sephia

1999-2000 ENGINES

1.8L 4-Cylinder

ENGINE IDENTIFICATION

Engine can be identified by the eighth character of the Vehicle Identification Number (VIN) stamped on metal plate located on left side of dash panel. The VIN is also stamped into passenger side of engine compartment bulkhead.

ENGINE IDENTIFICATION CODE

ADJUSTMENTS

VALVE CLEARANCE ADJUSTMENT

Engine is equipped with Hydraulic Lash Adjusters (HLA). No adjustment is required.

TROUBLE SHOOTING

To trouble shoot engine mechanical components, see appropriate table in TROUBLE SHOOTING article in GENERAL INFORMATION.

REMOVAL & INSTALLATION

FUEL PRESSURE RELEASE

To release fuel pressure, remove rear seat cushion. Disconnect fuel pump connector. See Fig. 1 . Start and run engine until it stalls. Turn ignition off. Connect fuel pump connector. Install rear seat cushion.

NOTE: For repair procedures not covered in this article, see ENGINE OVERHAUL PROCEDURES article in GENERAL INFORMATION.

Application Code

1.8L DOHC 5

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.

CAUTION: When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. Obtain radio anti-theft codes, if necessary, before disconnecting battery.

CAUTION: Fuel system is under pressure. Release pressure before servicing fuel system components.

1999 Kia Sephia

1999-2000 ENGINES 1.8L 4-Cylinder

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lunes, 12 de agosto de 2013 12:02:36 a.m. Page 1 © 2005 Mitchell Repair Information Company, LLC.

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Fig. 1: Locating Fuel Pump Electrical ConnectorCourtesy of KIA MOTORS AMERICA, INC.

ENGINE

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

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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 on 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 .

INTAKE MANIFOLD

EXHAUST MANIFOLD

Removal & Installation

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 to 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 .

NOTE: Removal and installation procedures are not available from manufacturer.

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CYLINDER HEAD

Removal

1. Disconnect negative battery cable. Release fuel pressure. See FUEL PRESSURE RELEASE . 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 . Loosen cylinder head bolts in 2-3 steps in sequence. See Fig. 2 . Remove cylinder head.

Fig. 2: Cylinder Head Bolt Removal Sequence

Courtesy of KIA MOTORS AMERICA, INC.

Inspection

Carefully clean carbon and gasket material from all mating surfaces. Clean threads of cylinder head bolts. Use tap to clean threads in engine block. Check cylinder head for warpage and cracks. Resurface or replace head if not within specification. Check valve train components. Replace or resurface components if not within specification. See CYLINDER HEAD and VALVES & VALVE SPRINGS tables under ENGINE SPECIFICATIONS.

CAUTION: Rotate crankshaft in clockwise direction only.

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Installation

1. Install cylinder head gasket. Install cylinder head assembly and cylinder head bolts. Using 5-6 steps, tighten cylinder head bolts in specified sequence. See Fig. 3 . See TORQUE SPECIFICATIONS .

2. To complete installation, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS . Add all fluids as necessary. Operate engine until cooling fans cycle. Check ignition timing.

Fig. 3: Cylinder Head Bolt Tightening SequenceCourtesy of KIA MOTORS AMERICA, INC.

CRANKSHAFT FRONT SEAL

Removal & Installation

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 .

TIMING BELT

Removal

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. See Fig. 4 . 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. See Fig. 5 .

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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.

Inspection

Check timing belt for cracks, peeling, abrasion or other damage. Check tensioner bearing for looseness or roughness of rotation. Inspect tensioner spring for stretching. Replace parts as necessary.

Installation

1. Install tensioner pulley. Pull tensioner pulley to its farthest point, and tighten lock bolt. Ensure timing belt and engine marks align. See Fig. 4 . Ensure intake and exhaust camshaft sprocket marks align. See Fig. 5 .

2. Install timing belt onto crankshaft sprocket first, then idler pulley, exhaust camshaft sprocket, intake camshaft sprocket, and tensioner pulley in order. See Fig. 6 . 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 . 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 .

NOTE: DO NOT move camshaft or crankshaft once timing marks have been correctly positioned.

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Fig. 4: Aligning Crankshaft Timing Marks


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Fig. 5: Identifying Camshaft Sprocket Timing Marks

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Fig. 6: Installing Timing Belt


HYDRAULIC LASH ADJUSTER

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Removal

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 .

2. Remove cylinder head cover. Align camshaft and crankshaft timing belt alignment marks. See Fig. 4

and Fig. 5 .

3. Remove phase sensor. Remove camshaft sprockets. Loosen camshaft bearing caps bolts in 5 or 6 steps in sequence. See Fig. 7 . Remove camshafts. Reference mark HLAs to identify their original position if they will be reused.

Inspection

Inspect face of HLA for wear or damage, replace as necessary.

Installation

1. Apply engine oil to friction surfaces of HLA. Install HLA in bores of cylinder head. Ensure HLA moves smoothly in cylinder head bore. Apply engine oil to 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 to camshaft bearing caps, and tighten in 5 or 6 steps in sequence. See Fig. 7

2. Apply engine oil to 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. See Fig. 5 .

3. To complete installation, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS .

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.

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Fig. 7: Camshaft Bearing Cap Bolt Removal/Installation SequenceCourtesy of KIA MOTORS AMERICA, INC.

CAMSHAFT

Removal

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

2. Remove cylinder head cover. Align camshaft and crankshaft timing belt alignment marks. See Fig. 4and Fig. 5 .

3. Remove phase sensor. Remove camshaft pulleys. Loosen camshaft bearing caps bolts in 5 or 6 steps in sequence. See Fig. 7 . Remove camshafts.

Inspection

Check camshaft journals and bearings for wear. Check camshaft lobes for wear and damage. Check camshaft runout. See CAMSHAFT table under ENGINE SPECIFICATIONS. If any measurements are not within specification, replace camshaft and/or cylinder head.

Installation

1. Apply engine oil to 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 to camshaft bearing caps, and tighten in 5 or 6 steps in sequence. See Fig. 7

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2. Apply engine oil to 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. See Fig. 5 .

3. To complete installation, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS .

REAR CRANKSHAFT OIL SEAL

Removal

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 AUTOMATIC TRANSMISSION REMOVAL & INSTALLATION article in AUTOMATIC TRANSMISSION SERVICING. On all models, remove rear cover. Using seal remover, remove oil seal from rear cover.

Installation

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 .

WATER PUMP

Removal

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.

Installation

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

OIL PAN

Removal

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.

Installation

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

CAUTION: DO NOT force pry bar between engine block and oil pan contact surfaces when removing oil pan.

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Install oil strainer. Apply continuous bead of silicone sealant to 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. See Fig. 8 To complete installation, reverse removal procedure. Tighten all bolts to specification. See TORQUE SPECIFICATIONS . Fill engine with oil.

Fig. 8: Identifying Oil Pan Mounting Bolts


CAUTION: If reusing oil pan mounting bolts, ensure old sealant is completely removed from bolt threads. Failure to do so may cause bolt holes to crack.

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

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OVERHAUL

CYLINDER HEAD

Cylinder Head

Ensure all mating surfaces are clean. Check cylinder head for warpage. Resurface cylinder head if warpage exceeds .004" (.10 mm). Check manifold contact surfaces for warpage. Resurface manifold surfaces or replace cylinder head if warpage exceeds .008" (.20 mm). Check cylinder head height. See CYLINDER

HEAD table under ENGINE SPECIFICATIONS. If measurements are not as specified, replace cylinder head.

Valve Springs

Ensure valve spring free length and out-of-square are within specification. See VALVES & VALVE

SPRINGS table under ENGINE SPECIFICATIONS. Replace valve spring as necessary.

Valves

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

Valve Guides

1. Check valve stem-to-valve guide oil clearance. Ensure valve guide inside diameter is within specification. See CYLINDER HEAD table under ENGINE SPECIFICATIONS.

2. Measure valve guide installed height. If installed height is not within specification, adjust or replace valve guide or cylinder head as necessary. See CYLINDER HEAD table under ENGINE SPECIFICATIONS.

Valve Seat

1. Service valve guide as needed before servicing valve seat. Valve seat replacement information is not available from manufacturer. Inspect valve seat for roughness, pitting, cracks and damage. Check valve seat angle and seat width.

2. Measure seat contact width on valve, and ensure seat contact position should be in center of valve face. Service seat if angle and width are not within specification. See CYLINDER HEAD table under ENGINE SPECIFICATIONS. Measure valve installed height after servicing valve seat.

Valve Seat Correction Angles

1. Measure seat contact width on valve. See CYLINDER HEAD table under ENGINE SPECIFICATIONS. Ensure valve/seat contact position is at center of valve face. If width and position are not within specification, cut seats as necessary.

2. If seat contact position is too high, correct using 63-degree cutter and 45-degree cutter. Finish angle using 45-degree stone until contact width is corrected.

3. If seat contact position is too low, correct using 0-degree and 45-degree cutter. Finish angle using 45-degree stone until contact width is corrected. Seat valve to seat using lapping compound.

Valve Stem Installed Height

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1. After servicing valves, measure valve stem installed height. See VALVE INSTALLED HEIGHT

table. See Fig. 9 . If installed valve height is within standard specification, no adjustment is necessary.

2. If installed valve height exceeds standard specification but does not exceed service limit specification, install adjusting shim on spring seat to bring installed height back within standard specification.

3. If valve stem installed height exceeds specification, replace valve. If valve stem installed height still exceeds limit, replace cylinder head. See VALVE INSTALLED HEIGHT table.

Fig. 9: Measuring Valve Stem Installed Height (Typical)Courtesy of KIA MOTORS AMERICA, INC.

VALVE INSTALLED HEIGHT

Application In. (mm)

Intake

Standard 1.432-1.467 (36.37-37.26)

Service Limit (1) 1.467-1.495 (36.37-37.97)

Beyond Limit (2) 1.495 (36.37)

Exhaust

Standard 1.431-1.467 (36.35-37.26)

Service Limit (1) 1.467-1.494 (36.37-37.95)

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CYLINDER BLOCK ASSEMBLY

Piston & Connecting Rod Assembly

1. Before removing rod cap from crankshaft, measure and record rod side play. See CONNECTING

RODS table under ENGINE SPECIFICATIONS. Before removal, ensure all rods, pistons and caps are marked for reassembly reference.

2. Before removing rod and piston assembly from block, check and record rod bearing oil clearance. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS.

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 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.

Fitting Pistons

1. Check piston-to-cylinder wall clearance in 3 different vertical levels of piston travel. If clearance is not within specification, rebore cylinders to fit oversize pistons.

2. Using NEW piston ring, measure piston ring side clearance around entire piston circumference. If clearance is not within specification, replace piston. See PISTONS, PINS & RINGS table under ENGINE SPECIFICATIONS.

Piston Rings

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

Connecting Rod Bearings

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

BEARINGS table under ENGINE SPECIFICATIONS.

Crankshaft & Main Bearings

1. Before removing main caps, measure and record crankshaft end play. Using Plastigage, measure and

Beyond Limit (2) 1.494 (37.95)

(1) If installed height exceeds specification, adjust with washer on spring seat area of cylinder head.

(2) If installed height exceeds specification, replace cylinder head.

NOTE: During disassembly, match mark components for reassembly reference.

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record main bearing oil clearance. DO NOT rotate crankshaft when measuring oil clearances.

2. Remove crankshaft. Measure and record each main journal diameter in 2 places. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS. Machine or replace crankshaft as necessary. Main bearing upper halves are grooved.

3. Install main bearing caps in original positions. Tighten bearing cap bolts in sequence and to specification. See Fig. 10 . See TORQUE SPECIFICATIONS .

Fig. 10: Main Bearing Cap Bolt Tightening SequenceCourtesy of KIA MOTORS AMERICA, INC.

Thrust Bearings

1. Check crankshaft end play with crankshaft bearings and caps installed, but without connecting rods attached to crankshaft.

2. Replace thrust bearing if end play is not within specification. See CRANKSHAFT, MAIN &

CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS. Ensure thrust bearings are installed with oil groove facing crankshaft. Oversize thrust bearings are available.

Cylinder Block

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

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ENGINE OILING

ENGINE LUBRICATION SYSTEM

Oil pressure is provided by a rotor-type pump driven by crankshaft. Pump draws oil from oil pan through oil strainer. From oil pump, oil is sent through oil filter to cylinder block and up to cylinder head. Oil then drains back to oil pan. See Fig. 11 .

Crankcase Capacity

Crankcase capacity is 3.8 qts. (3.6L) without oil filter change, and 4.0 qts. (3.8L) with oil filter change.

Oil Pressure

With engine at operating temperature, oil pressure should be 43-57 psi (3.0-4.0 kg/cm2 ) at 3000 RPM.

Oil Pressure Relief Valve

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

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Fig. 11: Cross-Sectional View Of Engine Oil Circuit


OIL PUMP

Removal

1. Disconnect negative battery cable. Drain engine oil. Remove timing belt. See TIMING BELT under REMOVAL & INSTALLATION. Remove oil pan and strainer. See OIL PAN 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

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sealing/mating surfaces. Remove all sealant from components and bolts. Check oil pump clearances. See OIL PUMP SPECIFICATIONS table. Replace oil pump as necessary.

Installation

1. Use NEW gaskets when installing oil pump and pick-up tube. Tighten oil pump bolts to specification. See TORQUE SPECIFICATIONS . Apply light oil coat of clean oil to 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 . Check oil fluid level, and add if necessary.

OIL PUMP SPECIFICATIONS

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Application Maximum Clearance - In. (mm)

Inner Gear Tip-To-Outer Gear Clearance .007 (.18)

Outer Gear-To-Pump Body Clearance .015 (.38)

Gear-To-Pump Body Side Clearance .0035 (.089)

Application Ft. Lbs. (N.m)

A/C Compressor Bracket Bolt

12-mm 14-18 (19-24)

14-mm 28-38 (38-51)

A/C Compressor Mounting Bolt 27-38 (37-51)

Automatic Transaxle Linkage Nut/Washer 24-34 (32-46)

Battery Tray 10-12 (14-16)

Camshaft Bearing Cap Bolts (1) 13-20 (18-27)

Camshaft Pulley Bolts 36-45 (49-61)

Clutch Release Cylinder & Pipe (M/T) 14-19 (19-26)

Connecting Rod Nut 35-37 (47-50)

Coolant Bypass Pipe 66-86 (89-117)

Crankshaft Pulley Bolt 9-13 (12-17)

Crankshaft Sprocket Bolt 116-123 (157-167)

Cylinder Head Bolt (2) (3)

Step 1 36 (49)

Step 2 (4) Loosen Bolts In Sequence

Step 3 29 (39)

Step 4 (5)

Step 5 Turn Additional 90-Degrees


Dynamic Damper Bolt 55-76 (74-103)

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Engine Ground Strap Bolts

At Engine 28-38 (38-51)

At Frame (6)

Engine Hanger 27-38 (37-51)

Engine Mount Bolts/Nuts

No. 1 (3 Bolts) 49-69 (67-93)

No. 2 (2 Nuts) 28-38 (38-51)

No. 3 (1 Bolt) 63-86 (85-117)

No. 4

Bolt (1) 47-66 (64-89)

Nut (3) 51-69 (68-93)

Exhaust Manifold Heat Shield Bolt 14-22 (19-30)

Exhaust Manifold-To-Head Bolt/Nut

Manifold-To-Head (9) 28-38 (38-51)

Manifold-To-TWC Warmup Converter (5) 16-21 (22-28)

Extension Bar (M/T) 23-34 (31-46)

Front Exhaust Pipe

Pipe-To-TWC Warmup Converter Nuts 30-39 (40-53)

Converter Hanger Nuts 51-69 (69-94)

Clamp Nuts 15-20 (20-27)

Intake Manifold Support Bracket 27-38 (37-51)

Joint Shaft Support Bracket Bolts 32-46 (43-62)

Main Bearing Cap Bolt (2) (7)

Step 1 29 (39)

Step 2 (8)

Step 3 15 (20)

Step 4 (5)



Manual Transaxle Linkage (M/T) 12-17 (16-23)

Oil Pump Bolt 14-19 (19-26)

Pinch Bolts 35-38 (47-51)

Power Steering Pump Mounting Bolt 28 (38)

Rear Seal Cover Bolts

Short Bolts (6) (6)

Long Bolts (2) 30-41 (40-55)

Splash Shield 10-12 (14-16)

Stabilizer Control Link Bolts 32-45 (43-61)

Starter Bolt 27-38 (37-52)

Tensioner Pulley Lock Bolt 28-41 (38-55)

Thermostat Housing 14-19 (19-26)

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ENGINE SPECIFICATIONS

GENERAL SPECIFICATIONS

CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS

Timing Belt Guide Plate Bolt 9-13 (12-17)

Valve Cover Bolts 6-9 (8-12)

Water Pump Bolt 14-19 (19-26)

Wheel Lug Nuts 65-87 (88-118)

INCH Lbs. (N.m)

Center Cover Bolt 44-80 (5-9)

Oil Pan Bolts

Except Bolt "E" 70-97 (8-11)

"E" (9)

Oil Pressure Switch 106-160 (12-18)

Oil Strainer Bolt 70-106 (8-12)

Timing Belt Cover Bolt 70-97 (8-11)

Water Pump Pulley Bolt 70-97 (8-11)

(1) Tighten bolts in proper sequence. See Fig. 7 .

(2) Tighten bolts in 5 or 6 steps.

(3) Tighten bolts in proper sequence. See Fig. 3 .

(4) See Fig. 2 .

(5) Mark bolts for rotational reference.

(6) Tighten bolts to 70-106 INCH lbs. (8-12 N.m)

(7) See Fig. 10 .

(8) Loosen bolts in reverse order shown. See Fig. 10 .

(9) Tighten bolt to 28-38 ft. lbs. (38-51 N.m).

Application Specification

Displacement 109.4 Cu. In. (1.8L)

Bore 3.19" (81 mm)

Stroke 3.43" (87 mm)

Compression Ratio 9.4:1

Fuel System SFI


Crankshaft

End Play

Standard .0032-.0111 (.080-.282)

Service Limit (1)

Maximum Runout .00098 (.0249)

Main Journal Bearings

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CONNECTING RODS

PISTONS, PINS & RINGS

Journal Diameter (1)

Undersize 1 - .010 (.25) 2.1728 (55.189)

Undersize 2 - .020 (.50) 2.1826-2.1833 (55.438-55.456)

Undersize 3 - .030 (.75) 2.1924-2.1931 (55.687-55.705)

Journal Out-Of-Round & Taper (1)

Oil Clearance

Standard .00095-.00165 (.0241-.0419)

Service Limit (1)

Connecting Rod Bearings

Journal Diameter (1)

Oversize - 1 .010 (.25) .1034-.1053 (2.626-2.675)

Oversize - 2 .20 (.50) .1083-.1102 (2.751-2.799)

Oversize - 3 .30 (.75) .1132-.1151 (2.875-2.924)

Standard .0985-.1003 (2.502-2.548)

Journal Out-Of-Round & Taper (1)

Oil Clearance

Standard .0008-.0017 (.020-.0431)

Service Limit .004 (.10)

(1) Information is not available from manufacturer.


Bore Diameter

Connecting Rod Bearing Bore (1)

Piston Pin Bore (1)

Center-To-Center Length (1)

Maximum Bend (1)

Side Play

Standard .0044-.0103 (.112-.262)

Service Limit .012 (.30)



Pistons

1999 Kia Sephia


El Tallo


CYLINDER BLOCK

Clearance

Standard .0015-.0021 (.038-.053)

Service Limit (1)

Diameter 3.1872-3.1879 (80.955)

Pins

Diameter .7869-.7871 (19.987-19.992)

Piston Fit .0004-.0010 (.010-.025)

Rod Fit (1)

Rings

No. 1

End Gap

Standard .006-.011 (.15-.28)

Service Limit .039 (1.0)

Side Clearance

Standard .002-.003 (.051-.076)


No. 2

End Gap

Standard .012-.018 (.30-.46)


Side Clearance

Standard .001-.003 (.025-.076)


No. 3 (Oil)

End Gap

Standard .008-.027 (.20-.69)


(1) Information is not available from manufacturer


Cylinder Bore

Standard Diameter 3.1892-3.1897 (81.006-81.018)

Maximum Taper & Out-Of-Round .0007 (.018)

Deck Height

Standard (1)

Minimum (1)

Maximum Deck Warpage (2) .006 (.15)


(2) Replace cylinder block if material removed from deck is more than .004" (10 mm).

1999 Kia Sephia


El Tallo


VALVES & VALVE SPRINGS


Valves

Face Angle 45°

Head Diameter (1)

Minimum Margin

Intake .035" (0.9 mm)

Exhaust .039" (1.0 mm)

Minimum Refinish Length

Intake

Standard 4.052" (121.92 mm)

Minimum (1)

Exhaust

Standard 3.993" (101.42 mm)

Minimum (1)

Stem Diameter

Intake .2350-.2356" (5.97-5.984 mm)

Minimum (1)

Exhaust .2348-.2354" (5.964-5.979 mm)

Minimum (1)

Installed Height (2)

Intake

Standard 1.432-.1467 (36.37-37.26)

Service Limit (3) 1.467-1.495 (36.37-37.97)

Beyond Limit (4) 1.495 (36.37)

Exhaust

Standard 1.431-1.467 (36.53-37.26)

Service Limit (3) 1.467-1.494 (36.37-37.95)

Beyond Limit (4) 1.494 (37.95)

Out-Of-Square

Intake & Exhaust .0638" (1.621 mm)


(2) Valve height is measured from top of installed valve to spring seat.

(3) If installed height exceeds specification, adjust with washer on spring seat area of cylinder head.

(4) If installed height exceeds beyond limit specification, replace cylinder head.

1999 Kia Sephia


El Tallo


CYLINDER HEAD

CAMSHAFT


Cylinder Head Height 5.272-5.280" (133.91-134.11 mm)

Maximum Warpage .004" (.10 mm)

Valve Seats

Seat Angle 45°

Seat Width .078-1.059" (1.98-26.90 mm)

Valve Guides

Valve Guide I.D. .2367-.2374" (6.012-6.030 mm)

Valve Guide Installed Height

Intake .539-.563" (13.69-14.30 mm)

Exhaust .658-.681" (16.71-17.30 mm)

Valve Stem-To-Guide Oil Clearance

Intake .0010-.0023" (.025-.058 mm)

Exhaust .0012-.0025" (.030-.064 mm)

Service Limit .008" (.20 mm)


Bore Diameter

Journals No. 1-5 (1)

End Play .0003-.0004 (.008-.010)

Journal Diameter

Standard 1.0606-1.0616 (26.939-26.965)

Minimum 1.0594 (26.909)

Maximum Journal Out-Of-Round .002 (.05)

Maximum Journal Runout .0012 (.030)

Journal Oil Clearance .0014-.0031 (.036-.079)

Lobe Height

Intake

Standard 1.6415 (41.694)

Exhaust

Standard 1.7560 (42.238)


1999 Kia Sephia


El Tallo


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