Removal and Installation

REMOVAL
1. REMOVE HOOD
2. REMOVE 4 NUTS AND SUSPENSION UPPER BRACE
3. REMOVE BATTERY AND AIR CLEANER CASE ASSEMBLY WITH AIR HOSE





4. REMOVE CRUISE CONTROL ACTUATOR
a. Disconnect the cruise control actuator connector.
b. Remove the 3 bolts and cruise control actuator with the bracket.
5. REMOVE STARTER
a. Disconnect the connector, nut and wire from the starter.
b. Remove the 2 bolts and starter.





6. DISCONNECT CLUTCH RELEASE CYLINDER
a. Remove the 2 bolts and disconnect the release cylinder.
b. Remove the 2 set bolts and nut of the clutch accumulator.
c. Remove the set bolt of the clutch line bracket.





7. DISCONNECT GROUND CABLE
Remove the set bolt of the ground cable from the transaxle.





8. DISCONNECT ENGINE WIRE FROM CLAMP
9. DISCONNECT VEHICLE SPEED SENSOR AND BACK-UP LIGHT SWITCH CONNECTORS
10. 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 transaxle.





11. REMOVE 5 TRANSAXLE UPPER SIDE MOUNTING BOLTS
12. REMOVE FRONT WHEEL
13. RAISE VEHICLE

NOTICE: Make sure that the vehicle is securely supported.

14. REMOVE ENGINE REAR SIDE SHUTTER PLATE AND LH AND RH FENDER APRON SEALS





15. DRAIN TRANSAXLE OIL
16. REMOVE LH AND RH DRIVE SHAFTS





17. REMOVE FRONT EXHAUST PIPE
a. Remove the 2 bolts and exhaust pipe support stay.
b. Remove the 4 nuts and 2 gaskets from the exhaust manifold.
c. Remove the 2 bolts, nuts and gasket.
d. Remove the 2 set bolts of the No. 1 exhaust pipe support bracket.
e. Remove the front exhaust pipe.
18. DISCONNECT PS GEAR ASSEMBLY FROM FRONT FRAME ASSEMBLY





a. Remove the 2 nuts and disconnect the stabilizer bar link from the stabilizer bar.
b. Remove the 4 set bolts of the stabilizer bar bracket.
c. Remove the 2 bolts, nut and No. 1 fuel tube protector.





d. Tie the PS gear assembly to the proper position with a cord or an equivalent to suspend the assembly securely.
e. Remove the 2 set bolts and nuts of the PS gear assembly.





19. DISCONNECT FRONT ENGINE ABSORBER FROM TRANSAXLE
Remove the 2 bolts.





20. REMOVE RH EXHAUST MANIFOLD STAY
Remove the bolt, nut and stay.





21. REMOVE 3 ENGINE FRONT SIDE MOUNTING BOLTS





22. REMOVE LH ENGINE MOUNTING INSULATOR WITH BRACKET
a. Remove the 2 hole plugs, nuts and 3 bolts.
b. Lift up the transaxle and remove the LH engine mounting insulator with the bracket.





23. REMOVE HOLE PLUG AND 4 ENGINE REAR SIDE MOUNTING NUTS
24. ATTACH ENGINE SLING DEVICE TO ENGINE HANGER
25. REMOVE FRONT FRAME ASSEMBLY WITH LOWER SUSPENSION ARM





a. Remove the 2 bolts and disconnect the steering return pipe from the front frame assembly.





b. Remove 4 screws on the front side of the LH and RH fender liners.





c. Remove 4 screws on the rear side of LH and RH fender liners.





d. Bend the fender liners under to remove the 6 bolts and 4 nuts for the LH and RH front and rear braces, then remove the front and rear braces on both sides and the front frame assembly with lower suspension arm.
26. JACK UP 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.
b. Remove the 3 bolts of the transaxle lower side.
28. REMOVE TRANSAXLE
Lower the engine left side and remove the transaxle from the engine.

INSTALLATION
1. RAISE VEHICLE

NOTICE: Make sure that the vehicle is securely supported.





2. INSTALL TRANSAXLE TO ENGINE
a. Using a transmission jack, lift up the transaxle.
b. Align the input shaft with the clutch disc and install the transaxle to the engine.
c. Temporarily tighten the 3 transaxle lower side mounting bolts.
3. INSTALL FRONT FRAME ASSEMBLY WITH LOWER SUSPENSION ARM
a. Remove the transmission jack.





b. Bend the fender liners under to install the front frame assembly with lower suspension arm and LH and RH front and rear braces, then install the 6 bolts and 4 nuts.
Torque:
Bolt A: 181 Nm (1,850 kgf-cm, 134 ft. lbs.)
Bolt B: 32 Nm (330 kgf-cm, 24 ft. lbs.)
Nut C: 36 Nm (370 kgf-cm, 27 ft. lbs.)





c. Install the screw on the rear side of the LH and RH fender
d. Install the screws on the front side of the LH and RH fender liners.





e. Connect the steering return pipe to the front frame assembly and install the 2 bolts.
Torque: 10 Nm (100 kgf-cm, 7 ft. lbs.)
4. REMOVE ENGINE SLING DEVICE FROM ENGINE HANGER





5. INSTALL 4 ENGINE REAR SIDE MOUNTING NUTS AND HOLE PLUG.
Torque: 66 Nm (670 kgf-cm, 48 ft. lbs.)





6. INSTALL LH ENGINE MOUNTING INSULATOR WITH BRACKET
Install the LH engine mounting insulator with the bracket, 3 bolts, 2 nuts and hole plugs.
Torque:
Bolt: 64 Nm (650 kgf-cm, 47 ft. lbs.)
Nut: 80 Nm (820 kgf-cm, 59 ft. lbs.)





7. INSTALL 3 ENGINE FRONT SIDE MOUNTING BOLTS
Torque:
Silver bolt: 44 Nm (450 kgf-cm, 33 ft. lbs.)
Green bolt: 66 Nm (670 kgf-cm, 48 ft. lbs.)





8. TORQUE 3 TRANSAXLE LOWER SIDE MOUNTING BOLTS
a. Torque the 3 bolts of the transaxle lower side.
Torque:
14 mm head A: 46 Nm (470 kgf-cm, 34 ft. lbs.)
14 mm head B: 37 Nm (380 kgf-cm, 27 ft. lbs.)
b. Install the cover and 2 bolts.
Torque: 7.8 Nm (80 kgf-cm, 69 inch lbs.)





9. INSTALL RH EXHAUST MANIFOLD STAY
Install the stay, bolt and nut.
Torque: 20 Nm (200 kgf-cm, 14 ft. lbs.)





10. CONNECT FRONT ENGINE ABSORBER AND INSTALL 2 BOLTS TO TRANSAXLE
Torque: 48 Nm (490 kgf-cm, 35 ft. lbs.)
11. CONNECT PS GEAR ASSEMBLY TO FRONT FRAME ASSEMBLY





a. Install the PS gear assembly, 2 bolts and nuts.
Torque: 181 Nm (1,850 kgf-cm, 134 ft. lbs.)
b. Untie the PS gear assembly.
c. Install the No. 1 fuel tube protector, 2 bolts and nut.





d. Install the stabilizer bar bracket and 4 set bolts.
Torque: 19 Nm (195 kgf-cm, 14 ft. lbs.)
e. Connect the stabilizer bar link to the stabilizer bar, then install the 2 nuts.
Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.)





12. INSTALL FRONT EXHAUST PIPE
a. Install the front exhaust pipe, then install the No. 1 exhaust pipe support bracket and 2 set bolts.
Torque: 33 Nm (330 kgf-cm, 24 ft. lbs.)
b. Install the 2 bolts and new nuts with a new gasket.
Torque: 56 Nm (570 kgf-cm, 41 ft. lbs.)
c. Install 4 new nuts to the exhaust manifold with 2 new gaskets.
Torque: 62 Nm (630 kgf-cm, 46 ft. lbs.)
c. Install the exhaust pipe support stay and 2 bolts.
Torque: 33 Nm (330 kgf-cm, 24 ft. lbs.)
13. INSTALL LH AND RH DRIVE SHAFTS





14. FILL TRANSAXLE OIL
Oil grade: API GL-4 or GL-5
Viscosity: SAE 75W-90
Capacity: 4.2 liters (4.4 US qts, 3.7 Imp. qts)
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
15. INSTALL LH AND RH FENDER APRON SEALS AND ENGINE REAR SIDE SHUTTER PLATE
16. LOWER VEHICLE





17. INSTALL 5 TRANSAXLE UPPER SIDE MOUNTING BOLTS
Torque:
17 mm head: 64 Nm (650 kgf-cm, 47 ft. lbs.)
18. CONNECT CONTROL CABLE
a. Connect the 2 control cables to the transaxle.
b. Install the 2 clips to the cables.
c. Install the 2 clips and washers.
19. CONNECT BACK-UP LIGHT SWITCH AND VEHICLE SPEED SENSOR CONNECTORS





20. CONNECT ENGINE WIRE TO CLAMP





21. CONNECT GROUND CABLE
Install the bolt and ground cable to the transaxle.





22. CONNECT CLUTCH RELEASE CYLINDER
a. Install the clutch line bracket and set bolt.
Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.)
b. Install the clutch accumulator, 2 set bolts and nut.
Torque:
Bolt: 21 Nm (210 kgf-cm, 15 ft. lbs.)
Nut: 26 Nm (270 kgf-cm, 20 ft. lbs.)
c. Connect the release cylinder, then install the 2 bolts.
Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.)
23. INSTALL STARTER
a. Install the starter and 2 bolts.
Torque: 37 Nm (378 kgf-cm, 28 ft. lbs.)
b. Connect the connector and, nut wire to the starter.





24. INSTALL CRUISE CONTROL ACTUATOR
a. Install the cruise control actuator with the bracket and 3 bolts.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
b. Connect the cruise control actuator connector.
25. INSTALL BATTERY AND AIR CLEANER CASE ASSEMBLY WITH AIR HOSE
26. INSTALL SUSPENSION UPPER BRACE AND 4 NUTS
Torque: 80 Nm (820 kgf-cm, 59 ft. lbs.)
27. INSTALL HOOD
28. INSTALL FRONT WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
29. INSPECT FRONT WHEEL ALIGNMENT
30. DO ROAD TEST
Check for abnormal noises and smooth shifting.