sensor DODGE NEON 2000 Service Owner's Manual

junction block. A label on the underside of the PDC
cover identifies the locations of the ABS fuses.
(2) Inspect the 25-way electrical connector at the
CAB for damaged, spread, or backed-out wiring ter-
minals. Verify that the 25-way connector is fully
inserted in the socket of the CAB. Be sure that wires
are not stretched tight or pulled out of the connector.
(3) Verify that all the wheel speed sensor connec-
tions are secure.
(4) Look for poor mating of connector halves or ter-
minals not fully seated in the connector body.
(5)
Check for improperly formed or damaged termi-
nals. All connector terminals in a suspect circuit should
be carefully reformed to increase contact tension.
(6) Look for poor terminal-to-wire connections.
This requires removing the terminal from the connec-
tor body to inspect it.
(7) Verify pin presence in the connector assembly
(8) Check for proper ground connections. Check all
ground connections for signs of corrosion, loose fas-
teners, or other potential defects. Refer to the wiring
diagrams for ground locations.
(9) Look for problems with the main power sources
of the vehicle. Inspect the battery, generator, ignition
circuits and other related relays and fuses.
If a visual check does not find the cause of the
problem, operate the car in an attempt to duplicate
the condition and record any trouble codes.
Most failures of the ABS disable the ABS function
for the entire ignition cycle even if the fault clears
before key-off. There are some failure conditions,
however, that allow ABS operation to resume during
the ignition cycle in which the trouble occurred even
if the trouble conditions are no longer present.
The following trouble conditions may result in
intermittent illumination of the amber ABS warning
lamp.
²Low system voltage. If Low System Voltage is
detected by the CAB, the CAB will turn on the ABS
Warning Lamp until normal system voltage is
achieved. Once normal voltage is seen at the CAB,
normal operation resumes.
²High system voltage. If high system voltage is
detected by the CAB, the CAB will turn on the
Amber ABS Warning Lamp until normal system volt-
age is achieved. Once normal voltage is again
detected by the CAB, normal ABS operation resumes.
Additional possible causes that may result in the
illumination of the amber ABS warning lamp are as
follows:
²Any condition that interrupts electrical current
to the CAB may cause the amber ABS warning lamp
to turn on intermittently.
²If PCI communication between the body control-
ler and the CAB is interrupted, the body controller
can turn on the amber ABS warning lamp.
TONE WHEEL
Tone wheels can cause erratic wheel speed sensor
signals. Inspect tone wheels for the following possible
causes:
²missing, chipped, or broken teeth
²contact with the wheel speed sensor
²wheel speed sensor to tone wheel alignment
²wheel speed sensor to tone wheel clearance
²excessive tone wheel runout
²tone wheel loose on its mounting surface
If a front tone wheel is found to need replacement,
the drive shaft must be replaced. No attempt should
be made to replace just the tone wheel. Refer to the
DIFFERENTIAL AND DRIVELINE group in this
service manual for removal and installation.
If a rear tone wheel is found to need replacement,
the rear hub and bearing must be replaced. No
attempt should be made to replace just the tone
wheel. Refer to the SUSPENSION group in this ser-
vice manual for removal and installation.
If wheel speed sensor to tone wheel contact is evi-
dent, determine the cause and correct it before
replacing the wheel speed sensor or tone wheel.
Check the gap between the speed sensor head and
the tone wheel to ensure it is within specifications.
Refer to SPECIFICATIONS in this section of the ser-
vice manual for the minimum and maximum wheel
speed sensor to tone wheel clearance.
Excessive wheel speed sensor runout can cause
erratic wheel speed sensor signals. Refer to SPECI-
FICATIONS in this section of the service manual for
the maximum allowed tone wheel runout. If tone
wheel runout is excessive, determine if it is caused
by a defect in the driveshaft assembly or hub and
bearing. Replace as necessary.
Tone wheels are pressed onto their mounting sur-
faces and should not rotate independently from the
mounting surface. Replacement of the front drive-
shaft or rear hub and bearing is necessary.
BRAKE FLUID CONTAMINATION
Indications of fluid contamination are swollen or
deteriorated rubber parts. Swelling indicates the
presence of petroleum in the brake fluid.
To test for contamination, put a small amount of
drained brake fluid in clear glass jar. If the fluid sep-
arates into layers, there is mineral oil or other fluid
contamination of the brake fluid.
If the brake fluid is contaminated, drain and thor-
oughly flush the brake system. Replace all the rubber
parts or components containing rubber coming into
contact with the brake fluid including: the master
cylinder; proportioning valves; caliper seals; wheel
cylinder seals; ABS hydraulic control unit; and all
hydraulic fluid hoses.
5 - 76 BRAKESPL
DIAGNOSIS AND TESTING (Continued)

(5) Disconnect the primary and secondary brake
tubes from master cylinder (Fig. 12). Install plugs in
the master cylinder outlet ports.
(6) Clean the area around where the master cylin-
der attaches to the power brake booster using a suit-
able brake cleaner such as MopartBrake Parts
Cleaner or an equivalent.
(7) Remove the 2 nuts attaching master cylinder to
power brake booster (Fig. 12).
(8) Slide the master cylinder straight out of the
power brake booster.
INSTALLATION
NOTE: The master cylinder must be bled before
installing it on the vehicle.
(1) Bleed the master cylinder before installing it
on the vehicle. Refer to MASTER CYLINDER
BLEEDING in SERVICE PROCEDURES within this
section of this service manual group.
(2) Wipe the face of the power brake booster clean
where the master cylinder seal comes in contact
when it's installed. Do not get any cleaner or debris
inside the booster.(3) Position the master cylinder on the studs of
power brake vacuum booster aligning the booster
push rod with the master cylinder push rod. Care-
fully push the master cylinder onto the studs until it
contacts the face of the booster.
(4) Install the two master cylinder mounting nuts
(Fig. 12). Tighten the mounting nuts to a torque of
28 N´m (250 in. lbs.).
(5) Connect the primary and secondary brake
tubes to the master cylinder primary and secondary
ports (Fig. 12). Tighten the nuts to a torque of 17
N´m (145 in. lbs.).
(6) Install the wiring harness connector on the
master cylinder reservoir fluid level switch.
(7) Install the battery and clamp in place.
(8) Connect the positive, then the negative
(ground) cable on the battery.
(9) Fill the master cylinder to the proper fill level.
(10) Road test the vehicle to ensure proper opera-
tion of the base and antilock brake systems.
INTEGRATED CONTROL UNIT
NOTE: Before proceeding with this procedure,
review SERVICE WARNINGS AND CAUTIONS at the
beginning of REMOVAL AND INSTALLATION in this
section.
REMOVAL
(1) Using a brake pedal holder, depress the brake
pedal past its first one inch of travel and hold it in
this position (Fig. 13). This will isolate the master
cylinder from the brake hydraulic system and will
not allow the brake fluid to drain out of the master
cylinder reservoir.
(2) Disconnect negative (ground) cable from the
battery and isolate the cable.
(3) Disconnect the positive cable from the battery,
then remove the battery from the battery tray. There
is one nut securing the clamp on the backside of the
battery holding it in place.
(4) Remove the one nut and one bolt securing the
air cleaner box in place, then disconnect the wiring
harness connector at the air inlet sensor.
(5) Lift the air cleaner box upward enough to clear
its grommeted alignment post (Fig. 14), then move
the air cleaner box forward just enough to access the
battery tray mounting bolts.
(6) Remove the 2 bolts, then the 2 nuts mounting
the battery tray to its bracket (Fig. 14). Remove the
battery tray.
Fig. 12 Master Cylinder
1 ± POWER BRAKE BOOSTER
2 ± CONNECTOR
3 ± BRAKE FLUID LEVEL SWITCH
4 ± MOUNTING NUTS
5 ± SECONDARY BRAKE TUBE
6 ± PRIMARY BRAKE TUBE
PLBRAKES 5 - 79
REMOVAL AND INSTALLATION (Continued)

(14) Refer to DISASSEMBLY AND ASSEMBLY in
this section of this group for the procedure on sepa-
rating and reattaching the CAB to the HCU.
INSTALLATION
(1) Install the ICU onto its mounting bracket.
(2) Install the 3 bolts attaching the ICU to the
mounting bracket (Fig. 17). Tighten the 3 mounting
bolts to a torque of 11 N´m (97 in. lbs.)
(3) Install the four brake tubes going to the brakes
into their respective outlet ports on the ICU HCU
(Fig. 15). Using a crow foot on a torque wrench,
tighten the four brake tube nuts to a torque of 17
N´m (145 in. lbs.).
NOTE: When installing the brake tubes from the
master cylinder on the HCU, the brake tube with the
small tube nut is to be installed in the forward-most
port on the HCU with the small end going toward
the master cylinder secondary port.
(4) Install the primary and secondary brake tubes
from the master cylinder onto the HCU (Fig. 15). Do
not completely tighten the primary and secondary
tubes at this time.
(5) Connect the primary and secondary brake
tubes to the master cylinder ports (Fig. 15).
(6) Using a crow foot on a torque wrench, tighten
the primary and secondary brake tube nuts at both
the master cylinder and HCU to a torque of 17 N´m
(145 in. lbs.).
CAUTION: Before installing the 25-way connector
in the CAB, be sure the seal is properly installed in
the connector.(7) Install the 25-way connector into the socket of
the CAB as follows:
²Position the 25-way connector in the socket of
the CAB and carefully push it down as far as possi-
ble (Fig. 16).
²When the connector is fully seated into the CAB
socket, push the connector lock inward. This pulls
the connector into the socket of the CAB and locks it
in the installed position.
(8) Position the battery tray back in place. Install
the two bolts, then the two nuts mounting the bat-
tery tray to its bracket (Fig. 14). Tighten the two
bolts and nuts to a torque of 15 N´m (135 in. lbs.).
(9) Reinstall the air cleaner box onto its grom-
meted alignment post (Fig. 14).
(10) Install the one nut and one bolt securing the
air cleaner box in place, then connect the wiring har-
ness connector at the air inlet sensor.
(11) Install the battery and clamp it in place.
Tighten the hold-down clamp bolt to a torque of 12
N´m (105 in. lbs.).
(12) Connect the positive, then the negative
(ground) cable on the battery.
(13) Bleed the base and the ABS hydraulic sys-
tems. Refer to ANTILOCK BRAKE SYSTEM
BLEEDING in this section of this service manual
group.
(14) Fill the master cylinder to the proper fill
level.
(15) Road test the vehicle to ensure proper opera-
tion of the base and antilock brake systems.
WHEEL SPEED SENSOR (FRONT)
NOTE: Before proceeding with this procedure,
review SERVICE WARNINGS AND CAUTIONS at the
beginning of REMOVAL AND INSTALLATION in this
section.
REMOVAL
(1) Raise the vehicle. Refer to HOISTING in the
LUBRICATION AND MAINTENANCE group for the
proper lifting procedure.
(2) Disconnect the wheel speed sensor cable con-
nector from the wiring harness on the inside of the
frame rail above the front suspension crossmember
(Fig. 18). The connector has a locking tab which that
must be pulled back before the connector release
tang can be depressed, releasing the connection.
(3) Remove the speed sensor cable grommet from
the retaining bracket attached to the brake hose on
the outside of the frame rail.
(4) Remove the bolt mounting the wheel speed sen-
sor head to the steering knuckle (Fig. 19).
Fig. 17 ICU Mounting Bolts
1 ± ICU
2 ± ICU MOUNTING BOLTS
PLBRAKES 5 - 81
REMOVAL AND INSTALLATION (Continued)

CAUTION: When removing a wheel speed sensor
from the knuckle, do not use pliers on the sensor
head. This may damage the sensor head. If the sen-
sor has seized, use a hammer and a punch to tap
the edge of the sensor head ear, rocking the sensor
side-to-side until free.
(5) Carefully, remove the sensor head from the
steering knuckle.(6) Remove the screw securing the wheel speed
sensor to the rear of the strut (Fig. 20). Remove the
wheel speed sensor.
INSTALLATION
CAUTION: Failure to install speed sensor cables
properly may result in contact with moving parts or
an over extension of cables causing an open cir-
cuit. Be sure that cables are installed, routed, and
clipped properly.
(1) Attach the wheel speed sensor to the strut
using the its mounting screw (Fig. 20).
(2) Install the wheel speed sensor head in the
steering knuckle (Fig. 19). Install the mounting bolt.
Tighten the mounting bolt to a torque of 12 N´m (105
in. lbs.).
(3) From the sensor bracket on the strut, loop the
sensor cable upward, then downward at the outside
of the frame rail. Install the speed sensor cable grom-
met onto the retaining bracket attached to the brake
hose on the outside of the frame rail.
(4) Loop the wheel speed sensor cable around the
bottom of the frame rail and connect it to the wiring
harness connector on the inside of the frame rail
(Fig. 18). Remember to push in the locking tab on the
connector.
(5) Install the tire and wheel assembly.
(6) Lower the vehicle.
(7) Road test vehicle to ensure proper operation of
the base brakes and ABS.
Fig. 18 Wiring Harness Connector
1 ± RIGHT FRONT WHEEL SPEED SENSOR CONNECTOR
2 ± RIGHT FRONT DRIVESHAFT
3 ± ENGINE OIL FILTER
Fig. 19 Wheel Speed Sensor
1 ± RIGHT FRONT WHEEL SPEED SENSOR
2 ± TONE WHEEL
Fig. 20 Wheel Speed Sensor At Strut
1 ± ABS WHEEL SPEED SENSOR ROUTING BRACKET (IF
EQUIPPED)
2 ± GROUND STRAP
3 ± GROUND STRAP SCREW
4 ± ABS SENSOR BRACKET SCREW (IF EQUIPPED)
5 - 82 BRAKESPL
REMOVAL AND INSTALLATION (Continued)

WHEEL SPEED SENSOR (REAR)
NOTE: Before proceeding with this procedure,
review SERVICE WARNINGS AND CAUTIONS at the
beginning of REMOVAL AND INSTALLATION in this
section.
REMOVAL
(1) Raise the vehicle. Refer to HOISTING in the
LUBRICATION AND MAINTENANCE group for the
proper lifting procedure.
(2) Remove the tire and wheel assembly from the
vehicle.
(3) Disconnect the wheel speed sensor cable con-
nector from the vehicle wiring harness (Fig. 21).
Remove the clip attaching wheel speed sensor cable
connector to the vehicle's body.
(4) Remove the wheel speed sensor cable routing
bracket from under rear brake flex hose mounting
bracket. Then remove the speed sensor cable from
the routing clips on the rear brake flex hose and
chassis brake tube.
(5) Remove the bolt attaching the wheel speed sen-
sor cable routing bracket to rear strut.
CAUTION: When removing a wheel speed sensor
from the rear disc brake adapter, do not use pliers
on the sensor head. This may damage the sensor
head. If the sensor has seized, use a hammer and apunch to tap the edge of the sensor head ear, rock-
ing the sensor side-to-side until free.
(6) Remove the bolt attaching the wheel speed sen-
sor to the rear disc brake adapter (Fig. 22), then
carefully remove the sensor head from the rear disc
brake adapter and vehicle.
INSTALLATION
CAUTION: Failure to install speed sensor cables
properly may result in contact with moving parts or
an over extension of cables causing an open cir-
cuit. Be sure that cables are installed, routed, and
clipped properly.
(1) Install the wheel speed sensor head into the
disc brake adapter (Fig. 22).
(2) Install the wheel speed sensor mounting bolt.
Tighten the mounting bolt to a torque of 12 N´m (105
in. lbs.).
(3) Install the wheel speed sensor cable routing
bracket on the rear strut.
(4) Install wheel speed sensor cable into the rout-
ing clips on the rear brake hose and brake tube.
(5) Connect the wheel speed sensor cable connector
into vehicle wiring harness (Fig. 21). Install the clip
attaching the wheel speed sensor cable connector to
vehicle's body.
(6) Install the tire and wheel assembly on vehicle.
(7) Lower the vehicle.
(8) Road test the vehicle to ensure proper opera-
tion of the base brakes and ABS.
Fig. 21 Wheel Speed Sensor Connector
1 ± FUEL TANK
2 ± TENSION STRUT
3 ± WHEEL SPEED SENSOR CONNECTOR
4 ± LOCKING TAB
5 ± CLIP
Fig. 22 Rear Wheel Speed Sensor
1 ± RIGHT REAR WHEEL SPEED SENSOR
2 ± TENSION STRUT
PLBRAKES 5 - 83
REMOVAL AND INSTALLATION (Continued)

SPECIFICATIONS
TONE WHEEL RUNOUT
FRONT TONE WHEEL:
Maximum Runout.........0.25 mm (0.009 in.)
REAR TONE WHEEL:
Maximum Runout.........0.25 mm (0.009 in.)
WHEEL SPEED SENSOR-TO-TONE WHEEL
CLEARANCE
FRONT WHEEL:
Minimum Clearance.......0.28 mm (0.011 in.)
Maximum Clearance.......1.42 mm (0.056 in.)
REAR WHEEL:
Minimum Clearance.......0.45 mm (0.018 in.)
Maximum Clearance.......1.12 mm (0.044 in.)
BRAKE FASTENER TORQUE SPECIFICATIONS
DESCRIPTION TORQUE
BRAKE TUBES:
Tube Nuts............... 17N´m(145 in. lbs.)
MASTER CYLINDER:
Mounting Nuts.......... 28N´m(250 in. lbs.)
POWER BRAKE BOOSTER:
Mounting Nuts.......... 34N´m(300 in. lbs.)
DISC BRAKE CALIPER:
Caliper Banjo Bolt......... 48N´m(35ft.lbs.)
Guide Pin Bolts.......... 22N´m(192 in. lbs.)
Bleeder Screw........... 15N´m(125 in. lbs.)
WHEEL CYLINDER (REAR):
Mounting Bolts.......... 13N´m(115in.lbs.)
Bleeder Screw............ 10N´m(80in.lbs.)
DRUM BRAKE SHOE SUPPORT PLATE
(REAR):
Mounting Bolts........... 75N´m(55ft.lbs.)
DISC BRAKE ADAPTER (REAR):
Mounting Bolts........... 75N´m(55ft.lbs.)
HUB AND BEARING (REAR):
Retaining Nut.......... 217N´m(160 ft. lbs.)
PARKING BRAKE:
Lever Mounting Nuts..... 28N´m(250 in. lbs.)
TIRE AND WHEEL:
Wheel Mounting Nut...........109±150 N´m
(80±110 ft. lbs.)
INTEGRATED CONTROL UNIT:
Mounting Bolts........... 11N´m(97in.lbs.)
CAB Mounting bolts........ 2N´m(17in.lbs.)
Bracket-to-Frame Rail Bolts.......... 23N´m
(200 in. lbs.)
WHEEL SPEED SENSOR:
Head Mounting bolt...... 12N´m(105 in. lbs.)
PLBRAKES 5 - 85

housing does not move, it is improperly installed or
defective.
(3) Route cable to the transaxle and connect cable
end to the clutch release lever and transaxle housing
(Fig. 7).
(4) Install bellhousing cap (Fig. 7).
(5) Install and fasten battery tray.
(6) Install battery and hold-down clamp.
(7) Connect both battery cables.
(8) Verify that the clutch cable is working properly.
CLUTCH INTERLOCK/UPSTOP SWITCH
REMOVAL
(1) Disconnect and isolate battery negative cable.
(2) Remove instrument panel assembly. Refer to
Group 8E, Instrument Panel and Systems for the
proper procedure.
(3) Disconnect the clutch interlock/upstop switch
connector (Fig. 9).
NOTE: Proper switch harness routing is critical to
switch durability. Note the harness routing and
location of fasteners intended to keep wires from
contacting pedals.
(4) Remove the interlock/upstop switch assembly
from the brake/clutch pedal bracket assembly by
depressing the four plastic wing tabs on each switch.
INSTALLATION
(1) Install switches into the pedal bracket assem-
bly as shown in (Fig. 9). Route harness as was prior
to removal.
(2) Connect interlock/upstop switch connector.
(3) Install instrument panel assembly. Refer to
Group 8E, Instrument Panel and Systems for the
proper procedure.
(4) Connect battery negative cable.
(5) Verify proper switch operation. Refer to
Description and Operation in this Group.
MODULAR CLUTCH ASSEMBLY
REMOVAL
(1) Raise hood.
(2) Disconnect and isolate both battery cables,
remove battery hold down clamp and bolt, and
remove battery.
(3) Remove air cleaner/throttle body assy. (Fig. 10)
as follows:
(a) Disconnect proportional purge solenoid (PPS)
and crankcase vent hose from throttle body.
(b) Disconnect the Throttle Position Sensor
(TPS) and Idle Air Control (IAC) connectors.
(c) Disconnect throttle body air duct at intake
manifold.
Fig. 8 Clutch Cable at Brake/Clutch Pedal Assembly
1 ± SNAP RING
2 ± CLUTCH PEDAL SPACER
3 ± CLUTCH PEDAL
4 ± CLUTCH CABLE
Fig. 9 Interlock and Upstop Switch Mounting
Locations
1 ± UPSTOP SWITCH
2 ± CLUTCH PEDAL
3 ± INTERLOCK SWITCH
4 ± CONNECTOR
6 - 8 CLUTCHPL
REMOVAL AND INSTALLATION (Continued)

(d) Remove mounting bolt and nut (Fig. 10) and
partially remove air cleaner assembly.
(e) Disconnect accelerator and speed control (if
equipped) cables after the assy. is removed from
position. Remove air cleaner assembly from vehi-
cle.
(4) Remove battery tray from bracket.
(5) Disconnect ground cable at battery tray
bracket.
(6) Disconnect back-up lamp switch connector.
(7) Remove bellhousing cap (Fig. 11).
(8) Disconnect clutch cable from release lever and
remove from transaxle (Fig. 11).
(9) Remove shift cable-to-bracket clips (Fig. 12).
(10) Disconnect shift selector and crossover cable
from levers (Fig. 12). Remove cables and secure out
of the way.
(11) Disconnect the vehicle speed sensor connector
(Fig. 13).
(12) Raise vehicle on hoist.
(13) Remove transaxle oil drain plug and drain oil
into a suitable container.
(14) Remove both axle shafts. Refer to Group 3,
Differential and Driveline for the correct procedures.
(15) Remove structural collar (Fig. 14).
(16) Remove the left engine-to-transaxle lateral
bending brace (Fig. 14).
(17) Remove bellhousing dust cover (Fig. 14).
(18) Remove the right engine-to-transaxle lateral
bending brace (Fig. 15).(19) Remove starter motor (Fig. 16).
(20) Remove drive plate-to-clutch module bolts.
(21) Support engine at oil pan with screw jack and
wood block.
(22) Remove transaxle upper mount thru-bolt.
Gain access to this bolt through the driver's side
wheel house (Fig. 17).
(23) Carefully lower engine and transaxle on screw
jack until proper removal clearance is obtained.
Fig. 10 Air Cleaner Assembly Removal/Installation
1 ± AIR CLEANER ASSY.
2 ± THROTTLE BODY DUCTFWD
Fig. 11 Clutch Cable at Transaxle
1 ± CLUTCH CABLE
2 ± TRANSAXLE
3 ± BELLHOUSING CAP
Fig. 12 Shift Cables at Transaxle
1 ± SHIFT CABLES
2 ± CLIPS
3 ± BRACKET
PLCLUTCH 6 - 9
REMOVAL AND INSTALLATION (Continued)

(24) Obtain a helper to assist in holding transaxle
while removing transaxle-to-engine mounting bolts
(Fig. 18).
(25) Remove transaxle from vehicle (Fig. 18).
(26) Remove modular clutch assembly from tran-
saxle input shaft.
INSTALLATION
(1) Inspect clutch release bearing and lever for
excessive wear and replace as necessary.
(2) Install clutch module onto input shaft. Install
transaxle into position.
(3) Install transaxle-to-engine mounting bolts (Fig.
18) and tighten to 95 N´m (70 ft. lbs.) torque.
(4) Raise engine and transaxle with screw jack
until through hole in upper mount aligns with hole
in mount bracket. Install mount bolt and tighten to
108 N´m (70 ft. lbs.) torque (Fig. 17).
(5) Remove screwjack.
(6) Install NEW drive plate-to-clutch module bolts
and progressively tighten all bolts in a criss-cross
pattern until the modular clutch assembly seats
against the drive plate. Final torque the bolts to 88
N´m (65 ft. lbs.) torque.
(7) Install starter motor and tighten bolts to 54
N´m (40 ft. lbs.) torque. Make sure to fasten ground
cable to upper starter bolt as shown in (Fig. 16).
Fig. 13 Vehicle Speed Sensor Connector
1 ± CONNECTOR
2 ± SENSOR
3 ± O-RING
4 ± SPEEDO PINIONFig. 14 Left Lateral Bending Brace and Structural
CollarÐTypical
1 ± LATERAL BENDING BRACE
2 ± STRUCTURAL COLLAR
3 ± DUST COVER
Fig. 15 Right Lateral Bending Brace Removal/
InstallationÐTypical
1 ± TRANSAXLE
2 ± ENGINE
3 ± LATERAL BENDING BRACE
6 - 10 CLUTCHPL
REMOVAL AND INSTALLATION (Continued)

(8) Connect starter electrical harness and tighten
positive cable nut to 10 N´m (90 in. lbs.) torque.
(9) Install bellhousing dust cover (Fig. 14).
(10) Install left engine-to-transaxle bending brace
(Fig. 14).(11) Install structural collar (Fig. 14) as follows:
(a) Position collar and install all bolts finger
tight.
(b) Tighten the collar-to-oil pan bolts to 3 N´m
(30 in. lbs.) torque.
(c) Tighten the collar-to-transaxle bolts to 108
N´m (80 ft. lbs.) torque.
(d) Final torque the collar-to-oil pan bolts to 54
N´m (40 ft. lbs.) torque.
(12) Install the right lateral bending brace and
tighten bolts to 81 N´m (60 ft. lbs.) torque (Fig. 15).
(13) Install both front axle driveshafts. Refer to
Group 3, Differential and Driveline for the correct
procedures.
(14) Fill transaxle with suitable amount of Mopart
Manual Transaxle Lubricant (PN 04874465).
(15) Lower vehicle.
(16) Connect vehicle speed sensor connector (Fig.
13).
(17) Connect shift crossover and selector cables to
shift lever. Install cables to bracket and install
retaining clips (Fig. 12).
(18) Connect clutch cable to fork and secure to
transaxle (Fig. 11).
(19) Install bellhousing cap (Fig. 11).
(20) Connect back-up lamp switch connector.
(21) Connect ground strap to transaxle upper
mount bracket.
(22) Install battery lower tray and battery, and
tighten battery hold down clamp to secure battery.
(23) Install the air cleaner/throttle body assy. as
follows:
(a) Connect the accelerator and speed control (if
equipped) cables to the air cleaner/throttle body
assy.
(b) Install assy into position, making sure the
air cleaner locating slot is engaged to the battery
bracket tab, and tighten fasteners to 14 N´m (120
in. lbs.) torque.
(c) Verify throttle body duct is fully seated to
intake manifold and tighten clamp to 5 N´m (40 in.
lbs.) torque.
(d) Connect the Throttle Position Sensor (TPS)
and Idle Air Control (IAC) connectors.
(e) Connect proportional purge solenoid (PPS)
and crankcase vent hose from throttle body.
(24) Connect the battery cables.
(25) Road test vehicle and inspect for leaks.
Fig. 16 Starter Motor Removal/InstallationÐTypical
1 ± BOLT
2 ± GROUND
3±STARTER
4 ± BOLT
Fig. 17 Transaxle Upper Mount Thru-BoltÐTypical
1 ± MOUNT BRACKET
2 ± BOLT
3 ± MOUNT
PLCLUTCH 6 - 11
REMOVAL AND INSTALLATION (Continued)