Transmission Replacement (Engine and Transmission)

Transmission Replacement (Engine and Transmission)


Special Tools
* KM-313 Sliding Hammer
* OTC 1726 / KM-412-31-1/KM-412-31-2 Engine Overhaul Stand
* KM-460-B Axle Shaft Remover
* KM-6003 Remover
* KM-6349 Fixing Rod



Removal Procedure






Important: Engine with manual transmission removed.


1. Remove the coolant return hose, throttle valve pre-heating (1) from the coolant surge tank.

* Release the clamp.
* Unclip from the bracket.





2. Remove the upper radiator hose (1) from the thermostat (2).
Release the clamp.
3. Remove the lower radiator hose from the coolant pump.

* Release the clamp.
* Unclip from the bracket.





4. Remove the refrigerant lines (1) from the air conditioning (A/C) compressor.
Remove the bolt (2).




5. Disconnect the 3 wiring harness plugs.

* Compressor (1)
* Manometric switch, condenser (2)
* Disconnect the wiring harness.
* Temperature sensor, radiator (3)





6. Remove the radiator (1).
Remove from the lower radiator brackets.
7. Place the collecting basin underneath.
8. Remove the right-hand axle body.

* Remove the axle body with KM-460-B (1) from the differential gear.
* Seal the opening in differential with the sealing plug.





9. Remove the left-hand axle body.

* Remove the axle body with KM-313 and KM-6003 (1) from the differential gear.
* Seal the opening in the differential with the sealing plug.





10. Remove the oil dipstick guide tube (2).

* Remove the bolt (1).
* Remove the oil dipstick guide tube upward.

11. Remove the wiring harness plug of the catalytic converter control oxygen sensor.

* Disconnect the wiring harness connector.
* Unclip from the bracket.





12. Remove the ribbed V-belt.

* Apply tension to the ribbed V-belt tensioner in the direction of the arrow at the projection (1) and lock with KM-6349 (2).
* Remove the ribbed-V-belt.

13. Remove the exhaust manifold heat shield.
Remove the 3 bolts.




14. Remove the bracket for the catalytic converter (1) from the cylinder block.
Remove the 2 bolts (2, 3).




15. Remove the exhaust manifold.
Remove the 9 nuts (1).




16. Remove the compressor.
Remove the 3 bolts (1).




17. Remove the coolant pipe (1) between the thermostat housing and the oil filter housing.

* Remove the 2 bolts (2).
* Draw out of the oil filter housing.





18. Remove the coolant pipe (1) from the coolant pump.

* Remove the 2 bolts (2).
* Push the coolant pipe into the oil filter housing.





19. Remove the oil filter housing (3).

* Release the coolant pipe (1) and push into the oil filter housing.
* Remove the bolt (2).
* Remove the 4 bolts (4).





20. Remove the intake manifold support (2).

* Disconnect the wiring harness plug of the catalytic converter control oxygen sensor.
* Unclip the wiring harness plug (1) from the bracket.
* Remove the 2 bolts (3).





21. Disconnect the generator from the power supply.
Remove the 2 nuts (1, 2).
22. Remove the generator.
Remove the 2 bolts (3, 4).




23. Remove the negative cable (1) from the starter.
Remove the nut.
24. Remove the 2 positive cables (2) from the starter.
Remove the 2 nuts.




25. Remove the starter.

* Unclip the wiring harness plug for the oxygen sensor of the catalytic converter control from the bracket.
* Remove the 2 bolts (1, 2).





26. Attach OTC 1726 (1).
Tighten the 3 bolts (2)




27. Install OTC 1726 (1).
Tighten the 3 bolts.
28. Attach the engine up to the workshop crane.
Install the holding ropes to the engine transport shackles.




29. Remove the front engine damping block.
Remove the screwed connection (1).
30. Remove the rear engine damping block.
Remove the screwed connection (2).
31. Lift the motor away from the front frame.
32. Install the engine on the engine overhaul stand OTC 1726 .
Remove the holding ropes from the engine transport shackles.





Important: One bolt remains as a retaining device.


33. Remove the transmission (1) from the engine.
Remove 8 bolts.
34. Remove the transmission.

* Install the holding ropes.
* Attach the transmission up to the workshop crane.

Important: Ensure that the attached parts and the wiring harnesses are undamaged.


* Remove the bolt.




Installation Procedure

1. Install the transmission.

* Attach the transmission up to the workshop crane.
* Install the transmission to the engine.
* Install the bolt.
* Disconnect the workshop crane.
* Remove the holding ropes.


Notice: Refer to Fastener Notice (Fastener Notice) .

2. Install the transmission to the engine.

* Install the transmission to the cylinder block.

Tighten the 4 bolts to 60 N.m (44 lb ft).

* Install the transmission to the oil pan.

Tighten the 3 bolts to 40 N.m (30 lb ft).


3. Hitch the engine up to the workshop crane.
Install holding ropes to the engine transport shackles.
4. Remove the engine from the engine overhaul stand OTC 1726 .
Raise the engine carefully.
5. Install the rear engine damping block, front frame.

Tighten the screwed joint to 55 N.m (40 lb ft).
Use new nuts.
6. Install the front engine damping block to the front frame.

Tighten the screwed joint to 55 N.m (40 lb ft).
Use new nuts.
7. Remove OTC 1726 and OTC 1726 from the cylinder block.
Remove the 6 bolts.
8. Install the generator.

Tighten the 2 bolts to 35 N.m (26 lb ft).

9. Fit the starter.

Tighten the 2 bolts to 25 N.m (18 lb ft).
Clip in the wiring harness plug for the oxygen sensor of the catalytic converter control to bracket.
10. Install the starter wiring harness.

Tighten the 2 nuts to 12.5 N.m (110 lb in).


* Install the ground cable.

Tighten the nut to 5 N.m (44 lb in).

* Clip in 2x.

11. Connect the alternator wiring harness.

Tighten the 2 nuts to 7 N.m (67 lb in).

12. Install the intake manifold bracket.

Tighten the 2 bolts to 8 N.m (70 lb in).


* Connect the wiring harness plug into the bracket.
* Connect the wiring harness plug for the catalytic converter control oxygen sensor.

13. Clean the sealing surface.
14. Replace the 4 coolant pipe seal rings.

* Remove the 2 coolant pipes from the oil filter adapter.
* Install the 2 coolant pipes in the oil filter adapter.

15. Install the oil filter adapter.

Tighten the 4 bolts to 25 N.m (18 lb ft).


* Install 3 new gaskets.
* O-rings with white silicone grease

16. Install the coolant pipe to the coolant module.

* Draw the coolant pipe out of the oil filter adapter.
* Install the coolant pipe to the oil filter adapter.

Tighten the bolt to 25 N.m (18 lb ft).


17. Install the coolant pipe to the coolant module.
Draw the coolant pipe out of the oil pump housing.

Tighten the 2 bolts to 25 N.m(18 lb ft) .

18. Remove the coolant pipe, oil filter housing to the thermostat housing.

* Replace the 2 gaskets.
* Push into the oil filter housing.
* Connect to the thermostat housing.

Tighten the 2 bolts to 8 N.m (70 lb in).


19. Install the compressor.

Tighten the 3 bolts to 22 N.m (16 lb ft).

20. Clean the sealing surface.
21. Install the exhaust manifold with the catalytic converter.

* Use a new gasket.

Tighten the 9 new nuts to 20 N.m (15 lb ft).

* Install the bracket to the cylinder block.

Tighten the 2 bolts to 20 N.m (15 lb ft).


22. Install the heat shield.

Tighten the 3 bolts to 8 N.m (70 lb in).


Important: Be careful of the wiring harness bracket.


23. Install the wiring harness plug of the catalytic converter control oxygen sensor.

* Install the wiring harness plug.
* Clip in.

24. Install the dipstick guide tube.

* Use a new gasket.
* Insert the guide tube into the oil pan.

Tighten the bolt to 8 N.m (70 lb in).






25. Install the left-hand axle body.

* Attach the new circlip (1) to the axle body.
* Lubricate the teeth and the bearing points with engine oil.
* Push the axle body into the transmission until the circlip engages.

26. Install the right-hand axle body.

* Attach the new circlip to the front frame.
* Lubricate the teeth and the bearing points with engine oil.
* Push the axle body into the transmission until the circlip engages.

27. Place the cooling module in position.
28. Connect the 3 wiring harness plugs.

* Temperature sensor, radiator
* Compressor
* Manometric switch, condenser
* Install the wiring harness.

29. Install the refrigerant line to the compressor.
Use a new gasket.

Tighten the bolt to 20 N.m (15 lb ft).

30. Install the lower radiator hose to the radiator.

* Fasten the clamp.
* Clip into the bracket.

31. Install the upper radiator hose to the thermostat.
Fasten the clamp.
32. Install the coolant return hose, throttle valve pre-heating to coolant surge tank.

* Fasten the clamp.
* Clip into the bracket.

33. Inspect and correct the transmission fluid level. Refer to Front Wheel Drive Shaft Seal Replacement (Front Wheel Drive Shaft Seal Replacement) .