Removal and Installation

TRANSAXLE REMOVAL




1. Remove battery and air cleaner case assembly with air hose.




2. Remove clutch release cylinder and line.
Remove the 2 set bolts of the clutch line bracket.

Torque: 4.9 Nm (50 kgf/cm, 43 in.lbs.)

Remove the 2 bolts and release cylinder and line.

Torque: 12 Nm (120 kgf/cm, 9 ft.lbs.)

3. Disconnect back-up light switch connector.
4. Disconnect control cable.
a. Remove the 2 clips and washers.
b. Remove the 2 clips from the cables.




5. Remove starter set bolt.
Remove the 2 set bolts of the starter from the transaxle upper side.

Torque: 39 Nm (400 kgf/cm, 29 ft.lbs.)

6. Remove transaxle mounting bolt.
Remove the 3 bolts of transaxle upper side.

Torque: 17 mm head: 64 Nm (650 kgf/cm, 47 ft.lbs.)




7. Disconnect ground cable.
Remove the 2 set bolts of the ground cable.




8. Install engine support fixture.
9. Remove front wheel.

Torque: 103 Nm (1,050 kgf/cm, 76 ft.lbs.)

10. Raise vehicle.

NOTE: Make sure that the vehicle is securely supported.

11. Remove LH and RH engine under covers.




12. Drain transaxle oil.

Oil grade: API GL-4 or GL-5
Viscosity: SAE 75W-90
Capacity: 1.9 liters (2.0 US Qts, 1.7 Imp. Qts)
Torque: 39 Nm (400 kgf/cm, 29 ft.lbs.)

13. Remove LH and RH drive shafts.
14. Remove front exhaust pipe.
a. Disconnect the oxygen sensor connector.
b. Remove the 2 bolts, springs and gasket from the exhaust manifold.

Torque: 62 Nm (630 kgf/cm, 46 ft.lbs.)

c. Remove the bolt, clamp and gasket.

Torque: 19 Nm (190 kgf/cm, 14 ft.lbs.)

d. Disconnect the pipe from the 2 rings and remove it.




15. Remove engine rear mounting insulator.
a. Remove the 4 set bolts of the stabilizer bar bracket.

Torque: 19 Nm (195 kgf/cm, 14 ft.lbs.)

b. Disconnect the stabilizer bar from the body.
Remove the 8 bolts, left and right steering member braces and insulator.

Torque:
- Bolt A: 90 Nm (920 kgf/cm, 67 ft.lbs.)
- Bolt B: 78 Nm (800 kgf/cm, 58 ft.lbs.)




- Bolt C: 64 Nm (650 kgf cm, 47 ft lbs.)

16. Remove intake manifold stay.

Remove the bolt, nut and stay.

Torque: 20 Nm (200 kgf/cm, 14 ft.lbs.)

17. Remove starter.
Disconnect the connector and wire and remove the starter.
18. Disconnect speedometer cable.
19. Jack up transaxle slightly.
Using a transmission jack, support the transaxle.




20. Disconnect engine left mounting bracket from engine left mounting insulator.
Remove the 2 bolts.

Torque: 48 Nm (490 kgf/cm, 35 ft.lbs.)




21. Remove transaxle lower side mounting bolt.
Remove the 4 bolts.

Torque:
- 14 mm head A: 46 Nm (470 kgf/cm, 34 ft.lbs.)
- 14 mm head B: 24 Nm (240 kgf/cm, 17 ft.lbs.)
- 10 mm head: 7.4 Nm (75 kgf/cm, 65 in.lbs.)




22. Remove transaxle.
Lower the engine left side and remove the transaxle from the engine.

NOTE:
- Align the input shaft with the clutch disc and install the transaxle to the engine.

Install and torque the 7 bolts.

Torque:
- Upper side mounting bolts:
- 17 mm head: 64 Nm (650 kgf/cm, 47 ft.lbs.)
- Lower side mounting bolts:
- 14 mm head A: 46 Nm (470 kgf/cm, 34 ft.lbs.)
- 14 mm head B: 24 Nm (240 kgf/cm, 17 ft.lbs.)
- 10 mm head: 7.4 Nm (75 kgf/cm, 65 in.lbs.)



TRANSAXLE INSTALLATION
Installation is in the reverse order of removal.

NOTE: After installation, check and inspect items as follows.
- Front wheel alignment.
- Do the road test.