Special Tools Required
Engine support hanger ( AAR-T1256-J00)
| 1. | Install the torque converter (A) on the mainshaft (B) with the new O-ring (C).
|
| 2. | Install the 14 x 20 mm dowel pins (D) in the torque converter housing. |
| 3. | Place the transmission on the jack, and raise the transmission to the engine level. |
| 4. | Install the lower transmission housing mounting bolt (A) part-way in the bolt hole on the engine, then attach the transmission to the engine.
|
| 5. | Install the lower transmission housing mounting bolt (B), and tighten the bolts. |
| 6. | Install the rear transmission housing mounting bolts.
|
| 7. | Install the front transmission housing mounting bolts.
|
| 8. | Install the upper transmission housing mounting bolts.
|
| 9. | Secure the transmission mount bracket on the transmission housing with the new mounting bolts.
|
| 10. | Install the new set ring (A) on both driveshafts (B).
|
| 11. | Clean the areas where the driveshaft contacts the transmission (differential) with solvent or carburetor cleaner, and dry with compressed air. Then install the driveshaft, be sure not to allow dust or other foreign particles to enter the transmission. Turn the steering knuckle fully outward, and slide the driveshaft into the differential until you feel its set ring fully engage the side gear. |
| 12. | Attach the torque converter to the drive plate with eight bolts (A). Rotate the crankshaft pulley as necessary to tighten the bolts to 1/2 of the specified torque, then to the final torque, in a crisscross pattern. After tightening the last bolt, check that the crankshaft rotate freely.
|
| 13. | Install the torque converter cover (B). |
| 14. | Install the shift cable holder bracket.
|
| 15. | Install the control lever (A) over the selector control shaft (B).
|
| 16. | Install the shift cable holder (C) on the holder bracket (D) with tightening bolts loosely. Tighten the bolts (E) in the lateral position to the specified torque, then tighten the bolt (F) in the vertical position. |
| 17. | Secure the control lever with the new lock washer (G) and the lock bolt (H), then bend the lock tab of the lock washer against the bolt head. |
| 18. | Install the shift cable cover (I). |
| 19. | Support the front subframe with a wood piece and a jack, and lift it up to the body.
|
| 20. | Loosely install the new subframe mounting bolts.
|
| 21. | Align the reference marks (A) on the subframe (B) with the edge (C) of the body, and tighten the mounting bolts to the specified torque.
|
| 22. | Secure the lower torque rod with the new bolts.
|
| 23. | Remove the engine support hanger. |
| 24. | Position the steering gearbox on the gearbox mounting bracket of the subframe. |
| 25. | Install the gearbox stiffener (A) in the direction shown and bolts, and tighten the bolts loosely. NOTE: Steps 25 thru 30 describe steering gearbox installation for the LHD model with hydraulic assisted power steering; RHD model is symmetrical. If you install the gearbox on the model with electrical power steering, go to 31.
|
| 26. | Install the gearbox stiffener (A) and bolts, and tighten the bolts loosely.
|
| 27. | Secure the power steering fluid line clamp bracket (B) with the bolt. |
| 28. | Align the slit (A) of the gearbox mounting rubber (B) with the front bracket surface (C), and install the steering gearbox mounting bracket (D) with pointing the arrow (E) to the front.
|
| 29. | Tighten the steering gearbox mounting bolts and stiffener mounting bolts to the specified torque. |
| 30. | Secure the power steering fluid line bracket (A) with the bolt, and secure the line (B) with the clamp (C).
|
| 31. | Install the gearbox stiffener (A), steering gearbox mounting bolt (B), and stiffener mounting bolt (C), and tighten the bolts loosely. Secure the harness clamp bracket (D) with the bolt. NOTE: Steps 31 thru 35 describe gearbox installation for electrical power steering model.
|
| 32. | Install the stiffener (A), steering gearbox mounting bolt (B), and stiffener mounting bolt (C), and tighten the bolts loosly.
|
| 33. | Install the steering gearbox bracket mounting bolts.
|
| 34. | Tighten the steering gearbox mounting bolts and stiffener mounting bolts to the specified torque. |
| 35. | Secure the harness clamp bracket with the bolt.
|
| 36. | Install both body mount brackets with the new bolts.
|
| 37. | Install both lower arms (A) to both ball joints (B), and loosely install the new mounting nuts and bolts.
|
| 38. | Tighten the nuts and bolts to 59 N·m (6.0 kgf·m, 43 lbf·ft) in the following order; the nut on the front (C), the nut on the rear (D), then the bolt (E). |
| 39. | Remove the hanger plate (A) and bolt (B), and install the harness cover bracket (C) on the engine.
|
| 40. | Install the air cleaner housing mounting bracket (A).
|
| 41. | Install the harness cover (B) on its bracket, and secure it with the bolts. |
| 42. | Connect disconnected connectors (C) and vacuum tube (D), and secure the tube with the clip. |
| 43. | Install the ACG terminal (A), connect the connectors (B), and install the harness clamp (C) on its bracket (D).
|
| 44. | Secure the harness cover with the bolts.
|
| 45. | Install the engine cover.
|
| 46. | Connect the shift solenoid harness connector (A) and the 3rd clutch transmission fluid pressure switch connector (B), and install the harness clamps (C) on the clamp bracket (D).
|
| 47. | Install the harness clamp (A) in its bracket (B), and install the radiator hose (C) in the clamp (D).
|
| 48. | Install the ATF warmer (A) on the bracket (B).
|
| 49. | Connect the ATF warmer hoses (A) to the ATF lines (B), and secure the hoses with the clips (C).
|
| 50. | Connect the input shaft (mainshaft) speed sensor connector (A) and the 2nd clutch transmission fluid pressure switch connector (B).
|
| 51. | Connect the transmission range switch connector (A) and output shaft (countershaft) speed sensor connector (B), and install the harness clamps (C) on the brackets (D).
|
| 52. | Install the air cleaner housing mounting bracket (A), and install the harness clamp (B) on its bracket (C).
|
| 53. | Connect the A/T clutch pressure control solenoid valve A connector, solenoid valve B connector, and solenoid valve C connector.
|
| 54. | Secure the harness cover (D) with the mounting bolts, and install the harness clamp (E) on tis bracket (F). |
| 55. | Refill the transmission with ATF. |
| 56. | Install the battery base and resonator. |
| 57. | Install the air intake duct and air cleaner housing. |
| 58. | Install the bulkhead cover. |
| 59. | Install the under-cowl panel and cowl cover. |
| 60. | Install the windshield wiper arms. |
| 61. | Install the battery tray and battery, then secure the battery with its hold-down bracket. |
| 62. | Connect the battery terminals, and apply grease around the battery terminals. |
| 63. | Set the parking brake. Start the engine, and shift the transmission through all positions three times. |
| 64. | Check the shift lever operation, A/T gear position indicator operation, and shift cable adjustment. |
| 65. | Check and adjust the front wheel alignment. |
| 66. | Install the splash shield. |
| 67. | Start the engine in the P or N position, and warm it up to normal operating temperature (the radiator fan comes on). Turn off the engine, and check the ATF level. |
| 68. | Enter the radio (and navigation) anti-theft code, then enter the radio presets, and set the clock. |
| 69. | Do the power window control unit reset procedure. |
| 70. | Perform the road test. |