Operation CHARM: Car repair manuals for everyone.

Installation

1. Gradually raise transmission with a transmission jack until mainshaft is aligned with clutch disc at their splines and engage them at splines. If they are not aligned properly rotate crankshaft as required.
2. Install rear crossmember to rear cushion rubber, torque to 27 - 47 Nm (20 - 35 ft.lbs).
3. Install rear crossmember to car body taking care not to damage threads. Torque front bolts to 118 - 157 Nm (87 - 116 ft.lbs), torque rear bolts to 54 - 83 Nm (40 - 61 ft.lbs).
4. Tighten engine to transmission nuts on the lower side, torque to 46 - 54 Nm (34 - 40 ft.lbs).
5. Remove transmission jack.






6. Install axle shaft to axle drive shaft and drive a new spring pin into place.

Caution: Be sure to align the two shafts at the chamfered holes and engage shaft splines.

7. Align bolt holes using a cross-head screwdriver, insert bolt into holes from the front side and temporarily install the transverse link to the front crossmember with a new lock nut.
8. Temporarily install stabilizer to the transverse link.
9. Connect rod CP to transmission.
10. Connect stay CP to transmission and install spring.
10. Install propeller shaft, torque propeller shaft to rear differential to 18 - 27 Nm (13 - 20 ft.lbs) and center bearing location to 34 - 44 Nm (25 - 33 ft.lbs).
11. With the tires placed on the ground but the vehicle not loaded, torque the transverse link to front crossmember mounting bolt to 59 - 69 Nm (43 - 51 ft.lbs) and the transverse link to stabilizer mounting bolt to 20 - 29 Nm (14 - 22 ft.lbs).
12. Connect the engine and transmission and torque the bolt on the right side to 46 - 54 Nm (34 - 40 ft.lbs).
13. lift up the car and install the front and rear exhaust pipes using new gaskets.
14. Torque front exhaust pipe to engine to 25 - 34 Nm (18 - 25 ft.lbs), front exhaust pipe to bracket to 25 - 34 Nm (18 - 25 ft.lbs), the front exhaust pipe to rear exhaust pipe to 13 - 23 Nm (9 - 17 ft.lbs), and the rear exhaust pipe to muffler to 39 - 49 Nm (29 - 36 ft.lbs).
15. Remove the engine support assembly.
16. Install connector holder bracket.
17. Install pitching stopper, torque the bolt for body side first to 47 - 67 Nm (35 - 49 ft.lbs) and then the one for engine to transmission side to 44 - 54 Nm (33 - 40 ft.lbs).
18. Install the starter assembly, torque upper bolt to 46 - 54 Nm (34 - 40 ft.lbs), torque lower nut to 30 - 36 Nm (22 - 27 ft.lbs).
19. Connect the following harness connectors:

- Transmission ground terminal
- Transmission harness connectors
- Knock sensor connector
- Cam angle sensor connector
- Crank angle sensor connector
- Oxygen sensor connector

20. Connect clutch cable, return spring and hill-holder cable.
21. Test hill-holder on an upgrade.
22. Connect battery cables to battery.
23. Check transmission oil level and fill as necessary.