Operation CHARM: Car repair manuals for everyone.
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With Manual Transmission

1. Disarm airbag.
2. Relieve fuel system pressure.
3. Disconnect battery cables, then remove battery and battery tray from vehicle.
4. Disconnect engine compartment lamp electrical connector, then carefully remove and set aside hood assembly.
5. Remove air intake system.
6. Drain engine coolant, then remove radiator and radiator hoses.
7. Drain engine oil.
8. Remove A/C compressor mounting bolts, if equipped, and position compressor aside. Support compressor assembly with wire.
9. Disconnect fuel lines from fuel rail assembly and position aside.

WARNING: Plug disconnected fuel lines to prevent any fuel leakage. Label fuel lines for installation reference.

10. Disconnect all engine wiring connectors and position aside. Label connectors for installation reference.
11. Remove power steering pump belt shield, then loosen power steering pump adjustment bolt.
12. Loosen power steering pump lock bolt and through bolt, then remove power steering belt.
13. Remove power steering hose hold-down bracket mounting bolts and brackets from cylinder head cover.
14. Remove power steering belt adjuster, then disconnect power steering pressure switch connector.
15. Remove power steering pump through bolt and position pump aside.
16. Loosen alternator adjusting bolt, then remove alternator upper mounting bolt and alternator belt.
17. Drain engine coolant and remove both radiator hoses.
18. Disconnect speed control vacuum line from back righthand side of intake manifold, if necessary.
19. Disconnect vacuum line connecting carbon canister to metal EGR vacuum line.
20. Disconnect EGR temperature sensor connector, if equipped.
21. Disconnect accelerator cable, then the brake booster vacuum line from back lefthand side of intake manifold.
22. Disconnect heater hoses and remove starter motor upper attaching bolts.
23. Disconnect speed control actuator electrical connector.
24. Remove two speed control actuator attaching nuts and set actuator aside.
25. Remove two fuel filter mounting bracket bolts and set fuel filter and bracket aside.
26. Remove ignition control module.
27. Remove ground wire bracket mounted between transaxle and rear transaxle mount.
28. Remove rear transaxle mount through bolt, then the transaxle ground located at the top rear of the transaxle.
29. Disconnect Brake ON/OFF (BOO) switch and Vehicle Speed Sensor (VSS) connectors from rear of transaxle.
30. Remove slave cylinder line fitting from slave cylinder. Plug metal line to prevent fluid leakage.
31. Pull spring clips from slave cylinder line mounting brackets, then remove rubber line from metal line.
32. Disconnect Park/Neutral Position (PNP) switch from front of transaxle.
34. Raise and support vehicle, then remove front wheels and splash shields.
35. Remove six transverse member attaching bolts, then the transverse member.
36. Remove six transaxle cradle nuts and two bolts, then the transaxle cradle.
37. Remove two transaxle lower mount bolts and the transaxle lower mount.
38. Remove halfshafts as follows:
a. Using hammer and chisel, carefully raise staked portion of halfshaft attaching nut.
b. Apply brakes, then remove halfshaft attaching nut.

NOTE: Discard nut after removal, never reuse nut.

c. Remove righthand stabilizer control link from lower control arm attaching bracket.
d. Remove righthand side ball joint clamp bolt, then pry lower control arm from ball joint clamp.
e. Separate righthand side halfshaft from wheel hub. If halfshaft splines bind, use jaw puller D80L-1002-L or equivalent.

CAUTION: Never strike halfshaft with any object.

Removing Left Halfshaft:





f. Using an angled pry bar or equivalent, remove lefthand halfshaft by prying between the constant velocity joint outer race and transaxle housing. Carefully tap pry bar end to unseat circlip on side gear end of halfshaft.
g. Remove three halfshaft support bearing attaching bolts.
h. Separate righthand halfshaft assembly from differential by carefully prying halfshaft from transaxle.
i. Support halfshaft assemblies and slide out of transaxle.
j. Using transaxle plug set T88C-7025-AH or equivalent, plug transaxle openings to prevent leakage.
39. Remove intake manifold support bracket.
40. Remove rear transaxle mount bolts, then the mount.
41. Disconnect starter motor electrical connector, then remove starter motor.
42. Disconnect oil pressure sensor and oxygen sensor electrical connectors.
43. Remove converter inlet pipe to catalytic converter attaching nuts.
44. Remove exhaust support attaching bolts, then the converter inlet pipe to exhaust manifold attaching nuts.
45. Support exhaust system with wire.
46. Remove extension bar nut and washer, then disengage the bar from the transaxle.
47. Remove transaxle shift linkage through bolt and nut, then disengage shift linkage from transaxle.
48. Remove wiring harness hold-down bracket from back of alternator, then the alternator lower through bolt.
49. Disconnect remaining alternator wiring and remove alternator.
50. Using crankshaft pulley holder T92C-6316-AH or equivalent, remove crankshaft pulley attaching bolt.
51. Remove crankshaft pulley and guide plate.
52. Lower vehicle, then slightly raise engine with a jack and remove righthand engine mount.
53. Attach an engine hoist to lifting eyes on engine, then remove lefthand transaxle mount nuts and bolts.
54. Remove lefthand transaxle mount through bolt, then the mount.
55. Remove engine and transaxle assembly from vehicle.
56. Remove transaxle to engine mounting bolts and separate engine from transaxle.
57. Remove clutch and flywheel.
58. Remove crankshaft rear cover plate bolt and plate.
59. Reverse procedure to install, noting the following:

Fig. 7, Transaxle To Engine Bolt Locations (M/T):





a. Tighten transaxle to engine mounting bolts as follows: torque bolts marked ``A'' to 66-86 ft lb, torque bolts marked ``B'' to 28-38 ft lb, torque bolts marked ``C'' to 14-18 ft lb, torque bolts marked ``D'' to 28-38 ft lb, torque bolts marked ``E'' to 66-86 ft lb.

Fig. 8, Transaxle Cradle Bolt Locations:





b. Tighten transaxle cradle nuts as follows: torque bolts marked ``A'' 55-77 ft lb, torque bolts marked ``B'' 50-68 ft lb, torque bolts marked ``C'' 32-44 ft lb.
c. Rearm airbag system.