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MAINTENANCE AND REPAIR

ON-VEHICLE SERVICE


C7A15B87
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Transaxle Fluid Checking Procedure

    Important : It is not necessary to check the fluid level unless the fluid has been changed or a leak is suspected. Inspect the fluid level only when the engine is off. Ensure the vehicle is level.

  1. Raise and support the vehicle.
  2. Remove the fluid level check plug.
  3. Verify that the fluid is level with the opening.
  4. If the transaxle is not properly filled, carefully add SAE75W90 fluid until it begins to flow out of the fill/check plug.
  5. Install a new fluid level check plug.

    6. Tighten
    Tighten the fluid level check plug to 6 N•m (53 lb-in) + 45°~180°.

  6. Lower the vehicle.

Transaxle Fluid Replacement

    Caution : The transaxle fluid is hot. Caution must be taken to prevent personal injury when the transaxle fluid drains from the transaxle.

  1. Raise and support the vehicle.
  2. Remove the transaxle drain plug and allow the transaxle to drain completely.
  3. Remove the fluid level check plug.
  4. Install a new transaxle drain plug.

    5. Tighten
    Tighten the transaxle drain plug to 6 N•m (53 lb-in) + 45°~180°.

  5. Add SAE75W90 transaxle fluid until it seeps out of the fluid level check plug.
  6. Install a new fluid level check plug.

    7. Tighten
    Tighten the fluid level check plug to 6 N•m (53 lb-in) + 45°~180°.

  7. Lower the vehicle and verify proper operation.
    8. Fluid Specification
    SAE75W90
    Fluid Capacity
    FWD
    2.1L (2.22 qt)
    AWD
    2.3L (2.43 qt)

C7A15B85
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Shift Control Lever Housing

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Remove the console. Refer to Section 9G, Interior Trim.
  3. Disconnect the shift control cables from the shift control lever housing. Refer to "Shift Control Cable" in this section.
  4. Remove the nuts from the shift control lever housing.
  5. Remove the shift control lever housing.

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Installation Procedure

  1. Install the shift control lever housing.
  2. Install the nuts to the shift control lever housing.

    3. Tighten
    Tighten the shift control lever housing bolts to 8 N•m (71 lb-in).

  3. Connect the shift cables to the shift control lever housing, and adjust the cable. Refer to "Shift Control Cable" in this section.
  4. Install the console. Refer to Section 9G, Interior Trim.
  5. Connect the negative battery cable.

C7A15B74
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Shift Control Cable

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Remove the console. Refer to Section 9G, Interior Trim.
  3. Remove the shift control cable adjust locks (1).
  4. Remove the shift control cables (2) from the shift control lever housing bracket.
  5. Disconnect the shift control cables from the shift control adjusters.

    6. C7A15B79
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  6. Remove the shift control cables (1) from the transaxle using a suitable tool.
  7. Remove the cables (2) from the shift control cable bracket.

    8. L7B53BB2
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  8. Remove the grommet from the dash pannel.
  9. Remove the shift control cables from the vehicle.

L7B53BB2
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Installation Procedure

  1. Install the shift control cables to the vehicle.
  2. Install the grommet from the dash pannel.

    3. Important : Ensure that the shift control cable pass-through grommet is properly seated and the grommet arrow is pointing up.


    C7A15B79
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  3. Install the cables (2) to the shift control cable bracket.
  4. Install the shift control cables (1) to the transaxle.
  5. Position the transaxle into NEUTRAL.

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  6. Connect the shift control cables into the shift control adjusters.
  7. Install the shift control cables to the shift control lever housing bracket.

    8. L7B53BB4
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  8. Position the shift lever into NEUTRAL.
  9. With the shift cable ends in the adjusters, adjust the cables by pushing the neutral lock pin. Move the shifter slightly to center the neutral lock pin.

    10. C7A15B75
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  10. Press and lock the shift control cable adjust locks.
  11. Pull the neutral lock pin to the original position.
  12. Install the console. Refer to Section 9G, Interior Trim.
  13. Connect the negative battery cable.

C7A15B98
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Shift Control Cable Adjustment

  1. Disconnect the negative battery cable.
  2. Position the transaxle into NEUTRAL.
  3. Connect the shift control cables into the shift control adjusters.
  4. Install the shift control cables to the shift control lever housing bracket.

    5. L7B53BB4
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  5. Position the shift lever into NEUTRAL.
  6. Adjust the cable by pushing the neutral lock pin. Move the shifter slightly in order to center the neutral lock pin.

    7. C7A15B75
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  7. Press and lock the shift control cable adjust locks.
  8. Pull the neutral lock pin to the original position.
  9. Connect the negative battery cable.

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Transaxle Assembly

Tools Required

DW110-060 Engine Assembly Support Fixture

Removal Procedure

  1. Remove the battery and the battery tray. Refer to Section 1E1, Engine Electrical - 2.0 Diesel ; Section 1E2, Engine Electrical - FAM II 2.4D.
  2. Remove the power steering oil reservoir mounting bolts and put the reservoir aside.
  3. Remove the pin and the clutch actuator cylinder pipe.

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  4. Remove the upper transaxle-to-engine bolts.

    5. C7A11C45
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  5. Install the DW110-060.
  6. Raise and suitably support the vehicle.

    7. C7A19N01
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  7. Remove the engine under cover. Refer to Section 9N, Frame and Underbody.
  8. Remove the left side dust cover.

    9. C7A11C33
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  9. Remove the front exhaust pipe. Refer to Section 1G1, Engine Exhaust - 2.0 Diesel ; Section 1G2, Engine Exhaust - FAM II 2.4D.

    10. C7A12C13
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  10. Carefully remove the cradle from the vehicle. Refer to Section 2C, Front Suspension.
  11. Remove the drive axle shafts. Refer to Section 3A, Front Drive Axle.

    12. C7A15B79
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  12. Remove the shift control cables (1) from the transaxle using a suitable tool.
  13. Remove the cables (2) from the shift control cable bracket.

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  14. Disconnect the backup lamp switch electrical wiring connector.

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  15. Remove the front damper bush mounting bolts and the front damper bush.

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  16. Remove the rear transaxle mounting bracket bolts.
  17. Remove the rear damper bush and the rear transaxle mounting bracket.

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  18. For AWD, remove the transfer case from the transaxle. Refer to Section 5D, Transfer Case.

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  19. Remove the starter. Refer to Section 1E1, Engine Electrical - 2.0 Diesel ; Section 1E2, Engine Electrical - FAM II 2.4D.

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  20. Support the transaxle assembly using the supporting jack.

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  21. Remove the oil pan flang-to-transaxle bolts (1).
  22. Remove the right lower engine-to-transaxle bolts (2) near the front damper bush.

    23. Notice : For bolts removal of 2.0S Diesel. Refer to Section 1B, Engine Mechanical - 2.0 Diesel.


    C7A15B84
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  23. Remove the left upper transaxle mounting bracket bolts.

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  24. Carefully remove the transaxle assembly from the vehicle.

L7B53BC3
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Installation Procedure

  1. Install the transaxle into the vehicle and support the transaxle assembly using the supporting jack.

    2. C7A15B84
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  2. Install the left upper transaxle mounting bracket bolts.

    3. Tighten
    Tighten the left upper transaxle mounting bracket bolts to 50 N•m (37 lb-ft).


    C7A15BA1
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  3. Install the right lower engine-to-transaxle bolts (2) near the front damper bush.

    4. Tighten
    Tighten the right lower engine-to-transaxle bolts (2) to 75 N•m (55 lb-ft).

  4. Install the oil pan flange-to-transaxle bolts (1).

    5. Tighten
    Tighten the oil pan flange-to-transaxle bolts (1) 50 N•m (37 lb-ft).

    Notice : For bolts installation and torque value of 2.0S Diesel. Refer to Section 1B, Engine Mechanical - 2.0 Diesel.

  5. Remove the transaxle support jack.

    6. C7A15B81
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  6. Install the starter. Refer to Section 1E1, Engine Electrical - 2.0 Diesel ; Section 1E2, Engine Electrical - FAM II 2.4D.

    7. C7A15D34
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  7. For AWD, install the transfer case into the transaxle. Refer to Section 5D, Transfer Case.

    8. C7A15A04
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  8. Install the rear damper bush and the rear transaxle mounting bracket.
  9. Install the rear transaxle mounting bracket bolts.

    10. Tighten
    Tighten the rear transaxle mounting bracket bolts to 90 N•m (66 lb-ft).


    C7A15B78
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  10. Install the front damper bush and the front damper bush mounting bolts.

    11. Tighten
    Tighten the front damper bush mounting bolts to 50 N•m (37 lb-ft).

  11. Install the drive axle shafts. Refer to Section 3A, Front Drive Axle.

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  12. Connect the backup lamp switch electrical wiring connector.

    13. C7A15B79
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  13. Install the cables (2) to the shift control cable bracket.
  14. Install the shift control cables(1) to the transaxle.

    15. C7A12C13
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  15. Carefully install the cradle into the vehicle. Refer to Section 2C, Front Suspension.

    16. C7A11C33
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  16. Install the front exhaust pipe. Refer to Section 1G1, Engine Exhaust - 2.0 Diesel ; Section 1G2, Engine Exhaust - FAM II 2.4D.

    17. C7A19N01
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  17. Install the left side dust cover.
  18. Install the engine under cover. Refer to Section 9N, Frame and Underbody.
  19. Lower the vehicle.
  20. Remove the DW110-060 from the engine.

    21. C7A15B76
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  21. Install the upper transaxle-to-engine bolts.

    22. Tighten
    For FAM II 2.4D or 2.0S Diesel, tighten the upper transaxle-to-engine bolts to 75 N•m (55 lb-ft).


    C7A15B77
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  22. Install the pin and the clutch actuator cylinder pipe.
  23. Install power steering oil reservoir mounting.
  24. Install the battery and the battery tray. Refer to Section 1E1, Engine Electrical - 2.0 Diesel ; Section 1E2, Engine Electrical - FAM II 2.4D.
  25. Execute the air bleeding. Refer to Section 5C, Clutch
  26. Adjust the shift control cable. Refer to "Shift Control Cable Adjustment" in this section.
  27. Check the fluid level. Refer to "Transaxle Fluid Checking Procedure" in this section.


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