MANUAL TRANSAXLE ASSEMBLY INSTALLATION

INSTALL MANUAL TRANSAXLE ASSEMBLY
1. Align the input shaft with the clutch disc and install the manual transaxle onto the engine.
2. 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.
INSTALL ENGINE MOUNTING INSULATOR LH
1. Install the engine mounting insulator and engine mounting bracket with the 7 bolts.
  
  Torque:
  
  52 N*m { 530 kgf*cm, 38 ft.*lbf }
INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY
1. Using a transmission jack, support the front suspension crossmember sub-assembly.
2. 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. Install the 3 bolts onto the engine mounting control bracket (for 1KR-FE).
  
  Torque:
  
  52 N*m { 530 kgf*cm, 38 ft.*lbf }
4. 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).
INSTALL STARTER ASSEMBLY
1. 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 }
INSTALL FRONT DRIVE SHAFT ASSEMBLY LH
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.
INSTALL FRONT DRIVE SHAFT ASSEMBLY RH

Tech Tips

The installation procedure for the RH side is the same as that for the LH side.
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.
INSTALL FRONT AXLE ASSEMBLY RH

Tech Tips

The installation procedure for the RH side is the same as that for the LH side.
INSTALL FRONT SUSPENSION LOWER ARM SUB-ASSEMBLY LH
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.
INSTALL FRONT SUSPENSION LOWER ARM SUB-ASSEMBLY RH

Tech Tips

The installation procedure for the RH side is the same as that for the LH side.
INSTALL FRONT STABILIZER BAR
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 }
INSTALL TIE ROD END SUB-ASSEMBLY LH
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.
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.
INSTALL FRONT AXLE SHAFT NUT LH
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.
INSTALL FRONT AXLE SHAFT NUT RH

Tech Tips

The installation procedure for the RH side is the same as that for the LH side.
INSTALL FRONT SPEED SENSOR LH
1. Connect the speed sensor wire to the shock absorber assembly.
  
  Note
  
  Insert a rubber grommet into the bracket with the painted line placed between the bracket cutouts.
2. Install the bolt and speed sensor front onto the steering knuckle.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
  Note
  
  Do not damage the speed sensor.
  
  Keep the speed sensor free of any foreign material.
  
  Do not twist the sensor wire when installing the speed sensor.
INSTALL FRONT SPEED SENSOR RH

Tech Tips

The installation procedure for the RH side is the same as that for the LH side.
INSTALL EXHAUST FRONT PIPE ASSEMBLY
1. 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. 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 }
  Note
  
  Clamp marks and stamping should be aligned.
INSTALL FLYWHEEL HOUSING UNDER COVER
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 }
CONNECT NO. 3 ENGINE WIRE
1. Connect the No. 3 engine wire (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 }
CONNECT WIRE HARNESS CLAMP BRACKET
1. Connect the wire 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 heated oxygen sensor connector.
CONNECT CLUTCH RELEASE CABLE ASSEMBLY
1. Connect the clutch release cable to the manual transaxle.
CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY
1. Connect the transmission select cable to the manual transaxle with the new clip A and clip B.
2. Connect the transmission shift cable to the manual transaxle with the new clip A and clip B.
INSTALL CLUTCH RELEASE FORK RETURN TENSION SPRING
1. Install the clutch release fork return tension spring onto the release fork retracting spring hanger.

Minimum length
40.5 mm (1.594 in.)

INSPECT AND ADJUST CLUTCH PEDAL SUB-ASSEMBLY

Turn up the floor carpet.

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.)

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 }
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.)
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.
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. 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.)

INSTALL NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY
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.
INSTALL NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY
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.
INSTALL STEERING COLUMN HOLE COVER PLATE
1. Engage the steering hole plate.
INSTALL BATTERY CLAMP SUB-ASSEMBLY
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.
INSTALL ENGINE ROOM RELAY BLOCK
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 }
INSTALL BATTERY
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. 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 }
INSTALL COWL TOP PANEL OUTER
1. Install the cowl top panel with the 10 bolts.
  
  Torque:
  
  9.2 N*m { 94 kgf*cm, 81 in.*lbf }
2. Install the grommet of the wire harness.
3. Install the clamp of the wire harness.
INSTALL FRONT WIPER MOTOR AND LINK ASSEMBLY
1. Connect the connector.
2. Install the front wiper motor and link assembly with the 2 bolts.
  
  Torque:
  
  13 N*m { 127 kgf*cm, 9 ft.*lbf }
INSTALL COWL TOP VENTILATOR LOUVER RH
1. Connect the washer hose.
2. Engage the 8 claws and install the cowl top ventilator louver RH.
3. Install the clip.
INSTALL COWL TOP VENTILATOR LOUVER LH
1. Connect the washer hose.
2. Engage the 9 claws and install the cowl top ventilator louver LH.
3. Install the clip.
INSTALL HOOD TO COWL TOP SEAL
1. Engage the 8 clips and install the hood to cowl top seal.
INSTALL FRONT WIPER ARM
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. 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 }
INSTALL FRONT WIPER ARM HEAD CAP
1. Engage the claw and install the front wiper arm head cap.
ADD MANUAL TRANSAXLE OIL
INSPECT MANUAL TRANSAXLE OIL
1. Stop the vehicle in a level place.
2. Remove the manual transaxle filler plug and the gasket.
3. 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 }
INSTALL FRONT WHEELS

Torque:

103 N*m { 1050 kgf*cm, 76 ft.*lbf }
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Torque:

5.4 N*m { 55 kgf*cm, 48 in.*lbf }
INSPECT FRONT WHEEL ALIGNMENT

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INSPECT FOR MANUAL TRANSAXLE OIL LEAK
INSPECT FOR EXHAUST GAS LEAK