Dismantling
1. Disconnect "negative" battery terminal.
2. Fix a cowl in vertical position.
3. Remove the intake air hoses.
DIESEL ENGINE FUEL SUPPLY, REPAIR WORKS, Intake air ducts.
4. Remove the heat exchanger for cooling the working fluid.
AUTOMATIC TRANSMISSION: JATCO, REPAIR WORK, Fluid cooling heat exchanger: cars with Td4 engine.
5. Remove the starter.
SYSTEM OF STARTING THE ENGINE AND CHARGING THE BATTERY, REPAIR WORKS, Starter - engine Td4.
6. Remove the transfer case (IRD).
TRANSFER BOX, REPAIRS, Transfer case: models with Td4 engine.
7. Install tool LRT-54-026 on the drive shaft inner joint. Using the lever, release the inner joint from the gearbox.
8. With the help of a partner, move the hub outward and remove the left drive shaft from the gearbox.
CAUTION: When pulling out the shaft, keep it in a horizontal position so as not to damage the differential oil seal.
9. Remove and discard the drive shaft retaining ring.
10. Loosen the nut securing the selector cable to the gear lever.
11. Remove the clip, disconnect the selector cable and remove the lever.
12. Turn away a bolt of fastening of a cover to a transmission.
13. Remove the plug from the hatch of the crankcase of the drive disk to gain access to the torque converter mounting bolts.
14. Mark the mutual position of the drive disk and the torque converter for subsequent assembly.
15. Turning the engine shaft, open access to the four bolts securing the drive disc to the torque converter and remove them.
16. Turn out a bolt and disconnect the tire "masses" from the gearbox.
17. Loosen the clamp and disconnect the hose from the turbocharger outlet.
18. Release the electrical connectors from the fasteners and disconnect the 2 connectors from the main harness.
19. Attach lifting chains to the lifting eyes and lift the engine to remove its weight from the supports.
20. Take out a through bolt of fastening of an arm of a transmission to the left support.
21. Lower the box so that it is clear of the support.
22. Turn out 4 bolts of fastening of the left arm of a support to a transmission and remove an arm.
23. Install the lifting eyes on the gearbox and secure them with bolts.
24. Attach lifting chains to the eye and hang the gearbox.
25. Turn away 2 bolts of fastening of a transmission to the engine.
26. Turn away the bottom bolt of fastening of a transmission.
27. Turn away 2 top bolts of fastening of a transmission to the engine.
28. Release the gearbox from the two guide pins.
29. Lower the gearbox to the floor.
30. If necessary, remove the cover from the gearbox
31. Install the torque converter fixing plate and secure with screws.
Installation
1. Clean the gearbox cover.
2. Check that the cover is on the dowel pins.
3. Wipe the drive disc and check that it is not cracked or deformed.
4. Wipe the mating surfaces of the engine and gearbox, dowel pins and pin sockets.
5. Remove the torque converter fixing plate.
6. Check that the torque converter is fully seated on the oil pump drive by measuring dimension 'A' shown in the figure. Dimension A = 27 mm.
7. Attach lifting chains to the lifting eyes and hang the gearbox.
8. Lift the gearbox and slide it over the dowel pins. Screw in the bolts securing the gearbox to the engine and tighten them to a torque of 85 Nm.
9. Screw a bolt of fastening of a cover and tighten it. Tightening torque 10 Nm.
10. Remove the rigging from the gearbox.
11. Establish the left arm on a transmission, screw in bolts and tighten them the moment of 85 Nanometers.
12. Raise the engine, move the gearbox bracket to the support, tighten the through bolt to 100 Nm.
13. Disconnect the lifting chains from the engine.
14. Align the position marks of the drive disc and the torque converter and tighten the bolts to 45 Nm.
15. Install the grommet on the hatch cover.
16. Establish the selector lever, attach a selector cable and fix a cable cover on an arm.
17. Adjust the selector cable.
AUTOMATIC TRANSMISSION: JATCO, ADJUSTMENTS, Selector cable adjustment.
18. Attach connectors of a plait of a transmission and fix them in brackets.
19. Put a wire on the gearbox "masses" and tighten the mounting bolt. Tightening torque 25 Nm.
20. Connect the heat exchanger hose and tighten the clamp.
21. Install a new retaining ring on the end of the left drive shaft.
22. With the help of a partner, insert the left drive shaft into the gearbox, holding it at the right angle so as not to damage the gearbox oil seal.
23. Install the transfer case (IRD).
TRANSFER BOX, REPAIRS, Transfer case: models with Td4 engine.
24. Reinstall the starter.
SYSTEM OF STARTING THE ENGINE AND CHARGING THE BATTERY, REPAIR WORKS, Starter - engine Td4.
25. Install the heat exchanger for cooling the working fluid.
AUTOMATIC TRANSMISSION: JATCO, REPAIR WORK, Fluid cooling heat exchanger: cars with Td4 engine.
26. Establish air hoses of inlet system.
DIESEL ENGINE FUEL SUPPLY, REPAIR WORKS, Intake air ducts.
27. Attach "negative" battery terminal.
28. Untie the hood and close it.
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