Control System, Replacing
Control system, replacing
Special tools:
999 5716 Reading off tool 999 5716 Reading Off Tool
999 5460 Lifting hook 999 5460 Lifting Hook
998 5972 JACK 998 5972 Jack
999 5972 FIXTURE 999 5972 Fixture
999 5477 JOINT WEDGE 999 5477 Joint Wedge
Note! As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information is always correct.
Preparatory work
Engine wash
Wash the engine.
Use compressed air to blow clean around the control system cover.
Transmission fluid, draining
Warning! The fluid will be extremely hot if the vehicle has recently been driven. Avoid skin contact.
Remove:
- the protective cover under the engine
- the oil plug. Drain the fluid from the transmission.
Install the oil plug. Use a new gasket.
Tighten the plug according to applicable specfications.
Flushing the transmission
Detach the return hose on the control system cover.
Install a plastic plug on the connection in the cover.
Remove the return hose in the radiator. Direct the hose upwards and reconnect to the radiator.
Install a transparent plastic hose on the return hose connection.
Position a container for the fluid beneath the hose.
Apply the parking brake. Shift the gear selector to position P.
Fill with 5 liters of fluid.
Start the engine and allow to idle.
Switch off when air bubbles are visible in the hose.
Fill with 3 liters of fluid.
Start the engine again and allow to idle.
Switch off when air bubbles are visible in the hose.
Fill with 2 liters of fluid.
Start the engine again and allow to idle.
Check the color of the fluid. When the fluid is bright red (like new oil), switch off the engine.
Removing the air cleaner (ACL) housing
Note! Check that the ignition is off.
Remove the air cleaner (ACL) housing assembly with inlet pipe. Pull the air cleaner (ACL) housing assembly from its mountings.
Removing the cable harness
Note! Applies to model year 2000.
Remove:
- the transmission cable from the lever on the transmission
- the 2 x screws for the cable bracket. Move the cable to the side.
Remove:
- the connector from the transmission
- the tie strap holding the cable harness.
Separate the connectors.
Disconnect the small connector from the bracket.
Note! Only applies when replacing the control system.
Set the transmission lever to position N. Shift the lever as far forward as possible to position P and then back two steps to position N.
Remove:
- the tie-straps around the connector rubber seal and cable harness
- the rubber seal.
Insert a screwdriver between the casing and the socket.
Press in the catch and at the same time slide out the sockets from the casing.
Remove the oil temperature sensor and solenoid sockets from the others.
Remove:
- the lever on the control shaft
- the screw for the gear selector sensor/cable harness
Turn the tab outward on the cable harness holder.
Removing the cable harness
Note! Applies to model year 2001.
Unhook the mounting with the connector for the transmission from the bracket for the air cleaner (ACL) housing.
Remove the tie-straps from the cable harness.
Detach the mounting from the control system cover.
Separate the connectors. Remove the connectors from the mounting.
Remove:
- the lever on the control shaft
- the screw for the gear selector sensor/cable harness
Turn the tab outward on the cable harness holder.
Removing components
Install: 999 5716 Reading off tool 999 5716 Reading Off Tool directly over the engine lifting eyelet.
Position the lifting beam brackets as illustrated.
Connect: 999 5460 Lifting hook 999 5460 Lifting Hook to the lifting eyelet at the rear edge of the engine. Apply the hook to relieve the load from the engine pads.
Note! Position the front lift arms so that they do not obstruct the sub-frame support plates.
Remove both screws for the front splash guard. Press in the catches at the front edge of the guard. Pull the cover straight back.
Remove:
- the screw for the ground lead bracket on the sub-frame
Note! Only applies to vehicles with parking heaters.
- the 3 x screws for the heater on the sub-frame.
Hang or tie up the heater on the left front wing.
Unhook the fuel line from the mountings on the sub-frame.
Remove:
- the screws for the bracket
Note! Applies only to right-hand drive vehicles.
- the front cross member
Note! Applies to all vehicles.
- the screws for the cross member
- the screws for the rubber mounting
- the brake pipe from its holders.
Note! Applies only to right-hand drive vehicles.
Remove the screws from the collision protection system.
Leave the collision protection system in place on the steering gear.
Remove the anti-roll bar link from the anti-roll bar.
Caution! Use a torx wrench (1) as a counterhold. Do not damage the boot.
Remove:
- the nuts and screws for the steering gear
- the screw for front engine pad and sub-frame
- the screws securing the torque rod mounting on the transmission.
Unhook the power steering fluid line from the sub-frame.
Remove the screws for the sub-frame support brackets on both sides.
Apply: 998 5972 JACK 998 5972 Jack together with: 999 5972 FIXTURE 999 5972 Fixture lightly under the right-hand side of the sub-frame.
Remove the sub-frame screws on the right-hand side. Unscrew the screws so that at least five threads remain. Remove the jack.
Position the mobile jack lightly applied under the left side of the sub-frame. Remove the front and rear screws from the sub-frame.
Carefully lower the frame a little. Check that the screws for the steering gear release from the frame and the control arm releases from the ball joint.
Lower the sub-frame completely and let it hang free.
Install a spacer between the body and the sub-frame at the front left-hand mounting so that there is a distance of approximately 175 mm. Use a 125 mm extension and 36 mm sleeve.
Cleaning:
Using compressed air, blow clean the area around the control system cover.
Carefully clean the sub-frame by the cover to avoid dirt penetrating the transmission.
Removal
Removing the control system
Position a container under the transmission.
Remove the clamp for the cable harness on the control system cover. Disconnect the ground lead from the transmission. Tie up the cable harness and ground lead.
Disconnect the pipe/hose for the oil cooler from the transmission. Move the pipe to one side.
Remove the Torx TX40 screws for the control system cover.
Clean the sealing compound from the threads. Use tap M8 x 1.25.
Remove the cover. Use 999 5477 JOINT WEDGE 999 5477 Joint Wedge. Carefully tap in the tool between the cover and the transmission to prevent deforming the sealing flange of the cover.
Clean gasket residue from the cover and transmission.
Note! Ensure that no debris enters the transmission. Wash the cover thoroughly.
Remove:
- the connectors for the solenoid valves
- the screw for the oil temperature sensor holder. Remove the sensor from the control system
- the cable harness from the holder on the control system.
Remove the cable harness.
Remove:
- the screws for the control system
- the control system from the transmission.
Note! Ensure that there are no cracks on the top of the lever for the gear selector slider.
The digits in the illustration specify the screw lengths.
Replacing the sealing rings.
Remove the sealing rings from the transmission.
Note! Ensure that no debris enters the transmission.
Install new sealing rings in the transmission.
Note! Check that petroleum jelly does not seal the oil hole.
Checking the gear selector slider
Check that the lever for the gear selector slider is correctly positioned.
Installation
Installing the control system
Note! Ensure the lever for the gear selector is set to neutral.
Align the control system lever with the gear selector lever.
Install:
- the screws for the control system
Note! The different screw lengths are given in mm. See the illustration.
- a new gasket for the cover on the control system.
Tighten the screws alternately to light contact. Then tighten to applicable specifications.
Install:
- the new cable harness. Connect the connectors to the solenoids
- the oil temperature sensor with the holder and screw. Tighten. See the relevant specifications.
Note! Screw length given in mm as illustrated.
Install the cable harness on the holder. Check that the cable harness is correctly positioned.
Installing the control system cover
Check that the mating surface for the cover is level.
Wipe the cleaned mating surfaces on the cover and transmission.
Note! Ensure that no dirt gets into the transmission.
Apply an approximately 3 mm thick bead of sealing compound to the cover.
Also apply sealing compound around the screw holes.
Reinstall the control system cover on the transmission. Tighten according to applicable specifications.
Hint: Diagonally install 2 x 30 mm studs, correctly aligned in the cover.
Pull the cable up to the oil temperature sensor.
Install:
- the oil pipe to the transmission. Use a new O-ring
- the return line for the control system cover
- the cable harness for the holder on the cover.
Finishing
Installing components
Remove the spacer.
Position 998 5972 JACK 998 5972 Jack under the left-hand side of the sub-frame.
Press the frame up against the car body. Install 2 x M14 new screws to the sub-frame. Lubricate the threads. Tighten according to applicable specifications. Install the support plate screws at the same time.
Right-hand side:
Position the mobile jack under the right side of the sub-frame. Press the frame up. Install 2 x M14 new screws in the same way as on the left-hand side. Remove the jack.
Finally tighten the four frame screws. See applicable specifications.
Tighten the support plates. See applicable specifications.
Install:
- new locking nuts and screws for the steering gear. Tighten. See the relevant specifications.
- the screw for the front engine pad. Tighten. See the relevant specifications.
- new screws for the torque rod mounting. Tighten. See applicable specifications
Press the power steering line into the holders on the sub-frame.
Install the anti-roll bar link on the anti-roll bar.
Use a new nut.
Tighten. See applicable specifications
Caution! Use a torx wrench (1) as a counterhold. Do not damage the boot.
Note! Applies only to right-hand drive vehicles.
Install the screws for the collision protection system. Tighten. See applicable specifications
Install:
- the bracket for the heated oxygen sensor (HO2S).
Note! Applies only to right-hand drive vehicles.
- the cross member.
Ensure that the brake pipe is pressed into place in its holder.
Tighten the member. See applicable specifications
Install:
- the screw for the cable conduit
- the holder for the ground lead.
Note! Only applies to vehicles with parking heaters:
Install:
- the heater to the sub-frame
- the fuel line for the heater to the holders on the sub-frame
- the radiator hose.
Remove:
- 999 5716 Reading off tool 999 5716 Reading Off Tool
- 999 5460 Lifting hook 999 5460 Lifting Hook.
Installing the cable harness and transmission cables.
Note! Applies only to model year 2000.
Turn in the tab on the cable harness holder.
Install the screw for the gear shift position sensor/holder. Tighten. See applicable specifications.
Install the lever on the gear shift linkage rod. Tighten the nut. See applicable specifications.
Assembling the connectors
Assemble the sockets for the oil temperature sensor and solenoids with the other sockets.
Install the sockets in the casing.
Install the rubber seal in position.
Secure the cable harnesses and the rubber sleeves. Use cable ties.
Installing the connectors and cable harness
Install:
- the small connector to the bracket
- the connectors to the transmission. Tighten. See the relevant specifications.
- the transmission cable harness to the connectors
- the gear selector cable and bracket. Tighten. See applicable specifications.
Connect the cable to the lever.
Installing the cable harness and transmission cables.
Note! Applies only to model year 2001.
Turn in the tab on the cable harness holder.
Install:
- the screw for the gear shift position sensor holder. Tighten. See the relevant specifications.
- the lever for the gear shift linkage rod. Tighten the nut. See applicable specifications.
Installing the connector and cable harness
Hook the connectors into place on the mounting. Connect the connectors.
Install:
- the tie straps around the cable harness. Secure the cable harness in the cover for the control system
- the mounting for the cable harness on the bracket for the air cleaner (ACL)
- the gear selector cable and bracket. Tighten. See applicable specifications. Connect the cable to the lever.
Install the air cleaner (ACL) housing.
Oil level, checking and adjusting
Top up the transmission with 1.5 L of oil.
Check and adjust the oil level. See: Oil level, checking Checking Oil Level.
Installing splashguard under engine
Raise the vehicle.
Check for leakage.
Install:
- the front splash guard
- the outer front splash guards.