Removal and Installation

REMOVAL

1. Remove hood.

INSTALLATION HINT: Adjust the hood. See Body and Frame.

2. Remove battery and air cleaner case assembly with air hose.





3. w/ Cruise Control:
- Remove cruise control actuator.
Disconnect the cruise control actuator connector.
b. Remove the 3 bolts and cruise control actuator with the bracket.
Torque: 13 N.m (130 kgf/cm, 9 ft. lbs.).
4. Remove starter.
a. Disconnect the connector and wire from the starter.
b. Remove the 2 bolts and starter.
Torque: 39 N.m (400 kgf/cm, 29 ft. lbs.).





5. Remove clutch release cylinder.
a. Remove the 2 bolts and release cylinder.
Torque: 12 N.m (120 kgf/cm, 9 ft. lbs.).
b. Remove the 2 set bolts and nut of the clutch accumulator.
Torque:
- Bolt: 21 N.m (210 kgf/cm, 15 ft. lbs.).
- Nut: 26 N.m (270 kgf/cm, 20 ft. lbs.).
c. Remove the set bolt of the clutch line bracket.
Torque: 12 N.m (120 kgf/cm, 9 ft. lbs.).





6. Disconnect ground cable.
- Remove the set bolt of the ground cable from the transaxle.





7. Disconnect engine wire from clamp.
8. Disconnect vehicle speed sensor and back-up light switch connectors.
9. Disconnect control cable.
a. Remove the 2 clips and washers.
b. Remove the 2 clips from the cables.





10. Remove 5 transaxle upper side mounting bolts.
Torque:
- 17 mm head: 64 N.m (650 kgf/cm, 47 ft. lbs.).
11. Remove front wheel.
Torque: 103 N.m (1,050 kgf/cm, 76 ft. lbs.).
12. Raise vehicle.

NOTICE: Make sure that the vehicle is securely supported.

13. Remove engine rear side shutter plate and LH and RH fender apron seals.





14. Drain transaxle oil.
Oil grade: API G L-4 or G L-5
Viscosity: SAE 75W-90
Capacity: 4.2 liters (4.4 US Qts).
Torque: 49 N.m (500 kgf/cm, 36 ft. lbs.).
15. Remove LH and RH drive shafts.





16. Remove front exhaust pipe.
a. Remove the 2 bolts and exhaust pipe support stay.
Torque: 33 N.m (330 kgf/cm, 24 ft. lbs.).
b. Remove the 4 nuts and 2 gaskets from the exhaust manifold.
Torque: 62 N.m (630 kgf/cm, 46 ft. lbs.).
c. Remove the 2 bolts, nuts and gasket.
Torque: 56 N.m (570 kgf/cm, 41 ft. lbs.).
d. Remove the 2 set bolts of the No.1 exhaust pipe support bracket.
Torque: 33 N.m (330 kgf/cm, 24 ft. lbs.).

e. Remove the front exhaust pipe.
17. Disconnect PS gear assembly from front suspension member.





a. Remove the 2 nuts and disconnect the stabilizer bar link from the stabilizer bar.
Torque: 39 N.m (400 kgf/cm, 29 ft. lbs.).
b. Remove the 4 set bolts of the stabilizer bar bracket.
Torque: 19 N.m (195 kgf/cm, 14 ft. lbs.).
c. Remove the 2 bolts, nut and No.1 fuel tube protector.
d. Tie the PS gear assembly to the proper position with a code or an equivalent to suspend the assembly securely.





e. Remove the 2 set bolts and nuts of the PS gear assembly.
Torque: 181 N.m (1,850 kgf/cm, 134 ft. lbs.).





18. Disconnect front engine absorber from transaxle.
- Remove the 2 bolts.
Torque: 48 N.m (490 kgf/cm, 35 ft. lbs.).





19. Remove RH exhaust manifold stay.
- Remove the bolt, nut and stay.
Torque: 20 N.m (200 kgf/cm, 14 ft. lbs.).





20. Remove 3 engine front side mounting bolts.
Torque:
- Silver bolt: 44 N.m (450 kgf/cm, 33 ft. lbs.).
- Green bolt: 66 N.m (670 kgf/cm, 48 ft. lbs.).





21. Remove LH engine mounting insulator with bracket.
a. Remove the 2 hole plugs, nuts and 3 bolts.
Torque:
- Bolt: 64 N.m (650 kgf/cm, 47 ft. lbs.).
- Nut: 80 N.m (820 kgf/cm, 59 ft. lbs.).
b. Lift up the transaxle and remove the left engine mounting insulator with the bracket.





22. Remove hole plug and 4 engine rear side mounting nuts.
Torque: 66 N.m (67Q kgf/cm, 48 ft. lbs.).
23. Attach engine sling device to engine hanger.
24. Disconnect steering return pipe from front suspension member.
- Remove the 2 bolts.
Torque: 10 N.m (100 kgf/cm, 7 ft. lbs.).





25. Remove front suspension member with lower suspension arm.
a. Remove the LH and RH fender liner set screws.
b. Remove the 6 bolts, 4 nuts, front LH and RH suspension member braces, rear LH and RH suspension member braces and front suspension member with lower suspension arm.
Torque:
- Bolt A: 181 N.m (1,850 kgf/cm, 134 ft. lbs.).
- Bolt B: 32 N.m (330 kgf/cm, 24 ft. lbs.).
- Nut C: 36 N.m (370 kgf/cm, 27 ft. lbs.).

26. Jack up the transaxle slightly.
- Using a transmission jack, support the transaxle.





27. Remove flywheel housing under cover and transaxle lower side mounting bolt.
a. Remove the 2 bolts and cover.
Torque: 7.8 N.m (80 kgf/cm, 69 inch lbs.)
b. Remove the 3 bolts of the transaxle lower side.
Torque:
- 14 mm head A: 46 N.m (470 kgf/cm, 34 ft. lbs.).
- 14 mm head B: 37 N.m (380 kgf/cm, 27 ft. lbs.).
28. Remove transaxle.
- Lower the engine left side and remove the transaxle from the engine.

INSTALLATION HINT:
- Align the input shaft with the clutch disc and install the transaxle to the engine.
- Temporarily tighten the transaxle mounting bolts.

INSTALLATION
- Installation is in the reverse order or removal.

HINT: After installation, check and inspect items as follows:
- Front wheel alignment. See Steering and Suspension.
- Do road test.