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Transmission Replacement

Transmission Replacement



Special Tools

• CH-49290 Engine Fixing Tool

• DT-47648 Transmission Holder

• EN-904 Base Frame

• EN-47649 Engine Bridge

• EN 47650 Retainer Plate


For equivalent regional tools, refer to Special Tools .

Removal Procedure


1. Remove the battery tray. Refer to Battery Tray Replacement (Diesel) Battery Tray Replacement (LHU/A20NFT) .

2. Release the intermediate steering shaft. Refer to Intermediate Steering Shaft Replacement .

3. Detach the clutch actuator cylinder rear pipe.


• Open the clamp (1).

• Pull out the clutch pipe (2) and close the clutch pipe with a cap.

4. Disconnect the electrical connector (1) from the backup lamp switch (2).


5. Release the 3 engine wiring harness brackets (1) from the transmission.

Remove the 3 fasteners (2).


6. Secure the engine wiring harness with cable ties.


7.
Note

For this remove use 3/8 " tool.


Remove both upper transmission fasteners(1) with a 3/8" tool (2).


8. Raise the vehicle by its half height. Refer to Lifting and Jacking the Vehicle .

9. Remove both front wheels. Refer to Tire and Wheel Removal and Installation .

10. Remove the left front wheel house front liner. Refer to Front Wheelhouse Front Liner Replacement .

11. Release both lower control arms. Refer to Lower Control Arm Replacement (GNA) Lower Control Arm Replacement (GNB) .

12. Release both front stabilizer shaft links. Refer to Stabilizer Shaft Link Replacement (GNA) Stabilizer Shaft Link Replacement (GNB) .

13. Release both steering linkage outer tie rods. Refer to Steering Linkage Outer Tie Rod Replacement .

14. Raise the vehicle by its full height.

15. Remove exhaust front pipe. Refer to Exhaust Front Pipe Replacement (LBY/A20DTR) Exhaust Front Pipe Replacement (LLU/A16LET) Exhaust Front Pipe Replacement (LBS/A20DTH) Exhaust Front Pipe Replacement (LHU/A20NFT, LAU/A28NER) .

16. Remove the catalytic converter. Refer to Catalytic Converter Replacement (LAU/A28NER) Catalytic Converter Replacement (LBY/A20DTR) Catalytic Converter Replacement (LLU/A16LET) Catalytic Converter Replacement (LBS/A20DTH) Catalytic Converter Replacement (LHU/A20NFT) Catalytic Converter Replacement (LHU/A20NFT - AWD) .

17. Lower the vehicle by its half height.

18. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement .

19. Disconnect the injector electrical connector.


20. Remove the turbocharger wastegate actuator vacuum control solenoid valve bracket fasteners (1) and disconnect the vacuum pipe (2).


21. Secure the turbocharger wastegate actuator vacuum control solenoid valve.

22. Secure the radiator module.


23. Fit the holder frame EN-47650 and the engine bridge EN-47649 . Refer to Engine support fixture (retainer frame for bridge LLU/A16LET) Engine support fixture (retainer frame for engine bridge LLU/A16) .

24. Install the left chain (1) of the engine bridge to the rear engine support fixture (2).


25. Install the right chain (1) of the engine bridge to the small engine support fixture (2).


26. Fit the engine mounting tool CH-49290 . Refer to Engine Support Fixture (Bridge Retainer Frame LLU/A16LET) Engine Support Fixture (Engine Bridge, Retainer Frame-LLU/A16) .

27. Remove the drivetrain and front suspension frame. Refer to Drivetrain and Front Suspension Frame Front Crossmember Replacement (GNA) Drivetrain and Front Suspension Frame Front Crossmember Replacement (GNB) .

28. Remove both wheel drive shafts from the transmission. Refer to Front Wheel Drive Shaft Replacement - Left Side (GNA) Front Wheel Drive Shaft Replacement - Left Side (GNB) and Front Wheel Drive Shaft Replacement - Right Side (GNB) Front Wheel Drive Shaft Replacement - Right Side (Petrol) .

29. Release the starter. Refer to Starter Replacement (2.0L Diesel) Starter Replacement (LAU/A28NER) Starter Replacement (LDE/A16XER, LLU/A16LET, 2H0/A18XER) Starter Replacement (LHU/A20NFT) .

30. Lower the powertrain unit.

31. Install the DT-47648 transmission holder on the EN-904 base frame.

• Install DT-47648-2 transmission holder to position 5.

• Install DT-47648-4 transmission holder to position 13.

• Install DT-47648-5 transmission holder to position E and to position B

32. Install the hydraulic jack with DT-47648 transmission holder to the transmission.

33. Remove both transmission fasteners (1) from the oil pan.


34. Remove both transmission fasteners (1) from the engine block.


35. Lower the transmission carefully and remove the transmission.


Installation Procedure


1. Lift the transmission carefully and install to the engine.

2. Install both transmission fasteners (1) to the engine block.


3. Install the transmission fastener (1) to the oil pan.


4. Remove the DT-47648 transmission holder with hydraulic jack from the transmission.

5. Lift up the powertrain unit.

6. Install the starter. Refer to Starter Replacement (2.0L Diesel) Starter Replacement (LAU/A28NER) Starter Replacement (LDE/A16XER, LLU/A16LET, 2H0/A18XER) Starter Replacement (LHU/A20NFT) .

7. Install both front wheel drive shafts. Refer to Front Wheel Drive Shaft Replacement - Left Side (GNA) Front Wheel Drive Shaft Replacement - Left Side (GNB) and Front Wheel Drive Shaft Replacement - Right Side (GNB) Front Wheel Drive Shaft Replacement - Right Side (Petrol) .

8. Install the drivetrain and front suspension frame. Refer to Drivetrain and Front Suspension Frame Front Crossmember Replacement (GNA) Drivetrain and Front Suspension Frame Front Crossmember Replacement (GNB) .

9. Remove the engine mounting tool CH-49290 . Refer to Engine Support Fixture (Bridge Retainer Frame LLU/A16LET) Engine Support Fixture (Engine Bridge, Retainer Frame-LLU/A16) .

10.
Note

For this installation use the 3/8" tool.


Install the both transmission upper fasteners (1).


11. Remove the holder frame EN-47650 and the engine bridge EN-47649 . Refer to Engine support fixture (retainer frame for bridge LLU/A16LET) Engine support fixture (retainer frame for engine bridge LLU/A16) .

12. Solve the radiator module.

13. Solve the turbocharger wastegate actuator vacuum control solenoid valve.

14. Install the turbocharger wastegate actuator vacuum control solenoid valve bracket fastener (1) and connect the vacuum pipe (2).


15. Connect the injector electrical connector.


16. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement .

17. Refer to Fastener Caution .

Note

For this tighten use 3/8" tool.


Tighten the transmission fasteners in sequence as shown.


• Tighten the fastener from the transmission to the engine block to 60 Nm (44 lb ft) .

• Tighten the fastener from the transmission to the oil sump to 40 Nm (30 lb ft) .

18. Install the catalytic converter. Refer to Catalytic Converter Replacement (LAU/A28NER) Catalytic Converter Replacement (LBY/A20DTR) Catalytic Converter Replacement (LLU/A16LET) Catalytic Converter Replacement (LBS/A20DTH) Catalytic Converter Replacement (LHU/A20NFT) Catalytic Converter Replacement (LHU/A20NFT - AWD) .

19. Install the exhaust front pipe. Refer to Exhaust Front Pipe Replacement (LBY/A20DTR) Exhaust Front Pipe Replacement (LLU/A16LET) Exhaust Front Pipe Replacement (LBS/A20DTH) Exhaust Front Pipe Replacement (LHU/A20NFT, LAU/A28NER) .

20. Install both steering linkage outer tie rods. Refer to Steering Linkage Outer Tie Rod Replacement .

21. Install both front stabilizer shaft links. Refer to Stabilizer Shaft Link Replacement (GNA) Stabilizer Shaft Link Replacement (GNB) .

22. Install both lower control arms. Refer to Lower Control Arm Replacement (GNA) Lower Control Arm Replacement (GNB) .

23. Install the left front wheel house front liner. Refer to Front Wheelhouse Front Liner Replacement .

24. Install both front wheels. Refer to Tire and Wheel Removal and Installation .

25. Solve the engine wiring harness.

26. Install the engine wiring harness bracket (1) to the transmission.

Install the 3 fasteners (2).


27. Connect the backup lamp switch connector (1) to the backup lamp switch (2).


28. Attach the clutch actuator cylinder rear pipe.


• Insert the clutch pipe (1)

• Close the clamp (2)

29. Install the battery tray. Refer to Battery Tray Replacement (Diesel) Battery Tray Replacement (LHU/A20NFT) .

30. Install the intermediate steering shaft. Refer to Intermediate Steering Shaft Replacement .