Clutch Assembly: Installation

1. Flywheel bolts are pre-coated from manufacturer with thread sealant. If flywheel bolt threads are not pre-coated, apply thread sealant to threads before installing. Install and alternately tighten flywheel bolts in a crisscross pattern to specification. See TORQUE SPECIFICATIONS .
2. Install clutch disc and clutch cover on flywheel using the following steps:
   1. Insert Clutch Guide (09301-00110) in clutch disc, then insert them in the flywheel taking care not to insert them in the wrong direction.
   2. Align matchmarks on clutch cover and flywheel. See Figure.
   3. Use clutch aligner to center clutch disc on flywheel. Install 6 bolts on clutch cover in crisscross pattern to specification. See TORQUE SPECIFICATIONS .
3. Apply appropriate grease to clutch release fork and hub contact surfaces, release fork and push rod contact and release fork pivot points. See Fig 1.
4. Apply appropriate grease to input spline shaft. See Fig 1.
5. Install boot and release bearing to release fork, and install them to transmission. See Figure.
6. Install transmission using the following steps:
   1. Raise front side of engine.
   2. Turn the transmission a little in the clockwise and jack up until just before the transmission housing touches the body. Align the input spline with a clutch disc and install the transmission to the engine.
   3. Install the transmission and wire harness clamp with 8 bolts. See Figure.
7. Install rear engine mounting with 4 bolts. See Figure.
8. Install rear engine mounting member with 4 bolts. See Figure.
9. Install starter using the following steps:
   1. Install starter with 2 bolts.
   2. Install wire with nut.
   3. Connect starter connector harness.
10. Connect speed sensor connector and wire harness using the following steps:
    1. Connect wire harness to clamp. See Figure.
    2. Connect speed sensor connector.
11. Connect back-up light switch connector. See Figure.
12. Connect clutch release cylinder, clutch line bracket and ground wire using the following steps:
    1. Connect clutch line and ground wire with bolt. See Figure.
    2. Connect clutch release cylinder with 2 bolts.
13. Install drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES.
14. Install front and center exhaust pipes. See appropriate MECHANICAL article in ENGINES.
15. Fill transmission with oil. See appropriate SERVICING article.
16. Install No. 1 rear floor board. See Figure.
17. Lower vehicle.
18. Install exhaust manifold using the following steps:
    1. Install 2 new gaskets to cylinder head.
    2. Install exhaust manifold with 8 nuts. Tighten nuts uniformly in several passes.
    3. Connect heated oxygen sensor connector. See Figure.
    4. Install case clamp.
19. Install air intake connector using the following steps:
    1. Install air intake resonator to throttle body and tighten 2 hose clamp bolts.
    2. Connect PCV hose to No. 2 cylinder head cover.
    3. Connect engine wire harness clamp to air cleaner case. See Figure.
    4. Connect MAF meter connector.
20. Connect upper radiator hose No. 1 to engine. See Figure.
21. Fill engine with coolant.
22. Install No. 1 engine cover. See Figure.
23. Install No. 1 and No. 2 engine under covers. See Figure.
24. Install transmission shift lever using the following steps:
    1. Install washer.
    2. Apply appropriate grease to tip of shift lever.
    3. Install shift lever with 4 bolts. See Figure.
    4. Install shift boot.
25. Install shift boot retainer using the following steps:
    1. Install shift boot retainer with 4 bolts.
    2. Connect 2 wire harness clamps. See Figure.
26. Reverse removal procedure to install upper console panel and console box. See REMOVAL .
27. Perform road test. Check for abnormal noises and smooth shifting.

Fig 1: Lubricating Clutch Release Fork

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