Installation

INSTALLATION




1. Install the dowel pins.




2. Apply grease to the parts as shown, then install the release bearing and release fork.

NOTE: Use only Super High Temp Urea Grease (P/N 08798-9002).

3. Install the release fork boot.
4. Place the transmission on the transmission jack, and raise it to the engine level.




5. Install the three lower transmission mounting bolts.




6. Install the two upper transmission mounting bolts.




7. Raise the transmission, then install the mount bracket and transmission mount.

NOTE:
- Torque mounting bolts and nuts in sequence shown.
- Make sure the bushings are not twisted or offset.




8. Install the three rear engine mount bracket mounting bolts.




9. Install the rear beam stiffener.




10. Install the intake manifold stay.




11. Install the front engine stiffener and clutch cover.

NOTE: Torque the front engine stiffener mounting bolts following the numbered sequence.




12. Install the center beam.




13. Install the intermediate shaft and driveshafts. Drive Axles, Bearings and Joints




14. Install the radius rod.

NOTE: Check for deterioration or damage of the radius rod rubber bushings.

15. Connect the ball joint to the lower arm, then install the ball joint nut.
16. Install the damper fork bolt.




17. Install the rear engine mount bracket stay.

NOTE: Loosely install the stay mounting bolt and nut, then torque in the sequence shown.




18. Install the clutch damper.




19. Install the slave cylinder, then install the clutch pipe joint and stay.

CAUTION: Take care not to bend the clutch pipe.




20. Install the vehicle speed sensor (VSS)/power steering speed sensor, then connect the VSS connector.




21. Install the shift cable and select cable to the shift lever and to select lever respectively.

CAUTION: Take care not to bend the cables.

NOTE:
- Check that the new cotter pin is seated firmly.
- Turn the boot of the shift lever so the hole is facing down.




22. Connect the transmission ground cable and back-up light switch connectors.
23. Install the wire harness clamp.
24. Install the starter motor, then connect the starter motor cables.

NOTE: When installing the starter motor cable, make sure that the crimped side of the ring terminal is facing out.




25. Install the bracket and intake control vacuum tank.




26. Install the air cleaner assembly and intake air duct.




27. Install the base stay and battery base.
28. Refill the transmission with oil. Maintenance
29. Install the battery, then connect the battery positive (+) and negative (-) cables to the battery.
30. Check the clutch operation.
31. Shift the transmission and check for smooth operation.
32. Check the front wheel alignment.




33. Loosen the three mounting bolts of the front engine mount bracket, then torque the three mounting bolts.

NOTE: Make sure the bushings are not twisted or offset.