Removal
1. Disconnect the negative and then the positive cable from the battery.
2. Drain the oil from the gearbox.
3. Remove the air intake and air filter.
4. Disconnect the starter wires, transmission ground wire, and reverse light switch connector.
5. Remove the wire fastenings.
6. Disconnect the speed sensor connector.
7. Remove the clutch tube bracket, clutch tube holder and slave cylinder.
Note:
- Do not press the clutch pedal with the slave cylinder disconnected.
- Be careful not to bend the tube.
8. Remove the drive shaft.
Note:
- Lubricate all machined surfaces with clean engine oil or grease.
- Cover the ends of the drive shaft with plastic bags.
9. Remove the muffler exhaust pipe A.
10. Remove the gear selector lever and gear shift lever.
11. Remove the engine mounts and clutch housing.
Engines D15Z6, D15Z7. D16Y5. D16Y6, D16Y8:
Engines D14A3, D14A4, D15Z4, D15Z5, D16Y4,D16Y7,D16Y9:
12. Screw the bolts into the cylinder head, attach a lift to them, and lift the engine.
13. Remove the protective cover.
14. Remove the right front bracket.
15. Place a jack under the transmission.
16. Remove the bracket and rubber mount from the gearbox.
17. Remove the three upper mounting bolts and the lower starter mounting bolt.
18. Remove the rear bracket mounting bolts and transmission mounting bolts.
19. Pull the transmission away from the engine until the shaft is completely out, then lower it onto the jack.
Note: Be careful not to bend the tube.
Installation
Install the gearbox in the reverse order of disassembly. Before installation, check that the two locating pins are installed in the clutch housing.
When connecting the starter wire, make sure the corrugated side of the lug is on the outside.
Lubricate the parts with grease as shown in the figure, then install the pressure fork and release bearing.
Tighten the mounting bolts and nuts in the sequence shown in the illustration.
Check that the bushings do not rotate and are installed correctly.
Install the clamps as shown in the figure. Turn the casing so that the hole is at the bottom. Make sure the cover is on the gear selector lever.
Lubricate the slave cylinder with grease.
Turn the ventilation cap with the arrow towards the front of the car.
Fill the gearbox with oil.
Connect the positive cable first and then the negative cable to the battery. Check clutch operation.
Check for smooth gear shifting. Adjust the ignition timing Check the angles of the front wheels.