Removal and Installation

REMOVAL
1. REMOVE HOOD

HINT: At the time of installation, please refer to the following item. Adjust the hood.

2. REMOVE BATTERY AND AIR CLEANER CASE ASSEMBLY WITH AIR HOSE





3. w/ Cruise Control:
REMOVE CRUISE CONTROL ACTUATOR
a. Disconnect the cruise control actuator connector.
b. Remove the 3 bolts and cruise control actuator with the bracket.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
4. REMOVE STARTER
a. Disconnect the connector and wire from the starter.
b. Remove the 2 bolts and starter.
Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.)





5. DISCONNECT CLUTCH RELEASE CYLINDER
a. Remove the 2 bolts and disconnect the release cylinder.
Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.)
b. Remove the 2 set bolts and nut of the clutch accumulator.
Torque:
Bolt: 21 Nm (210 kgf-cm, 15 ft. lbs.)
Nut: 26 Nm (270 kgf-cm, 20 ft. lbs.)
c. Remove the set bolt of the clutch line bracket.
Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.)





6. DISCONNECT GROUND CABLE
Remove the set bolt of the ground cable from the transaxle.





7. DISCONNECT ENGINE WIRE FROM CLAMP
8. DISCONNECT VEHICLE SPEED SENSOR AND BACK-UP LIGHT SWITCH CONNECTORS
9. DISCONNECT CONTROL CABLE
a. Remove the 2 clips and washers.
b. Remove the 2 clips from the cables.





10. REMOVE 5 TRANSAXLE UPPER SIDE MOUNTING BOLTS
Torque:
17 mm head: 64 Nm (650 kgf-cm, 47 ft. lbs.)
11. REMOVE FRONT WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
12. RAISE VEHICLE

NOTICE: Make sure that the vehicle is securely supported.

13. REMOVE ENGINE REAR SIDE SHUTTER PLATE AND LH AND RH FENDER APRON SEALS





14. DRAIN TRANSAXLE OIL
Oil grade: API GL-4 or GL-5
Viscosity: SAE 75W-90
Capacity: 4.2 liters (4.4 US qts, 3.7 Imp. qts)
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
15. REMOVE LH AND RH DRIVE SHAFTS





16. REMOVE FRONT EXHAUST PIPE
a. Remove the 2 bolts and exhaust pipe support stay.
Torque: 33 Nm (330 kgf-cm, 24 ft. lbs.)
b. Remove the 4 nuts and 2 gaskets from the exhaust manifold.
Torque: 62 Nm (630 kgf-cm, 46 ft. lbs.)
c. Remove the 2 bolts, nuts and gasket.
Torque: 56 Nm (570 kgf-cm, 41 ft. lbs.)
d. Remove the 2 set bolts of the No.1 exhaust pipe support bracket.
Torque: 33 Nm (330 kgf-cm, 24 ft. lbs.)
e. Remove the front exhaust pipe.
17. DISCONNECT PS GEAR ASSEMBLY FROM FRONT SUSPENSION MEMBER





a. Remove the 2 nuts and disconnect the stabilizer bar link from the stabilizer bar.
Torque 39 Nm (400 kgf-cm, 29 ft. lbs.)
b. Remove the 4 set bolts of the stabilizer bar bracket.
Torque: 19 Nm (195 kgf-cm, 14 ft. lbs.)
c. Remove the 2 bolts, nut and No.1 fuel tube protector.





d. Tie the PS gear assembly to the proper position with a code or an equivalent to suspend the assembly securely.
e. Remove the 2 set bolts and nuts of the PS gear assembly.
Torque: 181 Nm (1,850 kgf-cm, 134 ft. lbs.)





18. DISCONNECT FRONT ENGINE ABSORBER FROM TRANSAXLE
Remove the 2 bolts.
Torque: 48 Nm (490 kgf-cm, 35 ft. lbs.)





19. REMOVE RH EXHAUST MANIFOLD STAY
Remove the bolt, nut and stay.
Torque: 20 Nm (200 kgf-cm, 14 ft. lbs.)





20. REMOVE 3 ENGINE FRONT SIDE MOUNTING BOLTS
Torque:
Silver bolt: 44 Nm (450 kgf-cm, 33 ft. lbs.)
Green bolt: 66 Nm (670 kgf-cm, 48 ft. lbs.)





21. REMOVE LH ENGINE MOUNTING INSULATOR WITH BRACKET
a. Remove the 2 hole plugs, nuts and 3 bolts.
Torque:
Bolt: 64 Nm (650 kgf-cm, 47 ft. lbs.)
Nut: 80 Nm (820 kgf-cm, 59 ft. lbs.)
b. Lift up the transaxle and remove the left engine mounting insulator with the bracket.





22. REMOVE HOLE PLUG AND 4 ENGINE REAR SIDE MOUNTING NUTS
Torque: 66 Nm (670 kgf-cm, 48 ft. lbs.)
23. ATTACH ENGINE SLING DEVICE TO ENGINE HANGER
24. DISCONNECT STEERING RETURN PIPE FROM FRONT SUSPENSION MEMBER Remove the 2 bolts.
Torque: 10 Nm (100 kgf-cm, 7 ft. lbs.)





25. REMOVE FRONT SUSPENSION MEMBER WITH LOWER SUSPENSION ARM
a. Remove the LH and RH fender liner set screws.
b. Remove the 6 bolts, 4 nuts, front LH and RH suspension member braces, rear LH and RH suspension member braces and front suspension member with the lower suspension arm.
Torque:
Bolt A: 181 Nm (1,850 kgf-cm, 134 ft. lbs.)
Bolt B: 32 Nm (330 kgf-cm, 24 ft. lbs.)
Nut C: 36 Nm (370 kgf-cm, 27 ft. lbs.)
26. JACK UP TRANSAXLE SLIGHTLY
Using a transmission jack, support the transaxle.





27. REMOVE FLYWHEEL HOUSING UNDER COVER AND TRANSAXLE LOWER SIDE MOUNTING BOLT
a. Remove the 2 bolts and cover.
Torque: 7.8 Nm (80 kgf-cm, 69 inch lbs.)
b. Remove the 3 bolts of the transaxle lower side.
Torque:
14 mm head A: 46 Nm (470 kgf-cm, 34 ft. lbs.)
14 mm head B: 37 Nm (380 kgf-cm, 27 ft. lbs.)
28. REMOVE TRANSAXLE
Lower the engine left side and remove the transaxle from the engine.

HINT: At the time of installation, please refer to the following items.
- Align the input shaft with the clutch disc and install the transaxle to the engine.
- Temporarily tighten the transaxle mounting bolts.

INSTALLATION
Installation is in the reverse order of removal.

HINT: After installation, check and inspect items as follows.
- Front wheel alignment.
- Do the road test.