Manual Transmission Assembly Installation

Install the 2 wire harness clamp brackets with the 2 bolts.

Torque:

10 N*m{102 kgf*cm, 7 ft.*lbf}

Install the rear No. 1 engine mounting insulator to the manual transmission with the 4 bolts.

Torque:

25 N*m{255 kgf*cm, 18 ft.*lbf}

Install the manual transmission to the engine with the 9 bolts.

Torque:

Bolt A:

64 N*m{653 kgf*cm, 47 ft.*lbf}

Bolt B:

46 N*m{469 kgf*cm, 34 ft.*lbf}

NOTICE:

1. Check the contact surface between the engine and transmission, knock pins, and knock pin holes for foreign objects or burrs. If either is present, remove them using a shop rag, a piece of cloth, or compressed air.
   
2. When installing the transmission, do not allow the input shaft to hit the clutch disc plate.
   
3. Make sure that the knock pins are fully engaged and install the bolts with the transmission attached firmly to the engine.
   
4. 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.
   

Install the engine rear mounting member with the 4 bolts and 4 nuts.

Torque:

Nut:

13 N*m{130 kgf*cm, 10 ft.*lbf}

Bolt:

26 N*m{265 kgf*cm, 19 ft.*lbf}

Install the 2 bushings to the shift lever assembly.

Install the washer to the floor shift lever assembly.

Install the shift lever assembly with a new E-ring.

Install the shift and select lever boot.

Install the floor shift control shift lever retainer sub-assembly with the 2 nuts.

Torque:

20 N*m{204 kgf*cm, 15 ft.*lbf}

Install the wire harness bracket with the bolt.

Torque:

10 N*m{102 kgf*cm, 7 ft.*lbf}

Connect the back-up light switch connector and install the wire harness.

Connect the ground cable with the bolt.

Torque:

5.4 N*m{55 kgf*cm, 48 in.*lbf}

Install the starter assembly with the bolt and nut.

Torque:

64 N*m{650 kgf*cm, 47 ft.*lbf}

Connect the wire harness to terminal 30 and install the nut, and then attach the terminal cap.

Torque:

9.8 N*m{100 kgf*cm, 87 in.*lbf}

Connect the terminal 50 connector to the starter assembly.

Install the wire harness clamp bracket with the bolt.

Torque:

10 N*m{102 kgf*cm, 7 ft.*lbf}

Connect the 2 wire harness clamps.

Install the engine under cover air guide bracket with the 2 bolts.

Torque:

26 N*m{260 kgf*cm, 19 ft.*lbf}

Install the exhaust pipe No. 1 support bracket sub-assembly with the 2 nuts.

Torque:

22 N*m{224 kgf*cm, 16 ft.*lbf}

Apply grease to the flexible coupling centering bushings.

Grease:

Molybdenum disulphide lithium base NLGI No. 2 or equivalent

Align the matchmarks on the transmission companion flange and flexible coupling.

Install and tighten the 3 bolts, 3 washers and 3 nuts.

Torque:

79 N*m{805 kgf*cm, 58 ft.*lbf}

NOTICE:

Be careful not to damage the flexible coupling centering bushing.

HINT:

The bolts should be installed from the propeller shaft side.

Align the matchmarks on the differential companion flange and flexible coupling.

Install and torque the 3 bolts, 3 washers and 3 nuts.

Torque:

79 N*m{805 kgf*cm, 58 ft.*lbf}

NOTICE:

Be careful not to damage the flexible coupling centering bushing.

HINT:

The bolts should be installed from the propeller shaft side.

Temporarily install the 2 center support bearing washers, 2 bolts and 2 center support bearing dampers.

NOTICE:

Install the center support bearing damper with the pink area facing downwards.

Adjust the dimension between the edge surface of the center support bearing and the edge surface of the cushion to 11.5 to 13.5 mm (0.4528 to 0.5315 in.) respectively as shown in the illustration.

Check that the center line of the bracket is perpendicular to the shaft axial direction.

Tighten the 2 bolts.

Torque:

49 N*m{500 kgf*cm, 36 ft.*lbf}

Using SST, tighten the adjusting nut.

SST

09922-10010

Torque:

When not using SST:

69 N*m{700 kgf*cm, 51 ft.*lbf}

When using SST:

51 N*m{520 kgf*cm, 38 ft.*lbf}

HINT:

1. Use a torque wrench with a fulcrum length of 345 mm (13.5 in.).
   
2. Use 2 of the same type of SST.
   

Stabilize the propeller shaft and differential.

1. Turn the propeller shaft several times by hand to stabilize the center support bearing.
   

Check both the No. 2 and No. 3 joint angles.

1. Using SST, measure the installation angle of the intermediate shaft and propeller shaft.
   

   SST

   09370-50010
   

   HINT:

   The SST should be set directly on the bottom of the shaft.





2. Using SST, measure the installation angle of the differential.
   
   

   
   
   
   

   SST

   09370-50010
   

   HINT:

   Measure the installation angle by placing the SST in the positions shown in the illustration.

3. Calculate the No. 2 joint angle.
   

   No. 2 joint angle:

   A - B = -0°49' to -1°49'
   

   A:

   Intermediate shaft installation angle
   

   B:

   Propeller shaft installation angle
   

4. Calculate the No. 3 joint angle.
   

   No. 3 joint angle:

   B - C = 0°70' to 2°10'
   

   B:

   Propeller shaft installation angle
   

   C:

   Differential installation angle
   

   HINT:

   If the measured angle is not within the specified range, adjust it with the center support bearing washers.

Adjust the No. 2 joint angle.

1. Select the center support bearing washers for adjustment.
   

   Adjustment washer

   thickness mm (in.)

   2 (0.0787)

   4.5 (0.1772)

   6.5 (0.2559)

   9.0 (0.3543)

   11.0 (0.4331)

   NOTICE:

   The 2 washers should be the same thickness.

Install the front No. 1 floor heat insulator with the 4 nuts.

Torque:

5.4 N*m{55 kgf*cm, 48 in.*lbf}

Install the outside air guide plate RH with the 4 nuts.

Torque:

5.4 N*m{55 kgf*cm, 48 in.*lbf}

Temporarily install the No. 1 manifold stay.

Temporarily install a new turbine outlet elbow gasket and exhaust manifold converter with the 3 nuts.

Temporarily install the 2 bolts and nut.

Tighten the 3 nuts (Pushing the manifold converter against the No. 1 manifold stay).

Torque:

25 N*m{255 kgf*cm, 18 ft.*lbf}

Tighten the 2 bolts and nut.

Torque:

56 N*m{571 kgf*cm, 41 ft.*lbf}

Temporarily install the No. 2 exhaust manifold stay with the 2 bolts and nut.

Tighten the 2 bolts (Pushing the No. 2 exhaust manifold stay against the manual transmission).

Torque:

56 N*m{571 kgf*cm, 41 ft.*lbf}

Tighten the nut.

Torque:

56 N*m{571 kgf*cm, 41 ft.*lbf}

Using pliers, slide the clip to install the No. 1 and No. 2 vacuum transmitting hose assembly.

HINT:

Make sure that the paint marks on the No. 1 and No. 2 vacuum transmitting hose assemblies and No. 1 and No. 2 vacuum pipes are aligned.

Using vernier calipers, measure the free length of the compression springs.

Minimum length:

38.5 mm (1.516 in.)

Fully insert 2 new gaskets to the exhaust manifold converter and front exhaust pipe assembly by hand.

NOTICE:

1. Be careful with the installation direction of the gasket.
   
2. Do not reuse the gasket.
   
3. Do not damage the gasket.
   
4. To ensure a proper seal, do not use the tail exhaust pipe to force the gasket onto the front exhaust pipe.
   

   HINT:

   Using a plastic hammer, uniformly strike the gasket so that the gasket and front exhaust pipe are properly fit.

Install the front exhaust pipe assembly.

Install the 2 bolts and 2 compression springs.

Torque:

43 N*m{439 kgf*cm, 32 ft.*lbf}

NOTICE:

After installation, check that the clearance is almost the same at any point between the flanges of the tail exhaust pipe assembly and front exhaust pipe assembly.

Install the 2 bolts and 2 compression springs.

Torque:

43 N*m{439 kgf*cm, 32 ft.*lbf}

NOTICE:

After installation, check that the clearance is almost the same at any point between the flanges of the exhaust manifold converter and front exhaust pipe assembly.

Before installing the air fuel ratio sensor, twist the sensor wire counterclockwise 4 turns.

Using SST, install the air fuel ratio sensor to the front exhaust pipe.

SST

09224-00010

Torque:

44 N*m{449 kgf*cm, 33 ft.*lbf}

Install the front center floor brace with the 4 bolts.

Torque:

7.4 N*m{75 kgf*cm, 65 in.*lbf}

Install the rear No. 1 floor panel brace with the 4 bolts.

Torque:

19 N*m{195 kgf*cm, 14 ft.*lbf}

Temporarily install the shift lever cap with the 4 bolts.

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).

Fully tighten the 4 bolts.

Torque:

10 N*m{102 kgf*cm, 7 ft.*lbf}

Install the shift lever boot with the 4 bolts.

Install the No. 2 console box duct with the clip.

Engage the 2 claws and 2 clips.

Install the 2 bolts <C>.

Install the 2 bolts <C>.

Connect the connector.

Connect the connectors.

Engage the 2 clamps.

Install the 2 bolts <C>.

Engage the 2 claws and 4 clips, and then install the console box register assembly.

Install the rear ash receptacle assembly.

Connect the connectors.

Insert the protruding parts of the front ash receptacle sub-assembly into the 2 guide holes as shown in the illustration.

Install the front ash receptacle sub-assembly with the 2 screws <F>.

Engage the 6 clips.

Close the snap.

Engage the 7 claws and 2 clips.

Close the snap.

Install the side cover with the 2 clips.

Install the intake duct seal with the 11 clips.

Install the No. 1 engine cover.

Park the vehicle on a level surface.

Remove the transmission filler plug and gasket.

Check that the oil surface is within 5 mm (0.20 in.) below the lowest point of the transmission filler plug opening.

Oil grade:

API GL-4 or GL-5

Viscosity:

SAE 75W-90

NOTICE:

1. Problems may occur if the oil level is too high or too low.
   
2. After replacing the oil, drive the vehicle and check the oil level again.
   

Check for oil leakage if the oil level is low.

Install the transmission filler plug and a new gasket.

Torque:

37 N*m{377 kgf*cm, 27 ft.*lbf}

Park the vehicle on a level surface.

Remove the transmission filler plug and gasket.

Check that the oil surface is within 5 mm (0.20 in.) of the lowest point of the transmission filler plug opening.

NOTICE:

1. Problems may occur if the oil level is too high or low.
   
2. After replacing the oil, drive the vehicle and check the oil level again.
   

Check for oil leakage if the oil level is low.

Install a new gasket and the transmission filler plug.

Torque:

37 N*m{377 kgf*cm, 27 ft.*lbf}

Perform initialization procedure (Click here).

HINT:

Some vehicle systems require initialization after reconnecting the negative battery cable.