How to replace the CAS in a 6G7x V6 petrol Pajero

I have replaced the CAS in several pajeros, from 1987 through 1996. The later engines don't have a distributor so there will be a different process.
These are the original instructions, found at this web forum location:
http://www2.pajeroclub.com.au/forum/showthread.php?t=14705

You'll need a phillips head screwdriver, small flat screwdriver and small sockets or a spanner.

1. Remove a battery terminal so that the car can't be started.
2. Undo the two small bolts retaining the distributor cap. Remove the distributor cap and note which way the distributor arm is pointing so that you can put it back together the right way.
3. Unclip the CAS cable at the front of the distributor. You need to lever up the metal clip.
4. Note the position of the distributor and remove the bolt holding it to the engine block. Rotating the distributor body changes the timing, so it might help to mark the installed position before removal.
5. Pull the distributor out. Cover the hole with something to stop dirt entering the engine.
6. Undo the screw retaining the distributor arm and remove the distributor arm.
7. Undo the two screws retaining the cover plate that sits over the centre of the distributor. Remove the cover plate. You will see a slotted disk and a black plastic module; this is part of the CAS.
8. Remove the screw in the centre of the spacer that held the distributor arm, and remove the spacer.
9. Gently remove the slotted disk. Remember which side is up! Perhaps mark it before removal to make sure. There may be the letter E stamped on one side.
10. Remove the spacer under the slotted disk.
11. Remove the two screws holding the cover plate over the CAS sensor connector and remove the cover plate. The gasket may break.
12. Remove the three screws holding the CAS. Pull the CAS out of the distributor body.
Installation is the reversal of the above, noting that a) the CAS is a tight fit over the distributor shaft, so you need to push it in at the right angle; b) put the slotted disk back in the right way up; c) turn the distributor shaft gear so that when you put the distributor back in, the arm faces the same way it did before you took it out; d) the distributor body is installed to the same place it was before you pulled it out.

I would add these comments, based on my experience at this task (I have had a few Pajeros...). Hopefully they will help you :)

• I don't have a vice to hold a dizzy while it is out, so I do this without removing the distributor from the engine. Clambering over the front of a 4wd is no fun. Ah well ;) In the process I have confirmed that, with care, this task can be done without removing the dizzy from the vehicle :)
• The seal behind the cover plate is always gone and sealent used. I just use sealant again. The order is to:
• Get the CAS in place but do not yet screw it down,
• then add sealant in the space behind the cover plate, until you see a little inside the dizzy housing,
• loosely screw in the cover plate,
• then install the centre spacer,
• then tighten the CAS down (3 screws),
• then tighten the front cover plate.
• The metal plate that sits over the CAS (under the spacers) will not go in or out separately. Bring it out/in with the CAS module itself.
• Use pozidrive not phillips for the internal screws.
• Use a 7mm socket for the screw holding the rotor arm in place.
• The screws holding the front cover in place are usually well munted by previous repairers. It is likely that you will either replace or clean them up with a file before installing - much easier putting them back in!

There is a video slideshow on youtube that may help you do this task.

Enjoy!