Removing
Attention! The fuel system is under constant pressure, so depressurize the fuel system before disconnecting the lines.
Attention! The air conditioning system is under high pressure, so do not open the cooling circuit of the air conditioning system until the refrigerant has been recovered.
Attention! The air conditioning system must be serviced by technical personnel trained in safe work practices, using special equipment and in compliance with safety regulations for the collection and storage of automotive refrigerant.
Note. Removing the gearbox on all-wheel drive models is a very laborious job. The manufacturer recommends removing the power unit assembly and then disconnecting the gearbox from the engine.
Turn off the ignition and disconnect the wire «masses» from the battery.
Relieve the pressure in the fuel system.
Remove the hood.
Remove the air filter housing.
Disconnect the accelerator cable and set aside along with the bracket.
Remove the battery. On vehicles since 2001, remove the battery support.
On vehicles prior to 2001, remove the activated charcoal absorber.
Loosen the nuts securing the front wheels and drive shafts to the hubs.
Drain the engine oil and coolant.
On vehicles from 2001 release, remove the expansion tank.
Remove the accessory drive belts.
Mark and disconnect from the engine vacuum hoses and hoses of the cooling system, electrical connectors, wires connecting to «weight» and fuel pipes.
Release clips and disconnect from the engine plaits of wires. Also disconnect the wires from the transmission control unit (PCM) inside the car and pull the wires from inside the car into the engine compartment.
Turn out bolts of fastening of the pump of the amplifier of a steering, take it aside and fasten with a soft wire on a body.
Remove the radiator fan, fan shroud, and radiator. This operation is not mandatory, however, it will prevent them from being damaged when the engine is removed. If the radiator remains installed in the vehicle, disconnect the transmission oil cooler tubes from the radiator.
On models with an air conditioning system, remove the A/C compressor mounting bolts. Move the air conditioning compressor, together with the wires and tubes attached to it, to the side and secure it to the body with a soft wire.
Remove the exhaust pipe.
Remove the selector cable retaining nut and disconnect it from the selector lever on the front of the transmission.
Remove the clip and remove the cable sheath from the bracket on the gearbox.
Disconnect all electrical connectors from the transmission.
Remove the front drive shafts and driveshaft.
Remove the two bolts holding the steering gear to the front cross member and the pivot bolts to the lower wishbones.
Hook the hoist chain to the engine and tension it so that the weight of the engine and gearbox is supported by the hoist.
Check that nothing other than supports is connecting the engine and transmission to the vehicle.
Turn out bolts of fastening of the left and right support of the power unit.
Turn out bolts and remove longitudinal and cross beams.
Slowly lower the engine with gearbox. Disconnect the hoist chain from the engine.
Remove the starter.
Pic. 9.29. Arrangement of bolts of fastening of a plate of rigidity
On models up to 2001, unscrew the bolts and remove the stiffening plate (pic. 9.29).
On models since 2001, remove the plug covering the torque converter access hole, then mark the position of the torque converter and drive plate with paint.
Turn out bolts of fastening of the hydrotransformer. To access each subsequent bolt, turn the engine crankshaft in the direction of its working rotation by the central bolt of the crankshaft pulley.
Turn out bolts of fastening of a transmission to the engine, at the same time note an arrangement of bolts as they have various length.
Pull the gearbox away from the engine and check that the torque converter is separated from the drive plate. Clamp the torque converter, lower and remove the gearbox.
Installation
Install in the reverse order of removal, taking into account the following.
Align the marks on the torque converter and the drive plate made before removal.
Pour transmission fluid into the gearbox.
Adjust selector cable and throttle cable (on models up to 2001).