REMOVAL AND INSTALLATION <4J1>



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 13C - 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 ).
  • Engine-ECU Installation (Refer to GROUP 13C - Engine-ECU ).
  • Clutch Bleeding and Clutch Fluid Refilling (Refer to GROUP 21A - Clutch Bleeding ).
  • Battery and Battery Tray Installation (Refer to GROUP 54A - Battery ).
  • Air Cleaner Assembly and Air Cleaner Bracket Installation (Refer to GROUP 15 - Air Cleaner ).
  • Transmission Oil Draining and Refilling (Refer to ).
  • Engine Room Under Cover Installation (Refer to GROUP 51 - Under Cover ).





Removal steps


1.
Speed sensor connector connection


2.
Back-up lamp switch connector connection


3.
Neutral position switch connector connection
<<A>>
>>C<<
4.
Clutch tube connection


5.
Harness bracket
<<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 bolts


·
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<<
·
Injector protector mounting bolt


·
Vacuum pipe assembly (Refer to GROUP 14A - Water Hose and Water Pipe .)
<<E>>

·
Engine assembly holding


8.
Transmission assembly lower part coupling bolts

>>A<<
9.
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 REMOVAL <TRANSMISSION SIDE>



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>> INJECTOR PROTECTOR MOUNTING BOLT REMOVAL



Remove the injector protector mounting bolt (A shown in the illustration).

<<E>> ENGINE ASSEMBLY HOLDING



1.Tighten the engine hanger plate (special tool: MB992853) to the specified torque at A in the figure (injector protector rear mounting bolt) and B in the figure (vacuum pipe assembly mounting bolt).
Tightening torque: 20 ± 2 N·m (A in the figure)
Tightening torque: 11 ± 1 N·m (B in the figure)

2.Assemble the engine hanger (special tool: MB991527) with the chain of the engine hanger balancer (special tool: MB991454).


3.<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) Connect the engine hanger (Special tool: MB991928) to the engine hanger (special tool: MB991527). Remove the garage jack and then remove the transmission assembly upper part coupling bolts that have been loosened previously.


4.<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 engine hanger (special tool:MB991895) to balance the engine hanger.
(2) Connect the engine hanger (Special tool: MB991895) to the engine hanger (special tool: MB991527). Remove the garage jack and then remove the transmission assembly upper part coupling bolts that have been loosened previously.

INSTALLATION SERVICE POINTS



>>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<< INJECTOR PROTECTOR REAR MOUNTING BOLT INSTALLATION



Tighten the injector protector rear mounting bolt (A in the figure) to the specified torque.
Tightening torque: 20 ± 2 N·m

>>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.