MANUAL TRANSAXLE REMOVAL/INSTALLATION [G66M-R (MZR 2.0 DISI i-stop)]

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1.  Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

2.  Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

3.  Remove the battery and battery tray. (MZR 2.0 DISI i-stop)(See BATTERY REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

4.  Remove the air cleaner component. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

5.  Remove the exhaust manifold insulator installation bolts and set the exhaust manifold insulator aside. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

6.  Remove the following parts:

(1)  Exhaust manifold bracket
(2)  Front tires (See GENERAL PROCEDURES (SUSPENSION).)
(3)  Splash shield (See SPLASH SHIELD REMOVAL/INSTALLATION.)
(4)  Aerodynamic under cover No.2 (See AERODYNAMIC UNDER COVER NO.2 REMOVAL/INSTALLATION.)
(5)  Starter (See STARTER REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

7.  Drain the transaxle oil into a suitable container. (See TRANSAXLE OIL REPLACEMENT [G66M-R].)

8.  Remove in the order indicated in the table.

9.  Install in the reverse order of removal.

10.  Add the specified amount of specified transaxle oil. (See TRANSAXLE OIL REPLACEMENT [G66M-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 [G66M-R].)
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1
Ground
2
Back-up light switch connector
3
Neutral switch connector
4
Select cable
(See Shift Cable and Select Cable Removal Note.)
5
Shift cable
(See Shift Cable and Select Cable Removal Note.)
6
Cable bracket
7
Ground
8
Harness bracket
9
Clutch release cylinder
10
Transaxle mounting bolt (upper side)
11
Tie-rod end ball joint
(See FRONT CROSSMEMBER REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)
12
Stabilizer control link
13
Lower arm ball joint
14
Drive shaft
(See DRIVE SHAFT REMOVAL/INSTALLATION.)
15
Joint shaft
(See JOINT SHAFT REMOVAL/INSTALLATION [LF, MZR 2.0 DISI i-stop].)
16
No.1 engine mount bracket
(See No.1 Engine Mount and No.4 Engine Mount Installation Note.)
17
Battery tray bracket
18
No.4 engine mount rubber
(See No.4 Engine Mount Removal Note.)
(See No.1 Engine Mount and No.4 Engine Mount Installation Note.)
19
No.4 engine mount bracket
(See No.4 Engine Mount Removal Note.)
(See No.1 Engine Mount and No.4 Engine Mount Installation Note.)
20
Transaxle mounting bolt (lower side)
21
Manual transaxle
(See Manual Transaxle Removal Note.)
(See Manual Transaxle Installation Note.)


Shift Cable and Select Cable Removal Note

1.  Remove the shift and selector cable outer ends as shown in the figure.

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

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No.4 Engine Mount Removal Note

1.  Install the SST using the following procedure.

Caution
•  Refer to the SST instruction manual for the basic handing procedure.
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(1)  Align the bolt of the shock absorber (right side) shown in the figure with the rear shaft hole for the right side of the SST.
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(2)  Align the bolt of the shock absorber (left side) shown in the figure with the rear shaft hole for the left side of the SST.
(3)  Install one front foot No.2 to each of the left and right front shafts of the SST, and then align the holes of the SST front shafts with the bolt on the left and right side of each front side frame.
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(4)  Adjust the height of the left and right side bars so that they are leveled, then tighten each part of the SST.
(5)  Make sure each joint is securely tightened.

2.  Support the engine using the SST.

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3.  Remove the No.4 engine mount rubber and bracket.


Manual Transaxle Removal Note

Warning
•  Remove the transaxle carefully, holding it steady. If the transaxle falls it could be damaged or cause injury.

1.  Adjust the SST and lean the engine toward the transaxle.

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2.  Support the transaxle on a jack.

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3.  Remove the transaxle mounting bolts.

4.  Remove the transaxle.


Manual Transaxle Installation Note

Warning
•  Install the transaxle carefully, holding it steady. If the transaxle falls it could be damaged or cause injury.

1.  Set the transaxle on a jack and lift into place.

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2.  Install the transaxle mounting bolts.

3.  Adjust the SST (49 C017 5A0) so that the engine is located at the specified position.


No.1 Engine Mount and No.4 Engine Mount Installation Note

1.  Install the No.4 engine mount bracket on the transaxle case and tighten bolt and nuts.

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Tightening torque
61—76 N·m {6.3—7.7 kgf·m, 45—56 ft·lbf}

2.  Install the through bolt A on the front crossmember side until approximately three pitches are showing.

3.  Temporarily tighten bolts B.

Note
•  Do not tighten the bolts B and C during this step.

4.  Tighten the bolts in the order of B and C.

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5.  Tighten the No.4 engine mount rubber installation bolt as shown in the figure.

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Tightening torque
94—152 N·m {9.6—15 kgf·m, 70—112 ft·lbf}

6.  Tighten the No.1 engine mount rubber installation bolts as shown in the figure.

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Caution
•  Tighten the bolts in the order shown in the figure to prevent abnormal noise and vibration after assembly.

No.

Tightening torque
1
71—91 N·m {7.3—9.2 kgf·m, 53—67 ft·lbf}
2
73—90 N·m {7.5—9.1 kgf·m, 54—66 ft·lbf}

7.  Tighten the No.4 engine mount rubber and battery bracket bolts and nuts in the order as shown in the figure.

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Tightening torque
44—61 N·m {4.5—6.2 kgf·m, 33—44 ft·lbf}

8.  Remove the SST (49 C017 5A0).