Engines MR20DE and QP25DE
Removal and installation
Removal
Attention. When removing a manual transmission from a vehicle, always replace the concentric slave cylinder (CSC). To remove the manual transmission, the CSC insert is moved to its original position. Dust in the sliding components of the clutch plate can damage the CSC seal and cause clutch fluid to leak.
1. Disconnect the cable from the negative terminal of the battery.
2. Disconnect the breather hose. See above.
3. Remove the air cleaner housing and air duct (inlet). See chapter «Mechanical part of the engine».
4. Remove the battery.
5. Disconnect the connectors (A) and then remove the bracket (1).
6. Drain the clutch fluid and disconnect the clutch tube from the concentric slave cylinder (CSC). See above.
Attention. Do not press the clutch pedal during removal.
7. Disconnect the connector from the position switch «parking-neutral» (PNP).
8. Disconnect the connector from the reverse light switch.
9. Disconnect the connector from the 1st gear position switch (with HDC).
10. Disconnect the ground cable.
11. Remove the electrical wiring from the gearbox.
12. Disconnect the gear selector cable and shift cable from the transmission assembly. See above.
13. Remove the starter. See chapter «Electrical equipment».
14. Remove the engine protection from the bottom.
15. Drain the transmission oil. See above.
16. Disconnect the front exhaust pipe. See chapter «Accelerator, fuel system and exhaust system».
17. Remove the driveshaft (on 4WD models). See chapter «Power transmission».
18. Remove the front drive shafts. See chapter «Front axle and suspension».
Note. After removing the front drive shafts, install suitable plugs into the differential seals.
19. Remove the driveshaft (on 4WD models). See chapter «Power transmission».
20. Remove the rear engine mount brackets and rear torque rod. See chapter «Mechanical part of the engine».
21. Remove the suspension beam and suspension beam strut. See chapter «Front axle and suspension».
22. Support the transmission assembly and then the engine assembly with suitable jacks.
Attention. When installing a suitable jack, do not touch the switches.
23. Unscrew the transmission assembly mounting bolts or nuts.
24. Unscrew the nut securing the through bolt of the engine mount (on MR20DE and QP25DE engines). See chapter «Mechanical part of the engine».
25. Remove the manual transmission assembly from the vehicle.
Attention:
- When removing the gearbox, secure it to a jack.
- The gearbox assembly must not interfere with the electrical wiring or clutch tube.
26. Remove the concentric slave cylinder (CSC). See above.
Installation
Installation is carried out in the reverse order of removal, taking into account the following:
- Tighten the transmission assembly mounting bolts to the required torque. The figure shows a view from the engine side.
Engine MR20DE
Attaching the manual transmission to the engine.
Mounting the engine to the manual gearbox.
Bolt designation | A | IN |
Quantity | 3 | 6 |
Bolt length L, mm | 60 | 50 |
Tightening torque Nm (kg-m) | 62, 0 (6,3) |
Engine QR25DE
Attaching the manual transmission to the engine
Mounting the engine to the manual transmission
Bolt designation | A | IN | WITH | D | E | F |
Quantity | 1 | 3 | 1 | 2 | 2 | 1 |
Bolt length L, mm | 45 | 80 | 45 | 36 | 45 | |
Tightening torque, Nm (kg-m) | 35,3 (3 6) | 74,5 (7,6) | 42 6 (4,3) | 48 (49) |
Attention:
- The gearbox assembly must not interfere with the electrical wiring or clutch tube.
- When installing the transmission assembly, engage the drive shaft against the clutch housing.
- Concentric Slave Cylinder Installation Operations (CSC). See above.
- Operations for connecting the gear shift cable and gear selection cable. See above.
- Bleed the air from the clutch hydraulic drive. See above.
- After installation, check the oil level for leaks. See above.