MANUAL TRANSAXLE ASSEMBLY INSTALLATION

PROCEDURE


  1. INSTALL REAR ENGINE MOUNTING BRACKET


    1. A004NTZ

      Install the rear engine mounting bracket with the 5 bolts.

      Torque:
      45 N*m  { 459 kgf*cm, 33 ft.*lbf }

  2. INSTALL FRONT ENGINE MOUNTING BRACKET


    1. A004OYC

      Install the front engine mounting bracket with the 4 bolts.

      Torque:
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }

  3. INSTALL REAR ENGINE MOUNTING INSULATOR

    Click here

  4. INSTALL MANUAL TRANSAXLE ASSEMBLY

    Note


    • Be extremely careful that the body, clutch pipe line and radiator cooling fan do not interfere with the manual transaxle assembly when installing the transaxle.

    • When installing the manual transaxle assembly, it is necessary to move the engine assembly and manual transaxle assembly up and down, and back and forth. Therefore, continually confirm that the parts are properly supported and stable while performing this step.


    1. A004RJO

      Make sure that the dowel pins are not loose, bent, damaged or scratched.

    2. While adjusting the angle of the transmission jack raise the manual transaxle assembly until it is in line with the engine assembly.

      Note

      Be careful that the clutch pipe line does not interfere with the manual transaxle assembly.

    3. Adjust the height and angle of the transmission jack, align the input shaft with the clutch disc, and then install the manual transaxle assembly to the engine with the contact surfaces of the engine and transaxle flat against each other.

    4. A004R3L

      Temporarily install the manual transaxle assembly with the 6 bolts.

      Note

      Before tightening the bolts, insert the dowel pins into the dowel holes securely so that the end face of the transaxle assembly fits close against the engine assembly.

    5. Apply adhesive to the 4 bolts.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    6. A004S6I

      Install the engine mounting bracket LH with the 4 bolts.

      Torque:
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }
    7. A004TCE

      Install the 4 bolts and engine mount insulator LH.

      Torque:
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }

    8. Slowly raise the engine assembly and transmission assembly using a transmission jack, and then align the installation positions of the engine mounting insulator LH and engine mount bracket LH.

    9. A004QRD

      Install the nut and through bolt, and then connect the engine mounting insulator LH to the engine mount bracket LH.

      Torque:
      56 N*m  { 571 kgf*cm, 41 ft.*lbf }

  5. INSTALL NO. 2 MANIFOLD STAY


    1. Temporarily install the No. 2 manifold stay with the 2 bolts and nut.

  6. INSTALL STARTER ASSEMBLY


    1. Temporarily install the starter assembly with the 2 bolts.

  7. TIGHTEN ENGINE AND TRANSAXLE CONNECTING BOLT


    1. A004NLOE03

      Tighten the 10 bolts in the sequence shown in the illustration.

      Torque:
      Bolt A
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }
      Bolt B
      79 N*m  { 806 kgf*cm, 58 ft.*lbf }
      Bolt C
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }
      Bolt D
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }
      Text in Illustration
      A004NPW

      E14 "TORX" bolt

      Bolt length 100 mm (3.94 in.)
      A004NAK

      E14 "TORX" bolt

      Bolt length 80 mm (3.15 in.)
      A004PZH

      Hexagon Bolt

      Bolt length 40 mm (1.57 in.)

    2. Tighten the nut of the No. 2 manifold stay.

      Torque:
      21 N*m  { 218 kgf*cm, 16 ft.*lbf }

  8. INSTALL FRONT ENGINE MOUNTING INSULATOR


    1. Install the front engine mounting insulator with the through bolt and nut.

      Torque:
      145 N*m  { 1479 kgf*cm, 107 ft.*lbf }

  9. INSTALL FRONT CROSSMEMBER SUB-ASSEMBLY


    1. A004QOGE02

      Install the front crossmember sub-assembly with the 6 bolts.

      Torque:
      for bolt A
      99 N*m  { 1010 kgf*cm, 73 ft.*lbf }
      for bolt B
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }

    2. Remove the transmission jack.

  10. INSTALL FRONT SUSPENSION MEMBER

    Click here

  11. INSTALL ENGINE WIRE


    1. A004S8P

      Connect the ground cable with the bolt.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }
    2. A004RTV

      Connect the back-up light switch connector, neutral position switch connector and 2 bolts.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

  12. CONNECT CLUTCH RELEASE CYLINDER ASSEMBLY

    Click here

  13. INSTALL NO. 1 CLUTCH HOUSING COVER


    1. A004SXL

      Install the No. 1 clutch housing cover with the 2 bolts.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

  14. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY


    1. A004PH0E03
      Text in Illustration
      *a Anti-rotation Pin

      Connect the bracket of the transmission control cable assembly with the bolt.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

      Tech Tips

      Make sure the anti-rotation pin is contacting the rear engine mount insulator.

    2. A004TT5E01
      Text in Illustration
      *1 Clip
      *2 Metal Washer Plate

      Connect the 2 cables to the control cable bracket with 2 new clips.

      Note

      Do not bend the cable more than necessary.

    3. Connect the 2 cables to the manual transaxle assembly and install the 2 clips.

      Tech Tips

      Make sure that the metal washer plate of the shift cable is facing toward the outside of the vehicle.

  15. INSTALL NO. 1 AIR TUBE ASSEMBLY

    Click here

  16. CONNECT INTERCOOLER AIR HOSE

    Click here

  17. CONNECT COMPRESSOR OUTLET ELBOW

    Click here

  18. INSTALL NO. 4 WATER BY-PASS HOSE

    Click here

  19. CONNECT WIRE HARNESS

    Click here

  20. INSTALL AIR CLEANER BRACKET


    1. A004N28E03

      Install the air cleaner bracket with the 5 bolts.

      Torque:
      for Bolt A
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }
      for Bolt B
      18 N*m  { 178 kgf*cm, 13 ft.*lbf }
    2. A004QOL

      Connect the wire harness with the 3 clamps.

  21. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  22. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  23. INSTALL AIR CLEANER CAP SUB-ASSEMBLY WITH AIR CLEANER HOSE ASSEMBLY

    Click here

  24. INSTALL DRIVE SHAFT ASSEMBLY

    Click here

  25. INSTALL STARTER ASSEMBLY

    Click here

  26. INSTALL EXHAUST PIPE ASSEMBLY

    Click here

  27. INSTALL OUTER COWL TOP PANEL

    Click here

  28. INSTALL FRONT WIPER MOTOR AND LINK ASSEMBLY

    Click here

  29. ADD ENGINE COOLANT

    Click here

  30. ADD MANUAL TRANSAXLE OIL

    Click here

  31. FOR COOLANT LEAK

    Click here

  32. INSPECT FOR OIL LEAK

  33. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  34. INSPECT FOR EXHAUST GAS LEAK

    Click here

  35. INSTALL REAR ENGINE UNDER COVER LH

    Click here

  36. INSTALL REAR ENGINE UNDER COVER RH

    Click here

  37. INSTALL NO. 2 ENGINE UNDER COVER

    Click here

  38. INSTALL NO. 1 ENGINE UNDER COVER

    Click here

  39. INSTALL FRONT LOWER BUMPER ABSORBER


    1. A004R2R

      Install the front lower bumper absorber with the 8 bolts and 3 screws.

    2. A004ML6

      Install the 6 screws and 2 bolts.

  40. INSTALL NO. 1 ENGINE COVER

    Click here