Engine Assembly Removal & Installation: Installation

Install engine and transaxle into engine compartment as a unit.
Install three No. 1 engine mount bolts.
Tightening torque: 49.2~69 lb-ft (67~93.2 N.m, 6.8~9.5 kg-m)

Fig 1: Installing No. 1 Engine Mount Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Install No. 3 engine mount bolt.
Tightening torque: 62.9~86 lb-ft (85.3~116.6 N.m, 8.7~11.9 kg-m)
Install two No. 2 engine mount nuts.
Tightening torque: 28~38 lb-ft (38~51 N.m, 3.8~5.3 kg-m)

Fig 2: Installing No. 2 Engine Mount Nuts
Courtesy of KIA MOTORS AMERICA, INC.
Install No. 4 engine mount.
Tightening torque:
1. Nuts: 49~68 lb-ft (68~93 N.m, 6.8~9.5 kg-m)
2. Bolt: 47~66 lb-ft (64~89 N.m, 6.5~9.1 kg-m)
Fig 3: Installing No. 4 Engine Mount
Courtesy of KIA MOTORS AMERICA, INC.
Remove engine hoist.
Install new clips on driveshaft.
Push driveshaft and joint shaft into transaxle with opening of clips pointing upward.
Install joint shaft support bracket using three bolts.
Tightening torque: 32~46 lb-ft (43~62 N.m, 4.4~6.3 kg-m)
Install right and left lower ball joints into spindle then install pinch bolts.
Tightening torque: 32~39 lb-ft (43~52 N.m, 4.4~5.3 kg-m)
Install both right and left stabilizer control links.
Tightening torque: 32~45 lb-ft (43~61 N.m, 4.4~6.2 kg-m)

Fig 4: Installing Both Right And Left Stabilizer Control Links
Courtesy of KIA MOTORS AMERICA, INC.
Install front exhaust pipe.
1. Tightening torque:
  1. A: 29.7~40.5 lb-ft (40.2~54.9 N.m, 4.1~5.6 kg-m)
  2. B : 51~69 lb-ft (69~94 N.m, 6.9~9.4 kg-m)
  3. C : 15.2~20.2 lb-ft (20.6~27.4 N.m, 2.1~2.8 kg-m)
Fig 5: Installing Front Exhaust Pipe
Courtesy of KIA MOTORS AMERICA, INC.
Connect two ATF cooler hoses (A/T).

Fig 6: Connecting Two ATF Cooler Hoses (A/T)
Courtesy of KIA MOTORS AMERICA, INC.
Connect solenoid valve connector (A/T).
Connect auto transaxle range switch connector (A/T).
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)

Fig 7: Installing Clutch Release Cylinder And Pipe (M/T)
Courtesy of KIA MOTORS AMERICA, INC.
Install extension bar and manual transaxle linkage (M/T).
Extension bar tightening torque: 23~34 lb-ft (32~47 N.m)

Manual transaxle linkage tightening torque: 12~17 lb-ft (16~23 N.m)
Install washer and nut to auto transaxle linkage (A/T).
Tightening torque: 24~83 lb-ft (32~46 N.m, 3.2~4.7 kg-m)
Insert U-clip.

Fig 8: Installing Washer And Nut To Auto Transaxle Linkage (A/T)
Courtesy of KIA MOTORS AMERICA, INC.
Connect back-up light switch connector (M/T).
Connect vehicle speed sensor connector (M/T).

Fig 9: Connecting Vehicle Speed Sensor Connector (M/T)
Courtesy of KIA MOTORS AMERICA, INC.
Connect input turbine speed sensor connector.

Fig 10: Connecting Input Turbine Speed Sensor Connector
Courtesy of KIA MOTORS AMERICA, INC.
Connect ground strap to top of transaxle.

Fig 11: Connecting Ground Strap To Top Of Transaxle
Courtesy of KIA MOTORS AMERICA, INC.
Install A/C compressor mounting bracket (five bolts)
1. Tightening torque:
  1. Mounting bracket:
    1. Four (14 mm) bolts: 28~38 lb-ft (38~51 N.m, 3.9~5.2 kg-m)
    2. One (12 mm) bolt (oil pump side): 14~18 lb-ft (19~25 N.m, 1.9~25 kg-m)
  2. A/C compressor: 28~38 lb-ft (39~52 N.m, 3.9~5.3 kg-m)
  Fig 12: Installing A/C Compressor Mounting Bracket
  Courtesy of KIA MOTORS AMERICA, INC.
2. Install three P/S pump bracket bolts.
  Tightening torque: 28~38 lb-ft (39~52 N.m, 3.9~5.3 kg-m)
3. Install exhaust manifold heat shield.
  Tightening torque: 13.7~22.4 lb-ft (18.6~30.4 N.m, 1.9~3.1 kg-m)
  
  Fig 13: Installing Exhaust Manifold Heat Shield
  Courtesy of KIA MOTORS AMERICA, INC.
4. Install RH & LH splash shield.
  Tightening torque: 10~12 lb-ft (13.5~16 N.m, 1.4~1.6 kg-m)
  
  Fig 14: Installing RH & LH Splash Shield
  Courtesy of KIA MOTORS AMERICA, INC.
5. Install both front wheels.
  Tightening torque: 65~87 lb-ft (88~118 N.m, 9~12 kg-m)
6. Connect engine ground strap.
  1. Tightening torque:
    1. A:28~38 lb-ft (38~51 N.m, 3.8~5.3 kg-m)
    2. B:5.8~8.7 lb-ft (7.8~11.8 N.m, 0.8~1.2 kg-m)
  Fig 15: Connecting Engine Ground Strap
  Courtesy of KIA MOTORS AMERICA, INC.
7. Connect two generator connectors.
  (B-terminal connector and C121 to the generator)
  
  Fig 16: Connecting Two Generator Connectors
  Courtesy of KIA MOTORS AMERICA, INC.
8. Connect B-terminal and S-terminal connectors to the starter.
  
  Fig 17: Connecting B-Terminal And S-Terminal Connectors To The Starter
  Courtesy of KIA MOTORS AMERICA, INC.
9. Connect IAC and throttle position sensor connectors.
  
  Fig 18: Connecting IAC And Throttle Position Sensor Connectors
  Courtesy of KIA MOTORS AMERICA, INC.
10. Install connector bracket and connect electric connectors.
  Tightening torque: 27.5~38.3 lb-ft (37.2~51.9 N.m, 3.8~5.3 kg-m)
  
  Fig 19: Installing Connector Bracket And Connecting Electric Connectors
  Courtesy of KIA MOTORS AMERICA, INC.
11. Connect injector connectors.
  
  Fig 20: Connecting Injector Connectors
  Courtesy of KIA MOTORS AMERICA, INC.
12. Connect heater hoses.
  
  Fig 21: Connecting Heater Hoses
  Courtesy of KIA MOTORS AMERICA, INC.
13. Connect fuel hose to injector rail.
  
  Fig 22: Connecting Fuel Hose To Injector Rail
  Courtesy of KIA MOTORS AMERICA, INC.
14. Connect upper and lower radiator hoses.
  
  Fig 23: Connecting Upper And Lower Radiator Hoses
  Courtesy of KIA MOTORS AMERICA, INC.
15. Connect brake vacuum hose and purge control vacuum hose to dynamic chamber.
  
  Fig 24: Connecting Brake Vacuum Hose And Purge Control Vacuum Hose
  Courtesy of KIA MOTORS AMERICA, INC.
16. Install air cleaner assembly and connect air intake hose to throttle body.
17. Install fresh air duct.
18. Connect ventilation hose.
19. Install accelerator cable and auto cruise control cable, if equipped.
20. Insert data link connector into mass air flow sensor bracket.
21. Connect intake air temperature sensor connector and mass air flow sensor connectors.
  
  Fig 25: Installing Air Cleaner Assembly And Connecting Air Intake Hose To Throttle Body
  Courtesy of KIA MOTORS AMERICA, INC.
22. Install P/S and A/C belt. Turn adjustment screw until correct belt deflection is achieved. Tighten pivot bolt and mounting bolt.
  1. Deflection:
    1. New: 8.0~9.0 mm (0.32~0.35 in)
    2. Used: 9.0~10.0 mm (0.36~0.39 in)
  Fig 26: Installing P/S And A/C Belt
  Courtesy of KIA MOTORS AMERICA, INC.
23. Install battery tray and battery.
  Tightening torque: 10~12 lb-ft (13.5~16 N.m, 1.4~1.6 kg-m)
24. Fill engine coolant with specified type and amount.
25. Connect both battery cables.
26. Check and/or fill all fluids.
27. Test run engine and perform an overall check.