Installation

Special Tools

Installation

1. General note.
^ Only use new self-locking nuts.
2. Raise the vehicle.





3. Using a retaining strap and wooden blocks, secure the transaxle on a transmission jack.





4. Push the engine forwards and install an approximately 350 mm long wooden block between the engine and the subframe.
^ Move the transaxle into position.





5. Install the lower flange bolts.





6. Install the lower flange bolts.
7. Remove the retaining strap from the transaxle.
Take out the wooden block.





8. Install the connector to the vehicle speed sensor
9. Lower the vehicle.





10. Install the two upper flange bolts.





11. Install the starter motor.
^ Insert the three bolts (two bolts shown).





12. Install the rear engine mounting bracket.
13. Using the special tool 303-290, raise the engine and transaxle assembly slightly.





14. Install the rear engine mounting.





15. Remove the special tools (illustration shows battery installed)





16. Connect the connector to the reversing light switch.

17. WARNING: Escaping brake fluid. Do not allow brake fluid to come into contact with the skin or the eyes. If brake fluid does come into contact with the skin or the eyes, rinse the affected areas with water immediately. Failure to follow these instructions may result in personal injury.

CAUTION: If brake fluid is split on the paint work, the affected area must be immediately washed down with cold water.





Connect the high-pressure line to the clutch slave cylinder.
^ Insert the clip

l8. Raise the vehicle.





19. Install the drive belt cover





20. Put the gearshift lever and selector lever in neutral(move both levers to the vertical position).

21. NOTE: The adjusting mechanism must be unlocked.





Install the gearshift and selector cables to the transaxle and adjust.

NOTE: The abutment brackets are tensioned automatically once they are released.

1. Loosen the abutment collar by turning it counter-clockwise and insert the selector cable into the bracket.
2. Attach the selector cable to the selector lever.
3. Loosen the abutment collar by turning it counter-clockwise and insert the gearshift cable into the bracket.
4. Connect the gearshift cable to the gearshift lever.
5. Lock the adjusting mechanism by pressing in the tab.

22. CAUTION: The inner joint must not be bent at more than 18 degrees; the outer joint must not be bent at more than 45 degrees.

NOTE: Use new nuts and a new center bearing cap.





Install the right-hand driveshaft together with the intermediate shaft.

23. CAUTION: The inner joint must not be bent at more than 18 degrees; the outer joint must not be bent at more than 45 degrees.

NOTE: Insert the new snap-ring.





Install the left-hand driveshaft (illustration shows subframe removed).





24. Install the lower suspension arm.





25. Install the engine roll restrictor.





26. Install the flexible exhaust pipe.

27. Lower the vehicle.

28. NOTE: The resonator is plugged into the bracket.





Install the air cleaner intake with resonator.





29. Install the intake tube.





30. Connect the ground cable.





31. Install the air cleaner housing.
^ Press the air cleaner housing into the rubber bushes.
1. Connect the intake hose.
2. Install the crankcase ventilation hose.
3. Install the Mass Air Flow Sensor (MAF sensor) connector.

32. NOTE: Use an Allen key to prevent the piston rod from rotating.





Tighten the suspension strut lock nuts on both sides.





33. Install the battery tray.
1. Attach the wiring harness.
2. Tighten the bolts.
3. Fasten the connector and clip it in.
34. Install the battery.





35. Remove the special tool.
Install the gearshift lever cover.
36. Bleed the hydraulic clutch system.
37. Fill up the transaxle with Manual transmission fluid.

38. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy.

Finishing operations:
^ Connect the battery ground cable.
^ Carry out a road test to enable the Powertrain Control Module (PCM) to collect data.
^ Check the routing of the vacuum hoses and wiring and secure them with cable ties.
^ Check fluid level alter the road test and correct as necessary.
^ Check the engine and cooling system for leaks (visual inspection).