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Home >> Kia >> 2003 >> Rio Base, Standard >> Repair and Diagnosis >> Engine Mechanical >> Lubrication System >> 1.6L 4-Cylinder Engine >> Engine And Transaxle Assembly >> Installation
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Engine And Transaxle Assembly: Installation

  1. Install engine and transaxle into engine compartment as a unit.
  2. Install two nuts to No.3 engine mounting rubber.

    Tightening torque:

    49~69 lb-ft (66~93 N . m, 6.8~9.5 kg-m)

  3. Install No.2 engine mounting bracket bolts and install No.2 engine mounting rubber nut.

    Tightening torque:

    Nut: 49~69 lb-ft (66~93 N . m, 6.8~9.5 kg-m)

    Bolts: 28~38 lb-ft (37~52 N . m, 3.8~5.3 kg-m)

  4. Install four engine mounting member bolts nuts.

    Tightening torque:

    Nut: 28~38 lb-ft (37~52 N . m, 3.8~5.3 kg-m)

    Bolts:52~69 lb-ft (71~93 N . m, 7.2~9.5 kg-m)

    Fig 1: Installing Four Engine Mounting Member Bolts/Nuts
    G00325878Courtesy of KIA MOTORS AMERICA, INC.
  5. Remove engine hoist.
  6. Install new clips on driveshaft.
  7. Push driveshaft and joint shaft into transaxle with opening of clips pointing upward.
  8. Install damper to steering knuckles.
  9. Install both right and left lower arm to steering knuckles.
    Fig 2: Installing Both Right And Left Lower Arms
    G00325879Courtesy of KIA MOTORS AMERICA, INC.
  10. Install both right and left tie rod ends to steering knuckles.
  11. Install front exhaust pipe and catalytic converter.

    Tightening torque:

    27~38 lb-ft (37.2~52 N . m, 3.8~5.3 kg-m)

  12. Install A/C compressor.
  13. Connect B-terminal connector to generator.
    Fig 3: Connecting B-Terminal Connector To Generator
    G00325880Courtesy of KIA MOTORS AMERICA, INC.
  14. Connect B-terminal and S-terminal connector to starter.
    Fig 4: Connecting B-Terminal & S-Terminal Connector To Starter
    G00325881Courtesy of KIA MOTORS AMERICA, INC.
  15. Connect power steering pump hose.
    Fig 5: Connecting Power Steering Pump Hose
    G00325882Courtesy of KIA MOTORS AMERICA, INC.
  16. Connect ATF cooler hose (A/T).
  17. Connect solenoid valve connector (A/T).
  18. Connect transaxle range switch connector (A/T).
    Fig 6: Connecting Transaxle Range Switch Connector
    G00325883Courtesy of KIA MOTORS AMERICA, INC.
  19. Install clutch release cylinder and pipe (M/T).

    Tightening torque:

    13.7~18.8 lb-ft (18.6~25.5 N . m, 1.9~2.6 kg-m)

  20. Install extension bar and manual transaxle linkage (M/T).

    Tightening torque:

    Extension bar: 27~38 lb-ft

    (37.2~52 N . m, 3.8~5.3 kg-m)

    Manual transaxle linkage:

    12~17 lb-ft (16~23 N . m, 1.6-2.3 kg-m)

  21. Install transaxle linkage (A/T).

    Tightening torque:

    23.1~34.0 lb-ft (31.4~46.1 N . m, 3.2~4.7 kg-m)

  22. Connect electric connectors.
    Fig 7: Connecting Electric Connectors
    G00325884Courtesy of KIA MOTORS AMERICA, INC.
  23. Connect injector connectors to injector rail.
  24. Connect brake vacuum hose and purge control vacuum hose to dynamic chamber.
  25. Install heater hose.
  26. Connect fuel hose to injector rail.
  27. Install accelerator cable.
  28. Install upper and lower radiator hose.
  29. Install fresh air duct.
  30. Install battery tray and battery.

    Tightening torque:

    10~12 lb-ft (13.5~16 N . m, 1.4~1.6 kg-m)

    Fig 8: Installing Battery Tray & Battery
    G00325886Courtesy of KIA MOTORS AMERICA, INC.
  31. Fill engine coolant with specified type and amount.
  32. Connect both battery cables.
  33. Check and/or fill all fluids.
  34. Test run engine perform an overall check.
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