Installation

INSTALLATION





1. Attach a rope at 2 places on the transaxle. Place a flat board on a jack and set the transaxle on it.

Caution: The transaxle is not well balanced; be careful when positioning it on the lack.

2. Move the transaxle into place and attach the rope to the SST.
3. Mount the transaxle to the engine.

Tightening torque: 89-117 N.m (9.1-11.9 m-kg, 66-86 ft-lb)





Note: Lift the transaxle with the jack while pulling the rope. Align the torque converter bolts and drive plate holes.





4. Install engine mount No.4 and bracket.

Tightening torque:
Bolt 36-54 N.m (3.7-5.5 m-kg, 27-40 ft-lb)
Nut 64-89 Nm (6.5-9.1 m-kg, 47-66 ft-lb)





5. Install engine mount No.2.

Tightening torque:
(A) 85-117 Nm (8.7-11.9 m-kg, 63-86 ft-lb)
(B) 67-93 Nm (6.8-9.5 m-kg, 49-69 ft-lb)





6. Install the crossmember and the left side lower arm as an assembly.

Tightening torque:
Bolt 36-54 N.m (3.7-5.5 m-kg, 27-40 ft-lb)
Nut 75-93 N.m (7.6-9.5 m-kg, 55-69 ft-lb)

7. Remove the jack and the rope.
8. Remove the SST.





9. Install the starter and harnesses.

Tightening torque:
(A) 9.8-12 N.m (100-120 cm-kg, 87-104 in-lb)
(B) 37-52 N.m (3.8-5.3 m-kg, 27-38 ft-lb)

10. Install the manifold bracket.

Tightening torque:
(C) 37-52 N.m (3.8-5.3 m-kg, 27-38 ft-lb)
(D)37-52 Nm (3.8-5.3 m-kg, 27-38 ft-lb)





11. Install the torque converter nuts.

Tightening torque: 43-61 Nm (4.4-6.2 m-kg, 32-45 ft-lb)

12. Install the end plate.

Tightening torque: 8-11 N.m (80-110 cm-kg, 69-95 in-lb)





13. Install the gusset plates and exhaust pipe hanger.

Tightening torque:
Gusset plate
37-52 N.m (3.8-5.3 m-kg, 27-38 ft-lb)
Exhaust pipe hanger
19-25 Nm (1.9-2.6 m-kg, 14-19 ft-lb)





14. Replace the clips at the end of the driveshaft and joint shaft with new ones.
15. Install the joint shaft and right driveshaft as follows:

(1) Remove the SST (holder) and insert the joint shaft into the transaxle.
(2) Mount the joint shaft bracket onto the engine.
(3) Install and tighten the reamer bolts; then install and tighten the standard bolts.

Tightening torque:
Reamer bolts
6.9-9.8 N.m (70-100 cm-kg, 61-87 in-lb)
Standard bolts
42-62 N.m (4.3-6.3 m-kg, 31.1-45.6 ft-lb)





(4) Pull the front hub outward to connect the driveshaft to the joint shaft.
(5) Push the joint from the differential side to securely connect the driveshaft to the joint shaft.

Caution:
- Do not damage the oil seal.
- After Installation, pull the front hub outward to verify that the drlveahaft does not come out.

16. Install the left driveshaft as follows:
(1) Pull the front hub outward to insert the driveshaft into the transaxle.
(2) Push the joint from the differential side to connect the driveshaft to the differential side gear.

Caution:
- Do not damage the oil seal.
- After installation, pull the front hub outward to verify that the driveshaft does not come out.





17. Install the lower arm ball joints to the knuckles and tighten the bolts and nuts.

Tightening torque: 36-54 N.m (3.7-5.5 m-kg, 27-40 ft-lb)

18. Install the undercover.





19. Install the stabilizer bar control link as follows:
(1) Install the stabilizer bar control link.
(2) Adjust protrusion A to 20.1 +/- 2mm (0.79 +/- 0.08 in).
(3) Tighten nuts B to the specified torque.

Tightening torque: 16-23 Nm (1.6-2.3 m-kg, 12-17 ft-lb)





20. Install the tie-rod ends and new cotter pins.

Tightening torque: 42-57 N.m (4.3-5.8 m-kg, 31-42 ft-lb)





21. Connect the oil cooler outlet and inlet hoses as follows:
(1) Align the marks, and slide the oil cooler hoses onto the oil cooler pipes at least 3Omm (1.181 in).
(2) Install the hose clamps as shown and tighten them as specified.
(3) Verify that the hose clamps do not interfere with any other parts.

22. Install the splash shields.

Tightening torque: 8-11 N.m (80-110 cm-kg, 69-95 in-lb)

23. Install the front wheels.

Tightening torque: 88-118 N.m (9-12 m-kg, 65-87 ft-lb)

24. Connect the throttle cable.

Note: Adjust the throttle cable with the oil pressure test.





25. Connect the selector cable as follows:
(1) Disconnect the selector cable from the selector lever.
(2) Tighten the bolts and the nut.

Tightening torque:
Bolts
16-22 N.m (1.6-2.3 m-kg, 12-17 ft-lb)
Nut
44-64 N.m (4.5-6.5 m-kg, 33-47 ft-lb)

(3) Connect the selector cable to the selector lever, and adjust the selector lever.





26. Connect the ground wires to the transaxle case.

Tightening torque: 8-11 N.m (80-115 cm-kg, 69-99 in-lb)





27. Connect the EC-AT connectors as follows:
(1) Inhibitor switch
(2) Solenoid valve
(3) Pulse generator
(4) ATF thermoswitch

28. Connect the speedometer cable.
29. Install the intercooler hoses as follows: (Turbo)
(1) Air cleaner to turbocharger
(2) Intercooler to throttle body.

Tightening torque:
(A) 8-11 N.m (80-110 cm-kg, 69-95 in-lb)
(B) 64-89 N.m (6.5-9.1 rn-kg, 47-66 ft-lb)





30. Install the resonance chamber bracket.

Tightening torque: 8-11 N.m (80-110 cm-kg, 69-95 in-lb)

31. Install the resonance chamber and air cleaner hose.

Tightening torque: 8-11 N.m (80-110 cm-kg, 69-95 in-lb)

32. Install the air cleaner assembly; then connect the airflow meter connector and inlet hose.

Tightening torque:
Bolt 31-40 N.m (3.2-4.1 rn-kg, 23-30 in-lb)
Nut 8-11 N.m (80-110 cm-kg, 69-95 in-lb)

33. Connect the distributor lead.
34. Connect the main fuse block.

Tightening torque: 8-11 N.m (80-110 cm-kg, 69-95 in-lb)





35. Install the battery carrier and battery.

Tightening torque: 31-40 N.m (3.2-4.1 m-kg, 23-30 in-lb)





36. Pour in ATF and check following:
(1) With the engine idling, check that the fluid level is in the HOT (65 C) range on the dipstick.
(2) Check the manual linkage, and adjust if necessary.
(3) Check the inhibitor switch operation.
(4) Conduct a road test.
(5) Check that there is no fluid leakage from the transaxle.