MANUAL TRANSAXLE ASSEMBLY INSTALLATION
PROCEDURE
INSTALL REAR ENGINE MOUNTING BRACKET
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Temporarily install the rear engine mounting bracket with the 5 bolts.
Tighten the 5 bolts of the rear engine mounting bracket in the order shown in the illustration.
45 N*m
459 kgf*cm
33 ft.*lbf
-
INSTALL FRONT ENGINE MOUNTING BRACKET
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Temporarily install the front engine mounting bracket with the 4 bolts.
Tighten the 4 bolts of the front engine mounting bracket in the order shown in the illustration.
64 N*m
653 kgf*cm
47 ft.*lbf
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INSTALL REAR ENGINE MOUNTING INSULATOR
INSTALL MANUAL TRANSAXLE ASSEMBLY
Note:Be extremely careful that the body, clutch pipe line and radiator cooling fan do not interfere with the manual transaxle assembly when installing the manual transaxle assembly.
When installing 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.
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Make sure that the dowel pins are not loose, bent, damage or scratched.
While adjusting the angle of the transmission jack raise the manual transaxle assembly until it is in line with the engine assembly.
Note:Be careful that the clutch pipe line does not interfere with the manual transaxle assembly.
Adjust the height and angle of the transmission jack, align the input shaft with the clutch disc, and then install the manual transaxle assembly to the engine assembly with the contact surfaces of the engine assembly and manual transaxle assembly flat against each other.
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Temporarily install the manual transaxle assembly with the 6 bolts.
Note:Before tightening the bolts, insert the dowel pins into the dowel holes securely so that the end face of the manual transaxle assembly fits close against the engine assembly.
Apply adhesive to the 4 bolts.
Adhesive
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
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Temporarily install the engine mounting insulator LH with the 4 bolts.
Tighten the 4 bolt of the engine mounting bracket LH in the order shown in the illustration.
64 N*m
653 kgf*cm
47 ft.*lbf
-
Install the engine mounting insulator LH with the 4 bolts.
95 N*m
969 kgf*cm
70 ft.*lbf
Slowly raise the engine assembly and transmission assembly using a transmission jack, and then align the installation positions of the engine mounting insulator LH and engine mounting bracket LH.
-
Install the nut and through bolt, and then connect the engine mounting insulator LH to the engine mounting bracket LH.
56 N*m
571 kgf*cm
41 ft.*lbf
TEMPORARILY INSTALL NO. 2 MANIFOLD STAY
Temporarily install the No. 2 manifold stay with the 2 bolts and nut.
TEMPORARILY INSTALL STARTER ASSEMBLY
Temporarily install the starter assembly with the 2 bolts.
TIGHTEN ENGINE AND TRANSAXLE CONNECTING BOLT
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E14 "TORX" bolt
Bolt length 100 mm (3.94 in.)
E14 "TORX" bolt
Bolt length 80 mm (3.15 in.)
Hexagon Bolt
Bolt length 40 mm (1.57 in.)
Tighten the 10 bolts in the sequence shown in the illustration.
for bolt A
64 N*m
653 kgf*cm
47 ft.*lbf
for bolt B
79 N*m
806 kgf*cm
58 ft.*lbf
for bolt C
64 N*m
653 kgf*cm
47 ft.*lbf
for bolt D
24 N*m
245 kgf*cm
18 ft.*lbf
Tighten the nut of the No. 2 exhaust manifold stay.
19 N*m
194 kgf*cm
14 ft.*lbf
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INSTALL FRONT ENGINE MOUNTING INSULATOR
-
Install the front engine mounting insulator with the through bolt and nut.
145 N*m
1479 kgf*cm
107 ft.*lbf
-
INSTALL FRONT CROSSMEMBER SUB-ASSEMBLY
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Install the front crossmember sub-assembly with the 6 bolts.
for bolt A
99 N*m
1010 kgf*cm
73 ft.*lbf
for bolt B
95 N*m
969 kgf*cm
70 ft.*lbf
Remove the transmission jack.
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INSTALL FRONT SUSPENSION MEMBER
CONNECT WIRE HARNESS
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Install the 3 bolts and connect the 2 connectors.
19.1 N*m
195 kgf*cm
14 ft.*lbf
-
CONNECT CLUTCH RELEASE CYLINDER ASSEMBLY
-
Connect the clutch release cylinder assembly and clutch flexible hose bracket with the 4 bolts.
12 N*m
122 kgf*cm
9 ft.*lbf
-
CONNECT GROUND CABLE
-
Connect the ground cable with the bolt.
8.35 N*m
85 kgf*cm
74 in.*lbf
-
INSTALL NO. 1 CLUTCH HOUSING COVER
-
Install the No. 1 clutch housing cover with the 2 bolts.
30 N*m
306 kgf*cm
22 ft.*lbf
-
CONNECT TRANSAXLE CONTROL CABLE ASSEMBLY
-
*1
Clip
*2
Metal Washer Plate
Connect the transaxle control cable assembly to the control cable bracket with 2 new clips.
Note:Do not bend the transaxle control cable assembly more than necessary.
Connect the transaxle control cable assembly to the manual transaxle assembly and install the 2 clips.
Tip:Make sure that the metal washer plate of the shift cable facing toward the outside of the vehicle.
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INSTALL NO. 1 AIR TUBE ASSEMBLY
CONNECT NO. 2 AIR HOSE
CONNECT COMPRESSOR OUTLET ELBOW
INSTALL NO. 4 WATER BY-PASS HOSE
CONNECT ENGINE WIRE
INSTALL AIR CLEANER BRACKET
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Install the air cleaner bracket with the 5 bolts.
for bolt A
7.0 N*m
71 kgf*cm
62 in.*lbf
for bolt B
17.5 N*m
178 kgf*cm
13 ft.*lbf
-
Connect the wire harness with the 3 clamps.
-
INSTALL AIR CLEANER CASE SUB-ASSEMBLY
INSTALL AIR CLEANER CAP SUB-ASSEMBLY WITH AIR CLEANER HOSE ASSEMBLY
INSTALL DRIVE SHAFT ASSEMBLY
INSTALL STARTER ASSEMBLY
INSTALL EXHAUST PIPE ASSEMBLY
ADD ENGINE COOLANT
ADD MANUAL TRANSAXLE OIL
INSPECT FOR COOLANT LEAK
INSPECT FOR MANUAL TRANSAXLE OIL LEAK
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Note:When disconnecting the cable, some systems need to be initialized after the cable is reconnected.
INSPECT FOR EXHAUST GAS LEAK
INSTALL REAR ENGINE UNDER COVER LH
INSTALL REAR ENGINE UNDER COVER RH
INSTALL NO. 2 ENGINE UNDER COVER
INSTALL NO. 1 ENGINE UNDER COVER
INSTALL NO. 1 ENGINE COVER