MANUAL TRANSAXLE REMOVAL/INSTALLATION [B65M-R (MZ-CD 1.4 DI Turbo)]

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1.  Disconnect the negative battery cable.

2.  Remove the battery and battery tray. (See BATTERY REMOVAL/INSTALLATION [MZ-CD 1.4 DI Turbo].)

3.  Remove the wheels and tires.

4.  Remove the fresh-air duct No.1. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.4 DI Turbo].)

5.  Remove the air hose No.1. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.4 DI Turbo].)

6.  Remove in the order indicated in the table.

7.  Install in the reverse order of removal.

8.  Add the specified amount of specified transaxle oil. (See TRANSAXLE OIL INSPECTION [B65M-R].)

Note

•  If the transaxle is overhauled and installed to the vehicle, perform the "INSPECTION AFTER TRANSAXLE INSTALLATION" and verify that there is no abnormality. (See INSPECTION AFTER TRANSAXLE INSTALLATION [B65M-R].)

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1	Battery tray bracket
2	Back-up light switch connector
3	Clutch pipe (See Clutch Pipe Removal Note.) (See Clutch Pipe Installation Note.)
4	Clutch pipe bracket
5	Cable bracket
6	Cable box cover
7	Shift cable (See Shift Cable and Select Cable Removal Note.)
8	Select cable (See Shift Cable and Select Cable Removal Note.)
9	Cable box
10	Starter (See STARTER REMOVAL/INSTALLATION [MZ-CD 1.4 DI Turbo].)
11	Transaxle mounting bolt (upper side)
12	Nut (stabilizer control link upper side)
13	Bolt (brake hose bracket)
14	Tie-rod end ball joint (See FRONT CROSSMEMBER REMOVAL/INSTALLATION.)
15	ABS wheel-speed sensor (See ABS Wheel-Speed Sensor Removal Note.) (See ABS Wheel-Speed Sensor Installation Note.)
16	Front lower arm ball joint (See WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION.)
17	Drive shaft (LH) (See DRIVE SHAFT REMOVAL/INSTALLATION [MZ-CD 1.4 DI Turbo, MZ-CD 1.6 (Y6)].)
18	Drive shaft (RH) (See DRIVE SHAFT REMOVAL/INSTALLATION [MZ-CD 1.4 DI Turbo, MZ-CD 1.6 (Y6)].)
19	Joint shaft (See JOINT SHAFT REMOVAL/INSTALLATION [MZ-CD 1.4 DI Turbo, MZ-CD 1.6 (Y6)].)
20	No.1 engine mount (See No.1 Engine Mount Installation Note.)
21	No.4 engine mount rubber (See No.4 Engine Mount Removal Note.) (See No.4 Engine Mount Installation Note.)
22	No.4 engine mount bracket (See No.4 Engine Mount Removal Note.) (See No.4 Engine Mount Installation Note.)
23	Transaxle mounting bolt (lower side) (See Transaxle Mounting Bolt (lower side) Removal Note.)
24	Manual transaxle

Shift Cable and Select Cable Removal Note

1.  Remove the both shift cable end and select cable end using a fastener remover.

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2.  Remove the shift and select cable in the order shown in the figure.

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ABS Wheel-Speed Sensor Removal Note

1.  Remove the ABS wheel-speed sensor installation bolt, then remove the ABS wheel-speed sensor from the steering knuckle.

2.  Remove the bolts and nuts shown in the figure, then disconnect the steering knuckle from the shock absorber.

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3.  While pressing the tabs (2 locations) of the ABS wheel-speed sensor wiring harness clip, remove the ABS wheel-speed sensor wiring harness from the shock absorber.

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4.  Remove the ABS wheel-speed sensor wiring harness grommet from the shock absorber.

5.  Move the ABS wheel-speed sensor to a place out of the way.

6.  Install the steering knuckle to the shock absorber, insert the bolts from the direction shown as follows, then tighten them to the specified torque.

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―  Vehicle left side: Insert the bolts from the vehicle rear.

―  Vehicle right side: Insert the bolts from the vehicle front.

Clutch Pipe Removal Note

Caution

•  When disconnecting the clutch pipe, the seal ring installed to the end of the clutch pipe may fall off or remain on the clutch release cylinder side. If the clutch pipe is assembled with the seal ring not installed, it may cause fluid leakage from the clutch pipe connector or the clutch may not operate normally. When disconnecting the clutch pipe, remove the seal ring and clutch pipe as a single unit.

Note

R.H.D. only

•  A seal ring has been installed to the mid-connector between the clutch master cylinder and clutch release cylinder. Verify that the clutch pipe is removed together with the seal ring when disconnecting the mid-connector.

1.  Remove the clip from the clutch release cylinder.

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2.  Remove the clutch pipe connector straight.

3.  Verify that the seal ring is removed together with the clutch pipe.

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Transaxle Mounting Bolt (lower side) Removal Note

1.  Because the bolt shown in the figure cannot be pulled out completely, move the bolt in the direction of the arrow, and then remove the manual transmission.

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No.4 Engine Mount Removal Note

1.  Install front foot No.2 to the left/right front shaft of the SST (49 C017 5A0).

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2.  As shown in the figure, set the rear shafts of the SST to the left and right shock absorber upper bolts.

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3.  Remove the coolant reserve tank from the clip and set it out of the way.

4.  Remove the cooler pipe from the clips and set it out of the way to prevent interference between the SST and the front shaft.

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5.  Remove the front combination light connector from the clip and set it out of the way to prevent interference between the SST and the front shaft. (Except vehicles with HID)

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6.  As shown in the figure, set the front shaft groove of the SST to the folded part of the left and right body frames.

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Caution

•  Block the removed area using a clean rag so that foreign material or water does not penetrate.

7.  Remove the oil filler cap.

8.  Set the SST as shown in the figure.

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9.  Hang the engine using the SST.

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10.  Adjust the height of the left and right side bars so that they are leveled, then tighten each part of the SST.

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11.  Verify that the SST is properly set and the engine is securely hung.

12.  Remove the No.4 engine mount.

No.4 Engine Mount Installation Note

1.  Tighten the bolt A.

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2.  Adjust the SST (engine support) so that the stud bolts of the No.4 engine mount bracket and the bolt holes of the No.4 engine mount rubber are aligned.

3.  Using a jack, raise the transaxle until the stud bolts of the No.4 engine mount bracket project from the bolt holes of the No.4 engine mount rubber.

4.  Tighten the No.4 engine mount rubber in the order of nut B and bolt A.

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No.1 Engine Mount Installation Note

Caution

•  Align the transaxle bolt holes and the engine mount exactly. Any misalignment can result in bolts and bolt holes becoming damaged or stripped during installation.

1.  Adjust the SST (engine support), and align the hole of the No.1 engine mount with the bolt hole of transaxle.

2.  Tighten the bolt A,B from manual transaxle.

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3.  Tighten the bolt C.

ABS Wheel-Speed Sensor Installation Note

1.  Install the ABS wheel-speed sensor wiring harness grommet to the shock absorber as shown in the figure.

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2.  Install the ABS wheel-speed sensor wiring harness clip to the shock absorber.

3.  Install the ABS wheel-speed sensor to the steering knuckle, then tighten the bolt (ABS wheel-speed sensor) to the specified torque.

4.  Verify that the ABS wheel-speed sensor wiring harness is not twisted.

Clutch Pipe Installation Note

Note

R.H.D. only

•  A seal ring has been installed to the mid-connector between the clutch master cylinder and clutch release cylinder. Verify that a seal ring is installed to the clutch pipe when connecting the mid-connector.

1.  Verify that the seal ring is installed to the groove at the end of the clutch pipe.

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Caution

•  Verify that there is no chipping or damage to the seal ring of the clutch pipe.

2.  Install the clip from the clutch release cylinder.

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3.  Insert the clutch pipe connector straight.

4.  Pull the clutch pipe to verify that it does not come off, and reinsert it completely.