Automatic Transaxle: Installation

Installation is in the reverse order of removal. Perform the following:

• Adjust the shift cable.
• Refill the transaxle with fluid.
• Refill the radiator with engine coolant.
• Bleed air from the cooling system with the heater valve open.
• Clean the battery posts and cable terminals with sandpaper, assemble them, and apply grease to prevent corrosion.

1. Using a transmission jack, install the transaxle assembly.
2. Tighten the transaxle lower mounting bolts (B-4ea, C-1ea).

   TORQUE:

   [B] 40-47 N.m (4.0-4.7 kgf.m, 28.9-34.0 lb.ft)

   [C] 80-100 N.m (8-10 kgf.m, 57.9-72.3 lb.ft)

   Fig 1: Identifying Transaxle Lower Mounting Bolts

   Courtesy of KIA MOTORS AMERICA, INC.
3. Install the drive plate bolts (A) by turning the crankshaft.

   TORQUE:

   46-53 N.m (4.6-5.3 kgf.m, 33.3-38.3 lb.ft)

4. Install the cover (A).
   Fig 2: Identifying Cover

   Courtesy of KIA MOTORS AMERICA, INC.
5. Install the starter motor mounting bolts (A) and the two bolts (B).

   TORQUE:

   [A] 43-55 N.m (4.3-5.5 kgf.m, 31.1-39.8 lb.ft)

   [B] 33-50 N.m (3.3-5.0 kgf.m, 23.9-36.2 lb.ft)

   Fig 3: Identifying Starter Motor Mounting Bolts

   Courtesy of KIA MOTORS AMERICA, INC.
6. Install the left side cover (A).
   Fig 4: Identifying Left Side Cover

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7. After removing the jack, insert the drive shafts (A, B).
   Fig 5: Identifying Drive Shaft (A)

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   Fig 6: Identifying Drive Shaft (B)

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8. Install the inner shaft bracket bolts (A-3ea).
   Fig 7: Identifying Inner Shaft Bracket Bolts

   Courtesy of KIA MOTORS AMERICA, INC.
9. Install the front roll support (A) to the transaxle.

   TORQUE:

   60-80 N.m (6-8 kgf.m, 43.4-57.8 lb.ft)

   Fig 8: Identifying Front Roll Support

   Courtesy of KIA MOTORS AMERICA, INC.
10. Install the front muffler assembly (A).
    Fig 9: Identifying Front Muffler Assembly

    Courtesy of KIA MOTORS AMERICA, INC.
11. Install the sub frame supported by the special tool(09624-38000). Refer to FRONT SUSPENSION SYSTEM .
    Fig 10: Identifying Special Tool (09624-38000)

    Courtesy of KIA MOTORS AMERICA, INC.
12. Tighten the rear roll stopper mounting bolts (A-4ea) and the power steering tube mounting bolt (B).
    Fig 11: Identifying Rear Roll Stopper Mounting Bolts And Power Steering Tube Mounting Bolt

    Courtesy of KIA MOTORS AMERICA, INC.
13. Install the muffler hanger rubber (A).
    Fig 12: Identifying Muffler Hanger Rubber

    Courtesy of KIA MOTORS AMERICA, INC.
14. Tighten the front roll stopper mounting bolt (A).
    Fig 13: Identifying Front Roll Stopper Mounting Bolt

    Courtesy of KIA MOTORS AMERICA, INC.
15. Install the fork from the front lower arm. Refer to FRONT SUSPENSION SYSTEM .
16. Connect the lower arm, the tie rod end ball joint, the stabilizer bar link to the front knuckle. Refer to FRONT SUSPENSION SYSTEM .
17. Connect the power steering pressure tube (A) to the power steering oil pump.

    TORQUE:

    55-65 N.m (5.5-6.5 kgf.m, 39.8-47.0 lb.ft)

    Fig 14: Identifying Power Steering Pressure Tube

    Courtesy of KIA MOTORS AMERICA, INC.
18. Connect the return tube (A) with a clamp.
    Fig 15: Identifying Return Tube

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19. Install the under cover (A).
    Fig 16: Identifying Under Cover

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20. Install the front wheels and tires. Refer to FRONT SUSPENSION SYSTEM .
21. Install the steering column joint bolt.
    Fig 17: Identifying Steering Column Joint Bolt

    Courtesy of KIA MOTORS AMERICA, INC.
22. Tighten the transaxle insulator mounting bolt (A-4ea) and nuts (B-2ea).

    TORQUE:

    60-80 N.m (6-8 kgf.m, 43.4-57.8 lb.ft)

    Fig 18: Identifying Transaxle Insulator Mounting Bolt And Nuts

    Courtesy of KIA MOTORS AMERICA, INC.
23. Remove the special tool (09200-38001) holding the engine and transaxle assembly.
    Fig 19: Identifying Special Tool (09200-38001)

    Courtesy of KIA MOTORS AMERICA, INC.
24. Tighten the transaxle mounting bolts (A-3ea).

    TORQUE:

    65-85 N.m (6.5-8.5 kgf.m, 47.0-61.5 lb.ft)

    Fig 20: Identifying Transaxle Mounting Bolts

    Courtesy of KIA MOTORS AMERICA, INC.
25. Install the mounting bolts (C-2ea) and connect the oxygen sensor connectors (B-2ea) and the power steering pressure sensor connector (A).
    Fig 21: Identifying Power Steering Pressure Sensor Connector

    Courtesy of KIA MOTORS AMERICA, INC.
    Fig 22: Identifying Oxygen Sensor Connectors

    Courtesy of KIA MOTORS AMERICA, INC.
26. Install the CKP sensor connector (A).
    Fig 23: Identifying CKP Sensor Connector

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27. Install the wiring harness mounting bolts (4ea).
    Fig 24: Identifying Wiring Harness Mounting Bolts

    Courtesy of KIA MOTORS AMERICA, INC.
28. Install the shift cable assembly (C) by tightening the nut (A) and clip (B).

    TORQUE:

    8-12 N.m (0.8-1.2 kgf.m, 5.8-8.7 lb.ft)

    Fig 25: Identifying Shift Cable Assembly

    Courtesy of KIA MOTORS AMERICA, INC.
29. Connect the transaxle oil cooler hoses (A) to the tubes by fastening the clamps (B).
    Fig 26: Identifying Transaxle Oil Cooler Hoses

    Courtesy of KIA MOTORS AMERICA, INC.
30. Install the vehicle speed sensor connector (A) and output shaft speed sensor connector (B).
    Fig 27: Identifying Vehicle Speed Sensor Connector And Output Shaft Speed Sensor Connector

    Courtesy of KIA MOTORS AMERICA, INC.
31. Install the inhibitor switch connector (A), the solenoid valve connector (B) and the input shaft speed sensor connector (C).
    Fig 28: Identifying Inhibitor Switch Connector, Solenoid Valve Connector And Input Shaft Speed Sensor Connector

    Courtesy of KIA MOTORS AMERICA, INC.
32. Install the battery tray (A).
    Fig 29: Identifying Battery Tray

    Courtesy of KIA MOTORS AMERICA, INC.
33. Install the air cleaner assembly (C) and connect the air flow sensor connector (A) and tightening the clamp (B).
    Fig 30: Identifying Air Cleaner Assembly And Air Flow Sensor Connector

    Courtesy of KIA MOTORS AMERICA, INC.
34. Install the air duct (A).
    Fig 31: Identifying Air Duct

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35. Install the battery (A).
    Fig 32: Identifying Battery

    Courtesy of KIA MOTORS AMERICA, INC.
36. Refill the transaxle fluid. Refer to SERVICE ADJUSTMENT PROCEDURE .
37. Refill the power steering fluid and bleed the air. Refer to SERVICE ADJUSTMENT PROCEDURE .
38. Install the engine cover (A).
    Fig 33: Identifying Engine Cover

    Courtesy of KIA MOTORS AMERICA, INC.