Installation
NOTE: Component identifier numbers used in the following illustrations relate to specific steps in the procedures below.
1. Attach the lifting eye and lifting wire tool No. 87 92 442, or equivalent, to the transmission.
2. Install torque converter retaining tool, to hold the torque converter in position while installing the transmission.
- 6-cylinder engines: tool No. 87 92 285, or equivalent
- 4-cylinder engines: tool No. 87 92 277, or equivalent
3. Position the transmission under the car.
4. Attach the lifting wire to the transmission and hoist.
NOTE: Make sure that all cables are situated so that they will not be in the way when the transmission is lifted into place.
5. Lift the transmission into place.
6. Screw in the upper retaining bolts.
- 6-cylinder engines: 2 of 3 upper bolts:
- 4-cylinder engines: all three upper bolts:
- Tighten to: 75 Nm (55 ft. lbs.).
7. Detach the lifting wire from the hoist and transmission.
8. Lift up the engine and transmission by means of the lifting beam.
9. Raise the car.
10. On models with 6 cylinder engines, tighten the last of the three upper bolts.
- Tighten to: 75 Nm (55 ft. lbs.).
- Screw in the lower securing bolts which secure the transmission to the engine.
11. On all models, screw the front engine mount in place.
NOTE: Secure the torque converter retaining bolts with locking fluid.
12. Secure the torque converter to the driver plate by means of one of the six bolts and remove the tool holding the torque converter in position.
13. Install the five remaining bolts securing the torque converter to the driver plate.
- Tighten to: 60 Nm (44 ft. lbs.)
NOTE: The crankshaft will have to be rotated in order to install all the bolts.
14. Install the splash plate (secured with 2 bolts).
- Tighten to: 7 Nm (5 ft. lbs.).
15. Install the intermediate shaft to the righthand drive shaft.
6-cylinder engines:
- The intermediate shaft is secured with two screws
4-cylinder engines:
- Drive the bush back into the generator bolt's bracket on the intermediate shaft's bracket.
- Guide the bracket's locating dowel into place.
- Mount the bracket on the engine.
- Swing the generator down and install the lower generator bolt.
NOTE: Check the upper generator bolt when the transmission has been installed.
16. Install the righthand drive shaft to the intermediate shaft (splined connection).
17. Install the lefthand drive shaft (splined connection).
NOTE: Check that the splined connection has "clicked" in place properly by pulling and tugging the wheel hub.
18. After replacement of the transmission, the cooling circuit must be cleaned.
19. Install the inlet and outlet hoses for cooling the transmission fluid.
- Make sure that they do not rest against the subframe.
- Tighten to: 22 Nm (16 ft. lbs.)
20. Install the subframe.
- Position the subframe on the lifting table and raise the subframe until it is about 1-2 cm from the car.
- Install the nuts on the end pieces.
- Raise the subframe fully.
- Install the other retaining bolts and tighten the nuts on the end pieces.
NOTE: Washers are installed on the two rear retaining bolts.
- Lower the lifting table and remove same.
21. Install the front section of the exhaust pipe.
22. Install the oxygen sensor cable in its lower bracket.
- 6-cylinder engines: two oxygen sensors
- 4-cylinder engines: one oxygen sensor
23. Install the air deflectors and cover in the front righthand wheel housing.
24. Install the front wheels.
- Tighten to:
- Pressed steel wheels: 100 Nm (74 ft. lbs.)
- Light alloy wheels: 120 Nm (89 ft. lbs.)
25. Lower the car.
26. Remove the holder and lifting beam.
27. Plug in the oxygen sensor connectors.
- 6-cylinder engines: two oxygen sensors
- 4-cylinder engines: one oxygen sensor
28. Fasten the oxygen sensor cable in its upper bracket (front of engine).
NOTE: The front cable for the 6-cylinder engine and the cable for 4-cylinder engines should be run behind the lower water pipe so that the cable cannot move forwards against the exhaust pipe.
29. Plug in the transmission's electrical connectors (located on a bracket behind the battery).
CAUTION:
^ Ensure the correct connectors are connected.
^ It may be possible to cross connect the the transmission temperature sensor and the input shaft speed sensor.
^ This will cause a Diagnostic Trouble Code (DTC) of P1817 (input shaft speed missing) to be generated.
30. Secure the leads to the automatic transmission.
31. Install the selector lever wire by first fastening it to the selector lever arm on the transmission and then to the wire bracket on the transmission.
32. Connect the breather hose.
33. Mount the dipstick with tube in the transmission and secure:
- 6-cylinder engine: Secured to the pin bolt to the selector lever arm
- 4-cylinder engine: secure to the crankcase cover.
34. Install the cable to the sleeve with clips.
35. Connect the battery's negative cable to the grounding point on the valve housing.
36. Install the battery.
37. Fill up with transmission fluid.
38. Check the gear shifting play and, if necessary, adjust the position of the selector lever.
39. Drive the car on test at varying engine loads and speeds for 5 minutes and obtain readouts of any diagnostic trouble codes that are generated.