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 bracket.




11. Install the front engine stiffener (H22A1 engine) 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 right radius rod.

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

15. Connect the ball joints to the lower arms, then install the castle nuts on both sides.
16. Install the right damper fork bolt.




17. Install the clutch damper




18. Install the slave cylinder, then install the clutch pipe joint and bracket.

CAUTION: Take care not to bend the clutch pipe.




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




20. Install the shift wire and select wire to the shift lever and to the select lever respectively.

CAUTION: Take care not to bend the wires.

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




21. Connect the transmission ground cable and back-up light switch connectors.
22. Install the wire harness clamp.
23. 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.




24. Install the bracket and intake control vacuum tank.




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




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




32. 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.