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Manual Transaxle Assembly: Installation

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

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

      Fig 1: Identifying Rear Engine Mounting Bracket Bolts
      G05539610Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the rear engine mounting insulator with the bolt to the rear engine mounting bracket.

    Torque: 87 N*m (887 kgf*cm, 64 ft.*lbf) 

  2. INSTALL FRONT ENGINE MOUNTING BRACKET 
    1. Install the front engine mounting bracket and 2 bolts to the transaxle.

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

    2. Install the front engine mounting insulator, bolt and nut to the front engine mounting bracket.

    Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf) 

    Fig 2: Identifying Front Engine Mounting Bracket And Bolts
    G05539609Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL MANUAL TRANSMISSION CASE PROTECTOR 
    1. Install the case protector with the 2 bolts.

    Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 

    Fig 3: Identifying Case Protector With Bolts
    G05539613Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL MANUAL TRANSAXLE ASSEMBLY 
    1. Align the input shaft with the clutch disc and install the transaxle to the engine.
    2. Install the 10 bolts.

    Torque: 

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

    46 N*m (469 kgf*cm, 34 ft.*lbf) for bolt B 

    44 N*m (449 kgf*cm, 32 ft.*lbf) for bolt C 

    Fig 4: Identifying Manual Transaxle Assembly Bolts
    G05539614Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL ENGINE MOUNTING BRACKET LH 
    1. Install the engine mounting bracket to the transaxle with the 3 bolts.

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

    Fig 5: Identifying Engine Mounting Bracket And Bolts
    G05539615Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL ENGINE MOUNTING INSULATOR LH 
    1. Install the engine mounting insulator with the 5 bolts and nut.

    Torque: 

    52 N*m (530 kgf*cm, 38 ft.*lbf) for bolt A 

    87 N*m (887 kgf*cm, 64 ft.*lbf) for bolt B 

    Fig 6: Identifying Engine Mounting Insulator With Bolts And Nut
    G05539616Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY  (See INSTALLATION )
  8. CONNECT PRESSURE FEED TUBE ASSEMBLY  (See INSTALLATION )
  9. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH 
    1. Install the drive shaft (see INSTALLATION ).
  10. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH 
    1. Install the drive shaft (see INSTALLATION ).
  11. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY 
    1. Connect the 2 cable ends with the 2 washers and 2 clips.
    2. Install 2 new clips to the control cable bracket.
    Fig 7: Identifying Transmission Control Cable Assembly Clips And Washer
    G05539617Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY 
    1. Install the release cylinder with the 3 bolts.

    Torque: 

    7.8 N*m (80 kgf*cm, 69 in.*lbf) for bolt A 

    12 N*m (120 kgf*cm, 9 ft.*lbf) for bolt B 

    Fig 8: Identifying Release Cylinder With Bolts
    G05539618Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. CONNECT BACK-UP LIGHT SWITCH 
    Fig 9: Identifying Back-Up Light Switch
    G05539619Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. CONNECT WIRE HARNESS 
    1. Install the 3 wire harnesses with the 3 bolts.

    Torque: 

    26 N*m (260 kgf*cm, 19 ft.*lbf) for bolt A 

    8.4 N*m (85 kgf*cm, 74 in.*lbf) for bolt B 

    13 N*m (133 kgf*cm, 9.6 ft.*lbf) for bolt C 

    Fig 10: Identifying Wire Harnesses With Bolts
    G05539620Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL STARTER ASSEMBLY  (See INSTALLATION )
  16. INSTALL BATTERY CARRIER 
    1. Install the battery carrier with the 3 bolts.
  17. INSTALL BATTERY TRAY 
  18. INSTALL BATTERY 
  19. INSTALL BATTERY CLAMP SUB-ASSEMBLY 

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

  20. INSTALL AIR CLEANER ASSEMBLY 

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

  21. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY 
  22. INSTALL HOOD SUB-ASSEMBLY 

    Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) 

  23. ADJUST HOOD SUB-ASSEMBLY 
    1. Adjust the hood (See ADJUSTMENT ).
  24. INSTALL CENTER EXHAUST PIPE ASSEMBLY  (See INSTALLATION )
  25. ADD TRANSAXLE OIL  (See ON-VEHICLE INSPECTION  )
  26. INSPECT TRANSAXLE OIL  (See ON-VEHICLE INSPECTION )
  27. INSTALL FRONT WHEEL 

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

  28. INSTALL NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY 
  29. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY  (See INSTALLATION )
  30. INSTALL COLUMN HOLE COVER SILENCER SHEET 
  31. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  32. PERFORM INITIALIZATION 
    NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
    1. Perform initialization (see INITIALIZATION ).
  33. CHECK SRS WARNING LIGHT 
    1. Check the SRS warning light (see DIAGNOSIS SYSTEM ).
  34. PLACE FRONT WHEEL FACING STRAIGHT AHEAD 
  35. INSPECT STEERING WHEEL CENTER POINT 
  36. ADD POWER STEERING FLUID 
  37. BLEED AIR FROM POWER STEERING FLUID  (See ON-VEHICLE INSPECTION )
  38. CHECK POWER STEERING FLUID LEVEL IN RESERVOIR  (See ON-VEHICLE INSPECTION )
  39. INSPECT FOR POWER STEERING FLUID LEAK 
  40. INSPECT FRONT WHEEL ALIGNMENT 
    1. Inspect wheel alignment (see ADJUSTMENT ).
  41. INSTALL ENGINE UNDER COVER LH 
  42. INSTALL ENGINE UNDER COVER RH 
  43. CHECK ABS SPEED SENSOR SIGNAL 
    1. Check the sensor signal (see DTC C0200/31 RIGHT FRONT WHEEL SPEED SENSOR SIGNAL MALFUNCTION; DTC C0205/32 LEFT FRONT WHEEL SPEED SENSOR SIGNAL MALFUNCTION; DTC C1235/35 FOREIGN OBJECT IS ATTACHED ON TIP OF FRONT SPEED SENSOR RH; DTC C1236/36 FOREIGN OBJECT IS ATTACHED ON TIP OF FRONT SPEED SENSOR LH; DTC C1271/71 LOW OUTPUT SIGNAL OF FRONT SPEED SENSOR RH (TEST MODE DTC); DTC C1272/72 LOW OUTPUT SIGNAL OF FRONT SPEED SENSOR LH (TEST MODE DTC); DTC C1275/75 ABNORMAL CHANGE IN OUTPUT SIGNAL OF FRONT SPEED SENSOR RH (TEST MODE DTC); DTC C1276/76 ABNORMAL CHANGE IN OUTPUT SIGNAL OF FRONT SPEED SENSOR LH (TEST MODE DTC) ).
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