Installation

C59 MANUAL TRANSAXLE: MANUAL TRANSAXLE ASSEMBLY:

COMPONENTS













INSTALLATION

1. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET





(a) Install the engine mounting bracket RR and 3 bolts to the transaxle.
Torque: 64 Nm (653 kgf-cm, 47 ft-lbf)
(b) Install the engine mounting insulator RR and bolt to the engine mounting bracket RR.
Torque: 87 Nm (888 kgf-cm, 64 ft-lbf)
2. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET





(a) Install the engine mounting bracket FR and 2 bolts to the transaxle.
Torque: 64 Nm (653 kgf-cm, 47 ft-lbf)
(b) Install the engine mounting insulator FR, bolt and nut to the engine mounting bracket FR.
Torque: 52 Nm (530 kgf-cm, 38 ft-lbf)
3. INSTALL MANUAL TRANSAXLE ASSEMBLY





(a) Align the input shaft with the clutch disc and install the transaxle to the engine.
(b) Install the 6 bolts.
Bolt A - Torque: 64 Nm (650 kgf-cm, 47 ft-lbf)
Bolt B - Torque: 47 Nm (480 kgf-cm, 35 ft-lbf)
Bolt C - Torque: 23 Nm (230 kgf-cm, 17 ft-lbf)
4. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET





(a) Install the engine mounting bracket LH to the transaxle with the 3 bolts.
Torque: 52 Nm (530 kgf-cm, 38 ft-lbf)
5. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR





(a) Install the engine mounting insulator LH with the 5 bolts and nut.
Bolt A - Torque: 52 Nm (530 kgf-cm, 38 ft-lbf)
Bolt B - Torque: 80 Nm (816 kgf-cm, 59 ft-lbf)
6. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY
SST: 09670-00010
7. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH (Installation)

8. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (Installation)

9. CONNECT RETURN TUBE SUB-ASSEMBLY (Installation)

10. CONNECT PRESSURE FEED TUBE ASSEMBLY (Installation)

11. CONNECT TIE ROD END SUB-ASSEMBLY LH (Installation)

12. CONNECT TIE ROD END SUB-ASSEMBLY RH (Installation)

13. INSTALL STARTER ASSEMBLY





(a) Install the starter assembly and 2 bolts to the transaxle.
Torque: 37 Nm (378 kgf-cm, 27 ft-lbf)
(b) Connect the starter connector.
(c) Install the wire and nut to starter assembly.
Torque: 9.8 Nm (100 kgf-cm, 87 ft-lbf)
14. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY





(a) Connect the shift cable with the 2 clip from the bracket.
(b) Connect the shift cable end of the shift cable with the 2 washer and 2 clip to the transaxle.
15. CONNECT CLUTCH RELEASE CYLINDER ASSEMBLY





(a) Install the release cylinder with the 5 bolts.
Bolt A - Torque: 25 Nm (250 kgf-cm, 19 ft-lbf)
Bolt B - Torque: 12 Nm (120 kgf-cm, 9 ft-lbf)
Bolt C - Torque: 5.0 Nm (51 kgf-cm, 44 in-lbf)
16. CONNECT CONNECTOR





(a) Connect the back-up light switch connector.





(b) w/o ABS:
Connect the speed sensor connector.
17. CONNECT WIRE HARNESS





(a) Install the 2 wire harness clamps to the transaxle with the 2 bolts.
Bolt A - Torque: 26 Nm (260 kgf-cm, 19 ft-lbf)
Bolt B - Torque: 13 Nm (131 kgf-cm, 9 ft-lbf)
(1) Connect the wire harness clamp.





(b) Install the 2 bolts and 2 ground cables.
Torque: 13 Nm (133 kgf-cm, 10 ft-lbf)
18. INSTALL BATTERY CARRIER





(a) Install the battery carrier and 4 bolts.
Torque: 13 Nm (133 kgf-cm, 10 ft-lbf)
19. INSTALL BATTERY TRAY
20. INSTALL BATTERY
21. INSTALL BATTERY CLAMP SUB-ASSEMBLY
Bolt - Torque: 5.0 Nm (51 kgf-cm, 44 in-lbf)
Nut - Torque: 3.5 Nm (36 kgf-cm, 31 in-lbf)
22. INSTALL AIR CLEANER ASSEMBLY
Torque: 7.0 Nm (71 kgf-cm, 62 in-lbf)
23. INSTALL CYLINDER HEAD COVER NO. 2
Torque: 7.0 Nm (71 kgf-cm, 62 in-lbf)
24. INSTALL HOOD SUB-ASSEMBLY
Torque: 13 Nm (133 kgf-cm, 10 ft-lbf)
25. INSPECT HOOD SUB-ASSEMBLY
26. ADJUST HOOD SUB-ASSEMBLY (Adjustments)

27. ADD TRANSAXLE OIL (Installation)

28. INSPECT TRANSAXLE OIL (Testing and Inspection)

29. INSTALL FRONT WHEELS
Torque: 103 Nm (1,050 kgf-cm, 76 ft-lbf)
30. INSTALL STEERING COLUMN HOLE COVER SUB-ASSEMBLY NO. 1
31. CONNECT STEERING INTERMEDIATE SHAFT (Installation)

32. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
33. CENTER SPIRAL CABLE
34. STEERING WHEEL CENTER POINT
35. INSTALL EXHAUST PIPE ASSEMBLY

HINT: (Installation)

36. INSTALL ENGINE UNDER COVER LH
37. INSTALL ENGINE UNDER COVER RH
38. INSPECT FRONT WHEEL ALIGNMENT

HINT: (Service and Repair)

39. CHECK ABS SPEED SENSOR SIGNAL
(a) Anti-lock Brake System (Test Mode Procedure)

(b) Vehicle Stability Control System (Test Mode Procedure)