Installation
Special Tool(s)
303-021
Engine support bracket
303-662
Support Beam Arm and Hook Assembly, Engine
NOTE: Some variation in the illustrations may occur, but the essential information is always correct.
1. NOTE: This step is only required if previously removed.
2. NOTE: This step is only required if previously removed.
Torque: 12 Nm
3. NOTE: This step is only required if previously removed.
Torque: 11 Nm
4. NOTE: This step is only required if previously removed.
5. CAUTIONS: On removal and installation of the transmission, make sure that the transsmission does not damage the brake pipe.
Make sure that the component is correctly located on the locating dowels.
Make sure that the mating faces are clean and free of corrosion and foreign material.
NOTE: Automatic transmission shown, manual is similar.
6. Torque: 65 Nm
7. Torque: 60 Nm
8. Torque: 24 Nm
9. Torque:
10. Torque: 24 Nm
11. NOTE: Automatic transmission shown, manual is similar. Remove the transmission jack.
12. Torque: 65 Nm
13. Torque: 24 Nm
14. Torque:
15. Torque:
16. NOTE: This step is only required if previously removed.
17. CAUTION: Keep the halfshaft horizontal to avoid damaging the oil seal.
18. CAUTION: LH illustration shown, RH is similar.
19. Torque: 25 Nm
20. WARNING: Make sure that a new nut is installed.
CAUTIONS: Do not use air tools to install the nut. Failure to follow this instruction may result in damage to the component.
Install the halfshaft nut finger tight.
Torque: 120 Nm
21. NOTES: This step is only required if previously removed.
Automatic transmission shown, manual is similar.
22. To prevent oil seal damage use the protector when installing the shaft into the transmission. It is not a special tool but is available from the Parts Catalogue.
23.
24. CAUTION: Keep the halfshaft horizontal to avoid damaging the oil seal.
NOTE: Do not fully engage the halfshaft until the oil seal protector has been removed.
25.
26. WARNING: Make sure that a new nut is installed.
CAUTIONS: Do not use air tools to install the nut. Failure to follow this instruction may result in damage to the component.
Install the halfshaft nut finger tight.
Torque: 120 Nm
27. Refer to: Transmission Draining and Filling (308-03 Manual Transmission/Transaxle, General Procedures).
28. Refer to: Front Subframe (502-00 Uni-Body, Subframe and Mounting System, Removal and Installation).
29. Refer to: Engine Undershield (501-02 Front End Body Panels, Removal and Installation).
30. Install the front wheels and tires.
Refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation).
31. Lower the vehicle.
32.
33. Torque: 175 Nm
34. Torque:
35. Remove the special tools.
Special Tool(s): 303-021, 303-662
36. Repeat the above step for the other side.
37.
38.
39.
40.
41. Torque: 10 Nm
42.
43. Torque: 12 Nm
44.
45.
46.
47. Refer to: Starter Motor (303-06A Starting System - TD4 2.2L Diesel, Removal and Installation).
48. Refer to: Plenum Chamber (412-01 Climate Control, Removal and Installation).
49. Connect the battery ground cable.
Refer to: Specifications (414-01 Battery, Mounting and Cables, Specifications).
50. Refer to: Clutch System Bleeding (308-00 Manual Transmission/Transaxle and Clutch - General Information, General Procedures).
Manual Transmission
Principles of Operation
For a detailed description of the manual transmission/transaxle and clutch, refer to the relevant Description and Operation section in the workshop manual.
Inspection and Verification
CAUTION: Diagnosis by substitution from a donor vehicle is NOT acceptable. Substitution of control modules does not guarantee confirmation of a fault and may also cause additional faults in the vehicle being checked and/or the donor vehicle.
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical or electrical damage.
Visual Inspection
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
4. If the cause is not visually evident, verify the symptom and refer to the Symptom Chart.
Symptom Chart
NOTE: Check transmission fluid level prior to carrying out any further diagnosis.