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308-06 Manual Transmission-Transaxle External Controls > < Transaxle - Vehicles Built From: 07-2000

Ikon 1999 (01.2000-)

Manual Transmission/Transaxle - Transaxle Ikon 1999 (01/2000-)
Installation

Special Tool(s)

Support Bar, Engine

303-290 (21-140)

Adapter for 303-290

303-290-01 (21-140-01)

Adapter for 303-290

303-290-03 (21-140-03)
General Equipment
Engine lifting eye
Transmission jack
Auxiliary plugs
Retaining strap
Materials
Name
Specification
Manual transmission fluid
WSD-M2C200-C 
High-durability grease
WSD-M1C230-A 
Cable ties
 

Installation

All Vehicles
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Secure the transaxle with a retaining strap and position under the vehicle by using a transmission jack.

  1. Install the transaxle lower flange bolts.

  1. Install the transaxle right-hand flange bolts.

  1. Install the left-hand transaxle flange bolt and starter motor bolts.
Vehicles with 1.6L engine
  1. Remove the wooden block.
All vehicles
  1. Lower the vehicle.

  1. Using the special tools, raise the engine and transaxle.
  1. NOTE:
    NOTE:Do not tighten the nuts and bolts.
    Install the engine rear mounting bracket.
Vehicles with diesel engine
  1. NOTE:
    NOTE:Do not tighten the nuts.
    Install the engine front mounting bracket.
All vehicles
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.
  1. Adjust gearshift linkage. For additional information, refer to Section  308-00 Manual Transmission/Transaxle and Clutch - General Information.

  1. Attach the shift rod and gearshift mechanism stabilizer.
    1. Attach the shift rod
    1. Attach the shift rod stabilizer

  1. Install the engine roll restrictor.

  1. CAUTION:
    CAUTION:The inner joint must not be bend more than 18 degrees, the outer joint must not be bend more than 45 degrees.
    CAUTION:
    CAUTION:Use the installation sleeve (supplied with every new oil seal) to protect the oil seal when inserting the front halfshaft.
    NOTE:
    NOTE:Fill the inner constant velocity housing with High-durability grease.
    NOTE:
    NOTE:Make sure the snap rings are securely in place.
    Install the left-hand and the right-hand halfshaft in the transaxle together with new snap rings.

  1. Install the left-hand and right-hand lower arm ball joints.
Vehicles with 1.6L engine
  1. NOTE:
    NOTE:Use a new gasket.
    Install the three way catalytic converter (TWC).
    1. Install the nuts.
    1. Connect the exhaust hanger insulator.

  1. Install the halfshaft heat shield.
Vehicles with diesel engine
  1. Install the halfshaft heat shield.
All vehicles
  1. Connect the speedometer drive cable.

  1. Connect the reversing lamp switch electrical connector.
  1. Lower the vehicle.
Vehicles with 1.6L engine
  1. Tighten the bolts and nuts of the engine rear mounting bracket.

  1. Remove the special tools.

  1. Remove the engine lifting eye.
Vehicles with diesel engine
  1. CAUTION:
    CAUTION:Always tighten the engine front mounting before tightening the engine rear mounting.
    Tighten the engine front mounting.

  1. Tighten the engine rear mounting bracket.

  1. Remove the special tools.

  1. Install the transaxle upper flange bolts and the ground cable.

  1. Install the resonator.
Vehicles with 1.6L engine
  1. Install the transaxle upper flange bolt.

  1. Install the transaxle upper flange bolt and ground cable, connect the electrical connectors and the hose.
    1. Install the flange bolt with ground cable
    1. Reconnect the generator electrical connector
    1. Reconnect the starter motor electrical connector
    1. Attach the transaxle ventilation hose

  1. Connect the electrical connectors.
    1. Heated oxygen sensor (HO2S) electrical connector
    1. Ignition coil electrical connector
    1. Powertrain control module (PCM) electrical connector
    1. Vehicle speed sensor (VSS) electrical connector
All vehicles
  1. WARNING:
    WARNING:Escaping brake fluid. Do not allow brake fluid to come into contact with the skin or the eyes. If brake fluid does come into contact with the skin or the eyes, rinse the affected areas with water immediately. Failure to follow these instructions may result in personal injury.
    CAUTION:
    CAUTION:If brake fluid is spilt on the paintwork, the affected area must be immediately washed down with cold water.
    Install the clutch slave cylinder high-pressure line.
    • Insert the clutch slave cylinder high-pressure line in the bracket.
  1. Bleed the clutch hydraulic system. For additional information, refer to Section  308-00 Manual Transmission/Transaxle and Clutch - General Information.
Vehicles with 1.6L engine
  1. Install the air cleaner (ACL) intake pipe.
Vehicles with diesel engine
  1. Install the air cleaner intake hose.
    1. Install the resonator pipe (clip).
    1. Install the intake pipe to the air cleaner housing.
    1. Install the clip.
    1. Install the air cleaner housing to the intake manifold.
All Vehicles
  1. NOTE:
    NOTE:Use an Allen key to prevent the piston rod turning.
    Tighten the suspension strut nut on both sides.

  1. Install the battery tray.
    1. Install new the cable ties.
    1. Install the bolts.
  1. Install the battery. For additional information, refer to Section  414-01 Battery, Mounting and Cables.

308-06 Manual Transmission-Transaxle External Controls > < Transaxle - Vehicles Built From: 07-2000