Installation
INSTALLATION1. Flush the ATF cooler as described.
2. Remove the used grease in the flywheel hub cap and flywheel splines.
3. Fill the inside of the flywheel hub cap, and coat and the flywheel hub splines with Super High Temp Urea Grease (P/N 08798 - 9002) as shown.
4. Install a new sealing ring (rubber) on the input shaft, and install two 14 x 20 mm dowel pins in the flywheel housing.
5. Install the flywheel securely on the input shaft, then install the starter motor in the flywheel housing.
6. Place the transmission on a jack, and raise it to the engine assembly level.
7. Attach the transmission on the engine, then install the transmission housing mounting bolt and rear engine mounting bolts.
8. Install the transmission mount bracket. Tighten the long bolt loosely, and tighten the nuts and bolt on the mount bracket to the specified torque. Then tighten the long bolt to the specified torque.
9. Install the remaining transmission housing mounting bolts.
10. Remove the transmission jack and the hoist, then remove the hoist bracket from the engine.
11. Attach the flywheel to the drive plate with eight bolts and torque as follows:
Rotate the crankshaft pulley as necessary to tighten the bolts to half of the specified torque, then to the final torque, in a crisscross pattern.
After tightening the last bolt, check that the crankshaft rotates freely.
12. Install the flywheel cover and the engine stiffeners.
13. Tighten the crankshaft pulley bolt, if necessary.
14. Connect the ATF cooler hoses to the ATF cooler lines.
CAUTION: While connecting the ATF cooler hoses, be sure not to allow dust and other foreign particles to enter into the transmission.
15. Install the right front mount/bracket.
16. Install the exhaust pipe A.
17. Install a new set ring on the end of each driveshaft.
18. Install the right and left driveshafts.
CAUTION: While installing the driveshafts in the differential, be sure not to allow dust and other foreign particles to enter into the transmission.
NOTE:
- Clean the areas where the driveshafts contacts the transmission (differential) thoroughly with solvent or carburetor cleaner, and dry with compressed air.
- Turn the first and left steering knuckle fully outward, and slide each driveshaft into the differential until you feel its set ring clip engage the side gear.
19. Install the damper fork, then install the right and left ball joints to each lower arm with the castle nuts and new cotter pins.
20. Install the splash shield.
21. Connect the vehicle speed sensor connector, the driven pulley speed sensor connector and the secondary gear shaft speed sensor connector.
22. Install the shift cable end on the control lever, and install the shift cable on the shift cable bracket.
CAUTION: Take care not to bend the shift cable.
23. Install the clip in the direction shown.
24. Connect the solenoid harness connector, the drive pulley speed sensor connector, and the ground cable terminals.
25. Connect the starter motor cable on the starter motor, and install the cable holder.
NOTE: When installing the starter motor cable, make sure that the crimped side of the ring terminal is facing out.
26. Install all removed connectors and clamps.
27. Install the distributor.
28. Install the intake air duct and air cleaner housing assembly.
29. Refill the transmission with the recommended Genuine Honda CVT Fluid.
CAUTION: While filling the CVT Fluid, be sure not to allow dust and other foreign particles to enter into the transmission.
30. Connect the battery positive (+) terminal first, then the negative (-) terminal to the battery.
31. Check the ignition timing.
32. Start the engine. Set the parking brake, and shift the transmission through all gears three times. Check shift cable adjustments.
33. Check the front wheel alignment.
34. Let the engine reach operating temperature (the radiator fan comes on) with the tin [N] or [P] position, then turn it off and check fluid level.
35. Perform the start clutch calibration procedure.
36. Road test.