Contents: Removal ↓ Installation ↓
Removal
Caution: The fuel system is under constant pressure, so relieve the pressure in the fuel system before disconnecting the lines.
Caution: 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 extracted.
Attention! The air conditioning system must be serviced by technical personnel trained in safe working practices, using special equipment and observing safety rules for collecting and storing automotive refrigerant.
Note: Removing the gearbox on all-wheel drive models is a very labor-intensive job. The manufacturer recommends removing the powertrain assembly and then disconnecting the gearbox from the engine.
Turn off the ignition and disconnect the ground wire from the battery.
Relieve pressure in the fuel system.
Remove the hood.
Remove the air filter housing.
Disconnect the accelerator cable and move it to the side along with the bracket.
Remove the battery. On vehicles produced since 2001, remove the battery support.
On vehicles manufactured before 2001, remove the activated carbon canister.
Loosen the nuts securing the front wheels and drive shafts to the hubs.
Drain the engine oil and coolant.
On vehicles produced since 2001, remove the expansion tank.
Remove the accessory drive belts.
Label and disconnect the vacuum and coolant hoses, electrical connectors, ground wires, and fuel lines from the engine.
Release the clamps and disconnect the wiring harnesses from the engine. Also disconnect the wires from the powertrain control module (PCM) in the passenger compartment and pull the wires from the passenger compartment into the engine compartment.
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Remove the power steering pump mounting bolts, move it to the side and secure it to the body using soft wire.
Remove the radiator fan, fan shroud and radiator. This is not a necessary step, but it will prevent damage when removing the engine. If the radiator remains installed in the vehicle, disconnect the transmission oil cooler pipes from it.
On models with an air conditioning system, remove the air conditioning compressor mounting bolts. Move the air conditioning compressor with the wires and tubes attached to it to the side and secure it to the body with soft wire.
Remove the exhaust pipe.
Remove the selector cable mounting nut and disconnect it from the gear selector lever on the front of the gearbox.
Remove the clamp and remove the cable housing from the bracket on the transmission.
Disconnect all electrical connectors from the transmission.
Remove the front drive shafts and propeller shaft.
Remove the two bolts securing the steering gear to the front cross member and the bolts securing the hinges to the lower wishbones.
Attach the hoist chain to the engine and tighten it so that the weight of the engine and gearbox is supported by the hoist.
Check that nothing other than the mounts connects the engine and gearbox to the vehicle.
Remove the bolts securing the left and right powertrain supports.
Remove the bolts and the longitudinal and cross beams.
Slowly lower the engine with the gearbox. Disconnect the lifting chain from the engine.
Remove the starter.
Fig. 9.29. Location of stiffening plate mounting bolts
On models produced before 2001, unscrew the bolts and remove the stiffening plate (Fig. 9.29).
On 2001 and later models, remove the plug covering the torque converter access hole, then use paint to mark the position of the torque converter and drive plate.
Remove the torque converter mounting bolts. To access each subsequent bolt, rotate the engine crankshaft in the direction of its operating rotation using the central crankshaft pulley mounting bolt.
Remove the gearbox-to-engine mounting bolts, marking the location of the bolts as they vary in length.
Lift the transmission away from the engine and check that the torque converter is separated from the drive plate. Use clamps to secure the torque converter, lower and remove the transmission.
Installation
Installation is carried out 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.
Fill the transmission with transmission fluid.
Adjust the selector cable and throttle control cable (on models before 2001).