Repair Procedures (M5GF2)

REMOVAL

1. Remove the battery(A).




2. Remove the engine cover(A).




3. Disconnect the air flow sensor(AFS) connector(A) and ECU connector(B).




4. Remove the air cleaner assembly(A).




5. Remove the battery tray(A).




6. Remove the ground circuit line(A) from the transaxle.




7. Disconnect the vehicle speed sensor.
8. Disconnect the shift cable assembly(A).




9. Disconnect the back up lamp switch(A).




10. Disconnect the related connectors to transaxles.
11. After removing the clip(B) with clamping(A) the concentric slave cylinder tube, disconnect the tube(C).




12. Drain the power steering fluid and disconnect the power steering pressure hose(A) bolt(B).




13. Install the SST(09200-38001), the engine support fixture and the adapter on the engine and transaxle assembly.




14. Remove the under shield cover(A).




15. Drain the manual transaxle fluid after removing the transaxle drain plug(A). It can be easier when the oil filler plug(B) is removed.




16. Disconnect the electronic power steering connector.
17. Remove the lower arm ball joint and folk mounting bolts.
18. Remove the lower arm ball joint assembly mounting bolts.
19. Remove the stabilizer bar link mounting bolts.
20. After removing a split pin and nut from the steering bar tie rod, disconnect it.
21. Loosening the power steering return hose(A) clamp(B), disconnect the hose.




22. Disconnect the bracket(B) from the front roll stopper(A).




23. Disconnect the bracket(B) from the rear roll stopper(A).




24. Remove the steering column bolt.
25. Remove the transaxle lower mounting bolts(A).








26. After disconnecting the exhaust pipe(A), disconnect the hanger(B) and the oxygen sensor connector(C).




27. Supporting the cross member(A) with a jack, remove the stay(C) with the mounting bolts(B).












28. Disconnect the driveshafts(A) from the transaxle(B) .



29. Supporting the transaxle with a jack, remove the transaxle support bracket(A) and the upper mounting bolts(B).








30. Lowering the jack slowly, remove the transaxle.

INSTALLATION

1. Raising the jack slowly, tighten the transaxle mounting bolts(A) and support bracket mounting bolts(B).

TORQUE : 42.2-53.9Nm (430-550kgf.cm, 31.1-39.8lb-ft) (Support bracket mounting)59.2-78.9Nm (600-800kgf.cm, 43.6-58.2lb-ft) (Transaxle mounting bracket)








2. Tighten the transaxle lower mounting bolts.
3. Install the driveshafts.
4. Lifting the cross member up with the jack slowly, tighten the mounting bolts.

TORQUE : 137.3-156.9Nm (1400-1600kgf.cm, 101.3-115.7lb-ft) (Front mounting)(A)





TORQUE : 137.3-156.9Nm (1400-1600kgf.cm, 101.3-115.7lb-ft) (Rear mounting)(B)44.1-58.8Nm (450-600kgf.cm, 32.5-43.4lb-ft) (Stay mounting)(C)

TORQUE : 137.3-156.9Nm (1400-1600kgf.cm, 101.3-115.7lb-ft) (Front mounting)(A)




5. Tighten the steering column bolt.

TORQUE : 17.7-24.5Nm (180-250kgf.cm, 13.0-18.1lb-ft)

6. Assembling the exhaust pipe, connect the hanger and oxygen sensor connector.
7. Fix the front/rear roll stopper(A) to brackets(B) with the mounting bolts.

TORQUE : 49.0-63.7Nm (500-650kgf.cm, 36.2-47.0lb-ft)








8. Inserting the power steering return hose(A), fix it with a clamp(B).




9. Tightening the steering bar tie rod mounting nut, insert a new split pin.

TORQUE : 23.5-33.3Nm (240-340kgf.cm, 17.4-24.6lb-ft)

10. Tighten the stabilizer bar link mounting bolt.

TORQUE : 98.1-117.7Nm (1000-1200kgf.cm, 72.3-86.8lb-ft)

11. Fix the lower arm ball joint assembly to the front axle.

TORQUE : 98.1-117.7Nm (1000-1200kgf.cm, 72.3-86.8lb-ft)

12. Connect the electronic power steering connector.
13. After tightening the transaxle drain plug and filling the manual transaxle fluid, tighten the oil filler plug.

TORQUE : 29.4-34.3Nm (300-350kgf.cm, 21.7-25.3lb-ft)

Manual transaxle fluid: SAE 75W/85

TORQUE : 29.4-34.3Nm (300-350kgf.cm, 21.7-25.3lb-ft)

14. Install the under shield cover(A).




15. After tightening the power steering pressure hose(A) bolt(B), fill the power steering fluid.

TORQUE : 63.7-73.5Nm (650-750kgf.cm, 47.0-54.2lb-ft)




16. Install a clip on the concentric slave cylinder tube and push it till a 'click' sound is heard. Loosen the clamp.
17. Tighten the back up lamp switch(A).




18. Install the shift cable assembly(A).




19. Fix the vehicle speed sensor and the ground line.
20. Install the ground circuit line(A) from the transaxle.




21. Install the battery tray(A).




22. Install the air cleaner assembly(A).




23. Install the air flow sensor(AFS) connector(A) and ECU connector(B).




24. Install the engine cover(A).




25. Install the battery(A).