REMOVAL AND INSTALLATION <4B1>



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 room under cover front A, B <4WD>, D Removal and Installation (Refer to GROUP 51, Front Bumper ).
  • Transmission Oil Draining and Refilling (Refer to ).
  • Air Cleaner Assembly and Air Cleaner Bracket Removal and Installation (Refer to GROUP 15, Air Cleaner ).
  • Battery and Battery Tray Removal and Installation (Refer to GROUP 54A, Battery ).
  • Engine-ECU Removal and Installation (Refer to GROUP 13D, Engine-ECU ).
  • Engine Cover Removal and Installation (Refer to GROUP 11E, Camshaft ).
  • Starter Motor Assembly Removal and Installation (Refer to GROUP 16, Stator Motor Assembly ).
  • Drive Shaft Removal and Installation (Refer to GROUP 26, Drive Shaft Assembly .)
  • Wiper Arm · Blade Assembly and Front Deck Garnish Removal and Installation (Refer to GROUP 51 - Windshield Wiper .)
  • Strut Tower Bar Removal and Installation (Refer to GROUP 42A - Strut Tower Bar .)
  • Water Pipe Assembly Removal and Installation (Refer to GROUP 14 - Water Hose and Water Pipe .)
  • Clutch fluid draining.





Removal steps


1.
Speed sensor connector connection


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

3.
Clutch tube connection


4.
Harness bracket


5.
Cable bracket and transmission control cable assembly <Transmission side>


6.
Transmission assembly upper part coupling bolts


7.
Centre member assembly


8.
Rear roll stopper


9.
Transmission case rear roll stopper bracket


·
Transfer assembly (Refer to .) <4WD>


·
While supporting the engine and transmission assembly with a garage jack.


10.
Transmission mounting bracket

>>A<<
11.
Transmission mounting insulator stopper


12.
Transmission mounting insulator
<<B>>

·
Engine assembly supporting


13.
Transmission assembly lower part coupling bolts


14.
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 ASSEMBLY HOLDING



1. Install special tool engine hanger plate (MB991956) to the cylinder head.


2.<When special tool engine hanger (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 special tool engine hanger (MB991527) and special tool engine hanger balancer (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 special tool engine mechanical hanger (MZ203830 or MZ203831)>
(1) Set the foot of special tool engine mechanical hanger (MZ203830 or MZ203831) as shown in the figure.
note Slide the front foot of special tool engine mechanical hanger (MZ203830 or MZ203831) to balance the engine hanger.
caution Place rag between special tool engine mechanical hanger (MZ203830 or MZ203831) and the windshield to prevent the special tool from interfering with the windshield.
(2) Set the chains of special tool engine hanger (MB991527) and special tool engine hanger balancer (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.

INSTALLATION SERVICE POINTS



>>A<< TRANSMISSION MOUNTING INSULATOR STOPPER INSTALLATION



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