52.0 N-m (5.0 ~ 5.3 kg-m, 36.2 ~ 38.3 lb-ft) NOTE: Do not turn the crankshaft. Remove the 2 nuts, connecting rod cap and lower bearing. Measure the plastigage at its widest point. Standard oil clearance: 0.024 ~ 0.044 mm (0.0009 ~ 0.0017 in) If the plastigage measures too wide or too narrow, remove the upper and lower bearing and then install a new bearings with the same color mark. Recheck the oil clearance. CAUTION: Do not file, shim, of scrape the bearings or the caps to adjust clearance. If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing. Recheck the oil clearance. NOTE: If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, machine or replace the crankshaft and start over. CAUTION: If the alignment marks are unreadable because of an accumulation of grease or grime, don't clean with a wire brush or abrasive cleaner. Clean only with correct cleaning solvent or detergent. Select the bearing by using selection table.
3. Check the connecting rods. When reinstalling, make sure that cylinder numbers put on the connecting rod and cap at disassembly match. When a new connecting rod is installed, make sure that the notches for holding the bearing in place are on the same side. Replace the connecting rod if it is damaged on the thrust faces at either end. Also if step wear or a severely rough surface of the inside diameter of the small end is apparent, the rod must be replaced as well. Using a connecting rod aligning tool, check the rod for bend and twist. If the measured value is close to the repair limit, correct the rod with a press. Any connecting rod that has been severely bent or distorted should be replaced. Allowable bend of connecting rod: 0.05 mm / 100 mm (0.0020 in / 3.94 in ) or less Allowable twist of connecting rod: 0.1 mm / 100 mm (0.0039 in / 3.94 in) or less
4. Check the crankshaft bearing oil clearance. To check main bearing-to-journal oil clearance, remove the main bearing caps and lower bearings. Clean each main journal and lower bearing with a clean shop towel. Place one strip of plastigage across each main journal. Reinstall the lower bearings and caps, then tighten the bolts. Tightening torque : 27.5 ~ 31.4 N-m (2.8 ~ 3.2 kg-m, 20.3 ~ 23.1 lb~ft)+60° ~ 64° NOTE: Do not turn the crankshaft. Remove the cap and lower bearing again, and measure the widest part of the plastigage. Standard oil clearance: 0.028 ~ 0.048 mm (0.0011 ~ 0.0019 in) If the plastigage measures too wide or too narrow, remove the upper and lower bearing and then install a new bearings with the same color mark. Recheck the oil clearance. CAUTION: Do not file, shim, or scrape the bearings or the cap to adjust clearance. If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing. Recheck the oil clearance. NOTE: If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the crankshaft and start over. CAUTION: If the alignment marks are unreadable because of accumulation of grease or grime, don't clean with a wire brush or abrasive cleaner. Clean only with correct cleaning solvent or detergent. For cylinder block crankshaft journal bore mark location, see letters stamped on the end of the block as a mark for the size of each of the 5 main journal bores. Use them, and the numbers or letters stamped on the crank (marks for main journal size), to choose the correct bearings. Select the bearing by using selection table.
5. Check the crankshaft end play. Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver. End play: Standard: 0.06 ~ 0.26 mm (0.0024 ~ 0.0102 in) Limit : 0.30 mm (0.0118 in) If the end play is greater than maximum, replace the thrust bearings as a set. Thrust bearing thickness: 2.44 ~ 2.77 mm (0.0961 ~ 0.0972 in)
6. Inspect the crankshaft main journals and pin journals. Using a micrometer, measure the diameter of each main journal and pin journal. Main journal diameter: 56.942 ~ 56.962 mm (2.2418 ~ 2.2426 in) Pin journal diameter: 44.946 ~ 44.966 mm (1.7695 ~ 1.7703 in)

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1. Remove the gasket material. Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.
2. Clean the cylinder block. Using a soft brush and solvent, thoroughly clean the cylinder block.
3. Inspect the top surface of cylinder block for flatness. Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head gasket for warpage. Flatness of cylinder block gasket surface Total : Less than 0.05 mm (0.0020 in) Bore to bore : Less than 0.03 mm (0.0012 in)
4. Inspect the cylinder bore. Visually check the cylinder for vertical scratches. If deep scratches are present, replace the cylinder block.
5. Inspect the cylinder bore diameter. Using a cylinder bore gauge, measure the cylinder bore diameter at position in the thrust and axial direction. Standard diameter: 82.00 ~ 82.03 mm (3.2283 ~ 3.2295 in)
6. Check the cylinder bore size code on the cylinder block bottom face.
7. Check the piston size mark (A) on the piston top face.
8. Select the piston related to cylinder bore class. Piston-to-cylinder clearance: 0.02 ~ 0.04 mm (0.0008 ~ 0.0016 in)