Installation

TRANSAXLE - 2.3L INSTALLATION

Note
^ Carry out the transaxle fluid cooler backflushing and cleaning if the transaxle is being overhauled or if installing a new or remanufactured transaxle.

Note
^ Carry out the transaxle fluid cooler flow test if the transaxle is being overhauled or if installing a new or remanufactured transaxle.

Installation

All Vehicles

1. Lubricate the torque converter pilot hub with grease.
2. Rotate the torque converter to place the paint dot in the 6 o'clock position.
3. Install the special tool.

4. Position the transaxle in place.

5. Once the transaxle is in place, prior to bolting it to the engine, remove the special tool.

6. Move the transaxle assembly toward the engine assembly and install the 4 bolts.
^ Tighten to 48 N-m (4.8 kgf-m, 35 ft-lbf).
7. Install the transaxle retaining bolts.

^ Tighten to 48 N-m (4.8 kgf-m, 35 ft-lbf).
8. Install the 4 new torque converter nuts.

^ Tighten to 40 N-m (4.0 kgf-m, 30 ft-lbf).

Caution
^ Do not drop the torque converter nuts in the torque converter housing or the transaxle will have to be removed to retrieve them.

9. Install the transaxle fluid cooler tube.

^ Tighten to 25 N-m (2.5 kgf-m, 18 ft-lbf).
10. Install the output shaft speed (OSS) sensor.

^ Tighten to 12 N-m (1.2 kgf-m, 9 ft-lbf).
11. Install the fluid cooler tube.

(1) Connect the OSS sensor.
(2) Connect the turbine shaft speed (TSS) sensor (white connector).
1) Connect the wiring harness retainer to the transaxle case.
(3) Install the fluid cooler tube.
1) Tighten to 25 N-m (2.5 kgf-m, 18 ft-lbf).
(4) Install the fluid cooler bolt.
1) Tighten to 12 N-m (1.2 kgf-m, 9 ft-lbf).
12. Install the starter motor isolator.

13. Install the starter motor.

^ Tighten to 35 N-m (3.5 kgf-m, 26 ft-lbf).
14. Install the starter motor harness connector.

(1) Install the starter motor solenoid battery nut.
1) Tighten to 12 N-m (1.2 kgf-m, 9 ft-lbf).
(2) Install the starter motor solenoid nut.
1) Tighten to 5 N-m (0.5 kgf-m, 44 in-lbf).

15. Install the wire harness clip retainer and the ground wire to starter bolts.
^ Tighten to 25 N-m (2.5 kgf-m, 18 ft-lbf).
16. Install the lower front mount bracket.

^ Tighten to 55 N-m (5.5 kgf-m, 41 ft-lbf).
17. Using the special tools, raise the transaxle.

18. Install the LH upper transaxle mount through bolt.
^ Tighten to 103 N-m (10.3 kgf-m, 76 ft-lbf).
19. Remove the special tools.

20. Remove the special tools.

21. Install the upper transaxle bolts.

^ Tighten to 48 N-m (4.8 kgf-m, 35 ft-lbf).

22. Connect the transaxle range (TR) sensor electrical connector.

23. Position the shift cable and bracket in place, install the bolts and install the wiring harness retainer.
^ Tighten to 23 N-m (2.3 kgf-m, 17 ft-lbf).
24. Connect the shift cable to the manual lever.

25. Install the selector lever cable retainer on the transaxle fluid filler tube.

26. Install the main control cover vent tube.

27. Install the wire harness bracket nut and plug in the bulkhead electrical connector.
^ Tighten to 25 N-m (2.5 kgf-m, 18 ft-lbf).
28. Install the rear transaxle mount.

^ Tighten to 80 N-m (8.0 kgf-m, 59 ft-lbf).
29. Install the rear transaxle mount through bolt.

^ Tighten to 120 N-m (12.0 kgf-m, 89 ft-lbf).

Front Wheel Drive (FWD) Vehicles

30. Install the dampener.
^ Tighten to 40 N-m (4.0 kgf-m, 30 ft-lbf).

All Wheel Drive (AWD) Vehicles

31. Position the power transfer unit (PTU) in place and install the bolt.
^ Tighten to 47 N-m (4.7 kgf-m, 35 ft-lbf).
32. Install the PTU-to-transaxle bolts.

^ Tighten to 70 N-m (7.0 kgf-m, 52 ft-lbf).

33. Position the driveshaft in place and install the nuts.
^ Tighten to 48 N-m (4.8 kgf-m, 35 ft-lbf).
34. Align the index marks and install the driveshaft.

^ Tighten to 20 N-m (2.0 kgf-m, 15 ft-lbf).
35. Install the bracket.

^ Tighten to 55 N-m (5.5 kgf-m, 41 ft-lbf).

36. Install the front nuts on the exhaust-to intermediate, shaft bracket.
^ Tighten to 30 N-m (3.0 kgf-m, 22 ft-lbf).

37. Install the bolts on the rear of the exhaust-to intermediate shaft bracket.
^ Tighten to 30 N-m (3.0 kgf-m, 22 ft-lbf).

All Vehicles

38. Install the flexpipe on the exhaust manifold and install the nuts.
^ Tighten to 25 N-m (2.5 kgf-m, 18 ft-lbf).
39. Install the intermediate shaft.

40. Install the intermediate shaft retaining nuts.

^ Tighten to 27 N-m (2.7 kgf-m, 20 ft-lbf).
41. Install the LH and RH halfshafts; in the transaxle

42. Install the LH brake hose retainer and the ABS sensor bolt.
^ Tighten to 15 N-m (1.5 kgf-m, 11 ft-lbf).

43. Install the RH brake hose retainer and the ABS sensor bolt.
^ Tighten to 15 N-m (1.5 kgf-m, 11 ft-lbf).
44. Connect the LH suspension.

(1) Install the lower ball joint-to-knuckle bolt.
1) Tighten to 63 N-m (6.3 kgf-m, 46 ft-lbf).
(2) Install the tie-rod end retaining nut.
1) Tighten to 55 N-m (5.5 kgf-m, 41 ft-lbf).
(3) Connect the stabilizer bar link.
1) Tighten to 63 N-m (6.3 kgf-m, 46 ft-lbf).
45. Connect the RH suspension.

^ Tighten to 175 N-m (17.5 kgf-m, 129 ft-lbf).
47. Install the 2 bolts for the brace,

^ Tighten to 90 N-m (9.0 kgf-m, 66 ft-lbf).
48. Install the bolt for the mount.

^ Tighten to 115 N-m (11.5 kgf-m, 85 ft-lbf).
49. Install the cross brace and the 4 bolts.

^ Tighten to 115 N-m (11.5 kgf-m, 85 ft-lbf).
50. Install the LH splash shield and the 5 retainers.

51. Install the RH splash shield and the 5 retainers.
52. Install the front wheels and tires.

AWD Vehicles

53. Install the vent tube to the fluid level indicator.
54. Install the air cleaner assembly.

(1) Install the bolt.
1) Tighten to 10 N-m (1.0 kgf-m, 89 in-lbf).
(2) Connect the mass air flow (MAF) sensor.
(3) Connect the brake booster vacuum hose.
(4) Connect the wiring harness retainer.
(5) Connect the breather tube.
(6) Tighten the air cleaner clamp.
55. Install the battery tray.
56. Fill the transaxle with clean automatic transaxle fluid.
57. Verify that the shift cable is correctly adjusted. The vehicle should start in PARK and NEUTRAL and the reverse lamps should illuminate in REVERSE.
58. Check the fluid level and correct as necessary.