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 transaxle 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
INSTALL SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY
Coat a new O-ring with gear oil.
Install the O-ring to the speedometer driven hole cover sub-assembly.
Install the speedometer driven hole cover sub-assembly to the manual transaxle assembly with the bolt.
INSTALL WIRE HARNESS CLAMP BRACKET
Install the wire harness clamp bracket to the manual transaxle assembly with the bolt.
INSTALL CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY
REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY
INSPECT CLUTCH PIPE LINE
INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY
INSTALL CLUTCH ACCUMULATOR ASSEMBLY
INSTALL REAR ENGINE MOUNTING BRACKET
Install the rear engine mounting bracket to the manual transaxle assembly with the 4 bolts.
INSTALL ENGINE MOUNTING BRACKET LH
Clean the bolts and installation holes in the engine mounting bracket LH.
*a | Adhesive |
Apply adhesive to 2 or 3 threads on the ends of the 4 bolts.
Adhesive |
---|
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent |
Note
In order to ensure proper installation of the 4 bolts, apply adhesive to the 4 bolts and install them within 10 minutes of adhesive application.
Install the engine mounting bracket LH to the manual transaxle assembly with the 4 bolts.
INSTALL FRONT ENGINE MOUNTING BRACKET
Install the front engine mounting bracket to the manual transaxle assembly with the 4 bolts.
INSTALL MANUAL TRANSAXLE ASSEMBLY
Check that the 2 knock pins are installed on the engine assembly before installing the manual transaxle assembly.
Align the input shaft with the clutch disc and install the manual transaxle assembly to the engine assembly.
Install the 8 bolts.
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.
CONNECT WIRE HARNESS (w/ Stop And Start System)
Connect the wire harness to the manual transaxle assembly with the nut and bolt.
Connect the park/neutral position switch assembly connector.
Connect the back-up light switch assembly connector.
Engage the 5 clamps.
CONNECT WIRE HARNESS (w/o Stop And Start System)
Connect the wire harness to the manual transaxle assembly with the nut and bolt.
Connect the back-up light switch assembly connector.
Engage the 3 clamps.
INSTALL STARTER ASSEMBLY (w/ Stop And Start System)
INSTALL STARTER ASSEMBLY (w/o Stop And Start System)
INSTALL NO. 1 AIR TUBE
*a | Hose Clamp |
Install the No. 1 air tube and tighten the hose clamp.
Note
One minute after tightening the hose clamp, check that residual torque is 3.2 N*m (33 kgf*cm, 28 in.*lbf) or more.
Install the 4 bolts.
Connect the 2 wire harness clamps to the manual transaxle assembly.
TEMPORARILY TIGHTEN REAR ENGINE MOUNTING INSULATOR (w/ Glow Plug Controller)
TEMPORARILY TIGHTEN REAR ENGINE MOUNTING INSULATOR (w/o Glow Plug Controller)
TEMPORARILY TIGHTEN FRONT ENGINE MOUNTING INSULATOR (w/ Glow Plug Controller)
TEMPORARILY TIGHTEN FRONT ENGINE MOUNTING INSULATOR (w/o Glow Plug Controller)
INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (w/ Glow Plug Controller)
INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (w/o Glow Plug Controller)