REPAIR MAINTENANCE OPERATION OF MOTOR VEHICLES
Kia Rio (2000 release)

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Kia
	Rio
		Instructions
		Engines A3E, A5D
		Greasing system
		Cooling
		Fuel system
		Ignition system
		Coupling
		Transmission
			Manual Transmission
				Technical data
				Checking the oil level
				Change of oil
				Replacement of an oil sealing ring
				Removing and installing transmission
				Dismantling, check and transmission assemblage
				Carter couplings and components of the gearbox
				Gearbox output shaft
				The secondary shaft of a transmission
				Selecting shims
				Differential
				The gear change mechanism
			Automatic transmission F4E-K
		Axes and power shafts
		Suspension
		Wheels and tires
		Steering
		Brakes
		Body
		The air conditioning system
		Electrical equipment

printable version

Removing and installing transmission

Manual Transmission

1 - intake of fresh air;
2 - The air filter assembly;
3 - the holder of the battery;
4 - battery;
5 - a support battery;
6 - an arm of the battery;
7 - a coupling cable;
8 - wire connection with "weight";
9 - a tip of steering draft;
10 - the lower arm front suspension;
11 - Rod;

12 - right drive shaft;
13 - left drive shaft;
14 - protective plate of the engine;
15 - draft of a choice of transfers;
16 - draft of a gear change;
17 - starter;
18 - Transmission;
19 - support of the power unit ?„–2;
20 - support of the power unit ?„–1;
21 - earring of the stabilizer;
22 - anti-roll bar.

Withdrawal

PERFORMANCE ORDER

1. Remove the first wire from the negative battery terminal, then from positive.
	2. Remove coolant expansion tank to access the battery bracket.
3. Remove the battery holder, battery and battery support.
4. Remove the intake of fresh air and the air filter assembly.
5. Disconnect the reverse gear switch.
6. Disconnect the vehicle speed sensor is located on the right side of the gearbox.
7. Turn out one bolt and disconnect a wire of connection with "weight".
8. Disconnect transducer connector crank angle.
	9. After removing squeezing the clutch lever pull the clutch cable to the side.
	10. Remove the upper starter bolt.
	11. Remove the three screws on the clutch housing.
	12. Special adaptation OK201 170 AA0 support the engine so that the engine weight was perceived device.
13. Lift the car and fix on support.
14. Remove both front wheels.
15. Remove the two screws and remove the mudguard.
16. Remove the two screws and four nuts and remove a plate of protection of the engine.
17. Set the pan under the oil drain plug from the gearbox.
	18. Remove the oil drain plug and drain the oil from the gearbox.
	19. Disconnect the gearbox rod gear selection and shift rod.
20. Remove the two mounting bolts of the power unit ?„–1.
21. Remove the three screws on the support ?„–2 power units.
	22. Remove the nuts of the front longitudinal rods.
23. Remove the stabilizer and earrings stabilizer bar.
24. Remove the pins and remove the nuts tips of steering drafts in rotary fists.
	25. Special adaptation OK670 321 019 disconnect the left and right tips of steering drafts from rotary fists.
	26. Remove the locking pin of the hinge bolts to rotary fists on both sides of the car.
27. mount wring out the bottom lever downwards and separate a pin of the hinge from the steering knuckle on both sides of the car.
A warning Do not damage the protective cover of the hinge of the lower arm front suspension.
	28. Insert mount between an internal SHRUS drive shaft and a transmission and easy blow on mount take a power shaft from a transmission.
A warning If you remove the drive shaft of the transmission is not immediately made great efforts and these efforts gradually increase. To avoid damaging the outer CV joint drive shaft with steel wire tie up a power shaft.
	29. Remove the lower starter mounting bolts and remove the starter.
	30. Remove the three screws on the lower clutch and then support a transmission jack, and remove the last two screws on the clutch housing.
31. Carefully separate the transmission from the engine and slowly lower it under the car.

Setting

PERFORMANCE ORDER

1. On a jack lift a transmission and establish it under the car.
	2. Slowly lifting and moving to the engine establish a transmission into place. Secure the gearbox on the engine five bolts screwed through the clutch housing. Torque: Upper bolts 1, 2, 3, 4 (4EA): 64-89 N ??? m Lower bolts 5, 6, 7, 8, 9 (5EA): 37-52 N ??? m
3. Lower the jack.
4. Remove plastic plugs OK201 270 014 with gearbox.
5. Install the starter and tighten the bottom bolt of fastening of a starter.
	6. Install the retaining ring on the inner end of the drive shaft.
7. push, insert a power shaft into a transmission, thus a cut of a lock ring should settle down from above.
	8. Establish pins of spherical hinges of the left and right bottom levers in rotary fists and fix their coupling bolts. Torque: 54-68 N ??? m
9. Establish pins of spherical hinges of the left and right tips of steering drafts in rotary fists and fix their nuts. Torque: 30-44 N ??? m
10. cotter lock nut from loosening.
11. Install the left and right earrings of the stabilizer and fix them. Torque: 42-60 N ??? m
	12. Install the drag link and secure with nuts. Torque: 118-147 N ??? m
	13. Establish a support ?„–2 power units and secure it with bolts and nuts. Torque: Bolt: 43-54 N ??? m Nut: 67-93 N ??? m
	14. Establish a support ?„–1 power unit. Torque: 43-54 N ??? m
15. Connect draft of a gear change and draft gear selection.
16. Screw in the oil drain plug into the gearbox.
	17. Install the engine protection plate and fasten the bolts and nuts. Torque: Bolts and nuts plate: 47-66 N ??? m Nuts of fastening of support ?„–1 and ?„–2: 37-57 N ??? m
18. Install the two mudguard and secure them with screws.
19. Install the front wheels. Torque: 88-118 N ??? m
20. Lower the car.
	21. Remove special adaptation OK201 170 AA0, supporting the engine.
	22. Screw the three screws clutch housing to the engine block of the engine. Torque: 89-116 N ??? m
23. Replace the two top bolts of fastening of a starter. Torque: 37-52 N ??? m
24. Set the release lever.
25. Connect the sensor crank angle.
26. Connect the connection with "weight" and secure it with a bolt.
27. Connect the vehicle speed sensor.
28. Connect the reversing light switch.
29. Install the air filter housing.
30. Connect temperature sensor to the engine air.
31. Connect the air flow meter sensor.
32. Install the intake of fresh air and fix its bolt and nut.
33. Connect the first wire to the positive terminal of the battery, and then to negative.
34. Fill the gearbox.
35. Carry out road test the vehicle and check the fluid levels.

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Dismantling, check and transmission assemblage