Repair Procedures (A5HF1)

REMOVAL

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

NOTE:
a. Mark wires or hoses for identification.

1. Remove the battery (A).




2. Disconnect the AFS connector (A).




3. Remove the air cleaner upper cover (B) by loosening the clips (A).




4. Remove the air cleaner assembly (A).




5. Disconnect the air cleaner hose (B) by loosening the clamp (A).




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




7. Disconnect the transaxle wire harness connectors.
(1) Remove the inhibitor switch connector (A).




(2) Remove the solenoid valve connector (A).




(3) Remove the input speed sensor connector (A).




(4) Remove the output speed sensor connector (A).




(5) Remove the vehicle speed sensor connector (A).




(6) Remove the CKP sensor connector (A).




8. Remove the shift cable by removing the bolt (A) and clip (B).




9. Disconnect the transaxle oil cooler hoses (A) from the tubes (C) by loosening the clamps (B).




10. Remove the transaxle mounting bolts (B, C).




11. Using the SST(09200-38001), hold the engine and transaxle assembly safely.




12. Remove the transaxle insulator mounting bolt (A).




13. Remove the front wheels.
14. Remove the power steering column joint bolt. (see ST group)
15. Lift up the vehicle.
16. Remove the under cover (A).




17. Drain transaxle oil.
18. Drain power steering oil through the return tube. (see ST group)
19. Disconnect the power steering pressure tube (A) from the power steering oil pump.




20. Disconnect the lower arm, the tie rod end ball joint, the stabilizer bar link from the front knuckle. (see SS group)
21. Remove the roll stopper mounting bolts (A,B).








22. Remove the mounting bolts from the sub frame by supporting the sub frame with a jack. (see SS group)
23. Remove drive shaft from transaxle..
24. Install a jack for supporting the transaxle assembly.
25. Remove the transaxle under mounting bolts(A) and the drive plate bolts(B).




26. Lifting the vehicle up and lowering the jack slowly, remove the transaxle assembly.

INSTALLATION

Installation is in the reverse order of removal.
Perform the following :
a. Adjust the shift cable.
b. Refill the transaxle with fluid.
c. Refill the radiator with engine coolant.
d. Bleed air from the cooling system with the heater valve open.
e. 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.

TORQUE: 65 - 85 Nm (650 - 850 kgf.cm, 47.0 - 61.5 lb-ft)

3. Install the starter motor. (see EE group).

TORQUE: 65 - 85 Nm (650 - 850 kgf.cm, 47.0 - 61.5 lb-ft)

4. Tighten the transaxle under mounting bolts(A, B).

TORQUE: 46 - 53 Nm (460 - 530 kgf.cm, 33.3 - 38.3 lb-ft)




5. After removing a jack, insert the drive shafts. (see DS group)
6. Install the sub frame. (see SS group).
7. Tighten the roll stopper mounting bolts (A,B)

TORQUE: 90 - 110 Nm (900 - 1100 kgf.cm, 65.1 - 79.5 lb-ft)








8. Connect the return tube with a clamp. (see ST group)
9. Connect the lower arm, the tie rod end ball joint, the stabilizer bar link to the front knuckle. (see SS group)
10. Connect the power steering pressure tube (A) to the power steering oil pump.




11. Install the under cover (A).




12. Install the steering column joint bolt. (see ST group).
13. Install the front wheels and tires.
14. Tighten the transaxle insulator mounting bolt (A).

TORQUE: 90 - 110 Nm (900 - 1100 kgf.cm, 65.1 - 79.5 lb-ft)




15. Tighten the transaxle mounting bolts (B, C).

TORQUE: 65 - 85 Nm (650 - 850 kgf.cm, 47.0 - 61.5 lb-ft)




16. Remove the SST (09200-38001) holding the engine and transaxle assembly.




17. Connect the transaxle oil cooler hoses (A) to the tubes (C) by fastening the clamps (B).




18. Install the shift cable by tightening the bolt (A) and clip (B).

TORQUE: 10 - 14 Nm (100 - 140 kgf.cm, 7.2 - 10.1 lb-ft)




19. Connect the transaxle wire harness connectors.
(1) Install the inhibitor switch connector (A).




(2) Install the solenoid valve connector (A).




(3) Install the input speed sensor connector (A).




(4) Install the output speed sensor connector (A).




(5) Install the vehicle speed sensor connector (A).




(6) Install the CKP sensor connector (A).




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




21. Connect the air cleaner hose (B) by fastening the clamp (A).




22. Install the air cleaner assembly (A).




23. Install the air cleaner upper cover (B) by fastening the clips (A).




24. Connect the AFS connector (A).




25. Install the battery (A).