Repair Procedures
Removal
- Use fender covers to avoid damaging painted surfaces.
- To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
- Mark all wiring and hoses to avoid misconnection.
1. Remove the air cleaner assembly and the intake hose by removing the bolts and the clamps.
2. Remove the ECU by removing the bolts(2ea) and a nut.
3. Remove the battery (A).
4. Remove the battery tray by removing the bolts(3ea).
5. Disconnect the vehicle speed sensor connector (A) and the back lamp switch connector (B).
6. Remove the ground wire by removing a bolt.
7. Remove the snap pins (A) and clips (B).
8. Remove the control cable bracket by removing bolts(3ea).
9. Using the special tool (09200-38001), support the engine assembly safely.
10. Remove the transaxle upper mounting bolts (A-2ea) and the starter motor mounting bolts (B-2ea).
11. Remove the transaxle support bracket bolts (A-3ea,B-3ea).
12. Lifting up the vehicle.
13. Remove the front wheels and tires.
14. 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)
15. Remove the under shield cover.
16. Drain the transaxle fluid by removing the drain plug.
17. Disconnect the drive shafts from the transaxle. (refer to Front Driveshaft in DS group)
18. Remove the CKP sensor (A) by removing a bolt.
19. Remove the roll stopper bracket by removing bolts(A-1ea,B-2ea).
20. Remove the clutch release cylinder assembly.
21. Remove the bolt left in the engine side.
22. Supporting the transaxle with a jack, remove the transaxle lower mounting bolts(A-3ea, B-1ea).
23. Lowering the jack slowly, remove the transaxle.
Installation
1. Install the transaxle lower mounting bolts (A-3ea,B-1ea) after fitting the transaxle assembly into the engine assembly.
Tightening torque :
[A] 35 - 50 Nm (3.5 - 5.0 kgf.m, 25.3 - 36.2 lb-ft)
[B] 43 - 55 Nm (4.3 - 5.5 kgf.m, 31.1 - 39.8 lb-ft)
2. Install the bolt left in the engine side.
Tightening torque :
43 - 55 Nm (4.3 - 5.5 kgf.m, 31.1 - 39.8 lb-ft)
3. Install the clutch release cylinder assembly.
Tightening torque :
15 - 22 Nm (1.5 - 2.2 kgf.m, 10.8 - 15.9 lb-ft)
4. Install the roll stopper bracket by installing bolts(A-1ea,B-2ea).
Tightening torque :
[A] 90 - 110 Nm (9 - 11 kgf.m, 65 - 79 lb-ft)
[B] 50 - 65 Nm (5.0 - 6.5 kgf.m, 36.2 - 47.0 lb-ft)
5. Install the CKP sensor (A) by installing a bolt.
6. Connect the drive shafts to the transaxle. (refer to Front Driveshaft in DS group)
7. Refill the transaxle fluid through the filler hole. (refer to Service Adjustment Procedure)
8. Install the under shield cover.
9. Install the lower arm ball joint mounting nut and the stabilizer link mounting nut to the front knuckles.
(refer to Front suspension system in SS group)
10. Install the front wheels and tires. (refer to installation in SS group)
11. Install the transaxle support bracket bolts (A-3ea,B-3ea).
Tightening torque :
[A] 70 - 95 Nm (7.0 - 9.5 kgf.m, 50.6 - 68.7 lb-ft)
[B] 60 - 80 Nm (6.0 - 8.0 kgf.m, 43.4 - 57.9 lb-ft)
12. Install the transaxle upper mounting bolts (A-2ea) the starter motor mounting bolts (B-2ea).
Tightening torque :
[A] 60 - 80 Nm (6.0 - 8.0 kgf.m, 43.4 - 57.9 lb-ft)
[B] 39 - 60 Nm (3.9 - 6.0 kgf.m, 28.2 - 43.4 lb-ft)
13. Put aside the engine support fixture (09200-38001).
14. Install the control cable bracket by installing bolts(3ea).
Tightening torque :
15 - 22 Nm (1.5 - 2.2 kgf.m, 10.8 - 15.9 lb-ft)
15. Install the clips (B) and pins (A).
16. Install the ground wire by installing a bolt.
17. Connect the vehicle speed sensor connector (A) and the back lamp switch connector (B).
18. Install the battery tray by installing the bolts(3ea).
19. Install the battery (A).
20. Install the ECU by installing the bolts(2ea) and a nut.
21. Install the air cleaner assembly and the intake hose by installing the bolts and the clamps.