1.8L 4-CYLINDER Engine: Removal & Installation Kia Spectra I

REMOVAL & INSTALLATION

Note. For installation reference, label all electrical connectors, vacuum hoses, and fuel lines before removal. Also, place mating marks on engine hood and other major assemblies before removal.

Removal

1. Disconnect battery cables. Remove battery cover, battery and battery tray. Drain engine coolant. Remove data link connector upward from mass air flow sensor bracket.
2. Disconnect intake air temperature sensor connector and mass air flow sensor connector. Disconnect air intake hose from throttle body. Disconnect ventilation hose. Remove air duct. Remove accelerator cable and cruise control cable, if equipped. Remove air cleaner assembly.
3. Disconnect brake vacuum hose and purge control vacuum hose from dynamic chamber. Remove upper and lower radiator hoses. Disconnect fuel hose from fuel injector rail. Remove heater hoses. Disconnect IAC and throttle position sensor connectors. Disconnect injector connectors. Disconnect electric connectors and bracket, and reinstall engine hanger.
4. Disconnect terminal connectors from starter and generator. Remove right and left splash shields. Remove exhaust manifold heat shield and 3 power steering pump bracket bolts.
5. Remove A/C compressor bolts and A/C compressor mounting bracket bolts. Disconnect ground strap from top of transaxle. Remove No. 4 engine mounting nuts and bolt. Remove No. 4 engine mount.
6. On A/T models, disconnect input/turbine speed sensor connector. On M/T models, disconnect back-up light switch connector. On all models, disconnect vehicle speed sensor connector. On A/T models, remove "U" clip from selector cable at transaxle linkage. Remove nut and washer from transaxle linkage.
7. On M/T models, remove manual transaxle linkage and extension bar. Remove clutch release cylinder and pipe. On A/T models, disconnect transaxle range switch connector. Disconnect solenoid valve connector. Disconnect ATF cooler hoses.
8. On all models, raise and support vehicle. Remove front wheel assembly. Disconnect front oxygen sensor connector. Remove front exhaust pipe. Remove right and left tie rod ends from steering knuckles by removing cotter pin and nut from each tie rod end. Remove stabilizer control link bolt and nut from right and left stabilizer control links, and then remove stabilizer control link.
9. Remove pinch bolt and nut from right and left ball joints. Separate ball joints from control arms. Remove joint shaft support bracket from engine block. Pry axle shafts from transaxle.
10. Lower vehicle, and attach engine hoist for engine removal. Remove nuts from No. 2 engine mount-to-mounting member. Remove bolt from No. 3 engine mount. Remove No. 1 engine mount bolts. Lift engine and transaxle out as an assembly.

Installation

1. Install engine and transaxle into engine compartment as an assembly. Install No. 1 engine mount bolts. Install No. 3 engine mount bolt. Install No. 2 engine mount nuts. Install No. 4 engine mount.
2. Remove engine hoist. Install NEW clips onto axle shaft. Push drive shaft and joint shaft into transaxle with opening of clips pointing upward. Install joint shaft support bracket bolts. Install right and left lower ball joints into spindle. Install pinch bolts. Install right and left stabilizer control links. Install front exhaust pipe.
3. On A/T models, connect ATF cooler hoses. Connect solenoid valve connector. Connect automatic transaxle range switch connector. Install washer and nut at automatic transaxle linkage. On M/T models, install clutch release cylinder and pipe. Install extension bar and manual transaxle linkage. On all models, install "U" clip. On M/T models, connect back-up light switch connector and vehicle speed sensor connector.
4. On all models, connect input turbine speed sensor connector. Connect ground strap to top of transaxle. Install A/C compressor mounting bracket. Install power steering pump bracket bolts. Install exhaust manifold heat shield. Install right and left splash shields.
5. To complete removal procedure, reverse removal procedure. Tighten all bolts and nuts to specification. See «TORQUE SPECIFICATIONS»(ref-121770-S06482059022001090500000) .

1. Disconnect oxygen sensor. Remove exhaust manifold heat shield. Disconnect exhaust pipe and support bracket from exhaust manifold. Remove exhaust manifold.
2. To install, reverse removal procedure. Ensure gasket mating surfaces are clean and flat. Install gasket onto cylinder head. Install manifold and tighten manifold nuts/bolts evenly to specification, starting from center bolt and alternating outward. Install NEW donut gasket between exhaust pipe and manifold. See «TORQUE SPECIFICATIONS»(ref-121770-S06482059022001090500000) .

1. Disconnect negative battery cable. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-121770-S23544006102001090500000). Drain engine coolant and oil. Remove PCV hose and ventilation hose. Remove accelerator cable and cruise control cable, if equipped. Remove air intake hose and air inlet duct. Label and disconnect all necessary electrical connectors, ground wires, vacuum hoses, coolant hoses and control cables.
2. Remove exhaust manifold heat shield. Remove exhaust manifold pipe. Remove coolant bypass pipe. Remove intake manifold support bracket. Remove hydraulic lash adjuster. See «HYDRAULIC LASH ADJUSTER»(ref-121770-S27355375192001090500000). Loosen cylinder head bolts in 2-3 steps in sequence. (Scheme 17) Remove cylinder head.

Scheme 17

1. Install cylinder head gasket. Install cylinder head assembly and cylinder head bolts. Using 5-6 steps, tighten cylinder head bolts in sequence to specification. (Scheme 18) See «TORQUE SPECIFICATIONS»(ref-121770-S06482059022001090500000).
2. To complete installation, reverse removal procedure. Tighten bolts and nuts to specification. See «TORQUE SPECIFICATIONS»(ref-121770-S06482059022001090500000). Add all fluids as necessary. Operate engine until cooling fans cycle. Check ignition timing.

Scheme 18

Remove oil pump. See OIL PUMP . Using screwdriver, remove oil seal. To install, reverse, removal procedure. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS .

1. Disconnect negative battery cable. Remove all accessory drive belts. Remove water pump pulley. Remove crankshaft pulley and timing belt guide plate. Remove upper and lower timing belt covers.
2. Turn crankshaft so timing mark on timing belt pulley aligns with timing mark on engine. (Scheme 19) Ensure "I" mark on intake camshaft pulley aligns with mark on cylinder head cover. Ensure "E" mark on exhaust camshaft pulley aligns with mark on cylinder head cover. (Scheme 20)
3. If timing belt is to be reused, mark direction of timing belt rotation before removal. Loosen timing belt tensioner lock bolt. Move tensioner away from belt with spring fully extended. Tighten tensioner bolt while belt tension is released. Remove timing belt.
4. Loosen tensioner pulley lock bolt. Remove tensioner pulley. Remove timing belt. Mark direction of timing belt rotation for proper reinstallation.

1. Install tensioner pulley. Pull tensioner pulley to its farthest point, and tighten lock bolt. Ensure timing belt and engine marks align. (Scheme 19) Ensure intake and exhaust camshaft sprocket marks align. (Scheme 20)
2. Install timing belt onto crankshaft sprocket first, then idler pulley, exhaust camshaft sprocket, intake camshaft sprocket, and tensioner pulley in order. (Scheme 21) Ensure there is no looseness between belt and pulleys and sprockets.
3. Loosen timing belt tensioner lock bolt, and allow spring to apply tension on belt. Tighten tensioner pulley lock bolt to specification. See «TORQUE SPECIFICATIONS»(ref-121770-S06482059022001090500000). Rotate crankshaft clockwise 2 complete revolutions. Ensure timing marks align. If timing marks do not align, remove belt, realign all timing marks, and repeat installation procedure.
4. Check timing belt deflection. Check timing belt deflection with 22 lbs. (10 kg) of pressure applied to belt. Timing belt deflection should be.36-.45" (9.1-11.4 mm). If timing belt deflection is not within specification, repeat procedure and/or replace timing belt tensioner spring. If timing belt deflection is within specification, reverse removal procedure to complete installation. Tighten bolts and nuts to specification. See «TORQUE SPECIFICATIONS»(ref-121770-S06482059022001090500000).

Scheme 19

Identifying Camshaft Sprocket Timing Marks. Scheme 20

Scheme 21

1. Disconnect negative battery cable. Remove center cover. Remove ignition coils and spark plug wires. Disconnect PCV hose and ventilation hose. Remove timing belt. See «TIMING BELT»(ref-121770-S37509891342001090500000).
2. Remove cylinder head cover. Align camshaft and crankshaft timing belt alignment marks. (Scheme 19)and (Scheme 20).
3. Remove phase sensor. Remove camshaft sprockets. Loosen camshaft bearing caps bolts in 5 or 6 steps in sequence. (Scheme 22) Remove camshafts. Reference mark HLAs to identify their original position if they will be reused. NOTE: Install Hydraulic Lash Adjusters (HLA) in original locations. Failure to install HLAs in their original location will result in premature and uneven wear of HLAs and camshafts. Remove HLAs from cylinder head. Place HLAs upside down in an oil-filled container.

1. Apply engine oil onto friction surfaces of HLA. Install HLA into bores of cylinder head. Ensure HLA moves smoothly in cylinder head bore. Apply engine oil onto camshaft and camshaft bearing surfaces. Install camshaft so camshaft dowel pins point straight up. Install camshaft bearing caps according to cap number, with directional arrows pointing forward. Install bolts into camshaft bearing caps, and tighten in 5 or 6 steps in sequence to specification. (Scheme 22) See «TORQUE SPECIFICATIONS»(ref-121770-S06482059022001090500000).
2. Apply engine oil onto lip of NEW camshaft seal. Seat camshaft seal by hand, and tap seal into place until flush with edge of camshaft bearing cap. Install camshaft pulleys onto camshaft aligning "I" mark with intake camshaft dowel pin and "E" mark with exhaust camshaft dowel pin. (Scheme 20)
3. To complete installation, reverse removal procedure. Tighten bolts and nuts to specification. See «TORQUE SPECIFICATIONS»(ref-121770-S06482059022001090500000).

Scheme 22

1. Disconnect negative battery cable. Remove center cover. Remove ignition coils and spark plug wires. Disconnect PCV hose and ventilation hose. Remove timing belt. See «TIMING BELT»(ref-121770-S37509891342001090500000)
2. Remove cylinder head cover. Align camshaft and crankshaft timing belt alignment marks. (Scheme 19)and (Scheme 20).
3. Remove phase sensor. Remove camshaft pulleys. Loosen camshaft bearing caps bolts in 5 or 6 steps in sequence. (Scheme 22) Remove camshafts.

1. Apply engine oil onto camshaft and camshaft bearing surfaces. Install camshaft so camshaft dowel pins point straight up. Install camshaft bearing caps according to cap number, with directional arrows pointing forward. Install bolts into camshaft bearing caps, and tighten in 5 or 6 steps in sequence to specification. (Scheme 22) See «TORQUE SPECIFICATIONS»(ref-121770-S06482059022001090500000).
2. Apply engine oil onto lip of NEW camshaft seal. Seat camshaft seal by hand, and tap seal in place until it's flush with edge of camshaft bearing cap. Install camshaft pulleys onto camshaft aligning "I" mark with intake camshaft dowel pin and "E" mark with exhaust camshaft dowel pin. (Scheme 20)
3. To complete installation, reverse removal procedure. Tighten bolts and nuts to specification. See «TORQUE SPECIFICATIONS»(ref-121770-S06482059022001090500000).

Disconnect negative battery cable. On M/T, remove transaxle and flywheel. See appropriate article in CLUTCHES. For A/T, remove transaxle and drive plate. See TRANSMISSION REMOVAL & INSTALLATION article in AUTOMATIC TRANSMISSION SERVICING. On all models, remove rear cover. Using seal remover, remove oil seal from rear cover.

To install, lubricate seal lip with light coat of oil. Tap seal in until it is flush or no more than 0.02" (0.50 mm) below surface of cover. Install rear cover. On M/T install flywheel and manual transaxle. On A/T models, install drive plate and automatic transaxle. On all models, to complete installation, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS .

Disconnect negative battery cable. Drain coolant. Remove timing belt. See TIMING BELT . Remove water inlet pipe and gasket. Remove water pump bolts, and remove water pump. Remove gasket and clean gasket mating surface of engine block.

Ensure all gasket mating surfaces are clean. Install water pump gasket onto water pump. Install water pump. Tighten bolts to specification. See TORQUE SPECIFICATIONS .

Disconnect negative battery cable. Drain engine oil. Remove engine splash covers. Remove exhaust header pipe and support brackets from front exhaust system. Remove oil pan mounting bolts. Using screwdriver, remove oil pan. Remove oil strainer.

Note. Install oil pan within 5 minutes after silicone sealant is applied.

Install oil strainer. Apply continuous bead of silicone sealant onto baffle plate along inside of bolt holes on contact surfaces. Install oil pan. Install oil pan mounting bolts. Ensure appropriate bolt is installed. Tighten to specification. (Scheme 23)To complete installation, reverse removal procedure. Tighten all bolts to specification. See TORQUE SPECIFICATIONS. Fill engine with oil.

Scheme 23

Piston Pin Replacement

1. Match mark piston pin and rod piston for reassembly reference. Using arbor press and piston pin removal/installation set, press piston pin through rod and out of piston.
2. Check piston-to-pin clearance, and rod-to-pin interference fit. See «PISTONS, PINS & RINGS»(ref-121770-S03241246602001090500000) table under ENGINE SPECIFICATIONS. Ensure piston mark and rod identification mark are in proper position. Press pin into piston and rod until pin is centered. Piston should pivot freely.

1. Disconnect negative battery cable. Drain engine oil. Remove timing belt. See «TIMING BELT»(ref-121770-S37509891342001090500000) under REMOVAL & INSTALLATION. Remove oil pan and strainer. See «OIL PAN»(ref-121770-S13067140942001090500000) under REMOVAL & INSTALLATION. Remove generator.
2. Remove A/C compressor and mounting bracket (if equipped) from engine block. Remove crankshaft pulley lock bolt. Remove timing belt pulley. Remove oil pump mounting bolt. Remove oil pump.
3. Remove front oil seal. Carefully clean all gaskets and sealant from mating surfaces without damaging sealing/mating surfaces. Remove all sealant from components and bolts. Check oil pump clearances. See «OIL PUMP SPECIFICATIONS»(ref-121770-S20087568062001090500000) table. Replace oil pump as necessary.

1. Use NEW gaskets when installing oil pump and pick-up tube. Tighten oil pump bolts to specification. See «TORQUE SPECIFICATIONS»(ref-121770-S06482059022001090500000) . Apply light oil coat of clean oil onto oil seal lip, and tap oil seal into oil pump body until it is flush with edge of pump body. DO NOT bottom seal in pump body.
2. To complete installation, reverse removal procedure. Tighten bolts and nuts to specification. See «TORQUE SPECIFICATIONS»(ref-121770-S06482059022001090500000) . Check oil fluid level, and add if necessary.

OIL PUMP SPECIFICATIONS