MULTI-MODE MANUAL TRANSAXLE ASSEMBLY INSTALLATION

CAUTION / NOTICE / HINT

PROCEDURE

1. INSTALL CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY

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2. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

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3. INSPECT CLUTCH PIPE LINE

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4. INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

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5. INSTALL WIRE HARNESS CLAMP BRACKET

   
   

   1. Install the 2 wire harness clamps bracket with the 2 bolts.

      Torque:

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

6. INSTALL AIR TUBE SUPPORT

   
   

   1. Install the air tube support with the 2 bolts onto the manual transaxle assembly.

      Torque:

      20 N*m  { 199 kgf*cm, 14 ft.*lbf }

7. INSTALL MANUAL TRANSAXLE ASSEMBLY

   
   

   1. Make sure that the knock 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.

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

   3. 

      Text in Illustration

      *1	Knock Pin Hole

      Install the 8 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

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

   4. Connect the connector and install the clamp onto the transaxle.

8. INSTALL ENGINE MOUNTING BRACKET SUB-ASSEMBLY LH

   
   
   1. 

      Text in Illustration

      *1

      Adhesive

      Coat the thread of bolts with sealant.

      Sealant
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

   2. Install the engine mounting bracket sub-assembly LH with the 4 bolts.

      Torque:

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

9. INSTALL ENGINE MOUNTING INSULATOR LH

   
   

   1. Install the engine mounting insulator LH with the 5 bolts.

      Torque:

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

   2. Install the engine mounting bracket sub-assembly LH and engine mounting insulator LH with the bolt and nut.

      Torque:

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

10. INSTALL ENGINE MOVING CONTROL ROD BRACKET

    
    

    1. Install the engine moving control rod bracket with the 4 bolts.

       Torque:

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

11. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

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12. INSTALL OIL PAN COVER

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13. INSTALL FRONT DRIVE SHAFT ASSEMBLES

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14. INSTALL STARTER ASSEMBLY (for 1.6 kW Type)

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15. INSTALL STARTER ASSEMBLY (for 2.0 kW Type)

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16. CONNECT ENGINE WIRE

    
    

    1. Connect the 2 shift and select actuator connectors..

    2. Connect the 2 back-up light switch connector and revolution sensor connector.

    3. Engage the 3 clamps and connect the 5 connectors.

    4. Install the ground bolt.

       Torque:

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

17. INSTALL AIR PIPE SUB-ASSEMBLY

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18. INSTALL NO. 2 AIR HOSE

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19. INSTALL BATTERY CARRIER

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20. INSTALL BATTERY TRAY

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21. INSTALL BATTERY

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22. INSTALL CLUTCH ACTUATOR ASSEMBLY

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23. ADD TRANSAXLE OIL

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24. INSPECT AND ADJUST TRANSAXLE OIL

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25. INSTALL ENGINE UNDER COVER RH

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26. INSTALL ENGINE UNDER COVER LH

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27. INSTALL CENTER ENGINE UNDER COVER

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

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29. INSTALL STEERING SLIDING YOKE SUB-ASSEMBLY

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30. INSTALL COLUMN HOLE COVER SILENCER SHEET

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31. PERFORM INITIALIZATION OF MULTI-MODE MANUAL TRANSAXLE SYSTEM

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32. PERFORM LEARNING OF MULTI-MODE MANUAL TRANSAXLE SYSTEM

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33. PERFORM SYNCHRONIZATION POSITION CALIBRATION

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