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Home >> Kia >> 2009 >> Rio LX, Standard >> Repair and Diagnosis >> Transmission >> Manual Trans >> Manual Transaxle System (From 11.19.2008) >> Manual Transaxle >> Repair Procedure >> Installation

Repair Procedure: Installation

  1. Install the transaxle lower mounting bolts (A-3ea) after fitting the transaxle assembly into the engine assembly.

    Tightening torque:  35~50Nm (3.5~5.0kgf.m, 25.3~36.2lb-ft)

    Fig 1: Identifying Transaxle Lower Mounting Bolts
    G06405649Courtesy of KIA MOTORS AMERICA, INC.
  2. Supporting the sub frame (A) with a jack and the Special tool(09624-38000), install the mounting bolts.
    Fig 2: Supporting Sub Frame With Jack
    G06405650Courtesy of KIA MOTORS AMERICA, INC.
  3. Install the muffler hanger rubber (A).
    Fig 3: Identifying Muffler Hanger Rubber
    G06405651Courtesy of KIA MOTORS AMERICA, INC.
  4. Install the rear roll stopper mounting bolt (A).
    Fig 4: Identifying Rear Roll Stopper Mounting Bolt
    G06405652Courtesy of KIA MOTORS AMERICA, INC.
  5. Install the front roll stopper mounting bolt (A).
    Fig 5: Identifying Front Roll Stopper Mounting Bolt
    G06405653Courtesy of KIA MOTORS AMERICA, INC.
  6. Connect the drive shafts from the transaxle (refer to FRONT DRIVESHAFT ASSEMBLY ).
  7. Install the side cover.
  8. Install the lower arm ball joint mounting nut, the stabilizer link mounting nut, and the tie rod end mounting nut to the front knuckles (refer to FRONT SUSPENSION SYSTEM ).
  9. Install the front wheels and tires.
  10. Install the under cover (A).
    Fig 6: Identifying Under Cover With Screws
    G06405654Courtesy of KIA MOTORS AMERICA, INC.
  11. Install the power steering return hose (A).
    Fig 7: Identifying Power Steering Return Hose
    G06405655Courtesy of KIA MOTORS AMERICA, INC.
  12. Remove the transaxle upper mounting bolts (A-2ea) and the starter motor mounting bolts (B-2ea).
    Fig 8: Identifying Transaxle Upper Mounting Bolts
    G06405656Courtesy of KIA MOTORS AMERICA, INC.
    Fig 9: Identifying Starter Motor Mounting Bolts
    G06405657Courtesy of KIA MOTORS AMERICA, INC.
  13. Remove the transaxle support bracket bolts (A-3ea).
    Fig 10: Identifying Transaxle Support Bracket Bolts
    G06405658Courtesy of KIA MOTORS AMERICA, INC.
  14. Install the steering column shaft bolt (refer to STEERING COLUMN/SHAFT ).
  15. Remove the special tool (09200-38001).
  16. Install the power pump hose bolt (A).
    Fig 11: Identifying Power Pump Hose Bolt
    G06405659Courtesy of KIA MOTORS AMERICA, INC.
  17. Install the snap pin (A) and control cable bracket bolts (B-3ea).
    Fig 12: Identifying Snap Pin And Control Cable Bracket Bolts
    G06405660Courtesy of KIA MOTORS AMERICA, INC.
  18. Connect the vehicle speed sensor connector (A) and the back lamp switch connector (B).
    Fig 13: Identifying Vehicle Speed Sensor And Back Lamp Switch Connectors
    G06405661Courtesy of KIA MOTORS AMERICA, INC.
  19. Install the clutch release cylinder assembly (A).
    Fig 14: Identifying Clutch Release Cylinder Assembly
    G06405662Courtesy of KIA MOTORS AMERICA, INC.
  20. Install the ground wire by removing a bolt.
    Fig 15: Identifying Ground Wire With Bolt
    G06405663Courtesy of KIA MOTORS AMERICA, INC.
  21. Install the battery tray (A).
    Fig 16: Identifying Battery Tray
    G06405664Courtesy of KIA MOTORS AMERICA, INC.
  22. Install the intake air hose and air cleaner assembly.
    Fig 17: Identifying Intake Air Hose And Air Cleaner Assembly
    G06405665Courtesy of KIA MOTORS AMERICA, INC.
  23. Install the battery (A).
    Fig 18: Identifying Battery
    G06405666Courtesy of KIA MOTORS AMERICA, INC.
  24. After completing the installation perform the following procedure;
  1. Adjust the shift cable.
  2. Refill the transaxle fluid.
  3. Clean the battery posts and cable terminals with sandpaper and grease them to prevent corrosion before installing.
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