MANUAL TRANSAXLE ASSEMBLY(When Not Using the Engine Support Bridge) INSTALLATION

CAUTION / NOTICE / HINT

Note

When the manual transaxle assembly is removed, be sure to use a new clutch release with bearing cylinder assembly and new installation bolts. Removal of the manual transaxle assembly allows the compressed clutch release with bearing cylinder assembly to return to its original position. Dust from the moving section may damage the seal of the clutch release with bearing cylinder assembly, possibly causing clutch fluid leaks.

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 front transaxle case with the bolt.

      Torque:
      11.3 N*m  { 115 kgf*cm, 8 ft.*lbf }

  2. INSTALL CONTROL CABLE BRACKET ASSEMBLY


    1. Install the control cable bracket assembly to the manual transmission case with the 3 bolts.

      Torque:
      17 N*m  { 173 kgf*cm, 13 ft.*lbf }

  3. INSTALL WIRE HARNESS CLAMP BRACKET


    1. Install the wiring harness clamp bracket to the manual transmission case with the bolt.

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

  4. INSTALL NO. 1 HEATER BRACKET SUB-ASSEMBLY


    1. Install the No. 1 heater bracket sub-assembly to the manual transmission case with the bolt.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  5. INSTALL CLUTCH RELEASE CYLINDER WITH BEARING ASSEMBLY

    Click here

  6. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

    Click here

  7. INSPECT CLUTCH PIPE LINE

    Click here

  8. INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

    Click here

  9. INSTALL CLUTCH FLEXIBLE HOSE BRACKET


    1. Install the clutch flexible hose bracket to the manual transmission case with the bolt.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  10. INSTALL BLEEDER CLUTCH RELEASE TUBE

    Click here

  11. INSTALL ENGINE MOUNTING BRACKET LH


    1. A005Q1XC01
      *a Temporarily Tighten

      Install the engine mounting bracket LH to the manual transmission case with the 5 bolts in the order shown in the illustration.

      Torque:
      41 N*m  { 418 kgf*cm, 30 ft.*lbf }

  12. INSTALL NO. 2 ENGINE MOVING CONTROL ROD


    1. Install the No. 2 engine moving control rod to the manual transmission case with the 4 bolts.

      Torque:
      44 N*m  { 449 kgf*cm, 32 ft.*lbf }

  13. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY


    1. Install the front suspension crossmember sub-assembly to the No. 2 engine moving control rod with the bolt.

      Torque:
      170 N*m  { 1734 kgf*cm, 125 ft.*lbf }

  14. INSTALL ENGINE ASSEMBLY


    1. A005OBXC01
      *1 Knock Pin

      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 engine assembly to the manual transaxle assembly.

    3. A005OMIN01

      Temporarily install the bolt (A).

    4. Install the bolt (B), then fully tighten the bolt (A).

      Torque:
      for Flange Bolt
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }
      for Bolt with Washer
      33 N*m  { 337 kgf*cm, 24 ft.*lbf }

    5. Install the 5 bolts.

      Torque:
      for Flange Bolt
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }
      for Bolt with Washer
      33 N*m  { 337 kgf*cm, 24 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.

  15. INSTALL MANIFOLD SUPPORT BRACKET

    Click here

  16. INSTALL DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY

    Click here

  17. DISCONNECT WIRE HARNESS


    1. Engage the 3 clamps and install the wire harness to the manual transaxle assembly.

    2. Connect the neutral position switch connector.

    3. Engage the 3 clamps and install the heated oxygen sensor wire harness to the front suspension crossmember sub-assembly.

    4. Engage the clamp and install the wire harness to the manual transaxle assembly.

    5. Install the bolt.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

    6. Connect the transmission revolution sensor connector.

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

  18. INSTALL FLYWHEEL HOUSING SIDE COVER

    Click here

  19. INSTALL STARTER ASSEMBLY

    Click here

  20. REMOVE ENGINE HANGER

    Click here

  21. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

    Click here