REMOVAL AND INSTALLATION


caution
  • Do not disconnect the battery terminals or the clutch actuator connector for at least one minute after the ignition switch is turned "OFF". If the battery terminals or the clutch actuator connector is disconnected immediately after the ignition switch is turned "OFF", the clutch actuator push rod will be stuck before it is retracted fully. In that case, the clutch actuator will be damaged.
  • After the clutch actuator is removed, do not apply any load to the push rod (do not lift the push rod).
  • Do not disassemble the clutch actuator. If a fault occurs, entrust inspection and repair to the manufacturer (SACHS).
  • *: Indicates parts which should be temporarily tightened, and then fully tightened after installing the engine into the vehicle.
  • When replacing the clutch actuator, transmission assembly, clutch cover, clutch disk, perform the initialisation and learning with the M.U.T.-III special function.
Pre-removal and Post-installation Operation
  • Transmission Oil Draining and Supplying (Refer to ).
  • Front Bumper Assembly Removal and Installation (Refer to GROUP 51 ).
  • Headlamp Support Side <RH> Removal and Installation (Refer to GROUP 42, Loose Panel <COLT> or <COLT-CZ3>).
  • Washer Tank Removal and Installation (Refer to GROUP 51, Windshield Washer ).
  • Hood Removal and Installation (Refer to GROUP 42 ).
  • Air Cleaner assembly Removal and Installation (Refer to GROUP 15, Air Cleaner ).
  • Battery and Battery Tray Removal and Installation.
  • Engine-A-M/T-ECU Removal and Installation (Refer to GROUP 13B, Engine-ECU, ENGINE-A-M/T-ECU ).
  • Cowl Top Panel Removal and Installation (Refer to GROUP 42, Loose Panel <COLT> or <COLT-CZ3>).
  • Drive Shaft Removal and Installation (Refer to GROUP 26 ).




Removal steps
<<A>>
·
 Front bumper clip


1.
 Detonation sensor connector


2.
 Engine oil pressure switch connector


3.
 Electronic control throttle body assembly connector


4.
 Purge control solenoid valve connector


5.
 Engine coolant temperature sensor connector


6.
 Starter connector and terminal


7.
 Input speed sensor connector


8.
 Clutch actuator connector


9.
 Drum position sensor connector


10.
 Shift actuator connector


11.
 Starter

>>A<<
 12.
 Clutch actuator


13.
 Transmission assembly upper part mounting bolts




Removal steps


·
 Front exhaust pipe connection (Refer to GROUP 15 ).


14.
 Bell housing cover


15.
 Engine mounting stay


16.
 Engine roll stopper rod assembly
<<B>>
·
 Engine and transmission assembly supporting
<<B>>
17.
 Transmission mounting insulator
<<C>>
·
 Engine assembly supporting


18.
 Transmission assembly lower part mounting bolts


19.
 Transmission assembly

REMOVAL SERVICE POINTS

<<A>> FRONT BUMPER CLIP REMOVAL
For adoption of the under cover integrated with the front bumper assembly, remove the six front bumper clips, and lift the under cover part of front bumper assembly downward.

1.Remove the six front bumper clips shown in the figure.

2.Lift the under cover part of front bumper assembly downward.

<<B>> ENGINE AND TRANSMISSION ASSEMBLY SUPPORTING/TRANSMISSION MOUNTING INSULATOR REMOVAL

While supporting the engine and transmission assembly with a garage jack, remove the transmission mounting insulator.

<<C>> ENGINE ASSEMBLY SUPPORTING

caution Wrap a protective tape to avoid damage to the windshield.



1.<Engine hanger (special tool MB991895) is used>
(1) Remove the hook from the front side of engine hanger (special tool MB991895), and install engine hanger attachment (special tool MB991924) instead.
(2) Set the hook at the rear side of engine hanger (special tool MB991895) to the front strut mounting nut
(3) Set engine hanger attachment (special tool MB991924) to the front side member welded part.
(4) Attach the chain of engine hanger (special tool MB991895) to the engine assembly to support the engine and transmission assembly.



2.<Engine hanger (special tool MB991928) is used>
(1) Assemble the engine hanger (special tool MB991928). Set following parts to the base hanger.

  • Slide bracket (HI)
  • Engine hanger attachment (MB991925) <Front side>
  • Foot (short) (MB991933) <Rear side>
  • Joint (50) (MB991929) <Rear side>
(2) Set the foot (special tool MB991933) at the rear side of engine hanger (special tool MB991928) to the front strut mounting nut.
(3) Set engine hanger attachment (MB991925) to the front side member welded part.
(4) Attach the chain of engine hanger (special tool MB991928) to the engine assembly to support the engine and transmission assembly.

INSTALLATION SERVICE POINTS

>>A<< CLUTCH ACTUATOR INSTALLATION
caution Observe the specified installation procedure for the clutch actuator. If you fail to do so, the clutch actuator may be broken.
1.Tighten the clutch actuator mounting bolts temporarily at the point where the clutch actuator push rod contacts with the mechanical release unit.

2.Gently depress the clutch actuator further 4 mm to the arrow direction from the point where the push rod contacts with the mechanical release unit.
note The depression amount should be measured by using a scale.
3.Tighten the mounting bolts to the specified torque.
Tightening torque: 10 ± 1 N·m