S.A. ALPINE DEVELOPMENT

Specializing in Turbocharger and Supercharger Systems
KIASpectra Turbocharger Kit
KIA SPECTRA TURBOCHARGER KIT
Installation Instructions
S.A. Alpine Developments 7581 Acacia Avenue, Garden Grove, CA 92841 Phone 714-379-8066 Fax 714-379-8166

Table of Contents

Table of Contents Contents of kit Before you begin Initial disassembly Cylinder head removal/installation Preparation for installation Exhaust manifold and turbo installation Water and oil line installation Vacuum line installation Final Assembly Before Your First Drive 21

Contents of kit

Before you begin
This kit contains all specialty items required for installation. The kit does not contain common replacement parts that you may acquire at the Dealership, or standard tools required for installation. Below is a list of items you should have available before you begin. Metric socket set Metric Allen head set Metric wrench set Screwdriver set Anti-seize compound 9/16 Drill Bit 3/8 NPT Tap Cutting grease Thread sealer Wire cutter/stripper tool Soldering iron and solder Insulation tape

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. 5. Disconnect the brake booster hose from manifold. 6. Remove the support stay bolts from the manifold. 7. Disconnect plug wires and remove coils. 8. Remove the upper portion of the timing belt cover and locate the timing marks on the cam wheel. 9. Set the engine to TDC and check the cam timing marks to ensure TDC.
10. Remove cam belt tensioner and slip belt off cam gear. 11. Remove cam cover, head bolts and raise cylinder head. (Note: For ease of head removal use engine hoist to lift head.) 12. Install 2 new head gaskets with supplied stainless steel head spacer sandwiched in between.
13. Re-install cylinder head. Torque head bolts to factory specifications. 14. Reinstall cam belt and tensioner. (Note: Cam is to be installed slightly advanced!) 15. Reinstall all components removed in previous steps, except fuel rail. (Note: It will be necessary to loosen lower manifold support stays and raise them slightly to compensate for head spacer.)
Preparation for installation
A. Horn Relocation Using existing 6mm boltholes relocate horns as per picture.
B. Core Support Modification It is necessary to cut a section from the core support panel on the driver side to allow the intercooler pipes to pass through. Use a cut-off wheel to cut as marked.
C. Modification to power steering bracket It is necessary to make two modifications to this bracket. Using a cut-off wheel, clearance the bracket as marked A, and B.
D. Clearance Motor Mount As pictured, remove tab from front motor mount, again using cut-off wheel. (It is recommended to touch up bare metal with spray paint to avoid rust.)
F. Battery Tray Modification It is necessary to remove the plastic tab from the side of the battery tray, as pictured.
Exhaust manifold and turbo installation
Note: Your turbo kit is pre-assembled to ease installation. The turbo assembly includes pre-assembled exhaust down pipe. The turbo, exhaust manifold, and down pipe are installed as a single assembly.
Perform steps 1 through 5 of the water and oil line installation. Install wiring harness (See Wiring Instructions) Install fuel system (See Fuel System Installation)

1. Mock -install the manifold assembly. Determine the best position for the engine side water hose. Remove manifold and secure hose. 2. Lightly coat both sides of exhaust manifold gasket with anti-seize. Place gasket into position. 3. Install exhaust manifold assembly. Torque nuts to factory specifications, using factory torque sequence. It is extremely important to achieve the correct torque on all studs! 4. Attach exhaust down pipe to the exhaust system. Use supplied 10mm hardware. Lightly coat both sides of gasket with anti-seize. 5. Install modified power steering pump bracket, PS belt, alternator belt, and then PS pump. (Note: Loosen the alternator bracket to ease install of alternator support bracket bolts)
Perform step 6 of the water and oil line installation Perform step 3 of the vacuum line install Perform step 7 of the water and oil line installation Install cold air intake system 6. Install O2 sensor into manifold and reconnect.
Perform steps 8 and 9 of water and oil line installation 7. Route supplied breather hose from valve cover breather to cold air intake pipe barb.
Perform step 10 of water and oil line installation 8. Install dipstick tube. Bend to clear manifold and install dipstick. 9. Install manifold heat shield.
Water and oil line installation
Note: In order to prevent metal chips from entering the crankcase, it is recommended that compressed air is used to provide slightly pressurize to the crankcase via the crankcase vent on the cam cover. Note: PCV and dipstick holes must be blocked. If you are not comfortable with this method you will have to remove the oil pan to ensure no metal chips enter the crankcase. 1. Using the drilling jig supplied, drill a 9/16 hole between the ribs on the radius of the engine block. Tap hole for 3/8*18 NPT fitting. Use cutting grease to help alleviate ingress of fillings into sump. 2. Install the 3/8*18 NPT to JIC fitting into the engine block using a suitable thread sealer.
3. Remove the oil galley plug on the cylinder head, as pictured. (Hint: Drive a T35 Torq bit into plug, ease out slowly). 4. Install 1/8BSPT oil feed fitting into head using pipe sealant.
5. Install water tee fitting into lower radiator hose by first installing fitting into lower end of hose, and then adding supplied 115mm length to other side of fitting. Secure using supplied 25-40mm hose clamps. Use picture below as guide.
6. Connect oil return hose from fitting on turbo to oil fitting installed in block.
7. Connect water hose between lower radiator hose fitting and banjo fitting on radiator side of turbo. 8. Re-install upper radiator hose. Cut and insert water tee fitting, trimming hose as necessary to eliminate excessive kinks.
9. Connect water hose from engine side turbo fitting to upper radiator hose.
10. Connect oil feed hose from fitting in head to oil feed fitting top center on turbo.
Wiring Harness Installation

1. Mount the Unichip and bracket to the center bolt on the strut tower.
2. Locate the MAF sensor plug. Open the MAF wiring harness at the factory blue tape marking (200mm back from the connector). These sensor wires need to be lengthened to reach the relocated MAF sensor. There are two pink wires, cut at uneven points to indicate which ones go together. Cut remaining wires.
3. MAF connections MAF Blue wire is signal wire. This signal is interrupted. White wire from harness connects to blue wire on ECU side. Black wire from harness connects to blue wire sensor side. MAF black wire is sensor ground wire. This wire is extended through the harness. Short brown leg from harness connects to black wire on ECU side. Long brown wire from harness connects to black wire on sensor side. Lengthen the white and both pink wires 300mm.
4. Crank Position Sensor CPS white wire is signal wire. This signal is interrupted. Red w/white/White w/red wires from harness connect to white wire sensor side. Green wire from harness connects to white wire ECU side.
5. Power/Ground 12v power is obtained from the diagnostic port. Red wire from harness tees into Red w/ yellow on diagnostic port. 12v ground is obtained directly from the battery. Thick brown wire from harness must be routed to negative terminal and attached by means of supplied eyelet.
6. Fifth Injector Red wire from injector plug must be teed into 12v positive from an existing injector.

Fuel system installation

1. Remove fuel feed hose from fuel rail. (Note: System may be pressurized, use caution not to spray fuel when opening). 2. Unbolt and remove fuel rail and injectors intake manifold. 3. Remove stock injectors from fuel rail and replace with supplied injectors.
4. Reinstall fuel rail. 5. Locate most suitable location for fuel tee. Cut fuel feed hose and install fuel tee. Secure with hose clamps.
6. Reconnect fuel feed hose to fuel rail. 7. Connect 5th injector fuel feed hose from tee fitting to injector. 8. Attach the 5th injector electrical connector to the 5th injector.
9. Re-install accelerator cable. Check adjustment.

Vacuum line installation

1. Cut and insert supplied vacuum tee into EVAP hose between manifold and EVAP valve. 2. Route vacuum hose from tee to Unichip module vacuum port. 3. Block PCV valve with supplied 5/16 rubber vacuum cap. 4. Connect stepped actuator hose from port on intake manifold to actuator canister port on turbo.
Intercooler System Installation

1. Install intercooler-mounting bracket, using original horn mounting location. Use supplied 6mm hardware. 2. Mount the intercooler, using supplied 8mm hardware.
3. Referencing the pictures below, install the intercooler pipes, using the supplied silicon hoses and hose clamps.
Cold Air Intake installation
1. Install MAF sensor into cold air intake using supplied silicon hose and clamps. The system can be pre-assembled and installed as one unit (see picture below).
2. Secure air filter bend to inside of wheel well using supplied brackets and hardware.
3. Connect MAF sensor plug into MAF sensor.

Final Assembly

1. It is necessary to change spark plugs to a colder plug. These are supplied in your kit. 2. Fill the cooling system with a proper antifreeze mix. Check coolant system for leaks. 3. Re-install battery tray and battery. 4. Connect the negative battery terminal to the battery. Look, listen and smell for any possible problems. 5. Prime the fuel system by turning the ignition key to the on position for 15 seconds and then turning off. Check the fuel system for leaks! Once again look, listen and smell for any problems 6. Start engine and run for 2 to 3 minutes. Check coolant system for leaks. Check the fuel system for leaks. Check the oil system for leaks Look, Listen and Smell for any possible problems. 7. Top off coolant. 8. Re-install front bumper assembly. 9. Allow engine to reach operating temperature and ensure proper operation of cooling fan.

Before Your First Drive

Your vehicle has the ability to learn as you drive. The electronic control system runs in closed loop during normal driving and adjusts settings accordingly. As the battery was disconnected the system has lost its memory. In order to let the system start to adjust itself you should drive using light throttle for at least the first 10 minutes of driving time after the vehicle is at operating temperature. While it may be hard not to use your newfound horsepower, the vehicle will drive much better as it learns where settings should be.

Have fun and be safe!

2009 KIA SPECTRA AND SPECTRA5 Award-Winning Spectra Models Boast Impressive Fuel Economy Compact entry offers class-leading safety, spaciousness Standard features put Spectra and Spectra5 ahead of the rest
IRVINE, Calif., Nov. 17, 2008 Amid a steady uptick in gasoline prices and during a time when fuel economy is top-of-mind for consumers, the Kia Spectra and Spectra5 are standouts, leading the pack with high marks for their thrifty fuel-sipping ability combined with high style and class-leading safety features. Adding to Spectra and Spectra5s appeal, the line is recognized by The Car Book as a Best Bet in the Compact category and the National Highway Safety Administration (NHTSA) for five-star frontal crash safety rating in 2008. Spectra5 also is recognized by U.S. News & World Reports Best Cars and Trucks for being an affordable compact wagon. In 2007, the Spectra model line received two distinctions from Edmunds.com (Consumers Most-Wanted Wagons under $25,000 and Top 10 Cars under $15,000). These accolades paired with the Spectra sedan and five-doors style, outstanding safety features and exceptional value are sure to continue to impress consumers in 2009.
Following Kia Motors core philosophies of providing value, safety, warranty and fun to the driving experience, the Spectra line-up is available in several trim levels (LX, EX, and SX four-door; SX five-door) and offers a host of standard amenities to appeal to a wide range of consumers.

Polished Performance

Spectra and Spectra5 vehicles are powered by a 2.0-liter DOHC four-cylinder engine, which features Continuously Variable Valve Timing (CVVT) and multi-port electronic fuel injection.

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2009 Kia Spectra and Spectra5 Page 2 of 2 Producing 138 horsepower and 136 pound-feet of torque 1 , the Spectra line-up offers a more powerful punch than Toyota Corolla and Ford Focus. Two trims are available for 2009: a standard five-speed manual transmission or an optional electronically controlled four-speed automatic transmission. Fuel economy for 2009 Spectra models is 23/30 M/T and 24/32 A/T (city/highway).
Built on a front-wheel-drive unibody frame, independent front suspension with MacPherson struts, standard coil springs and stabilizer bars work with an independent dual-link rear suspension to provide the optimal balance of ride comfort. An engine-speed-sensitive, power-assisted rack-andpinion steering system adds the finishing touch for precise handling. In keeping with the sporty essence of the SX model line, a sport-tuned suspension and strut tower bar come standard to allow for more spirited driving.

Stylish Surface

Larger than Kias entry level Rio, the Spectra line personifies a more grown-up exterior body with smooth, clean lines. All trim levels feature body-color exterior door handles, body side moldings and rear garnishes to create a sleek canvas on which to outfit aggressive subtleties such as clear-lens halogen headlamps with black headlamp bezels.
LX and EX models smile at onlookers with a front grille enhanced with a sportier blend of black and chrome. SX models are fitted with an aggressive black mesh grille and the addition of standard fog lights, a wing-type rear spoiler (SX four-door models only), side sills as well as unique front and rear fascias. To complete the bold SX look, 16-inch, five-spoke alloy wheels are matched with 205/50R16-sized premium tires, while 15-inch wheels and 195/60R15-sized tires are standard on LXand EX-equipped models.
132 horsepower and 133 pound-feet of torque for SULEV engine on A/T models in CA, MA, ME, NY and VT.
2009 Kia Spectra and Spectra5 Page 3 of 3 Inviting Interior
High-quality, full cloth-trimmed seats are merely quiet echoes to the Spectra and Spectra5s host of standard features that scream behind-the-wheel comfort and convenience. A six-way adjustable drivers seat, tilt steering column, 60/40-split folding rear seat, rear defroster and dual 12volt power outlets in the center console are driver-conscious luxuries standard on every vehicle. Music aficionados are not forgotten with an AM/FM/CD audio system featuring six speakers and an auxiliary audio input jack for MP3 player connectivity as standard features. EX and SX models offer additional touches such as: power windows and door locks; remote keyless entry; air conditioning; dual front and rear cup holders; and floor mats. Spectra EX models also now include standard cruise control with optional sunroof and antilock brake system (ABS).
Upgrades for the Spectra and Spectra5 SX models include an interior fashioned with metalfinish trim and sport-cloth seats with matching door panel inserts. A leather-wrapped steering wheel and gearshift knob, metal sport pedals and cruise control are other standard features. An AM/FM/MP3 audio system with a six-disc in-dash CD changer and a power sunroof also are available as SX-only options.

Comfortably Cavernous

With the four-door sedan boasting 97.0 cubic feet of passenger volume and the five-door providing a welcoming 98.1 cubic feet of passenger volume, the Spectra line offers more breathing room than the Toyota Corolla, Honda Civic, and Ford Focus. Storage space does not take a backseat either with an ample 12.2 cubic feet of cargo volume available in the Spectra, while 18.3 cubic feet is offered in the Spectra5. When the 60/40-split folding rear seats are folded flat, storage capacity in the five-door expands to 52.8 cubic feet.
2009 Kia Spectra and Spectra5 Page 4 of 4 Superior Safety
All Spectra models now include active front headrests as standard equipment for 2009. Earning a five-star frontal crash safety rating in 2008 by the National Highway Traffic Safety Administration (NHTSA) 1 , Spectra and Spectra5 provide class-leading safety with an extensive, across-the-board list of standard technology, which includes: dual front advanced airbags, dual front seat-mounted side airbags, full-length side curtain airbags, front and rear three-point seatbelts, front seatbelt pretensioners and force limiters, Lower Anchors and Tethers for Children (LATCH), sideimpact door beams, front and rear crumple zones and a tire pressure monitoring system (TPMS).
Four-wheel vented disc brakes also are standard on EX and SX models while a four-sensor, four-channel ABS is an available option on EX models and SX four-door and five-door vehicles.
Industry-Leading Warranty
Like all Kia models, Spectra and Spectra5 are covered by a comprehensive warranty program, which offers unprecedented consumer protection. Included in this program are a 10-year/100,000mile limited powertrain warranty, a five-year/60,000-mile limited basic warranty, and a fiveyear/100,000-mile anti-perforation warranty. A five-year/60,000-mile roadside assistance plan also is part of the comprehensive coverage program.

About Kia Motors America

Kia Motors America (KMA) is the sales, marketing and distribution arm of Kia Motors Corporation based in Seoul, South Korea. KMA offers a complete line of vehicles through more than 640 dealers throughout the United States. For 2007, KMA recorded its 14th consecutive year of record U.S. sales. Kia Motors subscribes to a philosophy of building high value, high quality, safe and dynamic vehicles. Kia Motors prides itself on producing vehicles that are exciting and enabling and evoke the Kia tagline The Power to Surprise.

Kia Motors America is the Official Automotive Partner of the NBA. Information about Kia Motors America and its full vehicle line-up is available at its Web site www.kia.com. For media information, including photography, visit www.kiamedia.com. ###
Government star ratings are part of the National Highway Traffic Safety Administrations (NHTSAs) New Car Assessment Program (www.safercar.gov).