Installation (from 07/2011)
C50 MANUAL TRANSMISSION / TRANSAXLE: MANUAL TRANSAXLE ASSEMBLY (for Hatchback): INSTALLATION
1. INSTALL WIRE HARNESS CLAMP BRACKET
(a) Install the 3 wire harness clamp brackets with 3 bolts onto the manual transaxle assembly.
Torque : 13 Nm (130 kgf-cm, 9 ft-lbf)
2. INSTALL SPEEDOMETER DRIVEN HOLE COVER SUB-ASSEMBLY (w/ ABS)
(a) Coat a new O-ring with manual transaxle gear oil and install it onto the speedometer driven hole cover sub-assembly.
(b) Install the speedometer driven hole cover sub-assembly with the bolt.
Torque : 11 Nm (115 kgf-cm, 8 ft-lbf)
3. INSTALL SPEEDOMETER SENSOR (w/o ABS)
(a) Coat a new O-ring with manual transaxle gear oil and install it onto the speedometer sensor.
(b) Install the speedometer driven gear into the speedometer sensor with the E-ring.
(c) Install the speedometer sensor with the bolt.
Torque : 11 Nm (115 kgf-cm, 8 ft-lbf)
4. INSTALL MANUAL TRANSAXLE ASSEMBLY
(a) Align the input shaft with the clutch disc and install the manual transaxle assembly onto the engine.
(b) Install the 7 bolts.
Torque : 33 Nm (336 kgf-cm, 24 ft-lbf)
NOTICE:
* Insert knock pins into the knock pin holes securely so that the end face of the manual transaxle fits close against the engine before tightening the bolts.
* Be careful not to pinch wire harness, etc.
* To avoid damage to the input shaft, do not forcefully shake the manual transaxle.
5. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
(a) Remove any adhesive remaining in the 4 bolts holes on the transverse engine engine mounting bracket and 4 bolts.
(b) Apply adhesive to 2 or 3 threads on the end of the 4 bolts.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.
(c) Following the procedures shown in the illustration, Tighten the 4 bolts in order.
Text in Illustration
Torque : 64 Nm (653 kgf-cm, 47 ft-lbf)
6. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR
(a) Following the procedures shown in the illustration, Tighten the 5 bolts in order.
Torque : 52 Nm (530 kgf-cm, 38 ft-lbf)
(b) Install the transverse engine engine mounting bracket and transverse engine engine mounting insulator with the bolt and nut.
Torque : 52 Nm (530 kgf-cm, 38 ft-lbf)
HINT
Hold the nut and tighten the bolt.
7. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING CONTROL BRACKET
(a) Following the procedures shown in the illustration, tighten the 4 bolts in order.
Text in Illustration
Torque : 45 Nm (459 kgf-cm, 33 ft-lbf)
8. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY
Installation (from 07/2011)
9. INSTALL STARTER ASSEMBLY (for Cold Area Specification Vehicles)
Installation
10. INSTALL STARTER ASSEMBLY (except Cold Area Specification Vehicles)
Installation
11. CONNECT WIRE HARNESS (w/ ABS)
(a) Connect the back up light switch connector.
(b) Install the ground wire with the bolt.
Torque : 26 Nm (260 kgf-cm, 19 ft-lbf)
(c) Connect the 4 clamps and install the wire harness with the bolt.
Torque : 13 Nm (130 kgf-cm, 9 ft-lbf)
12. CONNECT WIRE HARNESS (w/o ABS)
(a) Connect the speedometer sensor connector.
(b) Connect the back up light switch connector.
(c) Install the ground wire with the bolt.
Torque : 26 Nm (260 kgf-cm, 19 ft-lbf)
(d) Connect the 4 clamps and install the wire harness with the bolt.
Torque : 13 Nm (130 kgf-cm, 9 ft-lbf)
13. INSTALL CONTROL CABLE BRACKET
(a) Install the control cable bracket with the 2 bolts.
Torque : 25 Nm (250 kgf-cm, 18 ft-lbf)
14. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY
(a) Connect the 2 transmission control cable ends and install the 2 washers and the 2 clips.
(b) Install 2 new clips onto the control cable bracket.
15. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY
(a) Install the clutch release cylinder assembly and clutch pipe with the 4 bolts.
Torque : 12 Nm (120 kgf-cm, 9 ft-lbf)
16. INSTALL BATTERY CARRIER Installation (from 07/2011)
17. INSTALL BATTERY TRAY
18. INSTALL BATTERY Installation (from 07/2011)
19. INSTALL AIR CLEANER BRACKET Installation (from 07/2011)
20. INSTALL AIR CLEANER ASSEMBLY Installation (from 07/2011)
21. INSTALL OUTER COWL TOP PANEL Installation (from 07/2011)
22. INSTALL INNER COWL TOP TO COWL BRACE Installation (from 07/2011)
23. INSTALL FRONT AIR SHUTTER SEAL RH Installation (from 07/2011)
24. INSTALL FRONT NO. 1 VENTILATOR SEAL Installation (from 07/2011)
25. INSTALL FRONT WIPER MOTOR AND LINK
Installation (from 07/2011)
26. ADD MANUAL TRANSAXLE OIL Service and Repair
27. INSPECT FOR MANUAL TRANSMISSION OIL LEAK