REMOVAL AND INSTALLATION


caution
  • Before replacing the transmission assembly, you should make a note of the serial No. which is stamped on the new transmission assembly (Refer to ).
  • When the transmission assembly is replaced, carry out the following operations.

    • Initialisation Procedure for CVT Learned Value (Refer to .)
    • Learning Procedure (Refer to .)
Pre-removal and post-installation operation
  • Engine Room Under Cover Front A, B and Engine Room Side Cover Removal and Installation.
  • CVT Fluid Draining and Refilling (Refer to ).
  • Engine Coolant Draining and Refilling.
  • Air Cleaner Assembly, Air Cleaner Bracket Removal and Installation.
  • Battery and Battery Tray Removal and Installation.
  • Engine-ECU Removal and Installation.
  • Drive Shaft Removal and Installation.
  • Transfer Assembly Removal and Installation. <4WD>




Removal steps
<<A>>
1.
 CVT assembly connector connection


2.
 Connector and wiring harness connection

>>C<<
 3.
 Transmission control cable connection


4.
 Transmission control cable bracket


5.
 Battery earth


6.
 Water hose connection


7.
 Oil cooler feed hose and oil cooler return hose connection <Vehicles with air-cooled oil cooler assembly> (Refer to .)


8.
 Oil filler tube assembly


9.
 O-ring


10.
 Starter mounting bolt
<<B>>
 >>B<<
 ·
 Injector protector mounting bolt


·
 Vacuum pipe assembly


11.
 Cover
<<C>>
12.
 Torque converter and drive plate coupling bolt


13.
 Transmission assembly coupling bolt
<<D>>
14.
 Transmission assembly coupling bolt


·
 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 and transmission mounting insulator (Refer to GROUP 32 - Transmission Mounting .)
<<E>>
·
 Engine assembly holding


15.
 Transmission assembly coupling bolt

>>A<<
 16.
 Transmission assembly

REMOVAL SERVICE POINTS

<<A>> CVT ASSEMBLY CONNECTOR DISCONNECTION

While pressing A in the figure, turn B anti-clockwise to unlock the CVT assembly connector, and disconnect the connector.

<<B>> INJECTOR PROTECTOR MOUNTING BOLT REMOVAL

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

<<C>> TORQUE CONVERTER AND DRIVE PLATE COUPLING BOLT REMOVAL
1.Remove the coupling bolts while turning the crankshaft.
2.Fully push the torque converter into the transmission side so that it does not remain on the engine side.

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

<<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.Set the foot of special tool engine hanger (MB991895) as shown in the figure.
note Slide the front foot of special tool engine hanger attachment (Special tool: MB992906) to balance the engine hanger.

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

INSTALLATION SERVICE POINTS

>>A<< TRANSMISSION ASSEMBLY INSTALLATION

Fully push the torque converter into the transmission side, and then assemble the transmission assembly to the engine.

>>B<< INJECTOR PROTECTOR MOUNTING BOLT INSTALLATION

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

>>C<< TRANSMISSION CONTROL CABLE INSTALLATION
1.Move the selector lever to the "N" range.
2.Move the manual control lever to Neutral position.

3.Align the hole at the end of the manual control lever and the hole in the inhibitor switch body flange (section A - A).
note Insert a Φ5 mm bar into the aligned holes in the inhibitor switch body flange and on the tip of the manual control lever to position the inhibitor switch body.

4.Use the adjusting nut to tighten the transmission control cable to the specified torque.
Tightening torque: 9.5 ± 3.5 N·m
5.Make sure that the transmission side ranges that are corresponding to the selector lever position operate and function without fail.