Installation
C59 MANUAL TRANSMISSION / TRANSAXLE: MANUAL TRANSAXLE ASSEMBLY: INSTALLATION
1. INSTALL REAR ENGINE MOUNTING BRACKET
(a) Install the rear engine mounting bracket with the 3 bolts.
Torque : 45 Nm (459 kgf-cm, 33 ft-lbf)
2. INSTALL REAR ENGINE MOUNTING INSULATOR Installation
3. INSTALL FRONT ENGINE MOUNTING BRACKET
(a) Install the front engine mounting bracket with the 3 bolts.
Torque : 64 Nm (653 kgf-cm, 47 ft-lbf)
4. INSTALL CONTROL CABLE BRACKET
(a) Install the control cable bracket with the 2 bolts.
Torque : 25 Nm (250 kgf-cm, 18 ft-lbf)
5. INSTALL MANUAL TRANSAXLE ASSEMBLY
(a) Align the input shaft with the clutch disc and install the manual transaxle onto the engine.
(b) Install the 7 bolts.
Torque : 33 Nm (337 kgf-cm, 24 ft-lbf)
NOTICE:
* Insert dowel pins into the dowel holes securely so that the end face of the transaxle assembly fits close against the engine assembly before tightening the bolts.
* Make sure that the dowel pins are not loose, bent, damaged or scratched and then install the transaxle onto the engine with the contact surfaces of the engine and transaxle flat against each other.
(c) Temporarily install the engine mounting bracket LH with the 4 bolts.
(d) Tighten the 4 bolts.
Torque : 52 Nm (531 kgf-cm, 38 ft-lbf)
(e) Install the engine mounting insulator LH with the through bolt and nut.
Torque : 56 Nm (571 kgf-cm, 41 ft-lbf)
6. INSTALL STARTER ASSEMBLY Installation
7. INSTALL FRONT ENGINE MOUNTING INSULATOR Installation
8. TEMPORARILY TIGHTEN CENTER ENGINE MOUNTING MEMBER SUB-ASSEMBLY Installation
9. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY Installation
10. FULLY TIGHTEN CENTER ENGINE MOUNTING MEMBER SUB-ASSEMBLY Installation
11. REMOVE ENGINE HANGER Installation
12. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH Installation
13. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING RH Installation
14. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH Installation
15. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH Installation
16. INSTALL FRONT AXLE ASSEMBLY LH Installation
17. INSTALL FRONT AXLE ASSEMBLY RH Installation
18. CONNECT FRONT LOWER SUSPENSION ARM SUB-ASSEMBLY LH Installation
19. CONNECT FRONT LOWER SUSPENSION ARM SUB-ASSEMBLY RH Installation
20. CONNECT TIE ROD END SUB-ASSEMBLY LH Installation
21. CONNECT TIE ROD END SUB-ASSEMBLY RH Installation
22. INSTALL FRONT STABILIZER LINK ASSEMBLY LH Installation
23. INSTALL FRONT STABILIZER LINK ASSEMBLY RH Installation
24. INSTALL FRONT SPEED SENSOR LH Installation
25. INSTALL FRONT SPEED SENSOR RH Installation
26. INSTALL FRONT AXLE SHAFT NUT LH Installation
27. INSTALL FRONT AXLE SHAFT NUT RH Installation
28. INSTALL FRONT EXHAUST PIPE ASSEMBLY Installation
29. INSTALL NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY Installation
30. INSTALL NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY Installation
31. INSTALL COLUMN HOLE COVER SILENCER SHEET Installation
32. CONNECT WIRE HARNESS AND CONNECTOR
(a) Connect the wire harness with the bolt.
Torque : 26 Nm (265 kgf-cm, 19 ft-lbf)
(b) Connect the wire harness clamp.
(c) Connect the back-up light switch connector.
33. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY Installation
34. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY
(a) Install the 2 transmission control cables to the control cable bracket with 2 new clips*1.
(b) Install the 2 transmission control cables to the transaxle with the 2 clips*2.
35. INSTALL BATTERY CARRIER Installation
36. INSTALL BATTERY Installation
37. INSTALL AIR CLEANER CASE Installation
38. INSTALL AIR CLEANER CAP SUB-ASSEMBLY Installation
39. INSTALL HOOD SUB-ASSEMBLY
(a) Install the hood sub-assembly with the 4 bolts.
Torque : 13 Nm (133 kgf-cm, 10 ft-lbf)
(b) Install the washer hose and 2 washer hose clamps.
40. INSPECT HOOD SUB-ASSEMBLY
41. ADJUST HOOD SUB-ASSEMBLY
Adjustments
42. INSTALL OUTER COWL TOP PANEL Installation
43. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Installation
44. INSTALL COWL TOP VENTILATOR LOUVER LH Installation
45. INSTALL COWL TOP VENTILATOR LOUVER RH Installation
46. INSTALL HOOD TO COWL TOP SEAL Installation
47. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH Installation
48. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH Installation
49. INSTALL FRONT WIPER ARM HEAD CAP Installation
50. ADD TRANSAXLE OIL Service and Repair
51. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
52. INSPECT TRANSAXLE OIL Testing and Inspection
53. INSPECT FOR OIL LEAK
54. INSPECT FOR EXHAUST GAS LEAK
55. INSTALL ENGINE UNDER COVER LH
56. INSTALL ENGINE UNDER COVER RH
57. INSTALL FRONT WHEELS Installation
58. ADJUST FRONT WHEEL ALIGNMENT
Service and Repair
59. INSTALL NO. 2 CYLINDER HEAD COVER Installation
60. CHECK SPEED SENSOR SIGNAL
Test Mode Procedure