Installation
INSTALLATIONTransaxle
Installation
1. General note.
- Only use new self-locking nuts.
2. Secure the transmission using a retaining strap and move into installation position using a transmission jack.
3. Tighten the flange bolts and install the catalytic converter bracket.
4. Stall the starter motor and tighten the flange bolts.
1. Starter motor bolt
2. Flange bolt
5. Remove the wooden block.
6. Lower the vehicle.
7. Using the special tool 303-290, raise the engine and transaxle compartment.
8. Raise and support the vehicle.
9. CAUTION: The inner joint must not be bent more than 18 degrees. The outer joint must not be bent more than 45 degrees.
CAUTION: Use the installation sleeve (supplied with every new oil seal) to protect the oil seal when inserting the front halfshaft.
NOTE: Make sure the retaining ring is securely in place.
Install the left-hand front halfshaft in the transaxle together with a new retaining ring.
10. CAUTION: The inner joint must not be bent more than 18 degrees. The outer joint must not be bent more than 45 degrees.
Insert the right-hand front halfshaft into the transaxle.
11. NOTE: Install a new mounting bracket and new nuts.
Install mounting bracket for center bearing on right-hand front halfshaft.
12. Install roll restrictor.
13. Install lower suspension arm ball joint on both sides.
14. Install the drive belt cover.
15. Install the shift and selector cable.
- Install the shift and selector cable end fittings to the shift and selector lever.
- Install the shift and selector cable to the bracket by turning the lower part of abutment clockwise and the upper part counter clockwise.
IB5 Manual Transmission:
16. Top up the transaxle with Manual transmission fluid until fluid level is 5 to 10 mm below the lower edge of the check hole.
17. Close the cover on the shift and selector cable.
18. Install the catalytic converter assembly.
19. Tighten the upper flange bolts and starter motor bolts.
1. Flange bolts
2. Starter motor bolts and ground lead.
20. Using special tool 308-290, raise the engine and transaxle until it becomes possible to install the rear engine mounting.
21. Install the rear engine mounting bracket.
22. Install the rear engine mounting.
23. Install the shift cable bracket mounting.
24. Remove the special tools.
25. Connect the reversing light switch connector.
26. Connect the Vehicle Speed Sensor (VSS) connector.
27. Connect the vacuum hoses.
28. Connect the brake servo vacuum hose.
29. WARNING: Escaping brake fluid. Do not allow brake fluid to come into contact with the skin or the eyes. If brake fluid does come into contact with the skin or the eyes, rinse the affected areas with water immediately. Failure to follow these instructions may result in personal injury.
CAUTION: If brake fluid is split on the paintwork, the affected area must be immediately washed down with cold water.
Install the clutch slave cylinder high-pressure line
- Insert the clutch slave cylinder high-pressure line in the bracket
30. Bleed the clutch hydraulic system.
31. Install the intake pipe.
32. Install the air cleaner.
1 Connect the plug of the MAP sensor.
2 Connect the intake pipe
33. Install the battery tray.
1. Attach the wiring loom.
2. Tighten the bolts.
3. Attach and clip in the connector.
34. Install the battery.
35. NOTE: Use an Allen key to prevent the piston rod from rotating.
Tighten the left-hand and the right-hand suspension strut.
36. Adjust the gearshift mechanism.
37. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy.
- Finishing operations:
- Connect the battery ground cable.
- Carry out a road test to enable the Powertrain Control Module (PCM) to collect data.
- Check the routing of the vacuum hoses and wiring and secure them with cable ties.
- Check fluid levels after the road test and correct as necessary.
- Check the engine and cooling system for leaks (visual inspection).