Installation
1. INSTALL SIDE GEAR SHAFT TO TRANSAXLEa. Insure that a new snap ring is positioned securely ii the groove of the side gear shaft.
b. (C52 M/T)
Using SST, drive in the side gear shaft until it makes contact with the pinion shaft.
SST 09520-32012
(E51 M/T)
Using a brass bar and hammer, drive in the side gear shaft until it makes contact with the pinion shaft.
NOTE: Whether or not the side gear shaft is making contact with the pinion shaft can be known by the sound of feeling when driving it in.
2. INSTALL TRANSAXLE TO ENGINE
Align the input shaft spline with the clutch disc, and install the transaxle to the engine. Torque the bolts.
Torque:
12 mm bolt 650 kg-cm (47 ft-lb, 64 N-m)
10 mm bolt 470 kg-cm (34 ft-lb, 46 N-m)
3. INSTALL LEFT ENGINE MOUNTING
Install the left engine mounting with the bolts.
Torque the bolts.
Torque: 530 kg-cm (38 ft-lb, 52 N-m)
4. INSTALL REAR ENGINE MOUNTING
Install the rear engine mounting with the bolts.
Torque the bolts.
Torque: 530 kg-cm (38 ft-lb, 52 N-m)
5. INSTALL FRONT ENGINE MOUNTING
a. Install the front engine mounting with the bolts to the body.
Torque 530 kg-cm (38 ft-lb, 52 N-m)
b. Loosen the insulator set bolt.
c. By bouncing the engine, confirm the front mount insulator is mounted on the middle of the insulator mount bracket.
d. Torque the insulator set bolt.
Torque: 800 kg-cm (58 ft-lb, 78 N-m)
6. INSTALL STARTER
a. Install the starter with the two bolts. Torque the bolts.
Torque: 400 kg-cm (29 ft-lb, 39 N-m)
b. Connect the connector and cable.
7. CONNECT DRIVE SHAFT TO SIDE GEAR SHAFT
a. Connect the drive shaft to the side gear shaft. Torque the nuts.
Torque: 370 kg-cm (27 ft-lb, 36 N-m)
b. Install the transaxle protector. Torque the bolts.
Torque: 130 kg-cm (9 ft-lb, 13 N-m)
8. INSTALL EXHAUST PIPE ASSEMBLY
a. Install the exhaust pipe assembly to the rear bracket.
b. Install the front bracket to the body.
c. Connect the exhaust pipe to the exhaust manifold. Torque the nuts.
Torque: 630 kg-cm (46 ft-lb, 62 N-m)
9. INSTALL CONTROL CABLE BRACKET AND CLUTCH RELEASE CYLINDER
a. Install the control cable bracket and clutch release cylinder.
Torque the bolts.
Torque:
Transaxle side 650 kg-cm (47 ft-lb, 64 N-m)
Release cylinder side 185 kg-cm (13 ft-lb, 18 N-m)
b. Install the No.2 control cable bracket. Torque the bolts.
Torque: 195 kg-cm (14 ft-lb, 19 N-m)
c. Install the water hose clamp to the control cable bracket.
(E51 M/T)
Install the clutch release cylinder pipe bracket and clamp.
Torque the bolts.
Torque: 185 kg-cm (13 ft-lb, 18 N-m)
10. CONNECT CONTROL CABLES
a. Install the two control cables with two retainers to the bracket.
b. Connect the two control cables to the linkages and install the three washers and two clips.
11. INSTALL FUEL TANK PROTECTOR
12. INSTALL ENGINE UNDER COVER
13. INSTALL NO.2 ENGINE REAR PLATE
14. INSTALL WATER INLET
a. Set the ground strap.
b. Install the water inlet with the bolts. Torque the bolts.
Torque: 200 kg-cm (14 ft-lb, 20 N-m)
15. INSTALL SPEEDOMETER CABLE
16. CONNECT BACK-UP LIGHT SWITCH CONNECTOR
17. (E51 M/T) INSTALL INTERCOOLER
Install the intercooler and four bolts, connect the two hose clamps.
Torque the bolts.
Torque: 175 kg-cm (13 ft-lb, 17 N-m)
18. INSTALL NEGATIVE BATTERY TERMINAL WIRE
19. FILL TRANSAXLE WITH GEAR OIL
(C52 M/T)
Oil grade: API GL-4 or GL-5
Viscosity: SAE 75W - 90 or 80W - 90
Capacity: 2.6 liters (2.7 US qts, 2.3 Imp. qts)
(E51 M/T)
Oil grade: API GL-4 or GL-5
Viscosity: SAE 75W - 90 or 80W - 90
Capacity: 4.2 liters (4.4 US qts, 3.7 Imp. qts)
20. PERFORM ROAD TEST
Check for abnormal noise and smooth operation.