Contents: Removal 🠛 Installation 🠛
Caution! To prevent damage to the contact disc under the steering wheel, follow these instructions:
- before disconnecting the steering shaft from the steering gear, be sure to lock the steering wheel with a special device with the wheels set to the straight-ahead position, and the steering wheel must remain locked for the entire duration of the work;
- if there is any doubt about the correct centering of the contact disk, remove the steering wheel and center the contact disk.
Removal
Place the vehicle on a two-post lift.
Remove the top engine covers.
Disconnect the wires from the battery terminals, starting with the negative terminal.
Remove:
- air intake pipe;
- battery;
- shelf for battery;
- Injection system ECU with bracket;
- air intake duct;
- wiring harness fastenings.
Remove the multifunction switch cable ball end using the tool and the cable itself.
Disconnect the wiring block from the speed sensor, release the movable part of the connector and unscrew the bolts securing the modular connector bracket.
Caution: Protect the connector by placing it in a waterproof plastic bag.
Remove the engine crankshaft speed sensor.
Clamp the hoses.
Disconnect the hoses from the cooler.
Remove the wiring harness from the transmission.
Unscrew the two starter mounting bolts and remove the engine oil pan guard.
Drain the oil from the gearbox.
Remove the wheels and mudguards.
Disconnect the wires from the ABS sensors and the wires from the xenon headlight corrector sensors (if they are installed).
Note: The xenon headlight range control sensor is located on the left suspension arm.
Work performed on the left side of the vehicle
Unscrew the hub nut using the tool (Rou. 604-01).
Remove the tie rod end ball joint using the tool (Tav. 476).
Remove the ball joint of the anti-roll bar using the tool (Tav. 476).
Remove the suspension arm ball joint.
Disconnect the wheel drive shaft from the steering knuckle.
Remove the left front wheel drive shaft.
Remove the transmission ECU wiring harness bracket and side amplifier.
Open the transmission ECU wiring harness retainer and disconnect the transmission ECU connector.
Work performed on the right side of the vehicle
Unscrew the hub nut using the tool (Rou. 604-01).
Remove the tie rod end ball joint using the tool (Tav. 476).
Remove the ball joint of the anti-roll bar using the tool (Tav. 476).
Remove the suspension arm ball joint.
Remove the intermediate support flange.
Disconnect the drive shaft from the steering knuckle.
Remove the right front wheel drive shaft.
Secure the engine cooling system radiator assembly with the condenser to the upper cross member using twine.
Remove the side reinforcement.
Remove the lower radiator cross member.
Engine K4M
Unscrew the exhaust pipe mounting nuts and remove the jet rod.
F4R Engine
Unscrew the exhaust pipe mounting nuts and remove the jet rod.
Remove the brace securing the manifold to the bottom of the engine.
Unscrew the mounting bolt and remove the starter.
Unscrew the three nuts securing the torque converter.
Note: The torque converter mounting nuts are accessible after the starter has been removed. Turn the crankshaft clockwise to gain access to the three nuts that connect the drive plate to the torque converter.
Remove the upper studs securing the gearbox housing to the engine block.
Secure the hood with straps.
Remove the gearbox mount cushion.
Place a hydraulic jack under the gearbox.
Remove the lower bolts securing the gearbox to the engine block.
Remove the gearbox mounting studs.
Remove the automatic transmission.
Secure the torque converter with a cord to prevent it from moving.
Installation
Caution! Do not reuse the removed torque converter and drive disk mounting nuts, be sure to replace them with new ones.
Check for the presence of mounting bushings.
Installation is carried out in the reverse order of removal.
When installing an automatic transmission on an engine, ensure that the input shaft of the transmission and torque converter are precisely aligned.
Tighten to the specified torque:
- wheel mounting bolts (110 Nm);
- brake caliper guide pin mounting bolts (7 Nm);
- nut for fastening the ball joint pin of the steering rod end (37 Nm);
- nut for fastening the ball joint pin of the suspension arm (62 Nm);
- bolts for fastening the reaction rod to the subframe (105 Nm);
- gearbox and starter mounting bolts to the engine (44 Nm);
- gearbox pendulum support nut (62 Nm);
- tie rod end ball joint mounting nut (62 Nm);
- torque converter mounting nut on the drive disk (37 Nm);
- modular connector bracket mounting bolts (20 Nm);
- engine crankshaft speed sensor mounting bolts (10 Nm);
- bolts for fastening the jet thrust to the K4M engine (105 Nm);
- f4R engine thrust mounting bolts (180 Nm);
- the nut securing the pendulum support to the cushion (180 Nm).
Fill the automatic transmission with oil and check its level.
in case of oil change, reset the adaptive correction parameters using the command: RZ 005 "Resetting self-tuning parameters" and reset the oil service life counter in the automatic transmission ECU by giving the command: CF074 "Record the date of oil change in the gearbox".
After executing command RZ005, be sure to drive the vehicle with multiple upshifts and downshifts to memorize the new settings.