NOTE: If the transmission is removed for access, it is not necessary to drain the transmission fluid since the transmission fluid cooler is not separated from the transmission assembly.
NOTE: If the transmission must be removed, do not drain the transmission fluid unless the fluid cooler is disconnected from the transmission assembly.
Installation
1. Remove the torque converter holder.
CAUTION: Make sure the pins are still in the engine and not in the transmission.
2. Install the gearbox and torque converter. Tightening torque: 47 Nm
Ensure that the torque converter remains in the transmission. Position the element correctly on the mounting pins. Clean the mating surfaces and remove any rust or foreign material. Ensure that the pins are located on the engine and not on the transmission.
NOTE: This step requires the assistance of a second mechanic.
3. Remove the jack. General equipment: Powertrain Jack
4. Fix the torque converter on the faceplate. Tightening torque: 60 Nm
CAUTION: Use new bolts.
5. Install the access cover.
6. Install the right half shaft. Tightening torque: Propeller shaft support 25 Nm
7. Install the left axle shaft.
8. Connect the transmission fluid cooler lines. Tightening torque: 10 Nm
Clean the area around the element and remove any foreign matter. Install new O-rings.
9. Install the turbocharger outlet pipe.
10. Install the adjusting tool on the front subframe.
11. Install the front subframe. Tightening torque: Support bracket bolts 25 Nm. Subframe Bolts - Step 1: 140 Nm. Step 2: 240°
CAUTION: Use only new subframe bolts.
NOTE: Install, but do not fully tighten, the front subframe mounting bolts.
12. Install the subframe crossmember. Tightening torque: Crossmember bolts 45 Nm. Subframe Bolts - Step 1: 140 Nm. Step 2: 240°
CAUTION: Use new bolts.
NOTE: Install, but do not fully tighten, the rear subframe mounting bolts.
13. Install the fuel line.
14. Secure the catalytic converter to the distribution pipe.
15. Connect the steering gear pressure lines. Tightening torque: 25 Nm
16. Secure the power steering lines.
17. Install the lower support cushion. Tightening torque: 110 Nm
18. Install the lower control arm ball joint. Tightening torque: 110 Nm
CAUTION: Install a new lower control arm ball joint nut.
CAUTION: Do not allow the ball joint to rotate.
19. Connect the ball joints of the tie rod end. Tightening torque: 80 Nm
WARNING: Use new nuts.
20. Attach both front struts to the stabilizer bar. Tightening torque: 55 Nm
WARNING: Use new nuts.
CAUTION: Do not allow the ball joint to rotate.
21. Install the left fender splash guard extension panel.
NOTE: The illustration shows the right side, the procedure is similar on the left side.
22. Install the front wheel and tire assemblies. Refer to procedure: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation).
23. Install the towbar hole plug. Tightening torque: Bumper cover mounting bolts 10 Nm
24. Secure and connect the selector lever cable.
25. Install the engine mount bracket. Tightening torque: 90 Nm
26. Install the ground strap. Tightening torque: 25 Nm
27. Install the left engine mount. Tightening torque: 175 Nm
28. Install the bracket. Tightening torque: M12 80 Nm. M8 25 Nm
29. Remove the support from under the engine.
30. Install the starter. Refer to procedure: Starter (303-06B Starting System - 2.2L Duratorq - Td4, Removal and Installation).
31. Install the battery tray. Refer to the procedure: Battery Installation Tray (414-01 Battery, Battery Fastener and Cables, Removal and Installation).
32. Connect the steering column to the steering gear. Tightening torque: 25 Nm
CAUTION: Install a new steering column flexible coupling bolt.
33. Fill the transmission with transmission fluid. Refer to procedure: Draining and Filling Transmission Fluid - 2.2L Duratorq - Td4 (307-01 Automatic/Transaxle Transmission, General Procedures).
CAUTION: Before starting the engine, make sure there is sufficient power steering fluid in the reservoir. Failure to do so may result in damage to the vehicle.
34. Fill the power steering system with fluid and bleed the system. Refer to the procedure: Bleeding the Power Steering System (211-00 Steering System - General Information, General Procedures).
35. If a new component is to be fitted, configure using Land Rover approved diagnostic equipment.
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