MANUAL TRANSAXLE ASSEMBLY INSTALLATION


  1. INSTALL MANUAL TRANSAXLE ASSEMBLY


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

    2. Install the 5 bolts.

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

      Note


      • Be careful not to pinch wire harnesses, etc.

      • Do not forcefully pry on the manual transaxle assembly.

      • To avoid damage to the input shaft, do not forcefully shake the manual transaxle assembly.

      • Insert knock pins into the knock pin holes securely so that the end face of the manual transaxle assembly fits close against the engine assembly before tightening the bolts.

  2. INSTALL ENGINE MOUNTING INSULATOR LH


    1. Install the engine mounting insulator LH with engine mounting bracket to the manual transaxle assembly with the 7 bolts.

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

  3. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY


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

    2. A01385KE01

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

      Torque:
      for bolt A
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }
      for bolt B
      128 N*m  { 1305 kgf*cm, 95 ft.*lbf }
      for bolt C
      48 N*m  { 489 kgf*cm, 35 ft.*lbf }

    3. Install the engine mounting control bracket with the 3 bolts.

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

    4. Remove the engine sling device.

    5. Remove the 2 bolts, No. 1 engine hanger and the No. 2 engine hanger.

  4. 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 }

  5. INSTALL FRONT DRIVE SHAFT ASSEMBLIES

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  6. INSTALL FRONT EXHAUST PIPE ASSEMBLY


    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.

  7. INSTALL FLYWHEEL HOUSING UNDER COVER


    1. Install the flywheel housing under cover to the manual transaxle assembly with the 3 bolts.

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

  8. INSTALL NO. 3 ENGINE WIRE


    1. A01362OE01

      Install the No. 3 engine wire to the manual transaxle assembly 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 }

  9. INSTALL WIRE HARNESS CLAMP BRACKET


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

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

    2. Connect the back-up light switch connector.

    3. Connect the heated oxygen sensor connector.

  10. INSTALL CLUTCH RELEASE CABLE ASSEMBLY


    1. Install the clutch release cable assembly to the manual transaxle assembly.

  11. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY


    1. Connect the transmission control shift cable to the shift lever retainer.

    2. Connect the transmission control shift cable to the floor shift shift lever.

    3. Connect the transmission control select cable to the shift lever retainer.

    4. A0138X1

      Connect the transmission control select cable to the floor shift shift lever.

      Note


      • Connect the select cable point with the serrated part facing upwards.

      • Insert the clip in the orientation shown in the illustration.

  12. INSTALL CLUTCH RELEASE FORK RETURN TENSION SPRING


    1. Install the clutch release fork return tension spring to the release fork retracting spring hanger.

  13. 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.)

  14. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

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

    A0137CHE02
    Text in Illustration
    *1 Clip A
    *2 Clip B

    1. Install clip B onto the body and install the No. 1 steering column hole cover sub-assembly onto the body with clip A.

      Note

      Fit the lip of the No. 1 steering column hole cover sub-assembly correctly onto the dash panel.

  16. INSTALL NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    A0137IGE06
    Text in Illustration
    *a Matchmark

    1. Align the matchmarks and install the No. 2 steering intermediate shaft assembly to the steering gear 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 assembly.

  17. INSTALL STEERING COLUMN HOLE COVER PLATE


    1. Engage the steering column hole cover plate.

  18. INSTALL BATTERY CLAMP SUB-ASSEMBLY

    A0135TUE03

    1. Install the battery clamp sub-assembly 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 }

  19. INSTALL ENGINE ROOM RELAY BLOCK


    1. Engage the 3 wire harness clamps.

    2. A0138XKE01

      Engage the claw and install the engine room relay block.

    3. 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 }

  20. INSTALL BATTERY

    A0136B5E01
    Text in Illustration
    *a Identification line
    *b A-A
    *c B-B

    1. Install the battery onto the battery clamp sub-assembly, 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. 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 }

  21. INSTALL COWL TOP PANEL OUTER


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

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

    2. Engage the grommet and install the wire harness.

    3. Engage the wire harness clamp.

  22. INSTALL FRONT NO. 1 VENTILATOR SEAL


    1. Install the No. 1 ventilator seal with the 2 clips.

  23. INSTALL FRONT AIR SHUTTER SEAL RH


    1. Install the front air shutter seal RH the 2 clips.

  24. INSTALL FRONT WIPER MOTOR AND LINK ASSEMBLY

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  25. ADD MANUAL TRANSAXLE OIL

  26. INSPECT MANUAL TRANSAXLE OIL


    1. Stop the vehicle in a level place.

    2. Remove the manual transaxle filler plug and the gasket.

    3. A01361GE50
      Text in Illustration
      *a 0 to 5 mm (0 to 0.20 in.)

      Check that the oil surface is within 5 mm (0.20 in.) of the bottom of the manual transaxle 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 manual transaxle filler plug and a new gasket.

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

  27. INSTALL FRONT WHEELS

    Torque:
    103 N*m  { 1050 kgf*cm, 76 ft.*lbf }

  28. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

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

  29. INSPECT FRONT WHEEL ALIGNMENT

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  30. INSPECT FOR MANUAL TRANSAXLE OIL LEAK

  31. INSPECT FOR EXHAUST GAS LEAK