Removal and Installation

TRANSAXLE REMOVAL





1. Remove air cleaner case assembly with air hose.
2. Remove clutch release cylinder and line.
a. Remove the set bolt of the line bracket.
b. Remove the 2 bolts and clutch release cylinder and line.
Torque: 12 N.m (9 ft. lbs.).
3. Disconnect back-up light switch connector and vehicle speed sensor connectors.





4. Disconnect ground cable.

- Remove the bolt and disconnect the ground cable from the transaxle.





5. Remove engine wires clamp.
- Remove the bolt and engine wires clamp from the transaxle.
6. Disconnect control cable.
a. Remove the 2 clips and washers.
b. Remove the 2 clips from the cables.
c. Disconnect the 2 control cables from the control lever housing support bracket.





7. Remove starter set bolt.
- Remove the set bolt of the starter from the transaxle upper side.
Torque: 39 N.m (29 ft. lbs.).





8. Remove 3 transaxle upper side mounting bolts





9. Install engine support fixture.
10. Remove front wheel.
Torque: 103 N.m (76 ft. lbs.).
11. Raise vehicle.

NOTICE: Make sure that the vehicle is securely supported.

12. Remove LH and RH engine under covers.





13. Drain transaxle oil.
- Oil grade: API GL-4 or GL-5
- Viscosity: SAE 75W-90
- Capacity: 1.9 liters (2.0 US Qts.).
Torque: 39 N.m (29 ft. lbs.).
14. Remove LH and RH drive shafts.





15. Remove exhaust front pipe.
a. Remove the 2 bolts from the exhaust front pipe support bracket.
Torque: 19 N.m (14 ft. lbs.).
b. Disconnect the oxygen sensor connector.





c. Remove the 2 nuts and gasket from the exhaust manifold.
Torque: 62 N-m (46 ft. lbs.).
d. Remove the 2 bolts and nuts.
Torque: 42 N.m (31 ft. lbs.).
e. Remove the gasket and exhaust front pipe.





f. Remove the 2 bolts, nut and front pipe support bracket.
Torque: 19 N.m (14 ft. lbs.).





16. Remove starter.
a. Disconnect the connector and wire from the starter.
b. Remove the set bolt of the starter from the lower side.
Torque: 39 N.m (29 ft. lbs.).
c. Remove the starter.





17. Remove center crossmember.
a. Remove the 2 grommets.
b. Remove the set bolt and 2 nuts of the engine rear mounting insulator from the suspension member.
Torque: 80 N.m (59 ft. lbs.).





c. Remove the grommet.
d. Remove the 2 set bolts of the engine front mounting insulator.
Torque: 80 N.m (59 ft. lbs.).
e. Remove the 2 bolts and center crossmember.
Torque: 35 N.m (26 ft. lbs.).





18. Remove engine rear mounting bracket and insulator.
- Remove the 3 bolts, engine rear mounting bracket and insulator.
- Torque:
Bolt A: 87 N.m (64 ft. lbs.).
Bolt B: 77 N.m (57 ft. lbs.).





19. Remove engine front mounting bracket and insulator.
- Remove the 3 bolts, nut, engine front mounting bracket and insulator.
- Torque:
Nut A: 87 N.m (64 ft. lbs.).
Bolt B: 77 N.m (57 ft. lbs.).





20. Disconnect engine left mounting bracket from engine left mounting insulator.
a. Raise the transaxle and engine left side slightly with a jack.
b. Remove the set nut of the engine left mounting insulator from the transaxle upper side.
Torque: 64 N.m (47 ft. lbs.).
c. Remove the 2 set bolts of the engine left mounting bracket from the transaxle lower side.
Torque: 64 N.m (47 ft. lbs.).





21. Jack up transaxle slightly.
- Using a transmission jack, support the transaxle.
22. Remove transaxle mounting bolt from engine rear end plate side.
- Remove the 4 transaxle mounting bolts.
- Torque:
Bolt A: 23 N.m (17 ft. lbs.).
Bolt B: 46 N.m (34 ft. lbs.).





23. Remove transaxle.
- Lower the engine left side and remove the transaxle from the engine.
Torque: 64 N.m (47 ft. lbs.).

INSTALLATION HINT: Align the input shaft with the clutch disc and install the transaxle to the engine.

TRANSAXLE INSTALLATION
- Installation is in the reverse order of removal.

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