Saab 2000-06

Transmission Removal & Installation

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  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Drain the transmission.
  4.  
  5. Remove or disconnect the following: Intake manifold cover or resonator with hoses and MAF sensorBatteryGround strap from the transmission housingDipstick and sleeve (plug opening in block)Vent hose from the transmission housingPositive cable routing strapsGearshift selector lever from housingElectrical harness on transmission housingOxygen sensor connectors and securing straps3 upper bolts on gearboxRemove strain from powertrain with engine hoistFront wheelsFront exhaust pipesCooler lines from the transmission (plug all openings)Air shields and cover in right wheel housingEnd pieces from suspension arms on both sides2 nuts from rear engine mount and 2 middle bolts from subframe

    Intake manifold cover or resonator with hoses and MAF sensor
     
    Battery
     
    Ground strap from the transmission housing
     
    Dipstick and sleeve (plug opening in block)
     
    Vent hose from the transmission housing
     
    Positive cable routing straps
     
    Gearshift selector lever from housing
     
    Electrical harness on transmission housing
     
    Oxygen sensor connectors and securing straps
     
    3 upper bolts on gearbox
     
    Remove strain from powertrain with engine hoist
     
    Front wheels
     
    Front exhaust pipes
     
    Cooler lines from the transmission (plug all openings)
     
    Air shields and cover in right wheel housing
     
    End pieces from suspension arms on both sides
     
    2 nuts from rear engine mount and 2 middle bolts from subframe
     

  6.  
  7. Position lifting trolley, 83 94 793, with fixture, 83 94 801, and front and rear holders, 83 94 819 and 83 90 827 under subframe.
  8.  
  9. Remove the remaining bolts securing the subframe. Note position of washers on rear mount.
  10.  
  11. Lower the lifting trolley assembly, with subframe and move it out of the way.
  12.  
  13. Detach the left driveshaft from the gearbox by releasing at the splines, then pulling straight out.
  14.  
  15. Suspend the driveshaft with a securing strap.
  16.  
  17. Remove or disconnect the following:
  18.  
  19. Remove the flywheel splash plate.
  20.  
  21. Remove the torque converter-to-driveplate bolts (rotate crankshaft to access bolts).
  22.  
  23. Remove the rubber plug and install a torque converter holding tool, 87 92 277, into opening.
  24.  


NOTE
Some transmissions may not have a hole in which to fit the tool. Therefore, drill a 5mm hole and thread it was an M6 tap.

  1. Remove the rear engine-to-transmission bolt.
  2.  
  3. Remove the front engine mount bolts.
  4.  
  5. Lower the car, then lower the engine and transmission assembly with the lifting equipment until there is a slight amount of play between the body and from transmission mount (play can be seen from left wheel housing).
  6.  
  7. Raise the car. Install a lifting tool,87 92 608, onto a pillar jack. Adjust the tool so it is centered with lifting lug on top of the transmission. Tighten it on the transmission.
  8.  
  9. Remove the front bolt between the engine and transmission.
  10.  
  11. Pull out and lower the transmission, using care with the pillar jack.
  12.  
  13. Lift transmission from pillar jack with engine lift.
  14.  


    Click image to see an enlarged view

    Fig. Installing torque converter holding tool-9-3 (2001)


To install:


NOTE
If installing a new transmission, transfer torque converter holding tool to new assembly.

  1. Turn torque converter so bolt holes line up with drive plate holes.
  2.  
  3. Be sure both guide sleeves are on the engine. Lubricate sleeves with a thin layer of anti-corrosion oil.
  4.  
  5. Install new driveshaft seals. Lubricate seals.
  6.  
  7. Using a hoist lift and pillar jack to lift the transmission.
  8.  
  9. Install a protective collar, 83 95 162, in right shaft seal on the transmission to protect the seal when the transmission is installed.
  10.  
  11. Position the transmission in the car. Push the transmission into place until about 0.8 inch (20 mm) remains, then remove the protective collar.
  12.  
  13. Tighten the lower transmission-to-engine mounting bolts to 55 ft. lbs. (75 Nm).
  14.  
  15. Install the rear engine mount on the transmission and torque the bolt to 30 ft. lbs. (40 Nm).
  16.  
  17. Lift powertrain and tighten left engine mount to body. Torque bolt to 46 ft. lbs. (62 Nm).
  18.  
  19. Remove torque converter holding tool. Install the rubber plug.
  20.  
  21. Apply thread sealer to torque converter bolt. Use original bolts with washers. Longer bolts will ruin the torque converter. Install all 6 bolts, then tighten the bolts to 44 ft. lbs. (60 Nm).
  22.  
  23. Install the flywheel splash guard.
  24.  
  25. Install a protective collar (16), 83 95 162, in the sealing ring prior to installing the driveshaft.
  26.  
  27. Make sure the driveshaft is clean. Install driveshaft, inserting all except about 0.8 inch (20 mm) into the transmission. Remove the protective collar tool before the shaft sealing surface reaches the shaft seal.
  28.  
  29. Push the driveshaft fully in until the circlip clicks, indicating engagement.
  30.  
  31. Reattach transmission oil cooler lines. If necessary, clean oil cooling system first. Make sure lines do not contact the subframe after installation. Use new lubricated seals. Tighten fittings to 20 ft. lbs. (27 Nm).
  32.  
  33. Carefully raise the subframe. Ensure washers on rear mounts are in place, then position suspension arm end pieces, but do not tighten at this time.
  34.  
  35. Adjust subframe so the bolt holes are aligned with the body.
  36.  
  37. Tighten the 4 corner subframe bolts as follows: Front bolts: 85 ft. lbs. (115 Nm)Rear bolts: 81 ft. lbs. (110 Nm), plus an additional 75 degrees.

    Front bolts: 85 ft. lbs. (115 Nm)
     
    Rear bolts: 81 ft. lbs. (110 Nm), plus an additional 75 degrees.
     

  38.  
  39. Lower the lifting trolley and move out of the way.
  40.  
  41. Tighten the remaining subframe bolts to 141 ft. lbs. (190 Nm).
  42.  
  43. Tighten the rear engine mount nuts to 37 ft. lbs. (50 Nm).
  44.  
  45. Tighten the suspension arm end pieces on both sides. Tighten nuts to 55 ft. lbs. (75 Nm).
  46.  
  47. Install or connect the following: Ground lead to transmissionAir shields and lining in right wheel housingFront exhaust pipe; torque exhaust flange nuts to 30 ft. lbs. (40 Nm)Install clips for oxygen sensor wiring.Front wheels; torque wheel nuts to 81 ft. lbs. (110 Nm)Remove engine hoist and tighten top bolts between engine and transmission to 55 ft. lbs. (75 Nm)Oxygen sensor (attach clips)Positive cable mount on engineConnectors for transmission (behind battery)Dipstick tubeTransmission vent tubeShift cable to bracket on transmission (install clamp)Shift cable to selector leverIntake manifold cover, or resonator, with hoses and MAF sensor

    Ground lead to transmission
     
    Air shields and lining in right wheel housing
     
    Front exhaust pipe; torque exhaust flange nuts to 30 ft. lbs. (40 Nm)
     
    Install clips for oxygen sensor wiring.
     
    Front wheels; torque wheel nuts to 81 ft. lbs. (110 Nm)
     
    Remove engine hoist and tighten top bolts between engine and transmission to 55 ft. lbs. (75 Nm)
     
    Oxygen sensor (attach clips)
     
    Positive cable mount on engine
     
    Connectors for transmission (behind battery)
     
    Dipstick tube
     
    Transmission vent tube
     
    Shift cable to bracket on transmission (install clamp)
     
    Shift cable to selector lever
     
    Intake manifold cover, or resonator, with hoses and MAF sensor
     

  48.  
  49. Check positions of selector lever and adjust if necessary.
  50.  
  51. Connect the battery negative cable to ground on transmission
  52.  
  53. Install the battery.
  54.  
  55. Refill the transmission with Dexron III®.
  56.  
  57. Test drive the car at varying speeds and loads. Check for diagnostic codes.
  58.  


    Click image to see an enlarged view

    Fig. Showing protective collar for using when installing the driveshaft-9-3 (2001-02)


  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Remove or disconnect the following: Front grille (2001 only)Intake manifold coverBattery and trayMAXI fuse board (2002-04 only)16 pin and 10 pin wire connectorsTransmission breather hoseGear selector arm from the transmission (place lever in L position)Shifting cableCable channel from the engine and gear case (3.0L engine only)3 upper bolts from the transmissionDipstick tube (plug hole in block)Oxygen sensor connectorsRear engine mount nutTop 2 bolts from the rear engine cushion, loosen only

    Front grille (2001 only)
     
    Intake manifold cover
     
    Battery and tray
     
    MAXI fuse board (2002-04 only)
     
    16 pin and 10 pin wire connectors
     
    Transmission breather hose
     
    Gear selector arm from the transmission (place lever in L position)
     
    Shifting cable
     
    Cable channel from the engine and gear case (3.0L engine only)
     
    3 upper bolts from the transmission
     
    Dipstick tube (plug hole in block)
     
    Oxygen sensor connectors
     
    Rear engine mount nut
     
    Top 2 bolts from the rear engine cushion, loosen only
     

  4.  
  5. Install a lifting beam to the engine and relieve the weight on the engine and transmission.
  6.  
  7. Remove or disconnect the following: Both front wheelsLower engine coverFront exhaust systemRear engine bracket and padSteering gear boltsRear clamps securing the power steering delivery pipe to the subframeA/C pipes from the subframe holderAir cleaner casing from the subframeEngine oil cooler from the charge air cooler (2.3L engine only)

    Both front wheels
     
    Lower engine cover
     
    Front exhaust system
     
    Rear engine bracket and pad
     
    Steering gear bolts
     
    Rear clamps securing the power steering delivery pipe to the subframe
     
    A/C pipes from the subframe holder
     
    Air cleaner casing from the subframe
     
    Engine oil cooler from the charge air cooler (2.3L engine only)
     

  8.  
  9. Attach a strap around the radiator and crossmember to restrain the radiator.
  10.  
  11. Remove or disconnect the following: Outer ball joint to steering knuckle boltsUpper anti-roll bar ball jointsTorque arm from the subframeRear support plates

    Outer ball joint to steering knuckle bolts
     
    Upper anti-roll bar ball joints
     
    Torque arm from the subframe
     
    Rear support plates
     

  12.  
  13. Position a lifting trolley with a holder under the vehicle. Align the trolley to the subframe.
  14.  
  15. Remove or disconnect the following: Remaining bolts from the subframe and slightly lower the subframePower steering delivery pipe clamps. Lower the lifting trolley and move the subframe asideSplash plate (2.3L engine only)Plug covering the torque converter bolts (3.0L engine only)Bolts securing the torque converter to the drive plate. Rotate the plate and pulley together

    Remaining bolts from the subframe and slightly lower the subframe
     
    Power steering delivery pipe clamps. Lower the lifting trolley and move the subframe aside
     
    Splash plate (2.3L engine only)
     
    Plug covering the torque converter bolts (3.0L engine only)
     
    Bolts securing the torque converter to the drive plate. Rotate the plate and pulley together
     

  16.  


NOTE
The crankshaft must be rotated to gain access for all the bolts.

  1. Press the torque converter against the transmission to keep the converter in place during transmission removal.
  2.  
  3. Remove or disconnect the following: Ground leadsTorque arm and bracketTransmission fluidOil cooler inlet and outlet hoses (plug openings)Left driveshaft and suspend itLeft side engine pad; lower transmission to clear structural memberTransmission bracketTransmission from the engine assembly using a single-column jackTransmission from the vehicle

    Ground leads
     
    Torque arm and bracket
     
    Transmission fluid
     
    Oil cooler inlet and outlet hoses (plug openings)
     
    Left driveshaft and suspend it
     
    Left side engine pad; lower transmission to clear structural member
     
    Transmission bracket
     
    Transmission from the engine assembly using a single-column jack
     
    Transmission from the vehicle
     

  4.  

To install:

  1. Rotate the torque converter so that the bolt holes align with the drive plate.
  2.  
  3. Make certain that the 2 guide sleeves are on the engine.
  4.  
  5. Lubricate and install new driveshaft seals.
  6.  
  7. Raise the transmission into position under the vehicle.
  8.  
  9. Install the transmission and torque the bottom bolts between the engine and transmission to 55 ft. lbs. (74 Nm) and the bolts between the transmission and oil pan to 34 ft. lbs. (47 Nm)
  10.  
  11. Remove the lifting beam from the transmission .
  12.  
  13. Install or connect the following: Transmission bolts and torque the bolts to 18 ft. lbs. (24 Nm)Engine pad mount to the transmission and torque the bolts to 62 ft. lbs. (84 Nm)Bolts securing the engine pad to the body and torque the bolts to 46 ft. lbs. (63 Nm)Protective sleeve in driveshaft sealDriveshaft and make certain that the circlip snaps into position (remove protective sleeve just before driveshaft is fully into transmission)Torque converter to drive plate and torque the bolts to 22 ft. lbs. (30 Nm)Splash plate (2.3L engine only)Plug covering the torque converter bolts (3.0L engine only)Cooler hoses and torque the fasteners to 20 ft. lbs. (27 Nm)Torque arm bracketGround cable to the bracket and raise the subframe into positionPower steering delivery pipe clampsOuter ball joints and A/C pipesSubframe and rear support plates and torque the subframe bolts to 74 ft. lbs. (100 Nm) plus 45 degrees and the support plate bolts to 44 ft. lbs. (60 Nm)Outer ball joints to the steering knuckles and torque the bolts to 63 ft. lbs. (85 Nm)Anti-Roll Bar link and torque the fastener to 68 ft. lbs. (92 Nm)Steering gear and torque the bolts to 66 ft. lbs. (90 Nm)Engine oil cooler and air filter housing (2.3L engine only)Rear engine cushionRear engine mount; torque bolts to 55 ft. lbs. (70 Nm)Oil pan-to-transmission bolts; torque to 34 ft. lbs. (47 Nm) (3.0L engine only)Torque arm-to-subframe; torque bolts to 19 ft. lbs. (25 Nm)Front exhaust system; torque bolts to 18 ft. lbs. (24 Nm) on 2.3L engine. On the 3.0L engine torque turbo bolts to 18 ft. lbs. (24 Nm) and exhaust manifold bolts to 30 ft. lbs. (40 Nm).Oxygen sensor wiring connectors and remove lifting beamTorque rear engine cushion bolts to 18 ft. lbs. (24 Nm) and nut to 33 ft. lbs. (45 Nm).Engine to transmission; torque bolts to 55 ft. lbs. (70 Nm)Cable channel to the transmission (3.0L engine only)Dipstick tubeTransmission breather hoseShifter cable to bracketShifter cable to selector lever; adjust if necessaryTorque rod and torque bolt to 34 ft. lbs. (47 Nm)MAXI fuse board (2002-04 only)Battery tray and batteryBattery cables and coverIntake manifold coverFront grille (2000-01 only)Front wheels

    Transmission bolts and torque the bolts to 18 ft. lbs. (24 Nm)
     
    Engine pad mount to the transmission and torque the bolts to 62 ft. lbs. (84 Nm)
     
    Bolts securing the engine pad to the body and torque the bolts to 46 ft. lbs. (63 Nm)
     
    Protective sleeve in driveshaft seal
     
    Driveshaft and make certain that the circlip snaps into position (remove protective sleeve just before driveshaft is fully into transmission)
     
    Torque converter to drive plate and torque the bolts to 22 ft. lbs. (30 Nm)
     
    Splash plate (2.3L engine only)
     
    Plug covering the torque converter bolts (3.0L engine only)
     
    Cooler hoses and torque the fasteners to 20 ft. lbs. (27 Nm)
     
    Torque arm bracket
     
    Ground cable to the bracket and raise the subframe into position
     
    Power steering delivery pipe clamps
     
    Outer ball joints and A/C pipes
     
    Subframe and rear support plates and torque the subframe bolts to 74 ft. lbs. (100 Nm) plus 45 degrees and the support plate bolts to 44 ft. lbs. (60 Nm)
     
    Outer ball joints to the steering knuckles and torque the bolts to 63 ft. lbs. (85 Nm)
     
    Anti-Roll Bar link and torque the fastener to 68 ft. lbs. (92 Nm)
     
    Steering gear and torque the bolts to 66 ft. lbs. (90 Nm)
     
    Engine oil cooler and air filter housing (2.3L engine only)
     
    Rear engine cushion
     
    Rear engine mount; torque bolts to 55 ft. lbs. (70 Nm)
     
    Oil pan-to-transmission bolts; torque to 34 ft. lbs. (47 Nm) (3.0L engine only)
     
    Torque arm-to-subframe; torque bolts to 19 ft. lbs. (25 Nm)
     
    Front exhaust system; torque bolts to 18 ft. lbs. (24 Nm) on 2.3L engine. On the 3.0L engine torque turbo bolts to 18 ft. lbs. (24 Nm) and exhaust manifold bolts to 30 ft. lbs. (40 Nm).
     
    Oxygen sensor wiring connectors and remove lifting beam
     
    Torque rear engine cushion bolts to 18 ft. lbs. (24 Nm) and nut to 33 ft. lbs. (45 Nm).
     
    Engine to transmission; torque bolts to 55 ft. lbs. (70 Nm)
     
    Cable channel to the transmission (3.0L engine only)
     
    Dipstick tube
     
    Transmission breather hose
     
    Shifter cable to bracket
     
    Shifter cable to selector lever; adjust if necessary
     
    Torque rod and torque bolt to 34 ft. lbs. (47 Nm)
     
    MAXI fuse board (2002-04 only)
     
    Battery tray and battery
     
    Battery cables and cover
     
    Intake manifold cover
     
    Front grille (2000-01 only)
     
    Front wheels
     

  14.  
  15. Fill the transmission to the proper level.
  16.  
  17. Start the vehicle, check for leaks and repair if necessary.
  18.  

  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Drain the transmission.
  4.  
  5. Remove or disconnect the following: Intake manifold cover or resonator with hoses and MAF sensorBatteryGround strap from the transmission housingDipstick and sleeve (plug opening in block)Vent hose from the transmission housingPositive cable routing strapsGearshift selector lever from housingElectrical harness on transmission housingOxygen sensor connectors and securing straps3 upper bolts on gearboxRemove strain from powertrain with engine hoistFront wheelsFront exhaust pipesCooler lines from the transmission (plug all openings)Air shields and cover in right wheel housingEnd pieces from suspension arms on both sides2 nuts from rear engine mount and 2 middle bolts from subframe

    Intake manifold cover or resonator with hoses and MAF sensor
     
    Battery
     
    Ground strap from the transmission housing
     
    Dipstick and sleeve (plug opening in block)
     
    Vent hose from the transmission housing
     
    Positive cable routing straps
     
    Gearshift selector lever from housing
     
    Electrical harness on transmission housing
     
    Oxygen sensor connectors and securing straps
     
    3 upper bolts on gearbox
     
    Remove strain from powertrain with engine hoist
     
    Front wheels
     
    Front exhaust pipes
     
    Cooler lines from the transmission (plug all openings)
     
    Air shields and cover in right wheel housing
     
    End pieces from suspension arms on both sides
     
    2 nuts from rear engine mount and 2 middle bolts from subframe
     

  6.  
  7. Position lifting trolley, 83 94 793, with fixture, 83 94 801, and front and rear holders, 83 94 819 and 83 90 827 under subframe.
  8.  
  9. Remove the remaining bolts securing the subframe. Note position of washers on rear mount.
  10.  
  11. Lower the lifting trolley assembly, with subframe and move it out of the way.
  12.  
  13. Detach the left driveshaft from the gearbox by releasing at the splines, then pulling straight out.
  14.  
  15. Suspend the driveshaft with a securing strap.
  16.  
  17. Remove or disconnect the following:
  18.  
  19. Remove the flywheel splash plate.
  20.  
  21. Remove the torque converter-to-driveplate bolts (rotate crankshaft to access bolts).
  22.  
  23. Remove the rubber plug and install a torque converter holding tool, 87 92 277, into opening.
  24.  


NOTE
Some transmissions may not have a hole in which to fit the tool. Therefore, drill a 5mm hole and thread it was an M6 tap.

  1. Remove the rear engine-to-transmission bolt.
  2.  
  3. Remove the front engine mount bolts.
  4.  
  5. Lower the car, then lower the engine and transmission assembly with the lifting equipment until there is a slight amount of play between the body and from transmission mount (play can be seen from left wheel housing).
  6.  
  7. Raise the car. Install a lifting tool,87 92 608, onto a pillar jack. Adjust the tool so it is centered with lifting lug on top of the transmission. Tighten it on the transmission.
  8.  
  9. Remove the front bolt between the engine and transmission.
  10.  
  11. Pull out and lower the transmission, using care with the pillar jack.
  12.  
  13. Lift transmission from pillar jack with engine lift.
  14.  


    Click image to see an enlarged view

    Fig. Installing torque converter holding tool-9-3 2001)


To install:


NOTE
If installing a new transmission, transfer torque converter holding tool to new assembly.

  1. Turn torque converter so bolt holes line up with drive plate holes.
  2.  
  3. Be sure both guide sleeves are on the engine. Lubricate sleeves with a thin layer of anti-corrosion oil.
  4.  
  5. Install new driveshaft seals. Lubricate seals.
  6.  
  7. Using a hoist lift and pillar jack to lift the transmission.
  8.  
  9. Install a protective collar, 83 95 162, in right shaft seal on the transmission to protect the seal when the transmission is installed.
  10.  
  11. Position the transmission in the car. Push the transmission into place until about 0.8 inch (20 mm) remains, then remove the protective collar.
  12.  
  13. Tighten the lower transmission-to-engine mounting bolts to 55 ft. lbs. (75 Nm).
  14.  
  15. Install the rear engine mount on the transmission and torque the bolt to 30 ft. lbs. (40 Nm).
  16.  
  17. Lift powertrain and tighten left engine mount to body. Torque bolt to 46 ft. lbs. (62 Nm).
  18.  
  19. Remove torque converter holding tool. Install the rubber plug.
  20.  
  21. Apply thread sealer to torque converter bolt. Use original bolts with washers. Longer bolts will ruin the torque converter. Install all 6 bolts, then tighten the bolts to 44 ft. lbs. (60 Nm).
  22.  
  23. Install the flywheel splash guard.
  24.  
  25. Install a protective collar (16), 83 95 162, in the sealing ring prior to installing the driveshaft.
  26.  
  27. Make sure the driveshaft is clean. Install driveshaft, inserting all except about 0.8 inch (20 mm) into the transmission. Remove the protective collar tool before the shaft sealing surface reaches the shaft seal.
  28.  
  29. Push the driveshaft fully in until the circlip clicks, indicating engagement.
  30.  
  31. Reattach transmission oil cooler lines. If necessary, clean oil cooling system first. Make sure lines do not contact the subframe after installation. Use new lubricated seals. Tighten fittings to 20 ft. lbs. (27 Nm).
  32.  
  33. Carefully raise the subframe. Ensure washers on rear mounts are in place, then position suspension arm end pieces, but do not tighten at this time.
  34.  
  35. Adjust subframe so the bolt holes are aligned with the body.
  36.  
  37. Tighten the 4 corner subframe bolts as follows: Front bolts: 85 ft. lbs. (115 Nm)Rear bolts: 81 ft. lbs. (110 Nm), plus an additional 75 degrees.

    Front bolts: 85 ft. lbs. (115 Nm)
     
    Rear bolts: 81 ft. lbs. (110 Nm), plus an additional 75 degrees.
     

  38.  
  39. Lower the lifting trolley and move out of the way.
  40.  
  41. Tighten the remaining subframe bolts to 141 ft. lbs. (190 Nm).
  42.  
  43. Tighten the rear engine mount nuts to 37 ft. lbs. (50 Nm).
  44.  
  45. Tighten the suspension arm end pieces on both sides. Tighten nuts to 55 ft. lbs. (75 Nm).
  46.  
  47. Install or connect the following: Ground lead to transmissionAir shields and lining in right wheel housingFront exhaust pipe; torque exhaust flange nuts to 30 ft. lbs. (40 Nm)Install clips for oxygen sensor wiring.Front wheels; torque wheel nuts to 81 ft. lbs. (110 Nm)Remove engine hoist and tighten top bolts between engine and transmission to 55 ft. lbs. (75 Nm)Oxygen sensor (attach clips)Positive cable mount on engineConnectors for transmission (behind battery)Dipstick tubeTransmission vent tubeShift cable to bracket on transmission (install clamp)Shift cable to selector leverIntake manifold cover, or resonator, with hoses and MAF sensor

    Ground lead to transmission
     
    Air shields and lining in right wheel housing
     
    Front exhaust pipe; torque exhaust flange nuts to 30 ft. lbs. (40 Nm)
     
    Install clips for oxygen sensor wiring.
     
    Front wheels; torque wheel nuts to 81 ft. lbs. (110 Nm)
     
    Remove engine hoist and tighten top bolts between engine and transmission to 55 ft. lbs. (75 Nm)
     
    Oxygen sensor (attach clips)
     
    Positive cable mount on engine
     
    Connectors for transmission (behind battery)
     
    Dipstick tube
     
    Transmission vent tube
     
    Shift cable to bracket on transmission (install clamp)
     
    Shift cable to selector lever
     
    Intake manifold cover, or resonator, with hoses and MAF sensor
     

  48.  
  49. Check positions of selector lever and adjust if necessary.
  50.  
  51. Connect the battery negative cable to ground on transmission
  52.  
  53. Install the battery.
  54.  
  55. Refill the transmission with Dexron III®.
  56.  
  57. Test drive the car at varying speeds and loads. Check for diagnostic codes.
  58.  


    Click image to see an enlarged view

    Fig. Showing protective collar for using when installing the driveshaft-9-3 2001-02


  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Remove or disconnect the following: Upper engine coverBattery coverBattery with coolant pipe, bonnet switch and fuse boxControl module connectorBattery trayConnector under control moduleVentilation hose from transmissionGear cable from selector lever arm (selector lever must be in N)Cable from the cable retainer (pull back locking sleeve)Ground cable from transmission casingUpper bolts on transmission casingExpansion tank from its holderInstall engine lifting eyes. Attach a lifting beam and hoist to lifting eyes.Dipstick

    Upper engine cover
     
    Battery cover
     
    Battery with coolant pipe, bonnet switch and fuse box
     
    Control module connector
     
    Battery tray
     
    Connector under control module
     
    Ventilation hose from transmission
     
    Gear cable from selector lever arm (selector lever must be in N)
     
    Cable from the cable retainer (pull back locking sleeve)
     
    Ground cable from transmission casing
     
    Upper bolts on transmission casing
     
    Expansion tank from its holder
     
    Install engine lifting eyes. Attach a lifting beam and hoist to lifting eyes.
     
    Dipstick
     

  4.  
  5. With the hoist, take weight off the engine and transmission.
  6.  
  7. Remove the upper bumper shell mountings.
  8.  
  9. Attach 2 straps above the radiator core so they are accessible from below (these will be used to restrain the radiator).
  10.  
  11. Remove or disconnect the following: Front wheelsLower front cover, then secure radiator core with strapsRadiator brackets from subframeExhaust pipe (cut about 3.5 inches (87mm) from front of muffler)Engine torque rod from subframeBolt and nut holding suspension arm to steering swivel member on both sidesAnti-roll bar from link armConnector and cable clip of headlamp angle sensor (if equipped)Steering gear from subframe (retain nuts and washers); leave steering gear hangingPower steering pipe from subframeFront part of fender liner (bend it out of the way)

    Front wheels
     
    Lower front cover, then secure radiator core with straps
     
    Radiator brackets from subframe
     
    Exhaust pipe (cut about 3.5 inches (87mm) from front of muffler)
     
    Engine torque rod from subframe
     
    Bolt and nut holding suspension arm to steering swivel member on both sides
     
    Anti-roll bar from link arm
     
    Connector and cable clip of headlamp angle sensor (if equipped)
     
    Steering gear from subframe (retain nuts and washers); leave steering gear hanging
     
    Power steering pipe from subframe
     
    Front part of fender liner (bend it out of the way)
     

  12.  
  13. Position a trolley lift with jig underneath. Remove the subframe bolts and the rear brackets. Lower the subframe slightly.
  14.  
  15. Separate the steering arm ball joints from the steering swivel members.
  16.  
  17. Remove the anti-roll bar from the subframe (protect the steering gear boot). Install the bolts loosely in the link arms so the anti-roll bar is kept hanging in place.
  18.  
  19. Lower the subframe.
  20.  
  21. Remove the torque rod bracket. Undo the bolt for the torque rod for easier fitting.
  22.  
  23. Remove or disconnect the following: Starter motorTorque converter from drive plate (6 bolts; turn crankshaft to access bolts)Undo plug and press torque converter towards transmission; install holding toolTransmission fluidOil cooling hoses; plug holes and hosesBolts in charge air pipe bracket and move pipe asideLower transmission bolts; leave one bolt loosely in placeGround lead from transmissionABS cable from clipLeft driveshaft; suspend driveshaft by means of a cable tie

    Starter motor
     
    Torque converter from drive plate (6 bolts; turn crankshaft to access bolts)
     
    Undo plug and press torque converter towards transmission; install holding tool
     
    Transmission fluid
     
    Oil cooling hoses; plug holes and hoses
     
    Bolts in charge air pipe bracket and move pipe aside
     
    Lower transmission bolts; leave one bolt loosely in place
     
    Ground lead from transmission
     
    ABS cable from clip
     
    Left driveshaft; suspend driveshaft by means of a cable tie
     

  24.  
  25. Lower the car, mark the location of the bolts on the left engine mount with a marker pen to ensure correct refitting. Remove the engine mount bracket.
  26.  
  27. Lower the powertrain with the lifting beam to facilitate removal of the transmission.
  28.  
  29. Undo the clip securing the power steering hose.
  30.  
  31. Raise the car and move the power steering cooling coil aside and restrain with a strap.
  32.  
  33. Install a holding device, 87 92 608, onto a column jack. Adjust and tighten the tool on the transmission. Use a bolt with 8.8 grade that is approx. 0.8 inch (20mm) longer than the removed bolt as well as a bolt (8.8 grade) with nut on the rear lifting eye.
  34.  
  35. Remove the remaining bolts securing the transmission to the engine.
  36.  
  37. Remove the last bolt, pull out the transmission and lower it.
  38.  
  39. Lift the transmission down from the column jack with an engine hoist.
  40.  

To install:


NOTE
If installing a new transmission, transfer the torque converter holder to the new transmission from the old one.

  1. Turn the torque converter so that the bolt holes line up with the holes in the drive plate. Install torque converter holder during bolt installation.
  2.  
  3. Make sure the 2 guide sleeves are on the engine and apply anti-corrosion agent to the sleeves.
  4.  
  5. Install new driveshaft seals (lubricate them before installation).
  6.  
  7. Install the holder, 87 92 608, onto the column jack. Secure the tool to the transmission as for removal.
  8.  
  9. Install a protective collar, 83 95 162, in the right shaft seal in the transmission. This is done to protect the seal while the transmission is being fitted. Lubricate the seal.
  10.  
  11. Place the transmission in position. Slide in the gearbox until about 0.8 inch (20mm) are remaining and remove the tool.
  12.  
  13. Push in the transmission until it is against the mating face. Tighten the bolts between the engine and the transmission that are accessible from below to 52 ft. lbs. (70 Nm).
  14.  
  15. Remove the lifting tool from the transmission and remove the jack. Fit the bolt into the transmission and torque it to 16 ft. lbs. (22 Nm).
  16.  
  17. Undo the strap and position the power steering cooling coil in place. Make sure it is fitted on the correct side of the rubber seal.
  18.  
  19. Lower the car and install the mounting for the engine bracket onto the transmission. Lift up the unit and install the bolts for the engine bracket as marked earlier. Tighten bolts to 69 ft. lbs. (93 Nm).
  20.  
  21. Remove the lifting beam and undo the lifting eyes.
  22.  
  23. Install the expansion tank in its holder.
  24.  
  25. Fit the remaining upper bolts in the transmission and torque to 52 ft. lbs.(70 Nm).
  26.  
  27. Fit Install a protective collar, 83 95 162, into the sealing ring. Lubricate the sealing ring.
  28.  
  29. Make sure the driveshaft is clean and align it with the tool. Slide in the gearbox until about 0.8 inch (20mm) are remaining and remove the tool. Push in the rest of the shaft until the circlip clicks in.
  30.  
  31. Attach the ABS cable to the clip.
  32.  
  33. Raise the car and remove the torque converter holding tool. Press the torque converter against the drive plate. Fit the plug.
  34.  
  35. Apply thread lock to the torque converter-to-drive plate bolts. Use the original bolts and washers. Using longer bolts will damage the torque converter. Fit the 6 bolts without tightening.
  36.  
  37. Rotate the engine clockwise and tighten the bolts once they are all in place. Torque bolts to 22 ft. lbs. (30 Nm).
  38.  
  39. Fit the starter motor with electrical connections. Torque bolts to 35 ft. lbs. (47 Nm).
  40.  
  41. Install the charge air pipe bracket. Torque the bolts to 15 ft. lbs. (20 Nm).
  42.  
  43. If original transmission is installed, change oil cooler hose seals. Fit new seals lubricated with Vaseline on the oil cooler hoses. Lubricate the pipes and fit the oil cooler hoses. The pipes will penetrate the seals when installed.
  44.  


CAUTION
Ensure that the surfaces in the gearbox gasket opening are not damaged.

  1. Install or connect the following: Ground cable to transmission; torque to 7 ft. lbs. (10 Nm)Bracket for torque arm on transmission; torque to 69 ft. lbs. (93 Nm).Place subframe on trolley lift with jig; lift the framePower steering pipeSuspension arm ball joints in steering swivel memberAnti-roll bar to subframe (opening of rubber bushes must face front); torque to 47 ft. lbs. (64 Nm)Subframe into positionGuide pins in fixture to holes in bodySubframe bolts and rear bracketsSubframe against body so bushings do not rotate when bolts are tightened (remove lift); torque to 55 ft. lbs. (75 Nm), plus an additional 90 degrees and to 60 ft. lbs. (90 Nm), plus an additional 45 degrees for rear bracket boltsSteering gear bolts, washers and nuts to 37 ft. lbs. (50 Nm), plus an additional 60 degreesEngine torque rod to subframe; torque to 52 ft. lbs. (70 Nm), plus an additional 90 degreesSuspension arms to steering swivel members; torque to 37 ft. lbs. (50 Nm)

    Ground cable to transmission; torque to 7 ft. lbs. (10 Nm)
     
    Bracket for torque arm on transmission; torque to 69 ft. lbs. (93 Nm).
     
    Place subframe on trolley lift with jig; lift the frame
     
    Power steering pipe
     
    Suspension arm ball joints in steering swivel member
     
    Anti-roll bar to subframe (opening of rubber bushes must face front); torque to 47 ft. lbs. (64 Nm)
     
    Subframe into position
     
    Guide pins in fixture to holes in body
     
    Subframe bolts and rear brackets
     
    Subframe against body so bushings do not rotate when bolts are tightened (remove lift); torque to 55 ft. lbs. (75 Nm), plus an additional 90 degrees and to 60 ft. lbs. (90 Nm), plus an additional 45 degrees for rear bracket bolts
     
    Steering gear bolts, washers and nuts to 37 ft. lbs. (50 Nm), plus an additional 60 degrees
     
    Engine torque rod to subframe; torque to 52 ft. lbs. (70 Nm), plus an additional 90 degrees
     
    Suspension arms to steering swivel members; torque to 37 ft. lbs. (50 Nm)
     

  2.  


CAUTION
Ensure that the steering knuckle stub is visible on the top of the steering knuckle housing before the bolt is fitted.



Radiator brackets to subframe; torque to 35 ft. lbs. (47 Nm); remove the straps
 

  1. Set up the engine centering kit, 83 96 152, and check that engine is located correctly in relation to the subframe. Remove the centering tool.
  2.  
  3. Fit the power steering pipe to the subframe. Insert all bolts first and then tighten.
  4.  
  5. Install a joint clamp on the front pipe and fit the front exhaust pipe to the catalytic converter. Use a new gasket and new nuts. Torque nuts to 18 ft. lbs. (25 Nm). Adjust the joint clamp so that the pipe ends are in the middle. Tighten the joint clamp nuts to 30 ft. lbs. (40 Nm).
  6.  
  7. Connect or install the following: Fender liner section on both sidesFront wheelsLower front coverUpper bumper shell mountingsCable to retainer (by pulling back the locking sleeve)Gear cable to selector lever arm

    Fender liner section on both sides
     
    Front wheels
     
    Lower front cover
     
    Upper bumper shell mountings
     
    Cable to retainer (by pulling back the locking sleeve)
     
    Gear cable to selector lever arm
     

  8.  
  9. Carry out selector lever cable adjustment as follows: Engage P with the gear selector on the transmission.Rock the car until the parking lock engages.Press down the locking brace by the selector lever housing securing the adjuster.Check the shifting positions.Fit the plastic cover for the selector lever and the rubber mat in the storage compartment.
    1. Engage P with the gear selector on the transmission.
    2.  
    3. Rock the car until the parking lock engages.
    4.  
    5. Press down the locking brace by the selector lever housing securing the adjuster.
    6.  
    7. Check the shifting positions.
    8.  
    9. Fit the plastic cover for the selector lever and the rubber mat in the storage compartment.
    10.  

  10.  
  11. Install or connect the following: T ransmission ventilation hose (lightly lubricated)Connectors under control moduleBattery trayControl module connectorHood switchCooling pipeMain fuse boxBattery, cables and coverUpper engine coverDipstickTransmission fluid

    T ransmission ventilation hose (lightly lubricated)
     
    Connectors under control module
     
    Battery tray
     
    Control module connector
     
    Hood switch
     
    Cooling pipe
     
    Main fuse box
     
    Battery, cables and cover
     
    Upper engine cover
     
    Dipstick
     
    Transmission fluid
     

  12.  
  13. Test drive the car with varying engine loads and speeds. Check for trouble codes. Also check the position of the steering wheel when driving straight ahead on a level road. Adjust if needed.
  14.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the transmission.
  4.  
  5. Remove or disconnect the following:

    Intake manifold cover or resonator with hoses and MAF sensor
     
    Battery
     
    Ground strap from the transmission housing
     
    Dipstick and sleeve (plug opening in block)
     
    Vent hose from the transmission housing
     
    Positive cable routing straps
     
    Gearshift selector lever from housing
     
    Electrical harness on transmission housing
     
    Oxygen sensor connectors and securing straps
     
    3 upper bolts on gearbox
     
    Remove strain from powertrain with engine hoist
     
    Front wheels
     
    Front exhaust pipes
     
    Cooler lines from the transmission (plug all openings)
     
    Air shields and cover in right wheel housing
     
    End pieces from suspension arms on both sides
     
    2 nuts from rear engine mount and 2 middle bolts from subframe
     

  6.  
  7. Position lifting trolley, 83 94 793, with fixture, 83 94 801, and front and rear holders, 83 94 819 and 83 90 827 under subframe.
  8.  
  9. Remove the remaining bolts securing the subframe. Note position of washers on rear mount.
  10.  
  11. Lower the lifting trolley assembly, with subframe and move it out of the way.
  12.  
  13. Detach the left driveshaft from the gearbox by releasing at the splines, then pulling straight out.
  14.  
  15. Suspend the driveshaft with a securing strap.
  16.  
  17. Remove or disconnect the following:
  18.  
  19. Remove the flywheel splash plate.
  20.  
  21. Remove the torque converter-to-driveplate bolts (rotate crankshaft to access bolts).
  22.  
  23. Remove the rubber plug and install a torque converter holding tool, 87 92 277, into opening.
    NOTE
    Some transmissions may not have a hole in which to fit the tool. Therefore, drill a 5mm hole and thread it was an M6 tap.

  24.  
  25. Remove the rear engine-to-transmission bolt.
  26.  
  27. Remove the front engine mount bolts.
  28.  
  29. Lower the car, then lower the engine and transmission assembly with the lifting equipment until there is a slight amount of play between the body and from transmission mount (play can be seen from left wheel housing).
  30.  
  31. Raise the car. Install a lifting tool,87 92 608, onto a pillar jack. Adjust the tool so it is centered with lifting lug on top of the transmission. Tighten it on the transmission.
  32.  
  33. Remove the front bolt between the engine and transmission.
  34.  
  35. Pull out and lower the transmission, using care with the pillar jack.
  36.  
  37. Lift transmission from pillar jack with engine lift.

    Click image to see an enlarged view

    Fig. Installing torque converter holding tool-9-3 2002 shown

  38.  

To install:


NOTE
If installing a new transmission, transfer torque converter holding tool to new assembly.

  1. Turn torque converter so bolt holes line up with drive plate holes.
  2.  
  3. Be sure both guide sleeves are on the engine. Lubricate sleeves with a thin layer of anti-corrosion oil.
  4.  
  5. Install new driveshaft seals. Lubricate seals.
  6.  
  7. Using a hoist lift and pillar jack to lift the transmission.
  8.  
  9. Install a protective collar, 83 95 162, in right shaft seal on the transmission to protect the seal when the transmission is installed.
  10.  
  11. Position the transmission in the car. Push the transmission into place until about 0.8 inch (20 mm) remains, then remove the protective collar.
  12.  
  13. Tighten the lower transmission-to-engine mounting bolts to 55 ft. lbs. (75 Nm).
  14.  
  15. Install the rear engine mount on the transmission and torque the bolt to 30 ft. lbs. (40 Nm).
  16.  
  17. Lift powertrain and tighten left engine mount to body. Torque bolt to 46 ft. lbs. (62 Nm).
  18.  
  19. Remove torque converter holding tool. Install the rubber plug.
  20.  
  21. Apply thread sealer to torque converter bolt. Use original bolts with washers. Longer bolts will ruin the torque converter. Install all 6 bolts, then tighten the bolts to 44 ft. lbs. (60 Nm).
  22.  
  23. Install the flywheel splash guard.
  24.  
  25. Install a protective collar (16), 83 95 162, in the sealing ring prior to installing the driveshaft.
  26.  
  27. Make sure the driveshaft is clean. Install driveshaft, inserting all except about 0.8 inch (20 mm) into the transmission. Remove the protective collar tool before the shaft sealing surface reaches the shaft seal.
  28.  
  29. Push the driveshaft fully in until the circlip clicks, indicating engagement.
  30.  
  31. Reattach transmission oil cooler lines. If necessary, clean oil cooling system first. Make sure lines do not contact the subframe after installation. Use new lubricated seals. Tighten fittings to 20 ft. lbs. (27 Nm).
  32.  
  33. Carefully raise the subframe. Ensure washers on rear mounts are in place, then position suspension arm end pieces, but do not tighten at this time.
  34.  
  35. Adjust subframe so the bolt holes are aligned with the body.
  36.  
  37. Tighten the 4 corner subframe bolts as follows:

    Front bolts: 85 ft. lbs. (115 Nm)
     
    Rear bolts: 81 ft. lbs. (110 Nm), plus an additional 75 degrees.
     

  38.  
  39. Lower the lifting trolley and move out of the way.
  40.  
  41. Tighten the remaining subframe bolts to 141 ft. lbs. (190 Nm).
  42.  
  43. Tighten the rear engine mount nuts to 37 ft. lbs. (50 Nm).
  44.  
  45. Tighten the suspension arm end pieces on both sides. Tighten nuts to 55 ft. lbs. (75 Nm).
  46.  
  47. Install or connect the following:

    Ground lead to transmission
     
    Air shields and lining in right wheel housing
     
    Front exhaust pipe; torque exhaust flange nuts to 30 ft. lbs. (40 Nm)
     
    Install clips for oxygen sensor wiring.
     
    Front wheels; torque wheel nuts to 81 ft. lbs. (110 Nm)
     
    Remove engine hoist and tighten top bolts between engine and transmission to 55 ft. lbs. (75 Nm)
     
    Oxygen sensor (attach clips)
     
    Positive cable mount on engine
     
    Connectors for transmission (behind battery)
     
    Dipstick tube
     
    Transmission vent tube
     
    Shift cable to bracket on transmission (install clamp)
     
    Shift cable to selector lever
     
    Intake manifold cover, or resonator, with hoses and MAF sensor
     

  48.  
  49. Check positions of selector lever and adjust if necessary.
  50.  
  51. Connect the battery negative cable to ground on transmission
  52.  
  53. Install the battery.
  54.  
  55. Refill the transmission with Dexron III®.
  56.  
  57. Test drive the car at varying speeds and loads. Check for diagnostic codes.

    Click image to see an enlarged view

    Fig. Showing protective collar for using when installing the driveshaft-9-3 2002 shown

  58.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Upper engine cover
     
    Battery cover
     
    Battery with coolant pipe, bonnet switch and fuse box
     
    Control module connector
     
    Battery tray
     
    Connector under control module
     
    Ventilation hose from transmission
     
    Gear cable from selector lever arm (selector lever must be in N)
     
    Cable from the cable retainer (pull back locking sleeve)
     
    Ground cable from transmission casing
     
    Upper bolts on transmission casing
     
    Expansion tank from its holder
     
    Install engine lifting eyes. Attach a lifting beam and hoist to lifting eyes.
     
    Dipstick
     

  4.  
  5. With the hoist, take weight off the engine and transmission.
  6.  
  7. Remove the upper bumper shell mountings.
  8.  
  9. Attach 2 straps above the radiator core so they are accessible from below (these will be used to restrain the radiator).
  10.  
  11. Remove or disconnect the following:

    Front wheels
     
    Lower front cover, then secure radiator core with straps
     
    Radiator brackets from subframe
     
    Exhaust pipe (cut about 3.5 inches (87mm) from front of muffler)
     
    Engine torque rod from subframe
     
    Bolt and nut holding suspension arm to steering swivel member on both sides
     
    Anti-roll bar from link arm
     
    Connector and cable clip of headlamp angle sensor (if equipped)
     
    Steering gear from subframe (retain nuts and washers); leave steering gear hanging
     
    Power steering pipe from subframe
     
    Front part of fender liner (bend it out of the way)
     

  12.  
  13. Position a trolley lift with jig underneath. Remove the subframe bolts and the rear brackets. Lower the subframe slightly.
  14.  
  15. Separate the steering arm ball joints from the steering swivel members.
  16.  
  17. Remove the anti-roll bar from the subframe (protect the steering gear boot). Install the bolts loosely in the link arms so the anti-roll bar is kept hanging in place.
  18.  
  19. Lower the subframe.
  20.  
  21. Remove the torque rod bracket. Undo the bolt for the torque rod for easier fitting.
  22.  
  23. Remove or disconnect the following:

    Starter motor
     
    Torque converter from drive plate (6 bolts; turn crankshaft to access bolts)
     
    Undo plug and press torque converter towards transmission; install holding tool
     
    Transmission fluid
     
    Oil cooling hoses; plug holes and hoses
     
    Bolts in charge air pipe bracket and move pipe aside
     
    Lower transmission bolts; leave one bolt loosely in place
     
    Ground lead from transmission
     
    ABS cable from clip
     
    Left driveshaft; suspend driveshaft by means of a cable tie
     

  24.  
  25. Lower the car, mark the location of the bolts on the left engine mount with a marker pen to ensure correct refitting. Remove the engine mount bracket.
  26.  
  27. Lower the powertrain with the lifting beam to facilitate removal of the transmission.
  28.  
  29. Undo the clip securing the power steering hose.
  30.  
  31. Raise the car and move the power steering cooling coil aside and restrain with a strap.
  32.  
  33. Install a holding device, 87 92 608, onto a column jack. Adjust and tighten the tool on the transmission. Use a bolt with 8.8 grade that is approx. 0.8 inch (20mm) longer than the removed bolt as well as a bolt (8.8 grade) with nut on the rear lifting eye.
  34.  
  35. Remove the remaining bolts securing the transmission to the engine.
  36.  
  37. Remove the last bolt, pull out the transmission and lower it.
  38.  
  39. Lift the transmission down from the column jack with an engine hoist.
  40.  

To install:


NOTE
If installing a new transmission, transfer the torque converter holder to the new transmission from the old one.

  1. Turn the torque converter so that the bolt holes line up with the holes in the drive plate. Install torque converter holder during bolt installation.
  2.  
  3. Make sure the 2 guide sleeves are on the engine and apply anti-corrosion agent to the sleeves.
  4.  
  5. Install new driveshaft seals (lubricate them before installation).
  6.  
  7. Install the holder, 87 92 608, onto the column jack. Secure the tool to the transmission as for removal.
  8.  
  9. Install a protective collar, 83 95 162, in the right shaft seal in the transmission. This is done to protect the seal while the transmission is being fitted. Lubricate the seal.
  10.  
  11. Place the transmission in position. Slide in the gearbox until about 0.8 inch (20mm) are remaining and remove the tool.
  12.  
  13. Push in the transmission until it is against the mating face. Tighten the bolts between the engine and the transmission that are accessible from below to 52 ft. lbs. (70 Nm).
  14.  
  15. Remove the lifting tool from the transmission and remove the jack. Fit the bolt into the transmission and torque it to 16 ft. lbs. (22 Nm).
  16.  
  17. Undo the strap and position the power steering cooling coil in place. Make sure it is fitted on the correct side of the rubber seal.
  18.  
  19. Lower the car and install the mounting for the engine bracket onto the transmission. Lift up the unit and install the bolts for the engine bracket as marked earlier. Tighten bolts to 69 ft. lbs. (93 Nm).
  20.  
  21. Remove the lifting beam and undo the lifting eyes.
  22.  
  23. Install the expansion tank in its holder.
  24.  
  25. Fit the remaining upper bolts in the transmission and torque to 52 ft. lbs.(70 Nm).
  26.  
  27. Fit Install a protective collar, 83 95 162, into the sealing ring. Lubricate the sealing ring.
  28.  
  29. Make sure the driveshaft is clean and align it with the tool. Slide in the gearbox until about 0.8 inch (20mm) are remaining and remove the tool. Push in the rest of the shaft until the circlip clicks in.
  30.  
  31. Attach the ABS cable to the clip.
  32.  
  33. Raise the car and remove the torque converter holding tool. Press the torque converter against the drive plate. Fit the plug.
  34.  
  35. Apply thread lock to the torque converter-to-drive plate bolts. Use the original bolts and washers. Using longer bolts will damage the torque converter. Fit the 6 bolts without tightening.
  36.  
  37. Rotate the engine clockwise and tighten the bolts once they are all in place. Torque bolts to 22 ft. lbs. (30 Nm).
  38.  
  39. Fit the starter motor with electrical connections. Torque bolts to 35 ft. lbs. (47 Nm).
  40.  
  41. Install the charge air pipe bracket. Torque the bolts to 15 ft. lbs. (20 Nm).
  42.  
  43. If original transmission is installed, change oil cooler hose seals. Fit new seals lubricated with Vaseline on the oil cooler hoses. Lubricate the pipes and fit the oil cooler hoses. The pipes will penetrate the seals when installed.
    CAUTION
    Ensure that the surfaces in the gearbox gasket opening are not damaged.

  44.  
  45. Install or connect the following:
    CAUTION
    Ensure that the steering knuckle stub is visible on the top of the steering knuckle housing before the bolt is fitted.



    Ground cable to transmission; torque to 7 ft. lbs. (10 Nm)
     
    Bracket for torque arm on transmission; torque to 69 ft. lbs. (93 Nm).
     
    Place subframe on trolley lift with jig; lift the frame
     
    Power steering pipe
     
    Suspension arm ball joints in steering swivel member
     
    Anti-roll bar to subframe (opening of rubber bushes must face front); torque to 47 ft. lbs. (64 Nm)
     
    Subframe into position
     
    Guide pins in fixture to holes in body
     
    Subframe bolts and rear brackets
     
    Subframe against body so bushings do not rotate when bolts are tightened (remove lift); torque to 55 ft. lbs. (75 Nm), plus an additional 90 degrees and to 60 ft. lbs. (90 Nm), plus an additional 45 degrees for rear bracket bolts
     
    Steering gear bolts, washers and nuts to 37 ft. lbs. (50 Nm), plus an additional 60 degrees
     
    Engine torque rod to subframe; torque to 52 ft. lbs. (70 Nm), plus an additional 90 degrees
     
    Suspension arms to steering swivel members; torque to 37 ft. lbs. (50 Nm)
     



    Radiator brackets to subframe; torque to 35 ft. lbs. (47 Nm); remove the straps
     

  46.  
  47. Set up the engine centering kit, 83 96 152, and check that engine is located correctly in relation to the subframe. Remove the centering tool.
  48.  
  49. Fit the power steering pipe to the subframe. Insert all bolts first and then tighten.
  50.  
  51. Install a joint clamp on the front pipe and fit the front exhaust pipe to the catalytic converter. Use a new gasket and new nuts. Torque nuts to 18 ft. lbs. (25 Nm). Adjust the joint clamp so that the pipe ends are in the middle. Tighten the joint clamp nuts to 30 ft. lbs. (40 Nm).
  52.  
  53. Connect or install the following:

    Fender liner section on both sides
     
    Front wheels
     
    Lower front cover
     
    Upper bumper shell mountings
     
    Cable to retainer (by pulling back the locking sleeve)
     
    Gear cable to selector lever arm
     

  54.  
  55. Carry out selector lever cable adjustment as follows:
    1. Engage P with the gear selector on the transmission.
    2.  
    3. Rock the car until the parking lock engages.
    4.  
    5. Press down the locking brace by the selector lever housing securing the adjuster.
    6.  
    7. Check the shifting positions.
    8.  
    9. Fit the plastic cover for the selector lever and the rubber mat in the storage compartment.
    10.  

  56.  
  57. Install or connect the following:

    T ransmission ventilation hose (lightly lubricated)
     
    Connectors under control module
     
    Battery tray
     
    Control module connector
     
    Hood switch
     
    Cooling pipe
     
    Main fuse box
     
    Battery, cables and cover
     
    Upper engine cover
     
    Dipstick
     
    Transmission fluid
     

  58.  
  59. Test drive the car with varying engine loads and speeds. Check for trouble codes. Also check the position of the steering wheel when driving straight ahead on a level road. Adjust if needed.
  60.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Intake manifold cover
     
    Battery and tray
     
    MAXI fuse board
     
    16 pin and 10 pin wire connectors
     
    Transmission breather hose
     
    Gear selector arm from the transmission (place lever in L position)
     
    Shifting cable
     
    Cable channel from the engine and gear case (3.0L engine only)
     
    3 upper bolts from the transmission
     
    Dipstick tube (plug hole in block)
     
    Oxygen sensor connectors
     
    Rear engine mount nut
     
    Top 2 bolts from the rear engine cushion, loosen only
     

  4.  
  5. Install a lifting beam to the engine and relieve the weight on the engine and transmission.
  6.  
  7. Remove or disconnect the following:

    Both front wheels
     
    Lower engine cover
     
    Front exhaust system
     
    Rear engine bracket and pad
     
    Steering gear bolts
     
    Rear clamps securing the power steering delivery pipe to the subframe
     
    A/C pipes from the subframe holder
     
    Air cleaner casing from the subframe
     
    Engine oil cooler from the charge air cooler (2.3L engine only)
     

  8.  
  9. Attach a strap around the radiator and crossmember to restrain the radiator.
  10.  
  11. Remove or disconnect the following:

    Outer ball joint to steering knuckle bolts
     
    Upper anti-roll bar ball joints
     
    Torque arm from the subframe
     
    Rear support plates
     

  12.  
  13. Position a lifting trolley with a holder under the vehicle. Align the trolley to the subframe.
  14.  
  15. Remove or disconnect the following:
    NOTE
    The crankshaft must be rotated to gain access for all the bolts.



    Remaining bolts from the subframe and slightly lower the subframe
     
    Power steering delivery pipe clamps. Lower the lifting trolley and move the subframe aside
     
    Splash plate (2.3L engine only)
     
    Plug covering the torque converter bolts (3.0L engine only)
     
    Bolts securing the torque converter to the drive plate. Rotate the plate and pulley together
     

  16.  
  17. Press the torque converter against the transmission to keep the converter in place during transmission removal.
  18.  
  19. Remove or disconnect the following:

    Ground leads
     
    Torque arm and bracket
     
    Transmission fluid
     
    Oil cooler inlet and outlet hoses (plug openings)
     
    Left driveshaft and suspend it
     
    Left side engine pad; lower transmission to clear structural member
     
    Transmission bracket
     
    Transmission from the engine assembly using a single-column jack
     
    Transmission from the vehicle
     

  20.  

To install:

  1. Rotate the torque converter so that the bolt holes align with the drive plate.
  2.  
  3. Make certain that the 2 guide sleeves are on the engine.
  4.  
  5. Lubricate and install new driveshaft seals.
  6.  
  7. Raise the transmission into position under the vehicle.
  8.  
  9. Install the transmission and torque the bottom bolts between the engine and transmission to 55 ft. lbs. (74 Nm) and the bolts between the transmission and oil pan to 34 ft. lbs. (47 Nm)
  10.  
  11. Remove the lifting beam from the transmission .
  12.  
  13. Install or connect the following:

    Transmission bolts and torque the bolts to 18 ft. lbs. (24 Nm)
     
    Engine pad mount to the transmission and torque the bolts to 62 ft. lbs. (84 Nm)
     
    Bolts securing the engine pad to the body and torque the bolts to 46 ft. lbs. (63 Nm)
     
    Protective sleeve in driveshaft seal
     
    Driveshaft and make certain that the circlip snaps into position (remove protective sleeve just before driveshaft is fully into transmission)
     
    Torque converter to drive plate and torque the bolts to 22 ft. lbs. (30 Nm)
     
    Splash plate (2.3L engine only)
     
    Plug covering the torque converter bolts (3.0L engine only)
     
    Cooler hoses and torque the fasteners to 20 ft. lbs. (27 Nm)
     
    Torque arm bracket
     
    Ground cable to the bracket and raise the subframe into position
     
    Power steering delivery pipe clamps
     
    Outer ball joints and A/C pipes
     
    Subframe and rear support plates and torque the subframe bolts to 74 ft. lbs. (100 Nm) plus 45 degrees and the support plate bolts to 44 ft. lbs. (60 Nm)
     
    Outer ball joints to the steering knuckles and torque the bolts to 63 ft. lbs. (85 Nm)
     
    Anti-roll bar link and torque the fastener to 68 ft. lbs. (92 Nm)
     
    Steering gear and torque the bolts to 66 ft. lbs. (90 Nm)
     
    Engine oil cooler and air filter housing (2.3L engine only)
     
    Rear engine cushion
     
    Rear engine mount; torque bolts to 55 ft. lbs. (70 Nm)
     
    Oil pan-to-transmission bolts; torque to 34 ft. lbs. (47 Nm) (3.0L engine only)
     
    Torque arm-to-subframe; torque bolts to 19 ft. lbs. (25 Nm)
     
    Front exhaust system; torque bolts to 18 ft. lbs. (24 Nm) on 2.3L engine. On the 3.0L engine torque turbo bolts to 18 ft. lbs. (24 Nm) and exhaust manifold bolts to 30 ft. lbs. (40 Nm).
     
    Oxygen sensor wiring connectors and remove lifting beam
     
    Torque rear engine cushion bolts to 18 ft. lbs. (24 Nm) and nut to 33 ft. lbs. (45 Nm).
     
    Engine to transmission; torque bolts to 55 ft. lbs. (70 Nm)
     
    Cable channel to the transmission (3.0L engine only)
     
    Dipstick tube
     
    Transmission breather hose
     
    Shifter cable to bracket
     
    Shifter cable to selector lever; adjust if necessary
     
    Torque rod and torque bolt to 34 ft. lbs. (47 Nm)
     
    MAXI fuse board
     
    Battery tray and battery
     
    Battery cables and cover
     
    Intake manifold cover
     
    Front wheels
     

  14.  
  15. Fill the transmission to the proper level.
  16.  
  17. Start the vehicle, check for leaks and repair if necessary.
  18.  

 
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