| Removal Special Tool(s) | | Support Bar, Engine 303-290A | | | Adapter for 303-290A 303-290-03A | | | Adapter for 303-290A 303-290-13 | | | Adapter for 303-290A 303-290A-15 | General Equipment Transmission jack Retaining straps | | -
Remove the battery carrier.
For additional information, refer to: Batteriekonsole - 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma)/1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) (414-01 Batterie, Befestigung und Batteriekabel, Removal and Installation).
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Remove the front wheels and tires.
For additional information, refer to: Rad und Reifen (204-04 Räder und Reifen, Removal and Installation).
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Remove the headlamp assembly on both sides.
For additional information, refer to: Scheinwerfereinheit (417-01 Außenbeleuchtung, Removal and Installation).
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Attach the special tool on both sides (right-hand side shown). | | | -
Raise the vehicle. For additional information, refer to: (100-02) Anheben mit Wagenheber (Description and Operation), Anheben mit Hebebühne (Description and Operation). | | | -
Remove the engine undershield. | | | -
Detach the radiator lower cover. | 9. Remove the components in the order indicated in the following illustration(s) and table(s). Removal Details Item 1 : Engine/transmission wiring harness connector | | -
Detach the engine/transmission wiring harness connector from the oil dipstick tube. | Item 2 : Engine/transmission wiring harness | | -
Detach the engine/transmission wiring harness from the oil dipstick tube holder. | Item 3 : Transmission upper bolts | | -
Remove the transmission upper retaining bolts. | Item 4 : Transmission fluid feed and return lines | | -
WARNING:Close off the transmission fluid cooler feed and return lines to prevent fluid loss or dirt ingress. CAUTION:Whenever releasing the transmission cooling system fluid, take care to prevent fluid scalding. Failure to follow this instruction may result in personal injury. NOTE:Installation positions of the feed and return lines are color coded in order to avoid confusion. Supply line to transmission fluid cooler: red identification on transmission quick-release coupling; return line from transmission fluid cooler: black identification on transmission quick-release coupling. Detach the transmission fluid cooler feed and return lines from the automatic transmission. - Push the transmission fluid cooler feed and return line quick release connector in direction of arrow.
- Press together the retaining tabs and detach the transmission fluid cooler feed and return lines from the automatic transmission.
- Drain the fluid into a suitable container.
| Item 5 : Automatic transmission electrical connector. | | -
Disconnect the transmission harness electrical connectors. | Item 6 : Turbine speed sensor (TSS). | | -
Disconnect the TSS sensor connector. | Item 7 : Output shaft speed (OSS) sensor. | | -
Disconnect the output shaft speed (OSS) sensor connector. | Item 8 : Starter motor. | | -
NOTE:Starter remains in installation position. Detach the starter motor from the transmission. - Detach the ground lead from the transmission.
| Item 9 : Left-hand radiator support bracket | | -
Raise the vehicle. For additional information, refer to: (100-02) Anheben mit Wagenheber (Description and Operation), Anheben mit Hebebühne (Description and Operation). | | | -
Detach the left-hand radiator support bracket. - Loosen the radiator support bracket front bolt by three turns.
- Remove the rear radiator support bracket bolt.
| Item 10 : Crash box Item 11 : Exhaust pipe | | -
Remove the strengthening bar. | | | -
WARNING:Excessive bending of the flexible exhaust pipe can cause damage that may lead to component failure. Support the flexible exhaust pipe using a suitable support gaiter or reinforcement. | | | -
WARNING:The flexible exhaust pipe must not be twisted by more than two degrees. Failure to follow this instruction may result in damage to the flexible exhaust pipe. NOTE:Use a tyre lever to prevent the flexible exhaust pipe from twisting when undoing the nuts. Detach the catalytic converter with flexible exhaust pipe from the silencer. - Discard the flexible exhaust pipe gasket and nuts.
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Unhook the front exhaust pipe from the rubber mountings. | Item 12 : Engine roll restrictor rubber mounting | | -
Remove the engine roll restrictor rubber mounting | Item 13 : Right-hand front drive halfshaft | | -
Remove the right-hand front drive halfshaft with intermediate shaft.
For additional information, refer to: Rechte Antriebswelle (205-04 Vorderradantriebswellen, Removal and Installation).
| Item 14 : Left-hand front drive halfshaft | | -
Remove the left-hand front drive halfshaft.
For additional information, refer to: Linke Antriebswelle (205-04 Vorderradantriebswellen, Removal and Installation).
| Item 15 : Rear engine mounting | | -
Install the special tool. | | | -
Remove and discard the rear engine mounting bolt. | Item 16 : Transmission (TR) sensor connector | | -
Raise the vehicle. For additional information, refer to: (100-02) Anheben mit Wagenheber (Description and Operation), Anheben mit Hebebühne (Description and Operation). | | | -
Disconnect the TR sensor connector. | Item 17 : Selector cable | | -
CAUTION:Do not kink the selector lever cable. Detach the selector lever cable from the transmission. - Detach the selector lever cable from the selector lever.
- Lift the locking tab, press the locking pins together and detach the selector lever cable from the abutment.
| Item 18 : Transmission lower retaining bolts | | -
Remove and dispose of the torque converter nuts (four nuts). | | | -
Remove the engine rear mount bracket (engine rear mount shown removed and from above for clarity). | | | -
Remove the transmission lower bolts. | | | -
NOTE:Use a suitable wooden block to protect the transmission. Secure the transmission on the transmission jack using suitable retaining straps. | | | -
Remove the transmission right-hand retaining bolts. | | | -
Remove the left-hand transmission bolt. | | | -
CAUTION:Make sure the torque converter remains in the torque converter housing. Support the transmission using the transmission jack and remove. | |
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