MANUAL TRANSAXLE ASSEMBLY (for 1WW) REMOVAL


  1. PRECAUTION

    Note

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work Click here.

  2. DISCONNECT NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  3. REMOVE NO. 1 ENGINE UNDER COVER


    1. A01IR30

      Remove the 6 bolts and 11 clips.

    2. Remove the No. 1 engine under cover.

  4. REMOVE STARTER ASSEMBLY

    Click here

  5. REMOVE EXHAUST PIPE ASSEMBLY

    Click here

  6. REMOVE FRONT LOWER BUMPER ABSORBER


    1. A01ISFZ

      Remove the 4 bolts.

    2. Detach the 2 hooks of the front lower bumper absorber from the installation holes in the body and remove the front lower bumper absorber.

  7. REMOVE ENGINE UNDER COVER REAR RH


    1. Remove the 5 clips and rear engine under cover RH.

  8. REMOVE ENGINE UNDER COVER REAR LH


    1. Remove the 5 clips and rear engine under cover LH.

  9. DRAIN MANUAL TRANSAXLE OIL


    1. A01IP1ME01
      Text in Illustration
      *1 Filler Plug
      *2 Drain Plug

      Remove the filler plug and gasket.

    2. Remove the drain plug and gasket to drain the manual transaxle oil.

    3. Install a new gasket and the drain plug.

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

  10. REMOVE DRIVE SHAFT ASSEMBLY

    Click here

  11. DRAIN ENGINE COOLANT

    CAUTION:

    Do not remove the reservoir cap and air release valve while the engine and radiator assembly are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.


    1. Loosen the radiator drain cock plug and drain the engine coolant.

      A01IUCQE01
      Text in Illustration
      *1 Reservoir Cap *2 Air Release Valve
      *3 Radiator Drain Cock Plug - -

      Tech Tips

      Collect the coolant in a container and dispose of it according to the regulations in your area.

    2. Remove the reservoir cap.

  12. REMOVE NO. 1 ENGINE COVER


    1. A01IRDDE01

      Lift the No. 1 engine cover to detach the 4 clips in the order shown in the illustration and remove the No. 1 engine cover.

      Note

      Attempting to disengage both front and rear clips at the same time may cause the No. 1 engine cover to break.

  13. REMOVE AIR CLEANER CAP SUB-ASSEMBLY WITH AIR CLEANER HOSE ASSEMBLY


    1. A01IUFHE01
      Text in Illustration
      *1 Retainer

      Detach the clamp and disconnect the mass air flow meter sub-assembly connector.

    2. Detach the clamp and disconnect the vacuum hose from the air cleaner hose assembly.

    3. Detach the clamp and disconnect the No. 1 fuel hose from the air cleaner hose assembly.

    4. Detach the clamp and disconnect the No. 2 fuel hose from the air cleaner hose assembly.

    5. Disconnect the ventilation hose from the cylinder head cover sub-assembly.

    6. Release the retainer and disconnect the air cleaner hose assembly from the turbocharger sub-assembly as shown in the illustration.

    7. Detach the 2 clamps and remove the air cleaner cap sub-assembly with air cleaner hose assembly.

  14. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  15. REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. A01IN4S

      Remove the 3 bolts and air cleaner case sub-assembly.

  16. REMOVE AIR CLEANER BRACKET


    1. A01IOXO

      Disconnect the 3 clamps and wire harness.

    2. A01IOXL

      Remove the 5 bolts and air cleaner bracket.

  17. REMOVE WIRE HARNESS


    1. A01IOUB

      Detach the 2 clamps from the No. 1 air tube assembly.

    2. Remove the 2 bolts and disconnect the engine wire from the No. 1 air tube assembly.

  18. REMOVE NO. 4 WATER BY-PASS HOSE


    1. A01IS6SE01
      Text in Illustration
      *1 Retainer

      Release the retainer and disconnect the No. 4 water by-pass hose from the EGR cooler assembly as shown in the illustration.

    2. Slide the clamp and remove the No. 4 water by-pass hose from the No. 2 radiator pipe.

  19. DISCONNECT COMPRESSOR OUTLET ELBOW


    1. A01IS1VE01
      Text in Illustration
      *1 Retainer

      Release the retainer and disconnect the compressor outlet elbow from the turbocharger sub-assembly as shown in the illustration.

  20. DISCONNECT INTERCOOLER AIR HOSE


    1. A01INBL

      Loosen the hose clamp and disconnect the intercooler air hose from the intercooler assembly.

  21. REMOVE NO. 1 AIR TUBE ASSEMBLY


    1. A01IQ8W

      Slide the clamp and disconnect the water by-pass hose assembly from the No. 2 radiator pipe.

    2. Slide the clamp and disconnect the radiator hose sub-assembly from the No. 1 radiator pipe.

    3. Detach the clamp and disconnect the water hose sub-assembly from the compressor outlet elbow.

    4. Slide the clamp and disconnect the water hose sub-assembly from the No. 1 radiator pipe.

    5. Slide the clamp and disconnect the outlet heater water hose from the No. 2 radiator pipe.

    6. Remove the 2 bolts and disconnect the No. 1 air tube assembly from the manual transaxle assembly.

  22. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY


    1. A01IRMX

      Remove the 2 clips and disconnect the 2 cables from the manual transaxle assembly.

    2. A01IRG8

      Remove the 2 clips and disconnect the 2 cables from the control cable bracket.

    3. A01IQVV

      Remove the bolt and detach the bracket of the transmission control cable assembly.

  23. REMOVE NO. 1 CLUTCH HOUSING COVER


    1. A01IRB3

      Remove the 2 bolts and No. 1 clutch housing cover.

  24. REMOVE NO. 2 MANIFOLD STAY


    1. A01INNU

      Using an E14 "TORX" socket wrench, remove the 2 bolts from the manual transaxle assembly.

    2. Remove the nut and No. 2 manifold stay.

  25. DISCONNECT CLUTCH RELEASE CYLINDER ASSEMBLY


    1. A01ITAS

      Remove the 4 bolts and disconnect the clutch release cylinder assembly with clutch flexible hose bracket.

  26. DISCONNECT ENGINE WIRE


    1. A01IRXD

      Remove the bolt and disconnect the ground cable.

    2. A01IQ4Z

      Disconnect the back-up light switch connector, neutral position connector, 2 bolts and engine wire.

  27. LOOSEN ENGINE AND TRANSAXLE CONNECTING BOLT


    1. A01ITFI

      Manual transaxle upper side:

      Using an E14 "TORX" socket wrench, loosen the 2 bolts.

    2. A01ISCB

      Manual transaxle lower side:

      Loosen the 4 bolts.

    3. A01IUKU

      Engine mounting insulator side:

      Loosen the bolt.

  28. REMOVE FRONT SUSPENSION MEMBER

    Click here

  29. SUPPORT MANUAL TRANSAXLE ASSEMBLY


    1. Support the manual transaxle assembly with a transmission jack and tie down band so that it is stable.

  30. REMOVE FRONT CROSSMEMBER SUB-ASSEMBLY


    1. A01IRWI

      Remove the 6 bolts and front crossmember sub-assembly.

  31. REMOVE FRONT ENGINE MOUNTING INSULATOR


    1. A01ITMQ

      Remove the through bolt, nut and front engine mounting insulator.

  32. REMOVE MANUAL TRANSAXLE ASSEMBLY

    Note


    • As there is very little space around the manual transaxle assembly, be extremely careful that the body, clutch pipe line and radiator cooling fan do not interfere with the manual transaxle assembly when removing the transaxle.

    • When removing the manual transaxle assembly, it is necessary to move the engine assembly and manual transaxle assembly up and down, and back and forth. Therefore, continually confirm that the parts are properly supported and stable while performing this step.


    1. A01IP2U

      Remove the nut and through bolt, and then disconnect the engine mounting insulator LH from the engine mount bracket LH.

    2. Lower the transmission jack a little at a time. Slightly tilt the engine assembly and manual transaxle assembly.

      Tech Tips

      Lower the engine assembly and manual transaxle assembly to a position where the engine mounting insulator LH can be removed.

    3. A01ISYE

      Remove the 4 bolts and engine mount insulator LH.

    4. A01IQ3R

      Remove the 4 bolts and engine mounting bracket LH.

      Note

      Make sure to clean the bolts and bolt holes after removing the transmission.

    5. A01IRV4

      Use a cloth, etc. to protect the clutch pipe line in the area indicated in the illustration.

    6. A01IT40E01
      Text in Illustration
      *a Body
      *b Crankshaft Damper Sub-assembly

      Lower the transmission jack a little at a time. Slightly tilt the engine assembly and manual transaxle assembly.

      Note

      Be careful that the body and crankshaft damper sub-assembly do not interfere with each other.

    7. A01IQJ9E01
      Text in Illustration
      *a Engine Support Point

      Support the engine assembly with an engine lifter as shown in the illustration so that it is stable.

    8. A01IPMBE01

      Remove the 6 bolts shown in the illustration.

    9. While making sure that the clutch pipe line does not interfere with the manual transaxle assembly, slowly disconnect the manual transaxle assembly from the engine assembly until the input shaft is clear of the diaphragm spring of the clutch cover.

    10. Slowly lower the transmission jack and remove the manual transaxle assembly.

  33. REMOVE REAR ENGINE MOUNTING INSULATOR

    Tech Tips

    Perform this procedure only when replacement of the rear engine mounting insulator is necessary.


    1. A01ISM7

      Remove the 2 bolts, 2 nuts and rear engine mounting insulator from the front suspension crossmember sub-assembly.

  34. REMOVE FRONT ENGINE MOUNTING BRACKET


    1. A01IPZU

      Remove the 4 bolts and front engine mounting bracket.

  35. REMOVE REAR ENGINE MOUNTING BRACKET


    1. A01IUP9

      Remove the 5 bolts and rear engine mounting bracket.