194002122 - 1004D20 POWER UNIT (AUTOMATIC TRANSMISSION) REMOVED, REMOVE AND RE-BUILD (AUTOMATIC TRANSMISSION)

Removing ( Refitting ) 1. Undo the nuts (1a) and disconnect the electrical connections (1b) from the starter motor.

	Description	Connector
1b	Starter motor	See A020 STARTER MOTOR

1. Undo the bolts (1a) and remove the starter motor (1b). 1. Rotate the crankshaft to gain access to and undo the six bolts fixing the torque converter to the engine flywheel. 1. Undo the automatic gearbox retaining bolts (1a), (1b) and nuts (1c).2. Separate the automatic gearbox from the engine. - Remove the torque converter.

Take care because the torque converter is full of oil.

Refitting ( Removing ) - Check and clean the threads on the torque converter housing the bolts securing it to the engine flywheel.- Check that the automatic gearbox centering bushes are correctly housed in the engine crankcase.- Lubricate the centering housing for the torque converter with a thin layer of lubricating grease.- Check the torque converter centering pin. check for rust, clean, if necessary, and lubricate with a thin layer of lubricating grease.- Place the torque converter back in its housing.1. Check that the torque converter is correctly positioned by using a sliding gauge to check that the distance between the torque converter connector threades and the matching surface of the automatic gearbox is about 16 mm. 1. Place the automatic gearbox back in its housing.2. Tighten the bolts (2a), (2b) and the nut (2c) securing the automatic gearbox to the specified torque.

Component	Fastening	dia	Value (daNm)	Validity
Automatic transmission	Bolt	M12	(engine side) 4.8 - 7.2	1.9 JTD 16v CAE2.4 JTD 20v CAE

Component	Fastening	dia	Value (daNm)	Validity
Automatic transmission	Nut	M12	(engine side) 4.8 - 7.2	1.9 JTD 16v CAE2.4 JTD 20v CAE

Component	Fastening	dia	Value (daNm)	Validity
Automatic transmission	Bolt	M10	(engine crankcase sump side) 3.2 - 4.8	1.9 JTD 16v CAE2.4 JTD 20v CAE

1. Place the six new bolts securing the torque converter to the engine flywheel back in their housings and tighten them to the recommended torque.

Use bolts of the same length as the ones that were removed.

Component	Fastening	dia	Value (daNm)	Validity
Torque converter	Bolt	M8	(engine flywheel side) 2.9 - 3.5	1.9 JTD 16v CAE

Component	Fastening	dia	Value (daNm)	Validity
Torque converter	Bolt (pretreated to be replaced)	M10	(engine flywheel side) 4.5 - 5.5	2.4 JTD 20v CAE

1. Place the starter motor (1a) in its housing and secure it tightening the bolts (1b) to the recommended torque.

Component	Fastening	dia	Value (daNm)	Validity
Starter motor	Bolt	M8	(automatic gearbox side) 2.3 - 2.8	1.9 JTD 16v CAE2.4 JTD 20v CAE

- Connect the electrical connections to the starter motor and secure them using the nuts.