Sephia 1995 1.6L

1995 Kia Sephia GS
1.6L 4-CYL VINS [1,3,4] 1995-96 Engines - 1.6L 4-Cylinder
1.6L 4-CYL VINS [1,3,4]
1995-96 Engines - 1.6L 4-Cylinder
ENGINE IDENTIFICATION
NOTE: For repair procedures not covered in this article, see ENGINE OVERHAUL -
GENERAL INFORMATION article in GENERAL INFORMATION section.
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

Application Code
1995
1.6L SOHC 1
1.6L DOHC 3
1995-96
1.8L DOHC 5
1996-96
1.6L B6 DOHC 4
ADJUSTMENTS
VALVE CLEARANCE ADJUSTMENT
All engines are equipped with Hydraulic Lash Adjusters (HLA). No adjustment is required.
REMOVAL & INSTALLATION
NOTE: For reassembly 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.
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.
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1995 Kia Sephia GS
Fig. 1: Locating Fuel Pump Electrical Connector

Courtesy of KIA MOTORS AMERICA, INC.
ENGINE
Removal & Installation
1. Release fuel pressure. See FUEL PRESSURE RELEASE. Disconnect battery cables. Remove battery
cover, battery and battery tray. Drain engine coolant and transaxle oil. Remove air cleaner assembly.
Disconnect radiator hoses and coolant reservoir hose.
2. Disconnect electric cooling fan connector. On A/T models, disconnect oil cooler hose. On all models,
remove radiator and cooling fan assembly. Remove accessory drive belts. Remove power steering pump
and A/C compressor from engine with hoses attached, and secure units away from engine.
3. Note locations and disconnect all necessary electrical connectors and ground wires. See Fig. 2 or Fig. 3 .
Note locations and disconnect vacuum hoses, fuel hoses, coolant hoses and control cables for engine
removal. Plug all fuel hoses to avoid leakage. Disconnect all oil cooler hoses (engine and transmission
oil). Plug all oil cooler hoses to avoid leakage. Raise and support vehicle. Disconnect exhaust manifold
downpipe. On A/T models, remove shift control cable.
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1995 Kia Sephia GS
Fig. 2: Wiring Harness Electrical Connector Locations (SOHC)

1995 Kia Sephia GS
1995 Kia Sephia GS
Fig. 3: Wiring Harness Electrical Connector Locations (DOHC)

4. On M/T models, remove shift control linkage and extension bar. Remove clutch slave cylinder and fluid
line bracket from transaxle housing, leaving fluid line connected to cylinder. Secure cylinder away from
transaxle.
5. On all models, remove transmission wiring harness connectors and speedometer cable. Remove wheel
assemblies and axle shaft nuts from hubs. Disconnect stabilizer bar from lower control arms. Separate
lower ball joints and steering tie-rod ends from steering knuckles.
6. Pry axle shafts out of transaxle. Remove and discard circlip from axle shafts. For further information on
axle shafts, see AXLE SHAFTS - FWD article in DRIVE AXLES section. Remove engine mount nuts
from crossmember, and loosen crossmember bolts. DO NOT remove crossmember bolts at this time.
7. Lower vehicle, and attach engine hoist for engine removal. Remove engine front mount and transaxle top
mount from inner fender panels. Remove engine crossmember. Remove engine and transaxle assembly
from top of vehicle.
8. To install, reverse removal procedure. Tighten bolts and nuts to specifications. See TORQUE
SPECIFICATIONS. Add all fluids as necessary.
INTAKE MANIFOLD
1. Release fuel system pressure. See FUEL PRESSURE RELEASE. Disconnect negative battery cable.
Drain cooling system. Remove air cleaner. Disconnect throttle cable, kickdown cable (A/T models),
wiring, and fuel lines from throttle body. Remove lower intake manifold bolts. Remove intake manifold
support bracket. Mark and remove vacuum hoses and electrical connectors as necessary. Remove vacuum
reservoir (if equipped).
2. Remove PCV valve and hose. Remove transaxle vent tube from upper intake manifold. Remove fuel rail.
Remove upper intake manifold bolts. Remove upper and lower manifolds as an assembly. If upper and
lower manifolds are separated, replace gasket. Remove intake manifold gasket.
Installation
Clean gasket mating surfaces. Position new gasket on cylinder head studs. Install upper and lower intake
manifolds as an assembly. To complete installation, reverse removal procedure. See Fig. 4 or Fig. 5 . Tighten
bolts to specification in sequence. See TORQUE SPECIFICATIONS.
1995 Kia Sephia GS
Fig. 4: Intake Manifold Nut Tightening Sequence (SOHC)

1995 Kia Sephia GS
Fig. 5: Intake Manifold Nut Tightening Sequence (DOHC)

EXHAUST MANIFOLD
1. Disconnect oxygen sensor. Remove exhaust manifold heat shield. Disconnect downpipe 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 header pipe and manifold. See
TORQUE SPECIFICATIONS.
CYLINDER HEAD
CAUTION: Rotate crankshaft in clockwise direction only.
Removal
1. Release fuel pressure. See FUEL PRESSURE RELEASE. Disconnect fuel inlet and return lines. Plug
1995 Kia Sephia GS
all fuel hoses to avoid leakage. Disconnect negative battery cable. Drain cooling system. Remove air inlet
duct. Note locations and disconnect all necessary electrical connectors, ground wires, vacuum hoses,
coolant hoses and control cables for cylinder head removal. Rotate crankshaft clockwise until timing
mark is at TDC. Remove timing covers.
2. Remove spark plug wires and spark plugs. Remove distributor. Remove all drive belts. Remove water
pump pulley. Remove timing belt cover(s). Loosen timing belt tensioner bolt, relieve timing belt tension
and tighten tensioner bolt. Remove timing belt from camshaft sprocket(s). Secure timing belt aside.
Remove valve cover.
3. Remove exhaust downpipe and support bracket from exhaust manifold. Remove intake manifold support
bracket. Loosen all cylinder head bolts evenly, in reverse order of tightening sequence, in 2-3 steps.
Remove bolts. Remove cylinder head and manifolds as an assembly.
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 it
is not within specification. Check valve train components. Replace or resurface components if they are not
within specification. See CYLINDER HEAD and VALVES & VALVE SPRINGS tables under ENGINE
SPECIFICATIONS.
NOTE: If intake and exhaust manifolds were remove for machining, install manifolds
onto cylinder head before installing cylinder head onto block.
Installation
1. Install cylinder head gasket. Install cylinder head assembly and cylinder head bolts. See Fig. 6 or Fig. 7 .
Using 2 steps, tighten cylinder head bolts in specified sequence. See TORQUE SPECIFICATIONS.
2. Ensure No. 1 piston is at TDC and timing mark is aligned. Install timing belt. Ensure timing belt has no
slack at idler pulley or between camshaft sprockets (DOHC). Release timing belt tensioner and tighten
tensioner bolt. Rotate crankshaft 2 full revolutions (clockwise), and verify all timing marks are aligned.
See TIMING BELT. To complete installation, reverse removal procedure.
1995 Kia Sephia GS
Fig. 6: Cylinder Head Bolt Tightening Sequence (SOHC)

1995 Kia Sephia GS
Fig. 7: Cylinder Head Bolt Tightening Sequence (DOHC)

CRANKSHAFT FRONT SEAL
Removal SOHC
1. Disconnect negative battery cable. Remove drive belts and crankshaft pulley. Remove timing belt covers
and timing belt. See TIMING BELT.
2. Use Crankshaft Sprocket Lock Tools (OK130-111-003 and OK130-111-004) to lock crankshaft sprocket
into position. Remove crankshaft sprocket bolt. Remove crankshaft sprocket using steering wheel puller.
Remove Woodruff key. Pry out seal.
Installation
1. Apply light coat of oil to lip of seal, and push seal over crankshaft. Tap seal into oil pump body until it is
flush with edge of pump body. DO NOT bottom seal in pump body. Align keyway slots, and install
crankshaft sprocket by tapping lightly using brass hammer.
2. Install Woodruff key with tapered side toward oil pump body. Install crankshaft sprocket lock bolt. Using
crankshaft sprocket lock tools, lock crankshaft sprocket into position. Tighten lock bolt to specification.
1995 Kia Sephia GS
See TORQUE SPECIFICATIONS.

3. Install timing belt. See TIMING BELT. Install timing belt covers, pulleys and drive belts. Reconnect
negative battery cable, and ensure timing is correct.
TIMING BELT
Removal
1. Disconnect negative battery cable. Remove all accessory drive belts. Remove water pump pulley.
Remove crankshaft pulley bolt, and remove pulley only. Remove upper and lower timing belt covers. On
DOHC models, remove upper, middle and lower timing covers. See Fig. 8. Disconnect spark plug wires
and remove spark plugs.
2. Rotate crankshaft clockwise until No. 1 piston is at TDC of compression stroke. Ensure camshaft
sprocket(s) and crankshaft sprocket timing marks align. See Fig. 9 or Fig. 10 . Lower timing marks are
similar on all applications.
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.
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.
1995 Kia Sephia GS
Fig. 8: Identifying Timing Belt Covers (DOHC)

1995 Kia Sephia GS
1995 Kia Sephia GS
Fig. 9: Aligning Timing Marks (SOHC)

Fig. 10: Aligning Timing Marks (DOHC)

Installation
1. Ensure camshaft and crankshaft timing marks are still aligned. See Fig. 9 or Fig. 10 . Install belt around
crankshaft sprocket. Keeping belt pulled tight on right side (facing engine), route belt around camshaft
sprocket(s).
2. Loosen timing belt tensioner lock bolt, and allow spring to apply tension on belt. Snug tensioner lock
bolt. Rotate crankshaft clockwise 2 complete revolutions. Ensure timing marks align. If timing marks are
not aligned, remove belt, realign all timing marks, and repeat installation procedure.
3. 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" (9.0-10.7 mm). If timing belt deflection is not within
specification, repeat steps 2) and 3) and/or replace timing belt tensioner spring. If timing belt deflection is
within specification, reverse removal procedure to complete installation.
1995 Kia Sephia GS
ROCKER ARM SHAFT ASSEMBLY
Removal & Installation (SOHC)
1. Remove valve cover. Loosen rocker arm shaft bolts evenly and in reverse order of tightening sequence.
Note component location for installation reference. Rocker arms are not interchangeable.
2. Remove rocker arm shaft assembly and bolts. Inspect all components for wear or damage. See ROCKER
ARM SHAFT ASSEMBLY under ENGINE SPECIFICATIONS.
3. To install, reverse removal procedure. Ensure oil holes in rocker arm shafts face down. Evenly tighten
bolts to specification in 2-3 steps in sequence. See Fig. 11. See TORQUE SPECIFICATIONS.
Fig. 11: Rocker Arm Tightening Sequence (Typical)

HYDRAULIC LASH ADJUSTER (HLA)
Removal
1. Disconnect negative battery cable. Remove valve cover. See Fig. 11. Loosen rocker arm shaft bolts
evenly in 2-3 steps in reverse order of tightening sequence. See ROCKER ARM SHAFT ASSEMBLY.
1995 Kia Sephia GS
CAUTION: If HLA is difficult to remove from rocker arm, pliers may be used for
removal; however, HLA or "O" ring may be damaged during removal
and require replacement.
2. Mark all parts for installation reference. Remove rocker arm shaft assembly from cylinder head. On
SOHC engines, disassemble rocker arm shaft assembly. Remove HLA from rocker arm. On DOHC
engines, remove HLA from bores in cylinder head.
Inspection
Inspect face of HLA for wear or damage, replace as necessary.
Installation
1. On SOHC engines, pour engine oil into oil reservoir in rocker arm. On DOHC engines, pour engine oil
into bores of cylinder head. On both engines, apply engine oil to HLA. On SOHC engines, install HLA in
rocker arm. On DOHC engines, install HLA in bores of cylinder head, being careful to not damage "O"
ring during installation.
NOTE: On SOHC engines, intake rocker arm shaft has a Yellow/Green

identification mark and exhaust rocker arm shaft has a Pink/Blue
identification mark. Ensure identification marks face upward.
2. On SOHC engines, assemble rocker arms to original location on rocker arm shafts. Install rocker arm
shaft assemblies to cylinder head. See Fig. 11. Tighten rocker arm shaft bolts to specification in sequence.
See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedure.
3. On DOHC engines, install camshafts. Install camshaft bearing caps to their original locations. See Fig.
12. Install and tighten bolts in sequence to torque specification. See TORQUE SPECIFICATIONS. To
complete installation, reverse removal procedure.
1995 Kia Sephia GS
Fig. 12: Tightening Sequence For Camshaft Bearing Caps (DOHC)

CAMSHAFT
Removal (SOHC)
1. Disconnect negative battery cable. Remove cylinder head valve cover. Remove upper timing cover. Set
timing marks to No. 1 TDC. Remove timing belt from camshaft sprocket. Remove rocker arm shaft
assembly by loosening rocker arm shaft bolts evenly in 2-3 steps, in reverse order of tightening sequence.
See Fig. 11.
2. Mark each component for installation reference. Rocker arms are not interchangeable. Remove
distributor. Using dial indicator, check camshaft end play. If camshaft end play is out of specification,
replace camshaft thrust plate during installation. Remove camshaft sprocket. Remove camshaft thrust
plate, and slide camshaft out of head. Remove oil seal from head.
1995 Kia Sephia GS
Inspection
Check camshaft journals and bearings for wear. Check camshaft lobes for wear and damage. Check camshaft
runout. Clean and check all measurements of camshaft and cylinder head. See CAMSHAFT under ENGINE
SPECIFICATIONS. If any measurements are not within specification, replace camshaft, thrust plate, camshaft
bearings and/or cylinder head as necessary.
Installation
Apply camshaft lube or engine oil to camshaft and bearings before installing. Tap camshaft oil seal in until
flush with head. Install camshaft and pulley with dowel pin straight up. To complete installation, reverse
removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS.
Removal (DOHC)
1. Disconnect negative battery cable. Remove timing belt upper and middle covers. Set timing marks to No.
1 TDC. See TIMING BELT. Loosen timing belt tensioner and tighten tensioner bolt with tension
removed from timing belt. Remove timing belt from camshaft sprockets. Disconnect spark plug wires.
Remove distributor. Remove valve cover.
2. Using a wrench to hold camshaft stationary, remove camshaft sprocket retaining bolts. Remove camshaft
sprockets. Remove camshaft bearing caps in reverse order of tightening sequence. See Fig. 12. Note
bearing cap locations for installation. Remove camshaft and oil seal.
Inspection
Check camshaft journals and bearings for wear. Check camshaft lobes for wear and damage. Check camshaft
runout. See CAMSHAFT under ENGINE SPECIFICATIONS. If any measurements are not within
specifications, replace camshaft and/or cylinder head.
Installation
1. Apply clean engine oil to camshaft journals and bearings. Install camshaft. Apply silicone sealant to areas
shown. See Fig. 13. Install camshaft bearing caps in their original locations.
2. Install camshaft bearing cap bolts and tighten in sequence to specification. See TORQUE
SPECIFICATIONS. Apply clean engine oil to lip of new camshaft oil seal and install. See Fig. 12. To
complete installation, reverse removal procedure. Tighten bolts to specification. See TORQUE
SPECIFICATIONS.
1995 Kia Sephia GS
Fig. 13: Silicone Sealant Application Locations

REAR CRANKSHAFT OIL SEAL
NOTE: Rear crankshaft oil seal can be removed without removing oil pan or crankshaft.
Removal
Remove transaxle. See TRANSMISSION REMOVAL & INSTALLATION - A/T article in AUTOMATIC
TRANS SERVICE section or TRANSMISSION REMOVAL & INSTALLATION - M/T article in MANUAL
TRANS SERVICE section. Mark all parts for reassembly reference. On A/T models, remove flex plate. On M/T
models, remove clutch assembly and flywheel. Remove rear cover. On all models, use a seal remover to remove
oil seal from rear cover.
Installation
To install, lubricate seal lip with light coat of oil. Tap seal into oil seal holder until it is flush with edge of seal
holder (1995 models). On 1996 models, tap seal in until nearly flush with surface of rear cover, 0-.02" (0-.5
mm). DO NOT bottom seal in holder. On M/T models, install flywheel and clutch assembly. On A/T models,
install flex plate. Reverse removal procedures to complete installation. On all models, tighten bolts to
specification. See TORQUE SPECIFICATIONS.
CAUTION: Always replace flywheel or flex plate bolts. DO NOT reuse old bolts.
1995 Kia Sephia GS
THERMOSTAT
Inspection
1. Visually check that the thermostat valve airtight.

2. Place the thermostat and a thermometer in water.
3. Heat the water and check the following :
Initial-opening temperature :
Main : 188-193°F (86.5-89.5°C)
Sub : 182-188°F (83.5-86.5°C)
Full-open temperature : 212°F (100°C)
Full-open lift :
Main : 0.30 in (8.0mm) minimum
Sub : 0.06 in (1.5mm) minimum
Fig. 14: Sub Valve And Main Valve

Installation
1. Install the thermostat into cylinder head with the jiggle pin at the top.
1995 Kia Sephia GS
Fig. 15: Thermostat And Jiggle Pin

Thermostat gasket
Install a new gasket with the print side facing the cylinder head.
Steps after installation
1. Fill the radiator with the specified amount and type of engine coolant.
2. Connect the negative battery cable.
3. Start the engine and check for leaks.
WATER PUMP
Removal
Disconnect negative battery cable. Drain coolant. Remove timing belt. See TIMING BELT. Remove water
inlet pipe and gasket. Remove "O" ring from coolant by-pass pipe. 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 new "O" ring on water by-pass pipe. Install water pump
gasket on water pump. Install new gasket on coolant inlet pipe. Install water pump and inlet pipe. To complete
installation, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS.
OIL PAN
Removal
1. Disconnect negative battery cable. Raise and support vehicle. Remove engine splash covers. Drain engine
1995 Kia Sephia GS
oil. Remove exhaust header pipe and support brackets from front exhaust system. Remove oil pan-to-
transaxle bolts. Remove oil pan stiffener (if equipped). See Fig. 16. Support oil pan. Remove oil pan-to-
engine block retaining bolts.
CAUTION: DO NOT force pry bar between engine block and oil pan contact
surfaces when removing oil pan.
2. DO NOT damage sealant contact surfaces. Remove oil pan. Remove oil pan upper block (1.6L DOHC),
or remove main bearing support plate (1.8L DOHC) retaining bolts from main bearing caps, and pry plate
from engine block. DO NOT deform support plate. Replace plate if it is deformed. Clean sealant from oil
pan, bolts, engine block and both sides of upper block or support plate.
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.
Installation
Apply oil resistant sealant to both sides of MBSP. Install MBSP. Align engine block/oil pan holes, and tighten
MBSP bolts 12-15 ft. lbs. (16-20 N.m). Apply sealant, and install oil pan. To complete installation, reverse
removal procedure. Tighten all bolts to specification. See TORQUE SPECIFICATIONS. Fill engine with oil
to specification.
1995 Kia Sephia GS
Fig. 16: Exploded View Of Oil Pan & Components

1995 Kia Sephia GS
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 .006" (.15 mm). Check cylinder head height. See CYLINDER HEAD 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 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 specifications. See VALVES & VALVE SPRINGS 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 under ENGINE SPECIFICATIONS.
2. To replace valve guide, completely disassemble cylinder head. Working from combustion chamber side
of cylinder head, install Valve Guide Remover (OK130-120-006) into valve guide. Drive valve guide out
of cylinder head.
3. If necessary, install new circlip on guide. Using proper components of Valve Guide Installer (OK993-
120-AA0), adjust installer guide depth (dimension "L") to specification using depth micrometer or
caliper. See Fig. 17.
4. Insert guide into pre-adjusted installer. Drive guide into cylinder head from camshaft side until guide
circlip and/or installer contact cylinder head. Measure dimension "L" to determine guide installed height.
See Fig. 17.
5. If installed height is not within specification, adjust or replace valve guide or cylinder head as necessary.
See CYLINDER HEAD under ENGINE SPECIFICATIONS.
1995 Kia Sephia GS
Fig. 17: Adjusting Valve Guide Installer & Installing Guide

Valve Seat
1. Service valve guide as needed before servicing valve seat. Valve seat replacement information is not
available at time of publication. Inspect valve seat for roughness, pitting, cracks and damage. Check valve
seat angle and seat width.
2. Measure seat contact width on valve, and note that seat contact position should be in center of valve face.
Service seat if angle and width are not within specification. See CYLINDER HEAD 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 under ENGINE SPECIFICATIONS.
Ensure valve/seat contact position is at center of valve face. If width and position are not within
specifications, cut seats as follows.
2. If seat contact position is too high, correct using 75-degree stone (intake) or 70-degree stone (exhaust).
Finish angle using 45-degree stone until contact width is corrected.
3. If seat contact position is too low, correct using 0-degree stone. Finish angle using 45-degree stone until
contact width is corrected. Seat valve to valve seat using lapping compound.
Valve Stem Installed Height
1. After servicing valves, measure valve stem installed height. See VALVE INSTALLED HEIGHT. If the
installed valve height is within standard specification, no adjustment is necessary. See Fig. 18.
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.
1995 Kia Sephia GS
Fig. 18: Measuring Valve Stem Installed Height (Typical)

VALVE INSTALLED HEIGHT

Application In. (mm)
1.6L SOHC 8-Valve
Intake & Exhaust Valve
Standard 1.535-1.555 (39.0-39.5)
Service Limit (1) 1.555-1.594 (39.5-40.5)
Beyond Limit (2) 1.594 (40.5)
1.6L SOHC 16-Valve
Intake Valve
Standard 1.673-1.693 (42.5-43.0)
Service Limit (2) 1.732 (44.0)
Exhaust Valve
Standard 1.614-1.634 (41.0-41.5)
1995 Kia Sephia GS
Service Limit (2) 1.673 (42.5)

1.6L DOHC
Standard 1.737-1.771 (44.1-45.0)
Service limit (1) 1.772-1.830 (45.1-46.5)
Beyond Limit (2) 1.831 (46.5)
1.8L DOHC
Standard 1.772-1.791 (45.0-45.5)
Service limit (1) 1.792-1.830 (45.5-46.5)
Beyond Limit (2)
1.831 (46.5)
(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.
CYLINDER BLOCK ASSEMBLY
NOTE: During disassembly, match mark components for reassembly reference.
Piston & Connecting Rod Assembly
1. Before removing rod cap from crankshaft, measure and record rod side play. See CONNECTING RODS
under ENGINE SPECIFICATIONS. Ensure all rods, pistons, and caps are marked before removal to
match upon reassembly.
2. Before removing rod from crankshaft, check and record rod bearing oil clearance. See CRANKSHAFT,
MAIN & CONNECTING ROD BEARINGS under ENGINE SPECIFICATIONS.
3. Remove rod cap from crankshaft. Install short pieces of rubber hose over connecting rod studs. Ensure
cylinder does not have excessive ring ridge at top of cylinder. If excessive ring ridge is present, remove it
with appropriate ring ridge remover. Push piston and rod assembly out of block.
4. To install, ensure parts are matched to cylinder. Ensure piston, rod, rings and bearings are properly fitted
and in related positions. See Fig. 19. Install piston and rod assembly into block.
1995 Kia Sephia GS
Fig. 19: Locations & Marks For Assembling Pistons, Rod & Rings
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 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. Ensure pistons are not scored or damaged. Measure piston diameter on piston skirt at .65" (16.5 mm)
below oil ring land. See PISTONS, PINS & RINGS under ENGINE SPECIFICATIONS.
2. Check piston-to-cylinder wall clearance in 3 different vertical places of piston travel. If clearance is not
within specification, rebore cylinders to fit oversize pistons.
3. 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 under ENGINE
SPECIFICATIONS.
NOTE: Pistons and rings are available in .010" (.25 mm) and .020" (.50 mm) oversize.
Piston Rings
Insert NEW piston ring into cylinder, and measure ring end gap. Grind ring ends or replace piston ring if ring
1995 Kia Sephia GS
end gap is not within specification. See PISTONS, PINS & RINGS 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
under ENGINE SPECIFICATIONS.
Crankshaft & Main Bearings
1. Before removing main caps, measure and record crankshaft end play. Using Plastigage, measure and
record main bearing oil clearance. DO NOT rotate crankshaft when measuring oil clearances.
2. Remove crankshaft. Measure and record each main journal diameter in 2 places. See CRANKSHAFT,
MAIN & CONNECTING ROD BEARINGS under ENGINE SPECIFICATIONS. Machine or replace
crankshaft as necessary. Main bearing upper halves are grooved.
3. Main bearing caps are marked and must be installed in original position. Tighten bearing cap bolts in
sequence and to specification. See Fig. 20. See TORQUE SPECIFICATIONS.
1995 Kia Sephia GS
Fig. 20: Main Bearing Cap Tightening Sequence

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 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 under ENGINE SPECIFICATIONS.
1995 Kia Sephia GS
ENGINE LUBRICATION
Oil pressure is provided by a rotor-type pump. Driven by the crankshaft, pump draws oil from oil pan through
oil strainer. From oil pump, oil is sent through oil filter then to cylinder block and up to cylinder head. Oil
drains back to oil pan. See Fig. 21 and Fig. 22 .
Crankcase Capacity
See CRANKCASE CAPACITY.
CRANKCASE CAPACITY
Without Oil Filter With Oil Filter
Engine Size/Application Quarts (Liters) Quarts (Liters)
1.6L
SOHC 3.2 (3.0) 3.4 (3.2)
DOHC 3.4 (3.2) 3.6 (3.4)
1.8L
DOHC 3.8 (3.6) 4.0 (3.6)
Oil Pressure
With engine at operating temperature, oil pressure should be 28-43 psi (2.0-3.0 kg/cm2 ) at 1000 RPM, and 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.
1995 Kia Sephia GS
Fig. 21: Cross-Sectional View Of Engine Oil Circuit (SOHC)

1995 Kia Sephia GS
Fig. 22: Cross-Sectional View Of Engine Oil Circuit (DOHC)

OIL PUMP
Removal
1. Disconnect negative battery cable. Remove timing belt. See TIMING BELT & SPROCKETS under
REMOVAL & INSTALLATION. Remove crankshaft sprocket and Woodruff key. Remove oil pan and
Main Bearing Support Plate (MBSP). See OIL PAN under REMOVAL & INSTALLATION.
1995 Kia Sephia GS
2. Remove oil pump pick-up tube. Remove A/C compressor and mounting bracket (if equipped) from
engine block. Remove dipstick tube. Remove generator lower mounting bolt and position generator away
from oil pump. Remove oil pump bolts. Remove oil pump and gasket.
3. Remove front oil seal. Carefully clean all gaskets and sealant from mating surfaces without damaging
sealing/mating surfaces. Remove all sealant from components and bolts. Check oil pump clearances. See
OIL PUMP SPECIFICATIONS. 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. Align keyway slots, and install crankshaft sprocket by tapping lightly using brass hammer. Install
Woodruff key with tapered side toward oil pump body. Install crankshaft sprocket lock bolt and tighten to
specification. See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedure.
OIL PUMP SPECIFICATIONS

Max. Clearance In.
Application (mm)
Inner Gear Tip-To-Outer Gear Clearance .0079 (.201)
Outer Gear-To-Pump Body Clearance .0087 (.221)
Gear Side-To-Pump Body Clearance .0055 (.140)
Pressure Spring Length
1995 1.791 (45.49)
1996 1.807 (45.9)
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
A/C Compressor Belt Tension Pulley Bolt 23-25 (31-34)
A/C Compressor Mounting Bolt 27-38 (37-52)
Ball Joint 32-43 (43-59)
Camshaft Sprocket Bolt 37-45 (50-61)
Clutch Cover 13-20 (18-26)
Connecting Rod Nut 35-37 (47-50)
Crankshaft Pulley Lock Bolt 80-87 (108-118)
Crankshaft Sprocket Bolt 116-123 (157-167)
Cylinder Head Bolt (1) (2)
Step 1 35-40 (47-54)
Step 2 56-60 (76-81)
Distributor Bolt 14-18 (19-25)
Dynamic Damper Bolt 55-76 (74-103)
1995 Kia Sephia GS
Engine Crossmember Bolt 47-66 (64-89)

Engine Hanger
Front 27-46 (37-63)
Rear 14-19 (19-26)
Engine Mount-To-Block 68-83 (93-113)
Engine Mount-To-Crossmember Nut 27-38 (37-52)
Engine Mount-To-Frame Through Bolt 49-69 (67-93)
Exhaust Downpipe Nut 27-38 (37-52)
Exhaust Manifold-To-Head Nut/Bolt
1.6L 12-17 (16-23)
1.8L 28-34 (38-46)
Extension Bar (M/T) 23-34 (31-46)
Flywheel/Flex Plate Bolt (3) 71-76 (96-103)
Fuel Rail Bolt 14-19 (19-26)
Generator Adjusting Bolt 14-19 (19-26)
Generator Mounting Bolt 27-38 (37-52)
Intake Manifold Bolt (1) (2) 14-19 (19-26)
Intake Manifold Support Bracket
1.6L DOHC 14-18 (19-25)
1.8L DOHC 23-34 (31-46)
Main Bearing Cap Bolt (1) (2) 40-44 (54-59)
Main Bearing Support Plate 12-15 (16-21)
Oil Cooler Mounting Nut 22-29 (30-39)
Oil Pan Stiffener-To-Transaxle Bolt 27-38 (37-52)
Oil Pump Bolt 14-19 (19-26)
Power Steering Pump Adjusting Bolt 14-19 (19-26)
Power Steering Pump Mounting Bolt 28 (38)
Pressure Plate Bolt 13-20 (18-26)
Rocker Arm Shaft Bolt (1) (2) 16-21 (22-28)
Shift Control Rod (M/T) 12-17 (16-23)
Slave Cylinder 12-17 (16-23)
Spark Plug 11-17 (15-23)
Starter Bolt
1.6L 14-18 (19-25)
1.8L 27-38 (37-52)
Thermostat Housing 14-18 (19-25)
Timing Belt Tensioner Bolt
SOHC 14-18 (19-25)
DOHC 28-38 (38-51)
Torque Converter Nuts 26-36 (35-49)
1995 Kia Sephia GS
Transaxle-To-Engine Bolt
Automatic Transaxle 41-59 (56-60)
Manual Transaxle 47-66 (64-89)
Water Pump Bolt 14-19 (19-26)
INCH Lbs. (N.m)
Camshaft Bearing Cap Bolt (2)
SOHC 100-126 (11-14)
DOHC 109-156 (12-18)
Camshaft Thrust Plate Bolt 69-97 (7.8-11)
Crankshaft Pulley Bolt 109-152 (12-17)
End Plate 69-97 (7.8-11)
Engine Coolant Temperature Sensor 57-82 (6.4-9.3)
Exhaust Manifold Insulator 69-97 (7.8-11)
Oil Dipstick Tube 70-97 (8-11)
Oil Jet 109-156 (12-18)
Oil Pan Bolt 69-97 (7.8-11)
Oil Pressure Switch 109-156 (12-18)
Oil Pump Pick-up Tube Bolt 69-97 (7.8-11)
Rear Cover Bolt 69-109 (7.8-12)
Timing Belt Cover Bolt 69-97 (7.8-11)
Valve Cover 43-78 (4.9-8.8)
Vehicle Speed Sensor 69-97 (7.8-11)
Water Pump Pulley Bolt 69-97 (7.8-11)
(1) Tighten bolts in two or three steps.
(2) Tighten bolts in proper sequence.

(3) Tighten in a crisscross pattern.
ENGINE SPECIFICATIONS
GENERAL ENGINE SPECIFICATIONS
GENERAL ENGINE SPECIFICATIONS

Application Specification
Displacement
1.6L 97.4 Cu. In.
1.8L 112 Cu. In.
Bore
1.6L 3.07" (78.0 mm)
1.8L 3.27" (83 mm)
Stroke
1995 Kia Sephia GS
1.6L 3.29" (83.6 mm)

1.8L 3.35" (85 mm)
Compression Ratio
2-Valve 9.3:1
4-Valve 9.0:1
Fuel System SFI
Horsepower @ RPM
1.6L 88 @ 5000
1.8L 127 @ 6500
Torque Ft. Lbs. @ RPM
1.6L 98 @ 4000
1.8L 114 @ 4500
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS SPECIFICATIONS
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS

Crankshaft End Play
Standard .0032-.0111 (.080-.282)
Service Limit .012 (.30)
Maximum Runout .0016 (.040)
Main Journal Bearings
Journal Diameter 1.9660-1.9668 (49.936-49.956)
Journal Out-Of-Round & Taper .002 (.051)
Oil Clearance
1995 1.6L SOHC
Standard .0007-.0014 (.018-.036)
1996 1.6L & 1.8L DOHC
Standard .0008-.0014 (.020-.036)
Connecting Rod Bearings
Journal Diameter 1.7693-1.7699 (44.940-44.956)
Journal Out-Of-Round & Taper .002 (.051)
Oil Clearance
1995
Standard .0011-.0027 (.028-.068)
1996
1.6L - Standard .0012-.0026 (.030-.066)
1.8L - Standard .0008-.0017 (.020-.043)
1995 Kia Sephia GS
Service Limit (1.6L & 1.8L) .004 (.10)
CONNECTING RODS SPECIFICATIONS
CONNECTING RODS
Bore Diameter
Connecting Rod Bearing Bore 1.8898-1.8904 (48.000-
48.016)
Piston Pin Bore
1.6L SOHC .7852-.7859 (19.944-
19.961)
1.6L & 1.8L DOHC .7876-.7879 (20.005-
20.012)
Center-To-Center Length 5.230-5.234 (132.84-
132.94)
Maximum Bend (1) .003 (.08)
Side Play
Standard .0043-.0103 (.110-.262)
(1) Maximum bend per 1.97" (50 mm)
PISTONS, PINS & RINGS SPECIFICATIONS
PISTONS, PINS & RINGS

Piston Clearance
1.6L
Standard .0015-.0020 (.038-.051)
1.8L
Standard .0013-.0023 (.033-.058)
Piston Diameter
1.6L 3.0690-3.0698 (77.953-77.973)
1.8L 3.2660-3.2666 (82.956-82.972)
Pin Diameter
1.6L SOHC .7864-.7866 (19.974-19.980)
1.6L & 1.8L DOHC .7869-.7871 (19.987-19.992)
Piston Fit
1.6L SOHC .0003-.0020 (.008-.051)
1.6L & 1.8L DOHC .0001-.0005 (.005-.013)
1995 Kia Sephia GS
Rod Fit
1.6L .0005-.0015 (.013-.038)
1.8L .0004-.0011 (.010-.027)
Rings
1.6L
No. 1
End Gap
Standard .006-.012 (.15-.30)
Service Limit .039 (1.0)
Side Clearance
SOHC - Standard .0012-.0028 (.030-.071)
DOHC - Standard .0012-.0025 (.030-.064)
No. 2
End Gap
Standard .012-.018 (.300-.46)
Side Clearance
Standard .0012-.0028 (.030-.071)
No. 3 (Oil)
End Gap
Standard .008-.028 (.20-.71)
1.8L
No. 1 & No. 2
End Gap
Standard .006-.012 (.150-.300)
Side Clearance
Standard .0012-.0028 (.030-.071)
No. 3 (Oil)
End Gap
Standard .008-.027 (.20-.69)
CYLINDER BLOCK SPECIFICATIONS
CYLINDER BLOCK
1995 Kia Sephia GS
Cylinder Bore Standard Diameter

1.6L 3.0711-3.0714
(78.006-78.014)
1.8L 3.2678-3.2684
(83.002-83.018)
Maximum Taper & Out-Of-Round .0007 (.018)
Deck Height
Standard 8.728 (221.7)
Minimum 8.720 (221.5)
Maximum Deck Warpage
1.6L SOHC (1) .006 (.15)
1.6L DOHC (2) .002 (.05)
1.8L DOHC (1) .006 (.15)
(1) Replace cylinder block if material removed from deck is more than .008" (20 mm)
(2) Replace cylinder block if material removed from deck is more than .004" (10 mm)
VALVES & VALVE SPRINGS SPECIFICATIONS
VALVES & VALVE SPRINGS

Valves
Face Angle 45°
Head Diameter
1.6L (1)
1.8L
Intake 1.295-1.303" (32.9-33.1 mm)
Exhaust 1.096-1.108" (27.85-28-15 mm)
Minimum Margin
1995
2-Valve
Intake .031" (0.8)
Exhaust .043" (1.1)
4-Valve
Intake 035" (0.9 mm)
Exhaust .039" (1.0 mm)
1996
1.6L
Intake .040" (1.1 mm)
1.8L
1995 Kia Sephia GS
Intake .035" (0.9 mm)

Minimum Refinish Length
1995
2-Valve
Intake
Standard 4.085" (103.76 mm)
Minimum 4.066" (103.27 mm)
Exhaust
Standard 4.042" (102.67 mm)
Minimum 4.022" (102.16 mm)
4-Valve
Intake
Standard 4.088" (103.84 mm)
Minimum 4.068" (103.33 mm)
Exhaust
Standard 4.181" (106.20 mm)
Minimum 4.112" (104.44 mm)
1996
1.6L
Intake
Standard 4.1453" (105.29 mm)
Minimum 4.1295" (104.89 mm)
Exhaust
Standard 4.1492" (105.39 mm)
Minimum 4.1334" (104.99 mm)
1.8L
Intake
Standard 4.0114" (101.89 mm)
Minimum 3.9524" (100.39 mm)
Exhaust
Standard 4.0153" (101.99 mm)
Minimum 3.9563" (100.49 mm)
Stem Diameter
1995
2-Valve
Intake .2744-.2750" (6.970-6.985 mm)
Exhaust .2742-.2748" (6.965-6.980 mm)
1995 4-Valve, 1996 1.6L & 1.8L
Intake .2350-.2356" (5.970-5.985 mm)
Minimum (1996) .2331" (5.920 mm)
Exhaust
1995 Kia Sephia GS
.2348-.2354" (5.964-5.979 mm)

Minimum (1996) .2329" (5.915 mm)
Installed Height (2)
1.6L SOHC 8-Valve
Intake & Exhaust 1.535-1.555" (39.00-39.50 mm)
1.6L SOHC 16-Valve
Intake 1.673-1.693" (42.50-43.00 mm)
Exhaust 1.614-1.634" (41.00-41.50 mm)
1.6L DOHC
1.8L DOHC
Valve Springs
Intake
Free Length
1.6L SOHC 8-Valve
Standard 1.7165" (43.60 mm)
Minimum Limit 1.398" (35.50 mm)
1.6L SOHC 16-Valve
Standard 1.815" (46.10 mm)
Minimum Limit (3) 1.535" (38.99 mm)
1.6L DOHC
Standard 1.890" (48.01 mm)
Minimum 1.555" (39.50 mm)
1.8L DOHC
Standard 1.821" (46.25 mm)
Exhaust
Free Length
1.6L SOHC 8-Valve
Standard 1.7165" (43.60 mm)
1.6L SOHC 16-Valve
Standard 1.687" (42.85 mm)
Minimum Limit (4) 1.496" (38.00 mm)
1.6L DOHC
Standard 1.903" (48.34 mm)
Minimum 1.555" (39.50 mm)
1.8L DOHC
Standard 1.821" (46.25 mm)
1995 Kia Sephia GS
Out-Of-Square
SOHC 8-Valve
Intake & Exhaust .060" (1.52 mm)
SOHC 16-Valve
Intake .063" (1.60 mm)
Exhaust .059" (1.50 mm)
DOHC Intake & Exhaust .064" (1.63 mm)
(1) Information is not available at time of publication.
(2) Valve height is measured from top of installed valve to spring seat.
(3) Measure with 46-52 lbs. (20.9-23.6 kg) of pressure applied to spring.
(4) Measure with 30-40 lbs. (13.6-18.1 kg) of pressure applied to spring.
CYLINDER HEAD SPECIFICATIONS
CYLINDER HEAD
Cylinder Head Height
SOHC 4.228-4.236" (107.39-107.59
mm)
DOHC 5.268-5.275" (133.81-134.00
mm)
Maximum Warpage
SOHC .006" (.15 mm)
DOHC .004" (.10 mm)
Valve Seats
Seat Angle 45°
Seat Width
SOHC .047-.063" (1.2-1.6 mm)
DOHC .031-.055" (.79-1.40 mm)
Valve Guides
1.6L SOHC 8-Valve I.D. .2760-.2768" (7.01-7.03 mm)
1.6L SOHC 16-Valve, 1.6L & 1.8L DOHC
Valve Guide I.D. .2366-.2374" (6.010-6.030
mm)
Installed Height (1)
SOHC 8-Valve
Intake & Exhaust .520-.543" (13.2-13.8 mm)
1.6L SOHC 16-Valve & DOHC
1.8L DOHC
1995 Kia Sephia GS

Valve Stem-To-Guide Oil Clearance
Intake .0010-.0024" (.025-.060 mm)
Exhaust .0012-.0026" (.030-.066 mm)
Service Limit .008" (.20 mm)
(1) Valve guide installed height is measured from top of installed guide to spring seat.
CAMSHAFT SPECIFICATIONS
CAMSHAFT
Bore Diameter
SOHC
8-Valve
Front & Rear 1.7132-1.7139 (43.515-43.533)
Center 1.7132-1.7139 (43.515-43.533)
End Play .0020-.0071 (.050-.180)
16-Valve
No. 1 & 5 1.7126-1.7132 (43.500-43.515)
No. 2, 3 & 4 1.7120-1.7128 (43.485-43.505)
End Play .0024-.0075 (.061-.191)
DOHC - 16-Valve End Play .003-.008 (.08-.20)
Journal Diameter
SOHC
8-Valve
Front & Rear 1.7102-1.7110 (43.440-43.460)
Center 1.7098-1.7108 (43.430-43.454)
16-Valve
Journals No. 1 & 5 1.7102-1.7110 (43.440-43.460)
Journals No. 2 & 4 1.7096-1.7106 (43.425-43.450)
Journal No. 3 1.7091-1.7100 (43.410-43.434)
1.6L DOHC 1.3371-1.3385 (33.962-34.000)
1.8L DOHC 1.0213-1.0222 (25.940-25.964)
Maximum Journal Out-Of-Round
SOHC & DOHC .002 (.05)
Maximum Journal Runout
SOHC .0004 (.010)
DOHC .0012 (.030)
Journal Oil Clearance
SOHC
8-Valve
1995 Kia Sephia GS
Front & Rear .0021-.0037 (.055-.094)

Center .0023-.0041 (.058-.104)
16-Valve
No. 1 & 5 .0016-.0030 (.040-.076)
No. 2 & 4 .0014-.0031 (.036-.079)
No. 3 .0020-.0037 (.050-.094)
DOHC .0014-.0032 (.036-.081)
Lobe Height
SOHC
8-Valve
Intake & Exhaust
Standard 1.4351 (36.451)
Service Limit 1.4272 (36.251)
16-Valve
Intake
Standard 1.4106 (35.829)
Exhaust
Standard 1.4039 (35.659)
1.6L DOHC
Intake
Standard 1.6098 (40.888)
Exhaust
Standard 1.6097 (40.886)
1.8L DOHC
Intake
Standard 1.7360 (44.094)
Exhaust
Standard 1.7560 (44.602)
ROCKER ARM SHAFT ASSEMBLY SPECIFICATIONS
ROCKER ARM SHAFT ASSEMBLY

1995 Kia Sephia GS
8-Valve
Rocker Arm I.D. .7087-.7097 (18.000-18.026)
Rocker Arm Shaft O.D. .7070-.7079 (17.958-17.980)
Rocker Arm-To-Shaft Clearance
Standard .0008-.0027 (.0203-.0685)
16-Valve
Rocker Arm I.D. .7480-.7493 (19.000-19.033)
Rocker Arm Shaft O.D. .7464-.7472 (18.959-18.980)
Rocker Arm-To-Shaft Clearance
Standard .0008-.0029 (.0203-.0737)

Sephia 1995 1.6L

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1995 Kia Sephia GS

1.6L 4-CYL VINS [1,3,4] 1995-96 Engines - 1.6L 4-Cylinder

1.6L 4-CYL VINS [1,3,4]

1995-96 Engines - 1.6L 4-Cylinder

ENGINE IDENTIFICATION CODE

REMOVAL & INSTALLATION

FUEL PRESSURE RELEASE

sábado, 6 de febrero de 2021 11:23:17

Fig. 1: Locating Fuel Pump Electrical Connector

Removal & Installation

Fig. 2: Wiring Harness Electrical Connector Locations (SOHC)

Fig. 3: Wiring Harness Electrical Connector Locations (DOHC)

Removal & Installation

Fig. 4: Intake Manifold Nut Tightening Sequence (SOHC)

Fig. 5: Intake Manifold Nut Tightening Sequence (DOHC)

Removal & Installation

CAUTION: Rotate crankshaft in clockwise direction only.

Fig. 6: Cylinder Head Bolt Tightening Sequence (SOHC)

Fig. 7: Cylinder Head Bolt Tightening Sequence (DOHC)

CRANKSHAFT FRONT SEAL

See TORQUE SPECIFICATIONS.

Fig. 8: Identifying Timing Belt Covers (DOHC)

Fig. 9: Aligning Timing Marks (SOHC)

Fig. 10: Aligning Timing Marks (DOHC)

ROCKER ARM SHAFT ASSEMBLY

Removal & Installation (SOHC)

Fig. 11: Rocker Arm Tightening Sequence (Typical)

HYDRAULIC LASH ADJUSTER (HLA)

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

NOTE: On SOHC engines, intake rocker arm shaft has a Yellow/Green

Fig. 12: Tightening Sequence For Camshaft Bearing Caps (DOHC)

Fig. 13: Silicone Sealant Application Locations

REAR CRANKSHAFT OIL SEAL

1. Visually check that the thermostat valve airtight.

Main : 188-193°F (86.5-89.5°C)

Sub : 182-188°F (83.5-86.5°C)

Full-open temperature : 212°F (100°C)

Main : 0.30 in (8.0mm) minimum

Sub : 0.06 in (1.5mm) minimum

Fig. 14: Sub Valve And Main Valve

Fig. 15: Thermostat And Jiggle Pin

Steps after installation

Fig. 16: Exploded View Of Oil Pan & Components

Fig. 17: Adjusting Valve Guide Installer & Installing Guide

Valve Seat Correction Angles

Valve Stem Installed Height

Fig. 18: Measuring Valve Stem Installed Height (Typical)

VALVE INSTALLED HEIGHT

Service Limit (2) 1.673 (42.5)

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

CYLINDER BLOCK ASSEMBLY

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

Piston & Connecting Rod Assembly

Piston Pin Replacement

Connecting Rod Bearings

Crankshaft & Main Bearings

Fig. 20: Main Bearing Cap Tightening Sequence

See CRANKCASE CAPACITY.

Oil Pressure Relief Valve