Service Workbook Powertrain
2012Year
Your name Au th or ized repai r c ent er Tel. and fax of th e authorized repair center Model year and model VIN Description of your concern(s) Necessary relevant in form ation (e.g. sample or marked page) An y appl ic abl e electr on ic in fo rmat io n part id ent if icati on nu mber
Submitting you r concern t o relevant service engineer Consulting relevant service engineer Satisfying yo ur concern within 10 working days.
General Information ........................................................................................ 1-1 Introduction .......................................................................................................................... 1-1 General Precautions ............................................................................................................ 1-2
Manual transmission ....................................................................................... 2-1 Technical data...................................................................................................................... 2-1 Parameters ................................................................ ................................................................................. ....... 2-1 End play ..................................................................... ........................................................................................ 2-1 Torque............................................... ................................................................................................ ................. 2-2
Layout .................................................................................................................................. 2-3 Layout of transmission ......................................................... .............................................................................. 2-3 Exploded diagram of transmission housing ..................................................... ................................................. 2-4 Exploded diagram of transmission control mechanism........................................... .......................................... 2-5 Exploded diagram of gear transmission mechanism .............................................................................. .......... 2-7 Disassembly / assembly of differential assembly........................................ ....................................................... 2-9 Layout of transmission accessories ..................................................... ............................................................ 2-10 Layout of transmission lever and cable....................................... ............................................................. ........ 2-11
Fault diagnosis information and procedure ........................................................................ 2-12 SPECIAL TOOLS............................................................................................................... 2-14 Repair instructions ............................................................................................................. 2-15 Replacement of manual transmission assembly...................................... ........................................................ 2-15 Disassembly of manual transmission assembly ................................................................... ........................... 2-19 Disassembly of differential assembly............................................................. .................................................. 2-51 Disassembly of differential assembly............................................................. .................................................. 2-51 Replace, check and adjust gear lever cable ........................................................ ............................................ 2-52 Replace shift mechanism knob ............................................................ ............................................................ 2-53
CLUTCH.......................................................................................................... 3-1 Technical Data ..................................................................................................................... 3-1 Parameters ................................................................ ................................................................................. ....... 3-1 Torque............................................... ................................................................................................ ................. 3-1
Layout .................................................................................................................................. 3-2 Layout of clutch system .............................................................. ....................................................................... 3-2
Diagnosis information and procedure .................................................................................. 3-3 SPECIAL TOOLS................................................................................................................. 3-5 Repair instructions ............................................................................................................... 3-6 Replace driven plate and disc.............................................................. .............................................................. 3-6
Replace master cylinder......................... ....................................................................... ..................................... 3-7 Replace slave cylinder .............................................................. ......................................................................... 3-9 Hydraulic clutch air expelling............... ................................................................ ............................................. 3-10
Drive Shaft .................................................................................................... 4-11 Technical data..................................................................................................................... 4-11 Parameters...................................... .................................................................... ............................................. 4-11 Torque ........................................................................... ................................................................................... 4-11
Layout ................................................................................................................................. 4-12 Layout of drive shaft ............................................................... .......................................................................... 4-12
Fault diagnosis information and procedure ........................................................................ 4-13 SPECIAL TOOLS................................................................................................................ 4-13 Repair instructions .............................................................................................................. 4-14 Replace left drive shaft.................................................................................. ................................................... 4-14 Replace right drive shaft......................................................... .......................................................................... 4-17 Replace CV joint gaiter............................................................................................................................ ......... 4-19 Replace CV joint.................................................................. ............................................................................. 4-20 Replace tripod universal joint / gaiter .................................................. ............................................................. 4-21 Replace drive shaft oil seal ........................................................... ................................................................... 4-22
1-1
1-2
Manual transmission Technical data Parameters Model
Driving mode of transmission
Manufacturer
WIA
Driving mode of transmission
Transversal arrangement and front wheel drive
Gear ratios - 1st - 2nd - 3rd - 4th - 5th - Reverse - Final drive
3.769 2.105 1.300 0.941 0.750 3.167 4.188
Oil capacity
2.30L
End play Items
Standard Value(mm)
1st gear end play
0.07-0.29 毫米 （Loosen）
2st gear end play
0.06-0.21 毫米 （Loosen）
3st gear end play
0.06-0.21 毫米 （Loosen）
4st gear end play
0.135-0.335 毫米 （Loosen）
REV gear end play
0.07-0.25 毫米 （Loosen）
Input shaft rear bearing end play
0.00-0.10 毫米 （Loosen）
Output shaft rear bearing end play Diferential side bearing end play
0.03-0.10
毫米 （Loosen）
0.05-0.10
毫米 （Tighten）
2-1
Manual transmission Torque Appl icati on
Torque v alu e (Nm)
Engine assembly to transmission bolt
47 ~ 53
Transmission to engine assembly bolt
47 ~ 53
Transmission to block bolt
89 ~ 98
Vehicle speed sensor screw
7 ~ 9
Clutch release guide sleeve bolt
6 ~ 8
Output shaft bearing cap screw
45 ~ 55
Selector lever unit bolt
19 ~ 26
Drain plug
40 ~ 60
Filler plug
65
Transmission housing and clutch housing bolts Reverse idler gear shaft bolt
44 ~ 55 6 ~ 8
Reverse idler bolt
45 ~ 55
Transmission housing rear cover bolt
20 ~ 25
Reverse lever assembly bolt
8 ~ 11
Differential sealing bolt
130 ~ 140
5 gear/Reverse interlock device bolt
8 ~ 11
Locking spring locknut
15 ~ 21
Output shaft locknut
150 ~ 220
Reverse lever supporting spring bolt
8 ~ 11
Balancing block bolt
23 ~ 29
Transmission cable mounting bolt
13 ~ 17
Transmission lever to instrument desk framework bolt
16 ~ 18
Transmission shift lever fitting reinforced plate nut
18 ~ 22
Transmission suspension nut
2-2
95 ~ 105
Manual transmission Layout Layout of transmission
CS120001
2-3
Manual transmission Exploded diagram of transmission housing
6 24 7 7
13 8
12 27 6
4 5 26
1
10 9
6 14
3 21
11
15 16 18
19
17 22 2
20
23 2
25 E121C-001
1
Transmission assembly
15 Reverse cone stop pin support bolt
2
Transmission housing to clutch housing bolts
16 Bush
3
Wiring harness carrier
17 Drain plug
4
Ventilation plug assembly
18 Gasket
5
Oil feed gutter
19 Pin
6
Flanged bolt
20 Transmission housing rear cover bolt
7
Needle roller bearing
21 Rear cover assembly
8
Clutch release guide sleeve
22 Filler plug
9
Oil feed gutter
23 Gasket
10 Bush
24 Spring clip
11 Reverse cone stop pin support
25 Reverse light switch assembly
12 Clutch housing
26 Transmission housing to clutch housing bolt
13 Clutch release guide sleeve bolt
27 Plug
14 Magnet
2-4
Manual transmission Exploded diagram of transmission control mechanism
4
2
1
9
10
3 5 6 8 7 11 13
12
15 17
16
21 20 22
1 14
19 18
18
18
23 19
27 26
25
21 20 22
29
21 20 22
24
28 32
30
31
CE121E-001
1
Flanged bolt
10 Spring pin
2
5th/Reverse interlock device
11 Return spring
3
Oil seal
12 Selector lever unit
4
Shift lever unit
13 Reamed bolt
5
Spring seat
14 Selector lever unit bolt
6
Interlock plate
15 Reverse lever supporting spring
7
Shift finger
16 Reverse lever assembly
8
Bolt
17 Reverse lever supporting spring bolt
9
Spring pin
18 Spring pin
2-5
Manual transmission 19 Spring pin
26 Pin
20 Locking spring
27 3rd/4th shift guide block
21 Setting screw
28 3rd/4th shift fork
22 Steel ball
29 3rd/4th shift transverse lever
23 1st/2nd shift guide block
30 5th/Reverse shift guide block
24 1st/2nd shift fork
31 5th/Reverse shift fork
25 1st/2nd shift transverse lever
32 5th/Reverse shift transverse lever
2-6
Manual transmission Exploded diagram of gear transmission mechanism
2 45
4
1
5 14 13 12
3 10
11
9 8
7
22
6
23
21 32
11
20 19
15
16
25
24
17
31
18 46 29
30
38
28
39
26 26
27
37 36 34
35
44
33 41
42
43
40
CE121D-001
1
Reverse idler gear shaft
8
Retaining ring
2
Reverse idler gear
9
4th synchromesh ring
3
Input shaft
10 3rd/4th synchro unit
4
Ball bearing
11 Synchromesh guide block
5
Oil seal
12 Needle roller bearing
6
Needle roller bearing
13 3rd synchromesh ring
7
4th gear assembly
14 3rd gear assembly
2-7
Manual transmission 15 Retaining ring
31 Output shaft
16 Adjusting shim
32 Sealing cap
17 Ball bearing
33 4th output gear
18 Reverse cone shaft sleeve
34 3rd output gear
19 Clutch reverse cone stop pin
35 2nd gear shaft sleeve
20 Reverse synchromesh ring
36 Needle roller bearing
21 5th/Reverse synchro unit
37 2nd gear assembly
22 5th synchromesh ring
38
23 Needle roller bearing
39 Synchromesh guide block
24 5th gear assembly
40 Output shaft locknut
25 5th gear shaft sleeve
41 Tapered roller bearing
26 Twin cone synchromesh ring
42 Adjusting shim
27 Needle roller bearing
43 Spacer
28 1st gear assembly
44 5th output gear
29 Bearing cap
45 Reverse idler gear shaft bolt
30 Tapered roller bearing
46 Bearing cap screw
2-8
1st/2nd synchro unit
Manual transmission Disassembly / assembly of differential assembly
2
1 4
6 5
14
13
8
4 3 2 7 11
9 10
7 12 10 9
11
7
7
CE121F-001
1
Differential assembly
8
Differential assembly
2
Oil seal
9
Oil seal
3
Adjusting shim
10 Adjusting shim
4
Tapered roller bearing
11 Tapered roller bearing
5
Differential driven gear
12 Differential driven gear
6
Differential sealing bolt
13 Differential sealing bolt
7
Gasket
14 Gasket
2-9
Manual transmission Layout of transmission accessories
5 4 6 3
7
8
2 9 1 CE121B-001
1
Clutch release fork assembly
6
Transmission to block bolt
2
Clutch release fork to transmission stud
7
Clutch release fork cover
3
Balancing block nut
8
Transmission to engine assembly bolt
4
Balancing block
9
Engine assembly to transmission bolt
5
Balancing block to transmission bolt
2-10
Manual transmission Layout of transmission lever and cable
1
2 3
5 6
8
9
4 7
11 10
13
8
12
9
CE152A-001
1
Shift mechanism handle assembly
7
E ring
2
Shift handle leather sheath
8
Lock pin
3
Leather sheath retaining ring
9
Gasket
4
Manual transmission lever assembly
10 Selection cable assembly
5
Manual transmission lever to instrument desk framework bolt
11 Shift cable assembly
6
Transmission shift lever fitting reinforced plate nut
12 Cable mounting assembly 13 Cable mounting assembly to transmission bolt
2-11
Manual transmission Fault di agnosis infor mation and procedure Fault Gear lever cannot shift gears flexibly or is difficult to shift gears
Possible cause
Solution
Gear lever ball cup seized
Replace
Control rod joint seized
Replace
Control rod bent
Replace
Excessive gear lever clearance
Gear lever ball bush worn
Replace
Needle roller bearing of control shaft worn
Replace
Difficult to shift gears
No grease in gear lever
Replace
Inadequate lubrication
Apply lubricant
Lubricant unqualified
Replace with qualified lubricant
Shift fork or shift fork rail worn or excessive clearance
Replace
Synchromesh gear ring worn
Replace
Inner ring of synchromesh gear worn
Replace
Excessive gear side clearance
Replace
Bearing worn
Replace
Synchromesh strut spring worn
Replace
Fail to mesh with gears
2-12
Excessive main shaft bearing pretightening force
Adjust
Poor contact between synchromesh gear ring and inner gear ring
Replace
Control rod bush worn
Replace
Poor gear lever ball spring
Replace
Improperly fitted extension rod
Tighten
Shift fork worn
Replace
Clutch hub worn
Replace
Clutch hub socket worn
Replace
Shaft gear sliding surface worn
Replace
Gear sliding surface worn
Replace
Gear lever end gate worn
Replace
Poor setting spring
Replace
Excessive thrust clearance
Replace
Bearing worn
Replace
Engine carrier improperly fitted or loose
Tighten
Manual transmission Abnormal sound
Inadequate lubrication
Apply lubricant
Lubricant unqualified
Replace with qualified lubricant
Bearing worn
Replace
Synchromesh gear ring worn
Replace
Gear sliding surface or shaft worn
Replace
Excessive gear lateral clearance
Replace
Gear damaged
Replace
Foreign objects in gear
Replace
Differential gear damaged or excessive lateral clearance
Replace
2-13
Manual transmission SPECIAL TOOLS Maintenance special tooling table (same tooling number on each tool) Name
Name
Illustration
Illustration
Housing separator Ball joint separator
C00017044
C00017036
Universal driven handle Universal puller
C00017045
C00017040
Gear lever mounting pin Input shaft retainer
C00017046
C00017041
Engine supporting carrier Thrust journal
C00017050
C00017042
Power set installation tool Bearing installer
C00017051
C00017043
2-14
Manual transmission Repa Repair ir i nstruct ions Replaceme Replacement nt of manual transmissi on
assembly Tools r equired
C00017051,C00017050
Removal
1 2
Remo Remove ve tri trim m cov cover er of fro front nt lef leftt whe wheel el and and transmission shaft nuts, and slacken front left wheel bolts.
3
Separ eparat ate e air air int intake ake pip pipe. e.
4
Sepa Separat rate e gear gear lev lever er cab cable le at at tran transm smis issi sion on end end..
5
Slac Slacke ken n 6 bol bolts ts fitt fitted ed in lef leftt pow power er tra train in (arrowed).
6
Slac Slacke ken n all all remo remova vabl ble e hous housin ing g bolt bolts s from from abov above. e.
7
Remo Remove ve fro front nt lef leftt whe wheel el afte afterr the the veh vehic icle le supported by lifting jack.
Disconnect batt attery.
CS123094 8
Separat Separate e clutc clutch h slav slave e cyli cylinde nderr. Make Make hard pipe pipe upward to prevent brake fluid leakage when removing.
9
Drai Drain n bra brake ke flui fluid d to to pro prope perr con conta tain iner er..
CS123086
10
Remove Remove left left drive drive shaf shaftt and pull pull right right drive drive shaft shaft out of transmission (see "Replace drive shaft").
11 Remove Remove starte starterr motor motor (see (see "Repla "Replace ce start starter er motor").
2-15
Manual transmission 12 Discon Disconnec nectt rever reverse se ligh lightt harne harness ss ① and remove cable from housing harness buckle.
1
CS123087 13 Separa Separate te engine engine rear rear carr carrier ier..
CS123088
14 Remove Remove 2 bolts bolts of of clutch clutch housi housing ng and and fit engin engine e bracket C00017050 and preset screw length of 90 - 100 mm. 15 Suppor Supportt transmi transmissi ssion on with with proper proper bracke bracket. t.
CS123089
2-16
Manual transmission 16 Remove Remove bolt bolt arrow arrowed ed and and remove remove left left powe powerr train mounting.
CS123090
17 Pull engine / transmis transmission sion toward the front front part part of of vehicle until the rear part of engine aligns and contacts with screw on tool C00017050 bracket.
C00017050
CS123091
18
Remove Remove remain remaining ing bolts bolts and lower lower transm transmiss ission ion to detach it. (Engine left side shall be supported by tool C00017050).
CAUTION: If refit the original transmission, oil seal of transmissio n shaft shall be replaced.
2-17
Manual transmission Fitting
1
Fitt Fittin ing g is rev rever erse se of of remo removal val proce procedu dure re,, but but the the following must be noted: — Slightly lubricate input shaft spline.
— Don't "hang" transmission on input shaft before fitting fitting bolts. — When fitting left support of power train, tool C00017051 must be used to check equal 5 mm clearance of support on both sides (as shown in the figure)
CS123087
5MM
5MM
CS123092
through filler plug hole — Fill 2.30 litres specified oil through after fitting transmission shaft. Remove oil level plug and allow excess oil to run out. Refit plug.
— Check all shifts right after connecting gear change cable. If necessary, adjust cable (see "Replace, check and adjust gear lever cable mechanism").
— As a self-locking nut, transmission suspension nut shall be used only once at most so as to provide strong fastening performance.
2-18
Manual transmission Disassembly of manual transmission assembly
C00017041,C00017042,C00017043, C00017044,C00017046 Removal
Tools required
2
1
Remove 7 securing screws.
Carefully tap rear cover to open it with straight screwdriver and hammer.
CS123000
3
Engage the gear with shift lever.
CS123001
4
Secure input shaft with C00017041.
C00017041
CS123002
2-19
Manual transmission 5
Remove output shaft locknut.
CS123003
6
Remove setting screw ①, locking spring ②, steel ball ③ and reverse light switch ④ .
2 1
4
CS123004
7
Remove reverse idler gear shaft screw.
CS123005
2-20
3
Manual transmission 8
Remove 17 transmission housing screws.
CS123006
9
Remove transmission housing with C00017044.
C00017044
CS123007
10 Remove magnet ① , output shaft adjusting shim ② , output shaft spacer ③ and output shaft adjusting shim ④ .
2
4
3
1
CS123008
2-21
Manual transmission 11 Remove reverse idler gear ① and gear shaft ② .
2
1
CS123009
12 Remove reverse lever ① and reverse lever supporting spring ② . 1
CS123010
13 Remove 5th / reverse fork, 5th / reverse shift transverse lever and shift guide block.
CS123011
2-22
2
Manual transmission 14
Remove 3rd /4th shift transverse lever, 3rd /4th and 5th / reverse shift fork, 3rd /4th shift guide block.
CS123012
15
Reverse 1st /2nd shift transverse lever, 1st / 2nd shift fork and 1st /2nd shift guide block.
CS123013
16 Check gear clearance and compare obtained clearance with the information provided in "Technical Data". If outside tolerance, adjust again.
CS123014
2-23
Manual transmission 17 Remove steel cable retaining ring of input shaft.
CS123015
18 Remove input shaft bearing ① and 5th gear assembly ② with gear puller C00017040 at the same time.
1
2
CS123016
19 Remove 5th gear shaft sleeve.
CS123017
2-24
Manual transmission 20 Remove output shaft 4th / 5th gear with gear puller C00017040.
CS123018
21 Remove 5th gear shaft sleeve, 4th gear, 4th gear bearing and 4th synchromesh ring with gear puller C00017040.
CS123020 22 Remove 3rd / 4th steel cable retaining ring of synchro unit.
CS123021
2-25
Manual transmission 23 Remove 3rd /4th gear synchro unit, 3rd synchromesh ring and 3rd gear with gear puller C00017040 and take out 3rd needle roller bearing.
CS123022
24 Remove output shaft 2nd / 3rd gear with gear puller C00017040.
CS123023
25 Remove output shaft needle roller bearing and 2nd gear shaft sleeve.
CS123024
2-26
Manual transmission 26 Remove twin cone synchro ring on output shaft.
CS123025
27 Lift 1st /2nd synchro unit, 1st synchro, 1st gear, needle roller bearing from output shaft and remove input shaft ① at the same time.(arrowed). 1
CS123026
28 Remove output shaft bearing cap screws with hex wrench to remove bearing cap. CAUTION:Engage removal tool with screw slot securely with hammer or similar tools and then remove bearing cap.
CS123027
2-27
Manual transmission 29 Remove output shaft. CAUTION:Fit transmission housing temporarily with stop shim and tighten output shaft locknut, and then pry output shaft assembly out with proper tools as shown in the figure. Remove transmission housing.
CS123028
30 Remove differential after removing odometer transmission gear. CAUTION:Position clutch housing inclined and remove differential. Differential assembly is heavy and may fall out after output shaft has been removed.
CS123029
31 Remove input shaft oil seal with screwdriver or proper tools and then remove sealing cover.
CS123030
2-28
Manual transmission 32 Remove differential oil seal with screwdriver or proper tools. (Oil seal must be replaced every time / gently separated when replacing).
CS123031
33 Remove outer ring of taper roller bearing with proper tools (replace only when bearing replacement required).
CS123032
34 Remove output bearing with proper tools.
CS123033
2-29
Manual transmission 35 Remove two spring pins and pull out shift lever unit.
CS123034
36 Remove oil feed gutters ① and reverse cone stop pin ② .
1
2
CS123035
Inspection
1
Check input and output shafts.
Press bearing clear of input shaft and if the bearing or output shaft placement is required, press to remove bearing. CAUTION:Input
shaft
bearing
is
pre-packed
sealed unit and mu st not be washed.
CS123078
2-30
Manual transmission Check that all oil ways are clear. Inspect for wear, damage signs of overheating as appropriate:
– All splined areas. – All bearing running surfaces. – Thread. – Retaining ring grooves.
CS123079
2
Check gear / bearing / bush
– Gear teeth for blueing, chips, wear etc., including dog teeth。 – Wear on shaft bearings, needle roller bearings and bushes.
Pay particular attention to gears / bushes etc., which show excessive end-float when measurements are taken during removal. Check 1st gear end-float as follows - Assemble 1st gear and its bearing to output shaft. - Press 1st / 2nd synchro unit to hub. - Pull off hub.
Replace components as necessary.
CS123080
Fitting
1
Fit oil feed gutters ① and reverse cone stop pin ②
1
2
CS123035
2-31
Manual transmission 2
Fit shift lever assembly.
CS123034
3
Fit new oil seal on transmission housing with special tool C00017047.
CS123036
4
Select and fit differential bearing shim.
a.
After fitting differential assembly, measure distance (A) between sealing surface of clutch housing and outer ring of differential.
A
CS123037
2-32
Manual transmission b.
Measure distance (B) between sealing surface of transmission housing and mounting surface of outer ring of transmission housing bearing with height indicator. Standard value B: 16.3 - 16
B
CS123038
c. Selection of shim Shim thickness: B-A- Differential end clearance Standard differential end clearance:-0.1 - -0.2 mm
5
Part No.
Shim thickness (mm)
C00013929
0.10
C00013930
0.20
C00013931
0.30
C00013932
0.15
C00013933
0.25
C00013934
0.35
Fit differential into clutch odometer transmission gear.
housing
and
fit
CAUTION: Lubr icate components b efore fitting.
CS123029
2-33
Manual transmission 6
Apply transmission oil to input shaft oil seal and fit it on clutch housing with proper tools.
CS123039
7
Fit output shaft taper roller bearing and fit output shaft to clutch housing.
CS123040
8
Apply Loctite on screw and tighten it progressively and fit output shaft bearing cap. Screw tightening torques: 45 ~ 55Nm.
CS123027
2-34
Manual transmission 9
Fit needle roller bearing ① to output shaft and assemble 1st gear ② and twin cone synchro ring ③ before fitting to output shaft. Fit input shaft ④ at the same time.
4 3 2 1
CS123041
10 Fit 1st /2nd synchro unit after aligning with correlation marks made earlier.
CS123042
11 Fit twin cone synchro ring.
CS123043
2-35
Manual transmission 12 Fit 2nd gear shaft sleeve.
CS123044
13 Fit output shaft 2nd gear needle roller bearing.
CS123045
14 Fit output shaft 2nd gear (engage gears of input shaft).
CS123046
2-36
Manual transmission 15 Fit output shaft 3rd gear.
CS123047
16 Fit input shaft 3rd gear needle roller bearing.
CS123048
17 Fit input shaft 3rd gear.
CS123049
2-37
Manual transmission 18 Fit input shaft 3rd synchromesh ring.
CS123050
19 Fit input 3rd /4th synchro unit.
CS123051
20 Fit new retaining ring.
CS123052
2-38
Manual transmission 21 Fit input shaft 4th synchromesh ring.
CS123053
22 Fit input shaft 4th gear needle roller bearing.
CS123054
23 Fit input shaft 4th gear.
CS123055
2-39
Manual transmission 24 Fit output shaft 4th gear (engage with gears of input shaft).
CS123056
25 Fit input shaft 5th gear shaft sleeve.
CS123057
26 Fit input shaft 5th gear needle roller bearing.
CS123058
2-40
Manual transmission 27
Fit input shaft 5th gear.
CS123059
28 Fit output shaft 5th gear to engage with input shaft.
CS123060
29 Fit 5th synchromesh ring and 5th / reverse synchro unit. (3 grooves turn upward)
CS123062
2-41
Manual transmission 30 Fit reverse synchromesh ring.
CS123063
31
Fit clutch reverse cone stop pin.
CS123064
32 Fit reverse cone shaft sleeve.
CS123065
2-42
Manual transmission 33 Press input shaft bearing ② and secure with retaining ring ① . 1 2
CS123066
34 Position 1st /2nd shift guide block ③ to interlock plate and assemble 1st /2nd shift fork ① and shift transverse lever ② before engaging with 1st / 2nd shift guide block ③ . CAUTION:Do not secure sprin g pin at th is step.
2 1
3
CS123067
35 Fit 3rd / 4th shift fork ② and 5th / reverse shift fork ① .Position 3rd /4th shift guide block ④ on shift lever unit and fit 3rd /4th shift transverse 1
lever ③ . CAUTION:Do not fit and secure spring pin.
2 3
4
CS123068
2-43
Manual transmission 36 Position 5th / reverse shift guide block ② to interlock plate and then fit 5th / reverse transverse lever ① and fit fixed spring pin ③ . 3 1 2
3
CS123069
37 Fit reverse lever ① and reverse supporting spring ② . Bolt tightening torque: 8 ~ 11Nm. 1
CS123010
38
Fit reverse idler gear and gear shaft.
2
1
CS123009
2-44
2
Manual transmission 39 Fit magnet ① , output shaft spacer ③ , output shaft adjusting shim ② and input shaft adjusting shim ④ .
4
2 3
1
CS123008 40 Selection of input shaft shim a. Measure C dimension (C = C' - C") ·"Use height indicator to measure C' dimension of transmission housing.
C’
< Measure > C’
CS123070
·"Measure C" dimension with microcallipers.
C’’
< Measure > C’
CS123071
2-45
Manual transmission ·"Calculate C dimension (C = C' - C")
Standard value of C dimension: 243.87 mm ~ 244.0 mm. C’’
C’ Transaxle casing
CS123072
b. Measure distance (D) between sealing surface of clutch housing and input shaft ball bearing with height indicator.
D
CS123074
c. Selection of shim Shim thickness: (D-C) - (end clearance of input shaft) Standard end clearance of input shaft: 0 ~ 0.10 mm Input shaft shim table.。
2-46
Part No.
Shim thickness (mm)
C00013855
0.20
C00013856
0.15
C00013857
0.30
C00013858
0.10
C00013859
0.25
C
Manual transmission 41 Selection of output shaft shim a. Temporarily fit original shim and transmission housing.
CS123006
b. Temporarily fit output shaft taper roller bearing and tighten output shaft locknut and fit dial gauge.
CS123075
c. Place two screwdrivers under nut to measure end-float of output shaft. Note reading. Standard end clearance of output shaft: 0.03 ~ 0.1 mm If measured end-float is incorrect, thickness of shim pack must be adjusted after removing housing.
CS123076
2-47
Manual transmission Output shaft shim table.。 Part No.
Shim thickness (mm)
C00013885
0.10
C00013886
0.15
C00013887
0.20
C00013888
0.30
C00013889
0.50
C00013890
0.25
42 Remove transmission housing and fit new adjusting shim to bearing seats of input and output shafts in transmission housing.
CS123077
43 Fit transmission housing. Bolt tightening . torque: 44 ~ 55Nm
CS123006
2-48
Manual transmission 44 Fit reverse idler gear shaft bolt. Bolt tightening torque: 45 ~ 55Nm
CS123005
45 Fit setting screw ① , locking spring ② , steel ball ③ and reverse light switch ④ . Screw tightening torques: 15 ~ 21Nm.
2
3
1
4
CS123004
46 Turn shift lever to engage gear and secure input shaft with C00017041. C00017041
CS123002
2-49
Manual transmission 47 Fit output shaft taper roller bearing and tighten output shaft locknut. Nut tightening torques: 150 ~ 220Nm
CS123003 48 Fit rear cover and tighten securing screw. Screw tightening torques: 20 ~ 25Nm
CS123000
2-50
Manual transmission Disassembly of diff erential assembly Tools required: C00017042, C00017043 proper bearing puller. Removal 1
Remove transmission assembly (see "Replace manual transmission assembly").
2
Disassemble "Disassembly
transmission assembly (see of manual transmission
assembly").。 3
Use C00017042 to remove differential bearing after withdrawing differential assembly.
1
Disassembly differential
Tools require C00017043 p puller.
CS123082 3
Remove taper roller bearing ① .
4
Remove differential sealing bolts and differential gear housing and driven gear.
5
Remove differential spider, side gear, differential planet gear and thrust washer.
Removal
1
CS123084
Inspect: – Gear teeth for blueing, chips, wear etc. – Wear on bearing and thrust washer surfaces. – Wear on transmission shaft splines.
Fitting
Fitting is the reverse of removal, but note the following: 1
Wash can not be used again after removal.
2
Clean and apply slight smear of oil to bearing location in casing.
2-51
Manual transmission Replace, check and adjust gear lever cable Removal
1
Disconnect battery (negative cable first).
2
Disconnect cable at gear lever of transmission.
3
Remove E ring ② from cable mounting to release cable ① .
2
1
CS123093 4
Remove lower central panel assembly (see "Replace upper and lower central panel".
5
从 Remove E ring from manual transmission lever assembly.
6
Pry cable joint off manual transmission lever assembly with proper lever.
CS153004 7
Withdraw gear lever cable.
Check and adjust:
If poor gear changing is experienced, and before attempting to adjust the cables. It is recommended to proceed as follows to eliminate possible faults in the gear lever mechanism. Check gear lever: 1
Select neutral.
2
Disconnect both cables of transmission.
3
Move the gear lever in all directions and check for indications of seizure.
4
This plastic joint shall be replaced during any repair that may lead to cable joint disconnection
2-52
Manual transmission If gear lever mechanism is normal, proceed as the following to adjust cable: 1
Check cable has been disconnected.
2
Install gear lever setting pin C00017046 to lock gear lever in neutral position.
3
Adjust cable lengths until positioned correctly. Secure cable eyes and tighten locknuts.
4
Remove setting pin C00017046.
5
Select all gear positions to check for right adjustment. Gears should be engaged smoothly and fully. Re-adjust if necessary.
C00017046
CS153005 Fitting
1
Fitting is reverse of removal procedure. Note the following:
– The cable must be checked / adjusted for length. Do the following after connecting cable to the gear lever mechanism. – Check correct engagement of all gears. – Check that lower central panel controls all operations correctly after reconnection.
Replace shift mechanism kn ob Removal
1
Disconnect the negative cable of battery.
2
Place shift knob in neutral position.
3
Disconnect shift knob leather sheath buckle from console.
4
Upturn shift knob leather sheath.
5
Turn retaining ring of shift leather sheath to remove it
6
Remove shift knob
CS123095
2-53
Manual transmission Fitting
1
Fitting is reverse of removal procedure.
2-54
CLUTCH Techni cal Data Parameters Model
Hydraulic power-assisted clutch
Oil capacity
Share: brake fluid
Inner diameter of driven plate
175mm
Outer diameter of disc
259mm
Inner diameter of disc
174mm
Material of friction disk
Raybestos B-8805
Thickness of driven plate when newly fitted and compressed Limit wearing capacity of driven plate
7.2 ± 0.3mm Single face 1mm
Torque Ap pl ic ati on Master and slave cylinders and clutch fuel pipe joint Clutch disc to flywheel bolt
Tor qu e value (Newt on metres) 16 ± 2Nm 36Nm
3-1
CLUTCH Layout Layout of clutch system
4
6
2 1
3
5
1
Clutch disc
5
Slave cylinder and release mechanism
2
Driven plate
6
Clutch pedal
3
Release bearing
7
Clutch to flywheel bolt
4
Master cylinder
3-2
CLUTCH Diagnosis in formation and procedure Faul When pressing clutch pedal down to the end, shift lever fails to engage gears and disengage the reverse easily
Clutch slipping
Clutch shaking
Clutch clattering
Release bearing makes noise when clutch engaged.
Possible
Solution
Link mechanism loose.
If necessary, repair or replace loose link mechanism.
Clutch disk damaged.
Replace damaged clutch disk.
Fork shaft improperly fitted..
Remove fork shaft and properly fit it again. Apply slight wheel bearing grease to fork ends at release bearing.
Clutch disk hub seized on input shaft splines.
Repair or replace clutch disk hub.
Clutch disk warped or bent..
Replace warped or bent clutch disk.
Driver incorrectly operates the vehicle.
Correct driver's operation to vehicle when necessary.
Clutch disk wet..
Clear leakage faults at oil leakage points and fit new clutch disk.
Friction surface of clutch worn or spit.
Replace worn clutch disk with new disk.
Disc or flywheel warped.
Replace warped disc or flywheel.
Diaphragm spring weakened.
Replace diaphragm spring.
Driven plate not in position.
Start engine 30-40 times. Don't over heat engine.
Driven plate overheated
Cool driven plate.
Friction surface burnt or burnished due to oil on it.
Clear leakage faults at oil leakage points and fit new clutch disk.
Wear on input shaft splines.
Replace worn input shaft.
Disc or flywheel warped.
Replace warped disc or flywheel.
Burnt or smeared resins on disc or flywheel.
Remove burnt or smeared resins on surface clearly. Replace any burnt or heat cracked parts.
Retractable spring weakened.
Replace disc.
Release fork loose.
Remove and refit release fork properly.
Oil in driven plate bump stop.
Clear oil leakage fault and replace driven plate.
Driven plate damping spring damaged.
Replace driven plate.
Driver incorrectly operates vehicle.
Correct driver's operation to vehicle when necessary.
Release bearing seized.
Clean and lubricate release bearing again. Check burrs or breaches on release bearing.
Check release lever improperly installed.
Remove and refit release lever properly.
Return spring of connection rod weakened.
Replace weakened return spring of connection rod.
3-3
CLUTCH Clutch makes noise
Pedal fails to return when stopping on floor.
3-4
Release bearing worn.
Replace worn release bearing.
Release lever improperly installed.
Remove fork shaft and properly fit it again. Apply slight wheel bearing grease to fork ends at release bearing.
Connection rod or release bearing seized.
Lubricate and move seized connection rod or release bearing.
Disc spring weakened.
Replace disc.
CLUTCH SPECIAL TOOLS Maintenance special tooling table (same tooling number on each tool） Name
Illustration
Clutch aligner
C00016994
3-5
CLUTCH Repair i nstruct ions Replace driven pl ate and di sc Tools r equir ed: C00016994 Removal
1
Remove vehicle transmission. (See "Replacement of manual transmission assembly")
2
Support clutch driven plate with C00016994 and progressively remove securing bolts.
3
Remove disc and driven plate.
CS123083
4
Remove release fork ① , release bearing ② and guide sleeve ③ .
1
3 2
CS123081 Fitting
1
Fit driven plate and disc and align driven plate with C00016994. Progressively tighten securing bolts. Tightening torques: 36Nm
2
Fit transmission release fork① , release bearing ② and guide sleeve ③ and refit transmission. ③ Tightening torques: 6~8Nm
CAUTION: Check driven plate thic kness and replace it when beyond or approaching lim it wearing capacity. Clutch disc must be replaced if it drops accidentally. If driv en plate is replaced for wearing, it is recommended to replace disc.
3-6
CLUTCH Replace master cylinder Removal
1
Disconnect negative cable of the battery. (Refer to battery chapter for safety cautions)
2
Empty brake fluid reservoir.
CAUTION: Be careful: Cool water mus t be used t o wash paint surf ace where brake fluid splashed on immediately.
FRT CS153001
3
Disconnect spring clamp and remove oil supply hose of clutch master cylinder with both ends capped tightly to prevent dirt ingress.
4
Disconnect clutch high pressure hard pipe from master cylinder.
5
Remove bolt and clutch master cylinder from pedal.
3
5 4
CS153003 6
When separating the main pump and pedal, press the inside of the fastener and pull out lightly along the axial direction together with the metal pole so that the fastener is not damaged. Be sure not to hold the metal pole and shake it fiercely or pull it out too quickly.
CS153006
3-7
CLUTCH Fitting
1
Fitting is reverse of removal procedure.
Tightening torque of master cylinder fitting bolt: 15± 2Nm Tightening torque of master cylinder and clutch hard pipe: 16 ± 2Nm 2
Expel air. See "hydraulic clutch air expelling".
3
Fill brake fluid to MAX (maximum) mark on reservoir and connect negative cable of battery.
3-8
CLUTCH Replace slave cylinder Removal
1
Empty brake fluid.
2
Disconnect clutch hard pipe from slave cylinder.
3
Remove bolts and clutch slave cylinder from transmission.
4
Disconnect hard pipe form master cylinder.
5
Remove hose and hard pipe assembly from each pipe clip (arrowed).
2
3
CS153000
Fitting
1
Fitting is reverse of removal procedure. Tightening torque of master cylinder and hard pipe:
16 ± 2Nm Tightening torque of slave cylinder fitting bolt: 15 ± 2Nm Tightening torque of slave cylinder and clutch hard pipe: 16 ± 2Nm 2
Expel air. See "hydraulic clutch air expelling".
3
Fill brake fluid to MAX (maximum) mark on reservoir and connect negative cable of battery.
3-9
CLUTCH Hydraulic clutc h air expelling 1
Expel air coming into hydraulic system when disconnecting pipeline for repair. When expelling air, brake fluid in clutch reservoir shall stay in minimum (MIN) or slightly higher position.
2
Connect vinyl plastic hose to exhaust plug of clutch slave cylinder. Insert the other end of vinyl plastic hose into glass container that contains half brake fluid.
3
Press clutch pedal slowly.
CS153002
4
When pressing clutch pedal, release exhaust screw until oil starts to flow out, and then tighten exhaust screw and release pedal.
5
Repeat step 3 and 4 until no bubbles in oil.
6
Fill brake fluid to maximum (MAX) mark position.
CAUTION:Electrical joi nt and p aint surf ace will be damaged by brake fluid, which shall be protected from contacting with brake fluid by using cotton cloth, proper container and wing cover. CAUTION:System discharged oil is inhibited to fill into reservoir of clutch master cylinder again.
Reasons are as below: 1
Possibl e air in oil
2
Possible contaminated oil
3
Possible too much water in oil
3-10
Technical data Parameters Max oscillation angle of tripod universal joint (movable joint)
>45°
Max oscillation angle of constant velocity joint (fixed joint)
>23°
Press-in force between internal transfer wheel and solid shaft
500-15000 （N）
Press-in force between tripod and solid shafts
500-20000 （N）
Torque Ap pl ic ati on Anti-roll bar link nut Hub locknut
Tor qu e value (Newt on met res) 50 ± 5
① 100 ± 10，② 300 ± 30，③ 450 ± 16
Knuckle ball pin to knuckle screw
90 ± 9
Track rod ball joint to knuckle nut
85-95
Bearing plate to bearing carrier bolt Wheel bolt
8-10 180 ± 13
4-11
Layout Layout of drive shaft
10 9
3
4
1
8 7
6
14
11
5 2 3 9 10
14 13
12
7 6
1
Drive shaft (LH)
8
Spring retaining ring
2
Drive shaft (RH)
9
Hub washer
3
CV joint
10 Locknut
4
Tripod universal joint (LH)
11 Bearing plate
5
Tripod universal joint (RH)
12 Bolt
6
CV joint gaiter
13 Bearing seat carrier
7
Tripod universal joint gaiter
14 Transmission box
4-12
Fault di agnosis infor mation and procedure Fault
Possible cause
Drive shaft noise
Drive shaft unbalanced
Solution Calibrate to clear fault or replace
Universal joint's ball, steel ball, retainer or outer
Replace the universal joint
housing worn Knocking when start and abnormal
Universal joint worn or damaged
Replace the universal joint
sliding noise
Transmission output shaft splines worn
Replace parts
SPECIAL TOOLS Maintenance special tooling table (same tooling number on each tool)） Name
Illustration
Ball joint separator
C00017036
4-13
Repair i nstruct ions Replace left drive shaft Tools requi red: C00017036 Removal
1
Remove wheel with vehicle supported by lift (see "Replace wheel").
2
Remove nuts connecting track rod ball joint and knuckle and separate track rod ball joint with C00017038.
3
Remove nuts connecting anti-roll bar link and control arm.
4
Disconnect the front ABS speed sensor harness.
5
Loosen the front brake hose on front strut carrier.
6
Remove locknut and hub washer on drive shaft.
3
CS173008 7
Remove 4 screws securing knuckle ball pin.
CS223005 8
Use suitable pry bar to pry knuckle clear of ball joint.
CAUTION:Do not damage gait er.
9
Pry spring retaining ring of left drive shaft out as shown in the figure for it is secured in differential. If difficult, turn the shaft 1/3 turn and another 1/3 turn if necessary.
CAUTION:Pull out left drive shaft horizontally to prevent damaging differential oil seal.
10 Pull front hub outward to separate front hub and left drive shaft. 11 Place proper drain tray under differential connector and remove left drive shaft.
4-14
CS173004
2
12 After removing left drive shaft, cap the differential connector with a plug to prevent dirt ingress.
CS173007 Fitting
1
Clean left drive shaft ends, mounting areas in front hub and connection areas of differential.
2
Position spring retaining ring on the topmost of left drive shaft and fit left drive shaft in differential and push into position.
CS173003 3
Fit left drive shaft in knuckle. Fit 4 screws securing knuckle ball pin and tighten with a torque of:90 ± 9Nm.
4
Fit anti-roll bar link nut and tighten with a torque of: 50 ± 5Nm.
5
Fit track rod ball joint to knuckle and secure with nuts tightened with a torque of: (85-95) Nm.
6
Fasten the front brake hose to front strut carrier.
7
Connect the front ABS speed sensor harness.
4-15
8
Fit hub washer and locknut and tighten the torque in accordance with 3 steps below. Fit wheel and lower lift to ground firstly. – Pre-tightening torques: 100 ± 10Nm. – Turn drive shaft 10 turns and fit hub bearing into
position and tighten with a torque of: 300 ± 30 Nm.
– Turn drive shaft again and tighten with a torque of: 450 ± 16Nm.
9
Stake locknuts of left drive shaft to make them caught in the groove of half rear axle.
10 Fit the wheel (see "Replace wheel").
CS173012
4-16
Replace right drive shaft Tools r equir ed: C00017036 Removal
1
Remove the wheel with vehicle supported by lift (see "Replace wheel").
2
Remove securing bolts of bearing seat plate and bearing carrier to remove bearing carrier.
CS173006 3
Remove nut connecting track rod ball joint and knuckle and separate track rod ball joint with C00017036.
4
Remove nuts connecting anti-roll bar link and control arm.
5
Disconnect the front ABS speed sensor harness.
6
Loosen the front brake hose on front strut carrier.
7
Remove locknut and hub washer on drive shaft.
4
3
CS173014 8
Remove 4 screws securing knuckle ball pin.
9
Use suitable pry bar to pry knuckle clear of ball joint.
CAUTION:
Do not damage gaiter.
10 Pull front hub outward to separate front hub and right drive axle. 11 Loosen right drive shaft from differential. 12 Place proper drain tray under differential connector and remove right drive shaft. 13 After removing right drive shaft, cap the differential connector with a plug to prevent dirt ingress.
CS223005
4-17
Fitting
1
Clean right drive shaft ends, mounting areas in front hub and connection areas of differential.
2
Fit bearing carrier in bearing seat plate and secure bolts by tightening a torque of: 8-10 Nm.
3
Fit right drive shaft in knuckle. Fit 4 screws of knuckle ball pin and tighten with a torque of:90 ± 9 Nm.
4
Fit anti-roll bar link nut and tighten with a torque of: 50 ± 5 Nm.
5
Secure knuckle and knuckle with nuts and tighten a torque of: 85-95 Nm.
6
Fasten the front brake hose to front strut carrier.
7
Connect the front ABS speed sensor harness.
8
Fit hub washer and locknut and tighten the torque in accordance with 3 steps below. Fit wheel and lower lift to ground firstly. – Pre-tightening torques: 100 ± 10Nm. – Turn drive shaft 10 turns and fit hub bearing into
position and tighten with a torque of: 300 ± 30 Nm.
– Turn drive shaft again and tighten with a torque of: 450 ± 16Nm.
9
Stake locknuts of right drive shaft to make them caught in the groove of half rear axle. 10 Fit the wheel (see "Replace wheel").
4-18
CS173012
Replace CV joint gaiter Removal
1
Remove drive shaft from vehicle (see "Replace left drive shaft" and "Replace right drive shaft")
2
Clamp drive shaft with a vise.
3
Remove 2 gaiter clamps and discard.
3
6 3 5
CS173009 4
Hold CV shaft in alignment with drive shaft and slightly tap CV housing with a copper hammer to detach it.
5
Remove snap ring from drive shaft and discard.
6
Remove gaiter.
CS173005 Fitting
1
Fit new gaiter to drive shaft, positioning its end to the outboard of the two grooves (arrowed).
2
Fit new snap ring on drive shaft.
3
Fill CV joint with grease supplied and apply any remaining grease into the gaiter.
4
Press drive shaft fully home into CV joint.
5
Clean the connection area of gaiter and CV joint gaiter and secure gaiter clamp.
6
CV joint is sure to turn in all directions freely without disturbing gaiter.
7
CS173000
Fit drive shaft (see "Replace left drive shaft" and "Replace right drive shaft").
4-19
Replace CV join t Removal
1
Remove drive shaft (see "Replace left drive shaft" and "Replace right drive shaft").
2
Clamp drive shaft with a vise.
3
Loosen 1 large clamp securing the gaiter and push the gaiter back.
4
Hold CV shaft in alignment with drive shaft and slightly tap CV housing with a copper hammer to detach it.
5
Remove snap ring from drive shaft and discard.
6
Remove CV joint.
CS173005 Fitting
1
Fit 1 large clamp securing the gaiter to drive shaft.
2
Fit new snap ring on drive shaft.
3
Fill CV joint with grease supplied and apply any remaining grease into the gaiter.
4
Press drive shaft fully home into CV joint.
5
Clean the connection area of gaiter and CV joint and secure 1 gaiter clamp.
6
Fit drive shaft assembly (see "Replace left drive shaft" and "Replace right drive shaft").
4-20
Replace tripod u niversal joint / gaiter Removal
1
Remove drive shaft (see "Replace left drive shaft" and "Replace right drive shaft").
2
Clamp drive shaft with a vise.
3
Loosen 2 clamps and discard and make correlation marks on tripod universal joint and housing temporarily.
4
Pull tripod universal joint out of the gaiter.
3 7
3
CS173010 5
Remove intermediate drive shaft snap spring with nippers and discard.
6
Remove tripod universal shaft from intermediate drive shaft.
7
Remove gaiter.
CS173002 Fitting
1
Clean drive shaft and tripod universal joint gaiter
2
Fit 2 new clamps and gaiter to intermediate drive shaft.
3
Position tripod universal joint on intermediate drive shaft.
4-21
