Removal and Installation

Removal
1. Select N gear position.
2. Open the engine compartment and fit paintwork protection sheets.
3. Open the driver's door, or both doors if necessary, to allow the side glass to drop. Ensure that the doors remain open until after the battery has been disconnected.
4. Disconnect battery ground cable.





Remove the battery cover.
5. Remove the engine covers.
6. Remove the air intake tube, MAFM and air cleaner cover assembly.





7. Install engine lifting bracket 303-536 at the rear RH.
8. Reposition the coolant header tank for access.





Remove the securing bolt.
Reposition the tank.





9. Install engine lifting bracket 303-536 at the rear LH.
10. Support the engine using 303-021.





Adjust and locate the stands in the LH and RH fender channels and tighten the beam fixings.
Engage the support hooks in the lifting brackets.
Tighten the support hook adjusters and take the weight of the engine.
11. Raise the vehicle for access.
12. Remove the LH downpipe catalytic converter, refer to Powertrain Management.
13. Remove the front muffler, refer to Exhaust Systems.
14. Remove the RH downpipe catalytic converter, refer to Powertrain Management.
15. Drain the transmission fluid.
16. Locate a transmission jack, Epco V-100 or similar, under the transmission unit.
Adjust the angle of the jack to suit the transmission.
Secure the side clamps.





Pass the safety chain over the transmission unit and secure.
17. Remove the engine rear mounting bracket.





Remove the engine rear mounting to bracket bolt.
Remove the mounting bracket to body bolts.
18. Detach the driveshaft from the transmission drive flange.
If the transmission is to be refitted, mark the position of the coupling to drive flange.

CAUTION: Under no circumstances remove the driveshaft to flexible coupling fixings.





Remove the transmission drive flange to flexible coupling three fixings.





19. Lower the transmission unit by carefully releasing the engine support beam and by lowering the transmission jack.





20. Detach the gear selector cable from the transmission unit.
Remove the selector cable ball pin to selector lever nut.
Remove the selector cable to transmission casing bolts.





21. Disconnect the transmission harness multiplug.
Rotate the locking lever to release.
Disconnect the multiplug.





22. Detach the rotary switch.
Remove the switch fixings.
Displace the switch harness from the clips.
23. Disconnect the fluid cooler pipes.





Unscrew the cooler pipe tube nuts, one at each side of the transmission casing.
Discard the O-rings.
Plug the pipes and transmission.
24. Remove the three bolts which secure the torque converter to the drive plate.





Remove the access cover.
Rotate the crankshaft and hold to prevent movement, and remove the bolts.
25. Remove the LH and RH catalyst mounting brackets from the transmission case.





Remove the bolts.





26. Remove the bolts which secure the engine harness connector mounting bracket and move the bracket aside for access.
27. On the RH side, clear the cooler pipe for access.

28. NOTE: Viewed from the rear of the vehicle.





Remove the four upper transmission to engine bolts.

29. NOTE: Viewed from the rear of the vehicle.





Remove the ground lead bolt.
30. On the LH side.

31. NOTE: Viewed from the rear of the vehicle.





Remove the upper cooler pipe clip to transmission case bolt.

32. NOTE: Viewed from the rear of the vehicle.





Remove the six remaining transmission case to cylinder block bolts.

33. NOTE: Do not allow the converter to detach from the transmission.





Remove the transmission/converter assembly from the vehicle.
Lower the transmission jack and remove the transmission, ensuring that the torque converter spigot disengages cleanly from the engine.
34. If appropriate, fit retaining straps to the converter/transmission assembly.

Installation
1. Clean all mating faces and relevant parts.





2. Apply lubricant, Molycote or equivalent, to the spigot of the torque converter.
3. Align the engine drive plate.





Rotate the crankshaft to position the ORANGE dot within the indicated sector.

NOTE: Viewed from the rear of the vehicle.

Keeping the dot within the sector, align the nearest converter fixing hole to the access aperture.
4. Align the torque converter





Rotate the converter to position the BLUE dot within the indicated sector.
Keeping the dot within the sector, align the nearest fixing boss as indicated, so that when the two units are mated, the converter need only be moved the minimum amount.
5. Fit the transmission to the engine.
Loosely assemble - Cooler pipe clip.
Loosely assemble - Ground lead.
Loosely assemble - Catalyst brackets.





Tighten in sequence 1, 2, 3, 4 as shown on the illustration, then the others in any order.





6. Reposition the mounting bracket for the engine harness connector and fit the securing bolts.





7. Connect the drive shaft, aligning any marks made when removing - if applicable. Tighten the bolts to the specified torque figure.





8. Fit the engine rear mounting and tighten the center bolt and outer bolts to the specified torque figures.
Check that the hooks of the engine support beam are not trapped, before tightening the rear mounting.
Check that the safety chain on the transmission jack will not be trapped when the mounting is fitted.





9. Remove the transmission jack.
10. Fit the three bolts which secure the torque converter to the drive plate.





Loosely assemble all three drive plate to torque converter bolts. Whilst preventing crankshaft rotation, tighten the three converter bolts to the specified torque figure.
Fit the blanking plug.





11. Connect the transmission harness multiplug.
Engage the multiplug.
Rotate the locking lever to secure.





12. Connect the selector cable to the selector lever and fit the abutment bracket to the transmission casing. Tighten the nut and two bolts to the specified torque figure.





13. Refit the rotary switch and tighten the two screws to the specified torque figure. Locate the switch harness into the clips.





14. Connect the fluid cooler pipes to the transmission.
Remove the blanking plugs.
Fit new 'O' ring seals.





Tighten the union nuts to the specified torque figure.
15. Remove the engine support beam.
Remove both engine lifting brackets 303-536.
16. Refit the RH downpipe catalytic converter. Refer to Powertrain Management.
17. Refit the front muffler. Refer to Exhaust Systems.
18. Refit the LH downpipe catalytic converter. Refer to Powertrain Management.
19. Lower the vehicle on the ramp.





20. Reposition the coolant header tank and tighten the securing bolt to the specified torque figure.
21. Refit the air intake tube, MAFM and air cleaner cover assembly. Refer to Powertrain Management.
22. Refit the engine covers.
23. Perform the Battery Reconnection Procedure described in Starting and Charging.
24. Refill the transmission with new fluid.
25. Remove the protection sheets and close the engine compartment.