REMOVAL AND INSTALLATION <BSY>


caution
  • The part indicated by the *1 mark should be temporarily tightened, and then fully tightened with the engine and transmission assembly weight applied on the vehicle body.
  • The bolts marked with *2 are coated with the friction coefficient stabilizer. After removing these bolts, make sure that they are free of damage, remove any dust and dirt on the bearing surfaces and the threads, and then securely tighten to the specified torque.
Pre-removal and Post-installation Operation
  • Engine cover Removal and Installation (Refer to GROUP 11A, Engine assembly ).
  • Air Cleaner assembly Removal and Installation (Refer to GROUP 15, Air Cleaner ).
  • Air Intake Hose Removal and Installation (Refer to GROUP 15, Air Cleaner ).
  • Battery and Battery Tray Removal and Installation. (Refer to GROUP 54A, Battery ).
  • Starter Motor Assembly Removal and Installation (Refer to GROUP 16, Stator Motor Assembly ).
  • Clutch Fluid Draining.
  • Engine Room Under Cover A, C Removal and Installation (Refer to GROUP 51, Under Cover ).
  • Transmission Oil Draining and Refilling (Refer to ).
  • Drive Shaft Removal and Installation (Refer to GROUP 26, Drive Shaft assembly ).
  • Strut Tower Bar Removal (Refer to GROUP 42A - Strut Tower Bar .)




Removal steps


1.
 Back-up lamp switch connector connection
<<A>>
2.
 Clutch tube


3.
 Cable bracket and transmission control cable assembly <Transmission side>


4.
 Transmission assembly upper part coupling bolts


5.
 Flanged nut


6.
 Centre member assembly


7.
 Flanged nut


·
 Transfer assembly (Refer to ).


8.
 Rear roll stopper


9.
 Transmission case rear roll stopper bracket
<<B>>
·
 Engine and transmission assembly supporting


10.
 Transmission mounting bracket

>>B<<
 11.
 Transmission mounting insulator stopper


12.
 Transmission mounting insulator
<<C>>
·
 Engine assembly supporting


13.
 Transmission assembly lower part coupling bolts
<<D>>
 >>A<<
 14.
 Stud bolt


15.
 Transmission assembly

REMOVAL SERVICE POINTS

<<A>> CLUTCH TUBE REMOVAL



caution
  • Do not remove the O-rings and the clips from the clutch tube and the concentric slave cylinder adapter.
  • If the O-rings or the clips of the clutch tube and the concentric slave cylinder adapter are damaged, replace each assembly.

<<B>> ENGINE AND TRANSMISSION ASSEMBLY SUPPORTING/TRANSMISSION MOUNTING INSULATOR ASSEMBLY REMOVAL

While supporting the engine and transmission assembly with a garage jack, remove the transmission mounting insulator assembly.

<<C>> ENGINE ASSEMBLY HOLDING


1.Set the engine hanger balancer (special tool: MB991454) to the engine hanger bracket shown in the figure on the left.


2.<When engine hanger (Special tool: MB991928) is used>
(1) Assemble the engine hanger (Special tool: MB991928). (Set the components below to the base hanger.)

  • Slide bracket (HI)
  • Foot x 2 (standard) (MB991932)
  • Foot x 2 (short) (MB991933)
  • Joint x 2 (90) (MB991930)
(2) Set the feet of the special tool as shown in the figure.
note Adjust the engine hanger balance by sliding the slide bracket (HI).
(3) Set the chains of the engine hanger (Special tool: MB991527) and the engine hanger balancer (Special tool: MB991454) to support the engine and transmission assembly. Remove the garage jack and then remove the transmission assembly upper part coupling bolts that have been loosened previously.



3. <When using engine mechanical hanger (Special tool: MB991895)>
(1) Set the foot of the engine mechanical hanger (Special tool: MB991895) as shown in the figure.
note Slide the front foot of the engine mechanical hanger (Special tool: MB991895) to balance the engine hanger.
caution Place rag between the engine mechanical hanger (Special tool: MB991895) and the windshield to prevent the special tool from interfering with the windshield.
(2) Set the chains of the engine hanger (Special tool: MB991527) and the engine hanger balancer (Special tool: MB991454) to support the engine and transmission assembly. Remove the garage jack and then remove the transmission assembly upper part coupling bolts that have been loosened previously.

<<D>> STUD BOLT REMOVAL

Remove the stud bolt using a commercial stud bolt remover.

INSTALLATION SERVICE POINTS

>>A<< STUD BOLT INSTALLATION
Use a tap (pitch: M12 × 1.25) to remove adhesive in the transmission case screw holes, and clean the holes by blowing air.

>>B<< TRANSMISSION MOUNTING INSULATOR STOPPER INSTALLATION

Install the transmission mounting insulator stopper as shown in the figure.