Install automatic transmission (AISIN GA8G45)

• Make sure that the hole (1) of the flywheel is accessible from the recess on the oil pan.
• Check for correct fit of fitting sleeves (2).

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• Turn the torque converter until the bore of the torque converter is aligned with the bore of the flywheel.
• Replace the bolts (arrows).

  Parts:  Screws

• Flange-mount automatic transmission to engine and screw on.
• Tighten screws (arrows).

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  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Transmission to engine
  M8	Tightening torque	19 Nm
  M12	Tightening torque	66 Nm

• Turn the engine with the special tool  0 493 380 (11 6 480)  at the vibration damper in the direction of  rotation.
• Replace nuts (1).

  Parts:  Nuts

• Tighten all 6 nuts (1) of the torque converter.
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Torque converter to flywheel
  M10	Replace nuts. (Remove any adhesive residue from the threads)	56 Nm

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• Replace screws (1).

  Parts:  Screws

• Screw the transmission onto the transmission mount with screws (1).
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Transmission mounting
  M10 Replace screws.	Joining torque	40 Nm
  	Angle of rotation	90°

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• Replace the screw (1).

  Parts:  Screw

• Screw the ground strap (2) onto the transmission with the screw (1).
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Standard screw connection M8
  M8	Tightening torque	19 Nm

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• Secure clamps (2) with wiring harness (3) to the transmission.
• Connect connectors (1) and lock.

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• Version A: 

  Slide the coolant hoses (2) onto the transmission oil cooler (3).

  Secure hose clamps (1).

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• Version B: 

  Slide the coolant hoses onto the transmission oil cooler and snap-in the locks (1).

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• Version C: 

  Replace seals (1).

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• Connect transmission oil lines (2).
• Tighten the bolt (1).
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Transmission oil line to transmission
  M8	tightening torque	19 Nm

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• Loosening the luggage strap (3).
• Remove special tools  0 490 133 (00 2 030)  and 0 495 827 (23 4 150) 

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  Install battery carrier 

• Insert and install battery carrier (5).
• Hand-tighten the bolt (4).
• Hand-tighten the bolts (3).
• Tighten down screw (4).
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Battery carrier to engine mount
  Hexagon screw M8x30	Tightening torque	19 Nm

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• Tighten down screws (3).
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Battery carrier to engine mount
  Hexagon screw M8x30	Tightening torque	19 Nm

• Attach coolant line (2) on battery carrier (5).
• Attach cable clip (1) on battery carrier (5).

  Install E-box 

  Precondition 

  Battery ground lead is disconnected.

  NOTE: RISK OF DAMAGE 
  Improper routing of cables and wiring harnesses.
  Trapped, crushed or damaged cables may cause short circuits and malfunctions.

  • Route all cables without abrasions, do not trap and crush.
• Feed in the E-Box (1) into the guide (2) in the arrow direction and install.

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• Ensure that the E-Box (1) is positioned correctly on the cowl (2).

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• Tighten down screw (1).
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  E-box to battery tray
  M8x16	15 Nm

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• Feed the holder (1) into the E-Box (2) in the arrow direction and install.
• Make sure the holder (1) engages audibly.

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• Feed in and install the wiring harness section (2) of the engine in the arrow direction.
• Ensure that the locking mechanisms (1) engage audibly.

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• Feed in and install the wiring harness section (2) of the Valvetronic servomotor in the arrow direction.
• Ensure that the locking mechanisms (1) engage audibly.

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• Feed in the wiring harness section (3) for the injectors and ignition coils in the arrow direction and install.
• Make sure the locking mechanism (2) engages audibly.
• Insert and install the positive battery cable (1).

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• Connect all connectors (1) and lock.
• Ensure that the connectors (1) engage audibly.

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• Connect and lock all connectors (1) in the arrow direction.
• Ensure that the connectors (1) engage audibly.

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• Connect connectors (1) and lock.
• Make sure the connector (1) engages audibly.
• Feed the connector (1) into the E-Box (2) in the arrow direction and install.

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• Feed the cover (2) into the guides (3) in the arrow direction and install.
• Ensure that the cover (2) engages audibly into the guides (3).
• Tighten down screw (1).
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Cover panel to E-box
  RF5x26.5	Tightening torque	2.5 Nm

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• Insert and install the positive battery cable (2) on the holder (3).
• Insert and install the battery positive terminal (1).
• Tighten the battery positive terminal (1).
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Positive battery terminal to battery
  Nut M6	Tightening torque	5 Nm

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Follow-up work 

• Refer to INSTALLING THE LEFT OUTPUT SHAFT AT THE TRANSMISSION END
• Refer to INSTALLING RIGHT OUTPUT SHAFT AT TRANSMISSION END .
• Refer to INSTALLING STARTER MOTOR .
• Refer to INSTALLING AND SECURING COMPLETE FRONT AXLE .
• Refer to SECURING MOUNTED PARTS ON THE FRONT AXLE SUPPORT .
• Refer to CONNECTING PURGE AIR LINE .
• Refer to CONNECTING CONNECTOR ON STEERING GEAR .
• Refer to FASTENING THE RUBBER MOUNT ON THE FRONT AXLE SUPPORT .
• Refer to SECURING THE ANTI-ROLL BAR ON THE LEFT AND RIGHT ON THE ANTI-ROLL BAR LINK .
• Refer to FASTENING THE CABLE FOR THE RIDE HEIGHT SENSOR .
• Refer to INSTALLING WHEEL ARCH COVER AT FRONT LEFT AND RIGHT .
• Refer to IF INSTALLED: INSTALLING UNDERBODY PROTECTION AT REAR .
• Refer to INSTALLING THE FRONT LEFT AND RIGHT WHEELS .
• Refer to REMOVING THE MOUNTING FOR THE COOLANT RADIATOR ON THE LEFT AND RIGHT .
• Refer to SECURING THE STEERING SHAFT AT THE BOTTOM ON THE STEERING GEAR .
• Refer to TAKING ENGINE OUT OF INSTALLATION ORIENTATION .
• Refer to INSTALLING THE BATTERY .
• Refer to CHECKING/TOPPING UP OIL LEVEL IN AUTOMATIC TRANSMISSION (AISIN GA8G45) .
• Refer to INSTALLING THE BATTERY COVER .
• Refer to INSTALLING SECOND UPPER BULKHEAD .
• Refer to INSTALLING THE RIGHT WINDSHIELD PANEL COVER .
• Refer to INSTALLING THE LEFT WINDSHIELD PANEL COVER .
• Refer to INSTALLING THE REAR HOOD SEAL .
• Refer to INSTALLING LEFT AND RIGHT WIPER ARM .
• Refer to INSTALLING ACOUSTIC COVER .
• Refer to INSTALLING INTAKE SILENCER HOUSING .
• Refer to INSTALLING INTAKE PORT .