Transmisssion Installation
MANUAL TRANSMISSION ASSEMBLYINSTALLATION
1. INSTALL TRANSMISSION UPPER COVER SUB-ASSEMBLY
a) Install the transmission upper cover sub-assembly with the 2 bolts.
Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.)
2. INSTALL REAR NO.1 ENGINE MOUNTING INSULATOR
a) Install the rear No.1 engine mounting insulator to the manual transmission with the 4 bolts.
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)
3. INSTALL CLUTCH COVER ASSEMBLY
4. INSTALL CLUTCH DISC ASSEMBLY
5. INSTALL CLUTCH RELEASE FORK SUB-ASSEMBLY
a) Apply release hub grease to the contact surface between, the release fork and release bearing hub, the contact surface between the release fork and push rod, and release fork pivot points as shown in the illustration.
Sealant: Part No.08887-01806, RELEASE HUB GREASE or equivalent
b) Install the clutch release fork sub-assembly to the release fork support.
NOTICE:
^ Do not use excess force to install the clutch release fork sub-assembly.
^ After installation, move the fork back and forth to check that the clutch release bearing hub slides smoothly.
6. INSTALL MANUAL TRANSMISSION ASSEMBLY
a) Install the manual transmission to the engine with the 9 bolts.
Torque: Bolt A 72 Nm (730 kgf-cm, 53 ft. lbs.)
Bolt B 37 Nm (380 kgf-cm, 28 ft. lbs.)
NOTICE: Temporarily tighten bolt *1, fully tighten bolt *2, lift the rear end of the transmission, and fully tighten bolt *1 and the other bolts. Make sure that excessive force is not applied to the knock pins when lifting the rear end of the transmission.
7. INSTALL ENGINE REAR MOUNTING MEMBER
a) Install the engine rear mounting member with the 4 bolts and 4 nuts.
Torque: Nut 13 Nm (130 kgf-cm, 10 ft. lbs.)
Bolt 26 Nm (265 kgf-cm, 19 ft. lbs.)
8. INSTALL FLOOR SHIFT LEVER ASSEMBLY
a) Install the 2 bushings to the shift lever assembly.
b) Install the washer to the floor shift lever assembly.
c) Install the shift lever assembly with a new E-ring.
d) Install the shift and select lever boot.
9. INSTALL FLOOR SHIFT CONTROL SHIFT LEVER RETAINER SUB-ASSEMBLY
a) Install the floor shift control shift lever retainer sub assembly with the 2 nuts.
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
10. INSTALL CLUTCH COVER ASSEMBLY
a) Align the matchmarks on the clutch cover assembly and the flywheel sub-assembly.
b) Install the clutch cover to the flywheel sub-assembly with the new 6 bolts.
Torque: 19 Nm (195 kgf-cm, 14 ft. lbs.)
NOTICE: Tighten the bolts a little at a time in a diagonal pattern until they are all tightened.
11. INSTALL NO.1 CLUTCH HOUSING COVER
a) Install the No.1 clutch housing cover with the 4 bolts.
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)
Bolt length: 20 mm (0.79 inch)
12. INSTALL NO.2 CLUTCH HOUSING COVER
a) Install the No.2 clutch housing cover with the 4 bolts.
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)
Bolt length: 16 mm (0.63 inch)
13. CONNECT WIRE HARNESS
a) Connect the back-up light switch connector and install the wire harness.
14. CONNECT GROUND CABLE
a) Connect the ground cable with the bolt.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
15. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY
a) Install the clutch release cylinder assembly with the 2 bolts.
Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.)
16. INSTALL CLUTCH ACCUMULATOR ASSEMBLY
a) Install the clutch accumulator assembly with the 2 bolts and 2 nuts.
Torque: Bolt 12 Nm (120 kgf-cm, 9 ft. lbs.)
Nut 5.4 Nm (55 kgf-cm, 48 inch lbs.)
17. INSTALL STARTER ASSEMBLY
18. INSTALL ENGINE UNDERCOVER AIR GUIDE BRACKET
a) Install the engine undercover air guide bracket with the 2 bolts.
Torque: 26 Nm (260 kgf-cm, 19 ft. lbs.)
19. INSTALL PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY
20. INSPECT AND ADJUST NO.2 AND NO.3 JOINT ANGLE
21. INSTALL FRONT FLOOR NO.1 HEAT INSULATOR
22. INSTALL OUTSIDE AIR GUIDE PLATE RH
23. INSTALL FRONT EXHAUST PIPE ASSEMBLY
24. INSTALL HEATED OXYGEN SENSOR
25. INSTALL FRONT CENTER FLOOR BRACE
26. INSTALL NO.1 REAR FLOOR PANEL BRACE
27. INSTALL NO.2 ENGINE UNDER COVER
28. INSTALL ENGINE UNDER COVER
29. INSTALL SHIFT LEVER CAP
a) Move the shift lever to the 2nd gear position. Adjust the guide plate so that dimension A is as shown in the illustration with the shift lever cap pushed toward neutral (select direction).
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)
30. INSTALL NO.1 SHIFT AND SELECT LEVER BOOT
a) Install the shift lever boot with the 4 bolts.
31. INSTALL NO.2 CONSOLE BOX DUCT
32. INSTALL CONSOLE BOX
33. INSTALL CONSOLE BOX REGISTER ASSEMBLY
34. INSTALL FRONT ASH RECEPTACLE SUBASSEMBLY
35. INSTALL FRONT CONSOLE PANEL SUB-ASSEMBLY
36. INSTALL REAR CONSOLE PANEL SUB-ASSEMBLY
37. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY
38. ADD MANUAL TRANSMISSION OIL
39. INSPECT AND ADJUST MANUAL TRANSMISSION OIL LEVEL
40. CHECK FOR EXHAUST GAS LEAKS