Installation Procedure
- Transfer components as necessary.
- If the removed transmission will be reinstalled, clean the threads of the torque converter.
- Raise the transmission with the transmission jack and position the transmission to the engine.
- CAUTION:
Install the transmission front upper bolt (1) and tighten a first pass to 10 N.m (89 lb in), in order to align the transmission and the engine flush.
- CAUTION:
Tighten the transmission converter cover carefully to prevent it from becoming deformed. A deformed transmission converter cover may wear on the starting ring gear or the front wheel drive shaft resulting in noise emission and improper protecting properties.
Install the transmission converter cover (2).
- Install the transmission rear bolt (1) and tighten a first pass to 10 N.m (89 lb in), in order to align the transmission and the engine flush.
Install the transmission lower bolt (1) and tighten to 58 N.m (43 lb ft).
- Tighten the transmission front upper bolt and the transmission rear bolt a final pass to 58 N.m (43 lb ft).
- Remove the transmission jack.
Tighten the transmission front lower bolt (1) to 58 N.m (43 lb ft).
Install the transmission lower bolt (1) and tighten to 58 N.m (43 lb ft).
Torque Converter @ Flex Plate - Install
- Turn the engine at the crankshaft pulley (2) clockwise with the EN-49979 holder (3) along with the EN-49979-100 pins and the EN-956-1 extension (4) until a torque converter bolt hole shows up.
- Install a NEW torque converter bolt (1) and tighten to 60 N.m (44 lb ft).
- Turn the engine at the crankshaft pulley clockwise 60 degrees.
- Install the next NEW torque converter bolt and tighten to 60 N.m (44 lb ft).
- Repeat the previous 2 steps until the sixth torque converter bolt is installed.
NOTE:Service may offer bolts without micro-encapsulated thread locking adhesive. If this is the case, apply thread locking adhesive to the bolt.
If fasteners are micro-encapsulated, install NEW torque converter bolts. DO NOT reuse the old bolts.
- Starter - Install - Starter Replacement (1.6L Diesel LH7)
- Lower the vehicle.
Wiring Harness Retainer (1) - Install [2x]
Raise the engine/transmission unit into original position, using the EN-51007 support (1).
- Transmission Mount Bolt (2) - Install and tighten [4x] - Use NEW bolts.
- First Pass: 100 N.m (74 lb ft)
- Final Pass: 60-75 degrees
- Engine Support Fixture - Remove - Engine Support Fixture
- Engine Sight Shield - Install - Engine Sight Shield Replacement
- Raise the vehicle.
Remove the left drive shaft (2) from the hoist (1).
- Left Front Wheel Drive Shaft @ Transmission - Connect - Front Wheel Drive Shaft Replacement
Remove the right drive shaft from the hoist.
- Right Front Wheel Drive Shaft @ Transmission - Connect - Front Wheel Drive Shaft Replacement
- Transmission Mount Strut Bracket - Install - Transmission Mount Strut Bracket Replacement
- Drivetrain and Front Suspension Cradle - Install - Drivetrain and Front Suspension Cradle Replacement
- Exhaust Front Pipe - Install - Exhaust Front Pipe Replacement (1.6L Diesel LH7)
- Front Wheelhouse Liner - Install [2x] - Front Wheelhouse Liner Replacement
- Front Compartment Insulator - Install - Front Compartment Insulator Replacement
- Front Bumper Fascia Extension - Install - Front Bumper Fascia Extension Replacement (without Front Bumper Shutter)Front Bumper Fascia Extension Replacement (with Front Bumper Shutter)
- Lower the vehicle.
- NOTE:
The graphic shows the radiator without the front bumper fascia in front of it, for the sake of clarity.
Loosen the radiator (2) from the body, remove the belts (1).
Install the 3 transmission upper bolts (1) and tighten to 58 N.m (43 lb ft).
- Install the range selector lever cable bracket. Range Selector Lever Cable Bracket Replacement
- Transmission Fluid Cooler Inlet Pipe @ Transmission - Install - Transmission Fluid Cooler Inlet and Outlet Pipe Replacement (1.6L Diesel LH7)
- Transmission Fluid Cooler Outlet Pipe @ Transmission - Install - Transmission Fluid Cooler Inlet and Outlet Pipe Replacement (1.6L Diesel LH7)
Engine Wiring Harness Bracket (3, 4) - Install [2x]
- Engine Wiring Harness Bracket Bolt (5) - Install and tighten 58 N.m (43 lb ft)
- Engine Wiring Harness Bracket Nut (1, 2) - Install and tighten [3x] 9 N.m (80 lb in)
- Install the body ground cable and wiring harness assembly to the front of the transmission.
Connect the control valve body transmission control module electrical connector (1), then clip the 12 wiring harness retainers (2) to the cover.
Generator and Starter Cable (1) - Install [5x]
Connect the auxiliary fluid accumulator electrical connector (1).
- Charge Air Cooler Outlet Air Hose - Install - Charge Air Cooler Outlet Air Hose Replacement
Install the range selector lever cable (4) to the range selector lever cable lever and the range selector lever cable bracket.
- Automatic Transmission Range Selector Lever Cable Bolt (1) - Install and tighten 9 N.m (80 lb in)
- Depress the cable adjustment retainer (3) locking the retainer completely.
- Slide the retainer lock (2) rearward to cover the cable adjustment retainer (3).
- Range Selector Lever Cable - Adjust - Range Selector Lever Cable Adjustment
- Transmission Fluid - Fill - Transmission Fluid Drain and Fill
- Engine Control Module and Electronic Brake Control Module Bracket - Install - Engine Control Module and Electronic Brake Control Module Bracket Replacement
- After repairs, refer to Control Module References for programming and set up procedures.
- Reprogram the performance characteristics data for the solenoid valves. Solenoid Valve Characterization Reprogramming