Kia_Sephia_Rio_Spectra_Optima_1998-2006

Alternator

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Temporarily loosen the water pump pulley bolts, 1.6L (VIN 3) engine only.
  6.  
  7. Remove the front air intake inlet pipe bolts, 1.8L engine only.
  8.  
  9. Remove the top hose from the air intake inlet pipe, 1.8L engine only.
  10.  
  11. Remove the air intake inlet pipe clamp and the pipe, 1.8L engine only.
  12.  
  13. Remove the power steering pump, 2.0L engine only.
  14.  
  15. Remove the power steering pump bracket, 2.0L engine only.
  16.  
  17. Remove the alternator B terminal cover cap.
  18.  
  19. Disconnect the alternator electrical connections.
  20.  
  21. Loosen, but do not remove the alternator pivot bolt and the tensioner mounting bolt.
  22.  
  23. Remove the drive belt(s); relieve tension on the belt by rotating the adjustment bolt.
  24.  
  25. Remove the water pump pulley, 1.6L (VIN 3) engine only.
  26.  
  27. Remove the power steering pump, 1.6L (VIN 3) engine only.
  28.  
  29. Remove the power steering pump bracket, 1.6L (VIN 3) engine only.
  30.  
  31. Remove the alternator tensioner mounting bolt and the belt tensioner.
  32.  
  33. Remove the alternator pivot bolt.
  34.  
  35. Loosen the bolt at the base of the adjusting bracket and rotate the bracket up.
  36.  
  37. Remove the alternator.

    Click image to see an enlarged view

    Fig. Alternator mounting-1.5L and 1.6L (VIN 5) engine shown



    Click image to see an enlarged view

    Fig. Alternator mounting-2.0L and 1.6L (VIN 3) engines shown



    Click image to see an enlarged view

    Fig. Alternator mounting-2.4L and 2.7L engine

  38.  

To install:

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Install the alternator.
  4.  
  5. Install the alternator pivot bolt and hand-tighten at this time.
  6.  
  7. Rotate the adjusting bracket into position, place the belt tensioner into position. Hand-tighten the mounting bolt.
  8.  
  9. Install the drive belt.
  10.  
  11. Adjust the belt tension by rotating the adjustment bolt.
  12.  
  13. The belt deflection for 1.5L, 1.6L (VIN 5), 2.4L and 2.7L engines, is as follows:
    1. New belt: 0.22-0.28 in. (5.5-7mm).
    2.  
    3. Used belt: 0.24-0.28 in. (6-7mm).
    4.  

  14.  
  15. The belt deflection for 1.6L (VIN 3) engine is as follows :
    1. New belt: 0.13-0.15 in. (3.3-3.7mm).
    2.  
    3. Used belt: 0.17-0.19 in. (4.2-4.7mm).
    4.  

  16.  
  17. The belt deflection for the 2.0L engine, is as follows:
    1. New belt: 0.22-0.31 in. (5.5-8mm).
    2.  
    3. Used belt: 0.33-0.45 in. (8.5-11.5mm).
    4.  

  18.  
  19. The belt deflection for the 1.8L engine, is as follows:
    1. New belt: 0.23-0.31 in. (6-8mm).
    2.  
    3. Used belt: 0.28-0.35 in. (7-9mm).
    4.  

  20.  
  21. Tighten the tensioner bolt to 14-19 ft. lbs. (19-26 Nm) and the pivot bolt to 28-38 ft. lbs. (38-51 Nm).
  22.  
  23. Connect the alternator electrical connections.
  24.  
  25. Install the alternator B terminal cover cap.
  26.  
  27. Install the power steering pump and adjust the power steering belt tension, 2.0L and 1.6L (VIN 3) engines only.
  28.  
  29. Install the water pump pulley, 2006 1.6L engine only.
  30.  
  31. Install the air intake inlet pipe and fasten the clamp, 1.8L engine only.
  32.  
  33. Install the top hose to the air intake inlet pipe, 1.8L engine only.
  34.  
  35. Install the front air intake inlet pipe bolts, 1.8L engine only.
  36.  
  37. Connect the negative battery cable.
  38.  

 
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