Removal and Installation
REMOVAL
1. Disconnect battery terminals and then remove battery.
2. Remove air cleaner assembly.
3. Disconnect throttle cable.
Torque: 15 Nm (11 ft. lbs.).
4. Remove cruise control actuator, as follows:
a. Disconnect the connector.
b. Remove the three bolts and the cruise control actuator with the bracket.
5. Remove ground cable.
6. Disconnect vehicle speed sensor connector.
7. Disconnect direct clutch speed sensor connector.
8. Disconnect park/neutral position switch connector.
9. Disconnect solenoid connector.
10. Disconnect shift control cable.
11. Disconnect shift control cable from park/neutral switch. Remove the nut and disconnect shift control cable from park/neutral position switch.
Torque: 15 Nm (11 ft. lbs.).
12. Disconnect oil cooler hose.
13. Remove two engine mounting absorber bolts.
Torque: 48 Nm (35 ft. lbs.).
14. Remove two front side engine mounting bolts.
Torque:
Green color bolt: 66 Nm (48 ft. lbs.).
Silver color bolt: 44 Nm (32 ft. lbs.).
15. Remove starter, as follows:
a. Disconnect the connector and remove the nut.
b. Remove the two bolts, starter and shift control cable clamp.
Torque: 39 Nm (29 ft. lbs.).
16. Remove exhaust manifold bracket mounting bolt.
17. Remove four upper transaxle-to-engine bolts.
Torque: 64 Nm (47 ft. lbs.).
18. Install engine support fixture.
19. Support steering gear housing securely from engine support fixture, as shown.
20. Raise and support vehicle securely.
21. Remove front wheels.
Torque: 103 Nm (76 ft. lbs.).
22. Remove exhaust front pipe, as follows:
a. Remove the bolts and the exhaust front pipe stay.
Torque: 33 Nm (24 ft. lbs.).
b. Remove the four nuts.
Torque: 62 Nm (46 ft. lbs.).
INSTALLATION NOTICE: Replace used gaskets and nuts with new gaskets and nuts.
c. Remove the two bolts and exhaust front pipe support bracket.
Torque: 33 Nm (24 ft. lbs.).
d. Remove the two bolts, nuts, three gaskets and the exhaust front pipe.
Torque: 56 Nm (41 ft. lbs.).
INSTALLATION NOTICE: Replace the used nuts and three gaskets with new nuts and three gaskets.
23. Remove differential fluid drain plug and gasket.
INSTALLATION NOTICE: Replace used gasket with a new gasket.
24. Drain differential fluid into a suitable container.
25. Remove right and left hand engine side cover No. 2.
26. Remove engine under front cover No. 1 and No. 2.
27. Remove drive shafts.
28. Remove front side engine mounting insulator nut.
Torque:
Green color bolt: 66 Nm (48 ft. lbs.).
Silver color bolt: 44 Nm (32 ft.lbs.).
29. Disconnect shift control cable. Remove clip and disconnect shift control cable from bracket.
30. Remove rear side engine mounting nuts, as follows:
a. Remove the two grommets.
b. Remove the four nuts.
Torque: 66 Nm (48 ft. lbs.).
31. Remove four left side transaxle mounting bolts.
Torque: 64 Nm (47 ft. lbs.).
32. Remove steering gear housing, as follows:
a. Remove the four bolts and disconnect the stabilizer bar bushing bracket from the front frame assembly.
Torque: 19 Nm (14 ft. lbs.).
b. Remove the two steering gear housing mounting bolts and nuts.
Torque: 181 Nm (134 ft. lbs.).
33. Remove front frame assembly. as follows:
a. Hold the front frame assembly with a jack.
b. Remove the two set screws from the right and left fender liners.
c. Remove the two bolt and steering return pipe mounting brackets.
Torque: 10 Nm (84 inch lbs.).
d. Remove the six bolts and four nuts.
Torque:
19 mm head bolt: 181 Nm (134 ft. lbs.).
14 mm head bolt: 32 Nm (24 ft. lbs.).
Nut: 36 Nm (27 ft. lbs.).
e. Remove the front frame assembly.
34. Hold transaxle with a transmission jack.
35. Remove torque converter clutch mounting bolts, as follows:
a. Remove the two bolts and hole cover.
b. Turn the crankshaft to gain access to each bolt, remove the six bolts with holding the crankshaft pulley set bolt by a wrench.
Torque: 41 Nm (30 ft. lbs.).
INSTALLATION NOTE: First install the dark green colored bolt and then the five other bolts.
36. Remove exhaust manifold plate mounting nut.
Torque: 20 Nm (14 ft. lbs.).
37. Remove four transaxle to engine bolts.
Torque:
12 mm head bolt: 64 Nm (47 ft. lbs.).
10 mm head bolt: 46 Nm (34 ft. lbs.).
38. Remove and separate transaxle and engine, and lower transaxle.
39. Remove torque converter clutch from transaxle.
TORQUE CONVERTER CLUTCH AND DRIVE PLATE INSPECTION
1. Inspect one-way clutch, as follows:
a. Install Special Service Tool (SST) 09350-32014 (09351-32010) or equivalents into the inner race of the one-way clutch.
b. Install SST 09350-32014 (09351-32020) or equivalents so that it fits in the notch of the converter hub and outer race of the one-way clutch.
c. With the torque converter clutch standing on its side, the clutch locks when turned counterclockwise, and rotates freely and smoothly clockwise. If necessary, clean the converter and retest the clutch. Replace the torque converter clutch if the clutch still fails the test.
2. Measure drive plate runout and inspect ring gear. Set up a dial indicator, then measure the drive plate runout.
Maximum runout: 0.20 mm (0.0079 inch).
If the runout is not within the specification or if the ring gear is damaged, replace the drive plate. If installing a new drive plate, note the orientation of spacers and tighten the bolts.
Torque: 83 Nm (61 ft. lbs.).
3. Measure torque converter clutch sleeve runout. Temporarily mount the torque converter clutch to the drive plate. Set up a dial indicator, measure the torque converter clutch sleeve runout.
Maximum runout: 0.30 mm (0.0118 inch).
If the runout is not within the specification, try to the correct by reorienting the installation of the converter.
NOTE: Mark the position of the torque converter clutch to ensure the correct installation.
TORQUE CONVERTER INSTALLATION
Check the torque converter clutch installtion. Using calipers and a straight edge, measure from the installed surface to the front surface of the transaxle housing.
Correct distance: More than 13.7 mm (0.539 inch).
TRANSAXLE INSTALLATION
Installation is in the reverse order of removal.
NOTE: After installation, check and inspect these items as follows:
^ Fluid Level.
^ Front wheel alignment.
^ Road test the vehicle.