Servicing - A/t: Other Kia Sephia I facelift

Transmission

Check transmission fluid at every engine oil change. Under normal conditions, replace fluid and screen every 30,000 miles. Under severe conditions, replace fluid and screen every 15,000 miles. Replace fluid if unusual odor and/or discoloration is present.

Transfer Case

Check transfer case fluid at every engine oil change. Under normal conditions, replace fluid every 30,000 miles. Under severe conditions, replace fluid every 15,000 miles. Replace fluid if unusual odor and/or discoloration is present.

1. Park vehicle on level ground. Apply parking brake. Warm engine to normal operating temperature. With engine idling, briefly place selector lever in all gears and return it to "P" position.
2. With engine idling, remove transmission dipstick. Transmission fluid level should be between "L" and "F" marks. Check fluid for discoloration and unusual odor. Add recommended fluid if necessary. See «RECOMMENDED FLUID»(ref-91656-S40135982222001032600000) . DO NOT overfill.

Note. Some transfer cases have a check and fill plug in chain cover.

1. Raise and support vehicle in level position. Remove transfer case side mount. Remove oil check/fill plug. Oil level should be even with bottom of oil check/fill plug hole. Add recommended fluid as necessary. See «RECOMMENDED FLUID»(ref-91656-S40135982222001032600000) .
2. Reinstall oil check/fill plug with new washer. Tighten oil check/fill plug to 22 ft. lbs. (30 N.m). Reinstall transfer case side mount. Tighten side mounts bolts and nuts to 38 ft. lbs. (52 N.m).

RECOMMENDED FLUID

For 1995 models, use Dexron-IIE or equivalent automatic transmission fluid. For 1996-97 models, use 90W gear oil.

Raise and support vehicle. Drain transmission fluid into a suitable container. If oil pan is removed, discard old oil pan gasket. Clean oil pan, and install it using NEW gasket. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Add fluid, and check level. DO NOT overfill.

1. Raise and support vehicle in level position. Remove transfer case side mount. Remove oil check/fill plug. Remove transfer case drain plug and drain fluid into a suitable container.
2. Reinstall drain plug with NEW washer. Tighten drain plug to 22 ft. lbs. (30 N.m). Add recommended fluid as necessary. See «RECOMMENDED FLUID»(ref-91656-S40135982222001032600000) . Oil level should be even with bottom of oil check/fill plug hole. Reinstall oil check/fill plug with new washer. Tighten oil check/fill plug to 22 ft. lbs. (30 N.m). Reinstall transfer case side mount. Tighten side mounts bolts and nuts to 38 ft. lbs. (52 N.m).

Sephia

1. Support engine. Raise and support vehicle. Drain transaxle fluid. Remove engine crossmember. Remove transaxle oil pan, gasket and valve body assembly. Remove snap ring and 2-4 band servo assembly. (Scheme 117)
2. Install servo piston onto Adapter (K94A-4206-AT). Remove "O" ring from servo retainer. Coat "O" ring with ATF, and install ring onto adapter. Install 2-4 band servo assembly into transaxle case and secure it using snap ring. Position dial indicator against piston stem. (Scheme 117)
3. Using a rubber-tipped air nozzle, apply compressed air through fluid passage and measure piston stem stroke. (Scheme 117) Piston stem stroke should be.040-.067" (1.00-1.70 mm) at 57 psi (4.0 kg/cm 2 ). If piston stem stroke is not as specified, replace piston stem.
4. Nine different length piston stems are available in.02" (.5 mm) increments ranging from 3.74" (95.0 mm) to 3.90" (99.1 mm). Remove 2-4 band servo assembly and adapter. Install servo retainer using NEW "O" ring.
5. Install valve body assembly. Tighten bolts to specification. Install oil pan with NEW gasket. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-91656-S08212522302001032600000). Install engine crossmember. Lower vehicle. Add fluid, and check level. DO NOT overfill.

Scheme 117

Sportage

Information not provided by manufacturer.

1. Remove center console. Place gearshift lever in Park. Loosen selector cable mounting bolts. (Scheme 118) Push selector lever against "P" range; hold it in this position.
2. Tighten selector cable mounting bolts. Ensure starter operates in Park and Neutral only. Ensure position of gearshift lever and indicator correspond with each other.
3. Ensure lock button returns after it has been depressed. Ensure gearshift lever operates smoothly when engaged in all positions. Install center console.

Scheme 118

Information is not provided by manufacturer.

THROTTLE CABLE

Note. On Sephia, oil pressure gauge is needed to properly adjust throttle cable.

1. Remove left splash shield, near left front tire. Remove transaxle lower pressure port plug. Install oil pressure gauge to port. (Scheme 119) Move gearshift lever Park. Start engine, and warm to normal operating temperature.
2. Ensure engine is at normal idle speed. Check throttle pressure. See «THROTTLE PRESSURE SPECIFICATIONS»(ref-91656-S32042647182001032600000) table. If pressure is not within specification, adjust throttle cable.
3. With engine running, loosen adjustment bolts No. 1 and 2. Verify throttle is fully closed. Tighten bolt No. 1. Adjust throttle cable until pressure reading is within specification. (Scheme 120) Tighten throttle cable adjustment bolt No. 2 to 61-87 INCH lbs. (6.9-9.8 N.m) when pressure is within specification.
4. Turn engine off. Remove oil pressure gauge. Install pressure port plug, and tighten it to 44-87 INCH lbs. (5.0-9.8 N.m).

THROTTLE PRESSURE SPECIFICATIONS

Scheme 119

Scheme 120

1. Check throttle cable and housing for damage and replace as necessary. Depress accelerator pedal fully and ensure throttle valve is fully open. Adjust accelerator cable as necessary.
2. Slide throttle cable rubber boot down cable housing. Pull lightly on inner cable until slight resistance is felt. Measure distance between cable housing end and cable stop. Distance should be 0.031-0.059" (0.8-1.5 mm). Adjust cable housing as necessary to obtain specified distance. (Scheme 121)

Scheme 121

1. Disconnect negative battery cable. Remove battery, air cleaner assembly and battery carrier. Remove nut and clip. Disconnect selector cable. Rotate manual shaft to "N" position. Disconnect range switch connector.
2. Loosen range switch mounting bolts. Connect ohmmeter between terminals No. 5 and 7. Adjust switch to the point where continuity exists between terminals No. 5 and 7. Tighten switch mounting bolts to 70-95 INCH lbs. (7.9-10.7 N.m).
3. Verify selector lever range position and transaxle range correspond. Connect range connector and selector cable. Install battery carrier, air cleaner assembly and battery. Verify vehicle starts only in Park and Neutral.

Place gearshift lever to Neutral. Loosen transmission range switch attaching bolt. Align neutral base line groove on switch housing and groove on selector shaft. (Scheme 122) Tighten switch attaching bolt to 35-61 INCH lbs. (3.9-6.9 N.m). Ensure starter operates in Neutral and Park.

Scheme 122