Removing
Before you start removing parts, do the following:
- A) (4WD Models) Remove transfer case (see section "Transfer box assy").
- 6) Remove the bottom protective casing of the power unit.
- V) Drain the working fluid from the variator (see chapter "Maintenance and general inspection and adjustment procedures").
- G) Drain the coolant (see chapter "Maintenance and general inspection and adjustment procedures").
- d) Remove the engine cover (see chapter "Engine - mechanical part").
- e) Remove the battery and battery bracket.
- and) Remove elements of system of release of the fulfilled gases (see chapter "Intake and exhaust systems").
- Parts are removed in the order of the numbers shown in the figure "Removing the variator assembly".
Removing the variator assembly. 1 - connector for variator control solenoid valves, 2 - connector for start inhibit switch, 3 - connector for variator working fluid pressure sensor, 4 - connector for main line pressure sensor, 5 - connector for drive pulley speed sensor, 6 - connector, 7 - connector driven pulley speed sensor, 8 - nationality sensor connector, 9 - coolant temperature sensor connector, 10 - working fluid temperature indicator connector, 11 - CVT control cable connection (from the side of the variator), 12 - starter, 13 - CVT bracket bolt, 14 - coolant hoses, 15 - CVT support, 16 - support stop, 17 - support, 18 - driveshaft locknut, 19 - wheel speed sensor, 20 - brake hose retainer, 21 - stabilizer mounting nut, 22 - anti-roll bar, 23 - ball joint of the lower arm of the front suspension, 24 - tie rod end, 25 - left drive shaft, 26 - circlip, 27 - right drive shaft, 28 - cross beam bolt, 29 - cross beam, 30 - variator support, 31 - torque converter cover, 32 - torque converter drive plate, 33 - mounting bolt, 34 - variator assembly.
Note:
- - The nut fastening the variator to the cross beam should first be tightened only preliminary, and the final tightening to the specified torque should be made after the variator is completely lowered onto the supports.
- - Items marked "*" - only for models with 4G15 engine.
- - Items marked "**" - only for models with 4G93 engine.
− To remove some elements or separate them from other parts, refer to the relevant chapters:
- - starter - see chapter "Engine start system";
- − drive shafts - see chapter "Drive shafts and axle shafts";
- − front suspension lower arm and anti-roll bar - see chapter "Suspension";
- − wheel speed sensor - see chapter "Brake system".
Installation
− Installation of parts is carried out in the reverse order of removal.
− When installing parts, pay attention to the following operations:
1. Installation of the variator assembly.
Fully move the torque converter towards the variator so that the value "A", shown in the figure corresponds to the rated value, then install the variator assembly on the engine.
Value "A" - 12.2 mm
2. CVT support limiter.
Install the variator support limiter so that the arrow on the limiter is located as shown in the figure.
− After completing the installation of the parts, perform the following operations:
- A) Establish elements of system of release of the fulfilled gases (see chapter "Intake and exhaust systems").
- b) Install the battery and battery bracket.
- V) Install the engine cover (see chapter "Engine - mechanical part").
- G) Fill with coolant (see chapter "Maintenance and general inspection and adjustment procedures").
- d) Pour working fluid into the variator (see chapter "Maintenance and general inspection and adjustment procedures").
- e) Install the lower protective casing of the power unit.
- and) (4WD Models) Install transfer case (see section "Transfer box assy").
- h) Perform the following checks and adjustments (see section "Checking the CVT control system"):
- - check and, if necessary, adjust the engine start inhibit switch and the variator control cable;
- - check the operation of the variator selector;
- - check and, if necessary, adjust the ignition lock mechanism;
- - check and, if necessary, adjust the variator selector blocking system;
- - if necessary, adjust the variator control cable.