Repair procedures

Removal

1. Remove the battery (A).




2. Remove the intake air hose and air cleaner assembly.




3. Remove the battery tray(A).




4. Remove the ground wire by removing a bolt.




5. Remove the clutch release cylinder assembly.




6. Disconnect the vehicle speed sensor connector(A) and the back lamp switch connector (B).




7. Remove the snap pin(A) and control cable bracket bolts(B-3ea).




8. Remove the power pump hose bolt(A).




9. Using the special tool (09200-38001), support the engine assembly safely.
10. Remove the steering column shaft bolt. (refer to ST group)
11. Remove the transaxle support bracket bolts(A-3ea).




12. Remove the transaxle upper mounting bolts (A-2ea) and the starter motor mounting bolt(B-2ea).








13. Lifting up the vehicle.
14. Remove the power steering return hose(A).




15. Remove the under cover(A).




16. Drain the transaxle fluid by removing the drain plug.




17. Remove the front wheels and tires.
18. Remove the lower arm ball joint mounting nut and the stabilizer link mounting nut from the front knuckles. (refer to Front suspension system in SS group)
19. Remove the side cover.
20. Disconnect the drive shafts from the transaxle.(refer to DS group)
21. Remove the front roll stopper mounting bolt(A).




22. Remove the rear roll stopper mounting bolt(A).




23. Disconnect the muffler hanger rubber(A).




24. Supporting the sub frame (A) with a jack and the Special tool (09624-38000), remove the mounting bolts.(refer to SS group)




25. Remove the transaxle lower mounting bolts(A).




26. Remove the transaxle assembly by lifting vehicle.

CAUTION:
When removing the transaxle assembly, be careful not to damage any surrounding parts or body components.

Installation

1. Install the transaxle lower mounting bolts (A-3ea) after fitting the transaxle assembly into the engine assembly.

Tightening torque :
35 - 50Nm (3.5 - 5.0kgf.m, 25.3 - 36.2lb-ft)





2. Supporting the sub frame (A) with a jack and the Special tool(09624-38000), install the mounting bolts. (refer to SS group)




3. Install the muffler hanger rubber (A).




4. Install the rear roll stopper mounting bolt(A).




5. Install the front roll stopper mounting bolt(A).




6. Connect the drive shafts from the transaxle.(refer to DS group)
7. Install the side cover.
8. Install the lower arm ball joint mounting nut, the stabilizer link mounting nut, and the tie rod end mounting nut to the front knuckles. (refer to Front suspension system in SS group)
9. Install the front wheels and tires.
10. Install the under cover(A).




11. Install the power steering return hose(A).




12. Remove the transaxle upper mounting bolts (A-2ea) and the starter motor mounting bolts (B-2ea).








13. Remove the transaxle support bracket bolts (A-3ea).




14. Install the steering column shaft bolt. (refer to ST group)
15. Remove the special tool (09200-38001).
16. Install the power pump hose bolt(A).




17. Install the snap pin(A) and control cable bracket bolts(B-3ea).




18. Connect the vehicle speed sensor connector(A) and the back lamp switch connector (B).




19. Install the clutch release cylinder assembly(A).




20. Install the ground wire by removing a bolt.




21. Install the battery tray(A).




22. Install the intake air hose and air cleaner assembly.




23. Install the battery (A).




24. After completing the installation perform the following procedure;
A. Adjust the shift cable.
B. Refill the transaxle fluid.
C. Clean the battery posts and cable terminals with sandpaper and grease them to prevent corrosion before installing.