Some 1998-2001 Kia Sephia 1.8L vehicles built between Oct. ‘97 and May ’01, and some 1.8L Spectra vehicles built between Feb.’00 and March ‘04 may experience battery discharge when operated in high ambient temperatures for extended periods of time at low speeds or at idle with A/C, headlamps and other accessories on. Typically, this results in customers reporting an inability to restart the vehicle. To reduce the incidence of battery discharge customer complaints, a new higher-capacity alternator battery insulator pad (cover) is available.

Battery Test Procedure:

Test battery using the Micro 570 tester and refer to TSB SST 002 for instructions.

Alternator Installation Procedure:

1. Relieve the fuel system pressure by removing the fuel pump relay and running the engine until it stops.

2. Write down the preset radio stations, then disconnect the negative battery cable.

Warning: Fuel vapors are highly flammable. Death or serious injury could result if they are ignited. Make sure there are no open flames or cigarette smoking in the area of the repair. Adequate ventilation is necessary to prevent a buildup of fumes.

3. Remove the engine cover, if equipped.

4. Unbolt the cruise control assembly from the bulkhead and lay it on top of the engine.

5. Remove the engine ground strap.

6. Remove the fuel line using the Quick Connect Fuel Line Tool (refer to TSB Fuel 005).

7. Disconnect the alternator electrical connections.

8. Loosen, but do not remove, the pivot bolt and belt tensioner bolts.

9. Relieve the tension on the drive belt by rotating the adjustment bolt.

10. Remove the drive belt.

11. Remove the belt tensioner hardware.

12. Remove the alternator pivot bolt.

13. Remove the power steering hose bracket bolt and nut.

14. Move the hose to obtain the best access.

15. Remove the alternator.

16. Install the new alternator onto the pivot bolt.

17. Rotate the upper bracket into position.

18. Place the tensioner hardware on the alternator.

19. Install the tensioner mounting bolt.

20. Inspect the alternator belt.

21. Place the belt on the alternator pulley.

22. Adjust the alternator belt by rotating the adjustment bolt. Allowable Belt Deflection: New Belt: 0.23”-0.31.” Used Belt: 0.28”-0.35.”

23. Tighten the tensioner bolt to 14-19 ft.-lbs.

24. Tighten the pivot bolt to 28-38 ft.-lbs.

25. Connect the electrical connectors.

26. Reinstall the fuel line, engine ground strap, cruise control assembly, power steering hose brackets, fuel pump relay and engine cover.

Courtesy of Mitchell 1.