Installation

Special Tools:

General Equipment:

NOTE: The locations of engine mountings and engine support insulators are given looking from the transaxle to the engine.

1. Position the transaxle to the engine using Hi-Lift Transmission Jack.

2. Install the eight bellhousing bolts.

3. Disconnect the holding strap and remove Hi-Lift Transmission Jack.

4. NOTE: Do not tighten the bolts.

Install subframe and subframe bolts.

5. NOTE: Install new seals for the power steering lines.

Install the power steering line bracket bolt and connect the power steering lines.

6. Install the shifter cables and bracket.
1 Position the shifter cable bracket.
2 Install the nuts.
3 Attach the shifter cables.

7. NOTE: The power steering pressure hose must be correctly routed while positioning the subframe.

NOTE: The intermediate shaft must be correctly aligned to the steering gear while positioning the subframe.

Tighten the subframe.
1 Install the special tools.
^ Align the subframe with the locating holes in the body.
2 Install the subframe bolts working diagonally.

8. Install the RH support insulator bracket.

9. Install the RH support insulator.
1 Install the bolts.
2 Install the through bolt finger-tight.

10. Install the special tool.
1 Position the special tool.
2 Install the bolts.
3 Install the through bolt finger-tight.

11. Install the intermediate shaft pinch bolt.

12. Attach the heated oxygen sensor (HO2S) electrical connector to the subframe.

13. Install the suction accumulator bracket bolts to the subframe (if A/C equipped).

14. Install the bumper bracket.

15. NOTE: LH side shown, RH side similar.

Install the radiator support brackets.
1 Position the brackets.
2 Install the bolts.

16. Install the secondary three-way catalytic converter (TWC).
1 Position the secondary TWC.
2 Install the nuts.

17. Install the radiator splash shield.
1 Position the radiator splash shield.
2 Install the bolts.
3 Install the push pins.

18. Install a new snap ring.

CAUTION: To avoid to damage the halfshaft joints and boots, do not bend the inner halt shaft joint by more than 18 degrees, the outer one by not more than 45 degrees.

19. CAUTION: Do not damage the oil seal.

Install the left-hand halfshaft.
^ Check that the snap ring engages correctly

20. CAUTION: Do not damage the oil seal.

Install the right-hand halfshaft and intermediate shaft.
^ Check that the snap ring engages correctly

21. CAUTION: Do not damage boot and ABS sensor ring

Connect the lower suspension arm ball joints and the stabilizer link rods (right-hand side shown).
^ Attach the ABS wiring harness bracket to the suspension strut.

22. Install the inner fender splash shields (right-hand side shown).
23. Install the front wheels.

24. NOTE: The fill level is 0-5 mm below the lower edge of the filler hole.

Check the transmission fluid level and fill Merkur manual transmission fluid as necessary.
25. Lower the vehicle.

26. Install the four upper bellhousing bolts.

27. Install the rear transaxle support insulator studs.

28. NOTE: Do not tighten the bolts and nuts.

Install the rear support insulator.
1 Install the insulator.
2 Install the bolts.
3 Install the nuts.

29. Install the starter motor.

30. Install the starter motor electrical connections.

31. CAUTION: Do not spill brake fluid onto painted surfaces.

Install the clutch slave cylinder hydraulic line.
32. Connect the fuel lines.

33. Connect the vehicle speed sensor (VSS) electrical connector and reversing lamp switch electrical connector.

34. Loosen front engine support insulator nuts.

35. NOTE: Install new self-locking nuts.

Tighten the rear support insulator.

36. Tighten the front support insulator nuts.
1 Tighten the nuts.
2 Connect the wire retainer.

37. Install the air cleaner (ACL) bracket and the starter motor bracket.
1 Install the starter motor bracket.
2 Install the ACL bracket.

38. Connect the ground cable.
39. Raise and support the vehicle.

40. NOTE: Verify that RH support insulator is centered in the bracket and in perfect front to rear alignment before tightening the through bolt. As necessary, loosen the support insulator to subframe mounting bolts and reposition the support insulator.

Tighten the RH support insulator through bolt.

41. Remove the special tool.
1 Remove the through bolt.
2 Remove the bolts.
3 Remove the special tool.

42. NOTE: Verify that the LH support insulator is centered in the transaxle bracket and in perfect front to rear alignment before tightening the through bolt.

Install the LH support insulator.
1 Position the front support insulator.
2 Install the nuts.
3 Install the through bolt.
43. Lower the vehicle.

44. Remove the special tools.

45. Connect the throttle cable and speed control cables.
1 Connect speed control cables, if equipped.
2 Connect the throttle cable.

46. Connect the accelerator and speed control cables.
1 Connect the accelerator and speed control cables.
2 Clip the cable into the bracket.

47. Connect the power steering reservoir hose.
1 Position the hose.
2 Position the hose clamp.
3 Install the power steering reservoir.

48. Install the water pump cover.
^ Attach the engine coolant hose and install the bolts.
49. Install the air cleaner (ACL).

50. Remove the radiator supports.

51. Tighten the front wheels (right-hand side shown).

52. NOTE: Use an Allen key to stop the piston rod from turning.

Tighten the suspension strut locknuts (right-hand side shown).

53. Tighten the suspension strut locknuts (right-hand side shown) (continued).
54. Install the battery.

55. 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 l6 km (10 miles) or more to relearn the strategy.

Connect the battery ground cable.
56. Bleed the clutch slave cylinder hydraulic system with High performance DOT 3 brake fluid or High performance DOT 4 brake fluid.
57. Fill and bleed the power steering system.