Description Component Part no. BR2 + grease Converter
centring fit- ting
REMOVAL
a Position the vehicle on a two-post lift.
a Remove the engine covers.
a Disconnect the battery, starting with the negative terminal.
a Remove the scuttle grille ( (see 85A, Wiping -
Washing) ). Essential special tooling
Rou. 604-01 Hub locking tool.
Tav. 476 Ball joint extractor.
Mot. 1453 Multiple-adjusting engine mounting support with retai- ning straps.
Bvi. 1531 Tool for centring the torque converter for the automatic transmission converter.
Essential equipment
component jack
Tightening torquesm
wheel bolts 13 daNm
brake calliper guide pin bolts
0.7 daNm
track rod end nut 3.7 daNm
lower ball joint nut 6.2 daNm
engine tie-bar bolts on the subframe
10.5 daNm
starter and gearbox bell housing bolts
4.4 daNm
suspended mounting nut on the gearbox
4.4 daNm
track rod end nut 6.2 daNm
drive plate converter mounting nut
3.7 daNm
m o d u l a r c o n n e c t o r mounting bolts
2 daNm
engine speed sensor mounting bolts
1 daNm
engine tie-bar bolts on F engines
18 daNm
suspended mounting nut on the rubber pad
18 daNm
battery cover mounting bolts
0.4 daNm
101821
a Remove:
- the two air filter access panel mounting bolts (1) , - the air filter access panel,
- the scuttle panel partition mounting bolt (2) .
a Remove:
- the scuttle panel partition mounting bolts (3) , - the scuttle panel partition,
a Remove:
- the multifunction switch cable ball joint (4) ,
- the wiring (5) from the multifunction switch cable, unlocking the cable sleeve stop,
- the wiring harness mountings.
a Disconnect:
- the engine speed sensor,
- the connector (6) by detaching the connector slide.
a Remove the mounting bolts (7) from the modular connector support plate.
104343
104246
103409
WARNING
Protect the connector by sliding it into a water- proof plastic bag.
a Remove the engine speed sensor.
a Remove the engine speed sensor.
a Remove:
- the two bolts (8) from the starter, - the engine undertray.
a Drain the gearbox.
a Remove: - the wheels,
- the wheel arch liners.
a Disconnect:
- the ABS system sensor wiring,
- the discharge bulb beam adjustment sensor wiring (if fitted to the vehicle).
K4M 103753 F4R 103420 103423 Note:
The discharge bulb beam adjustment sensor is fitted onto the left-hand lower wishbone.
I - LEFT-HAND SIDE OF THE VEHICLE
a Remove:
- the hub nut using the (Rou. 604-01), - the track rod end using the (Tav. 476), - the anti-roll bar ball joint using the (Tav. 476), - the lower ball joint.
a Release the stub axle carrier from the driveshaft.
a Remove the left-hand driveshaft.
a Remove:
- the clip (10) from the gearbox computer wiring har- ness,
- the side reinforcement (9)
102129
II - RIGHT-HAND SIDE OF THE VEHICLE
a Remove:
- the hub nut using tool (Rou. 604-01), - the track rod end using the (Tav. 476), - the anti-roll bar ball joint using the (Tav. 476), - the lower ball joint.
a Remove the relay bearing bracket.
a Release the stub axle carrier from the driveshaft.
a Remove the right-hand driveshaft.
a Attach the cooling radiator assembly to the upper cross member using rope.
102129
a Remove the cooling radiator lower cross member.
a Remove:
- the exhaust mounting nuts (13) , - the engine tie-bar.
a Remove:
- the lower engine - manifold strut, - the starter mounting bolt (15) , - the starter,
- the three converter nuts.
102009
103421
103418
Note:
The converter nuts are accessed by removing the starter. Rotate the crankshaft clockwise to access the three starter plate - converter connec- ting nuts and remove them.
a Remove the upper studs (16) from the gearbox bell housing.
a Open the cover (13) .
a Remove cover (14) .
a Fit the (Mot. 1453).
a Remove the gearbox support rubber pad.
a Fit the component jack under the gearbox.
a Secure the converter with string to prevent it being dislodged.
REFITTING
a 103423 102449 13790 WARNING- Do not reuse the converter mounting nuts or the inertia flywheel nuts if they have been removed: always use new nuts.
a Refit the inertia flywheel on the converter using tool
(Bvi. 1531) ;.
a To refit, proceed in the reverse order of removal.
When refitting the automatic transmission on the en- gine, make sure that the converter is properly enga- ged on the input shaft pin.
16361
WARNING
a The distance between the base of the threading (17) and the engine coupling face (18) should be 17 mm.
a Torque tighten:
- the wheel bolts (13 daNm),
- the brake calliper guide pin bolts (0.7 daNm), - the track rod end nut (3.7 daNm),
- the lower ball joint nut (6.2 daNm),
- the engine tie-bar bolts on the subframe (10.5
daNm),
- the starter and gearbox bell housing bolts (4.4
daNm),
- the suspended mounting nut on the gearbox
(4.4 daNm),
- the track rod end nut (6.2 daNm),
- the drive plate converter mounting nut (3.7
daNm),
- the modular connector mounting bolts (2
daNm),
- the engine speed sensor mounting bolts (1
daNm),
- the engine tie-bar bolts on F engines (18 daNm),
a If replacing the oil, reset the auto-adaptives using command RZ005: « Clear auto-adaptives » and reset the automatic transmission computer oil ageing counter with command CF074: « Enter date
of gearbox oil change » .
After using command RZ005, it is important to carry out a test drive performing all gear changes, both up and down, several times in order to store the new values.
a Torque tighten the battery cover mounting bolts
(0.4 daNm).
13790
WARNING
Connect the battery; carry out the necessary pro- gramming ( (see 8, Electrical equipment) ).
REMOVAL
a In order to remove and refit the automatic gearbox, the "engine - gearbox" assembly must be removed (see Engine/gearbox assembly: Removal - Refit-
ting) (10A, Engine and peripherals).
a Remove the nuts from the converter (1) through the starter opening.
Essential equipment
workshop hoist diagnostic tool
Tightening torquesm
gearbox bell housing bolts
44 Nm
converter nuts 44 Nm
Note:
Replacing the automatic gearbox AJ0 requires the automatic gearbox computer to be replaced (see 2 3 A , Automatic gearbox, A utomatic
transmission computer: Removal - Refitting,
page 23A-81) .
REFITTING
a Check that the drive plate is not damaged or runout
(0.2 mm permitted runout).
a Check that the torque converter is coupled correctly onto the automatic gearbox using a flat ruler and a tape measure. The distance (X) between the con- verter maintenance bolt bead and the cover should be at least 20.5 mm.
a Mount the gearbox and finger tighten the automatic gearbox bell housing bolts.
11911
Note:
Failure to observe this procedure can lead to the destruction of the gearbox.
118394
Note:
Align the converter blots with their location on the drive plate before fitting the automatic gearbox.
a Position the converter retaining nuts (3) through the starter opening.
a Tighten to torque:
- the gearbox bell housing bolts (44 Nm), - the converter nuts (44 Nm).
a Refit the starter (see Starter: Removal - Refitting) (16A, Starting - Charging).
a Proceed in the reverse order to removal.
a Refit the engine - gearbox assembly (see Engine/
gearbox assembly: Removal - Refitting) (10A,
Engine and peripherals).
a Connect the battery (see Battery: Removal - Refit-
ting) (80A, Battery).
a Perform the programming procedure using the dia-
gnostic tool (see Fault finding - Replacement of components) (23A, Automatic gearbox).