Volvo Cars 1999-05

Transaxle Removal & Installation

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  1. Drain the transaxle fluid.
  2.  


NOTE
Leave the key in the ignition switch.

  1. Remove or disconnect the following:

    Negative battery cable
     
    Battery box
     
    Front wheels
     
    Engine splash guard
     
    Halfshafts
     
    Anti-roll bar
     
    Steering gear and hang securely out of the way
     
    Sub-frame
     
    Oil line, and plug the line and hole with plastic plugs
     
    Transmission ground lead
     
    Torque rod mounting
     
    Torx® bolts from the torque converter
     
    Air intake assembly
     
    Coolant hose bracket
     
    Gear selector cable bracket
     
    Starter motor
     
    Top four bolts between the engine and transmission
     

  2.  
  3. Install lifting beam 999-7103 and lifting hook 999-7102 to the engine.
  4.  
  5. Remove the left hand engine mount and lower the engine slightly.
  6.  
  7. Remove or disconnect the following:

    Engine mount bracket and tighten to 37 ft. lbs. (50 Nm)
     

  8.  
  9. Install transaxle fixture 999 5463 on transaxle jack, using the torque rod mounting bolts to hold it in place. At the same time, fit tool 999 5463-2 support plate and raise the jack so that it is making light contact.
  10.  
  11. Remove the remaining mounting bolts between the engine and transmission.
  12.  
  13. Remove the transmission.
  14.  

To install:

  1. Install or connect the following:

    Transmission and tighten the lower six mounting bolts to 37 ft. lbs. (50 Nm)
     
    Engine mount bracket and tighten to 37 ft. lbs. (50 Nm)
     

  2.  
  3. Raise the transmission slight and install the left hand engine mount bolt and tighten to 96 ft. lbs. (130 Nm).
  4.  
  5. Install or connect the following:

    Top four mounting bolts between the engine and transmission and tighten to 37 ft. lbs. (50 Nm)
     
    Starter motor
     
    Coolant hose bracket
     
    Gear selector cable bracket and tighten to 18 ft. lbs. (24 Nm)
     
    Air intake assembly
     
    Torx® bolts for the torque converter
     
    Oil line
     
    Transmission ground lead
     
    Torque rod mounting and tighten to 37 ft. lbs. (50 Nm)
     
    Sub-frame
     
    Anti-roll bar
     
    Steering gear
     
    Halfshafts
     
    Engine splash guard
     
    Front wheels
     
    Battery box and battery
     

  6.  
  7. Fill the transmission to the correct level.
  8.  
  9. Start the engine and check for leaks.
  10.  

  1. Drain the transaxle fluid.
    NOTE
    Leave the key in the ignition switch.

  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Battery box
     
    Front wheels
     
    Engine splash guard
     
    Halfshafts
     
    Anti-roll bar
     
    Steering gear and hang securely out of the way
     
    Sub-frame
     
    Oil line, and plug the line and hole with plastic plugs
     
    Transmission ground lead
     
    Torque rod mounting
     
    Torx® bolts from the torque converter
     
    Air intake assembly
     
    Coolant hose bracket
     
    Gear selector cable bracket
     
    Starter motor
     
    Top four bolts between the engine and transmission
     

  4.  
  5. Install lifting beam 999-7103 and lifting hook 999-7102 to the engine.
  6.  
  7. Remove the left hand engine mount and lower the engine slightly.
  8.  
  9. Remove or disconnect the following:

    Engine mount bracket and tighten to 37 ft. lbs. (50 Nm)
     

  10.  
  11. Install transaxle fixture 999 5463 on transaxle jack, using the torque rod mounting bolts to hold it in place. At the same time, fit tool 999 5463-2 support plate and raise the jack so that it is making light contact.
  12.  
  13. Remove the remaining mounting bolts between the engine and transmission.
  14.  
  15. Remove the transmission.
  16.  

To install:

  1. Install or connect the following:

    Transmission and tighten the lower six mounting bolts to 37 ft. lbs. (50 Nm)
     
    Engine mount bracket and tighten to 37 ft. lbs. (50 Nm)
     

  2.  
  3. Raise the transmission slight and install the left hand engine mount bolt and tighten to 96 ft. lbs. (130 Nm).
  4.  
  5. Install or connect the following:

    Top four mounting bolts between the engine and transmission and tighten to 37 ft. lbs. (50 Nm)
     
    Starter motor
     
    Coolant hose bracket
     
    Gear selector cable bracket and tighten to 18 ft. lbs. (24 Nm)
     
    Air intake assembly
     
    Torx® bolts for the torque converter
     
    Oil line
     
    Transmission ground lead
     
    Torque rod mounting and tighten to 37 ft. lbs. (50 Nm)
     
    Sub-frame
     
    Anti-roll bar
     
    Steering gear
     
    Halfshafts
     
    Engine splash guard
     
    Front wheels
     
    Battery box and battery
     

  6.  
  7. Fill the transmission to the correct level.
  8.  
  9. Start the engine and check for leaks.
  10.  

4-Cylinder



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

    Engine cover
     
    Battery and tray
     
    Air intake assembly
     
    Air intake hose
     
    Gear selector cable
     
    Transaxle ground lead
     
    Vehicle speed (VSS) sensor
     

  6.  
  7. Raise and support the engine.
  8.  
  9. Remove or disconnect the following:

    Heat deflector plate
     
    Rear engine bracket
     
    Front engine bracket
     
    Axle half shafts
     
    Transaxle oil pipes
     
    Oil pipe clamp
     

  10.  
  11. Install transaxle fixture 999 5463 on the transaxle jack and install the fixture on the transmission. At the same time align the support plate 999 5463-1 on the raise the jack so it making light contact.
  12.  
  13. Remove or disconnect the following:

    5 bolts between the transaxle and the engine and starter
     
    Left-hand engine mount
     
    Remaining 7 bolts between the engine and transaxle
     

  14.  
  15. Carefully detach the transaxle from the engine and lower the engine slightly.
  16.  
  17. Turn the transaxle slightly and remove it.
  18.  


    Click image to see an enlarged view

    Fig. Using the transaxle fixture

    Using the transaxle fixture

To install:

  1. Install or connect the following:

    Transaxle and tighten the bolts to 37 ft. lbs. (50 Nm)
     
    Transaxle mount and tighten to the bolts to 37 ft. lbs. (50 Nm)
     

  2.  
  3. Remove the transaxle fixture and jack from the transmission.
  4.  
  5. Using new bolts, tighten the 2 bolts for the transaxle and the starter motor to 37 ft. lbs. (50 Nm). Tighten the remaining transaxle to engine bolts to 37 ft. lbs (50 Nm).
  6.  
  7. Align the torque converter against the carrier plate by turning engine with the nut for the crankshaft pulley while turning the torque converter. Tighten the bolts to 26 ft. lbs. (35 Nm).
  8.  
  9. Install or connect the following:

    Front engine bracket and tighten to 49 ft. lbs. (67 Nm)
     
    Rear engine bracket and tighten to 49 ft. lbs. (67 Nm)
     
    Axle half shafts
     
    Heat deflector plate
     
    Oil pipe clamp
     
    Transaxle oil pipes
     
    Transaxle ground lead
     
    VSS sensor
     
    Gear select cable
     
    Air intake hose
     
    Air intake assembly
     
    Battery and tray
     
    Engine cover
     

  10.  
  11. Fill the transaxle to the correct level.
  12.  
  13. Start the engine and check for leaks.
  14.  

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

    Engine cover
     
    Battery and tray
     
    Air intake assembly
     
    Air intake hose
     
    Gear selector cable
     
    Transaxle ground lead
     
    Vehicle speed (VSS) sensor
     

  6.  
  7. Raise and support the engine.
  8.  
  9. Remove or disconnect the following:

    Heat deflector plate
     
    Rear engine bracket
     
    Front engine bracket
     
    Axle halfshafts
     
    Transaxle oil pipes
     
    Oil pipe clamp
     

  10.  
  11. Install transaxle fixture 999 5463 on the transaxle jack and install the fixture on the transmission. At the same time align the support plate 999 5463-1 on the raise the jack so it making light contact.

    Click image to see an enlarged view

    Fig. Using the transaxle fixture

    Using the transaxle fixture
  12.  
  13. Remove or disconnect the following:

    5 bolts between the transaxle and the engine and starter
     
    Left-hand engine mount
     
    Remaining 7 bolts between the engine and transaxle
     

  14.  
  15. Carefully detach the transaxle from the engine and lower the engine slightly.
  16.  
  17. Turn the transaxle slightly and remove it.
  18.  

To install:

  1. Install or connect the following:

    Transaxle and tighten the bolts to 37 ft. lbs. (50 Nm)
     
    Transaxle mount and tighten to the bolts to 37 ft. lbs. (50 Nm)
     

  2.  
  3. Remove the transaxle fixture and jack from the transmission.
  4.  
  5. Using new bolts, tighten the 2 bolts for the transaxle and the starter motor to 37 ft. lbs. (50 Nm). Tighten the remaining transaxle to engine bolts to 37 ft. lbs (50 Nm).
  6.  
  7. Align the torque converter against the carrier plate by turning engine with the nut for the crankshaft pulley while turning the torque converter. Tighten the bolts to 26 ft. lbs. (35 Nm).
  8.  
  9. Install or connect the following:

    Front engine bracket and tighten to 49 ft. lbs. (67 Nm)
     
    Rear engine bracket and tighten to 49 ft. lbs. (67 Nm)
     
    Axle halfshafts
     
    Heat deflector plate
     
    Oil pipe clamp
     
    Transaxle oil pipes
     
    Transaxle ground lead
     
    VSS sensor
     
    Gear select cable
     
    Air intake hose
     
    Air intake assembly
     
    Battery and tray
     
    Engine cover
     

  10.  
  11. Fill the transaxle to the correct level.
  12.  
  13. Start the engine and check for leaks.
  14.  

6-Cylinder Engine



  1. Drain the transaxle fluid.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Air intake assembly
     
    Charge air cooler (CAC) pipe, if equipped
     
    Upper engine stabilizer brace
     
    Charge air hose and clamp
     
    Gear selector cable
     
    Heater hose
     
    Clamp holding oil pipe to power steering
     
    Boost pressure turbo pipe, if equipped
     
    Transmission dipstick tube assembly
     

  4.  
  5. Install lifting fixture 999-7018 on the left hand side of the engine.
  6.  
  7. Remove or disconnect the following:

    Top three bolts between the engine and transmission
     
    Ignition setting sender
     
    Starter motor
     
    Positive cable from engine
     
    Torx® bolts for torque converter
     

  8.  
  9. Install lifting beam 999-5716 and lifting hook 999-5460 on the engine.
  10.  
  11. Raise the vehicle and remove or disconnect the following:

    Front wheels
     
    Splash guard
     
    Parking heater, if equipped
     
    Lower ball joints
     
    Control arms
     
    Sub-frame support plates
     
    Right axle half shaft
     
    Steering gear
     
    Cross members
     
    Heated oxygen (HO2S) sensor and bracket
     
    Left axle half shaft
     
    Rear engine mount bolt
     

  12.  
  13. Lower the sub-frame approximately 5.5 in. (140mm) and secure the steering gear.
  14.  


    Click image to see an enlarged view

    Fig. Lifting beam installed on engine

    Lifting beam installed on engine


NOTE
The steering shaft must not slide out of the rubber boot.

  1. Remove or disconnect the following:

    Rear engine mount
     
    Transmission oil pipes
     

  2.  
  3. Lower the left side of the engine and transaxle assembly slightly.
  4.  
  5. Install fixture 999 5463 on fixture 999 5972. Install this assembly on the transaxle jack. Install fixture 999 5735 on the entire assembly.
  6.  
  7. Install the transaxle jack against the transaxle and secure the side mountings.
  8.  
  9. Remove the transmission flange bolts.
  10.  
  11. Remove the transmission.
  12.  

To install:

  1. Install or connect the following:

    Transmission and tighten crosswise the bolts to 37 ft. lbs. (50 Nm)
     

  2.  


NOTE
If necessary, turn the engine so the stator shaft is correctly aligned in the torque converter.



Splash guard above the transmission
 
HO2S sensor and bracket and tighten to 18 ft. lbs. (25 Nm)
 

  1. Raise the engine and transmission up to the horizontal position.
  2.  
  3. Install or connect the following:

    Transmission oil pipes and tighten to 22 ft. lbs. (30 Nm)
     
    Rear engine mount and tighten the bolts to 37 ft. lbs. (50 Nm)
     
    Rear engine pad and tighten the bolt to 37 ft. lbs. (50 Nm)
     
    Sub-frame, using new bolts. Tighten the frame bolts to 79 ft. lbs. (105 Nm) plus 120 degrees. Tighten the bracket bolts to 38 ft. lbs. (50 Nm).
     
    Left axle half shaft
     
    Right axle half shaft
     
    Cross members
     
    Steering gear
     
    Lower ball joints
     
    Control arms
     
    Parking heater, if equipped
     
    Torx® bolts for torque converter to 26 ft. lbs. (35 Nm)
     
    Clamp for power steering oil pipe
     
    Charge air hose and clamp
     
    Top three bolts between the engine and transmission and tighten to 37 ft. lbs. (50 Nm)
     
    Ignition setting sensor and tighten to 84 inch lbs. (10 Nm)
     
    Positive cable to the engine
     
    Starter motor and tighten to 30 ft. lbs. (40 Nm)
     
    Transmission dipstick tube assembly
     
    Splash guard
     
    Boost pressure turbo pipe, if equipped
     
    Heater hose
     
    Gear selector cable
     
    Upper engine stabilizer brace and tighten the bolts to 38 ft. lbs. (50 Nm)
     
    CAC pipe, if equipped
     
    Air intake assembly
     
    Negative battery cable
     

  4.  
  5. Fill the transmission to the correct level
  6.  

  1. Drain the transaxle fluid.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Air intake assembly
     
    Charge air cooler (CAC) pipe, if equipped
     
    Upper engine stabilizer brace
     
    Charge air hose and clamp
     
    Gear selector cable
     
    Heater hose
     
    Clamp holding oil pipe to power steering
     
    Boost pressure turbo pipe, if equipped
     
    Transmission dipstick tube assembly
     

  4.  
  5. Install lifting fixture 999-7018 on the left hand side of the engine.
  6.  
  7. Remove or disconnect the following:

    Top three bolts between the engine and transmission
     
    Ignition setting sender
     
    Starter motor
     
    Positive cable from engine
     
    Torx® bolts for torque converter
     

  8.  
  9. Install lifting beam 999-5716 and lifting hook 999-5460 on the engine.

    Click image to see an enlarged view

    Fig. Lifting beam installed on engine

    Lifting beam installed on engine
  10.  
  11. Raise the vehicle and remove or disconnect the following:

    Front wheels
     
    Splash guard
     
    Parking heater, if equipped
     
    Lower ball joints
     
    Control arms
     
    Subframe support plates
     
    Right axle halfshaft
     
    Steering gear
     
    Cross members
     
    Heated oxygen (HO 2 S) sensor and bracket
     
    Left axle halfshaft
     
    Rear engine mount bolt
     

  12.  
  13. Lower the sub-frame approximately 6 in. (140mm) and secure the steering gear.
    NOTE
    The steering shaft must not slide out of the rubber boot.

  14.  
  15. Remove or disconnect the following:

    Rear engine mount
     
    Transmission oil pipes
     

  16.  
  17. Lower the left side of the engine and transaxle assembly slightly.
  18.  
  19. Install fixture 999 5463 on fixture 999 5972. Install this assembly on the transaxle jack. Install fixture 999 5735 on the entire assembly.
  20.  
  21. Install the transaxle jack against the transaxle and secure the side mountings.
  22.  
  23. Remove the transmission flange bolts.
  24.  
  25. Remove the transmission.
  26.  

To install:

  1. Install or connect the following:
    NOTE
    If necessary, turn the engine so the stator shaft is correctly aligned in the torque converter.



    Transmission and tighten crosswise the bolts to 37 ft. lbs. (50 Nm)
     



    Splash guard above the transmission
     
    HO 2 S sensor and bracket and tighten to 18 ft. lbs. (25 Nm)
     

  2.  
  3. Raise the engine and transmission up to the horizontal position.
  4.  
  5. Install or connect the following:

    Transmission oil pipes and tighten to 22 ft. lbs. (30 Nm)
     
    Rear engine mount and tighten the bolts to 37 ft. lbs. (50 Nm)
     
    Rear engine pad and tighten the bolt to 37 ft. lbs. (50 Nm)
     
    Sub-frame, using new bolts. Tighten the frame bolts to 79 ft. lbs. (105 Nm) plus 120°. Tighten the bracket bolts to 38 ft. lbs. (50 Nm).
     
    Left axle halfshaft
     
    Right axle halfshaft
     
    Cross members
     
    Steering gear
     
    Lower ball joints
     
    Control arms
     
    Parking heater, if equipped
     
    Torx® bolts for torque converter to 26 ft. lbs. (35 Nm)
     
    Clamp for power steering oil pipe
     
    Charge air hose and clamp
     
    Top three bolts between the engine and transmission and tighten to 37 ft. lbs. (50 Nm)
     
    Ignition setting sensor and tighten to 88 inch lbs. (10 Nm)
     
    Positive cable to the engine
     
    Starter motor and tighten to 30 ft. lbs. (40 Nm)
     
    Transmission dipstick tube assembly
     
    Splash guard
     
    Boost pressure turbo pipe, if equipped
     
    Heater hose
     
    Gear selector cable
     
    Upper engine stabilizer brace and tighten the bolts to 38 ft. lbs. (50 Nm)
     
    CAC pipe, if equipped
     
    Air intake assembly
     
    Negative battery cable
     

  6.  
  7. Fill the transmission to the correct level
  8.  

Front Wheel Drive & AWD



  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the transaxle fluid.
  4.  
  5. Attach a support fixture to the engine lifting eyes.
  6.  
  7. Remove or disconnect the following:

    Battery and tray
     
    Air intake assembly
     
    Turbo control valve
     
    Turbocharger inlet tube
     
    Gear select cable
     
    Transaxle harness connector
     
    Transaxle ground cable
     
    Heated Oxygen (HO 2 S) sensor connector
     
    Transaxle oil cooler lines
     
    Transaxle dipstick tube
     
    Exhaust Gas Recirculation (EGR) valve hoses, if equipped
     
    Starter motor
     
    Coolant recovery tank
     
    Torque rod extension arm
     
    Front wheels
     
    Wheel speed sensors
     
    Brake line brackets
     
    Wheel speed sensor wiring brackets
     
    Inner fender liners
     
    Axle halfshafts
     
    Transfer case, if equipped
     
    Splash guards
     
    Lower ball joints
     
    Stabilizer bar links
     
    Evaporative Emissions (EVAP) canister and hoses
     
    Exhaust front pipe
     
    Oil line bracket
     
    Steering gear engine mount
     
    Steering gear mounting nuts
     
    Vehicle Speed (VSS) sensor connector
     
    Transaxle mount
     
    Torque converter
     

  8.  
  9. Loosen the 2 right side subframe-to-body bolts approximately 1 / 2 inch. Support the subframe with a jack and remove the subframe-to-body bolts on the left side.
  10.  
  11. Lower the jack and let the frame hang down from the right side bolts.
  12.  
  13. Tie the left side of the steering gear to the left side frame rail for support. Remove the steering gear engine mount.
  14.  
  15. Lower the engine and transaxle with the lifting hook.
  16.  
  17. Install transaxle fixture 5463 on the transaxle jack, using the torque rod mounting bolts to hold it in place. At the same time, fit tool 5463-1 support plate and raise the jack so that it is making light contact.
  18.  
  19. Remove the transaxle flange bolts.
  20.  
  21. Remove the transaxle.

    Click image to see an enlarged view

    Fig. Using the transaxle fixture

    Using the transaxle fixture
  22.  

To install:


NOTE
Use new fasteners where indicated.

  1. Install or connect the following:

    Transaxle and tighten the bolts to 37 ft. lbs. (50 Nm)
     
    Torque converter. Use new bolts and tighten them to 22 ft. lbs. (30 Nm).
     
    Rear transaxle mount and torque the bolts to 37 ft. lbs. (50 Nm)
     
    HO 2 S sensor connector
     
    VSS sensor connector
     

  2.  
  3. Install the subframe using new bolts. Starting on the left side, lift the frame with a jack. Mount the support brackets on both sides. Tighten the frame bolts to 78 ft. lbs. (105 Nm) plus 120 degrees. Tighten the bracket bolts to 37 ft. lbs. (50 Nm). Repeat the procedure for the right side. Remove the subframe jack.
  4.  
  5. Install or connect the following:

    Steering gear. Use new mounting nuts and tighten them to 37 ft. lbs. (50 Nm).
     
    Steering gear engine mount and tighten the bolts to 37 ft. lbs. (50 Nm)
     
    Oil line bracket
     
    Torque rod extension arm and tighten the bolts to 26 ft. lbs. (35 Nm) plus 40 degrees
     
    Exhaust front pipe
     
    EVAP canister and hoses
     
    Stabilizer bar links
     
    Lower ball joints
     
    Splash guards
     
    Transfer case, if equipped
     
    Axle halfshafts
     
    Inner fender liners
     
    Wheel speed sensor wiring brackets
     
    Brake line brackets
     
    Wheel speed sensors
     
    Front wheels
     
    Coolant recovery tank
     
    Starter motor
     
    EGR valve hoses, if equipped
     
    Transaxle dipstick tube
     
    Transaxle oil cooler lines
     
    Transaxle ground cable
     
    Transaxle harness connector
     
    Gear select cable
     
    Turbocharger inlet tube
     
    Turbo control valve
     
    Air intake assembly
     
    Battery and tray
     

  6.  
  7. Fill the transaxle to the correct level.
  8.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the transaxle fluid.
  4.  
  5. Attach a support fixture to the engine lifting eyes.
  6.  
  7. Remove or disconnect the following:

    Battery and tray
     
    Air intake assembly
     
    Turbo control valve
     
    Turbocharger inlet tube
     
    Gear select cable
     
    Transaxle harness connector
     
    Transaxle ground cable
     
    Heated Oxygen (HO 2 S) sensor connector
     
    Transaxle oil cooler lines
     
    Transaxle dipstick tube
     
    Exhaust Gas Recirculation (EGR) valve hoses, if equipped
     
    Starter motor
     
    Coolant recovery tank
     
    Torque rod extension arm
     
    Front wheels
     
    Wheel speed sensors
     
    Brake line brackets
     
    Wheel speed sensor wiring brackets
     
    Inner fender liners
     
    Axle halfshafts
     
    Transfer case, if equipped
     
    Splash guards
     
    Lower ball joints
     
    Stabilizer bar links
     
    Evaporative Emissions (EVAP) canister and hoses
     
    Exhaust front pipe
     
    Oil line bracket
     
    Steering gear engine mount
     
    Steering gear mounting nuts
     
    Vehicle Speed (VSS) sensor connector
     
    Transaxle mount
     
    Torque converter
     

  8.  
  9. Loosen the 2 right side subframe-to-body bolts approximately 1 / 2 inch. Support the subframe with a jack and remove the subframe-to-body bolts on the left side.
  10.  
  11. Lower the jack and let the frame hang down from the right side bolts.
  12.  
  13. Tie the left side of the steering gear to the left side frame rail for support. Remove the steering gear engine mount.
  14.  
  15. Lower the engine and transaxle with the lifting hook.
  16.  
  17. Install transaxle fixture 5463 on the transaxle jack, using the torque rod mounting bolts to hold it in place. At the same time, fit tool 5463-1 support plate and raise the jack so that it is making light contact.
  18.  
  19. Remove the transaxle flange bolts.
  20.  
  21. Remove the transaxle.

    Click image to see an enlarged view

    Fig. Using the transaxle fixture

    Using the transaxle fixture
  22.  

To install:


NOTE
Use new fasteners where indicated.

  1. Install or connect the following:

    Transaxle and tighten the bolts to 37 ft. lbs. (50 Nm)
     
    Torque converter. Use new bolts and tighten them to 22 ft. lbs. (30 Nm).
     
    Rear transaxle mount and torque the bolts to 37 ft. lbs. (50 Nm)
     
    HO 2 S sensor connector
     
    VSS sensor connector
     

  2.  
  3. Install the subframe using new bolts. Starting on the left side, lift the frame with a jack. Mount the support brackets on both sides. Tighten the frame bolts to 78 ft. lbs. (105 Nm) plus 120°. Tighten the bracket bolts to 37 ft. lbs. (50 Nm). Repeat the procedure for the right side. Remove the subframe jack.
  4.  
  5. Install or connect the following:

    Steering gear. Use new mounting nuts and tighten them to 37 ft. lbs. (50 Nm).
     
    Steering gear engine mount and tighten the bolts to 37 ft. lbs. (50 Nm)
     
    Oil line bracket
     
    Torque rod extension arm and tighten the bolts to 26 ft. lbs. (35 Nm) plus 40°
     
    Exhaust front pipe
     
    EVAP canister and hoses
     
    Stabilizer bar links
     
    Lower ball joints
     
    Splash guards
     
    Transfer case, if equipped
     
    Axle halfshafts
     
    Inner fender liners
     
    Wheel speed sensor wiring brackets
     
    Brake line brackets
     
    Wheel speed sensors
     
    Front wheels
     
    Coolant recovery tank
     
    Starter motor
     
    EGR valve hoses, if equipped
     
    Transaxle dipstick tube
     
    Transaxle oil cooler lines
     
    Transaxle ground cable
     
    Transaxle harness connector
     
    Gear select cable
     
    Turbocharger inlet tube
     
    Turbo control valve
     
    Air intake assembly
     
    Battery and tray
     

  6.  
  7. Fill the transaxle to the correct level.
  8.  

5-Cylinder Engine



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the transaxle fluid.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove or disconnect the following on turbocharged engines only:

    Torque rod
     
    Air intake hose
     
    Air intake assembly
     
    Charge air (CAC) pipe
     

  8.  
  9. Remove or disconnect the following on naturally aspirated engines only:

    Upper engine stabilizer brace
     
    Air intake assembly with the intake pipe and preheating hose
     
    Vacuum hoses from the intake pipe for the control valves
     
    Engine ground cable
     

  10.  
  11. Remove or disconnect the following:

    Gear selector cable and mount.
     
    Transaxle oil pipe
     
    Air intake housing bracket
     
    Heated oxygen (HO2S) sensor connector bracket
     
    Starter motor
     
    Turbo coolant hoses, if equipped
     

  12.  
  13. Raise and support engine.
  14.  
  15. Remove or disconnect the following:

    Air baffle
     
    Engine splash guard
     
    Sub-frame cable duct
     
    Parking heater, if equipped
     
    Cross members
     
    Exhaust bracket rubber mounts
     
    Torque rod mounting bolts
     
    Steering gear bolt
     
    Power steering line
     
    ABS line from the mounting in the spring strut
     
    Drive shaft bolt
     
    Anti-roll bar link
     
    Inner fender liner
     
    Sub-frame support plate bolts
     
    Control arm from the ball joint using tool 999 7076
     
    Spring strut
     
    Drive shaft
     
    Bevel gear, AWD only
     
    Rear engine mount
     
    Torque converter bolts
     
    Transaxle oil pipe
     
    Transaxle ground cable
     

  16.  
  17. Lower the left side of the engine and transmission to the lifting hook stop
  18.  
  19. Install transaxle fixture 999 5463 on transaxle jack, using the torque rod mounting bolts to hold it in place. At the same time, fit tool 999 5463-2 support plate and raise the jack so that it is making light contact.
  20.  
  21. Remove the transaxle flange bolts.
  22.  
  23. Remove the transaxle.
  24.  


    Click image to see an enlarged view

    Fig. Remove the ball joint from the control arm.

    Remove the ball joint from the control arm.

To install

  1. Install or connect the following:

    Transaxle and tighten the bolts to 37 ft. lbs. (50 Nm)
     
    Torque converter and tighten the bolts to 26 ft. lbs. (35 Nm)
     
    Rear engine mount
     
    Bevel gear, AWD only
     
    Transaxle oil pipe using new O-ring
     
    Transaxle ground cable
     
    Control arm
     
    Spring strut
     
    Drive shafts
     
    Sub-frame using new bolts
     
    Power steering line
     
    Cross members
     
    Anti-roll bar link using new lock nut
     
    ABS line in the mounting in the spring strut
     
    Inner fender liner
     
    Sub-frame cable duct
     
    Parking heater, if equipped
     
    Splash guard
     
    Turbo coolant hoses, if equipped
     
    Starter motor
     
    Heated oxygen (HO2S) sensor connector bracket
     
    Air intake housing bracket
     
    Transaxle oil pipe
     
    Gear selector cable and mount
     

  2.  
  3. Install or connect the following on turbocharged engines only:

    CAC pipe
     
    Air intake hose
     
    Air intake assembly
     
    Torque rod
     
    Engine ground cable
     

  4.  
  5. Install or connect the following on naturally aspirated engines only:

    Air intake assembly with the intake pipe and preheating hose
     
    Vacuum hoses for the intake manifold from the control valves
     
    Engine ground cable
     
    Upper engine stabilizer brace
     

  6.  
  7. Connect the negative battery cable
  8.  
  9. Fill the transaxle to the correct level.
  10.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the transaxle fluid.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove or disconnect the following on turbocharged engines only:

    Torque rod
     
    Air intake hose
     
    Air intake assembly
     
    Charge air (CAC) pipe
     

  8.  
  9. Remove or disconnect the following on naturally aspirated engines only:

    Upper engine stabilizer brace
     
    Air intake assembly with the intake pipe and preheating hose
     
    Vacuum hoses from the intake pipe for the control valves
     
    Engine ground cable
     

  10.  
  11. Remove or disconnect the following:

    Gear selector cable and mount.
     
    Transaxle oil pipe
     
    Air intake housing bracket
     
    Heated oxygen (HO 2 S) sensor connector bracket
     
    Starter motor
     
    Turbo coolant hoses, if equipped
     

  12.  
  13. Raise and support engine.
  14.  
  15. Remove or disconnect the following:

    Air baffle
     
    Engine splash guard
     
    Sub-frame cable duct
     
    Parking heater, if equipped
     
    Cross members
     
    Exhaust bracket rubber mounts
     
    Torque rod mounting bolts
     
    Steering gear bolt
     
    Power steering line
     
    ABS line from the mounting in the spring strut
     
    Drive shaft bolt
     
    Anti-roll bar link
     
    Inner fender liner
     
    Sub-frame support plate bolts
     
    Control arm from the ball joint using tool 999 7076
     
    Spring strut
     
    Drive shaft
     
    Transfer case, AWD only
     
    Rear engine mount
     
    Torque converter bolts
     
    Transaxle oil pipe
     
    Transaxle ground cable
     

  16.  
  17. Lower the left side of the engine and transmission to the lifting hook stop
  18.  
  19. Install transaxle fixture 999 5463 on transaxle jack, using the torque rod mounting bolts to hold it in place. At the same time, fit tool 999 5463-2 support plate and raise the jack so that it is making light contact.
  20.  
  21. Remove the transaxle flange bolts.
  22.  
  23. Remove the transaxle.

    Click image to see an enlarged view

    Fig. Remove the ball joint from the control arm.

    Remove the ball joint from the control arm.
  24.  

To install

  1. Install or connect the following:

    Transaxle and tighten the bolts to 37 ft. lbs. (50 Nm)
     
    Torque converter and tighten the bolts to 26 ft. lbs. (35 Nm)
     
    Rear engine mount
     
    Transfer case, AWD only
     
    Transaxle oil pipe using new O-ring
     
    Transaxle ground cable
     
    Control arm
     
    Spring strut
     
    Drive shafts
     
    Subframe using new bolts
     
    Power steering line
     
    Cross members
     
    Anti-roll bar link using new lock nut
     
    ABS line in the mounting in the spring strut
     
    Inner fender liner
     
    Sub-frame cable duct
     
    Parking heater, if equipped
     
    Splash guard
     
    Turbo coolant hoses, if equipped
     
    Starter motor
     
    Heated oxygen (HO 2 S) sensor connector bracket
     
    Air intake housing bracket
     
    Transaxle oil pipe
     
    Gear selector cable and mount
     

  2.  
  3. Install or connect the following on turbocharged engines only:

    CAC pipe
     
    Air intake hose
     
    Air intake assembly
     
    Torque rod
     
    Engine ground cable
     

  4.  
  5. Install or connect the following on naturally aspirated engines only:

    Air intake assembly with the intake pipe and preheating hose
     
    Vacuum hoses for the intake manifold from the control valves
     
    Engine ground cable
     
    Upper engine stabilizer brace
     

  6.  
  7. Connect the negative battery cable
  8.  
  9. Fill the transaxle to the correct level.
  10.  

 
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