Engines MR20DE and QP25DE
Removal and installation
Removal
Caution: Always replace the concentric slave cylinder (CSC) when removing a manual transmission from a vehicle. To remove the manual transmission, the CSC insert is returned to its original position. Dust in the sliding components of the clutch driven plate can damage the CSC seal and cause clutch fluid leakage.
1. Disconnect the cable from the negative battery terminal.
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 line from the concentric slave cylinder (CSC). See above.
Caution: Do not press the clutch pedal during removal.
7. Disconnect the connector from the park-neutral position (PNP) switch.
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 the 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 gearbox assembly and then the engine assembly with suitable jacks.
Caution: When installing a suitable jack, do not touch the switches.
23. Remove the gearbox assembly mounting bolts or nuts.
24. Unscrew the nut securing the through bolt of the engine mount (on engines MR20DE and QP25DE). See chapter "Mechanical part of the engine".
25. Remove the manual transmission assembly from the vehicle.
Attention:
- When removing the gearbox, secure it with a jack.
- The gearbox assembly must not touch the electrical wiring and 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 specified torque. The illustration shows the engine side view.
Engine MR20DE
Fastening the manual transmission to the engine.
Fastening the engine to the manual transmission.
| Bolt designation | A | IN |
| Quantity | 3 | 6 |
| Bolt length L, mm | 60 | 50 |
| Tightening torque Nm (kg-m) | 62, 0 (6,3) | |
Engine QR25DE
Fastening the manual transmission to the engine
Fastening 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 touch the electrical wiring and clutch tube.
- When installing the gearbox assembly, do not allow the drive shaft to touch the clutch housing.
- Concentric Slave Cylinder (CSC) installation operations. See above.
- Operations for connecting the gear shift cable and gear selector cable. See above.
- Bleed the air from the clutch hydraulic system. See above.
- After installation, check the oil level and check for leaks. See above.