With Manual Transaxle
Engine - iB5 Transaxle
Special Tool(s)
Material
Installation
All vehicles
1. Install the transaxle.
2. Install the transaxle LH retaining bolts.
3. Install the transaxle RH retaining bolts.
4. Install the starter motor.
^ Attach the ground cable to the transaxle.
5. Connect the starter motor electrical connectors.
6. Install the transaxle upper retaining bolts.
7. NOTE: Install a new exhaust flange gasket and new nuts.
Attach the catalytic converter to the exhaust manifold.
^ Install the heated oxygen (H02S) sensor.
8. Install the catalytic converter bracket.
^ Install the catalytic monitor sensor.
9. Using a retaining strap, secure the engine and transmission assembly on the assembly stand.
^ Remove the special tools.
10. Raise and support the vehicle.
11. Position the engine and transmission assembly under the vehicle.
^ Carefully lower the vehicle.
12. NOTE: Do not tighten the bolts and nuts at this stage.
Install the engine front mount.
13. NOTE: Do not tighten the bolts at this stage.
Install the engine rear mount.
14. Remove the retaining strap from the engine and transmission assembly, and remove the assembly stand.
15. Raise and support the vehicle.
16. CAUTION: Support the halfshaft. The inner joint must not be bent more than 18 degrees. The outer joint must not be bent more than 45 degrees.
CAUTION: Do not damage the halfshaft oil seal.
NOTE: Install a new halfshaft center bearing cap and locknuts.
Attach the RH halfshaft and the intermediate shaft to the transaxle.
^ Install the center bearing cap.
17. CAUTION: Support the halfshaft. The inner joint must not be bent more than 18 degrees. The outer joint must not be bent more than 45 degrees.
CAUTION: Do not damage the halfshaft oil seal.
CAUTION: Make sure the snap ring is correctly seated.
NOTE: Install a new snap ring.
Attach the LH halfshaft to the transaxle.
18. Install the crossmember.
19. Install the flexible exhaust pipe.
20. Lower the vehicle.
21. Tighten the engine rear mount nuts and bolts.
22. Tighten the engine front mount nuts.
23. Attach the power steering pump and the bracket to the engine.
24. Attach the power steering line bracket to the cylinder head.
25. Install the power assisted steering (PAS) reservoir.
26. Install the coolant expansion tank.
27. Raise and support the vehicle.
28. Connect the power steering pressure (PSP) switch electrical connector.
29. Connect the crankshaft position (CKP) sensor electrical connector.
30. Connect the radiator lower coolant hose to the coolant pump housing.
31. Connect the radiator lower coolant hose to the oil cooler.
Vehicles with air conditioning
32. Attach the air conditioning compressor.
All vehicles
33. Install the accessory drive belt.
34. Lower the vehicle.
35. Connect the oil cooler hose.
36. Attach the gearshift cables to the transaxle.
1. Attach the retaining bracket to the transaxle.
2. Attach the gearshift cable and the selector cable to the selector levers.
37. Connect the starter field wire electrical connector.
38. Attach the coolant hoses to the thermostat housing.
39. Attach the fuel pipes to the fuel rail.
40. Attach the brake servo vacuum hose to the intake manifold.
41. Attach the vacuum hoses to the throttle body.
42. Connect the reversing lamp switch electrical connector.
^ Clip on the wiring loom.
43. Connect the vehicle speed sensor (VSS) electrical connector.
44. Connect the wiring harness connectors.
45. WARNING: Escaping brake fluid. Do not allow brake fluid to come into contact with the skin or eyes. If brake fluid should come into contact with your skin or eyes, rinse the affected area immediately with water.
CAUTION: If any brake fluid gets on the paintwork, wash it off immediately with water.
Attach the clutch supply line to the clutch slave cylinder.
^ Install the clip.
46. Connect the generator electrical connector.
47. Connect the fuel injector wiring harness.
48. Install the electronic ignition (EI) coil cover.
49. Attach the accelerator cable and the speed control cable (if equipped) to the throttle body.
50. Install the splash shield.
51. Connect the engine block heater (if equipped).
52. Connect the intake manifold runner control (IRMC).
1. Rotate the IMRC lever.
2. Connect the IMRC actuator cable.
53. Install the air cleaner intake tube and resonator.
54. Tighten the strut and spring assembly upper mounting retaining nuts.
55. Attach the ground cable to the inner fender.
56. Install the air cleaner.
57. Install the battery tray.
58. CAUTION: 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 16 km (10 miles) or more to relearn the strategy.
Install and connect the battery.
59. Fill the cooling system.
60. Fill the transaxle.
61. Fill the engine with engine oil.
62. Bleed the hydraulic clutch operating system.
63. Fill and bleed the PAS system.