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1.8L 4-CYLINDER Engine: Other Kia Spectra I

Mechanical 3 illustrations ~845 words

FUEL PRESSURE RELEASE

To release fuel pressure, remove rear seat cushion. Disconnect fuel pump connector. (Scheme 24) Start and run engine until it stalls. Turn ignition off. Connect fuel pump connector. Install rear seat cushion.

Scheme 24

Scheme 24: FUEL PRESSURE RELEASE
Scheme 24: FUEL PRESSURE RELEASE

INTAKE MANIFOLD

Note. Removal and installation procedures are not available from manufacturer.

CYLINDER HEAD

CAUTIONRotate crankshaft in clockwise direction only.

REAR CRANKSHAFT OIL SEAL

Note. Rear crankshaft oil seal can be removed without removing oil pan or crankshaft.

Ensure all mating surfaces are clean. Check cylinder head for warpage. Resurface cylinder head if warpage exceeds .004" (.10 mm). Check manifold contact surfaces for warpage. Resurface manifold surfaces or replace cylinder head if warpage exceeds .008" (.20 mm). Check cylinder head height. See CYLINDER HEAD table under ENGINE SPECIFICATIONS. If measurements are not as specified, replace cylinder head.

Valve Springs

Ensure valve spring free length and out-of-square are within specification. See VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS. Replace valve spring as necessary.

Valves

Check valve face angle, margin thickness and stem diameter. Service or replace valves if measurements are not within specification. See VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS.

Valve Guides

  1. Check valve stem-to-valve guide oil clearance. Ensure valve guide inside diameter is within specification. See «CYLINDER HEAD»(ref-121770-S00059299262001090500000) table under ENGINE SPECIFICATIONS.
  2. Measure valve guide installed height. If installed height is not within specification, adjust or replace valve guide or cylinder head as necessary. See «CYLINDER HEAD»(ref-121770-S00059299262001090500000) table under ENGINE SPECIFICATIONS.

Valve Seat

Note. Valve seat replacement information is not available from manufacturer.

  1. Service valve guide as needed before servicing valve seat. Inspect valve seat for roughness, pitting, cracks and damage. Check valve seat angle and seat width.
  2. Measure seat contact width on valve, and ensure seat contact position should be in center of valve face. Service seat if angle and width are not within specification. See «CYLINDER HEAD»(ref-121770-S00059299262001090500000) table under ENGINE SPECIFICATIONS. Measure valve installed height after servicing valve seat.

Valve Seat Correction Angles

  1. Measure seat contact width on valve. See «CYLINDER HEAD»(ref-121770-S00059299262001090500000) table under ENGINE SPECIFICATIONS. Ensure valve/seat contact position is at center of valve face. If width and position are not within specification, cut seats as necessary.
  2. If seat contact position is too high, correct using 63-degree cutter and 45-degree cutter. Finish angle using 45-degree stone until contact width is corrected.
  3. If seat contact position is too low, correct using 0-degree and 45-degree cutter. Finish angle using 45-degree stone until contact width is corrected. Seat valve to seat using lapping compound.

Valve Stem Installed Height

  1. After servicing valves, measure valve stem installed height. See «VALVE INSTALLED HEIGHT»(ref-121770-S17968953342001090500000) table. (Scheme 25) If installed valve height is within standard specification, no adjustment is necessary.
  2. If installed valve height exceeds standard specification but does not exceed service limit specification, install adjusting shim on spring seat to bring installed height back within standard specification.
  3. If valve stem installed height exceeds specification, replace valve. If valve stem installed height still exceeds limit, replace cylinder head. See «VALVE INSTALLED HEIGHT»(ref-121770-S17968953342001090500000) table.

Scheme 25

Scheme 25
Scheme 25
ApplicationIn. (mm)
Intake
Standard1.432-1.467 (36.37-37.26)
Service Limit(1) 1.467-1.495 (36.37-37.97)
Beyond Limit(2) 1.495 (36.37)
Exhaust
Standard1.431-1.467 (36.35-37.26)
Service Limit(1) 1.467-1.494 (36.37-37.95)
Beyond Limit(2) 1.494 (37.95)
(1) If installed height exceeds specification, adjust with washer on spring seat area of cylinder head. (2) If installed height exceeds specification, replace cylinder head.
(1)If installed height exceeds specification, adjust with washer on spring seat area of cylinder head.
(2)If installed height exceeds specification, replace cylinder head.

VALVE INSTALLED HEIGHT

Fitting Pistons

  1. Check piston-to-cylinder wall clearance in 3 different vertical levels of piston travel. If clearance is not within specification, rebore cylinders to fit oversize pistons.
  2. Using NEW piston ring, measure piston ring side clearance around entire piston circumference. If clearance is not within specification, replace piston. See «PISTONS, PINS & RINGS»(ref-121770-S03241246602001090500000) table under ENGINE SPECIFICATIONS.

Piston Rings

Insert NEW piston ring into cylinder, and measure ring end gap. Grind ring ends or replace piston ring if ring end gap is not within specification. See PISTONS, PINS & RINGS table under ENGINE SPECIFICATIONS.

Connecting Rod Bearings

Check crankshaft connecting rod journals for wear, out-of-round, taper and undersize. Machine or replace crankshaft and/or bearings as necessary. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS.

Crankshaft & Main Bearings

  1. Before removing main caps, measure and record crankshaft end play. Using Plastigage, measure and record main bearing oil clearance. DO NOT rotate crankshaft when measuring oil clearances.
  2. Remove crankshaft. Measure and record each main journal diameter in 2 places. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(ref-121770-S22678511062001090500000) table under ENGINE SPECIFICATIONS. Machine or replace crankshaft as necessary. Main bearing upper halves are grooved.
  3. Install main bearing caps in original positions. Tighten bearing cap bolts in sequence and to specification. (Scheme 26) See «TORQUE SPECIFICATIONS»(ref-121770-S06482059022001090500000).

Scheme 26

Scheme 26
Scheme 26

Thrust Bearings

  1. Check crankshaft end play with crankshaft bearings and caps installed, but without connecting rods attached to crankshaft.
  2. Replace thrust bearing if end play is not within specification. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(ref-121770-S22678511062001090500000) table under ENGINE SPECIFICATIONS. Ensure thrust bearings are installed with oil groove facing crankshaft. Oversize thrust bearings are available.

Cylinder Block

Check cylinder bore out-of-round, taper, and piston-to-cylinder bore clearance. Check head gasket surface for warpage. If warpage is not within specification, machine or replace cylinder block as necessary. See CYLINDER BLOCK table under ENGINE SPECIFICATIONS.

Oil Pressure

With engine at operating temperature, oil pressure should be 43-57 psi (3.0-4.0 kg/cm 2 ) at 3000 RPM.

Oil Pressure Relief Valve

Pressure relief valve is located in oil pump body and is not adjustable.

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