CVT (CONTINUOUSLY VARIABLE TRANSAXLE) REMOVAL/INSTALLATION [DJVA-EL]

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Caution

•  Secure the steering wheel using tape or a cable to prevent the steering shaft from rotating after disconnecting the steering shaft. If the steering wheel rotates after the steering shaft and the steering gear and linkage are disconnected, the internal parts of the clock spring could be damaged.

1.  Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [MZR 1.5, MZR 1.6].)

2.  Disconnect the negative battery cable.

3.  Remove the aerodynamic under cover No. 2 and front splash shield as a single unit. (See AERODYNAMIC UNDER COVER NO.2 REMOVAL/INSTALLATION.) (See SPLASH SHIELD REMOVAL/INSTALLATION.)

4.  Drain the CVT fluid. (See CVT (CONTINUOUSLY VARIABLE TRANSAXLE) FLUID REPLACEMENT [DJVA-EL].)

5.  Disconnect and/or remove the following parts in the engine compartment.

(1)  Remove the battery component (ex: battery, battery tray). (See BATTERY REMOVAL/INSTALLATION [MZR 1.5, MZR 1.6].)

(2)  Remove the fresh-air duct and the air cleaner as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 1.5, MZR 1.6].)

(3)  Disconnect the selector cable from the transaxle. (See CVT (CONTINUOUSLY VARIABLE TRANSAXLE) SHIFT MECHANISM REMOVAL/INSTALLATION.)

(4)  Disconnect the connectors and GND wiring harness from the transaxle.

(5)  Remove the bracket from the transaxle.

(6)  Remove the oil cooler from the transaxle with the hose connected. (See OIL COOLER REMOVAL/INSTALLATION [DJVA-EL].)

(7)  Remove the starter. (See STARTER REMOVAL/INSTALLATION [MZR 1.5, MZR 1.6].)

6.  Disconnect and/or remove the following parts related to the suspension and axle.

(1)  Remove the front tires. (See GENERAL PROCEDURES (FRONT AND REAR AXLES).)

(2)  Disconnect the ABS wheel-speed sensor connectors from the steering knuckles. (See FRONT ABS WHEEL-SPEED SENSOR REMOVAL/INSTALLATION.)

(3)  Disconnect the clip securing the brake hose (LH) from the shock absorber. (See BRAKE HOSE (FRONT) REMOVAL/INSTALLATION [EXCEPT MZR 2.3 DISI Turbo].)

(4)  Disconnect the brake hose from the shock absorber. (See BRAKE HOSE (FRONT) REMOVAL/INSTALLATION [EXCEPT MZR 2.3 DISI Turbo].)

(5)  Disconnect the tie-rod end ball joints from the steering knuckles. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION [MZR 1.5, MZR 1.6, MZR 2.0, MZR 2.3 DISI Turbo, MZR 2.5, MZ-CD 1.6].)

(6)  Disconnect the front lower arms from the steering knuckles. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION [MZR 1.5, MZR 1.6, MZR 2.0, MZR 2.3 DISI Turbo, MZR 2.5, MZ-CD 1.6].)

(7)  Disconnect the stabilizer control links from the shock absorbers (upper side). (See FRONT STABILIZER REMOVAL/INSTALLATION [EXCEPT MZR 2.3 DISI Turbo].)

(8)  Disconnect the drive shaft (LH) from the transaxle. (See DRIVE SHAFT REMOVAL/INSTALLATION.)

(9)  Disconnect the drive shaft (RH) from the joint shaft. (See DRIVE SHAFT REMOVAL/INSTALLATION.)

(10)  Remove the joint shaft. (See JOINT SHAFT REMOVAL/INSTALLATION [MZR 1.5, MZR 1.6, MZR 2.3 DISI Turbo, MZR 2.5].)

7.  Install the SST using the following procedures.

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Caution

•  Refer to the SST instruction manual for the basic handing procedure.

(1)  Remove the brake vacuum hose bracket bolt, then set the brake vacuum hose bracket out of the way.

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(2)  Set the fuel pipe bracket out of the way to prevent interference with the SST as shown in the figure.

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(3)  Using the bolts part number 99794 1025 or M10×1.25, length 25 mm {0.98 in} to install the SST to the position shown in the figure.

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Tightening torque

38—51 N·m {3.9—5.2 kgf·m, 29—37 ft·lbf}

(4)   Remove the installation bolt for the bracket securing the lower radiator hose.

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(5)   Set the bracket securing the lower radiator hose aside to prevent it from interfering with the front shaft of the SST (right side)

(6)  As shown in the figure, set the rear shafts of the SST to the left and right shock absorber bolts.

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(7)  Install front foot No.2 to the left/right front shaft of the SST, then align the groove of the front shaft of the SST with the folded up part of the vehicle as shown in the figure.

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(8)  Adjust the positions of the SST side bars so that they are the same height (left and right) and horizontal. Make sure each joint is securely tightened.

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8.  Remove in the order indicated in the table.

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1	Torque converter installation nut (See Torque Converter Installation Nuts Removal Note.)
2	Transaxle mounting bolt (upper side)
3	No.1 engine mount bracket (See No.1 Engine Mount and No.4 Engine Mount Installation Note.)
4	Battery tray bracket (See No.1 Engine Mount and No.4 Engine Mount Installation Note.)
5	No.4 engine mount rubber (See No.1 Engine Mount and No.4 Engine Mount Installation Note.)
6	No.4 engine mount bracket (See No.1 Engine Mount and No.4 Engine Mount Installation Note.)
7	Transaxle mounting bolt (lower side) (See Transaxle Mounting Bolts (Lower Side) Removal Note.)
8	Transaxle (See Transaxle Installation Note.)

Warning

•  Improperly jacking a transaxle is dangerous. It can slip OFF the jack and may cause serious injury.

Caution

•  To prevent the torque converter and transaxle from separating, remove the transaxle without tilting it toward the torque converter.

9.  Install in the reverse order of removal.

10.  Adjust the CVT fluid level. (See CVT (CONTINUOUSLY VARIABLE TRANSAXLE) FLUID LEVEL ADJUSTMENT [DJVA-EL].)

11.  Perform the “Oil Pressure Sensor Learning”. (See TCM LEARNING [DJVA-EL].)

Torque Converter Installation Nuts Removal Note

1.  Hold the crankshaft pulley to prevent drive plate from rotating.

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2.  Remove the torque converter installation nuts from the starter installation hole.

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Transaxle Mounting Bolts (Lower Side) Removal Note

1.  Adjust the SST (49 C017 5A0) and lean the engine toward the transaxle.

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2.  Support the transaxle ON a jack.

3.  Remove the transaxle mounting bolts (lower side).

4.  Remove the transaxle.

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Transaxle Installation Note

Caution

•  Do not drop the torque converter.

1.  If the transaxle is replaced with a new one, perform the following procedure.

(1)  Remove the shipping plug from the new transaxle.

(2)  Remove the plug from the transaxle removed from the vehicle.

(3)  Perform the CVT fluid adjustment for the new transaxle. (See CVT (CONTINUOUSLY VARIABLE TRANSAXLE) FLUID LEVEL ADJUSTMENT [DJVA-EL].

(4)  Install the removed plug and a new washer to the new transaxle.

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2.  To verify that the torque converter is correctly installed, measure the distance from the surface edge of the housing to the installation surface of the torque converter plate bolt.

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Caution

•  Verify that the torque converter stud bolts are inserted into the drive plate bolt holes, and install the transaxle mounting bolts. Otherwise, the drive plate could be damaged.

3.  Verify that the torque converter stud bolts are inserted into the drive plate bolt holes from the starter installation hole.

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

1.  Install the No.4 engine mount bracket to the transaxle case, and then tighten the nuts.

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2.  Install the No.1 engine mount bracket to the converter housing, and then tighten the bolts.

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3.  Install the No.1 engine mount rubber to the front crossmember, and then temporarily tighten the bolts.

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4.  Align the No.4 engine mount rubber installation hole to the stud bolts ON the body.

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5.  Install the No.4 engine mount rubber to the No.4 engine mount bracket, and then tighten the bolt.

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

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7.  Align the battery tray bracket installation hole to the stud bolts ON the body.

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8.  Install the battery tray bracket to the No.4 engine mount rubber, and then tighten the nuts.

9.  Remove the SST(49 C017 5A0).