Manual 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. Lowering the vehicle or lifting up a jack, install the transaxle assembly.
   CAUTION: When installing the transaxle assembly, be careful not to damage any surrounding parts or body components. 
   Fig 1: Lifting Transaxle Assembly

   Courtesy of HYUNDAI MOTOR CO.
2. Install the transaxle lower mounting bolts (A).
   Fig 2: Identifying Transaxle Lower Mounting Bolts

   Courtesy of HYUNDAI MOTOR CO.
3. Install drive shaft to transaxle. (See DRIVESHAFT ) article.
   Fig 3: Identifying Drive Shaft

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4. Install the sub frame. (see INSTALLATION ).
   Fig 4: Identifying Sub Frame Bolts

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5. Install the exhaust pipe mounting rubber (A) to the sub frame.
   Fig 5: Identifying Exhaust Pipe Mounting Rubber

   Courtesy of HYUNDAI MOTOR CO.
6. Connect the power steering return hose (A).
   Fig 6: Identifying Power Steering Return Hose

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7. Install the rear roll stopper mounting bolt. (see INSTALLATION ).
8. Install the front roll stopper mounting bolt. (see INSTALLATION ).
9. Connect the stabilizer bar link. (see FRONT STABILIZER BAR )
10. Connect the tie rod end ball joint from the knuckle after removing the split pin. (see DRIVESHAFT ) article.
11. Connect the lower arm assembly from the knuckle. (see DRIVESHAFT ) article.
12. Install the bolt connecting the universal joint and the pinion shaft. (Refer to 'GENERAL(STEERING SYSTEM) ).
13. Install the under cover (A).
    Fig 7: Identifying Under Cover Bolts

    Courtesy of HYUNDAI MOTOR CO.
14. Install the two side cover nut (A).
    Fig 8: Identifying Side Cover Nut

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15. Install the transaxle upper mounting bolts from the engine.
16. Install the transaxle mounting support bracket (A).
    Fig 9: Identifying Transaxle Mounting Support Bracket

    Courtesy of HYUNDAI MOTOR CO.
17. Remove the SST (09200-38001).
    Fig 10: Holding Engine & Transaxle Assembly

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18. Install the engine start motor mounting bolts (A).
    Fig 11: Identifying Engine Start Motor Mounting Bolts

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19. Install the two cable bracket bolts (A).
    Fig 12: Identifying Cable Bracket Bolts

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20. Install the transaxle wire harness connectors and control cable to transaxle.
    1. Connect the back lamp switch connector (B).
    2. Connect the vehicle speed sensor (A).
       Fig 13: Identifying Vehicle Speed Sensor & Back Lamp Switch

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    3. Install the transaxle control cable (A).
       Fig 14: Identifying Transaxle Control Cable

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    4. Install the clutch release cylinder (A).
       Fig 15: Identifying Clutch Release Cylinder

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    5. Install the two bolts (A) of the bracket holding the flexible hose.
       Fig 16: Identifying Flexible Hose Bracket Bolts

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    6. Install the tube bracket (A) from the transaxle.
       Fig 17: Identifying Tube Bracket

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21. Install the ground cable to transaxle (A).
    Fig 18: Identifying Ground Cable

    Courtesy of HYUNDAI MOTOR CO.
22. Install the battery tray (A).
    Fig 19: Identifying Battery Tray Bolts

    Courtesy of HYUNDAI MOTOR CO.
23. Install the intake air hose and air cleaner assembly.
    1. Install the air cleaner element and lower cover (C).
    2. Connect the ECM connector (A, B).
    3. Install the intake air hose and air cleaner upper cover (C).
       Fig 20: Identifying ECM Connector & Intake Air Hose

       Courtesy of HYUNDAI MOTOR CO.
    4. Connect the air cleaner hose (D) from the bleeder hose (B).
    5. Connect the air flow sensor connector (A).
24. Install the battery (A) after installing the battery terminal.
    Fig 21: Identifying Battery Terminal

    Courtesy of HYUNDAI MOTOR CO.