Manual Transaxle Assembly (For Sedan) Installation

Align the input shaft with the clutch disc and install the manual transaxle onto the engine.

Install the 7 bolts.

Torque:

33 N*m{336 kgf*cm, 24 ft.*lbf}

Install the engine mounting bracket LH with the 4 bolts.

Torque:

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

Install the engine mounting insulator LH with the 5 bolts.

Torque:

52 N*m{530 kgf*cm, 38 ft.*lbf}

Install the engine mounting bracket LH and engine mounting insulator LH with the bolt and nut.

Torque:

52 N*m{530 kgf*cm, 38 ft.*lbf}

Install the engine mounting control bracket with the 4 bolts.

Torque:

39 N*m{398 kgf*cm, 29 ft.*lbf}

Place wooden blocks or plate lift attachments on an engine lifter, and then set the front suspension crossmember sub-assembly so that the attachments are in the positions shown in the illustration.

Text in Illustration

	Front of the Vehicle
	Attachment Placement Positions

Provisionally install the front suspension crossmember onto the body with the 6 bolts.

By inserting SST into the datum holes in the front suspension crossmembers RH and LH alternately, tighten bolts A, B and C on both sides to the specified torque, in several steps.

SST

09670-00011

Torque:

Bolt A:

87 N*m{887 kgf*cm, 64 ft.*lbf}

Bolt B:

151 N*m{1540 kgf*cm, 111 ft.*lbf}

Bolt C:

98 N*m{999 kgf*cm, 72 ft.*lbf}

NOTICE:

1. Insert SST into the datum hole in a vertical orientation.
   
2. If SST cannot be inserted into the datum hole vertically, loosen all the bolts and then insert SST again.
   

Text in Illustration

*a	Datum Hole	-	-
	Front of the Vehicle	-	-

Install the engine moving control rod with the bolt.

Torque:

120 N*m{1224 kgf*cm, 89 ft.*lbf}

for Automatic Transaxle:

1. Coat the spline of the inboard joint with ATF.
   

for Manual Transaxle:

1. Coat the spline of the inboard joint with gear oil.
   

Align the inboard joint splines and install the drive shaft with a screwdriver and hammer.

NOTICE:

1. Face the cut area of the front drive inboard joint hole snap ring downward.
   
2. Do not damage the oil seal.
   
3. Do not damage the inboard joint boot.
   

HINT:

Confirm whether the drive shaft is securely driven in by checking the reaction force and sound.

Push the front axle out of the vehicle to align the spline of the drive shaft with the front axle and insert the front axle.

NOTICE:

1. Do not push the front axle further out of the vehicle than is necessary.
   
2. Do not damage the outboard joint boot.
   
3. Check for any foreign matter on the speed sensor rotor and insertion part.
   
4. Do not damage the speed sensor rotor.
   

Install the lower arm onto the steering knuckle with a new castle nut.

Torque:

98 N*m{1,000 kgf*cm, 72 ft.*lbf}

NOTICE:

If the holes for the clip are not aligned, tighten the nut by a further turn of up to 60°.

Install a new clip.

Install the tie rod end onto the steering knuckle with a new castle nut.

Torque:

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

NOTICE:

If the holes for the clip are not aligned, tighten the nut by a further turn of up to 60°.

Install a new cotter pin.

Install the stabilizer link with the nut.

Torque:

74 N*m{755 kgf*cm, 55 ft.*lbf}

HINT:

If the ball joint turns together with the nut, use a socket hexagon wrench 6 to hold the stud.

Install the speed sensor onto the steering knuckle with the bolt.

Torque:

8.5 N*m{87 kgf*cm, 75 in.*lbf}

NOTICE:

1. Check that the speed sensor tip and installation portion are free of foreign matter.
   
2. Install the speed sensor without turning it from its original installation angle.
   

Install the flexible hose and speed sensor with the bolt.

Torque:

29 N*m{300 kgf*cm, 22 ft.*lbf}

NOTICE:

Install the flexible hose and speed sensor without twisting them.

Using a 30 mm socket wrench, install a new axle hub nut.

Torque:

216 N*m{2,203 kgf*cm, 160 ft.*lbf}

Using a chisel and hammer, caulk the axle hub nut.

Install the starter assembly with the 2 bolts.

Torque:

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

Connect the connector.

Connect terminal 30 with the nut.

Torque:

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

Close the terminal cap.

Connect the back-up light switch connector.

Connect the wire harness with the bolt.

Torque:

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

Install the control cable bracket with the 2 bolts.

Torque:

25 N*m{250 kgf*cm, 18 ft.*lbf}

Connect the 2 cable ends and install the 2 washers and the 2 clips.

Install 2 new clips onto the control cable bracket.

Install the clutch release cylinder and clutch pipe with the 4 bolts.

Torque:

12 N*m{120 kgf*cm, 8.7 ft.*lbf} for bolt A

12 N*m{122 kgf*cm, 8.9 ft.*lbf} for bolt B

Install the battery carrier with the 5 bolts.

Torque:

17 N*m{175 kgf*cm, 13 ft.*lbf}

Install the air cleaner bracket with the 2 bolts.

Torque:

19 N*m{194 kgf*cm, 14 ft.*lbf}

Install the air cleaner case with air cleaner inlet No. 1 with the 2 bolts.

Torque:

7.8 N*m{80 kgf*cm, 69 in.*lbf}

Connect the wire harness to the air cleaner case.

Install the air cleaner element.

Install and lock the air cleaner cap and the air cleaner hose and then tighten the air cleaner hose clamp.

Torque:

4.0 N*m{41 kgf*cm, 35 in.*lbf}

Connect the ventilation hose to the air cleaner hose.

Connect the vacuum switching valve connector and the wire harness clamp.

Connect the fuel vapor feed hose to the vacuum switching valve assembly and air cleaner hose.

Connect the intake air flow meter connector and the wire harness clamp.

Tighten the 2 A nuts, then the 2 B nuts.

Torque:

7.0 N*m{71 kgf*cm, 62 in.*lbf}

Install the cowl top panel outer with the 8 bolts.

Torque:

6.5 N*m{66 kgf*cm, 58 in.*lbf}

Install the cowl top to cowl inner brace with the 2 bolts.

Torque:

6.5 N*m{66 kgf*cm, 58 in.*lbf}

Connect the wire harness clamp.

Engage the 3 claws to install the front air shutter seal RH.

Connect the connector.

Slide the wiper link as shown in the illustration and engage the rubber pin with the body.

Install the front wiper motor and link with the 2 bolts.

Torque:

5.5 N*m{56 kgf*cm, 49 in.*lbf}

Connect the washer hoses.

Engage the 5 hooks.

Engage the 8 hooks and the 4 claws.

Install the cowl top ventilator louver sub-assembly with the 3 clips.

Engage the 3 claws and install the cowl side ventilator sub-assembly LH.

Scrape any metal powder off the serrated part of the wiper arm with a round file or the equivalent (when reinstalling).

Clean the wiper pivot serrations with a wire brush.

Operate the wiper, then stop the windshield wiper motor in the automatic stop position.

Align the blade tip with the mark on the windshield glass, as shown in the illustration.

Tighten the nut of the front wiper arm.

Torque:

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

Scrape any metal powder off the serrated part of the wiper arm with a round file or the equivalent (when reinstalling).

Clean the wiper pivot serrations with a wire brush.

Operate the wiper, then stop the windshield wiper motor in the automatic stop position.

Align the blade tip with the mark on the windshield glass, as shown in the illustration.

Tighten the nut of the front wiper arm.

Torque:

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

Engage the claw and install the 2 front wiper arm head caps.

Check that the clearance measurements are within the standard ranges.

Standard:

Area	Measurement	Area	Measurement
A	2.35 to 6.35 mm (0.092 to 0.250 in.)	C	2.0 to 5.0 mm (0.079 to 0.197 in.)
B	-2 to 2 mm (-0.079 to 0.079 in.)	-	-

Loosen the hood side hinge bolts.

Move the hood to adjust the clearance to within the standard range.

Tighten the hood side hinge bolts after the adjustment.

Torque:

13 N*m{133 kgf*cm, 10 ft.*lbf}

Adjust the height of the hood front end by turning the cushion rubber.

HINT:

The cushion rubber can be raised and lowered by turning it.

Adjust the hood lock.

1. Loosen the 3 bolts.
   

2. Adjust the hood lock position so that the striker can enter it smoothly.
   

3. Tighten the 3 bolts after the adjustment.
   

   Torque:

   7.5 N*m{76 kgf*cm, 66 in.*lbf}

Stop the vehicle in a level place.

Remove the transmission filler plug and the gasket.

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

NOTICE:

1. Excessively large or small amounts of oil may cause problems.
   
2. After replacing the oil, drive the vehicle and check the oil level again.
   

Check for oil leakage when the oil level is low.

Install the transmission filler plug and a new gasket.

Torque:

39 N*m{400 kgf*cm, 29 ft.*lbf}

Align the matchmarks and install the sliding yoke onto the intermediate shaft with bolt B.

Torque:

35 N*m{360 kgf*cm, 26 ft.*lbf}

Tighten bolt A.

Torque:

35 N*m{360 kgf*cm, 26 ft.*lbf}

Install the column hole cover silencer sheet with the 2 clips.

Install the floor carpet.