Removal/Installation

Removal





1. Disconnect negative battery cable (first) and positive battery cable (second).





2. Put aside the coolant reserve tank to remove the battery bracket.
3. Remove the battery, battery tray and battery fixing holder.
4. Remove the fresh air duct and air cleaner assembly.
After disconnecting hose from intake manifold, disconnect MAF sensor connector and air temperature sensor connector.
5. Disconnect back-up switch connector from connector bracket in case.
6. Disconnect vehicle speed sensor connector from right side of transaxle.
7. Disconnect ground strap (one bolt).
8. Disconnect the crankshaft position sensor connector.





9. After removing the release lever, put the release lever and the clutch pipe aside.





10. Remove one starter upper bolt.





11. Remove three clutch housing bolts.





12. Support engine with engine support bar SST (0K201 170 AA0A).
13. Raise and properly support vehicle.
14. Remove the front wheels and tires.
15. Remove both splash shields.
16. Remove the engine mounting member (two bolts, four nuts)
17. Place drain pan under the transaxle drain plug.





18. Remove transaxle drain plug and drain transaxle oil.





19. Remove the extension bar and shift control rod.
20. Remove two engine mounting bolt No. 1.
21. Remove three engine mounting bolt No. 2.





22. Remove the tension rod mounting nuts.
23. Remove the stabilizer bar and control link
24. Remove the cotter pin and loosen the nuts.





25. Disconnect the tie-rod end from the knuckle arm by using SST.





26. Remove the ball joint clamp bolt and nut from the lower arm.





27. Pry down the lower arm and disconnect the balljoint.

Notice: Be careful not to damage the ball-joint dust boot.





28. Separate the driveshaft from the transaxle.

Notice: Separate the shaft by pulling the hub outward. Do not use too much force at once, increase the force gradually.





Caution: Suspend the driveshaft with a rope to protect a bearing and a boot from damage.

29. Remove one starter lower bolt and set aside starter.





30. Remove three lower clutch housing bolts and support transaxle with jack or suitable floor jack and then remove remaining two bolts.
31. Gently separate transaxle assembly from engine and lower.

Installation
1. Raise the transaxle into the position and seat it against the back of the engine.





2. Connect the transaxle to the engine using five mounting bolt through clutch housing.
Tightening torque:
Upper bolt (4EA): (1), (2), (3), (4). 47 - 66 ft. lbs. (64 - 89 Nm, 6.5 - 9.1 kg-m)
Lower bolt (SEA): (5), (6), (7), (8), (9) 28 - 38 ft. lbs. (37 - 25 Nm, 3.8 - 5.3 kg-m)
3. Remove floor jack from the transaxle.
4. Remove the SST (OK201 270 014).
5. Install starter using lower starter bolt.





6. Install new clip onto driveshaft.
7. Push the driveshaft into the transaxle with opening of clip pointing upward.





8. Install the lower arm ball joint into the steering knuckle then install the ball joint clamp bolt and nut.
Tightening torque: 43 - 50 ft. lbs. (54 - 68 Nm, 5.5 - 6.9 kg-m)
9. Connect the tie-rod end to the steering knuckle then install the tie-rod end nut.
Tightening torque: 22 - 33 ft. lbs. (30 - 44 Nm, 3.0-4.5 kg-m)
10. Insert cotter pin.
11. Install the stabilizer bar and control link
Tightening torque: 32 - 45 ft. lbs. (43 - 60.8 Nm, 4.4 - 6.2 kg-m)





12. Install the tension rod mounting nut.
Tightening torque: 87 - 108 ft. lbs. (118 - 147 Nm, 12 - 15 kg-m)





13. Install the engine mounting No.2.
Tightening torque:
Bolt: 32 - 40 ft. lbs. (43 - 54 Nm, 4.4 - 5.5 kg-m)
Nut: 49 - 69 ft. lbs. (67 - 93 Nm, 6.8 - 9.5 kg-m)





14. Install the engine mounting No.1.
Tightening torque: 43 - 54 Nm (4.4 - 5.5 kg-m, 32 - 40 ft. lbs.)
15. Install the extension bar and shift control rod.
16. Install the drain plug.





17. Install the engine mounting member-to-chassis bolts and nuts. (bolt two, four nuts) After tightening the No. 1 & 2 engine mount-to mounting member nuts.
Tightening torque:
Engine mounting member bolt and nuts: 47 - 66 ft. lbs. (64 - 89 Nm, 6.5 - 9.1 kg-m)
No.1 and 2 engine mounting nut: 27 - 38 ft. lbs. (37 - 52 Nm, 3.8 - 5.3 kg-m)
18. Install the splash shields.
19. Install the wheels and tires.
Tightening torque: 88 - 118 Nm (9 - 12 kg-m, 65 - 98 ft. lbs.)
20. Lower vehicle.





21. Remove the engine support bar SST (OK201 170 AAOA).





22. Install three clutch housing bolts.
Tightening torque: 66 - 86 ft. lbs. (89 - 116 Nm, 9.1 - 11.9 kg-m)
23. Install two starter upper bolts.
Tightening torque: 27 - 38 ft. lbs. (37 - 52 Nm, 3.8 - 5.3 kg-m)
24. Install the release lever.
25. Reconnect the crankshaft position sensor connector.
26. Reconnect the ground strap with one bolt.
27. Reconnect the speed sensor connector.
28. Reconnect the back-up switch connector.
29. Reinstall the air cleaner assembly.
30. Reconnect the air temperature sensor connector.
31. Reconnect the MAF sensor connector.
32. Reinstall the fresh air duct.
33. Reconnect positive (first) then negative (last) battery cables.
34. Add gear oil, refer to oil inspection.
35. Test vehicle and check fluid levels.