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 (A, B).

   Tightening torque: 

   34.3~41.2 Nm (350~420 Kgf.cm, 25.3~30.4 lb.ft) - A

   45.1~52.0 Nm (460~530 Kgf.cm, 33.3~38.3 lb.ft) - B

   Fig 1: Identifying Transaxle Under Mounting Bolts

   Courtesy of HYUNDAI MOTOR CO.
3. After removing a jack, insert the drive shafts. (see FRONT HUB )
4. Supporting the cross member with the SST (09624-38000), tighten the steering column bolt and the cross member mounting bolts. (see HYDRAULIC POWER STEERING SYSTEM )
   Fig 2: Supporting Cross Member With SST (09624-38000)

   Courtesy of HYUNDAI MOTOR CO.
5. Tighten the rear roll stopper mounting bolt. (seeHYDRAULIC POWER STEERING SYSTEM )

   Tightening torque: 

   49.0~63.7 Nm (500~650 Kgf.cm, 36.2~47.0 lb.ft)

6. Install the front exhaust pipe. (see INTAKE AND EXHAUST SYSTEM )
7. Tighten the front roll stopper mounting bolt. (see HYDRAULIC POWER STEERING SYSTEM )

   Tightening torque: 

   49.0~63.7 Nm (500~650 Kgf.cm, 36.2~47.0 lb.ft)

8. Install the steering bar tie rod, the stabilizer bar link and the lower arm assembly. (see HYDRAULIC POWER STEERING SYSTEM )
9. Clamp the power steering pump hose (A).
   Fig 3: Identifying Power Steering Pump Hose

   Courtesy of HYUNDAI MOTOR CO.
10. Install the under cover (A).
    Fig 4: Identifying Under Cover

    Courtesy of HYUNDAI MOTOR CO.
11. After lowering the vehicle, tighten the transaxle insulator mounting bolt (A).

    Tightening torque: 

    63.7~83.4 Nm (650~850 Kgf.cm, 47.0~61.5 lb.ft)

    Fig 5: Identifying Transaxle Insulator Mounting Bolt

    Courtesy of HYUNDAI MOTOR CO.
12. Tighten the transaxle mounting bolts (B, C).

    Tightening torque: 

    32.4~49.0 Nm (350~420 Kgf.cm, 23.9~36.2 lb.ft) - A

    63.7~83.4 Nm (650~850 Kgf.cm, 47.0~61.5 lb.ft) - B

    Fig 6: Identifying Transaxle Mounting Bolts

    Courtesy of HYUNDAI MOTOR CO.
13. Remove the SST (09200-38001) holding the engine and transaxle assembly.
    Fig 7: Holding Engine And Transaxle Assembly Using SST (09200-38001)

    Courtesy of HYUNDAI MOTOR CO.
14. Connect the EPS connector (A) and install the front wheels and tires.
    Fig 8: Identifying EPS Connector

    Courtesy of HYUNDAI MOTOR CO.
15. Install the power steering hose mounting bolts (A-2EA).
    Fig 9: Identifying Power Steering Hose Mounting Bolts

    Courtesy of HYUNDAI MOTOR CO.
16. Connect the power steering pressure sensor connector (A).
    Fig 10: Identifying Power Steering Pressure Sensor Connector

    Courtesy of HYUNDAI MOTOR CO.
17. Connect the transaxle wire harness connector and the control cable.
    1. Install the wiring brackets (A).
       Fig 11: Identifying Wiring Brackets

       Courtesy of HYUNDAI MOTOR CO.
    2. Connect the inhibitor switch connector (A) and the shift cable (B) and install the transaxle bracket.
       Fig 12: Identifying Inhibitor Switch Connector And Shift Cable

       Courtesy of HYUNDAI MOTOR CO.
    3. Connect the solenoid valve connector (A).
       Fig 13: Identifying Solenoid Valve Connector

       Courtesy of HYUNDAI MOTOR CO.
    4. Connect the input/output speed sensor connectors (A, B) and vehicle speed sensor connector (C).
       Fig 14: Identifying Input Speed Sensor

       Courtesy of HYUNDAI MOTOR CO.
       Fig 15: Identifying Output Speed Sensor

       Courtesy of HYUNDAI MOTOR CO.
       Fig 16: Identifying Vehicle Speed Sensor Connector

       Courtesy of HYUNDAI MOTOR CO.
    5. Connect the ground wire (A).
       Fig 17: Identifying Ground Wire

       Courtesy of HYUNDAI MOTOR CO.
18. Connect engine wiring.
    1. Connect the RH rear oxygen sensor connector (A).
       Fig 18: Identifying RH Rear Oxygen Sensor Connector

       Courtesy of HYUNDAI MOTOR CO.
    2. Connect the LH rear oxygen sensor connector (A) and the CPS connector (B).
       Fig 19: Identifying LH Rear Oxygen Sensor Connector And CPS Connector

       Courtesy of HYUNDAI MOTOR CO.
19. Clamp the transaxle oil cooler hoses (A).
    Fig 20: Identifying Transaxle Oil Cooler Hoses

    Courtesy of HYUNDAI MOTOR CO.
20. After disconnecting the positive terminal from the battery, remove the battery.
21. Install the intake air hose (D) and the air cleaner assembly (A).
    1. Connect the AFS connector (B).
    2. Clamp the breather hose (C) from the air cleaner hose (D).
    3. Connect the PCM connectors.
    4. Install the intake air hose (D) and the air cleaner assembly (A).
       Fig 21: Identifying Intake Air Hose, Air Cleaner Assembly, AFS Connector And Breather Hose

       Courtesy of HYUNDAI MOTOR CO.
22. Install the engine cover (A).
    Fig 22: Identifying Engine Cover

    Courtesy of HYUNDAI MOTOR CO.
23. Connect the negative terminal (B) from the battery (A).
    Fig 23: Identifying Battery And Negative Terminal

    Courtesy of HYUNDAI MOTOR CO.