CLUTCH UNIT (for C551) INSTALLATION


  1. INSTALL CLUTCH DISC ASSEMBLY

    A0136R3E01

    1. Insert SST into the clutch disc, and then insert them into the flywheel.

      SST
      09301-00131

      Note

      Do not insert the clutch disc in the wrong direction.

  2. INSTALL CLUTCH COVER ASSEMBLY

    A0137J5E01

    1. Align the matchmark on the clutch cover with the one on the flywheel.

    2. Tighten the 6 bolts uniformly in the order shown in the illustration, starting with the bolt located near the knock pin on the top.

      Torque:
      19 N*m  { 195 kgf*cm, 14 ft.*lbf }

      Tech Tips

      After checking that the disc is in the center, gently move SST up and down, right and left to tighten the bolts.

      SST
      09301-00131

  3. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY

    A01378S

    1. Using a dial indicator with a roller instrument, check the diaphragm spring tip alignment.

      Maximum non-alignment
      0.5 mm (0.0197 in.)
    2. A0138QME02

      If the alignment is not as specified, using SST, adjust the diaphragm spring tip alignment.

      SST
      09333-00013

  4. INSTALL CLUTCH HOUSING COVER NO. 1

    A013662

    1. Install the clutch housing cover No. 1 onto the manual transaxle case.

  5. INSTALL CLUTCH RELEASE FORK LEVER SHAFT OIL SEAL

    A0138FCE01

    1. Using SST and a hammer, tap in a new select lever shaft oil seal until its surface is flush with the manual transaxle case.

      SST
      09950-60010   ( 09951-00290 )
      09950-70010   ( 09951-07150 )

  6. INSTALL CLUTCH RELEASE FORK LEVER


    1. A01385M

      Apply clutch release grease to the contact surface between the release bearing and the release fork, the rotating and sliding parts of the release lever and the spline coupling part.

      Note

      Apply grease uniformly to the rotating and sliding parts of the release lever and spline coupling part. Remove any grease extending beyond the release lever joining part.

    2. A01379J

      Install the release fork lever onto the transaxle case together with the torsion spring, spring stopper and the release fork.

    3. A013754

      Using a screwdriver and hammer, install a new E-ring.

    4. A01387T

      Secure the torsion spring to the release fork.

      Note

      Hold the spring and spring stopper up to the upper end of the release fork lever first, and then secure the spring.

  7. INSTALL CLUTCH RELEASE BEARING ASSEMBLY

    A0138DD

    1. Install the release bearing onto the transaxle case.

  8. INSTALL RELEASE FORK RETRACTING SPRING HANGER

    A01367T

    1. Install the release fork retracting spring hanger onto the release fork lever with the bolt.

      Torque:
      33 N*m  { 336 kgf*cm, 24 ft.*lbf }

  9. INSTALL MANUAL TRANSAXLE ASSEMBLY


    1. Align the input shaft with the clutch disc and install the manual transaxle onto the engine.

    2. A013625

      Install the 5 bolts.

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

      Note


      • Insert dowel pins into dowel holes securely so that the end face of transaxle assembly fits close against engine assembly before tightening the bolts between the engine and transaxle.

      • Make sure that the dowel pins are not loose, bent, damaged or scratched and then install the transaxle onto the engine with the contact surfaces of the engine and transaxle flat against each other.

  10. INSTALL ENGINE MOUNTING INSULATOR LH

    A0138IH

    1. Install the engine mounting insulator and engine mounting bracket with the 7 bolts.

      Torque:
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }

  11. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY


    1. A0138HUE01

      Using a transmission jack, support the front suspension crossmember sub-assembly.

    2. A01385KE01

      Install the 6 bolts and the front suspension crossmember sub-assembly.

      Torque:
      85 N*m  { 867 kgf*cm, 63 ft.*lbf, for bolt A }
      128 N*m  { 1,305 kgf*cm, 95 ft.*lbf, for bolt B }
      48 N*m  { 489 kgf*cm, 35 ft.*lbf, for bolt C }
    3. A0137IIE02

      Install the 3 bolts onto the engine mounting control bracket (for 1KR-FE).

      Torque:
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }
    4. A0137Q9

      Install the control rod onto the engine mounting control bracket with the bolt (2WZ-TV).

      Torque:
      120 N*m  { 1,224 kgf*cm, 89 ft.*lbf }

    5. Remove the engine sling device.

    6. Remove the No. 1 and No. 2 engine hangers (for 1KR-FE).

  12. INSTALL STARTER ASSEMBLY


    1. A01374KE02

      Install the starter with the 2 bolts.

      Torque:
      37 N*m  { 380 kgf*cm, 27 ft.*lbf }

    2. Connect the wire harness to terminal 30 and install the nut.

      Torque:
      9.5 N*m  { 97 kgf*cm, 84 in.*lbf }

    3. Connect the wire harness to terminal 50 and install the nut.

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

    4. Install the wire harness clamp with the bolt.

      Torque:
      8.4 N*m  { 85 kgf*cm, 74 in.*lbf }

  13. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH

    A0137MQ

    1. Coat the spline of the inboard joint shaft assembly with transaxle oil.

    2. Align the shaft splines and install the drive shaft assembly with a screwdriver and hammer.

      Note


      • Face the snap ring cut area downward.

      • Do not damage the oil seal.

      • Do not damage the front drive shaft assembly boot.

      Tech Tips

      Whether the front drive shaft assembly is securely driven in or not can be confirmed from the brass bar reaction force or sound.

  14. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH

    Tech Tips

    The installation procedure for the RH side is the same as that for the LH side.

  15. INSTALL FRONT AXLE ASSEMBLY LH


    1. Push the front axle assembly out of the vehicle to align the spline of the front drive shaft assembly with the front axle assembly and insert the front axle assembly.

      Note


      • Do not push the front axle assembly further out of the vehicle than is necessary.

      • Do not damage the oil seal.

      • Do not damage the front drive shaft assembly boot.

      • Do not damage the speed sensor rotor.

      • Check for any foreign matter on the speed sensor rotor and insertion part.

  16. INSTALL FRONT AXLE ASSEMBLY RH

    Tech Tips

    The installation procedure for the RH side is the same as that for the LH side.

  17. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO. 1 LH

    A0136N3

    1. Push the front suspension lower arm No. 1 downward, install the front lower ball joint and tighten the castle nut and a new clip.

      Torque:
      98 N*m  { 1,000 kgf*cm, 72 ft.*lbf }

      Note

      Retighten the castle nut and clip within a turning angle of 60° after aligning the hole of the clip with the castle nut.

  18. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO. 1 RH

    Tech Tips

    The installation procedure for the RH side is the same as that for the LH side.

  19. INSTALL FRONT STABILIZER BAR

    A01388W

    1. Install the stabilizer bar front with the 2 cushion retainers, 2 cushions and a nut, as shown in the illustration.

      Note

      Be sure to install the cushion and retainer in the correct direction.

    2. Tighten the nut with a spanner (10 mm).

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

  20. INSTALL TIE ROD END SUB-ASSEMBLY LH

    A013608

    1. Connect the tie rod end to the steering knuckle and install it with the castle nut and a new cotter pin.

      Torque:
      33 N*m  { 336 kgf*cm, 24 ft.*lbf }

      Note

      Retighten the castle nut and cotter pin within a turning angle of 60° after aligning the hole of the cotter pin with the castle nut.

  21. INSTALL TIE ROD END SUB-ASSEMBLY RH

    Tech Tips

    The installation procedure for the RH side is the same as that for the LH side.

  22. INSTALL FRONT AXLE SHAFT LH NUT

    A0135U4E01

    1. Install a new front axle hub nut.

      Torque:
      216 N*m  { 2,202 kgf*cm, 160 ft.*lbf }

    2. Using a hammer and chisel, stake the front axle hub nut.

  23. INSTALL FRONT AXLE SHAFT RH NUT

    Tech Tips

    The installation procedure for the RH side is the same as that for the LH side.

  24. INSTALL SPEED SENSOR FRONT LH

    Click here

  25. INSTALL SPEED SENSOR FRONT RH

    Tech Tips

    The installation procedure for the RH side is the same as that for the LH side.

  26. INSTALL EXHAUST PIPE ASSEMBLY FRONT


    1. A0137UN

      Using vernier calipers, measure the free length of the compression spring.

      Minimum length
      40.5 mm (1.594 in.)

      • If the length is not as specified, replace the compression spring.

    2. A0138PGE01

      Using a plastic hammer and a wooden block, tap in a new exhaust pipe gasket until its surface is flush with the exhaust manifold.

      Note


      • Be sure to install the exhaust pipe gasket in the correct direction.

      • Do not damage the outer surface of the exhaust pipe gasket.

      • Do not reuse the exhaust pipe gasket.

      • Do not push in the gasket with the exhaust pipe when connecting it.

    3. Install the exhaust front pipe assembly and a new exhaust pipe gasket with the 2 compression springs and 2 bolts.

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

    4. Install the exhaust pipe No.4 support.

    5. Install the bolt and clamp.

      Torque:
      32 N*m  { 326 kgf*cm, 24 ft.*lbf }
      A0135VGE04

      Note


      • Clamp marks and stamping should be aligned.

  27. INSTALL FLYWHEEL HOUSING UNDER COVER

    A0138XW

    1. Install the flywheel housing under cover onto the clutch housing with the 3 bolts.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

  28. CONNECT ENGINE WIRE NO. 3

    A01362OE01

    1. Connect the engine wire No. 3 (ground cable) onto the transaxle with the 2 bolts.

      Torque:
      Bolt A
      26 N*m  { 260 kgf*cm, 19 ft.*lbf }
      Bolt B
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

  29. CONNECT WIRING HARNESS CLAMP BRACKET

    A0138M6

    1. Connect the wiring harness clamp bracket with the bolt.

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

    2. Connect the back-up light switch connector.

    3. Connect the oxygen sensor connector.

  30. CONNECT CLUTCH RELEASE CABLE ASSEMBLY

    A01391Y

    1. Connect the clutch release cable to the manual transaxle.

  31. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

    A0136KNE01

    1. Connect the transmission select cable to the manual transaxle with the new clip A and clip B.

    2. A0135UNE01

      Connect the transmission shift cable to the manual transaxle with the new clip A and clip B.

  32. INSTALL CLUTCH RELEASE FORK RETURN TENSION SPRING


    1. A0137Q6E01

      Apply lithium soap base glycol grease to the clevis of the clutch pedal.

    2. Install the clutch release cable onto the clevis of the clutch pedal.

    3. A01391YE02

      Apply lithium soap base glycol grease to the clevis of the clutch release lever.

    4. Install the clutch release cable onto the manual transaxle.

    5. A0138CPE02

      While holding the clutch release lever, turn the cable end clamp and secure it to the flat area of the clutch release lever.

    6. Move your hand away from the clutch release lever and turn the cylinder portion of the cable end clamp and push it into the groove of the clutch release lever.

    7. LHD:

      A01368LE01

      1. Engage the clutch release cable with the 3 brackets (A) and install the grommet (B) into the piercing hole.

    8. A01371VE01

      RHD:


      1. Engage the clutch release cable with the bracket (A) and install the grommet (B) into the piercing hole.

    9. Depress the clutch pedal a few times to ensure the clutch release cable works smoothly.

      Note

      Depress the clutch pedal 50 times or more when replacing the clutch release cable with a new one.

    10. A0138CPE03

      Gently push the clutch release lever down by hand and make sure that it stops at the position shown in the illustration.

  33. INSPECT AND ADJUST CLUTCH PEDAL SUB-ASSEMBLY


    1. Turn up the floor carpet.

    2. A0137UAE01

      Check whether the pedal height is correct.

      Pedal height from floor panel
      LHD
      135 to 145 mm (5.31 to 5.71 in.)
      RHD
      161 to 171 mm (6.34 to 6.74 in.)

    3. Adjust the pedal height.


      1. Loosen the lock nut and turn the stopper bolt until the height is correct.

      2. Tighten the lock nut.

        Torque:
        25 N*m  { 250 kgf*cm, 18 ft.*lbf }
    4. A013903E01

      Check that the pedal free play is correct.


      1. Depress the pedal until the resistance begins to be felt.

        Pedal free play
        13 to 23 mm (0.512 to 0.906 in.)
    5. A01391EE01

      Adjust the pedal free play.


      1. Turn the clutch release cable adjusting nut until the pedal free play is correct.

        Note

        Confirm that the clutch cable boot is installed.

      2. After adjusting the pedal free play, check the pedal height.

    6. Check the clutch release point.


      1. Pull the parking brake lever and install the wheel stopper.

      2. Start the engine and allow it to idle.

      3. A0137CGE01

        Without depressing the clutch pedal, slowly adjust the shift lever to the reverse position until the gears come into contact with the clutch pedal.

      4. Gradually depress the clutch pedal and measure the stroke distance from the point that the gear noise stops (release point) up to the full stroke end position.

        Standard distance
        20 mm (0.787 in.) or more (from pedal stroke end position to release point)

        If the distance is not as specified, perform the following operations.


        • Check the pedal height.

        • Check the pedal free play.

        • Check the clutch cover and disc.

        • Check the pedal stroke.

        Pedal stroke
        148 mm (5.83 in.)

  34. INSTALL BATTERY HOLD DOWN CLAMP

    A0135TUE03

    1. Install the battery clamp with the 3 bolts.

      Torque:
      Bolt A
      7.4 N*m  { 75 kgf*cm, 65 in.*lbf }
      Bolt B
      17 N*m  { 175 kgf*cm, 13 ft.*lbf }

    2. Engage the 2 wire harness clamps.

  35. INSTALL ENGINE ROOM RELAY BLOCK

    A0138XKE01

    1. Engage the claw and install the relay block.

    2. Install the 2 bolts.

      Torque:
      Bolt A
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }
      Bolt B
      8.4 N*m  { 85 kgf*cm, 74 in.*lbf }

  36. INSTALL BATTERY

    A0136YXE02

    1. Install the battery onto the battery clamp, as shown in the illustration.

      Note


      • The identification line should be seen after installing the battery.

      • The battery clamp should be in contact with the battery after the installation.

    2. A0136EQE01

      Install the battery clamp with the bolt.

      Torque:
      15 N*m  { 154 kgf*cm, 11 ft.*lbf }

    3. Connect the battery positive terminal with the nut.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  37. INSTALL COWL TOP PANEL OUTER

    A01377P

    1. Install the cowl top panel with the 10 bolts.

      Torque:
      9.2 N*m  { 94 kgf*cm, 81 in.*lbf }
    2. A01390L

      Install the grommet of the wire harness.

    3. Install the clamp of the wire harness.

  38. INSTALL FRONT WIPER MOTOR AND LINK ASSEMBLY


    1. Connect the connector.

    2. A0136OQ

      Install the front wiper motor and link assembly with the 2 bolts.

      Torque:
      13 N*m  { 127 kgf*cm, 9 ft.*lbf }

  39. INSTALL COWL TOP VENTILATOR LOUVER RH


    1. Connect the washer hose.

    2. A0136GYE01

      Engage the 8 claws and install the cowl top ventilator louver RH.

    3. Install the clip.

  40. INSTALL COWL TOP VENTILATOR LOUVER LH


    1. Connect the washer hose.

    2. A0136Y2E01

      Engage the 9 claws and install the cowl top ventilator louver LH.

    3. Install the clip.

  41. INSTALL HOOD TO COWL TOP SEAL

    A01379NE01

    1. Engage the 8 clips and install the hood to cowl top seal.

  42. INSTALL FR WIPER ARM LH

    A01390ME03

    1. Scrape any metal powder off the serrated part of the wiper arm with a round file or equivalent (when reinstalling).

    2. Clean the wiper pivot serrations with a wire brush.

    3. Operate the wiper, then stop the windshield wiper motor assembly in the automatic stop position.

    4. Provisionally install the front wiper main arm with the nut.

    5. Install the front wiper secondary arm onto the front wiper motor and link assembly.

    6. A0138WNE04

      Align the blade tip with the mark on the windshield glass, as shown in the illustration.

    7. Tighten the nut of the front wiper main arm.

      Torque:
      21 N*m  { 209 kgf*cm, 15 ft.*lbf }

  43. INSTALL FRONT WIPER ARM HEAD CAP

    A0137M4

    1. Engage the claw and install the front wiper arm head cap.

  44. INSTALL STEERING COLUMN HOLE COVER SUB-ASSEMBLY NO. 1

    A0137CHE01

    1. Install clip B onto the vehicle body and install the steering column hole cover onto the vehicle body with clip A.

      Note

      Fit the lip of the steering column hole cover correctly onto the dash panel.

  45. INSTALL STEERING INTERMEDIATE SHAFT ASSEMBLY NO. 2

    A0137IGE05

    1. Align the matchmarks and install steering intermediate shaft assembly No. 2 onto the steering gear sub-assembly with bolt B.

      Torque:
      35 N*m  { 360 kgf*cm, 26 ft.*lbf }

    2. Tighten bolt A.

      Torque:
      35 N*m  { 360 kgf*cm, 26 ft.*lbf }

    3. Release the seat belt from the steering wheel.

  46. ADD MANUAL TRANSAXLE OIL

  47. INSPECT MANUAL TRANSAXLE OIL


    1. Stop the vehicle in a level place.

    2. Remove the transmission filler plug and the gasket.

    3. A01361GE03

      Check that the oil surface is within 5 mm (0.20 in.) of the bottom of the transmission filler plug opening.

      Note


      • Excessively large or small amounts of oil may cause trouble.


      • After replacing the oil, drive the vehicle and check the oil level again.

    4. Check for oil leakage if the oil level is low.

    5. Install the transmission filler plug and a new gasket.

      Torque:
      39 N*m  { 400 kgf*cm, 29 ft.*lbf }

  48. INSTALL FRONT WHEELS

    Torque:
    103 N*m  { 1,050 kgf*cm, 76 ft.*lbf }

  49. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Torque:
    5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  50. INSPECT FRONT WHEEL ALIGNMENT

    Click here

  51. CHECK FOR MANUAL TRANSAXLE OIL LEAKAGE

  52. CHECK FOR EXHAUST GAS LEAKAGE