Note: If the transmission is removed for repair, test it in the vehicle first. Some tools will be required to support the weight of the transmission.
1. Park the car on a level surface, apply the handbrake, set the selector lever to position "P".
2. Open the hood, disconnect and remove the battery.
3. Remove the left front engine guard and the left fender liner.
4. Drain the transmission fluid. Loosen the clamps, disconnect the two flexible hoses. Label each hose.
5. Disconnect the kickdown cable from the transmission.
6. Disconnect the selector lever cable from the transmission.
7. Disconnect the electrical wiring.
8. Disconnect the speedometer drive cable.
9. Block the rear wheels, lift the front of the vehicle, and disconnect both drive shafts.
10. Working under the vehicle, unscrew the clutch housing dust cover and the exhaust system mount.
11. Mark the position of the transformer on the drive plate, unscrew the three bolts securing the drive plate to the transformer. Rotate the assembly by the crankshaft pulley bolt so that each mounting bolt is visible in the hole in the clutch housing (see figure 7.17.) First loosen each bolt, then loosen them completely again in a circle.
Figure 7.17. Bolt for fastening the drive disk to the torque converter (marked with an arrow)
12. Support the transmission with a jack or winch.
13. Remove the bolts and nut securing the clutch housing to the engine. Remove the starter. On 2.0L fuel injection models, remove the bolts securing the intake manifold to the transmission.
14. The left engine/transmission mount is in two pieces. One is attached to the inner fender assembly, the other, which has a large rubber grommet, is attached to the transmission. Remove the bolt and nut that secure the two halves of the mount.
15. Disconnect the transmission from the engine and lower it.
16. When installing, ensure that the engine and transmission mating surfaces are completely clean and dry and that the engine/transmission coupling plate is correctly positioned on the pins.
17. If the torque converter has been drained, fill it with approximately 2 liters of the specified fluid, install the torque converter into the transmission, being careful not to damage the seal.
18. Check that the torque converter is fully seated in the transmission. Referring to Figure 7.18, check that the distance 'A' between the mating surface of the clutch housing and the torque converter bulge is at least 19 mm.
Figure 7.18. Checking the torque converter installation: A = at least 19 mm
19. Installation is carried out in reverse order, please pay attention to the following points:
- (a) Use the marks made during disassembly to align the transformer and drive disc
- (b) Tighten the nuts and bolts to the tightening torque specified in Specifications
- (c) Adjust the gear selector lever mechanism and the reverse shift cable
- (d) Fill the transmission with the correct type of fluid
- (e) Check the operation of the transmission