Removal and Installation

REMOVAL
1. REMOVE BATTERY AND AIR CLEANER CASE ASSEMBLY WITH AIR HOSE





2. DISCONNECT CLUTCH RELEASE CYLINDER AND LINE
a. Remove the 4 set bolts of the clutch line bracket.
b. Remove the 2 bolts and disconnect the clutch release cylinder and line.
3. DISCONNECT BACK-UP LIGHT SWITCH AND VEHICLE SPEED SENSOR CONNECTORS





4. DISCONNECT GROUND CABLE
Remove the set bolt of the ground cable from the transaxle.
5. 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.





6. REMOVE STARTER SET BOLT
Remove the set bolt of the starter from the transaxle upper side.
7. REMOVE 2 TRANSAXLE UPPER SIDE MOUNTING BOLTS





8. INSTALL ENGINE SUPPORT FIXTURE





9. REMOVE ENGINE LEFT MOUNTING STAY
Remove the 2 bolts and engine left mounting stay.
10. REMOVE ENGINE LEFT MOUNTING BRACKET 3 SET BOLTS AND NUT





11. REMOVE ENGINE LEFT MOUNTING BRACKET
Lower the transaxle side and remove the bolt and bracket.
12. RAISE VEHICLE

NOTICE: Make sure that the vehicle is securely supported.

13. REMOVE FRONT WHEEL
14. REMOVE LH AND RH ENGINE UNDER COVERS
15. DRAIN TRANSAXLE OIL
16. REMOVE LH AND RH DRIVE SHAFTS





17. REMOVE HEAT INSULATOR
Remove the 2 bolts, nut and heat insulator.
18. REMOVE BRACE
Remove the 2 nuts and brace.
19. REMOVE FRONT SUB-FRAME AND LOWER SUSPENSION ARM





a. Support the suspension crossmember with a jack.
b. Remove the 2 set bolts of the stabilizer bar bracket.





c. Remove the 14 bolts and 3 nuts.
d. Remove the front sub-frame and lower suspension arm.





20. REMOVE STARTER
a. Disconnect the starter connector.
b. Remove the nut and disconnect the starter wire.
c. Remove the set bolt of the starter from the lower side.
d. Remove the starter.
21. JACK UP TRANSAXLE SLIGHTLY
Using a transmission jack, support the transaxle.





22. REMOVE 4 TRANSAXLE LOWER SIDE MOUNTING BOLTS
23. 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 4 transaxle lower side mounting bolts.
3. LOWER VEHICLE





4. INSTALL ENGINE LEFT MOUNTING BRACKET
Install the bracket with the bolt.
Torque: 52 Nm (530 kgf-cm, 38 ft. lbs.)





5. INSTALL ENGINE LEFT MOUNTING BRACKET 3 SET BOLTS AND NUT
Torque:
Bolt A: 52 Nm (530 kgf-cm, 38 ft. lbs.)
Nut B: 87 Nm (890 kgf-cm, 64 ft. lbs.)
6. INSTALL ENGINE LEFT MOUNTING STAY
Install the stay with the 2 bolts.
Torque: 21 Nm (210 kgf-cm, 15 ft. lbs.)
7. REMOVE ENGINE SUPPORT FIXTURE
8. RISE VEHICLE





9. TIGHTEN TRANSAXLE LOWER SIDE MOUNTING BOLT
a. Tighten the 4 transaxle mounting bolts.
Torque:
Bolt A: 23 Nm (230 kgf-cm, 17 ft. lbs.)
Bolt B: 47 Nm (480 kgf-cm, 35 ft. lbs.)
b. Remove the transmission jack.





10. INSTALL STARTER
a. Install the starter.
b. Temporarily tighten the set bolt of the starter from the lower side.
c. Connect the starter connector.
d. Install the starter wire with the nut.
11. INSTALL FRONT SUB-FRAME AND LOWER SUSPENSION ARM
a. Install the front sub-frame and lower suspension arm.





b. Install 2 new bolts, the 12 bolts and 3 nuts.
Torque:
Bolt A: 175 Nm (1,790 kgf-cm, 129 ft. lbs.)
Bolt B: 147 Nm (1,500 kgf-cm, 109 ft. lbs.)
Bolt C: 225 Nm (2,305 kgf-cm, 167 ft. lbs.)
Bolt D: 64 Nm (650 kgf-cm, 47 ft. lbs.)
Bolt E: 60 Nm (620 kgf-cm, 45 ft. lbs.)
Nut F: 57 Nm (580 kgf-cm, 42 ft. lbs.)





c. Install the 2 set bolts of the stabilizer bar bracket.
Torque: 147 Nm (1,500 kgf-cm, 109 ft. lbs.)
12. INSTALL BRACE
Install the brace with the 2 nuts.
Torque: 69 Nm (700 kgf-cm, 51 ft. lbs.)





13. INSTALL HEAT INSULATOR
Install the heat insulator, 2 bolts and nut.
Torque: 17 Nm (170 kgf-cm, 12 ft. lbs.)
14. INSTALL LH AND RH DRIVE SHAFTS
15. LOWER VEHICLE





16. INSTALL 2 TRANSAXLE UPPER SIDE MOUNTING BOLTS
Torque: 64 Nm (650 kgf-cm, 47 ft. lbs.)
17. INSTALL STARTER SET BOLT
Install the set bolt of the starter from the upper side.
Torque: 37 Nm (378 kgf-cm, 28 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 GROUND CABLE
Install the set bolt of the ground cable to the transaxle.
20. CONNECT BACK-UP LIGHT SWITCH AND VEHICLE SPEED SENSOR CONNECTORS





21. CONNECT CLUTCH RELEASE CYLINDER AND LINE
a. Install the clutch release cylinder with the 2 bolts.
Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.)
b. Install the 4 set bolts of the clutch line bracket.
Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.)
22. INSTALL BATTERY AND AIR CLEANER CASE ASSEMBLY WITH AIR HOSE
23. RAISE VEHICLE

NOTICE: Make sure that the vehicle is securely supported.

24. TIGHTEN STARTER SET BOLT
Tighten the set bolt of the starter from the lower side.
Torque: 37 Nm (378 kgf-cm, 28 ft. lbs.)





25. FILL TRANSAXLE OIL
Oil grade: API GL-4 or GL-5
Viscosity: SAE 75W-90
Capacity: 1.9 liters (2.0 US qts, 1.7 Imp. qts)
Torque: 37 Nm (400 kgf-cm, 29 ft. lbs.)
26. INSTALL LH AND RH ENGINE UNDER COVERS
27. INSTALL FRONT WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
28. INSPECT FRONT WHEEL ALIGNMENT
29. DO ROAD TEST
Check for abnormal noises and smooth shifting.