Powertrain with Automatic Transmission

Removal WARNING: The engine may be removed from the vehicle together with the power unit (i.e. assembled with the transmission), after which the transmission is separated from the engine for major overhaul.

The power unit is lowered and removed from under the vehicle. To remove the engine this way without obstruction, raise the vehicle to a height of at least 75 cm (from the floor to the front bumper) and support it on stands.

PROCEDURE

1. Perform the operations described in items 1–10 of subsection 3.2.2.

3. Port fuel injection engines

2. On port fuel injection engines, remove the air cleaner.

3. Relieve the fuel system pressure. Disconnect the fuel supply hose and the fuel return hose from the throttle body. Plug all openings to prevent fuel loss and contamination.

4. Disconnect the throttle cable.

5. Disconnect the wiring connectors from the throttle body, intake manifold and other components.

6. Disconnect the brake booster vacuum hose, the coolant hose, the vacuum hoses of the valves and the crankcase ventilation hoses mounted on the intake manifold.

7. Remove the intake manifold support bracket.

8. Remove the muffler inlet pipe.

Direct injection engines

9. On direct injection engines, remove the air cleaner duct.

10. Relieve the fuel system pressure. Disconnect the fuel supply hose and the fuel return hose from the throttle body. Plug all openings to prevent fuel loss and dirt ingress.

11. Disconnect the throttle cable from the throttle body.

12. Disconnect the wiring harness connectors from the throttle body, intake manifold and other components. Move the wiring aside from the intake manifold and cylinder head so that it does not obstruct engine removal.

13. Disconnect the brake booster vacuum hose, the coolant hose, the valve vacuum hoses and the crankcase ventilation hoses mounted on the intake manifold.

14. Remove the intake manifold support bracket.

15. Remove the muffler inlet pipe.

16. Loosen the clamps and disconnect the heater hoses and other cooling system hoses from the engine. Mark the original position of each hose before disconnecting.

17. On vehicles equipped with air conditioning, remove the compressor mounting bolts and move the compressor aside. Tie the compressor to the body so that its weight is not supported by the air conditioning lines and hoses. Do not disconnect the air conditioning hoses.

18. Remove the drive axles with the constant velocity joints (refer to Subsection 10.2).

19. Disconnect the gear selector cable from the transmission.

20. Disconnect the low range shift cable from the throttle body.

21. Disconnect the wiring harness connectors from the transmission.

22. Disconnect the transmission fluid cooler hoses from the transmission.

23. Disconnect the speedometer cable.

24. Attach the hoist to the cylinder head brackets and tension the hoist so that it supports the weight of the powertrain.

25. Loosen and remove the nut of the rear engine mount through-bolt, then remove the bolt from the mount.

26. Remove the four center member mounting bolts and take the center member out from under the powertrain. Remove the stopper ring installed between the rear engine mount and the bracket.

27. Remove the nut and the through-bolt of the right engine mount. Then remove the mounting bolts and take the mount out of the engine compartment. If the rubber cushions installed on both sides of the body-side bracket are loose, remove the cushions.

28. Remove the through-bolt of the left engine mount. Then remove the three mount bolts from the transmission case and move the mount aside. Remove the cushions installed on both sides of the mount bracket.

29. Check once more that all components, wires and hoses that may interfere with powertrain removal are disconnected or removed. Also make sure that no other vehicle parts (for example, the drive axles) will be damaged during removal.

30. If a low trolley is available, roll it under the engine to make it easier to remove the powertrain from under the vehicle. Lower the powertrain, taking care not to damage or catch adjacent components. This operation is best performed with an assistant, as the unit must be tilted slightly to avoid hitting body panels. Be extremely careful when lowering the engine.

31. Roll the powertrain out from under the vehicle.

Separating the Transmission from the Engine

PROCEDURE

1. Secure the removed powertrain with wooden blocks, placing it on a workbench or on a clean, level surface in the workshop.

2. Remove the mounting bolts and remove the starter motor from the transmission case.

3. Remove the bolts and remove the mounting plate from the oil pan flange. This gives access to the torque converter mounting bolts. Remove the first accessible bolt. Then, turning the crankshaft with a socket on the pulley, remove the remaining torque converter-to-drive plate bolts one by one as they become accessible. There are four bolts in total.

4. Take measures to prevent the torque converter from falling out during transmission removal. Secure the torque converter with a length of metal strap bolted to one of the starter mounting holes.

5. Make sure the powertrain is securely supported, then remove the bolts securing the transmission case to the engine. Mark the position of the bolts (and of the corresponding brackets on some vehicles) so they can be installed in their original locations.

6. Carefully separate the transmission from the engine. If the guide dowels in the transmission case or cylinder block are loose, remove them and store them so they can be installed in their original positions.

Installation

PROCEDURE

1. If the transmission was removed from the engine, perform the operations described in steps 2–7 below. If the transmission was not removed, follow step 8 and onward.

2. Before installation, make sure the torque converter is correctly seated in the transmission. Check this by measuring the distance from the torque converter mounting bolt holes to the transmission case mating surface, which must be at least 15.9 mm.

3. Install the guide dowels in the engine or transmission (if removed).

4. Carefully install the transmission on the engine, aligning it with the guide dowels. Install the transmission case bolts, making sure all brackets are correctly positioned, and tighten the bolts to the specified torque.

5. Remove the strap that held the torque converter in place during removal. Align the torque converter holes with the holes in the drive plate and install the mounting bolts.

6. Tighten the torque converter bolts to the specified torque. Install the mounting plate on the oil pan and secure it with bolts, tightening them fully.

7. Install the starter motor and tighten the bolts.

8. Position the powertrain under the vehicle and attach the hoist to the engine brackets.

9. With an assistant, raise the powertrain into the engine compartment, taking care not to catch adjacent components.

10. Install the rubber cushions on the left powertrain mount bracket, making sure the cushion studs enter the bracket holes. Install the mount in place, tighten the mount bolts to the transaxle to the specified torque. Insert the through bolt and tighten the nut by hand.

11. Install the rubber cushions on the right suspension bracket from the body side, making sure the cushion studs enter the holes in the bracket. Install the mount on the bracket and tighten the bolts to the specified torque. Insert the through bolt and tighten the nut by hand.

12. Make sure all rubber cushions are in their correct positions, and install the stopper ring on the rear engine mount. Install the center member, align it with the engine mount, and install the bolts with washers. Tighten the center member bolts to the specified torque.

13. Install the rear mount through-bolt and tighten the nut by hand.

14. Rock the powertrain to seat it in position, then tighten the tension bolts of the front, right and left mounts to the specified torque.

15. Install the powertrain in the reverse order of removal.

16. When installing, make sure that the wiring is routed along its original paths and secured with clips and brackets, and that all connectors are connected.

17. Replace the axle shaft seals and install the axle shaft assemblies with joints to the transaxle (see subsection 9.1.3).

18. Connect all cooling system hoses and secure them with clamps.

19. Adjust the throttle cable (see subsection 6.1.7).

20. Connect and adjust the gear selector cable and the low range shift cable (see subsection 9.2.4).

21. Install and adjust the drive belt(s) (see subsection 2.3.1.3).

22. Change the engine and transmission oil. For recommended oil grades, fluids and fill capacities, see subsection 1.12.7.

23. Fill the cooling system with coolant.

24. After completion, start the engine and check for leaks.