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Installation: - Manual Transmission Unit

1. The document provides installation instructions for a manual transmission. 2. Key steps include installing the transmission, engine rear mounting, rear engine mounting member, starter, speed sensor and connectors, clutch components, and filling the transmission with oil. 3. Additional steps include installing exhaust and intake components, the radiator hose, transmission shift lever, and road testing the vehicle.

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Eduardo Santos
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© © All Rights Reserved
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128 views

Installation: - Manual Transmission Unit

1. The document provides installation instructions for a manual transmission. 2. Key steps include installing the transmission, engine rear mounting, rear engine mounting member, starter, speed sensor and connectors, clutch components, and filling the transmission with oil. 3. Additional steps include installing exhaust and intake components, the radiator hose, transmission shift lever, and road testing the vehicle.

Uploaded by

Eduardo Santos
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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MT-8

MANUAL TRANSMISSION - MANUAL TRANSMISSION UNIT


MT0FU-02

A
A INSTALLATION
1. INSTALL TRANSMISSION
A
(a) Raise the engine front side.
(b) Align the input spline with a clutch disc and install the
transmission to the engine.
A
A HINT:
Turn the transmission a little in the clockwise and jack up until
B just before the transmission housing touches the body.
B B D11481
(c) Install the transmission and wire harness clamp with the
8 bolts.
Torque:
Bolt A (12 mm head bolt):
71.6 N·m (730 kgf·cm, 53 ft·lbf)
Bolt B (10 mm head bolt):
37.3 N·m (380 kgf·cm, 28 ft·lbf)

2. INSTALL ENGINE REAR MOUNTING


Install the engine rear mounting with 4 the bolts.
Torque: 25.5 N·m (260 kgf·cm, 19 ft·lbf)

D11480

3. INSTALL REAR ENGINE MOUNTING MEMBER


Install the rear engine mounting member with the 4 bolts and
4 nuts.
Torque:
Bolt: 25 N·m (255 kgf·cm, 18 ft·lbf)
Nut: 13.5 N·m (138 kgf·cm, 10 ft·lbf)
4. INSTALL STARTER
(a) Install the starter with the 2 bolts.
D05120 Torque: 37.3 N·m (380 kgf·cm, 28 ft·lbf)
(b) Install the wire with the nut.
Torque: 9.8 N·m (10 kgf·cm, 7 ft·lbf)
(c) Connect the connector.

2005 LEXUS IS300 (RM1140U)

Author: Date: 1582


MT-9
MANUAL TRANSMISSION - MANUAL TRANSMISSION UNIT

5. CONNECT SPEED SENSOR CONNECTOR AND WIRE


HARNESS
(a) Connect the wire harness to the clamp.
(b) Connect the connector.

D11479

6. CONNECT BACK-UP LIGHT SWITCH CONNECTOR

D11478

7. CONNECT CLUTCH RELEASE CYLINDER, CLUTCH


B LINE BRACKET AND EARTH WIRE
(a) Connect the clutch line and earth wire with the bolt.
A Torque:
Bolt A: 37.3 N·m (380 kgf·cm, 28 ft·lbf)
(b) Connect the clutch release cylinder with the 2 bolts.
Torque:
Bolt B: 11.7 N·m (119 kgf·cm, 9 ft·lbf)
D11477 8. INSTALL PROPELLER SHAFT (See page PR-10 )
9. INSTALL FRONT AND CENTER EXHAUST PIPES (See
page EM-100 )

Oil Level 10. FILL WITH TRANSMISSION OIL


0 - 5 mm Torque:
(0 - 0.20 in.) Filler Plug Filler and Drain plug:
38 N·m (387 kgf·cm, 28 ft·lbf)
Oil grade: API GL-4 or GL-5
Viscosity: SAE 75W-90
Capacity: 2.6 litter (2.7 US qts, 2.3 lmp. qts)
11. INSTALL NO. 1 REAR FLOOR BOARD
Drain Plug D11482 12. INSTALL LH FRONT FLOOR CENTER COVER
13. LOWER VEHICLE
2005 LEXUS IS300 (RM1140U)

Author: Date: 1583


MT-10
MANUAL TRANSMISSION - MANUAL TRANSMISSION UNIT

Case
14. INSTALL EXHAUST MANIFOLD
Clamp (a) Install 2 new gaskets to the cylinder head.
(b) Install the exhaust manifold with the 8 nuts. Uniformly
tighten the nuts in several passes.
Torque: 40 N·m (408 kgf·cm, 29 ft·lbf)
(c) Connect the heated oxygen sensor (bank 2 sensor 1)
connector.
(d) Install the case clamp.
A09755

15. INSTALL INTAKE AIR CONNECTOR


(a) Install the intake air resonator to the throttle body, tighten
the 2 hose clamp bolts.
(b) Connect the PCV hose to the No. 2 cylinder head cover.
(c) Connect the engine wire harness clamp to the air cleaner
case.
(d) Connect the MAF meter connector.
16. CONNECT RADIATOR UPPER HOSE NO. 1 FROM EN-
A13975 GINE
17. FILL WITH ENGINE COOLANT
18. INSTALL ENGINE COVER NO. 1
Torque: 5.0 N·m (51 kgf·cm, 44 in.·lbf)
19. INSTALL NO. 1 AND NO. 2 ENGINE UNDER COVERS

20. INSTALL TRANSMISSION SHIFT LEVER


(a) Install the washer.
(b) Apply MP grease to the tip of shift lever.
(c) Install the shift lever with the 4 bolts.
Torque: 8.0 N·m (82 kgf·cm, 71 in.·lbf)
21. INSTALL SHIFT BOOT

D05109

22. INSTALL SHIFT BOOT RETAINER


(a) Install the shift boot retainer with the 4 bolts.
(b) Connect the 2 wire harness clamps.
23. INSTALL UPPER CONSOLE PANEL AND CONSOLE
BOX (See page BO-149 )
24. DO ROAD TEST
Check for abnormal noises and smooth shifting.

D05108

2005 LEXUS IS300 (RM1140U)

Author: Date: 1584

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