MANUAL TRANSAXLE ASSEMBLY INSTALLATION

PROCEDURE

1. INSTALL SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY

   1. Coat a new O-ring with gear oil.

   2. Install the O-ring to the speedometer driven hole cover sub-assembly.

   3. Install the speedometer driven hole cover sub-assembly to the manual transaxle assembly with the bolt.

      5.5 N*m

      56 kgf*cm

      49 in.*lbf

2. INSTALL REAR ENGINE MOUNTING BRACKET

   1. Install the rear engine mounting bracket to the manual transaxle assembly with the 5 bolts.

      45 N*m

      459 kgf*cm

      33 ft.*lbf

3. INSTALL FRONT ENGINE MOUNTING BRACKET

   1. Install the front engine mounting bracket to the manual transaxle assembly with the 3 bolts.

      for Green Bolt

      64 N*m

      653 kgf*cm

      47 ft.*lbf

      for Silver Bolt

      45 N*m

      459 kgf*cm

      33 ft.*lbf

4. INSTALL ENGINE MOUNTING BRACKET LH

   1. Apply sealant to the 4 bolts.

      Sealant

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

   2. Install the engine mounting bracket LH to the manual transaxle assembly with the 4 bolts.

      64 N*m

      653 kgf*cm

      47 ft.*lbf

5. INSTALL WIRE HARNESS CLAMP BRACKET

   1. Install the wire harness clamp bracket to the manual transaxle assembly with the bolt.

      12.5 N*m

      127 kgf*cm

      9 ft.*lbf

6. INSTALL MANUAL TRANSAXLE ASSEMBLY

   1. Check that the 2 knock pins are installed on the engine assembly before installing the manual transaxle assembly.

   2. Align the input shaft with the clutch disc and install the manual transaxle assembly to the engine assembly.

   3. 

      Install the 5 bolts.

      Bolt A

      46 N*m

      469 kgf*cm

      34 ft.*lbf

      Bolt B

      64 N*m

      653 kgf*cm

      47 ft.*lbf

      Note:

      • Make sure that the wire harness or similar items are not pinched between the contact surfaces.

      • Do not forcibly pry on the manual transaxle assembly when installing it to the engine assembly.

      • Do not apply excessive force to the manual transaxle assembly as this will break the input shaft.

      • Make sure that the knock pins fit securely into the holes when installing the manual transaxle assembly to the engine assembly.

      • Make sure that the contact surfaces of the engine assembly and manual transaxle assembly are flat against each other before tightening the bolts.

7. INSTALL STIFFENER PLATE LH

   1. Install the stiffener plate LH to the engine assembly and manual transaxle assembly with the 4 bolts.

      46 N*m

      469 kgf*cm

      34 ft.*lbf

8. INSTALL STIFFENER PLATE RH

   1. Install the stiffener plate RH to the engine assembly and manual transaxle assembly with the 4 bolts.

      46 N*m

      469 kgf*cm

      34 ft.*lbf

9. INSTALL OIL PAN INSULATOR

   1. Install the oil pan insulator to the stiffener plate RH and stiffener plate LH with the 2 bolts.

      9.0 N*m

      92 kgf*cm

      80 in.*lbf

10. INSTALL AIR TUBE SUPPORT

    1. Install the air tube support to the manual transaxle assembly with the 2 bolts.

       30 N*m

       306 kgf*cm

       22 ft.*lbf

11. INSTALL STARTER ASSEMBLY

    Click here

12. INSTALL NO. 1 AIR TUBE

    1. 

       *a	Bolt
       *b	Hose Clamp

       Install the No. 1 air tube to the air tube support and hose with the 2 bolts and tighten the hose clamp.

       Bolt

       20 N*m

       204 kgf*cm

       15 ft.*lbf

       Hose clamp

       6.5 N*m

       66 kgf*cm

       58 in.*lbf

13. CONNECT ENGINE WIRE

    1. Connect the engine wire to the manual transaxle assembly with the 2 clamps.

    2. Install the engine wire to the manual transaxle assembly with the bolt.

       12.5 N*m

       127 kgf*cm

       9 ft.*lbf

    3. Connect the 3 clamps to the manual transaxle assembly.

    4. Connect the park/neutral position switch assembly connector.

    5. Connect the back-up light switch assembly connector.

14. TEMPORARILY TIGHTEN REAR ENGINE MOUNTING INSULATOR

    Click here

15. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

    Click here