Installation

INSTALLATION

2.4L GAS

1. Install modular clutch assembly to transaxle. Assemble transaxle to engine.
2. Install and torque transaxle-to-engine bolts to 95 Nm (70 ft. lbs.).
3. Raise transaxle/engine assembly into position and install upper mount through-bolt. Torque through-bolt to 75 Nm (55 ft. lbs.).
4. Remove screw jack.
5. Install and torque modular clutch assembly-to-drive plate bolts to 88 Nm (65 ft. lbs.)
6. Install structural collar.
7. Connect back-up lamp switch connector.
8. Install starter motor into position (Figure 1). Install and torque bolts to 54 Nm (40 ft. lbs.).




Figure 1 Starter Motor Removal/Installation






9. Install engine front mount bracket. Install and torque bracket-to-transaxle bolts to 102 Nm (75 ft. lbs.). Install and torque bracket-to-engine bolts to 68 Nm (50 ft. lbs.). Torque through-bolt and nut to 68 Nm (50 ft. lbs.).
10. Install clutch slave cylinder into position, noting orientation of different sized lugs (Figure 2). While depressing inward, rotate slave cylinder clockwise 60(R)� into position until nylon locating tab rests within transaxle case cutout, and hydraulic tube is vertical. Connect "quick-connect" connection until an audible "click" is heard. Verify connection by pulling outward on connection.




Figure 2 Slave Cylinder Removal/Installation






11. Install halfshafts and front wheel/tire assemblies.
12. Lower vehicle.
13. Install right mount bracket to transaxle (Figure 3).




Figure 3 Transaxle Right Mount and Bracket






14. Connect gearshift cables to shift levers/cover assembly (Figure 4). Install cables into position at mount bracket and secure with retaining clips.




Figure 4 Gearshift Cables at Transaxle






15. Connect battery cables.
16. Check transaxle fluid and engine coolant levels. Adjust if necessary.

2.5L TD

1. Assemble transaxle to engine, while aligning transaxle input shaft to clutch disc splines.
2. Install and torque transaxle-to-engine bolts to 95 Nm (70 ft. lbs.) (Figure 5).




Figure 5 Transaxle Removal/Installation






3. Install transaxle upper mount (Figure 6). Install and torque four (4) mount-to-transaxle bolts to 54 Nm (40 ft. lbs.).




Figure 6 Transaxle Upper Mount






4. Raise transaxle/engine assembly into position and install upper mount through-bolt. Torque through-bolt to 75 Nm (55 ft. lbs.).
5. Remove screw jack.
6. Connect back-up lamp switch connector.
7. Install starter motor into position (Figure 7). Install and torque bolts to 54 Nm (40 ft. lbs.).




Figure 7 Starter Motor Removal/Installation






8. Install engine front mount bracket. Install and torque bracket-to-transaxle bolts to 102 Nm (75 ft. lbs.). Install and torque bracket-to-engine bolts to 68 Nm (50 ft. lbs.). Torque through-bolt and nut to 68 Nm (50 ft. lbs.).
9. Install clutch slave cylinder into position, noting orientation of different sized lugs (Figure 8). While depressing inward, rotate slave cylinder clockwise 60� into position until nylon locating tab rests within transaxle case cutout, and hydraulic tube is vertical. Connect "quick-connect" connection until an audible "click" is heard. Verify connection by pulling outward on connection.




Figure 8 Slave Cylinder Removal/Installation






10. Install underbody splash panel.
11. Install halfshafts and front wheel/tire assemblies.
12. Lower vehicle.
13. Install right mount bracket to transaxle (Figure 9).




Figure 9 Transaxle Right Mount and Bracket






14. Connect gearshift cables to shift levers/cover assembly (Figure 10). Install cables into position at mount bracket and secure with retaining clips.




Figure 10 Gearshift Cables at Transaxle






15. Install coolant recovery bottle bracket (Figure 11).




Figure 11 Coolant Recovery Bottle Bracket






16. Install coolant recovery bottle to bracket.
17. Connect battery temperature sensor and install battery tray (Figure 12).




Figure 12 Battery Tray


1 - BATTERY TRAY

18. Install battery, hold-down clamp and nut (Figure 13).




Figure 13 Battery and Hold-Down Clamp






19. Install battery thermal shield and clutch cable eyelet (Figure 14).




Figure 14 Battery Thermal Shield


1 - BATTERY THERMAL SHIELD

20. Connect battery cables.
21. Check transaxle fluid and engine coolant levels. Adjust if necessary.