| Last Modified: 05-13-2024 | 6.11:8.1.0 | Doc ID: RM100000002714Z |
| Model Year Start: 2023 | Model: Corolla Hatchback | Prod Date Range: [09/2022 - 11/2022] |
| Title: EG60 (MANUAL TRANSMISSION / TRANSAXLE): MANUAL TRANSAXLE ASSEMBLY: INSTALLATION; 2023 MY Corolla Corolla Hatchback [09/2022 - 11/2022] | ||
INSTALLATION
CAUTION / NOTICE / HINT
NOTICE:
When the manual transaxle assembly is removed, be sure to use a new clutch release with bearing cylinder assembly and new installation bolts. Removal of the manual transaxle assembly allows the compressed clutch release with bearing cylinder assembly to return to its original position. Dust from the moving section may damage the seal of the clutch release with bearing cylinder assembly, possibly causing clutch fluid leaks.
PROCEDURE
1. INSTALL TRANSMISSION CASE PLUG ASSEMBLY
HINT:
Perform this procedure only when replacement of the manual transaxle assembly is necessary.
(a) Coat the O-ring of a new transmission case plug assembly with gear oil.
(b) Install the transmission case plug assembly to the transaxle(MTM) case sub-assembly.
2. INSTALL CONTROL CABLE BRACKET ASSEMBLY
(a) Install the control cable bracket assembly to the manual transmission case and transaxle(MTM) case sub-assembly with the 3 bolts.
Torque:
17 N·m {173 kgf·cm, 13 ft·lbf}
3. INSTALL WIRE HARNESS CLAMP BRACKET
(a) Install the 2 wire harness clamp brackets to the transaxle(MTM) case sub-assembly with the 2 bolts.
Torque:
10 N·m {102 kgf·cm, 7 ft·lbf}
(b) Install the 2 wire harness clamp brackets to the manual transmission case with the 2 bolts.
Torque:
10 N·m {102 kgf·cm, 7 ft·lbf}
4. INSTALL CLUTCH FLEXIBLE HOSE BRACKET
(a) Install the clutch flexible hose bracket to the manual transmission case with the bolt.
Torque:
10 N·m {102 kgf·cm, 7 ft·lbf}
5. INSTALL CLUTCH RELEASE CYLINDER WITH BEARING ASSEMBLY TO BLEEDER TUBE
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![2023 MY Corolla Corolla Hatchback [09/2022 - 11/2022]; CLUTCH: CLUTCH UNIT (for EG60): INSTALLATION+](/t3Portal/stylegraphics/info.gif)
6. INSTALL CLUTCH RELEASE CYLINDER WITH BEARING ASSEMBLY
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7. INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY
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8. INSTALL BLEEDER TO FLEXIBLE HOSE TUBE
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9. SUPPORT MANUAL TRANSAXLE ASSEMBLY
(a) Using a transmission jack, support the manual transaxle assembly.
NOTICE:
- Adjust the attachment of the transmission jack to securely fix the manual transaxle assembly to the transmission jack.
- Using a lashing belt or a rope, fix the manual transaxle assembly to the transmission jack.
10. INSTALL MANUAL TRANSAXLE ASSEMBLY
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(a) Check that the 2 knock pins are installed on the engine assembly before installing the manual transaxle assembly. |
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(b) Align the input shaft with the clutch disc and install the manual transaxle assembly to the engine assembly.
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(c) Temporarily install the bolt (A). HINT: Bolt (A): Install from the manual transaxle assembly side. |
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(d) Install the bolt (B).
Torque:
64 N·m {653 kgf·cm, 47 ft·lbf}
HINT:
Bolt (B): Install from the manual transaxle assembly side.
(e) Install the bolt (C), then fully tighten the bolt (A).
Torque:
Bolt (C) :
64 N·m {653 kgf·cm, 47 ft·lbf}
Bolt (A) :
46 N·m {469 kgf·cm, 34 ft·lbf}
HINT:
Bolt (C): Install from the manual transaxle assembly side.
(f) Install the bolt (D).
Torque:
25 N·m {255 kgf·cm, 18 ft·lbf}
HINT:
Bolt (D): Install from the manual transaxle assembly side.
(g) Install the 4 bolts (E).
Torque:
46 N·m {469 kgf·cm, 34 ft·lbf}
NOTICE:
- Make sure that the wire harness or similar items are not pinched between the contact surfaces.
- Do not forcibly pry on the manual transaxle assembly when installing it to the engine assembly.
- Do not apply excessive force to the manual transaxle assembly as this will break the input shaft.
- Make sure that the knock pins fit securely into the holes when installing the manual transaxle assembly to the engine assembly.
- Make sure that the contact surfaces of the engine assembly and manual transaxle assembly are flat against each other before tightening the bolts.
HINT:
Bolt (E): Install from the engine assembly side.
11. CONNECT NO. 1 CLUTCH HOSE
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12. INSTALL ENGINE MOUNTING BRACKET LH
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(a) Install the engine mounting bracket LH to the manual transmission case with the 6 bolts in the order shown in the illustration. Torque: 44 N·m {449 kgf·cm, 32 ft·lbf} |
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13. INSTALL ENGINE MOUNTING STAY LH
HINT:
Perform this procedure only when replacement of the engine mounting stay LH is necessary.
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(a) Install the engine mounting stay LH to the engine mounting bracket LH with the 5 bolts in the order shown in the illustration. Torque: 41 N·m {418 kgf·cm, 30 ft·lbf} |
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14. INSTALL ENGINE MOUNTING INSULATOR LH
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(a) Install the engine mounting insulator LH to the vehicle body with the 4 bolts and nut in the order shown in the illustration. Torque: 42 N·m {428 kgf·cm, 31 ft·lbf} |
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(b) Insert the bolt to the engine mounting insulator LH and engine mounting bracket LH, and temporarily tighten the nut.
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*a |
Temporarily Tighten |
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Bolt |
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Nut |
(c) Install the engine mounting insulator LH to the engine mounting bracket LH with the bolt and nut.
Torque:
44 N·m {449 kgf·cm, 32 ft·lbf}
NOTICE:
While holding the nut in place, tighten the bolt.
15. INSTALL NO. 2 ENGINE MOVING CONTROL ROD
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(a) Install the No. 2 engine moving control rod to the manual transmission case with the 5 bolts in the order shown in the illustration. Torque: 44 N·m {449 kgf·cm, 32 ft·lbf} |
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16. INSTALL DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY
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(a) Install the drive shaft heat insulator sub-assembly to the cylinder block sub-assembly with the 3 bolts in the order shown in the illustration. Torque: 17.6 N·m {179 kgf·cm, 13 ft·lbf} |
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17. INSTALL MANIFOLD STAY
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18. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY
(a) Slowly jack up the front suspension crossmember sub-assembly with an engine lifter using 4 attachments or equivalent tools.
CAUTION:
- The front suspension crossmember sub-assembly is a very heavy component. Make sure that it is supported securely.
- If the front suspension crossmember sub-assembly is not securely supported, it may drop, resulting in serious injury.
NOTICE:
Use attachments to keep the front suspension crossmember sub-assembly level.
(b) Install the front suspension crossmember sub-assembly to the vehicle body with the 4 bolts.
Torque:
141 N·m {1438 kgf·cm, 104 ft·lbf}
(c) Lower the engine lifter.
(d) Install the engine moving control rod with the bolt.
Torque:
170 N·m {1734 kgf·cm, 125 ft·lbf}
19. INSTALL REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY LH
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20. INSTALL REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY RH
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21. CONNECT NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY
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22. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY
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23. INSTALL COLUMN HOLE COVER SILENCER SHEET
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24. REMOVE ENGINE SUPPORT BRIDGE
(a) Remove SST from the vehicle body.
NOTICE:
Prevent SST from contacting the vehicle body or windshield glass.
(b) Connect the neck to the windshield washer jar assembly with the clip.
25. INSTALL STARTER ASSEMBLY
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26. REMOVE ENGINE HANGERS
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27. INSTALL FUEL DELIVERY GUARD
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28. CONNECT WIRE HARNESS
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(a) Engage the 3 clamps. |
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(b) Engage the 2 clamps. |
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(c) Install the earth bolt.
Torque:
20 N·m {204 kgf·cm, 15 ft·lbf}
(d) Connect the transmission revolution sensor connector.
(e) w/ Neutral Position Switch:
(1) Connect the neutral position switch connector.
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(f) Engage the 2 clamps. |
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(g) Install the bolt.
Torque:
10 N·m {102 kgf·cm, 7 ft·lbf}
(h) Connect the back-up light switch assembly connector.
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(i) Engage the clamp. |
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(j) Install the bolt and 2 nuts. Torque: 10 N·m {102 kgf·cm, 7 ft·lbf} |
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(k) Connect the engine coolant temperature sensor connector. |
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29. INSTALL FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst)
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30. INSTALL FRONT FLOOR CENTER BRACE
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31. INSTALL FRONT FLOOR COVER LH
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32. INSTALL FRONT FLOOR COVER RH
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33. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY
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34. INSTALL BATTERY CLAMP SUB-ASSEMBLY
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35. INSTALL BATTERY
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36. INSTALL ECM
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37. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY
(a) Remove the 4 nuts.
(b) Install the outer cowl top panel sub-assembly with the 9 bolts and 4 nuts.
Torque:
Bolt :
12 N·m {122 kgf·cm, 9 ft·lbf}
Nut :
50 N·m {510 kgf·cm, 37 ft·lbf}
38. INSTALL NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL
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39. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY
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40. INSTALL FRONT DRIVE SHAFT ASSEMBLY
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41. BLEED CLUTCH LINE
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42. ADJUST TRANSMISSION CONTROL CABLE ASSEMBLY
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43. INSPECT MANUAL TRANSAXLE OIL
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44. INSPECT MANUAL TRANSAXLE OIL LEAK
45. INSPECT FOR EXHAUST GAS LEAK
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