Installation
TRANSAXLE INSTALLATION1. Do not lubricate the splines on the input shaft.
2. Raise and position the transaxle to the engine.
Warning
^ Secure the transaxle to the transaxle jack with a safety strap. Failure to follow this instruction may result in personal injury.
3. Install the 2 short transaxle-to-engine bolts.
^ Tighten to 47 N-m (4.7 kgf-m, 35 ft-lbf}.
4. Install the LH transaxle support insulator bracket.
(1) Raise the transaxle, aligning the bracket to the insulator. Install the 3 nuts.
^ Tighten to 40 N-m (4.0 kgf-m, 30 ft-lbf).
5. Install the rear transaxle support insulator. Install the nuts, the bolt and through bolt. Tighten the through bolt to specification. Do not tighten the nuts and bolt at this time.
^ Tighten to 103 N-m (10.3 kgf-m, 76 ft-lbf).
6. After removing the transaxle jack, install 4 long transaxle-to-engine bolts.
^ Tighten to 47 N-m (4.7 kgf-m, 35 ft-lbf).
7. If equipped, install the power transfer unit (PTU).
8. Install the intermediate shaft.
9. Install the RH halfshaft.
10. Connect the RH ball joint.
^ Tighten to 63 N-m (6.3 kgf-m, 46 ft-lbf).
^ Install the lower screws.
11. Connect the RH stabilizer bar link.
^ Tighten to 55 N-m (5.5 kgf-m, 41 ft-lbf).
12. Connect the RH tie-rod end.
^ Tighten to 55 N-m (5.5 kgf-m, 41 ft-lbf).
13. Install the brake hose and the clip.
14. Position the ABS wire then install the bolt.
15. Install the LH halfshaft.
16. Connect the LH ball joint.
^ Tighten to 63 N-m (6.3 kgf-m, 46 ft-lbf).
17. Connect the stabilizer bar link.
^ Tighten to 55 N-m (5.5 kgf-m, 41 ft-lbf).
18. Connect the RH tie-rod end.
^ Tighten to 55 N-m (5.5 kgf-m, 41 ft-lbf).
19. Connect the brake hose and install the clip.
20. Position the ABS wire then install the bolt.
21. Install the starter motor assembly.
22. Install the front-to-aft crossmember.
(1) Position the crossmember.
(2) Install the 2 bolts and a nut.
(3) Tighten the bolts to 90 N-m (9.0 kgf-m, 66 ft-lbf).
(4) Tighten the new nut to 175 N-m (17.5 kgf-m, 129 ft-lbf).
23. Install the crossmember.
(1) Position the crossmember.
(2) Install the bolts.
1) Tighten the new nut to 115 N-m (11.5 kgf-m, 85 ft-lbf).
24. Install the front transaxle mount through bolt.
^ Tighten the new nut to 115 N-m (11.5 kgf-m, 85 ft-lbf).
25. Tighten the LH transaxle mount fasteners to specification.
^ Tighten the bolts to 40 N-m (4.0 kgf-m, 30 ft-lbf).
26. Tighten the transaxle rear support insulator fasteners to specification.
^ Install the nuts and bolt.
^ Tighten to 80 N-m (8.0 kgf-m, 59 ft-lbf).
27. Remove the 3-bar engine support.
28. Install the RH engine support bolt,
^ Tighten the bolts to 90 N-m (9.0 kgf-m, 66 ft-lbf).
29. Install the 3 upper transaxle-to-engine bolts.
^ Tighten the bolts to 45 N-m (4.5 kgf-m, 33 ft-lbf).
30. Connect the clutch hydraulic tube.
(1) Position the clutch hydraulic tube.
(2) Connect the clutch hydraulic tube from the clutch slave cylinder.
(3) Install the clutch hydraulic tube bracket-to-transaxle bolt.
1) Tighten to 2.5 N-m (0.25 kgf-m, 22 in-lbf).
31. Install the shift cable bracket.
(1) Position the shift cable bracket.
(2) Install the 3 bolts.
1) Tighten to 22 N-m (2.2 kgf-m, 16 ft-lbf).
32. Connect the shift cables.
33. Connect the reverse switch and vehicle speed sensor (VSS) connectors.
34. Install the wiring harness bracket nut.
^ Tighten to 12 N-m (1.2 kgf-m, 9 ft-lbf).
35. Install the battery tray.
36. Install the air cleaner assembly.
37. Fill the transaxle fluid.
38. Fill and bleed the clutch.
Warning
^ Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. Failure to follow these instructions may result in personal injury.
Caution
^ Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, wash it immediately with cold water.
39. Install the LH side splash shield.
(1) Position the LH splash shield.
(2) Install the 2 screws.
40. Install the RH side splash shield.
41. Clean the wheel mounting surfaces.
Warning
^ When installing a wheel and tire, make sure to remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel and brake disc. Installing a wheel without correct metal-to-metal contact at the mounting surfaces can cause the wheel nuts to loosen in motion, causing loss of control. Failure to follow these instructions may result in personal injury.
42. Install the wheel and tire assembly.
43. Install the 5 wheel nuts.
^ Tighten the wheel nuts in a star pattern.
^ Tighten to 133 N-m (13.3 kgf-m, 98 ft-lbf).
Warning
^ Retighten the wheel nuts at 800 km (500 miles) after any wheel change or any time the wheel nuts are loosened. Failure to retighten the wheel nuts at the mileage specified could allow the wheels to come off while the vehicle is in motion, possibly causing a loss of control. Failure to follow these instructions may result in personal injury.
Caution
^ Failure to tighten the wheel nuts in a star pattern can result in high brake disc runout, which will speed up the development of brake roughness, shudder and vibration.