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Kia Spectra 2004, Manual, Page: 316 / 368

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Kia Spectra 2004 Manual Download Page 316

REMOVAL

1. Disconnect negative battery cable. 

2. Remove flywheel, in case of A/T, remove drive plate. 

3. Remove rear cover. 

Fig. 323: Removing Rear Cover
Courtesy of KIA MOTORS AMERICA, INC.

NOTE:

Use a flywheel locking tool or equivalent when removing flywheel or drive 
plate.

2004 Kia Spectra

2004 ENGINES 1.8L 4-Cylinder

domingo, 7 de febrero de 2021 08:29:55 a. m.

Page 316

© 2011 Mitchell Repair Information Company, LLC. 

Summary of Contents for Spectra 2004

Page 1: ...3 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 49 a m Page 1 2011 Mitchell Repair Information Company LLC domingo 7 d...

Page 2: ...TORS AMERICA INC Fig 2 Service Tools 2 Of 3 Courtesy of KIA MOTORS AMERICA INC 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 49 a m Page 2 2011 Mitchell Repair Infor...

Page 3: ...ools 3 Of 3 Courtesy of KIA MOTORS AMERICA INC TROUBLESHOOTING GUIDE ENGINE 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 49 a m Page 3 2011 Mitchell Repair Informat...

Page 4: ...gine Troubleshooting Chart 1 Of 3 Courtesy of KIA MOTORS AMERICA INC 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 49 a m Page 4 2011 Mitchell Repair Information Com...

Page 5: ...gine Troubleshooting Chart 2 Of 3 Courtesy of KIA MOTORS AMERICA INC 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 49 a m Page 5 2011 Mitchell Repair Information Com...

Page 6: ...3 Of 3 Courtesy of KIA MOTORS AMERICA INC TIMING BELT Fig 7 Timing Belt Troubleshooting Chart 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 49 a m Page 6 2011 Mitch...

Page 7: ...n ENGINE ASSEMBLY REMOVAL INSTALLATION REMOVAL 1 Disconnect battery cables Item Engine model T8 DOHC Type Gasoline 4 cycle Cylinder arrangement and number In line 4 cylinders Combustion chamber Pentro...

Page 8: ...s Courtesy of KIA MOTORS AMERICA INC 2 Remove battery and battery tray 3 Drain engine coolant 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 49 a m Page 8 2011 Mitche...

Page 9: ...ature sensor connector and mass air flow sensor connector 6 Disconnect air intake hose from throttle body 7 Disconnect ventilation hose 8 Remove fresh air duct 9 Remove accelerator cable and cruise co...

Page 10: ...of KIA MOTORS AMERICA INC 10 Remove air cleaner assembly 11 Disconnect brake vacuum hose and purge control vacuum hose from dynamic chamber 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de f...

Page 11: ...pper 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 2004 Kia Spectra 2004 ENGI...

Page 12: ...cting Fuel Hose Courtesy of KIA MOTORS AMERICA INC 14 Remove heater hoses 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 49 a m Page 12 2011 Mitchell Repair Informati...

Page 13: ...urtesy of KIA MOTORS AMERICA INC 15 Disconnect IAC and throttle position sensor connectors 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 49 a m Page 13 2011 Mitchell...

Page 14: ...f KIA MOTORS AMERICA INC 16 Disconnect injector connectors Fig 15 Disconnecting Injector Connectors Courtesy of KIA MOTORS AMERICA INC 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrer...

Page 15: ...1 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 2004 Kia Spectra 2004 ENGINES...

Page 16: ...Starter Courtesy of KIA MOTORS AMERICA INC 19 Disconnect generator B terminal connector and connector C121 from generator 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08...

Page 17: ...nd Connector C121 From Generator Courtesy of KIA MOTORS AMERICA INC 20 Disconnect engine ground strap 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 49 a m Page 17 20...

Page 18: ...gine Ground Strap Courtesy of KIA MOTORS AMERICA INC 21 Remove RH LH splash shield 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 49 a m Page 18 2011 Mitchell Repair...

Page 19: ...sy of KIA MOTORS AMERICA INC 22 Remove exhaust manifold heat shield and three P S pump bracket bolts 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 49 a m Page 19 201...

Page 20: ...Bolts Courtesy of KIA MOTORS AMERICA INC 23 Remove four A C compressor bolts and five A C compressor mounting bracket bolts 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021...

Page 21: ...ting Bolts Courtesy of KIA MOTORS AMERICA INC 24 Disconnect ground strap from top of transaxle 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 49 a m Page 21 2011 Mitc...

Page 22: ...A 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 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7...

Page 23: ...tesy of KIA MOTORS AMERICA INC 27 Disconnect back up light switch connector M T 28 Disconnect vehicle speed sensor connector 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021...

Page 24: ...ORS AMERICA INC 29 Remove U clip from selector cable to transaxle linkage A T 30 Remove nut and washer from transaxle linkage A T 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de...

Page 25: ...AMERICA INC 31 Remove manual transaxle linkage and extension bar M T 32 Remove clutch release cylinder and pipe M T 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 49...

Page 26: ...CA INC 33 Disconnect transaxle range switch connector A T 34 Disconnect solenoid valve connector A T 35 Disconnect two ATF cooler hoses A T 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de f...

Page 27: ...ERICA INC 36 Remove both front wheels four lug nuts each 37 Disconnect front oxygen sensor connector 38 Remove front exhaust pipe 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de...

Page 28: ...0 Remove stabilizer control link bolt and nut from both right and left stabilizer control links then remove stabilizer control link 41 Remove pinch bolt and nut from both right and left ball joints 42...

Page 29: ...S AMERICA INC 43 Remove joint shaft support bracket from engine block three bolts 44 Gently pry both driveshafts from transaxle 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 20...

Page 30: ...s From Transaxle Courtesy of KIA MOTORS AMERICA INC 45 Support engine with engine hoist 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 49 a m Page 30 2011 Mitchell Re...

Page 31: ...st Courtesy of KIA MOTORS AMERICA INC 46 Remove two nuts from No 2 engine mount to mounting member 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 49 a m Page 31 2011...

Page 32: ...urtesy of KIA MOTORS AMERICA INC 47 Remove one bolt from No 3 engine mount 48 Remove three No 1 engine mount bolts 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 50 a...

Page 33: ...INSTALLATION 1 Install engine and transaxle into engine compartment as a unit 2 Install three No 1 engine mount bolts Tightening torque 49 2 69 lb ft 67 93 2 N m 6 8 9 5 kg m 2004 Kia Spectra 2004 EN...

Page 34: ...unt 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 Tightening torque 28 38 lb ft 38 51 N m 3 8 5 3 kg m 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cyl...

Page 35: ...Engine Mount Nuts Courtesy of KIA MOTORS AMERICA INC 5 Install No 4 engine mount 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 50 a m Page 35 2011 Mitchell Repair I...

Page 36: ...ft 8 Push driveshaft and joint shaft into transaxle with opening of clips pointing upward 9 Install joint shaft support bracket using three bolts Tightening torque 32 46 lb ft 43 62 N m 4 4 6 3 kg m 1...

Page 37: ...ht 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 B 51 69 lb ft 69 94 N m 6 9 9 4 kg...

Page 38: ...Exhaust Pipe Courtesy of KIA MOTORS AMERICA INC 13 Connect two ATF cooler hoses A T 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 50 a m Page 38 2011 Mitchell Repair...

Page 39: ...tor A T 15 Connect auto transaxle range switch connector A T 16 Install clutch release cylinder and pipe M T Tightening torque 13 7 18 8 lb ft 18 6 25 5 N m 1 9 2 6 kg m 2004 Kia Spectra 2004 ENGINES...

Page 40: ...ening torque 23 34 lb ft 32 47 N m Manual transaxle linkage tightening torque 12 17 lb ft 16 23 N m 18 Install washer and nut to auto transaxle linkage A T Tightening torque 24 83 lb ft 32 46 N m 3 2...

Page 41: ...urtesy of KIA MOTORS AMERICA INC 20 Connect back up light switch connector M T 21 Connect vehicle speed sensor connector M T 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021...

Page 42: ...Connector M T Courtesy of KIA MOTORS AMERICA INC 22 Connect input turbine speed sensor connector 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 50 a m Page 42 2011 M...

Page 43: ...Sensor Connector Courtesy of KIA MOTORS AMERICA INC 23 Connect ground strap to top of transaxle 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 50 a m Page 43 2011 Mi...

Page 44: ...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 A C compressor 28 38 lb ft 39 52 N m 3 9 5 3 kg m...

Page 45: ...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 2004 Kia Spectra 2004 ENGINES 1 8L...

Page 46: ...sy 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 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 50 a m...

Page 47: ...g 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 2004 Kia Spectra 2004 ENGINES 1 8...

Page 48: ...of KIA MOTORS AMERICA INC Connect two generator connectors B terminal connector and C121 to the generator 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 50 a m Page 4...

Page 49: ...ors Courtesy of KIA MOTORS AMERICA INC Connect B terminal and S terminal connectors to the starter 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 50 a m Page 49 2011...

Page 50: ...ctors To The Starter Courtesy of KIA MOTORS AMERICA INC Connect IAC and throttle position sensor connectors 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 50 a m Page...

Page 51: ...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 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de feb...

Page 52: ...nd Connecting Electric Connectors Courtesy of KIA MOTORS AMERICA INC Connect injector connectors 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 50 a m Page 52 2011 Mi...

Page 53: ...Injector Connectors Courtesy of KIA MOTORS AMERICA INC Connect heater hoses 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 50 a m Page 53 2011 Mitchell Repair Inform...

Page 54: ...ter Hoses Courtesy of KIA MOTORS AMERICA INC Connect fuel hose to injector rail 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 50 a m Page 54 2011 Mitchell Repair Inf...

Page 55: ...Injector Rail Courtesy of KIA MOTORS AMERICA INC Connect upper and lower radiator hoses 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 50 a m Page 55 2011 Mitchell R...

Page 56: ...ourtesy of KIA MOTORS AMERICA INC Connect brake vacuum hose and purge control vacuum hose to dynamic chamber 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 50 a m Pag...

Page 57: ...air duct Connect ventilation hose Install accelerator cable and auto cruise control cable if equipped Insert data link connector into mass air flow sensor bracket Connect intake air temperature senso...

Page 58: ...P S and A C belt Turn adjustment screw until correct belt deflection is achieved Tighten pivot bolt and mounting bolt Deflection New 8 0 9 0 mm 0 32 0 35 in Used 9 0 10 0 mm 0 36 0 39 in 2004 Kia Spe...

Page 59: ...kg m Fill engine coolant with specified type and amount Connect both battery cables Check and or fill all fluids Test run engine and perform an overall check ENGINE DISASSEMBLY INSPECTION REASSEMBLY...

Page 60: ...To Transaxle Disassembly Courtesy of KIA MOTORS AMERICA INC 1 Remove No 2 engine mount 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 50 a m Page 60 2011 Mitchell Rep...

Page 61: ...ine Mount Courtesy of KIA MOTORS AMERICA INC 2 Remove No 3 engine mount and bracket 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 50 a m Page 61 2011 Mitchell Repair...

Page 62: ...ving No 3 Engine Mount And Bracket Courtesy of KIA MOTORS AMERICA INC 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 50 a m Page 62 2011 Mitchell Repair Information C...

Page 63: ...ve 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 2004 Kia Spectra 2004 ENGINES 1...

Page 64: ...front and rear engine hangers 9 Remove generator by loosening adjusting bolt and removing mounting bolts and pivot bolt 10 Remove intake manifold support bracket 2004 Kia Spectra 2004 ENGINES 1 8L 4...

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: ...g Intake Manifold Courtesy of KIA MOTORS AMERICA INC 12 For timing belt removal see TIMING SYSTEM 13 Loosen cylinder head bolts in two or three steps following order shown in figure 2004 Kia Spectra 2...

Page 67: ...Courtesy of KIA MOTORS AMERICA INC 14 Remove cylinder head by lifting it off from cylinder block 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 50 a m Page 67 2011 M...

Page 68: ...or additional cylinder head removal and disassembly information see CYLINDER HEAD ASSEMBLY 16 Remove external engine components 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 20...

Page 69: ...tch 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 2004 Kia Spectra 2004 ENGI...

Page 70: ...19 Remove pilot bearing with SST Bearing puller or equivalent if necessary 20 Hold flywheel with SST Ring gear brake or equivalent 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero d...

Page 71: ...Bearing Courtesy of KIA MOTORS AMERICA INC 21 Remove six bolts to remove flywheel 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 50 a m Page 71 2011 Mitchell Repair I...

Page 72: ...lywheel Courtesy of KIA MOTORS AMERICA INC 22 Remove oil pan mounting bolts 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 50 a m Page 72 2011 Mitchell Repair Informa...

Page 73: ...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 b Do not damage sealing surface when removing old sealant 2004 Kia Spec...

Page 74: ...A Screwdriver Or Suitable Tool Courtesy of KIA MOTORS AMERICA INC 24 Remove oil strainer 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 50 a m Page 74 2011 Mitchell R...

Page 75: ...il Strainer Courtesy of KIA MOTORS AMERICA INC 25 Remove timing belt pulley 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 50 a m Page 75 2011 Mitchell Repair Informa...

Page 76: ...C 26 Remove oil pump mounting bolt and oil pump 27 Using a screwdriver covered by a rag remove oil seal from pump cover side 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021...

Page 77: ...Mounting Bolt And Oil Pump Courtesy of KIA MOTORS AMERICA INC 28 Remove rear cover 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 50 a m Page 77 2011 Mitchell Repair...

Page 78: ...KIA MOTORS AMERICA INC 29 Wrap a prying tool with a shop towel and slowly pry out rear oil seal 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 50 a m Page 78 2011 Mi...

Page 79: ...Out Rear Oil Seal Courtesy of KIA MOTORS AMERICA INC 30 Remove water pump 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 50 a m Page 79 2011 Mitchell Repair Informati...

Page 80: ...mp Courtesy of KIA MOTORS AMERICA INC 31 Remove oil filter and oil pressure switch 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 50 a m Page 80 2011 Mitchell Repair...

Page 81: ...ng Oil Filter And Oil Pressure Switch Courtesy of KIA MOTORS AMERICA INC 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 50 a m Page 81 2011 Mitchell Repair Informatio...

Page 82: ...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 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder d...

Page 83: ...cylinder number 37 Rotate crankshaft so that cylinders No 2 and No 3 are at Bottom Dead Center BDC and repeat marking procedure 38 Remove connecting rod nuts and gently loosen rod caps by tapping cap...

Page 84: ...on piston to release it from cylinder 41 Repeat this procedure for each cylinder Fig 85 Removing Piston Assemblies NOTE Cover connecting rod bolts to protect crankshaft journals 2004 Kia Spectra 2004...

Page 85: ...IA MOTORS AMERICA INC 44 Hold piston upright and gently move connecting rod 45 Release connecting rod and observe its movement NOTE Do not swing connecting rod wildly Constant hard contact with piston...

Page 86: ...s of piston pin bore 48 Tilt piston and allow piston pin to slide out into your hand Piston pins may need to be pressed out 49 Remove connecting rod from piston Keep individual piston piston pin and p...

Page 87: ...three steps following order shown in figure 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 ex...

Page 88: ...les INSPECTION CYLINDER BLOCK 1 Check cylinder block for following conditions and repair or replace cylinder block as needed a Leakage damage b Cracks c Scoring of cylinders 2 Check distortion of cyli...

Page 89: ...sy 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 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cyl...

Page 90: ...See Fig 92 Cylinder bore size Standard 3 1892 3 1897 in 81 006 81 019 mm Bore 0 010 in 0 25 mm 3 1990 3 1996 in 81 256 81 269 mm Bore 0 020 in 0 50 mm 3 2089 3 2094 in 81 506 81 519 mm NOTE Before sur...

Page 91: ...der diameter taper and out of round Taper 0 0007 in 0 019 mm Maximum Out of round 0 0007 in 0 019 mm Maximum NOTE Boring cylinders should be based on maximum oversized piston that can be installed wit...

Page 92: ...MERICA INC CONNECTING ROD 1 Check connecting rod bushing inside diameter Inside diameter 0 9055 0 9063 in 23 0 23 021 mm 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 2...

Page 93: ...hing inside diameter to determine piston pin fit Clearance 0 0004 0 0010 in 0 010 0 027 mm 3 If clearance is not within specification replace connecting rod bushing 4 Check each connecting rod for ben...

Page 94: ...ds if necessary MAIN BEARING AND CONNECTING ROD BEARINGS NOTE Connecting rods must always be replaced as an assembly Rod cap rod bolts and nuts are a matched set 2004 Kia Spectra 2004 ENGINES 1 8L 4 C...

Page 95: ...ankshaft bearing and crank pin journals for damage and scoring 2 Check oil holes for clogging 3 Set crankshaft on V blocks 4 Measure crankshaft run out at center journal Replace crankshaft if it is no...

Page 96: ...ometer to measure crankshaft main bearing journals and crank pin journals at X and Y direction as shown in figure CRANKSHAFT JOURNAL DIAMETER 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de...

Page 97: ...rankshaft Journal Diameter Chart Courtesy of KIA MOTORS AMERICA INC 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 51 a m Page 97 2011 Mitchell Repair Information Com...

Page 98: ...is excessive 7 Only grind crankshaft amount necessary to correct condition 8 If a crankshaft must be ground 0 020 in 0 50 mm or more heat treat crankshaft to ensure durability MAIN JOURNAL DIAMETER U...

Page 99: ...OURNAL DIAMETER UNDERSIZES Fig 101 Crank Pin Journal Diameter Undersize Chart Courtesy of KIA MOTORS AMERICA INC PISTON ASSEMBLIES PISTON COOLING JETS 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder dom...

Page 100: ...ir does not pass replace piston cooling jet valve Air pressure 35 6 44 1 psi 245 3 304 1 kpa 3 1 2 5 kg cm2 maximum 2 Check piston cooling jet nozzle for clogs Replace nozzle if necessary 2004 Kia Spe...

Page 101: ...ogs Courtesy of KIA MOTORS AMERICA INC PISTON NOTE Replacing a piston also requires replacing piston rings 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 51 a m Page...

Page 102: ...e 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 PISTON...

Page 103: ...rtesy of KIA MOTORS AMERICA INC NOTE If piston is collapsed or bell mouthed replace piston 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 51 a m Page 103 2011 Mitchel...

Page 104: ...in 0 15 mm 4 If clearance exceeds maximum replace piston or rebore cylinders and fit oversized pistons to all cylinders Fig 106 Measuring Piston To Cylinder Wall Clearance Courtesy of KIA MOTORS AMERI...

Page 105: ...ston Ring To Side Clearance Chart Courtesy of KIA MOTORS AMERICA INC 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 51 a m Page 105 2011 Mitchell Repair Information C...

Page 106: ...abnormal wear or breakage 4 Replace piston rings if necessary 5 Insert piston ring into cylinder by hand 6 Square ring in cylinder by inverting a piston into cylinder and pushing ring to the bottom o...

Page 107: ...of KIA MOTORS AMERICA INC 7 Place a feeler gauge in end gap and check end gap clearance END GAP CLEARANCE 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 51 a m Page...

Page 108: ...ston Ring End Gap Clearance Chart Courtesy of KIA MOTORS AMERICA INC 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 51 a m Page 108 2011 Mitchell Repair Information C...

Page 109: ...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 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de...

Page 110: ...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 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cyli...

Page 111: ...piston pin to piston clearance Clearance 0 00004 0 00006 in 0 001 0 015 mm 4 If clearance exceeds specification replace piston and piston pin REASSEMBLY NOTE Piston and piston pin are a matched set 20...

Page 112: ...Apply a coat of clean engine oil to all sliding and rotating parts before assembly 3 Replace main bearings and rod bearings if they are peeling burned or otherwise damaged 2004 Kia Spectra 2004 ENGIN...

Page 113: ...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 NOTE Do not reuse old gaskets or seals NOTE Veri...

Page 114: ...the oil ring expander and upper and lower oil rings b Install expander onto piston so that expander ends face upward c Install lower oil ring onto piston Ring may be installed with either face upward...

Page 115: ...MERICA INC 9 Check that oil ring expander separates upper and lower oil rings and that oil ring assembly spins freely on piston 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 20...

Page 116: ...xpander 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 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder doming...

Page 117: ...ng Position Courtesy of KIA MOTORS AMERICA INC 12 Align piston ring gaps as shown in figure 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 51 a m Page 117 2011 Mitche...

Page 118: ...l holes and main bearing journals thoroughly and dry components with compressed air 14 Install grooved main bearings into saddles on engine block 15 Install thrust bearings with oil groove facing cran...

Page 119: ...rankshaft on installed bearings 17 Install remaining main bearings into main bearing caps 18 Position Plastigage on crankshaft journals 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febre...

Page 120: ...Tightening torque 28 9 lb ft 39 2 N m 4kg m b Loosen bolts in reverse of order shown c Retighten bolts in order shown Tightening torque 14 5 lb ft 19 6 N m 2kg m d Mark bolts for rotational reference...

Page 121: ...ion grind and polish crankshaft and use undersized main bearings Oil Clearance 0 00095 0 00165 in 0 024 0 042 mm NOTE The widest point of Plastigage is the smallest clearance and the narrowest point o...

Page 122: ...ft main bearing journals and on main bearings on main bearing caps 26 Install main bearing caps along with lower main bearings according to cap number and mark 27 Tighten main bearing cap bolts accord...

Page 123: ...kshaft to ensure it does not bind 29 Place a dial indicator against front of crankshaft and zero gauge 30 Using a prying tool move crankshaft forward and zero dial indicator 31 Move the crankshaft tow...

Page 124: ...ay exceeds specification grind crankshaft and install oversized thrust bearings or replace crankshaft and thrust bearings THRUST BEARING WIDTH 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 d...

Page 125: ...Measuring Thrust Bearing Width Courtesy of KIA MOTORS AMERICA INC 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 51 a m Page 125 2011 Mitchell Repair Information Comp...

Page 126: ...nstall a bearing into connecting rod 34 Place rubber sleeves rubber fuel line works well on connecting rod bolts to protect crankshaft from damage 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo...

Page 127: ...ton and connecting rod assembly into a piston ring compressor 37 Rotate crankshaft so that crank pin journal for specific cylinder is at its lowest point bottom dead center 38 Lower piston and connect...

Page 128: ...connecting rod caps aligning marks made previous to disassembly and torque to specification Tightening torque 34 7 36 9 lb ft 47 50 N m 4 8 5 1 kg m NOTE Follow this procedure for remaining piston and...

Page 129: ...n 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 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domin...

Page 130: ...47 Install connecting rod cap and torque to specification Tightening torque 34 7 36 9 lb ft 47 50 N m 4 8 5 1 kg m 48 Insert a thickness gauge between connecting rod and crankshaft and check connecti...

Page 131: ...urtesy of KIA MOTORS AMERICA INC 49 If side clearance exceeds maximum side clearance specification replace connecting rod and cap 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de...

Page 132: ...eal 51 Install rear oil seal into rear cover by hand 52 Press oil seal into rear cover Protrusion 0 0 02 in 0 0 5 mm NOTE Oil seal must be pressed in until it is nearly flush with surface of rear cove...

Page 133: ...ickness 0 08 in 2 mm 54 Install the rear cover Tightening torque 5 8 8 0 lb ft 7 8 10 8 N m 0 8 1 1 kg m 55 Remove any sealant that protrudes from rear cover onto oil pan mounting surface 2004 Kia Spe...

Page 134: ...57 Install front oil seal by hand 58 Press oil seal into oil pump body Protrusion 0 02 0 04 in 0 5 1 0 mm NOTE Oil seal must be pressed in until it is nearly flush with front surface of oil pump body...

Page 135: ...ead of silicone sealant to oil pump body as shown in figure Thickness 0 04 0 08 in 1 2 mm CAUTION Oil pump body must be installed within 5 minutes after silicone sealant is applied 2004 Kia Spectra 20...

Page 136: ...t protrudes from oil pump onto oil pan mounting surface 63 Remove all foreign material from water pump mounting surface 64 Install water pump with a new gasket and torque to specification Tightening t...

Page 137: ...1 2 1 8 kg m 66 Apply a small amount of engine oil to rubber seal of oil filter 67 Install oil filter until rubber seal contacts base and then tighten filter 1 and 1 6 turn using an oil filter wrench...

Page 138: ...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 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 0...

Page 139: ...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 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cyl...

Page 140: ...OTORS 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 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 2...

Page 141: ...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 2004...

Page 142: ...ing 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 75 Install bolts apply sealant to reused bolts 2004 Kia...

Page 143: ...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 specificat...

Page 144: ...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 2004 Kia Spectra 2004 ENGIN...

Page 145: ...ure See Fig 148 Tightening torque 36 1 lb ft 49 N m 5 kg m b Loosen bolts in reverse of order shown c Retighten cylinder head bolts in order shown Tightening torque 28 9 lb ft 39 2 N m 4 kg m d Mark c...

Page 146: ...see TIMING SYSTEM 88 Install new intake manifold gasket 89 Install intake manifold Tightening torque 13 7 18 8 lb ft 18 6 25 5 N m 1 9 2 6 kg m 90 Install intake manifold bracket Tightening torque 27...

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: ...l bolts to specified torque Tightening torque Mounting bolts 27 38 lb ft 37 52 N m Adjusting bolt 14 19 lb ft 19 52 N m 94 Install front and rear engine hangers Fig 150 Installing Front And Rear Engin...

Page 149: ...nstalling 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 2004 Kia Spectra 2004 ENGINES...

Page 150: ...lling No 3 Engine Mount And Bracket Courtesy of KIA MOTORS AMERICA INC 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 52 a m Page 150 2011 Mitchell Repair Information...

Page 151: ...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 Tigh...

Page 152: ...ct 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 2004 Kia Spectr...

Page 153: ...g Radiator Drain Plug Courtesy of KIA MOTORS AMERICA INC 4 Drain engine oil 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 52 a m Page 153 2011 Mitchell Repair Inform...

Page 154: ...S AMERICA INC 5 Remove PCV hose and ventilation hose 6 Remove accelerator cable and auto cruise control cable if equipped 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08...

Page 155: ...se Control Cable Courtesy of KIA MOTORS AMERICA INC 7 Remove air intake hose and fresh air duct 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 52 a m Page 155 2011 Mi...

Page 156: ...urtesy of KIA MOTORS AMERICA INC 8 Disconnect brake vacuum hose and purge control vacuum hose at dynamic chamber 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 52 a m...

Page 157: ...And Purge Control Vacuum Hose Courtesy of KIA MOTORS AMERICA INC 9 Remove upper radiator hose 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 52 a m Page 157 2011 Mitc...

Page 158: ...isconnect fuel hose from injector rail WARNING Keep open flames and sparks away from open fuel lines or a fire or explosion may result 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrer...

Page 159: ...l Hose From Injector Rail Courtesy of KIA MOTORS AMERICA INC 11 Remove heater hoses 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 52 a m Page 159 2011 Mitchell Repai...

Page 160: ...urtesy of KIA MOTORS AMERICA INC 12 Disconnect IAC and throttle position sensor connectors 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 52 a m Page 160 2011 Mitchel...

Page 161: ...KIA MOTORS AMERICA INC 13 Disconnect injector connectors Fig 164 Disconnecting Injector Connectors Courtesy of KIA MOTORS AMERICA INC 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrer...

Page 162: ...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 2004 Kia Spectra 2004 EN...

Page 163: ...und Strap Courtesy of KIA MOTORS AMERICA INC 16 Remove exhaust manifold heat shield 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 52 a m Page 163 2011 Mitchell Repai...

Page 164: ...nifold Heat Shield Courtesy of KIA MOTORS AMERICA INC 17 Remove exhaust manifold pipe 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 52 a m Page 164 2011 Mitchell Rep...

Page 165: ...t Manifold Pipe Courtesy of KIA MOTORS AMERICA INC 18 Remove coolant bypass pipe 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 52 a m Page 165 2011 Mitchell Repair I...

Page 166: ...ass Pipe Courtesy of KIA MOTORS AMERICA INC 19 Remove intake manifold support bracket 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 52 a m Page 166 2011 Mitchell Rep...

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: ...ylinder head bolts in two or three steps following order shown in figure Fig 171 Cylinder Head Bolt Loosening Sequence Courtesy of KIA MOTORS AMERICA INC 23 Remove cylinder head INSTALLATION 1 Install...

Page 169: ...ft 49 N m 5 kg m b Loosen bolts in reverse of order shown c Retighten cylinder head bolts in order shown Tightening torque 28 9 lb ft 39 2 N m 4 kg m d Mark cylinder head bolts for rotational referen...

Page 170: ...G SYSTEM 5 For camshaft and HLA installation procedure see HYDRAULIC LASH ADJUSTER HLA 6 Install intake manifold support bracket Tightening torque 27 5 38 3 lb ft 37 2 51 9 N m 3 8 5 3 kg m 2004 Kia S...

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: ...6 N m 9 1 11 9 kg m Fig 175 Installing Coolant Bypass Pipe Courtesy of KIA MOTORS AMERICA INC 8 Install exhaust manifold Tightening torque A 28 34 lb ft 38 46 N m 3 9 4 7 kg m B 16 21 lb ft 22 28 N m...

Page 173: ...IA 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 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08...

Page 174: ...t Manifold Heat Shield Courtesy of KIA MOTORS AMERICA INC 10 Reconnect ground strap 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 52 a m Page 174 2011 Mitchell Repai...

Page 175: ...l 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 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febre...

Page 176: ...econnecting Electrical Connectors Courtesy of KIA MOTORS AMERICA INC 12 Connect injector connectors 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 52 a m Page 176 201...

Page 177: ...IAC and throttle position sensor connectors Fig 181 Connecting IAC And Throttle Position Sensor Connectors Courtesy of KIA MOTORS AMERICA INC 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 d...

Page 178: ...ling Heater Hoses Courtesy of KIA MOTORS AMERICA INC 15 Connect fuel hose to fuel injector rail 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 52 a m Page 178 2011 Mi...

Page 179: ...To Fuel Injector Rail Courtesy of KIA MOTORS AMERICA INC 16 Install upper radiator hose 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 52 a m Page 179 2011 Mitchell R...

Page 180: ...e Courtesy of KIA MOTORS AMERICA INC 17 Connect brake vacuum hose and purge control vacuum hose 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 52 a m Page 180 2011 Mi...

Page 181: ...rol Vacuum Hoses Courtesy of KIA MOTORS AMERICA INC 18 Install air intake hose and fresh air duct 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 52 a m Page 181 2011...

Page 182: ...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 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7...

Page 183: ...KIA MOTORS AMERICA INC 20 Install cruise control cable if equipped 21 Install PCV hose and ventilation hose 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 52 a m Page...

Page 184: ...ount and type of engine oil Refer to LUBRICATION SYSTEM 23 Fill engine with specified amount and type of coolant Refer to COOLING SYSTEM 24 Connect negative battery cable 2004 Kia Spectra 2004 ENGINES...

Page 185: ...BLY INSPECTION REASSEMBLY DISASSEMBLY 1 For camshaft and HLA disassembly see HYDRAULIC LASH ADJUSTER HLA 2 Protect HLA bore with SST K95A 1000 E or equivalent Compress valve springs with SST or equiva...

Page 186: ...Cylinder Head Courtesy of KIA MOTORS AMERICA INC 4 Remove valve seals with SST or equivalent 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 52 a m Page 186 2011 Mitch...

Page 187: ...ove lower spring seals from cylinder head INSPECTION CYLINDER HEAD 1 Inspect cylinder head for damage cracks and leakage of oil and water Replace cylinder head if necessary 2 Clean cylinder head and c...

Page 188: ...C 4 If distortion exceeds specification resurface or replace cylinder head Only remove the amount of material required to achieve a flat surface Maximum material removal 0 004 in 0 1 mm 5 Check cylind...

Page 189: ...t manifold mating surface distortion at two directions shown in figure Distortion 0 008 in 0 20 mm Maximum NOTE If cylinder head requires machining remove intake and exhaust manifolds and check their...

Page 190: ...replace cylinder head Maximum material removal 0 008 in 0 20 mm 9 Check cylinder block for distortion of cylinder head mating surface block deck in six directions shown in figure Distortion 0 006 in...

Page 191: ...8 in 0 20 mm CAMSHAFT 1 Set front and rear camshaft bearing journals on V blocks 2 Position a dial indicator on center bearing journal and zero dial 3 Rotate camshaft in V blocks and check runout Runo...

Page 192: ...terns cracks or damage 5 Measure cam lobe heights at two points as shown in figure See Fig 197 Lobe height Intake 1 6415 in 41 6949 mm Exhaust 1 6629 in 42 2369 mm 2004 Kia Spectra 2004 ENGINES 1 8L 4...

Page 193: ...on both sides A and B of journal as shown in figure See Fig 198 Standard diameter 1 0606 1 0616 in 26 940 26 965 mm Minimum diameter 1 0594 in 26 910 mm Out of round 0 002 in 0 05 mm maximum 2004 Kia...

Page 194: ...ts onto cylinder head 11 Position Plastigage on journals in axial direction 12 Do not rotate camshafts 13 Install camshaft caps according to cap number and arrow mark 14 Install cap bolts Tighten them...

Page 195: ...KIA MOTORS AMERICA INC 15 Loosen camshaft cap bolts in five or six steps in order shown in figure 16 Remove camshaft caps 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08...

Page 196: ...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 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domi...

Page 197: ...ove camshaft as far forward as possible 22 Zero dial 23 Using prying tool move camshaft as far rearward as possible 24 Check gauge to determine how much end play is present End play 0 0003 0 0004 in 0...

Page 198: ...amaged or bent valve stem b Rough or damaged face c Damaged or unevenly worn stem tip 2 Resurface or replace valve as needed Margin thickness Intake 0 0472 in 1 2 mm Exhaust 0 0472 in 1 2 mm 2004 Kia...

Page 199: ...TORS AMERICA INC 3 Measure length of each valve Length Intake 4 052 in 102 92 mm Exhaust 3 993 in 101 42 mm 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 53 a m Page...

Page 200: ...Length Courtesy of KIA MOTORS AMERICA INC 4 Measure diameter of each valve stem 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 53 a m Page 200 2011 Mitchell Repair I...

Page 201: ...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 2004 Kia Spectra 2004...

Page 202: ...uter diameter of valve stem from inside diameter of respective valve guide Clearance Intake valve 0 0010 0 0023 in 0 025 0 060 mm Exhaust valve 0 0012 0 0025 in 0 030 0 065 mm Max 0 008 in 0 20 mm 200...

Page 203: ...replace valve and or valve guide 8 Measure protrusion height of each valve guide Replace valve guide as needed A Intake 0 539 0 563 in 13 7 14 3 mm B Exhaust 0 658 0 681 in 16 7 17 3 mm 2004 Kia Spect...

Page 204: ...y of KIA MOTORS AMERICA INC NOTE Intake and exhaust valve guides are different Be sure to use correct valve guide 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 53 a...

Page 205: ...fying Proper Valve Guides Courtesy of KIA MOTORS AMERICA INC VALVE SEAT 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 53 a m Page 205 2011 Mitchell Repair Informatio...

Page 206: ...ks 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 2004 Kia Spectra 2004 ENGINES 1...

Page 207: ...against seat and rotating valve 360 a If Dychem blue is not removed 360 around valve face replace valve b If Dychem blue is not removed 360 around valve seat resurface valve seat 5 Measure seat conta...

Page 208: ...e face a If valve seating position is too high correct valve seat with a 63 valve seat cutter and a 45 cutter b If seating position is too low correct valve seat with a 0 and a 45 cutter 2004 Kia Spec...

Page 209: ...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 2004 Kia Spectra...

Page 210: ...AMERICA INC 9 Check for valve sink by measuring protruding length Dimension L of valve stem to lower valve spring seat 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29...

Page 211: ...5 Valve Sink Dimension Chart Courtesy of KIA MOTORS AMERICA INC 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 53 a m Page 211 2011 Mitchell Repair Information Compan...

Page 212: ...ng for cracks and damage 2 Measure free length and out of square Replace valve springs as needed Free length 1 84 in 46 7 mm Out of square 0 0638 in 1 62 mm maximum 2004 Kia Spectra 2004 ENGINES 1 8L...

Page 213: ...seal over seal over valve stem and onto valve guide 2 Install valves guide seal installer over valve seal NOTE Intake and exhaust valve seals are different Only exhaust valve seals have four teeth 20...

Page 214: ...Installer Courtesy of KIA MOTORS AMERICA INC CAUTION Using a hammer will damage valve seals 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 53 a m Page 214 2011 Mitch...

Page 215: ...g seat on cylinder head 5 Install HLA protector SST K95A 1000 E if available 6 Install valve spring with narrow spring coils B toward cylinder head and wider coils A toward upper spring seat 2004 Kia...

Page 216: ...sy of KIA MOTORS AMERICA INC 7 Install upper spring seat and compress valve spring with SST or equivalent 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 53 a m Page 2...

Page 217: ...ee times with a plastic hammer to verify that valve locks are fully seated 10 Remove HLA protector K 95A 1000 E if used Repeat procedure for remaining valve assembles HYDRAULIC LASH ADJUSTER HLA REMOV...

Page 218: ...Negative Battery Cable Courtesy of KIA MOTORS AMERICA INC 2 Remove center cover 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 53 a m Page 218 2011 Mitchell Repair In...

Page 219: ...TORS AMERICA INC 3 Remove ignition coils and high tension cords 4 Disconnect PCV hose and ventilation hose 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 53 a m Page...

Page 220: ...s Courtesy of KIA MOTORS AMERICA INC 5 Remove timing belt See TIMING SYSTEM 6 Remove cylinder head cover 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 53 a m Page 22...

Page 221: ...ourtesy of KIA MOTORS AMERICA INC NOTE Align camshaft and crankshaft timing belt alignment marks 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 53 a m Page 221 2011 M...

Page 222: ...kshaft Timing Belt Alignment Marks Courtesy of KIA MOTORS AMERICA INC 7 Remove phase sensor 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 53 a m Page 222 2011 Mitche...

Page 223: ...Phase Sensor Courtesy of KIA MOTORS AMERICA INC 8 Remove camshaft pulleys 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 53 a m Page 223 2011 Mitchell Repair Informa...

Page 224: ...28 Removing Camshaft Pulleys Courtesy of KIA MOTORS AMERICA INC 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 53 a m Page 224 2011 Mitchell Repair Information Compan...

Page 225: ...dentify their original position if they will be reused NOTE Hydraulic Lash Adjusters HLA must be installed in location from which they were removed Failure to install HLA s in their original location...

Page 226: ...f KIA MOTORS AMERICA INC 12 Remove HLA s from cylinder head 13 Store HLA s upside down in an oil filled container 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 53 a...

Page 227: ...replace if necessary 2 With HLA filled with engine oil hold A and press down on B by hand If B moves replace HLA NOTE Never attempt to repair or disassemble an HLA 2004 Kia Spectra 2004 ENGINES 1 8L...

Page 228: ...232 Testing HLA Function Courtesy of KIA MOTORS AMERICA INC 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 53 a m Page 228 2011 Mitchell Repair Information Company L...

Page 229: ...ICA 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 5 Calculate clearance between HLA diameter and relate...

Page 230: ...Measuring HLA Clearance Courtesy of KIA MOTORS AMERICA INC INSTALLATION 1 Apply a coat of clean engine oil to friction surfaces of HLA 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febre...

Page 231: ...up 5 Install camshaft bearing caps according to cap number with the directional arrows pointing forward 6 Install bolts to camshaft bearing caps and tighten in five or six steps in order shown in fig...

Page 232: ...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 2004 Kia Spectra 2004 ENGINES 1 8L 4...

Page 233: ...mshaft aligning I mark with the intake camshaft dowel pin and E mark with exhaust camshaft dowel pin Tightening torque 36 2 44 8 lb ft 49 60 8 N m 5 0 6 2 kg m 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cyl...

Page 234: ...Camshaft Pulleys Courtesy of KIA MOTORS AMERICA INC 10 Install phase sensor 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 53 a m Page 234 2011 Mitchell Repair Infor...

Page 235: ...OTORS 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 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 53 a m Page...

Page 236: ...12 Install timing belt See TIMING SYSTEM 13 Connect PCV hose and ventilation hose 14 Install high tension cords and ignition coils 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero d...

Page 237: ...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 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 53...

Page 238: ...nter Cover Courtesy of KIA MOTORS AMERICA INC 16 Connect negative battery cable 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 53 a m Page 238 2011 Mitchell Repair In...

Page 239: ...Cable Courtesy of KIA MOTORS AMERICA INC OIL PAN REMOVAL 1 Disconnect negative battery cable 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 53 a m Page 239 2011 Mitc...

Page 240: ...g Negative Battery Cable Courtesy of KIA MOTORS AMERICA INC 2 Drain engine oil 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 53 a m Page 240 2011 Mitchell Repair Inf...

Page 241: ...e Oil Courtesy of KIA MOTORS AMERICA INC 3 Remove LH and RH side splash shields 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 53 a m Page 241 2011 Mitchell Repair In...

Page 242: ...Side Splash Shields Courtesy of KIA MOTORS AMERICA INC 4 Remove front exhaust pipe 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 53 a m Page 242 2011 Mitchell Repai...

Page 243: ...Exhaust Pipe Courtesy of KIA MOTORS AMERICA INC 5 Remove oil pan mounting bolts 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 54 a m Page 243 2011 Mitchell Repair I...

Page 244: ...rewdriver Or Suitable Tool Courtesy of KIA MOTORS AMERICA INC 7 Remove oil strainer CAUTION a Do not force tools between cylinder block and oil pan because this may damage sealing surfaces b Do not da...

Page 245: ...bolt holes on contact surfaces 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 CA...

Page 246: ...IA 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 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 d...

Page 247: ...haust 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 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinde...

Page 248: ...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 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 54 a m...

Page 249: ...sy of KIA MOTORS AMERICA INC 6 Fill with specified amount and type of engine oil 7 Connect negative battery cable 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 54 a...

Page 250: ...ERICA INC 8 Start engine and check for leaks 9 Check oil level and add oil if necessary COOLING SYSTEM TROUBLESHOOTING GUIDE 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021...

Page 251: ...of KIA MOTORS AMERICA INC SPECIFICATION Fig 257 Cooling System Specifications Courtesy of KIA MOTORS AMERICA INC 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 54 a m...

Page 252: ...essary WARNING Never remove radiator cap while engine is hot Wrap a thick cloth around radiator cap before removing When removing radiator cap loosen slowly to first stop and wait until pressure in ra...

Page 253: ...here 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 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinde...

Page 254: ...4 If not check system for coolant leakage REPLACEMENT 1 Remove radiator cap and loosen drain plug WARNING Never open radiator cap while engine is hot Wrap a thick cloth around cap before loosening Use...

Page 255: ...sed coolant Coolant Capacity 6 3 Us qt 6 0 liters 5 3 lmp qt 6 Run the engine with the radiator cap removed until the upper radiator hose is hot 7 With the engine idling add coolant to the radiator un...

Page 256: ...y of KIA MOTORS AMERICA INC 2 Drain engine coolant CAUTION Do not disassemble water pump assembly If a problem is found replace assembly as a unit 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo...

Page 257: ...urtesy of KIA MOTORS AMERICA INC 3 Remove timing belt See TIMING SYSTEM 4 Remove tensioner and idler 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 54 a m Page 257 20...

Page 258: ...iming Belt Tensioners Courtesy of KIA MOTORS AMERICA INC 5 Remove water pump 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 54 a m Page 258 2011 Mitchell Repair Infor...

Page 259: ...bnormal noise bearing sticking or loose 3 Replace water pump if necessary INSTALLATION 1 Remove any gasket fragments dirt or oil from sealing surfaces 2 Install new gasket on water pump 2004 Kia Spect...

Page 260: ...r idler and timing belt See TIMING SYSTEM 5 Fill engine coolant 6 Connect negative battery cable NOTE To prevent dropping the gasket when installing put sealant in gasket groove But do not apply to se...

Page 261: ...Cable Courtesy of KIA MOTORS AMERICA INC 7 Start engine and check for leaks RADIATOR COMPONENT 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 54 a m Page 261 2011 Mit...

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: ...sconnect negative battery cable Fig 269 Disconnecting Negative Battery Cable Courtesy of KIA MOTORS AMERICA INC 2 Drain engine coolant 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrer...

Page 264: ...Radiator Drain Plug Courtesy of KIA MOTORS AMERICA INC 3 Remove fresh air duct 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 54 a m Page 264 2011 Mitchell Repair Inf...

Page 265: ...hose 5 Disconnect cooling fan motor connector 6 Disconnect condenser fan motor connector 7 Disconnect coolant reservoir hose 8 Remove radiator brackets 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder d...

Page 266: ...rtesy of KIA MOTORS AMERICA INC 9 Disconnect Automatic Transaxle Fluid ATF inlet and outlet pipe 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 54 a m Page 266 2011 M...

Page 267: ...assembly from engine compartment 12 Remove cooling fan assembly and condenser fan assembly INSPECTION 1 Check for cracks damage or water leakage 2 Check for bent fins If bent repair with a fin comb or...

Page 268: ...NSTALLATION 1 Install cooling fan assembly and condenser fan assembly 2 Install radiator assembly into engine compartment 3 Connect lower radiator hose 4 Connect ATF inlet and outlet pipes 2004 Kia Sp...

Page 269: ...6 Connect coolant reservoir hose 7 Connect condenser fan motor connector 8 Connect cooling fan motor connector 9 Connect upper radiator hose 10 Install fresh air duct 2004 Kia Spectra 2004 ENGINES 1 8...

Page 270: ...sh Air Duct Courtesy of KIA MOTORS AMERICA INC 11 Connect negative battery cable 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 54 a m Page 270 2011 Mitchell Repair I...

Page 271: ...ttery Cable Courtesy of KIA MOTORS AMERICA INC 12 Fill engine coolant See ENGINE COOLANT 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 54 a m Page 271 2011 Mitchell...

Page 272: ...esy of KIA MOTORS AMERICA INC 13 Start engine and check for leaks RADIATOR FAN MOTOR COMPONENT 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 54 a m Page 272 2011 Mit...

Page 273: ...an Motor Courtesy of KIA MOTORS AMERICA INC REMOVAL 1 Disconnect negative battery cable 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 54 a m Page 273 2011 Mitchell R...

Page 274: ...Negative Battery Cable Courtesy of KIA MOTORS AMERICA INC 2 Drain engine coolant 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 54 a m Page 274 2011 Mitchell Repair I...

Page 275: ...Engine Coolant Courtesy of KIA MOTORS AMERICA INC 3 Remove fresh air duct 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 54 a m Page 275 2011 Mitchell Repair Informa...

Page 276: ...y of KIA MOTORS AMERICA INC 4 Disconnect cooling fan motor connector 5 Remove upper radiator hose 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 54 a m Page 276 2011...

Page 277: ...KIA MOTORS AMERICA INC 6 Remove upper two radiator cowling bolts 7 Remove lower two radiator cowling bolts 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 54 a m Page...

Page 278: ...owling from engine compartment 9 Remove clip and fan Remove three fan motor bolts and nuts INSPECTION Check current as shown with an ammeter Current A 8 13A 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylind...

Page 279: ...ing to radiator 4 Install and tighten two upper radiator cowling bolts Tightening torque 5 8 7 9 lb ft 7 8 10 8 N m 0 8 1 1 kg m 5 Install and tighten lower two radiator cowling bolts Tightening torqu...

Page 280: ...er Two Radiator Cowling Bolts Courtesy of KIA MOTORS AMERICA INC 6 Install upper radiator hose 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 54 a m Page 280 2011 Mit...

Page 281: ...IA MOTORS AMERICA INC 7 Connect cooling fan motor connector 8 Install fresh air duct and tighten bolt and nut 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 54 a m Pa...

Page 282: ...Nut Courtesy of KIA MOTORS AMERICA INC 9 Fill engine coolant See ENGINE COOLANT 10 Connect negative battery cable 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 54 a...

Page 283: ...ON RADIATOR CAP VALVE 1 Remove foreign material from radiator cap valve and the valve seat 2 Attach radiator cap to a radiator cap tester Apply pressure gradually to 15 psi 103 kPa 1 05 kg cm2 2004 Ki...

Page 284: ...or cap as necessary NEGATIVE PRESSURE VALVE 1 Pull negative pressure valve to open it Verify that it closes completely when released 2 Check for damage on contact surfaces and for a cracked or deforme...

Page 285: ...y of KIA MOTORS AMERICA INC 3 Replace radiator cap as necessary THERMOSTAT REMOVAL 1 Disconnect negative battery cable 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29...

Page 286: ...Negative Battery Cable Courtesy of KIA MOTORS AMERICA INC 2 Drain engine coolant 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 54 a m Page 286 2011 Mitchell Repair I...

Page 287: ...olant Courtesy of KIA MOTORS AMERICA INC 3 Remove bolt and nut of thermostat housing 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 54 a m Page 287 2011 Mitchell Repa...

Page 288: ...g Bolt and Nut Courtesy of KIA MOTORS AMERICA INC 4 Remove thermostat housing and thermostat 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 54 a m Page 288 2011 Mitch...

Page 289: ...ce thermostat and a thermometer in water 3 Gradually heat water and check following Initial opening temperature 177 182 F 80 5 83 5 C Full open temperature 203 F 95 C Full open lift 0 31 in 8 0 mm min...

Page 290: ...AMERICA INC INSTALLATION 1 Install thermostat into cylinder head with jiggle pin positioned up 2 Install new gasket 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 55...

Page 291: ...nder Head Courtesy of KIA MOTORS AMERICA INC 3 Place thermostat housing and tighten bolt and nut 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 55 a m Page 291 2011 M...

Page 292: ...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 5 Connect negative battery cable 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder...

Page 293: ...esy of KIA MOTORS AMERICA INC 6 Start engine and check for leaks LUBRICATION SYSTEM TROUBLESHOOTING GUIDE 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 55 a m Page 2...

Page 294: ...s driven by crankshaft The oil pump has a pressure relief valve which controls lubrication system pressure by bypassing oil back to oil pan The oil pump rotates and draws oil from the oil pan through...

Page 295: ...der block and cylinder head oil is returned by gravity to the oil pan Those internal parts that have no direct oil feed are supplied with lubrication by either gravity or splash from other direct feed...

Page 296: ...y Fig 303 Checking Oil Level And Condition Courtesy of KIA MOTORS AMERICA INC REPLACEMENT 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 55 a m Page 296 2011 Mitchell...

Page 297: ...asket Tightening torque 22 30 lb ft 29 41 N m 3 0 4 2 kg m 5 Refill engine with specified type and amount of engine oil 6 Install oil filler cap 7 Run engine and check for leaks 8 Check oil level and...

Page 298: ...eal 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 5 Tighten filter 1 1 6 turns with filter wre...

Page 299: ...SURE 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 2...

Page 300: ...i 294 392 kPa 3 0 4 0 kg cm2 5 If pressure is not within specification check for cause and repair See TROUBLESHOOTING GUIDE 6 Remove oil pressure gauge and install oil pressure switch Tightening torqu...

Page 301: ...ump Components Courtesy of KIA MOTORS AMERICA INC REMOVAL 1 Disconnect negative battery cable 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 55 a m Page 301 2011 Mitc...

Page 302: ...g Negative Battery Cable Courtesy of KIA MOTORS AMERICA INC 2 Drain engine oil 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 55 a m Page 302 2011 Mitchell Repair Inf...

Page 303: ...AN 5 Remove generator See CHARGING SYSTEMS 6 Remove A C compressor and A C compressor bracket if equipped 7 Remove crankshaft pulley lock bolt 8 Remove timing belt pulley 9 Remove oil pump mounting bo...

Page 304: ...icone sealant to oil pump sealing surface 2 Apply grease to a new O ring and install it in oil pump CAUTION The oil pump must be installed no longer than 5 minutes after silicone sealant is applied 20...

Page 305: ...orque 14 19 lb ft 19 26 N m 1 9 2 6 kg m 4 Install timing belt pulley and crankshaft pulley lock bolt Tightening torque 115 7 122 9 lb ft 156 8 166 6 N m 16 17 kg m 2004 Kia Spectra 2004 ENGINES 1 8L...

Page 306: ...6 Install generator See CHARGING SYSTEMS 7 Install oil strainer and oil pan See OIL PAN 8 Install timing belt See TIMING SYSTEM 9 Fill with specified amount and type of engine oil 10 Connect negative...

Page 307: ...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 2004 Kia Spectra 2004 ENGINES 1 8L...

Page 308: ...al Courtesy of KIA MOTORS AMERICA INC 2 Remove seven screws and remove pump cover 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 55 a m Page 308 2011 Mitchell Repair...

Page 309: ...owing and replace any faulty parts Distorted or damaged oil pump body or cover Worn or damaged plunger Weak or broken plunger spring 2 Measure side clearance Clearance 0 0035 in 0 09 mm Max 2004 Kia S...

Page 310: ...urtesy of KIA MOTORS AMERICA INC 3 Measure tooth tip clearance Clearance 0 007 in 0 18 mm Max 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 55 a m Page 310 2011 Mitc...

Page 311: ...of KIA MOTORS AMERICA INC 4 Measure outer rotor to pump body clearance Clearance 0 015 in 0 376 mm Max 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 55 a m Page 311...

Page 312: ...nce Courtesy of KIA MOTORS AMERICA INC REASSEMBLY 1 Assemble outer rotor and inner rotor into oil pump body 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 55 a m Page...

Page 313: ...ply thread locking compound to cover mounting screw threads 3 Assemble oil pump cover to oil pump body Tightening torque 4 3 6 5 lb ft 6 9 N m 0 6 0 9 kg cm 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylind...

Page 314: ...seal and oil pump body 5 Press oil seal into oil pump body Protrusion 0 02 0 04 in 0 5 1 0 mm CAUTION Oil seal must be pressed in until it is protruding with front face of oil pump body 2004 Kia Spect...

Page 315: ...L SEAL REMOVAL 1 Remove oil pump See OIL PUMP 2 Remove front oil seal REPLACEMENT 1 Install oil seal See OIL PUMP 2 Install oil pump REAR OIL SEAL 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo...

Page 316: ...e rear cover Fig 323 Removing Rear Cover Courtesy of KIA MOTORS AMERICA INC NOTE Use a flywheel locking tool or equivalent when removing flywheel or drive plate 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cy...

Page 317: ...slowly pry old seal out Fig 324 Prying Out Oil Seal Courtesy of KIA MOTORS AMERICA INC REPLACEMENT 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 55 a m Page 317 201...

Page 318: ...Courtesy of KIA MOTORS AMERICA INC 3 Cut away silicon sealer that has been squeezed out from rear cover assembly toward oil pan mounting NOTE Oil seal must be tapped in until it is nearly flush with...

Page 319: ...er 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 CAUTION Do not scratch rear cover assembly 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder dom...

Page 320: ...flywheel and manual transaxle see Fig 144 In case of A T install drive plate and automatic transaxle 6 Connect negative battery cable 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero...

Page 321: ...Courtesy of KIA MOTORS AMERICA INC INTAKE AND EXHAUST SYSTEM TROUBLESHOOTING GUIDE EXHAUST SYSTEM 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 55 a m Page 321 2011...

Page 322: ...he operating temperature of the warm up catalytic converter increases very rapidly after initial cold start to decrease the amount of emissions emitted during cold engine operation The three way catal...

Page 323: ...lustrating Exhaust System 1 Of 2 Courtesy of KIA MOTORS AMERICA INC 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 55 a m Page 323 2011 Mitchell Repair Information Co...

Page 324: ...s to a vehicle s passengers because carbon monoxide is poisonous CAUTION Do not touch the catalytic converter heat shield when the engine is running The conversion process produces high heat Even when...

Page 325: ...and let exhaust system cool WARM UP THREE WAY CATALYTIC TWC CONVERTER REMOVAL 1 Remove one nut and one bolt attaching fresh air duct 2 Remove five bolts attaching heat shield and remove 3 Remove five...

Page 326: ...INC 7 Remove warm up TWC converter 8 Remove two gaskets INSTALLATION 1 Clean mating surfaces as required 2 Install new gaskets 3 Raise vehicle 4 Position warm up TWC converter for installation 5 Tigh...

Page 327: ...Lower vehicle 8 Tighten five nuts that attach warm up TWC converter to exhaust manifold Tightening torque 27 4 38 3 lb ft 37 2 51 9 N m 3 8 5 3 kg m 9 Install heat shield Tightening torque 69 95 lb i...

Page 328: ...pe Tightening torque 27 4 38 3 lb ft 37 2 51 9 N m 3 8 5 3 kg m 6 Install three nuts that attach front exhaust pipe to warm up TWC converter Tightening torque 27 4 38 3 lb ft 37 2 51 9 N m 3 8 5 3 kg...

Page 329: ...ition TWC converter for installation 4 Tighten two nuts at the forward pre silencer flange Tightening torque 27 4 38 3 lb ft 37 2 51 9 N m 3 8 5 3 kg m 5 Tighten two nuts at spring loaded flange of fr...

Page 330: ...3 Remove two nuts at main silencer flange Fig 336 Removing Silencer Flange Nuts Courtesy of KIA MOTORS AMERICA INC CAUTION A hot exhaust system can produce a serious burn 2004 Kia Spectra 2004 ENGINES...

Page 331: ...8 5 3 kg m 5 Install pre silencer in two hangers 6 Install two nuts at forward flange of the pre silencer Tightening torque 27 4 38 3 lb ft 37 2 51 9 N m 3 8 5 3 kg m MAIN SILENCER REMOVAL 1 Remove tw...

Page 332: ...AMERICA INC 3 Remove one gasket INSTALLATION 1 Lubricate inside of three main silencer hangers with a silicone lubricant 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 2...

Page 333: ...3 kg m AIR CLEANER ACL REMOVAL 1 Disconnect intake air temperature sensor connector 2 Disconnect mass air flow sensor connector 3 Loosen clamp on outlet hose of air cleaner housing Fig 338 Loosening...

Page 334: ...dirt or dust INSTALLATION 1 Install new air cleaner element 2 Reinstall top of air cleaner housing and three bolts 3 Install air intake hoses and tighten clamps 4 Connect intake air temperature sensor...

Page 335: ...Components Courtesy of KIA MOTORS AMERICA INC REMOVAL 1 Disconnect negative battery cable 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 56 a m Page 335 2011 Mitchell...

Page 336: ...lock bolts and nuts accordingly and remove tension from power steering P S and or air conditioning A C compressor drive belt 3 Remove P S and or A C drive belt 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cy...

Page 337: ...sy of KIA MOTORS AMERICA INC 4 Loosen generator mounting bolts and adjusting bolt 5 Remove generator bolts 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 56 a m Page...

Page 338: ...unting And Adjusting Bolts Courtesy of KIA MOTORS AMERICA INC 6 Remove water pump pulley 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 56 a m Page 338 2011 Mitchell...

Page 339: ...y Courtesy of KIA MOTORS AMERICA INC 7 Remove crankshaft pulley and timing belt guide plate 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 56 a m Page 339 2011 Mitche...

Page 340: ...ing Belt Guide Plate Courtesy of KIA MOTORS AMERICA INC 8 Remove upper and lower timing belt covers 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 56 a m Page 340 201...

Page 341: ...KIA MOTORS AMERICA INC 9 Turn crankshaft so that timing mark on timing belt pulley is aligned with timing mark on engine 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08...

Page 342: ...th mark on cylinder head cover and E mark on exhaust camshaft pulley is aligned with mark on cylinder head cover Do not move camshaft or crankshaft once timing marks have been correctly positioned 200...

Page 343: ...TORS AMERICA INC 11 Loosen tensioner pulley lock bolt 12 Protect timing belt with a rag 13 Remove tensioner pulley 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 56 a...

Page 344: ...grease NOTE Mark the direction of timing belt rotation on the timing belt for proper reinstallation NOTE Never forcefully twist turn inside out or bend timing belt Do not allow oil or grease to come...

Page 345: ...ig 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 2004 Kia Spectra 2004 ENGINES 1...

Page 346: ...MOTORS AMERICA INC 4 Inspect both idler pulley and tensioner pulley for uneven wear and smooth bearing operation 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 56 a...

Page 347: ...ngth 1 402 in 35 6 mm 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 af...

Page 348: ...ace any component that shows damage excessive wear or that appears prone to a possible failure Do not clean pulleys with cleaning fluids If needed use a soft cloth to wipe them clean and avoid scratch...

Page 349: ...nt and tighten lock bolt 3 Check that timing mark on timing belt pulley is aligned with timing mark on engine NOTE Replace tensioner spring whenever timing belt is replaced 2004 Kia Spectra 2004 ENGIN...

Page 350: ...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 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder d...

Page 351: ...MERICA INC NOTE If existing timing belt is being reused install belt in proper rotation direction marked prior to removal 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08...

Page 352: ...stall timing belt onto timing belt pulley first then idler pulley exhaust camshaft pulley intake camshaft pulley and tensioner pulley in that order 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder doming...

Page 353: ...ft pulley or between intake and exhaust camshaft pulleys Fig 357 Illustrating Proper Timing Belt Position Courtesy of KIA MOTORS AMERICA INC 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de...

Page 354: ...2 kg m 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 KI...

Page 355: ...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 tens...

Page 356: ...RICA 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 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021...

Page 357: ...lt Covers Courtesy of KIA MOTORS AMERICA INC 14 Install timing belt guide plate and crankshaft pulley 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 56 a m Page 357 2...

Page 358: ...e 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 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder...

Page 359: ...tall 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 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febr...

Page 360: ...18 19 25 14 mm 28 38 38 51 A C Compressor Mounting Bolt 29 38 39 52 Automatic Transaxle Linkage Nut 24 34 32 46 Camshaft Timing Belt Pulley Bolt 36 45 49 61 Connecting Rod Nut 35 37 47 50 Crankshaft T...

Page 361: ...aust Pipe Nuts Clamp Nuts 15 20 20 27 Converter Hanger Nuts 51 69 69 94 Pipe To TWC Warmup Converter Nuts 30 41 40 55 Intake Manifold Bolt 14 18 19 25 Intake Manifold Support Bracket Bolt 27 38 37 52...

Page 362: ...l Cover Short Bolt 71 97 8 11 Timing Belt Cover Bolt 71 97 8 11 Timing Belt Guide Plate Bolt 106 150 12 17 Water Pump Pulley Bolt 106 150 12 17 1 Tighten in sequence to specification See Fig 365 2 For...

Page 363: ...nder Head Bolt Tightening Sequence Courtesy of KIA MOTORS AMERICA INC 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 56 a m Page 363 2011 Mitchell Repair Information...

Page 364: ...Illustrating Engine Mount No 1 Courtesy of KIA MOTORS AMERICA INC 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 56 a m Page 364 2011 Mitchell Repair Information Comp...

Page 365: ...Illustrating Engine Mount No 2 Courtesy of KIA MOTORS AMERICA INC 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 56 a m Page 365 2011 Mitchell Repair Information Comp...

Page 366: ...Illustrating Engine Mount No 4 Courtesy of KIA MOTORS AMERICA INC 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 56 a m Page 366 2011 Mitchell Repair Information Comp...

Page 367: ...Bearing Cap Bolt Tightening Sequence Courtesy of KIA MOTORS AMERICA INC 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 56 a m Page 367 2011 Mitchell Repair Informatio...

Page 368: ...ring Cap Bolt Removal Installation Sequence Courtesy of KIA MOTORS AMERICA INC 2004 Kia Spectra 2004 ENGINES 1 8L 4 Cylinder domingo 7 de febrero de 2021 08 29 56 a m Page 368 2011 Mitchell Repair Inf...

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