Installation

INSTALLATION
Transaxle





Installation
1. General note
- Only use new self-locking nuts.
2. Raise the vehicle.





3. Using a retaining strap and wooden blocks, secure the transaxle on a transmission jack.





4. Push the engine forwards and install an approximately 350 mm long wooden block between the engine and the crossmember.
- Move the transaxle into position.





5. Install the transaxle right-hand flange bolts.





6. Install the transaxle lower flange bolts.
7. Remove the retaining strap from the transaxle. Remove the wooden block.
8. Remove the transmission jack.





9. Connect the Vehicle Speed Sensor (VSS) electrical connector.
10. Lower the vehicle.





11. Install the two transaxle upper flange bolts.





12. Install the starter motor.
- Insert the three bolts (two bolts shown).





13. Install the engine rear mount bracket.
14. Using the special tool 303-290, raise the engine and transaxle assembly slightly.





15. Install the engine rear mount.





16. Remove the special tools (illustration shows battery installed)





17. Connect the reversing light switch electrical connector





18. 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.

Connect the clutch slave cylinder supply line
- Insert the clip





19. Attach the gearshift and selector cables to the bracket and turn the abutment sleeves counter clockwise
20. Install the power distribution
21. Raise the vehicle.





22. Install the drive belt cover.





23. CAUTION: The inner joint must not be bent at more than 18 degrees; the outer joint must not be bent at more than 45 degrees.

NOTE: Use new nuts and a new center bearing cap.

Install the right-hand driveshaft together and the intermediate shaft.





24. CAUTION: The inner joint must not be bent at more than 18 degrees; the outer joint must not be bent at more than 45 degrees.

NOTE: Insert the new snap-ring

Install the left-hand driveshaft (illustration shows subframe removed).





25. Install the lower arm ball joints on both sides.





26. Install the engine roll restrictor.





27. Install the flexible exhaust pipe.
28. Install the front wheels.
29. Lower the vehicle.





30. NOTE: The resonator is a push fit into the bracket.

Install the air cleaner intake and resonator.





31. Install the intake tube.





32. Connect the ground cable.





33. Install the air cleaner housing.
1. Connect the intake hose.
2. Install the crankcase ventilation hose.
3. Install the Mass Air Flow Sensor (MAP sensor) connector.





34. NOTE: Use an Allen key to prevent the piston rod from rotating.

Tighten the suspension strut lock nuts on both sides.





35. Install the battery tray.
1. Attach the wiring harness.
2. Tighten the bolts.
3. Fasten the connector and clip it in.
36. Install the battery.
37. Adjust the gearshift cables.
38. Bleed the hydraulic clutch system.
39. Fill up the transaxle with Manual transmission fluid.

40. 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 level after the road test and correct as necessary. Check the engine and cooling system for leaks (visual inspection).