Installation
INSTALLATION - 2.5L Turbo Diesel1. Assemble transaxle to engine, while aligning transaxle input shaft to clutch disc splines.
2. Install and torque transaxle-to-engine bolts to 95 Nm (70 ft. lbs.) (Fig. 82).
3. Install transaxle upper mount (Fig. 83). Install and torque four (4) mount-to-transaxle bolts to 54 Nm (40 ft. lbs.).
4. Raise transaxle/engine assembly into position and install upper mount through-bolt. Torque through-bolt to 75 Nm (55 ft. lbs.).
5. Remove screw jack.
6. Connect back-up lamp switch connector.
7. Install starter motor into position (Fig. 84). Install and torque bolts to 54 Nm (40 ft. lbs.).
8. Install engine front mount bracket. Install and torque bracket-to-transaxle bolts to 102 Nm (75 ft. lbs.). Install and torque bracket-to-engine bolts to 68 Nm (50 ft. lbs.). Torque through-bolt and nut to 68 Nm (50 ft. lbs.).
9. Install clutch slave cylinder into position, noting orientation of different sized lugs (Fig. 85). While depressing inward, rotate slave cylinder clockwise 60° into position until nylon locating tab rests within transaxle case cutout, and hydraulic tube is vertical. Connect "quick-connect" connection until an audible "click" is heard. Verify connection by pulling outward on connection.
10. Install underbody splash panel.
11. Install halfshafts and front wheel/tire assemblies.
12. Lower vehicle.
13. Install right mount bracket to transaxle (Fig. 86).
14. Connect gearshift cables to shift levers/cover assembly (Fig. 87). Install cables into position at mount bracket and secure with retaining clips.
15. Install coolant recovery bottle bracket (Fig. 88).
16. Install coolant recovery bottle to bracket.
17. Connect battery temperature sensor and install battery tray (Fig. 89).
18. Install battery, hold-down clamp and nut (Fig. 90).
19. Install battery thermal shield and clutch cable eyelet (Fig. 91).
20. Connect battery cables.
21. Check transaxle fluid and engine coolant levels. Adjust if necessary.