Repair Procedures (A5HF1): 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. Lowering the vehicle or lifting up a jack, install the transaxle assembly.
2. Tighten the transaxle under mounting bolts.

   TORQUE:

   65~85 Nm (650~850 kgf.cm, 47.0~61.5 lb-ft)

3. Install the starter motor. (see STARTER ).

   TORQUE:

   65~85 Nm (650~850 kgf.cm, 47.0~61.5 lb-ft)

4. Tighten the transaxle under mounting bolts (A, B).

   TORQUE: 46~53 Nm (460~530 kgf.cm, 33.3~38.3 lb-ft)

   Fig 1: Identifying Transaxle Under Mounting Bolts

   Courtesy of KIA MOTORS AMERICA, INC.
5. After removing a jack, insert the drive shafts. (see INSTALLATION )
6. Install the sub frame. (see FRONT SUSPENSION SYSTEM ).
7. Tighten the roll stopper mounting bolts (A, B)

   TORQUE:

   90~110 Nm (900~1100 kgf.cm, 65.1~79.5 lb-ft)

   Fig 2: Identifying Roll Stopper Mounting Bolts (1 Of 2)

   Courtesy of KIA MOTORS AMERICA, INC.
   Fig 3: Identifying Roll Stopper Mounting Bolts (2 Of 2)

   Courtesy of KIA MOTORS AMERICA, INC.
8. Connect the return tube with a clamp. (see HYDRAULIC POWER STEERING SYSTEM )
9. Connect the lower arm, the tie rod end ball joint, the stabilizer bar link to the front knuckle. (see FRONT LOWER ARM )
10. Connect the power steering pressure tube (A) to the power steering oil pump.
    Fig 4: Identifying Power Steering Pressure Tube

    Courtesy of KIA MOTORS AMERICA, INC.
11. Install the under cover (A).
    Fig 5: Identifying Under Cover

    Courtesy of KIA MOTORS AMERICA, INC.
12. Install the steering column joint bolt. (see INSTALLATION ).
13. Install the front wheels and tires.
14. Tighten the transaxle insulator mounting bolt (A).

    TORQUE:

    90~110 Nm (900~1100 kgf.cm, 65.1~79.5 lb-ft)

    Fig 6: Identifying Transaxle Insulator Mounting Bolt

    Courtesy of KIA MOTORS AMERICA, INC.
15. Tighten the transaxle mounting bolts (B, C).

    TORQUE:

    65~85 Nm (650~850 kgf.cm, 47.0~61.5 lb-ft)

    Fig 7: Identifying Transaxle Mounting Bolts

    Courtesy of KIA MOTORS AMERICA, INC.
16. Remove the SST (09200-38001) holding the engine and transaxle assembly.
    Fig 8: Holding Engine And Transaxle Assembly Using SST

    Courtesy of KIA MOTORS AMERICA, INC.
17. Connect the transaxle oil cooler hoses (A) to the tubes (C) by fastening the clamps (B).
    Fig 9: Identifying Transaxle Oil Cooler Hoses

    Courtesy of KIA MOTORS AMERICA, INC.
18. Install the shift cable by tightening the bolt (A) and clip (B).

    TORQUE:

    10~14 Nm (100~140 kgf.cm, 7.2~10.1 lb-ft)

    Fig 10: Identifying Shift Cable Bolt And Clip

    Courtesy of KIA MOTORS AMERICA, INC.
19. Connect the transaxle wire harness connectors.
    1. Install the inhibitor switch connector (A).
       Fig 11: Identifying Inhibitor Switch Connector

       Courtesy of KIA MOTORS AMERICA, INC.
    2. Install the solenoid valve connector (A).
       Fig 12: Identifying Solenoid Valve Connector

       Courtesy of KIA MOTORS AMERICA, INC.
    3. Install the input speed sensor connector (A).
       Fig 13: Identifying Input Speed Sensor Connector

       Courtesy of KIA MOTORS AMERICA, INC.
    4. Install the output speed sensor connector (A).
       Fig 14: Identifying Output Speed Sensor Connector

       Courtesy of KIA MOTORS AMERICA, INC.
    5. Install the vehicle speed sensor connector (A).
       Fig 15: Identifying Vehicle Speed Sensor Connector

       Courtesy of KIA MOTORS AMERICA, INC.
    6. Install the CKP sensor connector (A).
    Fig 16: Identifying CKP Sensor Connector

    Courtesy of KIA MOTORS AMERICA, INC.
20. Install the battery tray (B) by tightening the four mounting bolts (A).
    Fig 17: Identifying Mounting Bolts

    Courtesy of KIA MOTORS AMERICA, INC.
21. Connect the air cleaner hose (B) by fastening the clamp (A).
    Fig 18: Identifying Air Cleaner Hose

    Courtesy of KIA MOTORS AMERICA, INC.
22. Install the air cleaner assembly (A).
    Fig 19: Identifying Air Cleaner Assembly

    Courtesy of KIA MOTORS AMERICA, INC.
23. Install the air cleaner upper cover (B) by fastening the clips (A).
    Fig 20: Identifying Air Cleaner Upper Cover

    Courtesy of KIA MOTORS AMERICA, INC.
24. Connect the AFS connector (A).
    Fig 21: Identifying AFS Connector

    Courtesy of KIA MOTORS AMERICA, INC.
25. Install the battery (A).

Fig 22: Identifying Battery

Courtesy of KIA MOTORS AMERICA, INC.