Removal and Installation
REPLACEMENT1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
2. SEPARATE STEERING INTERMEDIATE SHAFT
3. REMOVE FRONT WHEELS
4. REMOVE ENGINE UNDER COVER LH
5. REMOVE ENGINE UNDER COVER RH
6. REMOVE EXHAUST PIPE
7. DRAIN TRANSAXLE OIL
8. REMOVE HOOD SUB-ASSY
9. REMOVE CYLINDER HEAD COVER No. 2
a. C59 T/M: Remove the 2 nuts caps, clips and No. 2 cylinder head cover.
b. C60 T/M: Remove the 3 bolts, nut and No. 2 cylinder head cover.
10. REMOVE AIR CLEANER ASSY
11. REMOVE BATTERY CLAMP SUB-ASSY
12. REMOVE BATTERY
13. REMOVE BATTERY TRAY
14. REMOVE BATTERY CARRIER
a. Remove the 4 bolts and battery carrier.
15. REMOVE CRUISE CONTROL ACTUATOR ASSY (W/ CRUISE CONTROL)
16. DISCONNECT WIRE HARNESS
a. Disconnect the wire harness clamp.
b. Remove the 2 bolts and disconnect the 2 wire harness brackets.
c. Remove the 2 bolts and 2 ground cables.
17. DISCONNECT CONNECTOR
a. Disconnect the back-up lamp switch connector.
b. w/o ABS: Disconnect the speed sensor connector.
18. SEPARATE CLUTCH RELEASE CYLINDER ASSY
a. Remove the 5 bolts, separate the release cylinder assy with clutch piping from the transaxle.
19. SEPARATE FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT
a. Remove the clip, washer and disconnect the shift cable from the transaxle.
b. Remove the clip and disconnect the shift cable from the bracket.
20. SEPARATE FLOOR SHIFT CABLE TRANSMISSION CONTROL SELECT
a. Remove the clip, washer and disconnect the select cable from the transaxle.
b. Remove the clip and disconnect the select cable from the bracket.
21. REMOVE STARTER ASSY
a. Remove the nut and disconnect the starter wire.
b. Disconnect the connector.
c. Remove the 2 bolts and starter assy.
22. DISCONNECT TIE ROD END SUB-ASSY LH
SST 09628-62011
23. DISCONNECT TIE ROD END SUB-ASSY RH
SST 09628-62011
24. DISCONNECT PRESSURE FEED TUBE ASSY
SST 09023-38400
25. DISCONNECT RETURN TUBE SUB-ASSY
SST 09023-38400
26. REMOVE FRONT DRIVE SHAFT ASSY LH
SST 09520-01010, 09520-24010 (09520-32040)
27. REMOVE FRONT DRIVE SHAFT ASSY RH
SST 09520-01010, 09520-24010, (09520-32040)
28. SUSPEND ENGINE ASSY
a. Remove the 2 PCV hoses.
b. C59 T/M: Install the N0. 1 and N0. 2 engine hangers in the correct direction.
Parts No.:
No. 1 engine hanger: 12281-22021
No. 2 engine hanger: 12281-15040
Bolt: 91512-B1016
Torque: 38 Nm (387 kgf-cm, 28 ft. lbs.)
c. C60 T/M: Install the No. 1 and No. 2 engine hangers in the correct direction.
Parts No.:
No. 1 engine hanger: 12281-88600
No. 2 engine hanger: 12282-88600
Bolt: 91512-61020
Torque: 38 Nm (387 kgf-cm, 28 ft. lbs.)
d. Attach the engine chain hoist to the hangers.
CAUTION: Do not attempt to hang the engine by hooking the chain to any other oars.
29. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSY
30. SUPPORT MANUAL TRANSAXLE ASSY
a. Support the transaxle with a transmission lack.
31. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR
a. Remove the 5 bolts, nut and engine mounting insulator LH from the body.
32. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
a. Remove the 3 bolts and engine mounting bracket LH from the transaxle.
33. REMOVE MANUAL TRANSAXLE ASSY
a. Remove the 6 bolts and transaxle from the engine.
34. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
a. Remove the bolt, nut and engine mounting insulator FR from the engine mounting bracket FR.
b. Remove the 2 bolts and engine mounting bracket FR from the transaxle.
35. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
a. Remove the bolt and engine mounting insulator RR from the engine mounting bracket RR.
b. Remove the 3 bolts and engine mounting bracket RR from the transaxle.
36. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
a. Install the engine mounting bracket RR and 3 bolts to the transaxle.
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)
b. Install the engine mounting insulator RR and bolt to the engine mounting bracket RR.
Torque: 87 Nm (888 kgf-cm, 64 ft. lbs.)
37. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
a. Install the engine mounting bracket FR and 2 bolts to the transaxle.
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)
b. Install the engine mounting insulator FR, bolt and nut to the engine mounting bracket FR.
Torque: 52 Nm (530 kgf-cm, 38 ft. lbs.)
38. INSTALL MANUAL TRANSAXLE ASSY
a. Align the input shaft with the clutch disc and install the transaxle to the engine.
b. Install the 6 bolts.
Torque:
Bolt A: 64 Nm (650 kgf-cm, 47 ft. lbs.)
Bolt B: 47 Nm (480 kgf-cm, 35 ft. lbs.)
Bolt C: 23 Nm (230 kgf-cm, 17 ft. lbs.)
39. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
a. Install the engine mounting bracket LH to the transaxle with the 3 bolts.
Torque: 52 Nm (530 kgf-cm, 38 ft. lbs.)
40. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR
a. Install the engine mounting insulator LH with the 5 bolts and nut.
Torque:
Bolt A: 52 Nm (530 kgf-cm, 38 ft. lbs.)
Bolt B: 80 Nm (816 kgf-cm, 59 ft. lbs.)
41. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSY
SST 09670-00010
42. INSTALL FRONT DRIVE SHAFT ASSY LH
43. INSTALL FRONT DRIVE SHAFT ASSY RH
44. CONNECT RETURN TUBE SUB-ASSY
SST 09023-38400
45. CONNECT PRESSURE FEED TUBE ASSY
SST 09023-38400
46. CONNECT TIE ROD END SUB-ASSY LH
47. CONNECT TIE ROD END SUB-ASSY RH
48. INSTALL STARTER ASSY
a. Install the starter assy and 2 bolts to the transaxle.
Torque: 37 Nm (378 kgf-cm, 27 ft. lbs.)
b. Connect the starter connector.
c. Install the wire and nut to starter assy.
Torque: 9.8 Nm (100 kgf-cm, 87 ft. lbs.)
49. CONNECT FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT
a. Connect the shift cable end, and install the washer and clip.
50. FLOOR SHIFT CABLE TRANSMISSION CONTROL SELECT
a. Connect the select cable end, and install the washer and clip.
51. CONNECT CLUTCH RELEASE CYLINDER ASSY
a. Install the release cylinder with the 5 bolts.
Torque:
Bolt A: 25 Nm (250 kgf-cm, 19 ft. lbs.)
Bolt B: 12 Nm (120 kgf-cm, 9 ft. lbs.)
Bolt C: 5.0 Nm (51 kgf-cm, 44 ft. lbs.)
52. CONNECT CONNECTOR
a. Connect the back-up lamp switch connector.
b. w/o ABS: Connect the speed sensor connector.
53. CONNECT WIRE HARNESS
a. Install the 2 wire harness clamps to the transaxle with the 2 bolts.
Torque:
Bolt A: 25.5 Nm (260 kgf-cm, 19 ft. lbs.)
Bolt B: 12.8 Nm (131 kgf-cm, 9 ft. lbs.)
1) Connect the wire harness clamp.
b. Install the 2 bolts and 2 ground cables.
Torque: 13 Nm (133 kgf-cm, 10 ft. lbs.)
54. INSTALL CRUISE CONTROL ACTUATOR ASSY (W/ CRUISE CONTROL)
55. INSTALL BATTERY CARRIER
a. Install the battery carrier and 4 bolts.
Torque: 13 Nm (133 kgf-cm, 10 ft. lbs.)
56. INSTALL BATTERY TRAY
57. INSTALL BATTERY
58. INSTALL BATTERY CLAMP SUB-ASSY
Torque:
Bolt: 5.0 Nm (51 kgf-cm, 44 inch lbs.)
Nut: 3.5 Nm (36 kgf-cm, 31 inch lbs.)
59. INSTALL AIR CLEANER ASSY
Torque: 7.0 Nm (71 kgf-cm, 62 inch lbs.)
60. INSTALL CYLINDER HEAD COVER No. 2
Torque: 7.0 Nm (71 kgf-cm, 62 inch lbs.)
61. INSTALL HOOD SUB-ASSY
Torque: 13 Nm (133 kgf-cm, 10 ft. lbs.)
62. INSPECT HOOD SUB-ASSY
63. ADJUST HOOD SUB-ASSY
64. ADD TRANSAXLE OIL
65. INSPECT TRANSAXLE OIL
66. INSTALL FRONT WHEELS
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
67. INSTALL STEERING COLUMN HOLE COVER SUB-ASSY No. 1
68. CONNECT STEERING INTERMEDIATE SHAFT
69. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
70. CENTER SPIRAL CABLE
71. STEERING WHEEL CENTER POINT
72. INSTALL EXHAUST PIPE
73. INSTALL ENGINE UNDER COVER LH
74. INSTALL ENGINE UNDER COVER RH
75. INSPECT FRONT WHEEL ALIGNMENT
76. CHECK ABS SPEED SENSOR SIGNAL