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Manual Transaxle Assembly: Installation

  1. INSTALL MANUAL TRANSAXLE ASSEMBLY 
    1. Align the input shaft with the clutch disc and install the transaxle to the engine.
    2. Install the 7 bolts.

      Torque: 33 N*m (340 kgf*cm, 24 ft.*lbf) 

      Fig 1: Installing Bolts
      G04228092Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL REAR ENGINE MOUNTING BRACKET 
    1. Install the rear engine mounting bracket to the transaxle with the 4 bolts.
      Fig 2: Installing Rear Engine Mounting Bracket To Transaxle With Bolts
      G04228093Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) for bolt A 

      18 N*m (180 kgf*cm, 13 ft.*lbf) for bolt B 

  3. INSTALL ENGINE MOUNTING BRACKET LH 
    1. Install the engine mounting bracket LH to the transaxle with the 3 bolts.

      Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) for bolt A 

    2. Connect the engine mounting bracket LH to the engine mounting insulator with the 2 bolts.
      Fig 3: Installing Engine Mounting Bracket LH To Transaxle With Bolts
      G04228094Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf) for bolt B 

    3. Install the ground cable to the engine mounting bracket with the bolt.
      Fig 4: Installing Ground Cable To Engine Mounting Bracket With Bolt
      G04228095Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 26 N*m (260 kgf*cm, 19 ft.*lbf) 

  4. INSTALL STARTER ASSEMBLY 
    1. Install the starter with the 2 bolts.
      Fig 5: Installing Starter With Bolts
      G04228096Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 37 N*m (380 kgf*cm, 27 ft.*lbf) 

    2. Connect the starter connector.
    3. Install the wire with the nut.

      Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 

    4. Install the flywheel housing side cover.
  5. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY (See  INSTALLATION  ) 
  6. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH 
    1. Install the front drive shaft (see REASSEMBLY ).
  7. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH 

    HINT:

    Install the RH side by the same procedures as the LH side.

  8. INSTALL FRONT AXLE ASSEMBLY LH 
    1. Install the front axle (see INSTALLATION ).
  9. INSTALL FRONT AXLE ASSEMBLY RH 

    HINT:

    Install the RH side by the same procedures as the LH side.

  10. INSTALL FRONT EXHAUST PIPE ASSEMBLY (See  INSTALLATION  ) 
  11. INSTALL FRONT FLOOR PANEL BRACE (See  INSTALLATION  ) 
  12. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY 
    1. Connect the 2 cable ends to the transaxle with the 2 washers and 2 clips.
    2. Install 2 new clips to the control cable bracket.
      Fig 6: Connecting Cable Ends To Transaxle With Washers And Clips
      G04228097Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL AIR CLEANER BRACKET 
    1. Install the air cleaner bracket with the bolt.

      Torque: 19 N*m (195 kgf*cm, 14 ft.*lbf) 

      Fig 7: Installing Air Cleaner Bracket With Bolt
      G04228098Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. CONNECT CLUTCH RELEASE CYLINDER TO FLEXIBLE HOSE TUBE 
    1. Using SST, connect the flexible hose tube.

      SST 09023-00101 

      Torque: 15 N*m (155 kgf*cm, 11 ft.*lbf) 

    2. Connect the flexible hose tube with the 2 bolts.

      Torque: 19 N*m (195 kgf*cm, 14 ft.*lbf) 

  15. CONNECT CONNECTOR 
    1. Connect the back-up light switch connector.
      Fig 8: Connecting Flexible Hose Tube
      G04228099Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. CONNECT WIRE HARNESS 
    1. Connect the wire harness clamp with the bolt.

      Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 

  17. INSTALL BATTERY 
  18. INSTALL AIR CLEANER ASSEMBLY 
  19. INSTALL NO. 2 CYLINDER HEAD COVER 

    Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) 

  20. INSTALL COWL TOP PANEL OUTER (See  INSTALLATION  ) 
  21. INSTALL HOOD SUB-ASSEMBLY (See  ON-VEHICLE INSPECTION  ) 
    Fig 9: Connecting Flexible Hose Tube With Bolts
    G04228100Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSPECT HOOD SUB-ASSEMBLY (See  ON-VEHICLE INSPECTION  ) 
  23. ADJUST HOOD SUB-ASSEMBLY (See  ON-VEHICLE INSPECTION  ) 
  24. INSTALL FRONT WHEEL 

    Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) 

  25. ADD TRANSAXLE OIL (See  REPLACEMENT   ) 
  26. INSPECT AND ADJUST TRANSAXLE OIL (See  MANUAL TRANSAXLE OIL   ) 
  27. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  28. PERFORM INITIALIZATION 
    1. Perform initialization (see PRECAUTION ).
      NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
  29. INSTALL ENGINE UNDER COVER RH 
  30. INSTALL ENGINE UNDER COVER LH 
  31. INSPECT FRONT WHEEL ALIGNMENT 
    1. Inspect the FRONT WHEEL ALIGNMENT .
  32. CHECK ABS SPEED SENSOR SIGNAL 
    1. Check the ABS speed sensor signal (see PROBLEM SYMPTOMS TABLE ).
  33. CHECK FOR EXHAUST GAS LEAKS 
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