Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

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Note: This system is designed to use the stock hanger locations. Please check the alignment of your OEM system before installation. If the tips of your OEM system are not straight or centered in the rear valance, then the replacement system will also be misaligned. Removal of the O.E.M. system: 1. Park the vehicle on a smooth level asphalt or concrete surface and set the parking brake firmly. Place a block in front of and behind the front wheels. Jack up the rear of the vehicle and place on jack stands under the frame in the manufactures specified locations. Alternatively, it would be best to have the vehicle raised on a hydraulic lift. Warning: Do not work under a vehicle being held up by only a jack. Place jack stands securely under the vehicle in the manufacture-specified location. 2. Spray all the rubber hangers with a spray lubricant to ease removal of the system. See (Fig.1) 3. Remove the 2 nuts at the flange. Pull the muffler out of the hangers. See (Fig.2) 4. Next you will be removing the black cover covering the bumper in order to make the cutout for the exhaust tip. You will be removing various screws holding it on from underneath/backside of the bumper. See (Fig.3) 5. Unbolt the reflectors by removing the screw holding them on. This will be needed in order to gain access to the 2 inner screws holding on the black cover. Figure 4 See (Fig.4) They easily pop off once the screw has been removed. Set aside carefully. 6. When the reflector has been removed you will need to unscrew the upper portion of the black bumper cover where shown in (Fig.5) There is 1 screw holding each corner of the upper black cover. Set aside as they will be reused. Figure 5

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Initial disassembly 1. Disconnect the battery. Remove battery and the battery tray. 2. Using floor jack, elevate front end and place securely on jack stands. 3. Drain the coolant from the radiator. Capture and save for re-use. 4. Remove both upper and lower radiator hoses. 5. Remove front bumper. 6. Remove both headlights. 7. Remove steel inner bumper. 8. Remove the entire air cleaner assembly, including housing, ducting, and the MAF sensor. 9. Disconnect and remove horns. 10. Remove dipstick and dipstick tube. 11. Remove exhaust manifold. Remove oxygen sensor from manifold for reuse. 12. Loosen alternator tensioner and remove alternator belt. 13. Remove power steering pump belt and then pump (Note: Do not remove lines from pump, lay pump over towards inner fender). 14. Remove power steering pump bracket. 15. Remove bracket holding wires to Crank Position Sensor and Oil Temp Sensor. Cylinder head removal/installation NOTE: THIS PROCEDURE DOES NOT INCLUDE DETAILED INSTRUCTIONS FOR THE REMOVAL/REPLACEMENT OF MAJOR COMPONENTS. PLEASE REFER TO THE MANUFACTURERS SERVICE MANUAL. 1. Remove all electrical connections from the intake manifold. This includes disconnecting all sensor plugs from the throttle body and manifold, removing the fuel injector wiring harness, removing the ground strap, and disconnecting the knock sensor. 2. Disconnect the throttle and cruise control cables from the throttle body and lay cables to sides of engine bay. 3. Disconnect the fuel rail supply hose. Remove fuel rail, complete with injectors. 4. Disconnect the hose from the EVAP canister to the manifold, and unclip canister from manifold.

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REMOVAL 1. Disconnect negative battery cable. 2. Loosen power steering 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. 4. Loosen generator mounting bolts and adjusting bolt. 5. Remove generator bolts. 6. Remove water pump pulley. 7. Remove crankshaft pulley and timing belt guide plate. 8. Remove upper and lower timing belt covers. 9. Turn crankshaft so that timing mark on timing belt pulley is aligned with timing mark on engine. 10. Check that “I” mark 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. NOTE: Do not move camshaft or crankshaft once timing marks have been correctly positioned. 11. Loosen tensioner pulley lock bolt. 12. Protect timing belt with a rag. 13. Remove tensioner pulley. 14. Remove timing belt. NOTE: Mark the direction of timing belt rotation (on the timing belt) for proper reinstallation. INSPECTION NOTE: Never forcefully twist, turn inside out or bend timing belt. Do not allow oil or grease to come in contact with timing belt. 1. Replace timing belt if it is contaminated with oil or grease.

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ON-VEHICLE SERVICE If noise or vibration is present in the vehicle driveline, the driveshaft may be out of round due to damage. This inspection will help determine if the driveshaft and its attaching driveline components are “true” or turning with an absolute minimum amount of lateral movement. SPLINE BACKLASH Check for spline backlash by shaking driveshaft back and forth. LOOSE UNIVERSALS Check for loose universal yoke bolts and nuts. Tighten if necessary. DRIVESHAFT DEFLECTION 1. Place transmission in neutral. 2. Raise and support vehicle. 3. Install a dial indicator to the vehicle undercarriage and place the indicator plunger on the driveshaft. 4. Measure both shafts in three separate locations: At the center and 3 in (76.2 mm) from each yoke weld. Slowly turn one of the wheels to turn the driveshaft and record the highest indicator reading in all three locations. REMOVAL 1. Raise and support vehicle. 2. Place index marks (reference marks) on the driveshafts and their matching transfer case and differential input/output shafts.

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Vehicle Level Powertrain Management Ignition System Ignition Coil Service and Repair Service and Repair REPLACEMENT IGNITION COIL 1. Remove the engine cover. 2. Disconnect the spark plug cables and the ignition coil connector. 3. Remove the ignition coil (A). 4. Installation is the reverse of removal. 2006 Kia Spectra L4-2.0L – Service and Repair