Installation

Special Tools:

Installation

1. NOTE: The self-locking nuts must be reserved.
General Instructions
- The location of engine mountings and roll resistors are described locking from the automatic transaxle to the engine.

2. CAUTION The torque converter is heavy. Install the special tool before raising the transaxle

CAUTION: The torque converter must remain at the correct installation depth throughout the whole installation procedure.

NOTE: The torque converter studs must be aligned with the flywheel holes before any transaxle to engine bolts are installed.





Install the special tool (if not installed yet).

3. NOTE: The torque converter hub must engage fully in the oil pump drive gear.

Check the installation depth of the torque converter.





1 Lay a steel straightedge on the automatic transaxle flange.
2 Check the installation depth between the transaxle flange and the torque converter centering spigot for the correct clearance: 2 mm.
3 Apply a thin layer of High-temperature grease or equivalent to the centering spigot bore on the torque converter.





4. Using the Transmission Jack and the CD4E transaxle adapter raise and position the transaxle into place.
- Remove the special tool 307-346.





5. Install the transaxle to engine bolts.

6. NOTE: The special tool 307-346 (T94-7902A) must be removed.





Install the lower transaxle to engine bolts.





7. Install the torque converter nuts.
- Install torque converter inspection cover.





8. Connect the main control cover tube.

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

9. NOTE: Do not damage the oil seal.





Install the right-hand halfshaft and intermediate shaft.





10. Install a new snap ring.

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

NOTE: Do not damage the oil seal. Check that the snap ring engages correctly.





Install the left-hand halfshaft.

12. CAUTION: Do not loosen connector cooler inlet to transaxle.





Position and install the lower transaxle cooling tube.

13. CAUTION Do not loosen connector cooler inlet to transaxle.





Position and install the upper transaxle cooling tube.

14. NOTE: Do not tighten the bolt.





Install the right-hand roll restrictor center bolt.

15. WARNING: Support the subframe using Rotunda Powertrain Lift. Place wooden block approximately one meter (40 inches) in length secured to lift under subframe.

NOTE: Do not tighten the bolts.





Install the subframe.





16. Install the steering intermediate shaft.





17. Install the transaxle cooler line brackets, and bolt.
- Position the suction accumulator (A/C), if equipped.





18. Install the power steering hoses to the subframe (one nut and two bolts).





19. Using the special tool, install the steering gear (two bolts) (left-hand side shown).





20. Install the steering gear heat shield.
22. Using the special tool, align the sub-frame and tighten the bolts.





1 Install the special tool.
2 Align the subframe with the locating holes in the body.
3 Install the subframe bolts working diagonally.

23. Remove the left-hand support insulator and install the special tool.





1 Install the special fool.
2 Install the bolts.
3 Install the through bolt.

24. Lower the vehicle.





25. Tighten the rear transaxle support bracket nuts.
26. Raise and support the vehicle.





27. Tighten the right-hand support insulator through bolt.
28. Remove special tool 502-003 and install the lefthand support isolator.





1 Install the through bolt.
2 Install the bolts.

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





Connect the lower suspension arm ball joints and the stabilizer link rods.
- Attach the ABS wiring harness bracket to the suspension strut.

30. CAUTION: Extreme extension of the flexible tube can lead to damages.





Install the flexible tube and the rear Three-Way Catalytic Converter (TWC).
- Install the new gaskets.
- Remove the protection collar.





31. Install the flexible tube and the TWC to the exhaust manifold..
- Install the gaskets.





32. Install the cable ties.

Vehicles With Air Conditioning





33. Install the suction accumulator bracket bolts.

All Vehicles





34. Install the bumper brackets on both side (left-hand side shown).





35. Install the right-hand fender splash shield.





36. Install radiator splash shield.
- Install the bolts and clips.

37. Lower the vehicle.





38. Install both front wheels (right hand side shown).





39. Disconnect the selector cable from the transaxle.
1 Selector lever selector cable
2 Bracket





40. Connect the Turbine Shaft Speed Sensor (TSS) (shown from below).
- Clip the cable.





41. Connect the OSS-sensor connector.

42. NOTE: Ground lead.





Install the upper bellhousing bolts (1999 MY four bolts).





43. Remove the special tools.





44. Check that the selector lever position indicator agrees with the transaxle operation.
- Parking lock in selector lever position "P'', reverse gear in selector lever position "R" and forward in selector lever position "D".

45. If the selector lever position indicator does not agree with the transaxle operation in all settings:
- Raise the vehicle and disconnect the head shield (four clips).

46. NOTE: The mark line up in position "D". There is no need to hold after engaging a gear as there is an integral detent mechanism.





Move the selector lever to position "D".
1 Prevent the selector cable from turning.
2 Disconnect the selector cable adjusting cap.
3 Move the selector lever to position "D".

47. Adjust the selector lever scale position.
- Remove the selector lever nuts.

48. NOTE: The selector lever has its own detent mechanism. Holding the selector lever is not necessary.

Slide the whole selector assembly forwards or backwards until the reading on the scale and the position of the selector lever indicator corresponds.





49. Tighten the selector lever nuts.

50. NOTE: The selector lever has its own detent mechanism. It is not necessary to hold in after engaging a gear.





Move the automatic transaxle selector lever to position "D".
51. Lock the selector cable.





1 Prevent the selector cable from turning.
2 Lock the selector cable adjustment cap.
- Fit the heat shield.





52. Install the starter motor bolts.





53. Install the water pump cover.
- Attach the engine coolant hose and install the bolts.

54. Connect the electrical connections.





1 Ground cable
2 Automatic transaxle control
3 Transmission Range (TR) switch
4 Wiring harness retaining clip

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





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





56. Tighten the suspension strut locknuts with a torque wrench (right-hand side shown).





57. Remove the radiator supports.


See TSB 06-14-4





58. Fill the transaxle with MERCON (R) Multipurpose automatic transmission fluid. MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid, as per TSB 06-14-4.

59. 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 160 km (100 miles) or more to relearn the strategy.

Install the battery tray.
60. Fill and bleed the power steering system.