REMOVAL AND INSTALLATION <4N1>


Pre-removal operation
  • Engine Room Under Cover Removal (Refer to GROUP 51 - Under Cover ).
  • Transmission Oil Draining (Refer to ).
  • Air Cleaner Assembly and Air Cleaner Bracket Removal (Refer to GROUP 15 - Air Cleaner ).
  • Battery and Battery Tray Removal (Refer to GROUP 54A - Battery ).
  • Engine-ECU Removal (Refer to GROUP 13D - Engine-ECU ).
  • Drive Shaft Removal (Refer to GROUP 26 - Drive Shaft Assembly ).

 Post-installation operation
  • Drive Shaft Installation (Refer to GROUP 26 - Drive Shaft Assembly ).
  • Clutch Bleeding and Clutch Fluid Refilling (Refer to GROUP 21A - Clutch Bleeding ).
  • Engine-ECU Installation (Refer to GROUP 13D - Engine-ECU ).
  • Battery and Battery Installation (Refer to GROUP 54A - Battery ).
  • Air Cleaner Assembly and Air Cleaner Bracket Installation (Refer to GROUP 15 - Air Cleaner ).
  • Transmission Oil Refilling (Refer to ).
  • Engine Room Under Cover Installation (Refer to GROUP 51 - Under Cover ).




Removal steps


1.
 Back-up lamp switch connector


2.
 Neutral position switch connector


·
 Connection of the centre exhaust pipe and the catalytic converter (Refer to GROUP 15 - Exhaust Pipe, Main Muffler and Catalytic Converter <2WD>, <4WD>.)


3.
 Catalytic converter bracket <2WD>


·
 Transfer assembly (Refer to .) <4WD>
<<A>>
 >>C<<
 4.
 Clutch tube connection


5.
 Water hose connection
<<B>>
6.
 Cable bracket and transmission control cable assembly (Transmission side)


·
 Starter mounting bolt (Refer to GROUP 16 - Starter Motor Assenbly )
<<C>>
7.
 Transmission assembly upper part coupling bolt


8.
 Bell housing cover


·
 Engine roll rod assembly (Refer to GROUP 32 - Engine Roll Stopper Rod )


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


·
 Transmission mounting bracket (Refer to GROUP 32 - Transmission Mounting )
<<D>>
 >>B<<
 ·
 Engine assembly holding


9.
 Transmission assembly lower part coupling bolt

>>A<<
 10.
 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>> CABLE BRACKET AND TRANSMISSION CONTROL CABLE ASSEMBLY (TRANSMISSION SIDE) REMOVAL

caution Be careful not to pull out the cable directly to disconnect the joint because the cable could be broken.
Use the clip remover (special tool: MB992277), and disconnect the joint.

<<C>> TRANSMISSION ASSEMBLY UPPER PART COUPLING BOLT REMOVAL
Only loosen the bolts from the engine and transmission assembly (do not remove).

<<D>> ENGINE ASSEMBLY HOLDING
1.Remove the harness bracket assembly (Refer to GROUP 13D - Common Rail ).
2.Remove the bracket B (Refer to GROUP 11F - Vacuum Pump ).


3.Install special tool engine hanger plate (MB991956) to the position shown in the figure.


4.<When using engine hanger (special tool: MB991928)>
(1) Assemble the engine hanger (special tool: MB991928). (Set the components below to the base hanger.)

  • Slide bracket (HI)
  • Foot x 4 (standard) (MB991932)
(2) Set the foot of the special tool as shown in the figure.
note Adjust the engine hanger balance by sliding the slide bracket (HI).
(3) Set 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.


5.<When engine hanger (Special tool: MB991895) and engine hanger attachment (Special tool: MB992906) are used>
(1) Set the foot of engine hanger (special tool: MB991895) as shown in the figure.
note Slide the front foot of the engine hanger (special tool: MB991895) to balance the engine hanger.
(2) Set 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.

INSTALLATION SERVICE POINT

>>A<< TRANSMISSION ASSEMBLY INSTALLATION

When installing the transmission assembly, apply the specified grease to the spline of clutch disc and input shaft.
Specified grease: MITSUBISHI MOTORS GENUINE Part No.0101011 or equivalent

>>B<< ENGINE ASSEMBLY HOLDING
1.Install the bracket B (Refer to GROUP 11F - Vacuum Pump ).
2.Install the harness bracket assembly (Refer to GROUP 13D - Common Rail ).

>>C<< CLUTCH TUBE INSTALLATION

caution
  • Check that the O-ring and the clip are not damaged before installing the clutch tube and the concentric slave cylinder adapter.
  • If the O-ring of the clutch tube and the concentric slave cylinder adapter and their installation positions are contaminated, clean with the clutch fluid before installation.
After installing the clip to the concentric slave cylinder adapter, install the clutch tube assembly to the concentric slave cylinder adapter.