Repair Procedures (A5HF1)

Removal

CAUTION:
- Use fender covers to avoid damaging painted surfaces.
- To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

NOTE:
- Mark all wiring and hoses to avoid misconnection.
- Turn the crankshaft pulley so that the No.1 piston is at top dead center.

1. Disconnect the negative terminal from the battery.
2. Remove the engine cover.
3. Remove the air duct.
4. Remove the intake air hose and air cleaner assembly.
(1) Disconnect the AFS connector.
(2) Disconnect the breather hose from air cleaner hose.
(3) Disconnect the PCM connectors.
(4) Remove the intake air hose and air cleaner (A).




5. Remove the front wheels.
6. Remove the under cover(A).




7. Drain the engine coolant and remove the radiator cap to speed up draining.
8. Remove the upper radiator hose and the lower radiator hose(A).




9. Remove transaxle oil cooler hose(A).




10. Remove engine wiring.
(1) Disconnect RH oxygen sensor connector(A).




(2) Disconnect LH front oxygen sensor connector(A).




(3) Disconnect LH rear oxygen sensor connector(A) and CPS connector(B).




11. Disconnect the transaxle wire harness connector and remove transaxle control cable.
(1) Remove the wiring brackets(A, B).








(2) Remove the inhibitor switch connector(A) and shift cable(B).




(3) Remove the solenoid valve connector(A).




(4) Remove the input speed sensor, output speed sensor(A).




12. Disconnect EPS connector.
13. Remove power steering pump hose(A).




14. Using the SST(09200-38001), hold the engine and transaxle assembly safely.
15. Drain transaxle oil.
16. Remove lower arm ball joint.
17. Remove tie rod end ball joint.
18. Remove stabilizer bar link.
19. After removing a split pin and nut from the steering bar tie rod, disconnect it.
20. Remove front roll stopper mounting bolt.
21. Remove rear roll stopper mounting bolt.
22. Remove steering u-joint mounting
23. Remove front exhaust pipe.
24. Supporting the cross member(A) with a jack, remove the stays(B) with the mounting bolts.




25. Remove the cross member.
26. Remove drive shaft from transaxle.
27. Install a jack for supporting the transaxle assembly.
28. Remove the transaxle mounting bolts(A, B, C).








29. Lower the vehicle and remove the transaxle mounting bracket.
30. Jack up the vehicle and disassemble the transaxle assembly.

Installation

Installation is in the reverse order of removal.
Perform the following :
- Adjust the shift cable.
- Adjust the throttle cable.
- Refill the engine with engine oil.
- Refill the transaxle with fluid.
- Refill the radiator with engine coolant.
- Bleed air from the cooling system with the heater valve open.
- Clean the battery posts and cable terminals with sandpaper, assemble them, and apply grease to prevent corrosion.
- Inspect for fuel leakage.
After assembling the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump runs for approximately two seconds and fuel line pressurizes.
Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.