MANUAL TRANSAXLE REMOVAL/INSTALLATION [J65M-R]

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1.  Remove the following parts:

(1)  Battery and battery tray (See BATTERY REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)

(2)  Air cleaner component (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)

(3)  Inter cooler pipe bracket (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)

(4)  Catalytic converter bracket (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)

(5)  Wheels, tires and splash shields

(6)  Under cover

(7)  Vacuum chamber

(8)  Starter (See STARTER REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)

2.  Drain the transaxle oil into a suitable container.

3.  Remove in the order indicated in the table.

4.  Install in the reverse order of removal.

5.  Add the specified amount of specified transaxle oil.

6.  Perform the clutch fluid line air bleeding. (See CLUTCH FLUID AIR BLEEDING/REPLACEMENT.)

Note

•  If the transaxle is overhauled and installed to the vehicle, perform the "INSPECTION AFTER TRANSAXLE INSTALLATION" and verify that there is no abnormality. (See INSPECTION AFTER TRANSAXLE INSTALLATION [J65M-R].)

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1	Back-up light switch connector
2	Harness bracket
3	Select cable (See Shift Cable And Select Cable Removal Note.)
4	Shift cable (See Shift Cable And Select Cable Removal Note.)
5	Cable bracket
6	Clutch pipe connector (See Clutch Pipe Connector Removal Note.) (See Clutch Pipe Connector Installation Note.)
7	Transaxle mounting bolt (upper side)
8	Tie-rod end ball joint (See FRONT CROSSMEMBER REMOVAL/INSTALLATION.)
9	Stabilizer control link
10	Lower arm ball joint
11	Drive shaft (See DRIVE SHAFT REMOVAL/INSTALLATION.)
12	Joint shaft (See JOINT SHAFT REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)
13	No.1 engine mount rubber (See No.1 Engine Mount and No.4 Engine Mount Installation Note.)
14	Battery tray bracket
15	No.4 engine mount rubber (See No.4 Engine Mount Removal Note.) (See No.1 Engine Mount and No.4 Engine Mount Installation Note.)
16	No.4 engine mount bracket (See No.4 Engine Mount Removal Note.) (See No.1 Engine Mount and No.4 Engine Mount Installation Note.)
17	Transaxle mounting bolt (lower side)
18	Manual transaxle (See Manual Transaxle Removal Note.) (See Manual Transaxle Installation Note.)

Shift Cable And Select Cable Removal Note

1.  Remove both the shift cable end and select cable end using a fastener remover.

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Clutch Pipe Connector Removal Note

Caution

•  When disconnecting the clutch pipe, the seal ring installed to the end of the clutch pipe connector may fall off or remain on the clutch release cylinder side. If the clutch pipe connector is assembled with the seal ring not installed, it may cause fluid leakage from the clutch pipe connector or the clutch may not operate normally. When disconnecting the clutch pipe connector, remove the seal ring and clutch pipe connector as a single unit.

Note

•  A seal ring has been installed to the mid-connector between the clutch master cylinder and clutch release cylinder. Verify that the clutch pipe connector is removed together with the seal ring when disconnecting the mid-connector.

1.  Pull the clutch release cylinder clip to the position shown in the figure and pull the clutch pipe connector straight out to detach.

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2.  Verify that the seal ring is removed together with the clutch pipe connector.

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No.4 Engine Mount Removal Note

1.  Use the bolt to install the SST to the position shown in the figure.

Note

•  Fixing bolt: M8 x P 1.25 x L 25 mm {1.0 in}

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2.  To install the front shaft (RH) of the SST (49 C017 5A0), remove the clip shown in the figure.

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3.  Set the SST as shown in the figure.

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4.  Set the SST as shown in the figure.

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5.  Install the SST using the following procedure.

Caution

•  Refer to the SST instruction manual for the basic handing procedure.

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(1)  Install the right rear shaft of the SST to the bolt of the right shock absorber as shown in the figure.

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(2)  Install the left rear shaft of the SST to the bolt of the left shock absorber (Identical position to right side).

(3)  Install front foot No.2 to the left/right front shaft of the SST, then align the groove of the front shaft of the SST with the folded up part of the vehicle as shown in the figure.

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(4)  Adjust the positions of the SST side bars so that they are the same height (left and right) and horizontal.

(5)  Make sure each joint is securely tightened.

6.  Support the engine using the SST.

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7.  Remove the battery tray bracket, No.4 engine mount rubber and bracket.

Manual Transaxle Removal Note

Warning

•  Remove the transaxle carefully, holding it steady. If the transaxle falls it could be damaged or cause injury.

1.  Adjust the SST and lean the engine toward the transaxle.

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2.  Support the transaxle on a jack.

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3.  Remove the transaxle mounting bolts.

4.  Remove the transaxle.

Manual Transaxle Installation Note

Warning

•  Install the transaxle carefully, holding it steady. If the transaxle falls it could be damaged or cause injury.

1.  Set the transaxle on a jack and lift into place.

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2.  Install the transaxle mounting bolts.

3.  Adjust the SST (49 C017 5A0) so that the engine is located at the specified position.

No.1 Engine Mount and No.4 Engine Mount Installation Note

1.  Install the No.4 engine mount bracket on the transaxle case and tighten bolt and nuts.

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2.  Install the No.1 engine mount rubber to the cross member and temporarily tighten bolts.

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3.  Place the No.4 engine mount rubber with the body stud bolts passing through the holes and tighten a bolt shown in the figure.

Caution

•  If the engine mount rubber installation bolt is type A, replace it with type B bolt and tighten.

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4.  Place the battery tray bracket on the No.4 engine mount rubber with body stud bolts passing through the holes and tighten bolts and nuts in the order as shown in the figure.

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5.  Remove the SSTs.

6.  Install the clip as shown in the figure.

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7.  Fully tighten the bolts.

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Caution

•  Tighten the bolts in the order shown in the figure to prevent abnormal noise and vibration after assembly.

•  Tighten the bolts while being careful of their length to prevent interference between the steering gear housing and bolt.

Clutch Pipe Connector Installation Note

Note

•  A seal ring has been installed to the mid-connector between the clutch master cylinder and clutch release cylinder. Verify that a seal ring is installed to the clutch pipe connector when connecting the mid-connector.

1.  Verify that the seal ring is installed to the groove at the end of the clutch pipe connector.

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Caution

•  Verify that there is chipping or damage to the seal ring of the clutch pipe connector.

2.  Return the clutch master cylinder clip to the position shown in the figure.

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3.  Insert the clutch pipe connector straight.

4.  Pull the clutch pipe connector to verify that it does not come off and then reinsert completely.