Damper Installation on Vehicle
1. Remove air induction system.
2. Remove battery.
2.1 Disconnect negative battery cable.
2.2 Disconnect positive battery cable.
2.3 Remove battery hold down bracket fasteners and remove bracket.
2.4 Lift battery out of vehicle and place in a safe location.
3. Remove battery tray.
3.1 Remove battery tray attachment bolts. (One bolt is located in fender well area.)
3.2 Remove PCM attachment bolts and lay PCM aside.
3.3 Unclip battery cables from battery tray.
3.4 Remove battery tray from vehicle.
IMPORTANT:
Do not make the slot any wider than the original width of the hole. Make sure to slot the hole outboard (toward the left front tire if the battery tray was mounted in the vehicle).
4. Modify battery tray front vertical bolt hole.
4.1 Place battery tray in a vice.
4.2 Use a rat-tail file to elongate the front vertical bolt hole. Create an oblong slot that measures 18 mm (23/32 in.) at location (1) shown in illustration. (This is approximately an 8 mm [5/16 in.] increase in the size of the existing bolt hole.)
5. Remove corner of battery tray.
5.1 Refer to illustration and mark location of pilot hole to be drilled.
^ Dimension (1) should be 30 mm (1-3/16 in.)
^ Dimension (2) should be 27 mm (1-1/16 in.)
5.2 Drill a 5 mm (3/16 in.) hole at marked location.
NOTICE:
It is essential to maintain a rounded corner in the cutout section of the battery tray. This rounded corner will help relieve stress at the corner and prevent the battery tray from cracking.
5.3 Use a hacksaw to cut in from the bottom and the side of the battery tray to remove remainder of battery tray corner.
6. Remove transaxle strut. (Refer to "Transaxle Strut" in the Powertrain Mounts section of the 2000-2002 S-Series Chassis Service Manual.)
7. Remove the two transaxle strut bracket fasteners and remove the transaxle strut bracket.
8. Install bench-assembled damper kit by securing it in place with the two transaxle strut bracket fasteners
Torque:
Transaxle Strut Bracket-to-Transaxle
Bolts: 54 N.m (40 ft-lbs)
9. Finger start forward vertical battery tray bolt through the damper kit's upper bracket. Tighten loosely to secure bracket location while making sure that the horizontal hole in the upper bracket aligns with its mating hole in the midrail.
10. Raise vehicle on a hoist.
11. Remove left front wheel and tire assembly.
IMPORTANT:
The hole created in the next two steps will be used to gain access to the inside of the frame rail for installation of the M8 x 20 mm bolt.
12. Refer to illustration and locate the forward hole in frame rail that was used in first design vehicles to secure battery tray to the frame rail.
13. Using a metric or SAE dimension stepped uni-bit, enlarge hole to 17 mm (11/16 in.).
14. To install M8 x 20 mm bolt, use an extension and a 10 mm socket. Use a magnetic socket or secure the bolt in the socket with RTV.
15. Slide bolt, socket and extension through 17 mm or 11/16 in. hole created in a previous step. Slide the bolt through the opposite hole in the inside of the midrail and through the hole in the damper kit's upper bracket.
16. Install M8 nut onto bolt and tighten.
Torque:
Damper Bracket-to-Frame Rail
Fasteners: 30 N.m (22 ft-lbs)
17. Using 3M WIND0-WELD Primer (Black) (P/N 08643) or equivalent, prime edge of 17 mm or 11/16 in. hole enlarged in outside of midrail.
18. Install wheel and tire assembly.
Torque:
Wheel Nuts: 140 N.m (103 ft-lbs)
19. Lower vehicle from hoist.
20. Install transaxle strut to the new modified transaxle strut bracket.
Torque:
Transaxle Strut-to-Transaxle Strut Bracket
Bolt: 70 N.m (52 ft-lbs)
21. Install battery tray and loosely install all three battery tray bolts starting with horizontal bolt.
22. Torque front vertical battery tray bolt.
Torque:
Battery Tray Bolt (Front
Vertical): 20 N.m (15 ft-lbs)
23. Torque rear vertical battery tray bolt.
Torque:
Battery Tray Bolt (Rear Vertical): 10 N.m (89 in-lbs)
24. Torque horizontal battery tray bolt.
Torque:
Battery Tray Bolt (Horizontal): 10 N.m (89 in-lbs)
25. Position PCM to battery tray and install bolts.
Torque:
PCM-to-Battery Tray Bolts: 6 N.m (53 in-lbs)
IMPORTANT:
The damper-to-upper bracket bolt must be properly torqued.
26. Verify damper-to-upper bracket bolt is properly torqued.
Torque:
Damper-to-Upper Bracket
Bolt: 70 N.m (52 ft-lbs)
27. Install transaxle strut-to-frame rail bolt.
Torque:
Transaxle Strut-to-Frame Rail
Bolt: 70 N.m (52 ft-lbs)
28. Install battery.
28.1 Make sure that the battery is in good physical condition (e.g., no cracks, or obvious damage).
28.2 Make sure that battery terminals are clean.
28.3 Make sure the battery cable ends are clean.
28.4 Install battery carefully in the battery tray; make sure that the terminals do not short against any metal during the installation.
28.5 Install battery hold down bracket.
Torque:
Battery Hold Down Bracket
Fasteners: 9 N.m (80 in-lbs)
28.6 Connect positive battery cable.
Torque:
Battery Terminal Bolts: 17 N.m (13 ft-lbs)
28.7 Connect negative battery cable.
Torque:
Battery Terminal Bolts: 17 N.m (13 ft-lbs)
IMPORTANT:
It may be necessary to use a 2 mm thick shim between the forward mounting foot on air cleaner assembly and frame rail.
29. Install air induction system.
30. Road test vehicle to verify that vibration has been corrected.