Contents: Removal ⤓ Installation ⤓
Removal
Before you begin removing parts, perform the following operations:
- a) (4WD models) Remove the transfer case (see section "Transfer case assembly").
- 6) Remove the lower protective cover of the power unit.
- c) Drain the working fluid from the variator (see chapter "Maintenance and general check and adjustment procedures").
- d) Drain the coolant (see chapter "Maintenance and general check and adjustment procedures").
- d) Remove the engine casing (see chapter "Engine - mechanical part").
- e) Remove the battery and battery bracket.
- g) Remove the exhaust system components (see chapter "Intake and exhaust systems").
− The parts are removed in the order of the numbers indicated in the figure "Removing the variator assembly".
Removal the variator assembly. 1 - CVT control electromagnetic valve connector, 2 - start inhibit switch connector, 3 - CVT working fluid pressure sensor connector, 4 - main line pressure sensor connector, 5 - drive pulley speed sensor connector, 6 - coupling connector, 7 - driven pulley speed sensor connector, 8 - deco nation sensor connector, 9 - coolant temperature sensor connector, 10 - working fluid temperature gauge connector, 11 - CVT control cable connection (from CVT side), 12 - starter, 13 - CVT bracket bolt, 14 - coolant hoses, 15 - CVT support, 16 - support stopper, 17 - support, 18 - drive shaft lock nut, 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 - retaining ring, 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 securing the variator to the cross beam should first be tightened only preliminarily, and the final tightening to the specified torque should be performed after the variator has been completely lowered onto the supports.
- - Items marked with "*" - only for models with 4G15 engine.
- - Items marked with "**" - only for models with 4G93 engine.
− To remove some elements or to disconnect them from other parts, use the relevant chapters:
- - starter - see chapter "Engine starting system";
- - drive shafts - see chapter "Drive shafts and axle shafts";
- - lower arm of the front suspension 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. Installing the variator assembly.
Move the torque converter fully toward the CVT so that the value "A" shown in the figure matches the nominal value, then install the CVT assembly onto the engine.
Size "A" - 12.2 mm
2. Variator support limiter.
Install the variator support limiter so that the arrow on the limiter is positioned as shown in the figure.
- After completing the installation of the parts, perform the following operations:
- a) Install the exhaust system components (see chapter "Intake and exhaust systems").
- b) Install the battery and battery bracket.
- c) Install the engine casing (see chapter "Engine - mechanical part").
- d) Fill with coolant (see chapter "Maintenance and general check and adjustment procedures").
- d) Fill the working fluid into the variator (see chapter "Maintenance and general check and adjustment procedures").
- e) Install the lower protective cover of the power unit.
- g) (4WD models) Install the transfer case (see section "Transfer case assembly").
- c) Perform the following checks and adjustments (see section "Checking the CVT control system"):
- - check and, if necessary, adjust the engine start prohibition 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 locking system;
- - if necessary, adjust the variator control cable.