2003 Kia Spectra GSX, AutomaticFACTORY OEM SERVICE PROCEDURE

Charging Systems: General: Generator: Installation

  1. Position generator on engine.
  2. Install pivot bolt (leave loose).
  3. Rotate bracket into position on top of generator.
  4. Place belt tensioner into position on adjustment bracket.
  5. Install tensioner mounting bolt (leave loose).
  6. Place drive belt on generator pulley.
  7. Adjust belt tension by rotating adjustment bolt.
    1. Allowable deflection: 
      1. New belt: 0.23 - 0.31 in (6 - 8 mm) 
      2. Old belt: 0.28 - 0.35 in ( 7 - 9 mm) 
    Fig 1: Adjusting Drive Belt Tension
    G01078396Courtesy of KIA MOTORS AMERICA, INC.
  8. Tighten tensioner bolt.

    Tighten tensioner bolt to: 14~19 lb-ft (19~26 N.m) 

  9. Tighten pivot bolt and bracket bolt.

    Tighten pivot and bracket bolt to: 28~38 lb-ft (38~51 N.m) 

  10. Connect generator L and S terminal connectors.
  11. Connect B terminal lead.
  12. Install and tighten B terminal nut.
  13. Close B terminal nut cover.
  14. Install air intake inlet pipe and tighten end clamp.
  15. Connect top hose to air intake inlet pipe.
  16. Install front air intake inlet pipe bolts.
  17. Connect negative battery cable.
    CAUTION:
    1. Be sure battery connections are not reversed. This will damage rectifier.
    2. Do not  use high voltage testers, such as a megger. They will damage the rectifier.
    3. Remember that battery voltage is always applied to alternator B terminal.
    4. Do not  ground L terminal while engine is running.
    5. Do not  start engine while L and S terminals are disconnected from generator.
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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.