Kia Rio: Manual Transaxle Removal

Remove the following items;

A.	Air cleaner assembly (A) and air duct (B) . (Refer to "Intake and Exhaust system" in EM group)

B.	Battery and battery tray (C). (Refer to "Charging system" in EE group)

C.	ECM (D). (Refer to "Engine Control System" in FL group)

Remove the following items;

(1)	Remove the pin (A) and washer.

(2)

Remove the shift cable bracket bolts (B).

Tightening torque:

14.7 ~ 21.6 N.m (1.5 ~ 2.2 kgf.m, 10.8 ~ 15.9 lb-ft)

(3)	Disconnect the back up lamp switch connector (C) and vehicle speed sensor connector (D).

Remove the ground cable bolt (A) and tube bracket bolt (B).

Tightening torque:

14.7 ~ 21.6 N.m (1.5 ~ 2.2 kgf.m, 10.8 ~ 15.9 lb-ft)

Remove the transaxle upper mounting bolt (B-2ea) and the start motor mounting bolt (A-2ea).

Tightening torque:

(A,B) 42.2 ~ 54.0 N.m (4.3 ~ 5.5 kgf.m, 31.1 ~ 39.8 lb-ft)

5.	Remove the cowl top cover. (Refer to BD group.)

6.	Using the engine support fixture (Support SST No.: 09200-2S200, Adapter SST No.: 09200-1P000, 4X000, Beam SST No.: 09200-38001/3N000), hold the engine and transaxle assembly safely.

7.	Remove the mounting cover (A).

8.	Remove the transaxle support mounting bracket bolts (A-2ea).

Remove the transaxle support mounting bracket bolts (A-3ea).

Tightening torque:

58.8 ~ 78.5 N.m (6.0 ~ 8.0 kgf.m, 43.4 ~ 57.9 lb-ft)

10.	Lifting up the vehicle.

11.	Remove the under cover (A).

12.

Remove the clutch release cylinder assembly (A) by removing bolts (B-2ea).

Tightening torque:

14.7 ~ 21.6 N.m (1.5 ~ 2.2 kgf.m, 10.8 ~ 15.9 lb-ft)

13.	Remove the drive shaft assembly. (Refer to "Drive shaft assembly" in DS group.)

14.	Remove the drive shaft cover (A).

15.	Remove the brackets (A).

16.

Remove the roll rod bracket (C) after removing bolt (A,B).

Tightening torque:

(A) 49.0 ~ 63.7 N.m (5.0 ~ 6.5 kgf.m, 36.2 ~ 47.0 lb-ft)

(B) 107.9 ~ 127.5 N.m (11.0 ~ 13.0 kgf.m, 79.6 ~ 94.1 lb-ft)

17.

Remove the mounting bolts (A-3ea, B-2ea) of lower part of the transaxle, and the left side cover and remove the transaxle assembly by supporting it with a jack.

Be careful not to damage other system or parts near by when removing the engine and transaxle assembly.

Tightening torque:

(A) 43 ~ 49 N.m (4.3 ~ 4.9 kgf.m, 31.1 ~ 35.4 lb-ft)

(B) 42.2 ~ 53.9 N.m (4.3 ~ 5.5 kgf.m, 31.1 ~ 39.8 lb-ft)

Manual Transaxle Components

1. Transaxle support mounting bracket 2. Control shaft complete 3. Back up lamp switch 4. Vehicle speed sensor ...

Manual Transaxle Installation

When replacing a clutch housing or transaxle assembly, the wiring bracket should be installed in accordance with the clu ...

Kia Rio: Manual Transaxle Removal

Manual Transaxle Components

Manual Transaxle Installation

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