Greetings From Honduras :-) Includes cars and pictures - Kia Forum
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post #1 of 1064 (permalink) Old 12-06-2009, 04:35 AM Thread Starter
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Talking Greetings From Honduras :-) Includes cars and pictures

Hi Everyone!

I am not New to Car Mechanics but New to Kia...

I Recently obtained for my wife, a Kia Sephia 2000 (Almost New 'cos its Previous Owner didn't use it very Much, it sat for long time!) I Hope I Can Find Help here and Eventually I Hope I Will Help other Members too.

I'll post here the Progress and Mods I will do to the Car.


Kind Regards.
JesZeK.


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Last edited by Loyale 2.7 Turbo; 07-30-2012 at 10:49 AM. Reason: Wrong Year Model, Corrected!
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post #2 of 1064 (permalink) Old 12-08-2009, 02:01 PM
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post #3 of 1064 (permalink) Old 07-30-2012, 10:58 AM Thread Starter
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I'll Try to do my Best to Help people with my Posts and upload Pictures here for all my Procedures & Parts with Numbers, as Usual.

I Had to Change the Engine in the Sephia...

I am more the kind of "Repair it" Guy, not the "Swap it" kind; but I Had to do it...

In the Past I Worked in other Engine Swaps, in Other car brands, such like the Flat (Boxer) 6 Cyl. 2.7L engine (H6 - ER27 Engine) from the Subaru XT6 Coupe, onto my Subaru Loyale Wagon which originally came with a Flat (Boxer) Four Cyl. 1.8L Engine (H4 - EA82 Engine). That is the Origin of my Screen Name, "Loyale 2.7 ..."


Subaru uses Boxer Engines.



Also I've worked in Complete Drivetrains' Swaps, such like the V6 Automatic Chevrolet Blazer who was a Real Gasoline Hungry Machine; to a in-Line 4 Cyl. Toyota 22R EFi Engine complete with its Manual Transmission, to make the car more economic to Drive, Manual and here is easier to find parts for Toyotas.


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post #4 of 1064 (permalink) Old 07-30-2012, 11:00 AM Thread Starter
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Why I had to Change the Sephia's Engine?

When my Wife and I Purchased the Kia Sephia, it came from USA to Honduras in Regular shape, but the engine was Blowin' a cloud of white smoke that with time got worse, as you can read about that in this Thread:


~►
http://www.kia-forums.com/kia-sephia...ia-help-3.html

After changing the Muffler with a Brand New one and other minor jobs, we used the kia Normally as Daily Driver without issues but the White cloud of smoke became even worse; the Head gasket was Fine: I Test Compression plus there was no oil in water, nor water in oil and everything was working just Fine.

I thought it had worn Valve's seals, so I scheduled a Complete Engine Reseal, but then, after Checkin' the Timing Belts and Outer Belts, I Found a "Dancing"
(Wiggling) Main Pulley, let me Explain:

I Noticed that the Main Pulley, that comes at the Bottom of the Engine, was moving almost an inch side by side on each Turn, so I Obtained a New one...





...Thinking that maybe the Old one was somehow, Bent.
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post #5 of 1064 (permalink) Old 07-30-2012, 11:01 AM Thread Starter
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I started to Change that Main pulley and What an unholy Surprise I Found!!!


The Timing Belt's Sprocket were Loose and the Previous Owner (or its Mechanic, I Don't Know), instead of Obtaining it New, or at least a Good used one, did This:





With That Stupid Idea of Welding the Sprocket to the Crankshaft, not only the Sprocket wasn't well alligned (Making the Main Pulley to "Dancing" -Wiggling- as it is attached to the Sprocket) but also the Welding Burnt the Oil Seal there!!!

So the T8D engine was Leakin' Oil from that seal and the Welded Sprocket to the Crankshaft makes to Change it a Nightmare that involves to Change the Crankshaft and the Sprocket too...

First I Obtained a Good used Crankshaft at a Junk Yard, then I Was Searchin' for a Good Sprocket and evertything involved, but then I Realized that the Pulley's Vibration must have "Eaten" part of the Engine's Life with its Vibration that should damaged the engine's inner parts...

We continue to use the car as Daily driver while we got enough amount of Money to do a Complete engine Overhaul.

The engine was Blowin' White Clouds of Smoke and leakin' oil from that seal, but otherwise it was working Great.
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post #6 of 1064 (permalink) Old 07-30-2012, 11:02 AM Thread Starter
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That days, my other daily driver, my Subaru "BumbleBeast" Wagon, was in need for brand New two timing Belts, plus tensioners, etc...
and we were short of Money & Time.

So instead of Doin' a complete Overhaul... I did a Crazy Engine Swap!

I Obtained another T8D engine but Second Generation.
(From the '03 Kia Spectra, the Sephia came with the First Gen T8D engine) but I Only Purchased the Block along with the Head (Long Block) Already Assembled as it came from Factory, in other Words: my Wallet wasn't enough big to purchase the Complete engine from the Junk Yard, so they Taken off This Parts from the Engine:

(Parts Removed from the new Engine, in order to Lower the Price)

► Intake Manyfold complete.
► Exhaust manyfold Complete
► Flywheel.
► Front main Pulley
► Engine Mounts, except the one in front of the Timin' Belt Cover.
(The old one was Damaged)
► All the E.F.i. Stuff, including ignition Coils, etc...

My Sephia still Ran with its original engine
(Blowin' a Cloud of Smoke) and I Went to Purchase the New engine Driving it.

The New
(to me) engine was Pretty Clean, came from a Spectra with 67,000 Miles; the car was in a Huge rear Crash and the engine was inmaculate, even its oil was Clear.

Since it came without intake or exhaust manyfolds, Flywheel, etc... I wanted to Use the ones from the old engine on the New; that way I will be Able to Run the New Engine with the EFi / Computer Stuff from the Old one... and the Swap becomes Cheaper!
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post #7 of 1064 (permalink) Old 07-30-2012, 11:07 AM Thread Starter
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Talking

All the Information about the Swap was Already posted on this Thread:

~► Here.


Here you can see the Spectra's T8D Engine, inside the Sephia's Trunk, as it Came from the Junk Yard:


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post #8 of 1064 (permalink) Old 07-30-2012, 11:07 AM Thread Starter
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This is the Sephia's original T8D engine (First Gen, says K6-1) when I Just Removed it from the Car:





Compare it to the Spectra's (Second Gen, Says K6-2) T8D Engine:


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post #9 of 1064 (permalink) Old 07-30-2012, 11:09 AM Thread Starter
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The Port Shapes & Sizes are Different: The Sephia'a T8D engine Ports are Oval while the Spectra's T8D Engine's Ports are Squarier and bigger.

But the intake Manifold of the Sephia, does Cover Perfectly the ports on the Spectra Engine: I've Just "Been There, Done That"




So I Used my Sephia's old Engine Stuff on the Spectra engine and Worked 100% Well!

Now has more than a Whole Year Working Flawlessly.
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post #10 of 1064 (permalink) Old 07-30-2012, 11:10 AM Thread Starter
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These are the Differences between the '00 Sephia

and the '03 Spectra intakes & Head ports:








A Closer View of How the Sephia's Manifold cover the Spectra's Engine:




Here Both engines together,

the Spectra's one is Inside the Car,

while the Old sephia's one is Lying on the Floor:





I had to use the Sephia's engine Valve Cover,

because the Spectra's engine came without the Oil filler Cap,

and the Older one does Not match the New one.

Last edited by Loyale 2.7 Turbo; 06-07-2014 at 01:53 PM. Reason: center the images
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