Repair procedures (M5GF2)

Removal

CAUTION:
- Use a cover not to damage the vehicle surface.
- Disconnect connectors carefully not to be damaged.

NOTE:
- Mark wires or hoses for identification not to be confused.

1. Remove the engine cover.
2. Remove the battery (A).




3. Disconnect the AFS connector (A).




4. Remove the air cleaner hose(B) and loosen the clamp bolt(A).




5. Remove the air cleaner upper cover(B) by removing the clips(A).




6. Remove the air cleaner assembly (B) by removing the two mounting bolts(A).




7. Remove the battery tray (B) by removing the four mounting bolts (A).




8. Remove the ground wire (A) from the transaxle case.




9. Disconnect the vehicle speed sensor and the back up lamp switch integrated connector(A).




10. Remove the control cable assemblies(A) by removing the snap pins(B) and clips(C).




11. Remove C.S.C (Concentric Slave Cylinder) tube(A) which is being clamped by loosening the nut(B).




12. Remove the four mounting bolts of upper part of the transaxle.
13. Support the engine and transaxle by using the special tool (09200-38001).




14. Remove the transaxle insulator bracket (B) by removing the bolts (A).




15. Remove the front wheels and tires. (refer to Front Stabilizer Bar in SS group)
16. Lift up the vehicle.
17. Remove the steering column joint bolt. (refer to Power Steering Gear Box in ST group)
18. Remove the under cover(A).




19. Drain power steering oil through the return tube. (refer to Power Steering Gear Box in ST group)
20. Disconnect the power steering pressure hose (A) from the power steering oil pump.
21. Drain the tranaxle fluid through the drain plug.
22. Disconnect the lower arm, the tie rod end ball joint, the stabilizer bar link from the front knuckle. (refer to Front Stabilizer Bar in SS group)
23. Remove the roll stopper mounting bolts.
24. Remove the mounting bolts from the sub frame by supporting the sub frame with a jack. (refer to Front Stabilizer Bar in SS group)
25. Remove the drive shafts from the transaxle. (refer to Front Driveshaft in DS group)
26. Disconnect the starter motor connector and remove the starter motor. (refer to Starter in EE group)
27. In case of 4WD, remove the transfer case assembly. (refer to Transfer Case).
28. Remove the mounting bolts of lower part of the transaxle, and the left side cover and remove the transaxle assembly by supporting it with a jack.

Installation

Installation is in the reverse order of removal.
Perform the following :
- Adjust the shift cable.
- Refill the transaxle with fluid.
- Refill the radiator with engine coolant.
- Bleed air from the cooling system with the heater valve open.
- Clean the battery posts and cable terminals with sandpaper, assemble them, and apply grease to prevent corrosion.
1. Lowering the vehicle or lifting up a jack, install the transaxle assembly.
2. Tighten the transaxle under mounting bolts.

Tightening torque :
65 - 85 Nm(6.5 - 8.5 kgf.m, 47.0 - 61.5 lb-ft)


3. Install the starter motor and connect the starter motor connector. (refer to Starter in EE group)
4. In case of 4WD, install the transfer case assembly.(refer to Transfer Case)
5. Install the drive shafts to the transaxle. (refer to Front Driveshaft in DS group)
6. Install the transaxle insulator (B) and mounting bracket (C) by tightening the bolts (A).

Tightening torque :
60 - 80 Nm (6 - 8 kgf.m, 43.6 - 58.2 lb-ft)





7. Install the sub frame. (refer to Front Stabilizer Bar in SS group)

Tightening torque :
60 - 80 Nm(6.0 - 8.0 kgf.m, 65.1 - 79.5 lb-ft)


8. Connect the power steering return hose. (refer to Power Steering Gear Box in ST group)
9. Connect the lower arm, the rod end ball joint, the stabilizer bar link to the front knuckle.(refer to Front Stabilizer Bar in SS group)
10. Install the steering column joint bolt. (refer to Power Steering Gear Box in ST group)
11. Install the C.S.C (Cincentric Slave Cylinder) tube(A) by tightening the nut(B).




12. Refill transaxle oil through the inlet hole(A).

Tightening torque :
30 - 35 Nm(3.0 - 3.5 kgf.m, 21.8 - 25.4 lb-ft)


13. Install the under cover(A).




14. Install the front wheels and tires. (refer to Front Stabilizer Bar in SS group)
15. Tighten the transaxle mounting bolts and remove the SST (09200-38001) holding the engine and transaxle assembly.

Tightening torque :
65 - 85 Nm (6.5 - 8.5kgf.m, 47.0 - 61.5 lb-ft)





16. Connect the power steering pressure hose (A) to the power steering oil pump.
17. Install the control cable assemblies(A) by installing the clips (C) and snap pins (B).

CAUTION:
Do not reuse the clip(C) and use a new one.




18. Install the vehicle speed sensor and the back up lamp integtated connector (A).




19. Install the ground wire (A) from the transaxle case.




20. Install the battery tray (B) by removing the four mounting bolts (A).




21. Install the air cleaner assembly (B) by tightening the two mounting bolts(A).




22. Install the air cleaner upper cover (A).




23. Install the air cleaner hose(B) and tighten the clamp bolt(A).




24. Connect the AFS connector (A).




25. Install the battery (A).




26. Install the engine cover.
27. Refill the power steering fluid. (refer to Power Steering Gear Box in ST group)

CAUTION:
Bleed air in the system, after installing the inter cooler assembly and the engine cover.