Installation
MANUAL TRANSAXLE ASSEMBLYINSTALLATION
1. INSTALL ENGINE MOUNTING INSULATOR LH
(a) Install the engine mounting insulator LH with the 4 bolts.
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)
HINT: Tighten the bolts in order: A, B, C and D.
2. INSTALL ENGINE MOUNTING FRONT BRACKET
(a) Install the engine mounting front bracket with the 3 bolts.
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)
3. INSTALL MANUAL TRANSMISSION CASE PROTECTOR
(a) Install the manual transmission case protector with the 2 bolts.
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)
4. INSTALL WIRE HARNESS CLAMP
(a) Install the 2 wire harness clamps with the 2 bolts.
Torque: 8.4 Nm (86 kgf-cm, 74 inch lbs.)
5. INSTALL CLUTCH LINE
(a) Install the clutch line and bracket with the 2 bolts.
Torque:
Bolt A 12 Nm (122 kgf-cm, 9 ft. lbs.)
Bolt B 7.0 Nm (71 kgf-cm, 62 inch lbs.)
6. INSTALL MANUAL TRANSAXLE ASSEMBLY
(a) Align the input shaft with the clutch disc and install the transaxle to the engine.
(b) Install the 10 bolts.
Torque:
Bolt A 64 Nm (653 kgf-cm, 47 ft. lbs.)
Bolt B 46 Nm (470 kgf-cm, 34 ft. lbs.)
Bolt C 44 Nm (449 kgf-cm, 32 ft. lbs.)
Bolt D 46 Nm (470 kgf-cm, 34 ft. lbs.)
Bolt E 64 Nm (653 kgf-cm, 47 ft. lbs.)
Bolt length:
Bolt A: 60 mm (2.3622 inch)
Bolt B: 60 mm (2.3622 inch)
Bolt C: 32 mm (1.2598 inch)
Bolt D: 65 mm (2.5591 inch)
Bolt E: 74.5 mm (2.9331 inch)
7. CONNECT WIRE HARNESS
(a) Install the wire harness.
(b) Connect the back-up light switch connector.
(c) Install the ground cable with the bolt.
Torque: 12 Nm (122 kgf-cm, 9 ft. lbs.)
8. INSTALL STARTER ASSEMBLY
9. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH
10. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH
11. INSTALL FRONT FRAME ASSEMBLY
12. INSTALL VANE PUMP ASSEMBLY
13. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
14. INSTALL STEERING SLIDING YOKE
15. INSTALL FRONT AXLE ASSEMBLY LH
16. INSTALL FRONT AXLE ASSEMBLY RH
HINT: Use the same procedures described for the LH side.
17. INSTALL FRONT SUSPENSION LOWER NO. 1 ARM LH
18. INSTALL FRONT SUSPENSION LOWER NO. 1 ARM RH
HINT: Use the same procedures described for the LH side.
19. INSTALL TIE ROD ASSEMBLY LH
20. INSTALL TIE ROD ASSEMBLY RH
HINT: Use the same procedures described for the LH side.
21. INSTALL FRONT SPEED SENSOR LH
22. INSTALL FRONT SPEED SENSOR RH
HINT: Use the same procedures described for the LH side.
23. INSTALL FRONT STABILIZER LINK ASSEMBLY LH
24. INSTALL FRONT STABILIZER LINK ASSEMBLY RH
HINT: Use the same procedures described for the LH side.
25. INSTALL FRONT AXLE HUB NUT LH
26. INSTALL FRONT AXLE HUB NUT RH
HINT: Use the same procedures described for the LH side.
27. INSTALL FRONT EXHAUST PIPE ASSEMBLY
28. INSTALL COMPRESSOR AND MAGNETIC CLUTCH
29. INSTALL GENERATOR ASSEMBLY
30. CONNECT FUEL TUBE SUBASSEMBLY
31. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY
32. INSTALL CLUTCH ACCUMULATOR ASSEMBLY
33. CONNECT RETURN TUBE SUBASSEMBLY
34. CONNECT NO. 1 OIL RESERVOIR TO PUMP HOSE
35. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY
36. CONNECT ENGINE WIRE
37. INSTALL ECM
38. CONNECT HEATER INLET WATER HOSE
39. CONNECT HEATER OUTLET WATER HOSE
40. CONNECT OIL COOLER INLET HOSE
41. CONNECT OIL COOLER OUTLET HOSE
42. CONNECT RADIATOR HOSE INLET
43. CONNECT RADIATOR HOSE OUTLET
44. CONNECT NO. 1 VACUUM HOSE CONNECTOR
45. INSTALL NO. 2 ENGINE MOUNTING BRACKET RH
46. INSTALL ENGINE MOVING CONTROL ROD SUBASSEMBLY
47. INSTALL NO. 2 ENGINE MOUNTING STAY RH
48. INSTALL BATTERY
49. INSTALL AIR CLEANER CASE SUBASSEMBLY
50. REMOVE AIR CLEANER CAP SUBASSEMBLY
51. INSTALL AIR CLEANER INLET ASSEMBLY
52. INSTALL V-RIBBED BELT
53. INSTALL COWL TOP PANEL OUTER SUBASSEMBLY
54. INSTALL WINDSHIELD WIPER LINK ASSEMBLY
55. INSTALL FRONT WHEEL
56. ADD ENGINE OIL
57. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
58. BLEED CLUTCH LINE
59. ADD ENGINE COOLANT
60. ADD MANUAL TRANSAXLE OIL
61. ADD POWER STEERING FLUID
62. BLEED POWER STEERING FLUID
63. CHECK FOR FUEL LEAKS
64. CHECK FOR ENGINE OIL LEAKS
65. CHECK FOR ENGINE COOLANT LEAKS
66. CHECK FOR EXHAUST GAS LEAKS
67. ADJUST FRONT WHEEL ALIGNMENT
68. CHECK IGNITION TIMING
69. CHECK ENGINE IDLE SPEED
70. INSPECT CO/HC
71. INSTALL FRONT FENDER APRON SEAL RH
72. INSTALL ENGINE UNDER COVER LH
73. INSTALL ENGINE UNDER COVER RH
74. INSTALL NO. 1 ENGINE COVER SUBASSEMBLY
75. CHECK ABS SPEED SENSOR SIGNAL