MANUAL TRANSMISSION ASSEMBLY INSTALLATION

INSTALL MANUAL TRANSMISSION UNIT ASSEMBLY
1. Align the input shaft with the clutch disc and install the transmission to the engine.
2. 2KD-FTV:
  
  Install the 5 bolts.
  
  Torque:
  
  72 N*m { 730 kgf*cm, 53 ft.*lbf }
3. 1TR-FE:
  
  Install the 7 bolts.
  
  Torque:
  
  72 N*m { 730 kgf*cm, 53 ft.*lbf, for bolt A }
  
  37 N*m { 377 kgf*cm, 27 ft.*lbf, for bolt B }
INSTALL STIFFENER PLATE (2KD-FTV)
1. Install the stiffener plate RH with the 4 bolts.
  
  Torque:
  
  72 N*m { 730 kgf*cm, 53 ft.*lbf }
2. Install the stiffener plate LH with the 4 bolts.
  
  Torque:
  
  72 N*m { 730 kgf*cm, 53 ft.*lbf }
INSTALL EXHAUST MANIFOLD STAY (for 1TR-FE)
1. Install the exhaust manifold stay with the 3 bolts.
  
  Torque:
  
  44 N*m { 449 kgf*cm, 32 ft.*lbf, for bolt A }
  
  30 N*m { 306 kgf*cm, 22 ft.*lbf, for bolt B }
  
  72 N*m { 730 kgf*cm, 53 ft.*lbf, for bolt C }
INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR
1. Install the mounting insulator with the 4 bolts.
  
  Torque:
  
  44 N*m { 449 kgf*cm, 32 ft.*lbf }
INSTALL NO. 3 FRAME CROSSMEMBER SUB-ASSEMBLY
1. Install the frame crossmember with the 4 bolts and 4 nuts.
  
  Torque:
  
  50 N*m { 510 kgf*cm, 37 ft.*lbf }
2. Install the 4 set bolts to the No. 1 engine mounting insulator rear.
  
  Torque:
  
  17 N*m { 173 kgf*cm, 13 ft.*lbf }
INSTALL STARTER ASSEMBLY

for 2KD-FTV for 2.0kW Type: Click here

for 2KD-FTV for 2.2 kW Type: Click here

for 1TR-FE for 1.0kW Type: Click here

for 1TR-FE for 1.7kW Type: Click here
CONNECT CLUTCH RELEASE CYLINDER ASSEMBLY
1. Install the clutch release cylinder with the 2 bolts.
  
  Torque:
  
  12 N*m { 120 kgf*cm, 9 ft.*lbf }
CONNECT WIRE HARNESS
1. Connect the back-up light switch connector and speedometer sensor connector.
INSTALL FRONT EXHAUST PIPE ASSEMBLY

for 2KD-FTV: Click here

for 1TR-FE: Click here
INSTALL REAR PROPELLER SHAFT ASSEMBLY

for TSAM Made: Click here

for TMT Made: Click here
INSTALL NO. 2 FRAME CROSSMEMBER ASSEMBLY
1. Install the frame crossmember with the 4 bolts and 4 nuts.
  
  Torque:
  
  50 N*m { 510 kgf*cm, 37 ft.*lbf }
ADD MANUAL TRANSMISSION OIL
1. Stop the vehicle on a level surface.
2. Remove the filler plug and gasket.
3. Check that the oil level is between 0 to 5 mm (0 to 0.20 in.) from the bottom lip of the filler plug opening.
  
  If the result is not as specified, add transmission oil.
  
  Oil grade
  
  GL-4
  
  Viscosity
  
  SAE 75W-90, 80w or 80W-90
  
  Capacity
  
  2.2 liters (2.3 US qts, 1.9 Imp. qts)
  Note
  - Too much or too little oil will lead to transmission problems.
  - After adjusting the oil level, drive the vehicle and check the oil level again.
4. Check for oil leakage when the oil level is low. If leakage is found, repair the area necessary to stop the leak. Replace damaged parts as necessary.
5. Install a new gasket and the filler plug.
  
  Torque
  
  37 N*m (377 kgf*cm, 27 ft.*lbf)
INSTALL NO. 1 ENGINE UNDER COVER

Torque:

28 N*m { 286 kgf*cm, 21 ft.*lbf }
INSTALL ENGINE UNDER COVER

Torque:

28 N*m { 286 kgf*cm, 21 ft.*lbf }
INSTALL FLOOR SHIFT SHIFT LEVER ASSEMBLY
1. Cover the shift lever cap with a cloth.
2. Press down on the shift lever cap and rotate it clockwise to install it.
  
  Tech Tips
  
  Apply MP grease to the tip of the shift lever.
INSTALL SHIFT LEVER BOOT ASSEMBLY
1. Install the shift lever boot with the 4 screws and 2 clips.
INSTALL CONSOLE BOX ASSEMBLY

Click here
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
PERFORM INITIALIZATION
1. Perform initialization Click here.
  
  Note
  
  Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
CHECK SRS WARNING LIGHT

Click here