Automatic gearbox (page 4 of 4)

Refit

1. Clean mating faces of engine and flywheel housing.

CAUTION: Do not apply grease to gearbox input shaft splines.

2. Position gearbox beneath vehicle and connect lifting equipment.
3. With assistance, raise gearbox and manoeuvre into position. Locate on 2 dowels.
4. Fit 2 lower bolts securing gearbox to engine.
5. Clean and degrease threads of 2 upper bolts securing gearbox to engine.
6. Apply Loctite 243 to threads of 2 upper bolts.
7. Models with air conditioning: Position air conditioning pipe bracket to flywheel housing.
8. Fit 2 upper bolts securing gearbox to engine and tighten to 85 Nm.
9. Tighten 2 lower bolts securing gearbox to engine to 85 Nm.
10. Raise engine and gearbox into position and locate on engine LH mounting.
11. Fit new Nylock nut securing engine LH mounting to bracket on gearbox and tighten to 160 Nm.
12. Remove jack positioned to support engine.
13. Fit flywheel rear cover plate to flywheel housing, fit bolts and tighten to 9 Nm.
14. Connect both drive shafts to gearbox, as detailed in Differential oil seal. See AUTOMATIC GEARBOX - ’CVT’, Repairs.
15. Models with air conditioning: Align air conditioning pipe to bracket, fit bolt and tighten to 9 Nm.
16. Remove bolt securing lifting bracket to gearbox.
17. Remove plugs from fluid cooler hose unions, lubricate new ’O’ rings with gearbox fluid and fit to unions.
18. Connect fluid cooler hoses to gearbox and tighten unions to 37 Nm.
19. Clean mating faces of front pipe and catalytic converter.
20. Fit new gasket to catalytic converter flange.
21. Connect front pipe to catalytic converter, fit nuts and tighten to 50 Nm.
22. Secure front pipe rubber mounting to bracket on body.
23. Fit kickdown cable to abutment bracket.
24. Connect kickdown inner cable to throttle cam.
25. Fit selector cable to abutment bracket and push anti-vibration rubbers into position.
26. Tighten selector cable lock nut to abutment bracket.
27. Slide selector cable rod to sleeving into position.
28. Connect selector cable rod to selector lever but DO NOT tighten nut.
29. Connect multiplug to starter inhibitor/reverse switch and secure harness to clip on gearbox.
30. Connect multiplug to vehicle speed sensor.
31. Position battery tray in vehicle.
32. Tighten 3 bolts securing battery tray to body to 10 Nm.
33. Position engine compartment fuse box to body, fit bolt and tighten to 10 Nm.
34. Fit 4 bolts securing battery tray to body and tighten to 10 Nm.
35. Fit and tighten bolt securing engine compartment fuse box to battery tray.
36. Fit engine management relay module. See ENGINE MANAGEMENT SYSTEM - MEMS, Repairs.
37. Fit ECM. See ENGINE MANAGEMENT SYSTEM - MEMS, Repairs.
38. Fit starter motor. See ELECTRICAL, Repairs.
39. Adjust selector cable. See AUTOMATIC GEARBOX - ’CVT’, Adjustments.
40. Adjust throttle and kickdown cables. See AUTOMATIC GEARBOX - ’CVT’, Adjustments.
41. Refill gearbox with fluid. See AUTOMATIC GEARBOX - ’CVT’, Adjustments.
42. Remove stand(s) and lower vehicle.