Vehicle on Hoist, Engine Off
REAR TRANSAXLE MOUNT (1991 VEHICLES)
1. Loosen the front transaxle mount bolts and rear transaxle mount through bolt, and rock the powertrain to make sure that it is free. Tighten the front mount bolts.
IMPORTANT:
To access the front mount-to-transaxle bolts, remove forward, lower left-hand, wheel well splash shield pushpins and move the shield aside.
Torque: Front transaxle mount bolt 48 N-m (35 lbs.ft.)
2. The rear transaxle mount bracket should now move vertically 6.35-12.70 mm (1/4-1/2 in.) when measured at the mount through the bolt hole slot.
NOTE:
If the powertrain cannot be rocked, the powertrain is probably bound at the front transaxle mount. Refer to "Front Transaxle Mount" in this bulletin.
IMPORTANT:
A knocking or clicking sound can be emitted from either the transaxle front or rear mount. This noise, which frequently comes from the rear mount, is normally heard during acceleration, a sharp turn of the wheels, shifting gears or initially letting out the clutch and under other normal operating conditions. The suspected mount attachment fastener torques must be checked. If the fastener torques are correct, the suspect mount must be replaced.
3. The rear transaxle mount through-bolt should move freely in the bracket and mount. If the bracket has been damaged by the bolt head/nut from previous adjustments, the rear transaxle mount must be replaced. Torque the nut using a box end wrench and a torque wrench.
Torque: Rear transaxle mount nut 70 N-m (52 lbs.ft.)
IMPORTANT:
Do not pull vertically downward on the mount bolt/nut when tightening, as this will preload the mount's rubber insert.
4. Check the torque of the two rear transaxle mount-to-cradle bolts.
Torque: 70 N-m (52 lbs. ft.)
IMPORTANT:
The rear transaxle mount through-bolt and nut must be loosened and the powertrain rocked to adjust the mount when an A/C option is installed. Refer to steps 1-4 of rear transaxle mount.
FRONT TRANSAXLE MOUNT (1991 VEHICLES)
1. Check for front transaxle mount housing position, relative to the transaxle case. The mount housing must be both horizontally and vertically parallel with the transaxle housing.
IMPORTANT:
The rubber insert must be flush with the aluminum housing edge. If it isn't flush, the mount is probably misaligned. The mount may have to be removed for inspection of debris on the cradle and/or housing under the mount assembly. A short, straight edge (such as a credit card) can be used to evaluate housing and rubber insert position.
2. To check and correct an improperly positioned mount, perform the following procedures:
a. Remove the two rearward, lower radiator splash shield pushpins and lower the rear side of the shield.
b. Check the front transaxle mount housing to make sure it is parallel with the rubber insert, horizontally and vertically as shown with arrows.
c. If vertical alignment is not correct, remove the forward, lower left-hand side wheelwell splash shield pushpin and move the shield aside for access to the front mount-to-transaxle bolts.
d. Remove both cradle attachment nuts and the two bolts which attach the mount to the transaxle.
e. Inspect the mount casting and cradle surfaces for debris under the mount assembly. If the mount has to be removed, it can be checked with a 90 degree square on the side of a bench to make sure the cradle mounting and rubber insert casting surfaces are at a 90 degree angle.
f. If the mount is not repairable, it must be replaced.
g. If horizontal alignment is not correct. loosen both transaxle front mount-to-cradle attachment nuts 1/4 of a turn. Continue loosening each nut alternately by 1/4 of a turn until the mount housing is parallel to the transaxle surface.
IMPORTANT:
A large screwdriver can be wedged between the outer mount housing and the transaxle case to keep the mount parallel with the transaxle case when tightening the nuts.
h. Hold the mount in place and tighten the two nuts.
Torque: 48 N-m (35 lbs. ft.)
FRONT ENGINE MOTION RESTRAINT CABLE AND MOTION RESTRICTOR (SLAP/SNAP) (1991 VEHICLES)
The large restraint cable located at the rearward side of the engine mount can make a squeaking noise during vehicle starts, stops, acceleration, etc. The cable can be lubricated with chassis grease to eliminate this noise.
The motion restrictor cable is only used on the DOHC (LLO) engine equipped with a manual transaxie. The cable is located at the right-hand, forward side of the engine. This cable is attached to the forward side of the engine block and cradle. If the motion restrictor emits a slapping or clicking noise during shifts or harsh accelerations, it must be replaced.
ENGINE STRUT CRADLE BRACKET (1992-1994 VEHICLES)
Check the powertrain for binding and strut noises (squeaks) by pushing forward and rearward on the engine oil pan. The powertrain should travel a minimum of 3.18mm (1/8 in.).
If the powertrain does not move:
1. Check cradle-to-body alignment at the two front cradle alignment holes. Adjust cradle-to-body, only if necessary.
2. Check the struts (engine and transaxle) for correct installation and bushing wear.
3. Loosen the two engine strut bracket to cradle fasteners. Refer to "Engine Strut Cradle" section in the "Powertrain Mounts Service Manual."
4. Shake the powertrain by pushing forward and rearward on the engine oil pan.
5. Allow the powertrain to settle to its natural position and tighten the two engine strut bracket to cradle fasteners.
Torque: 70 N-m (52 lbs. ft.)
6. If the strut noises cannot be eliminated during powertrain adjustment, replace the strut assembly.
INTERMEDIATE EXHAUST PIPE ISOLATOR (1991 VEHICLES)
The new intermediate exhaust pipe isolator can be installed on vehicles equipped with the old-type intermediate exhaust pipe isolator to reduce interior vehicle noise, if the exhaust heat shield is modified (as shown in Figure). If the heat shield is not modified and the new intermediate exhaust pipe isolator is installed, the isolator will contact the exhaust heat shield. To modify the exhaust heat shield and install the new intermediate exhaust pipe isolator, refer to the following procedure.
IMPORTANT:
A new intermediate exhaust pipe isolator is released for all vehicles, built before MZ117347, except the SOHC (LKO) engine equipped with an automatic transaxle. All SOHC (LKO) engines with an automatic transaxle, and all other vehicles built after VIN MZ117347, have the new intermediate exhaust pipe isolator installed during production (Figure, View B).
CAUTION:
HEAVY WORK GLOVES AND EYE PROTECTION MUST BE WORN WHEN MODIFYING THE EXHAUST HEAT SHIELD, AND WHEN REMOVING AND INSTALLING THE INTERMEDIATE EXHAUST PIPE ISOLATOR. THE EXHAUST HEAT SHIELD EDGES ARE EXTREMELY SHARP AND CONTACT WITH THE EDGES COULD CAUSE PERSONAL INJURY.
1. Raise the vehicle on a hoist.
2. Remove the intermediate exhaust pipe bolt and isolator.
3. Using tin snips, vertically cut 25.4 mm (1 in.) of tin away from the end of the heat shield as shown in Figure. Shortening the heat shield behind the isolator allows the new (thicker) isolator room for forward and rearward movement.
NOTE:
The new isolator holt is a smaller diameter then the original and must be used to secure the isolator to the exhaust pipe.
4. Install the new intermediate exhaust pipe isolator (P/N 2101 1418) and bolt (P/N 21011417). The new rubber isolator has to be held squarely in place when tightening the bolt or the isolator will become bound.
Torque: 25 N-m (18 lbs. ft.)
CATALYTIC CONVERTER (1991 VEHICLES)
Inspect exhaust system isolators used at the catalytic converter. Verify that an interference fit exists between each body attachment hanger and isolator. Also, check to see if the attachment hole on the isolator is worn (shown in Figure). If a loose fit exists or if the isolator attachment hole is worn, replace them with a new isolator (P/N 21011302). The isolator bolt will crush the rubber of the new hangers slightly to make sure they remain tight against the catalytic converter flange.
MUFFLER (1991-1994 VEHICLES)
Verify that the muffler can be moved both yertically and horizontally in the isolator block. The muffler should move in the isolator block a minimum of 1.60 mm (1/16 in.) vertically (direction "A", in Figure) and 3mm (1/8 in.) horizontally (direction "B", in Figure).
If the muffler does not move freely, perform the following steps.
1. Loosen the band clamp and position the muffler to allow the movement previously described.
IMPORTANT:
Two rows of bumps have been formed in the muffler sheet metal and the muffler clamp must be between them.
2. Tighten the band clamp. Check for proper muffler movement.
Torque: 31 N-m (23 lbs. ft)
IMPORTANT:
If muffler movement cannot be obtained, the exhaust system will have to be carefully lowered and the muffler isolator block will have to be adjusted or shimmed. Washers, with an inside diameter of 9.53mm (3/8 in.), can be installed on the attachment bolt(s) between the muffler block and frame rail to align the hanger parallel with the muffler.
3. To lower the exhaust system:
a. Remove the intermediate exhaust pipe center isolator, muffler band clamp and carefully lower the exhaust system.
b. Loosen the muffler isolator block fasteners and inspect the isolator and body surfaces for debris.
c. Clean the surfaces or rotate the block to align it with the muffler band insert. If necessary, install washers between the muffler and frame rail.
d. Tighten the muffler block fasteners and band clamp. Check for proper muffler movement.
Torque: Muffler Block Fasteners:
18 N-m (159 lbs. in.)
Torque: Muffler Band Clamp:
31 N-m (23 lbs. ft.)
MUFFLER (1992 EARLY PRODUCTION VEHICLES)
The exhaust system may contact the rear cross-member (suspension), rear muffler heat shield or muffler isolator block during forward or reverse transaxle shifts.
Check the exhaust system pipe for contact with the rear suspension cross-member and muffler band clamp for contact with the heat shield/isolator block. If the exhaust pipe or band clamp are contacting the crossmember, heat shield or isolator block, the muffler band clamp will have to be positioned as follows:
1. Loosen the muffler band clamp.
2. Align the forward leading edge of the muffler band clamp with the front leading edge of the forward set of bumps on the muffler. This will position the forward leading edge of the band clamp on top of the muffler bumps.
3. Hold the muffler band clamp in place and tighten the fastener.
Torque: 31 N-m (23 lbs. ft.)
4. Check the leading edge of the muffler band clamp to make sure it is positioned on the forward set of muffler bumps.
5. Check the joint on the band clamp to make sure it is centered over the muffler seam. The muffler should move a minimum of 1.60mm (1/16 in.) vertically and horizontally when the band clamp is torqued.
NOTE:
If a rattle noise is heard at the rear of the vehicle with the engine at idle, the muffler band clamp support bracket locating tab and bolt may be loose. The band clamp support bracket must be torqued.
Torque: 20 N-m (15 lbs. ft.)